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Black Box Network Hardware Cold Row DX User's Manual

1. Screen Lock Feature 724 746 5500 blackbox com Page 61 Chapter 4 E2 Controller You may lock any of the status display screens bypassing the display screen time out function This is sometimes useful to maintain visibility to a specific screen when testing making adjustments or troubleshooting the system Simultaneously press the program PO key and Enter Y key for approximately 3 seconds to turn the screen lock feature On or Off When a screen is locked it remains displayed unless you press the Up A or Down arrow keys to select a different screen within the menu loop A symbol El appears in the upper right corner indicating the screen lock feature is On Continued from previous page 4 5 2 5 Remote Supply Temperature Humidity Sensor Rem Suppl Temp Sensor 00 0 F The remote temperature and humidity screens appear if your unit is configured H for a remote supply T H sensor The screens display the supply air temperature and humidity as measured by the sensor that is to be customer installed in the Lo J cold aisle Remote dewpoint is calculated by the controller based on the Press for fen Key remote supply T H sensor inputs and shown at the bottom of the display screen Values measured by the sensor may be used to control the Rem Supp Sensor idi Rem Suppl Hum Sensor temperature and humidity 00 rh Remote dewpoint 00 0 F be coe be 4 or 4 Key 4 5 2 6 Discharge Pressure r The
2. Startup delay Time delay before blower s begin operating after pushing the Enter U key after turning the unit on with a remote on command Airflow delay Time delay for allowing the blowers to reach adequate speed before the air proving sensor actively monitors an airflow alarm condition Shutdown delay Time delay before unit stops operating after pressing the Enter U key for three seconds or after turning it off with a remote off command Recovery time Time period after startup that temperature and humidity alarms are masked from signaling nuisance high or low temperature and humidity alarms T H Offset Scaling _1 H Offset Multiplier Temperature Scale 1 0 Humidity Scale 1 0 Scales effect all the cut in cut out values Figure 4 53 T H Offset Scaling screen The Service gt Options gt T H Offset Multiplier screen allows you to enter a multiplier to apply to scale both the temperature and humidity cut in cut out offsets The multipliers are factored to the system offset values set by the factory shown below Default Cut in Cut out Offsets Temp Cut in Offset 2 0 F Cut out Offset 0 3 F Humidity Cut in Offset 5 0 Cut out Offset 2 0 Page 76 724 746 5500 blackbox com Chapter 4 E2 Controller EXAMPLE 1 Temperature Offset Multiplier With the default cut in offset for temperature at 2 0 F a multiplier of 1 0 x 2 F 2 F This means the unit will begin operating
3. Display Description Unit Total in Network Min Number Active Enb lead override Lead Unit Unit ACTIVE Total in Network Min Number Active En lead override Lead Unit Chapter 4 E2 Controller Figure 4 76 Factory gt Groups gt Groups Contig Screen 1 See Table 4 12 Table 4 12 Factory gt Groups gt Groups Config Screen 1 parameters Description Assign the duty of the A C unit within the group The duty must be assigned for each A C unit at its local display terminal Enter the total number of A C units in the group Enter the total number of active A C units in the group If set to yes you may manually assign the lead unit in the following field Lead Unit Identifies which A C unit controller is currently the lead unit in the group If Enb lead override is set to yes you may select which unit is lead aa Group Rotation Force Rotation Off Number of Days 00 Hour of Day 00 Cur lead L Ret Unit O Next lead 0 Value 0 Variables Default O Out of Service 1 Active 2 Standby 3 Assist 4 Active_No_Rot 5 Standby_No_Rot 6 Assist_No_Rot 0 to 9 1 0 to 9 1 O No No 1 Yes 1to8 1 Figure 4 77 Factory gt Group gt Group Rotation Screen 2 From this screen you may set the schedule to rotate operation of the A C units to promote equal run times 724 746 5500 blackbox com Page 91 Chapter 4 E2 Controller Display Description Force Rotation Number of Days Ho
4. If the offset for the humidity alarm is set at 5 default the high humidity alarm will cancel when the actual humidity drops to the High Humidity Alarm setpoint 70 0 the Offset 5 0 Or 70 0 5 0 65 0 The High Humidity Alarm will cancel at 65 724 746 5500 blackbox com Page 69 Chapter 4 E2 Controller Dirty Filter Timer Ze Dirty Filter Alarm Enable Yes Days between filter change alarms 45 Figure 4 36 Dirty filter timer This screen allows you to enable the dirty filter notification timer which provides an alarm indication when it s time to clean or change the air filter The filter change period is adjustable and should be set according to the conditions at the site Extremely dusty environments may require more frequent filter changes 4 5 4 3 Clock Screen CONTROL Alarm Set CLOCK Version Figure 4 37 Clock screen The Clock screens may be accessed from the Control menu From this screen you may set the time date and day Set ee POC kK Time 00 00 Date 00 00 0000 Day XXXXXXX Figure 4 38 Set Clock screen The Set Clock screen allows you to set and or adjust the current time date and day 4 5 5 Service Menu Loop Control SERVICE OQ Factory Figure 4 39 Service Menu Loop screen The service screens enable the user to enter cut in and cut out values calibrate the system control sensor s save and restore parameters and view the event log The Servic
5. Model Liquid Line Discharge Line Condensate Drain CRDX W FS 12W cys i CRDX W FS 24WwW P he 2 CRDX G FS 12W l CRDX G FS 24W A 2 2 8 1 1 DX Refrigerant Piping Connections CONDENSATE DRAIN i FPT SUCTION LINE LIQUID LINE Ks S N z d X S KC wi SEN LIQUID LINE SUCTION LINE TOP ACCESS PIPING BOTTOM ACCESS PIPING Figure 2 11 DX refrigerant piping connections Page 30 724 746 5500 blackbox com Chapter 2 Installation 2 8 1 2 Refrigerant Pipe Sizing Refrigerant lines for split systems must be sized according to the piping distance between the evaporator and the condenser Each valve fitting and bend in the refrigerant line must be considered in this calculation Pipe sizes are given for equivalent feet not linear feet Do not confuse the terminologies For example a 57 standard 90 elbow has an equivalent length of 1 5 feet a 7 branch tee has an equivalent length of 3 5 feet These corrections must be accounted for when sizing your piping NOTE Refrigerant piping between the Cold Row unit and the remote condenser must not exceed 150 feet total equivalent length The maximum level drop from the Cold Row unit to the condenser must not exceed 20 feet NOTE Consult ASHRAE standards and refer to the C
6. misapplication improper or lack of maintenance negligence accident normal deterioration including wear and tear or the use of improper parts or improper repair Purchaser s remedies are limited to replacement or repair of non conforming materials in accordance with the written warranty This warranty does not include costs for transportation travel expenses costs for removal or reinstallation of equipment or labor for repairs except as set forth above or replacements made in the field If any sample was shown to the buyer such sample was merely to illustrate the general type and quality of the product and not to represent that the equipment would necessarily conform to the sample This is the only warranty given by the seller and such warranty is only given to the buyer for commercial or industrial purposes The warranty is not enforceable until the invoice s is paid in full THIS FOREGOING SHALL CONSTITUTE BLACK BOX NETWORK SERVICES ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY IN NO EVENT SHALL BLACK BOX NETWORK SERVICES BE LIABLE FOR ANY DEFECT INDIRECT SPECIAL INCIDENTAL CONSEQUENTIAL OR EXEMPLARY DAMAGES INCLUDING LOST PROFITS EVEN IF ADVISED OF THE POSSIBILITY THEREOF ARISING IN ANY WAY OUT OF THE INSTALLATION USE OR MAINTENANCE OF THE EQUIPMENT THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty superse
7. 1 33 44 7 20 1 50105 10 97 1 72 11 15 53 H 158 29 34 09 Example Estimate the amount of refrigerant required for a refrigeration circuit in a system using R410A refrigerant consisting of a CRDX A FS 12KW unit connected with a x 30 foot liquid line and x 30 foot discharge line to a BB O60 SEC or BB 060 SSA condenser A C Unit 3 9 lb Liquid Line 30 x 5 88 100 1 764 lb 7 Discharge Line 30 x 4 22 100 1 266 Ib Condenser 2 8 lb Estimated Refrigerant Charge 9 73 Ib Round off to nearest 0 1 lb 9 7 Ib 2 10 2 2 Preparing System For Charging 1 With all the system piping connections made perform a dry nitrogen leak detection test on the system Using dry nitrogen only pressurize the system to 150 psig Ensure all service and solenoid valves are energized open and that no part of the system is isolated from the pressurized nitrogen 2 Since there is no refrigerant in the system to detect at this point leaks may be detected by observing if there s been a change in the standing pressure after 12 hours A significant drop in pressure gt 10 psig indicates a leak in the system that needs to be repaired After the system is determined to be free of leaks you may evacuate the system Evacuate the System CAUTION J A proper vacuum must be drawn on the refrigerant system to remove moisture prior to charging If this is not done the refrigerant charge will combine with moisture in the pipes to form a
8. Ce Figure 4 58 Digiral In screens The Service gt Digital In screen is provided for information only It shows the state of each digital input as either Closed 24 V or Open Gnd 4 5 5 7 Run Hours SERVICE Digital In RUN HOURS CR BMS Comm Press Enter a Key n Star Ss Rum HOUrS Compressor D se SC SES Reset GEE Figure 4 59 Run hours screens From the Service gt Run Hours menu you may access a loop consisting of the component run hours display screens applicable to your unit using the Up and Down arrow keys Each screen displays the number of run hours and number of starts logged for the component i e compressor fans air filter changes etc The run hours and start values may be reset to O from the display screens The values displayed in each screen are the values logged since the last time the screen was reset Page 82 724 746 5500 blackbox com Chapter 4 E2 Controller 4 5 5 8 BMS Communications SERVICE Run Hours BMS COMM CR Save Cfg Press Enter aH Key BMS Communications Address 01 Baud Rate 19200 Prococel s BACnet BMS keep alive 0 Figure 4 60 BMS Communcations screens The Service gt BMS Comm menu is used to set up parameters to allow a BMS BAS to interface with the controller See Section 4 7 2 tor a description of this screen and instructions for setting up BMS communication 4 5 5 9 Save Configuration SERVICE BMS Comm SAVE CFG CR Factory
9. F Displayed 0 0 F Figure 4 44 Display screens Additional sensor offset screens are available for optional sensors if enabled at the factory such as Remote Supply Air Temp and Remote Supply Air Humidity NOTE When calibrating sensors an offset at one extreme may produce an error at the other extreme Always verify that any offset is valid over the entire range of the sensor 724 746 5500 blackbox com Page 73 Chapter 4 E2 Controller 4 5 5 4 Blower SERVICE Sensors BLOWER Options Figure 4 45 Blower screen From the Service gt Blower menu you may access screens to view and adjust the blower speed parameters Temp Zone Setup Upper Temp Min Fan Speed Max Fan Speed Var Dampening Prop Temp Bnd Current Speed Var from Avg Middle Temp Zone Min Fan Speed Max Fan Speed Var Dampening Prop Temp Bnd 3 Prop Temp Bnd Current Speed 0 Current Speed Var from Avg j Var from Avg Figure 4 46 Temperature zone setup screen If your unit is configured for zone temperature control Blower gt Temp Zone display screens are available for the upper middle and lower fan These screens allow you to adjust minimum and maximum fan speed settings and modify the fan speed proportional integral PI control response parameters The variable dampening value used with Variance From Average fan speed control see Section 4 4 4 1 adjusts the effect of the variance on the final fan speed Blower Setu
10. n ser le das antes de que el aparato el ctrico sea operado Las instrucciones de seguridad y operaci n deber n ser guardadas para referencia futura Todas las advertencias en el aparato el ctrico y en sus instrucciones de operaci n deben ser respetadas Todas las instrucciones de operaci n y uso deben ser seguidas El aparato el ctrico no deber ser usado cerca del agua por ejemplo cerca de la tina de ba o lavabo s tano mojado o cerca de una alberca etc El aparato el ctrico debe ser usado nicamente con carritos o pedestales que sean recomendados por el fabricante El aparato el ctrico debe ser montado a la pared o al techo s lo como sea recomendado por el fabricante Servicio El usuario no debe intentar dar servicio al equipo el ctrico mas alla a lo descrito en las instrucciones de operaci n Todo otro servicio deber ser referido a personal de servicio calificado El aparato el ctrico debe ser situado de tal manera que su posici n no interfiera su uso La colocaci n del aparato el ctrico sobre una cama sofa alfombra o superficie similar puede bloquea la ventilaci n no se debe colocar en libreros o gabinetes que impidan el flujo de aire por los orificios de ventilaci n El equipo el ctrico deber ser situado fuera del alcance de fuentes de calor como radiadores registros de calor estufas u otros aparatos incluyendo amplificadores que producen calor El aparato el ctrico deber se
11. whether it comes from a real sensor or a BMS analog output Refer to Section 4 9 for the E2 controller s BMS parameters 4 7 2 BMS Communication SERVICE Alarms BMS Comm 9 Run Hours Figure 4 92 BMS Comm screen 1 The Service gt BMS Comm menu is used to set up the parameters to allow a BMS BAS interface for monitoring controller opera tion for the serial based networks such as BACnet MS TP Units using the BACnet over IP BACnet over Ethernet or HTTP proto cols do not need to change anything in this menu loop BMS Communications Address 1 Baud Rate 19200 Protocol BACnet BMS keep alive 1 Figure 4 93 BMS Comm screen 2 The BMS address and baud rate have meaning only on RS 485 networks and with the serial protocols of Modem Modbus RTU Commission and Carel The baud rate is fixed for BACnet Systems using a 10BASE T interface should use the defaults of address 1 baud rate 19200 and protocol BACnet Certain Integer and Digital variables that start with BMS see Sections 4 9 7 4 9 9 require that the BMS keep alive parameter changes between 1 and 2 within a 10 minute span The general procedure is to set up variables like the BMS low fan speed and then write a 1 to the BMS keep alive address Page 102 724 746 5500 blackbox com Chapter 4 E2 Controller 4 8 Troubleshooting the Control I O Module Signal LEDs The E2 control I O module includes three signal LEDs red yellow and green tha
12. 5500 blackbox com Chapter 4 E2 Controller Humidity Alarm Low alarm Enable Yes Setpoint 30 STATUS Hum 45 6 set 45 0 Dew 50 1 R Figure 4 33 Low humidity alarm Following the alarm enable screens are the alarm offset screens From these screens you may adjust offsets for the high and low alarm setpoints at which the alarm will be cancelled The entered offset applies to both the upper and lower values entered in the alarm setpoints screens The offset is subtracted when it s applied to the high alarm setpoint and it is added when it s applied to the low alarm setpoint EXAMPLE 1 Temperature Alarm Offset we temperature Alarm Offset 50 F STATUS Temp 72 6 F Sett 72 0 F Dew 50 1 F Figure 4 34 Temperature alarm offset If the offset for the temperature alarm is set at 5 0 F default the high temperature alarm will cancel when the actual temperature drops to the High Temperature Alarm setpoint 80 0 F the Offset 5 0 F Or 80 07 E 5 0 P 750 F The High Temperature Alarm will cancel at 75 F Conversely the low temperature alarm will cancel when the actual temperature rises to the Low Temperature Alarm setpoint 60 0 F the Offset 5 0 F Or 60 0 F 5 0 F 65 0 F The Low Temperature Alarm will clear at 65 0 F EXAMPLE 2 Humidity Alarm Offset Humidity Alarm Offset STATUS Tempo 72 6 F Set 72 0 F Dew 50 1 F Figure 4 35 Humidity alarm screen
13. CLOCK CR Version Figure 4 7 Flashing window From this position the Up 4 and Down arrow keys may be used to access additional selections within the current display menu Each screen supports a specific functional requirement Pressing the Enter i key allows you access to the selected display screens to adjust any of the modifiable fields If a screen with modifiable values is accessed you may use the Enter key to insert a flashing cursor in the modifiable fields within that screen SET CLOCK Time 00 00 Flashing Date 00 00 0000 Cursor Day XXXXXXX Figure 4 8 Flashing cursor If the flashing cursor is located in a modifiable field the value of the field will be changed using the up 4 and down arrow keys Press the Enter lt key to move the cursor to the next modifiable field After entering the last modifiable field within a screen press the Enter lt 4 key to remove the cursor and the enable the flashing window to reappear in the left hand corner of the upper most field of the current screen To get to the next adjacent menu loop screen press the up ZP or down arrow key Press the Enter lt 4 key successively to advance the cursor through the various modifiable fields of the display screen eventually returning to the first field Values that are already correct may simply be skipped over by using the Enter S key without modification of the variable The current value if not changed will be retained afte
14. Discharge Pressure Status screen only appears if your unit is a water or Discharge Pressure water glycol cooled DX system It displays the current operating head pressure 000psi Discharge pressure is managed by the system controller based on the input of the head pressure transducer SSS Press t or 4 Key 4 5 2 7 Setpoint Values Displays the current operating temperature and humidity setpoints and control DS E a M method If configured for dewpoint control the controller displays the Humidity 45 calculated dewpoint setpoints for dehumidification and humidification as PEN SE derived from the operating temperature and humidity setpoints Dehumidify rh S203 Humidify DP 46 4 Pees orig Se 4 5 2 8 Compressor Status Displays the status icon On or Off for the system compressor and shows the Compressor 1 Status status of the high pressure and low pressure switches Open or Closed It also E oh shows the current status On or Off of the compressor and indicates Min SE On if the compressor minimum off time has elapsed If the minimum off time ee e has not elapsed the display will show Min Off and the actual minimum off time will appear next to it 4 5 2 9 EEV Status Kar 1 ae Displays the current operating position of the electronic expansion valve The current suction pressure and temperature and the superheat temperature appear below The bar gauge next to the valve icon provides a visual representation of the output s
15. H sensor may be provided for field installation see Section 2 6 2 This is to be mounted in the supply cold aisle space for monitoring or control purposes Refer to the electrical drawing supplied with your unit for wiring details specific to your system 1 6 2 Water Detector As an option Black Box offers spot type or strip cable type water detectors see Section 2 6 1 Upon sensing a leak the water detector control circuit will signal the system controller of the alarm condition The system controller is programmed to shut down the compressor and the fans when a leak is detected 1 6 3 Smoke Detector Optionally mounted in the return air side of the cabinet a photo electric smoke detector senses the presence of smoke and signals the controller when a smoke alarm condition exists and shuts down the air conditioner 1 6 4 Firestat Optionally mounted in the return air side of the cabinet a fire detector senses high return air temperature and signals the controller when a fire alarm condition exists and shuts down the air conditioner Page 18 724 746 5500 blackbox com Chapter 2 Installation 2 Installation 2 1 Receiving the Equipment Your Cold Row precision A C system has been tested and inspected prior to shipment Carefully remove the protective packaging and perform a visual inspection of the equipment immediately upon delivery to confirm that your equipment has been received in excellent condition Remove the access panels and
16. in the cooling mode at 74 0 F Setpoint 72 0 F Offset 2 F Conversely with the default cut out offset at 0 3 F the cooling mode will turn off at 72 3 F EXAMPLE 2 Temperature Offset Multiplier If 2 0 is entered the offset for temperature is multiplied by 2 0 2 0 x 2 F 4 F This means the unit will begin operating in the cooling mode at 76 0 F Setpoint 72 0 F Oftset 4 F Conversely the cooling mode will turn off at 72 6 F Setpoint 72 0 F 2 0 x Cut out Offset 0 3 F 72 0 F 0 6 F 72 6 F EXAMPLE 3 Humidity Offset Multiplier If 1 3 is entered the offset for humidity is multiplied by 1 3 1 3 x 5 6 5 This means the unit will begin operating in the dehumiditication mode at 38 5 Setpoint 45 0 Offset 6 5 Conversely the dehumidification mode will turn off at 42 4 Setpoint 45 0 1 3 x Cut out Offset 2 0 45 0 2 6 42 4 Custom Setup Custom Ssecup Setup the alarm text custom alarms and any custom sensors CUSTOM OQ Figure 4 54 Custom Setup screen From the Service gt Options gt Custom Setup screen press the Enter key to access a menu loop to set up custom alarm features Any controller alarm or signal failure will activate the summary alarm output Upon receiving an alarm indication press the alarm key to call up alarm screen messages Customer Alarm Input Optional If enabled a customer provided alarm input may be used to activa
