ENP DCD Commissioning Protocol
Contents
1. ST Wire Grounding 250 6 RA5xRA5 ST EARTH WIRE 200 6 RASxFH6 3pl ST M5 TENSILOCK NUT bag nr 1 ST M5 MOUNTING NUT MIR EXTRUSION ST washer M5 30 ST Star Screw M5x10 bag nr 2 16 ST Spring Nut M5 broad bag nr 3 8 ST DIN965 M6x16 bag nr 4 To unpack ENP DCD shipped separately follow the instructions shown in Fig 6 ENP DCD 01 998 355 0 Page Seite 17 54 ENP DCD Se User manual Network Power Cut binding straps o N 2 Remove the protective foam covers Fig 6 Unpacking ENP DCD To unpack the ENP DCD as a part of the rack follow instructions show in Fig 7 ENP DCD 01 998 355 0 Page Seite 18 54 ENP DCD 4 EMERSON User manual 3 Lift the unit off the pallet by forklift or manually Remove the shrink wrap and the corner protectors 4 Slide the pallet out 2 Unscrew the braces 4 pcs 5 Adjust the feet Fig 7 Unpacking the ENP DCD part of the rack ENP DCD 01 998 355 0 Page Seite 19 54 ENP DCD kd EMERSON User manual 1 After removing the packaging first lift the ENP DCD frame of the pallet Fig 8 At this point the door and the frame are not fixed together yet Fig 8 Lifting the frame 2 Then align the frame of the ENP DCD to server rack properly Mark the positions of the frame holes there are 16 holes on the aluminium profile of the server rack and put the frame aside again Fig 9 Marking the position2. Fig 32 Aluminium frame submittal drawing ss nn Fig 33 Server rack with the ENP DCD net Fig 34 Connection Set Fig 35 Connection set detail 2 Fig 36 Performance chart 1 sse n nanna nanna Fig 37 Performance chart 3 Fig 38 Performance chart 3 Fig 39 Air side pressure drop Fig 40 Water side pressure drop ENP DCD 01 998 355 0 e EMERSON Page Seite 6 54 ENP DCD l EMERSON User manual List of tables Tab 1 Listof tools Ce ITT elem ee ee 17 Tab 2 Packaging liS tai c e tor ete at TA 17 Tab 3 Operati n Conditions ine rein in rei 32 Ee M8 oe TIR Ee EE 35 Tab 5 Aluminium frame dimensions nennen 38 Tab RE nl Ee le te E 39 Tab 7 Hydrological requirements ssssssssssssssssssssssesee eene ennt enne nter nnan nanne ennn 45 Tab 8 Setup checklist rm 46 Tab 9 Unit conversion i alay aydan eku ata ida e lala araya 53 ENP DCD 01 998 355 0 Page Seite 7 54 ENP DCD gl EMERSON User manual 0 Abstract ENP DCD is an air water heat exchanger that is integrated into the rear door of a server rack The heat exchanger is suitable for absorbing heat loads from server racks of up to 35 kW It can be configured in such way that no heat is released to the installation area Cooling effect occurs when the server exhaust air passes through the heat exchanger in the rear section of the server rack The cooling air is moved through the heat exchanger only by the s
3. protection G 1200 mm 47 2 8 S Seaworthy air freight long 3 3 part rack adaptor distance wooden crate 0 no rack 22 SFA special features M modification custom SFA only X SFAs included 9 Chilled water connection hinge position A no SFAs 1 top left 23 25 Order identifier 2 top right 3 bottom left 4 bottom right Detail A Bottom View Facing the Aide Facing the Rack 1 Upper Swivel Joint Cover i Lower Swivel Joint Cover Chilled Water Dutlet Chilled Water Inlet Handle Frame Door Lower piping Door Door upper piping f cub Er per pc Bottom View 10 Aluminum Profile 11 Condensate Drain Plug 12 Condensate Tray 13 Condensate Hos Adaptor Fig 1 Component location ENP DCD User manual me Contents Unit code and component location uunnsserennnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnernnn nennen nenn nennen 3 CONTENTS i iaaii 5 List OF GUTES e 6 List OF tables sisien a aaa a a EA 7 0 AS e ae e en er e e accuse 8 1 LE G REK AM DRAM EA ME MM Eee RA ei eee Eeee e SEE e 8 L Symbols EE 8 1 2 Safety notice i iii i ee nnd 9 Storage and Ken EE 11 Installation and commissioning erresnnsennnnnnnennnnnnnnnnnnnnennnnannennnnan nennen anne nennt nnne nnn anne 12 3 1 Preparations
4. 1 ENP DCD 01 998 355 0 Page Seite 41 54 ENP DCD EMERSON User manual Network Power Fig 33 Connection se Fig 34 Connection set detail Note All parts of the set are supplied as individual parts and are connected by the customer ENP DCD 01 998 355 0 Page Seite 42 54 ENP DCD User manual EMERSON 6 Maintenance and repairs A All maintenance and repair jobs are to be performed by qualified personnel only All actions must be in accordance with regulations and instructions of the manufacturer For maintenance and repair jobs use only the tools and spare parts approved by manufacturer of the device Before commencing anv work on the chilled water svstem let the svstem drain General maintenance actions to be carried out e Check the heat exchanger pollution dust etc e Check functionality of the valves e Check the chilled water system for leaks visually Please note that dirt dust layer etc on the heat exchanger reduces the performance of the device increased pressure loss worse heat transfer Vacuum cleaner soft brush or compressed air can be used to clean the fins of the heat exchanger ENP DCD 01 998 355 0 Page Seite 43 54 ENP DCD PIN User manual 7 Disassembly and disposal Disassembly of the ENP DCD may be performed by qualified personnel only Shut down the chilled water system before disassem
