Panduit SynapSense CRAC User manual

Release 6.8
Issue 2
CRAC/CRAH Sensor Hardware
Installation Manual

CRAC/CRAH Sensor Hardware Installation Manual
-2-
Copyright © 2016 Panduit Corp. All rights reserved. No part of this book shall be reproduced, stored in a retrieval system, or transmitted
by any means, electronic, mechanical, photocopying, recording or otherwise, without written permission from Panduit. No patent liability
is assumed with respect to the use of the information contained herein.
Although every precaution has been taken in the preparation of this book, Panduit assumes no responsibility for errors or omissions.
Neither is any liability assumed for damages resulting from the use of the information contained herein.

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Table of Contents
Introduction 4
Overview 4
About this Installation Guide 4
Organization 4
Document Conventions 5
Document References 5
Warnings and Precautions 5
Getting Started 7
Required Hardware 7
Required Software 8
Required Tools and Materials 8
Installing CRAC/CRAH Sensors 10
General Installation Guidelines 10
Installation Process Flow 11
Preparing to Install the CRAC/CRAH Sensor Kits 11
Installing the CRAC/CRAH Sensor Kits 12
Initial Installation Steps 12
Upflow Units 13
Upflow Units with a Plenum 17
Downflow Units – Raised Floor 20
Downflow Units – Floor Stand 25
Row (Rack) Cooling Units 29
Validating and Commissioning the Installation 32
ThermaNode LEDs 33
Inspecting the Installation 35
Appendix A – Battery Replacement 36
Appendix B – Environmental Monitoring System Commissioning Form 37
FRM-007 Environmental Monitoring System 37
Appendix C – Technical Support 46
Panduit Technical Support 46
Severity 1 & 2 Issues: 46
Severity 3 & 4 Issues, Email - normal business hours: 46

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Introduction
This chapter provides an overview of the SynapSense CRAC/CRAH Sensor and Ther-
maNode™ hardware, introduces this installation guide, and lists general warnings and
precautions.
Overview
CRACs and CRAHs monitor and maintain the temperature, air distribution, and humidity
in a data center. CRACs use mechanical refrigeration; CRAHs use fans, cooling coils,
and a water-chiller or glycol cooling system.
The CRAC and CRAH configurations described in this document are upflow, downflow,
and row cooling loosely based on the leading manufacturers of CRACs and CRAHs,
Liebert® and Stulz®. The diagrams and illustrations in this guide detail the general
installation of cable assemblies, sensors, and ThermaNodes for common CRAC/CRAH
configurations.
About this Installation Guide
This document provides guidelines and instructions for installing SynapSense Ther-
maNode kits to designated service companies or the customer.
The intended audience for this document includes SynapSense customers, partners,
and installers (or installation teams) who have received training from SynapSense prior
to installing the hardware detailed in this document.
SynapSense “Tier 1” training is highly recommended for installation engineers and oth-
ers who are installing cabinet sensor hardware or closely involved with the installation of
equipment for data center optimization.
Organization
This installation guide describes the tasks for installing sensor kits for CRAC/CRAH
units. The following list shows the chapters and appendices in this document with a
short summary describing content.
lIntroduction: Introduces this guide and lists warnings and precautions
lGetting Started: Lists the hardware, software, and tool and additional material
requirements for installing the CRAC/CRAH sensor kits
lInstalling CRAC/CRAH Sensors: Provides guidelines and specific procedures for
installing CRAC/CRAH sensor kits and includes validating and inspecting the
installation.
lAppendix A – Battery Replacement: Describes ThermaNode battery replacement
lAppendix B – Environmental Monitoring System Commissioning Form: Provides
lists of necessary information and checklists to commission an Environmental Mon-
itoring System

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lAppendix C – Technical Support: Describes the process for contacting Technical
Support, opening a Support Case, and the Return Material Authorization (RMA)
process
Document Conventions
"Table 2 – Installation Guide Style Conventions" below defines the style conventions
used throughout this document.
Table 2 – Installation Guide Style Conventions
Item Description
Bold Used for anything a user types, clicks, presses, or taps For example, Click OK.
NOTE: Exceptions to the rule and other important information
Denotes a warning
Denotes a safety warning of a physical or electrical nature
Document References
The documents listed in this section affect the activities in this document. Refer to the
appropriate document for user-specific information.
lSynapSense Software Installation Guide
lWeb Console™ User Guide
lMapSense™ User Guide
lActive Control™ User Guide
Warnings and Precautions
The following warnings and precautions pertain to the CRAC/CRAH sensor installation.
Failure to adhere to warnings and precautions could result in physical injury or damage
to equipment, which may void the warranty.
Warning: When performing subfloor work in a data center, be careful not to
stress, crush, pull, or disconnect wiring and hoses running underneath electrical
and data cables, leak detectors, etc. (including fire alarm/suppression systems).
Warning: Subfloor work poses significant trip/fall hazards and eye hazards from
airflow-borne debris. Eye protection must be worn at all times when removing or
replacing floor tiles and when working in or around areas with removed tiles.

