RackCDU™ Service Manual April 2015
Contents
1. Connect the plug on the new LED cable to the socket on the control box harness labeled LED Replace the top cover Page 25 of 30 v1 0 2015 04 6 11 Replacing the Leak Sensor The leak sensor is mounted in the spill tray at the bottom of the RackCDU and is slightly underneath the decorative wig on the RackCDU manifold There are two connectors on the leak sensor cable one in the top of the RackCDU near the control box and another at the bottom of the RackCDU When changing the leak sensor only disconnect the bottom connection Note this sensor looks very much like the reservoir level sensor However the function is different and the two sensors are not interchangeable Double check the label on the cable to make sure you have the correct part 6 11 1 Parts needed Asetek P N 11 900 0000106 Leak sensor RackCDU 6 11 2 Tools needed 6 11 3 Work Steps 1 Lift the right side of the spill tray up while sliding it to the right The leak sensor is on the left side of the drip pan 2 Unplug the Leak sensor from the cable in the bottom of the RackCDU The cable is tucked up under the decorative wing 3 Remove the spill tray fully from the RackCDU extension 4 Remove the Leak Sensor from the bracket by rotating it out with wrench 5 Install the new Leak Sensor to the bracket Plug the Leak Sensor cable to the cable in the bottom of the RackCDU 7 Slide the left end of the spill tray under the decorative wig of the RackCDU ma2. gt Q o gt p O o m gt A o l Illustration showing UE 2 Philips Screwdriver screw locations of NE 3 Philips Screwdriver RackCDU Cover Ce Step Ladder looking from rack side of RackCDU Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip of the cover return wings Lift off the cover and set it aside Disconnect Power to the Power supply Screw locations for removing cover Disconnect these two cable harnesses from the control box Remove the Monitoring Box by removing the 2 bolts one in each side Open the Monitoring box by pressing the two tabs on either side of the box and pulling the connector end out of the box end Cable Harness B Cable Harness A Monitoring Box Press these tabs to remove the electronics Ov 83 D9 EV 0 00 OVW Power Supply Page 16 of 30 v1 0 2015 04 7 Check the position of the control signal jumper a If itis in the 0 10V position you can install the replacement monitoring box without opening it b Ifthe jumper is in the 0 20uAmp position you must first open the replacement monitoring box and move the jumper from the 0 10V position to the 0 20UAmp position and close the box 8 Install the new Control Box using the two screws removed in step 5 9 Connect the two cables harness to the control box These cable connections are keyed differently and cannot be
3. Pressure Facilities Return Temp U nit Server Supply Temp Facilities Supply Temp Leak Sensor Server Liquid Supply Facilities Liquid Supply Facilities Liquid Return Server Liquid Return T Cable Harness A Cable Harness B Socket Connector P Pressure Sensor G Temperature Flow Sensor Sensor Level Sensor Optional Motorized Valve LED Indicator Drip Tray in bottom of RackCDU Heat Exchanger Page 9 of 30 v1 0 2015 04 6 1 Update Firmware for RackCDU Monitoring System Before you begin you will need to have a copy of the new firmware on a laptop computer and know the network address of the RackCDU monitoring box that you want to update If you do not know the network address of the RackCDU Monitoring box you can discover it using Asetek s RackCDU TCPIP Discoverer software see section 6 2 The current firmware version number can be viewed on the About page of the RackCDU monitoring system To view the about page connect a PC to the same network as the monitoring system Open a browser and type the network address of the RackCDU Monitoring system into the website address bar at the top of the browser window When the RackCDU window displays click on the About button at lower left The Software Revision number is near the top center of the page Firmware updates may be accomplished from either Windows or Linux operating systems Trivial File Transport Protocol TFTP is used to move the new firmware from the comput
4. and set to the side Place a funnel in the reservoir opening and add server coolant a When replacing coolant in response to a low level alarm from the RackCDU monitoring system add 3 5 liters b There should be an air gap of 20 mm 3 4 inch between the top of the liquid and the top of the tank Replace the cap the seal does not need to be replaced Screw the cap fully into the reservoir i Unscrew the cap until the line on the cap is aligned with the OPERATION line on the top cover of the RackCDU as shown at right This allows the tank to breathe with changing temperature and fluid volume Align these two lines Page 8 of 30 v1 0 2015 04 6 Servicing the RackCDU Monitoring System The RackCDU Monitoring system provides real time information on the operating condition of a RackCDU and can be configured to send warnings and alarms when operating conditions move beyond acceptable limits The RackCDU monitoring system consists of the RackCDU Monitoring System box a power supply a network connection and an array of sensors The diagram below illustrates the RackCDU monitoring system This section focuses on the Monitoring Unit and Power Supply Servicing of sensors is covered in subseguent chapters Liguid Level Recervoir 24 VDC Power 100to240vac A Pp Server Pressure Su pply 50 to 60Hz Flow Valve Control RJ45 Network Bi LED Indicator 44 Monitori ng Server Return Temp Facilities Liquid Flow Facilities
