Black Box CRDX-G-FS-12KW, CRDX-G-FS-24KW, CRDX-A-FS-12KW, CRDX-W-FS-24KW, CRDX-W-FS-12KW User Manual
...
-FS
CRDX-A-FS-24KW CRDX-G-FS-12KW
CRDX-A-FS-12KW CRDX-W-FS-24KW
CRDX-G-FS-24KW CRDX-W-FS-12KW
Cold Row™ DX User Manual
This precision data center air-conditioning system
uses the latest, state-of-the-art control technology.
Customer
Support
Information
Order toll-free in the U.S.: Call 877-877-BBOX (outside U.S. call 724-746-5500)
FREE technical support 24 hours a day, 7 days a week: Call 724-746-5500 or fax 724-746-0746
Mailing address: Black Box Corporation, 1000 Park Drive, Lawrence, PA 15055-1018
Web site: w ww.blackbox.com • E-mail: info @blackbox.com
724-746-5500 | blackbox.com
Trademarks Used in this Manual
Trademarks Used in this Manual
Black Box and the Double Diamond logo are registered trademarks, and Cold Row is a trademark, of BB Technologies, Inc.
Schrader is a registered trademark of Schrader-Bridgeport International, Inc.
Teflon is a registered trademark of E.I. du Pont de Nemours & Co.
Any other trademarks mentioned in this manual are acknowledged to be the property of the trademark owners.
Page 2
We‘re here to help! If you have any questions about your application
or our products, contact Black Box Tech Support at 724-746 -5500
or go to blackbox.com and click on “Talk to Black Box.”
You’ll be live with one of our technical experts in less than 30 seconds.
724-746-5500 | blackbox.com
FCC and IC RFI Statements
Federal Communications Commission and Industry Canada Radio Frequency Interference
Statements
This equipment generates, uses, and can radiate radio-frequency energy, and if not installed and used properly, that is, in strict
accordance with the manufacturer’s instructions, may cause inter ference to radio communication. It has been tested and found to
comply with the limits for a Class A computing device in accordance with the specifications in Subpart B of Part 15 of FCC rules,
which are designed to provide reasonable protection against such interference when the equipment is operated in a commercial
environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user at his own
expense will be required to take whatever measures may be necessary to correct the interference.
Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to
operate the equipment.
This digital apparatus does not exceed the Class A limits for radio noise emis sion from digital apparatus set out in the Radio
Interference Regulation of Industry Canada.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de
la classe A prescrites dans le Règlement sur le brouillage radioélectrique publié par Industrie Canada.
724-746-5500 | blackbox.com
Page 3
724-746-5500 | blackbox.com
NOM Statement
Instrucciones de Seguridad
(Normas Oficiales Mexicanas Electrical Safety Statement)
1. Todas las instrucciones de seguridad y operación deberán ser leídas antes de que el aparato eléctrico sea operado.
2. Las instrucciones de seguridad y operación deberán ser guardadas para referencia futura.
3. Todas las advertencias en el aparato eléctrico y en sus instrucciones de operación deben ser respetadas.
4. Todas las instrucciones de operación y uso deben ser seguidas.
5. El aparato eléctrico no deberá ser usado cerca del agua—por ejemplo, cerca de la tina de baño, lavabo, sótano mojado o cerca
de una alberca, etc.
6. El aparato eléctrico debe ser usado únicamente con carritos o pedestales que sean recomendados por el fabricante.
7. El aparato eléctrico debe ser montado a la pared o al techo sólo como sea recomendado por el fabricante.
8. Servicio—El usuario no debe intentar dar servicio al equipo eléctrico más allá a lo descrito en las instrucciones de operación.
Todo otro servicio deberá ser referido a personal de servicio calificado.
9. El aparato eléctrico debe ser situado de tal manera que su posición no interfiera su uso. La colocación del aparato eléctrico
sobre una cama, sofá, alfombra o superficie similar puede bloquea la ventilación, no se debe colocar en libreros o gabinetes
que impidan el flujo de aire por los orificios de ventilación.
10. El equipo eléctrico deber ser situado fuera del alcance de fuentes de calor como radiadores, registros de calor, estufas u otros
aparatos (incluyendo amplificadores) que producen calor.
11. El aparato eléctrico deberá ser connectado a una fuente de poder sólo del tipo descrito en el instructivo de operación, o como
se indique en el aparato.
12. Precaución debe ser tomada de tal manera que la tierra fisica y la polarización del equipo no sea eliminada.
13. Los cables de la fuente de poder deben ser guiados de tal manera que no sean pisados ni pellizcados por objetos colocados
sobre o contra ellos, poniendo particular atención a los contactos y receptáculos donde salen del aparato.
14. El equipo eléctrico debe ser limpiado únicamente de acuerdo a las recomendaciones del fabricante.
15. En caso de existir, una antena externa deberá ser localizada lejos de las lineas de energia.
16. El cable de corriente deberá ser desconectado del cuando el equipo no sea usado por un largo periodo de tiempo.
17. Cuidado debe ser tomado de tal manera que objectos liquidos no sean derramados sobre la cubierta u orificios de ventilación.
18. Servicio por personal calificado deberá ser provisto cuando:
A: El cable de poder o el contacto ha sido dañado; u
B: Objectos han caído o líquido ha sido derramado dentro del aparato; o
C: El aparato ha sido expuesto a la lluvia; o
D: El aparato parece no operar normalmente o muestra un cambio en su desempeño; o
E: El aparato ha sido tirado o su cubierta ha sido dañada.