5. 3 After that insert the spring nuts into the groove of the rack aluminium profile in to previously marked position Fig 10 ENP DCD 01 998 355 0 Page Seite 20 54 ENP DCD 4 EMERSON User manual Fig 10 Inserting the spring nuts 4 Insert 3 diamond nuts into the grove of each horizontal member of the rack aluminium profile in the previously marked position Fig 11 Fig 11 Diamond nuts 5 Before proceeding to the next step connect the hose adaptor piece 5 8 into the condensate tray remove the white plastic plug first Fig 12 ENP DCD 01 998 355 0 Page Seite 21 54 amp ENP DCD EMERSON User manual Network Power Fig 12 Hose piece adaptor 6 In the next step place the adhesive strip of foam included on the rack s aluminium profile hinge side in such way that when the ENP DCD frame is in the position the foam strip will seal the gap between rack and the ENP DCD frame It might be necessary to trim the foam strip with utility knife Fig 13 Fig 13 Position of the sealing foam ENP DCD 01 998 355 0 Page Seite 22 54 ENP DCD 4 EMERSON User manual 7 Now you can start attaching the frame of ENP DCD to the rack using the socket screw driver Fig 14 Tighten the screws all around the perimeter of the frame first lightly and then to 3 Nm 2 pound foot This is the only way to prevent the frame from twisting and to ensure the parts fit properly Fig 14 Tightening the s
6. 53 6 F 64 4 F other temperatures on request 18 C 24 C 64 4 F 75 2 F other temperatures on request 10 bar 145 psi 1 F on the frame DIN ISO 228 1 01 998 355 0 Page Seite 39 54 ENP DCD y EMERSON User manual 5 Variants and options 5 1 ENP DCD built in the server rack Optional ENP DCD is typically delivered as a part of a specially prepared server rack The DCM server rack offers guaranteed air separation between the hot and the cold air within the cabinet For a detailed description check the Kn rr DCM manual Fig 32 Server rack with the ENP DCD ENP DCD 01 998 355 0 Page Seite 40 54 ENP DCD kd EMERSON User manual 5 2 Connection set ENP DCD Optional This set is for recommended connection of the ENP DCD with the on site chilled water system ENP DCD connection set consists of e Reinforced hose with nickel plated connections EPDM resistant to water and anti freeze Temperature range 0 C 110 C 32 F 230 F Maximum operating pressure 10 bar 145 psi Inner diameter 25 mm 1 Connection 1 F 1 M DIN ISO 228 1 Length 1500 mm 59 1 1 mm 0 0394 in e Ball valve with fitting Ventilation and drain connection 342 possibility of pressure and temperature measurements Connection 1 F DIN ISO 228 1 e Shut off and regulation valve Discharge vent 34 possibility of pressure and temperature measurements Connection 1 F DIN ISO 228
7. manual Performance chart Kn rr DCD 1 8m h 7 9USgpm HA OC HA o o ri 5 fi i E 3 m a a a a o 10 Heat load kW ZC cw sippy Emperatte 18 C cw sipph temperate 22 C ew sippy empe rattie Fig 37 Performance chart 3 Kn rr DCD air side pressure drop Airflow cfm 2000 2500 to o Fressure Drop Fa N o Pressure Drop inH20 3000 4000 Airflow mih Fig 38 Air side pressure drop ENP DCD 01 998 355 0 Page Seite 52 54 ENP DCD S EMERSON User manual Kn rr DCD water side pressure drop Waeflow USgpm 10 15 8 8 3 a a a H g 2 un d N d i N m Waterflow m Fig 39 Water side pressure drop 9 5 Unit conversion chart Tab 10 Unit conversion 1mm 0 0394 in 1kg 2 205 Ibs 1 bar 14 504 psi F ec 1 8 32 ENP DCD 01 998 355 0 Page Seite 53 54 As at August 2013 Version 1 0 Emerson Network Power a business of Emerson NYSE EMR Locations ay e mn Emerson Network Power EMEA protects and optimizes critical infrastructure for data centers AN communications networks healthcare and industrial facilities Kn rr GmbH Mariakirchener Stra e 38 J 1 94424 Arnstorf 7 Germany The company provides new to the world solutions as well as T 49 8723270 established expertise and smart innovation in areas including F 49 8723 27 154 AC and DC power and renewable en
8. one of its affiliated companies 2013 Emerson Electric Co
9. the unit to be disconnected from the system for repairs and maintenance without taking the whole system down 600mm 23 5 8 Floor Cut Out uiu Qz T 54mm 2 1 8 Floor Cut Out 700mm 27 1 2 54mm 2 1 8 Floor Cut Out 800mm 31 1 2 WULUOZT 54mm i 1 8 Fig 4 Floor cut outs unit itself ENP DCD 01 998 355 0 Page Seite 14 54 EMERSON ENP DCD User manual Floor Cut Out 600mm 23 5 8 54mm 2 1 8 700mm 27 1 2 Floor Cut Out 54mm 2 1 8 800mm l 31 1 2 Floor Cut Out uiuiggT 54mm 2 1 8 Fig 5 Floor cut outs unit with aluminium frame 01 998 355 0 Page Seite ENP DCD 15 54 ENP DCD g EMERSON User manual 3 3 Assembly procedure and tools required Assembly of the ENP DCD must be carried out in vertical position of the device Please use a level to make sure this requirement is met when commencing the installation ENP DCD and the rack must be vertically aligned to provide proper functionality Strict separation between the hot and cold air within the case must exist To ensure suficient air circulation please make sure there are no obstructions e g packaging materials tools etc left in e Grids e Heat exchanger e Air intake e Air outlet This guideline only applies if you have bought ENP DCD as a separate product not being part of a rack already If you
