Pentair VARISTAR SHX 30 User manual

EQUIPMENT PROTECTION SOLUTIONS 2015-03-23
VARISTAR Cooling unit SHX 30
Instruction Manual
60130-716
- Original instruction manual -
Product number:
62139-097

VARISTAR Cooling unit SHX 30
2
Produced by
Pentair Equipment Protection
Schroff GmbH
Langenalber Str. 96 - 100
75334 Straubenhardt, Germany
The details in this manual have been carefully compiled and
checked - supported by certified Quality Management System
to EN ISO 9001/2000
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 © 2013
All rights and technical modifications reserved

VARISTAR Cooling unit SHX 30
3
1 Safety ...............................................................................................................................................................5
1.1 General information regarding safety............................................................................................................... 5
1.2 Warning notices ................................................................................................................................................ 6
1.3 Safety of personnel ........................................................................................................................................... 7
1.4 Intended use ..................................................................................................................................................... 8
1.5 Terms of warranty ............................................................................................................................................. 8
1.6 Installation site .................................................................................................................................................. 9
1.7 Safety instructions for transport ....................................................................................................................... 9
1.7.1 General information ..................................................................................................................................... 9
1.8 Safety instructions for set-up .......................................................................................................................... 10
1.9 Safety instructions for maintenance ............................................................................................................... 11
1.10 Disclaimer........................................................................................................................................................ 11
2 Description / Overview ...................................................................................................................................12
2.1 General information........................................................................................................................................ 12
2.2 Variants ........................................................................................................................................................... 12
2.3 Mode of operation .......................................................................................................................................... 13
2.4 Air circuit ......................................................................................................................................................... 14
2.5 Water circuit.................................................................................................................................................... 14
2.6 Control method ............................................................................................................................................... 15
2.7 Alarms ............................................................................................................................................................. 16
2.8 Incorrect use ................................................................................................................................................... 16
3 System Layout ................................................................................................................................................18
3.1 Overview ......................................................................................................................................................... 18
3.2 Connections..................................................................................................................................................... 20
3.3 Electrical box ................................................................................................................................................... 22
3.4 Schematic system diagram.............................................................................................................................. 23
3.5 Function overview........................................................................................................................................... 24
3.6 Symbols / labels on the unit............................................................................................................................ 25
4 Components ...................................................................................................................................................26
4.1 Control valve ................................................................................................................................................... 26
4.2 Control unit ..................................................................................................................................................... 27
4.3 Interface board................................................................................................................................................ 28
4.4 Fuse board....................................................................................................................................................... 30
4.5 Basic electronic system ................................................................................................................................... 31
5 Setting Up .......................................................................................................................................................32
5.1 General information........................................................................................................................................ 32
5.2 Transport and packaging material .................................................................................................................. 34
5.3 Start-up ........................................................................................................................................................... 34
5.4 Installation....................................................................................................................................................... 35
5.5 Connections..................................................................................................................................................... 35
5.6 Electrical connection ....................................................................................................................................... 37
5.7 Antifreeze and anti-corrosion agents.............................................................................................................. 39
5.8 Adjustments .................................................................................................................................................... 40

