Lennox EMEA INNOV CD-CU-CX Service manual

www.lennoxemea.com
INSTALLATION, USE AND MAINTENANCE
MANUAL
INNOV@-DHF-IOM-0922-EN
INNOV@ DHF Chilled water
CD-CU-CX
Air Conditioning Units for Close Control Application

1 General description 1
1.1 Structure 5
1.2 Application limits 5
1.3 Cooling circuit 5
1.4 Installation warnings
2 Inspection / Transport / Positioning 11
2.1 Inspection on receipt 11
2.2 Lifting and transport 11
2.3 Unpacking 11
2.4 Positioning 11
3 Installation 13
4 Supply water properties 15
5 Humidifier 17
6 Electrical connections 21
6.1 Generalities 21
7 Operating diagrams 23
8 Start-Up 25
8.1 Preliminary checks 25
8.2 Starting operations 25
Setting operating parameters 27
.1 Generalities 27
10 Maintenance 2
10.1 2
10.2
Warnings
Generalities 2
11 Troubleshooting 33
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INNOV@-DHF-IOM-0922-EN

1General description
DH_C CCAC chilled water units are specially designed for installation in technological
environments such as Computer rooms, laboratories and in general where a high precision in
climate control and a 24h/day operation are requested.
TREF units represent the state of the art between technology and design as well as all ours.
products. furthermore, the innovative design and the high-tech selected colours make TREF units
complementary to the last generation of IT devices. The internal design of the units in firstly made
looking to efficiency and reliability but don’t loosing accessibility.
All components, including electrical heaters, fans, compressors, valves, etc. can be maintained
from the front and furthermore the door(s) are dismountable in few seconds thanks to an
innovative hinge: this is very important when units are installed in small corridors. The exclusive
use of primary brands components and a fully integrated development process (CAD+CAM, CAE)
stands for highest possible quality level regarding efficiency, reliability, maintenance time, pre and
after sales support.
DH units can be ordered in different air flow configuration, according with the needs and the
datacenter layout. Downflow, upflow, displacement (D, U, X) versions are available.
DH units can be ordered in different configurations, designed to optimize the unit according to the
working condition of the datacenter. For this reason, three different versions are available for
every model (A, B, C) that work with high, middle, low water flow respectively.
Finally, DH units can be ordered in double circuit with double water valve, this allow hight
redundancy and the use of less space in the datacenter.
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Table 1
DH synoptic.
1 Unit name
DH Close control unit
2 Size
040 Cooling capacity [kW] at the nominal working conditions
. . .
240
3 Configuration
A High water flow configuration
B Middle water flow configuration
C Low water flow configuration
4 Execution
C Chilled water unit
5 Air flow
D Downflow unit
U Upflow unit
X Displacement unit
Example:
DH 040 A _ C D
↓ ↓ ↓ ↓ ↓
1 2 3 4 5
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INNOV@-DHF-IOM-0922-EN

Figure 1
Downflow unit components.
DH_CD
Table 2
Position Description Position Description
1 Chilled water coil 2 Water valve
3 Fan 4 Air filter
5 Stainless steel drain pan 6 Electrical pane
7 Electrical heaters 8 Humidifier
5
1
3
4
8
7
6
2
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Figure 2
Displacement unit components.
DH_CX
Table 3
Position Description Position Description
1 Chilled water coil 2 Water valve
3 Fan 4 Air filter
5 Stainless steel drain pan 6 Electrical pane
6
3
5
2
4
1
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INNOV@-DHF-IOM-0922-EN