17. is ready to charge 8 Replace the Schrader valve cores if you removed them during the evacuation steps You may now introduce the refrigerant charge through the Schrader valves 2 10 2 3 Refrigerant Charging Procedures R410A refrigerant must be weighed in when performing the charge Referring to Section 2 10 2 1 calculate the estimated amount of refrigerant needed for your system When charging a system using a blended refrigerant it is essential that the composition of the refrigerant is maintained To ensure correct composition introduce the refrigerant R410A into the system in liquid form rather than vapor form Cylinders that do not have dip tubes should be inverted to allow only liquid refrigerant to charge the system Keeping the temperature of the cylinder below 85 F will help maintain the correct refrigerant composition while the cylinder is emptied WARNING If refrigerant gas is released in an enclosed area it may accumulate in low areas and near the floor displacing available oxygen If a major leak occurs there is a risk of asphyxiation In such case the area should be immediately evacuated and ventilated Personnel should remain away from the area until it is determined to be safe Initial System Charge Follow the step by step instructions below to charge systems using R410A refrigerant The initial charge will be performed by introducing liquid refrigerant to the discharge side of the compressor or an available liquid li
18. is signaled and a designated set of N O amp N C Custom Alarm relay contacts may be energized to provide remote indication of the specific alarm condition s For example you may want to be notified when a change filter alarm is annunciated notifying that the air filters need to be cleaned or replaced That way you are alerted before the filters are so badly clogged that airflow is reduced to a point where a Loss of airflow alarm is activated 4 4 Controller Operation The E2 Series controller is designed to control an air conditioning system in a space or process application to temperature and humidity levels as defined by the user Conditioned air is supplied to the space as needed to maintain the temperature humidity control setpoints The controller I O module includes inputs and outputs as depicted in Figure 4 18 Not all the inputs and outputs shown below are used therefore only the inputs outputs needed for the specific A C system type and application are enabled Page 54 724 746 5500 blackbox com Chapter 4 E2 Controller Upper Supply Air Temperature my Fluid Control Valve 1 Middle Supply Air Temperature A Variable Fan Speed Upper Lower Supply Air Humidity L Variable Fan Speed Middle Analog Analog Inputs Outputs Return Air Temperature Return Air Humidity CG Variable Fan Speed Lower A DX Head Pressure Static Pressure gt Summary Alarm gt Custom Alarm 1 Remote Shutdown GE VPP E C
19. may be operated with the doors open by using a pair of channel lock pliers to turn the shaft of the main power disconnect switch to the On position When the switch is turned on high voltage will be present inside the cabinet Exercise caution to prevent injury Keep hands clothing and tools clear of the electrical terminals and rotating components Ensure that your footing is stable at all times Symptom Airflow too low Probable Cause Dirty air filters reduced airflow Recommendation Clean replace filters Symptom EC fan s fail to start Probable Causes Recommendations a Power failure Check main voltage power source input cable D Motor starter protector tripped Reset motor starter protector and check amperage of motor c Control transformer circuit breaker tripped Check for short circuit or ground fault if none reset circuit breaker d Condensate overflow switch open 1 Ensure unit is level 2 Check that condensate pan is draining e Defective contactor Repair or replace f No control signal to fan s Check the control I O board for a 0 10 VDC control signal to the fan s Refer to the electric drawing to determine the correct I O board terminal numbers This must done within 15 seconds of turning the disconnect switch On or the controller will go into Air Proving Alarm mode g EC fan s internal overheat protection Determine the cause of the interruption and correct Possible causes are 1 Block
20. system until the solution is discharging from the vent with minimal signs of foaming caused by air in the system 2 10 2 Remote Air Cooled Systems Remote air cooled systems are provided with a dry nitrogen holding charge that must be removed before piping and charging the unit Before charging check the unit nameplate to confirm the type of refrigerant to use NOTE Refrigerant charging must be performed by a qualified air conditioning technician Cold Row systems use R410A refrigerant R410A is a blended refrigerant recognized for being safe for the environment Refrigerants that are multicomponent blends have component parts with different volatilities that result in a change in composition and saturation temperature as evaporation and condensation occur The composition of liquid R410A refrigerant however remains relatively constant Page 36 724 746 5500 blackbox com Chapter 2 Installation CAUTION POE oil is used in systems with R410A refrigerant POE oil quickly absorbs moisture when exposed to air High POE oil moisture levels react with refrigerant to form acid which results in system contamination Keep the entire system sealed as much as possible and minimize exposure of POE oil to outside air R410A operates at high pressures which must be considered when checking the operating temperatures pressures while charging or troubleshooting the system Tables are provided in Section 2 10 3 showing the temperature pressure characteris
21. tees as shown in the previous table e Table 2 7 Recommended liquid line sizes Equivalent Length Ft Model Number 50 ft or less 100 ft or less 150 ft or less CRDX A FS 12KW 1 2 E Ya CRDX A FS 24KW 724 746 5500 blackbox com Page 31 Chapter 2 Installation Vertical runs are based on a total rise of 30 equivalent feet For longer rises make individual calculations Sizes assume the use of single risers double risers may be necessary CAUTION AP Do not exceed 150 foot maximum liquid line length If the condenser is installed above the evaporator the discharge line should include a p trap at the lowest point in the piping The highest point in the discharge line should be above the condenser coil and should include an inverted trap to help prevent oil and liquid from flooding back to the compressor during off cycles If the condenser is installed below the evaporator an inverted trap the height of the evaporator coil is required on the liquid line to help prevent oil and liquid trom flooding back to the compressor during off cycles 2 8 3 Condensate Drain Line A condensate pump is factory installed The drain line connection is typically a 1 2 FPT fitting The installer must connect a drain line customer supplied to the drain fitting to remove water from the cabinet Access the condensate drain fitting through the top or bottom of the cabinet as contigured with the water glycol or refrigerant piping con
22. that apply to your application A safety alert symbol precedes a general WARNING or CAUTION safety statement A safety alert symbol precedes an electrical shock hazard WARNING or CAUTION safety statement 1 4 2 Safety Summary The following statements are general guidelines followed by warnings and cautions applicable throughout the manual Before performing any installation operation maintenance or troubleshooting procedure read and understand all instructions recommendations and guidelines contained within this manual CAUTION N All maintenance and or repairs must be performed by a journeyman refrigeration mechanic or air conditioning technician CAUTION a When moving the unit it should be kept in its normal installed position If the unit is not kept level and vertical damage to the compressors will result WARNING Never operate the unit with any cover guard screen panel etc removed unless the instructions specifically state otherwise then do so with extreme caution to avoid personal injury CAUTION bs Never lift any component in excess of 35 pounds without help If a lifting device is used to move a unit make sure it is capable of supporting the unit CAUTION A When working on electrical equipment remove all jewelry watches rings etc Keep one hand away from the equipment to reduce the hazard of current flowing through vital organs of the body CAUTION J Always turn off the service disconnect switch a
23. thoroughly inspect the interior of the unit for any signs of transit incurred damage If there is shipping damage it must be noted on the freight carrier s delivery forms BEFORE signing for the equipment Any freight claims MUST be done through the freight carrier Black Box ships all equipment FOB We can assist in the claim Tiling process with the freight carrier If any damage is present notify Black Box Technical Support at 724 746 5500 or info blackbox com prior to attempting any repairs Refer to Chapter 6 of this manual for instructions A unit data package has been sent with your unit It contains this manual system drawings applicable MSDSs warranty registration other component manuals and applicable instructions based on the configuration of your unit The data package has been placed in your unit in a clear plastic bag These documents need to be retained with the unit for future reference The unit should always be stored indoors in a dry location before installation NOTE Items that have been shipped loose such as the controller display panel temperature humidity sensors water detectors etc are shipped inside the air conditioner unless specified otherwise by the customer Unpack and store these items in a safe place unless you are using them immediately 2 2 Moving the Equipment Cold Row systems are designed to be kept in a vertical position The cabinet is equipped with shipping support brackets that are bolted to the skid t
24. 24 Month Precision A C Upgraded Limited Warranty The 12 Month Precision A C Limited Warranty applies when Factory Authorized startup is not purchased at the time of order entry The 24 month Precision A C Upgraded Limited Warranty applies only if Factory Authorized startup was purchased at the time of Order Entry The 12 Month Precision A C Limited Warranty provided by Black Box Network Services warrants your purchase including compressors to be free from defects in material and workmanship Black Box Network Services obligation under this warranty Is to repair or replace at its option any part or parts that are determined by Black Box Network Services to be defective for a period of 12 months trom the date of shipment when an accurately completed Precision Cooling Limited Warranty Registration and Startup Checklist Form has been submitted to Black Box Network Services within 90 days from shipment Parts repaired or replaced under this warranty are shipped FOB Factory and warranted for the balance of the original warranty period or for 90 days trom the date of installation whichever is greater If the factory startup form Is not returned to Black Box Network Services within 90 days from the date of equipment shipment the equipment warranty will be terminated on the 91st day from shipment This limited warranty does not include labor freon or any other expense required to replace the defective component and bring the unit back to a working statu
25. 24w M 2 THERMAL EXPANSION VALVE DISTRIBUTOR BODY EVAPORATOR COIL Chi Ti me Bessi REFRIGERANT z UTC PRESSURE TTT WATER COOLED CONDENSER TRANSDUCER KOTAS T O REGULATOR SCHRADER VALV A OPTIONAL PIPING CONNECTION TEMPERATURE SENSOR P LOW PRESSURE ae LIMIT SWITCH WATER REGULATING VALVE HIGH PRESSURE SWITCH LIMIT COMPRESSOR CONDENSER WATER CONNECTIONS Figure 2 7 Typical W G piping diagram 724 746 5500 blackbox com Page 25 Chapter 2 Installation Piping Connections CAUTION N The cooling coil and associated piping circuits are pressurized up to 100 psi and sealed when they leave the factory Before installing the interconnecting piping release the pressure via an available stem valve or Schrader valve prior to uncapping the pipes Fluid supply and return lines are routed to either the top or bottom of the cabinet as specified when the Cold Row system is ordered see Figures 2 8 and 2 9 On units that are piped from the top the supply and return connections are made outside the cabinet On units that are piped from the bottom the supply and return connections are made inside the cabinet H HM Pipe connections are threaded NPT connections The pipes are labeled i e Supply Teflon tape thread sealant is recommended to minimize internal fouling of the piping Return When making the connections a Field piping is not necess
26. 6 285ms Two Version screens are provided for information only They show controller hardware and software details that are useful to Black Box Technical Support if you need help 724 746 5500 blackbox com Chapter 4 E2 Controller 4 5 4 1 Setpoint Screens CONTROL Version SET Alarm Set Figure 4 25 Set screen The Setpoints SET screens below may be accessed from the Control menu Tenpera rure Setpoint 12 0 E Controlling bo Sup STATUS Temp 72 6 F Set 72 0 F Dew S A F Press r i Key Humidity Setpoint 45 0 Controlling to Ret DP calculated from temp at same location STATUS Hum 45 5 Set 45 0 Dew 42 0 F Press h Key Figure 4 26 Temperature Humidity Setpoint screens The Temperature and Humidity Setpoint screens enable you to view and adjust the control setpoints and compare them to system level operating data derived from the various sensor transmitter inputs Pan C oben et Fan links ALl inked spd CEEL Kr E ee SS o Figure 4 27 Fan Control screens linked The Fan Control screen enables you to select a fan speed control method Variance trom Average Temperature Proportional or Manual see Section 4 4 4 1 for each of the three fans You may also link the fan temperature zones together in any combination so selected fans operate at the same speed The linked zones use the average of the linked temperature sensors to control fan speed Link bars appear to t
27. 724 746 5500 blackbox com Page 51 Chapter 4 E2 Controller NOTE You may turn the A C unit on and off at any time by pressing and holding the Enter key for 3 seconds Other status messages that may appear at the bottom of the screen are OFF by remote shutdown indicates the Remote Start Stop feature is enabled and requires a remote start switch to be turned On OFF by Network indicates the unit is part of a group and is off because of a grouping priority command such as a compressor alarm or loss of airflow or the BMS communication feature is enabled and the unit received a network signal to pause operation OFF by Internal Alarm indicates that the unit is off because of a group alarm condition Only active with grouped units Unit on CL Lockout indicates cooling has been locked out while there is a demand for dehumiditication because the temperature is below the minimum temperature allowable for dehumidification factory default setting is 4 F below setpoint 4 After the initialization period expires the controller enables the control output to the fluid control valve CRDX W FS 12KW CRDX W FS 24KW CRDX G FS 12KW CRDX G FS 24W and the fans are allowed to begin operating 5 The Black Box logo in the display is replaced with a blower iF symbol The fans begin operating in stages with five second time delays The middle fan starts first then the upper fan then the lower fan 6 Following a 45 second time
28. ACnet MS TP BMS interface port wn cen e status r ethernet GC LJE Figure 4 5 BACnet IP BACnet Ethernet HTTP SNMP and Modbus IP BMS interface port 724 746 5500 blackbox com Page 47 Chapter 4 E2 Controller 4 2 Navigating Controller Display Screens 4 2 1 Menu Selection The E2 Series controller provides five user selectable menus needed to view operating data and enter setpoints for the system see Figure 4 6 These menus may be accessed from a scrolling Main Menu screen by pressing the Program Prg key You are then allowed to scroll between adjacent menu selections within the Main Menu by using the up T and down arrow keys When the desired menu is centered in the screen with bold capital letters and an arrow symbol is pointing towards the Enter SP key you may press the Enter lt key to access that menu loop The user can access the menu loop screens located within the designated menu selection using the up and down arrow keys Access to some menus may be protected by a built in security protocol and may require the use of a password to gain access 4 2 2 Menus From the Main screen you may press the Program Prg key to select from among the five menus shown in Figure 4 6 01 01 09 00 00 00 00 0 F MAIN gt 00 rh SCREEN Dp 00 0 F From the Main Menu SSES PS Screens Press Enter lt 4 Key To Access Menu Loops Press 4 or Key Info MENU SCREENS LOOP DISPLAYS ALARM LOG Q B
29. CRDX A FS 24KW CRDX G FS 12KW S e CRDX A FS 12KW CRDX W FS 24KW lt gt BLACK ROX CRDX G FS 24KW CRDX W FS 12KW NETWORK SERVICES Customer Order toll free in the U S Call 877 877 BBOX outside U S call 724 746 5500 Support FREE technical support 24 hours a day 7 days a week Call 724 746 5500 or fax 724 746 0746 Inf ti Mailing address Black Box Corporation 1000 Park Drive Lawrence PA 15055 1018 HANOI ATE on Web site www blackbox com E mail info blackbox com Trademarks Used in this Manual Trademarks Used in this Manual Black Box and the Double Diamond logo are registered trademarks and Cold Row is a trademark of BB Technologies Inc Schrader is a registered trademark of Schrader Bridgeport International Inc Teflon is a registered trademark of E I du Pont de Nemours amp Co Any other trademarks mentioned in this manual are acknowledged to be the property of the trademark owners We re here to help If you have any questions about your application or our products contact Black Box Tech Support at 724 746 5500 or go to blackbox com and click on Talk to Black Box You ll be live with one of our technical experts in less than 30 seconds Page 2 724 746 5500 blackbox com FCC and IC RFI Statements Federal Communications Commission and Industry Canada Radio Frequency Interference Statements This equipment generates uses and can radiate radio frequency energy and if not installed and used properly t
30. E E N AOA EN A 10 ka POCUCA E EE 13 E AMY E 14 AEE EE 14 E el Ee 14 La TECH DE EE 16 Lor TCC ECA OPiS ON eect cers saree enee ebeegiegg 17 15 2 CiruitBreakers Motor Start POC C IONS boasiscectcnsnscsnsnenscehecuneseessiooxsaech ATEENA REER REEE ETAR EAEEREN 17 BE E une EE 17 1 5 3 1 Electronic Thermal Expansion Valve oscs2cra0snsecesndnnccncednscontesnesn eegene 17 Tee Fe ne ege E 17 E E we N O E E NEA E E E 17 E Londen e FU E 17 Wee E e e E E E E EA E EE E E E EE E E EE EE E 17 157 Temperature Hurnmidity CNS EC 18 Io Opta E NE E 18 1 6 1 Remote Mounted Supply Temperature Humidity Sensor 18 TO E Ee 18 LOS Moke DEE Eege 18 Aa E EE 18 Di a O EE 19 ZR RECEIO e E le TEE 19 22 WONG ING he e Il 19 D WPD O EE 19 2A KOUN EEN 20 Fis A DDU EE 21 26 Optional Equipment Field Metaleg EE 23 Vid om ne E E er EE 23 Elend eeler 24 203 Outdoor Ge p16 eege 25 2A AEE ATT Gol Coded DA EE 25 Tee E 29 EC H gea POM ee A E E edecteadeceuns se chcenpasseeuectee teas 29 28 11 DX Refrigerant Piping EECH ses sssrinin E nnen aE A eeEEeeg 30 EE ARDE SUING EE 31 282 Remote Air Cooled COMES ELS sissioni eioi spann S EAEE Te AASE EERE ONES eb araen 31 ee EI 32 SEENEN EE EE SE BAN MVEA A e 32 ZO Ne Me ase e E 34 A NC Wer Ma Se GIS EE 34 ins WO O Onar Een ene meee ene ee nen Pn veneer E Peer eer ee 34 2 9 2 1 Remote Water Detector cccccscscssssseeeceeeesccssesseseeceeecccenansseeseeescesceseeseeceeeeeecseeeusesseceeeecsseenaessee
31. Figure 4 61 Save Configuration screen The default setpoints may be restored and passwords may be changed from the Service gt Save Cfg menu Customer Save Save Parameters No Restore Parameters To Customer No TO Beete No Figure 4 62 Customer Save screen The first Service gt Save Cfg menu screen allows you to save any adjustments made in service level menu screens as the new Customer parameters or restore the controller to the previously saved Customer parameters The user may also restore the controller to the original factory default parameter values shown in Table 4 10 Use the Enter key to move the flashing cursor to the field you wish to confirm and press the Up or Down arrow key The word No will momentarily change to Yes indicating the command has been accepted Then press the Enter key sequentially until the flashing cursor returns to the top left corner of the screen The table that follows are the factory default parameters 724 746 5500 blackbox com Page 83 Chapter 4 E2 Controller Table 4 10 Factory default setpoints Parameter Default Value Temperature Setpoint Var Compressor Cut in 74 gt F Compressor Cut out EE Minimum Fan Speed 40 Maximum Fan Speed 100 Dehumidification Fan Speed 60 Humidity Setpoint 45 RH Dehumidify Cut in 50 RH Dehumidify Cut out 47 RH Set Passwords Contre Service Figure 4 63 Set Passwords screen The second Service gt Save C
32. Loop SERVICE Blower OPTIONS CR Digital In Figure 4 50 Options Menu Loop screen From the Service gt Options menu you may press the Enter S key to access a menu loop with screens used to set up and adjust various options Control Startup EE Control Standard Auto on powerup AUCO Of PeMore BPO Option suppress Buzzer Figure 4 51 Control Startup screen The Service gt Options gt Control Startup screen allows you to select the control method Standard Temperature Humidity Control Dewpoint Dewpoint Control 724 746 5500 blackbox com Page 75 Chapter 4 E2 Controller lt Reserved gt For future use DO NOT select this control method Auto on powerup If set to On the A C unit turns on automatically when main power is applied Auto on remote If set to On the A C unit may be turned on via a remote On Off switch EPO Option Emergency Power Off lIf set to On the off delay timers are bypassed so compressors blowers etc stop operating immediately when the unit is turned off by a remote on off signal or a critical alarm Suppress Buzzer allows you to enable or disable the alarm signal buzzer Unit Timers Unit Timers Startup delay Airflow delay Shutdown delay Recovery time 30mins Figure 4 52 Unit Timers screen The Service gt Options gt Unit Timers screen allows you to adjust the unit timers controlling various startup or shutdown delay periods
