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Precision CoolingFor Business-Critical ContinuityLiebert Challenger™ 3000Installation Manual - 3 & 5 Tons, 50 & 60Hz

Installation4Figure 2 Upflow (BU) cabinet dimensions32 1/2 "32 1/2 "18 "6 7/8 "(175mm)(826mm)OverallDimension(826mm)OverallDimensi

Installation5Figure 3 Downflow (BF) cabinet dimensionsSL-11897 PG 7 32 1/2 "(826mm)OverallDimension32 1/2 "(826mm)OverallDimension30 1/2 &q

Installation62.5 Piping ConsiderationsAll piping below the elevated floor must be located so that it offers the least resistance to air flow. Careful

Installation7Figure 4 Piping connections for air cooled unitsCondensate Drain, 3/4” FPTField pitch minimum of1/8” (3.2mm) per foot (305mm).The drain l

Installation8Figure 5 Piping connections for split system fan coil unitsSL-11900 PG 8Piping outlet locations through the plenum arethe same as the uni

Installation9Figure 6 Piping connections for water/glycol and GLYCOOL unitsCondensate Drain 3/4” FPTField pitch a min. of 1/8" (3.2mm) per ft. (3

Installation10Figure 7 Piping connections for chilled water self-contained unitsSL-11898 PG 9Piping outlet locations throughthe plenum are the same as

Installation11

Installation122.6 Electrical ConnectionsThree-phase electrical service is required for all models in either 208, 230, 460, or 575 V, 60 Hz; or 200, 23

Installation1313. Smoke detector alarm connections. Field-supplied 24V. Class 1 wiring to remote alarm circuits. Factory-wired contacts from optional

Installation142.7.2 Ducted ApplicationsFor ducted applications on units, the duct work may be attached to the top perimeter of the unit. Refer to Figu

Installation15

Air Cooled Models163.0 AIR COOLED MODELS3.1 Condenser LocationThe air cooled condenser should be located for maximum security and maintenance accessib

Air Cooled Models17Figure 9 Air cooled condensersTable 4 Air cooled condenser statisticsModel Numberof Fans Connection Sizes(OD Copper)Net Weightlbs (

Air Cooled Models183.3 Refrigerant PipingAll refrigeration piping should be installed with high temperature brazed joints. Prevailing good refrigerati

Air Cooled Models193.4 Fan Speed Control SystemsFan Speed Control provides an infinite number of speed variations on specially designed, permanent spl

Air Cooled Models203.4.2 Dehydration/Leak Test and Charging Procedures for R22 (standard) or R407C (Optional)Fan Speed Control Type CondenserDehydrati

Air Cooled Models21Figure 10 Air cooled fan speed control general arrangementSL-11897 PG 5CondenserCoilSchraderValveFusiblePlugInverted Traps* on disc

Air Cooled Models223.4.3 Charging1. Make sure unit is OFF. Open all disconnect switches and, on units supplied with circuit breakers, open all breaker

Air Cooled Models233.5.2 Materials Supplied1. Built-in pre-wired condenser control box2. Air cooled condenser3. Piping access cover to be reinstalled

iTABLE OF CONTENTS1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cooled Models24Dehydration/Leak Test1. Make sure unit is OFF. Open all disconnect switches and pull all fuses except control fuses. On units suppl

Air Cooled Models25Figure 11 Air cooled, Lee-Temp general arrangementFACTORY PIPINGFIELD PIPINGSINGLE CIRCUIT SHOWNSL-10061 PG 4 SL-10071 PG 4Pipin

Water Cooled Models264.0 WATER COOLED MODELS4.1 Piping ConsiderationsManual shut-off valves should be installed at the supply and return lines of each

Water Cooled Models27Figure 12 Water cooled general arrangementSL-11898 PG 5EvaporatorCoilExpansionValveSensingBulbExternalEqualizersHot GasBypassValv

Water Cooled Models284.3 Water Regulating ValveThe water regulating valve automatically regulates the amount of fluid necessary to remove the heat fro

Water Cooled Models294.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3 Ton Units (Metrex Valve)AdjustmentThe valve may be adjusted using a

Glycol/GLYCOOL Cooled Models305.0 GLYCOL/GLYCOOL COOLED MODELS5.1 Drycooler LocationThe drycooler should be located for maximum security and maintenan

Glycol/GLYCOOL Cooled Models315.4 Glycol PipingIt is recommended that manual service shut-off valves be installed at the supply and return connec-tion

Glycol/GLYCOOL Cooled Models325.4.1 Expansion Tanks, Fluid Relief Valves and Other DevicesAn expansion tank must be provided for expansion and contrac

Glycol/GLYCOOL Cooled Models335.5.2 Glycol SolutionsWhen considering the use of any glycol products in a particular application, you should review the

ii5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.3 Ele

Glycol/GLYCOOL Cooled Models345.5.3 Filling the SystemInstallation of hose bibs at the lowest point of the system is recommended. When filling a glyco

Glycol/GLYCOOL Cooled Models35Figure 15 Drycoolers and pump packages Notes1. Single pump packages are 17-1/4" (438 mm) wide. Dual pump packages a

Glycol/GLYCOOL Cooled Models36Figure 16 Pump packages—expansion tankTable 17 Mounting hole dimensional dataPUMP PACKAGE Ain (mm) Bin (mm)Cin (mm)SINGL