VARISTAR Cooling unit SHX 30
4
5.9 Venting ............................................................................................................................................................ 41
5.10 Removal/installation ....................................................................................................................................... 44
6 Operation .......................................................................................................................................................45
6.1 General information........................................................................................................................................ 45
6.2 Adjustments .................................................................................................................................................... 45
6.3 Switching off the unit ...................................................................................................................................... 46
6.4 Control unit ..................................................................................................................................................... 47
6.4.1 General information ................................................................................................................................... 47
6.4.2 Activating/deactivating functions............................................................................................................... 48
6.4.3 Selecting and setting values........................................................................................................................ 48
6.4.4 Program overview....................................................................................................................................... 49
6.4.5 Screen contents and descriptions............................................................................................................... 50
7 Maintenance...................................................................................................................................................51
7.1 General information........................................................................................................................................ 51
7.2 Maintenance plan ........................................................................................................................................... 53
7.3 Replacement ................................................................................................................................................... 54
7.3.1 Fans............................................................................................................................................................. 54
7.3.2 Actuator of the control valve ...................................................................................................................... 55
7.3.3 Temperature sensor.................................................................................................................................... 60
7.3.4 Replacement of other components ............................................................................................................ 60
7.4 Antifreeze and anti-corrosion agents.............................................................................................................. 61
7.5 Cooling module ............................................................................................................................................... 62
7.5.1 Rinsing process ........................................................................................................................................... 62
8 Troubleshooting .............................................................................................................................................64
8.1 General information........................................................................................................................................ 64
8.2 Electrical connection ....................................................................................................................................... 65
8.3 Unit-specific .................................................................................................................................................... 65
8.4 Control unit ..................................................................................................................................................... 66
9 Disconnecting the device ................................................................................................................................68
9.1 General information........................................................................................................................................ 68
9.2 Dismantling ..................................................................................................................................................... 68
9.3 Transport and storage..................................................................................................................................... 69
9.4 Recycling.......................................................................................................................................................... 70
10 Technical Data ................................................................................................................................................71
11 Spare Parts .....................................................................................................................................................74

