Operation and Maintenance InRow® RD 10kW Air Cooled ACRD100 ACRD101
This manual is available in English on the enclosed CD. Dieses Handbuch ist in Deutsch auf der beiliegenden CD-ROM verfügbar. Deze handleiding staat in het Nederlands op de bijgevoegde cd. Este manual está disponible en español en el CD-ROM adjunto. Ce manuel est disponible en français sur le CD-ROM ci-inclus. Questo manuale è disponibile in italiano nel CD-ROM allegato. 本マニュアルの日本語版は同梱の CD-ROM からご覧になれます。 Instrukcja Obsługi w jezyku polskim jest dostepna na CD.
American Power Conversion Legal Disclaimer The information presented in this manual is not warranted by the American Power Conversion Corporation to be authoritative, error free, or complete. This publication is not meant to be a substitute for a detailed operational and site specific development plan.
Contents General Information ........................................................ 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Symbols used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Cross-reference symbol used in this manual . . . . . . . . . . . . . . . . 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Commissioning ...........................
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 View the state of input and output contacts . . . . . . . . . . . . . . . . 17 Edit the normal state of input and output contacts . . . . . . . . . . 17 Cooling Group Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Configure the cooling group . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Identify the cooling unit . . . . . . . . . . . . . . . . . . . . . . . . .
Network Management Card.......................................... 32 Quick Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 TCP/IP configuration methods . . . . . . . . . . . . . . . . . . . . . . . . . . 32 APC Device IP Configuration Wizard . . . . . . . . . . . . . . . . . . . . . 33 .ini file utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Overview Note the definitions for the icons here and be observant for them throughout this manual. They are intended to call attention to potential hazards and important information. Symbols used in this manual Electrical Hazard: Indicates an electrical hazard which, if not avoided, could result in injury or death. Danger: Indicates a hazard which, if not avoided, could result in severe personal injury or death.
Safety Read and adhere to the following important safety considerations when working with this cooling unit. Note: All work must be performed by American Power Conversion (APC®) authorized personnel only. Caution: Keep your hands, clothing, and jewelry away from moving parts. Check the equipment for foreign objects before closing the doors and starting the equipment. Heavy: The equipment is heavy. For safety purposes, at least two people must be present when moving this equipment.
Commissioning Warning: APC authorized personnel must perform the following procedures. Electrical Hazard: Perform Lockout/Tagout procedures on the cooling unit before servicing the cooling unit. Failure to remove power before servicing this equipment could result in serious injury or death. After installation is complete, verify that all components are working properly and that the cooling unit is ready to begin operation.
Electrical inspection checklist The electrical inspection verifies that all electrical connections are secure and correct and that the cooling unit is properly grounded. Electrical Hazard: All electrical wiring must comply with local and national codes and regulations. Electrical Hazard: The equipment must be grounded (do not use a water-pipe ground). Ensure that the: 4 Incoming voltages match the phase and voltage listed on the nameplate.
Mechanical inspection checklist The mechanical inspection verifies that all mechanical components and connections are secure and tight and ready for start-up and system charging. The inspection ensures that field piping is properly installed to promote oil return to the compressor. Warning: The equipment is shipped from the factory with a nitrogen holding charge. Remove the nitrogen holding charge using the Schrader valves located on the internal refrigerant piping.
User interface inspection checklist The user interface inspection verifies that the sensors and internal communications links of the cooling unit are installed properly. Ensure that: An A-Link bus is connected to each cooling unit in the group and a terminator is plugged into all unused A-Link connectors. The input contacts and output relays are connected correctly. The building management system is connected correctly and a terminator is wired into the final unit between Modbus D0 and Modbus D1.
Charging With Refrigerant Calculating R410A charge Use the following table and formula when calculating the total R410A charge. Selected ambient temp. in °C (°F) Condenser model Condenser flooded charge in kg (lb) for different minimum outdoor ambient temperatures Condenser summer charge in kg (lb) 4°C (40°F) -7°C (20°F) -18°C (0°F) -29°C (-20°F) -40°C (-40°F) ACCD75214 35 (95) 2.2 (4.9) 5.48 (12.1) 5.85 (12.9) 6.03 (13.3) 6.17 (13.6) 6.30 (13.9) ACCD75214 40 (105) 2.2 (4.9) 5.48 (12.
Quantity of R410A in 1/2 in OD liquid line: (area) x (length in ft) x (density): 0.0010554 (ft2) x L (ft) x 61.0 (lbm/ft3) Density of liquid R410A at 40.6 °C (105 °F) and 260 psig: 0.98 g/cm3 (61.0 lbm/ft3 ) Cross sectional area for 1/2 in OD pipe is 0.0010554 ft2. Liquid line charge for 1/2 in OD ACR copper tube: 0.095 kg/m (0.0644 lb/ft). Cross sectional area for 5/8 in OD pipe is 0.001619 ft2. Quantity of R410A in 5/8 in OD liquid line: (area) x (length in ft) x (density): 0.001619 (ft2) x L (ft) x 61.
