-FS CRDX-A-FS-24KW CRDX-A-FS-12KW CRDX-G-FS-24KW CRDX-G-FS-12KW CRDX-W-FS-24KW CRDX-W-FS-12KW Cold Row™ DX User Manual This precision data center air-conditioning system uses the latest, state-of-the-artBLACK control BOX technology. ® Customer Support Information Order toll-free in the U.S.: Call 877-877-BBOX (outside U.S.
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.
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 interference to radio communication.
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.
Table of Contents Table of Contents 1. Introduction ......................................................................................................................................................................... 10 1.1 General......................................................................................................................................................................... 10 1.2 Product Description...............................................................................
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...................................................................................
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.
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.
Table of Contents 5.3.3 5.3.4 5.3.2.3 Refrigerant Piping.............................................................................................................................. 120 Refrigeration System Repairs.......................................................................................................................... 120 5.3.3.1 Compressor Failure................................................................................................................
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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). \ Figure 2-3. Front-diverted air distribution. Page 22 724-746-5500 | blackbox.
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.
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.
Chapter 2: Installation 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.
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).
Chapter 2: Installation Water-Water/Glycol Supply and Return Piping Connections CONDENSATE DRAIN— 1 ⁄2" FPT FEMALE PIPE THREADS SCHRADER VALVE Figure 2-8. Top access piping. 724-746-5500 | blackbox.
Chapter 2: Installation SCHRADER VALVE MALE PIPE THREADS Figure 2-9. Bottom access piping. Page 28 724-746-5500 | blackbox.
Chapter 2: Installation 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.
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.
Chapter 2: Installation 2.8.1.2 Refrigerant Pipe Sizing Refrigerant lines for split systems must be sized according to the piping distance between the evaporator and the condenser. Each valve, fitting, and bend in the refrigerant line must be considered in this calculation. Pipe sizes are given for “equivalent feet,” not linear feet. Do not confuse the terminologies. For example, a 7⁄8" standard 90° elbow has an equivalent length of 1.5 feet; a 7⁄8" branch tee has an equivalent length of 3.5 feet.
Chapter 2: Installation Vertical runs are based on a total rise of 30 equivalent feet. For longer rises, make individual calculations. Sizes assume the use of single risers; double risers may be necessary. CAUTION Do not exceed 150-foot maximum liquid line length. If the condenser is installed above the evaporator, the discharge line should include a p-trap at the lowest point in the piping.
Chapter 2: Installation Figure 2-12. Sample nameplate. The unit is provided with terminals for all required field wiring. Refer to the electrical drawing supplied with the unit for all power and control field wiring. It is important to identify the options that were purchased with the unit to confirm which field connections are required. NOTE: All wiring must conform to local and national electrical code requirements. Use of copper conductors only is required.
Chapter 2: Installation CAUTION Before operating the unit, you must connect an adequate unit-to-ground to the unit. 2.9.1.1 Single-Phase Units 208/230 V The supply voltage for units that are designed for 208-V operation must have a tolerance within -5% and +10%. If the measured supply voltage is 230 V, the unit can operate with a tolerance of ±5% if the following change is made.
Chapter 2: Installation 2.9.3.2 Glycol-Cooled Systems (CRDX-G-FS-12KW, CRDX-G-FS-24KW) Glycol-cooled systems equipped with a pump package require field wiring between the A/C unit and the pump package (see Figure 2-13). The installer must wire two control conductors from the terminal board within the A/C unit, to the pump package electrical box. Refer to the electrical drawings supplied with your unit for the number of field wires needed and for the appropriate wire terminations required for your system.
Chapter 2: Installation Figure 2-14. Interconnecting field wiring remote condenser. 2.10 System Charging Procedures 2.10.1 Water–Water/Glycol Cooled Systems No field refrigerant charging is required for fluid-cooled units. The following precautions must be observed when installing and filling the water–water/glycol loop: • The piping system must be cleaned prior to allowing water or water/glycol to flow through the system. • Glycol must be mixed with water before it is added to the system.
Chapter 2: Installation CAUTION POE oil is used in systems with R410A refrigerant. POE oil quickly absorbs moisture when exposed to air. High POE oil moisture levels react with refrigerant to form acid, which results in system contamination. Keep the entire system sealed as much as possible and minimize exposure of POE oil to outside air. R410A operates at high pressures, which must be considered when checking the operating temperatures/pressures while charging or troubleshooting the system.
Chapter 2: Installation Table 2-10. Weight of R410A refrigerant (lbs./100 ft. of type L tubing). Line Size O.D. R410A Charge (less receiver) R410A Charge (with receiver) ⁄2 5.88 1.27 ⁄8 9.44 2.03 7 ⁄8 19.52 4.22 11⁄8 33.44 7.20 13⁄8 50.95 10.97 15⁄8 72.11 15.53 2 ⁄8 158.29 34.