10. 55 0 Page Seite 36 54 ENP DCD EMERSON User manual Network Power T 73 plug door grounding cable l item 21 here Ansicht von unten connection B bottom view T internal thread tomertion A 1 internal thread Fig 30 Submittal drawings ENP DCD left hinges f mm 0 0394 in ENP DCD 01 998 355 0 Page Seite 37 54 ENP DCD EMERSON User manual network Pov Fig 31 Aluminium frame submittal drawing 1 mm 0 0394 in Tab 6 Aluminium frame dimensions mm in B 592mm Cz1954mm D 65 9mm E 53 5mm B 23 2 8 C 76 7 8 D 2 5 8 E 2 1 8 F 49 5mm G 48 7mm H 37 7mm l 22 6mm F 2 G 1 7 8 Hz1 1 2 l 7 8 J220 5mm K 18 6mm L 15mm M 20 6mm J 6 8 K 6 8 L 5 8 M 6 8 N 7 9mm N 2 8 ENP DCD 01 998 355 0 Page Seite 38 54 ENP DCD User manual Tab 7 Technical specifications Cooling air side Housing material Operating ambient temperature Maximum absolute air humidity on site Air outlet temperature Air temperature difference IN OUT Chilled water side Cooling performance Chilled water temperature inlet Chilled water temperature outlet Maximum operating pressure Pipe connection IN OUT ENP DCD e EMERSON Steel plate powder coated 10 C 35 C 50 F 95 F other temperatures on request 8 g kg 18 C 27 C 64 4 F 80 6 F in accordance with ASHARE 15K 20K 35 kW 12 C 18 C
11. B 85 3 4 C 23 5 8 D 19 3 8 F 12 5 8 G 6 H 4 6 8 F 12 5 8 G 6 H 4 6 8 l 1 6 8 J 1 5 8 K 1 l 1 6 8 J 1 5 8 K 1 L 2 M 2 7 8 N 1 L 2 M 2 7 8 N 1 B 1954mm C 700mm D 593mm B 2176mm C 700mm D 593mm F 372mm G 151mm H 120mm F 372mm G 151mm H 120mm 700 mm l 45mm J 40 7mm K 24mm l 45mm J 40 7mm K 24mm 27 1 2 L 52mm M 73mm N 25mm L 52mm M 73mm N 25mm B 77 7 8 C 27 1 2 D 23 3 8 B 85 3 4 C 27 1 2 D 23 3 8 F 14 5 8 G 6 H 4 6 8 F 14 5 8 G 6 H 4 6 8 l 1 6 8 J 1 5 8 K 1 l 1 6 8 J 1 5 8 K 1 L 2 M 2 7 8 N 1 L 2 M 2 7 8 N 1 B 1954mm C 800mm D 693mm B 2176mm C 800mm D 693mm F 422mm G 151mm H 120mm F 422mm G 151mm H 120mm 800 mm l 45mm J 40 7mm K 24mm l 45mm J 40 7mm K 24mm 31 1 2 L 52mm M 73mm N 25mm L 52mm M 73mm N 25mm B 77 7 8 C 31 1 2 D 27 1 4 B 85 3 4 C 31 1 2 D 27 1 4 F 16 5 8 G 6 H 4 6 8 F 16 5 8 G 6 H 4 6 8 l 1 6 8 J 1 5 8 K 1 l 1 6 8 J 1 5 8 K 1 L 2 M 2 7 8 N 1 L 2 M 2 7 8 N 1 Please find the reference to the dimensions stated in this table in the Fig 29 and Fig 30 ENP DCD 01 998 355 0 Page Seite 35 54 ENP DCD EMERSON User manual Network Powe plug door grounding cable item 21 here water supply r 1 1 internal thread bottom view water return T internal thread Fig 29 Submittal drawings ENP DCD right hinges 1 mm 0 0394 in ENP DCD 01 998 3
12. Bottom Swivel Joint Fig 23 Inside swivel joint covers 15 In the last step connect the grounding wire of the door to the frame of the ENP DCD Fig 24 Fig 24 Attaching the grounding wire Check if this connection is alright e g by using diode or continuity test on a multimeter 16 Check functionality of the door lock ENP DCD is equipped with DIRAK 1333 lock It is a 2 inch cylinder lock Keys are provided ENP DCD 01 998 355 0 Page Seite 29 54 ENP DCD User manual e EMERSON 3 3 Chilled water connection A Check the chilled water system for leaks visually before commissioning Please check the chilled water pipe connection to the heat exchanger regularly Tighten this connection if necessary When setting up the heat exchanger for the first time please inspect the mechanical condition of the chilled water supply and connection thoroughly Note Using the optional connection set chapter 5 2 improves the ventilation and enables chilled water flow monitoring and regulation There is a risk of frost damage to the device during longer stops e g storing etc Make sure the heat exchanger and the supply pipes are free of any water use compressed air if necessary and remove all the vents and the screws before storing The coil and piping can be damaged due to thermal expansion of the cooling fluid with no means of expansion e g closing the ball valves on b
13. Kn rr DCD User manual amp EMERSON e EMERSON User manual Emerson Network Power DCD Kn rr DCD Liebert DCD Rear door heat exchanger up to 35kW for mounting on a rack Date Datum Issue Ausgabe Author Erstellt Reviewed Gepr ft 24 11 14 01 998 355 0 Martin BLASS Heiko EBERMANN e EMERSON Unit code and component location Model number part 1 2 Model details Part 2 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 DjC D 3 5 1A 6 3 3 0 0 0 0 0 0 1 0 0 0 0 S X10 0 1 3 Product identification 10 Options DCD ENP DCD 0 No options Not available at the 4 5 Nominal cooling capacity moment 35 35 kW 11 15 Not in use 6 Rack height 0 No options Not available at the A 2000 mm 78 6 8 moment B 2100 mm 82 5 8 16 Color C 2200 mm 86 5 8 1 RAL 7035 light grey M modification custom SFA only G RAL 7021 dark grey 7 Rack width 2 non standard color SFA 6 600 mm 23 5 8 17 20 Not in use 7 700 mm 27 4 8 0 No options Not available at the 8 800 mm 31 4 8 moment M modification custom SFA only 21 Packaging 8 Rack depth P Land freight short distance E 1000 mm 39 3 8 pallet shrink wrap cardboard F 1100 mm 43 3 8