5. at the top of the RackCDU The only service available fora Facilities Pressure Sensor is to remove and replace it This service reguires shutting down all the servers attached to the RackCDU disconnecting the RackCDU from facilities liguid and at least partially draining facilities liguid from the RackCDU Once the malfunctioning sensor is replaced the RackCDU must be reconnected to facilities liguid and in the case of a RackCDU that receives liguid from the bottom air must be bled from the system 6 7 1 Parts Needed Asetek P N 11 900 0000099 Pressure Sensor Facilities Liguid 6 7 2 Tools Needed n n n a a a a m Wevfaryvacwm SSS 6 7 3 Work Steps 1 Shut down power off all servers connected to the RackCDU 2 Shut off the valves on both the supply and return side of the facilities liquid loop These valves are part of the facilities loop and are not located in the RackCDU 3 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip Screw locations for removing cover of the cover return wings 4 Set the cover aside 5 Use the Tool Kit Air bleeding Schrader valve and the low sided pan to take the pressure off of the liquid in the RackCDU and to partially drain the system a Put the open end of the tool in the low sided pan and hold in place Pressure will cause the tube to come out of the pan if not
6. held in place b Put the hose from the wet dry vacuum into the low sided pan and hold in place Turn on the wet dry vacuum c Put the Schrader valve end of the tool on the Schrader valve and allow the pressure to bleed off into the pan The Schrader valve is located at the opposite end of the RackCDU from where the RackCDU is connected to facilities liquid Schrader valve is on the top for bottom fed RackCDUs and on the bottom for top fed RackCDUs i For top fed RackCDUs allow all of the liquid to drain into the pan and get sucked into the wet dry vacuum there are about 3 liters of liquid in the RackCDU plus the liquid in the tubes plumbing between the RackCDU and shutoff valve Then remove the Schrader Bleed kit Page 19 of 30 v1 0 2015 04 ii For bottom fed units install a second bleed kit and use the wet dry vacuum to draw about a guarter of a liter of liguid out of the RackCDU Then remove both Schrader bleed kits 6 The pressure sensor is located at the top of the RackCDU It screwed into a T at the top of the facilities liguid supply line Facilities Pressure Sensor 7 Disconnect the pressure sensor from the RackCDU Monitoring system cable harness 8 Use the 24mm wrench to remove the malfunctioning pressure sensor 9 Install the new pressure sensor into the T fitting with the wrench 10 Connect the pressure sensor cable to the cable harness for of the monitoring system 11 Check the Sensors page on Ra
7. remaining glue Use a small amount of Acetone solvent and a cleaning cloth to dissolve and remove any remaining glue Take care that glue chips are not pushed into the RackCDU as they may foul quick connector filters Place three small drops of Loctite near the front of the threads on the male connector Install a new male quick connector using male quick connector wrench and a torque wrench set to 4Nm Wait 30 seconds to allow Loctite 480 to cure Connect the reservoir to RackCDU and remove the filling cap from the reservoir With the funnel pour the server coolant from the low sided pan into the reservoir CAUTION the connecting tube between the reservoir and the RackCDU manifold is small and the reservoir does not drain rapidly into the manifold Refill the reservoir in small steps allowing the liquid to drain from the reservoir into the manifold If needed the pump priming kit can be used to speed up the draining process i Install gender reversing connectors on the pump primer to reverse the flow direction ii Pumping direction should be from reservoir to RackCDU ii Connect the Pump Priming Kit between the top cold manifold quick connector and the reservoir v Squeeze the pump bladder repeatedly to push coolant into the RackCDU manifold If some server coolant spilled and was not captured in the low sided pan replace it with coolant from the 5L bottle DO NOT use water or some other coolant to refill the server side of the RackCDU Doing so wi
8. 5 gallon capacity Funnel with a small end opening of 18 mm or less Screwdriver 2 Philips Screwdriver 3 Philips Drip Pan 4 cm 1 75 inches tall 1 liter 1 quart capacity Hex Wrench size 16mm Hex Wrench size 22mm Hex Wrench size 24mm Adjustable Crescent Wrench Wire cutters Diagonal cutter Page 7 of 30 v1 0 2015 04 5 Routine Maintenance 5 1 Refilling Server Coolant Reservoir There is a reservoir at the top of the RackCDU extension As the liquid cooling system runs liquid gradually permeates through the rubber tubing and plastic parts in the system The reservoir contains sufficient fluid to replenish the liquid that permeates out of the system for more than 50 000 hours of 24 7 365 operation The RackCDU monitoring system will alert you when the fluid in the reservoir reaches a low point When a low coolant alert is received additional coolant may be added to the reservoir via a fill port at the top of the RackCDU The RackCDU must be filled with manufacturer DANGER provided server coolant Using water or other types of coolant will damage the server ELECTROCUTION cooling system RISK 5 1 1 5 1 2 mn Parts Needed Asetek P N 35 650 0000006 Asetek Coolant 35 Glycol 5L Tools Needed Funnel with a small end opening of 18 mm or less Work Steps Remove power from the entire rack This is to avoid the risk of electrical shock in the event of a spill Remove the fill cap
