Operation and Maintenance Pumped Refrigerant System Refrigeration Distribution Unit (RDU) and Cooling Modules ACDA901 ACOA500 ACOA501 ACRA100 ACRA101
This manual is available in English on the enclosed CD. Dieses Handbuch ist in Deutsch auf der beiliegenden CD-ROM verfügbar. Deze handleiding staat in het Nederlands op de bijgevoegde cd. Este manual está disponible en español en el CD-ROM adjunto. Ce manuel est disponible en français sur le CD-ROM ci-inclus. Questo manuale è disponibile in italiano nel CD-ROM allegato. 本マニュアルの日本語版は同梱の CD-ROM からご覧になれます。 Instrukcja Obsługi w jezyku polskim jest dostepna na CD.
American Power Conversion Legal Disclaimer The information presented in this manual is not warranted by the American Power Conversion Corporation to be authoritative, error free, or complete. This publication is not meant to be a substitute for a detailed operational and site specific development plan.
Contents General Information ........................................................ 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Save these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Commissioning ............................................................... 3 Inspection Checklists . . .
Group Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Modify a Cooling Module (CM) ID . . . . . . . . . . . . . . . . . . . . . . . . . . . View the groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unassign CMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23 23 23 Control the Environment .
Network Management Card .......................................... 44 Quick Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 TCP/IP configuration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 APC Device IP Configuration Wizard . . . . . . . . . . . . . . . . . . . . . . . . 45 .ini file utility . . . . . . . . . . . . . . . . . . . . . .
General Information Overview The pumped refrigerant system is composed of at least one 160 kW Refrigeration Distribution Units (RDUs) circulating R-134a refrigerant to the Cooling Modules. Each RDU can support multiple overhead or in row Cooling Modules. Cooling Modules are identified as CMs on the display interface screens of the RDU and in this manual. The exact type of Cooling Module is identified where specificity is required on both the display interface and in this manual.
Safety Read and adhere to the following important safety considerations when working with this unit. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. All electrical work should be performed by licensed electricians. Practice lockout/tagout procedures. Do not wear jewelry when working with electrical equipment. Failure to follow these instructions can result in death or serious injury.
Commissioning After installation, verify that all components are working properly and that the equipment is ready to begin operation. Inspection Checklists Initial Inspection Checklist The initial inspection ensures that the equipment has been properly installed, the location of the equipment has been properly prepared and the equipment is free of damage.
Electrical Inspection Checklist The electrical inspection verifies that all electrical connections are secure and correct and that the equipment is properly grounded. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. All electrical work should be performed by licensed electricians. Practice lockout/tagout procedures. Do not wear jewelry when working with electrical equipment.
Mechanical Inspection Checklist The mechanical inspection verifies that all mechanical components and connections are secure and tight and ready for start-up and system charging. Note: Improperly installed piping may result in improper operation and possible damage to the cooling unit or surrounding equipment. Ensure that the: 5 Chilled water pipe fittings are tight, and have been leak checked. Leak check pressure can not exceed 300 psi (2068 kpa). 5 Air is bled from the water system.
User Interface Inspection Checklist The user interface inspection verifies that the sensors and internal communication links are installed properly. Check that the outdoor heat exchanger is connected to the RDU(s). Ensure that: 6 5 An A-Link bus is connected to each RDU or cooling module (CM) and a terminator is plugged into all unused A-Link connectors. 5 An A-Link bus is connected to the external temperature and humidity sensor (APC part number AP9520TH).
Start-up Inspection Checklist The start-up inspection ensures that the equipment is operating properly after the initial start-up. This inspection verifies that all modes of operation are working correctly and that the equipment is ready for normal operation. See “Start the RDU” on page 1 for startup information. While the equipment is operating, ensure that: 5 The unit is free from malfunctions, including chilled water leaks, or other irregularities, in each mode of operation.
Operation The Pumped Refrigerant System System Operation The primary function of the Pumped Refrigerant System is to capture the heat generated by IT equipment and neutralize it before it mixes with the room air. The pumped refrigerant system uses two circuits to remove heat. In the first circuit, water or a water/glycol mixture is pumped from the chiller into a brazed plate heat exchanger located inside the RDU.
In the absence of an IT load or when all the CMs are turned off, the RDU refrigerant pumps continue to operate by bypassing the refrigerant through a pump head pressure control valve. This head pressure control valve allows continuous operation of the pumps regardless of the load. While in bypass, the refrigerant pumps reduce to a minimum speed allowing minimal power consumption and avoid the wear of frequent starts and stops.
