Knurr CoolAdd User manual

CoolAdd
®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 1/59
Manual
CoolAdd
®
Retrofit Heat Exchanger
for Existing Server Cabinets
Effective cooling capacity 8 kW
Bedienungsanleitung
Cool Add
®
Nachrüst - Wärmetauscher
für vorhandene Schaltsch ränke
Nutzkühlleistung 8 KW
(ab Seite 31)
date / Datum issue / Ausgabe author / erstellt reviewed / geprüft
2006-02-09 01.998.350.0 issue / Ausgabe b Carsten Dietze Heiko Ebermann

CoolAdd
®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 2/59
Contents
page
1. Safety.........................................................................................................................................3
1.1 Work safety symbols ................................................................................................................3
1.2. Safety instructions....................................................................................................................4
2. Operating conditions................................................................................................................6
3. Description................................................................................................................................7
3.1 General function........................................................................................................................7
3.2. Principle of cooling...................................................................................................................7
3.3 Dimensions ...............................................................................................................................8
3.4 Technical Data...........................................................................................................................8
3.5 Control.......................................................................................................................................9
4. Storage and transportation.......................................................................................................9
5. Installation and commissioning.............................................................................................10
5.1 Preparation for installation.....................................................................................................10
5.2 Positioning the units...............................................................................................................12
5.3 Cooling water connection.......................................................................................................15
5.4 Condensed water connection.................................................................................................18
5.5 Electrical connection..............................................................................................................18
5.6 Sealing of cabinet ...................................................................................................................20
6. Service and maintenance .......................................................................................................20
7. Dismantling and disposal.......................................................................................................23
8. Customer service, manufacturer's address...........................................................................23
9. Appendix.................................................................................................................................24
9.1 Quality requirements for water used in CoolAdd..................................................................24
9.2 Checklist for unit installation .................................................................................................25
9.3 Commissioning certificate......................................................................................................26
9.4 Wiring scheme ........................................................................................................................30

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®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 3/59
1. Safety
1.1 Work safety symbols
The following symbols identify specific hazards or provide information on safe
operation
Attention! Danger! Safety Instruction!
Risk of electric shock or danger due to high voltage
Caution! Hot surface
Caution! Rotating parts
Break voltage before work
Attention! Identifies possible damage to the unit
Risk of electric shock
Note! Identifies possible hazards for the environment
Important note, Information

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CoolAdd 01.998.350.0 issue a page / Seite 4/59
1.2. Safety instructions
Our engineers will provide comprehensive advice on how to install
CoolAdd.
Extensive material, function and quality checks ensure that you
benefit fully from the product and that the product has a long service
life. Nevertheless, this machine can produce hazards if it is used
incorrectly by untrained personnel or is not used for the correct purpose
Prior to commissioning the CoolAdd, read these
operating instructions carefully.
The electrical equipment complies with the applicable VDE and accident prevention
regulations. Hazardous voltages (greater than 50 V AC or greater than 100 V DC)
are present:
→Behind the server cabinet doors
→On the power supply in the unit's housing
Use only original fuses with the correct rating.
Immediately shut down the unit if there are problems with the supply of electrical
power or supply of cold water.
Risk of electric shock
Repair and cleaning work should only be performed only
qualified staff.
The staff must ensure that the unit is electrically isolated
whilst it is serviced and cleaned. For this reason shut down
theunitbeforestartingwork.
Risk due to incorrect work on the unit.
Cleaning and servicing is only allowed to be performed by
qualified staff. To ensure that the unit remains
safe to use and has a long service life, it is imperative
that you observe the maintenance and cleaning intervals.

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®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 5/59
Only operate the CoolAdd correctly within the correct
ratings and with approved equipment.
.
During all work on and with the unit, observe:
•The related applicable regulations (e. g. VDE regulations or
other applicable national regulations)
•The applicable accident prevention instructions (BGV)
•The applicable rules
•The applicable laws on the protection of the environment
Only operate the unit if it is in correct working condition. On the
occurrence of malfunctions or faults, you must shut down the unit
immediately and inform the responsible member of staff
in the operating organisation.
You are only allowed to use the unit again after its correct function
has been re-established.
Caution hot surface
Faulty fans, power supplies, control circuit boards can run hot.
Prior to starting work, leave these to cool down.

