Cooling Distribution Unit INSTALLATION GUIDE Models: CD150W4 CD150W3 Coolcentric, a Division of Vette Corp 201 Boston Post Road West, Marlborough, MA 01752 Email: info@coolcentric.com Website: www.coolcentric.
Cooling Distribution Unit 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.
Cooling Distribution Unit CONTENTS Section 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 SAFETY INSTRUCTIONS General Notice Installation/Handling Application Warranty Electrical connection Maintenance Service parts Codes of Practice Waste disposal Documentation 5 6 6 6 6 6 6 6 6 6 Section 2 2.1 INTRODUCTION General 7 Section 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 TECHNICAL DATA Handling Pipe Connections Electrical Connection Volume Capacity Noise Secondary Circuit Primary Circuit 9 9 9 9 9 9 10 Section 4 4.1 4.
Cooling Distribution Unit CONTENTS (continued) Section 7 7.1 7.2 7.3 7.4 7.5 7.6 PREVENTATIVE MAINTEANCE General Every 3 Months Every 6 Months Every 12 Months Filter Flushing Unit Draining 39 39 39 39 39 40 Section 8 8.1 8.2 TROUBLE SHOOTING Summary of Event Messages Temperature Sensor Chart 41 46 Section 9 SPARE PARTS LIST 47 Section 10 10.1 10.
Cooling Distribution Unit SAFETY INSRUCTIONS Section 1 * * * IMPORTANT NOTICE * * * ALL PERSONNEL involved in the installation and maintenance of the Process and Ancillary Equipment, 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.
Cooling Distribution Unit SAFETY INSTRUCTIONS (continued) 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.
Cooling Distribution Unit Section 2 INTRODUCTION 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, 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.
Cooling Distribution Unit INTRODUCTION (continued) Primary Filter Primary By-pass Circuit Primary Isolation Valves Secondary Return Quick Release Couplings Internal manifold option Secondary Supply Quick Release Couplings Secondary Hose Clips Optional Secondary Flow Control/Balancing Valves Secondary Pump Non-Return Valve Cone seat union couplings Rear View (with optional Internal Manifold or Flex Tails for external Manifold) CDU Installation Guide Page 8 Flex Tails option for external manifold
Cooling Distribution Unit Section 3 TECHNICAL DATA 3.1 Physical Model: CD120W4 CD150W4 CD120W3 CD150W3 Cabinet dimensions: Width Height Depth 800mm (31½”) 1825mm (71⅞”) 1085mm (42¾”) Width Height Depth 940mm (37”) 1985mm (78⅛”) 1220mm (48”) Shipping dimensions: Weight (inc. manifold): Dry Operational Shipping 3.2 398kg (877½lb) 441.5kg (973½lb) 540kg (1190lb) 407kg (897½lb) 454.5kg (897½lb) 549kg (1210½lb) 398kg (877½lb) 441.5kg (973½lb) 540kg (1190lb) 407kg (897½lb) 454.
Cooling Distribution Unit TECHNICAL DATA (continued) Pressure available from CDU 0 5 10 15 20 25 Flow (Usgpm) 30 35 40 45 50 55 60 4.5 64 62 60 4.0 58 56 54 52 50 48 46 44 3.0 42 40 Pressure (PSI) Pressure (Bar) 3.5 38 2.5 36 34 32 30 2.0 28 26 24 1.
Cooling Distribution Unit TECHNICAL DATA (continued) 3.7 Primary Circuit Primary Flow/Temperature Graph for 120kW CDUs 39 41 43 45 Temperature (o F) 47 49 51 320 300 80 280 75 260 70 65 240 60 220 55 200 50 180 45 160 40 140 35 120 Flow (Usgpm) Flow (L/M) Note: To keep pipe velocities within limits, it is recommended that the brown shaded area is avoided.
