SL 11962 9

Precision Cooling
For Business-Critical Continuity™
Liebert Challenger™ 3000 with iCOM

Installation Manual - 3 & 5 Tons, 50 & 60Hz
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER
SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Self-Contained Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Chilled Water Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Split Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 INSTALLATION (APPLICABLE TO ALL MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Equipment Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 Handling With Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.2 Removal of Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.2 Humidifier Supply Water—Optional Infrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Facility Fluid and Piping Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Balancing the Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8.1 Under-Floor Discharge Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8.2 Ducted Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8.3 Plenum Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.9 Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Condenser Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.3 Liebert Lee-Temp/Flood Back Head Pressure Control Condensers . . . . . . . . . . . . . . . . . . . . 23
3.3 Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Fan Speed Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.0 WATER-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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4.3 Water Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.1 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls
Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson
Controls Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) . . . . . . . 38
4.4 Motorized Ball Valve—Digital Scroll Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.1 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.3 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.4 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.5 Manual Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . . 41
5.1 Drycooler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.3 Pump and Drycooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Glycol Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.1 Preparing the System for Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.2 Glycol Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5.3 Filling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.5.4 Motor Ball Valve—Digital Scroll Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.6 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7 Glycol Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7.1 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls
Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson
Controls Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) . . . . . . . 53
5.7.3 Testing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.0 CHILLED WATER MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.0 SPLIT SYSTEM MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1.1 Air-Cooled Condensing Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1.2 Water/Glycol-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3.1 Refrigerant Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3.2 Quick Connect Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Outdoor Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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7.5 Centrifugal Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.5.1 Installing the Indoor Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.5.2 Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 Water and Glycol-Cooled Condensing Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.1 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.2 Condenser Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.3 Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.4 Glycol Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.0 R407C REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.1 Calculating Subcooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
FIGURES
Figure 1 Removing Challenger from skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2 Upflow (BU) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3 Downflow (BF) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4 Piping connections for air-cooled units - Downflow models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 5 Piping connections for air-cooled units - Upflow models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6 Piping connections for split system fan coil units - Downflow models . . . . . . . . . . . . . . . . . . . . . 12
Figure 7 Piping connections for split system fan coil units - Upflow models . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models . . . . . . . . . . . . . . 14
Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models . . . . . . . . . . . . . . . . . 15
Figure 10 Piping connections for chilled water self-contained units - Downflow models . . . . . . . . . . . . . . . 16
Figure 11 Piping connections for chilled water self-contained units - Upflow models . . . . . . . . . . . . . . . . . 17
Figure 12 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 13 Electrical field connections for Liebert iCOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 14 Air-cooled condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 15 General arrangement—Air-cooled models with fan speed control. . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control . . . . . . . . . . 30
Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 18 General arrangement—Air-cooled models with digital scroll and Liebert Lee-Temp . . . . . . . . . 34
Figure 19 General arrangement—Water-cooled models with scroll compressor . . . . . . . . . . . . . . . . . . . . . . 36
Figure 20 General arrangement diagram—Water-cooled models with digital scroll . . . . . . . . . . . . . . . . . . 37
Figure 21 Johnson Controls valve adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 22 Metrex Valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 23 Drycoolers and pump packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 24 Pump packages—expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 25 General arrangement—Glycol-cooled models with scroll compressor . . . . . . . . . . . . . . . . . . . . . . 49
Figure 26 General arrangement—Glycol-cooled models with digital scroll . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 27 General arrangement—GLYCOOL models with scroll compressor. . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 28 General arrangement—GLYCOOL models with digital scroll compressor . . . . . . . . . . . . . . . . . . 52
Figure 29 Chilled water general arrangement - Upflow (BU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 30 Chilled water general arrangement - Downflow (BF) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 31 Refrigerant piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models . . . . . . . . . . . . . . . . . . . . . 60
Figure 33 Outdoor air-cooled condensing unit—top air discharge models . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 34 Electrical field connections, prop fan condensing module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 35 Detail of ceiling hanging bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections . . . . . . . . . 67
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Figure 37 3-ton centrifugal air-cooled condensing unit (con't.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.) . . . . . . . . . . . . . . . . . . . . . 70
Figure 40 Split systems general arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 41 3-ton water/glycol-cooled condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 42 3-ton water/glycol-cooled condensing unit (con't.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 43 5-ton water/glycol-cooled condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 44 5-ton water/glycol-cooled condensing unit (con't.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TABLES
Table 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2 Piping connection size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 4 Air-cooled condenser statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 5 Recommended line sizes — OD copper (inches)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 6 Equivalent lengths (feet) for various pipe fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 7 Indoor unit refrigerant charge lb (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube . . . . . . . . . . . . . . . . . . . . . . 26
Table 9 Condenser refrigerant (per serial tag) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 10 Fan speed suction pressure transducer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 11 Liebert Lee-Temp suction pressure transducer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 12 Refrigerant control settings psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 13 Room dew point temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 14 Indoor unit glycol volume approximate gallons (liters) max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 15 Volume in standard Type “L” copper piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 16 Ethylene glycol concentrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 17 Mounting hole dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 18 Drycooler data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 19 Glycol pump data* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 20 Refrigerant control settings psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 21 Unit refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube . . . . . . . . . . . . . . . . . . . . . . 58
Table 23 Recommended refrigerant lines (R407C) sizes OD copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 24 Line coupling sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 25 Equivalent lengths (feet) for various pipe fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 26 Horizontal air discharge cabinet and floor planning dimensional data. . . . . . . . . . . . . . . . . . . . . 61
Table 27 Horizontal air discharge piping and electrical connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air
discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 29 Piping and electrical connections - top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 30 Indoor centrifugal condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 31 Airflow CFM (CMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 32 Water and glycol-cooled condensing unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and
suction gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements). . . . . . . . . . . . . . 78
iv
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation
and maintenance of the Liebert Challenger 3000™. Read this manual thoroughly before attempting to
install or operate this unit.
Only qualified personnel should move, install or service this equipment.
Adhere to all warnings, cautions and installation, operating and safety instructions on the unit and in
this manual. Follow all operating and user instructions.
! WARNING
Risk of electric shock. Can cause injury or death.
Disconnect local and remote power supplies before working within.
Before proceeding with installation, read all instructions, verify that all the parts are included
and check the nameplate to be sure the voltage matches available utility power.
The Liebert iCOM® microprocessor does not isolate power from the unit, even in the “unit off”
mode. Some internal components require and receive power even during the “unit off” mode of
Liebert iCOM control.
The factory-supplied optional disconnect switch is inside the unit. The line side of this switch
contains live high-voltage.
The only way to ensure that there is NO voltage inside the unit is to install and open a remote
disconnect switch. Refer to unit electrical schematic.
Follow all local codes.
! WARNING
Risk of explosive discharge from high-pressure refrigerant. Can cause injury or death.
This unit contains fluids and gases under high pressure. Relieve pressure before working with
piping.
! WARNING
Risk of refrigerant system rupture or explosion from overpressurization. Can cause
equipment damage, injury or death.
Local building or plumbing codes may require that a fusible plug or other type of pressure
relief device be installed in the system.
For systems requiring EU CE compliance (50Hz), the system installer must provide and
install a discharge pressure relief valve rated for a maximum of 500psig (34bar) in the high
side refrigerant circuit. Do not install a shutoff valve between the compressor and the
field-installed relief valve. The pressure relief valve must be CE certified to the EU Pressure
Equipment Directive by an EU “Notified Body.”
NOTE
The Liebert indoor cooling unit has a factory-installed high-pressure safety switch in the high
side refrigerant circuit. A pressure relief valve is provided with Liebert Lee-Temp™ condensers.
Consult local building codes to determine whether the Liebert Fan Speed Control and VFD
condensers will require field-provided pressure relief devices. A fusible plug kit for Liebert FSC
and VFD condensers is available for field installation.
1
! WARNING
Risk of high-speed moving parts. Can cause injury or death.
Disconnect all local and remote electric power supplies before working in the unit.
Do not operate upflow units without installing a plenum, ductwork or guard over the blower
opening(s) on the top surface of the unit cabinet.
Ductwork must be connected to the blower(s), or a plenum must be installed on the blower
deck for protection from rotating blower wheel(s) on upflow units.
! CAUTION
Risk of contact with hot surfaces. Can cause injury.
The compressor, refrigerant discharge lines, humidifiers and reheats are extremely hot
during unit operation. Allow sufficient time for them to cool before working within the unit
cabinet. Use extreme caution and wear protective gloves and arm protection when working on
or near hot compressors, discharge lines, humidifiers and reheats.
NOTICE
Risk of leaking water. Can cause equipment and building damage.
This unit requires a water drain connection. It may also require an external water supply to
operate.
Improper installation, application and service practice can result in water leakage from the
unit. Water leakage can result in severe property damage and loss of critical data center
equipment.
Do not locate unit directly above any equipment that could sustain water damage.
Emerson recommends installing leak detection equipment for unit and supply lines.
2
Introduction
1.0 INTRODUCTION
1.1 System Descriptions

Challenger 3000™ environmental control systems are available in three main system configurations:
• self-contained system with a scroll compressor in the room unit
• self-contained chilled water system
• split system with an evaporator section and a remote condensing unit
All three types are available in upflow or downflow configurations. The standard upflow configuration
is front return. All models require three-phase power. Units are available in 208, 230, 460, or 575V,
60Hz; and 200, 230 or 380/415V, 50Hz.
The following features are included as standard in all room units regardless of the type of system:
Liebert iCOM control, A-frame coil (V-frame on upflows), infrared humidifier, finned tubular
stainless steel electric reheat, 2" filter, individual high voltage fused protection and fan assembly.
1.1.1 Self-Contained Systems

Air-Cooled Models
Complete refrigeration system including hot gas bypass and crankcase heater with standard scroll
compressor, standard condenser and fan speed control for 95°F (35°C) ambient at sea level. Optional
Digital scroll compressor with unloading solenoid valve is also available. Digital scroll compressor
systems do not include hot gas bypass.
Water-Cooled Models
Compete refrigeration system including hot gas bypass with standard scroll compressor, water/glycol-
cooled condenser and two-way water regulating valve with bypass. Optional digital scroll compressor
with unloading solenoid valve is also available. Digital scroll compressor systems use a 2-way
motorized ball valve in lieu of the regulating valve; they do not include hot gas bypass.
Glycol-Cooled Models
The water-cooled model as described above plus pump package and 95°F (35°C) design ambient
drycooler.
GLYCOOL Models (5-Ton Only)
Complete refrigeration system including hot gas bypass with standard scroll compressor, glycol
condenser and three-way water regulating valve plus an integrally piped Econ-O-Coil with three-way
modulating control valve. Optional digital scroll compressor with unloading solenoid valve is also
available. Digital scroll compressor systems use a 3-way motorized ball valve in lieu of the regulating
valve; they do not include hot gas bypass.
1.1.2 Chilled Water Models

Chilled Water models include chilled water piping, three-way modulating valve, and actuator
assembly.
3
Introduction
1.1.3 Split Systems

Each air-cooled split system consists of an evaporator section and one of the following condensing
units.
Prop Fan Air-Cooled
Prop Fan units include scroll compressor, condenser coil, prop fan, high pressure switch, hot gas
bypass and Liebert Lee-Temp head pressure control. Unit is designed for outdoor location.
Centrifugal Fan Air-Cooled
Centrifugal Fan units include scroll compressor, condenser coil, centrifugal blower assembly,
high-pressure switch, hot gas bypass and Liebert Lee-Temp head pressure control. Unit must be
mounted indoors. Duct flanges are optional.
Water-Cooled
Each water-cooled split system consists of an evaporator section and a water/glycol condensing unit,
which includes scroll compressor, coaxial condenser, water regulating valve, hot gas bypass and
high-pressure switch. Design pressure is 150 psi (1034 kPa) as standard and 350 psi (2413 kPa) as
optional.
Glycol-Cooled
Each glycol-cooled split system consists of an evaporator section, a water/glycol condensing unit (as
described above), a pump package, and a 95°F (35°C) design ambient drycooler.
4
Installation (Applicable to all Models)
2.0 INSTALLATION (APPLICABLE TO ALL MODELS)
2.1 Room Preparation

The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the
ceiling can be a polyethylene film type. Use a rubber or plastic base paint on concrete walls and floors.
Doors should not be undercut or have grilles in them.
Outside (or fresh) air should be kept to an absolute minimum. Outside air adds to the heating,
cooling, humidifying and dehumidifying loads of the site. It is recommended that outside air be kept
below 5% of the total air circulated in the room and be preconditioned.
2.2 Equipment Inspection

Upon arrival of the unit, inspect all items for visible and concealed damage. Damage should be
immediately reported to the carrier and a damage claim filed with a copy sent to Liebert or to your
sales representative.
2.3 Location Considerations

The unit can sit on top of an accessible elevated flooring system. It may be necessary to furnish
additional pedestal support below the unit to ensure maximum structural support (see Table 1). A
separate floor stand for the unit may be used as support, independent of the elevated floor and
installed prior to the flooring system.
Provide approximately 34" (864 mm) service clearance on the front of the unit.
NOTE
GLYCOOL units require 34" (864 mm) service clearance on the right side of the unit in
addition to front service clearance.
Avoid placing units in an alcove or at the extreme end of a room that has a high aspect ratio (long,
narrow room). Ducted units can be placed in room corners or ends as long as front access is
maintained. Placing units too close together will reduce the effectiveness of the air distribution.
NOTE
Locate and remove shipping screw on fan motor base.
2.4 Equipment Handling
! WARNING
Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or
death.
Read all of the following instructions before attempting to move, lift, remove packaging from
or preparing unit for installation.
The instructions below are to be adhered to when handling this unit with or without the skid.
There is the potential for this unit to tip over if it is handled improperly.
5
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, avoid-
ing 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 inches or
2108 mm 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 Challenger 3000 off the skid. Liebert 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 Challenger from skid
Raise unit with forklift
Remove plywood skirting holding or similar machine.
unit and skid in place.
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)
6
Figure 2 Upflow (BU) cabinet dimensions

32-1/2"
A (826mm)
30-1/2"
UNIT
STD 3 & 5T 11-3/4 (299mm) (775mm) TOP VIEW
Hi Static 3T 8 5/8 (219mm) A
8-1/2" 9-5/8"
Hi Static 5T 11-3/4 (299mm)
(216mm) (244mm)
10-1/4" 1-5/8"
(260mm) 13"
(41mm)
(330mm)
30-1/2"
(775mm)
Standard Piping Location
12-1/2"
32-1/2"
1-7/8" (826mm)
(318mm)
Projection of Display (48mm)
Bezel 5/8" (16mm)
5-1/2" (140mm)
Standard Electrical Outlet
32-1/2" 32-1/2" Location Through Unit
(826mm)
(826mm)
Overall
Overall
Dimension
Dimension
6-7/8" (175mm)
7-1/2" Filter Access Standard Electrical Outlet
18"
(191mm) Through Top Location Through Plenum
(457mm)
Air Discharge Grille
29-3/4"
(756mm) Plenum available with:
1" (25mm) -2, 3 or 4 grilles.
FRONT &
-Solid sides with a 7/8" (22mm)
SIDES
3/4" (19mm) duct flange on top.
REAR
94"
(2388mm) Blower Outlet with
1" (25.4mm) Flange
29" 2-1/2"
(737mm) (67mm) 76" 7/8" (22.2mm) Flange for
(1930mm) Duct or Plenum Connection
REAR VIEW 1-3/4 " Return Air Louvers

(rear return configuration) (44mm)
Shaded area indicates a recommended

clearance of 34" (864mm) for component
access. Right side access suggested for
GLYCOOL units.
DPN000350
FRONT VIEW Rev. 01
(front return configuration)
7
Figure 3 Downflow (BF) cabinet dimensions

32-1/2" 32-1/2"
(826mm) (826mm) Projection of Display
Overall Overall Bezel 5/8" (16mm)
Dimension Dimension
30-1/2"
(775mm) 30-1/2"
(775mm)
Optional 1-5/8" (41mm)

Flange for Duct or
Plenum Connection
76"
(1930mm)
1" (25mm) FRONT & SIDES

3/4" (19mm) REAR
Shaded area indicates

a recommended clearance of
1" 34” (864mm) for component
(25.4mm) access. Right side access
30-1/2" 1"
30-1/2" suggested for GLYCOOL units
(775mm) (25.4mm)
(775mm)
12"
4" (305mm) 30-1/2"
9"
(102mm) (775mm)
(229mm)
1"
1" (25.4mm) (25.4mm)
Standard Electrical Location 28-1/2"

