CDU - Rack Mount Installation Guide
Contents
1. l St D l a l L l oL 5 8 L 9 S u z z S DEEN Ava AINO AISAS G O NO Aal a 0 603vI Y ON 940 y Z um n Her Uddv zzonaa 17009 mol ays NUO T081N05 FINGOW NGO AVAVA ONISIM gui s0 90 61 3140 1 aas as E TINIOHINOI 90X4 Ze Zi a 210024 Sunan vuam di ato ti BEEN 3000 sunaino WII li r d r r d r asas DESEN Lois mn Vo anid 015 1841 WA 204 2310 wi wei anne T wu me on nm Ser 8 g EF 3 z g g g SS g g sod m ind EJ Fa lt m 4 E EI EI Fa EI lt e z ge a e a o z lo a o z z a e s s E 5 g 8 S E s a O31SWL ja g Ra 3 a z B C h I A 3 la z E 5 BCS BIN Ss BC SZ R E a sc a is N a 2 Z b la iI vw Ze Sib la E g E u S H is gd N annon N 3 k BA amp SH0HNOT H mea E 40 Livo 31372 E al z fs Hi 9 Ea lo NO D OVE lo e lo 232 P FE 8 bi E 535 Bs roams sv 5 8 4 A 232 A gi TES anid TI E Is S Sep ge oa E IP a k as gt I 1 m N E 1 s r e JA l I l I DR zl i 018 1016 SL ote i016 8L S i z 5 sand eene 2 3 namol sam x aima A Ehe J ve vumm 2 Je B A W DI ta ESTEN anna Tu b le Sc g ac EJ 8 09 TEN amio 00 3 3 O NOS TWNINYIL Warz eer As feg A VG ewen H H lo 3 i TUI mt men mon 2 Y vaonosnva tt a Te A Bia ja fe a se la TE 2 is INN 1X3N OL YOLOINNOD JAL NIC Nic S Pa o ava E 20 l va2. The graph above shows the maximum pressure drops through the CDU for both plain water and water with 30 glycol CDU Module Installation Guide Page 12 Cooling Distribution Unit Module Distribution Unit Module INSTALLATION Section 4 4 1 Mechanical Arrival on site The CDU module is despatched bubble wrapped and packed with corner protectors in a purpose made crate On arrival at site the packaging should be removed and the module inspected for any transit damage If damage is found it must be reported to the manufacturer immediately The CDU module is intended for mounting on slide rails or a shelf within a standard 19 x 1000mm deep rack If support is to be provided by the customer care should be taken to ensure that the full weight of the unit 51kg can be accommodated Bolt the front fascia to the 19 uprights of the cabinet with M6 fixings 4 2 Electrical An IEC connector is provided at the back of the unit along with a 2m matching flying lead for connection to a power supply Suitable 4A for 230v 50Hz 6A for 208v 60Hz or 10A for 120v 60Hz upstream protection must be provided in the form of either MCB or fuses If the module is supplied as part of a multiple unit installation in a dedicated cabinet then the power will be taken from the power supply distribution module within the cabinet Also on the back of the unit is a 9 way D connector PL2 for remote general alarm indication anf for LON
3. Cooling Distribution Unit Module Distribution Unit Module OPERATION continued Menu 04 PASSWORD entry of user e Master password not issued for factory use only Master password does not hold any additional control parameters but is only for setting display contrast brightness screen colour etc 1 To enter password when viewing the USER page pressing will change the first character to a 0 zero 2 To select the reguired number press the up O key Then press the key again to move to the second character 3 Use the up O key to again select the reguired number Carry on until all 4 numbers have been entered 5 Confirm the password entry by pressing the key The additional menus will now be available Menu 04 PASSWORD after entry of user password After entering the USER password the function of Menu 04 will change slightly as below Use new menu structure to change password or to Log Off passion To change password exercise care Gi as there is no override if new password is forgotten Re enter new password to confirm Log off Return to default display menus Note Controller will automatically Log Off from USER menu after 15 minutes of inactivity CDU Module Installation Guide Page 21 Cooling Distribution Unit Module Distribution Unit Module Menu 05 Menu 06 Menu 07 Menu 05 SYSTEM SETTINGS read amp edit parameters OPE RATION continued Additional
4. EI S XIN 40 pv TN en H SE a evo W RS SC A A un n00 van ven e N SE A EE an Los wer onore w ana KEEN cent mee a ome E Ge eg e Se wh 2008 0016 xH z WNL OG mima Wa aL ROSSA TH LIN anne 154 DS NASAS IT EECH wss 30 zess eum ba TED wech OL 193NN0D a le 02009 lt lt 0nd9 a m D ba vase Luu soniugri avid Aorzl Jee be n VXL MOS e s mm KEI ans x ue INASI 1 H St D m a m oi 5 EI L 9 G v z Page 39 de ion Gu CDU Module Installat Cooling Distribution Unit Module VS C E0VNEV OILVWAHOS 3Jdld JINAON NAI Wsa maa aL 20 90 84 EI quiod 1114 I u I MOBY gt 0 z MEH gt spuijdnog se j y MOIE JlOA49S9H youmg 4A9BueuSx3 S37 19997 1e H I8ss A oisuedxy uoleuluu 3 AY ssa osoit kejdsia ossi E 49 04 UO9 i 10suoas une MOL 428M P Il uO Page 40 CDU Module Installation Guide Cooling Distribution Unit Module Distribution Unit Module WARRANTY amp SUPPORT Section 11 To obtain service technical assistance or warranty information please contact Technical Support and Service To obtain technical support or service please contact Coolcentric directly at Toll free US Canada 1 877 248 3883 DDI 1 508 203 4690 Email info coolcentric com Limited Product and Service Warranty To obtain a copy of Coolcentric s Limited
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6. HIGH Secondary water temperature has risen more than 2 default above set point for a period in excess of 120 seconds Alarm can be cleared when temperature falls to 1 above set point or lower Action Check operation of primary circuit control valve Check primary chilled water flow amp temperature are within the requirements shown in Section 3 7 Ensure data rack load does not exceed the modular CDU capacity SEC TEMP LOW Secondary water temperature has fallen more than 2 default below set point for a period in excess of 120 seconds Alarm can be cleared when temperature rises to 1 below set point or higher Action Check operation of primary circuit control valve PRI TEMP HIGH Primary water temperature has exceeded the 10 C default threshold for a period in excess of 120 seconds Alarm can be cleared when temperature falls to 9 c or lower Action Check chilled water supply PRI TEMP LOW Primary water temperature has exceeded the 4 default threshold for a period in excess of 120 seconds Alarm can be cleared when temperature rises to 5 or lower Action Check chilled water supply PUMP O L TRIP unit shutdown Pump has stopped through drawing too much current Action Check the overload has been set correctly Reset trip and restart unit then measure current drawn by pump If current exceeds the value shown on the wiring diagram then pump is most likely faulty and should be repl