14. ables connected with server cabinet Temperature sensors optional Server shut down optional Door contact optional Unit connected with set of external valves optional Valve drive Flow meter with temperature sensors optional Optional automatic door opening adjusted at server cabinet No remainders of packaging inside ENP DCD All assembly tools removed Bushings into the device proper and air tight Chilled water connection leak proof pressure tested Chilled water system de aerated Volume flow of chilled water adjusted Condensed water line unobstructed Smell trap of chilled water system functional Condensate tray connected to condensed water line All front panels closed air ducts technically separated ENP DCD 01 998 355 0 Signature of Tester Page Seite 46 54 ENP DCD gl User manual EMERSON 9 3 Commissioning Protocol 1 2 ENP DCD Commissioning Protocol General Details Customer Site of installation Customers name eese Customers address I I Contact partner 0 II Phone number rr Site of installation room number Genn Humidity at site of installation 2eeeeee rel humidity Ambient temperature eosecesesseeeeeeee C Configuration Cabinet type ENP DCD 35 kw LI Commissioning number if applicable 000000 Serial number NIN Special re
15. bly and prevent it from A restarting Dispose all the components and parts in accordance with local waste management and regulations We recommend a recvcling companv All components consist of e Aluminium steel brass copper e Marked plastic components 8 Customer service All Kn rr products are subject to continuous quality control and comply with applicable regulations For any questions you have related to our products please contact the manufacturer of your system directly Kn rr GmbH Glash ttenstra e 1 01623 Lommatzsch Tel 49 0 800 000 6295 Email service knuerr com ENP DCD 01 998 355 0 Page Seite 44 54 ENP DCD User manual 9 Annexes e EMERSON 9 1 Quality Requirements for water used in the ENP DCD In order to safeguard the maximum lifetime of air water heat exchangers the water applied for chilling purposes must meet the VGB Chilled Water Guidelines VGB R 455 P The chilled water used must be soft enough to prevent deposits but it must not be too soft which would lead to corrosion of the heat exchanger The following table contains the most important impurities and counter measures for their removal Water impurity Method for removal Mechanical impurity dp 0 3 mm Filter the water Excess hardness Soften the water by ion exchange Moderate level of mechanical impurities and hardeners Add dispersion or stabilizing agents Mod
16. bought the ENP DCD as a part of the rack it would come already assembled In this case please proceed after unpacking Fig 7 to attaching the hose adaptor piece from beneath Fig 12 The procedure described is valid for Kn rr racks DCM only Installation and commissioning of the ENP DCD must be performed only by qualified A personnel All actions must be in accordance with regulations and instructions of the manufacturer Warningl Protective equipment e g boots must be worn during installation and A maintenance of this device Please check vour local regulations on using safetv equipment before commencing anv operations This procedure also requires at least 2 persons to complete The unit weighs 95 kg approx 210 pounds ENP DCD 01 998 355 0 Page Seite 16 54 ENP DCD y EMERSON User manual Tab 2 List of tools required Socket hexagonal screw driver 8 mm 5 16 for M5 screws Open jaw wrench 41 mm 1 5 8 Open jaw wrench 36 mm 1 7 16 Phillips screw driver PH3 Utility knife Forklift pallet jack or similar device Tab 3 Packaging list Quantity Component description ST mounting bracket for miracel ST mounting bracket for miracel ST cover swivel joint fixed compo ST cover swivel joint fixed compo individual components ST cover swivel joint door compon ST cover swivel joint door compon ST foam UL94 HF1 20mmx32mm ST Condensate Drain Set
17. crews Make sure there is no twist in the frame before proceeding The next step in installation is to attach the heat exchanger door to the frame Attention Risk of injury The heat exchanger door is very heavy 95 kg approx 210 pounds At least 2 persons are required for manipulation with the door 8 Carefully align the door to the frame and insert the door into the frame Fig 15 ENP DCD 01 998 355 0 Page Seite 23 54 ENP DCD EMERSON User manual Network Powe Fig 15 Installing the door 9 Hinges are already attached to the door Fasten them to the frame of the ENP DCD using the Phillips screw driver Then check if the door moves freely all the way If you notice any irregularities or roughness in the movement of the door check for obstructions or loosen the screws of the hinges and tighten them again The rough movement might have occurred because of the twist in the hinges 10 Pull the flexible piping slightly to elongate This allows the piping enough length to connect the union nuts ENP DCD 01 998 355 0 Page Seite 24 54 ENP DCD Sg EMERSON User manual Fig 16 Flexible piping 11 Before connecting the heat exchanger in the door with the pipe work in the frame of the ENP DCD put sealing rings in this connection Fig 17 Use two wrenches when tightening the union nuts to reduce the stress on the pipes Fig 18 Torque value for this connection is 85 Nm 64 foot pound Fi
