Vertiv Challenger 3000 User manual

Challenger 3000 w/ iCOM
While every precaution has been taken to ensure accuracy and completeness in this manual,
Vertiv Co. assumes no responsibility, and disclaims all liability for damages resulting from
use of this information or for any errors or omissions.
© 2016 Vertiv Co. All rights reserved throughout the world. Specifications are subject to
change without notice.
® Vertiv and the Vertiv logo are the registered trademarks of the Vertiv Co.

Table of Contents
September 2011 - i -
1. Product Description ............................................................................. 1
2. Model Number Definition ..................................................................... 2
3. Blower/Motor Section.......................................................................... 3
3.1. Blower ............................................................................................ 3
3.2. Motor.............................................................................................. 3
4. Coil Section.......................................................................................... 5
4.1. 3T Upflow........................................................................................ 5
4.1.1. Chilled Water ............................................................................ 5
4.1.2. R-407C..................................................................................... 5
4.2. 3T Downflow.................................................................................... 7
4.2.1. Chilled Water ............................................................................ 7
4.2.2. R-407C..................................................................................... 7
4.3. 5T Upflow........................................................................................ 8
4.3.1. Chilled Water ............................................................................ 8
4.3.2. R-407C..................................................................................... 8
4.4. 5T Downflow.................................................................................... 9
4.4.1. Chilled Water ............................................................................ 9
4.4.2. R-407C..................................................................................... 9
5. Compressor Section ........................................................................... 10
5.1. Scroll.............................................................................................10
5.2. Digital Scroll...................................................................................11
6. Condenser Section ............................................................................. 12
7. Electrical Section ............................................................................... 14
7.1. EP Controls.....................................................................................14
7.2. EP Display......................................................................................15
7.3. EP Compressor................................................................................16
7.4. EP Backpanel..................................................................................18
7.5. EP Humidifier..................................................................................21
7.6. EP Fan Coil .....................................................................................23
7.7. EP Motor ........................................................................................24
7.8. EP Reheat ......................................................................................26
7.9. EP SCR Reheat................................................................................28
7.10. EP Extra Common Alarm...............................................................29
7.11. EP Compressor / Main Fan Overload...............................................30
7.12. EP Reheat Humidifier Lockout........................................................31
7.13. EP Smoke Detector ......................................................................32
7.14. EP Firestat ..................................................................................33
7.15. EP Disconnect..............................................................................34
7.16. Terminal Strips............................................................................35
7.17. Intellislot ....................................................................................36
7.18. Smoke Detector...........................................................................37
7.19. T/H Sensor / Remote Sensor .........................................................38
8. Exterior Section ................................................................................. 39
8.1. Accent Panel...................................................................................39
8.2. Upflow ...........................................................................................40
8.3. Downflow .......................................................................................41
9. Filter Section...................................................................................... 42
9.1. Upflow ...........................................................................................42
9.2. Downflow .......................................................................................42

