Compu-aire SYSTEM 2100 User manual

SYSTEM 2100
AIR COOLED CAA-6 TO 12 TON KOMPACT
-INSTALLATION OPERATIONS AND MAINTENANCE MANUAL
8167 Byron Road Whittier, CA 90606
Phone: [phone] Fax: [phone]
www.compu-aire.com

Rev. 01
Page 2 of 42
Compu-Aire
05/27/2016
Table of Contents
1.0 CONTACTING COMPU-AIRE FOR TECHNICAL ASSISTANCE ................................................................... 4
2.0 PRODUCT MODEL INFORMATION......................................................................................................... 5
3.0 GENERAL EQUIPMENT DESCRIPTION.................................................................................................... 7
4.0 RECEIPT OF UNIT AND TRANSPORTATION............................................................................................ 7
5.0 LOCATING THE UNIT ............................................................................................................................. 8
6.0 UNIT DIMENSIONS ..............................................................................................................................10
6.1 Front Layout................................................................................................................................11
6.2 Sensors........................................................................................................................................ 13
6.3 Low Voltage Control Panel.......................................................................................................... 13
6.4 Refrigeration Components.......................................................................................................... 14
6.5 Unit Left Access........................................................................................................................... 15
7.0 REMOTE ALARMS................................................................................................................................ 16
8.0 INSTALLATION..................................................................................................................................... 17
8.1 Room Preparation....................................................................................................................... 17
8.2 Location Considerations..............................................................................................................17
8.3 Piping...........................................................................................................................................18
8.4 Drain Connection ........................................................................................................................18
8.5 Refrigeration Piping ....................................................................................................................19
8.6 EVACUATION PROCEDURES .........................................................................................................20
8.7 Charging Procedure ..................................................................................................................... 21
8.8 Liquid Charge ............................................................................................................................... 22
8.9 Vapor Charge .............................................................................................................................. 22
8.10 Leak Testing ................................................................................................................................ 23
8.11 How to Save the Refrigerant Charge...........................................................................................23
8.12 Electrical Connection ..................................................................................................................24
9.0 STARTUP AND TEST PROCEDURE........................................................................................................25
10.0 GENERAL MAINTENANCE.................................................................................................................... 27
11.0 TROBLESHOUTING GUIDE ...................................................................................................................28

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12.0 REFERENCE DOCUMENTS ................................................................................................................... 38
Table of Figures
Figure 1: LOADING UNITS ............................................................................................................................. 8
Figure 2: SYSTEM OVERVIEW......................................................................................................................10
Figure 3: FRONT VIEW LAYOUT................................................................................................................... 11
Figure 4: HIGH VOLTAGE CONTROL PANEL LAYOUT................................................................................... 12
Figure 5: LOW VOLTAGE CONTROL PANEL LAYOUT ...................................................................................13
Figure 6 UNIT RIGHT ACCESS ......................................................................................................................15
Figure 7: TERMINAL BLOCK W/ SYSTEM CUT-OUT .....................................................................................16
Figure 8: P-TRAP SCHEMATIC...................................................................................................................... 18
Figure 9: DRAIN CONNECTION.................................................................................................................... 19
Figure 10: AIR PRESSURE DIFFERENTIAL SWITCH .......................................................................................27
Figure 11: TYPICAL SCHEMATIC ..................................................................................................................40

Rev. 01
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Compu-Aire
05/27/2016
1.0 CONTACTING COMPU-AIRE FOR TECHNICAL ASSISTANCE
Compu-Aire, Inc. uses the latest in electronic and software technologies to develop some of the
most reliable and cost efficient air conditioning systems in the world. Since many of our
customer installations are sensitive to down time, we stock nearly all components for your
system ready for same day shipment. In addition, our service departments can usually
diagnose and repair the electronic components and return them to you within a few days.
Our customer support staff is available should you require assistance in diagnosing a problem
or in setting up your air conditioning system. During usual business hour, you may call at (562)
945-8971 between 8:00am and 5:00pm Pacific time, Monday through Friday except holidays, or
you may send a facsimile message at [phone] anytime. Finally, you may write us at
Compu-Aire, Inc., 8167 Byron Road, Whittier, CA 90606.
Please do not return system components without prior authorization from Compu-Aire.
Whether repair or replacement is required for in warranty or out of warranty parts, Compu-Aire
must know what is being returned to keep proper records of returned parts. Call Compu-Aire’s
service center for a returned materials authorization number (RMA) and clearly mark all
packages on the outside with the number before sending them to us.
When contacting the factory, please have information ready as to the model and size of the air
conditioner system and most important, the job number. Compu-Aire keeps a file on each
machine sold detailing system components using this latter number. All such information can
be found on the Warranty Plate attached to each machine.

Rev. 01
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Compu-Aire
05/27/2016
2.0 PRODUCT MODEL INFORMATION
SAFETY INSTRUCTIONS
This user’s manual contains important safety instructions that should be followed to properly
install and maintain Compu-Aire system 2100 Kompact series. Read this manual thoroughly
before attempting to install or operate this unit. Store this manual at safe place for future
reference.
Adhere to all warnings, cautions and safety instructions on the unit and in this manual.
Follow all local codes and safety requirements to install and service this unit.
WARNING
Installation and service of this equipment should be done by qualified personnel who have
been specially trained and qualified in the installation of specific HVAC equipment. Improper installation
could result in unaccountable loss or damage. COMPU-AIRE System 2100 series equipment requires a
permanent power connection from an isolated circuit breaker. Customer must provide earth ground
to the unit per NEC, CEC and local codes as applicable.
Risk of high speed moving parts can cause injury or death.