7. Months 29 7 5 Module Drainage 29 Section 8 TROUBLE SHOOTING 8 1 Summary of Alarm Messages 31 8 2 Temperature Sensor Chart 32 Section 9 SPARE PARTS LIST 33 Section 10 DIAGRAMS 10 1 Wiring Diagram 38 10 2 Pipe Schematic 40 Section 11 WARRANTY amp SUPPORT 41 CDU Module Installation Guide Page 3 Cooling Distribution Unit Module Distribution Unit Module CDU Module Installation Guide Page 4 Cooling Distribution Unit Module Distribution Unit Module SAFETY INSRUCTIONS Section 1 IMPORTANT NOTICE ALL PERSONNEL involved in the installation and maintenance of the Process and Ancillary Eguipment whether directly or indirectly MUST read this notice and this complete document prior to the commencement of ANY WORK 1 The following information must be READ FULLY UNDERSTOOD and ADHERED to AT ALL TIMES 2 The SAFETY of YOU and OTHER PERSONS MUST be your main concern 3 NEVER carry out a task until you fully understand what you are being asked to do and how to do it safely 4 NEVER carry out a task you feel could be DANGEROUS to you and other persons 5 DO NOT carry out any task that you are not qualified to undertake 6 ALWAYS comply with all SAFETY RULES as laid down by the relevant Authorities 7 H you have any questions or concerns over the safety of YOU or OTHER PERSONS you MUST consult your supervisor within the Company prior to the commencement of any task 8 NEVER start work on a unit or remove
8. Page 9 Cooling Distribution Unit Module TECHNICAL DATA continued Pump Flow Pressure graphs 4 0 35 3 0 2 5 2 0 Pressure Bar Flow Usgpm 10 11 12 13 14 15 1577 1 0 0 5 0 0 30 Flow L M 35 40 45 50 55 60 55 50 45 40 35 30 25 r 20 r 15 r 10 Pressure PSI These graphs show the pressure differential available at the supply and return connections of the CDU module taking into account the guick release couplings and losses within the unit Graph above for 50Hz model graph below 60Hz models 4 0 35 3 0 25 2 0 Pressure Bar 15 W Flow Usgpm 10 11 12 13 14 15 1 0 0 5 0 0 30 Flow L M 35 40 4 5 50 55 60 55 50 45 40 35 30 25 20 15 r 10 Pressure PSI CDU Module Installation Guide Page 10 Cooling Distribution Unit Module TECHNICAL DATA continued Minimun Temperature Differential C 00 Minimum Temperature Differential F 20 30 40 50 60 70 80 90 100 Percentage of Full Load Water oer Water 30 glycol The above gra
9. The cooling performance of the CDU module has been calculated on a chilled water supply temperature between 5 and 10 e Flow of primary chilled water through the plate heat exchanger is controlled via a 3 way modulating valve This valve will allow more or less chilled water to flow through the heat exchanger according to the cooling demand Excess flow is sent to by pass e The temperature PI control loop will be operational from when the Start Stop button is pressed If the secondary circuit temperature starts to rise above the set point then the control valve will start to open to allow more primary cooling water through the heat exchanger The control valve will then modulate between flow amp by pass as demand dictates e The demand to the valve can be monitored on the controller by going to Menu 01 System Values and scrolling to VALVE PCT which shows the valve demand as a percentage 100 represents full cooling and the valve will be diverting all flow through the heat exchanger 0 represents zero cooling demand and the valve will divert all flow to by pass e The actual position of the valve can also be monitored by dropping down the front fascia and observing the actuator dial where it protrudes into the electrical compartment 0 on the dial represents valve in by pass position 0 demand amp 1 on the dial represents valve in full flow position 100 demand In the event of signal or controller fail the
10. View 1 CDU Module Installation Guide Page 7 Cooling Distribution Unit Module Distribution Unit Module INTRODUCTION continued Secondary Temp Sensor Primary Temp Sensor Reservoir Tank Plate Heat Exchanger 3 Way Valve amp Actuator View 2 CDU Module Installation Guide Page 8 Cooling Distribution Unit Module Distribution Unit Module Section 3 TECHNICAL DATA 3 1 Physical Model CD020W2A CD020W1A CD020WO0A Cabinet dimensions Width 483mm 19 Height 267mm 10 Depth 730mm 2834 Shipping dimensions Width 605mm 24 Height 495mm 1812 Depth 890mm 35 Weight Dry 46kg 101 Vib Operational 51kg 112 Yn Shipping 61 Vokg 1351 2b 3 2 _ Pipe Connections Secondary Circuit 24 ISO B ORC Primary Circuit 74 BSPP male ORC Ouick Release Coupling self sealing 3 3 Electrical Connection see also Section 4 2 n Supply 1ph ground 220 240 50Hz 208V 60Hz 120V 60Hz Full Load Amps 3 0A 230V 4 9 208V 9 8 120V Max Installed Load 0 69kVA 1 02kVA 1 12kVA 3 4 CDUFluid Capacity Secondary Circuit Volume 3 5L 0 92Usgall Primary Circuit Volume 1 5L 0 4USgall 3 5 Noise Sound power level at 3m 10ft Less than 55dBA 3 6 Secondary Circuit Rated Cooling Capacity 20kw Pump Capacity 401 m 10 6USgpm CDU Module Installation Guide
11. active in DPOV or DPTR control mode CDU Module Installation Guide Page 25 Cooling Distribution Unit Module Distribution Unit Module OPE RATION continued 6 3 Automatic operation After commissioning the unit will be ready to run in automatic mode press the Start Stop button on the control panel to start the unit Secondary Circuit Operation e On receiving a start signal the green Unit Running lamp will illuminate and the main pump will start after a 2 second delay e The controller display will remain illuminated with a blue backlight for 10 minutes after initial power up or after the last button press display will change to red backlight in the event of an alarm and will remain so until alarm has been acknowledged e On initial start up temperature amp pressure alarms will be ignored for 900 seconds to allow the system to stabilise e Air is automatically purged from the secondary circuit through automatic air vents providing the air release screws have been loosened during installation e The CDU default operational mode is DPOV Fixed Set Point with Dew Point Override This means that the unit will control to a programmed set point default 18 c adjustable 10 to 25 unless the monitored dew point in the room rises to within 2 C of set point and there is a risk of condensation occurring at the rear door heat exchanger In this instance the controller will automatically raise the set point to main