9. 8 Pressure Sensor Server Coolant Faty Hy 6 8 2 Tools Needed tavvsided Pan O JJ no Funnel with a small end opening of 18 mm or less 6 8 3 Work Steps 1 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip of the cover return wings 2 Set the cover aside Disconnect the power to the control box 4 Disconnect Reservoir from the Server Coolant Supply and Return manifolds by disconnecting the top guick connector on each manifold Push the guick connector toward the RackCDU until it stops While still pushing rotate it counter clockwise until it stops and pull the connector away from the manifold 5 Remove the 5 screws holding the reservoir to the extension one in each side and two at the lower rear edge of Reservoir and one below the shelf holding the Reservoir 6 Disconnect level sensor and the pressure sensor cables from the cable harness 7 Uninstall the control box from the Reservoir by removing the 2 screws at the top and bottom of the box 8 Lift the reservoir from the extension and move it to a workbench 9 Remove the cap on the top of the reservoir 10 Make sure the low sided pan is clean and then invert the reservoir over the pan to drain the cooling liquid from the reservoir 11 Set the pan and coolant aside 12 Use the 24mm wrench to remove the old pressure sensor 13 Apply
10. Disconnect all external power from the Rack 3 Disconnect the quick connectors for the reservoir tubes at the very top of RackCDU manifolds Push the quick connector in until it stops While still pushing rotate the connector counter clockwise until it stops Then slide the connectors apart 4 Disconnect all servers connected to both manifolds above at the same level and one level below the quick connector that will be changed 5 Make sure the low sided pan is clean Place the open end of the tube from the RackCDU Draining tool into the low sided pan 7 Connect the quick connector end of the RackCDU Draining tool on the quick connector immediately below the connector that is being changed 8 Place the vent quick connector from the RackCDU Draining tool on the top quick connector on one of the manifolds 9 Drain all of the coolant that will come out into the low sided pan 10 Set the pan of coolant aside and out of the way 11 Disconnect the drain tube and the vent quick connector from the RackCDU Page 29 of 30 v1 0 2015 04 S 12 13 14 15 16 17 18 19 20 21 22 Place the tool for removing male guick connectors over the connector to be removed and unscrew the old guick connector from the RackCDU a Ifthe body of the male quick connector breaks use the hex key Allen Wrench in the quick connector wrench kit to remove the base of the connector from the RackCDU Clean threads in RackCDU of any
11. LED assembly If the LED Light is on but the web page from the monitoring box does not display begin by checking the network address of the monitoring system using TCPIP Discoverer If you are unable to determine the network address by using the TCPIP Discoverer program it may be necessary to reset the monitoring box Page 14 of 30 v1 0 2015 04 6 4 Resetting the Monitoring box Resetting the monitoring box will replace all of the current settings in the box with the original factory defaults Doing this turns on automatic network address assigning from a DHCP server and resets the static network address of the box to the factory defaults The user name and password are both reset to admin This allows direct access to the monitoring box web page using a browser and by connecting directly from a notebook to the box with a network cable Configure the notebook s network adaptor to use the same subnet mask and gateway as the monitoring box and an address in the subnet besides 199 Point your browser at the box using the following address information Use your browser to reset the network address IP address 192 168 0 199 Gateway 192 168 0 1 Subnet mask 255 255 255 0 1 Remove the 4 screws holding the top cover of the RackCDU in place Two are Illustration showing located bottom far side edge of the cover and two more are located on the screw locations of bottom lip of the cover return wings RackCDU Cover 2 Lift off the cover and set it asid