The example below shows two RDUs employed to control three groups of CMs.
Pumped Refrigerant System Piping Diagram Cooling modules Chilled water supply na3346a RDU Item Description Item Description Sight glass Filter dryer Refrigerant pump output temperature sensor ! Liquid level sensor Check valves " Refrigerant HXGR output temperature sensor Refrigerant pump 2 output pressure sensor # Refrigerant HXGR output pressure sensor Refrigerant pump 1 output pressure sensor $ Condenser Isolation valves % Refrigerant HXGR input temperature sens
OA Piping Diagram Supply air To RDU na3386a From RDU Return air Item 12 Description Item Description Supply air temperature sensors Solenoid valve Micro-channel coil Supply liquid temperature sensor Fans Refrigerant liquid pressure sensor Return air temperature sensors Evaporator pressure regulator (EPR) Electronic expansion valve (EEV) Refrigerant vapor pressure sensor Remote rack inlet temperature sensor Return vapor temperature sensor Pumped Refri
RA Piping Diagram To RDU From RDU 7/8'’ ACR 1 1/8'’ ACR Supply Air na3391a Return Air Item Description Item Description Fan Return air temperature sensors Micro-channel coil Solenoid valve Return vapor temperature sensor Refrigerant liquid pressure sensor Refrigerant vapor pressure sensor Supply liquid temperature sensor Evaporator pressure regulator (EPR) Electronic expansion valve (EEV) Service port Rotalock adapter Remote rack inlet temperature se
Display Interface The display interface in the RDU also displays information pertinent to itself and to other system components. OAs, RAs, and other Cooling Modules are identified as CMs on the display interface screens. Status Check Log ESC ? Warning na3093a Critical 14 Item Description Function Critical Alarm LED (red) When lit, a critical alarm condition exists and requires your immediate attention. Warning Alarm LED (yellow) When lit, a warning alarm condition exists.
Using the Display Every time you apply power to the cooling unit, the display interface initializes, causing the LEDs to cycle and the alarm-tone to activate. Scrolling status screens After start-up, the interface displays the firmware revision number of the display interface. The display interface then scrolls automatically and continuously through screens of status information. Status Screen Name Status Information Displayed System Status • Alarms Present • IP: xxx.xxx.xxx.
Navigating the screens Clear Event Log Configure Modbus Set Date & Time Set Password na1623d Selector arrow. Press the up or down arrow key to move the selector arrow to a menu option. Press the ENTER key to view the selected sub-menu screen. In the example shown below, the selector arrow points to the Set Date and Time setting. To select that item, press the ENTER key.
Using the Path statement Select the main- and sub-menu options specified in the path statement to view or configure a setting. The path statement lists the main- and sub-menu items you select to navigate to the item to view or modify. The parts of the path statement are defined below: Path: Main > Set Password > Change Passwords Main >Your starting point is the main menu. Set Password > Scroll to and select this option from the main menu.
Start the RDU Path: Main > Operate > Operate To start the RDU, Select On. The pumps will start when the pump starting conditions are met. There must be a refrigerant reserve of at least 20% in the receiver. The Subcooler Outlet Temperature must be less than or equal to 55°F and the Subcooler Outlet Temperature must be at least 0.3°F cooler than the Condensing Temperature. The RDU will run according to the configured settings. Note: Operate only affects the local RDU.
General Configuration The configuration options are set during the commissioning of the RDU(s) and cooling modules (CMs) in the group. CAUTION HAZARD TO EQUIPMENT OR PERSONNEL All work must be performed by American Power Conversion (APC®) by Schnieder Electric authorized personnel. Failure to follow these instructions can result in death, serious injury, or equipment damage. Note: The Admin Password is required before configuration changes can be entered.
Power Source. The RDU has two AC inputs. One input is redundant. When Dual Feed is selected, an alarm will initiate if either of the AC inputs fails. If only one feed is used, select Single Feed. Fluid Temp High Thres. Fluid Temperature High Threshold: configure the entering fluid temperature high threshold. An alarm will initiate when the inlet water temperature exceeds the threshold. Bypass Mode. Enable/Disable. Select Enable to operate the Bypass Valve. Reset Options.
CM Configuration Path: Main > Cooling Modules > Select CM > Configuration > Parameters Startup Dly. Enter a value for the delay. The startup delay begins when the unit is started and initialized. The CM cannot begin operation until this delay expires. Use the startup delay to restart equipment sequentially after a scheduled downtime or a power outage. Power Source. The CM has two AC inputs. One input is redundant. When Dual Feed is selected, an alarm will initiate if either of the AC inputs fails.
