Chatsworth Products Hot Aisle Containment User Manual
Build To Spec Kit
Aisle Containment Solution
User’s Manual
Version 1.0
December 2013
©2013 Chatsworth Products, Inc. All rights reserved. CPI, CPI Passive Cooling, GlobalFrame,
MegaFrame, Saf-T-Grip, Seismic Frame, SlimFrame, TeraFrame, Cube-iT Plus, Evolution,
OnTrac, Velocity and QuadraRack are federally registered trademarks of Chatsworth Products.
eConnect and Simply Efficient are trademarks of Chatsworth Products.
All other trademarks belong to their respective companies. 12/13 MKT-60020-601
techsupport@chatsworth.com
www.chatsworth.com
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Contents
INTRODUCTION .......................................................................................................................... 4!
Legal Information ...................................................................................................................... 4!
Warranty .................................................................................................................................... 4!
SAFETY INFORMATION ............................................................................................................. 5!
INTENDED USE ....................................................................................................................... 5!
STORAGE OF COMPONENTS ................................................................................................ 5!
TOOLS REQUIRED FOR ASSEMBLY AND INSTALLATION .................................................. 6!
SITE PREPARATION ............................................................................................................... 6!
UNPACKING ................................................................................................................................ 7!
BUILD TO SPEC KIT – THE AISLE CONTAINMENT DUCT ...................................................... 8!
INTRODUCTION ....................................................................................................................... 8!
COMPONENTS ........................................................................................................................ 8!
ASSEMBLING THE BUILD TO SPEC KIT .............................................................................. 10!
CREATE THE DUCT ........................................................................................................... 12!
CREATE DROP PANELS ................................................................................................... 22!
CREATE AN END FACIA OVER THE DOOR ..................................................................... 25!
FULL HEIGHT CABINET BLANKING PANELS ....................................................................... 27!
INTRODUCTION ..................................................................................................................... 27!
COMPONENTS ...................................................................................................................... 27!
INSTALLATION ....................................................................................................................... 28!
AISLE CONTAINMENT DOOR SYSTEM .................................................................................. 31!
INTRODUCTION ..................................................................................................................... 31!
COMPONENTS ...................................................................................................................... 31!
INSTALLATION ....................................................................................................................... 32!
FLOOR PREPARATION ..................................................................................................... 32!
FLOOR MOUNTING ANGLE INSTALLATION .................................................................... 35!
DOOR FRAME ASSEMBLY ................................................................................................ 36!
DOOR FRAME INSTALLATION .......................................................................................... 41!
DOOR INSTALLATION ....................................................................................................... 49!
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AISLE CONTAINMENT FLOOR SEAL KITS ............................................................................ 52!
INTRODUCTION ..................................................................................................................... 52!
FOR GF-SERIES GLOBALFRAME GEN 1 CABINET AND F-SERIES TERAFRAME GEN 3
CABINET ................................................................................................................................. 52!
FOR F-SERIES TERAFAME GEN 2 CABINET ...................................................................... 53!
FOR ALL OTHER CABINETS ....................................................................... 54ACCESSORIES
................................................................................................................................................ 55!
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INTRODUCTION
This document is the User’s Manual for CPI Build To Spec Kit Aisle Containment
Solution. It includes basic assembly and installation instructions for the Build To Spec
Kit, Aisle Containment Door Assembly; Full Height Cabinet Blanking Panels and
Cabinet To Floor Sealing Kits, which are used together to create an Aisle Containment
Solution.
Build To Spec Kit Aisle Containment Solution User’s Manual
©2013 Chatsworth Products, Inc. All rights reserved.
Legal Information
The information contained in this guide is subject to change without notice.
Chatsworth Products, Inc. (CPI) shall not be liable for technical or editorial errors or
omissions contained herein; nor is it liable for any injury, loss, or incidental or
consequential damages resulting from the furnishing, performance, or use of this
material and equipment.
Warranty
Chatsworth Products, Inc. (CPI) guarantees manufactured products and each part or
component thereof against all defects in material and/or workmanship. CPI agrees to
remedy any manufacturing defect either through replacement or repair at no charge
provided that the defective unit is returned, transportation prepaid, to the CPI factory.
The warranty extends for a period of one year from the date of installation or initial use,
provided that this period shall not exceed 18 months from the original date of shipment
from the factory.
Any product that has been repaired or replaced shall be similarly warranted on its repair
or replacement for the remaining product warranty period or 90 days from the date of
repair or replacement, whichever expires last.
This warranty does not extend to products that have been subjected to neglect, accident
or improper use, nor to units that have been altered by non-CPI personnel.