Cooling Distribution Unit TECHNICAL DATA (continued) Primary Circuit Pressure Drops 0 5 10 15 20 Flow (USgpm) 25 30 35 40 45 50 55 60 0.9 13 12 0.8 11 0.7 10 8 0.5 7 6 0.4 5 0.3 Pressure Drop (PSI) Pressure Drop (Bar) 9 0.6 4 3 0.2 2 0.1 1 0.
Cooling Distribution Unit INSTALLATION 4.1 Section 4 Mechanical Arrival on site: The CDU cabinet is crated and dispatched on a load bearing pallet. On arrival at site the top and side panels of the crate and the protective bubble wrap should be removed and the cabinet inspected for any transit damage. If damage is found, it must be reported to the manufacturer immediately.
Cooling Distribution Unit INSTALLATION (continued) A room temperature & RH sensor is provided with every CDU. As standard this is fitted on the cabinet front door behind a ventilation grille. If required the sensor can be mounted remotely with the appropriate cable kit, to be installed on a wall adjacent to the IT enclosures at a height of approx 1.8M (71”). Fig. 2 – Control Transformer tappings Common tapping (208 - 230v tapping) 380 - 415v tapping 460 - 480v tapping 4.
Cooling Distribution Unit INSTALLATION (continued) 4.4 Heat Transfer Fluids 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°C (7°F). The secondary circuit should be filled with particulate free deionized water treated with suitable corrosion inhibitors and preservatives.
Cooling Distribution Unit CDU Installation Guide Page 16
Cooling Distribution Unit COMMISSIONING 5.1 Section 5 Pre-Commissioning Checks Check that all items within the unit are secure and undamaged. Pay particular attention to the pipework. Inspect all wiring and check that all terminations are tight, especially any ground (earth) connections. Ensure that the power supply is correctly connected – see wiring diagram/data plate for rating.
Cooling Distribution Unit COMMISSIONING (continued) Select ‘site setup’ and press OK . Use keys to set the number of RDHx attached to the unit, then press OK . Likewise, set the units to SI or imperial* as required & press OK , followed by the Daylight Saving hours, Date Format and Date & Time followed by OK on each occasion. Press the ESC key to return to welcome screen. Screen title Selected screen ref.
Cooling Distribution Unit COMMISSIONING (continued) 5.6 Inverter Setup The inverter drive has a separate display and keypad as detailed on the left. The display is set as standard to show the frequency output to the pump motors, but repeated pressing of the key with the circular arrow, will also show also the frequency reference value and current drawn by the pump.
Cooling Distribution Unit COMMISSIONING (continued) 5.7 System Filling Refer to Section 3.4 for system fluid capacities Operation – for secondary circuit filling It will not be possible to start the unit with the ‘Unit Start/Stop’ pushbutton until the system has been manually filled with deionized water (i.e. system start is inhibited by reservoir low level and low pressure interlocks). Position container of pre-treated deionized water in front of the cabinet.
Cooling Distribution Unit COMMISSIONING (continued) The ‘Status’ & ‘Sec. pressure’ screens can be used to monitor the secondary circuit pressure during the system filling process. See Section 6.1 for further information on how to access. status 3-4 room sensor sec. pressure prim. pressure OK sec. pressure ps1 ps2 dp 5.8 0.50bar 0.50bar 0.
Cooling Distribution Unit COMMISSIONING (continued) digital outputs use arrow keys 1000100000 0 = digital output OFF 1 = digital output ON (e.g.
Cooling Distribution Unit COMMISSIONING (continued) To adjust the primary flow rate: Set the controller to ‘Manual Control’ as described in Section 5.9 and adjust Valve 1 (screen ref. 4-4-2-1 under ‘Heat Exchanger’) to 100%, this will force Valve 1 to open fully. Next go back to the ‘Status’ mode of the controller and scroll to the ‘Primary Flow’ screen (screen ref. 3-8) to see the actual primary flow rate. Use the primary return ball valve (see Fig.