Identify the cooling modules Path: Main > CMs In Network > Unconfigured CMs To add an unconfigured CM to the group: Physically note on paper the temporary ID number as it appears on the display of the CM once power is applied. Bring the note with the number back to the RDU and proceed to configure the CM using the temporary ID number to identify the CM from the list that appears on the RDU display interface. Note: Be careful to add only CMs that are physically piped to the RDU.
Group Configuration Group settings determine which modules are available in each group and how the groups should operate. CAUTION HAZARD TO EQUIPMENT OR PERSONNEL All work must be performed by American Power Conversion (APC®) by Schnieder Electric authorized personnel. Failure to follow these instructions can result in death, serious injury, or equipment damage. Modify a Cooling Module (CM) ID Path: Main > Cooling Modules > Select CM > Configuration > Modify CM ID RDU ID.
Control the Environment The primary function of the Pumped Refrigerant System is to capture the heat generated by IT equipment and neutralize it before it mixes with the room air. Controls in the RDU monitor room conditions to ensure the leaving refrigerant temperature to the CMs is always above the room dew point. In a HACS or RACS environment, the CMs neutralize the heat accumulated in the common hot aisle and expel it into the surrounding environmental space at the desired temperature.
Air Flow. Manual/Auto (RA only) Cfg Type. Select the cooling configuration from the following options: • In-Row: The air flow is not ducted. The hot-aisle air is cooled and the cooled-air supply is shared by all loads in the row. • RACS (Rack Air Containment System): Air flow in the enclosure is controlled by a ducting system fitted to the enclosure. • HACS (Hot Aisle Containment System): Air flow in the room is controlled by enclosing the hot air aisle. The loads share an enclosed common hot aisle.
Group PIDs Path: Main > Groups > Select Group Set Cool PID. Tune the Rack Inlet Temperature Controller. (InRow mode only) Reset to Defaults. Resets to the default settings. The Proportional plus Integral plus Derivative (PID) loop controls the output of the fans. NOTICE HAZARD TO EQUIPMENT This procedure is to be performed by APC authorized personnel only. Improperly set PID controls could result in equipment damage. Failure to follow these instructions can result in equipment damage. Gain (P).
Tune the PID loop Tune the PID loop to optimize the performance of the cooling group. NOTICE HAZARD TO EQUIPMENT This procedure is to be performed by APC authorized personnel only. The PID loop must be tuned after the equipment in the room is installed and running. Failure to follow these instructions can result in equipment damage. Note: The PID loop should be tuned periodically to account for changes in the room load. 1.
Further tune the PID loop in the following ways to account for changes in the room load: Loop Behavior PID Tuning Correction Slow response to temperature changes Increase the proportional multiplier or increase the derivative multiplier. Increase the derivative or the proportional multiplier. Overcooling/undercooling after changes in the room load or changes in setpoint Environmental temperature never reaches the setpoint Overcooling/undercooling on constant room load Increase the integral multiplier.
Service intervals Path: Main >Cooling Modules > Select CM > Configuration > Service Intervals The service interval depends on environmental cleanliness. Each component interval setting has an alarm. If enabled, the alarm will sound when the interval has elapsed. The alarm is cleared by selecting Clear Alarms in the main menu. Set the number of weeks to service the following: Air Filter Maintenance Interval. (Only displays for CMs with air filters.) The default is 18 weeks.
Display Settings Set display interface settings, including time and date, units of measure, passwords, and time-out settings. You can also adjust the contrast, key click, beeper volume, and beep on alarm settings. Password and timeout Path: Main > Set Password Note: The default user password is apc (lowercase). See “Password entry” on page 1 for more information on how to enter the password. Change passwords. Set the Admin and Device passwords. 1.
Adjust display Path: Main Menu > Configure Display Contrast. Adjust the visibility of the screen text. Lower numbered settings provide darker text; higher numbers provide lighter text. Settings range from 0–7. Key Click. Enable or disable an audible tone that will sound every time a key is pressed on the display interface. Beeper Volume. Set the volume of the display interface alarm tone, and for the audible tone that sounds every time a key is pressed on the display interface. Beep On Alarm.