Page 4
724-746-5500 | blackbox.com
Table of Contents
Table of Contents
1. Introduction ........................................................................................................................................................................10
1.1 General ........................................................................................................................................................................ 10
1.2 Product Description .....................................................................................................................................................10
1.3 Product Warranty ........................................................................................................................................................ 13
1.4 Safety ........................................................................................................................................................................ 14
1.4.1 General ............................................................................................................................................................ 14
1.4.2 Safety Summary............................................................................................................................................... 14
1.5 General Design ............................................................................................................................................................16
1.5.1 Electrical Compartment ...................................................................................................................................17
1.5.2 Circuit Breakers/Motor Start Protectors ........................................................................................................... 17
1.5.3 Compressor ..................................................................................................................................................... 17
1.5.3.1 Electronic Thermal Expansion Valve .................................................................................................... 17
1.5.3.2 Electronic Hot Gas Bypass ..................................................................................................................17
1.5.4 Coils ................................................................................................................................................................. 17
1.5.5 Condensate Pump ........................................................................................................................................... 17
1.5.6 EC Fans ............................................................................................................................................................ 17
1.5.7 Temperature/Humidity Sensors ........................................................................................................................ 18
1.6 Optional Equipment ....................................................................................................................................................18
1.6.1 Remote Mounted Supply Temperature/Humidity Sensor ................................................................................. 18
1.6.2 Water Detector ................................................................................................................................................ 18
1.6.3 Smoke Detector ............................................................................................................................................... 18
1.6.4 Firestat ............................................................................................................................................................. 18
2. Installation ........................................................................................................................................................................ 19
2.1 Receiving the Equipment ............................................................................................................................................. 19
2.2 Moving the Equipment ................................................................................................................................................ 19
2.3 Site Preparation ...........................................................................................................................................................19
2.4 Mounting/Placement ...................................................................................................................................................20
2.5 Air Distribution ............................................................................................................................................................21
2.6 Optional Equipment (Field Installed) ............................................................................................................................ 23
2.6.1 Remote Water Detectors .................................................................................................................................23
2.6.2 Remote Temperature/Humidity Sensor ............................................................................................................ 24
2.6.3 Outdoor Condensers .......................................................................................................................................25
2.7 Water-Water/Glycol Cooled DX ...................................................................................................................................25
2.8 Split Air Cooled Systems ..............................................................................................................................................29
2.8.1 Refrigerant Piping ............................................................................................................................................29
2.8.1.1 DX Refrigerant Piping Connections .....................................................................................................30
2.8.1.2 Refrigerant Pipe Sizing .........................................................................................................................31
2.8.2 Remote Air-Cooled Condensers ....................................................................................................................... 31
2.8.3 Condensate Drain Line.....................................................................................................................................32
2.9 Utility Connections ...................................................................................................................................................... 32
2.9.1 Main Power .....................................................................................................................................................32
2.9.1.1 Single-Phase Units 208/230 V .............................................................................................................34
2.9.1.2 Three-Phase Units ............................................................................................................................... 34
2.9.2 Optional Equipment .........................................................................................................................................34
2.9.2.1 Remote Water Detector .......................................................................................................................34
2.9.2.2 Remote Temperature/Humidity Sensor ................................................................................................34
2.9.2.3 Remote On/Off ...................................................................................................................................34
2.9.3 Outdoor Equipment .........................................................................................................................................34
724-746-5500 | blackbox.com
Page 5
724-746-5500 | blackbox.com
Table of Contents
2.9.3.1 Water-Cooled Systems (CRDX-W-FS-12KW, CRDX-W-FS-24KW) ........................................................34
2.9.3.2 Glycol-Cooled Systems (CRDX-G-FS-12KW, CRDX-G-FS-24KW) ........................................................35
2.9.3.3 Remote Condenser (CRDX-A-FS-12KW, CRDX-A-FS-24KW) ...............................................................35
2.10 System Charging Procedures ......................................................................................................................................36
2.10.1 Water-Water/Glycol Cooled Systems ...............................................................................................................36
2.10.2 Remote-Air Cooled Systems ............................................................................................................................36
2.10.2.1 Estimating Refrigerant Charge ........................................................................................................... 37
2.10.2.2 Preparing System for Charging .........................................................................................................38
2.10.2.3 Refrigerant Charging Procedures ......................................................................................................39
2.10.2.4 -30° F Ambient Applications .............................................................................................................40
2.10.3 Refrigerant Characteristics ...............................................................................................................................41
2.10.3.1 Pressure/Temperature Settings .......................................................................................................... 41
2.10.3.2 Saturated Refrigerant Pressure .......................................................................................................... 41
2.11 Settings and Adjustments ............................................................................................................................................ 42
2.11.1 Water–Water/Glycol Circuit .............................................................................................................................42
2.11.2 Low-/High-Pressure Limit Switch .....................................................................................................................42
2.11.3 Thermal Expansion Valve ................................................................................................................................. 42
2.11.4 Hot Gas Bypass ................................................................................................................................................ 42
2.11.5 EC Fans ............................................................................................................................................................ 42
3. Startup/Commissioning .......................................................................................................................................................43
3.1 Initial Operation ...........................................................................................................................................................43
3.2 Step-by-Step Startup Instructions ................................................................................................................................43
3.3 Microprocessor Controller Programming ..................................................................................................................... 43
4. E2 Controller .......................................................................................................................................................................44
4.1 General ........................................................................................................................................................................44
4.1.1 Featu re s ...........................................................................................................................................................44
4.1.1.1 Fi el d Co nfigur ab le ................................................................................................................................44
4.1.1.2 Password Protection ............................................................................................................................44
4.1.1.3 Restorable Setpoint Parameters ...........................................................................................................44
4.1.1.4 A/C Grouping pLAN Operation ..........................................................................................................44
4.1.2 User Interface Display Panel ............................................................................................................................. 45
4.1.2.1 Function Keys ......................................................................................................................................45
4.1.2.2 Contrast Adjustment ...........................................................................................................................46
4.1.2.3 Alarms ................................................................................................................................................46
4.1.3 Controller I/O Module .....................................................................................................................................46
4.1.4 BMS Interface ..................................................................................................................................................47
4.2 Navigating Controller Display Screens ..........................................................................................................................48
4.2.1 Menu Selection ...............................................................................................................................................48
4.2.2 Menus .............................................................................................................................................................48
4.2.3 Display Variables .............................................................................................................................................. 49
4.2.4 Cursor Position in Screens ................................................................................................................................ 49
4.2.5 Modifiable Variables ........................................................................................................................................50
4.2.6 Password Authorization Levels ......................................................................................................................... 50
4.2.6.1 Password-Protected Screen ................................................................................................................50
4.2.6.2 Wrong Password ................................................................................................................................ 51
4.2.6.3 Setting the Passwords ........................................................................................................................ 51
4.3 System Operation ........................................................................................................................................................ 51
4.3.1 Setpoint Adjustment ........................................................................................................................................ 52
4.3.1.1 Saving and Restoring Setpoint Parameters ..........................................................................................54
4.3.2 Alarms .............................................................................................................................................................54
Page 6
724-746-5500 | blackbox.com
Table of Contents
4.3.2.1 Summary Alarm ..................................................................................................................................54
4.3.2.2 Customer Alarms................................................................................................................................54
4.3.2.3 Custom Alarms ...................................................................................................................................54
4.4 Controller Operation....................................................................................................................................................54
4.4.1 Control Signals ................................................................................................................................................. 55
4.4.4.1 On/Off Digital Control ........................................................................................................................ 55
4.4.4.2 Proportional/Integral (P/I) Control ......................................................................................................56
4.4.2 Control Methods .............................................................................................................................................56
4.4.2.1 Temperature/RH Control.....................................................................................................................56
4.4.2.2 Dewpoint Control ..............................................................................................................................56
4.4.3 Operating Configurations ................................................................................................................................ 57
4.4.3.1 Compressor Operation .......................................................................................................................57
4.4.3.2 Water–W/G Operation ....................................................................................................................... 58
4.4.3.3 Dehumidifying .................................................................................................................................... 58
4.4.4 Airlfow/Fan Speed Control ..............................................................................................................................58
4.4.4.1 Independent Fan Speed Control .........................................................................................................59