33. R E E A EEE E A E E sense 61 D lege e werte E 61 A ad ROUN WE lee EE 61 a452 WRN MC Sen SOF ne ttt ease ger pec nc let emcee saree E E se eet estate E 61 e kee 61 4 5 2 5 Remote Supply Temperature HUMICIty Sensor 62 1 Bs 7 ome DE fe 0 EE 62 See UE 62 AS EE NUS EE 62 I EO peepee crys nn A otsciemaer E EA E tian causa E aettaembonssaesnencine eats 62 EVO TE EE tocar sepsis ace ge cece ee ine eerste Soe eee E gata eee ee eee 63 Beal e E 63 45 212 Gro p Information Menu SCKC EE 63 AD 21 SON ANS Eege 63 Fe PNM OG E 64 BEE EE 64 Eo TOM RIC AN E E 64 Bese SUMAN AAI E 64 4 5 3 4 Alarm Screen Messages nsessunninseeeuniirsssekiiiiiittkiiirtn nettir r nn nert tEn r EnA EEEEEEEEEEEEEEEEEEEEEEEEEEEEPEE EEEE nne een 65 AA E TO A Kee 66 E NN tee e 67 aAa PAIN SOOM CGS SIN hee 68 A CO e 70 ee FCS E E LOO EE 70 ra S le ee TE 71 Bs 5 2 RAVING EE 72 da RS 2 68 a E E E E EE E E E EE 73 PV e 74 e TOO IS I na Eeer 75 724 746 5500 blackbox com Page 7 Table of Contents DE ON MA cetera tte cs E st ete ct ne ice ac octet A 82 et Eege EE 82 E VEER eege E 83 455g Save COMMON AMO EE 83 Be oO TACO EE 84 46 Communication with the Controller eebe 85 en Weeer T EE 85 PES Mal EE 86 Ae am ee ee ee ee ee ee ee re ee ee 86 Aao Uat ROO E 86 PAIN oy Or EON UE EE 86 SEENEN 86 4 6 2 1 Configure the Terminal Address eher eet 87 4 6 2 2 Configure the Controller I O Board pLAN Address 88 4 6 2 3 Assign the Terminal to the Control
34. TERCONNECTING FIELD WIRING TO BE INSTALLED INACCORDANCE WITH NFPA 70 N E C SEE NOTE 1 PUMP PACKAGE GLYCOL UNITS ONLY INTERCONNECTING FIELD WIRING TO BE INSTALLED IN ACCORDANCE WITH NFPA 70 N E C SEE NOTE 1 MAIN POWER SUPPLY 208 460V 1PH 3PH 60Hz NOTES 1 PHANTOM WIRES NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES Figure 2 13 Interconnecting field wiring glycol systems 2 9 3 3 Remote Condenser CRDX A FS 12KW CRDX A FS 24KW For systems equipped with a remote condenser the installer must provide main power wiring to the main power distribution block located within the remote condenser electric box A separate equipment ground lug is provided within the electrical box for termination of the earth ground wire Refer to the electrical drawing supplied with your unit and the wiring diagram supplied with the condenser typically located in the condenser electric box Control wires are not required between the remote condenser and the A C system see Figure 2 14 As an option control wiring may be installed between the A C system and the condenser for the system controller to enable condenser operation only when the compressor is running You must remove the jumper from the remote condenser terminal board see the condenser wiring diagram Wire 24 VAC control conductors trom the terminal board within the A C unit to the remote condenser terminal board If control wires aren t installed and the jump
35. WARRANTY Always consult Black Box Technical Support before replacing the compressor A CAUTION POE oil is used in systems with R410A refrigerant If a replacement compressor is provided ensure that it is filled with POE oil before installing NOTE Cleaning operations must be performed by a journeyman refrigeration mechanic or air conditioning technician Page 120 724 746 5500 blackbox com Chapter 5 Maintenance 5 3 3 2 Standard Cleanout Procedure 1 Turn off power to unit at the main power disconnect switch 2 Remove the old compressor and install the new compressor 3 Remove the liquid line drier and install an oversized liquid line filter drier one size larger than the normal selection size 4 Evacuate the system according to standard procedures Normally this will include the use of a high vacuum pump and a low vacuum micron gauge for measuring the vacuum obtained 5 Recharge the system 6 Turn on the power at the main power disconnect switch and start the system 5 3 3 3 Burn Out Acidic Cleanup Procedure 1 These systems should be cleaned using the suction line Tilter drier method Turn off power to the unit at the main power disconnect switch Remove the burned out compressor and install the new compressor Install a suction line filter drier designed for acid removal Remove the liquid line drier and install an oversized liquid line filter drier one size larger than the normal selection size Che
36. X unit is housed in a steel frame type cabinet rated for indoor use The exterior of the cabinet is coated with a powder coat finish to protect against corrosion Removable access panels are located on the front and rear of the cabinet for easy access to all components Operator controls are conveniently located on the front of the cabinet NOTE Customer specified non standard features or design variations may not be described in this manual Refer to the installation and or electrical drawings supplied with your unit for details of additional feature s In some cases an addendum to this manual may also be included to further describe the feature s Figure 1 2 depicts a typical internal layout and identifies the major components of a typical Cold Row unit using direct expansion DX refrigerant The location of some components may vary depending on the cooling configuration selected water water glycol or air cooled PIPE TRANSITION PLATE ELECTRICAL KNOCK OUTS CONDENSER DISCONNECT SWITCH TEMPERATURE SENSOR T H SENSOR EVAPORATOR COIL AIR FILTERS ELECTRIC BOX COMPRESSOR SWING OUT HINGE TEMPERATURE CASTER SENSOR HOUSING 4 LEVEL ADJUSTMENT SCREW 4 ELECTRICAL KNOCK OUTS IN BOTTOM OF BOX e a a iB TEMPERATURE PIPING ELECTRICAL Sech a SENSOR DRAIN PANS KNOCK OUTS IN FLOOR OF CABINET FLOAT SWITCH NOTE 1 CABINET ACCESS PANELS REMOVED TO SHOW INTERNAL PARTS Figure 1 2 Typical
37. a 6 key menu driven loop structure and offers an alarm log plus four different interface menu levels to the operator Information Control Service and Factory These menus permit the user to easily view control and configure operating parameters for the A C unit See Menu Selections Figure 4 6 4 1 2 1 Function Keys Prg Esc gt 4 Table 4 1 Function keys Function Accesses the active alarm screen s Silences audible alarms Resets active alarms in the alarm menu Accesses the main menu Prg Illuminates yellow when unit is on Returns to the previous menu level Cancels a changed entry Steps to the next screen in the display menu Increases the value of a modifiable numeric field Starts Stops system operation Accepts current value of a modifiable field Advances the cursor to the next active alarm screen Steps back to the previous screen in display menu Decreases the value of a modifiable numeric field 724 746 5500 blackbox com Page 45 Chapter 4 E2 Controller 4 1 2 2 Contrast Adjustment Press and hold the Alarm and Prg keys then use the Up and Down keys to adjust the contrast 4 1 2 3 Alarms Alarm conditions activate a red LED indicator that backlights the alarm function key As an option an alarm condition may also be enunciated by an audible alarm signal An alarm is acknowledged by pressing the alarm key This calls up alarm display screen s that provide a text messa
38. a pipe stub located either at the top or the bottom of the A C unit depending on the piping configuration see Section 2 7 1 and 2 8 1 1 A float switch in the lower condensate pan detects if the water level rises If the condensate pan fails to drain the float switch signals the controller to sound an alarm and turn off the compressor and the fans 1 5 5 Condensate Pump A condensate pump is factory installed in the lower drain pan The pump automatically eliminates condensate water from the drain pan The pump has an internal float switch that turns the pump on and off based on the water level 1 5 6 EC Fans The unit is equipped with three high efficiency Electronically Commutated EC fans EC fans use a brushless motor equipped with permanent magnets and permanently lubricated ball bearings The fan impellers are curved backward and attached to the rotor casing The fan is balanced and aerodynamically optimized to minimize vibration The fans do not use drive belts Fan speed is variable via a O to 10 VDC signal from the system controller The fan motor is equipped with integral electronics and does not require the addition of secondary electronics such as thermal protection inverters or filters The fan will not produce AC inverter whine 724 746 5500 blackbox com Page 17 Chapter 1 Introduction During startup the fans begin operating in stages with Tive second time delays The middle fan starts first then the upper fan then t
39. analyzing signal inputs from the sensor s and developing the appropriate digital or proportional response 4 4 1 1 On Off Digital Control Based on control inputs the controller provides an on off output signal to activate certain modes of operation for the air conditioner i e humidifier fans or annunciate an operating condition status that is alarm condition 724 746 5500 blackbox com Page 55 Chapter 4 E2 Controller 4 4 1 2 Proportional Integral P I Control The controller calculates proportional control output signal s based on the analysis of input signals and then determines the air conditioner s required mode s of operation Signals representing temperature and humidity are each compared by the controller as a percentage value to the maximum control setpoint value resulting in control output values that are directly proportional to the input signal The integral value is used to gradually adjust the proportional output when the calculated output does not move the process variable closer to setpoint in a given period of time Decreasing the integral value decreases the interval for the output corrections speeding the rate of adjustment Increasing the integral value increases the interval for corrections slowing the rate of adjustment 4 4 2 Control Methods System operation depends on the controller s programmed operating configuration Control takes place by means of the controller analyzing signal inputs from the su
40. andal Temperature Variance from o control proportionate average Type of unit Not selected CW 12 CW 24 AR 12 AR 24 W G 12 W G 24 4 9 3 Boolean Values for HTTP SNMP Modbus Coils Binary Values for BACnet Table 4 31 Boolean Values for HTTP SNMP Modbus Coils Binary Values for BACnet BMS Modbus BACnet Address Address Address Description Default Direction 1 002 1 Global alarm output 0 R r 003 2 System on status 0 R 3 004 3 Airflow has been proven 0 R 4 005 4 Call for cooling O R 5 006 5 Call for humidification 0 R 6 007 6 Call for dehumidification 0 R 100 101 100 BMS value to pause the unit 0 R W 101 102 101 BMS value to reset alarms 0 R W 102 103 102 Force rotation of units in group manual or BMS 0 R W 103 104 103 BMS value to switch CW sources 0 R W 104 105 104 BMS value to switch dual power primary 0 R W 105 106 105 BMS value to activate lockout function 0 R W 106 107 106 Reset dirty filter alarm 0 R W 724 746 5500 blackbox com Page 107 Chapter 4 E2 Controller 4 9 4 Alarm Packed Bit Variables Table 4 32 Alarm Packed Bit Variables Page 108 Bit Alarms 1 Alarms 2 Alarms 3 0 Emergency shutdown Middle fan alarm Reserved 1 Remote shutdown Upper fan alarm Reserved 2 Customer Alarm 1 Lower fan alarm Reserved 3 Airflow High temperature Reserved 4 Filter Low temperature Reserved 5 Fire Smoke High humidity Reserved 6 Water detection Low humidity Reserved 7 Condensate pan High water temp CW1 Reserved 8 Moisture Low
41. are applied to the control setpoints Each unit in the group should be assigned incrementally increasing decreasing offsets for cooling humiditying and dehumiditying so they will turn on one at a time only if the unit s currently operating are unable to satisfy the demand Capacity Assist 2 pee CaDaCity Assist Homia cut H 4 0 Cie GUC 0 0 Deman ma ia 4 0 Cut gut 0 0 aS SA Figure 4 87 Capacity Assist 2 screen The second Service gt Options gt Capacity Assist screen allows you to adjust local capacity assist humidification and dehumidification setpoints Group Sensors Groupi Sensors Use lead sensor avg Mins or Max of group Temp Hum Local Figure 4 88 Group Sensors screen The lead controller polls the controllers from all the A C units in the workgroup and calculates the averaged value of their temperature sensors and humidity sensors It also determines the minimum lowest temperature sensor value and the lowest humidity sensor value in the A C group and conversely determines the maximum highest temperature sensor value and maximum humidity sensor value in the A C group Page 98 724 746 5500 blackbox com Chapter 4 E2 Controller The Service gt Options gt Group Sensors screen allows you to select whether to control the A C workgroup using the T H sensors connected to individual A C units Local or control the workgroup using network sensor values transmitted from the lead controller You may
42. arily the same size as the unit s pipe connections Piping should be sized to match the system pressure drop and flow capacity and may require reducing fittings to match the connection size on the air conditioner An air vent and several Schrader valves are installed in the precision A C unit piping We recommend providing manual shut off valves for both the supply and return fluid for isolating the unit when performing routine maintenance or repairs Refer to the piping diagram supplied with your unit NOTE Install a 60 mesh strainer in the supply pipe Make sure the strainer is readily accessible for servicing or replacement For pipe connection sizes refer to the following table Table 2 3 Pipe connection sizes Model Water Glycol Inlet Outlet Condensate Drain CRDX G FS 12W gy y CRDX G FS 24W R S CRDX W FS 12W ayy y CRDX W FS 24W F NOTE Use standard refrigeration practices for piping leak testing and filling the water glycol circuit Use vibration isolating supports to isolate the piping Provide supports clamps or hangers as necessary every 5 to 10 feet along piping runs to minimize vibration and noise transmission To reduce vibration transmission and prevent pipe damage seal openings in walls using a soft flexible material to pack around the piping After the piping is installed seal the gaps between the pipes and the entrance holes so air won t leak around the pipes NOTE Water glycol lines should be insulated t
43. asic status information no INFO MENU Control password needed Press 4 or 4 Key ALARM LOG Logged Alarms in chronological sequence ES MAIN MENU i Alarm Log CONTROL MENU Basic user values i e setpoints CONTROL gt Level 1 password required Service SERVICE MENU Advanced user values i e offsets Level 2 password reqd Press 4 or Key FACTORY MENU Factory values i e sensor Access is limited scaling Level 3 password read Control SERVICE QO Factory Call for Assistance Press 4 or Key MAIN MENU Service FACTORY Info Figure 4 6 Menu selections Page 48 724 746 5500 blackbox com Chapter 4 E2 Controller 4 2 3 Display Variables The user interface display panel provides screens with three different forms of both the read only and the modifiable variables e Numbers are displayed as positive or negative integers e Dual State can be toggled between two 2 values i e On Off Yes No e Word Variables have a unique text message for each of the variable s possible choices 4 2 4 Cursor Position in Screens The following display screen is shown as an example after accessing a new menu loop display screen using the function keys The name of the menu loop is the line in the upper most field of the screen A flashing window also appears in the left of the uppermost field indicating that you re in the top level of that menu loop CONTROL MENU _ t Flashing Alarm Set Window
44. assword Modifications to the control setpoints require the use of a password 4 1 1 2 Password Protection You can access the Info menu and Alarms log without a password The controller recognizes predetermined security levels before allowing access to display screens containing critical variables Three secured menu levels Control Service and Factory support unique passwords that must be entered to access the menu screens so only authorized personnel may perform modifications to the settings 4 1 1 3 Restorable Setpoint Parameters Upon initial startup the A C system operates using the setpoints programmed by the factory The customer may enter new operating parameters in the Control and Service menus and the system will then operate accordingly The new setpoints may be stored as Customer Default setpoints The primary setpoints entered by the factory still remain stored in the controllers memory as Factory setpoints The setpoints for the system may be re adjusted in the Control menu at any time If it becomes necessary the customer may restore the setpoints back to the Customer Default setpoint values or to the original Factory primary setpoint values in the Service menu See Section 4 5 5 9 4 1 1 4 A C Grouping pLAN Operation Multiple A C system controllers can be connected grouped to a Private LAN pLAN local network allowing the communication of data and information from each controller to a central control terminal or lead con
45. at If customer provided the remote On Off control contacts must be sized appropriately The Remote On Off contacts must have a minimal rating of 24 VAC Refer to the electrical drawing included with the A C unit for the electrical specifications and for wiring details 4 5 Menu Screens 4 5 1 Main Menu Factory INFO Alarm Log Figure 4 21 Main menu The Main Menu is accessed from the Main screen by pressing the Prg key The Main Menu screen provides a complete listing of the menu loops that are available You may scroll through the menu categories using the Up and Down arrow keys From the Main Menu screen you may select from among the following standard menus Into displays basic read only status information Allows you to monitor system operational parameters No password is needed at this level Alarm Log displays all alarms and power ups in sequential order with a time and date stamp No password is needed at this level 724 746 5500 blackbox com Page 59 Chapter 4 E2 Controller Control allows modification of basic control parameters such as setpoints and clock Level 1 password is needed to enter this menu Service allows modification of advanced control parameters such as offsets blower soeed and BMS setup and permits the user to save customer parameters and reset the controller to the customer or factory default values Level 2 password is needed to enter this menu Fact
46. at follow As an example for a custom alarm based only on the occurrence of moisture alarm fire smoke condensate pan failure of the return humidity sensor you would enter the following bitmask values for the applicable alarm numbers and enter O for the rest Custom Alarm number 1 8 Moisture alarm No 4 8 Custom Alarm number 9 16 Fire smoke No 10 Condensate pan No 12 10 2 8 Custom Alarm number 25 32 Return humidity sensor No 29 16 The custom alarms are set up by entering the bitmask totals developed from the tables shown next Table 4 4 Alarms 1 to 8 Number Description Bitmask Default 1 Upper fan alarm 1 1 2 Lower fan alarm 2 2 3 Middle fan alarm 4 4 4 Moisture alarm 8 8 5 Emergency shutdown 16 16 6 Remote shutdown 32 32 7 Customer alarm 64 0 8 Airflow alarm 128 128 Factory Default Bitmask Total 191 Page 78 724 746 5500 blackbox com Chapter 4 E2 Controller Table 4 5 Alarms 9 to 16 Number Description Bitmask Default 9 Filter alarm 1 0 10 Fire smoke alarm 2 2 11 Water detection alarm 4 4 12 Condensate pan alarm 8 8 13 Circuit low pressure alarm 16 16 14 Circuit high pressure 32 P alarm 15 Dual power Input A alarm 64 0 16 Dual power Input B alarm 128 0 Factory Default Bitmask Total 62 NOTE The default values shown in bold italics are factory set to generate a custom alarm output on any of the major alarms and any sensor failure Only the enabled sensors can g
47. at the Info level following the network sensors screen If an alarm condition appearing in the following tables is detected it needs to be reset at the unit s display terminal or via the BMS for the unit to return to Active and resume operation 724 746 5500 blackbox com Page 93 Chapter 4 E2 Controller Table 4 17 Group alarms 1 to 8 Number Description Bitmask Default 1 Humidifier 1 0 2 Pump 2 0 3 Customer alarm 1 4 0 4 Circuit 1 high pressure 8 0 5 Circuit 1 low pressure 16 0 6 DX lockout 32 0 7 Humidifier lockout 64 0 8 FC AWS lockout 128 0 Table 4 18 Group alarms 9 to 16 Number Description Bitmask Default 9 Upper fan alarm 1 0 10 Middle fan alarm 2 0 11 Lower fan alarm 4 0 12 Water detection 8 0 13 Condensate pan 16 0 14 Moisture 32 0 15 Filter 64 0 16 Reserved 128 0 Page 94 724 746 5500 blackbox com Chapter 4 E2 Controller Table 4 19 Group alarms 17 to 24 Number Description Bitmask Default 17 High temperature 1 0 18 Low temperature 2 0 19 High humidity 4 0 20 Low humidity 8 0 21 High water temperature CW1 16 0 22 Low water temperature CW1 32 0 23 Reserved 64 0 24 Reserved 128 0 Table 4 20 Group alarms 25 to 32 Number Description Bitmask Default 235 Upper temperature sensor 1 0 26 Middle temperature sensor 2 0 27 Lower temperature sensor 4 0 28 Return humidity sensor 8 0 29 Optional temperature sensor 16 0 30 Circuit 1 discharge pressure 32 0 31 Circuit 1 suction pressure 64 0 32 Circ
48. at will be air conditioned CAUTION AN Make sure the mounting surface is capable of supporting the weight of the equipment Before installing the unit refer to the weight table provided on the installation drawing 724 746 5500 blackbox com Page 19 Chapter 2 Installation When determining the installation location consider how you ll route the piping and wiring into the cabinet and ensure access is available see Sections 2 7 1 and 2 8 1 The Cold Row system is ordered trom the factory with pilot holes for piping and wiring in either the top or the bottom of the cabinet See the installation drawing provided with your unit for the pilot hole locations Conditioned Space Take certain steps to minimize the effects of the environment surrounding the conditioned space This is especially important for critical precision room preparation computer data centers that require close tolerance control of temperature and humidity The conditioned space should be well insulated and include a vapor barrier The installer should ensure that the proper insulation rating is used based on the design of the space which was the basis for the system selected The following table lists recommended minimum R value thermal resistance values for optimum equipment operation Table 2 1 Recommended minimum thermal resistance Structure R Value Ceiling R 38 Wall R 21 Floor R 19 Door R 5 The vapor barrier is the single most important requirement f