No warranties other than those set forth in this section are given or implied with respect
to the products furnished. CPI shall, in no event, be liable for consequential damages,
for loss, damage or expense directly or indirectly arising from the use of the products,
for any inability to use materials or from any other cause.
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SAFETY INFORMATION
WARNING: Improper use of this product may lead to serious injury or
death. Read and understand all instructions for proper installation and use
of this product.
WARNING: Installation of aisle containment products may require the use
of ladders, scaffolds, and other climbing tools. Follow all climbing device
procedures and observe all safety and warning precautious.
WARNING: The aisle containment products are heavy and large. This
requires that at least two personnel be used for assembly and installation.
Obtain adequate assistance or hire professional equipment riggers.
WARNING: Depending on the configurations of the deployed system, the
static weight of the duct can result in heavy loads. Consult with the local
building engineer to verify that floor and/or ceiling loading prior to
assembling and installing the structure. Failure to provide adequate
support and anchoring for the frame could result in severe injury of death.
WARNING: Failure to properly support structural members during
assembly colud result in severe injury or death.
WARNING: The aisle containment system is designed to support the
weight of the duct, but is not designed for significant additional loading. Do
not climb on or support heavy items such as cable runways from the
containment structure as doing such could result in severe injury or death.
INTENDED USE
The Build To Spec Kit Aisle Containment Solution should only be used in a restricted
service environment, such as a data center. Use indoors only, in environmentally
controlled areas; do not use outdoors or in harsh environments. Not for use in plenums.
Use this solution for computer server, storage and network equipment. Allow only
qualified service personnel to use this solution.
STORAGE OF COMPONENTS
All system components should be stored indoors only in environmentally controlled
areas. Do not store outdoors. Do not expose to harsh or humid areas.
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TOOLS REQUIRED FOR ASSEMBLY AND INSTALLATION
The following tools are required to assemble the Build To Spec Kit and Aisle Containment
Doors. Additional tools may be required depending on site-specific requirements.
Tool
Application
Mitre saw with metal/aluminum cutting blade
For cutting frame components
Jig/reciprocating saw with metal cutting blade
For cutting corner brackets
Utility Knife or Flute Cutter
For cutting poly panels/bulb seal
Straight edge or Guardian Knife Guide*
For cutting poly panels/bulb seal
#2 Phillips screwdriver or bit for drill/driver
Assembly, BTS Kit
#3 Phillips screwdriver or bit for drill/driver
Assembly, Door
8 mm socket and open end wrench
Assembly, Door
10 mm socket and open end wrench
Assembly, Door
13 mm socket and open end wrench
Assembly, Door
Ladders
Installation
Levels
Installation
Drill, bits
Installation
*For best results when cutting corrugated plastic sheet use specialized cutting tools, like
the Guardian Knife Guide by Saw Trax Mfg. Inc.
SITE PREPARATION
Floor
In an access floor installation, ensure that the floor is strong enough to support the fully
populated computer cabinets, and the additional weight of the Build To Spec Kit (aisle
containment duct) and Aisle Containment Door Systems. If required, add subfloor
bracing to provide the proper support for equipment.
Subfloor bracing.
Ceiling
If supporting from threaded rod, ensure that the ceiling is strong enough to support the
Build To Spec Kit (aisle containment duct). Threaded rod used to support the duct
should only be used to support the duct.
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UNPACKING
The containment system components are packaged in separate crates. Inspect the
components for damage as they are unpacked. If any damage is observed, contact your
distributor or CPI Customer Service.
CAUTION: Aisle containment components are heavy. Use a
minimum of two (2) people to unpack and remove components from
the pallet.
1. Components are packaged in protective crates. The upper crate will need to be
removed to access the components. Carefully remove the mounting screws from the
steel plates that tie the upper and lower crate. The upper crate will need to be lifted
and set aside.
CAUTION: The upper crate is heavy. Use a minimum of two (2)
people to remove.
2. Individual component pieces will be individually wrapped with foam. The foam
should be used to provide protection when the components are staged on the floor
prior to assembly. Use a utility knife to cut any tape. Be careful not to allow the knife
to contact the components as this causes damage.
RECYCLABLE MATERIALS: CPI uses only recyclable materials in all
of its containment packaging. Please save packaging for later use or
dispose of properly. All wood components of CPI pallets have been
properly treated to comply with the pest-free certifications required by
foreign countries.
3. After the all of the components have been unpacked, locate the hardware kit and
inspect the product for concealed damage. If any damage to the aisle containment
solution is observed, contact your distributor or CPI Customer Service.