12. OASETEK DATA CENTER LIQUID COOLING RackCDU Service Manual April 2015 Page 1 of 30 v1 0 2015 04 Table of Contents E IEF OCIUCTION sie ee po E o a a oa ee a ei 3 2 Spare PASS o A ea o al a aaa ON A A a 4 3 NOUS TOOLS a o ae a ee JA O kle din 6 a STANO TOON ae N ee oa Se ie 7 5 ROUNE Malntenan Ce see ja ei ea Ke ole a eki a nin danas ole oe ae a ej 8 S1 REM server Coolant Reservo aedes ea ea ee eV ee a coetanoneesetaeeartacceees 8 6 Servicing the RacKCDU Monitoring Systemsa snn an N ANAN 9 6 1 Update Firmware for RackCDU Monitoring System sssessesesssesesrrresrrerssreresrrerssrrreserereseereserereserresene 10 6 2 Determining the Network Address of a RackCDU Monitoring BOX ccccccssssccecessececeeeceseeeceeeeees 13 6 3 Trouble Shooting the RackCDU Monitoring System ccccccccsssccccesseccceesececeeecceseuseceseenececeueeceesenes 14 64 Ppesettine tne WIOMILOMING DOM ee a ee E a ee ja ee a eo 15 6 5 Replacing THE Monitoring BOX ia po ad ee a Ve ee en aa ie aus 16 6 6 iReplacetne POWETSUPPIV sa ee ee o a o be ve a ae ee ee ii 18 6 Replacing ThE Facilities Pressure SANSOM ni ie ea a ee ke ana ei rde beda neja 19 6 8 Replacing the Server Coolant Pressure SenSor ccccssseccccseccccescccceesececseeceesescceseuseceseuecessugeceesenes 21 6 9 Replacing The Facilities Flow SEMSON nin ja N obd ib a obu velike 23 6 10 REplacine tne LED INGICATOR ae a ai ed pode Siw lje eko ete bje ue teutauton
13. ackCDU Monitoring Box 6 2 1 Tools Needed Asetek P N Asetek RackCDU TCPIP Discoverer software n a Laptop PC n a Network Cable terminating with RJ45 connector 6 2 2 Work Steps 1 Connect a PC with Java and the TCPIP Software TCPIP Discoverer jar on it to the network with the DHCP server and the RackCDU Monitoring system on it 2 Open the program TCPIP Discover jar from the desktop or at the Command line type java jar TCPIP Discoverer jar 3 Click the Discover Devices button to scan for connected RackCDU monitoring boxes 4 The program will automatically find all the control boxes on the same subnet IP Address Host Name MAC Address Other Info 192 168 0104 SNMPAGENT 00 1E CO BF 2B E F Agent Page 13 of 30 v1 0 2015 04 6 3 Trouble Shooting the RackCDU Monitoring System This section covers replacing the monitoring box and or it s power supply Both the monitoring box and its power supply are located at the top of the RackCDU under the top cover 6 3 1 Tools Needed Asetek P N ee 2 Philips Screwdriver Step ladder ee Network Cable terminating with RJ45 connector multimeter 6 3 2 Trouble Shooting a RackCDU Monitoring Box When the RackCDU monitoring system is functioning properly the white LED near the top of the RackCDU should be Network illuminated and the web interface should be viewable by s Power pointing a web browser at the network address of the monitoring box If the w
14. ckCDU monitoring system web page Both the Facility pressure and Facilities water flow should read zero and show red indicators 12 Open the valves on both the supply and return side of the facilities liguid loop 13 Recheck the RackCDU Monitoring system Facilities pressure should show a positive pressure and both Facilities pressure and Facilities water flow should have green indicators A red on Facilities water flow would indicate that at least one facilities side valve was not opened properly If there is a red recheck the valves 14 For bottom fed systems place the open end of a Schrader bleed valve kit in the low sided pan Then bleed the air from the system by attaching the kit to one of the two Schrader valves until bubbles stop flowing from the tube Repeat this process on the second Schrader valve If the low sided pan starts to fill use the wet dry vacuum to suck the liquid out of the pan Air bleeding is not needed for top fed RackCDUs 15 Replace the top cover 16 Once the Facilities water flow shows green power on all of the servers connected to the RackCDU Page 20 of 30 v1 0 2015 04 6 8 Replacing the Server Coolant Pressure Sensor The server coolant pressure sensor is connected to the server coolant reservoir located at the top of the RackCDU extension The only service available for the server coolant pressure sensor is to remove and replace it 6 8 1 Parts Needed Asetek P N 11 900 000010
15. e looking from rack 3 Disconnect all of the sensor cables that share the same block header to the side of RackCDU monitoring box as the power supply 4 Disconnect the remaining block header 5 Remove the screw holding the box in place and take both the power supply and the control box out of the RackCDU 6 Ona bench separate the block header section of the monitoring box from the main housing by pinching the latches on the narrow sides of the box and pull out the PCA 7 Connect the power supply to power 8 With power on the monitoring PCB press and hold the switch at location SW2 for about 10 seconds 9 Use the default network address information above to directly connect to the monitoring box with a PC 10 When the web page displays you can reset the network addressing to what it needs to be for your network If the web page does not display and your PC s network card is setup properly to access this address directly via a local connection replace the monitoring box Location SW2 JTAG UART1 UART2 Page 15 of 30 v1 0 2015 04 6 5 Replacing the Monitoring Box The monitoring box is located at the top of the RackCDU under the top cover All of the connections to the monitoring box are made with a pair of connectors that are easily disconnected from the box should it need to be replaced 6 5 1 Parts needed 6 5 2 Tools needed 6 5 3 Work Steps 1 Asetek P N 11 900 0000104 Control Box for RackCDU