49. ation temperature at a given suction pressure By controlling superheat the EEV keeps nearly the entire evaporator surface active while preventing liquid refrigerant from returning to the compressor As a standard superheat is factory set at 12 15 F and should not need adjustment The superheat temperature is monitored and controlled by the auxiliary control module EVD Driver mounted on the door of the electric box We recommend that you contact Black Box Technical Support if adjustment is required CAUTION N Do not exceed 20 F superheat Exceeding this temperature may cause failure of the compressor 2 11 4 Hot Gas Bypass A electronic hot gas bypass system is provided for freeze protection and capacity control The auxiliary control module EVD Driver mounted on the door of the electric box manages operation of the hot gas valve The hot gas regulator valve allows refrigerant to flow from the discharge line directly to the evaporator through an auxiliary connection downstream of the thermal expansion valve This is used to maintain the evaporator at a minimum constant pressure as the heating load varies The hot gas discharge regulating valve is set to prevent the surface temperature of the evaporator coil from dropping below 35 F The bypass temperature is factory set and no adjustment should be necessary Contact Black Box Technical Support at 724 746 5500 or info blackbox com if adjustment is required 2 11 5 EC Fans The speed o
50. ations When BMS communication are used the controller must be equipped with an optional expansion card designed for one of a variety of serial communications protocols available see Section 4 1 4 A communications port on the expansion card allows the controller to be field connected to a central Building Management System BMS for monitoring and control of data points An RS 485 serial port is available for Modbus or BACnet MS TP protocols and a 10BASE T port is available for TCP IP based protocols such as BACnet over IP BACnet over Ethernet SNMP or HTTP Table 4 25 BMS communications parameters Supported Protocols Media Connection BACnet over IP 10BASE T RJ 45 direct BACnet over Ethernet 10BASE T RJ 45 direct HTTP 1OBASE T RJ 45 direct SNMP V1 V2c 1OBASE T RJ 45 direct Modbus over IP 10BASE T RJ 45 direct BACnet MS TP Twisted pair Daisychain Modbus RTU Twisted pair Daisychain Direct Connection Daisychain Connection Figure 4 91 Direct connection vs daisychain connection If multiple A C units are grouped together each controller added to the group must be configured with a CPU address for BMS communication For complete details on using BMS control contact Black Box Technical Support see Chapter 6 724 746 5500 blackbox com Page 101 Chapter 4 E2 Controller 4 7 1 Direct BMS Control The controller may be configured to accept proportional analog signals that mimic a sensor The controller will act on that signal
51. ay address set to 32 As such a normal standalone controller does not need any changes made to either the controller or the terminal address The method to setting up workgroups is to retain the first group lead controller s ol AN address as 1 and terminal address as 32 so that the sum of the addresses equals 33 The first controller added to the group is assigned pLAN address 2 and Its terminal is assigned address 31 the sum of which again equals 33 NOTE The sum of the controller and terminal address numbers must always equal 33 Page 86 724 746 5500 blackbox com Chapter 4 E2 Controller A workgroup should ALWAYS start with controller address 1 and go up from there DO NOT skip over controller addresses The list of suitable controller display terminal address pairs is shown below Table 4 11 Corresponding Controller to Terminal ol AN Addresses Controller I O board 1 2 3 4 5 6 2 8 Display Terminal 32 31 30 29 28 27 26 25 You must assign the terminal and controller O board addresses for each controller to be grouped Review Sections 4 6 2 1 to 4 6 2 3 first before turning power on and assigning addresses Do not interconnect the controllers together before assigning their terminal and I O board ol AN addresses The first step is to change the terminal address of each controller to O referring to Section 4 6 2 1 below You must set the terminal address to 0 before you can assign the controller I O board address NOTE If
52. bit for BMS digital outputs 0 R 13 142 1013 Packed bit for BMS digital outputs 0 R 15 144 1015 Prop humidifier control output 0 R 16 145 1016 Head pressure control output 0 R 100 229 1100 BMS keep alive parameter 0 R W 101 230 1101 BMS low fan speed for CW units 0 R W 102 231 1102 BMS run fan speed for CW units 0 R W 103 232 1103 BMS dehumidifier fan speed for CW units 0 R W 104 233 1104 Fan link control 0 to 4 See 4 9 2 1 0 R W 105 234 1105 Control mode of dewpoint hybrid standard 0 R W 106 235 1106 Temperature control sensor selection 0 R W 107 236 1107 Humidity control sensor selection 0 R W 108 237 1108 Type of unit valid numbers O to 6 See 4 9 2 1 0 R W 110 239 1110 Lower fan speed control 0 to 2 See 4 9 2 1 0 R W 111 240 1111 Middle fan speed control 0 to 2 See 4 9 2 1 0 R W 112 241 1112 Upper fan speed control 0 to 2 See 4 9 2 1 0 R W 123 252 1123 Current day 0 R W 124 25B 1124 Current month 1 R W 125 254 1125 Current year 1 R W 126 255 1126 Current hour 0 R W 127 256 1127 Current minute 0 R W Page 106 724 746 5500 blackbox com Chapter 4 E2 Controller Variable Value Descriptions Table 4 30 Variable Value Descriptions Variable Description for Description for Description for Description for Description for Description for Description for Description Value 0 Value 1 Value 2 Value 3 Value 4 Value 5 Value 6 Fan link control None Upper amp middle Upper amp lower Middle amp lower All X fan speed M
53. ck the expansion valve sight glass and other controls to see if cleaning or replacement is required N OD WwW PS W N Evacuate the system according to standard procedures Normally this will include the use of a high vacuum pump and a low vacuum micron gauge for measuring the vacuum obtained 8 Recharge the system through the access valve on the suction line filter drier 9 Turn on power at the main power disconnect switch and start the system 10 A permanently installed suction line filter drier permits small system cleanup to be completed in one service call The pressure drop across the suction line filter drier should be measured during the first hour of operation If the pressure drop becomes excessive the suction line filter drier should be replaced See Sporlan Bulletin 40 10 for the maximum recommended pressure drop PSI tor the suction line filter drier 11 In 24 hours take an oil sample Observe the color and test for acidity If the oil is dirty or acidic replace the suction line filter drier 12 In two weeks examine oil to determine if another suction line filter drier change is necessary 5 3 4 Component Replacement Check all electrical connections to ensure they are tight and properly made Check all circuit breakers contactors and wiring The contactors should be examined and replaced if contacts are worn or pitted 1 Turn off power to the unit at the main power disconnect switch 2 Remove the old component a
54. d Table 4 27 BMS parameters Media 1OBASE T 1OBASE T 10BASE T 10BASE T 10BASE T Twisted pair Twisted pair 724 746 5500 blackbox com Connection RJ 45 direct unit connection RJ 45 direct unit connection RJ 45 direct unit connection RJ 45 direct unit connection RJ 45 direct unit connection Daisychain connection Daisychain connection Notes Uses BMS addresses Uses BMS addresses Uses BMS addresses Uses BMS addresses Uses Modbus addresses Uses BMS addresses Uses Modbus addresses Chapter 4 E2 Controller 4 9 1 Signed Values for HTTP SNMP Modbus Holding Registers Analog Values for BACnet Table 4 28 Signed Values tor HTTP SNMP Modbus Holding Registers Analog Values for BACnet BMS Modbus BACnet Address Address Address Description Default Read Write 1 002 1 Temperature setpoint 72 0 R W 2 003 2 Humidity setpoint 45 0 R Ws 3 004 3 Average supply temperature display value 0 0 R 4 005 4 Return humidity sensor current value 0 0 R 5 006 5 Dewpoint of return temperature and humidity 0 0 R 6 007 6 Dewpoint of remote temperature and humidity 0 0 R 7 008 7 Middle fan speed 0 0 R 8 009 8 Upper fan speed 0 0 R 9 010 9 Lower fan speed 0 0 R 10 011 10 Middle fan manual speed 0 0 R W 11 012 11 Upper fan manual speed 0 0 R W 12 013 12 Lower fan manual speed 0 0 R W 13 014 13 Static pressure sensor current value 0 0 R 14 015 14 C1 discharge pressure sensor current value 0 0 R 15 016 15 C1 suction press
55. d add more refrigerant to the receiver NOTE Do not exceed 80 of the total condenser and receiver volume to allow room for expansion 2 A refrigerant level sight glass is located on the side of the receiver to assist the service technician in charging the air conditioning system Determine the proper charge by viewing the level of refrigerant in the receiver while the unit is running at an elevated discharge pressure 3 Keep the air intake to the condenser blocked and maintain the discharge pressure at 445 psig and hold it constant The condenser fan nearest the condenser header should be operating continuously All other fans if additional fans exist should be off during this time 4 Add additional refrigerant charge to the receiver as needed until the refrigerant level rises to the center of the sight glass indicating that the receiver is 80 filled When the refrigerant in the receiver reaches the sight glass the unit is fully charged CAUTION Ax Remove the blockage to the air intake of the condenser 5 Fill out the applicable sections of the Warranty Registration and Start Up Checklist Page 40 724 746 5500 blackbox com 2 10 3 Refrigerant Characteristics 2 10 3 1 Pressure Temperature Settings The following table is provided to assist with the normal settings of the system for R410A refrigerant Where applicable minimum and maximum settings are given along with normal operating pressures Table 2 11 R410A refrigera
56. d as the new active unit 4 6 1 2 Capacity Assist The Capacity Assist option can be used to maximize efficiency for conservation of energy and to more precisely control capacity at low demand This feature enables Active A C units to handle the demand up to a certain temperature humidity setpoint and then enables additional units to begin operating as needed If the Active A C units are running and unable to satisfy the demand Capacity Assist A C unit s may be programmed to turn on to assist the Active units Each Capacity Assist unit may set to control operation based on its local temperature humidity sensor values or control operation based on network sensor values transmitted from the lead controller Multiple Capacity Assist units are typically set with each unit in the group assigned incrementally increasing decreasing offsets for cooling humidifying and dehumidifying so they will turn on one at a time only if the unit s currently operating are unable to satisfy the demand They should incrementally turn off as each unit reaches its cut out setpoint while active A C unit s continue to maintain room conditions at the desired level 4 6 1 3 Unit Rotation In this mode the lead controller will rotate duty between the grouped A C units to promote equal run time and will rotate the role of group lead When set up for unit rotation the A C units will rotate duty in order of their group addresses Active Capacity Assist and Standby units are al
57. d part is not a stocked item a 50 restocking charge may be applied Additionally a Return Material Authorization Number is required when returning parts To receive credit for returned repair replacement parts the parts must be returned to Black Box within 30 days of the purchase date Spare part sales over 30 days old will be considered final and the parts will remain the sole property of the ordering party Page 124 724 746 5500 blackbox com Appendix A Forms Appendix A Forms A 1 Checklist for Completed Installation of Cold Row DX d D D D D D O D DL 2 Proper clearances for service access have been maintained around equipment Equipment is level and mounting fasteners are tight Field installed piping completed All field installed piping leaks tested Condensate drain line connected Water supply line connected to humidifier if applicable H manual cut off valve is installed open valve Humidifier On Oft Drain switch is in On position Filters installed Incoming line voltage matches equipment nominal nameplated rating tolerances Main power wiring connections to the equipment including ground have been properly installed Customer supplied main power circuit breaker HACR type or fuses have proper ratings for equipment installed All wiring connections are tight Foreign materials have been removed from inside and around all equipment installed shipping materials construct
58. d terminal pLAN address you can examine the entire network setup Press the group setup keys up arrow a down arrow and Enter Y together as done to access the Address Configuration screen but continue holding after the Address Configuration screen appears for at least 5 seconds until the Network Status screen appears The Network Status screen shown below provides overview of the pLAN group indicating which and how many devices are connected and the corresponding pLAN addresses NetSTAT Term 32 if Press Enter to quit Figure 4 72 Network Status screen Key H Controllers I O Boards active in network e Terminals active in network mite No device connected The example shown represents Controllers active in network addresses 1 2 3 Terminals active in network addresses 30 31 32 The terminal for Controller 1 is always addressed 32 the terminal for Controller 2 is always addressed 31 and so on such that the sum of the controller address number and the terminal address number always equals 33 Therefore when viewing controller number 1 its terminal address will be 32 When viewing Controller 2 its terminal address will be 31 and so on Press an up arrow or down arrow de key to display the next screen showing the version of the firmware residing in the terminal 724 746 5500 blackbox com Page 89 Chapter 4 E2 Controller pGD1 vp Oe Feb 28 2006 HW A Figure 4 73 Firmware version To exi
59. de The speed settings are adjustable in the Service gt Blower gt Blower Set Up menu loop see Section 4 5 5 4 EC fan speed is automatically varied based on temperature There are mechanisms to trade off the control valve opening versus fan speed When the system enters the dehumiditication mode the fan speed automatically changes to the dehumiditication speed setting The E2 controller s software is equipped with an operational fail safe mode Upon sensing a temperature sensor failure the controller signals an alarm It continues to develop the fan control outputs by calculating the averaged value of the remaining sensors to replace the input value of the failed sensor If all the temperature sensors fail the controller develops the control outputs based on the entered temperature setpoint value minus a 3 F temperature offset This allows the Cold Row system to continue operating while the cause of the problem is corrected The controller continually monitors fan operation Cold Row DX units are equipped with a pneumatic air proving system connect ed to a flow switch that detects the loss of airflow when a fan Tails to operate If one of the fans fails to operate the controller alerts the operator with an alarm message and increases the speed of the remaining two fans to 99 9 to compensate for the loss of airflow If the fault does not clear the fans shut down for 5 seconds and then restart If the fault continues the fans reset a second tim
60. delay after the first fan turns on the controller polls the air proving switch If adequate airflow is detected the controller enables the compressor to turn on if there is a demand for cooling or dehumidification as defined by the control setpoints Initialization Air Proving Compressor Period Time Delay Time Delay 30 sec gt 4 45 sec gt 5s 5s 5s 1 od Fans 1 2 3 Figure 4 13 Controller polls screen 7 The controller records the date and time power is reinitialized in the alarm history log 8 If the actual room conditions are not within the range of the programmed setpoints the system will begin operating in the mode s needed to reach the setpoints cooling or dehumidifying Symbols appear to indicate the active operating modes D Blower On i SE Call For Cooling LA west Dehumiditying 9 Temperature and humidity alarms are masked out for 30 minutes to allow conditions to stabilize without triggering nuisance alarms 10 Operator interface to the menu loops is available from the Main screen by pressing the Program Prg key The controller starts a timer whenever a key sequence is initiated Every time a button is pressed the timer is reset If there is no key activity for 60 seconds the controller will return to the Main screen unless the Screen Lock feature is enabled in the Information menu loop see Section 4 5 2 4 3 1 Setpoint Adjustment 1 From the Main screen access the Main Me
61. des all other previously printed warranties dated prior to this document in regards to Diagnostic Labor Warranty Page 12 724 746 5500 blackbox com Chapter 1 Introduction 1 3 Product Warranty Black Box offers a two year standard limited warranty as stated on the previous page An extended warranty may be purchased on the unit s compressor The compressor warranty as stated below will be sent with your unit if the option is purchased Retain this for future reference You may consult Black Box Technical Support at 724 746 5500 or info blackbox com to verify if the extended compressor warranty was purchased for your system Cold Row Warranty Compressor This warranty applies only when Factory Authorized Start Up is purchased at the time of order entry Unit Model Warranty Start Date Warranty End Date Compressor 1 Serial Compressor 2 Serial Optional Compressor Summary Black Box warrants your purchase to be free trom defects in material and workmanship for up to 60 months original standard Is 24 months and purchased additional is 36 months The Black Box Optional Compressor Limited Warranty may be purchased in 1 year increments up to a total warranty period of 60 months trom the date of startup Black Box s obligation under this warranty is to repair or replace at its option free of charge to the customer any part or parts which are determined by Black Box to be defective for a period of 60 months from the date of
62. difications to secured menu settings Control Service and Factory These menus are configured with password protection requiring a higher level of authority to access them The screens must have accurate variables entered otherwise erratic operation may occur 4 2 6 1 Password Protected Screen When you first attempt to select a secure menu In a given session the Enter Password screen will be displayed This screen displays the current security level authorized EI Enter Password Access Current ID Code Security Level Figure 4 10 Enter password screen A session is defined as from the time access is gained to a secure menu until 60 seconds elapses with no key activity Security access will be terminated at this point and you will have to re enter the password to gain access The menus that may be password protected by the user are the Control and Service menus The tfactory level menu screens are also password protected however the password is set at the factory to limit access Access to the Factory menu screens will only be granted while the user is working with the guidance of Black Box Technical Support see Chapter 6 because incorrect settings made at that level could unintentionally damage the equipment The Access ID Code in the bottom left of the Enter Password screen is needed when contacting Technical Support to determine the correct factory menu password for your specific controller The level of authority i
63. e If the fault does not clear after the second reset the fan s that generated the fault are shut down and the remaining fans continue operation at 99 9 speed If the BMS monitoring control signal fails the E2 controller will default to local operation at the current setpoints for the fans The local sensors have priority over the BMS system Page 58 724 746 5500 blackbox com Chapter 4 E2 Controller 4 4 4 1 Independent Fan Speed Control The system controller may be configured for independent variable fan speed control for managing upper middle and lower zone cooling The controller continually monitors the actual cold aisle supply air conditions for each fan zone upper middle and lower as determined by temperature sensors mounted locally to each zone inside the Cold Row cabinet and it adjusts the speed of each fan to meet the supply air temperature setpoint for that zone The operator may select from three independent fan speed temperature control methods in the Control gt Set gt Fan Control menu loop Section 4 5 4 1 Minimum and maximum fan speed settings for each fan are user adjustable in the Service gt Blower gt Temp Zone Set Up menu loop see Section 4 5 5 4 The fans will not run at speeds outside of the envelope established in that menu loop 4 4 4 2 Variance from Average Fan Speed Control When contigured for variance from average fan speed control each fan operates independently The controller manages the speed of each
64. e 4 24 Control menu loop Page 66 Press lt Carel ZE SR Code rr Manual code Bros 5212 Boor ATOS 4 5 4 Control Menu Loop From the Control Menu you may select from four screen menus Setpoints Alarm Setpoints Clock and Version The controller may be programmed by the user to require Level 1 password authorization to enter this menu loop see Section 4 2 6 Once password access is granted you may select and adjust the setpoints controlling the performance of the unit enable alarms and determine their setpoints and set the clock The Setpoints SET screens allow you to view and adjust the temperature and humidity setpoint control parameters and compare them to system level operating data derived from the various sensor transmitter inputs See Section 4 5 4 1 The Alarm Setpoints ALARM SET screens allow you to enable and adjust the high and low temperature and humidity alarm setpoints and offsets and compare them to the control setpoints and to the system level operating data derived from the sensor transmitter inputs See Section 4 5 4 2 From the Clock screens you may view and adjust the current time date and day and set up operating schedule s and setpoints for the A C system See Section 4 5 4 3 IG aime sa chsh whe el ebsg eheiuth en etel Press pCO type pCO3 Large Key Toca Flash 2048KB LOY L5 12 Ram 512KB B Llt In type None Main cycle 324 cycles s wey Ly I 03870770