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Risk of heavy unit falling over
Risk of hot surfaces, sharp edges, splinters and exposed fasteners can cause injury
WARNING
High voltage danger!
Arc flash and electric shock hazard.
Disconnect main power supply from the feeder before working on this unit. Proceed with caution and
always wear protective equipment per NFPA 70E before working within electrical control
panel. Failure to comply can cause serious injury or death.
WARNING
Evaporator unit requires drain connections. Do not locate these connections above any equipment that
could sustain water damage.
NOTICE
Improper storage can cause unit damage. Keep the unit upright and store it indoor. Protect the
unit from dampness, freezing temperatures and contact damage.
Risk of overhead interference. The unit may be too tall to fit through a doorway. Measure the
unit and doorway heights and follow the installation plans to verify clearances prior to moving
the unit.
Risk of clogged or leaking drain lines. Drain line must be inspected and maintained to ensure
that drain water runs freely through the drain system. Improper installation, application and
service practices can result in water leakage from the unit. Water leakage can cause severe
property damage and loss of critical data center equipment. Suitable leak detection system shall
be installed for the unit and water supply lines to minimize the damage.
Risk of leaking unit coil/or piping due to freezing and/or corrosion can cause equipment and
building damage.

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3.0 GENERAL EQUIPMENT DESCRIPTION
The Compu-Aire System 2100 air cooled Kompact series is a complete environmental
control system, factory wired, tested, and specifically designed to provide temperature,
humidity, and dust control for computer room installation. System 2100 is designed to
provide precise temperature control by utilizing advanced digital and analog control via
a programmable logic controller. Discharge air in the unit is provided by utilizing
variable frequency fan blowers also known as plug or EC fans. The unit as shipped from
the factory includes blower/motor package, electrical control package, and other
specified special options.
4.0 RECEIPT OF UNIT AND TRANSPORTATION
Upon receipt of the unit, a visual inspection is required. The unit packaging should be
entirely intact and the crate should not be damaged. Transport the unit to the desired
location in the upright position to avoid damaging to any external panels or internal
components. Once the unit is uncrated and in the desired location, inspection of the
unit for any external damage is crucial as this may be indicative of internal damage. Any
signs of damage to the packaging or system panels or incomplete shipments require a
claim to be filed with the shipping company. Freight damage claims are the
responsibility of the receiver.
Any items designated as field installed shall be packaged inside of the unit and must be
removed and installed prior to startup of the equipment.
Optional articles such as jack-stand parts, condensate pump, and remote control panel
are packaged separately.
REPORT ANY DAMAGE TO THE CARRIER. COMPU-AIRE IS NOT RESPONSIBLE FOR
FILING OF ANY CLAIMS. ALL NEEDED INSPECTION AND CLAIM FILING IS THE
RESPONSIBILITY OF THE RECEIVER.

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Figure 1: LOADING UNITS
5.0 LOCATING THE UNIT
The location of the unit shall be selected based on air distribution in the room and service
access requirement. System 2100 air cooled series units are available with two air flow
configurations. The down flow units are used for raised floor applications. The up flow units
with plenum or duct connection are available for rooms without raised floor. Refer to unit
dimension drawing for dimension and access requirements. Proper clearance is important for
the unit function and access to various components for service.
Front clearance: 36”
Left clearance: 36”
Right clearance: 36”
Install unit on leveled solid floor that can support the unit weight and vibrations.
Securely mount the unit with floor and brace it with wall if needed.
Install the unit closer to the largest heat load.

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Air distribution is very important for proper unit operation. Air balancing is required to obtain
design CFM at site. Fan speed can be adjusted from the controller as needed. Several feet of
clearance must be maintained between the supply air and return air intake of the unit. In
existing room, the unit supply air shall be directed towards the air intake side of the heat load.
Always locate air intake of the servers and any other heat load in the cold aisle for efficient air
distribution. The unit supply air shall never be directed towards the exhaust fan of any heat
load in the room.
Down Flow Units:
Down flow units are required to be installed on floor stands. Verify that the raised floor has
been properly sized for the design air flow. The raised floor shall be free of air flow restrictions.
The height of the adjustable floor stand can be raised or lowered through the use of the
adjusting rods. The supply air shall be directed into the cold aisles and avoid any short cycling
of cold air back to the unit return air. Floor stand height for down flow models shall be
selected based on unit CFM, fan size and static pressure requirement. The floor stand must be
securely mounted and all locknuts must be tightened to assure rigidity. See provided floor
stand drawing for installation detail.
Up Flow units: The unit may be placed directly on the sub floor. The up flow unit may have duct
connection or an optional discharge air plenum. Typical up flow unit has front return
configuration but optional rear return with filter box is available.
WARNING
Risk of high-speed moving parts can cause injury or death. Disconnect all local and
remote electric power supplies and make sure blowers are stopped rotating before
working on the unit.
Do not operate up-flow units without installing a supply air plenum, ductwork or
protective guard over the blower openings.

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Compu-Aire
05/27/2016
6.0 UNIT DIMENSIONS
Figure 2: SYSTEM OVERVIEW
60.0 34.5
74.0
MICROPROCESSOR
* DIMENSIONAL DETAIL SHOWN
W/DOOR PANELS ON UNIT
DISPLAY
2.00
BOTTOM VIEW
PIPING CUTOUT 10.75
8.75
5.0
RETURN AIR
* 36" CLEARANCE ON FRONT
AND SIDES OF UNIT
COMPRESSOR AND
VALVE ACCESS
HUMIDIFIER
ACCESS
BLOWER & MOTOR
ACCESS
FRONT OF UNIT
20.00
15.25