4.4.4.2 Variance from Average Fan Speed Control .........................................................................................59
4.4.4.3 Temperature Proportionate Speed Control ......................................................................................... 59
4.4.4.4 Manual Speed Control .......................................................................................................................59
4.4.5 Remote On/Off ............................................................................................................................................... 59
4.5 Menu Screens ..............................................................................................................................................................59
4.5.1 Main Menu ...................................................................................................................................................... 59
4.5.2 Information Menu Loop ..................................................................................................................................61
4.5.2.1 Operating Conditions .........................................................................................................................61
4.5.2.2 Return Temperature Sensor ................................................................................................................ 61
4.5.2.3 Return Humidity Sensor ...................................................................................................................... 61
4.5.2.4 Temperature Sensors .......................................................................................................................... 61
4.5.2.5 Remote Supply Temperature/Humidity Sensor ...................................................................................62
4.5.2.6 Discharge Pressure ..............................................................................................................................62
4.5.2.7 Setpoint Values ...................................................................................................................................62
4.5.2.8 Compressor Status .............................................................................................................................62
4.5.2.9 EEV Status ..........................................................................................................................................62
4.5.2.10 EHGB Status .......................................................................................................................................63
4.5.2.11 Fan Status ...........................................................................................................................................63
4.5.2.12 Group Information Menu Screens ...................................................................................................... 63
4.5.2.13 Software Version/Date ....................................................................................................................... 63
4.5.3 Alarm Log ........................................................................................................................................................64
4.5.3.1 Alarms ................................................................................................................................................64
4.5.3.2 Non-Critical Alarms ............................................................................................................................64
4.5.3.3 Critical Alarms ....................................................................................................................................64
4.5.3.4 Alarm Screen Messages .....................................................................................................................65
4.5.4 Control Menu Loop .........................................................................................................................................66
4.5.4.1 Setpoint Screens .................................................................................................................................67
4.5.4.2 Alarm Setpoint Screens ......................................................................................................................68
4.5.4.3 Clock Screen ......................................................................................................................................70
4.5.5 Service Menu Loop ..........................................................................................................................................70
4.5.5.1 Humidity ............................................................................................................................................. 71
4.5.5.2 Alarms ................................................................................................................................................72
4.5.5.3 Sensors ...............................................................................................................................................73
4.5.5.4 Blower ................................................................................................................................................ 74
4.5.5.5 Options Menu Loop ........................................................................................................................... 75
724-746-5500 | blackbox.com
Page 7
Table of Contents
4.5.5.6 Digital In ............................................................................................................................................. 82
4.5.5.7 Run Hours ..........................................................................................................................................82
4.5.5.8 BMS Communication .........................................................................................................................83
4.5.5.9 Save Configruation .............................................................................................................................83
4.5.5.10 Factory Menu .....................................................................................................................................84
4.6 Communication with the Controller ............................................................................................................................85
4.6.1 Workgroup Setup ............................................................................................................................................85
4.6.1.1 S ta nd by ...............................................................................................................................................86
4.6.1.2 Capacity Assist ....................................................................................................................................86
4.6.1.3 Unit Rotation ......................................................................................................................................86
4.6.1.4 Out of Service .....................................................................................................................................86
4.6.2 Configuring a Workgroup ................................................................................................................................86
4.6.2.1 Configure the Terminal Address .........................................................................................................87
4.6.2.2 Configure the Controller (I/O Board) pLAN Address ..........................................................................88
4.6.2.3 Assign the Terminal to the Controller .................................................................................................88
4.6.2.4 Fault Messages ...................................................................................................................................89
4.6.2.5 Displaying the Network Status and Firmware Version ........................................................................89
4.6.2.6 Configure Workgroups ....................................................................................................................... 90
4.6.2.7 Service>Options>Group Menu Screens .............................................................................................97
4.6.2.8 Group Information Menu Screens ......................................................................................................99
4.7 BMS Communications ............................................................................................................................................... 101
4.7.1 Direct BMS Control ........................................................................................................................................ 102
4.7.2 BMS Communication ..................................................................................................................................... 102
4.8 Troubleshooting the Control I/O Module .................................................................................................................. 103
4.9 BMS Parameters, Version 1.2.....................................................................................................................................104
4.9.1 Signed Values for HTTP, SNMP/Modbus Holdling Registers/Analog Values for BACnet ................................105
4.9.2 Unsigned Values for HTTP, SNMP/Modbus Holdling Registers/Analog Values for BACnet ............................106
4.9.3 Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet .................................................... 107
4.9.4 Alarm Packed Bit Variables ............................................................................................................................108
4.9.5 Sensor Failure Packed Bit Variables ............................................................................................................... 109
4.9.6 Digital Input Packed Bit Variables ................................................................................................................... 110
4.9.7 Digital Output Packed Bit Variables.................................................................................................................111
4.9.8 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet ............................. 112
4.9.9 Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet .................................................... 112
5. Maintenance ...................................................................................................................................................................... 113
5.1 Periodic General Maintenance ................................................................................................................................... 113
5.1.1 Filt er s ............................................................................................................................................................. 113
5.1.1.1 Cle an ab le Fil te rs ................................................................................................................................. 113
5.1.1.2 Cartridge Filters ................................................................................................................................. 115
5.1.2 EC Fans .......................................................................................................................................................... 115
5.1.3 Coil ................................................................................................................................................................ 115
5.1.4 Drain Pans ...................................................................................................................................................... 115
5.1.5 Condensate Pump ......................................................................................................................................... 115
5.1.6 A/C System .................................................................................................................................................... 116
5.2 Troubleshooting ......................................................................................................................................................... 116
5.3 Field Service ............................................................................................................................................................... 119
5.3.1 Water–Water/Glycol System .......................................................................................................................... 119
5.3.2 DX System ..................................................................................................................................................... 119
5.3.2.1 Leak Detection .................................................................................................................................. 119
5.3.2.2 Leak Repair ....................................................................................................................................... 119
Page 8
724-746-5500 | blackbox.com
Table of Contents
5.3.2.3 Refrigerant Piping ............................................................................................................................. 120
5.3.3 Refrigeration System Repairs.......................................................................................................................... 120
5.3.3.1 Compressor Failure ...........................................................................................................................120
5.3.3.2 Standard Cleanout Procedure ........................................................................................................... 121
5.3.3.3 Burn-Out/Acidic Cleanup Procedure ................................................................................................. 121
5.3.4 Component Replacement .............................................................................................................................. 121
5.3.4.1 Fan Replacement .............................................................................................................................. 121
5.3.4.2 Condensate Pump Replacement ...................................................................................................... 12 2
6. Troubleshooting ................................................................................................................................................................. 123
6.1 Contacting Technical Support .................................................................................................................................... 123
6.2 Obtaining Warranty Parts .......................................................................................................................................... 123
6.3 Obtaining Spare/Replacement Parts ..........................................................................................................................123
Appendix A. Forms .................................................................................................................................................................125
A.1 Checklist for Completed Installation .......................................................................................................................... 125
A.2 Periodic General Maintenance Checks and Service Checklist .................................................................................... 126
Appendix B. Glossary: Definition of Terms and Acronyms ...................................................................................................... 127
724-746-5500 | blackbox.com
Page 9
Chapter 1: Introduction
1. Introduction
1.1 General
The Cold Row precision data center air-conditioning system covered by this manual uses the latest, state-of-the-art control
technology. It uses the finest materials available in the industry. The unit will provide years of trouble-free service if installed and
maintained in accordance with this manual. Damage to the unit from improper installation, operation, or maintenance is not covered by the warranty.
STUDY the instructions contained in this manual. They must be followed to avoid difficulties. Spare parts are available from
Black Box to ensure continuous operation. Using substitute parts or bypassing electrical or refrigeration components to continue
operation is not recommended and will VOID THE WARRANTY. Because of technical advancements, components are subject to
change without notice.
All Cold Row systems are designed to be installed indoors.
1.2 Product Description
Cold Row systems are available in water-cooled, water/glycol-cooled or air-cooled direct expansion (DX) configurations. DX-based
Cold Row systems are designed to operate with R410A refrigerant.
Table 1-1. Available models.
Produc t Code Produc t Name
CRDX-A-FS-24K W Cold Row DX, Air
CRDX-A-FS-12KW Cold Row DX, Air
CRDX-G-FS-24KW Cold Row DX, Glycol
CRDX-G-FS-12KW Cold Row DX, Glycol
CRDX-W-FS -24KW Cold Row DX, Water
CRDX- W-F S-12K W Cold Row DX, Water
DX-based Cold Row cabinets are 12" wide. The cooling capacity in KW/Hr will depend on the compressor size. Refer to the unit
nameplate to identify the capacity of your system.
NOTE: Cold Row systems capture and neutralize heat within close-coupled, rack-based environments. Any use beyond what is
described in this manual is deemed to be not intended. Black Box is not liable for any damage resulting from improper use.
The functional modes of operation are cooling and dehumidification, which provides localized cooling to offset hot spots in data
centers.
The Cold Row system captures high-temperature (hot aisle) discharge air from adjacent rack-based IT equipment and reintroduces
it as conditioned air through the front of the unit (cold aisle).
The system is equipped with highly reliable Electronically Commutated (EC) fans that offer considerable energy cost savings and
long life. Using an electronically commutated permanent magnet DC motor eliminates AC inverter whine. Fan speed is
continuously adjustable via a signal from the system controller without the use of VFDs. EC fans offer energy-efficient, quiet,
low-vibration operation.