Charging the equipment Caution: This procedure is to be done by APC-trained personnel only. R410A is a blend refrigerant. When charging equipment with blend refrigerants, only liquid refrigerant must be charged. Caution: Charging with other than liquid R410A refrigerant may damage the system. 1. Ensure the ball valves are open. 2. Confirm the calculated system charge. 3. Connect the refrigerant cylinder to the charging or gauge port on the receiver outlet valve.
Compressor Oil Charge Caution: This procedure is to be done by APC-trained personnel only. You may need to add oil to air-cooled equipment, depending on the condenser size and the lengths of tube running between the equipment and the condenser. Caution: Do not charge the compressor with too much oil, or compressor damage could result. The only way to drain oil from the compressor is to remove the compressor from the equipment, which cannot be done when the equipment is in the row. Oil charging procedure 1.
2. Prepare to add oil: a. Use a new, sealed oil can and a manual oil pump. The pump hose must be sized for 1/4 in flare fittings and must include a valve depressor at its end, which will open the valve on the Schrader service port of the compressor. b. At a minimum, use a quality POE oil with a viscosity of 32 cst, 160 sus at 40°C (104°F). Suggested oils: Danfoss Maneurop 160 PZ Polyolesteroil, the approved type of oil for this equipment.
Operation Display Interface Status ESC Check Log ? Warning na1582a Critical 12 Item Function Critical Alarm LED (red) When lit, a critical alarm condition exists and requires immediate attention. Warning Alarm LED (yellow) When lit, a warning alarm condition exists. Failure to correct this condition could cause a critical alarm. Check Log LED (yellow) When lit, at least one new event has been logged since the last time the log was checked.
Using the Display Interface Every time power is applied to the cooling unit, the display interface initializes, causing the LEDs to cycle and the alarm-tone to activate. Scrolling status screens After start-up, the interface displays the firmware revision number on the display interface. The display interface then scrolls automatically and continuously through screens of status information.
Navigating the main menu Clear Event Log Configure Modbus Set Date & Time Set Password na1623d Selector arrow. Press the up or down arrow key to move the selector arrow to a main menu option. Press the ENTER key to view the selected sub-menu screen. In the example shown below, the selector arrow points to the Set Date and Time setting. To select that item, press the ENTER key.
Using the Path statement Select the main- and sub-menu options specified in the path statement to view or configure a setting. The path statement lists the main- and sub-menu items you select to navigate to the item to view or modify. The parts of the path statement are defined below: Path: Main > Set Password > Change Passwords Main > Your starting point is the main menu. Set Password > Scroll to and select this option from the main menu.
Stop the cooling unit Path: Main > On/Standby Press the ENTER key to change the setting to Standby. The cooling unit enters the standby mode. Electrical Hazard: The Standby option does not remove power from the cooling unit. You must disconnect power at the mains to remove power from the cooling unit. General Configuration The cooling group configuration options are set during the commissioning of the cooling units in the cooling group.
Contacts View the state of input and output contacts Path: Main > Configure Unit > Discrete I/O Each cooling unit supports a user-defined input contact and a user-defined output contact. Each contact monitors a sensor and responds to changes in the state of the sensor (open or closed). Input State. Indicates the actual state of the input contact (Open or Closed). A cooling unit is On when the state is normal and in Standby when the state is not normal. Output State.
Type. Set the rack deployment strategy for the cooling units of this cooling group: • Spot: The cooling unit is used as a stand-alone unit. • In-Row: Air flow is not ducted. Hot-aisle air is cooled and the cooled-air supply is shared by all loads in the row. • RACS (Rack Air Containment System): Air flow in the enclosure is controlled by a ducting system fitted to the enclosure. • HACS (Hot Aisle Containment System): Air flow in the room is controlled by enclosing the hot air aisle.
Control the Environment The primary function of the cooling unit is to capture the heat generated by IT equipment and neutralize it before it mixes with the room. The control strategies employed by the cooling unit depend upon the deployment strategy of the cooling group. In an InRow environment, the cooling unit supplies constant-temperature supply air to the common cold aisle. The fan speed is modulated to ensure that the required volume of air reaches the IT equipment.