12. any casings guards doors or covers without first SWITCHING OFF and isolating the unit and controllers from the electrical supply 9 Make sure all ROTATING PARTS ARE AT REST before commencement of any work on the unit 10 The Safety Policy of the Company on whose premises the unit is installed should be read and understood by Maintenance Personnel ALWAYS THINK SAFETY CDU Module Installation Guide Page 5 Cooling Distribution Unit Module Distribution Unit Module SAFETY INSTRUCTIONS General Temperature control equipment presents mechanical electrical noise or vibration hazards Observe all safety installation operation and maintenance instructions Installation servicing and operation of the equipment can only be carried out by fully trained and technically competent personnel The Cooling Distribution Unit is designed to minimize mechanical and electrical hazards by fully restricting access through unit casings doors and covers while equipment is operational Some installations may require additional protective features to prevent accidental contact with components The CDU manufacturer can provide advice and make recommendations for additional protection to suit the application All installation work must be completed in accordance with the safety installation operation and maintenance instructions and the unit correctly grounded earthed before it is operated Prior to any maintenance work being carrie
13. e Coolcentric Making Data Centers Sustainable Cooling Distribution Unit Module INSTALLATION GUIDE Models CD020W2A CD020W1A CD020WO0OA ll II gt I IU wu wl il ul Coolcentric a Division of Vette Corp 201 Boston Post Road West Marlborough MA 01752 i ite www coolcentric com Email info coolcentric com Cooling Distribution Unit Module Distribution Unit Module ABOUT THIS DOCUMENT Using This Document This document has been designed for viewing as a PDF file and double sided printing subject to copyright see below for a hard copy Copies of this document can be obtained from the address on the front cover This is not a controlled document Distributed copies will not be updated All specifications are minimal and subject to change without prior notice as design improvements occur Copyright Notice The confidential information contained in this document is provided solely for use by the manufacturer s employees and system owners and is not to be released to or produced for anyone else Neither is it to be used for reproduction of this unit or any of its components All specifications are nominal and subject to change without prior notice as design improvements occur Disclaimer The manufacturer shall not be liable for any damages resulting from mis application or misuse of its products E amp OE GENERAL STATEMENT Product Standards Products installed and operated in accordance with instr
14. menus available after password entry SYSTEM SETTINGS CONTROL MODE SET TIME DATE USER password reguired for access wem CDU Module Installation Guide Page 22 Edit setpoint default value 18 0 C adjustable from 10 0 to 25 0 C Edit proportional band default value 10 0 C adjustable 1 0 to 50 0 C Edit integral action time default 30 seconds adjustable from 0 to 900 seconds Secondary high temp alarm default 2 C above setpoint adjustable from 1 0 to 10 0 C Secondary low temp alarm default 2 C below setpoint adjustable from 1 0 to 3 0 C Secondary high low alarm hysteresis default 1 C above setpoint adjustable from 0 5 to 2 0 C Primary high temp alarm default 10 C adjustable from 8 0 to 12 0 C Primary low temp alarm default 4 C adjustable from 3 0 to 7 0 C Primary high low alarm hysteresis default 1 C adjustable from 0 5 to 2 0 C Low flow alarm limit default 30 L M adjustable 10 to 35 L M Low flow alarm hysteresis default 5 0 L M adjustable 1 0 to 10 L M KU Cooling Distribution Unit Module OPERATION continued Menu 05 SYSTEM SETTINGS read amp edit parameters continued Cooling Distribution Unit Module Low pressure alarm limit default 0 3 Bar adjustable from 0 1 to 0 5 Bar Low pressure alarm hysteresis default 0 2 Bar adjustable from 0 1 to 0 3 Bar High pressure alarm limit def
15. the floor void to the rear door heat exchanger s Ouick release self sealing couplings are provided at the rear of the unit for hose connection see Fig 1 Crush and kink resistant 3 2 bore PVC hose should be used with a minimum working pressure of 10Bar 145PSI to connect the CDU module to each RDHx Process Circuit Ouick Release Couplings Primary Chilled Water Connections 3 4 BSP Male Hose tails Secondary Circuit Return Connection Fig 1 Hose Connections 3 4 Quick Release Couplings 4 4 Heat Transfer Fluid The CDU cabinet is designed for use with a primary circuit supply of plain water or up to 30 glycol water from by a site chilled water ring main or a dedicated chiller a 30 glycol concentration will give protection to approx 14 7 F The secondary circuit should be filled with particulate free deionized water treated with suitable corrosion inhibitors and preservatives For ease of installation and commissioning premixed treated water designed specifically for the requirements of closed secondary cooling circuits can be offered as an optional kit Failure to use proper water treatment may result in decreased system performance and reliability due to corrosion scaling fouling and microbiological growth CDU Module Installation Guide Page 14 Cooling Distribution Unit Module Distribution Unit Module COMMISSIONING Section 5 5 1 Pre Commissioning Checks e Check that all items within t
16. Product and Service Warranty Toll free US Canada 1 877 248 3883 DDI 1 508 203 4690 Visit www coolcentric com information documentation warranty CDU Module Installation Guide Page 41 Cooling Distribution Unit Module Distribution Unit Module Notes CDU Module Installation Guide Page 42 Cooling Distribution Unit Module Distribution Unit Module Disposals Procedure NOTE All oils and other waste materials must be disposed of in a professional and responsible manner in strict adherence to environmental regulations NOTE The de commissioning dismantling and disposal of Temperature Control Units should be undertaken only by experienced personnel and with full adherence to all safety rules in particular protection of lungs eyes and skin from chemical dust etc Only approved lifting gear and power tools should be used and access to the work area restricted to authorised personnel 1 Disconnect unit from electrical supply 2 Remove unit to approved recycling facilities O2010 Coolcentric a Division of Vette Corp Part no 104782 Rev B