16. e and allow the pressure to bleed off into the pan The Schrader valve is located at the opposite end of the RackCDU from where the RackCDU is connected to facilities liquid Schrader valve is on the top for bottom fed RackCDUs and on the bottom for top fed RackCDUs i For top fed RackCDUs allow all of the liquid to drain into the pan and get sucked into the wet dry vacuum there are about 3 liters of liquid in the RackCDU plus the liquid in the Return Page 23 of 30 v1 0 2015 04 10 11 12 13 14 15 16 17 tubes plumbing between the RackCDU and shutoff valve Then remove the Schrader Bleed kit ii For bottom fed units move the low sided pan to a location under where the facilities liguid lines connect to the RackCDU re secure the wet dry vacuum hose in the low sided pan and turn it on Disconnect the facilities liquid line that connects to the RackCDU line with the flow sensor On bottom fed units allow the RackCDU and the hose to drain into the low sided pan and get sucked up by the wet dry vacuum Use the wrenches to remove the hose connection hardware CamLock or Tri Clamp fittings from the facilities return connection on the RackCDU Disconnect the flow sensor cable from the RackCDU sensor harness For bottom fed units this connection should be near the bottom of the RackCDU and for top fed units it will be near the RackCDU monitoring box Use a wrench to remove the malfunctioning flow sensor Use a wr
17. ench to install the new flow sensor Connect the flow sensor cable to the RackCDU Monitor wire harness Use the wrenches to reinstall the hose connection hardware CamLock or Tri Clamp fittings on the facilities return connection of the RackCDU Open the valves on both the supply and return side of the facilities liquid loop Recheck the RackCDU Monitoring system Facilities water flow should have green indicators A red on Facilities water flow would indicate that at least one facilities side valve was not opened properly If there is a red recheck the valves For bottom fed systems place the open end of a Schrader bleed valve kit in the low sided pan Then bleed the air from the system by attaching the kit to one of the two Schrader valves until bubbles stop flowing from the tube Repeat this process on the second Schrader valve If the low sided pan starts to fill use the wet dry vacuum to suck the liquid out of the pan Air bleeding is not needed for top fed RackCDUs Replace the top cover Once the Facilities water flow shows green power on all of the servers connected to the RackCDU Page 24 of 30 v1 0 2015 04 6 10 Replacing the LED Indicator The LED indicator is mounted in a dispersing lens near the top of the decorative wing on the RackCDU 6 10 1 Parts needed 6 10 2 Tools Needed Asetek P N 11 900 0000115 LED cable RackCDU na sa Philips Serewariver JJ ma septer OO nja Small flathead jewelers screw ar
18. ent Hex file is saved in a folder named c test and the RackCDU Monitoring box has the network address 192 168 0 118 1 Save the file WebAgent hex in a folder on the Linux computer 2 Connect the network port of this computer to the network port of the RackCDU or to the network to which the monitoring box is connected 3 From the Linux command line 4 Navigate to the folder where the file WebAgent hex is saved using change directory commands 5 From the directory were the WebAgent hex file is stored type tftp connect 192 168 0 118 binary put WebAgent hex Page 11 of 30 v1 0 2015 04 6 Linux will respond with a message that tells you the number of bytes sent and the time spent sending them 7 Open the RackCDU web site and confirm that the firmware has been updated by looking at the software version number on the About tab Commands Mav De SET per packet retransmission Timeout Set total ISUETANO5SM 5510 timeout nose vi n m z LEG Lae print help information Page 12 of 30 v1 0 2015 04 6 2 Determining the Network Address of a RackCDU Monitoring Box If the RackCDU Monitoring is getting its network address assigned to it by a DHCP server the address assigned by the DHCP server can be discovered using Asetek TCPIP Discoverer software Asetek TCPIP Discoverer is a Java application that can run on any PC with Java installed This PC must be connected to the same network as the DHCP server and the R
19. er to the RackCDU The commands used are different between Windows and Linux systems Both command sets are below The DOS command tftp is used to transfer the new firmware into the monitoring box 6 1 1 Parts Needed Asetek P N n a WebAgent hex file this file contains the new firmware 6 1 2 Tools Needed Asetek P N Laptop PC Network Cable terminating with RJ45 connector 6 1 3 Work Steps when Updating Firmware from a Windows PC In the example used here the WebAgent Hex file is saved Fay yu in a folder named c test and the RackCDU Monitoring 7 i box has the network address 192 168 0 45 Tum Windows features on or off Totum a feature on select its check box To turn a feature off clear its 1 Save the file WebAgent hex in a folder on a laptop check box A filled box means that only part of the festure is turned on 2 Make sure that TFTP is enabled in Windows Do this by EE Subsystern for UNIX based Applications a opening the Control Panel and navigating to Control Na a a Panel Programs Programs and Features and selecting ry s no Turn Windows features on or off In the left navigation El Windows Gadget Platform menu make sure that TFTP Client is checked FE Windows Process Activation Service IK Windows Search EI Windows TIFF Filter s 47 K A PS Senaces Fld XPS Viewer Page 10 of 30 v1 0 2015 04 3 Connect the network port of this laptop to the network por