Chapter 2: Installation NOTE: When pulling a vacuum, the Schrader valves will unnecessarily restrict the openings, increasing the evacuation time. During the evacuation process, we recommend that you remove the Schrader valve cores with a Schrader valve removal tool and draw the vacuum through the port on the removal tool. 4. If you cannot evacuate the system below 1500 microns, close the vacuum pump isolation valve and perform a rate-of-rise test by observing the standing pressure over time.
Chapter 2: Installation 3. Referring to Chapter 3, start the A/C system and use the system controller to lower the room temperature setpoint 3–5° F below actual room temperature to ensure that cooling remains on as the unit is charged. When fine tuning the charge on cool days, it may be necessary to restrict the airflow across the condenser coil to raise the pressure. The fan closest to the header must be running.
Chapter 2: Installation 2.10.3 Refrigerant Characteristics 2.10.3.1 Pressure/Temperature Settings The following table is provided to assist with the normal settings of the system for R410A refrigerant. Where applicable, minimum and maximum settings are given along with normal operating pressures. Table 2-11. R410A refrigerant pressure/temperature settings. Normal Min. Max. Sub-cooling °F 10 5 20 Superheat °F 15 10 20 Design Condensing Temp.
Chapter 2: Installation 2.11 Settings and Adjustments 2.11.1 Water–Water/Glycol Circuit Condensing temperature is maintained by liquid flowing through a regulating valve and then into the condenser. The regulating valve opens to increase the liquid flow as the refrigerant pressure rises (or closes as the refrigerant pressure falls). The system controller monitors a signal from a pressure transducer to determine how far to open the valve.
Chapter 3: Startup/Commissioning 3. Startup/Commissioning 3.1 Initial Operation For new installations, make sure the unit is ready to operate by going through the Checklist for Completed Installation, located in Appendix A, before startup. NOTE: A Warranty Registration and Startup Checklist is provided in the unit data package. Complete it during startup and send it to Black Box Technical Support. This checklist should be used as a guideline for items that need to be confirmed during startup.
Chapter 4: E2 Controller 4. E2 Controller 4.1 General The advanced microprocessor-based E2 Series controller is a highly versatile and flexible A/C system controller. It is designed primarily for precision air conditioners. The controller is equipped with flexible software capable of meeting the specific needs of the application. The controller is completely programmed at the factory and most applications will require no field setup.
Chapter 4: E2 Controller 4.1.2 User Interface Display Panel Your unit is equipped with an interface display panel typically mounted on the front panel of the A/C unit. Figure 4-1. User interface display panel. The user interface display panel features an easy-to-read, backlit liquid-crystal alphanumeric display equipped with LED illuminated function keys. The screens that appear on the user interface display panel present data that originates from the controller I/O module (Figure 4-1).
Chapter 4: E2 Controller 4.1.2.2 Contrast Adjustment Press and hold the Alarm and Prg keys, then use the Up and Down keys to adjust the contrast. 4.1.2.3 Alarms Alarm conditions activate a red LED indicator that backlights the alarm function key. As an option, an alarm condition may also be enunciated by an audible alarm signal. An alarm is acknowledged by pressing the alarm key. This calls up alarm display screen(s) that provide a text message detailing the alarm condition(s).
Chapter 4: E2 Controller 4.1.4 BMS Interface The E2 series controller may incorporate a Building Management System (BMS) network card equipped with a communication port (Figure 4-3). This can be field connected through a serial interface to a Building Management System via Modbus, BACnet, SNMP, or HTTP protocol as configured by the factory. A controller intaced to a network must be configured for BMS communication. Figure 4-3. BACnet MS/TP BMS interface port. Figure 4-4. Modbus RTU BMS interface port.
Chapter 4: E2 Controller 4.2 Navigating Controller Display Screens 4.2.1 Menu Selection The E2 Series controller provides five user-selectable menus needed to view operating data and enter setpoints for the system (see Figure 4-6). These menus may be accessed from a scrolling Main Menu screen by pressing the Program key. You are then allowed to scroll between adjacent menu selections within the Main Menu by using the up and down arrow keys.
Chapter 4: E2 Controller 4.2.3 Display Variables The user interface display panel provides screens with three different forms of both the read-only and the modifiable variables: • Numbers are displayed as positive (+) or negative (-) integers. • Dual-State can be toggled between two (2) values, i.e. On/Off, Yes/No. • Word Variables have a unique text message for each of the variable's possible choices. 4.2.
Chapter 4: E2 Controller 4.2.5 Modifiable Variables Figure 4-9. Modifiable variable. Pressing the Enter key accepts the value displayed and advances the cursor to the next modifiable field. You can use the Up or Down key to modify the values of these fields. If the modifiable field is a positive (+) number, the positive value is indicated by the absence of a (+) or (-) symbol. The (-) negative symbol will be displayed to the left of the first digit for negative numbers. 4.2.