Cooling Distribution Unit CDU Installation Guide Page 24
Cooling Distribution Unit Section 6 OPERATION 6.1 Controller Introduction The CDU controller has been designed to control the supply of cooling water to up to 6 RDHx’s in unattended IT environments. Cooling water is supplied and controlled to a predefined set point at a controlled flow rate.
Cooling Distribution Unit OPERATION (continued) After initialization, the display panel will default to the welcome screen below: Date & time (this will alternate with the number of active warnings/alarms if present) set point dw o/r act. temp 18.0°C .0°C 18.
Cooling Distribution Unit OPERATION (continued) Use the & keys to scroll through the options within the ‘Status’ screen - refer to the ‘Controller Menu Summary’ in Section 6.2 for detail on the viewable information that can be displayed. When a title is highlighted, press the OK key to view the associated information. Example 1: By selecting the ‘Heat Exchanger’ title (screen ref. 3-2) and pressing OK , the screen below will be displayed.
Cooling Distribution Unit OPERATION (continued) 6.2 Controller Menu Summary All items shown on this background are available to all personnel with no requirement for an access code. All items shown on this background are only available to service engineers only with the correct access code. All items shown on this background are only available to factory authorized personnel with the correct ‘Engineering’ access code.
Cooling Distribution Unit OPERATION (continued) Title Service (screen 4) 4-1 Force pump c/o 4-2 Force valve c/o 4-3 Overrides 4-3-1 Auto/man mode 4-3-2 Digital outputs 4-3-3 AO1 – inverter 4-3-4 AO2 – valve 1 4-3-5 AO3 – valve 2 4-4 Manual Control 4-4-1 Secondary pumps 4-4-2 4-4-3 4-4-4 4-4-5 4-5 4-6 4-6-1 4-6-2 4-6-3 4-6-4 4-6-5 4-7 4-7-1 4-7-2 Heat exchanger Fill pump P3 Warning fault Alarm fault Suppress Events Reset Run Hours Pump P1 Pump P2 Valve V1 Valve V2 All Defer Active Event(s) Period Initiat
Cooling Distribution Unit OPERATION (continued) Screen / Level Title Options & (Info) 6-2-5 6-2-6 6-2-7 6-2-8 Pump DP delay DOL DP set point PV c/o interval PV c/o time Default 80 secs [adj. 1 to 300 secs] (time delay prior to pump low flow alarm) Default 2 Bar [adj. 1 to 5 bar] (pump differential pressure set point when DOL) Default 7 days [adj. 1 to 30 days] (pump/valve duty sharing period) Default 03:00 hrs [adj.
Cooling Distribution Unit OPERATION (continued) 6-8-2 6-8-3 6-8-4 6-9 Title Options & (Info) Flood op. u/f Threshold u/f Flood delay u/f Event relays Default Alarm [adj. alarm only / shutdown] (under floor sensor tape operation) Default 143 [adj. 75 to 250] (u/f sensor sensitivity) Default 10 secs [adj. 5 to 60 secs] (u/f sensor alarm/shutdown delay) Default N/O [adj.
Cooling Distribution Unit OPERATION (continued) * * * IMPERIAL UNITS * * * Screen / Level 6-4-2 6-4-3 6-4-4 6-4-5 6-4-6 6-4-7 6-5 6-5-1 6-5-2 6-5-3 6-5-4 6-5-5 6-5-6 6-5-7 6-5-8 6-5-9 6-6 6-7 6-8 6-8-1 6-8-2 6-8-3 6-8-4 6-9 Title Prim low temp Prim high temp Prim temp hys Prim filter dirty Prim filter hys Prim filter delay Offsets Prim temp T1 Sec. temp T2a Sec. temp T2b Room. temp T3 Room RH Pump PS1 Pump PS2 Prim filter PS3 Prim filter PS4 Manual period Event delay Flood operation Flood op.