An advanced E2 series microprocessor controller is mounted inside the Cold Row electric box. The controller provides the
following features: input/output monitoring status, full integrated control of cooling and dehumidification, multi-unit control, and
remote communication with a Building Management System (BMS). The controller may interface directly to a BMS, so you can
monitor the performance of the air conditioner and adjust operating parameters.
The E2 user interface display panel is typically factory mounted on the front access panel of the unit.
Page 10
724-746-5500 | blackbox.com
Chapter 1: Introduction
Figure 1-1. User interface display.
Refer to Chapter 4 for detailed instructions on operating the system controller.
724-746-5500 | blackbox.com
Page 11
724-746-5500 | blackbox.com
Chapter 1: Introduction
12-Month Precision A/C Limited Warranty/
24-Month Precision A/C Upgraded Limited Warranty
The 12-Month Precision A/C Limited Warranty applies when Factory-Authorized startup is not purchased at the time of order
entry.
The 24-month Precision A/C Upgraded Limited Warranty applies only if Factory-Authorized startup was purchased at the time of
Order Entry.
The 12-Month Precision A/C Limited Warranty provided by Black Box Network Services warrants your purchase, including
compressors, to be free from defects in material and workmanship. Black Box Network Services’ obligation under this warranty is
to repair or replace, at its option, any part or parts that are determined by Black Box Network Services to be defective for a
period of 12 months from the date of shipment when an accurately completed Precision Cooling Limited Warranty Registration
and Startup Checklist Form has been submitted to Black Box Network Services, within 90 days from shipment. Parts repaired or
replaced under this warranty are shipped FOB Factory, and warranted for the balance of the original warranty period or for 90
days from the date of installation, whichever is greater. If the factory startup form is not returned to Black Box Network Services
within 90 days from the date of equipment shipment, the equipment warranty will be terminated on the 91st day from shipment.
This limited warranty does not include labor, freon, or any other expense required to replace the defective component and bring
the unit back to a working status.
The 24-Month Precision A/C, Upgraded Limited Warranty provided by Black Box Network Services warrants your purchase,
including compressors, to be free from defects in material and workmanship for 24 months. Black Box Network Services’
obligation under this warranty is to repair or replace, at its option, any part or parts which are determined by Black Box Network
Services to be defective for a period of 24 months from the date of startup. This warranty also includes labor needed to perform
any warranty work for a period of 90 days from the date of startup. Parts repaired or replaced under this warranty are shipped
FOB factory ground, and warranted for the balance of the original warranty period or for 90 days from the date of installation,
whichever is greater. If the factory is not allowed to start the equipment within 90 days from the date of shipment, the warranty
will commence on the 91st day from equipment shipment. This limited warranty does not include labor, freon, or any other
expense required to replace the defective component and bring the unit back to a working status.
In the event equipment is shipped to Black Box for temporary storage for 6 months or less, warranty begins and startup checklist
is required to be on file with Black Box Network Services field service within 90 days of shipment to job site for installation.
Black Box Network Services’ warranty does not cover failures caused by improper installation, abuse, misuse, alteration,
misapplication, improper or lack of maintenance, negligence, accident, normal deterioration (including wear and tear), or the use
of improper parts or improper repair.
Purchaser’s remedies are limited to replacement or repair of non-conforming materials in accordance with the written warranty.
This warranty does not include costs for transportation, travel expenses, costs for removal or reinstallation of equipment or labor
for repairs (*except as set forth above) or replacements made in the field.
If any sample was shown to the buyer, such sample was merely to illustrate the general type and quality of the product, and not
to represent that the equipment would necessarily conform to the sample.
This is the only warranty given by the seller, and such warranty is only given to the buyer for commercial or industrial purposes.
The warranty is not enforceable until the invoice(s) is paid in full.
THIS FOREGOING SHALL CONSTITUTE BLACK BOX NETWORK SERVICES’ ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY. IN
NO EVENT SHALL BLACK BOX NETWORK SERVICES BE LIABLE FOR ANY DEFECT, INDIRECT, SPECIAL, INCIDENTAL,
CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF)
ARISING IN ANY WAY OUT OF THE INSTALLATION, USE, OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN LIEU
OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
This warranty supersedes all other previously printed warranties dated
prior to this document in regards to Diagnostic Labor Warranty.
Page 12
724-746-5500 | blackbox.com
Chapter 1: Introduction
1.3 Product Warranty
Black Box offers a two-year standard limited warranty as stated on the previous page. An extended warranty may be purchased
on the unit’s compressor. The compressor warranty as stated below will be sent with your unit if the option is purchased. Retain
this for future reference. You may consult Black Box Technical Support at 724-746-5500 or info@blackbox.com to verify if the
extended compressor warranty was purchased for your system.
Cold Row Warranty — Compressor
This warranty applies only when Factory Authorized Start-Up is purchased at the time of order entry.
Unit Model #:
Warranty Start Date:
Warranty End Date:
Compressor 1 Serial #:
Compressor 2 Serial #:
Optional Compressor Summary:
Black Box warrants your purchase to be free from defects in material and workmanship for up to 60 months (original standard is
24 months and purchased additional is 36 months). The Black Box Optional Compressor Limited Warranty may be purchased in
1-year increments, up to a total warranty period of 60 months from the date of startup. Black Box’s obligation under this
warranty is to repair or replace, at its option, free of charge to the customer, any part or parts which are determined by Black Box
to be defective for a period of 60 months from the date of startup. Startup must be completed within the first 90 days from
shipment. The 60-month warranty only covers original compressor(s) that were installed by Black Box or an original equipment
supplier contracted by Black Box to manufacture equipment solely for Black Box.
Compressors replaced under this warranty are shipped FOB Factory ground, and warranted for the balance of the original
warranty period or for 90 days from the date of installation, whichever is greater. If the factory is not allowed to start up the
equipment within 90 days from the date of shipment, the warranty will commence on the 91st day from equipment shipment.
Black Box’s warranty does not cover failures caused by improper installation, abuse, misuse, alteration, misapplication, improper or
lack of maintenance, negligence, accident, normal deterioration (including wear and tear), or the use of improper parts or
improper repair. Purchaser’s remedies are limited to replacement or repair of non-conforming materials in accordance with the
written warranty. This warranty does not include cost for torch charges, reclaim charges, Freon, transportation, travel expenses,
costs for removal or reinstallation of equipment, or labor for repairs or replacements made in the field.
If any sample was shown to the buyer, such sample was merely to illustrate the general type and quality of the product, and not
to represent that the equipment would necessarily conform to the sample.
This is the only warranty given by the seller, and such warranty is only given to buyers for commercial or industrial purposes. The
warranty is not enforceable until the invoice(s) is paid in full.
THIS FOREGOING SHALL CONSTITUTE BLACK BOX’S ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY. IN NO EVENT SHALL
BLACK BOX BE LIABLE FOR ANY DEFECT, INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES,
INCLUDING LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY WAY OUT OF THE INSTALLATION,
USE, OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty supersedes all other previously printed warranties dated prior to this document.
724-746-5500 | blackbox.com
Page 13
724-746-5500 | blackbox.com
Chapter 1: Introduction
1.4 Safety
1.4.1 General
This manual uses NOTES along with CAUTION and WARNING symbols to draw your attention to important operational and
safety information.
A NOTE marks a short message in the information to alert you to an important detail.
A CAUTION safety alert appears with information that is important for protecting your equipment and performance. Be especially
careful to read and follow all cautions that apply to your application.
A bold text WARNING safety alert appears with information that is important for protecting you from harm and the equipment
from damage. Pay very close attention to all warnings that apply to your application.
A safety alert symbol precedes a general WARNING or CAUTION safety statement.