20. etatanmmudaauets 25 611l REPla inE TNE Leal SENSO Vane aa ee ea oe s o ee re obeh a eni 26 612 IREDIACE LEVEl SENSOR ui nine a te Siw ates aaa k ete ee ba ote ded ib nika eja 27 Replacing Quick CONNECUOFS ani ie o ee ie oba ne a oe a eo bet delte 29 Page 2 of 30 v1 0 2015 04 1 Introduction This manual provides guidelines for servicing RackCDU systems Server coolant is the only item with a routine service interval This service consists of topping off the server coolant reservoir at the top of the RackCDU This service is reguired following roughly 50 000 hours of operation From time to time firmware updates may become available for the RackCDU monitoring system Each firmware update will come with its own firmware updating instructions However this manual includes general guideline for updating the firmware in a monitoring box The other serviceable items on the RackCDU include the sensors and monitoring system in the RackCDU and the RackCDU and guick connectors These items are not expected to fail during normal operation of a RackCDU The only reason to service these items is if they become damaged lost or cease to function during the operational life of the RackCDU A full list of the serviceable items appears in the Spare Parts List below Servicing some of the items on a RackCDU will require disconnecting the RackCDU from facilities water or the rack from power Guidelines for disconnecting and connecting facilities liqu
21. hite LED is off and the web page from the monitoring box does not display begin by checking the power system for the RackCDU 1 Check that the power cord for the monitoring box is fully plugged into a power strip and that the strip is on 2 Check that the power cord is fully plugged into the socket on the top right side of the RackCDU below the network port 3 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip of the cover return wings 4 Lift off the cover and set it aside 5 Check that the cord from the rear of the power cable socket is fully plugged into the power supply 6 Check that the cable from the power supply and the cable Screw locations for removing cover to the monitoring box are fully connected If all of these elements are in good working order begin by testing the power supply 7 Disconnect the cable between the power supply and the monitoring box Check that the power supply is delivering 24VDC Pin 1 is ground and pin 2 is 24VDC If it is not delivering the required voltage replace the power supply If the power supply is working check the power to the LED indicator 8 Disconnect the LED cable from the monitoring box and test that the monitoring box is delivering 3 3VDC to the LED Pin 1 is 3 3VDC and Pin 2 is ground If it is not change the monitoring box If 3 3VDC is being delivered replace the
22. id are included in this manual Servicing some items requires unique tools These tools are listed in the unique tools list below These tools are available from Asetek Page 3 of 30 v1 0 2015 04 Illustration of RackCDU showing location of serviceable parts 2 Spare Parts List 11 900 0000100 Quick Connector Male Thread RED 11 900 0000101 Quick Connector Male Thread BLUE 11 900 0000102 Hex Head Plug 1 2 Reservoir Cap 11 900 0000103 Power supply Assembly 24 V 80W 11 900 0000104 Control Box for RackCDU 11 900 0000115 LED cable RackCDU 11 900 0000107 Level sensor RackCDU 11 900 0000106 Leak sensor RackCDU 11 900 0000105 Flow sensor RackCDU Page 4 of 30 v1 0 2015 04 Ob 83 D9 EV 70 00 OVI AsetekP N Description Photo 11 900 0000099 Pressure Sensor Facilities liquid 11 900 0000108 Pressure Sensor Server Coolant 35 650 0000004 Coolant 35 Glycol 10L bottle Be 35 650 0000006 Coolant 35 Glycol 5L bottle Page 5 of 30 v1 0 2015 04 3 Unique Tools 35 699 0000002 Tool kit Pump Priming Kit Server Coolers 35 699 0000003 Tool kit Quick Connector Wrench Set 35 699 0000004 Tool kit RackCDU Test Cables 35 699 0000005 Tool kit Air Bleeding Schrader valve 35 699 0000006 Tool kit Flow Tester Asetek OC 35 699 0000007 Tool kit RackCDU drainer Page 6 of 30 v1 0 2015 04 4 Standard Tools Step Ladder Wet dry shop Vacuum 10 litter 2
23. interchanged 10 Connect the power to the power supply Jumper to select 0 10V or 4 20mA control Page 17 of 30 v1 0 2015 04 6 6 Replacing the Power Supply The power supply is located at the top of the RackCDU immediately behind the top cover All of the connections to the power supply are made with plugs that are easily disconnected from the supply should it need to be replaced 6 6 1 Parts needed Asetek P N 11 900 0000103 Power supply Assembly 24 V 80W Pe Double adhesive tape RS 685 1661 6 6 2 Tools needed O pouble adhesive tape RS 6854661 Fre pis screwdriver Jstepuadder O 6 6 3 Work Steps 1 Disconnect the power cable on the right outside face of the RackCDU top enclosure 2 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip of the cover return wings Disconnect the power to the Power Supply Disconnect the power core to the Control Box Remove the Power Supply which is fixed with tape Tape in the new Power Supply in at the same spot Connect the power core to the Control Box Connect the power cable to the power supply Replace the top cover 10 Reconnect the power cable on the right outside face of the RackCDU top enclosure ON DMA w Power Supply Page 18 of 30 v1 0 2015 04 6 7 Replacing the Facilities Pressure Sensor The facilities side pressure sensor is located
