Document Outline

• Important Safety Instructions
• Save These Instructions
• 1.0 Introduction
  • 1.1 System Descriptions
    • 1.1.1 Self-Contained Systems
      • Air-Cooled Models
      • Water-Cooled Models
      • Glycol-Cooled Models
      • GLYCOOL Models (5-Ton Only)
    • 1.1.2 Chilled Water Models
    • 1.1.3 Split Systems
      • Prop Fan Air-Cooled
      • Centrifugal Fan Air-Cooled
      • Water-Cooled
      • Glycol-Cooled
• 2.0 Installation (Applicable to all Models)
  • 2.1 Room Preparation
  • 2.2 Equipment Inspection
  • 2.3 Location Considerations
  • 2.4 Equipment Handling
    • 2.4.1 Handling With Skid
    • 2.4.2 Removal of Skid
      • Figure 1 Removing Challenger from skid
      • Table 1 Unit net weight
      • Figure 2 Upflow (BU) cabinet dimensions
      • Figure 3 Downflow (BF) cabinet dimensions
  • 2.5 Piping Considerations
    • 2.5.1 Drain Line
      • Table 2 Piping connection size
      • Figure 4 Piping connections for air-cooled units - Downflow models
      • Figure 5 Piping connections for air-cooled units - Upflow models
      • Figure 6 Piping connections for split system fan coil units - Downflow models
      • Figure 7 Piping connections for split system fan coil units - Upflow models
      • Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models
      • Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models
      • Figure 10 Piping connections for chilled water self-contained units - Downflow models
      • Figure 11 Piping connections for chilled water self-contained units - Upflow models
    • 2.5.2 Humidifier Supply Water—Optional Infrared
  • 2.6 Facility Fluid and Piping Maintenance
  • 2.7 Electrical Connections
    • Figure 12 Electrical connections
    • Figure 13 Electrical field connections for Liebert iCOM
  • 2.8 Balancing the Air Distribution
    • 2.8.1 Under-Floor Discharge Systems
      • Table 3 Recommended free area ft2 (m2) for grilles or perforated panels at output velocities of 550 and 600 fpm (2.8 and 3.1 m/s)
    • 2.8.2 Ducted Applications
    • 2.8.3 Plenum Installation
  • 2.9 Checklist for Completed Installation
• 3.0 Air-Cooled Models—Self-Contained Compressor
  • 3.1 Condenser Location
  • 3.2 Electrical Connections
    • 3.2.1 Line Voltage
    • 3.2.2 Low Voltage
    • 3.2.3 Liebert Lee-Temp/Flood Back Head Pressure Control Condensers
      • Figure 14 Air-cooled condensers
      • Table 4 Air-cooled condenser statistics
  • 3.3 Refrigerant Piping
    • Table 5 Recommended line sizes — OD copper (inches)*
    • Table 6 Equivalent lengths (feet) for various pipe fittings
    • Table 7 Indoor unit refrigerant charge lb (kg)
    • Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube
    • Table 9 Condenser refrigerant (per serial tag)
  • 3.4 Fan Speed Control Systems
    • Variable Fan Speed Control Piping
    • Variable Fan Speed Control Materials Supplied
    • Variable Fan Speed Control Leak Check and Evacuation Procedure
    • Variable Fan Speed Charging
      • Table 10 Fan speed suction pressure transducer settings
      • Figure 15 General arrangement—Air-cooled models with fan speed control
      • Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control
  • 3.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure Control System
    • Liebert Lee-Temp Piping
    • Liebert Lee-Temp Controlled Materials Supplied
    • Lee-Temp Leak Check and Evacuation Procedure
    • Lee-Temp Charging
      • Table 11 Lee-Temp suction pressure transducer settings
    • Lee-Temp Receiver Refrigerant Level
      • Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp
      • Figure 18 General arrangement—Air-cooled models with digital scroll and Lee-Temp
• 4.0 Water-Cooled Models—Self-Contained Compressor
  • 4.1 Piping Considerations
  • 4.2 Condenser
    • Figure 19 General arrangement—Water-cooled models with scroll compressor
    • Figure 20 General arrangement diagram—Water-cooled models with digital scroll
  • 4.3 Water Regulating Valve
    • 4.3.1 Standard Valve - 150 psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350 psig (2413 kPa) System for 5-Ton Units (Johnson Controls Valve)
      • Adjustment
        • Figure 21 Johnson Controls valve adjustment
    • 4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)
      • Adjustment
        • Figure 22 Metrex Valve adjustment
        • Table 12 Refrigerant control settings psi (kPa)
      • Manual Flushing
  • 4.4 Motorized Ball Valve—Digital Scroll Compressors
    • 4.4.1 Control
      • Control Method
    • 4.4.2 Adjustment
    • 4.4.3 Startup
    • 4.4.4 Location
    • 4.4.5 Manual Control
• 5.0 Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor
  • 5.1 Drycooler Location
  • 5.2 Drycooler Installation
  • 5.3 Electrical Connections
    • 5.3.1 Line Voltage
    • 5.3.2 Low Voltage
    • 5.3.3 Pump and Drycooler
  • 5.4 Glycol Piping
    • General Guidelines
      • Table 13 Room dew point temperatures
    • 5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices
  • 5.5 Filling Instructions
    • 5.5.1 Preparing the System for Filling
      • Table 14 Indoor unit glycol volume approximate gallons (liters) max.