PID settings Path: Main > Set Group PID The Proportional plus Integral plus Derivative (PID) loop controls the output of the fans. Caution: This procedure is to be performed by APC authorized personnel only. Improperly set PID controls could result in equipment damage. There are two sets of PID coefficients stored in the unit. One set is used when the unit is programmed for Spot (Proportional) mode and the other set is used when the cooling unit is programmed for InRow mode.
Tune the PID loop Tune the PID loop to optimize the performance of the cooling group. Caution: This procedure must be performed by APC authorized personnel only. The PID loop must be tuned after the equipment in the room is installed and running. The loop should be tuned periodically to account for changes in the room load. 1. Adjust the integral and derivative constants to zero and the proportional constant to 1.0. 2. Set the temperature setpoint value and start the cooling group. 3.
Run hours The cooling unit records the number of hours each of its components has operated. When a component is replaced, use the Reset Run Hours option to reset the run hours for the displayed component to zero. Path: Main > View Run Hours • Air Filter – Reset Run Hours Note: Replace air filters with APC part number 875-2013 only.
Display Settings Set display interface settings including the time and date, units of measure, passwords, and time-out settings. You can also adjust the contrast, key click, beeper volume, and beep-on-alarm settings. Password and time-out Path: Main > Set Password Note: The default user password is apc (lowercase). See “Password entry” on page 15 for information on passwords. Change passwords. Set the Admin and Device passwords. 1.
Adjust display settings Path: Main > Configure Display Contrast. Adjust the visibility of the screen text. Lower numbered settings provide darker text; higher numbers provide lighter text. Settings range from 0–7. Key Click. Set to ON or OFF will enable or disable an audible tone that sounds every time a key is pressed on the display interface. Beeper Volume. Set the volume (Low, Medium, High or OFF) of the audible tone that sounds every time a key is pressed on the display interface. Beep on Alarm.
Network Configuration The cooling unit is shipped with a Network Management Card that enables the cooling unit to be managed over a network. Configure the network settings for the Network Management Card for this cooling unit from the display interface. The management card allows remote control and configuration of the equipment. Configure network Path: Main > ConfigureNetwork MAC Address.
View Status Readings The display interface has several options for viewing the status of the cooling unit, the cooling group to which the cooling unit belongs, and the environment being controlled. The status readings for the cooling unit are available under the View Unit Status option in the main menu, and status readings for the cooling group are available under the View Group Status option on the main menu or on the scrolling status screens.
Cooling group status Path: Main > View Group Status View information about the cooling group. Cool Output. The combined output of the cooling group. Cool Demand. The cooling output required to meet the current heat load of the conditioned space. Cool Setpt. The temperature you set to maintain the room environment. Air Flow. The combined airflow output of the cooling units in the cooling group. Max Rack. The highest rack temperature reported by any cooling unit in the cooling group. Min Rack.
Event Log The event log saves status information and a message each time a change in the cooling group is detected. Alarms and events are recorded in the log and displayed on the active alarms screen. Status information and system configuration changes are displayed in the event log only. View the event log Path: Main > View Event Log The event log keeps a record of all alarms and events.
Respond to Alarms When an alarm is triggered, the cooling unit alerts you through the display interface by the following methods: • Active alarm screen entry on scrolling status screens • LEDs on the front panel display • An optional audible alarm, if enabled, every 30 seconds View active alarms Path: Main > View Alarms The View Alarms screen provides the number of alarms, the severity level of each active alarm, and a brief description of each alarm. Press the arrow keys to view the rest of the list.
Alarm Message Severity Action Required High Suction Pres (High Suction Pressure) Warning • Check the air filter and fans for obstructions • If the problem persists, contact APC at a number on the back cover of this manual. Fan Num Fault (Fan # Fault) Warning • A hardware failure exists. For assistance, contact APC at a number on the back cover of this manual. Water Detected Warning • Identify the source of the leak.
Alarm Message Severity Action Required Suction Pressure Sensor Failure Warning • Make sure the sensor is connected properly. • If the problem persists, replace the sensor or contact APC at a number on the back cover of this manual. Dischrg Pressure Sensor Failure Warning • Make sure the sensor is connected properly. • If the problem persists, contact APC at a number on the back cover of this manual.
Network Management Card Quick Configuration The cooling unit is shipped with a Network Management Card that enables the cooling unit to be managed over a network. Configure the Network Management Card to control this cooling unit through a network. Overview You must configure the following TCP/IP settings before the Network Management Card can operate on a network: • IP address of the Network Management Card • Subnet mask • Default gateway Caution: Never use the loopback address (127.0.0.
APC Device IP Configuration Wizard You can use the APC Device IP Configuration Wizard at a computer running Microsoft® Windows 2000, Windows Server 2003, or Windows XP to configure a Network Management Card. Note: Most software firewalls must be temporarily disabled for the Wizard to discover unconfigured Network Management Cards. To configure one or more Network Management Cards from a user configuration file, see the User’s Guide on the Utility CD. 1. Insert the Utility CD into a computer on your network.