Chapter 4: E2 Controller Operators who are allowed access to the Service menu (Level 2) for example, must know the password to enter that level. If the entered password equals or exceeds the level requested during a given session, the operator is allowed to access the requested loop. For example, if the entered password allows access to Level 2 and the Control menu (Level 1) is requested, access will be allowed.
Chapter 4: E2 Controller NOTE: You may turn the A/C unit on and off at any time by pressing and holding the Enter key for 3 seconds. Other status messages that may appear at the bottom of the screen are: “OFF by remote shutdown” indicates the Remote Start/Stop feature is enabled and requires a remote start switch to be turned On.
Chapter 4: E2 Controller Figure 4-14. Flashing cursor. Change the "0" to "1" (or to the current Control menu password if it was changed in the Service menu) with the Up arrow key and then press the Enter key to accept the password. Press the Enter key again to access the Control menu screens. 4. From the Control menu, select Setpoints by scrolling through the menu selections with the Up pressing the Enter key when “SET” appears in bold capital letters in the center of the screen.
Chapter 4: E2 Controller 8. Observe the indicator symbols in the Main screen to determine if the unit is operating in the required mode(s). 9. One to six hours may be required to see the desired temperature/humidity level in the conditioned space. Once room conditions have been programmed or set, a repeat visit to the conditioned site may be required to ensure the air conditioner is meeting the room's requirements.
Chapter 4: E2 Controller Figure 4-18. Control inputs and outputs. The E2 controller continually analyzes the demand for cooling, humidifying, and dehumidifying against the control setpoints and determines the appropriate response (control output signals) to operate the A/C system. The controller is equipped with analog input positions for monitoring temperature and humidity sensor(s).
Chapter 4: E2 Controller 4.4.1.2 Proportional/Integral (P/I) Control The controller calculates proportional control output signal(s) based on the analysis of input signals and then determines the air conditioner’s required mode(s) of operation. Signals representing temperature and humidity are each compared by the controller as a percentage value to the maximum control setpoint value resulting in control output values that are directly proportional to the input signal.
Chapter 4: E2 Controller Figure 4-19. Dewpoint control. 4.4.3 Operating Configurations The operating configuration for the controller depends on what type of air conditioner is being controlled (that is, AR, CW, W/G) and what features are selected. The operating configuration is preset by the factory according to the application. If certain features discussed in this manual are not factory enabled, no screens for that feature will appear in the controller user interface display. 4.4.3.
Chapter 4: E2 Controller 4.4.3.2 Water–W/G Operation When the system is turned on, the controller activates the fluid supply control valve with a proportional/integral (P/I), 0–10 VDC signal. The valve opens proportionally based on head pressure. The control parameters are adjustable in the Factory menu. If adjustment is required, contact Black Box Technical Support at 724-746-5500 or info@blackbox.com.
Chapter 4: E2 Controller 4.4.4.1 Independent Fan Speed Control The system controller may be configured for independent, variable fan speed control for managing upper, middle, and lower zone cooling.
Chapter 4: E2 Controller “Control” allows modification of basic control parameters such as setpoints and clock. Level 1 password is needed to enter this menu. “Service” allows modification of advanced control parameters such as offsets, blower speed, and BMS setup, and permits the user to save customer parameters and reset the controller to the customer or factory default values. Level 2 password is needed to enter this menu.
Chapter 4: E2 Controller 4.5.2 Information Menu Loop The Info menu screens may be accessed from the Main screen by simply scrolling with the Up and Down arrow keys. The same screens may also be viewed if you enter the Info menu by pressing the “Prg” key. The Info menu displays screens that provide current temperature and relative humidity conditions and shows the modes the A/C system is currently operating. There are no adjustable parameters in this loop.
Chapter 4: E2 Controller You may lock any of the status display screens, bypassing the display screen time-out function. This is sometimes useful to maintain visibility to a specific screen when testing, making adjustments, or troubleshooting the system. Simultaneously press the program key and Enter key for approximately 3 seconds to turn the screen lock feature On or Off.
Chapter 4: E2 Controller 4.5.2.10 EHGB Status Displays the current operating position of the electronic hot gas bypass valve. The current suction temperature appears below. The bar gauge next to the valve icon provides a visual representation of the output signal controlling the valve position. 4.5.2.11 Fan Status The Fan Status screen displays symbols indicating the operating status of the upper, middle, and lower fans. The symbols are animated when the fans are running.
Chapter 4: E2 Controller 4.5.3 Alarm Log Figure 4-23. Alarm Log screen. No password is required to view alarm display messages. If an alarm condition occurs, the first active alarm may be displayed by key. The alarm screen display text message will remain unchanged until the alarm condition is cleared. pressing the If the alarm log is entered from the main menu, any other active alarm message(s) may be viewed by using the Up arrow keys to scroll through alarm messages. and Down 4.5.3.