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Warning: Do not touch any data center electrical or computer/server equipment
without approval from data center operators (including loose cables, pushcarts,
and terminals).
Safety Warning: Installation of this equipment must be in accordance with local
and national electrical codes.
Safety Warning: This product contains Lithium metal primary cell batteries, which
are NOT rechargeable. Recharging can cause battery leakage or cause the
safety release vent to open. Inadvertent charging can occur if battery installation
is backwards. Dispose of batteries appropriately after use.
Safety Warning: Lithium metal batteries may pose a fire, explosion, or burn haz-
ard if misused. Do not open battery, dispose of in fire, heat above 100° C (212°
F), expose contents to water, recharge, put in backwards, mix with used or other
battery types as this may cause the batteries to explode or leak and cause per-
sonal injury.
Safety Warning: Lithium metal batteries must be properly packed and shipped in
accordance with transportation standards.
Safety Warning: Data centers may pose a risk of hearing loss. Use appropriate
ear protection prior to entry into high-noise areas.

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Getting Started
This chapter lists the required hardware, software, tools and materials for installing the
CRAC/CRAH sensor kits.
Required Hardware
The required hardware for this installation is contained in the CRAC/CRAH sensor kits.
CRAC/CRAH Sensors installation kits contain:
lThermaNode:
lTransmits data from cable assembly sensors and to the gateway
lContains four AA-size batteries
lContains a pin plug that accepts sensor assemblies
lCRAC/CRAH Cable Assembly:
ThermaNodes connect to a 2-sensor cable assembly that measures return and sup-
ply air temperature and humidity. The cable assembly includes:
lPlenum-rated material
lReturn and supply wires measuring 10’ in length
lStainless steel sensors
lLabels for supply and return wires
lAdhesive-backed cable clips

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lRegular and plenum-rated (purple) zip ties (not shown)
l3M Command Strips™ (not shown)
Required Software
The environmental server requires the installation of the following SynapSense soft-
ware:
lWeb Console™
lMapSense™ (including optional Active Control™ software with MapSense project
*.dlz file exported into the Web Console)
Installation of SynapSense software generally takes place prior to hardware installation,
which prevents redundancy of hardware verification activities. Refer to the SynapSense
Software, Web Console, and MapSense Installation and User Guides for more inform-
ation.
Required Tools and Materials
Table 3 lists the minimum tool and material requirements installers need to bring to the
job site.
Table 3 – Required Tools and Materials
Item Description/Comments
Attire Proper dress and shoes for performing work in a data center (including
areas inside the sub-floor and above ceiling tiles)
Ladder/Step
Stool
To access all areas of the CRAC/CRAH units
Additional
Parts
Spare ThermaNodes and batteries
Laptop To configure settings (for example Modbus gateway)
Fasteners Regular and plenum-rated zip ties, cable clips, and mounting brackets
Tools 7/32” Allen wrench, flashlight, diagonal cutters, utility knife, scissors,
tile pullers, thin blade screwdrivers, torque wrench, pliers, wire strip-
pers, and alcohol wipes

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Item Description/Comments
Multi-meter Measures voltage in power sources
Label Maker Create identification labels
Barcode scan-
ner
Use to scan ThermaNode MAC IDs
Documentation lA printed copy of this installation document
lWeb Console and MapSense User Guides
lPrinted MapSense layout of the data center showing installation
locations
Identification Photo ID to present to data center security personnel

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Installing CRAC/CRAH Sensors
This chapter describes guidelines and specific procedures for installing CRAC/CRAH
sensor kits.
General Installation Guidelines
Ensure software installation and required file exports before installing hardware
Be consistent. Match all installations in appearance including node/sensor locations,
centering, wiring, and method for securing extra cable.
Be neat.
lEnsure wiring is straight and vertical or horizontal as much as possible
lFollow the existing wire bundle path of the CRAC/CRAH where possible
Secure wires appropriately.
lPull slack wire taut
lLoop extra wire and tie securely at one or more of the sensor locations to prevent wir-
ing from dangling or moving
Install clips properly.
lClean surfaces thoroughly with alcohol wipes and allow cleaned surfaces to dry
lAlign clips neatly (vertical or horizontal) in the same direction as wiring
lHold clip in place for 30 seconds to ensure adhesive bonding
Use Zip Ties where needed.
lPull wire(s) taut to prevent slippage but not so tight to cause pinched wiring
lUse diagonal cutters to clip zip tie ends close to its locking mechanism
lUse fire code compliant, plenum-rated (usually purple) zip ties to secure cable
assembly and sensor wire to the CRAC/CRAH stand
lFollow all site safety procedures and protocols
Safety Warning: HIGH VOLTAGE! Most CRACs and CRAHs are 3-phase, which
can cause electric shock possibly resulting in injury or death.
Safety Warning: Ensure Facilities Supervisor or designer disconnects local and
remote power supplies before starting sensor installation work.
Safety Warning: Contact with moving parts, such as fans, could cause injury or
death.

