AIREDALE LogiCool OnRak Quick start guide

LogiCoolOnRak
IT Cooling
T e c h n ic a l , I n s t a ll a t i on , O p e ra t i o n a l a n d
M a i n te n a n c e M a n u a l

LogiCoolOnRak
IT Cooling
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IT Cooling
Technical, Installation and Maintenance Manual :6912497 V1.8.0_08_2014
About Airedale Products & Customer Services
Warranty, Commissioning
& Maintenance
As standard, Airedale guarantees all non consumable parts only for a period of 18 months,
variations tailored to suit product and application are also available; please contact
Airedale for full terms and details.
To further protect your investment in Airedale products, Airedale can provide full
commissioning services, comprehensive maintenance packages and service cover 24
hours a day, 365 days a year (UK mainland). For a free quotation contact Airedale or your
local Sales Engineer.
All Airedale products are designed in accordance with EU Directives regarding prevention
of build up of water, associated with the risk of contaminants such as Legionella.
For effective prevention of such risk it is necessary that the equipment is maintained in
accordance with Airedale recommendations.
CAUTION
Warranty cover is not a substitute for maintenance. Warranty cover is conditional to
maintenance being carried out in accordance with the recommendations provided during
the warranty period. Failure to have the maintenance procedures carried out will
invalidate the warranty and any liabilities by Airedale International Air Conditioning Ltd.
Spares
A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from
our Spares department on request.
Training
As well as our comprehensive range of products, Airedale offers a modular range of
Refrigeration and Air Conditioning Training courses, for further information please contact
Airedale.
Customer Services
For further assistance, please e-mail: [e-mail] or telephone:
UK Sales Enquiries
+ 44 (0) 113 238 7789
[e-mail]
International Enquiries
+ 44 (0) 113 239 1000
[e-mail]
Spares Hot Line
+ 44 (0) 113 238 7878
[e-mail]
Airedale Service
+ 44 (0) 113 239 1000
[e-mail]
Technical Support
+ 44 (0) 113 239 1000
[e-mail]
Training Enquiries
+ 44 (0) 113 239 1000
[e-mail]
For information, visit us at our Web Site: www.airedale.com
Legal Notices
AIAC Ltd endeavours to ensure that the information in this document is correct and fairly stated, but none of the
statements are to be relied upon as a statement or representation of fact. AIAC Ltd does not accept liability for any
error or omission, or for any reliance placed on the information contained in this document.
The development of Airedale products and services is continuous and the information in this document may not be
up to date. It is important to check the current position with AIAC Ltd at the address stated. This document is not
part of a contract or licence unless expressly agreed.
No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or information storage and retrieval systems, for any purpose other than the
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Cover image for illustration only
¤2014 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.

