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 Obs
O manual em Português está disponível no CD-ROM em anexo.
Данное руководство на русском языке имеется на прилагаемом компакт-диске.
您可以从包含的 CD 上获得本手册的中文版本。
您可以从付属的CD上获得本手册的中文版本。
ługi w jezyku polskim jest dostepna na CD.
동봉된 CD 안에 한국어 매뉴얼이 있습니다 .
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. Therefore, American Power Conversion
Corporation assumes no liability for damages, violations of codes, improper installation, system failures,
or any other problems that could arise based on the use of this Publication.
The information contained in this Publication is provided as is and has been prepared solely for the
purpose of evaluating data center design and construction. This Publication has been compiled in good
faith by American Power Conversion Corporation. However, no representation is made or warranty
given, either express or implied, as to the completeness or accuracy of the information this Publication
contains.
IN NO EVENT SHALL AMERICAN POWER CONVERSION CORPORATION BE LIABLE
FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL, PUNITIVE, SPECIAL, OR
INCIDENTAL DAMAGES (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS
OF BUSINESS, CONTRACT, REVENUE, DATA, INFORMATION, OR BUSINESS
INTERRUPTION) RESULTING FROM, ARISING OUT, OR IN CONNECTION WITH THE
USE OF, OR INABILITY TO USE THIS PUBLICATION OR THE CONTENT, EVEN IF
AMERICAN POWER CONVERSION CORPORATION HAS BEEN EXPRESSLY ADVISED
OF THE POSSIBILITY OF SUCH DAMAGES. AMERICAN POWER CONVERSION
CORPORATION RESERVES THE RIGHT TO MAKE CHANGES OR UPDATES WITH
RESPECT TO OR IN THE CONTENT OF THE PUBLICATION OR THE FORMAT
THEREOF AT ANY TIME WITHOUT NOTICE.
Copyright, intellectual, and all other proprietary rights in the content (including but not limited to
software, audio, video, text, and photographs) rests with American Power Conversion Corporation or its
licensors. All rights in the content not expressly granted herein are reserved. No rights of any kind are
licensed or assigned or shall otherwise pass to persons accessing this information.
This Publication shall not be for resale in whole or in part.
Contents
General Information........................................................ 1
InRow RD 10 kW Air Cooled Operation and Maintenanceiii
General Information
Overview
Note the definitions for the icons here and be observant for them throughout this manual. They are
intended to call attention to potential hazards and important information.
Symbols used in this manual
Electrical Hazard:Indicates an electrical hazard which, if not avoided, could result in
injury or death.
Danger:
death.
Warning: Indicates a hazard which, if not avoided, could result in personal injury or
damage to product or other property.
Heavy: Indicates a heavy load that should not be lifted without assistance.
Caution: Indicates a potential hazard which, if not avoided, could result in damage to the
equipment or other property.
Tip Hazard:
moving.
Note: Indicates important information.
Indicates that more information is available on the same subject.
Indicates a hazard which, if not avoided, could result in severe personal injury or
This equipment is easily tipped. Use extreme caution when unpacking or
Cross-reference symbol used in this manual
See another section of this document or another document for more information on this
subject.
1InRow RD 10 kW Air Cooled Operation and Maintenance
Safety
Read and adhere to the following important safety considerations when working with this cooling unit.
®
Note: All work must be performed by American Power Conversion (APC
personnel only.
Caution: Keep your hands, clothing, and jewelry away from moving parts. Check the
equipment for foreign objects before closing the doors and starting the equipment.
Heavy: The equipment is heavy. For safety purposes, at least two people must be present
when moving this equipment.
Tip Hazard: This equipment has a high center-of-gravity. Use extreme caution when
moving.
) authorized
Electrical Hazard:
Warning: Before performing any service, properly de-energize and remove access to
the equipment (Lockout). Physically label the equipment as intentionally out of service
(Tagout).
Do not wear jewelry when working near energized components.
InRow RD 10 kW Air Cooled Operation and Maintenance2
Commissioning
Warning: APC authorized personnel must perform the following procedures.
Electrical Hazard: Perform Lockout/Tagout procedures on the cooling unit before
servicing the cooling unit. Failure to remove power before servicing this equipment could
result in serious injury or death.
After installation is complete, verify that all components are working properly and that the cooling unit
is ready to begin operation.
Inspection Checklists
Initial inspection checklist
The initial inspection ensures that the cooling unit has been properly installed, the location of the cooling
unit has been properly prepared, and the cooling unit is free of damage.