VARISTAR Cooling unit SHX 30
Safety 5
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1 Safety
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1.1 General information regarding safety
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Personnel in charge of carrying out work on the unit or system must have read and
understood this manual and in particular the section on safety.
If necessary, in-house instruction should be provided, taking into account the technical
qualifications of the personnel concerned.
Certain components have additional warning plates or labels to enable safer operation.
Plates or labels must not be covered or removed.
Observe all safety instructions. Observation of these instructions is in the interest of
personal safety.
The relevant accident prevention regulations as well as other generally recognised
regulations concerning workplace health and safety must be observed.
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The manual must be stored so that it is easily available at any time. It must be complete,
kept close to the machine and must be available to all authorized persons.
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VARISTAR Cooling unit SHX 30
Safety 6
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1.2 Warning notices
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Explanation of warning notices used in this manual:
DANGER
Short description of danger
The signal word DANGER identified an immediately threatening danger.
Any non-adherence will result in most serious injuries or death.
WARNING
Short description of danger
The signal word WARNING identified a potential danger.
Any non-adherence may result in most serious injuries or death.
CAUTION
Short description of danger
The signal word CAUTION identified a potential danger.
The non-adherence may result in minor to medium injuries.
Notice
Short description
The signal word Attention identifies a potential risk of property damages.
The non-adherence may cause damages at the unit or at the plant.
Note
The signal word Note identifies further information on the unit or about its use.
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VARISTAR Cooling unit SHX 30
Safety 7
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1.3 Safety of personnel
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Avoid any working practice that:
• endangers the health and safety of the user or third parties,
• presents a danger to the unit or system or other property,
• impairs the safety or functionality of the unit or system,
• does not comply with the safety instructions.
Maintenance and service should be performed only by suitably qualified persons who are
familiar with the unit and who have been informed concerning the potential hazards.
WARNING
Danger for persons!
There is an increased risk of injury if the safety devices (e.g. fuses) are rendered
inoperative. Do not remove or deactivate any safety devices.
• Check the safety devices daily for correct operation.
• Malfunctions and defects concerning the safety devices must be reported
immediately to the after-sales service.
• The housing must be closed during the operation and may be opened only to
rectify malfunctions or to perform maintenance tasks.
• Repairs to pipe systems and tanks may only be carried out when the system is
depressurised.
• When handling chemicals, observe the applicable safety data sheets and disposal
instructions that are provided by the suppliers, as well as any relevant local safety
regulations. Wear protective clothing!
Any safety devices that have been removed for set-up, maintenance, or repair purposes
must be reinstalled and checked for correct operation immediately upon the completion
of the maintenance and repair work.
In the above case, particular attention must be paid to the general accident prevention
and safety regulations.
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VARISTAR Cooling unit SHX 30
Safety 8
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1.4 Intended use
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The unit or the system is intended solely for the application outlined in the
“Description/Overview” section and only with the components supplied and approved.
Using the unit for purposes other than those mentioned above is considered contrary to
the intended use. The manufacturer cannot be held liable for any damage resulting from
such use. The risk of such misuse lies entirely with the user.
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1.5 Terms of warranty
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The manufacturer is not liable for damage resulting from improper use, the failure to
observe this manual, the employment of insufficiently qualified personnel, or
unauthorised modifications. In these cases the manufacturer’s warranty is rendered void.
Notice
Unit function is affected when using incorrect spare parts!
When using components which have not been approved, correct operation can no longer
be guaranteed. Only use spare parts approved by the after-sales service.
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Notice
Caution - Loss of warranty!
The use of media that are not approved may result in damage to the unit or to the
system. The warranty will be rendered void. The same shall apply if different media are
mixed.
Use only media that have been approved by the manufacturer.
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Note
Removing type plates will make the warranty claim expire.
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Note
The warranty will be rendered void if seals are broken without authorisation.
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VARISTAR Cooling unit SHX 30
Safety 9
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1.6 Installation site
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When selecting an installation site, observe the following instructions:
• Keep the specified escape routes clear.
• Ensure firm support and a horizontal position of the unit.
• Comply with the data stated in the “Technical Data” section concerning the
ambient temperature for operation, transport, and storage when the unit is
completely empty.
• Ensure sufficient space for operating, maintaining, and cleaning the unit.
• Keep the air inlets and outlets free.
Comply with the relevant technical and building regulations.
Lay the hoses and electrical cables so that there is no danger of tripping and that they are
protected from damage.
When selecting an installation site, the applicable safety regulations and manufacturer
instructions concerning any substances that are used for, or located near, the machine
must be observed.
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1.7 Safety instructions for transport
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1.7.1 General information
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WARNING
Danger for persons!
Increased risk of injuries through improper transport.
The transport of the unit should be carried out only by suitably qualified persons who are
familiar with the unit and who have been informed as to potential hazards.
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Notice
Damaging of unit!
Damage due to improper transport.
• Make sure to follow signs (if attached) at unit when transporting unit.
• Transport units with suitable lifting gear only.
• Transport the unit only when it is empty.
• Transport on suitable and secured transporting pallet.
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WARNING
Danger of overturning!
Due to the slim set-up of the unit, there is a higher risk of injury when the unit tips over.
Ensure that the unit is sufficiently secured during the transport.
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VARISTAR Cooling unit SHX 30
Safety 10
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1.8 Safety instructions for set-up
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WARNING
Danger through faulty commissioning!
There is an increased risk of injury to persons who perform tasks for which they are not
suitably qualified or trained.
• The commissioning of the system shall only be carried out by persons familiar with
the system and instructed with respect to dangers and risks involved, also having
the required qualifications.
• Fulfil all safety-relevant conditions before commissioning.
• The location of the unit or of the system must correspond to the regulations
according to Chapter "Safety, Choice of Location".
Notice
Damage to components!
Danger of damage due to improper operation. Observe the description of additional
components, if included.
Note
Check all hoses and hose connections for leaks when commissioning the unit.
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VARISTAR Cooling unit SHX 30
Safety 11
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1.9 Safety instructions for maintenance
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WARNING
Carry out instructed maintenance works only!
There is an increased risk of injury to persons who perform tasks for which they are not
suitably qualified or trained.
• Maintenance works should be carried out only by suitably qualified personnel who
are familiar with the unit and who have been informed as to potential hazards.
• Repairs to pipe systems and tanks may only be carried out when the system is
depressurised.
WARNING
Connections alive!
Negligence can lead to electric shock.
Observe the following points when carrying out maintenance work on the electrical
system:
1. Disconnect the unit from the power supply in order to deenergise it.
2. Secure the unit so that it cannot be switched on again accidentally.
3. Check whether the unit is properly disconnected from power and absolutely
voltage-free
4. Earth and short-circuit the unit.
5. Cover any adjacent live parts and secure the danger area.
Notice
Damage to electronic components!
Take suitable measures (ESD protection measures) to prevent the electronic components
from being damaged due to electrostatic discharge.
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1.10 Disclaimer
Schroff shall not be held liable for any errors that may be included in this documentation.
Liability for direct and indirect damage that occurs in connection with the supply or use of
this documentation is excluded to the extent permitted by law.
Schroff reserves the right to change this document, including the disclaimer of liability, at
any time and Schroff shall not be liable for the potential consequences of these changes.
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VARISTAR Cooling unit SHX 30
Description / Overview 12
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2 Description / Overview
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2.1 General information
The cooling modules that are described in this instruction manual are part of a cooling unit
for the Schroff VARISTAR cabinet platform. In combination with the corresponding
VARISTAR cabinets, the cooling units are used to set up an enclosure.
Note
For the start-up of the cooling system, the cooling module must be connected to an
external re-cooling system (e.g. water chiller).
The unit is suitable for the use of water-glycol mixtures (33% glycol max.).
The power supply is ensured via a power supply unit. The power supply unit transforms
the mains voltage (AC, alternating voltage) into a direct voltage (DC) and it supplies
various components with power, including the control system and fans.
Since the fans are intended for a supply voltage of 48 V (DC), the cooling module can also
be used in telecommunications environments.
Note
See the circuit diagram.
2.2 Variants
The cooling modules are supplied as part of a Schroff VARISTAR cooling unit. The variants
and dimensions of the cooling units are configured based on the customer requirements
and VARISTAR cabinets that are used.
The following variants of the cooling modules are available:
• 60714-067: Cooling module, water connection at the bottom
• 60714-068: Cooling module, water connection at the bottom, redundant power
supply
• 60714-077: Cooling module, water connection at the top
• 60714-078: Cooling module, water connection at the top, redundant power supply
Note
• Cooling modules with a redundant power supply are equipped with two power
supply units and mains power inputs. They can be supplied with power via two
independent mains power sources.
• In the case of cooling modules with a water connection at the top, the condensate
outlet is also located at the top. These cooling modules are equipped with an
integrated condensate pump.