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BUILD TO SPEC KIT – THE AISLE CONTAINMENT DUCT
INTRODUCTION
The Build To Spec Kit from Chatsworth Products, Inc. (CPI) includes various
components that are field fabricated to create a single duct over the contained aisle.
The duct isolates and guides exhaust air from the contained aisle back to the air
handlers as part of a closed return system. The duct can be supported from the ceiling
or from the tops of cabinets. Clear polycarbonate panels allow light to enter the
contained aisle. Use Aisle Containment Door Assemblies (ordered separately) on each
end of the contained aisle. Use Full Height Blanking Panels (ordered separately) to fill
any gaps from missing cabinets or uneven rows. If cabinets vary in height, use
Universal Bulb Seal (ordered separately) on drop panels cut from extra panel material to
seal the gaps.
COMPONENTS
The basic components included with each Build To Spec Kit are illustrated below and
on the next page.
Extrusion, 94”L (2387 mm)
Use to build structure of the duct
Joiner Gusset
Use to splice Extrusion for longer duct
Plate Gusset
Use to splice corners/intersections
Inside
Containment
Outside
Containment
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Corner Cover
Use to reinforce outside corners
Mounting Bracket
Use to attach duct to ceiling or cabinets
Screws
Use to assemble Gussets and Extrusion
Panel Clamp
Use to secure Panels against Extrusion
Polycarbonate Panels
48” (1219 mm) W x 96” (2438 mm) L
Build To Spec Kit Assembled
Kits are available in several sizes.
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ASSEMBLING THE BUILD TO SPEC KIT - The following sections cover recommended
assembly and installation methods. Use alternate methods or order of assembly as required.
Step 1: Join Extrusions to form the bottom, sides of the
duct and support from ceiling or top of cabinets.
Step 2: Level the sides and connect the ends to
form the bottom of the duct.
Step 3: Cut and install vertical supports at
each corner.
Step 4: Cut and install cross braces and intermediate
vertical supports.
Step 5: Cut and install the frame and cross braces at the
top of the duct.
Step 6: Cut, fit and install the panels. You may also
need to add drop panels and end fascias.
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CREATE THE DUCT
1. Assemble Extrusions to make the two long sections for the bottom of the duct.
If cabinet row length is greater than 94” (2387 mm), join extrusions together using
the Joiner Gusset and (4) Screws as shown below.
Note:
• The flat side of the extrusion faces the inside of the containment/duct (see page 8).
• The Joiner Gusset faces the outside of the containment/duct.
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2. Cut the extrusions to match the Cabinet Row Length.
If cabinet row lengths are uneven, cut Extrusions to match the longest row length.
Consider the addition of future cabinets also. Open space at the end of the row can
be filled with a Full Height Blanking Panel (sold separately, see page 26).
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3. Use Mounting Brackets to attach extrusions to the ceiling or to the tops of cabinets.
• Position the extrusions
so Gusset Joiners
face the outside of the
containment/duct.
• Mounting brackets
attach to the outside of
the containment/duct.
• Support extrusions on
both sides of Joiner
Gussets and close to
the ends of the duct.
• Space brackets
approximately every
48” (1200 mm) of
span.
• Use 3/8” threaded rod
to support the duct
from the ceiling as
shown.
• When cabinets are the
same height, you can
support extrusion(s)
directly from the tops
of cabinets.
• Flip the Mounting
Bracket and use a 3/8”
hex bolt to attach the
extrusion directly to
the tops of cabinets.
• Hardware for ceiling or
cabinet attachment is
not included.
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4. Cut extrusions to cap the ends of the duct and attach with Plate Gussets as shown
below. Note the orientation of the Extrusion; the Plate Gusset goes inside the duct.
5. Attach the extrusions to the ends of the duct with the Plate Gussets. Note the
orientation of the Extrusion; the Plate Gusset goes inside the duct.
The flat side of the
Extrusion faces the inside
of the containment. The
curves face the outside of
the containment/duct.
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6. Cut two vertical extrusions per corner. Each vertical extrusion should be 3.25” (83
mm) less than the cabinet to ceiling distance to allow space for the top of the duct
frame. Attach the extrusions in the corners with Plate Gussets as shown below.
• After the duct frame is
complete, you will
attach Corner Covers
around the outside of
the corner extrusions.
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7. Add vertical extrusions every 48” (1200 mm) or at a smaller even interval across the
length of the duct. Use two gussets with two screws each to secure each vertical
extrusion as shown below. The flat side of the extrusion faces the inside of the duct.
This view is from the
outside of the
containment/duct.
The flat side of the
extrusions face the
inside of the
duct/containiment.
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