(724mm)
Standard Piping 30-1/2"
Location 8" (775mm)
Floor
(203mm)
Level
FLOOR CUTOUT DIMENSIONS
1"
(25.4mm) 30-1/2"
30-1/2"
(775mm)
(775mm)
See Specification
Sheet for Floor Stand
Height Ordered.
DPN000351
OPTIONAL FLOOR STAND DIMENSIONAL DATA Rev. 01
8
2.5 Piping Considerations

All piping below the elevated floor must be located so that it offers the least resistance to air flow.
Careful planning of the piping layout under the raised floor is required to prevent the air flow from
being blocked. When installing piping on the subfloor, it is recommended that the pipes be mounted in
a horizontal plane rather than stacked one above the other. Whenever possible, the pipes should be
run parallel to the air flow.
Condensate pumps for downflow units are shipped separately to be field-installed under the raised
floor. Pump height is 11 inches (279 mm).
2.5.1 Drain Line

A 3/4" (19.1 mm) female pipe thread (FPT) connection is provided for the evaporator coil condensate
drain. This drain line also drains the humidifier, if applicable. The drain line must be located so it will
not be exposed to freezing temperatures. The drain should be at least the full size of the drain
connection and pitched a minimum of 1/8" per ft. (11 mm per meter).
NOTE
This line may contain boiling water. Select appropriate drain system materials.
The drain line must include one and only one trap. Units without a condensate pump have a
factory-supplied trap in the unit, so a field trap should not be added. Units with a condensate
pump will require a field-supplied trap downstream from the pump. The drain line must
comply with all applicable codes.
Table 2 Piping connection size
Air-Cooled Unit Connection Sizes—in.
Model No. BF/BU Liquid Line O.D. Copper Hot Gas Line OD Copper
(50 Hz) L HG
042A (040A) 3/8 5/8
067A (065A) 1/2 7/8
Split System Fan Coil Unit Connection Sizes—in.
Model No. BF/BU (50 Hz) Liquid Line Suction Line
L SC
036E (035E) 5/8 - 18 Female (#6 QC) 1-1/8 - 12 Female (#11 QC)
060E (059E) 1/2 OD Cu 1-1/8 OD Cu
All Units: Connection Sizes—in.
Humidifier Line Condensate Condensate Pump Line Hot Water Reheat
OD Copper Drain Line OD Copper OD Copper
H C P
Supply Return
1/4 3/4 FPT 1/2 HWS HWR
5/8 5/8
Water/Glycol-Cooled Unit Connection Sizes—inches
Model No. BF/BU Supply Line Return Line
(50 Hz) S R
046WG (045WG) 7/8 7/8
071WG (070WG) 1-1/8 1-1/8
GLYCOOL Unit Connection Sizes —in.
Model No. BE/BK Supply Line Return Line
(50 Hz) S R
061G (058G) 1-1/8 1-1/8
Chilled Water Unit Connection Sizes—in.
Model No. BF/BU Supply Line Return Line
(50 Hz) CWS CWR
068C (072C) 1-1/8 1-1/8
102C (101C) 1-1/8 1-1/8
9
Figure 4 Piping connections for air-cooled units - Downflow models
Liebert iCOM
Control Panel
Condensate Drain 3/4" FPT Liquid Refrigerant Line

Field-pitch a minimum of 1/8" (3.2mm) 3/8" OD CU on Models BF042A/BF040A
per foot (305mm). The drain line 1/2" OD CU on Models BF067A/BF065A
must comply with all applicable codes.
Hot Gas Refrigerant Line
5/8" OD CU on Models BF042A/BF040A
7/8" OD CU on Models BF067A/BF065A
Hot Water Return
5/8" OD CU (optional)
Humidifier Water Supply Line
Hot Water Supply
1/4" OD CU
PIPING OUTLET LOCATIONS 5/8" OD CU (optional)
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.) DPN000353
Rev. 01
10
Figure 5 Piping connections for air-cooled units - Upflow models

Piping outlet locations through the plenum
are the same as the unit. See below for
descriptions and connection sizes.
Hot Water Return

1/4" OD CU 5/8" OD CU (optional)
Liquid Refrigerant Line
Hot Gas Refrigerant Line 3/8" OD CU on Models BU042A/BU040A
5/8" OD CU on Models BU042A/BU040A 1/2" OD CU on Models BU067A/BU065A
7/8" OD CU on Models BU067A/BU065A
Hot Water Supply
Condensate Pump Line 5/8" OD CU (optional)
1/2" OD CU
Used only if optional condensate
pump is ordered.
Liebert iCOM
Control
PIPING OUTLET LOCATIONS

Condensate Drain Opening Sizes.)
3/4" FPT
Field pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without
a condensate pump have a factory-supplied trap in the unit, so a DPN000352
field trap should not be added. Units with a condensate pump will Rev. 01
require a field-supplied trap downstream from the pump.The
drain line must comply with all applicable codes. (If condensate
pump is ordered piping is out top of unit).
11
Figure 6 Piping connections for split system fan coil units - Downflow models
Liebert iCOM
Control

(See Cabinet and Floor
Planning Dimensional Data
for Piping Opening Sizes.)
Liquid Refrigerant Line

Condensate Drain #6 Quick Connect on Models BF036E/BF035E
3/4" FPT
1/2" OD CU on Models BF060E/BF059E
Field pitch a minimum
of 1/8" (3.2mm) per ft. (305mm). Suction Refrigerant Line
The drainline must comply #11 Quick Connect on Models BF036E/BF035E
with all applicable codes. 1-1/8" OD CU on Models BF060E/BF059E
Hot Water Return
HumidifierWater Supply Line
1/4" OD CU Hot Water Supply
DPN000376
Rev. 01
12
Figure 7 Piping connections for split system fan coil units - Upflow models
Piping outlet locations through the

plenum are the same as the unit.
See below for descriptions and
connection sizes.
Humidifier Water Supply Line Hot Water Return

Suction Refrigerant Line Liquid Refrigerant Line
#11 Quick Connect on Models BU036E/BU035E #6 Quick Connect on Models BU036E/BU035E
1 1/8" OD CU on Models BU060E/BU059E 1/2" OD CU on Models BU060E/BU059E
Condensate Pump Line Hot Water Supply
1/2" OD CU; used only 5/8" OD CU (optional)
if optional condensate pump is ordered.
iCOM Control
Panel

Condensate Drain; 3/4" FPT Dimensional Data for Piping
Field-pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without Opening Sizes.)
a condensate pump have a factory-supplied trap in the unit, so a
field trap should not be added. Units with a condensate pump will
DPN000375
require a field-supplied trap downstream from the pump. The
Rev. 01
pump is ordered, piping is out top of unit).
13
Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models
iCOM Control
Panel
Condenser Supply Line

Condensate Drain 7/8" OD CU on Models BF046WG/BF045WG
3/4" FPT 1-1/8" OD CU on Models BF071WG/BF070WG
Field pitch a minimum Condenser Return Line
of 1/8" (3.2mm) per ft. (305mm). 7/8" OD CU on Models BF046WG/BF045WG
The drain line must comply with 1-1/8" OD CU on Models BF071WG/BF070WG
all applicable codes
Hot Water Return
1/4" OD CU Hot Water Supply
(See Cabinet and Floor Planning DPN000364
Dimensional Data for Piping Rev. 01
Opening Sizes.)
14
Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models
Piping outlet locations through the plenum

the same as the unit. See below for
descriptions and connection sizes.

Condenser Return Line Condenser Supply Line

7/8" OD CU on Models BU046WG/BU045WG 7/8" OD CU on Models BU046WG/BU045WG
1-1/8" OD CU on Models BU071WG/BU070WG 1-1/8" OD CU on Models BU071WG/BU070WG
Hot Water Supply
Condensate Pump Line 5/8" OD CU (optional)
1/2" OD CU
Used only if optional condensate
pump is ordered.
Liebert iCOM
Control

Condensate Drain (See Cabinet and Floor Planning
3/4" FPT Dimensional Data for Piping
Field pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without Opening Sizes.)
DPN000363
Rev. 01
pump is ordered piping is out top of unit).
15
Figure 10 Piping connections for chilled water self-contained units - Downflow models
Liebert iCOM
Control

Opening Sizes.)
Condensate Drain Chilled Water Supply Line

3/4" FPT 1-1/8" OD CU
Field pitch a minimum
of 1/8" (3.2mm) per ft. (305mm).
The drain line must comply Chilled Water Return Line
with all applicable codes. 1-1/8" OD CU
Hot Water Return

Humidifier Water Supply Line Hot Water Supply

DPN000371
Rev. 01
16
Figure 11 Piping connections for chilled water self-contained units - Upflow models
Piping outlet locations through
the plenum are the same as the unit.
See below for descriptions and
connection sizes.

Chilled Water Supply Line Chilled Water Return Line

1-1/8" OD CU 1-1/8" OD CU
Condensate Pump Line Hot Water Supply

1/2" OD CU; used only if optional 5/8" OD CU (optional)
condensate pump is ordered.
iCOM Control
Panel

Condensate Drain 3/4" FPT
Opening Sizes.)
Field-pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without
drain line must comply with all applicable codes. (If condensate DPN000370
pump is ordered, piping is out top of unit). Rev. 01
17
2.5.2 Humidifier Supply Water—Optional Infrared

• 1/4" supply line; maximum water pressure is 150 psi (1034kPa)
• Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa)
• Do not supply de-ionized water to the humidifier
2.6 Facility Fluid and Piping Maintenance

Facility water and glycol quality remain a requirement throughout the life of the piping system. Fluid
and piping system maintenance schedules must be established and performed. A local fluid
maintenance program must be established that will evaluate fluid chemistry and apply necessary
treatment. A periodic leak inspection of facility and unit fluid piping is recommended. Refer to 5.4 -
Glycol Piping.
2.7 Electrical Connections

Three-phase electrical service is required for all models in either 208, 230, 460, or 575 V, 60 Hz; or
200, 230, or 380/415 V, 50 Hz. Electrical service shall conform to national and local electrical codes.
Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to
electrical schematic when making connections.
A manual electrical disconnect switch should be installed within 5 feet (1.6 m) of the unit in
accordance with codes, or a factory-supplied disconnect switch may be factory mounted within the
unit accessible from the exterior.
! WARNING
Potentially lethal voltages exist within this equipment during operation. Observe all cautions
and warnings on unit and in this manual.
The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off”
mode. The only way to ensure that there is NO voltage inside the unit is to install and open a
remote disconnect switch. Refer to unit electrical schematic.
NOTICE
Risk of improper scroll compressor installation. Could cause poor performance and
compressor damage.
Three-phase power must be connected to the unit line voltage terminals in the proper
sequence so that the scroll compressor rotates in the proper direction. Rotation in the wrong
direction will result in poor performance and compressor damage. Use a phase sequence and
motor rotation sensor to ensure that the three-phase power is correctly connected and the
compressor is rotating properly.
18
Figure 12 Electrical connections
1
15
2
73
72
3 71
4
70
8 Electrical Handy Box
5
(factory-installed with cover;
7 1 inside unit on top for upflow
6
and on base for downflow.)
Terminal Block - for customer connections
14 14 9 9 10 11 13 12 16 17 18
75 76 94 95 96 97 37C38C37B38B 37 38 24 50 51 55 56 77 78 91 92 93 1 2 3 4 82 83 84 85 88 89
DPN000354
Rev. 01
1. Electric conduit knockouts on top and bottom of electric box. Knockout size 1-3/4" (44.5mm).
2. Three-phase connection. Electric service connection terminals when factory disconnect is NOT
supplied.
3. Three-phase connection. Electric service connection terminals when factory disconnect switch
is supplied.
4. Factory-installed disconnect switch. (Optional).
5. Three-phase electric service field-supplied.
6. Earth ground connection (50/60Hz). Connection terminal for field-supplied earth grounding
wire.
7. Earth ground bar (50Hz only). Connection terminals with factory ground from each high
voltage component for field supplied earth grounding wire.
8. Control and monitoring section of electric box.
9. Remote unit shutdown. Replace existing jumper between Terminals 37 + 38 with normally
closed switch having a minimum 75VA, 24VAC rating. Use field-supplied Class 1 wiring. Two
additional contact pairs available as an option (labeled as 37B & 38B, 37C & 38C). Replace
existing jumper for appropriate pair as done for 37 & 38.
10. Special alarm connections. Field-supplied 24V Class 1 wiring for special alarm. Connection
made by adding normally open contacts between terminals 24 + 50. Special alarm connections
may be factory-wired or field-wired. See schematic for factory wired special alarms. For
field-wired special alarms, use 24V Class 1 wiring to connect normally open contacts between
Terminals 24 & 50, 24 & 51, 24 & 55, or 24 & 56.
11. SiteScan connection. Terminals 77 (-) and 78 (+) are for connection of a 2-wire, twisted pair,
communication cable (available from Liebert or others) to optional Liebert SiteScan®.
12. Remote condensing unit connection. Field-supplied 24V Class 1 wiring to remote condensing
unit Terminals 1, 2, 3, & 4 from (R2) relay (split system only).
13. Smoke detector alarm connections. Field-supplied 24V Class 1 wiring to remote alarm
circuits. Factory-wired contacts from optional smoke detector are #91-comm., #92-NO, and
#93-NC.
14. Common alarm connection. Field-supplied 24V. Class 1 wiring to common alarm Terminals
75 + 76 (and optional 94 + 95, and 96 + 97), which are factory-connected to common alarm relay
(R3).
19
15. Heat rejection connection. Field-supplied 24V Class 1 wiring to interlock heat rejection from
pigtails 70 + 71 which are factory-connected to compressor side switch (self-contained units only)
or to GLYCOOL relay (K11, GLYCOOL units only). On Dual Cool units only, pigtails 72 + 73
connect auxiliary cooling source to GLYCOOL relay K11.
16. Reheat and Humidifier Lockout. Optional emergency power lockout of reheat and/or
humidifier: connections provided for remote 24V AC source.
17. Main Fan Auxiliary Switch. Optional main fan auxiliary side switch. Terminals located in field
wiring compartment for remote indication that the evaporator fan motor/unit is on. Field to
connect 24V maximum.
18. Optional Condensate Alarm (Dual Float Condensate Pump only). Relay terminals located in
field wiring compartment for remote indication.
Refer to specification sheet for full load amp. and wire size amp. ratings.
Figure 13 Electrical field connections for Liebert iCOM
24 22
23 21 22
20 19
25
24
23
20 25
19
DPN001734
DPN001733 Rev. 0
Rev. 0
Upflow Models with Liebert iCOM Downflow Models with Liebert iCOM
19. Network Cable “C” Connection. Eight-wire Ethernet cable from U2U networking switch.
20. Network Cable “D” connection. Eight-wire Ethernet cable from U2U networking switch.
Cable “D” connection supplied on units with large Liebert iCOM display only.
21. Opening for Field Wiring. Suggested entry point for all field wiring to unit. Hole size Ø2.5"
(63.5mm)
22. Loose Wire Ties. To secure field-supplied network cables. Tighten after all field-supplied wires
have been installed.
23. Vacant Liebert IntelliSlot®. May contain optional Liebert IntelliSlot cards.
24. Populated Liebert IntelliSlot. Optional Liebert IntelliSlot cards may be placed in either of the
two supplied Liebert IntelliSlot locations.
25. Remote Temperature / Humidity Sensor Connection. Six-wire CAN cable supplied with
optional remote T/H sensor
20
2.8 Balancing the Air Distribution

2.8.1 Under-Floor Discharge Systems
The systems are designed for constant air delivery, therefore any unusual restrictions within the air
circuit must be avoided. For under-floor air distribution, observe the following guidelines:
• Select the air supply grilles and perforated panels for the raised floor to ensure minimum loss of
pressure in the circuit. Air volume dampers on grilles, which extend several inches below the sur-
face of the raised floor, are usually detrimental to airflow.
• Consideration of the height of the damper on the grille in conjunction with the floor height will
determine whether this type of grille may be used.
• The grilles used in raised floors vary in size, the largest being approximately 18" x 6"
(457 x 152 mm). A larger grille size would be detrimental to the structural capacity of the raised
floor panel. An 18" x 6" (457 x 152 mm) heavy duty, pencil-proof type grille typically has 56 square
inches (0.036 m2) of free area.
• Perforated panels are available from various manufacturers of raised floors. These panels are
usually 2' x 2' (610 x 610 mm) square and have a nominal free area of approximately 108 to 144
square inches (0.07 to 0.09 m2). Use caution in selecting perforated panels as some manufacturers
have only 36 to 40 square inches (0.023 to 0.026 m2) of free area, requiring four times as many
panels.
• Avoid floor elevations below 7-1/2" (190.5 mm), loosely installed flooring systems, and below-floor
obstructions such as: electrical wiring chases, unusually long electronic system cables, or piping
clusters.
• Always check specifications of the floor supplier before specifying the total number of perforated
panels and grilles required to handle the air flow. The proper specifications for grilles and perfo-
rated panels should indicate the total free area required for air delivery rather than the number
of panels and grilles. (See Table 3 for recommended free area required for each model.) This table
indicates the recommended free area based on having the supply air grilles and perforated panels
sized to handle approximately 75% of the total cubic feet per minute (CFM) of the units at a veloc-
ity of 550 to 600 ft./min. (2.8 - 3.1 m/s). The remaining 25% of the air flow in the raised floor
passes through cable cutouts, cracks between the panels, and other leakage areas.
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)
50 Hz Units 60 Hz Units
550 2.8 600 3.1 550 2.8 600 3.1
Model FPM m/s FPM m/s Model FPM m/s FPM m/s
3-ton 2.5 (0.01) 2.3 (0.01) 3-ton 2.5 (0.01) 2.3 (0.01)
5-ton 3.5 (0.02) 3.3 (0.02) 5-ton 3.8 (0.02) 3.5 (0.02)
2.8.2 Ducted Applications
For ducted supply applications on upflow units, the duct work should be attached to the blower
discharge flanges of the unit. For ducted return air applications, the duct work should be attached to
the filter box flanges on upflow rear return units and on the unit top flange for downflow units. Refer
to Figure 2 for information on upflow units and to Figure 3 for downflow units.
The duct work on upflow units must allow access to the motors/blowers for maintenance. The duct
work on upflow units must be designed within the capacity of the unit, otherwise air flow and
performance will be compromised.
2.8.3 Plenum Installation
A solid plenum or plenum with discharge grille(s) may be installed. The plenum and instructions for
its installation ship separately from the unit.
21
2.9 Checklist for Completed Installation