18. erate level of chemical impurities Add deadening agents and inhibitors Biological impurities bacteria and algae Add biocides It is recommended to get as closest as possible to the following hydrological parameters Tab 8 Hydrological requirements Hydrological data pH values 7 10 5 Carbonate hardness 3 8 dH Free carbon dioxide 8 15 mg dm3 Combined carbon dioxide 8 15 mg dm3 Aggressive carbon dioxide 0 mg dm3 Sulphides lt 10 mg dm3 Oxygen lt 50 mg dm3 Chloride ions lt 250 mg dm3 Sulphate ions lt 10 mg dm3 Nitrates and nitrites lt 7 mg dm3 COB lt 5 mg dm3 Ammonia lt 5 mg dm3 Iron lt 0 2 mg dm3 Manganese lt 0 2 mg dm3 Conductivity lt 30 uS cm Solid residue from evaporation lt 500 mg dm3 Potassium manganese consumption lt 25 mg dm3 Suspended matter lt 3 mg dm3 partial flow cleaning is recommended 3 15 mg dm3 permanent cleaning gt 15 mg dm3 ENP DCD 01 998 355 0 Page Seite 45 54 ENP DCD User manual 9 2 Checklist for Setting up the Device Tab 9 Set up checklist EMERSON Performed checks Done to be signed upon completion Remarks Check device for damage upon receipt Check the ground for being horizontal Check bearing capacitv of ground Add on and align connect to server cabinet position feet of the rack and adjust them horizontally C
19. ergy precision cooling anfangen systems infrastructure management embedded computing ER ERN ERG EE EOS and power integrated racks and enclosures power switching 1050 Dearborn Drive and controls and connectivity Our solutions are supported Aaa An globally by local Emerson Network Power service technicians T41614 8880246 Learn more about Emerson Network Power products and Emerson Network Power Asia services at al Ka 3 7 F Dah Sing Financial Centre 108 Gloucester Road Wanchai www EmersonNetworkPower com Hong Kong T 852 2572220 F 852 28029250 While every precaution has been taken to ensure accuracy and completeness of this literature Emerson Network Power and or its affiliates makes no representations or warranty about the accuracy reliability completeness or timeliness of the materials and disclaims any and all liability for damages resulting from use of this information or for any errors or omissions 2013 Emerson Network Power All rights reserved Specifications subject to change without notice Emerson Network Power The global leader in Business Critical Continuity ES AC Power IM Embedded Computing ES Outside Plant ES Racks amp Solutions ES Connectivity ES Embedded Power IM Power Switching amp Controls JIM Services ES DC Power ES Infrastructure Management amp Monitoring Precision Cooling ES Surge Protection Emerson Business Critical Continuity and Emerson Network Power are trademarks of Emerson Electric Co or
20. erver fans ENP DCD thereby supports the cold room concept in which is the warm exhaust air from servers always led to a cooling device where its temperature is reduced to the temperature level of the server supply air The supply air for chilled water system flows freely through the installation area 1 Safety 1 1 Symbols N Attention Danger spot Safety notice Caution Hot surface Attention Refers to possible damage to the device Note Marks possible hazards for the environment Important note information ENP DCD 01 998 355 0 Page Seite 8 54 ENP DCD User manual EMERSON 1 2 Safety notice Our engineers can give you comprehensive advice in assembling the ENP DCD Extensive material functional and quality testing guaranty high benefit and a long lifecycle Nonetheless such devices may cause hazards if improperly handled by untrained personnel and if used for purposes they are not intended for Carefully read this assembly and operational manual prior to assembling and commissioning the ENP DCD Hazard by works on the device carried out by non experts Maintenance and cleaning operations are only permitted to be performed by trained personnel In order to keep the device in operationally safe condition and to grant its long lifecycle maintenance and cleaning intervals must be fulfilled bv all means Operate the ENP DCD only in accordance with its speci