65. e by wrapping with water soaked cloths 724 746 5500 blackbox com Page 119 Chapter 5 Maintenance 5 3 2 3 Refrigerant Piping When replacing components within the cabinet of the unit the following consumable materials are recommended When brazing copper to copper connections piping liquid line or suction line use a phosphorus copper brazing alloy with 15 silver Use general purpose silver brazing alloy with 45 silver for copper to brass or copper to steel For liquid line repairs at the drier strainer sight glass or expansion valve use a 95 tin to 5 antimony solder with flux When component replacement is complete remove all traces of flux After any repair pressure check the system to ensure there are no leaks prior to recharging the system 5 3 3 Refrigeration System Repairs 5 3 3 1 Compressor Failure The compressor is the most important component of the air conditioner Numerous safety devices are provided to protect the compressor from failing If a compressor failure occurs determine whether it is an electrical or a mechanical failure An electrical failure will be indicated by the distinct pungent odor once the system has been opened If a burnout has occurred the oil will be black and acidic A mechanical failure will have no burned odor and the motor will attempt to run an abnormal or excessive noise may be present An analysis of the oil is the only way to determine the proper procedure for cleaning the refrigeran
66. e menu may be entered and programmed by the user via the password menu requires Level 2 password Once password access is granted the user may access the service screens Page 70 724 746 5500 blackbox com Chapter 4 E2 Controller MAIN MENU Control SERVI CE gt Press Enter lt q Key Factory SERVICE SERVICE Save Cfg Cool 4 5 5 10 FACTORY Q HUMID Cool Alarms SERVICE SERVICE BMS Comm Humid 4 5 5 9 SAVE CFG CR mams 0252 Factory Sensors SERVICE SERVICE Run Hours Alarms 4 5 5 8 BMS COMM CR SENSORS 4 5 5 3 Save Cfg Blower SERVICE SERVICE Digital In Sensors 4 5 5 7 RUN HOURS Ch BLOWER 4 5 5 4 BMS Comm Options SERVICE SERVICE Options Blower 4 5 5 6 Digital In CR OPTIONS 4 5 5 5 Run Hours Digital In Figure 4 40 Service menu loop selections 4 5 5 1 Humidity The cut in cut out offsets for the Dehumidification modes may be adjusted from the Service gt Humid menu SERVICE Press Enter lt lt Key Cot In OrrSset Cut Out Mirrsec Cutout Temp Pom 2361 set 45 03 Dehum Off Press Down v i Key Figure 4 41 Humidity screens 724 746 5500 blackbox com Page 71 Chapter 4 E2 Controller 4 5 5 2 Alarms SERVICE Humid ALARMS Sensors Press Enter H Key Alarm History 1 5 11 09 L KS startup Temperature 00 30 F Humidity 00 0 Press Alarm to clear Figure 4 42 Alarms screens A log of events is st
67. e required to see the desired temperature and humidity level in the conditioned space Once room conditions have been programmed or set a repeat visit to the conditioned space may be required to ensure the system is meeting the room s requirements 3 3 Microprocessor Controller Programming The E2 microprocessor controller is factory programmed based on the features selected with the system A user provided Building Management System BMS may be used to directly interface to the E2 controller The operator may view all the available menu screens through a BMS however changes may be made only to basic parameters such as adjusting setpoints and setting and acknowledging alarms More advanced parameter adjustments may be made through the user interface display see Figure 4 1 Operating instructions for the E2 controller are provided in Chapter 4 724 746 5500 blackbox com Page 43 Chapter 4 E2 Controller 4 E2 Controller 4 1 General The advanced microprocessor based E2 Series controller is a highly versatile and flexible A C system controller It is designed orimarily for precision air conditioners The controller is equipped with flexible software capable of meeting the specific needs of the application The controller is completely programmed at the factory and most applications will require no field setup However you can easily view and adjust the default setpoints and their ranges trom the user interface display The program and operati
68. easing decreasing offsets for cooling humidifying and dehumidifying so they will turn on one at a time only if the unit s currently operating are unable to satisfy the demand Table 4 14 Factory gt Group gt Capacity Assist Screen 3 parameters Display Description Assist Time Cooling Cut in Cut out Page 92 Description Enter the delay period for capacity assist unit s to begin operating Enter a temperature setpoint offset for cooling capacity assist operation to begin Enter a temperature setpoint offset for cooling capacity assist operation to stop Capacity ASSISE EIDEL Cut if Cu One Dehum Cut in CUE OUE Variables O to 999 99 9 to 99 9 99 9 to 99 9 Figure 4 79 Factory gt Group gt Capacity Assist Screen 4 724 746 5500 blackbox com Default 300 1 0 0 0 Chapter 4 E2 Controller Table 4 15 Factory gt Group gt Capacity Assist Screen 4 parameters Display Description Description Variables Default Humid Cut in Enter relative humidity setpoint offset for humidifying capacity assist operation to begin 99 9 to 99 9 4 0 Cut out Enter relative humidity setpoint offset for humidifying capacity assist operation to stop 99 9 to 99 9 0 0 Dehum Cut in Enter relative humidity setpoint offset for dehumidifying capacity assist operation to begin 99 9 to 99 9 4 0 Cut out Enter relative humidity setpoint offset for dehumidifying capacity assist operation to stop 99 9 to 99 9 0 0 G
69. ed by the factory are listed in Section 4 5 3 4 3 2 1 Summary Alarm A summary alarm will activate when the controller senses any programmed alarm condition This illuminates the alarm key and if the option is selected a N O N C summary alarm contact may be energized for remote monitoring of alarm conditions If certain critical summary alarm conditions are detected they will cause the A C unit to shut down 4 3 2 2 Customer Alarms A customer provided digital on off switching alarm sensor may be connected to terminals provided in the electric box This alarm input may be for any site specific alarm condition the user wishes to monitor that may or may not be provided in the standard controller alarms menu that is Gas Detection Intrusion Alarm etc Upon detection of a customer alarm the controller will activate the summary alarm contact and display a screen message indicating a customer alarm message The screen message Customer Alarm 1 default will appear in the controller display or the user may reconfigure the controller to display any alphanumeric message desired up to 20 characters long in the Service gt Options gt Custom menu loop see Section 4 5 5 5 4 3 2 3 Custom Alarms A custom user configured alarm is activated upon detection of one or more programmed alarm conditions as set by the operator in the Service gt Options gt Custom menu loop see Section 4 5 5 5 When a custom alarm condition is detected a summary alarm
70. ed rotor 2 Low supply voltage gt 5 seconds 3 Loss of phase gt 5 seconds After causes 1 2 and 3 are corrected the motor will automatically reset After the causes below are corrected the fan s must be manually reset by turning off power for 20 seconds 4 Over temperature of electronics 5 Over temperature of motor Page 116 724 746 5500 blackbox com Chapter 5 Maintenance Symptom Control is erratic Probable Cause Wiring improperly connected or broken Recommendation Check wiring against electrical drawing Symptom Compressor fails to start Probable Causes Recommendations a Temperature setpoint too high Adjust to desired temperature D Compressor internal overload protector is open Check compressor Tor short circuit or ground c Complete loss of refrigerant charge low pressure safety switch tripped Locate and repair leak Recharge system d Condenser pressure too high high pressure safety switch tripped Check condenser for obstructions e Minimum off time has not expired Wait for time to expire Symptom System short of capacity Probable Causes Recommendations a Temperature setting too high Increase temperature setpoint b Discharge air short cycling back to return Check air barrier between hot cold aisles c Low airflow 1 Check filters Replace as needed 2 Check for and clear any obstructions across or in the supply discharge air stream Clear coil fins of debris 3 Check evap
71. ed to ensure the air conditioner is meeting the room s requirements Saving and Restoring Setpoint Parameters Upon initial startup the A C system operates using the setpoints programmed by the factory primary setpoints as the operating setpoints As described in Section 4 3 1 the user may enter new operating parameters in the Control menu anytime and the system will then operate accordingly The user may store the new setpoints in the Service menu if it is intended to save them Once stored the user setpoints now become the operating setpoints The primary setpoints entered by the factory still remain stored in the controller s memory as the factory setpoints At any time setpoints for the system may be re adjusted to any value and the system will operate accordingly If necessary the customer may enter the Service menu and restore the setpoints to the stored user operating setpoint values The original Factory primary setpoint values may also be restored from the Service menu Whichever setpoints are restored Factory or User become the current operating setpoints 4 3 2 Alarms As programmed into the system controller an alarm condition activates the summary alarm logic which illuminates the alarm key and energizes an audible alarm Some alarms are programmed by the factory to automatically shut down the A C unit until the alarm condition is remedied and the alarm is cleared by pressing the alarm key Some of the alarms that may be enabl
72. ed to use fuses or a HACR type circuit breaker to protect the system Other protection devices are not allowed based upon the product listing Page 32 724 746 5500 blackbox com Chapter 2 Installation lt BLACK BOX www blackbox com 1000 Park Drive Lawrence PA 15055 1018 724 746 5500 Sales Order Number Phase Hz lncluding Ground Ai MCA Max Ensei kt Bkr HACK type per NEC Heater kW Nominal Humidifier kW Nominal Evaporator Motor Ir HP FLA Evaporator Motor 2 HP FLA Condenser Motor 1k HP FLA Condenser Motor Or HP FLA Condensate Pump HP FLA Compressor 1 RLA LRA Compressor 2 RLA Refrigerant Type Charge Circuit 1 Ib oz Charge Cireuit 2 lb oz High Side Design Pressure psig Low Side Design Pressure psig Mus Output Air Temperature i Blower Fan Ext Static Press in wg Max Inlet Hot Water Temp E Hot Water or Steam Pressure psig Minimum Installation Clearance 0 0 in Remote Condenser Type Suitable for Indoor _ Outdoor _ Use Date of Manufacture Q A Acceptance Tei Figure 2 12 Sample nameplate The unit is provided with terminals for all required field wiring Refer to the electrical drawing supplied with the unit for all power and control field wiring It is important to identify the options that were purchased with the unit to confirm which field connections are required NOTE All wiring must conform to local and national electrical code requirement
73. een the setpoint value and the actual measured value The controller transmits a proportional O to 10 VDC signal to the regulating valve with 10 VDC corresponding to the valve opening 100 The system controller is factory set for the correct condensing pressure however it can be adjusted to increase or decrease the pressure To adjust the pressure enter the Factory menu in the E2 controller Contact Black Box Technical Support at 724 746 5500 or info blackbox com for a password to enter the Factory menu and for technical assistance if adjustment is necessary Make adjustments in small increments Allow adequate time between adjustments for the valve to Tully respond to the control signal so you can observe the changes in system operation 2 11 2 Low High Pressure Limit Switch Air conditioning systems using DX refrigerant are equipped with hermetically sealed high pressure and low pressure switches These switches are pre set by the manufacturer and cannot be adjusted The high pressure switch opens at 630 psig and has a manual reset The low pressure switch opens at 65 psig 10 and closes at 105 psig 10 and has an automatic reset 2 11 3 Thermal Expansion Valve An electronically controlled expansion valve EEV maintains constant superheat of the refrigerant vapor at the outlet of the evaporator by metering the flow of refrigerant into the evaporator Superheat is the difference between the refrigerant vapor temperature and its satur
74. eess 34 2 9 2 2 Remote Temperature Humidity SONSOF EE 34 Pio Wo E ene E 34 AS E ee ee e 0 EE 34 724 746 5500 blackbox com Page 5 Table of Contents 2 9 3 1 Water Cooled Systems CRDX W FS 12KW CRDSW ES ZAKMWL 34 2 9 3 2 Glycol Cooled Systems CRDX G FS 12KW CRDS G FS ZAKEMWI 35 2 9 3 3 Remote Condenser CRDX A FS 12KW CRDS A FS AAKW 35 210 System Charging Procedures escris saraan anaes ERAO OEA ARTROSE EA RETENE i ERATARA AERE ENSE TEE RAEES SEEREN 36 2101 WateteVWater Glycol COOIEG Sy EE 36 2 10 22 Remo t Air Cooled E 36 edel te Bug Teen ge Te a7 2102 2 Prepaning SYSte Tor Charging E 38 2 10 2 3 Refrigerant Charging Procedures eege 39 210 24 30 Ge eer 5 mee eee en e E ene ne E EE 40 210 dee Gaels SC eee nee eet nem E ee tee ee eee mere ee cree E ea ee 41 SE Pressure Temperature SENOS eet E EE deet 41 2 10 3 2 Saturated Refrigerant Pressure sce eege Eeer 41 Zee Nelle G A rn E 42 2 11 1 Water Water Glycol Circuit ccccccccccccceccscceceecesssseeeeccccesseeeececcesssseeecesccsssseeeececeeseiseeceeeceesiieeeeeeesersieeeeeeeeeas 42 ENER Lons Hidn Pressure Hnit Wi EE 42 211 Thermal EE 42 LNA A ETD E 42 ve Ni Reo E e E E E A EA E A 42 Eed ie COAT SION e EE SE Sch WEE 43 32 OVE AI EE 43 33a Microprocessor Controler I ROOM aI WG WE 43 Ek cia OROT eet 44 BO AIC AM cetera est ton cts ees at E cence E E A EE 44 PEMD WMS E 44 EE EE E E Ee 44 AT Password Prote CON E 44 411 3 Retorne Setpo
75. efault Bitmask Total 3 724 746 5500 blackbox com Chapter 4 E2 Controller Table 4 9 Alarms 41 to 48 Number Description Bitmask Default 41 System Off 1 0 42 BMS keep alive off Z 0 43 Customer alarm 2 4 0 44 Customer alarm 3 8 0 45 Flow switch alarm 16 0 46 Reserved 32 0 47 Reserved 64 0 48 Reserved 128 0 Factory Default Bitmask Total 0 Workgroup Screens The Service gt Group display screens shown below only appear if two or more units are wired together as a group They allow you to configure parameters that apply to how the A C units interact in the workgroup Group Setup Unit ACTIVE Total in Network 0 Wumbex of Active 0 plead Unit _ H Capacity Assis Assist Time Cooling Cut in c Cur aut OG mma C t in 4 0 Gut out 0 0 Lesen cut Tn 4 0 Cue ouf 0 0 Use lead sensor Avg min or max of Jroup Temp Hum Local Ee Press Local Use unit sensors when in Standby or Assist for Group Averaging Temp Hum Sensors Yes Pr Sensors SE Figure 4 57 Workgroup screens See Section 4 6 for a detailed description of how workgroups are set up and for information on setting the operating parameters available in these screens 724 746 5500 blackbox com Page 81 Chapter 4 E2 Controller 4 5 5 6 Digital In SERVICE Options Digital In CR Run Hours Press Enter a Key EE sye heen LGA Leon gos SEL poo cCCCcececccC Cee E TILA TLELI cece
76. ement the Cold Row minimizes hot spots It is best not to place a Cold Row unit at the end of a row unless an air barrier is in place to prevent the conditioned air from being drawn around to the hot aisle side bypassing the front of the servers An air barrier must also be present to prevent conditioned air from being drawn over the top of the row into the hot aisle Page 20 724 746 5500 blackbox com Chapter 2 Installation Recommended Clearance Front amp S Rear Figure 2 1 Recommended installation NOTE Placement of air barriers between the cold aisle hot aisle is important If the supply discharge Is too close to the hot aisle the conditioned supply air will be recirculated back to the intake in the hot aisle side of the cabinet before it has circulated through the equipment to be cooled Once the cabinet is removed from the shipping skid roll it into position on the casters that are mounted to the bottom of the unit Do not remove the shipping support brackets unless server racks are installed on each side of the Cold Row cabinet The cabinet is equipped with an adjustable foot at each corner to raise the cabinet off the casters after the unit is positioned in its operating location The adjustable feet are also used for leveling and overall height correction To adjust the height use a flat head screwdriver to turn the screws located at the top of the four caster housings accessed inside the front and rear corners o
77. en No password is required to view alarm display messages If an alarm condition occurs the first active alarm may be displayed by pressing the R key The alarm screen display text message will remain unchanged until the alarm condition is cleared If the alarm log is entered from the main menu any other active alarm message s may be viewed by using the Up 4 and Down arrow keys to scroll through alarm messages 4 5 3 1 Alarms The red LED backlight within the alarm key will illuminate any time an alarm condition is present or previous alarms existed without having been reset or cleared An audible alarm will also activate when an alarm condition occurs The audible alarm may be enabled or disabled in the Service gt Options menu loop The first active alarm screen may be displayed by pressing the Alarm key The Alarm display provides you with a text message describing the abnormal operating condition Use the Up A and Down arrow keys to scroll for any additional alarm messages Only active alarm screens will be displayed when the Alarm key is pressed The alarm screen display will remain unchanged until the alarm condition is corrected and the alarm R key is pressed again to clear the alarm When access is gained to the Alarm Log loop use the Up 4 and Down arrow keys to scroll through the log for a history of alarm messages The alarms log may be cleared in the Service gt Alarm log menu loop The application software supports two types o
78. enerate an alarm To enable an additional custom alarm add the alarm bitmask number to the factory default total and enter the new total for the applicable alarm numbers in the Custom Alarm Setup screen If an alarm condition appearing in the following tables is detected it needs to be reset at the interface display panel or via the BMS Table 4 6 Alarms 17 to 24 Number Description Bitmask Default 17 Humidifier alarm 1 1 18 High temperature alarm 2 0 19 Low temperature alarm 4 0 20 High humidity alarm 8 0 21 Low humidity alarm 16 0 22 High water temperature CW1 32 0 23 Low water temperature CW1 64 0 24 Loss of power 128 128 Factory Default Bitmask Total 129 724 746 5500 blackbox com Page 79 Chapter 4 E2 Controller Page 80 Table 4 7 Alarms 25 to 32 Sensor failure alarms Number Description Bitmask Default 25 Lower temperature sensor fail 1 1 26 Middle temperature sensor fail 2 2 27 Optional temperature sensor fail 4 4 28 Upper temperature sensor fail 8 8 29 Return humidity sensor fail 16 16 30 DX1 discharge pressure fail 32 32 31 Static air pressure sensor fail 64 64 32 DX1 suction press sensor fail 128 128 Factory Default Bitmask Total 255 Table 4 8 Alarms 33 to 40 Sensor failure alarms Number Description Bitmask Default 33 DX1 suction temp sensor fail 1 1 34 Custom sensor 1 fail 2 2 Si Reserved 4 0 36 Reserved 8 0 37 Reserved 16 0 38 Reserved 32 0 39 Reserved 64 0 40 Reserved 128 0 Factory D
79. enters The Cold Row system captures high temperature hot aisle discharge air trom adjacent rack based IT equipment and reintroduces it as conditioned air through the front of the unit cold aisle The system is equipped with highly reliable Electronically Commutated EC fans that offer considerable energy cost savings and long life Using an electronically commutated permanent magnet DC motor eliminates AC inverter whine Fan speed is continuously adjustable via a signal from the system controller without the use of VFDs EC fans offer energy efficient quiet low vibration operation An advanced E2 series microprocessor controller is mounted inside the Cold Row electric box The controller provides the following features input output monitoring status full integrated control of cooling and dehumidification multi unit control and remote communication with a Building Management System BMS The controller may interface directly to a BMS so you can monitor the performance of the air conditioner and adjust operating parameters The E2 user interface display panel is typically factory mounted on the front access panel of the unit Page 10 724 746 5500 blackbox com Chapter 1 Introduction wwiwiblackbox cam Figure 1 1 User interface display Refer to Chapter 4 for detailed instructions on operating the system controller 724 746 5500 blackbox com Page 11 Chapter 1 Introduction 12 Month Precision A C Limited Warranty
80. er remains in place the condenser is always enabled and will turn on and off based on the condenser s pressure control settings Refer to the electrical drawing for the correct number of field wires needed and for the appropriate wire terminations required for your system 724 746 5500 blackbox com Page 35 Chapter 2 Installation MAIN POWER SUPPLY 208 460V 1PH 3PH 60Hz 24VAC OPTIONAL AIR COOLED CONDENSER INTERCONNECTING FIELD WIRING TO BE INSTALLED INACCORDANCE WITH NFPA 70 N E C SEE NOTE 1 INTERCONNECTING FIELD WIRING TO BE INSTALLED IN ACCORDANCE WITH NFPA 70 N E C SEE NOTE 1 MAIN POWER SUPPLY 208 460V 1PH 3PH 60Hz NOTES 1 PHANTOM WIRES NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES Figure 2 14 Interconnecting field wiring remote condenser 2 10 System Charging Procedures 2 10 1 Water Water Glycol Cooled Systems No field refrigerant charging is required for fluid cooled units The following precautions must be observed when installing and filling the water water glycol loop e The piping system must be cleaned prior to allowing water or water glycol to flow through the system e Glycol must be mixed with water before it is added to the system Use only water glycol solution with inhibitors for corrosion protection e When filling the water water glycol loop all air must be bled from the piping system 1 Open a vent valve at highest point of the system 2 Fill the