___ 1. Unpack and check received material.
___ 2. Proper clearance for service access has been maintained around the equipment.
___ 3. Equipment is level and mounting fasteners are tight.
___ 4. Piping completed to refrigerant or coolant loop (if required). Piping has been leak checked,
evacuated and charged (if required).
___ 5. Check piping within the unit & outside of the unit. Remove potential of rub-through or
chaffing.
___ 6. Condensate pump installed (if required).
___ 7. Drain line connected.
___ 8. Water supply line connected to humidifier (if required).
___ 9. Field provided pan with drain installed under all ceiling mounted fluid condensing units (if
installed).
___ 10. Filter box installed (if applicable).
___ 11. Ducting completed (if applicable).
___ 12. Filter(s) installed.
___ 13. Line voltage to power wiring matches equipment serial tag.
___ 14. Power wiring connections completed between disconnect switch, evaporator and condensing
unit, including earth ground.
___ 15. Power line circuit breakers or fuses have proper ratings for equipment installed.
___ 16. Control wiring connections completed to evaporator and condensing unit.
___ 17. Verify water detection is properly installed around all units (if installed).
___ 18. All wiring connections are tight.
___ 19. Control panel DIP switches set based on customer requirements.
___ 20. Foreign materials have been removed from, in and around all equipment installed (literature,
shipping materials, construction materials, tools, etc.).
___ 21. Fans and blowers rotate freely.
___ 22. Inspect all piping connections for leaks during initial operations. Correct as needed.
___ 23. Verify that a blank startup sheet has been sent with the unit(s) and is ready to be completed
by the installer.
22
Air-Cooled Models—Self-Contained Compressor
3.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR
3.1 Condenser Location

The air-cooled condenser should be located for maximum security and maintenance accessibility.
Avoid ground level sites with public access or areas that contribute to heavy snow or ice
accumulations. Utilize centrifugal condensers whenever interior building locations must by used. To
assure adequate air supply, it is recommended that condensers be located in a clean air area, away
from loose dirt and foreign matter that may clog the coil. In addition, condensers should not be located
in the vicinity of steam, hot air, or fume exhausts. Also, condensers should be located no closer than
three feet (1 meter) from a wall, obstruction, or adjacent unit.
NOTE
If the condenser is located below the level of the room unit, the factory should be consulted.
Install condensers in a level position to assure proper refrigerant flow and oil return. For roof
installation, mount condensers on steel supports in accordance with local codes. To minimize sound
and vibration transmission, mount steel supports across load bearing walls. For ground installation, a
concrete pad will provide adequate support. Condenser legs have mounting holes for securing the
condenser to the steel supports or concrete pad.
electrical schematic when making connections. Make all wiring and electrical connection in
accordance with local and national codes.
! WARNING
Use voltmeter to make sure power is turned off before making any electrical connections.
3.2.1 Line Voltage
Line voltage electrical service is required for all air-cooled condensers at the location of the condenser.
This power supply does not have to be the same voltage as the indoor unit. This separate power source
may be 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. The disconnect switch may be
factory-supplied and mounted in the electrical panel or field-supplied and mounted per local and
national codes.
3.2.2 Low Voltage
A control interlock between the condenser and the indoor unit is required and is connected between
70 and 71 in the handy box of the indoor unit and the electric panel of the air-cooled condenser. NEC
Class 1 wiring is required.
3.2.3 Liebert Lee-Temp/Flood Back Head Pressure Control Condensers
Liebert Lee-Temp condensers require a separate power supply for the heated receivers. This power
supply is connected to the electrical connection box on the end of the receiver.
23
Figure 14 Air-cooled condensers

LIEBERT LEE-TEMP CONDENSER
FAN SPEED AND VFD CONDENSER Liebert Lee-Temp heater
pad connection box *B
Hot gas
line
Electric service
supplied by Electric
others service
*B supplied by
Liquid line others
Hot gas line
*B - Inverted traps are to be field-supplied and installed
Liquid line (typ). When installing traps, provide clearance for swing
end of access door. Traps are to extend above base of
Secure each leg to condenser frame at all coil by a minimum of 7-1/2" (190 mm)
points shown using hardware provided.
SINGLE FAN AIR-COOLED CONDENSERS
51-7/16" 43-9/16"
(1306.5mm) (1106mm)
18" (457.2mm)
37-7/8"
(962mm)
CONDENSER MOUNTING 1" typ.

(25.4mm)
43-3/16" 1-3/4"
44" (44.5mm)
(1097mm) (1118mm)
9/16" (14.3mm)
diameter holes 1" typ.
8 places for (25.4mm)
37-11/16" 1/2" (12.7mm)
(957.3mm) diameter bolts
1" 1-3/4" 4-1/4"
(25.4mm) (44.5mm) (108mm)
1-3/4"
(44.5mm) 1-3/4" 1-3/4"
(44.5mm) (44.5mm)
4-1/4" 1" A
(108mm) (25.4mm)
Common to all models. See Table 4
below for key to “A” dimension.
TYPICAL FOOTPRINT
Table 4 Air-cooled condenser statistics

Connection Sizes
(OD Copper)
Number Net Weight “A” Dimension
Model of Fans Hot Gas (in.) Liquid (in.) lb (kg) in (mm)
083 1 7/8 5/8 295 (133.8) 42 (1067)
104 1 1-1/8 5/8 315 (142.8) 42 (1067)
165 2 1-1/8 7/8 425 (193) 82 (2083)
24
3.3 Refrigerant Piping

All refrigeration piping should be installed with high temperature brazed joints. Prevailing good
refrigeration practices should be employed for piping supports, leak testing, dehydration and
charging of the refrigeration circuits.
Unit refrigeration components and piping are shipped from the factory with a nitrogen holding
charge.
NOTICE
Risk of improper installation. Can cause equipment and property damage.
The refrigeration piping should be isolated from the building by the use of vibration isolating
supports.
When installing field piping, care must be taken to protect all refrigerant lines from the
atmosphere, especially when using refrigerants with POE oils. Do not allow the piping to
stand open to air for more than 15 minutes. Units designed for R407C have a compressor that
contains POE oil that is very hygroscopic; that is, it quickly absorbs water from the air. The
longer the compressor piping is left open to air, the harder it will be to fully evacuate. If left
open too long, the POE oil may need to be replaced before achieving the required vacuum
level.
Keep the evaporator unit and condenser closed with their factory charge of dry nitrogen while
all field piping is installed. Keep the field piping clean and dry during installation, and do not
allow it to stand open to the atmosphere. When all the field interconnecting piping is in place,
vent the condenser dry nitrogen charge and connect to the field piping. Finally, vent the
evaporator unit dry nitrogen charge and make its piping connections last.
Follow all proper brazing practices including a dry nitrogen purge to maintain system
cleanliness.
NOTE
Piping, including inverted trap(s), must be routed to allow unobstructed access to the panel
per the NEC.
Traps should be installed in the hot gas line on vertical risers at the base and every 25 feet (7.6
meters) in elevation. These traps will collect condensed refrigerant and refrigerant oil during the off
cycle of the unit and ensure flow of refrigerant oil during operation.
A check valve is factory-supplied with the unit to be field-installed on the discharge side of the scroll
compressor. Be sure to install the check valve with the refrigerant flow in the proper direction. When
soldering or brazing the valve, it is very important to protect the internal parts by wrapping the valve
with a damp cloth to keep the valve temperature below 250°F (121°C).
Approval is required whenever:
• a refrigerant piping run exceeds 150 ft. (46 m) equivalent length
• an R407C system condenser must be located below the level of the cooling coil.
Total discharge line pressure drop must not exceed 10 PSIG (69 kPa).
Consult your local Liebert representative when considering installations outside these guidelines.
Table 5 Recommended line sizes — OD copper (inches)*

3.5-ton 042A (040A) 5-ton 067A (065A)
Equivalent Length Hot Gas Line Liquid Line Hot Gas Line Liquid Line
50 ft. (15 m) 5/8 1/2 7/8 1/2
100 ft. (30 m) 3/4 1/2 7/8 5/8
150 ft. (45 m) 3/4 5/8 7/8 5/8
*Recommended vertical line sizes must be used for proper oil return at all cooling and dehumidification steps.
25
Table 6 Equivalent lengths (feet) for various pipe fittings

Copper Pipe 90 Degree 90 Degree 45 Degree Gate Globe Angle
O.D. in. Elbow Copper Elbow Cast Elbow Tee Valve Valve Valve
1/2 0.8 1.3 0.4 2.5 0.26 7.0 4.0
5/8 0.9 1.4 0.5 2.5 0.28 9.5 5.0
3/4 1.0 1.5 0.6 2.5 0.3 12.0 6.5
7/8 1.45 1.8 0.8 3.6 0.36 17.2 9.5
1-1/8 1.85 2.2 1.0 4.6 0.48 22.5 12.0
1-3/8 2.4 2.9 1.3 6.4 0.65 32.0 16.0
1-5/8 2.9 3.5 1.6 7.2 0.72 36.0 19.5
Refrigerant trap = 4 times equivalent length of pipe per this table.
Table 7 Indoor unit refrigerant charge lb (kg)

R407C
Approximate Charge
Model lb (kg)
42A/40A 0.9 (0.4)
67A/65A 1.4 (0.6)
Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube
R407C
Liquid Line Hot Gas Line
O.D. lb (kg) lb (kg)
1/2" 7.3 (3.3) 1.3 (0.6)
5/8" 11.7 (5.3) 2.1 (1.0)
3/4" 16.6 (7.5) 3.0 (1.4)
7/8" 24.4 (11.1) 4.4 (2.0)
Table 9 Condenser refrigerant (per serial tag)

R407C
Approximate Charge
lb (kg)
Liebert
Model Fan Speed Lee-Temp*
083 5 (2.3) 26 (11.8)
104 8 (3.6) 37 (16.8)
165 15 (6.8) 50 (22.7)
* Charge includes the receiver charge.
3.4 Fan Speed Control Systems

The Variable Fan Speed Control systems (FSC & VFD) uses pressure-activated electronic fan speed
control systems and remotely located thermostat(s) to ensure operation at ambient temperatures as
low as 0°F (-18°C). For this ambient temperature range, the VFD Control Condenser must be used
with digital scroll indoor units and can be used for energy savings with any Liebert Challenger 3000
unit.
Variable Fan Speed Control Piping

A discharge line and a liquid line must be field-installed between the indoor unit and the outdoor
condenser. See Figures 15 and 16 for details.
26
Variable Fan Speed Control Materials Supplied

• Built-in, pre-wired condenser control box
• Air-Cooled condenser
• Piping access cover to be reinstalled when piping is complete
• Bolts—four per leg (3/8" x 5/8")
• Terminal block for two-wire, 24V interlock connection between unit and condenser
• Condenser legs—four with 1-fan, 2-fan and 3-fan models; six with 4-fan models
Variable Fan Speed Control Leak Check and Evacuation Procedure

Proper leak check and evacuation can be accomplished only with all system solenoid valves open and
check valves accounted for.
NOTE
Systems with a scroll or digital scroll compressor include a factory-installed check valve and
an additional downstream Schrader valve with core in the compressor discharge line. Proper
evacuation of the condenser side of the compressor can be accomplished only using the
downstream Schrader valve. See piping schematic (Figures 15 and 16).
1. If unit power is available, open the unit liquid line solenoid valves using the evacuation function
in the diagnostic section of the Liebert iCOM control (refer to the Liebert iCOM user manual,
SL-18835). If unit power is not available, a field-supplied 24VAC / 75VA power source must be
directly connected to each of the unit solenoid valves.
2. For scroll and digital scroll compressors, connect refrigerant gauges to the suction rotalock valves
and discharge line Schrader valves (see Note above) on the compressor.
3. Open the service valves and place a 150 PSIG (1034 kPa) of dry nitrogen with a tracer of
refrigerant. Check system for leaks with a suitable leak detector.
4. After completion of leak testing, release the test pressure (per local code) and pull an initial deep
vacuum on the system with a suitable pump.
5. After four hours, check the pressure readings and, if they have not changed, break vacuum with
dry nitrogen. Pull a second and third vacuum to 250 microns or less. Recheck the pressure after
two hours. After completing this step, proceed to Variable Fan Speed Charging on page 28.
27
Variable Fan Speed Charging

1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending
on refrigerant type.
2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist for Completed
Installation.
3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line
charge data in Tables 6, 7, 8 and 9.
4. Weigh in as much of the system charge as possible before starting the unit.
! CAUTION
Risk of improper refrigerant charging. Can cause equipment damage.
Refrigerant R407C is a blend of three components and must be introduced and charged from
the cylinder only as a liquid.
When adding liquid refrigerant to an operating system, it may be necessary to add the
refrigerant through the compressor suction service valve. Care must be exercised to avoid
damage to the compressor. Emerson recommends connecting a sight glass between the
charging hose and the compressor suction service valve. This will permit adjustment of the
cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the
compressor.
5. Turn on unit disconnect switch. Operate the unit for 30 minutes using the charging function for
the system in the diagnostic section of the Liebert iCOM control (see Liebert iCOM user manual,
SL-18835). The charging function operates the compressor at full capacity and energizes the
blower motor and the liquid line solenoid valve. The reheat and humidifier are disabled. A
minimum 20psig (138kPa) must be established and maintained for the compressor to operate.
The charging function can be reset as many times as required to complete unit charging.
Table 10 Fan speed suction pressure transducer settings
R-407C
Gauge (Sea Level) Absolute
Function psiG (kPa) psiA (kPa)
Pump-Down Cutout 20 (138) 35 (241)
Pump-Down Reset 65 (448) 80 (552)
Minimum to Start-Cooling 35 (241) 50 (344)
Low-Pressure Cutout (DX only) 52 (358) 67 (461)
6. Charge the unit until the liquid line sight glass becomes clear. Then add one additional pound
(2.2kg) of refrigerant.
NOTE
A digital scroll compressor will have a clear sight glass only when operating at 100% capacity.
When operating below 100%, the sight glass may show bubbles with each 15-second unloading
cycle.
7. As head pressure builds, the variable fan speed controlled condenser fan begins rotating. The fan
will run at full speed when sufficient head pressure is developed—fan starts to rotate at 190 psig
(1310 kPA) and is full speed at 250 psig (1724 kPA).
28
Figure 15 General arrangement—Air-cooled models with fan speed control

Condenser
Coil
Schrader
* Inverted trap on Valve
discharge and liquid lines
to extend above base of Schrader
coil by a minimum Valve
of 7-1/2" (190mm)
Optional Field-Installed
Fusible Plug
* For rises over

25ft. (7.6m), trap Evaporator
every 20ft. (6m) or Coil
at evenly spaced
points
Hot Gas
Bypass
Valve Expansion
Valve
Liquid Return
Solenoid Sensing
Valves Bulb
Shutoff* Sight
Valve Glass
Filter
External
Drier
Service Equalizers
Hot Gas Valves
Bypass
Scroll
Compressor
Check
Valve SINGLE CIRCUIT SHOWN
Hot Gas
Discharge FACTORY PIPING
FIELD PIPING
* Components are not supplied by Liebert but
are recommended for proper circuit operation
and maintenance.
* Trap at base
of risers longer
than 5ft. (1.5m)
DPN000349
Rev. 5
29
Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control
Condenser
Coil
Schrader
* Inverted trap on Valve
discharge and liquid lines
to extend above base of Schrader
coil by a minimum Valve
of 7-1/2" (190mm)
Optional Field-Installed
Fusible Plug
* For rises over