21. fied purpose within its limits of capacitv and approved operating means When performing anv works on and with the device please mind e Anv respectivelv applicable regulations e g VDE regulations or other nationallv applicable guidelines Any applicable accident prevention regulations BGV e Anv respective provisions e Anv applicable environment protection acts Operate the device onlv in its proper condition In the event of functional disturbances or deficiencies the device must immediatelv be taken out of operation and the operator s responsible person must be informed of its state The device must oniv be taken into operation again after the flawless function of the device has been restored ENP DCD 01 998 355 0 Page Seite 9 54 ENP DCD EMERSON User manual Caution Hot surface Defect fans power supply units or control boards may have run hot Allow them to cool down before commencing any operations ENP DCD 01 998 355 0 Page Seite 10 54 ENP DCD kd EMERSON User manual 2 Storage and transportation e Keep the device in its original packaging protected from the weather and in dry conditions e Protect the working parts from dirt e g sand rain dust etc e Store at temperatures between 30 C and 50 C 22 F and 122 F e Chilled water circuit must be empty during storage risk of frost damage e After long period of storage 1 year inspect functional
22. for installatiQn cucciolo ke dot red ae 12 3 2 Piping ANG CONNECTION Methods sosise ae ea 13 3 3 Assembly procedure and tools required nn 16 3 9 Chilled water c nnettion unsurneesee een ee ae 30 3 4 Pilling With gn 31 3 5 Kn en i e ni l ae a ki ka ander up e e eee 31 3 6 Application conditons aaa 32 4 Description ELE 33 4 1 General function ERE 33 42 Cooling principle HIER 34 43 Submittal drawings esses ener enne aaa 35 5 Variants and options EE 40 5 1 ENP DCD built in the server rack Option digit 8 L 40 5 2 Connection set ENP DCD Separate product nanna eene 41 6 Maintenance and repairs unresnnssnnnnnnnennnnnnnnnnnnnnnnnnnan nennen nennen nennen nennen nns saints assu nns inse nier inni 43 7 Disassembly and disposal ee eee e eese eene enne nena nnne nnn nnne nna sain nns anne 44 8 Customer Service iii iii mv 44 9 TE EE 45 9 1 Quality Requirements for water used in the ENP DCD 45 9 2 Checklist for Setting up the Device nnne 46 9 9 Commissioning ProtoCol 2 erre P ald execu P ERR na daya a eda 47 9 4 ENP DCD performance charts PA entente reser snnt enne 51 GE Wull dE 53 ENP DCD 01 998 355 0 Page Seite 5 54 ENP DCD User manual List of figures Fig 1 Component location nanna Fig 2 RINO PIPING simetrik i be aaa Fig 3 Tichelmann ring piping L Fig 4 Non interlaced pipiNg anne Fig 5 Floor cut outs unit eet Fig 6 Fl
23. g 17 Inserting sealing rings ENP DCD 01 998 355 0 Page Seite 25 54 ENP DCD EMERSON User manual kull Fig 18 Tightening the union nuts Fig 19 Piping connected 12 Check again if the door is moving freely at this point If so you can attach the swivel joint covers ENP DCD 01 998 355 0 Page Seite 26 54 ENP DCD S EMERSON User manual 13 The two outmost swivel joint covers are to be attached to the hinge side of the door The two inside swivel joint covers are to be attached to the hinge side of the frame Fig 21 Use hexagonal screw driver to fasten the screws Correct orientation of the hinge covers is indicated by slotted holes See picture T j 4 number of slotted holes left hand side hinges right hand side hinges Fig 20 Hinge covers orientation and position ENP DCD 01 998 355 0 Page Seite 27 54 ENP DCD Q EMERSON User manual b Top Swivel Joint Bottom Swivel Joint Fig 21 Outmost swivel joint covers connection points Al Fig 22 Attaching the swivel joint covers 14 Locate the inside swivel joint cover connection points The two inside swivel joint covers are to be attached to the hinge side of the frame Correct orientation of the hinge covers is indicated by a sticker on the covers themselves Use hexagonal screw driver to fasten the screws Fig 22 ENP DCD 01 998 355 0 Page Seite 28 54 ENP DCD EMERSON User manual Top Swivel Joint
24. ity of water bearing hinges e Remove all the packaging before commencing operation of the device e Chilled water connections are not to be used as a transport handles e When transporting always make sure the device is properly fastened and secured against slipping Dry net weight 5 kg Ib Width DCD 600 mm 700 mm 95 kg 210 Ib 800 mm Land freight packaging 40 kg 88 Ib Seaworthy packaging 125 kg 276 Ib Tab 1 Unit weight ENP DCD 01 998 355 0 Page Seite 11 54 ENP DCD y User manual 3 3 1 EMERSON Installation and commissioning Preparations for installation A Before installing the device it is crucial You check each of the following points These checks will ensure safe and trouble free operation of ENP DCD Perform these tests with great care Check the device for shipping damage Packaging may not appear to have been damaged however it is necessary to inspect the device before proceeding to installation Ignoring this advice may at worst lead to a functional failure When returning the device because of the shipping damage If the device is not being sent in its original packaging please make sure the distance between the device and the new packaging is at least 30 mm 1 18 in Qualified installation Please find the checklist enclosed in the annex to help with installation Commissioning can also be done by specialised compan