17. UCTION Section 2 2 1 General This guide describes the basic Installation Operation and Maintenance of the Cooling Distribution Unit CDU and contains a detailed explanation covering the Technical Specification and Mode of Operation description of the alarms that can be generated and the action to be taken at those alarms a Spare Parts List and all relevant Schematic Diagrams It is assumed that the people involved with the maintenance of this unit are familiar with basic theory and practice Consequently only features that are of particular significance to this unit are identified The CDU module has been designed to provide close controlled cooling water for a single IT enclosure Rear Door Heat Exchanger RDHx with a total maximum cooling capacity of 20kW The process side water referred to as the Secondary Circuit is a sealed pressurised system with the heat extracted from the rear door heat exchanger being rejected to a chilled water circuit The chilled water can either be part of the Building Services Chilled Water system or from a dedicated chiller This chilled water supply loop referred to as the Primary Circuit should be filtered to 300p using a filtration unit supplied by others Features of the CDU module include Auto Air Vents Pressure Sensors Fill Pump Electrical compartment Level Sensor Controller Display user interface Secondary Main Pump Fill Pump Connection Point
18. aced LOW PRESS Pump inlet pressure has dropped to less than 0 3Bar Action Top system up using fill pump as described in Section 5 4 Check secondary circuit for leaks Ensure automatic bleed valve screws are loose HIGH PRESS Pump outlet pressure has exceeded 5Bar default threshold Alarm can be cleared when temperature falls to 4 5Bar or lower Action Check secondary circuit for blockages Check heat exchanger has not ruptured between primary amp secondary circuit WATER LEAK unit shutdown Leak detected in flood tray Action Inspect internal pipework and components for leakages and repair replace Empty and allow drain tray to dry out Note Flood sensor needs to be completely dry before a healthy condition can be restored CDU Module Installation Guide Page 31 Cooling Distribution Unit Module Distribution Unit Module TROU B LESHOOTI NG continued LOW FLOW Secondary circuit flow rate has dropped below the 3OL M default threshold Alarm can be cleared when flow rises to 35L M or higher Action Check secondary circuit for blockages Check pump differential pressure on flow pressure graph on page 10 SENSOR FAIL Either a temperature sensor or a pressure sensor is reading outside its normal range Action Check sensor wiring amp connections If no fault found replace sensor LOW LEVEL unit shutdown Water level in secondary circuit reservoir tank too low for pump operation Alarm ca
19. ation Guide Page 23 Cooling Distribution Unit Module Distribution Unit Module OPE RATION continued CONTROL MODE Mode selection Description FXSP Fixed setpoint Secondary temperature is controlled to the default set point DPTR Dew point tracking Set point is maintained at 2 C above the room dew point condition at all times DPOV Dew point override default Set point is maintained at the default setting however if the room dew point temperature approaches to within 2 C of the default setting the set point is overridden to follow the tracked set point and always remain 2 C above the room condition Note In this control mode the Sec Hi Alarm Limit will need to be adjusted higher to prevent nuisance activation Menu 07 SET TIME DATE edit parameters amp activate Real Time Clock USER password required for access A Enter the date select from 1 to 31 N s Eeer Enter the year select from 2008 to 2049 Enter the hour select from 0 to 23 Enter the minute select from 0 to 59 Important Once the date amp time have been set select YES on this screen then reset to RTC Note The alarm delay on start up will only apply to operational alarms such as temperatures amp pressures to allow the system time to stabilize Safety alarms that result in unit shutdown will not be delayed CDU Module Installation Guide Page 24 Cooling Distribution Unit Module D
20. ault 5 0 Bar adjustable from 3 0 to 6 0 Bar High pressure alarm hysteresis default 0 5 Bar adjustable from 0 2 to 1 0 Bar Alarm delay on start up default 900 secs adjustable from 0 to 1800 secs Secondary high temp alarm set point for dew point tracking default 18 0 C adjustable from 5 0 to 35 0 C Pump frequency selection for flow monitoring default 50Hz on metric units 60Hz on Imperial adjustable 50 60Hz Delay before alarms register default 120 secs adjustable 5 to 300 secs Fail safe valve actuator position in event of control temperature sensor failure default 50 adjustable 0 to 100 Note The alarm delay on start up only applies to operational alarms i e temperatures amp pressures to allow the system time to stabilize Safety alarms that result in unit shutdown are not delayed Note The actual switch point for the alarm activation will be the set value plus 2 C e g with default alarm set point of 18 C alarm will activate at 20 C Menu 06 CONTROL MODE read amp edit parameters USER password required for access Edit setpoint default value 18 0 C A Adjustable from 10 0 to 25 0 C Control mode selection default Q DPOV Choose from FXSP DPTR or DPOV see description below Actual setpoint This will show the setpoint currently in use and may be different from the default value depending on the control mode selected CDU Module Install
21. communication if optional LON card has been fitted to controller There are two other 5 pin DIN sockets on the back of the unit SK2 is the connection point for a wall mounting room temperature amp RH sensor Typically SK3 is not used unless there are more than one CDU modules installed in which case SK3 is used to daisy chain the room temp amp RH input to all modules as below Wall mounted temperature RH sensor Module 1 Module 2 Module 3 Module 4 CDU Module Installation Guide Page 13 Cooling Distribution Unit Module Distribution Unit Module NSTAL LATION continued 43 Hydraulic The primary chilled water hoses can be routed either through the floor void to enter the housing cabinet for the CDU module from below along with the process secondary circuit hoses or from above Flat face seal union hose barbs BSPP will be required for hose connection available as an optional extra It is also recommended that isolation valves are installed on both primary flow amp return circuits available as an optional extra All primary circuit pipework hoses and valves should be insulated against condensation Primary chilled water should be filtered to 300j as a minimum using a filtration unit supplied by others Crush and kink resistant 34 bore PVC hose should be used with a minimum working pressure of 10Bar 145PSI The secondary circuit hoses should be routed out through the bottom of the cabinet and through