25ft. (7.6m), trap Evaporator
every 20ft. (6m) or Coil
at evenly spaced
points
Expansion
Valve
Liquid Return
Solenoid
Valve
Sensing
Shutoff* Sight Bulb
Valve Glass
Filter
Drier External
Equalizers
Service
Valves Digital
Solenoid Valve
Digital
Compressor
Check
Valve SINGLE CIRCUIT SHOWN
Hot Gas FACTORY PIPING

Discharge FIELD PIPING
* Trap at base
and maintenance.
of risers longer DPN001726
than 5ft. (1.5m)
Rev. 2
30
3.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head

Pressure Control System
The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated
receivers with heater pads to ensure operation at ambient temperatures as low as -30°F (-34.4°C).
The Liebert Lee-Temp system can be used with any compressor choice.
Liebert Lee-Temp Piping

A discharge line and a liquid line must be field-installed between the indoor unit and the outdoor
condenser. See Figures 17 and 18 for details.
Liebert Lee-Temp Controlled Materials Supplied

• Built-in, pre-wired condenser control box
• Air-Cooled condenser
• Piping access cover to be reinstalled when piping is complete (models with one to four fans only)
• Bolts—four per leg (3/8" x 5/8")
• Terminal block for two-wire, 24V interlock connection between unit and condenser
• Condenser legs—four with 1-fan, six on two-, three- and six-fan models and eight on four- and
eight-fan models
• Bolts—six per receiver (3/8" x 1")
• Liebert Lee-Temp system:
• Insulated storage receiver
• Head pressure control valve with integral check valve
• Service valve
• Pressure relief valve
• Liquid level sight glass
• Check valve
NOTE
Liebert Lee-Temp heater pads require a separate, continuous electrical source. See nameplate
on unit for proper voltage.
Liebert Lee-Temp Leak Check and Evacuation Procedure
Proper leak check and evacuation can be accomplished only with all system solenoid valves open and
check valves accounted for.
NOTE
Systems with scroll or digital scroll compressors include a factory-installed check valve and an
additional downstream Schrader valve with core in the compressor discharge line. Proper
evacuation of the condenser side of the compressor can be accomplished only using the
downstream Schrader valve. See piping schematic (Figure 18).
1. If unit power is available, open the unit liquid line solenoid valves using the evacuation function
in the diagnostic section of the Liebert iCOM control. If unit power is not available, a field-
supplied 24VAC / 75VA power source must be directly connected to each of the unit solenoid
valves.
2. Attach a jumper hose from the service valve fitting on the outlet of the receiver and the Schrader
fitting on the discharge header of the condenser. Front-seat the service valve approximately
two (2) turns.
3. For scroll and digital scroll compressors, connect refrigerant gauges to the suction rotalock valves
and discharge line Schrader valves (see Note above).
4. Open the service valves and place a 150 PSIG (1034 kPa) of dry nitrogen with a tracer of
refrigerant. Check system for leaks with a suitable leak detector.
5. After completion of leak testing, release the test pressure (per local code) and pull an initial deep
vacuum on the system with a suitable pump.
31
6. After four hours, check the pressure readings and, if they have not changed, break vacuum with
dry nitrogen. Pull a second and third vacuum to 250 microns or less. Recheck the pressure after
two hours.
7. Remove the jumper hose installed previously from between the service valve fitting and the
condenser. After completing this step, proceed to Liebert Lee-Temp Charging.
Liebert Lee-Temp Charging
1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending
on refrigerant type.
2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist for Completed
Installation.
3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line
charge data in Tables 6, 7, 8 and 9.
4. Weigh in as much of the system charge as possible before starting the unit.
! CAUTION
Risk of improper refrigerant charging. Can cause equipment damage.
Refrigerant R407C is a blend of three components and must be introduced and charged from
the cylinder only as a liquid.
When adding liquid refrigerant to an operating system, it may be necessary to add the
refrigerant through the compressor suction service valve. Care must be exercised to avoid
damage to the compressor. Emerson recommends connecting a sight glass between the
charging hose and the compressor suction service valve. This will permit adjustment of the
cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the
compressor.
5. Turn on unit disconnect switch. Operate the unit for 30 minutes using the charging function for
the system in the diagnostic section of the Liebert iCOM control. The charging function operates
the compressor at full capacity and energizes the blower motor and liquid line solenoid valve. The
reheat and humidifier are disabled. A minimum 20psig (138kPa) must established and
maintained for the compressor to operate. The charging function can be reset as many times as
required to complete unit charging.
Table 11 Liebert Lee-Temp suction pressure transducer settings
R-407C
Gauge Reading
(Sea Level) Absolute
Function psiG (kPa) psiA (kPa)
Pump-Down Cutout 20 (138) 35 (241)
Pump-Down Reset 65 (448) 80 (552)
Minimum to Start-Cooling 50 (345) 65 (448)
Low-Pressure Cutout (DX only) 52 (358) 67 (461)
6. Charge the unit until the liquid line sight glass becomes clear. Then add one additional pound
(2.2 kg) of refrigerant.
NOTE
A digital scroll compressor will have a clear sight glass only when operating at 100% capacity.
When operating below 100%, the sight glass may show bubbles with each 15-second unloading
cycle.
Liebert Lee-Temp Receiver Refrigerant Level
On each receiver at the condenser are two refrigerant-level sight glasses. Refrigerant level will vary
with outside temperature. Check refrigerant level after the unit has been on for at least 15 minutes.
Sight Glass Levels
40°F (4.5°C) and lower—bottom sight glass is 3/4 full
40 to 60°F (4.5 to 15.5°C)—bottom sight glass is full
60°F (15.5°C) and higher—top sight glass is 3/4 full.
32
Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp
Condenser Coil
Inverted trap * on
discharge and liquid
lines to extend above base **Piping Assembly
of coil by a minimum Check
of 7-1/2" (190mm) Valve **Rotalock Valve
Head Pressure
Control with 1/4" ( 6.4mm)
Integral Check Pressure Relief
Valve Liebert Valve * *
Lee-Temp
Receiver
Sight Glass
* For rises over
25ft. (7.6m), trap
every 20ft. (6m) or
Liquid Return
at evenly spaced Evaporator
from
points (hot gas Expansion Coil
Condenser
line only) Valve
Hot Gas
Bypass
Valve
Solenoid
Valves
Sensing Bulb
Shutoff
Valve * Sight Glass
r
D rie
Liquid Return
ter
Fil External
Service Equalizers
Valves
Hot Gas Scroll

Bypass Compressor
* Components are not supplied by Liebert

Check
but are recommended for proper
Valve
circuit operation and maintenance.
** Components supplied by Liebert
Hot Gas Discharge
and must be field-installed.
* Trap at base FACTORY PIPING
of risers longer OPTIONAL PIPING DPN000674
than 5ft. (1.5m)
FIELD PIPING Rev. 3
33
Figure 18 General arrangement—Air-cooled models with digital scroll and Liebert Lee-Temp
Condenser Coil
Inverted trap * on
discharge and liquid
lines to extend above base Piping Assembly **
of coil by a minimum
Check Valve
of 7-1/2" (190mm) Rotalock Valve **
Head Pressure 1/4" ( 6.4mm)

Control with Pressure Relief
Integral Check
Liebert Valve * *
Valve
Lee-Temp
Receiver
Sight Glass
* For rises over
25ft. (7.6m), trap
every 20ft. (6m) or
at evenly spaced Liquid Return Evaporator Coil
points (hot gas from Condenser Expansion Valve
line only)
Solenoid Valve
Sensing Bulb
Shutoff Sight Glass

Valve *
External Equalizer
Liquid Return
Filter
Drier Service Digital
Valves Solenoid Valve
Digital
Compressor
* Components are not supplied by Liebert

Check
but are recommended for proper
Valve
circuit operation and maintenance.
** Components supplied by Liebert
Hot Gas Discharge and must be field-installed.
* Trap at base FACTORY PIPING

of risers longer OPTIONAL PIPING DPN001725
than 5ft. (1.5m) FIELD PIPING Rev. 1
34
Water-Cooled Models—Self-Contained Compressor
4.0 WATER-COOLED MODELS—SELF-CONTAINED COMPRESSOR

Manual shutoff valves should be installed at the supply and return lines of each unit. This will
provide for routine maintenance or emergency isolation of the unit.
When the water source for the condenser is of poor quality, it is good practice to provide cleanable
filters in the supply line. These filters will trap the particles in the water supply and extend the
service life of the water-cooled condenser.
To provide for the emergency of water leaks and the consequences of sub-floor flooding, floor drains
should be provided with wet traps or a water detection system such as a Liebert Liqui-tect™ sensor
that is installed near the base of the unit or below the elevated floor.
4.2 Condenser
The condenser is designed to operate in conjunction with either a cooling tower or city water. The
maximum water pressure is 150 psig (1034 kPa). A high pressure system rated at 350 psig (2413 kPa)
is available as an option.
35
Figure 19 General arrangement—Water-cooled models with scroll compressor
Evaporator
Coil
Expansion
Valve
Sensing
Bulb
Sight
Glass
Hot Gas External
Bypass Equalizers
Filter Valve
Dryer
Hot Gas Service

Bypass Valves
Solenoid
Scroll
Valve
Compressor
Hot Gas
Bypass
Tube
in Tube
Condenser
Bypass Tube
Valve in Tube
Fluid
Condenser
Supply
Fluid To
Return Unit
From
Unit
2-Way Water
Shutoff* Regulating
Valves Valve
3-Way Water
Regulating Valve
(optional)
Fluid
Supply
Hose Bibs* Field-Supplied To * Components are not supplied
Reducers Unit Fluid by Liebert but are recommended
Required Return for proper circuit operation
on 3-Ton Units From and maintenance.
Unit
FACTORY PIPING DPN000359
FIELD PIPING REV 02
36
Figure 20 General arrangement diagram—Water-cooled models with digital scroll

Evaporator
Coil
Expansion
Valve
Sensing
Sight Bulb
Glass External
Equalizer
Digital
Filter Service Solenoid
Dryer Valves Valve
Digital
Compressor
Tube
in Tube
Condenser
Tube
Fluid in Tube
Supply Condenser
Fluid
To
Return
Unit
From
Unit
Shutoff* To Liebert
Valves iCOM Control
2-Way
Motorized
Ball Valve
To Liebert
iCOM Control
3-Way
Fluid Motorized
Hose Bibs* Supply Ball Valve
Field-Supplied To Unit (optional)
Reducers
Required Fluid *Components are not supplied
on 3- Ton Units Return by Liebert but are recommended
From Unit for proper circuit operation
FACTORY PIPING and maintenance.
DPN001727
FIELD PIPING Rev. 0
37
4.3 Water Regulating Valve

The water regulating valve automatically regulates the amount of fluid necessary to remove the heat
from the refrigeration system, permitting more fluid to flow when load conditions are high and less
fluid to flow when load conditions are low. The valve consists of a brass body, balance spring, valve
seat, valve disc holders, capillary tube to discharge pressure, and adjusting screw.
4.3.1 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve)
High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson Controls Valve)
Adjustment
The valve may be adjusted with a standard refrigeration service valve wrench or screw driver.
To lower the head pressure setting, turn the square adjusting screw clockwise until the high pressure
gauge indicates the desired setting.
To raise the head pressure setting, turn the adjusting screw counterclockwise until the desired
setting is obtained.
Figure 21 Johnson Controls valve adjustment
Range
spring
Valve spring
guide
Range adjustment screw
Top
retainer
Insert screwdrivers underneath
the valve spring guide
4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)
Adjustment
The valve may be adjusted using a 1/8" diameter rod. Turn the adjusting collar nut counterclockwise
to raise head pressure; turn it clockwise to lower head pressure. Rotation directions are viewed from
top of valve spring housing.
38
Figure 22 Metrex Valve adjustment
Adjusting collar nut
Table 12 Refrigerant control settings psi (kPa)

Low Pressure Low Pressure High Pressure
Cut Out Cut In Cut Out
20 (137.9) 65 (448.2) 400 (2758)
Manual Flushing
The valve may be flushed by rotating the socket head screw clockwise. This screw must be in the OUT
position (counterclockwise) for normal valve operation.
4.4 Motorized Ball Valve—Digital Scroll Compressors

On digital scroll units, discharge pressure is controlled by a motorized ball valve. During unloaded
operation, the pressure changes during each digital cycle could cause excessive repositions with a
pressure-operated water regulating valve. The control algorithm for the motorized ball valve uses an
intelligent sampling rate and adjustable pressure thresholds to reduce valve repositions. The valve
assembly consists of the brass valve, linkage and actuator.
4.4.1 Control
The valve actuator operates on 24VAC power and is controlled by a 2-10VDC proportional control
signal. The valve will move from fully open to fully closed in 60 seconds. At 2VDC, the valve is closed;
at 10VDC, the valve is fully open. There is a 20-second delay to position the motorized ball valve
before starting the compressor.
Control Method
The control utilizes an upper and lower pressure threshold with a 35psi (241kPa) deadband to reduce
valve movement. If the liquid pressure is between the upper and lower threshold, the valve remains
at the current position. If the liquid pressure exceeds the upper threshold the valve opens, and if the
pressure falls below the lower threshold the valve closes. There are multiple adjustment bands to ease
discharge pressure back into control range.
39
4.4.2 Adjustment
Both pressure thresholds can be shifted simultaneously over a 50psi (345kPa) range (the 35psi
[241kPa] differential remains constant). The ball valve setpoint offset parameter in the Liebert iCOM
Service menu can be adjusted from 0 to 50 PSI (345 kPa) to raise or lower the control band similar to
the pressure adjustment on a water regulating valve. Changing the setpoint offset will adjust the
pressure thresholds for both circuits. Units are factory-set at a 30psi (207 kPa) setpoint offset (30psi
[207 kPa] above minimum). This results in a 220psiA (1517kPa) lower threshold and a 255psiA
(1758kPa) upper threshold pressure.
4.4.3 Startup
The setpoint offset is adjusted to the minimum value during startup, then changes to the set value
once the compressor reaches normal operating pressures. Changes in fluid temperature could cause
pressure changes that do not result in valve movement within the deadband. Fan cycling stats should
be set to prevent continuous fluid temperature swings greater than 10°F (5.6°C).
4.4.4 Location
The motorized ball valve is located in the condenser fluid return line. Three-way valves are piped in a
mixing arrangement with the common port at the valve outlet.
4.4.5 Manual Control

The valve can be manually set by disconnecting AC power, depressing the manual override button on
the valve actuator and adjusting the valve position with the handle. The motorized ball also can be
controlled through the Liebert iCOM’s Service menu using manual mode to override the normal
control.
40
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor
5.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR
5.1 Drycooler Location

The drycooler should be located for maximum security and maintenance accessibility. Avoid ground-
level sites with public access or areas which contribute to heavy snow or ice accumulations. To assure
adequate air supply, it is recommended that drycoolers be located in a clean air area, away from loose
dirt and foreign matter that may clog the coil. In addition, drycoolers should not be located in the
vicinity of steam, hot air or fume exhausts. Also, drycoolers should not be located closer than 3 feet
(1 meter) from a wall, obstruction or adjacent unit.
5.2 Drycooler Installation

For roof installation, mount drycoolers on steel supports in accordance with local codes. To minimize
sound and vibration transmission, mount steel supports across load bearing walls. For ground
installation, a concrete pad will provide adequate support. Drycooler legs have mounting holes for
securing the drycooler to steel supports or concrete pad.

electrical schematic when making connections. Make all wiring and electrical connections in
! WARNING
5.3.1 Line Voltage

Line voltage electrical service is required for all drycoolers at the location of the drycooler. This power
supply does not have to be the same voltage as the indoor unit. This separate power source may be
208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. The disconnect switch is factory-
supplied and mounted in the electric panel.
5.3.2 Low Voltage

A control interlock between the drycooler and the indoor unit is required and is connected between 70
and 71 in the handy box of the indoor unit and the pump and drycooler control box of the drycooler.
NEC Class 1 wiring is required.
5.3.3 Pump and Drycooler

All wiring to the pump and drycooler from the control box should be done in accordance with the
electrical schematic on the inside lid of the drycooler control box and with local and national codes.
41
5.4 Glycol Piping