1.1 Structure
DH units are designed with a self-supporting frame and all components are produced using
sophisticated computer driven machines and special tools. All sheet metals are galvanized, and all
external panels are powder coated RAL 7016 giving to the units the image and the quality like last
generation of IT devices. Units are completely closed, and only frontal access is requested.
Anyway, it is also possible to have side access to reach the steam piping and the drain pan, or
simply to substitute a damaged side panel: all these problems are very rare, but with TREF units it
is possible to solve them. The shape of the units is characterized with the curved edges with
variable radium as for all HiRef products: this feature is obtained using special tools and gives both
a good aesthetic and advantages against injuries. The compressor compartment is separated from
the air flow and the special internal design allows the simple dismounting of the upper part of it
ensuring an insuperable accessibility to all refrigerating components.
All fixing elements are made in stainless steel or in non-corroding materials. The dray pan is made
in stainless steel to ensure long time operation without damages.
All panels are thermally insulated with a polyurethane foam class 1 according to UL 4 norms: this
material, thanks to the open cells, gives good performances in sound absorption. As an option,
sandwich panels are available: in this case mineral fibres are closed between the panel and a
second sheet of metal giving the maximum in terms of internal cleaning. Double skin panels are
classified between non-flammable materials class A1 according to DIN 4102 norms: the sound
insulation is better than the standard solution, but the internal reflected sound power will
increase the amount in delivery side (+2dB).
1.2 Application limits
Table 4
Power supply * [V / Ph / Hz] 400 (±10%) / 3+N / 50
Storage conditions
Temperature
Min -10°C
Max 60°C
Relative humidity Max 0%
* In case of different power supply see the electrical drawing attached.
1.3 Cooling circuit
The entire refrigerating circuit is assembled in our production line including all pipe work and using
only primary brand for components. The workers involved in the welding and pipe work process
are qualified by a third part according to CEE 7/23.
Cooling components
•Three/two-way water valves with 0-10 V regulation
•Relief valves
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Electric control board
Electric control board: The electric control board is constructed and wired in accordance with
Directives 73/23/EEC and 8 /336/EEC and related standards. The board may be accessed through
a door after the main switch has been turned off. All the remote controls use 24 V signals powered
by an insulating transformer situated on the electric control board.
NOTE
The mechanical safety devices such as the high pressure switched are of the kind
that trigger directly; their efficiency will not be affected by any faults occurring in
the microprocessor control circuit, in compliance with 7/23 PED.
Microprocessor control
The microprocessor built into the unit allows the different operating parameters to be controlled
from a set of pushbuttons situated on the electric control board:
•Alarm management:
oDirty filters alarm (optional);
oAir flow alarm;
•Alarm signalling;
•Display of operating parameters;
•RS232, RS485 serial output management (optional).
See microprocessor control manual attached for further details, also in relation to customer
specifications.
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INNOV@-DHF-IOM-0922-EN

Figure 3
Base refrigerant circuit.
3-way valve 2-way valve (optional)
Table 5
Riferimento Descrizione Riferimento Descrizione
1 Inlet chilled water 2 Chilled water coil
3 Relief valve 4 Water valve
5 Outlet chilled water 6 Fan
1
2
3
4
5
6
1
2
3
4
5
6
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Figure 4
Base refrigerant double circuit optional).
Valvola 3-vie Valvola 2-vie (opzionale)
Table 6
Riferimento Descrizione Riferimento Descrizione
1 Inlet chilled water 2 Chilled water coil
3 Relief valve 4 Water valve
5 Outlet chilled water 6 Fan
1
3
4
5
6
2
4
3
1 5 1
3
4
5
6
2
4
3
1 5
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INNOV@-DHF-IOM-0922-EN

Installation warnings
1.4
General rules
•When installing or servicing the unit, you must strictly follow the rules provided in this
manual, comply with the directions on the units themselves and take all such precautions
as are necessary.
•The fluids under pressure in the cooling circuit and the presence of electrical components
may cause hazardous situations during installation and maintenance work.
WARNING
All work on the unit must be carried out by qualified personnel only, trained to do
their job in accordance with current laws and regulations.
•Failure to comply with the rules provided in this manual or any modification made to the
unit without prior authorisation will result in the immediate invalidation of the warranty.
WARNING
Before performing any kind of work on the unit, make sure it has been disconnected
from the power supply.
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2Inspection / Transport / Positioning
2.1 Inspection on receipt
On receiving the unit, check that it is perfectly intact: the unit left the factory in perfect
conditions; immediately report any signs of damage to the carrier and note them on the
“Delivery Slip” before signing it.
The Manufacturer or its Agent must be promptly notified of the entity of the damage. The
Customer must submit a written report describing every significant sign of damage.
2.2 Lifting and transport
While the unit is being unloaded and positioned, utmost care must be taken to avoid abrupt or
violent manoeuvres. The unit must be handled carefully and gently; avoid using machine
components as anchorages or holds and always keep it in an upright position.
The unit should be lifted using the pallet it is packed on; a transpallet or similar conveyance
means should be used.
WARNING
In all lifting operations make sure that the unit is securely anchored to prevent
accidental falling or overturning.
2.3 Unpacking
The packing must be carefully removed to avoid the risk of damaging the unit. Different
packing materials are used: wood, cardboard, nylon etc. It is recommended to keep them
separately and deliver them to suitable waste disposal or recycling facilities to minimise their
environmental impact.
2.4 Positioning
Bear in mind the following aspects when choosing the best site for installing the unit and the
relative connections:
•Positioning and dimensions of the water connections;
•Location of power supply;
•Solidity of the supporting floor.
It is recommended to first prepare holes in the floor/wall for passing through the power cables
and for the air outlet (downflow units).
The dimensions of the flange (optional) and the holes for power cable are shown in the
dimensional drawing of the unit attached.
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INNOV@-DHF-IOM-0922-EN