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Technical, Installation and Maintenance Manual :6912497 V1.8.0 _08_2014
Warranty
Warranty
All AIAC products or parts (non consumable) supplied for installation within the UK mainland
and commissioned by an AIAC engineer, carry a full Parts & Labour warranty for a period of 12
months from the date of commissioning or 18 months from the date of despatch, whichever is
the sooner.
Parts or Equipment supplied by AIAC for installation within the UK or for Export that are
properly commissioned in accordance with AIAC standards and specification, not
commissioned by an AIAC engineer; carry a 12 month warranty on non consumable Parts only
from the date of commissioning or 18 months from the date of despatch, whichever is the
sooner.
Parts or equipment installed or commissioned not to acceptable AIAC standards or
specification invalidate all warranty.
Warranty is only valid in
the event that
In the period between delivery and commissioning the equipment: is properly protected &
serviced as per the AIAC installation & maintenance manual provided where applicable the
glycol content is maintained to the correct level.
In the event of a problem being reported and once warranty is confirmed as valid under the
given installation and operating conditions, the Company will provide the appropriate warranty
coverage (as detailed above) attributable to the rectification of any affected Airedale equipment
supplied (excluding costs for any specialist access or lifting equipment that must be ordered by
the customer).
Any spare part supplied by Airedale under warranty shall be warranted for the unexpired period
of the warranty or 3 months from delivery, whichever period is the longer.
To be read in conjunction with the Airedale Conditions of Sale - Warranty and Warranty
Procedure, available upon request.
Procedure
When a component part fails, a replacement part should be obtained through our Spares
department. If the part is considered to be under warranty, the following details are required to
process this requirement.
Full description of part required, including Airedale's part number, if known
The original equipment serial number
An appropriate purchase order number
A spares order will be raised under our warranty system and the replacement part will be
despatched, usually within 24 hours should they be in stock.
When replaced, the faulty part must be returned to Airedale with a suitably completed and
securely attached "Faulty Component Return" (FCR) tag. FCR tags are available from Airedale
and supplied with each Warranty order.
On receipt of the faulty part, suitably tagged, Airedale will pass to its Warranty department,
where it will be fully inspected and tested in order to identify the reason for failure, identifying at
the same time whether warranty is justified or not.
On completion of the investigation of the returned part, a full "Report on Goods Returned" will
be issued. On occasion the release of this complete report may be delayed as component
manufacturers become involved in the investigation.
When warranty is allowed, a credit against the Warranty invoice will be raised. Should warranty
be refused the Warranty invoice becomes payable on normal terms.
Exclusions
Warranty may be refused for the following reasons:
xMisapplication of product or component
xIncorrect site installation
xIncomplete commissioning documentation
xInadequate site installation
xInadequate site maintenance
xDamage caused by mishandling
xReplaced part being returned damaged without explanation
xUnnecessary delays incurred in return of defective component
Returns analysis
All faulty components returned under warranty are analysed on a monthly basis as a means of
verifying component and product reliability as well as supplier performance. It is important that
all component failures are reported correctly.

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Health and Safety
IMPORTANT
The information contained in this manual is critical to the correct operation and
maintenance of the unit and should be read by all persons responsible for the installation,
commissioning and maintenance of this Airedale unit.
The equipment has been designed and manufactured to meet international safety
standards but, like any mechanical/electrical equipment, care must be taken if you are to
obtain the best results.
CAUTION
Installation, service and maintenance of Airedale equipment should only be carried out by
technically trained competent personnel.
CAUTION
When working with any air conditioning units ensure that the electrical isolator is switched
off prior to servicing or repair work and that there is no power to any part of the
equipment.
Also ensure that there are no other power feeds to the unit such as fire alarm circuits,
BMS circuits etc.
Electrical installation commissioning and maintenance work on this equipment should be
undertaken by competent and trained personnel in accordance with local relevant
standards and codes of practice.
Personal Protective
Equipment
Airedale recommends that Personal Protective Equipment is used whilst installing,
maintaining and commissioning equipment.
Electrical Bonding
It is important that the components attached to the server rack are electrically bonded to
earth correctly.
It is recommended that a mechanical earth strap is used at the following locations
xDoors
xMating Flange
xLogiCool OnRak
xLogiCool OnRak Chilled Water Coil
xDual Power Supplies