These guidelines apply to the field leak checking and fluid requirements for field piping systems.
General Guidelines
• Equipment damage and personal injury can result from improper piping installation, leak check-
ing, fluid chemistry and fluid maintenance.
• Follow local piping codes, safety codes.
• Qualified personnel must install and inspect system piping.
• Contact a local water consultant regarding water quality, corrosion protection and freeze protec-
tion requirements.
• Install manual shutoff valves at the supply and return line to each indoor unit and drycooler to
permit routine service and emergency isolation of the unit.
! CAUTION
Risk of frozen fluids. Can cause equipment damage and building damage.
Freezing system fluids can rupture piping. Complete system drain-down cannot be ensured.
When the field piping or unit may be exposed to freezing temperatures, charge the system
with the proper percentage of glycol and water for the coldest design ambient.
Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system.
! CAUTION
Risk of corrosion. Can cause equipment damage.
Read and follow individual unit installation instructions for precautions regarding fluid
system design, material selection and use of field-provided devices. Liebert systems contain
iron and copper alloys that require appropriate corrosion protection.
Contact a local water consultant regarding water quality, corrosion and freeze protection
requirements.
Water chemistry varies greatly by location, as do the required additives, called inhibitors,
that reduce the corrosive effect of the fluids on the piping systems and components. The
chemistry of the water used must be considered, because water from some sources may
contain corrosive elements that reduce the effectiveness of the inhibited formulation.
Preferably, surface waters that are classified as soft and are low in chloride and sulfate ion
content should be employed. Proper inhibitor maintenance must be performed in order to
prevent corrosion of the system. Consult glycol manufacturer for testing and maintenance of
inhibitors.
Commercial ethylene glycol (Union Carbide Ucartherm, Dow Chemical Dowtherm SR-1 and
Texaco E.G. Heat Transfer Fluid 100), when pure, is generally less corrosive to the common
metals of construction than water itself. It will, however, assume the corrosivity of the water from
which it is prepared and may become increasingly corrosive with use if not properly inhibited.
! CAUTION
Risk of oxide layer formation. Can cause equipment damage.
Idle fluid allows the collection of sediment that prevents the formation of a protective oxide
layer on the inside of tubes. Keep unit switched ON and system pump operating.
42
NOTICE
Risk of debris or precipitate clogging pipes. Can cause equipment damage.
Galvanized pipe must not be used in or with systems or units that contain glycol. The
phosphates in the inhibitor can react with the zinc in the galvanized pipe, precipitating an
insoluble material that can eventually foul the system.
Fluid-cooled condensers have small internal flow passages. To avoid clogging and other
resulting system operation problems, install a 16-20 mesh filter in the fluid supply line to the
indoor unit. The filter should be located where it can be easily serviced or replaced.
Do not install unit on open loop systems. Debris carried by the fluid will clog the brazed plate
condenser.
NOTICE
Risk of improper installation. Can cause equipment or structural damage.
Supply and return lines must be supported in a way that keeps their weight from bearing on
the piping of the unit, drycooler or pumps. Failure to support piping can strain the
equipment’s structural integrity.
A relief valve must be installed in the system to avoid the possibility of burst pipes. This valve
may be obtained from the supplier as an option or obtained from another vendor.
Emerson recommends installing manual service shut-off valves at the supply and return connections
to each unit. This enables routine service and/or emergency isolation of the unit. In addition, multiple
pump packages require a check valve at the discharge of each pump to prevent back flow through the
standby pump(s).
To facilitate filling, installation of hose bibs at the lowest point of the system is recommended.
Consideration of the minimum glycol temperature to be supplied from the drycooler will determine if
the need exists to insulate the glycol supply and return lines. Insulation will prevent condensation on
the glycol lines in low ambient conditions.
All fluid piping must comply with local codes. Care in sizing pipes will help reduce pumping power
and operating costs.
Table 13 Room dew point temperatures
Dry Bulb Wet Bulb Relative Dew Point*
°F (°C) °F (°C) Humidity °F (°C)
70 (21.1) 57.2 (14.0) 45 48.0 (8.9)
70 (21.1) 58.5 (14.7) 50 50.5 (10.3)
72 (22.2) 58.9 (24.9) 45 50.0 (10.0)
72 (22.2) 60.0 (15.5) 50 52.4 (11.3)
75 (23.8) 61.2 (16.2) 45 52.4 (11.3)
75 (23.8) 62.5 (16.9) 50 55.0 (12.7)
* Minimum glycol temperature before condensation will occur.
43
5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices

An expansion tank must be provided for expansion and contraction of the fluid due to temperature
change in this closed system. Vents are required at system high points to vent trapped air when
filling the system. A relief valve is a also a necessary piping component.
Depending on the complexity of the system, various other devices may be specified. Pressure gauges,
flow switches, automatic air separator, tempering valves, standby pumps, sensors for electrical
controls, and flow switches are just a few of these devices.
NOTICE
Risk of freezing temperatures. Can cause equipment and piping damage.
Immediately following the use of water for leak testing or system cleaning, charge the tested
system with the proper percentage of glycol and water for your coldest design ambient.
Complete system drain-down cannot be assured and damage to the system could result from
freezing of residual water.
5.5 Filling Instructions
5.5.1 Preparing the System for Filling
It is important to remove any dirt, oil or metal filings that may contaminate the cooling system piping
in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping. The
system should be flushed thoroughly using a mild cleaning solution or high-quality water and then
completely drained before charging with glycol. Cleaning new systems is just as important as
cleaning old ones. New systems can be coated with oil or a protective film; dirt and scale are also
common. Any residual contaminants could adversely affect the heat transfer stability and
performance of your system. In many cases, in both old and new systems, special cleaners are needed
to remove scale, rust and hydrocarbon foulants from pipes, manifolds and passages. Clean heat
transfer surfaces are important in maintaining the integrity of the heating/cooling system. For more
information on cleaners and degreasers, contact your sales representative. Follow the manufacturer's
instructions when using these products.
Calculate the internal volume of the system as closely as possible. See Table 14 and Table 16 for
unit volumes. Use volume in Table 15 for glycol piping volumes.
Table 14 Indoor unit glycol volume approximate gallons (liters) max.
Model (50 Hz) Glycol-Cooled GLYCOOL
046WG/(045WG) 1.2 (4.5) —
071WG/(070WG) 2.0 (7.5) —
061G/(058G) — 4.0 (15.1)
Table 15 Volume in standard Type “L” copper piping

Diameter (in.) Volume
Outside Inside Gal/Ft L/M
1/2 0.123 0.008 0.01
5/8 0.555 0.012 0.15
3/4 0.666 0.018 0.22
7/8 0.785 0.025 0.31
1-1/8 1.025 0.043 0.53
44
5.5.2 Glycol Solutions

NOTE
Glycol solutions should be considered for protection of the coil. When it is not used, damage can
occur from either freezing or corrosion from water.
When considering the use of any glycol products in a particular application, you should review the
latest Material Safety Data Sheets and ensure that the use you intend can be accomplished safely.
For Material Safety Data Sheets and other product safety information, contact the supplier nearest
you. Before handling any other products mentioned in the text, you should obtain available product
safety information and take necessary steps to ensure safety of use.
NOTICE
Risk of improper handling of glycol. Can cause environmental damage and violate national,
regional and local laws.
When mishandled, glycol products pose a threat to the environment. Before using any glycol
products, review the latest Material Safety Data Sheets and ensure that you can use the
product safely.
Glycol manufacturers request that the customer read, understand and comply with the
information on the product packaging and in the current Material Safety Data Sheets. Make
this information available to anyone responsible for operation, maintenance and repair of the
drycooler and related equipment.
No chemical should be used as or in a food, drug, medical device, or cosmetic, or in a product or
process in which it may contact a food, drug, medical device, or cosmetic until the user has
determined the suitability and legality of the use. Since government regulations and use conditions
are subject to change, it is the user's responsibility to determine that this information is appropriate
and suitable under current, applicable laws and regulations.
NOTICE
Risk of using improper cooling agent. Can cause reduced cooling performance and damage to
equipment and piping.
Proper formulations of inhibited formula ethylene glycol and propylene glycol must be used in
the Challenger 3000 system. Automotive antifreeze is unacceptable and must NOT be used.
Typical inhibited formula ethylene glycol and propylene glycol manufacturers and suppliers are
Union Carbide (Ucartherm) or Dow Chemical (Dowtherm SR-1, Dowfrost). These glycols are supplied
with corrosion inhibitors and do not contain a silicone anti-leak formula. Commercial ethylene glycol,
when pure, is generally less corrosive to the common metals of construction than water itself.
Aqueous solutions of these glycols, however, assume the corrosivity of the water from which they are
prepared and may become increasingly corrosive with use if not properly inhibited.
There are two basic types of additives: corrosion inhibitors and environmental stabilizers. The
corrosion inhibitors function by forming a surface barrier that protects the metals from attack.
Environmental stabilizers, while not corrosion inhibitors in the strictest sense of the word, decrease
corrosion by stabilizing or favorably altering the overall environment. An alkaline buffer such as
borax is a simple example of an environmental stabilizer since its prime purpose is to maintain an
alkaline condition (pH above 7).
The percentage of glycol to water must be determined by using the lowest design outdoor temperature
in which the system is operating. Table 16 indicates the solution freeze point at several
concentration levels of ethylene glycol. Propylene glycol concentrations should be 1% higher than the
ethylene glycol table values to find the freeze point. For example, 41% propylene glycol freezes at
-10°F.
45
Table 16 Ethylene glycol concentrations

% Glycol by Volume 0* 10 20 30 40 50
Freezing Point °F (°C) 32 (0) 25 (-3.9) 16 (-8.9) 5 (-15.0) -10 (-23.3) -32 (-35.5)
Apparent Specific Gravity
1 1.014 1.028 1.042 1.057 1.071
@ 50°F (10°C)
* A minimal amount of glycol should be considered for inhibitive coil protection.
NOTICE
Risk of corrosion from water impurities. Can cause equipment damage.
The quality of water used for dilution must be considered because water may contain
corrosive elements which reduce the effectiveness of the inhibited formulation. Water that is
classified as soft (low in chloride and sulfate ion content less than 100 parts per million each)
should be used.
5.5.3 Filling the System

Installation of hose bibs at the lowest point of the system is recommended. When filling a glycol
system keep air to a minimum. Air in glycol turns to foam and is difficult and time-consuming to
remove. (Anti-foam additives are available and may be considered.) Open all operating systems to the
loop. With the top vent(s) open, fill the system from the bottom of the loop. This will allow the glycol to
push the air out of the top of the system, minimizing trapped air. Fill to approximately 80% of
calculated capacity. Fill slowly from this point, checking fluid levels until full.
NOTE
For glycol solution preparation and periodic testing, follow manufacturer's recommendations.
Do not mix products of different manufacturers.
46
Figure 23 Drycoolers and pump packages
DRYCOOLER 43-9/16"
(1105mm) GLYCOL PUMP PACKAGE
A
See Note 1 30-1/4"
(768mm)
37-7/8"
(1095mm)
19"
(483mm)
B
43-3/16"
(1097mm)
Provided on
See Table 18 for keys to dual pump
dimensions “A”, “B” and “C”. package only
PUMP PACKAGE 1/2" diameter holes

MOUNTING ANGLES for mounting (4 typ) Notes
1. Single pump packages are 17-1/4"
Note: Angles located
inside, bottom of pump (438 mm) wide. Dual pump packages ar
package. View used for 32-1/4" (819 mm) wide.
mounting reference. 2. Mounting holes are 15-1/4" (387 mm)
apart on single pump packages and 30-
3/4" 1/4" (768 mm) apart on dual pump
(19mm) packages.
3. Connection sizes apply to primary pump
supplier.
C
A
B See Table 17 for keys to

dimensions “A”, “B” and “C”.
For expansion tank dimensions,
see Figure 24 on page -48.
1-3/4" 4-1/4"
(25.4mm) (25.4mm)
1"
(25.4mm)
B
1-3/4" C
(25.4mm)
4-1/4" 1"
(25.4mm) (25.4mm)
37-11/16"
(957mm)
1/2" (12.7mm) diameter
anchor bolts (typ)
TYPICAL
FOOTPRINT UNIT ANCHOR PLAN
47
Figure 24 Pump packages—expansion tank

30-1/2
(774.7mm)
O 9" 6-13/16" 17-1/4"
1/2" FPT (228.6mm) 1/2" FPT (173mm) (438.2mm)
Fitting Fitting
2-3/4" 2-1/2"
(69.9mm) 7"
(63.5mm)
(177.8mm)
4"
1" (25.4mm) 1" (101.6mm) O 1/2" (12.7mm) 8 holes
(25.4mm) EXPANSION TANK
1-1/2" 1-1/2" (38.1mm) 8.8 gal. (33.3L)
(38.1mm) 6-1/8"
(155.6mm) 3" SL-10065 Pg. 7B
(76.2mm) SL-10070 Pg. 6B
Table 17 Mounting hole dimensional data

A B C
PUMP PACKAGE in (mm) in (mm) in (mm)
SINGLE (0.75 - 7.5 Hp) 15-1/4 (387.4) 2-1/2 (63.5) 22-1/2 (571.5)
DUAL (0.75 - 5 Hp) 30-1/4 (768.4) 2-1/2 (63.5) 22-1/2 (571.5)
Table 18 Drycooler data

Drycooler
Model No. of Weight Conn. Sizes “A” Dimension “B” Dimension “C” Dimension Coil Internal
No. Fans lb (kg) (Suct. & Disc.) in. in. (mm) in. (mm) in. (mm) Volume gal. (l)
-069 1 410 (186) 1-1/4 51-1/2 (1308) 44 (1118) 42 (1067) 2.4 (9.2)
-092 1 430 (195) 1-1/2 51-1/2 (1308) 44 (1118) 42 (1067) 3.7 (13.9)
-109 1 450 (204) 2 51-1/2 (1308) 44 (1118) 42 (1067) 4.9 (18.6)
-112 1 470 (213) 2 51-1/2 (1308) 44 (1118) 42 (1067) 5.8 (22.0)
-139 2 565 (256) 2 91-1/2 (2324) 84 (2134) 82 (2083) 4.8 (18.2)
-197 2 605 (274) 2 91-1/2 (2324) 84 (2134) 82 (2083) 9.0 (34.1)
Table 19 Glycol pump data*

Pump
Pump Suction Pump Discharge
Hp Hz Connection in. Connection in.
3/4 60 1-1/4 3/4
1-1/2 60 1-1/4 3/4
2 60 1-1/4 3/4
3 60 1-1/2 1
5 60 1-1/2 1-1/4
3/4 50 1-1/4 3/4
1 50 1-1/4 3/4
1-1/2 50 1-1/4 3/4
2 50 1-1/4 3/4
3 50 1-1/2 1-1/4
* Connection sizes apply to primary pump supplier
48
Figure 25 General arrangement—Glycol-cooled models with scroll compressor
Expansion Tank Field-Installed at Glycol

Highest Point in System Drycooler Pump Pump
Unions*
Fill* Electric Box Housing
Drycooler
Coil
Fluid
Expansion Return Isolation Evaporator
Port* to Pump Valves* Coil
Unions* Fluid Expansion
Supply Valve
from
Hose Pump
Sensing
Air Vents* Bibs* Flow Regulating Sight Bulb
at Top of Valve*
Risers Pressure Glass
Hot Gas External
Port*
Bypass Equalizers
Filter Valve
Dryer
Service
Hot Gas Valves
Bypass
Solenoid Scroll
Valve Compressor
Hot Gas
Bypass
Tube
in Tube
Condenser
Tube
in Tube
Fluid Bypass Condenser
Supply Valve
to Unit
Fluid
Return
from Isolation
Unit
Valves*
2-Way Water
Regulating 3-Way Water
Valve Regulating Valve
(optional)
*Components are not

Fluid
supplied by Liebert but
Supply
Hose are recommended for
to Unit
Bibs* proper circuit operation
Fluid and maintenance
Return
from Field-Supplied
FACTORY PIPING Unit Reducers Required
on 3-Ton Units DPN000361
FIELD PIPING Rev. 02
49
Figure 26 General arrangement—Glycol-cooled models with digital scroll

Highest Point in System. Pump Pump
Drycooler Unions*
Housing
Fill* Electric
Box Drycooler
Coil
Fluid Evaporator
Expansion Return Coil
Port* Isolation
to Pump
Valves*
Unions* Expansion
Fluid Supply Valve
from Pump
Sensing
Hose
Bulb
Air Vents* Bibs* Flow Regulating Sight
at Top of Valve* Glass External
Risers Pressure Equalizer
Port*
Digital
Compressor
Filter
Dryer Service Digital
Valves Solenoid
Valve
Tube
in Tube
Condenser
Tube
in Tube
Fluid Condenser
Supply
to Unit
Fluid
Return
from
Unit Isolation
Valves*
To iCOM Control
2-Way
To iCOM Control
Motorized
Ball Valve 3-Way
Motorized
Ball Valve
Hose Fluid
(optional)
Bibs* Supply
to Unit
Fluid
Field-Supplied
FACTORY PIPING Return
From Reducers
Hose FIELD PIPING Unit Required on 3
Bibs* Ton Units
*Components are not supplied by Liebert but DPN001722
are recommended for proper circuit operation Rev. 0
and maintenance.
50
Figure 27 General arrangement—GLYCOOL models with scroll compressor