Challenger 3000 w/ iCOM
- ii - September 2011
10. Humidifier Section.......................................................................... 43
10.1. Drain Options..............................................................................43
10.2. Infrared......................................................................................44
10.2.1. IR Assembly ............................................................................45
10.2.2. 009261 Socket Assembly...........................................................46
10.2.3. 035-0342 Hum Reset Safety......................................................46
10.2.4. Valve Solenoid Autoflush ...........................................................46
10.2.5. 009-0262 Socket Assembly........................................................46
10.3. Steam Generating........................................................................47
10.3.1. Humidifier Canister...................................................................48
11. Piping Section................................................................................. 49
11.1. Chilled Water ..............................................................................49
11.1.1. Upflow: Chilled Water ...............................................................49
11.1.2. Upflow: CW HP w/ HWRH ..........................................................50
11.1.3. Upflow: CW High Pressure .........................................................51
11.1.4. Upflow: CW w/ HWRH ...............................................................52
11.1.5. Upflow: CW w/ FS ....................................................................53
11.1.6. Downflow: Chilled Water ...........................................................55
11.1.7. Downflow: CW High Pressure.....................................................56
11.1.8. Downflow: CW w/ Hot Water Reheat...........................................57
11.1.9. Downflow: CW HP w/ HWRH ......................................................58
11.1.1. Downflow: CW w/ FS ................................................................59
11.2. Air Cooled...................................................................................61
11.2.1. Suction Line Assembly 3/5T.......................................................63
11.2.2. Liquid Line Assembly 3T A D/U (14142G1)...................................63
11.2.3. Discharge Line Assembly D/U.....................................................64
11.2.4. Hot Gas ASM 3/5T (141141G1) ..................................................64
11.2.5. Discharge Line Assembly (179738G2) .........................................65
11.2.6. Digital Solenoid Valve Assembly.................................................65
11.3. Water/Glycol ...............................................................................66
11.3.1. Water/Glycol Cooled POE...........................................................66
11.3.2. Liquid Line Assembly 3T D/U 3000 (141143G1)............................67
11.3.3. Liquid Line Assembly ½ (196665G1-G2)......................................67
11.3.4. Discharge Line Assembly 3T/5T C3000........................................68
11.3.5. Water/Glycol Cooled R-407C......................................................69
11.3.6. Digital Solenoid Valve Assembly.................................................70
11.3.7. Hot Gas Reheat........................................................................71
11.3.8. Suction Assembly (196088G1) ...................................................72
11.4. Glycool Cooled.............................................................................73
11.4.1. Standard/High Pressure ............................................................73
11.4.2. Suction Line Assembly (196693G1) ............................................74
11.4.3. Digital.....................................................................................75
11.4.4. Suction Line Assembly 5T Upflow (196693G1)..............................76
11.4.5. Scroll......................................................................................76
11.5. Evaporator..................................................................................78
11.5.1. Upflow ....................................................................................78
11.5.2. Downflow ................................................................................79
11.5.3. Suction Line Assembly 3T/5T Evap Upflow (141144).....................80
11.5.4. Liquid Line Assembly 3T/5T Evap Upflow (141145).......................81
11.5.5. Suction Assembly (196835G1) ...................................................82
11.5.6. Liquid Assembly (196836G1) .....................................................83
12. Reheat Section ............................................................................... 84
13. Parts Gallery................................................................................... 85
14. Revision Page................................................................................. 92

Product Description
September 2011 - 1 -
1. Product Description
Liebert Challenger 3000 is available in 10.5 and 17.5 kW (3 and 5 tons) capacities, 60 Hz
and 50 Hz models. Air cooled, water cooled, glycol cooled, GLYCOOL™ and chilled water
configurations. Upflow and downflow models available.
Flexibility:
Liebert iCOM controls are available in large and small graphic models, to provide the level of
information and control needed for unique IT spaces.
Self-contained systems available with energy efficient Digital Scroll compressor.
Provides enhanced temperature control with optional SCR-controlled reheat.
Reduces noise levels within the room unit, when installed as a split system with remotely
located compressor and condenser.
Higher Availability:
Features reliable refrigeration components, such as digital scroll or scroll compressor, A-
Frame evaporator coil, all factories pre-piped, wired, and tested in a rugged, easy-access
tubular-steel frame.
Lowest Total Cost of Ownership:
Utilizes digital scroll or scroll compressor for energy efficiency.
Minimizes short cycling and other wasteful operating patterns with fast response
microprocessor controls.
iCOM controls are proven to improve energy efficiency, with teamwork and zone
configurations.
Ideally Suited For:
Laboratories and medical imaging suites
Telecommunications switching offices
Industrial process control
Data centers