Cooling Distribution Unit OPERATION (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 On receiving a start signal, the green Start/Stop push button will illuminate and providing the reservoir level switch is made, Pump 1 will start to increase in speed – the pump speed as a percentage of maximum can be read from the second welcome screen (see Section 6.
Cooling Distribution Unit OPERATION (continued) If either sensor goes open circuit, then a ‘Sec Temp Out of Range’ alarm will be raised and the controller will read the remaining working sensor only. The secondary temperature should correspond to the desired set point temperature – default fixed set point is 18°C (65°F) as displayed on the welcome screen and is used by the control loop to regulate the primary water control valve position to achieve and maintain the set point.
Cooling Distribution Unit OPERATION (continued) Primary Circuit Operation The primary water temperature is monitored at the inlet to the CDU cabinet. The cooling performance of the CDU cabinet has been calculated on a water temperature between 5 and 10°C (41 and 50°F). - If the primary temperature rises to 11°C (52°F), a ‘Primary Water Temp High’ warning will be generated. This warning will remain present until the temperature falls below the default 1°C (2°F) hysteresis value.
Cooling Distribution Unit OPERATION (continued) 6.4 Acknowledgement of Event Messages Event messages will break through onto the welcome screen as and when they occur, as in the example below. Events are categorised into two levels: ‘Warnings’ and ‘Alarms’. See Section 8.1 for identification of all event messages.
Cooling Distribution Unit OPERATION (continued) 6.5 Defer Active Event(s) When a Warning or Alarm event is generated, volt free relay contacts are also activated within the controller to give a remote monitoring/extended event facility. Where these event outputs are utilised by the customer, they can be deferred by a service engineer (see screen 4-7) for a period of 24, 48 or 72 hours. This means that if an engineer is unable to immediately rectify a warning or alarm condition when called to site (e.g.
Cooling Distribution Unit OPERATION (continued) 6.
Cooling Distribution Unit Section 7 MAINTENANCE PREVENTATIVE MAINTENANCE 7.1 General The CDU 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 electrically isolated/disconnected. 7.2 At 3 Months (or less) Flush out or replace the strainer element on the cooling water inlet (see Section 7.5).
Cooling Distribution Unit MAINTENANCE (continued) If flushing the filter does not improve conditions, then the filter screen should be replaced. For the primary circuit, this will mean isolating the cabinet from the chilled water supply by closing the 1½” ball valves at the rear of the cabinet (see Section 5.2), then draining the filter with the drain hose as used for the flushing procedure. Once drained the filter bowl may be unscrewed and the filter screen removed & replaced.
Cooling Distribution Unit Section 8 TROUBLESHOOTING 8.1 Summary of Event Messages See Section 6.4 for instruction on acknowledging events. Events refer to either Warning or Alarm messages. !! alarm !! code : a12 pump 1 inverter low flow Typical Alarm screen Warnings Warnings are non-urgent events that are not critical to the operation of the unit, but will require investigation on a routine maintenance visit.
Cooling Distribution Unit TROUBLESHOOTING (continued) Code: w24 – ‘Primary water low temp’ (self clear) Primary water temperature has exceeded the 4°C (40°F) threshold (default). Alarm will cancel when temperature rises to 5°C (42°F) or above (default 2 minute delay applies). Action: Check chilled water supply. Code: w25 – ‘Primary water high temp’ (self clear) Primary water temperature has exceeded the 11°C (52°F) threshold (default).
Cooling Distribution Unit TROUBLESHOOTING (continued). Code: a03 – ‘Sec temp T2a out of range’ (self clear) Reading from secondary temperature sensor T2a is outside the nominated range of 31°C to +66°C (-23.8°F to +150.8°F). Action: Check sensor connections to the control board. Code: a04 – ‘Room temp out of range’ (self clear) Reading from room temperature sensor T3 is outside the nominated range of -31°C to +66°C (-23.8°F to +150.8°F). Action: Check sensor connections to the control board.