Pump
Highest Point in System Pump
Drycooler Unions*
Drycooler Housing
Fill* Electric Box
Coil
Fluid Evaporator
Pressure Return to Coil
Pump
Isolation
Port* Valves*
Unions*
Fluid Expansion
Supply Valve
from Pump
Hose Sensing
Bib* Flow Regulating Bulb
Air Vents* Sight
at Top of Valve* Glass
Pressure Hot Gas
Risers
Port* Bypass External
Filter Valve Equalizers
Dryer
Service
Valves
Scroll
Compressor
Hot Gas
Bypass
Econ-O-Coil
3-Way Water
Regulating
Fluid Valve Valve Tube
Supply to Actuator in Tube
Fluid Unit Condenser
Return
from Econ-O-Cycle
Unit Comparator 3-Way Chilled
Glycol Valve
Isolation
Valves*
Econ-O-Coil
Circuit *Components are not supplied
by Liebert but are recommended
Field-Supplied for proper circuit operation
Reducers and maintenance.
Required on 3-Ton Units
Hose
FACTORY PIPING
Bibs* DPN000379
FIELD PIPING Rev. 03
51
Figure 28 General arrangement—GLYCOOL models with digital scroll compressor

Pump Pump
Highest Point in System Drycooler Housing
Unions*
Elect ric Drycooler
Fill*
Box Coil
Fluid
Pressure Evaporat or
Return to
Port* Isolation Coil
Pump
Valves*
Unions* Expansion
Fluid
Supply Valve
from
Hose Pump Sensing
Air Vents* Bib* Bulb
Flow Regulating Valve* External
at Top of
Pressure Equalizer
Risers
Port* Sight
Glass
Filter Digital
Dryer Solenoid
Service Valve
Valves
Digital
Compressor
Tube
in Tube Econ-O-Coil
Condenser
r
Fluid
Valve
Supply to
Actuator
Fluid Unit
Return
from Econ-O-Cycle To iCOM Cont rol
Unit Comparat or
3-Way Chilled 3-Way Motorized
Isolation
Glycol Valve Ball Valve
Valves*
Econ-O-Coil
Circuit
Field-Supplied *Components are not supplied by Liebert but

Reducers are recommended for proper circuit operation
Required on 3-Ton Units and maintenance.
Hose
Bibs*
FACTORY PIPING
DPN001724
FIELD PIPING Rev. 0
52
5.5.4 Motor Ball Valve—Digital Scroll Compressors

Refer to 4.4 - Motorized Ball Valve—Digital Scroll Compressors for details on the motorized ball
valve.
5.6 Condenser
The condenser is designed to operate in conjunction with a drycooler. The maximum coolant pressure
is 350 psig (2413 kPa).
5.7 Glycol Regulating Valve

The glycol regulating valve automatically regulates the amount of coolant necessary to remove the
heat from the refrigeration system, permitting more fluid to flow when load conditions are high and
less fluid to flow when load conditions are low. The valve consists of a brass body, balance spring,
valve seat, valve disc holders, capillary tube to discharge pressure, and adjusting screw.
5.7.1 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve)
High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson Controls Valve)
For details, refer to 4.3.1 - Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units
(Johnson Controls Valve) High Pressure Valve - 350psig (2413kPa) 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)
For details, refer to 4.3.2 - High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units
(Metrex Valve).
5.7.3 Testing Valve Function

When the refrigeration system has been off for approximately 10-15 minutes, the coolant flow should
stop.
Should the coolant continue to flow, the valve is either improperly adjusted (head pressure is too low)
or the pressure sensing capillary is not connected properly to the condenser.
Table 20 Refrigerant control settings psi (kPa)
Low Pressure Low Pressure High Pressure
Cut Out Cut In Cut Out
20 (137.9) 65 (448.2) 400 (2758)
53
Chilled Water Models
6.0 CHILLED WATER MODELS

Manual shut-off valves should be installed at the supply and return lines to each unit. This will
provide for routine service and emergency isolation of the unit.
Consideration of the minimum water temperature to be supplied from the chiller will determine if the
need exists to insulate supply and return lines. Insulation will prevent condensation on the supply
and return lines.
To provide for the emergency of water leaks and the consequences of sub-floor flooding, floor drains
should be provided with wet traps or a water detection system, such as a Liebert Liqui-tect, that is
installed near the base of the unit or below the elevated floor.
Figure 29 Chilled water general arrangement - Upflow (BU)
Air
Flow
Bleed
Valve
Chilled
Water
Supply
Chilled
Water
Chilled Valve Coil
Water Actuator
Return 3-WAY VALVE
Shutoff
Valves * A3-Way
AB Chilled
Water
B Valve
Flow
Switch Air
(optional) Flow
Hose
Bleed
Bibs *
Valve
Chilled Valve
Water Actuator
Supply 2-Way
Chilled
Chilled Chilled
Water
Water Water
Valve
Return Coil
2-WAY VALVE
Shutoff
Valves *
FACTORY PIPING
Hose FIELD PIPING SL-11899
Bibs * Pg. 5
*Components are not supplied by Liebert but
and maintenance.
54
Chilled Water Models
Figure 30 Chilled water general arrangement - Downflow (BF) models
Air
Flow
Bleed
Valve
Chilled Valve
Water Actuator
Return AB
Chilled A
3-Way Chilled
Water B Chilled Water
Supply
Water Coil
Shutoff Valve
Valves *
3-WAY VALVE
Flow
Switch
(optional)
Air
Chilled Flow
Hose Water
Bibs * Return Bleed
Valve
Valve
Chilled Actuator
Water
Supply Chilled
Water
Shutoff
Coil
Valves *
2-Way Chilled
Water Valve 2-WAY VALVE
FACTORY PIPING
FIELD PIPING
Hose
Bibs * *Components are not supplied by Liebert,
SL-11899
but are recommended for proper circuit
Pg. 6
operation and maintenance.
55
Split System Models
7.0 SPLIT SYSTEM MODELS

Three condensing unit styles are available: two air-cooled and one water/glycol-cooled condensing
unit.
7.1 Location Considerations

7.1.1 Air-Cooled Condensing Units
To assure an adequate air supply, it is recommended that all condensing units be located in a clean
air area, away from loose dirt and foreign matter that may clog the coil.
The outdoor condensing unit must not be located in the vicinity of steam, hot air, or fume exhausts or
closer than 18" from a wall, obstruction, or adjacent unit.
The outdoor condensing unit should be located for maximum security and maintenance accessibility.
Avoid ground-level sites with public access or areas that will contribute to heavy snow accumulations.
Do not allow the discharge air to blow into another condensing unit.
The outdoor condensing unit must be located at the same level or above the indoor Liebert Challenger
3000 unit. It must NOT be located below the indoor unit.
A solid base, capable of supporting the weight of the condenser and at least 2" (51 mm) higher than
the surrounding grade and at least 2" (51 mm) larger than the condensing unit base dimensions,
should be installed at the pre-determined location. In snow areas, a base of sufficient height to clear
snow accumulation must be installed.
The centrifugal fan air-cooled condensing unit may be located above the dropped ceiling or any remote
indoor area. If noise is of concern, the condensing unit should be located away from personnel. Normal
operating sound may be objectionable if the condensing unit is placed near quiet work areas.
To mount the unit in the ceiling, refer to 7.5.1 - Installing the Indoor Condensing Unit for
hanging guidelines and to Figure 35 - Detail of ceiling hanging bracket for dimensional data.
7.1.2 Water/Glycol-Cooled Condensing Units

The condensing unit may be located above the dropped ceiling or any remote indoor area. If noise is of
concern, the condensing unit should be located away from personnel. Normal operating sound may be
objectionable if the condensing unit is placed near quiet work areas. To mount the unit the in ceiling,
refer to 7.5.1 - Installing the Indoor Condensing Unit.

electrical schematic when making connections. Make all wiring and electrical connections in
! WARNING
Potentially lethal voltages exist within this equipment during operation. Observe all
cautions and warnings on unit and in this manual.
The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit
Off” mode. The only way to ensure that there is NO voltage inside the unit is to install and
open a remote disconnect switch. Refer to unit electrical schematic.
7.2.1 Line Voltage

Line voltage electrical service is required for all condensing units at the location of the condensing
unit. This power supply does not have to be the same voltage as the indoor unit. This separate power
source may be 208, 230, 460 or 575V, 60 Hz; or 200, 230, or 380/415V, 50 Hz. A disconnect switch is
required and must be mounted per local and national codes to isolate the unit for maintenance.
56
Split System Models
7.2.2 Low Voltage

The control cable between the condensing unit and the evaporator unit is connected between
terminals 1,2 and 3 on the terminal strip in the evaporator unit and the condensing unit control box.
A fourth wire is required on systems with hot gas bypass. NEC Class 1 wiring is required. Glycol-
cooled units also require a two-wire control connection to the drycooler and pump package.

7.3.1 Refrigerant Loop
NOTICE
Risk of improper refrigerant charge. Risk of equipment damage, environmental degradation
and violation of national, state and local law.
Follow all applicable codes for handling refrigerant.
R22 and R407C are similar in properties—proper safety equipment and proper refrigeration
tools are required on both types. Check unit nameplate for correct refrigerant type before
topping off or recharging a system.
R407C refrigerant must be introduced and charged from the cylinder only as a liquid.
NOTICE
Risk of improper piping installation. Can cause contamination of hygroscopic oil with water.
When installing field piping, care must be taken to protect all refrigerant lines from the
atmosphere, especially when using refrigerants, such as R407C which requires use of polyol
ester oils. Do not allow the piping to stand open to air for more than 15 minutes. Units
designed for R407C have a compressor that contains polyol ester oil, which is very
hygroscopic; that is, it quickly absorbs water from the air. The longer the compressor piping is
left open to air, the harder it will be to fully evacuate. If left open too long, the polyol ester oil
may need to be replaced before achieving the required vacuum level.
NOTE
Complete all piping and evacuate lines before connecting quick connects when using an
optional sweat adapter kit and field installed hard piping.
Follow all proper brazing practices including a dry nitrogen purge to maintain system
cleanliness.
All split systems require two refrigerant lines (an insulated copper suction line and a copper liquid
line) between the evaporator and the condensing unit.
Two possible methods exist for installing the copper suction and liquid lines.
1. Using an optional Sweat Adapter Kit and hard piping between the two units.
2. Using optional pre-charged line sets (for 3-ton models only).
All refrigeration piping should be installed with high temperature brazed joints. Prevailing good
refrigeration practices should be employed for piping supports, leak testing, evacuation, dehydration,
and charging of the refrigeration circuits. The refrigeration piping should be isolated from the
building by the use of vibration isolating supports.
It is important to handle the pre-charged lines for 3-ton units with care so they will not get kinked or
damaged. Use tube benders and make all bends before making connections to either end. Coil any
excess tubing in a horizontal plane with the slope of the tubing toward the condensing unit.
To prevent tube damage when sealing openings in walls and to reduce vibration transmission, use a
soft flexible material to pack around the tubes.
When installing remote condensing units mounted above the evaporator, the suction gas line should
be trapped at the evaporator. This trap will retain refrigerant oil in the off cycle. When the unit
starts, oil in the trap is carried up the vertical riser and returns to the compressor.
57
Split System Models
Refrigerant charge requirements: Total refrigerant charge will be required only if units are evacuated
during installation or maintenance. Total refrigerant charge = evaporator + lines + condensing unit.
NOTE
All condensing units and 3-ton evaporator units are fully charged with refrigerant. All 5 ton
evaporator units include a nitrogen holding charge only. See Table 21 for field charge
required. If field-supplied refrigerant piping is installed, refrigerant must be added to the
system.
Once all piping is complete, check for leaks and dehydrate the field piping as follows:
1. Pressurize the field piping to 150 PSIG (1034 kPa) using dry nitrogen with a trace of refrigerant.
Check system for leaks with a suitable leak detector.
2. After completion of leak testing, release the test pressure (per local code) and pull a deep vacuum
on the field piping with a suitable pump.
3. After 15 minutes, check the pressure readings and, if they have not changed, break vacuum with
dry nitrogen. Pull a second vacuum to 250 microns or less. Recheck the pressure after 15 minutes.
Table 21 Unit refrigerant charge
R407C Charge R407C Charge
Model lb (kg) Model lb (kg)
BF/BU 036E 0.5 (0.2) PF_042A-_H 25.8 (11.7)
BF/BU 035E 0.5 (0.2) PF_041A-_H 25.8 (11.7)
BF/BU 060E 0.8 (0.4) PF_067A-_L 25.8 (11.7)
BF/BU 059E 0.8 (0.4) PF_066A-_L 25.8 (11.7)
MC_40/39A 12.9 (5.8) PF_Z67A-_L 50.1 (22.7)
MC_65/64A 26.1 (11.8) PF_Z66A-_L 50.1 (22.7)
PF_042A-_L 12.9 (5.8) PF_067A-_H 50.1 (22.7)
PF_041A-_L 12.9 (5.8) PF_066A-_H 50.1 (22.7)
PF_Z42A-_L 25.8 (11.7) MC_44/43W 3.4 (1.5)
PF_Z41A-_L 25.8 (11.7) MC_69/68W 5.9 (2.7)
Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube
R407C
Liquid Line Suction Line
O.D. lb (kg) lb (kg)
1/2" 7.3 (3.3) -
5/8" 11.7 (5.3) 0.4 (0.2)
7/8" 24.4 (11.1) 1.0 (0.4)
1-1/8" 41.6 (18.9) 1.7 (0.7)
1-3/8" 63.3 (28.7) 2.7 (1.1)
Table 23 Recommended refrigerant lines (R407C) sizes OD copper

3.5-Ton 5-Ton
036E (035E) 060E (059E)
Equivalent Feet (m) Suction Liquid Suction Liquid
0-50 (0-15) 7/8" 1/2" 1-1/8" 1/2"
51-100 (16-30) 1-1/8" 1/2" 1-1/8" 5/8"
101-150 (31-45) 1-1/8" 5/8" 1-3/8" 5/8"
58
Split System Models
Table 24 Line coupling sizes

Model Line Size Coupling Torque
(Tons) OD Cu, in. Size lb-ft.
3 3/8 #6 10-12
5 1/2 & 5/8 #10 35-45
3 7/8 #11 35-45
5 1-1/8 #12 50-65
Table 25 Equivalent lengths (feet) for various pipe fittings
Copper Pipe 90 Degree 90 Degree 45 Degree Gate Globe Angle
OD in. Elbow Copper Elbow Cast Elbow Tee Valve Valve Valve
1/2 0.8 1.3 0.4 2.5 0.26 7.0 4.0
5/8 0.9 1.4 0.5 2.5 0.28 9.5 5.0
3/4 1.0 1.5 0.6 2.5 0.3 12.0 6.5
7/8 1.45 1.8 0.8 3.6 0.36 17.2 9.5
1-1/8 1.85 2.2 1.0 4.6 0.48 22.5 12.0
1-3/8 2.4 2.9 1.3 6.4 0.65 32.0 16.0
1-5/8 2.9 3.5 1.6 7.2 0.72 36.0 19.5
Refrigerant trap = 4 times equivalent length of pipe per this table
Figure 31 Refrigerant piping diagram
Condensing unit
Evaporator
Suction Line Piping

Condensing unit
above evaporator
Traps recommended at the base of riser and
every 25 feet (7.6m) of vertical rise.
7.3.2 Quick Connect Fittings
NOTE
When hard piping is used, complete all piping and evacuate lines before
connecting quick connects.
Be especially careful when connecting the quick connect fittings. Read through the following steps
before making the connections.
1. Remove protector caps and plugs.
2. Carefully wipe coupling seats and threaded surfaces with a clean cloth.
3. Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil.
4. Thread the coupling halves together by hand to ensure that the threads mate properly.
5. Tighten the coupling body hex nut and union nut with the proper sized wrench until the coupling
bodies “bottom out” or until a definite resistance is felt.
6. Using a marker or pen, make a line lengthwise from the coupling union nut to the bulkhead.
7. Tighten the nuts an additional quarter turn; the misalignment of the lines shows how much the
coupling has been tightened. This final quarter turn is necessary to ensure that the joint will not
leak. Refer to Table 24 for torque requirements.
8. Add charge for the additional piping (refer to Table 22).
59
Split System Models
7.4 Outdoor Air-Cooled Condensing Units

Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models
UNIT DIMENSIONS
(See Table 26)
C
Removable (Right) Panel