VARISTAR Cooling unit SHX 30
Description / Overview 13
2.3 Mode of operation
Fig. 1: Mode of operation of the cooling module (principle)
1 Cooling module
2 External recooler *)
3 Pump *)
4 Enclosure
*) (not included in the scope of supply)
The cooling units are positioned between the VARISTAR cabinets in an enclosure.
The fans of the cooling unit suck the warm air in at the back and guide it through an
air/water heat exchanger. The air will be cooled and blown out at the front.
The cooling system comprises an air circuit and a water circuit. In the air/water heat
exchanger, the thermal energy of the warm air is transferred to the water.
The air/water heat exchanger is connected to an external recooler (not included in the
scope of supply) that cools the heated water.
12366
1 2
3
4
4

VARISTAR Cooling unit SHX 30
Description / Overview 14
2.4 Air circuit
Example "cold aisle containment":
The fans of the cooling unit withdraw the heated air from the room and guide it through
an air/water heat exchanger. During this process, the thermal energy is transferred to the
water circuit. The cool air then fed into the cold aisle. A demister removes any condensate
that may have formed.
The condensate is collected in a condensate tray and discharged via the condensate pipe
at the top or bottom of the cooling module.
The fans that are distributed vertically over the entire cabinet height ensure a
homogeneous temperature stratification. As a result, the temperature difference can be
reduced and the efficiency of the cooling system can be increased.
Components of the air circuit:
• Air/water heat exchanger
• Demister
• Fans
• Temperature sensor (air)
2.5 Water circuit
The chilling medium of the external recooler (not included in the scope of supply) flows
through the air/water heat exchanger of the cooling modules and heats up. Then, it flows
back into the recooler. The temperature is controlled via an electric powered control valve
that controls the chilling medium flow based on the required cooling power.
Components of the water circuit:
• Control valve
• Air/water heat exchanger
• Water temperature sensor
Note
• The control valve in the water circuit of the cooling module is a straight-way valve
(2-way valve). The advantage of this solution is that only the quantity of water that
is required for cooling flows through the air/water heat exchanger. The circulation
pump can be operated with constant pressure and a variable quantity of water.
• For cooling systems that required three-way functionality, the cooling module can
also be supplied with a 3-way valve upon request.