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2. Operating conditions
Correct use: Installation on the rear side of the
server cabinet
Dimensions: hight from 2000 mm
Width from 600 mm
Depth of the door: 160 mm
Temperature in the installation location: max. 25°C / 77°F
Water temperature feed: 14°C / 57°C (other temperatures on
request)
Water temperature return: 20°C / 68°F (other temperatures on
request)
Air temperature outlet CoolAdd 22°C / 71°C
Temperature spread, water: 6 K / 10°F
Use of anti-freeze in the cooling
water: upon request
Water connection: from below
Nominal voltage: 230V AC
max. power input 525./ 725 W
max. current input 2,3 A / 3,2 A
Frequency 50 Hz / 60 Hz
max. operating pressure: 10 bar
For reliable function of the CoolAdd, cooling water must be
available in the correct amount, and at the correct temperature and
pressure. Observe water quality as per VGB-R 455 P.
(see Appendix)

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®
Manual / Bedienungsanleitung
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3. Description
3.1 General function
CoolAdd
®
is an easy to mount retrofit heat exchanger for overheated data processing
centres. When fitted directly to the cabinet it transfers the heat load to the water and
relieves the room air conditioning
CoolAdd
®
replaces the rear doors of common server cabinets and is easily mounted to
the rear frame. The layout of the server cabinet remains completely unchanged.
A connection to the data centre’s chilled water system is required.
The air/water heat exchanger is positioned in the fixed part of the upgrade kit and is
connected to the server cabinet via the frame.
Four fans are integrated into the rear door, which provides access to the cabling for the
rack components.
CoolAdd
®
consisits of three main componets:
- a frame for fixing at the cabinet
- a door with radial blowers
- a vertically fixed air/water heat exchanger
CoolAdd
®
complies with all requirements of EN 60950.
CoolAdd
®
design allowes the retrofitting on all existing standard cabinet dimensions.
3.2. Principle of cooling

CoolAdd
®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 8/59
The warm server waste air is cooled by heat exchanger to about 22°C / 71°F,
before it is fed into the installation room. The cooling water is provided by a chiller
made available on site.
On the failure of the cooling system the heat is dissipated into the room
in which the units are located.
3.3 Dimensions
Dimensions: for server racks from height 2000 mm
from width 600 mm
Depth of the door: 160 mm
CoolAdd is fixed by using an adapter frame and mounting angles onto the
existing cabinet.
3.4 Technical Data
Cooling capacity up to 8 kW
Operating temperature: maximum 25°C / 77°F
Feed temperature cooling water: 14°C / 57°F (other temperatures upon
request)
Return temperature cooling water: 20°C / 68°F (other temperatures upon
request)
Temperature spread water: 6K
Flow rate cooling water 1.15 m³/h
Use of anti-freeze in the cooling water on request
Water connection: from below,
Supply / Return ¾“ / ¾“ male threat
Pressure loss cooling water approx. 400 mbar (5.8 PSI)
max. operating pressure 10 bar
Condensed water connection ø 10 mm
CoolAdd return air temperature 22°C / 71°F
Server return air temperature 35°C / 95°F
Air flow 2500 m³/h
Rated voltages / current : 230V/ 3.2 amps / 725 W
Weight (depending on configuration) approx. 41 kg / 90.5 lbs.

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®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 9/59
3.5 Control
The return temperature is controlled manually by thermostatic valve.
In general a return temperature of 22°C / 71°F is recommended as a guide value.
Setting: - lower scale value means „colder“
- higher scale value means „warmer“
The thermostatic valve automatically controls the cooling water flow rate.
Fans:
By design all fans are operating at nominal speed all the time.
Door contact:
The door contact switches off the fans automatically, when the door is opened.
The power supply should be shut down before beginning service work on the fans.
4. Storage and transportation
•Store the CoolAdd in its original packaging in a dry place and protected from effects
of the weather. Cover open pallets with tarpaulins and protect the components from
soiling (e. g. sand, rain, dust, etc.).
•Keep to storage temperatures between –30 °C / -22°F and +40°C / 104°F
•The heat exchanger must be completely deflated (Risk of frost damage)
•After storage for more than 1 year, prior to installation check the fan bearings
(Turn fans manually.)
•CoolAdd can be transported by hand or with appropriate means of transportation.
The CoolAdd weighs, depending on the version, up to 41 kg
•Avoid twisting the housing or other damage.
•Use suitable aids during installation, e. g. approved scaffolding.
•All packaging has to be removed prior to commissioning CoolAdd.

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®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 10/59
5. Installation and commissioning
5.1 Preparation for installation
Before you can install the CoolAdd, you have to check several of points.
These checks are for safety reasons and to ensure the correct function
of the CoolAdd. Take great care when performing these checks
to ensure that the device functions correctly.
-Check unit for transport damage.
The packaging for the CoolAdd must not show signs of transport
damage on delivery. Any damage on the packaging is indicative of possible
transport damage. In the worst case this damage may result in the loss of
function.
-Returning the device in case of transport damage.
If the unit is not returned in the original packaging, the packaging used for return
must comply with the following criteria:
There must be a space of at least 30 mm between the unit and the packaging.
As an installation aid, there is a checklist in the appendix, that you should complete
prior to commissioning.
The commissioning also can be carried out by approved staff. Use the
commissioning certificate included in the appendix for this purpose.
Before the installation of the CoolAdd the stability under load
must be of the existing cabinet has to be ensured. An additional weight of 41kg
must be taken in to account when installing the CoolAdd to the rear of
the cabinet. Please note the change of the centre of gravity when
opening the door. There must be enough space for maintenance when
the door is opened.
To achieve good air circulation, ensure that there is no packaging
material or other equipment that could hinder or prevent the circulation
of air:
•in the area of the heat exchanger
•on the air inlet
•on the air outlet