Network Configuration The RDU is shipped with a Network Management Card that enables you to manage the RDU and attached CMs over your network. Configure the network settings for the Rack PDU Network Management Card from the display interface. The management card allows remote control and configuration of the equipment. Configure the network Path: Main > Configure Network MAC Address. Displays the unique network identifier assigned to the Network Management Card of the RDU at the factory. IP Address.
View Status Readings The display interface has several options for viewing the status of the RDU, the CMs in the cooling group either individually or as a group, and the environment being controlled. The status readings for the cooling unit are available under the View Unit Status option in the main menu, and status readings for the cooling group are available under the View Group Status option on the main menu or on the scrolling status screens.
Path: Main > RDU > Status > Measurements Temperatures. The temperature at each of the sensors in the RDU. • Water In: The temperature of the chilled water entering the RDU. • Water Out: The temperature of the chilled water leaving the RDU. • Condenser: The temperature of the refrigerant leaving the condenser. • Dew Point: The temperature at which condensation will occur in the conditioned environment. • Pump Outlet: The temperature of the refrigerant leaving the pump.
Path: Main > Cooling Modules > Select CM > Status > Overview Temperature. The temperature at each of the sensors in the selected CM. • Rack Inlet: The temperature of the air entering the rack at the remote temperature sensor. • Supply Air: The average temperature of the air entering the CM as measured by the supply air temperature sensors. • Return Air: The average temperature of the air leaving the CM as measured by the return air temperature sensors.
Cooling group status Path: Main > View Group Status View information about the group. Max Rack. The highest rack temperature reported by any sensor. Min Rack. The lowest rack temperature reported by any sensor. Air Flow. The combined airflow output of the modules in the group. Cool Output. The combined output of the group. Cool Demand. The cooling output required to meet the current heat load of the conditioned space. Cool Setpt. The temperature you set to maintain the room environment.
Event Log The event log saves status information and a message each time a change in the group is detected. Alarms and events are recorded in the log and displayed on the active alarms screen. Status events (informational) and system configuration changes are only displayed in the event log. View event log Path: Main > View Event Log The event log keeps a record of all alarms and events. The screen displays the following: • The name of the event. • The time and date the event occurred.
Alarm messages and suggested actions Alarm Message Severity Bypass Valve Actuator Fault Warning CM Communication Fault Critical Condenser Inlet Temperature Sensor Fault Warning Condenser Outlet Pressure Critical Sensor Fault Condenser Outlet Temperature Sensor Fault Critical Condensing Temperature High Violation Warning Condensing Temperature Low Violation Warning CW Valve Actuator Fault Critical DC Power Supply 1 Fault DC Power Supply 2 Fault Discrete Input Abnormal Entering Fluid Temperatur
Alarm Message Severity Persistent Receiver Pumped Critical Dry Primary Power Source Failure Warning Secondary Power Source Failure Warning Pump 1 Discharge Pressure Sensor Fault Pump 1 Fault Pump 1 High Head Pressure Pump 2 Discharge Pressure Sensor Fault Pump 2 Fault Pump 2 High Head Pressure Pumps Vapor Locked Pump Outlet Temperature Sensor Fault RDU Communication Fault Receiver Pumped Dry Critical Refrigerant Loss Detected Critical Refrigerant Loss Detection Disabled Warning Starting Conditio
Alarm Message Severity Action Required Unit is in Maintenance Mode Water Leak Detected Critical • Service Technician may be troubleshooting the unit. To return the unit to normal operation, reset the unit. • Identify and isolate the source of the leak. • For assistance, contact Technical Support. • Identify and isolate the source of the leak. • For assistance, contact Technical Support.
CM alarm messages Alarm Number 28 29 22 17 Alarm Message Severity Action Required Air Filter Service Interval Expired (RA only) Evaporative Temperature Below Dewpoint Fan 1 Door Open (OA only) Fan 1 Fault Warning • Clean or replace the air filter • Reset the alarm. Critical • Contact Technical Support. Critical • Make sure the door is closed. • Make sure the door interlock switch is connected properly. • Make sure the fan door is fully closed. • Make sure all intakes are clear of blockage.
Alarm Number 31 16 32 7 10 30 11 0 1 2 12 3 4 33 35 36 37 38 42 Alarm Message Severity Action Required Primary Power Source Overvoltage Secondary Power Source Failure Secondary Power Source Overvoltage Rack Temperature Sensor Fault Rack Temperature High Violation Critical • The input voltage is higher than the unit’s rated value. Connect the unit to a properly rated voltage input. Warning • Make sure the power source is connected properly and is within specifications.