Challenger 3000 w/ iCOM
- 2 - September 2011
2. Model Number Definition

Blower/Motor Section
September 2011 - 3 -
3. Blower/Motor Section
3.1. Blower
Item - Type
Part #
Description
Type
3T
5T
1
B-0080
BUSHING PULLEY H 1"DIA
-
1
1
3
136589P1
BLOWER W/H A12-06ATX1.00 CL2
-
1
1
136590P1
BLOWER W/H A12-09ATX1.00 CL2
-
1
1
8
136591P1
SHAFT 19.25 X 1.00 CLASSII
-
1
1
9
197699P1
BEARING PILLOW BLOCK 1" DIA
-
2
2
3.2. Motor
Item
HP
Part #
Description
Quantity
1
.75HP
1A21868P1
MOTOR .75HP 208//460-3-60 HIE
1
B13-0260
MOTOR .75HP 208-3-60 INTOL
1
B13-0270
MOTOR .75HP 230/460-3-60
1
136746P1
MOTOR .75HP 575 HI EFF
1
B13-0280
MOTOR .75HP 575-3-60 INTOL
1
1HP
B-1720
MOTOR 1.0HP 200/208-3-60 E+
1
B-0900
MOTOR 1.0HP 200/380/400-3-50
1
B13-0290
MOTOR 1.0HP 208-3-60 INTOL
1
B-1080
MOTOR 1.0HP 220/380-3-50
1
B13-0300
MOTOR 1.0HP 230/460-3-60
1
B-1730
MOTOR 1.0HP 230/460-3-60
1
B-2200
MOTOR 1.0HP 380-3-60
1
136746P2
MOTOR 1.0HP 575 HI EFF
1

Challenger 3000 w/ iCOM
- 4 - September 2011
Item
HP
Part #
Description
Quantity
B13-0310
MOTOR 1.0HP 575-3-60 INTOL
1
1.5HP
B-2210
MOTOR 1.5HP 190/380-3-60
1
B-1740
MOTOR 1.5HP 200/208 E+ OPD
1
B-0910
MOTOR 1.5HP 200/380/400-3-50
1
B-1090
MOTOR 1.5HP 220/380-3-50
1
B-1750
MOTOR 1.5HP 230/460 E+ OPD
1
136746P3
MOTOR 1.5HP 575 HI EFF
1
B13-0320
MOTOR 1.5HP 208/230-3-60 INTOL
1
B13-0330
MOTOR 1.5HP 230/460-3-60
1
B13-0340
MOTOR 1.5HP 575-3-60
1
160630P1
MTR 1.5HP 208-230/460 & 190/380
1
2HP
B-1760
MOTOR 2.0HP 200/208-3-60 E+
1
B-0920
MOTOR 2.0HP 200/380/400-3-50
1
B-022A
MOTOR 2.0HP 208/230/460-3-60
1
B-1100
MOTOR 2.0HP 220/380-3-50
1
B-1770
MOTOR 2.0HP 230/460-3-60
1
136746P4
MOTOR 2.0HP 575 HI EFF
1
B-023A
MOTOR 2.0HP 575-3-60
1
3HP
B-025A
MOTOR 3.0HP 208/230/460-3-60
1
B-026A
MOTOR 3.0HP 575-3-60
1
Item
Part #
Description
Quantity
2
B-0660
SHEAVE 1VP56X7/8
1
B-005A
SHEAVE 1VP50X7/8
1
136944P1
SHEAVE 1VP50X1-1/8
1
136945P1
SHEAVE 1VP56X1-1/8
1
B13-0120
SHEAVE 1VP44X7/8
1
B13-0110
SHEAVE 1VP40X7/8
1
B13-0080
SHEAVE 1VP34X5/8
1
183106P1
SHEAVE AK71H
1
183107P1
SHEAVE AK74H
1
B-0810
SHEAVE 1VP44X5/8
1
B13-0090
SHEAVE 1VP34X7/8
1
4
183105P1
SHEAVE AK66H
1
183106P1
SHEAVE AK71H
1
B13-0150
PULLEY AK61H
1
183107P1
SHEAVE AK74H
1
20
B13-0200
BELT A-36
1
B13-0210
BELT A-37
1
128179P1
BELT A-38 "V" BELT
1
B13-0220
BELT A-39
1
B13-0250
BELT A-40
1
B13-0230
BELT A-41
1
B-1690
BELT A-36
1
B-0550
BELT A-42
1
B-0600
BELT A-38
1
B13-0240
BELT A-42
1
B-1490
BELT A-34
1
30
136610P1
BASE MOTOR MTG
1
136983P1
PLATE MTG MTR C3000 ICS
1