Fan Rotation
for access to refrigeration
CCW (left side)
A components
Right Air
Discharge
Left Air
Intake
B
C
a minimum clearance
of 18" (457mm) for
proper air flow
C

Shaded area indicates a minimum clearance
a minimum clearance Removable (Front) Panel
of 24" (610mm) for component
of 18" (457mm) for for access to high-voltage and
access and removal
proper air flow low-voltage connections and
SL-11081
refrigeration components
Pg. 4
Liquid Line Suction Line
Quick Connect A Quick Connect
(Male Coupling) (Male Coupling)
Except as noted
G F
Electrical Entrance
for High-Voltage
Connection
B
C
Electrical Entrance
for Low-Voltage
Connection
D
E SL-11081
Pg. 6
60
Split System Models
Table 26 Horizontal air discharge cabinet and floor planning dimensional data
Model Numbers Dimensional Data in. (mm) Module
Weight
60 Hz 50 Hz A B C lb (kg) net
PFC042A-_L PFC041A-_L
48 (1219) 31 (787) 18 (457) 241 (109)
PFH042A-_L —
PFC042A-_H PFC041A-_H
PFH042A-_H —
PFCZ42A-_L PFCZ41A-_L 53 (1343) 36-1/4 (918) 18 (457) 351 (159)
PFH067A-_L —
Table 27 Horizontal air discharge piping and electrical connection data
Model Numbers Dimensional Data in. (mm) Piping Connections in. (mm)
60 Hz 50 Hz A B C D E F G
2 (51) 5-3/4 (146) 8-1/2 (216) 4-3/4 (121) 6-3/4 (171) — 8-1/2 (216)
PFH042A-_L —
PFH042A-_H PFCZ41A-_L
PFCZ42A-_L — 2 (51) 6 (152) 8-1/2 (216) 4-3/4 (121) 7-3/4 (197) — 8-1/2 (216)
PFH067A-_L —
61
Split System Models
Figure 33 Outdoor air-cooled condensing unit—top air discharge models

Guard Height
Top Air
Discharge
D
Right Air
UNIT DIMENSIONS Discharge
(see Table 28)
B

Left Air
a minimum clearance
Intake
of 18" (457mm) for
proper air flow
2"
(51mm)
A C

a minimum clearance
of 18" (457mm) for
Removable (Front) Panel a minimum clearance
proper air flow
for access to high-voltage and of 24" (610mm) for component
low-voltage connections and access and removal
refrigeration components
36-1/8"
4" (typ.) 53-3/16"
(918mm)
(102mm) (1351mm)
FOOTPRINT 2" (typ.)
DIMENSIONS 1/2" (13mm)
(51mm) Bolt-Down Holes
6 places
4-23/32"
(120mm)
25-3/32" 32-1/8"
(637mm) (816mm)
2"
46-7/32" (51mm) SL-11081
(1174mm) Pg. 5
Electrical Entrance
A for High-Voltage Connection
G F
PIPING & ELECTRICAL
CONNECTIONS
(see Table 29)
B
C
Liquid Line Electrical Entrance

Quick Connect for Low-Voltage
(Male Coupling) Connection
D Suction Line
Quick Connect SL-11081
E
(Male Coupling) Pg. 7
62
Split System Models
Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge
Model Numbers Dimensional Data in. (mm) Module
Weight
60 Hz 50 Hz A B C D lb (kg) net
PFH067A-_H — 53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140) 488 (222)
PFCZ67A-_L PFCZ66A-_L
Table 29 Piping and electrical connections - top air discharge
Model Numbers Dimensional Data in. (mm) Piping Connections in. (mm)
60 Hz 50 Hz A B C D E F
PFH067A-_H — 2 (51) 6 (152) 8-1/2 (216) 4-3/4 (121) 7-3/4 (197) 8-1/2 (216)
PFCZ67A-_L PFCZ66A-_L
63
Split System Models
Figure 34 Electrical field connections, prop fan condensing module
TOP AIR
DISCHARGE MODELS
Field-supplied unit (5-Ton High Ambient
disconnect switch & 5-Ton Quiet-Line)
HORIZONTAL AIR DISCHARGE MODELS
Field-supplied 24V NEC

Class 2 wiring to
evaporator module
Single- or
3-phase electric SL-11081
service; not by Pg. 8A
Liebert
Field-supplied 24V Single- or
NEC Class 2 wiring 3-phase
to evaporator electric
module service; not
by Liebert
Factory-wired
Electric service
to components on
connection to contactor
or terminal block electric panel.
Single- or 3-phase
electric service; not
by Liebert
High-voltage electric
power supply entrance
Low-voltage electric
Earth ground connection Heat rejection connection. Field

terminal for field wiring. supplied 24V NEC class 2 wiring.
Wire connections from evaporator module:
1. 24V GND
2. 24V Supply
3. High Pressure Alarm
4. Hot Gas Bypass Connection
(only on units with hot gas bypass.
If no hot gas bypass, connection is
NOTE: Refer to specification sheet for full load amp provided in the evaporator module.
SL-11081 Pg. 8 and wire size amp ratings Connect wire 4 with wire 2 to the
24V supply).
64
Split System Models
7.5 Centrifugal Air-Cooled Condensing Units

7.5.1 Installing the Indoor Condensing Unit
Refer to drawings for unit dimensions and component locations.
! WARNING
Risk of heavy unit falling from supports. Can cause equipment and building damage, injury
and death.
Be sure the supporting roof structure is capable of supporting the weight of the unit(s) and
the accessories during installation and service. (See Table 30 - Indoor centrifugal
condensing unit.)
Be sure to securely anchor the top ends of the suspension rods. Make sure all nuts are tight.
The indoor condensing unit is usually mounted above the ceiling and must be securely mounted to the
roof structure. The ceiling and ceiling supports of existing buildings may require reinforcements. Be
sure to follow all applicable codes. Use field-supplied threaded suspension rods and 3/8"-16 factory
hardware kit.
The indoor condensing unit must be located at the same level or above the Liebert Challenger 3000
unit. It must NOT be located below the Liebert Challenger 3000.
Recommended clearance between ceiling grids and building structural members is unit height plus
three inches.
Install the four field-supplied rods by suspending them from suitable building structural members.
Locate the rods so that they will align with the four mounting holes in the flanges that are part of the
unit base.
Using a suitable lifting device, raise the unit up and pass the threaded rods through the four
mounting holes in the flanges that are part of the unit base.
Attach the threaded rods to the unit flanges using the supplied nuts and grommets. (See Figure 35 -
Detail of ceiling hanging bracket, Threaded Rod and Hardware Kit Installation). The rubber
grommets provide vibration isolation.
1. Use the plain nuts to hold unit in place. Adjust these nuts so that the weight of the unit is
supported evenly by the four rods, does not rest on the ceiling grid, and is level.
NOTE
The units must be level in order to operate properly.
2. Use the Nylock nuts to “jam” the plain nuts.

Table 30 Indoor centrifugal condensing unit
Model
Net Weight
60 Hz 50 Hz lb (kg)
MC_40A MC_39A 240 (109)
MC_65A MC_64A 449 (204)
65
Split System Models
Figure 35 Detail of ceiling hanging bracket
3/8" threaded rod

(field-supplied)
3/8" hex nut

3/8" washer
Sleeve
Isolator
3/8" fender washer
3/8" hex nut

3/8" hex nut
Nylock
Unit base pan (ref)
7.5.2 Ducting
The total external static pressure for the inlet and outlet ducts, including grille, must not exceed
0.5 inches of H2O. Hood intake dimensions should be the same as the condensing unit duct
dimensions.
If the condensing unit is located close to the outside of the building, rain hoods must be installed. In
addition, install a triple layer bird screen over rain hood openings to eliminate the possibility of
insects, birds, water, or debris entering the unit.
Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control
vibration transmission to the building. Attach the ductwork to the unit using the flanges provided.
Locate the unit and ductwork so that the return air does not short circuit to the supply air inlet.
Avoid directing the hot exhaust air toward adjacent doors or windows.
Normal operating sound may be objectionable if the condensing unit is placed directly over quiet work
areas. Ductwork that runs through a conditioned space or is exposed to areas where condensation
may occur must be insulated. Whenever possible, ductwork should be suspended using flexible
hangers. Ductwork should not be fastened directly to the building structure. In applications where
the ceiling plenum is used as the heat rejection domain, the discharge air must be directed away from
the condensing unit air inlet and a screen must be added to the end of the discharge duct to protect
service personnel.
For multiple unit installations, space the units so that the hot condensing unit exhaust air is not
directed toward the air inlet of an adjacent unit.
Table 31 Airflow CFM (CMH)
3-Ton 5-Ton
60 Hz 2000 (3398) 3500 (5947)
50 Hz 1650 (2800) 3500 (5947)
66
Split System Models
Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections
Customer-supplied
50-1/4" (1276mm) 22-3/4" (578mm)
Overall Dimension
threaded rods for
Overall Dimension module support
21-1/2" (546mm)
46-1/2" (1181mm) from ceiling (typ. 4)
Cabinet Dimension
Cabinet Dimension C
19-1/2" (495mm)
48-1/4" (1225mm) Threaded Rod
Centers
Threaded Rod Centers
1/2" (13mm)
D
Air Outlet
20-3/4" Duct Connection
(527mm)
22-1/2" 20-7/16"
(572mm) (519mm)
Cabinet Coil Inlet
Air Outlet
Dimension Duct B
Conn. Duct Dimension
30-1/8" A
(765mm) Blower Motor Service Access
Holes for Module Coil Inlet Panel on Bottom of Unit
Rigging (typ. 2 each end) Duct Connection Minimum Clearance 33" (838mm)
1" Duct Flange for Component Access and Removal.
Integral Hanging
(25.4mm)
Bracket
2-1/4" Note:Unit is evenly spaced in
Minimum Clearance 33" (838mm) (57mm) reference to threaded for centers.
This End for Component Access
and Removal DIMENSIONAL DATA
7/8" (22.2mm) Dia.

Electrical Entrance
for Line-Voltage
Connection
7/8" (22.2mm) Dia.

Electrical Entrance
for Low-Voltage
Connection
Suction Line
Male Quick
Connect
Liquid Line
Male Quick
Connect PIPING CONNECTIONS SL-11085 Pg. 4
67
Split System Models
Figure 37 3-ton centrifugal air-cooled condensing unit (con't.)

Field-supplied unit disconnect
switch when optional disconnect
is not provided in unit
Single- or three-phase
electric service
not by Liebert
Field-supplied 24V
NEC Class 2 wiring
to fan/coil unit Factory-wired
to components
on electric panel
Optional factory-installed
Line voltage electric power disconnect switch
supply conduit entrance
Single- or three-phase
electric service
not by Liebert
Connection terminal
for field-supplied
grounding wire
Heat rejection connection.

Field-supplied 24V NEC
Class 2 wiring. See NOTE 2.
Wire connections from evaporator DPN000207
mod: Rev0
1. 24V ground
2. 24V supply
3. High-pressure alarm (optional) NOTES:
4. Hot gas bypass connection 1. Refer to specification sheet for full load amp. and wire size amp. ratings.
(only on units with hot gas 2. Control voltage wiring must be a minimum of 16 GA (1.6mm) for up to 75' (23m)
bypass) or not to exceed 1 volt drop in control line.
68
Split System Models
Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data
32"
(812.8mm)
54" Cabinet
(1371.6mm) Dimension
Cabinet 1-5/8"
Dimension (41.1mm) 15-3/4"
48" (400mm) 8-15/16"
Customer-supplied (1219.2mm) (227mm)
threaded rods for
module support 3-3/8"
from ceiling (typ. 4) (85.7mm)
14-1/2"
(368.3mm)
24"
21-1/4" (610mm)
(539.8mm) Cabinet
Dimension
1-3/4" Shaded area indicates a

(44.5mm) recommended clearance of
Hanger 30" (762mm) for component
33-5/8" 51-13/16"
Bracket access and removal.
(854.1mm) (1316mm)
Threaded Rod Threaded Rod
Centers Centers
NOTE: Unit is spaced evenly in
1/2" (12.7mm) dia. holes for reference to threaded
threaded rods (typ. 2 each end) rod centers.
7/8" (22.2mm) & 1-1/8" (28.6mm) 7/8" (22.2mm) & 1-1/8" (28.6mm)
dia. knockouts electrical entrance for high- dia. knockouts electrical entrance
voltage connection (Single Point Power Kit) for high-voltage connection
Single Point Power Kit

connection to Evaporator
Air Inlet Air

Outlet
Liquid Line male quick
connect location
Suction Line male quick

connect location
7/8" (22.2mm) dia.
7/8" (22.2mm) dia. knockout electrical entrance
electrical entrance for alternate for low voltage connection
control panel low-voltage routing SL-11087 Pg. 4
69
Split System Models
Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.)
Field-Supplied Unit Disconnect

Switch when Factory Unit
Disconnect Switch is not Supplied
Electric service
not by Liebert
Optional
Factory-Installed
Disconnect Switch
AIR COOLED
Connection terminal Line Voltage Electric Power
for field-supplied Supply Conduit Voltage
earth grounding wire
Removable Access Panels
Heat rejection connection. Field-supplied

24V NEC Class 2 wiring. See Note 2.
Field-Supplied 24V NEC Class 2
Wire connections from evaporator module.
wiring between condensing unit Low-voltage
1. 24V GND
and fan/coil unit electric power
2. 24V supply
supply conduit
3. High pressure alarm (optional)
entrance
4. Hot gas bypass connection (only on
NOTES: units with hot gas bypass)
Refer to specification sheet for full load amp and wire size amp ratings.
Control voltage wiring must be a minimum of 16 G A (1.6mm) for up
to 75’ (23m) or not to exceed 1 volt drop in control line. DPN000226_Rev0
70
Split System Models
Figure 40 Split systems general arrangement
Hot-Gas
Bypass Solenoid High-Pressure Condenser
Valve Switch Coil
Scroll
Compressor 1/2" (12.7mm) NPT
Liquid Injection
Pressure Relief Valve
Valve Bulb
Suction Line
Male Quick Check Sight
AIR COOLED Connect Valve Glass
Suction Line Coupling*
Female Quick
Service Head-Pressure Lee-Temp
Connect
Access Control with Receiver
Coupling*
Ports Integral Check Pressure
Valve Balancing Tube in
External Hot-Gas
Sensing Liquid Valve Tube
Equalizer Bypass Control
Bulb Injection Receiver Heater Condenser
Liquid Line Valve
Valve Pressure Limiting
Filter Male Quick Switch
Dryer Connect Liquid Line
Liquid Line Coupling* Solenoid Valve High-Pressure
Female Quick Switch
Connect
Expansion Coupling* Scroll
Valve Compressor
Hot-Gas
Liquid Injection
Bypass
Valve Bulb
Evaporator Solenoid Water/Glycol
Coil Valve Return
Line
Water/Glycol
Suction Line Supply Line
WATER COOLED Male Quick
Connect Fluid Return
GLYCOL COOLED Coupling* from Unit
Service Suction Line
Access Female Quick Shutoff
Ports Connect Valves *
Coupling* Fluid Supply
External Hot-Gas to Unit
Equalizer Sensing Liquid Bypass Control
Bulb Injection Valve Tube in
Liquid Line 2-Way Water Tube
Valve
Male Quick Regulating Valve Condenser
Filter
Dryer Connect
Liquid Line
Coupling* Hose Bibs *
Female Quick
Connect
Coupling*
Expansion
Valve
Evaporator
Coil FACTORY PIPING
OPTIONAL PIPING

maintenance.
Fluid
Return
from Unit
SL-11900 Pg. 5
Fluid Supply 3-Way Water
to Unit Regulating Valve (optional)
71
Split System Models
7.6 Water and Glycol-Cooled Condensing Units

For installation guidelines, refer to Installing the Indoor Condensing Unit on page 65.
7.6.1 Piping Considerations

It is recommended that manual service shut-off valves be installed at the supply and return line to
each unit. This will provide for routine service or emergency isolation of the unit.
When the water source for the condenser is of poor quality, it is good practice to provide cleanable
filters in the supply line. These filters will trap the particles in the water supply and extend the
service life of the water-cooled condenser.
3-Ton Connection Sizes
Condenser Water Inlet 7/8" OD Cu
Condenser Water Outlet 7/8" OD Cu
Suction Line 1-1/8 - 12 male #11 quick connect
Liquid Line: 5/8 - 18 male #6 quick connect
5-Ton Connection Sizes

Condenser Water Inlet 1-1/8" OD Cu
Condenser Water Outlet 1-1/8" OD Cu
Suction Line 1-7/16" - 16 male #12 quick connect
Liquid Line 1-1/16" - 12 male #10 quick connect
Table 32 Water and glycol-cooled condensing unit data

Net Weight, Glycol Volume,
Model lb (kg) gal (l)
MC_44W
200 (91) 1.7 (6.4)
MC_43W
MC_69W
282 (128) 2.0 (7.6)
MC_68W
7.6.2 Condenser Water Requirements