A safety alert symbol precedes an electrical shock hazard WARNING or CAUTION safety statement.
1.4.2 Safety Summary
The following statements are general guidelines followed by warnings and cautions applicable throughout the manual. Before
performing any installation, operation, maintenance, or troubleshooting procedure, read and understand all instructions,
recommendations, and guidelines contained within this manual.
CAUTION
All maintenance and/or repairs must be performed by a journeyman refrigeration mechanic or air-conditioning technician.
CAUTION
When moving the unit, it should be kept in its normal installed position. If the unit is not kept level and vertical, damage to the
compressors will result.
WARNING
Never operate the unit with any cover, guard, screen panel, etc. removed unless the instructions specifically state
otherwise; then do so with extreme caution to avoid personal injury.
CAUTION
Never lift any component in excess of 35 pounds without help. If a lifting device is used to move a unit, make sure it is capable of
supporting the unit.
CAUTION
When working on electrical equipment, remove all jewelry, watches, rings, etc. Keep one hand away from the equipment to
reduce the hazard of current flowing through vital organs of the body.
CAUTION
Always turn off the service disconnect switch and disconnect the main power supply to the equipment. Follow a lock-out tag-out
procedure to ensure that power is not inadvertently reconnected.
WARNING
This unit is fed by incoming power wires. Even with the service disconnect switch in the “Off” position, power may
still be “live” between the switch and the main power source. When performing service, always ensure that main
power is disconnected from the unit.
CAUTION
Equipment may contain components subject to electrostatic discharge (ESD). Before attempting to mount or service these
electronic devices, make sure you have no charge built up by touching a ground source. When possible, use a wrist-grounding
strap when working on or near electronic devices.
724-746-5500 | blackbox.com
Page 14
Chapter 1: Introduction
CAUTION
Never work on electrical equipment unless another person who is familiar with the operation and hazards of the equipment and
is competent in administering first aid is nearby.
CAUTION
All personnel working on or near equipment should be familiar with hazards associated with electrical maintenance. Safety
placards/stickers are placed on the unit to call attention to all personal and equipment damage hazard areas.
WARNING
Refrigerant (R410A) is used with this equipment. Death or serious injury may result if personnel fail to observe proper
safety precautions. Great care must be exercised to prevent contact of liquid refrigerant or refrigerant gas, discharged
under pressure, with any part of the body. The extremely low temperature resulting from the rapid expansion of
liquid refrigerant or pressurized gas can cause sudden and irreversible tissue damage.
As a minimum, all personnel should wear thermal protective gloves and face-shield/goggles when working with
refrigerant. Application of excessive heat to any component will cause extreme pressure and may result in a rupture.
Exposure of refrigerant to an open flame or a very hot surface will cause a chemical reaction that will form carbonyl
chloride (hydrochloric/hydrofluoric acid); a highly poisonous and corrosive gas commonly referred to as PHOSGENE.
In its natural state, refrigerant is a colorless, odorless vapor with no toxic characteristics. It is heavier than air and will
disperse rapidly in a well-ventilated area. In an unventilated area, it presents a danger as a suffocant.
Always refer to the manufacturer’s Material Safety Data Sheet (MSDS) provided with the unit.
CAUTION
Certain maintenance or cleaning procedures may call for the use and handling of chemicals, solvents, or cleansers. Always refer to
the manufacturer’s MSDS prior to using these materials. Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes
and prolonged exposure of skin to cleaning solvents. Wash exposed skin thoroughly after contact with solvents.
CAUTION
Do not use cleaning solvents near open flame or excessive heat. Wear eye protection when blowing solvent from parts. The
pressure-wash should not exceed 30 psig. Solvent solutions should be disposed of in accordance with local and state regulatory
statutes.
WARNING
When performing brazing or de-brazing operations, make certain the refrigeration system is fully recovered and
purged and dry nitrogen is flowing through the system at the rate of not less than 1–2 CFM (.03–.06 m3/minute).
CAUTION
The air-intake and discharge areas must be free of obstructions. Make sure access panels are secure and latched into position.
CAUTION
Cooling coils (and associated piping circuits) are pressurized and sealed when they leave the factory. Before installing the
interconnecting piping, observe appropriate safety precautions and release the pressure via an available stem valve or Schrader®
valve before uncapping the pipes.
CAUTION
After interconnecting piping is installed, you must clean the piping system. If you use solvents/cleaning solutions, be sure they are
completely flushed from the piping before connecting it to the unit. Failure to do so will result in equipment problems.
724-746-5500 | blackbox.com
Page 15
724-746-5500 | blackbox.com
Chapter 1: Introduction
CAUTION
When filling the water/glycol loop, all air must be bled from the piping system.
WARNING
Do not use chloride-based water-conditioning additives in the condensate drain pans. This will cause corrosion to
occur on the coil fins.
1.5 General Design
The Cold Row DX unit is housed in a steel frame type cabinet rated for indoor use. The exterior of the cabinet is coated with a
powder coat finish to protect against corrosion. Removable access panels are located on the front and rear of the cabinet for easy
access to all components. Operator controls are conveniently located on the front of the cabinet.
NOTE: Customer-specified non-standard features or design variations may not be described in this manual. Refer to the installation
and/or electrical drawings supplied with your unit for details of additional feature(s). In some cases, an addendum to this
manual may also be included to further describe the feature(s).
Figure 1-2 depicts a typical internal layout and identifies the major components of a typical Cold Row unit using direct expansion
(DX) refrigerant. The location of some components may vary depending on the cooling configuration selected (water, water/
glycol, or air cooled).
Page 16
Figure 1-2. Typical internal layout: Cold Row DX.
724-746-5500 | blackbox.com
Chapter 1: Introduction
1.5.1 Electrical Compartment
The electrical components are protected inside an electric box located behind the rear access panel. The electric box cover is
safety interlocked with the service disconnect switch (See Figure 1-2), preventing the cover from being opened when the switch in
the On position. The switch must be turned Off to gain access to the electrical compartment.
The service disconnect switch may be used to turn the unit off for emergency shutdown or when routine maintenance is
performed. The handle of the switch locks in the “Off” position to prevent unintended operation.
1.5.2 Circuit Breakers/Motor Start Protectors
Cold Row units incorporate state-of-the-art component protection using motor start protectors and circuit breakers. If an overload
occurs, you must manually reset the switches after clearing the overload condition.
1.5.3 Compressor
A scroll compressor is used in DX-based Cold Row systems. With fewer moving parts, scroll compressors have demonstrated
superior durability. The scroll compressor is designed around two identical spirals or scrolls that, when inserted together, form
crescent-shaped pockets. During a compression cycle, one scroll remains stationary while the other scroll orbits around the first.
As this motion occurs, gas is drawn into the scrolls and moved in increasingly smaller pockets toward the center. At this point, the
gas, now compressed to a high pressure, is discharged from a port in the center of the fixed scroll. During each orbit, several
pockets of gas are compressed simultaneously, creating smooth, nearly continuous compression.
1.5.3.1 Electronic Thermal Expansion Valve
An auxiliary control module mounted to the door of the electric box manages the operation of the electronic expansion valve
(EEV). The control module manages the EEV based on input signals from the suction pressure and temperature sensors. It
regulates the amount of refrigerant entering the evaporator to maintain the correct superheat temperature.
1.5.3.2 Electronic Hot Gas Bypass
Used for freeze protection and capacity control, an electronically controlled hot gas bypass valve is managed by the same auxiliary
control module that manages the EEV valve. The hot gas bypass system allows the compressor to run continuously instead of
cycling the compressor on and off for capacity control. The hot gas bypass system manages system capacity based on the suction
temperature. The hot gas regulator valve meters hot gas into the evaporator coil during low load periods or when evaporator
airflow is reduced.