Coil Section
September 2011 - 5 -
4. Coil Section
4.1. 3T Upflow
4.1.1. Chilled Water
Item
Part #
Description
Quantity
1
136653G4
COIL CW ASSY C3000 U
1
136653G2P
COIL CW ASSY C3000 U HERESITE
1
136688G4
COIL CW ASSY 3T W/HWRH U
1
2
136631G1
PAN DRAIN COIL U C3000
1
4.1.2. R-407C
Item
Part #
Description
Quantity
1
195621G4
COIL DX ASSY 3T HW/HG U RIF
1
195617G4
COIL ASSY 3T DX U RIFLED
1
195617G2P
COIL ASSY 3T DX U RIFLED
1
2
136631G1
PAN DRAIN COIL U C3000
1
99
128157P1
VALVE EXP 1/2X5/8X1/4ODF 3T
1

Challenger 3000 w/ iCOM
- 6 - September 2011

Coil Section
September 2011 - 7 -
4.2. 3T Downflow
4.2.1. Chilled Water
Item
Part #
Description
Quantity
1
136653G1
COIL CW ASSY C3000 D
1
136653G3P
COIL CW ASSY C3000 D LIBCOTED
1
136688G1
COIL CW ASSY 3T W/HWRH D
1
3
136778G1
PAN DRAIN COIL C3000
1
4.2.2. R-407C
Item
Part #
Description
Quantity
1
195621G1
COIL DX ASSY 3T HW/HG D RIFLED
1
195617G3P
COIL ASY 3T DX D W/LIBCOTE RIF
1
195617G1
COIL ASSY 3T DX D RIFLED
1
3
136778G1
PAN DRAIN COIL C3000
1
9
128157P1
VALVE EXP 1/2X5/8X1/4ODF 3T
1

Challenger 3000 w/ iCOM
- 8 - September 2011
4.3. 5T Upflow
4.3.1. Chilled Water
Item
Part #
Description
Quantity
1
136977G4
COIL CW ASSY C3000 5T U
1
136977G2P
COIL CW ASSY C3000 5T U HERE
1
136689G4
COIL CW ASSY 5T W/HWRH U
1
2
136631G1
PAN DRAIN COIL U C3000
1
4.3.2. R-407C
Item
Part #
Description
Quantity
1
194598G1
COIL ASSY 5T DX U
1
194598G3P
COIL 5T DX U W/HERESITE RIF
1
195583G1
COIL DX ASSY 5T U HW/HG RIFLED
1
195586G8
COIL ASSY 5T UF GLYCOOL RIFLED
1
195603G1P
COIL ASSY 5T UF GLYCOOL RIFLED
1
2
136631G1
PAN DRAIN COIL U C3000
1
12
P02-0290
VALVE CORE REFRIGERANT
1
99
128158P1
VALVE EXP 1/2X5/8X1/4ODF 5T
1

Coil Section
September 2011 - 9 -
4.4. 5T Downflow
4.4.1. Chilled Water
Item
Part #
Description
Quantity
1
136977G1
COIL CW ASSY C3000 5T D
1
136977G3P
COIL CW ASSY C3000 5T D HERE
1
136689G1
COIL CW ASSY 5T W/HWRH D
1
3
136778G1
PAN DRAIN COIL C3000
1
4.4.2. R-407C
Item
Part #
Description
Quantity
1
194598G2
COIL ASSY 5T DX D
1
194598G4P
COIL ASSY 5T DX D RIF W/HERE
1
195583G2
COIL DX ASSY 5T D HW/HG RIFLED
1
195586G7
COIL 5T DF RIF GLYCOOL C3000
1
195677G2P
COIL 5T GLYCOOL D RIF W/LIBC
1
33
136778G1
PAN DRAIN COIL C3000
1
99
128158P3
VALVE EXP 1/2X5/8X1/4ODF
1