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Primary air flow:
The required primary air flow for the cooling has to be ensured by
adequate air flow perforations. (e.g. perforated door)

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5.2 Positioning the units
The existing server cabinet is to be aligned vertically, before the CoolAdd may be
installed. The door should close easily after alignment.
Assembly order:
1.) Remove the existing server cabinet door (rear)
2.) Installation of additional frame for the door hinge
Additional frame for
door hinge (grey)
Frame of existing
cabinet

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3.) Installation of the brackets for the heat exchanger
Frame of existing
cabinet
Heat exchanger
Attaching brackets for
heat exchanger
Sealing
Thermostatic valve with
scale.

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4.) Assembling of the fan door
5.) Connection of cooling water
6.) Connection for condensed water
7.) Electrical connection
8.) Final check and commissioning
Fan door assembled on
hinges
Fan door Heat exchanger

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®
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5.3 Cooling water connection
When the heat exchanger is connected to the cooling water network
using threaded fittings, the pipe fitting must be supported on tightening.
Prior to commissioning the server cabinet, the pipe connections
should be checked for leaks.
Preparing heat exchanger for initial commissioning:
-Correct mechanical installation and connection of the supply pipe.
-Carefully bleed heat exchanger when filling the system.
-If necessary, re-tighten threaded fittings.
-When not used for a longer time, and particularly in case of risk of frost, the heat
exchanger and the supply pipe have to be completely drained. Drain completely by
blowing out with compressed air and remove all bleed and drain plugs.

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®
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Left door version:
Right door version

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®
Manual / Bedienungsanleitung
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Heat exchanger connection (front view)
Return
¾“ male threat Supply ¾“ male threat
Condensed water
connection
10 x 1 mm
To bleed CoolAdd heat
exchanger close the return
valve and open bleed valve.
Bleed very carefully until
only water runs out the bleed
valve. Make sure that all
pipes are perfused
Note: The bleed valve is no
delivery content.
connection set with
flexible hoses and
quick connection
(option)

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®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 18/59
The cooling water pipes have to be insulated to avoid condensation and losses using
a waterproof isolation.
Insulation thickness : „F“ (9 - 12mm) = 0,037 W/mK (10°C)
5.4 Condensed water connection
If the CoolAdd is operating below dew point, condensed water may form. There
is a standard condensed water connection, 10mm diameter, in the condensed
water tray for drainage.
Ensure that the condensed water pipe has a drop. The condensed water drain is
not pressurised. An optional condensed water pump can be used.
5.5 Electrical connection
The electrical connection is achieved by using a free socket in the existing
cabinet. Use fuses as specified to technical data on point 3.4.
Connecting cable with
plug)*
Existing
server cabinet
CoolAdd
Heat exchanger part

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®
Manual / Bedienungsanleitung
CoolAdd 01.998.350.0 issue a page / Seite 19/59
)* Configuration as ordered – cable to be ordered separately
NB. If a hard wired configuration is required please read the following
notes carefully
The unit should only be connected by appropriately
qualified personnel (electrician). The personnel must ensure
that the server cabinet is electrically isolated for the
duration of the connection work and is secured against
unauthorised switch on.
Check whether voltage and frequency at installation site and
the fuse ratings match the information on the rating plate.
The connection to power supply is made using a terminal block.
To connect the unit to the power supply:
•Correctly shutdown all fuses
•Check the secure connection of the earth wire.
Place the server cabinet correctly back in operation.
Switch on automatic fuses.
The unit's The unit’s fans rotate clockwise.
Power link between
fan door and heat
exchanger

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®
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5.6 Sealing of cabinet
To ensure optimal cooling a floating seal is provided between the CoolAdd an the
existing cabinet.
The gap between CoolAdd door und cabinet has to be closed by the seal.
6. Service and maintenance
Servicing and maintenance work is to be performed by
correctly trained personnel only, and in accordance with the
related regulations as well as the manufacturer’s specifications!
Only use original spare parts that have been tested and approved by us
(If necessary, request a complete list of spare parts from the
manufacturer)
For cleaning use only commercially available cleaning agents while
observing the stipulated safety measures and do not use any tools that
cause may scratching or tools for scraping (surface treatment will be
irreversibly damaged!)
Prior to all servicing work:
-correctly shut down fans and any other electrical
components and isolate from the power supply
-wait until the fan blades have stopped!
-secure against switch on
-Shut down the water cooling circuit and secure against
switch on
•General inspection on fans (annually)
- Check for unusual bearing noises (Check for excessive bearing play)