1.5.4 Coils
Cooling coils are constructed of aluminum finned/copper tube. The coils are leak tested and cleaned before installation by the
factory. Condensate drain pans are provided to collect water condensed by the coils. A condensate pump empties the drain pans
and directs the water to a pipe stub located either at the top or the bottom of the A/C unit depending on the piping
configuration (see Section 2.7.1 and 2.8.1.1).
A float switch in the lower condensate pan detects if the water level rises. If the condensate pan fails to drain, the float switch
signals the controller to sound an alarm and turn off the compressor and the fans.
1.5.5 Condensate Pump
A condensate pump is factory installed in the lower drain pan. The pump automatically eliminates condensate water from the
drain pan. The pump has an internal float switch that turns the pump on and off based on the water level.
1.5.6 EC Fans
The unit is equipped with three high-efficiency, Electronically Commutated (EC) fans. EC fans use a brushless motor equipped
with permanent magnets and permanently lubricated ball bearings. The fan impellers are curved backward and attached to the
rotor casing. The fan is balanced and aerodynamically optimized to minimize vibration.
The fans do not use drive belts. Fan speed is variable via a 0- to 10-VDC signal from the system controller. The fan motor is
equipped with integral electronics and does not require the addition of secondary electronics such as thermal protection,
inverters, or filters. The fan will not produce AC inverter whine.
724-746-5500 | blackbox.com
Page 17
724-746-5500 | blackbox.com
Chapter 1: Introduction
During startup, the fans begin operating in stages with five-second time delays. The middle fan starts first, then the upper fan,
then the lower fan. The system controller monitors fan operation. If one or two of the fans fails to operate, the controller alerts
the operator with an alarm message and increases the speed of the remaining fan(s) to compensate for the loss of airflow.
Use the system controller to configure the fans for zone temperature control with independently variable fan speeds or with all
three fans operating at the same variable speed (See Section 4.4.4).
1.5.7 Temperature/Humidity Sensors
Control and alarm recognition takes place by means of the controller analyzing signal inputs from the sensors to manage the
operation of the A/C unit consistent with the setpoints entered in the system controller. The system controller monitors three
NTC-type temperature sensors and a 4–20 mA temperature/humidity (T/H) sensor.
The NTC sensors are factory installed in predetermined supply air fan zones inside the cabinet. Each NTC sensor is used by the system controller to manage the speed of the fan for that zone to meet the supply air setpoint temperature. The return air is monitored by a temperature/humidity (T/H) sensor that is typically mounted inside the cabinet. As an option, you can remove the
return air T/H sensor from the cabinet and mount it in the hot aisle. View the actual sensor values from the controller user
interface display using the Information menu loop.
1.6 Optional Equipment
1.6.1 Remote Mounted Supply Temperature/Humidity Sensor
As an option, a supply T/H sensor may be provided for field installation (see Section 2.6.2). This is to be mounted in the supply
(cold aisle) space for monitoring or control purposes. Refer to the electrical drawing supplied with your unit for wiring details
specific to your system.
1.6.2 Water Detector
As an option, Black Box offers spot-type or strip-/cable-type water detectors (see Section 2.6.1). Upon sensing a leak, the water
detector control circuit will signal the system controller of the alarm condition. The system controller is programmed to shut down
the compressor and the fans when a leak is detected.
1.6.3 Smoke Detector
Optionally mounted in the return air side of the cabinet, a photo-electric smoke detector senses the presence of smoke and
signals the controller when a smoke alarm condition exists and shuts down the air conditioner.
1.6.4 Firestat
Optionally mounted in the return air side of the cabinet, a fire detector senses high return air temperature and signals the
controller when a fire alarm condition exists and shuts down the air conditioner.
Page 18
724-746-5500 | blackbox.com
Chapter 2: Installation
2. Installation
2.1 Receiving the Equipment
Your Cold Row precision A/C system has been tested and inspected prior to shipment. Carefully remove the protective packaging
and perform a visual inspection of the equipment immediately upon delivery to confirm that your equipment has been received in
excellent condition. Remove the access panels and thoroughly inspect the interior of the unit for any signs of transit-incurred
damage. If there is shipping damage, it must be noted on the freight carrier’s delivery forms BEFORE signing for the equipment.
Any freight claims MUST be done through the freight carrier. Black Box ships all equipment FOB. We can assist in the claim filing
process with the freight carrier. If any damage is present, notify Black Box Technical Support at 724-746-5500 or info@blackbox.
com prior to attempting any repairs. Refer to Chapter 6 of this manual for instructions.
A unit data package has been sent with your unit. It contains this manual, system drawings, applicable MSDSs, warranty
registration, other component manuals and applicable instructions based on the configuration of your unit. The data package has
been placed in your unit in a clear plastic bag. These documents need to be retained with the unit for future reference. The unit
should always be stored indoors in a dry location before installation.
NOTE: Items that have been shipped loose, such as the controller display panel, temperature/humidity sensors, water detectors,
etc., are shipped inside the air conditioner unless specified otherwise by the customer. Unpack and store these items in a
safe place unless you are using them immediately.
2.2 Moving the Equipment
Cold Row systems are designed to be kept in a vertical position. The cabinet is equipped with shipping support brackets that are
bolted to the skid to facilitate moving the unit before installation. Move the unit on the skid with a suitable device such as a
forklift, pallet jack, or roller bar, and dollies that are capable of handling the weight of the equipment. For reference, a weight
table is provided on the installation drawing. Unbolt the shipping support brackets from the skid, leaving them attached to the
unit during the installation process.
CAUTION
Tipping Danger. Keep the shipping support brackets attached to the front and rear of the cabinet after removing the Cold Row
unit from the skid. These must remain in place to prevent the unit from tipping over when moving and positioning the cabinet. It
is safe to remove the shipping brackets when a server rack is installed on each side of the cabinet.
CAUTION
Position someone on each side of the cabinet to stop it from tipping over if the shipping brackets must be removed before
installing the server racks on each side.
CAUTION
When moving the unit, lift it vertically and keep it in a level position to prevent damage.
2.3 Site Preparation
Removable access panels are located on the front and rear of the Cold Row cabinet for easy service access. For full-service access
to the internal components, do not place any permanent obstructions in front or behind the cabinet.
NOTE: Establish working clearance requirements before mounting the unit. Refer to local and national electrical codes.
CAUTION
Install the unit in the space that will be air conditioned.
CAUTION
Make sure the mounting surface is capable of supporting the weight of the equipment. Before installing the unit, refer to the
weight table provided on the installation drawing.
724-746-5500 | blackbox.com
Page 19
724-746-5500 | blackbox.com
Chapter 2: Installation
When determining the installation location, consider how you’ll route the piping and wiring into the cabinet and ensure access is
available (see Sections 2.7.1 and 2.8.1). The Cold Row system is ordered from the factory with pilot holes for piping and wiring in
either the top or the bottom of the cabinet. See the installation drawing provided with your unit for the pilot hole locations.
Conditioned Space
Take certain steps to minimize the effects of the environment surrounding the conditioned space. This is especially important for
critical/precision room preparation (computer data centers) that require close tolerance control of temperature and humidity. The
conditioned space should be well insulated and include a vapor barrier. The installer should ensure that the proper insulation
rating is used based on the design of the space, which was the basis for the system selected. The following table lists
recommended minimum R-value (thermal resistance values) for optimum equipment operation.
Table 2-1. Recommended
minimum thermal resistance.
Structure R-Value
Ceiling R-38
Wall R-21
Floor R-19
Door R-5
The vapor barrier is the single most important requirement for maintaining environmental control in the conditioned space. The
vapor barrier in the ceiling and walls can be a polyethylene film. Concrete walls and floors should be painted with a rubber- or
plastic-based paint. Doors and windows should be properly sealed, and a door sweep used to minimize leakage. Outside or fresh
air should be kept to a minimum (as it adds to the cooling load), while maintaining the requirement of the Indoor Air Quality
(IAQ) standard. Lack of these steps can cause erratic operation, unstable room control, and excessive maintenance costs.