Challenger 3000 w/ iCOM
- 10 - September 2011
5. Compressor Section
5.1. Scroll
Item
Part #
Description
Voltage
Quantity
1 – 3T
176751P1
COMP SCRL ZR47KCE-TF5 W/O ROTA
200/235
1
176751P2
COMP SCRL ZR47KCE W/O ROTA POE
380/420
1
176751P5
COMP SCRL ZR47KCE-TF7 W/O ROTA
386
1
179860P1
COMP SCRL ZR40K3E-TF5 W/ROTA
208/236
1
179860P2
COMP SCRL ZR40K3E-TFD W/ROTA
460
1
179860P3
COMP SCRL ZR40K3E-TFE W/ROTA
575
1
1 – 5T
169260P1
COMP SCRL ZR61KCE-TF5 W/ROTO
208/236
1
169260P2
COMP SCRL ZR61KCE-TFD W/ ROTA
460
1
169260P3
COMP SCRL ZR61KCE 575 W/ROTO
575
1
169260P5
COMP SCRL ZR61KCE-TF7 W/ ROTA
386
1
172139P1
COMP SCRL ZR72KCE-TF5 W/ ROTA
200
1
172139P2
COMP SCRL ZR72KCE-TFD W/ROTA
380/420
1
2
180970P1
PRESS SW HP SPDTAR C/OUT 400PS
-
1
1D14684P1
PRESS SW HI-LO 360/15-35 PSI
-
1
1D16204P1
PRESS SW DUAL PRESSURE
-
1
3
132102P1
HEATER C/CASE 240V 40W SCROLL
-
1
132102P2
HEATER C/CASE 480V 40W SCROLL
-
1
132102P3
HEATER C/CASE 575V 40W SCROLL
-
1
134142P1
HEATER C/CASE 240V 70W SCROLL
-
1
134142P2
HEATER C/CASE 480V 70W SCROLL
-
1
134142P3
HEATER C/CASE 575V 70W SCROLL
-
1
6
1D16206P1
SW PRES LOW 20/65PSI
1
1D15059P1
SW PRES LOW 15/35PSI
1

Compressor Section
September 2011 - 11 -
5.2. Digital Scroll
Item
Part #
Description
Quantity
1 – 3T
193788P1
COMP SCDG ZRD42KCE-TFD SWEAT
1
180406P1
COMP SCDG ZRD49KCE-TF5 W/ ROTA
1
180406P2
COMP SCDG ZRD49KCE-TFD W/ ROTA
1
1 – 5T
178013P1
COMP SCDG ZRD61KCE-TF5 W/ROTA
1
178013P2
COMP SCDG ZRD61KCE-TFD W/ROTA
1
178013P3
COMP SCDG ZRD61KCE-TFE W/ROTA
1
178013P5
COMP SCDG ZRD61KCE-TF7 W/ROTA
1
180407P1
COMP SCDG ZRD72KCE-TF5 W/ROTA
1
180407P2
COMP SCDG ZRD72KCE-TFD W/ROTA
1
2
180970P1
PRESS SW HP SPDTAR C/OUT 400PS
1
3
132102P1
HEATER C/CASE 240V 40W SCROLL
1
132102P2
HEATER C/CASE 480V 40W SCROLL
1
134142P1
HEATER C/CASE 240V 70W SCROLL
1
134142P2
HEATER C/CASE 480V 70W SCROLL
1
134142P3
HEATER C/CASE 575V 70W SCROLL
1
20
1D15059P1
SW PRES LOW 15/35PSI
1
1D16206P1
SW PRES LOW 20/65PSI
1
25
183151P1
SENSOR THERMISTOR ZRD94//125
1