Chapter 4: E2 Controller 4.5.3.4 Alarm Screen Messages Table 4-3. Alarm screen messages. Alarm Release Description of Alarm Conditiion High Temperature Air temperature is above user-defined alarm setpoint. Low Temperature Air temperature is below user-defined alarm setpoint. High Humidity Humidity is above user-defined alarm setpoint. Low Humidity Humidity is below user-defined alarm setpoint. Sensor Failure Sensor is disconnected or faulty. (The failed sensor is identified.
Chapter 4: E2 Controller 4.5.4 Control Menu Loop From the Control Menu, you may select from four screen menus: Setpoints, Alarm Setpoints, Clock, and Version. The controller may be programmed by the user to require Level 1 password authorization to enter this menu loop (see Section 4.2.6). Once password access is granted, you may select and adjust the setpoints controlling the performance of the unit, enable alarms and determine their setpoints, and set the clock.
Chapter 4: E2 Controller 4.5.4.1 Setpoint Screens Figure 4-25. Set screen. The Setpoints (SET) screens below may be accessed from the Control menu. Figure 4-26. Temperature/Humidity Setpoint screens. The Temperature and Humidity Setpoint screens enable you to view and adjust the control setpoints and compare them to system level operating data derived from the various sensor/transmitter inputs. Figure 4-27. Fan Control screens, linked.
Chapter 4: E2 Controller When fans are not linked, the controller adjusts the speed of each fan as necessary for that zone to meet the supply air temperature setpoint. When the system is in the dehumidification mode, the fan speeds are automatically linked and controlled to the same speed. 4.5.4.2 Alarm Setpoint Screens Figure 4-29. Alarm Set screen. You can access the Alarm Setpoints screens from the Control menu.
Chapter 4: E2 Controller Figure 4-33. Low humidity alarm. Following the alarm enable screens are the alarm offset screens. From these screens, you may adjust offsets for the high and low alarm setpoints at which the alarm will be cancelled. The entered offset applies to both the upper and lower values entered in the alarm setpoints screens. The offset is subtracted when it's applied to the high alarm setpoint and it is added when it’s applied to the low alarm setpoint.
Chapter 4: E2 Controller Dirty Filter Timer Figure 4-36. Dirty filter timer. This screen allows you to enable the dirty filter notification timer, which provides an alarm indication when it’s time to clean or change the air filter. The filter change period is adjustable and should be set according to the conditions at the site. Extremely dusty environments may require more frequent filter changes. 4.5.4.3 Clock Screen Figure 4-37. Clock screen. The Clock screens may be accessed from the Control menu.
Chapter 4: E2 Controller Figure 4-40. Service menu loop selections. 4.5.5.1 Humidity The cut-in/cut-out offsets for the Dehumidification modes may be adjusted from the Service>Humid menu. Figure 4-41. Humidity screens. 724-746-5500 | blackbox.
Chapter 4: E2 Controller 4.5.5.2 Alarms Figure 4-42. Alarms screens. A log of events is stored for view from the Service>Alarms menu. This menu displays the last 50 events sequentially numbered in order of occurrence. The alarm log is cleared by pressing the Alarm key while in this menu. NOTE: If the Alarm key is pressed when in any of the Service>Alarms screens, all stored alarm messages will be permanently erased from the controller's memory. Page 72 724-746-5500 | blackbox.
Chapter 4: E2 Controller 4.5.5.3 Sensors Figure 4-43. Service>Sensors screen. From the Service>Sensors menu, you may access multiple display screens to enter offsets for calibrating the unit’s various temperature, humidity, and pressure sensors. Figure 4-44. Display screens. Additional sensor offset screens are available for optional sensors if enabled at the factory such as: Remote Supply Air Temp and Remote Supply Air Humidity.
Chapter 4: E2 Controller 4.5.5.4 Blower Figure 4-45. Blower screen. From the Service>Blower menu, you may access screens to view and adjust the blower speed parameters. Temp Zone Setup Figure 4-46. Temperature zone setup screen. If your unit is configured for zone temperature control, Blower>Temp Zone display screens are available for the upper, middle, and lower fan.
Chapter 4: E2 Controller Figure 4-48. Fans will run at 60% of full speed during dehumidification. If the Dehum Speed is set to 80%, the lower fan will run at 75% during dehumidification as it is limited by the maximum speed setting for the lower temperature zone. Figure 4-49. Lower fan will run at 75% of full speed during dehumidification (limited by the temperature zone maximum). 4.5.5.5 Options Menu Loop Figure 4-50. Options Menu Loop screen.
Chapter 4: E2 Controller = For future use. DO NOT select this control method. “Auto on powerup” If set to On, the A/C unit turns on automatically when main power is applied. “Auto on remote” If set to On, the A/C unit may be turned on via a remote On/Off switch. “EPO Option” (Emergency Power Off)-—If set to On, the off delay timers are bypassed so compressors, blowers, etc. stop operating immediately when the unit is turned off by a remote on/off signal or a critical alarm.