81. esses of the controllers in the group that have the min lowest and max highest temperature and humidity sensor readings Group Sensor Status This screen appears only in the display of the controller that is designated as the Lead in a multi unit workgroup It shows what sensors exist on each A C unit for the lead controller to perform the group sensor averaging calculation The numbers are the sums of index values assigned to the sensors as shown in the following key 1 Supply Temperature Sensor 2 Return Humidity Sensor 4 Remote Supply Temperature Sensor 8 Remote Supply Humidity Sensor 16 Static Pressure Sensor To determine which sensors are enabled and operable for each unit simply determine which index numbers derived trom the key above will produce the number shown in the screen In the example shown the number for the lead unit is 15 This results trom adding 1 Supply Temperature 2 Return Humidity 4 Remote Supply Temperature 8 Remote Supply Humidity together confirming those sensors are operable 724 746 5500 blackbox com Chapter 4 E2 Controller The number shown for Unit 2 is three the result of adding 1 2 This confirms that Unit 2 s supply temperature and return humidity sensors are detected by the lead controller If a one appeared instead for Unit 2 it would indicate the signal for the return humidity sensor is not present That sensor is either not enabled or it has failed 4 7 BMS Communic
82. f alarms Non Critical and Critical Any alarm may be programmed to activate the Custom user contigured alarm relay contacts 4 5 3 2 Non Critical Alarms A non critical alarm will activate the alarm screen that it is associated with These alarms are programmed to activate the Summary Fault alarm and close the Summary Fault relay contacts without stopping unit operation Some examples of the factory programmed non critical alarms are e High Temperature e Moisture Detection e Low Temperature e Change Filter e High Humidity e Sensor Failure e Low Humidity e Communication Failure 4 5 3 3 Critical Alarms Critical alarms will coincide with automatic shutdown of the A C unit s equipment as needed to prevent possible system damage The A C unit s equipment will remain shut down until the alarm condition s are no longer sensed and the controller has been reset Some examples of critical alarms are e No Airflow Air Proving Switch e High Head Pressure e Fire Smoke Detection e Low Suction Pressure e Off by Internal Alarm Only for grouped systems Page 64 724 746 5500 blackbox com Chapter 4 E2 Controller 4 5 3 4 Alarm Screen Messages Table 4 3 Alarm screen messages Alarm Release High Temperature Low Temperature High Humidity Low Humidity Sensor Failure Communication Failure Condensate Pan Moisture Fan Failure Change Filter No Airflow Smoke Fire Optional Temp High Ala
83. f the EC fans is controlled via a O to 10 VDC signal from the system controller The controller is preset by the factory for the correct fan speed configuration and should not require adjustment If the airflow needs to be adjusted this may be done using the controller s programming menu selections Refer to Section 4 4 4 for instructions on adjusting airflow using the system controller Contact Black Box Technical Support at 724 746 5500 or info blackbox com when initially making adjustments to the controller Page 42 724 746 5500 blackbox com Chapter 3 Startup Commissioning 3 Startup Commissioning 3 1 Initial Operation For new installations make sure the unit is ready to operate by going through the Checklist for Completed Installation located in Appendix A before startup NOTE A Warranty Registration and Startup Checklist is provided in the unit data package Complete it during startup and send it to Black Box Technical Support This checklist should be used as a guideline for items that need to be confirmed during Startup Startup must be performed by a journeyman refrigeration mechanic or an air conditioning technician 3 2 Step by Step Startup Instructions 1 Replace all equipment removed before performing the startup checks 2 Turn the system on with the service disconnect switch Upon applying power to the controller it begins an initialization sequence conducting internal diagnostics to confirm functionality see Sec
84. f the cabinet per Figure 1 2 Raise or lower each foot until the cabinet is level and even with the adjacent equipment racks see Figure 2 1 2 5 Air Distribution Air from the hot aisle is drawn into the rear of the Cold Row cabinet and passes through the fins of the cooling coil The conditioned supply air discharges through the front of the cabinet see Figure 2 2 724 746 5500 blackbox com Page 21 Chapter 2 Installation Hot Aisle Server Rack Server Rack Server Rack Server Rack Cold Aisle Figure 2 2 Typical air distribution The front discharge panel directs the supply air out of the Cold Row unit where it will be drawn into the front of the server racks An optional front diverted air discharge panel is also available This directs the supply air sideways out of the Cold Row unit and directly into the front of the server racks see Figure 2 3 Hot Aisle Ki O e PE w D ras D 09 Server Rack Server Rack Server Rack Cold Aisle Figure 2 3 Front diverted air distribution Page 22 724 746 5500 blackbox com Chapter 2 Installation 2 6 Optional Equipment Field Installed NOTE Do not mount any optional equipment on the unit access panels 2 6 1 Remote Water Detectors The remote water detector is normally placed on the sub floor or in a field supplied auxiliary drain pan located beneath the unit Black Box provides two types of water detectors Spot type water detector Remove the pro
85. fan by comparing the variance of the fan s local zone temperature sensor to the overall average temperature measured by the sensors for all three fan zones The controller adjusts the speed of each fan as necessary to meet the supply air temperature setpoint for that zone 4 4 4 3 Temperature Proportionate Speed Control The controller adjusts the speed of each fan proportionally for that zone to meet the supply air temperature setpoint The controller compares the variance of each temperature zone to the temperature setpoint and develops a proportional control output to modulate the speed of each fan to meet the supply air temperature setpoint for that zone 4 4 4 4 Manual Speed Control The controller continually controls the speed of each fan to values manually entered in the system controller Control gt Set gt Fan Control menu loop Section 4 5 4 1 without regard to the temperature setpoint 4 4 5 Remote On Off For Remote On Off operation terminal positions are provided to connect a remotely located On Off switching control device If the A C unit is turned on and the E2 controller receives a remote input signal to turn off the A C unit the controller disables all control outputs and a message Off by Remote Shutdown appears in the main display screen The A C system will automatically be reenabled when the remote On Off signal calls for the A C unit to turn back on The control device may be an On Off switch thermostat or a humidist
86. fg menu screen allows you to set new passwords for entering the Control and Service menus 4 5 5 10 Factory Menu SERVICE Save Cfg FACTORY O Cool Figure 4 64 Factory Menu screen The Factory Menu loop may be accessed from the Service gt Factory screen You must enter the factory level password to gain access to the loop Contact Black Box Tech Support for the password and for guidance when adjustments must be made at this level Page 84 724 746 5500 blackbox com Chapter 4 E2 Controller 4 6 Communication with the Controller It is possible for the E2 controller to communicate in multiple ways The controller may be set up to use a pLAN network to link with additional E2 controllers to create a workgroup consisting of multiple A C units see Section 4 6 1 Using an expansion card the unit may also be connected to a BMS for monitoring and control of data points using a variety of different serial communication protocols see Section 4 7 Control Variables From BMS Temperature Sensor i Proportional Input Ae Humidity Sensor Signals From Sensors or BMS Analog Output Lead pLAN Controller Connection A C Unit 1 Temperature Sensor p Humidity Sensor Yt 4 Up to 8 F Series es Controllers in Work Group A C Unit 2 L sl Temperature Sensor Humidity Sensor AIC Units Oi Figure 4 65 Configuring multiple A C units 4 6 1 Workgroup Setup The controller ma
87. fter shutdown Replace compressor c Worn or scarred compressor bearings Replace compressor d Liquid slugging System overcharged Reclaim excess refrigerant e Scroll compressor not properly phased Phase correctly at main power source DO NOT REWIRE COMPRESSOR 5 3 Field Service Repairs must be performed by a journeyman refrigeration mechanic or air conditioning technician Turn off power to unit at the main power disconnect switch before attempting to make repairs NOTE Do not attempt to make repairs without the proper tools 5 3 1 Water Water Glycol System If the water or water glycol system isn t cooling or if cooling is reduced check for fluid leaks in the system Check for clogged water lines If filters are installed in the fluid lines check the condition of the filters Clean or replace the filters if necessary In sttuations where scaling could be heavy untreated water in the unit cooling coils may cause over a period of time a loss of heat exchange capacity from a mineral deposit build up inside the coil Only a qualified service mechanic should clean dirty coils Leak Detection Repair A leak in a fluid cooling system will usually form a puddle of fluid beneath the unit that can be easily seen Visually trace the leak up from the puddle to the area on the unit where fluid may be seen dripping When a leak is detected turn off the fluid supply before attempting repairs Adjacent piping must be thoroughly cleaned by
88. gas discharged under pressure with any part of the body The extremely low temperature resulting from the rapid expansion of liquid refrigerant or pressurized gas can cause sudden and irreversible tissue damage As a minimum all personnel should wear thermal protective gloves and face shield goggles when working with refrigerant Application of excessive heat to any component will cause extreme pressure and may result in a rupture Exposure of refrigerant to an open flame or a very hot surface will cause a chemical reaction that will form carbonyl chloride hydrochloric hydrofluoric acid a highly poisonous and corrosive gas commonly referred to as PHOSGENE In its natural state refrigerant is a colorless odorless vapor with no toxic characteristics It is heavier than air and will disperse rapidly in a well ventilated area In an unventilated area it presents a danger as a suffocant Always refer to the manufacturer s Material Safety Data Sheet MSDS provided with the unit CAUTION Certain maintenance or cleaning procedures may call for the use and handling of chemicals solvents or cleansers Always refer to the manufacturer s MSDS prior to using these materials Clean parts in a well ventilated area Avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning solvents Wash exposed skin thoroughly after contact with solvents CAUTION J Do not use cleaning solvents near open flame or excessive heat Wear eye protec
89. ge detailing the alarm condition s After an alarm condition is corrected the alarm can be cleared by pressing the alarm key 4 1 3 Controller UO Module The controller is a microprocessor based I O module mounted inside the A C system electric box see Figure 4 2 The controller I O module contains the software that manages the operating parameters of the A C system So Se a EA S dh a A m Wi e ek i M5 EN z UE IF KEERNNNNOHIN Aea Figure 4 2 Controller I O module Controller UO Module Layout The controller I O module contains the logic and input output terminals See Figure 4 2 for details of the controller I O module layout The item numbers that follow coincide with the call outs in Figure 4 2 1 Connection J10 for interface display panel 2 Connection for pLAN J11 3 Hatch for BMS or network card 4 Power on LED Yellow 5 Signal LEDs Red Yellow Green 6 Hatch for expansion I O module s 7 Power connector J1 Page 46 724 746 5500 blackbox com Chapter 4 E2 Controller 4 1 4 BMS Interface The E2 series controller may incorporate a Building Management System BMS network card equipped with a communication port Figure 4 3 This can be field connected through a serial interface to a Building Management System via Modbus BACnet SNMP or HTTP protocol as configured by the factory A controller intaced to a network must be configured for BMS communication Figure 4 3 B
90. gerant Reclaim excess refrigerant from system d Condenser fan not operating Check pressure temperature operating switches and motor Replace as needed Symptom Condenser pressure too high CRDX W FS 12KW CRDX W FS 24KW CRDX G FS 12KW CRDX G FS 24KW units Probable Causes Recommendations a Flow of water glycol too low 1 Check glycol solution level and concentration 2 Valves not open or partially open Repair replace as needed 3 Air in system bleed system 4 Check all strainers and clean if needed b Water glycol temperature too high Check flow and operation of drycooler c Control pressure set too high Adjust controller to obtain correct pressure d Water glycol solution not mixed prior to adding to system Remove solution and premix Refill system Symptom Condenser pressure too low Probable Causes Recommendations a Loss of refrigerant indicated by bubbles in sight glass Locate and repair leak Recharge system b Condenser fan controls not set properly Adjust or repair controls c Control pressure set too low R410A Readjust to 440 psig Page 118 724 746 5500 blackbox com Chapter 5 Maintenance Symptom Noisy compressor Probable Causes Recommendations a Expansion valve stuck in open position abnormally cold suction line Ensure feeder bulb is tight on suction line Check operation and superheat D Broken compressor valve compressor knocking suction pressure rises faster than 2 b min a
91. hat is in strict accordance with the manufacturer s instructions may cause interference to radio communication It has been tested and found to comply with the limits for a Class A computing device in accordance with the specifications in Subpart B of Part 15 of FCC rules which are designed to provide reasonable protection against such interference when the equipment is operated in a commercial environment Operation of this equipment in a residential area Is likely to cause interference in which case the user at his own expense will be required to take whatever measures may be necessary to correct the interference Changes or modifications not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment This digital apparatus does not exceed the Class A limits for radio noise emission from digital apparatus set out in the Radio Interference Regulation of Industry Canada Le pr sent appareil num rique n met pas de bruits radio lectriques d passant les limites applicables aux appareils num riques de la classe A prescrites dans le R glement sur le brouillage radio lectrique publi par Industrie Canada 724 746 5500 blackbox com Page 3 N In OM Statement strucciones de Seguridad Normas Oficiales Mexicanas Electrical Safety Statement 1 2 3 4 5 10 11 KZ 13 14 15 16 17 18 Pa Todas las instrucciones de seguridad y operaci n deber
92. he factory to 0001 for the Control menu Level 1 and to 0002 for the Service menu Level 2 Upon entering the Service gt Save Cfg menu the operator can change the passwords for the menus If changed from that point on only personnel who know the password can access that menu 4 3 System Operation CAUTION J Ensure all system hookups to the air conditioner s are completed and that power Is available 1 Turn the main power disconnect switch for the A C unit to On Upon applying control power the controller display function keys illuminate and the controller begins conducting internal diagnostics to confirm functionality The controller monitors the alarm inputs and alarm logic to determine if it s safe to start the unit After an initialization period of about 30 seconds the Main screen is displayed The Main Screen is a status screen displaying the current date and time It displays the current control temperature and relative humidity and the current temperature and dew point as calculated from the T H sensor It also displays the current system operating mode s 2 If the controller is configured for Automatic On operation standard a status message Unit On then appears in the display Figure 4 12 Main screen 3 If the status message OFF Manual Restart Req appears instead of Unit On the Automatic On feature may not be enabled In this case turn the air conditioner on by pressing the Enter key
93. he left of the fan icons indicating which fan zones have been linked iol e Kei ebe el NI Limes pone 7 we aa Upper Fan Sod Gen wt ot Var frm Av Upper Fan Tad Grae L Var frm Avg _ og Figure 4 28 Fan Control screens not linked 724 746 5500 blackbox com Page 67 Chapter 4 E2 Controller When fans are not linked the controller adjusts the soeed of each fan as necessary for that zone to meet the supply air temperature setpoint When the system is in the dehumidification mode the fan speeds are automatically linked and controlled to the same speed 4 5 4 2 Alarm Setpoint Screens CONTROL Figure 4 29 Alarm Set screen You can access the Alarm Setpoints screens from the Control menu These screens enable the high and low temperature and humidity alarms adjust their setpoints and compare them to the control setpoints and to the current system level operating data derived from the sensor inputs aa Temperature Alarm High alarm Enable Yes Setpoint 80 0 F STATUS Temp 72 6 F Set 72 0 F Dew 50 1 F High Temperature Alarm Press h Key Figure 4 30 High temperature alarm Temperature Alarm Low alarm Enable Yes Setpoint 60 0 F STATUS Temp 72 6 F Set 72 0 F Dew 50 1 F Figure 4 31 Low temperature alarm Humidity Alarm High alarm Enable Yes Setpoint 70 0 STATUS Bom 45 Ee Set 45 0 Dew Sel F Figure 4 32 High humidity alarm Page 68 724 746
94. he lower fan The system controller monitors fan operation If one or two of the fans fails to operate the controller alerts the operator with an alarm message and increases the speed of the remaining fan s to compensate for the loss of airflow Use the system controller to configure the fans for zone temperature control with independently variable fan speeds or with all three fans operating at the same variable speed See Section 4 4 4 1 5 7 Temperature Humidity Sensors Control and alarm recognition takes place by means of the controller analyzing signal inputs trom the sensors to manage the operation of the A C unit consistent with the setpoints entered in the system controller The system controller monitors three NTCtype temperature sensors and a 4 20 mA temperature humidity T H sensor The NTC sensors are factory installed in predetermined supply air fan zones inside the cabinet Each NTC sensor is used by the sys tem controller to manage the speed of the fan for that zone to meet the supply air setpoint temperature The return air is moni tored by a temperature humidity T H sensor that is typically mounted inside the cabinet As an option you can remove the return air T H sensor from the cabinet and mount it in the hot aisle View the actual sensor values from the controller user interface display using the Information menu loop 1 6 Optional Equipment 1 6 1 Remote Mounted Supply Temperature Humidity Sensor As an option a supply T
95. hin the unit electric box Refer to the supplied electrical schematic for the specific power rating of the switch and for wiring details See Section 4 4 5 for additional information on the remote on off feature 2 9 3 Outdoor Equipment The following sections detail field power wiring required for a typical system Additional conductors may be required depending on the options purchased with the equipment Refer to the electrical drawing supplied with your unit for the appropriate field wiring terminations required specifically for your system 2 9 3 1 Water Cooled Systems CRDX W FS 12KW CRDX W FS 24KW Models Systems equipped with an internal water cooled condenser do not require field wiring to external components other than to optional sensors as selected e g Flow Sensors Remote Supply Air T H sensor Air Pressure Customer Alarm Inputs Page 34 724 746 5500 blackbox com Chapter 2 Installation 2 9 3 2 Glycol Cooled Systems CRDX G FS 12KW CRDX G FS 24KW Glycol cooled systems equipped with a pump package require field wiring between the A C unit and the pump package see Figure 2 13 The installer must wire two control conductors from the terminal board within the A C unit to the pump package electrical box Refer to the electrical drawings supplied with your unit for the number of field wires needed and for the appropriate wire terminations required for your system MAIN POWER SUPPLY 208 460V 1PH 3PH 60Hz DRYCOOLER IN
96. ignal controlling the valve position Press 4 or 4 Key 0 0 ou omo Press 4 or 4 Key Continued on next page Figure 4 22 Information menu loop part 2 Page 62 724 746 5500 blackbox com Continued from previous page EHGB Status Pos 50 0 Temp 30 0 F Press 4 or Key Fan Status KOL mg 80 0 Var frm Avg OOO Damm 80 0 Var frm Avg OOO Mmm 80 03 Var frm Avg OOO Fan Status Mumm 80 03 Var frm Avg 000 E Leg 80 0 Var frm Avg OOO Mmmm 80 0 D D Var frm Avg Net T H Sensors eil 00 0 F 00 0 rh T H Sensor Value Local pL Unit 0 of 0 Lead CH Ip Group T H Sensors Avg 000 0 F 000 0 Min 000 0 F 000 0 Max 000 0 F 000 0 Min Temp 0 Min Hum Max Temp 0 Max Hum AP oP oO Group Alarms 1 1 8 000 9 16 000 17 24 000 25 32 000 33 40 000 41 48 000 49 56 000 L al Press 4 or 4 Key Il W G 12 09 20 12 Figure 4 22 Information menu loop part 3 Chapter 4 E2 Controller 4 5 2 10 EHGB Status Displays the current operating position of the electronic hot gas bypass valve The current suction temperature appears below The bar gauge next to the valve icon provides a visual representation of the output signal controlling the valve position 4 5 2 11 Fan Status The Fan Status screen displays symbols indicating the operating status of the upper middle and lower fans The symbols are animated when the fans are ru
97. ination of the ground wire 724 746 5500 blackbox com Page 33 Chapter 2 Installation CAUTION A Before operating the unit you must connect an adequate unit to ground to the unit 2 9 1 1 Single Phase Units 208 230 V The supply voltage for units that are designed for 208 V operation must have a tolerance within 5 and 10 If the measured supply voltage is 230 V the unit can operate with a tolerance of 5 if the following change Is made The control transformers within the system must have the primary wire connected to its respective 240V tap instead of the 208V tap 2 9 1 2 Three Phase Units Three phase units are designed to have the L1 L2 and L3 supply wires connected to corresponding L1 L2 and L3 line terminals of the non fused service switch The unit will operate correctly if the supply wires are connected in this manner CAUTION A Improper wire connections will result in the reverse rotation of the fans blower motors and compressor and may eventually result in damage to the compressor To correct this problem exchange any two of the incoming main power wires at the main power service disconnect switch Do NOT rewire the unit s individual components 2 9 2 Optional Equipment Additional control wires may be required depending on the options that were purchased with your unit Optional sensors are to be connected directly to the control terminal board in the Cold Row electric box You may route the wires through