3Installation
The DH air-conditioning unit is suitable for all environments except aggressive ones. Do not place
any obstacles near the units and make sure that the air flow is not impeded by obstacles and/or
situations causing back suction.
Figure 5
Service area.
Table 7
Service area for downflow units.
DH_CD A [mm] B [mm] C [mm] D [mm] E [mm]
040 060 1010 750 8 0 10 2000
070 080 1270 750 8 0 10 2000
0 0 100 1760 750 8 0 10 2000
110 130 2020 750 8 0 10 2000
150 170 2510 750 8 0 10 2000
180 210 3160 750 8 0 10 2000
240 3160 750 60 10 2000
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150 170 2510 750 8 0 10 2000
180 210 3160 750 8 0 10 2000
Table 9
Service area for displacement units.
DH_CX A [mm] B [mm] C [mm] D [mm] E [mm]
040 060 1010 750 8 0 10 2250
070 080 1270 750 8 0 10 2250
0 0 100 1760 750 8 0 10 2250
110 130 2020 750 8 0 10 2250
150 170 2510 750 8 0 10 2250
180 210 3160 750 8 0 10 2250
The following steps should be carried out to ensure proper installation:
•Apply an anti-vibration rubber lining between the unit and the bottom;
•Position the unit on the floor / floorstand (base frame).
The recommended sizes for the power cables and emergency line are shown in the related
electrical drawings attached.
Table 8
Service area for upflow units.
DH_CU A [mm] B [mm] C [mm] D [mm] E [mm]
040 060 1010 750 8 0 10 2000
070 080 1270 750 8 0 10 2000
0 0 100 1760 750 8 0 10 2000
110 130 2020 750 8 0 10 2000
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INNOV@-DHF-IOM-0922-EN

4Supply water properties
The quality and chemical composition of the cooling and heat transfer medium have a great
influence on the Lifetime and on heat transfer and thus on the performance of the specific unit.
Basically, avoid all types of floating matter in the cooling and heat transfer medium. When the
suspended matter accumulates in the heat exchanger the heat transfer and thus the performance
of the unit deteriorate.
Below are the values of the dissolved substances and the water properties recommended by the
manufacturer listed.
The information refers to the use of exchangers made of copper.
If the concentration of some components will be out of range, the customer has to introduce a
correction, otherwise the system will be out of warranty.
Table 10
Substance Concentration
Alkalinity HCO3- 70 – 300 ppm
Sulphate SO42- < 70 ppm
HCO3- / SO42- > 1.0 ppm
Electrical conductivity 10 – 500 μS/cm
Potential of hydrogen pH * 7.5 – .0
Ammonium NH4+ < 2 ppm
Chloride Cl- < 30 ppm
Free chlorine Cl2 < 0.5 ppm
Hydrogen sulphide H2S < 0.05 ppm
Carbon dioxide CO2 < 5 ppm
Total hardness 4.5 – 8.5 °dH
Nitrate NO3- < 100 ppm
Iron ** Fe < 0.2 ppm
Aluminium Al < 0.2 ppm
Manganese ** Mn < 0.05 ppm
Calcium carbonate CaCO3 < 200 ppm
Phosphate PO43- < 2 ppm
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Ammonia NH3 < 0.5 ppm
Temperature < 65 °C
Oxygen content < 0.1 ppm
* Generally, a low pH value (less than 6) increases the risk of corrosion, and a high pH (above 7.5) decreases the risk of
corrosion.
** Fe3+ e Mn4+ are powerful oxidants and may increase the risk of localized corrosion on stainless steel.
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INNOV@-DHF-IOM-0922-EN

