HP Modular Cooling System G2 Maintenance and Service Guide
Part Number 463066-003
February 2010 (Third Edition)
© Copyright 2008, 2010 Hewlett-Packard Development Company, L.P.
The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express
warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP
shall not be liable for technical or editorial errors or omissions contained herein.
Intended audience
This guide is for an experienced service technician. HP assumes you are qualified in the servicing of computer equipment and trained in
recognizing hazards in products with hazardous energy levels and are familiar with weight and stability precautions for rack installations.
Contents
Customer self repair ...................................................................................................................... 5
Parts only warranty service ......................................................................................................................... 5
Illustrated parts catalog ............................................................................................................... 16
Replaceable spare parts ........................................................................................................................... 16
Removal and replacement procedures ........................................................................................... 20
Overview ............................................................................................................................................... 20
Spare replacement tips ............................................................................................................................ 20
Spare replacement video.......................................................................................................................... 20
Component location ................................................................................................................................ 21
Required tools ......................................................................................................................................... 22
Safety considerations ............................................................................................................................... 23
Rack warnings and cautions ........................................................................................................... 23
Preparation procedures ............................................................................................................................ 23
Disconnecting the power ................................................................................................................ 23
Turning off the water ...................................................................................................................... 24
Draining water from the MCS G2 unit .............................................................................................. 24
AC transfer switch ................................................................................................................................... 25
Removing the AC transfer switch ..................................................................................................... 25
Replacing the AC transfer switch ..................................................................................................... 26
Air bleeder valve ..................................................................................................................................... 27
Removing the air bleeder valve ....................................................................................................... 27
Replacing the air bleeder valve ....................................................................................................... 28
Bottom fan unit ........................................................................................................................................ 28
Removing the bottom fan unit .......................................................................................................... 29
Replacing the bottom fan unit .......................................................................................................... 29
Condensation pump ................................................................................................................................ 30
Removing the condensation pump .................................................................................................... 30
Replacing the condensation pump ................................................................................................... 32
Fan controller.......................................................................................................................................... 34
Removing the fan controller ............................................................................................................. 34
Replacing the fan controller ............................................................................................................ 35
Fan unit ................................................................................................................................................. 36
Removing the fan unit ..................................................................................................................... 36
Replacing the fan unit .................................................................................................................... 37
Flow meter sensor ................................................................................................................................... 38
Removing the flow meter sensor ....................................................................................................... 38
Replacing the flow meter sensor ...................................................................................................... 40
Front automatic door release .................................................................................................................... 44
Removing the front automatic door release ........................................................................................ 44
Replacing the front automatic door release ....................................................................................... 45
Management module ............................................................................................................................... 46
Removing the management module .................................................................................................. 46
Replacing the management module ................................................................................................. 48
Operator display ................................................................................................................................
Removing the operator display ........................................................................................................ 49
..... 49
Replacing the operator display ........................................................................................................ 51
Rear automatic door release ..................................................................................................................... 53
Removing the rear automatic door release ........................................................................................ 54
Replacing the rear automatic door release ........................................................................................ 55
Water controller ...................................................................................................................................... 57
Removing the water controller ......................................................................................................... 57
Replacing the water controller ......................................................................................................... 59
Water level sensors ................................................................................................................................. 61
Removing the water level sensors ..................................................................................................... 61
Replacing the water level sensors .................................................................................................... 62
Water valve ........................................................................................................................................... 65
Removing the water valve ............................................................................................................... 65
Replacing the water valve ............................................................................................................... 69
Operation checklist .................................................................................................................................. 73
Reconnecting the main water hoses.................................................................................................. 73
Reconnecting the power ................................................................................................................. 73
Restoring water flow ...................................................................................................................... 74
Maintenance .............................................................................................................................. 75
Maintenance and service ......................................................................................................................... 75
Air and water heat exchanger maintenance ...................................................................................... 75
Water quality requirements and specifications ............................................................................................ 75
Acceptable water quality specifications ............................................................................................ 75
Frost damage ................................................................................................................................ 76
Water precautions ......................................................................................................................... 76
Plumbing materials to avoid ............................................................................................................ 77
Condensation management ...................................................................................................................... 77
Diagnostic tools ...................................................................................................................................... 77
Troubleshooting .......................................................................................................................... 78
HP Modular Cooling System troubleshooting ............................................................................................... 78
Specifications ............................................................................................................................. 79
MCS specifications .................................................................................................................................. 79
Thermal and air flow performance ................................................................................................... 80
Environmental specifications ........................................................................................................... 80
HP 10642 G2 Rack specifications ............................................................................................................. 80
Acronyms and abbreviations ........................................................................................................ 81
Index ......................................................................................................................................... 82
Customer self repair
HP products are designed with many Customer Self Repair (CSR) parts to minimize repair time and allow
for greater flexibility in performing defective parts replacement. If during the diagnosis period HP (or HP
service providers or service partners) identifies that the repair can be accomplished by the use of a CSR
part, HP will ship that part directly to you for replacement. There are two categories of CSR parts:
• Mandatory—Parts for which customer self repair is mandatory. If you request HP to replace these
parts, you will be charged for the travel and labor costs of this service.
• Optional—Parts for which customer self repair is optional. These parts are also designed for
customer self repair. If, however, you require that HP replace them for you, there may or may not be
additional charges, depending on the type of warranty service designated for your product.
NOTE: Some HP parts are not designed for customer self repair. In order to satisfy the customer warranty,
HP requires that an authorized service provider replace the part. These parts are identified as "No" in the
Illustrated Parts Catalog.
Based on availability and where geography permits, CSR parts will be shipped for next business day
delivery. Same day or four-hour delivery may be offered at an additional charge where geography
permits. If assistance is required, you can call the HP Technical Support Center and a technician will help
you over the telephone. HP specifies in the materials shipped with a replacement CSR part whether a
defective part must be returned to HP. In cases where it is required to return the defective part to HP, you
must ship the defective part back to HP within a defined period of time, normally five (5) business days.
The defective part must be returned with the associated documentation in the provided shipping material.
Failure to return the defective part may result in HP billing you for the replacement. With a customer self
repair, HP will pay all shipping and part return costs and determine the courier/carrier to be used.
For more information about HP's Customer Self Repair program, contact your local service provider. For
the North American program, refer to the HP website (http://www.hp.com/go/selfrepair
Parts only warranty service
Your HP Limited Warranty may include a parts only warranty service. Under the terms of parts only
warranty service, HP will provide replacement parts free of charge.
For parts only warranty service, CSR part replacement is mandatory. If you request HP to replace these
parts, you will be charged for the travel and labor costs of this service.
).
Réparation par le client (CSR)
Les produits HP comportent de nombreuses pièces CSR (Customer Self Repair = réparation par le client)
afin de minimiser les délais de réparation et faciliter le remplacement des pièces défectueuses. Si pendant
la période de diagnostic, HP (ou ses partenaires ou mainteneurs agréés) détermine que la réparation peut
être effectuée à l'aide d'une pièce CSR, HP vous l'envoie directement. Il existe deux catégories de pièces
CSR:
Customer self repair 5
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