Chapter 4: E2 Controller EXAMPLE 1: Temperature Offset Multiplier With the default cut-in offset for temperature at 2.0° F, a multiplier of 1.0 x 2° F = 2° F. This means the unit will begin operating in the cooling mode at 74.0° F (Setpoint 72.0° F + Offset 2° F). Conversely, with the default cut-out offset at 0.3° F, the cooling mode will turn off at 72.3° F. EXAMPLE 2: Temperature Offset Multiplier If 2.0 is entered, the offset for temperature is multiplied by 2.0. (2.0 x 2° F= 4° F).
Chapter 4: E2 Controller NOTE: Display screens shown with a dashed border appear only if the application feature is enabled. Custom Alarm Setup (Optional) The E2 controller may be enabled to activate a Custom Alarm output and energize a designated N.O./N.C. relay. A custom alarm output is set up by adding the binary bitmask numbers assigned to the specific alarms and signal failures you wish to monitor via the relay and then entering them in the Custom Alarm Setup screen. Figure 4-56.
Chapter 4: E2 Controller Table 4-5. Alarms 9 to 16.
Chapter 4: E2 Controller Table 4-7. Alarms 25 to 32 (Sensor failure alarms). Number Description Bitmask Default 25 Lower temperature sensor fail 1 1 26 Middle temperature sensor fail 2 2 27 Optional temperature sensor fail 4 4 28 Upper temperature sensor fail 8 8 29 Return humidity sensor fail 16 16 30 DX1 discharge pressure fail 32 32 31 Static air pressure sensor fail 64 64 32 DX1 suction press sensor fail 128 128 255 Factory Default Bitmask Total Table 4-8.
Chapter 4: E2 Controller Table 4-9. Alarms 41 to 48. Number Description Bitmask Default 41 System Off 1 0 42 BMS keep alive off 2 0 43 Customer alarm 2 4 0 44 Customer alarm 3 8 0 45 Flow switch alarm 16 0 46 Reserved 32 0 47 Reserved 64 0 48 Reserved 128 0 Factory Default Bitmask Total 0 Workgroup Screens The Service>Group display screens shown below only appear if two or more units are wired together as a group.
Chapter 4: E2 Controller 4.5.5.6 Digital In Figure 4-58. Digiral In screens. The Service>Digital In screen is provided for information only. It shows the state of each digital input as either Closed (+24 V) or Open (Gnd). 4.5.5.7 Run Hours Figure 4-59. Run hours screens. From the Service>Run Hours menu, you may access a loop consisting of the component run hours display screens applicable to your unit using the Up and Down arrow keys.
Chapter 4: E2 Controller 4.5.5.8 BMS Communications Figure 4-60. BMS Communcations screens. The Service>BMS Comm menu is used to set up parameters to allow a BMS (BAS) to interface with the controller. See Section 4.7.2 for a description of this screen and instructions for setting up BMS communication. 4.5.5.9 Save Configuration Figure 4-61. Save Configuration screen. The default setpoints may be restored and passwords may be changed from the Service>Save Cfg menu. Figure 4-62. Customer Save screen.
Chapter 4: E2 Controller Table 4-10. Factory default setpoints. Parameter Default Value Temperature Setpoint 72° F Compressor Cut- in 74° F Compressor Cut- out 72.3° F Minimum Fan Speed 40% Maximum Fan Speed 100% Dehumidification Fan Speed 60% Humidity Setpoint 45% RH Dehumidify Cut-in 50% RH Dehumidify Cut-out 47% RH Figure 4-63. Set Passwords screen. The second Service>Save Cfg menu screen allows you to set new passwords for entering the Control and Service menus. 4.5.5.
Chapter 4: E2 Controller 4.6 Communication with the Controller It is possible for the E2 controller to communicate in multiple ways. The controller may be set up to use a pLAN network to link with additional E2 controllers to create a workgroup consisting of multiple A/C units (see Section 4.6.1). Using an expansion card, the unit may also be connected to a BMS for monitoring and control of data points using a variety of different serial communication protocols (see Section 4.7). Figure 4-65.
Chapter 4: E2 Controller One controller may be designated as the workgroup lead and networked with the controllers from a series of up to 7 additional A/C units. If configured for multi-unit operation, the workgroup lead controller display panel allows access to the same data and group control sensor choices that are available from networked system controller display panels. 4.6.1.
Chapter 4: E2 Controller A workgroup should ALWAYS start with controller address 1 and go up from there. DO NOT skip over controller addresses. The list of suitable controller/display terminal address pairs is shown below: Table 4-11. Corresponding Controller to Terminal pLAN Addresses. Controller (I/O board) 1 2 3 4 5 6 7 8 Display Terminal 32 31 30 29 28 27 26 25 You must assign the terminal and controller I/O board addresses for each controller to be grouped. Review Sections 4.6.2.