Glycol/GLYCOOL Cooled Models37Figure 17 Glycol general arrangementSL-11898 PG 6GlycolPumpPumpHousingUnions*IsolationValves*ExpansionValveDrycoolerElec

Glycol/GLYCOOL Cooled Models38Figure 18 GLYCOOL general arrangementSL-11901 PG 5PumpHousingGlycolPumpUnions*IsolationValves*ExpansionValveEvaporatorCo

Glycol/GLYCOOL Cooled Models395.6 CondenserThe condenser is designed to operate in conjunction with a drycooler. The maximum coolant pressure is 350 p

Chilled Water Models406.0 CHILLED WATER MODELS6.1 Piping ConsiderationsManual shut-off valves should be installed at the supply and return lines to ea

Chilled Water Models41Figure 20 Chilled water general arrangement - downflow (BF) modelsSL-11899 PG 6AirFlowChilledWaterCoilBleedValveValveActuator3-W

Split System Models427.0 SPLIT SYSTEM MODELSThree (3) condensing unit styles are available: two (2) air cooled and one (1) water/glycol cooled con-den

Split System Models437.3 Piping Considerations7.3.1 Refrigerant LoopAll split systems require two refrigerant lines (an insulated copper suction line

iiiFIGURESFigure 1 Removing Challenger from skid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Split System Models44Once all piping is complete, check for leaks and dehydrate the field piping as follows:1. Pressurize the field piping to 150 PSIG

Split System Models45Figure 21 Refrigerant piping diagramTable 25 Equivalent lengths (feet) for various pipe fittingsCopper PipeOD in.90 DegreeElbow C

Split System Models467.3.2 Quick Connect FittingsBe especially careful when connecting the quick connect fittings. Read through the following steps be

Split System Models477.4 Outdoor Air Cooled Condensing UnitsFigure 22 Outdoor air cooled condensing unit—horizontal air discharge modelsABCINDICATES A

Split System Models48Table 26 Horizontal air discharge cabinet and floor planning dimensional dataModel Numbers Dimensional Data in. (mm) Module Weigh

Split System Models49Figure 23 Outdoor air cooled condensing unit—top air discharge modelsSL-11081 PG 5CA2"BLEFTAIRINTAKE(51mm)DGUARDHEIGHTTOPAI

Split System Models50Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air dischargeModel Numbers Dimensional Da

Split System Models51Figure 24 Electrical field connections, prop fan condensing moduleSL-11081 PG 8Factory wired to components onelectric panel.Heat

Split System Models527.5 Centrifugal Air Cooled Condensing Units7.5.1 Installing the Indoor Condensing UnitRefer to drawings for unit dimensions and c

Split System Models53Figure 25 Detail of ceiling hanging bracket3/8" threaded rod (field-supplied)3/8" hex nut3/8" washerSleeveIsolator

ivTABLESTable 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Split System Models547.5.2 DuctingThe total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5 inches of H

Split System Models55Figure 26 2 and 3 ton centrifugal air cooled condensing unit dimensional data & piping connections50 1/4" (1276mm)Overa

Split System Models56Figure 27 3 ton centrifugal air cooled condensing unit (con't.)DPN000207_Rev0NOTES:1. Refer to specification sheet for full

Split System Models57Figure 28 5 ton centrifugal air cooled condensing unit dimensional dataSL-11087 PG 451 13/16 "1 3/4 "21 1/4 "1 5/8

Split System Models58Figure 29 5 ton centrifugal air cooled condensing unit dimensional data (con't.)DPN000226_Rev0AIR COOLEDHeat rejection conne

Split System Models59Figure 30 Split systems general arrangementSL-11900 PG 5CondenserCoil1/2" (12.7mm) NPTPressure Relief ValveSightGlassCheckVa

Split System Models607.6 Water and Glycol Cooled Condensing UnitsFor installation guidelines, refer to Installing the Indoor Condensing Unit on page 5

Split System Models61Figure 31 2 and 3 ton water/glycol cooled condensing unit14" (356mm)Overall CabinetDimension8 7/8" (225mm)50 1/4"

Split System Models62Figure 32 3 ton water/glycol cooled condensing unit (con't.)DPN000209_Rev0Heat rejection connection.Field-supplied 24V NEC C

Split System Models63Figure 33 5 ton water/glycol cooled condensing unit dimensional dataSL-11087 PG 632 "32 "29 13/16 "33 5/8 "24

Introduction11.0 INTRODUCTION1.1 System DescriptionsChallenger 3000™ environmental control systems are available in three main system configurations:•

Split System Models64Figure 34 5 ton water/glycol cooled condensing unit (con't.)DPN000228_Rev0NOTES1. Refer to specification sheet for full load

R407C Refrigerant658.0 R407C REFRIGERANTTable 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas)Tempe

R407C Refrigerant668.1 Calculating SubcoolingExampleMeasure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that press

R407C Refrigerant67Notes

R407C Refrigerant68

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Installation22.0 INSTALLATION2.1 Room PreparationThe room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the ceil

Installation32.4.2 Removal of Skid• Remove the plywood skirting that keeps the skid and unit in place.• Raise the Challenger 3000 off the skid. Lieber