24. ll void your warranty and will very likely result in damage to the cooling system over time Once all of the server coolant is returned to the reservoir begin re connecting servers Start with the lowest servers and periodically use the pump priming tool to make sure that the servers are getting coolant If the rack was drained before the servers were disconnected use the pump priming tool on every server as it is reconnected Once the filling process is completed replace the reservoir cap screwing it all the way into the reservoir then rotating it counter clockwise until the line on the cap aligns with the OPERATION line on the RackCDU cover Reconnect the rack to external power Restart the servers Page 30 of 30 v1 0 2015 04
25. nifold while lowering the right edge down and into place3 m Page 26 of 30 v1 0 2015 04 6 12 Replace Level Sensor The server coolant level sensor is connected to the server coolant reservoir located at the top of the RackCDU extension The only service available for the sever coolant level sensor is to remove and replace it Note this sensor looks very much like the leak detection sensor However the function is different and the two sensors are not interchangeable Double check the label on the cable to make sure you have the correct part 6 12 1 Parts needed Asetek P N 11 900 0000107 Level sensor RackCDU 6 12 2 Tools needed T NIH Wrench 16 mm Low sided Pan Funnel with a small end opening of 18 mm or less 6 12 3 How to replace the Level Sensor 1 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located at either end of the reservoir 2 Set the cover aside Disconnect the power to the control box 4 Disconnect Reservoir from the Server Coolant Supply and Return manifolds by disconnecting the top guick connector on each manifold Push the guick connector toward the RackCDU until it stops While still pushing rotate it counter clockwise until it stops and pull the connector away from the manifold 5 Remove the 5 screws holding the reservoir to the extension one in each side and two at the lower rear edge of Rese
26. plumber s putty and install the new pressure sensor using the 24mm wrench to tighten it into place 14 Use the funnel and return the coolant from the low sided pan to the reservoir 15 Replace the cap screwing it fully into the reservoir with your fingers 16 Reattach the reservoir to the RackCDU extension five screws 17 Connect the pressure sensor and level sensor cables to the harness Page 21 of 30 v1 0 2015 04 18 T9 20 21 22 Reinstall control box on Reservoir Reconnect power to the control box Replace the top cover Reconnect the Reservoir to the RackCDU by connecting the Red Female Connector from the Reservoir to the top Red Male Connector on the RackCDU and the Blue Female Connector from the Reservoir to the top Blue Male Connector on the RackCDU Rotate the reservoir cap counter clockwise until the line on the cap aligns with the OPERATION line on the top cover Page 22 of 30 v1 0 2015 04 Op poi s of cf A 6 9 Replacing the Facilities Flow Sensor The flow sensor is located at the top or the bottom of a RackCDU at the point where the RackCDU is connected to facilities liguid The only service available for this sensor is to remove and replace it This service reguires shutting down all the servers attached to the RackCDU disconnecting the RackCDU from facilities liguid and at least partially draining facilities liguid from the RackCDU Once the malfunctioning sensor is
27. replaced the RackCDU must be reconnected to facilities liguid and in the case of a RackCDU that receives liquid from the bottom air must be bled from the system 6 9 1 Parts needed Asetek P N 11 900 0000105 Flow sensor RackCDU 6 9 2 Tools needed Asetek P N 35 699 0000005 Tool Kit Air bleeding Schrader valve 2 Philips Screwdriver n a n a n a 2 Adjustable Wrenches 8 inch n a a Low sided pan 10 cm 4 inches tall minimum 4 liter 4 quart capacity ma weyary vaewur 6 9 3 Work Steps 1 Shut down power off all servers connected to the RackCDU 2 Shut off the valves on both the supply and return side of the facilities liguid loop These valves are part of the facilities loop and are not located in the RackCDU 3 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip of the cover return wings 4 Set the cover aside 5 Use the Tool Kit Air bleeding Schrader valve and the low sided pan to take the pressure off of the liquid in the RackCDU and to partially drain the system a Put the open end of the tool in the low sided pan and hold in place Pressure will cause the tube to come out of the pan if not held in place b Put the hose from the wet dry vacuum into the low sided pan and hold in place Turn on the wet dry vacuum c Put the Schrader valve end on the tool on the Schrader valv