2.4 Mounting/Placement
The Cold Row precision A /C system uses a frame and panel construction for unit rigidity and full-service access while the unit is
mounted in place.
NOTE: The equipment must be level to operate properly.
Cold Row cabinets are designed to be installed in a row of servers between the server racks (see Figures 2-1–2-3). They have a
compact footprint that allows the units to be placed adjacent to the heat-producing equipment racks anywhere in the row. They
provide cool, conditioned air through the front grille to the adjacent server modules on the cold aisle side of the row. We
recommend positioning the unit to obtain optimum air circulation. Allow 36" clearance in the front and rear of the cabinet for
servicing the unit.
The optimal placement location is next to highly loaded servers that throw off the most significant heat into the hot aisle side of
the row. In this arrangement, the Cold Row minimizes hot spots. It is best not to place a Cold Row unit at the end of a row unless
an air barrier is in place to prevent the conditioned air from being drawn around to the hot aisle side, bypassing the front of the
servers. An air barrier must also be present to prevent conditioned air from being drawn over the top of the row into the hot
aisle.
Page 20
724-746-5500 | blackbox.com
Chapter 2: Installation
Figure 2-1. Recommended installation.
NOTE: Placement of air barriers between the cold aisle/hot aisle is important. If the supply discharge is too close to the hot aisle,
the conditioned supply air will be recirculated back to the intake in the hot aisle side of the cabinet before it has circulated
through the equipment to be cooled.
Once the cabinet is removed from the shipping skid, roll it into position on the casters that are mounted to the bottom of the
unit. Do not remove the shipping support brackets unless server racks are installed on each side of the Cold Row cabinet.
The cabinet is equipped with an adjustable foot at each corner to raise the cabinet off the casters after the unit is positioned in its
operating location. The adjustable feet are also used for leveling and overall height correction. To adjust the height, use a
flat-head screwdriver to turn the screws, located at the top of the four caster housings (accessed inside the front and rear corners
of the cabinet per Figure 1-2). Raise or lower each foot until the cabinet is level and even with the adjacent equipment racks (see
Figure 2-1).
2.5 Air Distribution
Air from the hot aisle is drawn into the rear of the Cold Row cabinet and passes through the fins of the cooling coil. The
conditioned supply air discharges through the front of the cabinet (see Figure 2-2).
724-746-5500 | blackbox.com
Page 21
724-746-5500 | blackbox.com
Chapter 2: Installation
Figure 2-2. Typical air distribution.
The front discharge panel directs the supply air out of the Cold Row unit where it will be drawn into the front of the server racks.
An optional front-diverted air discharge panel is also available. This directs the supply air sideways out of the Cold Row unit and
directly into the front of the server racks (see Figure 2-3).
\
Page 22
Figure 2-3. Front-diverted air distribution.
724-746-5500 | blackbox.com
Chapter 2: Installation
2.6 Optional Equipment (Field Installed)
NOTE: Do not mount any optional equipment on the unit access panels.
2.6.1 Remote Water Detectors
The remote water detector is normally placed on the sub-floor or in a field-supplied auxiliary drain pan located beneath the unit.
Black Box provides two types of water detectors:
Spot-type water detector: Remove the protective cover and connect two control wires to the terminals on the base. Run the
control wires into the electric box and connect them to the control terminal block as shown in the wiring diagram provided with
your unit. Replace the cover and place the water detector(s) on the floor with the metal electrodes facing down. When water is
present, current will flow between the electrodes. The base has a mounting hole in the center that you can use to secure the
water detector in place.
Figure 2-4. Spot-type water detector.
NOTE: Do not place the spot-type water detector on an electrically conductive surface.
Cable-type water detector: Lay the cable water detector flat across the sub-floor where water could collect. Secure the cable
every 12–18 inches with J-clips or cable ties with adhesive mounting pads when installing it in the airstream. Secure it at each turn
of the cable and when routing it around obstructions. Do not tie the water detector cable to a metal floor stand or to pipes.
Figure 2-5. Cable-type water detector.
When a water leak on the floor reaches the cable, current will flow between the cable wires. A two-conductor wire harness is
provided with a quick-connect fitting on the end. The harness mates to the fitting on the water detector and connects it to the
control terminal block inside the electric box as shown in the wiring diagram provided with your unit.
724-746-5500 | blackbox.com
Page 23
724-746-5500 | blackbox.com
Chapter 2: Installation
2.6.2 Remote Temperature/Humidity Sensor
Depending on the type of control selected, the temperature/humidity (T/H) sensor may be factory-mounted or shipped loose for
field installation. The remote sensor must be located so that it will properly sense the temperature/humidity conditions to be
controlled. The T/H sensor should not be mounted near a doorway or an area where it would be exposed to direct sunlight.
When locating the sensor, consider the length of wire to be used. The sensor is typically provided with a 20-foot long cable.
As an option, a 75-foot or 150-foot long cable may be provided. Follow the steps below to mount the sensor.
Figure 2-6. Temperature/humidity sensor.
1. Remove the cover from the base of the sensor by squeezing it at the top and bottom.
CAUTION
Be careful not to damage the exposed temperature/humidity sensors on the PC board when removing the cover. The sensors can
be damaged if handled improperly.
2. Place the base temporarily against the mounting surface.
3. Level the base. Mark and drill mounting holes through at least two of the available slotted holes.
4. Run the 3-conductor shielded cable through the opening in the base, then secure the base with screws ensuring the word
“TOP” on the PC board is oriented upward.
5. Make the wiring connections. Refer to Section 2.9, Utility Connections and refer to the wiring diagram supplied with your unit.
6. Seal the hole in the wall behind the sensor.
7. Replace the cover plate on the base.
CAUTION
The sensor can be damaged if handled improperly. Take care not to damage the exposed temperature/humidity sensor on the PC
board. Do not touch the sensor because this will affect its accuracy.
Page 24
724-746-5500 | blackbox.com
Chapter 2: Installation
TEMPERATURE
SENSOR
T
COMPRESSOR
CONNECTIONS
CONDENSER WATER
IN
WATER REGULATING
VALVE
OUT
OPTIONAL PIPING
CONNECTION
SWITCH LIMIT
SCHRADER
HIGH PRESSURE
HP
VALVE
WATER COOLED CONDENSER
DRIER/STRAINER
REFRIGERANT
LP
SCHRADER
VALVE
LIMIT SWITCH
LOW PRESSURE
DISTRIBUTOR BODY
EVAPORATOR COIL
PT
PRESSURE
TRANSDUCER
THERMAL
EXPANSION
VALVE
PT
PRESSURE
TRANSDUCER
REGULATOR
HOT GAS
ASC
ELECTRONIC
SIGHT
GLASS
2.6.3 Outdoor Condensers
Referring to the IOM manual provided with the condenser, install the remote condenser in a secure location where it cannot be
tampered with, and the service disconnect switch cannot be inadvertently turned off. Locate the remote condenser where the fan
is not likely to draw dirt and debris into the coil fins. The clearance around the condenser should be at least 1x the unit's width to
ensure adequate airflow to the coil. Secure the condenser to prevent the system from moving during operation. We recommend
installing the remote condenser with vibration mounts to reduce vibration transmitted to the mounting surface.
2.7 Water–Water-/Glycol-Cooled DX (CRDX-W-FS-12W, CRDX-W-FS-24W, CRDX-G-FS-12W, and
CRDX-G-FS-24W models)
The system uses an external source of fluid to provide coolant to the condenser inside the A /C unit. No refrigeration connections
are required for self-contained water- or glycol-cooled systems (see Figure 2-7).
