nVent Hoffman RackChiller CDU800 Guide

WE CONNECT AND PROTECT
RackChiller CDU800 Coolant Distribution
Unit
Operation and Instruction Manual
89217391

2
89217391 Rev. A
©2022 nVent
Produced by
nVent
2100 Hoffman Way
Anoka
MN 55303, USA
The details in this manual have been carefully compiled and
checked - supported by certified Quality Management System
to DIN EN ISO 9001/2015
The company cannot accept any liability for errors or misprints.
The company reserves the right to amendments of technical
specifications due to further development and improvement of
products.
Copyright © 2018
All rights and technical modifications reserved

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89217391 Rev. A
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1Contact Addresses.................................................................................................................................6
1.1 Manufacturer's address ..................................................................................................................... 6
1.2 Service addresses ............................................................................................................................. 6
1.3 Making contact................................................................................................................................... 6
2About this manual ..................................................................................................................................7
2.1 Use and storage ................................................................................................................................ 7
2.2 Target audience................................................................................................................................. 8
2.3 Explanation of the various notes ....................................................................................................... 9
2.4 Seal of quality .................................................................................................................................. 10
2.5 Further applicable documents ......................................................................................................... 10
3Terms of warranty ................................................................................................................................11
4Safety.....................................................................................................................................................13
4.1 General information ......................................................................................................................... 13
4.2 Intended use.................................................................................................................................... 14
4.3 Safety of personnel.......................................................................................................................... 14
4.4 Transport and installation/start-up................................................................................................... 16
4.5 Operation......................................................................................................................................... 17
4.6 Maintenance .................................................................................................................................... 17
4.7 Operating faults ............................................................................................................................... 17
4.8 Use of cleaning agents .................................................................................................................... 18
4.9 Use of chemicals ............................................................................................................................. 19
4.10 Residual risks .................................................................................................................................. 19
4.11 Safety labels .................................................................................................................................... 20
5Description / Overview.........................................................................................................................21
5.1 General information ......................................................................................................................... 21
5.2 Safety devices ................................................................................................................................. 21
5.3 Factory protective measures ........................................................................................................... 21
5.4 Foreseeable misuse ........................................................................................................................ 22
6System Layout......................................................................................................................................23
6.1 Overview.......................................................................................................................................... 23
6.1.1 Primary circuit.............................................................................................................................. 24
6.1.2 Secondary circuit ......................................................................................................................... 25
6.2 Unit connections and electrical components ................................................................................... 27
7Receiving the CDU ...............................................................................................................................28
8Handling the CDU.................................................................................................................................29
8.1 Installation site selection.................................................................................................................. 29
8.2 Transport to the installation location................................................................................................ 29
9Setting Up..............................................................................................................................................31
9.1 Notes................................................................................................................................................ 31
9.2 Overview.......................................................................................................................................... 32
9.3 Installation guidelines ...................................................................................................................... 34
9.4 Connections..................................................................................................................................... 36
9.4.1 Primary circuit.............................................................................................................................. 36
9.4.2 Secondary circuit ......................................................................................................................... 40
9.5 Electrical connection........................................................................................................................ 41

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9.5.1 Residual-current-operated circuit-breaker................................................................................... 41
9.5.2 General information ..................................................................................................................... 41
9.6 Filling................................................................................................................................................ 46
9.6.1 Antifreeze and anticorrosion agents............................................................................................ 47
9.6.2 Primary circuit.............................................................................................................................. 48
9.6.3 Secondary circuit ......................................................................................................................... 49
9.6.3.1 Using internal fill pump ........................................................................................................ 49
9.6.3.2 Using alternative filling procedure........................................................................................ 51
9.6.3.3 Using external fill kit............................................................................................................. 54
9.7 Venting of closed circuits................................................................................................................. 59
9.8 Final steps after start-up.................................................................................................................. 59
10 Operation...............................................................................................................................................60
10.1 Notes................................................................................................................................................ 60
10.2 Adjustments..................................................................................................................................... 61
10.2.1 Low water level........................................................................................................................ 61
10.3 Control unit....................................................................................................................................... 62
10.3.1 Selection and adjustment of values......................................................................................... 62
10.4 Password protection ........................................................................................................................ 64
10.5 Program overview............................................................................................................................ 65
10.6 Screen contents and descriptions ................................................................................................... 68
10.6.1 Direct selection ........................................................................................................................ 68
10.6.2 General functions/symbols ...................................................................................................... 69
10.6.3 Page 1300, Settings ................................................................................................................ 70
10.6.4 Page 1310 "Languages".......................................................................................................... 73
10.6.5 Page 1402 "Communication parameters" ............................................................................... 74
10.6.6 Page 1500, Information ........................................................................................................... 76
10.6.7 Page 2200 "Overview"............................................................................................................. 77
10.6.8 Page 2300, schematic system diagram................................................................................... 78
10.6.9 Page 4200, screen cleaning.................................................................................................... 80
10.6.10 Page 7492, sensor adjustment................................................................................................ 81
10.6.11 Page 7581, general settings.................................................................................................... 82
10.6.12 Page 7582, Einstellungen Data log settings............................................................................ 83
10.6.13 Page 7583, control settings..................................................................................................... 84
10.6.14 Page 7681, temperature PID settings ..................................................................................... 85
10.6.15 Page 7682, pump speed PID settings..................................................................................... 86
10.6.16 Page 7683, environment/primary circuit settings..................................................................... 87
10.6.17 Page 7684, low water/secondary circuit settings..................................................................... 88
10.6.18 Page 9999, Alarm.................................................................................................................... 90
10.6.19 Page 9998 "Message history".................................................................................................. 91
11 Maintenance..........................................................................................................................................93
11.1 Notes................................................................................................................................................ 93
11.2 Overview.......................................................................................................................................... 95
11.3 Maintenance plan ............................................................................................................................ 97
11.4 Maintenance jobs............................................................................................................................. 99
11.4.1 Primary circuit........................................................................................................................ 100
11.4.2 Secondary circuit ................................................................................................................... 102
11.4.3 Checking of the expansion vessel......................................................................................... 104