98. int E Er 44 A T14 A C Grouping PLAN ODER ATION serseri E O e EEE ENE O OE EEEE 44 A UT e TEE 45 ET E O ICY ea E EE EEEE EE E E AR 45 aea T el E E 46 ARA A EE 46 EE LOr E eege 46 AA E ee le 47 4 2 Navigating Controller eege ee deer 48 ALE Deet EE 48 E E E E E EE A A E E E EE A E E A T E 48 o e Boa VAN E ee e E E E A 49 424 Cuor EE WA ICG IS edel 49 A MOn ee 50 426 Password EE ee NEE 50 Ne 1K 1 tc 6 es WE 50 AED ON AS ee 51 EE EE 5 Ao a Ee Le 51 43l Seton AdU Ne EE 52 4 3 1 1 Saving and Restoring Setpoint Parameters ioc ccccccescun csiesevalesedenssuererendiew isles etichaadedasieeneeeeuseinietaaduenseenrts 54 E E E 54 Page 6 724 746 5500 blackbox com Table of Contents DEN ale PN EE 54 D Ce SIC gc Oc dg EE 54 AL UU OMG EE 54 AA COMUOUNCT ORCI WOM EE 54 AAT ee tee TEE 55 eh CO Oi Ia CON re 55 AZ Proporional integral P N CONIO E 56 aA ege NO OS E 56 4421 Temperature RA COIN CO eege 56 PE ZZ ICO GOON ees 56 AA ele eene EE 5 7 WA Dk TOMIDRESSO OPER aN ee ee 57 EVE ea e EE 58 A a E E e nc ee EEE EE ee EE E E 58 4 4 4 Airlfow Fan Speed Control 58 4441 Ind ependent Fan Speed Control EE 59 4 4 4 2 Variance from Average Fan Speed Control 59 444 3 Temperature Proportionate Ke e e ge E 59 EN AA Mnal peed CONTO sere erecta E E neeneeeeiee testes 59 A PNO E O EEN 59 ne E A OE E E E E E E N EE E E E E EE E EEE E 59 Sen Ee E E E E E A E E A EE A A ETE E A E T a 59 DZ e tege On Men OO cers E E
99. internal layout Cold Row DX Page 16 724 746 5500 blackbox com Chapter 1 Introduction 1 5 1 Electrical Compartment The electrical components are protected inside an electric box located behind the rear access panel The electric box cover is safety interlocked with the service disconnect switch See Figure 1 2 preventing the cover from being opened when the switch in the On position The switch must be turned Off to gain access to the electrical compartment The service disconnect switch may be used to turn the unit off for emergency shutdown or when routine maintenance is performed The handle of the switch locks in the Off position to prevent unintended operation 1 5 2 Circuit Breakers Motor Start Protectors Cold Row units incorporate state of the art component protection using motor start protectors and circuit breakers If an overload occurs you must manually reset the switches after clearing the overload condition 1 5 3 Compressor A scroll compressor is used in DX based Cold Row systems With fewer moving parts scroll compressors have demonstrated superior durability The scroll compressor is designed around two identical spirals or scrolls that when inserted together form crescent shaped pockets During a compression cycle one scroll remains stationary while the other scroll orbits around the first As this motion occurs gas is drawn into the scrolls and moved in increasingly smaller pockets toward the center At this
100. ion materials tools etc Inspect all piping connections for leaks during initial operation 724 746 5500 blackbox com Page 125 Appendix A Forms A 2 Periodic General Maintenance Checks and Services Checklist for Cold Row DX Date 2 Prepared By Model Number eee Serial Number Item Number Monthly Filters Blower Section Condensate Drain LY Cleanliness LY Blower turns LI Drain is open LJ Condensate pan safety switch operates freely Miscellaneous Ly check water glycol or chilled water circuit for air bleed as required LY Humidifier and controls operate properly Semi Annually LJ Check refrigerant charge bubbles in sight glass E Tighten electrical connections L Check suction and discharge pressure L Check contacts on contactors for pitting LJ Check glycol solution concentration in system L Clean the unit as necessary LJ Clean coils L Test the glycol solution inhibiters flush if necesary L Clean condensate pump Annually Chilled water systems L Inspect water glycol system for leaks and corrosion LJ Conduct a complete check of all services listed above and clean unit s interior Signature If factory assistance Is required for any reason provide the model number serial number and Black Box item number found on the unit nameplate This will soeed the process and ensure accuracy of information Page 126 724 746 5500 blackbox com Appendix B Glossary Definitio
101. ises the valve position continues to modulate open as needed up to 100 fully open to maintain the control setpoint The control output signal is matched to the valve If the valve typically opens at 2 5 VDC the control I O module will generate the appropriate voltage for opening the valve starting at the minimum voltage of 2 5 VDC From there the signal increases as needed until the valve position reaches 100 open 4 4 3 3 Dehumidifying When dehumidification is called for the blower speed automatically changes to the dehumidification fan speed setting The controller will operate the system in the cooling mode at full output to strip moisture from the air The system will remain in the cooling mode until the actual relative humidity or dewpoint reaches the control setpoint plus the dehumidification cut out offset If the control temperature drops below the low temperature cutout setpoint for the dehumidification mode temperature setpoint minus 4 F default cooling operations will stop 4 4 4 Airflow Fan Speed Control The E2 controller treats each EC fan as a variable speed fan The controller manages the speed of each fan from a factory set minimum up to a factory set maximum speed The minimum fan speed is used whenever the A C unit has no cooling operations running The maximum fan speed setting is used during times when the A C unit is cooling A dehumiditication fan speed setting is used when the system is in the dehumiditication mo
102. isolated by using vibration isolating supports Provide supports clamps or hangers as necessary every 5 to 10 feet along piping runs to minimize vibration and noise transmission To reduce vibration transmission and prevent pipe damage when sealing openings in walls use a soft flexible material to pack around the piping After the piping is installed seal the gaps between the pipes and the entrance holes in the cabinet so air won t leak around the pipes All refrigeration piping should be installed with high temperature brazed joints Use standard refrigeration practices for piping leak testing dehydration and charging of the refrigeration circuits For copper to copper brazing phosphorous alloy containing a minimum of 15 silver is recommended General purpose silver brazing alloy with 45 silver is recommended for brazing dissimilar metals 724 746 5500 blackbox com Page 29 Chapter 2 Installation Wrap wet rags around the pipes between the areas to be soldered and any nearby refrigeration components to keep excessive heat from traveling through the pipe and causing damage Clear all pipe connections of debris and prep connections for soldering Use only L or K grade refrigerant copper piping Be careful not to allow solder piping debris to get inside refrigerant lines Dry nitrogen should be flowing through the tubing while soldering at a rate of not less than 1 2 CFM 0 028 0 057 m minute Table 2 4 Pipe connection sizes
103. it5 0 Unit2 3 Unit6 0 Unies GE Kr be O Unit4 O Units O Figure 4 90 Group screens Page 100 Group Sensor Values This displays the current group temperature and humidity control values transmitted from the Lead controller The field below displays the selected control T H sensor arrangement lead avg min max local depending upon how the group is set up See Service gt Options screens Section 4 6 2 7 The last field shows the unit group address assigned to the controller within the group and the address of the current lead controller Group Alarms This screen only appears when the controller is wired with additional A C unit controllers It displays bitmask values indicating the alarm conditions that will initiate a group internal alarm causing the unit to switch over from Active to Unit Off See Factory gt Group Group Alarm Setup in Section 4 6 2 6 Lead Controller Group Sensors This screen appears only in the display of the controller that is designated as the lead in a multi unit workgroup The lead controller polls the temperature and humidity sensors from all the A C units in the work group and displays the averaged values It also displays the value of the minimum lowest temperature sensor and the value of the minimum humidity sensor in the A C group and conversely displays the value of the maximum highest temperature sensor and maximum humidity sensor in the A C group The fields at the bottom are the addr
104. kbox com BLACK BOX About Black Box Black Box provides an extensive range of networking and infrastructure products You ll find everything from cabinets and racks and power and surge protection products to media converters and Ethernet switches all supported by free live 24 7 Tech support available in 30 seconds or less Copyright 2013 Black Box Corporation All rights reserved CRDX A FS 24KW version 1 BB OWRO129 Dec 2012 724 746 5500 blackbox com
105. l in the rotation cycle so even a standby unit will be cycled into active duty on a scheduled basis A C units in the group may have their duty assignments locked so they do not join the rotation cycle and cannot take the lead In this case the message No_Rot appears after the duty assignment displayed in the main screen 01 01 09 00 00 00 00 0 F 00 rh Dp 00 0 F ef gem ACTIVE No Rot Figure 4 67 Unit rotation screen An Active_No_Rot unit is always On therefore it will not rotate out An Active_No_Rot unit will still be able to take the role as lead controller during a rotation Units designated as Out of Service do not rotate nor can they be used as lead units The rotation time period is typically 1 week however it may be set by the user via the Factory menu Call Black Box Technical Support for assistance when accessing the Factory menu 4 6 1 4 Out of Service A unit may be removed from the group entirely by placing it Out of Service In this mode the unit will not operate A unit may be placed in this mode as a safety measure to prevent it from unexpectedly starting when performing maintenance or repairs 4 6 2 Configuring a Workgroup A workgroup can consist of up to 8 controllers I O boards with pLAN addresses 1 to 8 Their corresponding display terminals will be assigned pLAN addresses from 32 down to 25 The E2 controller program is defaulted with the controller address set to 1 and its terminal displ
106. lding the clear plastic discharge line Remove the discharge line from the barbed stub fitting Release the cable retaining clip on the side of the pump and cut the wire ties holding the cable loop Maneuver the pump into the fan opening with the cable still attached and remove the cover to expose the wire terminals Remove the wires from the pump and remove the pump trom the cabinet Install the replacement pump in the same manner that the old pump was removed reversing the procedure Page 122 724 746 5500 blackbox com Chapter 6 Troubleshooting 6 Troubleshooting Black Box provides its customers with Technical Support that not only provides technical support and parts but also the following additional services as requested e Performance Evaluations e Start up Assistance e Training 6 1 Technical Support If a problem develops that cannot be resolved using this manual contact Black Box Technical Support at 724 746 5500 or info blackbox com When calling tor Tech Support it is important to have the following information readily available information is found on the unit s nameplate e Unit Model Number e Black Box Sales Order Number e Black Box Item Number e Unit Serial Number e Description of Problem 6 2 Obtaining Warranty Parts Warranty inquiries are to be made through Black Box Technical Support at 724 746 5500 or info blackbox com A service technician at Black Box will troubleshoot the system over the telepho
107. ler ccccccccccccccccssssseeeeeccesssseeeecceceesseeeeeeecessieeeeeeeeeesteneeeeeeeenas 88 AoA FUE E AO E E EE 89 4 6 2 5 Displaying the Network Status and Firmware Version 89 DTG 22 COMI NVO O oes E E se eae sone cence teseened aueanen dense 90 4 6 2 7 Se rvice gt OptionS gt Group Menu Screens cccccccccccceceeeeeeeeeseceeeeeeeceeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeseeeetteeeteaaaaes 97 4028 Gro p hiomaton Menu Ee fcc E 99 ONS O ON O E 101 AE E SE ht 102 AJA BIS Eelere 102 4g Troublesh dting the Control VO ee TEE 103 4 9 BMS Parameters Version V2 EEN 104 4 9 1 Signed Values for HTTP SNMP Modbus Holdling Registers Analog Values for BACnet ssssiiinsseeninnnsen 105 4 9 2 Unsigned Values for HTTP SNMP Modbus Holdling Registers Analog Values for BACnet s asaennnneeanan 106 4 9 3 Boolean Values for HTTP SNMP Modbus Coils Binary Values for BACnet sssssnnnssessnnniinssennirrssnrrrnrnsnn 107 POA Pilla Pakea BiG Va Ee ES eoe ce aezeteeepeetedenaieds sues eae da sa eceenceaeb EE 108 49 5 Sensor Failure Packed Bit Variables aneren eier 109 A90 Reie Materne Ee 110 497 Digital Output Packed DEE 111 4 9 8 Unsigned Values for HTTP SNMP Modbus Holding Registers Analog Values for BACnet 112 4 9 9 Boolean Values for HTTP SNMP Modbus Coils Binary Values for BACnet ssssssnnssessnniinseeinirrsssrrrnrnsnen 112 By IAIN I e E 113 51 EOC Gereral ANE ee 113 E Gin 113 Su Wee IONE Ir 113 CAE A IS sects ccs E unas anenensnceepeaseamee
108. ler is assigned Address 2 then the corresponding terminal address should be set to 31 as shown in Table 4 11 If the next controller is assigned Address 3 the corresponding terminal should be set to 30 After setting the correct terminal address press the Enter key once to confirm your selection A message NO LINK will appear At this point the terminal has been set with the correct address for the controller and the controller has been set for the terminal but now they need to be assigned to each other 4 6 2 3 Assign the Terminal to the Controller 1 Access the Terminal Address Configuration screen again using the up arrow vg down arrow L and Enter Y keys 2 Press the Enter Y key until the cursor moves to the field I O board address 3 Using the up 4 and down arrow Y keys enter the address 1 8 for the controller I O board 4 Press the Enter Y key twice to display the Terminal Configuration screen shown below P 02 Adr Priv Shared Prem 31 Pr Trm2 None E Trm3 None Ok No Figure 4 71 Terminal Contiguration screen 5 Here too the Enter 1 key moves the cursor from one field to the next and the up arrow 4 and down arrow keys change the value of the current field The field PO depicts the pLAN address 1 8 assigned to the I O board In the example shown the controller has been assigned address 2 6 Press the Enter H key to move to the field Trm1 xx The field represents the address of the te
109. n Time Dehum Cut out Min Temp Set 1 Point Figure 4 20 Compressor on off cycle The compressor runs at a constant speed and an electronic hot gas bypass system manages capacity in accordance with the demand for cooling The compressor is turned off when the control cut out setpoint is achieved provided the minimum run time is expired Operating setpoints for the compressor are programmed by the factory and no adjustment should be necessary If adjustment is required contact Black Box Technical Support at 724 746 5500 or info blackbox com The cooling cut in and cut out setpoints are set with a minimum span of 2 0 F NOTE If the compressor cut in cut out setpoints are set too closely together when adjusting setpoints the compressor could run below the setpoint temperature during periods of light heat loads because of the minimum run time cycle 724 746 5500 blackbox com Page 57 Chapter 4 E2 Controller 4 4 3 2 Water W G Operation When the system is turned on the controller activates the fluid supply control valve with a proportional integral Di 0 10 VDC signal The valve opens proportionally based on head pressure The control parameters are adjustable in the Factory menu If adjustment is required contact Black Box Technical Support at 724 746 5500 or info blackbox com The control valve changes position to adjust coolant flow to keep the head pressure to the control setpoint and maintain it If the head pressure r
110. n acid that will eventually lead to compressor failure A triple evacuation procedure with dry nitrogen is recommended especially for systems with newly installed refrigerant piping NOTE Use a vacuum pump that Is capable of evacuating the entire volume of the A C system including newly installed or existing piping It is essential to use a well maintained pump that Is in good operating condition Always ensure it contains clean fresh oil Manufacturers recommend that you change the oil in the pump regularly to maintain its ability to remove moisture NOTE Use high quality hoses that are free of defects and don t leak We recommend using copper tubing instead of hoses if possible because of the low vacuum that must be attained when evacuating the system Using short large diameter hoses helps reduce evacuation time 3 After ensuring there are no leaks relieve pressure and evacuate the entire system while maintaining all the solenoids open Pull an initial vacuum of 1500 microns or lower using the suction and discharge service ports Page 38 724 746 5500 blackbox com Chapter 2 Installation NOTE When pulling a vacuum the Schrader valves will unnecessarily restrict the openings increasing the evacuation time During the evacuation process we recommend that you remove the Schrader valve cores with a Schrader valve removal tool and draw the vacuum through the port on the removal tool 4 If you cannot evacuate the system below 1500 mic
111. n of Terms and Acronyms Appendix B Glossary Definition of Terms and Acronyms BTU Hr British Thermal Units per hour CFM Cubic feet per minute CNDCT Conductor CW Chilled water DX Direct expansion ESD Electrostatic discharge F Degrees Fahrenheit FLA Full load Amps FOB Freight on Board HACR Heating air conditioning refrigeration HP Horsepower Hz Hertz IAQ Indoor air quality KVA Kilo Volt Amps kW Kilowatt LRA Locked rotor amps MAX CKT BKR Maximum circuit breaker MAX FUSE Maximum fuse MCA Minimum circuit ampacity m i w g Milli inches of water gauge MSDS Material Safety Data Sheet NEC National Electric Code NFPA National Fire Protection Agency PH Phase PI Proportional integral control PSIG Pounds per square inch gauge R410A Refrigerant RLA Run load amps R Value Thermal resistance SPDT Single pole double throw TEV Thermostatic expansion valve V Volt VAC Volt alternating current 724 746 5500 blackbox com Page 12 7 Appendix B Glossary Definition of Terms and Acronyms VDC Volt direct current WG Water Glycol Page 128 724 746 5500 blackbox com NOTES 724 746 5500 blackbox com Page 129 NOTES Page 130 724 746 5500 blackbox com NOTES 724 746 5500 blackbox com Page 131 Black Box Tech Support FREE Live 24 7 Tech support the way it should be i K A Great tech support is just 30 seconds away at 724 746 5500 or blac
112. n the bottom of the rear access panel Lay the access panel down on a piece of cardboard and remove the four screws holding the end cap in place Remove the end cap and slide the old filters out of the tray as shown in Figure 5 2 Slide the new filters into the tray and replace the end cap Ensure the four screws are Tully tightened REAR ACCESS PANEL 4 SCREWS END CAP Figure 5 2 Cartridge filters 5 1 2 EC Fans Periodic checks of the EC fans should include checking the wiring fan motor mounts housing and impeller wheel Ensure all electrical connections are tight Check that all mounting fasteners are secure and the impeller wheel is tightly mounted The impeller blades must be kept free of debris 5 1 3 Coil The coil should be inspected semi annually and cleaned as required following standard coil cleaning practices Using a brush clean the coil fins of all debris that will inhibit airflow This can also be done with compressed air or with a commercial coil cleaner Check for bent or damaged coil fins and repair as necessary Check all refrigerant lines and capillaries for vibration isolation and support as necessary Check all piping for signs of leaks 5 1 4 Drain Pans To ensure proper drainage inspect the drain pans regularly Make sure the drain pan outlets are always free of debris so they empty readily and ensure the drain pans do not leak K WARNING Do not use chloride based water conditioning additives in the c
113. nd disconnect the main power supply to the equipment Follow a lock out tag out procedure to ensure that power Is not inadvertently reconnected WARNING This unit is fed by incoming power wires Even with the service disconnect switch in the Off position power may still be live between the switch and the main power source When performing service always ensure that main power is disconnected from the unit CAUTION N Equipment may contain components subject to electrostatic discharge ESD Before attempting to mount or service these electronic devices make sure you have no charge built up by touching a ground source When possible use a wrist grounding strap when working on or near electronic devices Page 14 724 746 5500 blackbox com Chapter 1 Introduction CAUTION AN Never work on electrical equipment unless another person who is familiar with the operation and hazards of the equipment and is competent in administering first aid is nearby CAUTION AP All personnel working on or near equipment should be familiar with hazards associated with electrical maintenance Safety placards stickers are placed on the unit to call attention to all personal and equipment damage hazard areas WARNING Refrigerant R410A is used with this equipment Death or serious injury may result if personnel fail to observe proper safety precautions Great care must be exercised to prevent contact of liquid refrigerant or refrigerant