Cooling Distribution Unit TROUBLESHOOTING (continued) Code: a14 – ‘Pump P2 inverter low flow’ (engineer to clear) Pump P2 has not reached the correct differential pressure in the specified time limit via the inverter drive. Alarm will cancel when inverter receives a reset signal. Action: Check unit has been set up for the correct number of racks. Check inverter drive for faults. Check non-return valves are not sticking open.
Cooling Distribution Unit TROUBLESHOOTING (continued) Code: a31 – ‘Room RH out of range’ (self clear) Reading from room relative humidity sensor is outside the nominated range of 5% to 95% RH. Action: Check sensor connections to the control board. Code: a32 – ‘Sec over pressure’ [when set as an alarm] (engineer to clear) Pressure at PS1 has increased above the set default value of 7.5Bar (105PSI). Note: Can also be configured as a warning (code w37) only.
Cooling Distribution Unit TROUBLESHOOTING (continued) 8.2 Temperature Sensor Chart Temperature Sensor Resistance Graph Temperature (o F) 32 37 42 47 52 57 62 67 72 77 82 87 92 97 102 107 112 117 122 127 132 137 34 32 30 28 26 24 Resistance (kΩ) 22 20 18 16 14 12 10 8 6 4 2 0 0 5 10 15 20 25 30 35 40 45 50 55 60 Temperature (o C) The chart above may be used to check the validity of any of the temperature sensors used in the unit or the remote room sensor.
Cooling Distribution Unit Section 9 SPARE PARTS ITEM PART No.
Cooling Distribution Unit SPARE PARTS (continued) 5 6 7 4 8 9 10 11 12 3 13 14 15 2 16 1 17 18 19 CDU Installation Guide Page 48 (not shown)
Cooling Distribution Unit SPARE PARTS (continued) 22 23 21 In-cabinet , or remote 24 25 26 29 27 28 (Internal manifold shown installed) 20 CDU Installation Guide Page 49
Cooling Distribution Unit SPARE PARTS (continued) 24v supply connector for Web Server * 2 x LON Network Connectors * 30 31 32 33 34 35 36 37 38 * 24v Power supply connection & LON network connections viewed from outside the electrical panel CDU Installation Guide Page 50
Cooling Distribution Unit Section 10 SCHEMATICS 10.1 Wiring Diagram A3 LAE029 10.
Cooling Distribution Unit CDU Installation Guide Page 52
Cooling Distribution Unit CDU Installation Guide Page 53
Cooling Distribution Unit CDU Installation Guide Page 54
CDU Installation Guide Page 55 Fill point T1 Bypass Valve Priming Pump P3 Redundant pump Level Sensor Heat Exchanger Redundant 2-way valve ## # PS4 Filter PS3 # Flowmeter Control Valves . Controller & Display T2a T2b Air Eliminator Air Eliminator PS1 Temp (T3) & Hum Sensor PS2 DR’N DATE DSM Quick Release Couplings RDHx 6 RDHx 5 RDHx 4 RDHx 3 RDHx 2 RDHx 1 RDHx 6 RDHx 5 RDHx 4 RDHx 3 RDHx 2 RDHx 1 DRG. No. A3NAD371 Iss. D CDU PIPE SCHEMATIC TITLE 40L/M (10.
Cooling Distribution Unit CDU Installation Guide Page 56
Cooling Distribution Unit WARRANTY & 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.
Cooling Distribution Unit Notes: CDU Installation Guide Page 58
Cooling Distribution Unit Disposals Procedure NOTE: All waste materials must be disposed of in a professional and responsible manner in strict adherence to environmental regulations. The de-commissioning, dismantling and disposal of Cooling Distribution Units should only be undertaken by experienced personnel with full adherence to all safety rules, in particular protection of lungs, eyes and skin from chemicals, dust etc.