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Technical, Installation and Maintenance Manual :6912497 V1.8.0 _08_2014
CONTENTS
About Airedale Products & Customer Services ...................................................................... 2
Warranty ..................................................................................................................................... 3
Health and Safety....................................................................................................................... 4
Personal Protective Equipment .............................................................................................. 4
Electrical Bonding .................................................................................................................. 4
6SHFLILHU¶V*XLGH,QGRRU8QLW................................................................................................... 6
Nomenclature......................................................................................................................... 6
Introduction ............................................................................................................................ 6
Standard Features ................................................................................................................. 7
Optional Features................................................................................................................... 9
Technical Data.......................................................................................................................... 12
Design Parameters .............................................................................................................. 12
Cooling Performance LOR 6042U-C028-0 (N+1 configuration, Fans at 75%) ..................... 13
Cooling Performance LOR 6042U-C033-0 (N Configuration, Fans at 100%)....................... 14
Cooling Performance LOR 8042U-C032-0 (N+1 configuration, Fans at 75%) ..................... 15
Cooling Performance LOR 8042U-C038-0 (N Configuration, Fans at 100%)....................... 16
Ethylene Glycol Correction Factors...................................................................................... 17
Mechanical Data .................................................................................................................. 18
Electrical Data ...................................................................................................................... 18
Waterside Pressure Drop ..................................................................................................... 18
Dimensional Data................................................................................................................. 20
Component Masses ............................................................................................................. 20
Sound Measurement Method ............................................................................................... 21
Noise Data ........................................................................................................................... 21
Pipework Schematics........................................................................................................... 22
Installation................................................................................................................................ 24
Positioning............................................................................................................................ 24
Data Rack Feet .................................................................................................................... 25
Rack Support Wheel ............................................................................................................ 26
Wheel Adjustment ................................................................................................................ 26
Door Latch Mechanism ........................................................................................................ 27
Floor Cut Outs...................................................................................................................... 28
Water Connections............................................................................................................... 29
Flexible Water Connection ................................................................................................... 30
Pipework Sweep .................................................................................................................. 30
Compression Fittings............................................................................................................ 31
Chilled Water Valve (2+3 Way) ...................................................................................... 32
Solenoid Valve ..................................................................................................................... 34
Customer Terminal Box........................................................................................................ 35
Dual Power Supply............................................................................................................... 35
Rack Mounted Temperature / Humidity Sensor ................................................................... 38
Rack Pressure Management................................................................................................ 39
Rack Sealing ........................................................................................................................ 40
Interconnecting Wiring.......................................................................................................... 41
Automatic Fan Disconnect ................................................................................................... 42
Controls .................................................................................................................................... 43
Addressing the Display Keypad ........................................................................................... 43
Extra Functions Buttons ....................................................................................................... 45
Navigation ............................................................................................................................ 45
Enabling the Unit.................................................................................................................. 46
Dew Point Control ................................................................................................................ 47
Modulated Cooling ............................................................................................................... 47
Temperature Sensor Locations ............................................................................................ 48
Modes of Operation ................................................................................................................. 49
Temperature Neutral Mode .................................................................................................. 49
Load Neutral Mode............................................................................................................... 50
Rack Pressure Management................................................................................................ 51
Commissioning Procedure ..................................................................................................... 52
General ................................................................................................................................ 52
Maintenance ............................................................................................................................. 54
Operational Maintenance checks ........................................................................................... 55
Owners Responsibility.......................................................................................................... 55
Maintenance Schedule......................................................................................................... 55
Troubleshooting....................................................................................................................... 56

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6SHFLILHU¶V*XLGH,QGRRU8QLW
Nomenclature
Example:
LOR
60
42U
-
C
033
-
0
LOR
LogiCool OnRak
60
80
Case width in centimetres
42U
Unit height in U
-
Separator
C
Chilled water cooling
028
Nominal cooling capacity in kW
033
-
Separator
0
230V / 1Ph / 50Hz / 60Hz
Introduction
The OnRak is a compact rear door heat exchanger designed to manage discharge
temperatures from a server rack into the aisle space.
In dealing with the heat load closer to the source, the OnRak is highly efficient in floor
Space and power usage. Elevated air temperature combined with increased water
temperature allows the OnRak to take advantage of free cooling applications.
Part of the LogiCool range of IT cooling solutions, the OnRak offers an expandable
cooling system that can be supplied with an industry standard data rack (42 - 48U) or a
mating frame to fit a customer-specific rack.
The OnRak is available in both 600mm and 800mm widths.
The slim configuration of the OnRak ensures minimal impact into the aisle.
The OnRak air volumes are based on an N (All four fans operating 100%) and N+1 (fans
operating at a reduced speed to 75%). This configuration greatly increases the energy
efficiency ratio (EER) of the equipment.
CE Directive
Airedale certify that the equipment detailed in this manual conforms with the following
EC Directives:
Electromagnetic Compatibility Directive (EMC)
2004/108/EC
Low Voltage Directive (LVD)
2006/95/EC
Machinery Directive (MD)
89/392/EEC in the version
2006/42/EC
Pressure Equipment Directive (PED)
97/23/EC
To comply with these directives appropriate national & harmonised standards have been
applied. These are listed on the Declaration of Conformity, supplied with each product.
Maximum and Minimum Operation Temperature (TS) and Pressure (PS)
Operating Temperature (TS), TS = Min -20°C to Max 120°C *
Maximum Operating Pressure (PS) PS = High Side 26 Barg
*Based upon the maximum machine running temperatures.