Chapter 4: E2 Controller 4.6.2.2 Configure the Controller (I/O Board) pLAN Address Immediately after turning power back on, press and hold the Alarm and the up-arrow keys simultaneously for 10 to 15 seconds. First you will see a display message “self test please wait” then the pLAN Address Configuration screen shown below will appear. Don’t press the Enter key; the cursor is already in the modifiable field. Figure 4-70. pLAN Address screen. key to set the pLAN address (1–8) for the controller (I/O board).
Chapter 4: E2 Controller 8. Enter the field “Ok?No,” choose ”Yes“ using the up-arrow save the data and exit the group setup procedure. and down-arrow keys and confirm by pressing Enter to 9. Referring to the wiring diagram provided with your A/C units, interconnect the units together with the pLAN cable(s) provided. 4.6.2.4 Fault Messages If the terminal detects the status of the I/O board it is associated with is off-line, the display shows the message: “I/O Board xx fault.
Chapter 4: E2 Controller Figure 4-73. Firmware version. To exit the Network Status loop, press Enter . The next step is to access the Factory>Group screens used to configure the workgroup parameters (Section 4.6.2.6). 4.6.2.6 Configure Workgroups The Factory>Group menu screens only appear when multiple A/C units are grouped. These menu screens allow you to define grouping parameters (duty, rotation, offsets, etc.) for the A/C units in the workgroup.
Chapter 4: E2 Controller Figure 4-76. Factory>Groups>Groups Config (Screen 1). (See Table 4-12.) Table 4-12. Factory>Groups>Groups Config (Screen 1) parameters. Display Description Description Variables Default 0= Out of Service 1= Active Unit Assign the duty of the A/C unit within the group. 2= Standby The duty must be assigned for each A/C unit at its local display terminal.
Chapter 4: E2 Controller Table 4-13. Factory>Group>Group Rotation (Screen 2) parameters. Display Description Description Variables Default Force Rotation This field only appears on the lead controller. If you select “On” and press ( ) it initiates a manual rotation cycle to rotate duty between active and standby units. It also rotates the role of lead controller. The fi eld will disappear after the role of Lead is rotated to the next A/C unit.
Chapter 4: E2 Controller Table 4-15. Factory>Group>Capacity Assist (Screen 4) parameters. Display Description Description Variables Default Humid Cut in Enter relative humidity setpoint offset for humidifying capacity assist operation to begin. -99.9 to 99.9 -4.0 Cut out Enter relative humidity setpoint offset for humidifying capacity assist operation to stop. -99.9 to 99.9 0.0 Dehum Cut in Enter relative humidity setpoint offset for dehumidifying capacity assist operation to begin. -99.
Chapter 4: E2 Controller Table 4-17. Group alarms 1 to 8. Number Description Bitmask Default 1 Humidifier 1 0 2 Pump 2 0 3 Customer alarm 1 4 0 4 Circuit 1 high pressure 8 0 5 Circuit 1 low pressure 16 0 6 DX lockout 32 0 7 Humidifier lockout 64 0 8 FC/AWS lockout 128 0 Table 4-18. Group alarms 9 to 16.
Chapter 4: E2 Controller Table 4-19. Group alarms 17 to 24. Number Description Bitmask Default 17 High temperature 1 0 18 Low temperature 2 0 19 High humidity 4 0 20 Low humidity 8 0 21 High water temperature CW1 16 0 22 Low water temperature CW1 32 0 23 Reserved 64 0 24 Reserved 128 0 Table 4-20. Group alarms 25 to 32.
Chapter 4: E2 Controller Table 4-21. Group alarms 33 to 40. Number Description Bitmask Default 33 Static air pressure 1 0 34 Differential air pressure 2 0 35 Dewpoint 4 0 36 Airspeed 8 0 37 Reserved 16 0 38 Reserved 32 0 39 Reserved 64 0 40 Reserved 128 0 There are several automatic crossover signals that will cause a switchover from Unit Active to Unit Off.
Chapter 4: E2 Controller Factory>Group>Group Status (Screen 8) provides an overview of the current duty status for all the A/C units combined in the group. Table 4-23. Factory>Group>Group Status (Screen 8) parameters. Display Description Description Variables Default Running Display indicates how many units in the group are currently operating. 0 to 8 0 Active Display indicates how many units in the group are currently active.
Chapter 4: E2 Controller The Service>Options>Group Setup screen allows you to select the workgroup duty assignment for the A/C unit. The duty must be assigned for each grouped A/C unit at its local display terminal. Enter the number of days between rotating active units. Enter the hour of day for unit rotation to occur. The screen also displays a status message indicating which A/C unit you are accessing and which unit is currently the lead unit in the group. Capacity Assist Figure 4-86.