22. d out ensure that Equipment is switched OFF Equipment and controls are disconnected from the electrical supply All rotating parts have come to rest If in any doubt as to the correct interpretation of performing the safety installation operation and maintenance instructions it is essential that the CDU manufacturer their agent or appointed distributor is consulted for advice and clarification 1 1 Installation Handling The installation and operation should be conducted in accordance with local regulations and accepted codes of good practice When moving or lifting the unit caution must be observed at all times to ensure the safety of all personnel Only appropriate and approved lifting eguipment must be used 1 2 Application The unit must be only used in the application for which it was designed The unit is not to be used in a hazardous environment unless it has been specially designed and approved for such application 1 3 Warranty Failure to comply with the manufacturer s installation instructions could affect the reliability and performance of the unit and invalidate the warranty CDU Module Installation Guide Page 6 Warranty is subject to the implementation of a planned service maintenance agreement see the warranty section Section 11 in this guide or the sales contract 1 4 Electrical Connection The unit must be connected to an external isolator disconnect if one is not fitted to the unit Electr
23. e Quick Release Coupling 3 4 23 CDUS 039 Male Quick Release Coupling 3 4 CDU Module Installation Guide Page 33 Cooling Distribution Unit Module Distribution Unit Module CDU Module Installation Guide Page 34 Cooling Distribution Unit Module CDU Module Installation Guide Page 35 Cooling Distribution Unit Module Distribution Unit Module CDU Module Installation Guide Page 36 Cooling Distribution Unit Module Distribution Unit Module DIAGRAMS Section 10 10 1 Wiring Diagram A3 LAE093 10 2 Pipe Schematic A4 NAD372 CDU Module Installation Guide Page 37 Cooling Distribution Unit Module gt st H sl H l 6 8 9 s H z L N A uddv NYO ava AINO MALSAS OYO NO AJOON N SSI 0 603V1 v ON 980 ag Ydy Yddy sv aus Jeoorez G3a0v saas INN avaata Q n09 GET way Las 002022 2 Si E N FP AINO ne NOTIZA NZINO A ND myyavid ON 0 9 Sa JUUL 40 9 71 ava EE ms 809061 v wu DS NI 3215 JM el aaan 2un7 Va ETI G3Minoaa SI VHL LINA AHL OL 10388109 A n IHV SINZO 3 Lat ONY AVO MIAO did i JNNA IVHL RINSNI SUNN 3BYHL S83A0O ONMENO Shu WAHL OL axu 1387 LAINAN NV HUM Vuen 3A OL IHV SISSYK TORHO3T3 JHL NO SININOANOD TW sanoTos SW S5 S ZMYS SNOUD3NNOD ema SUONI Z ASY SYTA 18000 NI di 1 SHON 390039 SI Ion LINO
24. ge The secondary temperature should correspond to the desired set point temperature default fixed set point is 18 as displayed on the default level controller screen and is used by the control loop to regulate the primary water control valve position to achieve and maintain the set point e High and low temperature alarms are set at a default value of 2 either side of set point floating with set point when either Fixed SP or Fixed SP Dew Point override control is selected with a default hysteresis of 1 C e Dew point is calculated by the controller from the room sensor temperature and relative humidity readings CDU Module Installation Guide Page 26 Cooling Distribution Unit Module Distribution Unit Module OP ERATION continued The secondary circuit parameters monitored within the Menu 01 System Values screen are Secondary temperature Set point Pump inlet pressure Pump outlet pressure Pump differential pressure Flow rate Pump run hours Room temperature Room humidity Dew point e Pressure on both the inlet and discharge of the pump is monitored The pump inlet sensor is used for control of the static fill and minimum operating pressure of the unit The pump discharge sensor monitors the system maximum pressure The differential between the two is used to calculate the pump flow rate Primary Circuit Operation e The primary water temperature is monitored at the inlet to the CDU module
25. gral Action Time to zero 2 Increase the loop Proportional Band in steps of 30 of the set value disturbing the control loop after each step by adjusting the set point to a new value and allowing time between the changes for the system to settle until the control loop ceases to oscillate Multiply the final Proportional Band value by 2 5 and set accordingly Set the Integral Action Time to its previous default value If the control loop becomes unstable decrease the Integral Action Time in steps of 50 of the set value again adjusting the set point and allowing the system to settle after each change until loop becomes stable CDU Module Installation Guide Page 28 Cooling Distribution Unit Module Distribution Unit Module MAINTENANCE Section 7 PREVENTATIVE MAINTENANCE 7 1 General The CDU module should be cleaned on a regular basis and checked for leaks and malfunctions DANGER Before starting any maintenance work inside the cabinet ensure that the unit is A electrically isolated 7 2 3 Monthly or less e Flush out or replace any strainer element on the primary cooling water inlet e Check for any abnormal noises from the pump s e Check for leaks 7 3 6 Monthly or less In addition to the 3 monthly checks e Check condition of hoses e Check all hose connections for tightness 7 4 12 Monthly or less In addition to the 3 amp 6 monthly checks e Check all bolts and seals 7 5 Module Drainage In t
26. he event that the unit needs to be drained or be relieved of internal pressure use the drain points located at the back of the unit as shown in Fig 3 To make this operation easier a special drain hose is supplied with the module To drain the primary circuit first isolate the chilled water supply with shut off valves then remove the screw on drain point caps Each drain point is fitted with a schrader valve which will be depressed when the drain hose is screwed into position Similarly with the secondary circuit first disconnect the rear door heat exchanger hoses at the quick release coupling location on the back of the unit then attach the drain hose to the relevant connection points CDU Module Installation Guide Page 29 Cooling Distribution Unit Module Fig 3 Module drain points Primary circuit drains Secondary circuit drains CDU Module Installation Guide Page 30 Cooling Distribution Unit Module Distribution Unit Module TROUBLESHOOTING os 8 1 Summary of Alarm Messages The controller screen will display a red background when in alarm condition with a static display showing the time of the alarm and the actual alarm message scrolling across the screen If more than one alarm is present then these can be viewed by using the up down arrow buttons Each alarm is given a numeric designation i e alarm 01 will be the first oldest alarm raised see Section 6 4 for alarm acknowledgement SEC TEMP