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Safety Warning: Ensure Facilities Supervisor or designer disconnects all local
and remote electric power supplies before starting sensor installation work.
Safety Warning: Contact with hot surfaces can cause burns.
Safety Warning: Ensure Facilities Supervisor or designer allowed sufficient time
for cooling before starting sensor installation work.
Safety Warning: Report unsafe conditions (leaks, hot surfaces, exposed wiring,
etc.) to the Facilities Supervisor or designee for correction prior to starting install-
ation work.
Safety Warning: Wear appropriate personal protection equipment such as
gloves, safety glasses, and safety shoes (as required) before starting sensor
installation work.
Safety Warning: CRAC/CRAH panels can weigh in excess of 35 pounds. Use
proper lifting techniques (for example, 2-person lift) to prevent injury.
Installation Process Flow
The diagram below shows the procedural flow for installing ThermaNode.
Preparing to Install the CRAC/CRAH Sensor Kits
The SynapSense Field Engineer is responsible for completing these steps to confirm
installation readiness:
1. Assure the following steps are complete:
lInstallation and configuration of required software
lInstallation and power on for all gateways
lAll products and tools necessary for installation are on site
2. Verify the receipt of quantities and contents listed on packing/shipping list found in
Box 1.

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3. Place kits in front of each cabinet number on the kit bag (or as numbered on the prin-
ted MapSense layout).
4. For ThermaNodes with MAC IDs that have not yet been recorded or scanned, follow
these steps:
a. Record the ThermaNode MAC IDs manually, or with a barcode scanner and
upload into MapSense.
b. Access the site layout from the MapSense application. Refer to the MapSense
User Guide.
c. Add and configure the appropriate ThermaNode objects and associated IDs in
the data center floor plan.
5. Export the MapSense project *.dlz file from MapSense for viewing in Web Console.
6. Review required safety precautions and procedures specific to the site (for example,
lockout/tagout [LOTO] procedures, CRAC/CRAH power down procedures, etc.)
7. Ensure CRAC/CRAH power is off and energy dissipated from unit.
8. Customer has completed all preinstall activities such as facilities, required electric
work by qualified electrician, server installation, and alarm deactivations.
9. Wear the appropriate personal protection equipment for the installation (for example,
safety glasses).
10. Ensure Facilities Supervisor disabled alarms connected to the CRAC/CRAH or Row
Cooling unit.
11. Ensure power to the CRAC/CRAH or Row Cooling unit is off and energy dissipated.
Use a multi-meter to verify energy dissipation.
12. Ensure unit is cool to the touch.
13. For installations with a raised floor, remove the necessary floor tiles to access sub-
floor area
Installing the CRAC/CRAH Sensor Kits
This section provides the steps for installing the CRAC/CRAH sensor kits.
After installation, refer to the Validating and Commissioning the ThermaNode Installation
section to validate and commission the installation. Then proceed to Inspecting the
Installation to complete the installation process.
Initial Installation Steps
For all CRAC/CRAH or row (rack) cooling sensor kit installations, complete the following
activities.
Warning: To avoid condensation and battery corrosion within the nodes, DO
NOT install the ThermaNode in the supply area of a CRAC or CRAH unit.
1. Open access panels and holes.
a. Remove or open the necessary access panels using an Allen wrench and set
aside.

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b. Investigate the location of the unit access holes for cable routing (where applic-
able).
2. Assemble the CRAC/CRAH Cable Assembly
a. Determine the best location for the ThermaNode installation in the unit filter
(return) area.
b. Remove filter from unit per manufacturer’s instructions to expose the mounting rim
in the filter area or the mounting rim in the plenum area (if necessary and applic-
able).
c. Separate the sensor strands in the cable assembly.
3. Determine gateway density of no more than 200 nodes per gateway.
NOTE:The illustrations in the following sections represent a generalization for wire rout-
ing and present only one method. Other wire routing methods are acceptable provided
they meet installation guidelines and requirements. Exaggeration of the space inside
the unit interior is for clarity purposes only and not indicative of the actual space avail-
able.
Continue with the following sections to install CRAC/CRAH sensor kits to the following
CRAC/CRAHs:
lUpflow Units
lUpflow Units with a Plenum
lDownflow Units – Raised Floor
lDownflow Units – Floor Stand
lRow (Rack) Cooling
Upflow Units
The return (hot) air enters through the sides (front or back) of the CRAC/CRAH units and
discharges through the top (front or back) (Figure 2) or through a plenum (Figure 3). Con-
sult with the plenum manufacturer’s operation manual to determine the best location for
installing the sensors.
In this installation:
lSensors installations are always in the airflow path
lReturn sensors are always where the return (hot) air enters
lSupply sensors install where the supply (cold) air exits
lThe ThermaNode installs in the same approximate location as the return wire and
sensor
Warning: To avoid condensation and battery corrosion within the nodes, DO
NOT install the ThermaNode in the supply area of a CRAC or CRAH unit.