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Technical, Installation and Maintenance Manual :6912497 V1.8.0 _08_2014
Standard Features
The OnRak unit comes with a series of standard features.
Standard Features
LOR 6042U-C0 28-0
LOR 6042U-C0 33-0
LOR 8042U-C032-0
LOR 8042U-C038-0
EC axial fans
y
y
y
y
EC fan node
y
y
y
y
0-10V 2 or 3 way chilled water valve
y
y
y
y
Advanced Airetronix controls
y
y
y
y
Water temperature sensor
y
y
y
y
Tri coloured LED (Alarm status) for easy fault detection
y
y
y
y
Rack mounted temperature / humidity sensor
y
y
y
y
Leak detection
y
y
y
y
Bleed and drain valves
y
y
y
y
yFeatures available

Construction
The cabinet shall be manufactured with galvanised sheet steel to provide a smooth
aesthetically pleasing finish. The galvanised sheet steel panels shall be coated with an
epoxy baked powder paint to provide a durable finish.
Standard unit colour shall be Black Grey to RAL 7021.
Fan & Motor Assembly
300mm diameter axial fans with EC motors mounted in bell mouth housing shall be
provided to ensure optimum efficiency.
The fan section shall be designed as a hot swap assembly which can be changed
quickly minimising downtime during replacement or maintenance.
Compact Cooling Coil
´SODLQWXEHFRROLQJFRLOZLWK8mm fin pitch and hydrophilic fins
0-10 Volts DC Chilled Water
3 Way Valve
A 0-10 VDC chilled water 3 way regulating valve shall be fitted. This shall be used to
govern the chilled water going to the coil when there is a demand for cooling.
or
0-10 Volts DC Chilled Water
2 Way Valve
A 0-10 VDC chilled water 2 way regulating valve shall be fitted. This shall be used to
govern the chilled water going to the coil when there is a demand for cooling.
Bleed and Drain Valves
Valves shall be factory fitted to easily bleed the system of any air and drain water for
maintenance.
Airetronix Controls
Advanced Airetronix controls strategy with integrated system control, free cooling mode,
dew point management, and fan and alarm management shall be provided.
Water Temperature Sensor
A water temperature sensor shall be fitted to the water inlet pipework.
Tri colour LED for Easy
Fault Detection
LED indication for alarm status shall be incorporated in the front face of the OnRak unit
(signals Healthy, Non Critical and Critical Alarm respectively) Green, Yellow and Red.

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Rack Mounted
Temperature/ Humidity
Sensor
Rack mounted temperature and Humidity sensor shall be supplied as standard. This
shall be supplied loose for onsite fitment in a customer rack.
Leak Detection
Leak detection for the water system, able to report alarm status to the BMS system shall
be provided. The unit shall then be shut down before any damage occurs.
The leak detection tape shall be fitted within the drip tray of the coil.
Bypass Regulating Valve
A bypass regulating valve shall be fitted in the bypass leg of the system to enable
constant flow when there is no cooling demand. This simulates the coil pressure drop
ensuring that the water flow rate does not change irrespective of amount of flow through
the chilled water coil.
This enables flow through each cooling module without the need for a Cooling
Distribution unit (CDU).
EC Fan Nodes
The fan nodes enable independent control. The fan can be interrogated by the controller
giving information such as temperature, fan speed, currents and power consumption.
If during a controller failure the fans resume operation at the last setpoint. This ensures
downtime is reduced.