25. lled water entering heat exchanger Chilled water leaving heat exchanger Cabinet temperature in front of heat exchanger Cabinet temperature behind of heat exchanger ENP DCD 01 998 355 0 C C C C e EMERSON existing no no Page Seite 49 54 ENP DCD EMERSON User manual Chilled water network bleeded yes O no O Pressure of chilled water network tested yes LI no LI customer s protocol available Volume flow adjusted ves LI no LI external O Water flow 0000000000 min external O Remarks Correctness of above values is hereby confirmed Commissioning was performed during on going operation yes LI no O Customer Date Signature ENP DCD 01 998 355 0 Page Seite 50 54 ENP DCD Sg EMERSON User manual 9 4 ENP DCD performance charts Performance diagrams Performance chart Kn rr DCD 5 2m h 22 9USgpmj HA C hi o OH o o 5 fu Du E 3 gt a a a 5 o 15 20 Heat load kW 2 C cw sippy emperatue 18 C cw sippy emperatie 22 C ew sippi em pe rati re Fig 35 Performance chart 1 Performance chart Kn rr DCD 3 5m h 15 4USgpmj EI L i HA OH o C Air supply temperature C o 45 Heat load kW 120 cw sippy emperatue 18 C cw s appli temperate 22 C cw suppl e m pe ratie Fig 36 Performance chart 2 ENP DCD 01 998 355 0 Page Seite 51 54 ENP DCD EMERSON User
26. marks State Check General State Customer s proof of bearing capacity of ground transport ways LI Check of alignment O Transport damage to housing yes LI no O ENP DCD 01 998 355 0 Page Seite 47 54 ENP DCD User manual e EMERSON Remarks Residual packaging removed yes Assembly tools removed yes Air ducts checked yes Server cabinet front plates closed 2 2 Chilled Water System within the Facility Chilled water with anti freeze LI ENP DCD Connected to CTU U Circuit in building direct Chilled water temperature primary Feed C Chilled water pressure Feed bar Connection with Kn rr connection set set of external valves Customer s hydraulic plant OK visual check yes REMARKS ia eier ENP DCD 01 998 355 0 no O no LI no O without anti freeze LI cold water svstem direct L Return G Return bar U LI no LI Page Seite 48 54 ENP DCD User manual 3 2 Functional Check Mechanical Functions Damage to heat exchanger Connections lamellas surface none Remarks Front door closing yes Remarks Rear door closing yes Remarks Pipe duct inlets cable bushings closed yes Remarks Condensed water drain open connected yes remarks Fans run perfectiv bearings OK Visual check yes Remarks Thermodynamic Checks Condensed water forming at heat exchanger yes Remarks Chi
27. oor cut outs unit with aluminium Trame sse esses Fig 7 Unpacking ENP DCD Leanne nanna Fig 8 Unpacking the ENP DCD part of the rack Fig 9 Lifting the frame snanar nanna Fig 10 Marking the position senser nn n Fig 11 Inserting the spring nuts nn Fig 12 Diamond a CR Fig 13 Hose piece adaptor ei a Fig 14 Position of the sealing foam eessessrssssrsssrsrrssrrrrssrrrnssrsrnsss Fig 15 Tightening the screws scsssrciicssiiiseniinicei a a Fig 16 Installing the door Fig 17 Flexible piping e a Fig 18 Inserting sealing rings L nn Fig 19 Tightening the union pute Lemna n anna Fig 20 Piping connected snanar nanna Fig 21 Hingecoversorientattonandposition Fig 22 Outmost swivel joint covers connection points Fig 23Attachingtheswiveljointcovers Fig 24insideswiveljointcovels Fig 25 Attaching the grounding wire m Fig 26 Chilled water connection ena ne Fig 27 Bleeding point rettet rre es Fig 28 Top view of the rack equipped with ENP DCD Fig 29 Side view of the rack equipped with ENP DCD Fig 30 Submittal drawings ENP DCD right hinges Fig 31 Submittal drawings ENP DCD left hinges
28. ot and cold air must exist within the rack e All the bushings cable lines piping etc must be sealed to prevent any leakages ENP DCD 01 998 355 0 Page Seite 31 54 ENP DCD 4 EMERSON User manual 3 6 Application conditions Appropriate use The device is a rear door heat exchanger for a server cabinet with integrated chilled water piping The server fans themselves remove the heat from the racks to protect the temperature sensitive components in the rack The waste heat from inside of the rack is transferred via the chilled water circuit to the outside and passed to the on site chilled water system For reliable function of the ENP DCD chilled water must be available in an appropriate amount at the appropriate temperature and pressure The water quality must be in accordance with VGB R 455 P see Annex Tab 4 Operation conditions 10 C 35 C other temperatures on request Operating ambient temperature 50 F 95 F Maximum absolute air humidity on site 8 g kg B Chilled water temperature intake 12 C 53 6 F other temperatures on request Chilled water temperature outlet 18 C 64 4 F other temperatures on request Water temperature difference 6 K 10 8 F Use of antifreeze Not recommended on request Rack rear side top or bottom connection 1 female threaded DIN ISO 228 1 Condensate tray drain connection Rack rear side Chilled water connection Maximum operating
