Emerson 3000 2.4.1 Handling With Skid, 2.4.2 Removal of Skid

Installation (Applicable to all Models)

7Liebert

® Challenger 3000™

2.4.1 Handling With Skid

• Always keep the unit upright, indoors and protected from damage.

• If possible, transport the unit using a fork lift; otherwise, use a crane with belts or cables,

avoiding pressing on the top edges of the packaging.

• If using a fork lift, make sure the forks, if adjustable, are spread to the widest allowable distance

to still fit under the skid.

NOTICE

Risk of overhead interference. Can cause unit and/or structure damage.

Refer to the installation plans prior to moving the unit to verify clearances.

While on the skid, the unit is too tall to fit through a standard height doorway (83 in. or

2108mm tall). Any attempt to move the unit, while on the skid, through a standard doorway

will cause damage to the unit.

2.4.2 Removal of Skid

• Remove the plywood skirting that keeps the skid and unit in place.

• Raise the Liebert Challenger 3000 off the skid. Emerson recommends using a fork lift (see

Figure 1) or similar machine to ensure that the unit is lifted properly.

• Once the unit is raised, the skid can be removed.

Figure 1 Removing the Liebert Challenger 3000 from skid

Table 1 Unit net weight

Model Lb. (kg)

036E/035E 535 (243)

060E/059E 545 (247)

042A/040A 615 (279)

067A/065A 670 (304)

046WG/045WG 700 (318)

071WG/070WG 750 (340)

061G/058G 785 (356)

068C/072C 545 (247)

102C/101C 555 (252)

Remove plywood skirting holding

unit and skid in place.

Raise unit with forklift

or similar machine.

Contents

Main Page TABLE OF CONTENTS 3.0 AIR-COOLED MODELSSELF-CONTAINED COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . .24 4.0 WATER-COOLED MODELSSELF-CONTAINED COMPRESSOR . . . . . . . . . . . . . . . . . . . . . .36 5.0 GLYCOL/GLYCOOL-COOLED MODELSSELF-CONTAINED COMPRESSOR . . . . . . . . . . . .42 FIGURES TABL ES IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS CAUTION Page 1.0 I 1.1 System Descriptions 1.1.1 Self-Contained Systems Air-Cooled Models Water-Cooled Models Glycol-Cooled Models Page 2.0 INSTALLATION (APPLICABLE TO ALL MODELS) 2.1 Room Preparation 2.4 Equipment Handling 2.2 Equipment Inspection 2.3 Location Considerations 2.4.1 Handling With Skid 2.4.2 Removal of Skid Installation (Applicable to all Models) Liebert Challenger 30008 Figure 2 Upflow (BU) cabinet dimensions A STD 3 & 5T 11-3/4 (299mm) Hi Static 3T 8-5/8 (219mm) Hi Static 5T 11-3/4 (299mm) Page 2.5 Piping Considerations 2.5.1 Drain Line Page Figure 5 Piping connections for air-cooled units - Upflow models Page Page Page Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models Page Page 2.5.2 Humidifier Supply WaterOptional Infrared 2.6 Facility Fluid and Piping Maintenance 2.7 Electrical Connections 2.7.1 Electrical Field Connections for Liebert Challenger 3000 Models 1 9910 Terminal Block (for Customer Connectons DPN000354 Rev. 2 Page 2.8 Balancing the Air Distribution 2.8.1 Under-Floor Discharge Systems 2.8.2 Ducted Applications 2.8.3 Plenum Installation 2.9 Checklist for Completed Installation 3.0 AIR-COOLED MODELSSELF-CONTAINED COMPRESSOR 3.1 Condenser Location 3.2 Electrical Connections 3.2.1 Line Voltage 3.2.2 Low Voltage 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 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 DPN000349 Rev. 5 DPN001726 Rev. 2 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 Liebert Lee-Temp Leak Check and Evacuation Procedure Liebert Lee-Temp Charging Liebert Lee-Temp Receiver Refrigerant Level DPN000674 Rev. 3 DPN001725 Rev. 1 4.0 WATER-COOLED MODELSSELF-CONTAINED COMPRESSOR 4.1 Piping Considerations 4.2 Condenser Figure 19 General arrangementWater-cooled models with scroll compressor Page 4.3 Water Regulating Valve 4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) Adjustment Manual Flushing 4.4 Motorized Ball ValveDigital 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 MODELSSELF-CONTAINED COMPRESSOR 5.1 Drycooler Location 5.2 Drycooler Installation 5.3 Electrical Connections 5.3.1 Line Voltage 5.4 Glycol Piping General Guidelines Page 5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices 5.5 Filling Instructions 5.5.1 Preparing the System for Filling 5.5.2 Glycol Solutions 5.5.3 Filling the System Figure 23 Drycoolers and pump packages Figure 24 Pump packagesexpansion tank Table 17 Mounting hole dimensional data Table 18 Drycooler data Table 19 Glycol pump data* Figure 25 General arrangementGlycol-cooled models with scroll compressor Figure 26 General arrangementGlycol-cooled models with digital scroll Page Figure 28 General arrangementGLYCOOL models with digital scroll compressor 5.5.4 Motor Ball ValveDigital Scroll Compressors 5.6 Condenser 5.7 Glycol Regulating Valve 5.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) 5.7.3 Testing Valve Function 6.0 CHILLED WATER MODELS 6.1 Piping Considerations Page 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 7.3 Piping Considerations 7.3.1 Refrigerant Loop Page Figure 31 Refrigerant piping diagram 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 7.3.2 Quick Connect Fittings 7.4 Outdoor Air-Cooled Condensing Units Figure 32 Outdoor air-cooled condensing unithorizontal air discharge models C C Table 26 Horizontal air discharge cabinet and floor planning dimensional data Table 27 Horizontal air discharge piping and electrical connection data Liebert Challenger 300064 Figure 33 Outdoor air-cooled condensing unittop air discharge models UNIT DIMENSIONS (see Table28) PIPING & ELECTRICAL CONNECTIONS (see Table29) 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 7.5.2 Ducting 69 Liebert Challenger 3000 Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections C D B A SL-11085 Pg. 4 DIMENSIONAL DATA PIPING CONNECTIONS Page Page Page 73 Liebert Challenger 3000 Figure 40 Split systems general arrangement AIR COOLED SL-11900 Pg. 5 WATER COOLED GLYCOL COOLED 7.6 Water and Glycol-Cooled Condensing Units 7.6.1 Piping Considerations 3-Ton Connection Sizes 5-Ton Connection Sizes 7.6.2 Condenser Water Requirements 7.6.3 Regulating Valve 7.6.4 Glycol Systems DPN000209 Rev. 0 Page Figure 44 5-ton water/glycol-cooled condensing unit (cont.) 8.0 R407C R 8.1 Calculating Subcooling Example Page Ensuring The High Availability Of Mission-Critical Data And Applications.