Warning: The cooling unit operates under pressure. Take proper safety precautions
when connecting gauges or servicing piping.
Warning: Do not operate the cooling unit with any cover, guard, door, or panel removed
unless the instructions indicate otherwise. Then, proceed with extreme caution.
Warning: Do not run service utilities in front of the fan outlets.
unit is required for service access. To roll the cooling unit out of the row, there must be a
minimum of 1200 mm (48 in) of clear floor space in front of or behind the cooling unit.
Out-of-row service requires 760 mm (30 in) of side clearance in addition to the front and rear
clearance.
Ensure that:
The installation procedure is complete according to the installation manual.
The walls, floor, and ceiling of the room where the cooling unit is located are sealed with a vapor barrier.
There is no evidence of damage to the cooling unit.
The cooling unit is level and joined to the adjacent racks.
The cooling unit is not installed at the open end of a row.
The clearance around the cooling unit is in accordance with local and national codes and regulations as
well as the installation manual.
Caution: The vapor barrier minimizes moisture infiltration. Without a vapor barrier, it will
be difficult to maintain the humidity in the room.
Caution: Do not introduce unconditioned outside air into the space.
Note: A minimum of 900 mm (36 in) of clear floor space in front of and behind the cooling
3InRow RD 10 kW Air Cooled Operation and Maintenance
Electrical inspection checklist
The electrical inspection verifies that all electrical connections are secure and correct and that the
cooling unit is properly grounded.
Electrical Hazard: All electrical wiring must comply with local and national codes and
regulations.
Electrical Hazard: The equipment must be grounded (do not use a water-pipe ground).
Ensure that the:
Incoming voltages match the phase and voltage listed on the nameplate.
Electrical wiring complies with local and national codes and regulations.
The cooling unit is properly grounded.
Electrical connections are tight, including contactors, terminal blocks, controllers, switches, relays,
auxiliary devices, and field connections.
InRow RD 10 kW Air Cooled Operation and Maintenance4
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. The inspection ensures that field piping is properly installed
to promote oil return to the compressor.
Warning: The equipment is shipped from the factory with a nitrogen holding charge.
Remove the nitrogen holding charge using the Schrader valves located on the internal
refrigerant piping.
Caution: Improperly installed piping may result in improper operation and possible damage
to the cooling unit or surrounding equipment.
Ensure that the:
Fans are turning freely and that the blades are not distorted or bent.
Condensate drain line is at least the size of the drain connection.
Piping joints are tight.
Mechanical connections are tight, including compressor and receiver rotolock connections.
Refrigerant piping size is correct according to the line size table in the installation manual.
Vertical, horizontal, and total run lengths of the liquid, discharge, and suction lines are recorded.
Number of 45- and 90-degree bends in the refrigerant piping are recorded.
Field-installed traps and piping are in accordance with the installation manual and follow proper piping
practices.
Refrigerant piping is adequately supported and isolated when necessary.
Field-installed service valves are open.
Pressure relief valve is installed in accordance with the installation manual as well as local and national
codes and regulations.
Piping in the building and on the roof is properly insulated.
Covers and guards are in place.
5InRow RD 10 kW Air Cooled Operation and Maintenance
User interface inspection checklist
The user interface inspection verifies that the sensors and internal communications links of the cooling
unit are installed properly.
Ensure that:
An A-Link bus is connected to each cooling unit in the group and a terminator is plugged into all unused
A-Link connectors.
The input contacts and output relays are connected correctly.
The building management system is connected correctly and a terminator is wired into the final unit
between Modbus D0 and Modbus D1.
The rack temperature sensors are installed correctly.
The network port is connected correctly and an IP address has been assigned to the equipment.
Start-up inspection checklist
The start-up inspection ensures that the cooling unit is operating properly after the initial start-up. This
inspection verifies that all modes of operation are working correctly and that the cooling unit is ready for
normal operation.
While the cooling unit is operating, ensure that the:
Cooling unit is free from malfunctions, unusual vibrations, or other irregularities in each mode of
operation.
Cool cycles engage.
Air filters are clean and free of debris. Replace air filters with APC part number 875-2013.
Clogged filter alarm is operating properly:
Cover 1/3 of the filter area and monitor alarm performance.
Compressor suction and discharge pressures are recorded.
Sight glass moisture sensor is green.
Final inspection checklist
The final inspection verifies that the system is clean and the start-up form has been sent to APC.
Ensure that:
System is clean and free from debris.
Packaging materials are disposed of properly.
Start-up form was completed and sent to APC.