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Technical, Installation and Maintenance Manual :6912497 V1.8.0 _08_2014
Optional Features
The OnRak unit comes with a series of optional features.
Optional Features
LOR 6042U-C0 28-0
LOR 6042U-C0 33-0
LOR 8042U-C032-0
LOR 8042U-C038-0
Various display options
y
y
y
y
Modbus / Carel BMS connection
y
y
y
y
Lon BMS connection
y
y
y
y
pCOWeb
y
y
y
y
BacNet protocol
y
y
y
y
Programming smart key
y
y
y
y
Threaded pipe connections
y
y
y
y
Quick coupling water connections
y
y
y
y
Flexible hoses of alternative lengths
y
y
y
y
Isolating solenoid valves
y
y
y
y
Dual power supply
y
y
y
y
Uninterrupted Power Supply
y
y
y
y
Static Transfer Switch
y
y
y
y
Room mounted temperature / humidity sensor
y
y
y
y
Rack Pressure Management
y
y
y
y
yFeatures available
Display Options
1. White backlit 8 x 22 character, semi-graphical LCD Display. Integrated for local
monitoring, adjustment of parameters and commissioning.
or
2. Semi-graphical LCD Display with Audible alarm.
or
3. Remote Handheld Display (unit fitted with RJ11 Connection port)
or
4. No Display (RJ11 Connection port only)
Modbus / Carel BMS
Connection
The Airedale controllers shall be able to communicate directly using the Modbus®
protocol.
The Modbus® card shall be a small PCB (60mm x 30mm), which can be plugged into
the controller to provide it with the following protocol support
xModbus® - JBus slave
xRTU mode (Remote Terminal Unit) with 8 bit encoding and error handling using
16 bit CRC
xCommunication standard connection options of RS485 (multipoint) or RS232
(point-point)
xMaximum Baud Rate of 19200
The data communication shall be asynchronous serial, 8 data bits, 2 stop bits and no
parity (in total 11 bits/datum).
The data/parameters from the controller shall be represented within Modbus® registers,
each register containing information pertaining to temperatures, pressures, setpoint,
status, etc and is available to the site integration company in a spreadsheet format

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Lon BMS Connection
The Airedale controllers, using special serial cards, shall be integrated into LonWorks®
networks. The RS485 and the FTT10 standards shall be supported by the LonWorks®
serial cards.
The two types of LonWorks® serial cards shall differ by the type of interface on the
LonWorks® network side:-
FTT-10A 78 kbs (TP/FT-10)
RS485 39 kbs (TP/485-39)
pCOWeb
pCOWeb is a new generation of Airedale supervisory plug-in cards which make
communicating with an Airedale unit simply a matter of logging onto the office Intranet or
via the web.
Based on Ethernet TCP/IP secure technology, pCOWeb shall require no proprietary
cabling. It shall have little or no set-up on site and can be pre-programmed with an IP
address prior to dispatch from airedale.
BacNet Protocol
The BACnet protocol option shall be supplied either with a pCOWeb (Ethernet) or
pCONet (RS485) interface card.
Programming Smart Key
A smart key shall be supplied to offer software back-up of the control strategy. The key
shall feature simple plug in operation and allow transfer of software programs from the
key to the microprocessor and vice versa. The use of a service laptop shall not be
necessary.
Water Pipework
Connections
Various water side connections shall be DYDLODEOH´%63(British Standard Pipe) and
1³self seal fittingsZLWK´%63FRQQHFWLRQV
Flexible Connections
Stainless steel flexible connections shall be supplied with the unit. They shall be
supplied either 1.5m or 3m long. Longer lengths can be provided. Please contact
Airedale.
Isolating Solenoid Valves
Isolating solenoid valves shall be fitted to the inlet and outlet connections. This shall
control the water flow to and from the cooling module in the event of fault or power
failure. The valves have a low pressure drop and are fast acting. The valves shall be
Normally Closed (NC) operation and are supplied loose.
Rack Pressure Management
The OnRak shall be fitted with rack pressure management, which allows the differential
pressure across the IT equipment to be monitored and controlled to achieve:
xPositive air pressure at the server inlet.
xNegative air pressure in the rear of the cabinet at the server outlet, to prevent
backwash of hot air (behind OnRak coil guard).
x&RQWUROOHGGLIIHUHQWLDOSUHVVXUHDFURVVWKH,7KDUGZDUHVRWKDWDLULVQRWµIRUFHG¶through the IT equipment.
Room Mounted
Temperature and Humidity
Sensor
A room mounted temperature and humidity sensor shall be supplied loose for onsite
fitment.