29. oth the supply and the return pipes Always allow for thermal expansion either by leaving at least one of the valves open or by opening the bleeding valve on the door Supply and return pipes are marked by label on the unit itself Torque value for this connection is 85 Nm 64 foot pound ENP DCD Fig 25 Chilled water connection 01 998 355 0 Page Seite 30 54 ENP DCD EMEN User manual For water supply from the bottom left or top right of the position the supply water connection is the outward pipe The return water connection is then the position towards the rack With water connection from top left or bottom right the water supply connection is the pipe towards the rack The return pipe then has the position toward the outside 3 4 Filling with water If using a chilled water distribution unit such as the Kn rr CoolTrans or Liebert XDPW refer to its user manual for instructions on filing the ENP DCD and starting the system Heat exchanger fluid volume is approximately 12 liters 3 17 US Gal Bleeding the air off the system 1 Find the bleeding valve This valve is located on the upper door piping seeFig 26 2 Manually depress the pin to open the valve 3 Keep the air bleed valve open until the eater coming out has no bubbles Fig 26 Bleeding point 3 5 Housing integrity To provide optimal cooling function following requirements must be met e Strict separation between the h
30. pressure 10 bar 145 psi The cold water supply temperature should be higher than the dew point temperature of the installation space ENP DCD is designed only for sensible cooling dehumidification of the room by means of ENP DCD should be avoided The built in condensate tray with condensate drain is designed only for a short term condensation ENP DCD 01 998 355 0 Page Seite 32 54 ENP DCD EMERSON User manual Network Power 4 Description 4 1 General function The design of ENP DOD allows installation in the back of a server cabinet Heat produced bv internal components e g servers etc is reliably removed by the door with built in chilled water system The cooling system is completely safe so that no water get into the server area The cooling system consists of a high efficiency air water heat exchanger By operating as a rear door heat exchanger with an appropriate design see Appendix no heat thermal load in the surrounding area is given Attention The cooling with ENP DCD works only if a strict air separation exists between server cold air intake and server warm air outlet Unused rack spaces must be sealed with empty plates air barrier COLD recirculation prevented Fig 27 Top view of the rack equipped with ENP DCD ENP DCD 01 998 355 0 Page Seite 33 54 ENP DCD EMERSON User manual Network Power 4 2 Cooling principle Cooling water connection
31. top Bir outlet Bir intake air barrier Cooling water connection bottom Fig 28 Side view of the rack equipped with ENP DCD Air heated by the server e g 40 C 104 F is forced through the special air water heat exchanger In the heat exchanger the air is cooled down to e g 20 C 25 C 68 F 77 F The server fans force the cooling air through the heat exchanger of ENP DCD The pressure drop flow rate dependency curve is shown in the Appendix 9 4 Prior to using ENP DCD the system and the servers must be checked whether they match hydraulically In particular the server fans must be able to generate sufficient Pressure to drive the air through the ENP DCD The chilled water is provided by chilled water onsite distribution In case of chilled water supply system failure the cooling is provided either by adjacent ENP DCDs and or the installation room cooling system In this case the server waste heat is released into the installation room ENP DCD 01 998 355 0 Page Seite 34 54 ENP DCD User manual 4 3 Submittal drawings Tab 5 Unit dimensions 2000 mm 78 3 4 e EMERSON 2200 mm 85 3 4 B 1954mm C 600mm D 493mm B 2176mm C 600mm D 493mm 600 mm F 322mm G 151mm H 120mm F 322mm G 151mm H 120mm 23 5 8 l 45mm J 40 7mm K 24mm l 45mm J 40 7mm K 24mm L 52mm M 73mm N 25mm L 52mm M 73mm N 25mm B 77 7 8 C 23 5 8 D 19 3 8
32. y In this case please find the commissioning protocol enclosed in the annex Room Preparation The room should be well insulated and must have a sealed vapour barrier The vapour barrier in the ceiling and walls can be a polyethylene film Paint on concrete walls and floors should contain either rubber or plastic The vapour barrier is the single most important requirement for maintaining environmental control in the conditioned space ENP DCD 01 998 355 0 Page Seite 12 54 ENP DCD m User manual 3 2 Piping and connection methods If possible when using a chilled water distribution unit such as the Kn rr CoolTrans or the Liebert XDPW connect the ENP DCD in an ring configuration see Fig 1 or Tichelmann ring Fig 2 In this system the pressure drop for each of the units is approximately the same which results in even cooling performance KH Chilled Water Chilled Water in Distribution 2 Kn rr DCD Kn rr DCD Chilled Water Distribution Kn rr DCD Kn rr DCD Kn rr DCD Fig 2 Tichelmann ring piping However if it is not possible connect the ENP DCD units in a non interlaced configuration as seen in Fig 3 ENP DCD 01 998 355 0 Page Seite 13 54 ENP DCD EMERSON User manual Chilled Water Distribution Kn rr DCD Kn rr DCD Kn rr DCD Fig 3 Non interlaced piping It is recommended to add a set of 2 ball valves to each unit Supply and return pipe to allow
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