27. he unit are secure and undamaged Pay particular attention to the pipework e Inspect all wiring and check that all terminations are tight especially any ground earth connections e Ensure that the power supply is correctly connected see wiring diagram data plate for rating e Check that the RDHx has been correctly piped up via guick release couplings to the supply and return connections of the CDU e Check that the primary chilled supply is connected and hose connections are tight e Check that drain caps are fitted to the drain points at the back of the unit e Check that fuse rating of the power supply is in accordance with the recommendations on the wiring diagram and motor overload device is set to 2 6A 230v 50Hz unit 4 4A 208v 60Hz unit or 8 8A 120v 60Hz unit e Ensure that cooling water supply does not exceed 10Bar 145PSI pressure e Ensure the bleed screws on the two automatic air vents are loose but have not been removed 5 2 Chilled water Crack open the inlet and return isolation valves for the chilled water if fitted to allow the primary circuit within the unit to gently fill from the chilled water supply Once the circuit is filled the isolation ball valves may be opened fully Check for leaks See Fig 1 for connections 5 3 Controller Setup When the power is first applied to the unit the controller screen will guickly turn from blue to red background with two alarms present These will be Low Level and Low P
28. ical connections should be carried out in accordance with national and local regulations Never make any connections in the unit circuits unless the electricity supply has been switched OFF at the disconnect isolator 1 5 Maintenance For further information please refer to Section 7 Preventative and General Maintenance 1 6 Service Parts Service parts must be of the same specification as those being renewed and should only be obtained from the CDU manufacturer The use of incorrect service parts can affect the unit operation and reliability and invalidate any warranty 1 7 Codes of Practice It is important that eguipment and products which have been installed and commissioned are maintained by or under supervision of technical competent personnel and that all work is carried out in accordance with good engineering practice and strict adherence to i IEE amp IEEE Standards ii Codes of good engineering practice ili Local Authorities iv Statutory requirements v Manufacturer s instructions and recommendations vi All other relevant information regulations and legislation 1 8 Waste disposal Waste materials must be disposed of in a professional and responsible manner and in strict adherence to environmental regulations For details consult local environmental agencies 1 9 Documentation All documentation must remain with the unit at all times Cooling Distribution Unit Module Distribution Unit Module INTROD
29. istribution Unit Module OP ERATION continued SYSTEM EVENTS ALARMS Display name Description SEC TEMP HIGH Secondary temperature high alarm display only 120s delay SEC TEMP LOW Secondary temperature low alarm display only 120s delay PRI TEMP HIGH Primary temperature high alarm display only 120s delay PRI TEMP LOW Primary temperature low alarm display only 120s delay PUMP O L TRIP Pump overload tripped system shutdown LOW PRESS Pump inlet low pressure alarm display only HIGH PRESS Pump outlet high pressure alarm display only WATER LEAK Water leak water detected in condensate tray system shutdown LOW FLOW Low flow rate detected display only SENSOR FAIL Sensor fail alarm 1 or more sensors unreliable display only LOW LEVEL Tank level low alarm system shutdown Display Icons The controller has a selection of standard display icons The display icons are used to indicate various system conditions on the default operational display FX06 Display Display Icons Alarm condition indicated When blinking alone indicates sensor fail alarm These icons indicate other alarm condition see table above including shutdown When blinking indicates secondary low temperature alarm When blinking indicates secondary high temperature alarm When blinking indicates dew point override
30. le lamp will change to a slow blink mode all the time the fill pump is running The system pressure may be monitored by going to Menu 01 System Values and scrolling down to Pump Inlet Pressure CDU Module Installation Guide Page 15 Cooling Distribution Unit Module Distribution Unit Module COMMISSIONING continued e The fill pump will pump the contents of the container into the system at the rate of approx um 0 25USgpm The pump will be noisy to start with as it self primes Note Filling wand intake should not be more than 1m below the fascia hose socket to ensure the fill pump self primes raise the container if necessary e If the container water level is about to drop below the wand intake stop the fill pump by again pressing the Fill Pump switch to avoid air being drawn into the system e f more than one container of water is required repeat the procedure above until the fill pump automatically stops pump will stop when main pump inlet pressure reaches 0 5Bar 8PSI and the Fill Pump Enable lamp will go out Leave the filling wand in the container as more water will be reguired during the initial stages of operation when air is expelled from the system and the main pump inlet pressure drops e Check for leaks e Once the unit is fully commissioned and running continuously without loss of pressure the filling wand may be disconnected at the white quick release coupling and stored in a
31. n be cleared when level is sufficient for unit operation Action Check float switch wiring amp connections If no fault found drain unit and replace float switch 8 2 Temperature Sensor Chart Temperature Sensor Graph 32 37 42 47 52 57 62 67 72 77 82 87 92 97 102 10 5 Temperature F Volts v DC 0 5 10 15 20 25 30 35 40 Temperature C CDU Module Installation Guide Page 32 Cooling Distribution Unit Module Distribution Unit Module SPARE PARTS ITEM PART No DESCRIPTION 1 CDUS 022 Relay 2 CDUS 023 Contactor 120 208 230v 50 60Hz CDUS 024 Thermal Overload 2 7 4A 230v 50Hz 3 CDUS 026 Thermal Overload 4 6A 208v 60Hz CDUS 025 Thermal Overload 8 11A 120v 60Hz 4 CDUS 027 Transformer 115 208 230v 50 60Hz 5 CDUS 035 Fuse 1A 6 CDUS 028 Lamp green 7 CDUS 029 Lamp Amber 8 CDUS 009 Fill Pump 9 CDUS 030 Temperature Sensor 10 CDUS 002 Float Switch Reservoir 11 CDUS 031 Pressure Sensor 12 CDUS 014 Main Pump 230v 50Hz CDUS 015 Main Pump 120 208v 60Hz 13 CDUS 011 Bulkhead Quick Release Coupling 1 4 14 CDUS 032 Rocker Switch Fill Pump 15 CDUS 033 Rocker Switch Start Stop 16 CDUS 034 Controller 17 CDUS 036 Fuse 2A 18 CDUS 037 Valve Actuator 19 CDUS 016 3 Way Valve 20 CDUS 017 Plate Heat Exchanger 21 CDUS 013 Flood Sensor 22 CDUS 038 Femal