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Follow these steps to install a sensor kit in an upflow CRAC/CRAH unit.
1. Route and install the supply sensor to the filter area.
a. Route the supply sensor wire along the mounting rim in the filter area.
b. Secure the supply wire with a cable clip, allowing the sensor to hang over the
mounting rim in the supply airflow path.
c. Route the supply wire to the corner filter area using cable clips as needed along
the mounting rim of the filter.

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2. Route the supply wire to the unit to follow the path of existing wires in the unit.
a. Secure the supply wire to unit wiring with zip ties
b. Leave enough length in the supply wire for the ThermaNode installation.
3. Route and install the return sensor.
a. Route the return sensor and return wire to a return air vent (front or back).
b. Secure the return wire with zip ties, allowing the sensor to hang in the return
airflow path.
c. Secure the return wire down the centerline of the return air vent with zip ties to,
or near, the bottom of the unit.
4. Route the return wire in the unit.

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a. Route the return wire from the return air vent areas to join the supply wire and
existing wires in the unit.
b. Secure the return wire with zip ties to the unit wiring, leaving enough length for
the ThermaNode installation.
5. Mount the ThermaNode.
a. Clean the ThermaNode installation area (in the return area) with alcohol wipes.
Allow area to dry.
b. Attach 3M Command Strips to the underside of the ThermaNode (if not already
present).
6. Plug the cable assembly connector into the ThermaNode.
7. Temporarily install the unit with the ThermaNode LED facing toward the open area
(ON/OFF switch accessible).

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8. Secure excess wiring.
a. Bundle and secure excess wiring with zip ties.
b. Secure bundle to existing wires in the unit.
Continue to Validating and Commissioning the Installation to validate and commission
the installation.
Upflow Units with a Plenum
1. Route and install the supply sensor and wire to a selected location in the plenum
area, which may include routing the sensor and wire through an access hole in the
plenum wall or bottom plate.
a. Install the supply sensor and wire to the plenum grill (front or back), and secure to
the grill with zip ties. If the plenum does not have a grill, uses cable clips on the
plenum wall.
b. Ensure the sensor hangs in the supply airflow path.
c. Secure the supply wire to the plenum grill or wall using zip ties or cable clips as
needed.
d. Secure the supply sensor to the mounting rim with cable clips.

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2. Route the supply wire to the unit to follow the path of existing wires in the unit.
a. Secure the supply wire to unit wiring with zip ties
b. Leave enough length in the supply wire for the ThermaNode installation.
3. Route and install the return sensor.
a. Route the return sensor and return wire to a return air vent (front or back).
b. Secure the return wire with zip ties allowing the sensor to hang in the return air-
flow path.
c. Secure the return wire down the return air vent with zip ties to, or near, the bottom
of the unit.
4. Route the return wire in the unit.
a. Route the return wire from the return area to join the supply wire and existing
wires in the unit.

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b. Secure the return wire with zip ties to the unit wiring, leaving enough length for
the ThermaNode installation.
5. Mount the ThermaNode.
a. Clean the ThermaNode installation area (in the return area) with alcohol
wipes. Allow area to dry.
b. Attach 3M Command Strips to the underside of the ThermaNode (if not
already present).
6. Plug the cable assembly connector into the ThermaNode.
7. Temporarily install the unit with the ThermaNode LED facing toward the open area
(ON/OFF switch accessible).

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8. Secure excess wiring.
a. Bundle and secure excess wiring with zip ties.
b. Secure bundle to existing wires in the unit.
Continue to Validating and Commissioning the Installation to validate and commission
the installation.
Downflow Units – Raised Floor
Figure 4 shows a downflow CRAC/CRAH installed on a raised floor with a stand on the
subfloor supporting the unit.
The return air (hot) enters the top of the CRAC/CRAH (or via optional plenums – not
shown) where the cooled air discharges through the bottom of the unit.
The supply sensor installs through a hole in the bottom of the unit and secures to the leg
of the stand with a plenum-rated, fire code compliant, zip tie (purple).