28. rvoir and one below the shelf holding the Reservoir 6 Disconnect level sensor and the pressure sensor cables from the cable harness 7 Uninstall the control box from the Reservoir by removing the 2 screws at the top and bottom of the box 8 Lift the reservoir from the extension and move it to a workbench 9 Remove the cap on the top of the reservoir 10 Make sure the low sided pan is clean and then invert the reservoir over the pan to drain the cooling liguid from the reservoir 11 Set the pan and coolant aside 12 Use the 16mm wrench rotate the old level sensor counter clockwise and remove it from the reservoir 13 Install the new level sensor Page 27 of 30 v1 0 2015 04 oe 14 15 16 17 18 19 20 21 22 Use the funnel and return the coolant from the low sided pan to the reservoir Replace the cap screwing it fully into the reservoir with your fingers Reattach the reservoir to the RackCDU extension five screws Connect the pressure sensor and level sensor cables to the harness Reinstall control box on Reservoir Reconnect power to the control box Replace the top cover O Reconnect the Reservoir to the RackCDU by connecting the a O Red Female Connector from the Reservoir to the top Red Male Connector on the RackCDU and the Blue Female Connector from the Reservoir to the top Blue Male Connector on the RackCDU S Rotate the reservoir cap counter clockwise until the line on ge
29. t of the RackCDU or to the network to which the monitoring box is connected 4 Opena Windows Command Prompt window 5 Navigate to the folder where the file WebAgent hex is saved using the change directory command cd In this example type cd cd cd test 6 Once in the directory containing the file called WebAgent hex type the tftp command In this example type tftp i 192 168 0 45 put WebAgent hex WebAgent hex 7 After about 15 second the Transfer successful will appear Close the command prompt 9 Confirm that the firmware has been updated by using a web browser to open the RackCDU monitoring page and checking the software revision on About screen EH Administrator Kommandoprompt cs nee Microsoft Windows Version 6 3 9600 fc 26135 Microsoft Corporation Alle rettigheder forbeholdes SWINDOWS systemi ed o slindows gt cd zt ed test test rdir Uolume in drive C is Windows Volume Serial Mumber is HCFHA DE 4 Directory of GC i test 21 10 2813 12 56 lt DIR gt 2171072013 12 58 lt DIR gt Sa 21 18 2013 12 58 1 297 366 WebAgent hex 1 Filets 1 297 366 bytes 2 Dirts 149 025 402 880 bytes free Cistest gt titp 192 168 60 45 put WehAgent hex WebAgent hex Transfer successful 1297366 bytes in 13 secondis 99797 bhytes s Gri test gt 6 1 4 Work Steps when Updating Firmware Update a Linux Computer In the example used here the WebAg
30. the cap aligns with the OPERATION line on the top cover A Page 28 of 30 v1 0 2015 04 7 Replacing Quick Connectors Replacing quick connectors requires shutting down and disconnecting all of the servers from the RackCDU The reservoir must also be disconnected and the RackCDU manifolds drained to the quick connector one below the connector being replace The two manifolds are connected to one another through the heat exchangers in the RackCDU Draining one manifold also drains the other There is no normal maintenance that requires draining server coolant from a RackCDU and in general this should not be done Should a RackCDU be drained of coolant while servers are still connected to the RackCDU will likely cause some of the server coolers to be drained as well The pumps inside a server cooler are not self priming Should a server cooler become drained use the Pump Priming Kit to make sure the cooler is fully primed before starting the server 7 1 1 Parts needed Asetek P N 11 900 0000100 Quick Connector Male Thread RED 11 900 0000101 Quick Connector Male Thread BLUE Coolant 35 Glycol 5L O Acetone solvent a m Loctite 480 thread locking glue 7 1 2 Tools needed Asetek P N 35 699 000000X RackCDU draining kit 35 699 0000002 Tool kit Pump Priming Kit Server Coolers o flowsidedPan O unmet rorave wrenchsettoanm JJ 7 1 3 Work Steps 1 Shut down turn off all servers in the RackCDU 2
31. ver nja 50cm of narrow gage wire or string n a n a n a n a a 6 10 3 Work Steps 1 Remove the 4 screws holding the top cover of the RackCDU in place Two are located bottom far side edge of the cover and two more are located on the bottom lip of the cover return wings 2 3 4 10 11 12 13 14 15 Set the cover aside Disconnect the LED cable from the harness attached to the control box the cable is labeled LED There is a black collar that surrounds the LED Use the jeweler s screw driver to gently pry the collar away from the manifold then pull the collar out of the manifold a short distance Remove the collar from the LED Note the collar has locking tabs When the collar is pushed into the hole in the RackCDU these tabs bite into the LED cable Twist the collar and the cable in opposite directions to disengage these tabs and then slide the collar over the LED Tie the string or wire around the cable at the base of the LED Slowly push out the LED and cable through the LED pocket in the RackCDU Pull the plug end of the cable up lifting the LED out of the RackCDU Take care not to pull the string all the way through the hole in the RackCDU Untie the string from the old LED and tie it to the new LED Pull on the string to guide the new LED to the hole in the RackCDU Untie the string Place the new collar over the new LED Insert the new LED and collar into the LED pocket in the RackCDU
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