5Humidifier
The installation of the humidifier requires the connection to the water supply and drain hoses.
Figure 6
Humidifier.
To simplify installation, it is recommended to use hose with an inside diameter of 6 mm and an
outside diameter of 8 mm and the revolving 3/4” G connection, either straight or 0°.
A shut-off tap and a mechanical filter should be installed to trap any solid impurities.
The drain water is connected using a section of rubber or plastic hose resistant to 100°C, with a
recommended inside diameter of 32 mm.
The drain connector is suitable for heat sealing with polypropylene drainpipes.
WARNING
The drain hose must be free, without backpressure and with a drain trap
immediately downstream of the connection to the humidifier.
The following conditions represent correct water connection:
•Installation of a shut-off tap in the supply water line;
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•Presence of a mechanical filter in the supply water line;
•Water temperature and pressure within the allowed values;
•Drain hose resistant to temperatures of 100°C;
•Minimum inside diameter of the drain hose of 25 mm;
•Minimum slope of the drain hose greater than or equal to 5°;
•Electrically non-conductive sleeve;
•Presence of a drain trap in the drain hose.
WARNING
When installation is completed, flush the supply hose for around 30 minutes by
piping the water directly into the drain without sending it into the humidifier. This
will eliminate any scale or processing residues that may block the fill valve or cause
foam when boiling.
Supply water
The humidifier must be supplied with mains water, with the following characteristics:
•Pressure between 0.1 and 0.8 MPa (1 to 8 bar, 14.5 to 116 psi);
•Temperature between 1 and 40°C;
•Instant flow rate not lower than the rated fill solenoid valve flow rate (0.6 l/min);
•Connection type 3/4” G Male.
Table 11
Limit values for the supply water with medium-high conductivity in an immersed electrode humidifier.
Substance Minimum Maximum
Potential of hydrogen pH 7 8.5
Specific conductivity at 20°C σR, 20°C 300 1250 μS/cm
Total dissolved solids TDS * * mg/l
Dry residue at 180°C R180 * * mg/l
Total hardness TH CaCO3 100 ** 400 mg/l
Temporary hardness CaCO3 60 *** 300 mg/l
Iron + Manganese Fe + Mn 0 0.2 mg/l
Chlorides Cl 0 30 ppm
Silica SiO2 0 20 mg/l
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Residual chlorine Cl- 0 0.2 mg/l
Calcium sulphate CaSO4 0 100 mg/l
Metallic impurities 0 0 mg/l
Solvents, diluents, soaps, lubricants 0 0 mg/l
* Values depending on specific conductivity; in general: TDS
≅
0. 3 * σ20; R180
≅
0.65 * σ20
** Not lower than 200% of the chloride content in mg/l of Cl-
*** Not lower than 300% of the chloride content in mg/l of Cl-
Table 12
Limit values for the supply water with medium-low conductivity I the immersed electrode humidifier.
Substance Minimum Maximum
Potential of hydrogen pH 7 8.5
Specific conductivity at 20°C σR, 20°C 125 500 μS/cm
Total dissolved solids TDS * * mg/l
Dry residue at 180°C R180 * * mg/l
Total hardness TH CaCO3 50 ** 250 mg/l
Temporary hardness CaCO3 30 *** 150 mg/l
Iron + Manganese Fe + Mn 0 0.2 mg/l
Chlorides Cl 0 20 ppm
Silica SiO2 0 20 mg/l
Residual chlorine Cl- 0 0.2 mg/l
Calcium sulphate CaSO4 0 60 mg/l
Metallic impurities 0 0 mg/l
Solvents, diluents, soaps, lubricants 0 0 mg/l
* Values depending on specific conductivity; in general: TDS
≅
0. 3 * σ20; R180
≅
0.65 * σ20
** Not lower than 200% of the chloride content in mg/l of Cl-
*** Not lower than 300% of the chloride content in mg/l of Cl-
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