Table 2-2. Pipe connection sizes.
Model # Water Glycol Inlet/Outlet Condensate Drain
CRDX-W-FS-12W,
CRDX-W-FS -24W
CRDX-G-FS-12W,
CRDX- G-FS-24W
Figure 2-7. Typical W/G piping diagram.
1
11⁄4"
1
⁄4"
1
1
⁄2
⁄2
"
"
724-746-5500 | blackbox.com
Page 25
724-746-5500 | blackbox.com
Chapter 2: Installation
Piping Connections
CAUTION
The cooling coil (and associated piping circuits) are pressurized (up to 100 psi) and sealed when they leave the factory. Before
installing the interconnecting piping, release the pressure via an available stem valve or Schrader valve prior to uncapping the
pipes.
Fluid supply and return lines are routed to either the top or bottom of the cabinet as specified when the Cold Row system is
ordered (see Figures 2-8 and 2-9). On units that are piped from the top, the supply and return connections are made outside the
cabinet. On units that are piped from the bottom, the supply and return connections are made inside the cabinet.
Pipe connections are threaded NPT connections. The pipes are labeled; i.e. “Supply,” “Return.” When making the connections, a
Teflon® tape thread sealant is recommended to minimize internal fouling of the piping.
Field piping is not necessarily the same size as the unit’s pipe connections. Piping should be sized to match the system pressure
drop and flow capacity, and may require reducing fittings to match the connection size on the air conditioner. An air vent and
several Schrader valves are installed in the precision A/C unit piping. We recommend providing manual shut-off valves for both
the supply and return fluid for isolating the unit when performing routine maintenance or repairs. Refer to the piping diagram
supplied with your unit.
NOTE: Install a 60-mesh strainer in the supply pipe. Make sure the strainer is readily accessible for servicing or replacement.
For pipe connection sizes, refer to the following table:
Table 2-3. Pipe connection sizes.
Model # Water Glycol Inlet/Outlet Condensate Drain
CRDX-G-FS-12W,
CRDX- G-FS-24W
CRDX-W-FS-12W,
CRDX-W-FS -24W
1
1
11⁄4"
⁄4"
1
⁄2
"
1
⁄2
"
NOTE: Use standard refrigeration practices for piping, leak testing, and filling the water glycol circuit.
Use vibration isolating supports to isolate the piping. Provide supports (clamps or hangers) as necessary, every 5 to 10 feet along
piping runs to minimize vibration and noise transmission. To reduce vibration transmission and prevent pipe damage, seal
openings in walls using a soft, flexible material to pack around the piping. After the piping is installed, seal the gaps between the
pipes and the entrance holes so air won’t leak around the pipes.
NOTE: Water/glycol lines should be insulated to prevent condensation from forming on the pipes if ambient dew point
temperatures are higher than the fluid temperatures.
CAUTION
After the interconnecting piping is installed, the entire piping circuit must be thoroughly flushed prior to operating the system.
If newly installed supply and return piping is used, we recommend cleaning the piping system before connecting it to the unit. If
you use solvents/cleaning solutions, ensure they are completely flushed from the piping before connecting it to the unit. Failure to
do so could result in equipment problems.
724-746-5500 | blackbox.com
Page 26
Water-Water/Glycol Supply and Return Piping Connections
CONDENSATE DRAIN—
1
⁄2" FPT
FEMALE PIPE THREADS
Chapter 2: Installation
SCHRADER VALVE
Figure 2-8. Top access piping.
724-746-5500 | blackbox.com
Page 27
724-746-5500 | blackbox.com
Chapter 2: Installation
SCHRADER VALVE
MALE PIPE THREADS
Figure 2-9. Bottom access piping.
Page 28
724-746-5500 | blackbox.com
Chapter 2: Installation
SIGHT
REFRIGERANT
FILTER/DRIER
REMOTE AIR COOLED CONDENSER
COMPRESSOR
HP
LIMIT SWITCH
HIGH PRESSURE
VALVE
SCHRADER
LP
VALVE
SCHRADER
LIMIT SWITCH
LOW PRESSURE
DISTRIBUTOR
THERMAL
EXPANSION
VALVE
RECEIVER
RELIEF VALVE
PRESSURE
CONTROL VALVE
HEAD PRESSURE
CHECK VALVE
CHECK VALVE
EVAPORATOR COIL
FIELD PIPING BY OTHERS
INTERCONNECTING
SCHRADER
VALVE
BODY
GLASS
OPTIONAL COMPONENTS FOR FLOODED HEAD PRESSURE CONTROL
ELECTRONIC
TEMPERATURE
SENSOR
T
PT
PRESSURE
TRANSDUCER
(OPTIONAL)
HOT GAS
REGULATOR
ASC
ELECTRONIC
2.8 Split Air-Cooled Systems
Split air-cooled systems with a remote condenser will require field-installed refrigerant piping. All split systems are shipped with a
dry nitrogen charge of 100 psig. Release the pressure via an available stem valve or Schrader valve prior to uncapping the pipes.
Do not release the pressure until the field-installed refrigerant piping is ready to connect. Systems using a remote condenser will
require a copper liquid line and discharge line. See Figure 2-10 and refer to the IOM documentation provided with the condenser.
2.8.1 Refrigerant Piping
Refrigerant lines for the A/C unit are routed to either the top or bottom of the cabinet as specified when the Cold Row system is
ordered (see Section 2.8.1.1). The connections are made inside the cabinet. The pipe stubs are labeled; i.e. “Discharge,” “Liquid
Line.”
The refrigerant piping should be isolated by using vibration-isolating supports. Provide supports (clamps or hangers) as necessary
every 5 to 10 feet along piping runs to minimize vibration and noise transmission. To reduce vibration transmission and prevent
pipe damage when sealing openings in walls, use a soft flexible material to pack around the piping. After the piping is installed,
seal the gaps between the pipes and the entrance holes in the cabinet so air won’t leak around the pipes.
All refrigeration piping should be installed with high-temperature brazed joints. Use standard refrigeration practices for piping,
leak testing, dehydration, and charging of the refrigeration circuits. For copper-to-copper brazing, phosphorous alloy containing a
minimum of 15% silver is recommended. General-purpose silver brazing alloy with 45% silver is recommended for brazing
dissimilar metals.
Figure 2-10. Typical remote air-cooled DX piping diagram.
724-746-5500 | blackbox.com
Page 29
724-746-5500 | blackbox.com
Chapter 2: Installation
Wrap wet rags around the pipes between the areas to be soldered and any nearby refrigeration components to keep excessive
heat from traveling through the pipe and causing damage. Clear all pipe connections of debris and prep connections for
soldering. Use only “L” or “K” grade refrigerant copper piping. Be careful not to allow solder/piping debris to get inside
refrigerant lines. Dry nitrogen should be flowing through the tubing while soldering at a rate of not less than
1.2 CFM (0.028–0.057 m3/minute).
Table 2-4. Pipe connection sizes.
Model # Liquid Line Discharge Line Condensate Drain
CRDX-W-FS-12W,
CRDX-W-FS -24W
CRDX-G-FS-12W,
CRDX- G-FS-24W
2.8.1.1 DX Refrigerant Piping Connections
CONDENSATE DRAIN—
1
⁄2" FPT
SUCTION LINE
LIQUID LINE
5
⁄8"
5
⁄8"
5
⁄8"
5
⁄8"
1
⁄2
"
1
⁄2
"
Page 30
TOP-ACCESS PIPING
BOTTOM-ACCESS PIPING
Figure 2-11. DX refrigerant piping connections.
724-746-5500 | blackbox.com
LIQUID LINE
SUCTION LINE
Loading...