Chapter 4: E2 Controller The Service>Options>Group Sensors screen allows you to select whether to control the A/C workgroup using the T/H sensors connected to individual A/C units (Local) or control the workgroup using network sensor values transmitted from the lead controller. You may select the network sensor values to be the Lead, Average, Min, or Max values. The selections made in this screen will affect all the controllers in the workgroup no matter which controller you access the screen from.
Chapter 4: E2 Controller Group Sensor Values This displays the current group temperature and humidity control values transmitted from the Lead controller. The field below displays the selected control T/H sensor arrangement (lead, avg, min, max, local) depending upon how the group is set up. See Service>Options screens, Section 4.6.2.7. The last field shows the unit group address assigned to the controller within the group and the address of the current lead controller.
Chapter 4: E2 Controller The number shown for Unit 2 is three, the result of adding 1 + 2. This confirms that Unit 2's supply temperature and return humidity sensors are detected by the lead controller. If a one appeared instead for Unit 2, it would indicate the signal for the return humidity sensor is not present. That sensor is either not enabled or it has failed. 4.
Chapter 4: E2 Controller 4.7.1 Direct BMS Control The controller may be configured to accept proportional analog signals that mimic a sensor. The controller will act on that signal whether it comes from a real sensor or a BMS analog output. Refer to Section 4.9 for the E2 controller's BMS parameters. 4.7.2 BMS Communication Figure 4-92. BMS Comm screen #1.
Chapter 4: E2 Controller 4.8 Troubleshooting the Control I/O Module Signal LEDs The E2 control I/O module includes three signal LEDs (red, yellow, and green) that provide information on the operation of the control module and status of the connection to the pLAN. These signal LEDs are positioned adjacent to the yellow “Power On” LED (see Figure 4-2). The signal LEDs may be used for diagnostic purposes if a problem arises with the controller. Key: LED off LED on LED flashing Table 4-26.
Chapter 4: E2 Controller 4.9 BMS Parameters, Version 1.2 Table 4-27. BMS parameters.
Chapter 4: E2 Controller 4.9.1 Signed Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet Table 4-28. Signed Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet. BMS Address Modbus Address BACnet Address Description Default Read/Write 1 002 1 Temperature setpoint 72.0 R/W 2 003 2 Humidity setpoint 45.0 R/Ws 3 004 3 Average supply temperature display value 0.0 R 4 005 4 Return humidity sensor current value 0.
Chapter 4: E2 Controller 4.9.2 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet Table 4-29. Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet.
Chapter 4: E2 Controller Variable/Value Descriptions Table 4-30. Variable/Value Descriptions.
Chapter 4: E2 Controller 4.9.4 Alarm Packed Bit Variables Table 4-32. Alarm-Packed Bit Variables.
Chapter 4: E2 Controller 4.9.5 Sensor Failure Packed Bit Variables Table 4-33. Sensor Failure Packed Bit Variables.
Chapter 4: E2 Controller 4.9.6 Digital Input Packed Bit Variables Table 4-34. Digital Input Packed Bit Variables.
Chapter 4: E2 Controller 4.9.7 Digital Output Packed Bit Variables Table 4-35. Digital Output Packed Bit Variables.
Chapter 4: E2 Controller 4.9.8 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet Table 4-36. Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet. BMS Address Modbus Address BACnet Address Description Default Direction 100 229 1100 BMS keep alive parameter 0 R/W 101 230 1101 BMS low fan speed for CW units 0 R/W 102 231 1102 BMS run fan speed for CW units 0 R/W 103 232 1103 BMS dehum fan speed for CW units 0 R/W 4.9.
Chapter 5: Maintenance 5. Maintenance 5.1 Periodic General Maintenance Systematic, periodic general maintenance of the Cold Row unit is required for optimum system performance.
Chapter 5: Maintenance F Fgure 5-1. Cleanable filters. Clean the filter media using a vacuum cleaner, low-pressure compressed air, or rinse with water. A mild detergent such as dishwashing liquid may be used. DO NOT use solvents or cleaning agents. Replace the filters every 2 to 3 years when they become too flimsy. Page 114 724-746-5500 | blackbox.
Chapter 5: Maintenance 5.1.1.2 Cartridge Filters Replaceable cartridge filters are held in place by an end cap in the bottom of the rear access panel. Lay the access panel down on a piece of cardboard and remove the four screws holding the end cap in place. Remove the end cap and slide the old filters out of the tray as shown in Figure 5-2. Slide the new filters into the tray and replace the end cap. Ensure the four screws are fully tightened. REAR ACCESS PANEL (4) SCREWS END CAP Figure 5-2.