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11.4.4 Check of the circuit breaker................................................................................................... 105
11.4.5 Antifreeze agent..................................................................................................................... 106
11.5 Restart ........................................................................................................................................... 106
12 Troubleshooting .................................................................................................................................107
12.1 Notes.............................................................................................................................................. 107
12.2 General malfunctions..................................................................................................................... 108
12.3 Electrical connection...................................................................................................................... 109
12.4 Unit-specific ................................................................................................................................... 110
12.5 Control valve.................................................................................................................................. 111
12.5.1 Replacement.......................................................................................................................... 112
12.6 User interface ................................................................................................................................ 116
12.7 Control unit..................................................................................................................................... 117
12.8 Restart ........................................................................................................................................... 118
13 Disconnecting the device..................................................................................................................119
13.1 Notes.............................................................................................................................................. 119
13.2 Transport and storage ................................................................................................................... 120
13.3 Dismantling.................................................................................................................................... 121
13.4 Recycling ....................................................................................................................................... 121
14 Technical Data....................................................................................................................................122
14.1 Dimensions, connections............................................................................................................... 122
14.2 General data.................................................................................................................................. 123
14.3 Weights.......................................................................................................................................... 123
14.4 Primary circuit................................................................................................................................ 124
14.5 Secondary circuit ........................................................................................................................... 125
14.6 Electrical connection...................................................................................................................... 126
14.6.1 Supply.................................................................................................................................... 126
14.6.2 Interfaces............................................................................................................................... 126
14.7 Performance curves....................................................................................................................... 127
14.8 Schematic flow chart...................................................................................................................... 129
15 Spare Parts..........................................................................................................................................130
15.1 Part type......................................................................................................................................... 130
15.2 Mechanical parts............................................................................................................................ 130
15.3 Electrical parts as indicated on the circuit diagram (equipment designations).............................. 131
15.4 Electrical cabinet............................................................................................................................ 132
16 Index ....................................................................................................................................................133

Contact Addresses
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89217391 Rev. A
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1 Contact Addresses
1.1 Manufacturer's address
nVent Hoffman
2100 Hoffman Way
Anoka
MN 55303,
USA
1.2 Service addresses
AFTERMARKET SUPPORT - REGIONAL LOCATIONS
NORTH AMERICA
2100 Hoffman Way
Minneapolis, Minnesota 55303-1745 USA
EUROPE
Langenalber Straße 96-100
75334 Staubenhardt, Germany
Tel: [phone]
1.3 Making contact
Please keep the following details ready (see the type plate of the unit) when
contacting us (e.g. for spare part orders, warranty claims, etc.):
•Product name
•Serial no.
NOTE
If necessary, enter the information, which is stated on the type plate of the unit,
into the table.
Name of the unit:
(Product Name)
……………………………………
Serial number:
(Serial No.)
……………………………………
Part number:
(Part No.)
……………………………………
Year of manufacture:
(Year of Manufacture)
……………………………………

About this manual
©2022 nVent
89217391 Rev. A
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2 About this manual
2.1 Use and storage
NOTE
Prior to performing any work on the unit/system, read the instruction manual.
The following points must be noted:
•The instruction manual is an integral part of the unit/system and must be
available to the operating personnel at the unit/system at all times.
•The instruction manual is indispensable for the safe start-up, operation and
maintenance of the unit/system in line with its intended purpose.
•The instruction manual applies solely to the product that is stated on the
cover sheet.
•We reserve the right to change the instruction manual due to further
technical developments.
•This instruction manual is part of the scope of supply.
•The instruction manual shall apply from the transport phase up to the final
disposal and must be absolutely observed.
•Keep the instruction manual in a place where it is readily accessible at all
times. It must be complete, remain with the machine and must be available
to all authorised persons.
•Maintain the instruction manual in a clearly legible state at all times.
•Hand over the instruction manual along with the device if it is resold.
•The unit/system may present unavoidable residual risks to persons and
property. This is why the instruction manual must be read, understood and
strictly complied with for all types of tasks by the personnel prior to
commencing any work. In addition, any person who works on or with the
unit/system in any way must be instructed and familiar with the potential
hazards.
•This instruction manual is solely intended for trained and authorised
personnel.
•It is the operator's responsibility to ensure that the manual is read and
understood by all operating personnel before starting work.
•The illustrations in this manual are for providing a basic understanding and
may differ from the actual unit/system.