32. ph shows the minimum temperature differential possible between the Primary chilled water supply temperature the Secondary set point temperature for the percentage of full CDU rated load Graph data based around full primary flow of 30L M 7 9USgpm and secondary flow of 40L M 10 6USgpm 3 7 Primary Circuit Flow Temperature graph Temperature F 39 41 43 45 47 49 51 Both the curves are based around a secondary supply temperature of 18 C 64 4 F to achieve the full duty of 20kw at the RDHx Flow L M Flow Usgpm 7 8 9 10 11 Temperature C Water Water 30 glycol The graph above is a guide for the primary water reguirements based on a single RDHx for either plain water or up to 30 ethylene glycol different of glycol can be estimated on a pro rata basis The primary water should fall either on the chosen curve or in the area above the curve Note The water flow should ideally not be more than 20 above that recommended CDU Module Installation Guide Page 11 Cooling Distribution Unit Module TECHNICAL DATA continued Primary Circuit Pressure Drops CRETA DS Eu Pressure Drop Bar Pressure Drop PSI N oO aA O N CO o O o o 10 15 20 25 30 35 40 45 50 Flow L M Water Water 30 Glycol
33. pressing the and buttons together for at least 2 seconds Note It will not be possible to re start the unit after a shut down alarm has been activated until the shut down alarm s has been manually cleared Alarm will only clear if conditions are healthy 6 5 Control Loop Set Up Control of the primary circuit modulating valve is controlled through a PI Proportional amp Integral control loop The CDU module has pre set PI loop settings already programmed that should give good overall control in the majority of applications However if it is found that these settings require adjustment i e the control valve is sluggish to respond to load or is over sensitive and oscillates hunts then follow the tuning procedure below For sluggish action 1 Setthe loop Integral Action Time to zero 2 Decrease the loop Proportional Band in steps of 50 of the set value disturbing the control loop after each step by adjusting the set point to a new value and always allow time between the changes for the system to settle down until the control loop begins to oscillate Multiply the final Proportional Band value by 2 5 and set accordingly Set the Integral Action Time to its previous default value If the control loop becomes unstable decrease the Integral Action Time in steps of 50 of the set value again adjusting the set point and allowing the system to settle after each change until loop becomes stable For oscillatory action 1 Setthe loop Inte
34. r access syster varues E Secondary temperature T1 Primary temperature T1 sample amp hold updates every 30secs Actual setpoint read only displays setpoint determined by control mode selection Pump inlet amp fill pressure P1 Pump outlet amp system pressure P2 sample amp hold updates every 30secs Pump differential pressure used to calculate flow System flowrate litres minute Hours run counter for pump Control valve position Room temperature T3 sample amp hold updates every 30secs Room relative humidity H1 sample amp hold updates every Room dew point temperature calculated from room temp amp RH Application Revision level Version of software loaded The screens shown in this guide are based around Software Version 11 1 CDU Module Installation Guide Page 19 Cooling Distribution Unit Module Distribution Unit Module OPE RATION continued Menu 02 VIEW TIME read only Password not reguired for access Review the date read only Review the month read only Review the year read only Review the hour read only Review the minute read only Menu 03 ALARM LOG summary of active alarms Password not reguired for access Default display when no alarms present Typical alarm display preceded by the alarm log number 01 02 etc CDU Module Installation Guide Page 20
35. ressure alarms because the secondary circuit has not yet been filled see Section 6 1 page 27 for more detail The Enable Fill Pump lamp will also come on Acknowledge these alarms by pressing the C button on the controller fascia to return the controller to its normal blue default display see Section 6 1 for more detail As described in Section 6 1 use the controller buttons to scroll to Menu 02 to View Time If the time and date are incorrect go to Menu 04 and enter the Password in as described on page 21 then scroll to Menu 07 and follow the method to set time amp date as shown on page 24 Note After adjustment select YES under Set Clock screen then set back to RTC Real Time Clock The unit is now ready to be filled as laid out in the following section 5 4 System Filling Refer to Section 3 4 for system fluid capacities Operation for secondary circuit filling e ltwil not be possible to start the unit with the unit Start Stop switch until the system has been filled with deionized water i e system start is inhibited by reservoir low level interlock e Position a container of pre treated deionized water in front of the unit e Place the filling wand into the container of water and plug into the white guick release socket on the front fascia of the unit see Fig 2 then press the Fill Pump switch Note The fill pump will only operate if the amber Fill Pump Enable lamp is on The Fill Pump Enab
36. roller display will be unlit during normal operation However when power is first applied to the unit or if any of the controller buttons are pressed the screen will display a blue backlight This blue backlight will stay on for 10 minutes after last button press The backlight will also change to red in an alarm condition and will remain red until alarm has been acknowledged or self clears See Section 6 4 for more information CDU Module Installation Guide Page 17 Cooling Distribution Unit Module Distribution Unit Module OPE RATION continued Controller operation On pressing any key the screen backlight will turn on In all menus text that exceeds the display width scrolls continuously indicated by menu on the display Use this button to toggle between the default screen and selection of the following menus You can also use this button at anytime to clear the display back to the default screen and to acknowledge active alarms REPORT MENUS Without password entry Menus Description 01 SYSTEM VALUES Live analogue data point s read only 02 VIEW TIME Review controller time and date after setting 03 ALARMLOG Contains summary of active alarms 04 PASSWORD Enter USER password for additional menus 05 to 07 password 1234 REPORT MENUS After password entered Menus Description 01 SYSTEM VALUES Live analogue data point s read only 02 VIEW TIME Re