The standard maximum water pressure is 150 psig (1034 kPa). For applications above this pressure,
consult the factory about high pressure systems.
The system will operate in conjunction with a cooling tower, city water, or drycooler.
7.6.3 Regulating Valve

For details, refer to sections 4.3.1 - Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton
Units (Johnson Controls Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton
Units (Johnson Controls Valve) and 4.3.2 - High Pressure Valve - 350 psig (2413 kPa) System
for 3-Ton Units (Metrex Valve).
72
Split System Models
7.6.4 Glycol Systems

For split system glycol systems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOL-
Cooled Models—Self-Contained Compressor. See Table 18 - Drycooler data.
Electrical control interconnect to drycooler is wired from water/glycol condensing unit.
Figure 41 3-ton water/glycol-cooled condensing unit
8-7/8" (225mm)
50-1/4" (1276mm) 14" (356mm)
3-7/8" (98mm) Overall Dimension Overall Cabinet
Dimension
48-1/4" (1225mm) 12" (305mm)
Threaded Rod Centers Threaded Rod
8-7/16" (214mm)
46-1/2" (1181mm) Centers
Cabinet Dimension 20-3/4"

(527mm)
22-1/2"
Customer-Supplied (572mm) Cabinet
Threaded Rods for Module Outlet Dimension
Support from Ceiling (typ. 4) Inlet
Holes for Module

Rigging (typ. 2 each end) Minimum Clearance
DIMENSIONAL DATA 33" (838mm) This side
for component access
Integral Hanging Bracket and removal
3/4" (19mm) NPT Female

Water/Glycol Inlet Connection
3/4" (19mm) NPT Female 7/8" (22mm) Dia.
Water/Glycol Outlet Connection Electrical Entrance
for High-Voltage
Connection
Suction Line
Male Quick
Connect
Liquid Line
Male Quick
Connect
PIPING CONNECTIONS
7/8" (22mm) Dia.
Electrical Entrance
SL-11085 Pg. 6
for Low-Voltage Connection
73
Split System Models
Figure 42 3-ton water/glycol-cooled condensing unit (con't.)
Single- or Field-supplied unit disconnect

three-phase switch when optional disconnect
electric service is not provided in unit
not by Liebert
Field-supplied 24V NEC Class 1

wiring to fan/coil unit
Field-supplied 24V NEC Class 1
wiring to drycooler
(glycol-cooled units only)
Earth/ground connection
Connection terminal for field-supplied
earth-grounding wire
Factory-wired components
Line-voltage electric on electric panel
disconnect switch
Remote drycooler connection

Terminals 70 & 71 supplied
for connection to remote drycooler
Field-supplied 24V NEC Class 2 wiring.
Use field-supplied 24V NEC Class 1
Wire connections from evaporator mod:
wiring (glycol-cooled units only)
1. 24V GND
NOTES 2. 24V supply
1. Refer to specification sheet for full load amp 3. High-pressure alarm (optional)
and wire size amp ratings. 4. Hot gas bypass connection
2. Control voltage wiring must be a minimum (only on units with hot-gas bypass)
of 16 GA (1.6mm) for up to 75' (23m) or
not to exceed 1 volt drop in control line. DPN000209_Rev0
74
Split System Models
Figure 43 5-ton water/glycol-cooled condensing unit dimensional data
32"
32"
(812.8mm) Customer-supplied
(812.8mm)
Cabinet threaded rods
Cabinet
Dimension for module support
Dimension
from ceiling (typ. 4).
Removable
Access Panel
1/2" (12.7mm) dia. holes for 24 "

module rigging (typ. 2 each end) (610mm)
Cabinet
Hanger Dimension
Bracket
Shaded area indicates a 33-5/8"

29-13/16 " (854.1mm)
recommended clearance of (757.2mm)
30" (762mm) for component Threaded Rod
Threaded Rod Centers
access and removal. Centers
NOTE: Unit is evenly spaced in reference
to threaded rod centers. 7/8" (22.2mm) & 1-1/8" (28.6mm)
dia. knockouts electrical entrance
7/8" (22.2mm) & 1-1/8" (28.6mm)
for line voltage connection
dia. knockouts electrical entrance for
8-7/16"
line voltage connection (Single Point
(214.4mm)
Power Kit)
3-3/4"
7"
(95.2mm)
(177.8mm)
Suction Line male quick
connect location
Liquid Line male quick 1" (25.4mm) NPT Female

connect location Water/Glycol Inlet Connection
1" (25.4mm) NPT Female

Water/Glycol Outlet Connection
7/8" (22.2mm) dia. electrical entrance
for low-voltage connection 7/8" (22.2mm) dia. knockout
electrical entrance for alternate SL-11087
control panel low-voltage routing Pg. 6
75
Split System Models
Figure 44 5-ton water/glycol-cooled condensing unit (con't.)
Field-supplied unit disconnect

switch when factory unit Electric service;
disconnect switch is not suplied not by Liebert
WATER/GLYCOL
disconnect switch
Field-supplied 24V
NEC Class 1 wiring
to fan/coil unit
Field-supplied 24V
NEC Class 1 wiring
to drycooler
(glycol-cooled units only) Line voltage electric
power supply conduit voltage
Removable
Access Panel

Field-supplied 24V NEC Class 2 wiring. Connection terminal
Wire connections from evaporator mod: for field-supplied
1. 24V ground earth grounding wire
2. 24V supply
3. High pressure alarm (optional)
4. Hot gas bypass connection Low-voltage electric
(only on units with hot gas bypass) power supply conduit
entrance
Remote drycooler Field-supplied 24V NEC

connection; field-supplied Class 1 wiring between
24V NEC Class 1 wiring glycol condensing unit
(glycol-cooled units only) and drycooler
DPN000228_Rev0
NOTES
1. Refer to specification sheet for full load amp. and wire size amp. ratings.
2. Control voltage wiring must be a minimum of 16 G A (1.6mm) for up to 75' (23m)
or not to exceed 1 volt drop in control line.
76
R407C Refrigerant
8.0 R407C REFRIGERANT

Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction
gas)
Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure
°F °C Psig kPa °F °C Psig kPa °F °C Psig kPa
0.0 -17.8 18.9 130 35.0 1.7 54.8 378 70.0 21.1 114.9 792
1.0 -17.2 19.6 135 36.0 2.2 56.1 387 72.0 22.2 119.3 822
2.0 -16.7 20.4 141 37.0 2.8 57.5 396 74.0 23.3 124 853
3.0 -16.1 21.2 146 38.0 3.3 58.9 406 76.0 24.4 128 885
4.0 -15.6 22.0 152 39.0 3.9 60.3 415 78.0 25.6 133 917
5.0 -15.0 22.8 157 40.0 4.4 62.2 429 80.0 26.7 138 950
6.0 -14.4 23.6 163 41.0 5.0 63.1 435 82.0 27.8 143 984
7.0 -13.9 24.5 169 42.0 5.6 64.6 445 84.0 28.9 148 1019
8.0 -13.3 25.4 175 43.0 6.1 66.1 456 86.0 30.0 153 1054
9.0 -12.8 26.2 181 44.0 6.7 67.6 466 88.0 31.1 158 1091
10.0 -12.2 27.1 187 45.0 7.2 69.1 476 90.0 32.2 164 1128
11.0 -11.7 28.0 193 46.0 7.8 70.7 487 92.0 33.3 169 1167
12.0 -11.1 28.9 200 47.0 8.3 72.2 498 94.0 34.4 175 1206
13.0 -10.6 29.9 206 48.0 8.9 73.8 509 96.0 35.6 181 1246
14.0 -10.0 30.8 213 49.0 9.4 75.4 520 98.0 36.7 187 1287
15.0 -9.4 31.8 219 50.0 10.0 77.1 531 100.0 37.8 193 1329
16.0 -8.9 32.8 226 51.0 10.6 78.7 543 102.0 38.9 199 1372
17.0 -8.3 33.8 233 52.0 11.1 80.4 554 104.0 40.0 205 1416
18.0 -7.8 34.8 240 53.0 11.7 82.1 566 106.0 41.1 212 1461
19.0 -7.2 35.8 247 54.0 12.2 83.9 578 108.0 42.2 219 1507
20.0 -6.7 36.9 254 55.0 12.8 85.6 590 110.0 43.3 225 1553
21.0 -6.1 38.0 262 56.0 13.3 87.4 603 112.0 44.4 232 1601
22.0 -5.6 39.0 269 57.0 13.9 89.2 615 114.0 45.6 239 1650
23.0 -5.0 40.1 277 58.0 14.4 91.0 628 116.0 46.7 247 1701
24.0 -4.4 41.3 284 59.0 15.0 92.9 640 118.0 47.8 254 1752
25.0 -3.9 42.4 292 60.0 15.6 94.8 653 120.0 48.9 262 1804
26.0 -3.3 43.6 300 61.0 16.1 96.7 666 122.0 50.0 269 1858
27.0 -2.8 44.7 308 62.0 16.7 98.6 680 124.0 51.1 277 1912
28.0 -2.2 45.9 317 63.0 17.2 100.5 693 126.0 52.2 285 1968
29.0 -1.7 47.1 325 64.0 17.8 102.5 707 128.0 53.3 294 2025
30.0 -1.1 48.4 333 65.0 18.3 104.5 721 130.0 54.4 302 2083
31.0 -0.6 49.6 342 66.0 18.9 106.5 735 132.0 55.6 311 2143
32.0 0.0 50.9 351 67.0 19.4 108.6 749 134.0 56.7 320 2203
33.0 0.6 52.1 359 68.0 20.0 110.7 763 136.0 57.8 329 2265
34.0 1.1 53.5 369 69.0 20.6 112.8 778 138.0 58.9 338 2329
- - - - - - - - 140.0 60.0 347 2393
NOTE
Use this table for superheat and for control adjustment (e.g., pressure switches). See
Table 34 for subcooling.
77
R407C Refrigerant
Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements)

Temperature Pressure Gauge Temperature Pressure Gauge Temperature Pressure Gauge
°F °C Psig kPa °F °C Psig kPa °F °C Psig kPa
36.0 2.2 73 500 59.0 15.0 114 786 94.0 34.4 203 1402
37.0 2.8 74 511 60.0 15.6 116 801 96.0 35.6 209 1444
38.0 3.3 76 522 61.0 16.1 118 815 98.0 36.7 216 1488
39.0 3.9 77 533 62.0 16.7 120 830 100.0 37.8 222 1532
40.0 4.4 79 544 63.0 17.2 123 845 102.0 38.9 229 1578
41.0 5.0 81 556 64.0 17.8 125 860 104.0 40.0 236 1624
42.0 5.6 82 567 65.0 18.3 127 875 106.0 41.1 242 1671
43.0 6.1 84 579 66.0 18.9 129 891 108.0 42.2 249 1720
44.0 6.7 86 591 67.0 19.4 131 906 110.0 43.3 257 1769
45.0 7.2 87 602 68.0 20.0 134 922 112.0 44.4 264 1819
46.0 7.8 89 615 69.0 20.6 136 938 114.0 45.6 271 1870
47.0 8.3 91 627 70.0 21.1 138 954 116.0 46.7 279 1922
48.0 8.9 93 639 72.0 22.2 143 987 118.0 47.8 287 1975
49.0 9.4 95 652 74.0 23.3 148 1021 120.0 48.9 294 2029
50.0 10.0 96 664 76.0 24.4 153 1055 122.0 50.0 302 2085
51.0 10.6 98 677 78.0 25.6 158 1090 124.0 51.1 310 2141
52.0 11.1 100 690 80.0 26.7 163 1126 126.0 52.2 319 2198
53.0 11.7 102 704 82.0 27.8 169 1163 128.0 53.3 327 2256
54.0 12.2 104 717 84.0 28.9 174 1201 130.0 54.4 336 2315
55.0 12.8 106 730 86.0 30.0 180 1239 132.0 55.6 345 2376
56.0 13.3 108 744 88.0 31.1 185 1279 134.0 56.7 354 2437
57.0 13.9 110 758 90.0 32.2 191 1319 136.0 57.8 363 2500
58.0 14.4 112 772 92.0 33.3 197 1360 138.0 58.9 372 2563
- - - - - - - - 140.0 60.0 381 2628
NOTE
Use this table for subcooling calculation ONLY. See Table 33 for superheat or control
adjustment.
8.1 Calculating Subcooling

Example
Measure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that pressure
on Table 34 (e.g., 93°F). Measure the temperature of the liquid line (e.g., 90°F). Subtract the actual
temperature from the liquid saturation temperature to obtain the subcooling (e.g., 93 – 90 = 3°F). If
the actual temperature is greater than the liquid saturation temperature, then there is no subcooling,
and the fluid may be a mixture of liquid and vapor.
Why There Are Two R407C Temperature and Pressure Tables
R407C is a blend of refrigerants that exhibits a temperature “glide” of approximately 8 to 12°F
(4 to 7°C). This “glide” is the difference between the liquid and vapor saturation temperatures at a
given pressure. Use the correct table for the saturation temperature you need. Table 33 is for
superheat or operating controls. Table 34 is for subcooling only.
78
R407C Refrigerant
NOTES
79
R407C Refrigerant
80
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Emerson Network Power service technicians. Liebert AC power, Outside North America: +00800 1155 4499
precision cooling and monitoring products and services Three-Phase UPS & Power Systems
from Emerson Network Power deliver Efficiency Without 800-543-2378
Compromise™ by helping customers optimize their data center Outside North America: 614-841-6598
infrastructure to reduce costs and deliver high availability. Environmental Systems
800-543-2778
Outside the United States: 614-888-0246
Locations
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
Europe
Via Leonardo Da Vinci 8
Zona Industriale Tognana
35028 Piove Di Sacco (PD) Italy
+39 049 9719 111
While every precaution has been taken to ensure the accuracy Fax: +39 049 5841 257
and completeness of this literature, Liebert Corporation assumes no Asia
responsibility and disclaims all liability for damages resulting from use of
this information or for any errors or omissions.
29/F, The Orient Square Building
© 2008 Liebert Corporation F. Ortigas Jr. Road, Ortigas Center
All rights reserved throughout the world. Specifications subject to change Pasig City 1605
without notice. Philippines
® Liebert is a registered trademark of Liebert Corporation.
All names referred to are trademarks +63 2 687 6615
or registered trademarks of their respective owners. Fax: +63 2 730 9572
SL-11962_REV3_03-11
Emerson Network Power.

The global leader in enabling Business-Critical Continuity™ EmersonNetworkPower.com
AC Power Embedded Computing Outside Plant Racks & Integrated Cabinets
Connectivity Embedded Power Power Switching & Controls Services
DC Power Infrastructure Management & Monitoring Precision Cooling Surge Protection
Emerson, Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks of Emerson Electric Co. or one of its affiliated companies.
©2008 Emerson Electric Co.

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Precision Cooling

For Business-Critical Continuity™

Liebert Challenger™ 3000 with iCOM

SAVE THESE INSTRUCTIONS

1.1 System Descriptions

1.1.1 Self-Contained Systems

1.1.2 Chilled Water Models

1.1.3 Split Systems

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

Table 1 Unit net weight

Figure 2 Upflow (BU) cabinet dimensions

REAR VIEW 1-3/4 " Return Air Louvers

Shaded area indicates a recommended

Figure 3 Downflow (BF) cabinet dimensions

Optional 1-5/8" (41mm)

1" (25mm) FRONT & SIDES

Shaded area indicates

Standard Electrical Location 28-1/2"

2.5 Piping Considerations

2.5.1 Drain Line

Figure 4 Piping connections for air-cooled units - Downflow models

Condensate Drain 3/4" FPT Liquid Refrigerant Line

Figure 5 Piping connections for air-cooled units - Upflow models

Hot Water Return

PIPING OUTLET LOCATIONS

PIPING OUTLET LOCATIONS

Liquid Refrigerant Line

Piping outlet locations through the

Humidifier Water Supply Line Hot Water Return

PIPING OUTLET LOCATIONS

Condenser Supply Line

Piping outlet locations through the plenum

Humidifier Water Supply Line Hot Water Return

Condenser Return Line Condenser Supply Line

PIPING OUTLET LOCATIONS

PIPING OUTLET LOCATIONS

Condensate Drain Chilled Water Supply Line

Hot Water Return

Humidifier Water Supply Line Hot Water Supply

Humidifier Water Supply Line Hot Water Return

Chilled Water Supply Line Chilled Water Return Line

Condensate Pump Line Hot Water Supply

PIPING OUTLET LOCATIONS

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

2.9 Checklist for Completed Installation

3.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR

3.1 Condenser Location

Figure 14 Air-cooled condensers

CONDENSER MOUNTING 1" typ.