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2.2 Target audience
When working with the unit/system, the various tasks must be assigned to specific
groups of persons.
Depending on the location of use, the necessary qualification of the personnel may
be subject to varying statutory provisions. The operator must ensure compliance
with the relevant laws. Unless regulated by law, the following list is used to define
the permissible personnel and their minimum qualification.
The following points must be noted:
•Any work on the unit/system must be performed by qualified and instructed
personnel.
•The personnel must have knowledge of the relevant standards, provisions,
accident prevention regulations and operating conditions.
•The personnel must be instructed and trained for the tasks that need to be
performed.
•The personnel must be able to identify and avoid any potential hazards.
Person
Task
Qualification
Lifcycle phase
Qualified
personnel for
transporting loads
Lifting/lowering and transport
of the system
Proven experience in the
handling of suspended loads
and in the securing of loads
Transport, installation,
disassembly and
removal
Qualified
personnel
(mechanics)
Mechanical work during: start-
up, elimination of faults and
malfunctions, maintenance
and shut-down
Training as an industrial
mechanic or an equivalent
professional qualification
Start-up, maintenance,
elimination of faults
and malfunctions,
shut-down,
disassembly and
removal
Qualified
personnel (trained
electricians)
Electrical work
Specialised electrical training
or an equivalent professional
qualification
Qualified
personnel
(refrigeration
specialists)
Work on the refrigeration unit
Training as a refrigeration
specialist or an equivalent
professional qualification
Qualified
personnel
(machine
operators and
fitters)
Operation and set-up of the
system
Person who has been trained
and instructed by the operator
based on the instructions for
use
Start-up, operation,
maintenance,
elimination of faults
and malfunctions
Qualified
personnel
(disposal
specialists)
Proper disposal of the system
Knowledge about the disposal
regulations applicable on site
Shut-down,
disassembly and
removal, disposal
Qualified
personnel (safety
specialists)
Implementation of the
applicable safety regulations
Knowledge about the safety
regulations applicable on site
All phases
Others (e.g.
visitors)
Site inspection
Person under the supervision
of a safety specialist
-

About this manual
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2.3 Explanation of the various notes
The warning notes are preceded by signal words indicating the severity of the
hazard.
Compliance with the warning notes is imperative in order to avoid accidents,
injuries and damage to property.
Explanation of warning notices used in this manual:
DANGER
Short description of danger
The signal word DANGER identifies an immediately threatening danger.
Any non-adherence will result in severe injuries or death.
WARNING
Short description of danger
The signal word WARNING identifies a potential danger.
Any non-adherence may result in severe injuries or death.
CAUTION
Short description of danger
The signal word CAUTION identifies a potential danger.
Non-compliance may result in minor to medium injuries.
NOTICE
Short description
The signal word NOTICE identifies a potential risk of damage to property.
Non-compliance may cause damage to the unit or system.
NOTE
The signal word NOTE identifies further information on the unit or about its use.
Note concerning the protection of the environment
The keyword Note concerning the protection of the environment indicates
information concerning the protection of the environment.

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2.4 Seal of quality
The seal of quality "gdsCert" of gds GmbH (service provider for technical
documentation) is a proof of quality for technical documentation.
With the "gdsCert" seal of quality, the manufacturer provides proof of the high
standard of the technical documentation and of the compliance with the relevant
standards and guidelines.
The seal of quality "ecoDoc" is used for the certification of instruction manuals
under ecological points of view. It is listed under the "green safety instruction".
With the "ecoDoc" seal of quality, the manufacturer indicates that the product
documentation includes notes concerning the potential ecological hazards
resulting from operating errors or other tasks that are performed with or on the
product. Companies thereby make a contribution to the protection of the
environment.
The seal of quality "ecoDoc" provides a proof of compliance with the relevant
standards and guidelines and/or of the ecological approach concerning the
contents of the documents.
2.5 Further applicable documents
In addition to this instruction manual, there are further applicable documents that
also need to be taken into consideration. These are usually the following
documents:
•spare parts catalogues/lists
•electrical documentation
•safety data sheets
•project drawings
•documentation of third-party manufacturers
NOTE
Information concerning the actual documents that are part of the product-
accompanying documents can be found in the specifications of the order
confirmation.