Alarm Number 39 40 41 42 14 26 9 6 Alarm Message Severity Action Required Lower Supply Temperature 1 Fault Lower Supply Temperature 2 Fault Lower Supply Temperature 3 Fault Lower Supply Temperature 4 Fault Unit ID Needs Configuration Unit Personality Not Configured Vapor Outlet Pressure Sensor Failure Critical Vapor Temperature Sensor Fault Critical • Make sure the sensor is connected properly. • If the problem persists, contact Technical Support. • Make sure the sensor is connected properly.
Network Management Card Quick Configuration Overview Note: Disregard the procedures described in this chapter if you have APC InfraStruxure® Central as part of your system. See the documentation for your device for more information.
APC Device IP Configuration Wizard You can use the APC Device IP Configuration Wizard at a computer running Microsoft® Windows® 2000, Windows Server® 2003, or Windows XP to discover unconfigured RDUs and configure their basic TCP/IP settings, one card at a time, over the network. Note: Most software firewalls must be temporarily disabled for the Wizard to discover unconfigured RDUs. 1. If autorun is enabled, the user interface of the CD starts when you insert the Utility CD into a computer on your network.
DHCP. You can use an RFC2131/RFC2132-compliant DHCP server to configure the TCP/IP settings for the RDU. This section summarizes the RDU’s communication with a DHCP server. For more detail about how a DHCP server can configure the network settings for a RDU, see “DHCP Configuration” in the RDU User’s Guide on the Utility CD. 1.
Note: After the RDU has its IP address configured, you can use Telnet, without first using ARP and Ping, to access that RDU. 1. Use the MAC address of the RDU in the ARP command to define the IP address. Note: Look for the MAC address on the back of the Network Management Card or on the Quality Assurance slip included in the package (with the replacement Network Management Card). For example, to define 156.205.14.
How to Recover from a Lost Password You can use a local computer that connects to the RDU through the serial port to access the command line interface. 1. Select a serial port at the local computer, and disable any service that uses that port. 2. The APC serial cable (not provided) is used to connect the console port at the RDU and to your computer. (This cable is available to order from APC.) 3.
CM Display InRow OA STATUS UNIT ID LIGHTS SUPPLY AIR TEMP WARNING RACK INLET TEMP CRITICAL ALARM CODE Cooling System na3132a OA display Item Description Infrared remote control receiver Status LED Lights LED Warning LED Critical alarm LED Menu selection scroll up key Enter key Menu selection scroll down key Alarm code LED Rack inlet temperature LED Supply air temperature LED Unit ID LED Motion sensor for lights ! Infrared remote control RA display Item Description InR
Display Operation The display scrolls automatically through the sensor readings and alarms from the items listed to the right side of the display screen. To view information from the items listed to the left of the display screen, press the ENTER key and use the up or down keys to move through the display. All CMs have a three digit LED display. The capability of the display is limited to relaying sensor readings, the identification number of the CM, and alarms by number only.
Maintenance Leak Detector Calibration The leak detection feature must be calibrated before it can be used. Note: In order for calibration to successfully complete, the RDU and CMs must be on with a minimum system load of 5 kW. Path: Main > RDU > Status > Measurements From the display interface, or BMS, start calibration from the above path. Choose Calibrating to initiate the feature. When Calibration is complete, the leak detector will automatically start leak monitoring.
Monthly Preventive Maintenance Photocopy the following pages and use them during the maintenance procedures. After they have been completed, save them for future reference.
Mechanical DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. All electrical work should be performed by licensed electricians. Practice lockout/tagout procedures. Do not wear jewelry when working with electrical equipment. Failure to follow these instructions can result in death or serious injury.
Quarterly Preventive Maintenance * Perform all the Monthly Preventive Maintenance items and the items below. Prepared By: _________________________________ Model Number: _______________________________ Serial Number: _______________________________ Date: ______________________________________ Mechanical DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. All electrical work should be performed by licensed electricians.
Troubleshooting Problem Possible Cause Display interface not • Display interface operational, but not connected equipment operates properly Alarms do not show up • External on monitoring equipment monitoring equipment is not (Customer Output receiving power or Contact) is not functioning properly Equipment does not shut • Drive voltage down on command No communication with • Improper building management connection system (BMS) port Cooling modules are not • A-Link failure communicating with the RDU Equi
APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways: • Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests. – www.apc.com (Corporate Headquarters) Connect to localized APC Web sites for specific countries, each of which provides customer support information. – www.apc.com/support/ Global support searching APC Knowledge Base and using e-support.