VARISTAR Cooling unit SHX 30
Description / Overview 15
2.6 Control method
The fans and the control valve of the water circuit are actuated by a closed loop and open
loop control unit. A closed loop control circuit controls the flow of water through the
air/water heat exchanger as a function of the air outlet temperature of the cooling
module.
The cooling module has four temperature sensors; two in the air outlet at the top and at
the bottom as well as two temperature sensors in the air inlet at the top and at the
bottom. In addition, an external temperature sensor (option) can be connected. The
output signal of these sensors is used as the reference value for the control system. The
reference sensor can be selected in the settings menu.
In order to compensate for temperature stratifications, the air outlet temperature is
measured by two temperature sensor on different levels. The average value of these
temperature sensors is the control variable for the opening characteristics of the control
valve.
Under normal operating conditions, the fans run at constant speed.
In order to ensure sufficient air circulation in the cabinet, the factory setting is 80% of the
nominal speed. The operator can set this value within a range of 30% to 100% via the
settings menu.
If the set temperature is exceeded by 4°C (factory setting), the system will switch to
maximum cooling power, i.e. the control valve will open by 100% and the fan speed will be
increased to 100% of the nominal speed.
If the actual value falls below the set temperature by 3°C, the normal mode will be
resumed.
Note
The control characteristic is defined at the factory. However, it can be changed and
adapted by the service department of Schroff or by a licensed service partner.

VARISTAR Cooling unit SHX 30
Description / Overview 16
2.7 Alarms
The electronic control system can detect various malfunctions (e.g. cable break of a
temperature sensor, temperatures exceeding the limit values) and indicate them via the
display or interface.
In order to issue a visual alarm, there is an LED (red) above the control unit on the cooling
module.
The following error messages will be signalled:
• The actual fan speed is below the minimum speed.
• Failure of a fan.
• Cable break of a temperature sensor.
• Supply voltage of the electronic control system: undervoltage.
• Faulty Modbus communication.
• Failure of power supply unit 1 or 2.
• The actual cooling water temperature is above the limit value.
• Malfunction of the condensate pump (option).
• Door opened (option)
Note
In the event of a malfunction, refer to the "Troubleshooting" section.
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2.8 Incorrect use
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In general:
any incorrect use is classed as 'not for the intended purpose'. The manufacturer cannot be
held liable for any damage resulting from such use. The risk of such misuse lies entirely
with the user. Moreover, intended use of the unit also involves use in accordance with the
applicable international and national safety instructions as well as the safety instructions
in the manual.
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Amongst others, the unit is NOT intended for the following applications:
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• Outdoor use.
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• Non-compliance with the permissible technical data. See the "Technical data"
section.
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VARISTAR Cooling unit SHX 30
Description / Overview 17
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VARISTAR Cooling unit SHX 30
System Layout 18
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3 System Layout
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3.1 Overview
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Fig. 2: Heat exchanger
12299-01
4
2
9
A
B
3
6
5
7
8
10
1
R2
R3
R5
R4
R1

VARISTAR Cooling unit SHX 30
System Layout 19
1 Control valve with actuator
2 Power supply unit
3 Heat exchanger (air/water)
4 Switch box
5 Condensate pump with float switch (option)
6 Condensate tray
7 Demister
8 Fan
9 Control unit (display and operating unit)
10 LED (red)
- flashing: malfunction *)
Views
A Front view
B Back view
Temperature sensor
R1 Chilling medium inlet
R2 Air inlet (top)
R3 Air inlet (bottom)
R4 Air outlet (top)
R5 Air outlet (bottom)
Note
*) In the event of a malfunction, refer to the "Troubleshooting" section.
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VARISTAR Cooling unit SHX 30
System Layout 20
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3.2 Connections
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Fig. 3: Connections
12299-01
Y
X
1 2 3
6
“X“ 1 2 3
4
5