InRow RD 10 kW Air Cooled Operation and Maintenance6
Charging With Refrigerant
Calculating R410A charge
Use the following table and formula when calculating the total R410A charge.
Discharge line (horizontal)
Discharge line (vertical)
Liquid line
Discharge line (horizontal)
Discharge line (vertical)
Liquid line
Discharge line (horizontal)
Discharge line (vertical)
Liquid line
5/8 inOD ACR
1/2 in OD ACR
1/2 in OD ACR
5/8 inOD ACR
1/2 in OD ACR
1/2 in OD ACR
5/8 inOD ACR
1/2 in OD ACR
1/2 in OD ACR
Note: All refrigerant pipes must be straight ACR to have 39 bar (565 psig) or above MWP.
Equivalent length of 1/2 in OD discharge line pipe should be kept less than 18 m (60 ft). Total
equivalent length of the discharge line should be less than 46 m (150 ft) to prevent excessive
hot gas pressure drop which can increase the discharge pressure during hot summer days. To
have 61 m (200 ft) total equivalent discharge pipe length the load must be reduced by 5%.
Total charge = Equipment charge + condenser summer charge + condenser flooded charge (for minimum
possible ambient temperature) + liquid R410A in liquid pipe
Equipment charge: 1.6 kg (3.5 lb)
7InRow RD 10 kW Air Cooled Operation and Maintenance
Quantity of R410A in 1/2 in OD liquid line: (area) x (length in ft) x (density): 0.0010554 (ft2) x L (ft) x
3
61.0 (lbm/ft
)
Density of liquid R410A at 40.6
°C (105°F) and 260 psig: 0.98 g/cm
Cross sectional area for 1/2 in OD pipe is 0.0010554 ft
2
.
3
(61.0 lbm/ft3 )
Liquid line charge for 1/2 in OD ACR copper tube: 0.095 kg/m (0.0644 lb/ft).
2
Cross sectional area for 5/8 in OD pipe is 0.001619 ft
Quantity of R410A in 5/8 in OD liquid line: (area) x (length in ft) x (density): 0.001619 (ft
3
61.0 (lbm/ft
).
.
2
) x L (ft) x
Liquid line charge for 5/8 in OD ACR copper tube: 0.146 kg/m (0.099 lb/ft).
Example:
Calculate the total R410A charge for an FCB5 condenser with 25 ft of 1/2 in OD liquid piping.
Minimum outdoor design temperature is -28.9
InRow RD 10 kW Air Cooled Operation and Maintenance8
Charging the equipment
Caution: Fast charge of liquid refrigerant through the suction
port may damage the compressor.
Caution: This procedure is to be done by APC-trained personnel only.
R410A is a blend refrigerant. When charging equipment with blend refrigerants, only liquid refrigerant
must be charged.
Caution: Charging with other than liquid R410A refrigerant may damage the system.
1. Ensure the ball valves are open.
2. Confirm the calculated system charge.
3. Connect the refrigerant cylinder to the charging or gauge port on the receiver outlet valve. Open
the receiver valve approximately half way.
4. Charge liquid refrigerant into the high side of the system until the system pressures equalize.
While the unit is NOT operational, charge liquid to the suction (low side) line to simply equalize
pressures throughout the system DO NOT start the system until the pressure equalizes. Please
note charging liquid to the suction port during operation may damage or reduce the life of the
compressor.
5. Prior to starting the system, make sure all system valves are open and the system high side
pressure remains above 24.8 bar (360 psi). This may require blocking the condenser inlet slightly.
Remove any blocking panels after charging is complete.
6. Start the cooling unit. See “Start the cooling unit” on page 15 for more information.
7. Once the system is operational, front seat the receiver service valve and continue charging liquid
at the Schrader port down stream of the receiver shutoff valve, until the calculated charge is
complete. When this procedure is complete, fully back seat the receiver shutoff valve. Leave
charging hoses in place in the event additional charging is required.
8. Charge the rest of the calculated liquid refrigerant very slowly through the suction port.
9. Verify that the sightglass is clear. If there is excessive bubbling in the sightglass, make sure the
system high side pressure is above 23.4 bar (340 psi) and Superheat and Subcooling are within
parameters (10-12 for Superheat and 8-10 for Subcooling). If additional charging is required,
front seat the receiver shutoff valve and weigh in the additional charge at the Schrader port.
Note: Since good performance during low ambient temperatures depends on proper
refrigerant charge, it is very important that this phase of the installation procedure be
done carefully. Poor system performance can be due to too little or too much charge.
9InRow RD 10 kW Air Cooled Operation and Maintenance
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