Chapter 5: Maintenance 5.1.6 A/C System Check the refrigerant sight glass on a monthly basis while the unit is running and ensure it is free of bubbles. Bubbles in the sight glass indicate a low refrigerant charge or a clogged filter-drier. Check for humidity in the refrigerant by viewing the color of the indicator in the center of the sight glass and comparing it to the color scale on the outer ring. If humidity is present, the system must be evacuated and recharged.
Chapter 5: Maintenance Symptom: Control is erratic. Probable Cause: Wiring improperly connected or broken. Recommendation: Check wiring against electrical drawing. Symptom: Compressor fails to start Probable Causes/Recommendations: a. Temperature setpoint too high. Adjust to desired temperature. b. Compressor internal overload protector is open. Check compressor for short circuit or ground. c. Complete loss of refrigerant charge (low pressure safety switch tripped). Locate and repair leak.
Chapter 5: Maintenance Symptom: Water–water/glycol valve fails to open or close. Probable Causes/Recommendations: a. Temperature setpoint too high. Adjust to correct temperature setting. b. No control power to the valve. Valve actuator is wired incorrectly. Check wiring diagram and rewire if required. c. Actuator failed. Replace actuator. Symptom: Condenser pressure too high (CRDX-A-FS-12KW, CRDX-A-FS-24KW units). Probable Causes/Recommendations: a. Non-condensable gas or air in the system.
Chapter 5: Maintenance Symptom: Noisy compressor. Probable Causes/Recommendations: a. Expansion valve stuck in open position (abnormally cold suction line). Ensure feeder bulb is tight on suction line. Check operation and superheat. b. Broken compressor valve (compressor knocking, suction pressure rises faster than 2 lb./min. after shutdown). Replace compressor. c. Worn or scarred compressor bearings. Replace compressor. d. Liquid slugging. System overcharged. Reclaim excess refrigerant. e.
Chapter 5: Maintenance 5.3.2.3 Refrigerant Piping When replacing components within the cabinet of the unit, the following consumable materials are recommended: When brazing copper-to-copper connections (piping liquid line or suction line), use a phosphorus copper brazing alloy with 15% silver. Use general-purpose silver brazing alloy with 45% silver for copper-to-brass or copper-to steel.
Chapter 5: Maintenance 5.3.3.2 Standard Cleanout Procedure 1. Turn off power to unit at the main power disconnect switch. 2. Remove the old compressor and install the new compressor. 3. Remove the liquid line drier and install an oversized liquid line filter-drier (one size larger than the normal selection size). 4. Evacuate the system according to standard procedures. Normally, this will include the use of a high-vacuum pump and a lowvacuum micron gauge for measuring the vacuum obtained. 5.
Chapter 5: Maintenance INLET RING FAN INLET RING M6 HEX BOLTS— TWO PER SIDE M5 HEX BOLTS— TWO PER SIDE POWER/CONTROL CONNECTORS Figure 5-3. Fan. 5.3.4.2 Condensate Pump Replacement The condensate pump is located behind the lower cabinet fan assembly. To access the pump, the lower fan must be removed as described in Section 5.3.4.1. PUMP CABLE LOOP RETAINING CLIP DISCHARGE LINE WIRE TIE Figure 5-4. Condensate pump. Reach inside the fan opening to grasp the pump.
Chapter 6: Troubleshooting 6. Troubleshooting Black Box provides its customers with Technical Support that not only provides technical support and parts but also the following additional services, as requested: • Performance Evaluations • Start-up Assistance • Training 6.1 Technical Support If a problem develops that cannot be resolved using this manual, contact Black Box Technical Support at 724-746-5500 or info@blackbox.com.
Chapter 6: Troubleshooting Quotes are given for specified listed parts for a specific unit. A 25% minimum restocking charge will be applied on returned stocked parts that were sold as spare/replacement parts. If the returned part is not a stocked item, a 50% restocking charge may be applied. Additionally, a Return Material Authorization Number is required when returning parts.
Appendix A: Forms Appendix A. Forms A.1 Checklist for Completed Installation of Cold Row DX 1. Proper clearances for service access have been maintained around equipment. 2. Equipment is level and mounting fasteners are tight. 3. Field-installed piping completed. 4. All field installed piping leaks tested. 5. Condensate drain line connected. 6. Water supply line connected to humidifier (if applicable). If manual cut-off valve is installed, open valve. 7.
Appendix A: Forms A.2 Periodic General Maintenance Checks and Services Checklist for Cold Row DX Date: ____________________________ Prepared By: ___________________________ Model Number: ____________________________ Serial Number: __________________________ Item Number: ____________________________ Monthly Filters: Blower Section: Cleanliness. Blower turns. Condensate Drain: Drain is open. ondensate pan safety switch C operates freely.
Appendix B: Glossary: Definition of Terms and Acronyms Appendix B.
Appendix B: Glossary: Definition of Terms and Acronyms VDC: Volt, direct current WG: Water Glycol Page 128 724-746-5500 | blackbox.
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