BOOTP. For the Network Management Card to use a BOOTP server to configure its TCP/IP settings, it must find a properly configured RFC951-compliant BOOTP server. 1. In the BOOTPTAB file of the BOOTP server, enter the MAC address of the Network Management Card, the IP address, the subnet mask, default gateway, and an optional bootup file name. Look for the MAC address on the display interface (Path: Main > Configure Network) or on the label on the back of the Network Management Card. 2.
Local access to the control console You can use a computer connected to the serial port on the main board holding the Network Management Card to access the control console. 1. Select a serial port at the local computer, and disable any service that uses that port. 2. Use the provided configuration cable to connect the selected port to the serial port on the main board holding the Network Management Card. 3.
1. Use Ping with a size of 113 bytes to assign the IP address defined by the ARP command. For the IP address defined in step 1, use one of the following Ping commands: – Windows command format: ping 156.205.14.141 -l 113 – LINUX command format: ping 156.205.14.141 -s 113 2. Use Telnet to access the Network Management Card at its newly assigned IP address. For example: telnet 156.205.14.141 3. Use apc for both user name and password. See “Control console” on page 36 to finish the configuration.
Access a Configured Network Management Card Overview After the Network Management Card is running on your network, you can access the configured Network Management Card through the following interfaces: • Web interface (HTTP or HTTPS protocol) • Telnet or Secure SHell (SSH) • SNMP • FTP or Secure CoPy (SCP) to upgrade firmware • Modbus For more information on the interfaces, see the User’s Guide. Web interface Use Microsoft Internet Explorer® (IE) 5.
Telnet and SSH You can access the control console through Telnet or Secure SHell (SSH), depending on which is enabled. Select the Administration tab, the Network option on the top menu bar, and then the access option under Console on the left navigation menu. By default, Telnet is enabled. Enabling SSH automatically disables Telnet. Telnet for basic access. Telnet provides the basic security of authentication by user name and password, but not the high-security benefits of encryption.
Simple Network Management Protocol (SNMP) SNMPv1 only. After you add the PowerNet® MIB to a standard SNMP MIB browser, you can use that browser to access the Network Management Card. All user names, passwords, and community names for SNMP are transferred over the network as plain text. The default read community name is public; the default read/write community name is private. SNMPv3 only. For SNMP GETs, SETs, and trap receivers, SNMPv3 uses a system of user profiles to identify users.
Recover From a Lost Password You can use a local computer (a computer that connects to the Network Management Card through the serial port) to access the control console. 1. Select a serial port at the local computer, and disable any service that uses that port. 2. Connect the provided RS-232 configuration cable to the selected port on the computer and to the RS-232 console port at the Network Management Card. 3.
Maintenance Monthly Preventive Maintenance Photocopy the following pages and use them during the maintenance procedures. After they have been completed, save them for future reference.
Mechanical Electrical Hazard: Turn off the cooling unit and disconnect all power sources. Perform Lockout/Tagout procedures before performing any electrical or mechanical service. Wear appropriate personal protective equipment when checking hazardous voltages. Check the fans. All components should be moving freely with no signs of binding or damages. Verify that the condensate line is flowing freely. Electrical Electrical Hazard: Turn off the cooling unit and disconnect all power sources.
Quarterly Preventive Maintenance Perform all the Monthly Preventive Maintenance items and the items below. Prepared By: _________________________________ Model Number: _______________________________ Serial Number: _______________________________ Date: ______________________________________ Mechanical Electrical Hazard: Turn off the cooling unit and disconnect all power sources. Perform Lockout/ Tagout procedures before performing any electrical or mechanical service.
Troubleshooting Problem Possible Cause Corrective Action Controls erratic or inoperative • Inlet temperature to cooling unit is higher than rated maximum temperature • Power supplies are not operating properly • Reduce the load or add additional cooling equipment.
Problem Possible Cause Cooling unit does not • Drive voltage shut down on command No communication with building management system (BMS) port • Improper connection Cooling units are not communicating with each other • A-Link failure • Upper or lower supply air Output air is 17°C sensor fault (62°F) and fans are running at a very high rate of speed. Corrective Action • Verify that there is a drive voltage entering the input of the cooling unit. You may use the available +12 V or +24 V.
APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways: • Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests. – www.apc.com (Corporate Headquarters) Connect to localized APC Web sites for specific countries, each of which provides customer support information. – www.apc.com/support/ Global support searching APC Knowledge Base and using e-support.