37. safe location Fig 2 Filling wand NOTE If there is already pressure in system and air is introduced into the fill pump suction line then the fill pump may not be able to purge this air through the unit and may cease to pump To rectify either switch unit off and relieve secondary circuit pressure via a drain point then refill system again as above or ensure the filling wand amp tube are vented of air and primed with fluid before connection CDU Module Installation Guide Page 16 Cooling Distribution Unit Module Distribution Unit Module OPERATION Section 6 6 1 Controller Introduction The CDU module controller has been designed to control the supply of cooling water to a single RDHx in unattended IT environments Cooling water is supplied and controlled to a predefined set point at a controlled flow rate When power is first applied to the unit the display will come on with a blue backlight and the amber lamp will come on if the unit has not been filled with water Fascia Displa Unit Running indicator pump running a FILL PUMP ENABLE a E Fill Pump Enable indicator ON low pressure condition Controller START STOP FILL PUMP i Fill Pump switch start stop fill pump when i enabled A Start Stop switch starts pump amp control The controller consists of a LCD display with four buttons which provide a means of navigating through the data lists and changing various parameters Cont
38. tain a 2 differential above dew point Alternative control modes are Fixed Set Point only FXSP where the dew point in the room has no effect on the operational set point and Dew Point Tracking DPTR where the set point is constantly adjusted to always be 2 above dew point Note When controller is set to Dew Point Tracking the set point may not always be achievable as it will often fall outside the cooling capacity of the unit i e if the dew point was 7 lt then the controller would re adjust the set point to 9 however the plate heat exchanger is sized for a minimum temperature differential between primary water inlet and secondary outlet temperatures of 8 Therefore if the primary water temperature was 10 then a secondary set point of IC would be unachievable and the actual temperature displayed would be unlikely to fall much below 18 lt In this instance the secondary high temperature alarm would be permanently on if left at the default value i e 2 above a floating set point Therefore when dew point tracking is selected the high temperature alarm will operate on a fixed value default 18 C 2 to give an alarm threshold of 20 still on a 1 hysteresis i e if temperature exceeds 20 for more than 120 seconds then an alarm will be generated This symbol will flash in the display when dew point override or dew point tracking is operational e The secondary water temperature is monitored at the pump dischar
39. uctions conform to the EMC directive and essential Health amp Safety reguirements of the Machinery Directive 91 368 EEC 93 44 EEC amp 93 68 EEC This includes the EMC compatibility directive 89 336 EEC As standard units comply with an IP21 rating The products are UL listed and certificates will be made available on application to the address on the front cover CDU Module Installation Guide Page 2 Cooling Distribution Unit Module Distribution Unit Module CONTENTS Section 1 SAFETY INSTRUCTIONS General Notice 5 1 1 Installation Handling 6 1 2 Application 6 1 3 Warranty 6 1 4 Electrical connection 6 1 5 Maintenance 6 1 6 Service parts 6 1 7 Codes of Practice 6 1 8 Waste disposal 6 1 9 Documentation 6 Section 2 INTRODUCTION 2 1 General 7 Section 3 TECHNICAL DATA 3 1 Handling 9 3 2 Pipe Connections 9 3 3 Electrical Connection 9 3 4 Volume Capacity 9 3 5 Noise 9 3 6 Secondary Circuit 9 3 7 Primary Circuit 11 Section 4 INSTALLATION 4 1 Mechanical 13 4 2 Electrical 13 4 3 Hydraulic 14 4 4 Heat Transfer Fluids 14 Section 5 COMMISSIONING 5 1 Pre Commissioning Checks 15 5 2 Chilled Water 15 5 3 Controller Setup 15 5 4 System Filling 15 Section 6 OPERATION 6 1 Controller Introduction 17 6 2 Controller Menu Summary 19 6 3 Automatic Operation 26 6 4 Acknowledgement of Alarm Messages 28 6 5 Control Loop set Up 28 Section 7 PREVENTATIVE MAINTEANCE 7 1 General 29 7 2 Every 3 Months 29 7 3 Every 6 Months 29 7 4 Every 12
40. valve position can be set manually with the control knob in the centre of the indicator dial Note if control signal is still present this will take precedence over any manual adjustment e The valve actuator will automatically drive the valve to a safe divert to by pass position in the event of a power failure This is achieved through power from a charged capacitor internal to the actuator Note This function will only operate if the main power supply has been on for at least 3 minutes to allow the capacitor time to charge CDU Module Installation Guide Page 27 Cooling Distribution Unit Module Distribution Unit Module OPE RATION continued The primary circuit parameters monitored within the Menu 01 System Values screen are Primary temperature Control Valve Position e f any sensor primary secondary temperature pressure or room temp hum goes open circuit then a SENSOR FAIL alarm will be raised 6 4 Acknowledgement of Alarm Messages Alarm s can be acknowledged by pressing the button It is only necessary to press this button once irrespective of how many alarms are present Once alarms have been acknowledged the display will return to the normal blue then un illuminated background but active alarms will still be indicated by flashing icons on the display screen see page 25 for more information All active alarms may still be viewed under the ALARM LOG menu Alarms must be manually cleared by
41. view controller time and date after setting 03 ALARM LOG Contains summary of active alarms 04 PASSWORD Change USER password or use to LOG OFF 05 SYSTEM SETTINGS Edit system parameter s 06 CONTROL MODE Select dew point setpoint operation mode 07 GET TIME Set controller time and date menus and to adjust parameters O EC parameter Additional menus accessible after password entry Use these buttons to scroll up and down through the above menus the points contained in the Use this button to enter a selected menu to open an editable field and to accept an adjusted Press and hold these two buttons together for 2 seconds to clear alarms that cause a system shutdown to enable unit to be restarted The alarms that cause shutdown are 1 Tanklow level alarm 2 Pump overload alarm 3 Water leak alarm Note Unit cannot be started if any of the shutdown alarms have not been cleared or if a Low Pressure alarm is present on initial start up Default operational screen Controller will sequentially return to this screen from sub menus after 90 seconds if no buttons are pressed To access the other menus press OM go to Menu 01 then scroll through as required CDU Module Installation Guide Page 18 Cooling Distribution Unit Module Distribution Unit Module OPERATION continued 6 2 Controller Menu Summary Menu 01 SYSTEM VALUES read only Password not reguired fo
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