Challenger 3000 w/ iCOM
- 12 - September 2011
6. Condenser Section
Item
Part #
Description
Type
Quantity
1
128159P1
CONDENSER COAXIAL
-
1
128159P2
CONDENSER COAXIAL 90/10 CU-NI
-
1
2
3T
136696P1
VALVE H2O REG 2WAY 3/4" UB
SP
1
136698P1
VALVE H2O REG 3WAY 3/4" UB
SP
1
185660P13
VALVE MBV 2W 1" BLM 24V
SP
1
185661P13
VALVE MBV 3W SR BLM 24V
SP
1
P-026A
VALVE H2O REG 2WAY 3/4" 350#
HP
1
P-4760
VALVE H2O REG 3WAY 3/4" 300#
HP
1
5T
131852P1
VALVE H2O REG 2WAY 1" UB
SP
1
131853P1
VALVE H2O REG 3WAY 1" UB
SP
1
185660P13
VALVE MBV 2W 1" BLM 24V
SP
1
185661P13
VALVE MBV 3W SR BLM 24V
SP
1
P-311A
VALVE H2O REG 2WAY 1" 300#
HP
1
P-311B
VALVE H2O REG 3WAY 1" 300#
HP
1
4
1C14431P4
VALVE BALL BRONZE 1/2SWT F/P
-
1

September 2011 - 13 -

Challenger 3000 w/ iCOM
- 14 - September 2011
7. Electrical Section
7.1. EP Controls
.
Item
Part #
Description
Quantity
1
416761G1
PWA ENV ICOM CTRL LARGE
1
6
135637P5
FUSE KIT QTY 6-4A/2-3A NON-TD
1
135637P6
FUSE KIT QTY 6-6A/2-3A NON-TD
1
57
417341G1
PWA ENV GLOBAL FUSE BOARD
1
60
135409P2
FUSE GLASS 250V 4AMP .25X1.25
5 (60Hz)
135409P3
FUSE GLASS 250V 6AMP .25X1.25
5 (50Hz)
71
180792P1
TRANSFORMER ISOLATION
1
180792P2
TRANSFORMER ISOLATION 27VA
1

Electrical Section
September 2011 - 15 -
7.2. EP Display
Item
Part #
Description
Quantity
1
180632G2
DISPLAY ASSY LRG GR LED GL
1
180633G1
DISPLAY ASSY LRG SM GR ICOM
1
3
179747P2
DISPLAY BEZEL NO LOGO
1
4
179751P1
DISPLAY CRADLE LARGE GLOBAL
1
8
181898P1
COUPLER XOVER CAT5E RJ45 F/F
1

Challenger 3000 w/ iCOM
- 16 - September 2011
7.3. EP Compressor

Electrical Section
September 2011 - 17 -
Item
Part #
Description
Type
Voltage
CB
FUSED
141 136233P1
CONTACTOR
3P30IND40RES24/50AUX
-
200/230
1
-
380/415
1
123273P1
CONTACTOR 3PL 25/30
NO/NC AUX
-
200//230
1
-
380//575
1
142
136241P10
CB MCB 3P 240/415V 16A K
CURVE
- 380/415 1
136241P12
CB MCB 3P 240/415V 25A K
CURVE
- 200/230 1
136241P13
CB MCB 3P 240/415V 32A K
CURVE
- 200/230 1
136811P1
FUSEBLOCK BUSS JP600V
30A 3P
- 380//575 1
E-1020
FUSEBLOCK 250V 3P 030A
-
200//230
1
143
136821P13
FUSE DUAL ELMNT "J" 600V
17.5A
- 380//575 3
E-2080
FUSE DUAL ELMNT 250V
25.0AMP
- 200//230 3
E-2090
FUSE DUAL ELMNT 250V
30.0AMP
- 200//230 3