      • Table 15 Volume in standard Type “L” copper piping
    • 5.5.2 Glycol Solutions
      • Table 16 Ethylene glycol concentrations
    • 5.5.3 Filling the System
      • Figure 23 Drycoolers and pump packages
      • Figure 24 Pump packages—expansion tank
      • Table 17 Mounting hole dimensional data
      • Table 18 Drycooler data
      • Table 19 Glycol pump data*
      • Figure 25 General arrangement—Glycol-cooled models with scroll compressor
      • Figure 26 General arrangement—Glycol-cooled models with digital scroll
      • Figure 27 General arrangement—GLYCOOL models with scroll compressor
      • Figure 28 General arrangement—GLYCOOL models with digital scroll compressor
    • 5.5.4 Motor Ball Valve—Digital Scroll Compressors
  • 5.6 Condenser
  • 5.7 Glycol Regulating Valve
    • 5.7.1 Standard Valve - 150 psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350 psig (2413 kPa) System for 5-Ton Units (Johnson Controls Valve)
    • 5.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)
    • 5.7.3 Testing Valve Function
      • Table 20 Refrigerant control settings psi (kPa)
• 6.0 Chilled Water Models
  • 6.1 Piping Considerations
    • Figure 29 Chilled water general arrangement - Upflow (BU)
    • Figure 30 Chilled water general arrangement - Downflow (BF) models
• 7.0 Split System Models
  • 7.1 Location Considerations
    • 7.1.1 Air-Cooled Condensing Units
    • 7.1.2 Water/Glycol-Cooled Condensing Units
  • 7.2 Electrical Connections
    • 7.2.1 Line Voltage
    • 7.2.2 Low Voltage
  • 7.3 Piping Considerations
    • 7.3.1 Refrigerant Loop
      • Table 21 Unit refrigerant charge
      • Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube
      • Table 23 Recommended refrigerant lines (R407C) sizes OD copper
      • Table 24 Line coupling sizes
      • Table 25 Equivalent lengths (feet) for various pipe fittings
      • Figure 31 Refrigerant piping diagram
    • 7.3.2 Quick Connect Fittings
  • 7.4 Outdoor Air-Cooled Condensing Units
    • Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models
    • Table 26 Horizontal air discharge cabinet and floor planning dimensional data
    • Table 27 Horizontal air discharge piping and electrical connection data
    • Figure 33 Outdoor air-cooled condensing unit—top air discharge models
    • Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge
    • Table 29 Piping and electrical connections - top air discharge
    • Figure 34 Electrical field connections, prop fan condensing module
  • 7.5 Centrifugal Air-Cooled Condensing Units
    • 7.5.1 Installing the Indoor Condensing Unit
      • Table 30 Indoor centrifugal condensing unit
      • Figure 35 Detail of ceiling hanging bracket
    • 7.5.2 Ducting
      • Table 31 Airflow CFM (CMH)
      • Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections
      • Figure 37 3-ton centrifugal air-cooled condensing unit (con't.)
      • Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data
      • Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.)
      • Figure 40 Split systems general arrangement
  • 7.6 Water and Glycol-Cooled Condensing Units
    • 7.6.1 Piping Considerations
      • Table 32 Water and glycol-cooled condensing unit data
    • 7.6.2 Condenser Water Requirements
    • 7.6.3 Regulating Valve
    • 7.6.4 Glycol Systems
      • Figure 41 3-ton water/glycol-cooled condensing unit
      • Figure 42 3-ton water/glycol-cooled condensing unit (con't.)
      • Figure 43 5-ton water/glycol-cooled condensing unit dimensional data
      • Figure 44 5-ton water/glycol-cooled condensing unit (con't.)
• 8.0 R407C Refrigerant
  • Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas)
  • Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements)
  • 8.1 Calculating Subcooling
    • Example