114. nd install the new one 3 Turn on power at the main power disconnect switch and start the system 5 3 4 1 Fan Replacement The EC Fans are located behind the front access panel The panel must be removed to access the fans The fans are equipped with quick connect fittings for the power and control cables to make swap out easy Lift the retaining latch on top of the power and control cable connector housings to unplug the cables Cut the wire ties holding the cable bundle in the cabinet Remove the tour hex bolts holding the inlet ring then remove the four hex bolts holding the fan mounting bracket Remove the fan assembly together with the inlet ring from the cabinet Remove the mounting bracket from the old fan and install it on the new fan Bolt the new fan assembly together with the inlet ring into the cabinet and plug the power and control cables into the connectors 724 746 5500 blackbox com Page 121 Chapter 5 Maintenance INLET RING FAN M6 HEX BOLTS TWO PER SIDE M5 HEX BOLTS TWO PER SIDE POWER CONTROL CONNECTORS Figure 5 3 Fan 5 3 4 2 Condensate Pump Replacement The condensate pump is located behind the lower cabinet fan assembly To access the pump the lower fan must be removed as described in Section 5 3 4 1 CABLE LOOP PUMP RETAINING CLIP DISCHARGE LINE WIRE TIE Figure 5 4 Condensate pump Reach inside the fan opening to grasp the pump Tilt the pump up and cut the wire ties ho
115. ne port with the A C unit turned Off 1 Bleed air from hoses and break the vacuum by supplying liquid refrigerant R410A to the discharge port near the compressor until the pressure is equalized This holding charge allows the low pressure switch to hold enabling the compressor to operate throughout the process of charging the system Fine Tuning the System Charge Once the initial charge is completed refrigerant will need to be added with the unit running CAUTION J An adequate heat load must be supplied to ensure a proper charge 2 Disconnect the refrigerant cylinder from the discharge side of the compressor and connect it to the suction side 724 746 5500 blackbox com Page 39 Chapter 2 Installation 3 Referring to Chapter 3 start the A C system and use the system controller to lower the room temperature setpoint 3 5 F below actual room temperature to ensure that cooling remains on as the unit is charged When fine tuning the charge on cool days it may be necessary to restrict the airflow across the condenser coil to raise the pres sure The fan closest to the header must be running When fine tuning the charge ensure the pressures are correct for the type of refrigerant used Refer to the tables in Section 2 10 3 for the operating temperature and pressure ranges for R410A refrigerant 4 Block off a portion of the intake air to the condenser until a constant discharge pressure can be obtained This will lower the
116. ne with a field service technician to determine the defect of the part If it is determined that the part may be defective a replacement part will be sent A written or faxed purchase order is required on warranty parts The purchase order must contain the following items e Purchase Order Number e Unit Model No Serial No and Black Box Item No e Date of Order e Black Box Stated Part Price e Customer Billing Address e Shipping Address e Customer s Telephone and Fax Numbers e Contact Name The customer is responsible for the shipping cost incurred for returning the defective part s back to Black Box Return of defective part s must be within 30 days at which time an evaluation of the part s is conducted and if the part is found to have a manufacturing defect a credit will be issued When returning defective part s complete the Return Material Authorization Tag and the address label received with the replacement part See the Black Box Standard Warranty located in Chapter 1 of this manual 6 3 Obtaining Spare Replacement Parts Spare and replacement parts requests are to be made through Black Box Technical Support Contact us at 724 746 5500 or intfo blackbox com 724 746 5500 blackbox com Page 123 Chapter 6 Troubleshooting Quotes are given for specified listed parts for a specific unit A 25 minimum restocking charge will be applied on returned stocked parts that were sold as spare replacement parts If the returne
117. nections Access the drain fitting from outside the cabinet on top piped units Access the drain fitting inside the cabinet behind the front discharge panel on bottom piped units An entrance hole for the drain line is provided in the floor of the fan compartment See the installation drawing provided with your unit for the location of the condensate drain fitting Connect the drain line to the fitting and direct the water to an appropriate place such as an open building drain with an air gap per local and national plumbing codes After the piping is installed seal the gap between the drain line and the cabinet entrance hole so air won t leak CAUTION N Do not use chloride based water conditioning additives in the condensate drain pans This will cause corrosion on the coil fins 2 9 Utility Connections 2 9 1 Main Power The Cold Row is available in single or three phase variations and a wide range of voltages Examine the unit nameplate to determine the operating voltage frequency and phase of the system see Figure 2 12 The nameplate also provides the full load amps FLA the current the unit will draw under full design load the minimum circuit ampacity MCA for wire sizing and the maximum fuse or heating air conditioning refrigeration HACR breaker size MAX FUSE CKT BKR for circuit protection The unit s nameplate is located inside the cabinet within the electrical box NOTE If the nameplate states MAX FUSE CKT BKR it is requir
118. neuesanoneeresaconwes pun A I S 115 SC EE 115 Me EE 115 A RTE EE 115 CAE COICO Se E 115 WEE EE 116 S MOUE ROO D 116 So FEOS T E 119 531 Vaer VV Cl GI CON SS EE 119 e D NEE 119 SEN TE ON tects sain sce ener teh sect wesc ancl acta E EEA ceeds ate E E A O EEE 119 a LEAK TEE 119 Page 8 724 746 5500 blackbox com Table of Contents E RO EELER 120 53 3 Refrigeration SVS Eu 120 che Egeter 120 5 3 3 2 Standard Cleanout ee e 121 Baa Bumu Addie Cleanup POOE sessir E EO E 121 534 Component EE eege 121 se A Er PRE e CINE Ae 121 5342 Condensate Pump Een EE 122 Ce TOU le EE 123 SE eelere RE er le SUDDO essere O E R E E E E 123 SE en Eat e 123 yo GENEE es Oreo nt 219 oS alg clg 1 a Gee ae ae enn ie ene ene ene E eee Cee eee Tee ee ee 123 ANOA en EE 125 A1 GAGES Toy Completed NIST Aa WOU E 125 A 2 Periodic General Maintenance Checks and Service Checker 126 Appendix B Glossary Definition ot Terms and ere EE 127 724 746 5500 blackbox com Page 9 Chapter 1 Introduction 1 Introduction 1 1 General The Cold Row precision data center air conditioning system covered by this manual uses the latest state of the art control technology It uses the finest materials available in the industry The unit will provide years of trouble free service if installed and maintained in accordance with this manual Damage to the unit trom improper installation operation or maintenance is not cov ered by the warranty STUDY the instructi
119. ng parameters are permanently stored on Flash memory in case of power failure The E2 Series controller is designed to manage temperature and humidity levels to user defined setpoints via control output signals to the A C system Control parameters have variable outputs from O to 100 of the full rated capacity The controller continually receives inputs for the measurable control conditions temperature and relative humidity via sensors installed in the cabinet The internal logic determines if the conditions require cooling or dehumidification Control setpoints are established to maintain the room s designed conditions The controller resoonds accordingly to changes and controls the output s to the air conditioning system so temperature humidity conditions reach the user defined control setpoints 4 1 1 Features 4 1 1 1 Field Configurable The program for the E2 Series controller is field configurable ao the operator can select control parameters and setpoints specific to the application Operator interface for the E2 controller is provided via an attractive door mounted user interface display panel The display panel has a backlit LCD graphical display and function keys giving the user complete control and monitoring capability of the precision cooling system The menu driven interface provides users with the ability to scroll through and enter various menu loops Monitoring of room conditions and A C system operation is allowed without entering a p
120. nication failure and the annunciation of a Comm alarm 0 No pLAN present Display indicates if a pLAN is detected by the controller fey Yes 4 6 2 7 Service gt Options gt Group Menu Screens Default 30 No Accessed in the Service menu the Service gt Options gt Group Setup screens only appear if two or more units are wired together as a workgroup Group Setup Group setup Unit ACTIVE Number of Days Hour of Day Ume L or 2 Figure 4 85 Group setup screen 724 746 5500 blackbox com Page 9 Chapter 4 E2 Controller The Service gt Options gt Group Setup screen allows you to select the workgroup duty assignment for the A C unit The duty must be assigned for each grouped A C unit at its local display terminal Enter the number of days between rotating active units Enter the hour of day for unit rotation to occur The screen also displays a status message indicating which A C unit you are accessing and which unit is currently the lead unit in the group Capacity Assist Capacity Assist Assist Time 300s Cooling Cie in h Cut cut 0 0 Fr Figure 4 86 Capacity Assist screen The first Service gt Options gt Capacity Assist screen allows you to enter the delay period for the unit to begin operating if It is in the capacity assist mode Also each A C unit in the group may be assigned local cut in and cut out setpoints for its capacity assist operation The values entered are offsets which
121. nning If a fan is not running the symbol will appear instead The value of the proportional output signal O to 100 that controls each fan appears in the field to the right of each symbol The animated icons are linked together indicating the three fans are being controlled to the same fan speed setting default The controller also displays the temperature value for the sensor from each fan zone The fans may be linked or unlinked in any combination for individual zone temperature control see Section 4 5 4 1 The message Var from Avg or Temp Prop appears indicating the speed control configuration see Section 4 4 4 1 The message in the field is replaced with Dehum when the system is in the dehumidification mode In the dehumidification mode the animated icons are always linked together indicating that the three fans are being controlled to the same dehumidification fan speed setting 4 5 2 12 Group Information Menu Screens The Group Information menu screens only appear if the controller is set up to operate multiple A C unit work groups See Section 4 6 2 8 for a more detailed description of these screens 4 5 2 13 Software Version Date Displays the type of A C system the controller is configured for W G AR and the Black Box software version and its release date 724 746 5500 blackbox com Page 63 Chapter 4 E2 Controller 4 5 3 Alarm Log Info ALARM LOG CR Control Figure 4 23 Alarm Log scre
122. nt pressure temperature settings Sub cooling F Superheat F Design Condensing Temp 95 F Ambient Suction Pressure psig Fan Cycling Control Fan On psig Fan Speed Control psig 2 10 3 2 Saturated Refrigerant Pressure The following refrigerant temperature pressure table is provided for reference for R410A refrigerant Normal M 5 10 105 105 330 n Max 20 20 140 140 480 Table 2 12 R410A refrigerant pressures Temperature F Pressure psig 20 18 4 22 Sg 24 65 5 26 89 2 28 93 1 30 S70 32 101 34 105 36 109 38 114 40 118 42 123 44 128 46 iss 48 137 50 143 55 155 60 170 65 185 70 201 Temperature F 75 80 85 90 95 100 105 110 115 120 125 130 135 140 Pressure psig 218 236 255 274 295 318 341 265 391 418 446 477 508 541 724 746 5500 blackbox com Chapter 2 Installation Page 41 Chapter 2 Installation 2 11 Settings and Adjustments 2 11 1 Water Water Glycol Circuit Condensing temperature is maintained by liquid flowing through a regulating valve and then into the condenser The regulating valve opens to increase the liquid flow as the refrigerant pressure rises or closes as the refrigerant pressure falls The system controller monitors a signal from a pressure transducer to determine how far to open the valve The controller automatically changes the control valve position to maintain head pressure based on the difference betw
123. nu screen by pressing the program Prg key 2 Scroll through the Main Menu selections with the Up 4 and Down arrow keys and select the Control menu by pressing the Enter Y key when CONTROL appears in bold letters in the center of the screen A password entry screen will be displayed 3 To access the Control menu press the Enter all key twice to insert a flashing cursor in the Enter Password field Page 52 724 746 5500 blackbox com Chapter 4 E2 Controller Reset No Enter Password E 0 JD 0 Level 0 Flashing Cursor Figure 4 14 Flashing cursor Change the 0 to 1 or to the current Control menu password if it was changed in the Service menu with the Up A arrow key and then press the Enter _ key to accept the password Press the Enter ZS key again to access the Control menu screens d From the Control menu select Setpoints by scrolling through the menu selections with the Up 4 and Down arrow keys and pressing the Enter key when SET appears in bold capital letters in the center of the screen CONTROL MENU Figure 4 15 Set screen 5 After entering the Setpoints screens select the Temperature setpoint screen by scrolling the menu selections with the Up up and Down arrow keys until the word Temperature appears in the field at the top of the screen Temperature Setpoint M72 0 F Controlling te Avg supply air temp STATUS Temp 73 0 F Set 72 0 F Dew 50 3 F Figure 4 16 Tem
124. o facilitate moving the unit before installation Move the unit on the skid with a suitable device such as a forklift pallet jack or roller bar and dollies that are capable of handling the weight of the equipment For reference a weight table is provided on the installation drawing Unbolt the shipping support brackets from the skid leaving them attached to the unit during the installation process CAUTION J Tipping Danger Keep the shipping support brackets attached to the front and rear of the cabinet after removing the Cold Row unit from the skid These must remain in place to prevent the unit from tipping over when moving and positioning the cabinet It is Safe to remove the shipping brackets when a server rack is installed on each side of the cabinet CAUTION J Position someone on each side of the cabinet to stop it from tipping over if the shipping brackets must be removed before installing the server racks on each side CAUTION AP When moving the unit lift it vertically and keep it in a level position to prevent damage 2 3 Site Preparation Removable access panels are located on the front and rear of the Cold Row cabinet for easy service access For full service access to the internal components do not place any permanent obstructions in front or behind the cabinet NOTE Establish working clearance requirements before mounting the unit Refer to local and national electrical codes CAUTION N Install the unit in the space th
125. o prevent condensation from forming on the pipes if ambient dew point temperatures are higher than the fluid temperatures CAUTION AP After the interconnecting piping is installed the entire piping circuit must be thoroughly flushed prior to operating the system If newly installed supply and return piping is used we recommend cleaning the piping system before connecting it to the unit If you use solvents cleaning solutions ensure they are completely flushed from the piping before connecting it to the unit Failure to do so could result in equipment problems Page 26 724 746 5500 blackbox com Chapter 2 Installation FPT o ON OOS H D EE EE Ka CET a O Eat zc aS b i IFAN YS S Page 2 7 Water Water Glycol Supply and Return Piping Connections CONDENSATE DRAIN L i FEMALE PIPE THREADS GE A IN Lu z gt oc Lu QO lt ac IL U WY 8 Top access piping Figure 2 724 746 5500 blackbox com SCHRADER VALVE COR AY LAE ei i DN rtp E WG B III SIFIITID VIJIJI JII E ENESE a wae Chapter 2 Installation MALE PIPE THREADS Figure 2 9 Bottom access piping 724 746 5500 blackbox com Page 28 Chapter 2 Installation 2 8 Split Air Cooled Systems Split air cooled systems with a remote condenser will require field installed refrigerant piping All
126. ommunicate with the controller I O board using point to point protocol not pLAN The display field I O Board address __ will disappear as it has no meaning until you set the controller I O board pLAN address 724 746 5500 blackbox com Page 87 Chapter 4 E2 Controller 4 6 2 2 Configure the Controller I O Board pLAN Address Immediately after turning power back on press and hold the Alarm and the up arrow T keys simultaneously for 10 to 15 seconds First you will see a display message self test please wait then the pLAN Address Configuration screen shown below will appear Don t press the Enter key the cursor is already in the modifiable field PLAN ADDRESS 1 UP INCREASE DOWN DECREASE ENTER SAVE amp EXIT Figure 4 70 pLAN Address screen Press the up arrow 4 key to set the pLAN address 1 8 for the controller I O board The pLAN Address 1 is already assigned by default to the first lead controller in the group Address 2 is to be assigned to the first controller added to the group Address 3 is to be assigned to the second controller added and so on Then press the Enter SE key to confirm your selection A message NO LINK will appear Next press the up arrow vg down arrow L and Enter Y keys simultaneously Reconfigure the terminal address following the steps in Section 4 6 2 again This time set the terminal address to match the corresponding controller I O board address If the control
127. ondensate drain pans This will cause corrosion to occur on the coil fins 5 1 5 Condensate Pump The condensate pump should be inspected semi annually and cleaned Remove the pump as described in Section 5 3 4 2 Inspect the water level switch and ensure that the float works freely Wipe the float with a wet cloth and detergent to remove dirt Check that the discharge line is open and water can pass through it freely 724 746 5500 blackbox com Page 115 Chapter 5 Maintenance 5 1 6 A C System Check the refrigerant sight glass on a monthly basis while the unit is running and ensure it is free of bubbles Bubbles in the sight glass indicate a low refrigerant charge or a clogged filter drier Check for humidity in the refrigerant by viewing the color of the indicator in the center of the sight glass and comparing it to the color scale on the outer ring If humidity is present the system must be evacuated and recharged Check the superheat and sub cooling temperatures semi annually and ensure they are within the range shown in the refrigerant pressure temperature table Tables 2 9 2 11 in Section 2 10 3 If necessary adjust the refrigerant charge to achieve the correct values If the refrigerant level is low check the system for leaks 5 2 Troubleshooting Turn off all power to the unit before conducting any troubleshooting procedures unless the procedure specifically requires the system to operate For troubleshooting purposes the system
128. ons contained in this manual They must be followed to avoid difficulties Soare parts are available trom Black Box to ensure continuous operation Using substitute parts or bypassing electrical or refrigeration components to continue operation is not recommended and will VOID THE WARRANTY Because of technical advancements components are subject to change without notice All Cold Row systems are designed to be installed indoors 1 2 Product Description Cold Row systems are available in water cooled water glycol cooled or air cooled direct expansion DX configurations DX based Cold Row systems are designed to operate with R410A refrigerant Table 1 1 Available models Product Code Product Name CRDX A FS 24KW Cold Row DX Air CRDX A FS 12KW Cold Row DX Air CRDX G FS 24KW Cold Row DX Glycol CRDX G FS 12KW Cold Row DX Glycol CRDX W FS 24KW Cold Row DX Water CRDX W FS 12KW Cold Row DX Water DxX based Cold Row cabinets are 12 wide The cooling capacity in KW Hr will depend on the compressor size Refer to the unit nameplate to identify the capacity of your system NOTE Cold Row systems capture and neutralize heat within close coupled rack based environments Any use beyond what Is described in this manual is deemed to be not intended Black Box is not liable for any damage resulting from improper use The functional modes of operation are cooling and dehumidification which provides localized cooling to offset hot spots in data c
129. opeland applications data guide for more detailed information regarding refrigerant line traps and line sizing Refer to the following table for standard equivalent lengths in feet of straight pipe Table 2 5 Equivalent length of straight pipe OD in Line Size Globe Valve Angle Valve 90 Elbow 45 Elbow Tee Line Tee Branch L 9 0 5 0 0 9 0 4 0 6 2 0 12 6 0 1 0 0 5 0 8 2 9 Ke 15 8 0 1 5 0 7 1 0 3 5 1 22 12 1 8 0 9 1 5 4 5 1 28 15 2 4 1 2 1 8 6 0 Oil traps must be included every 20 feet in the vertical risers and the refrigerant lines must be sloped 1 4 inch for every 10 feet in the horizontal lines to ensure proper oil return to the compressor An inverted trap is required on the discharge line of the remote condenser to help prevent oil and liquid from flooding back to the compressor 2 8 2 Remote Air Cooled Condensers Refer to the Recommended Discharge Line and Liquid Line sizing tables below Systems using air cooled condensers must not have a refrigerant line pressure drop over 14 psig across the condenser and the interconnecting piping to the condenser NOTE Ensure proper condenser selection to maintain reasonable sub cooling temperatures Table 2 6 Recommended discharge line sizes Equivalent Length Ft Model Number 50 ft or less 100 ft or less 150 ft or less CRDX A FS 12KW CRDX A FS 24KW Ke Ke Ke Equivalent feet accounts for the linear pipe length as well as equivalent length of valves elbows and
130. or maintaining environmental control in the conditioned space The vapor barrier in the ceiling and walls can be a polyethylene film Concrete walls and floors should be painted with a rubber or plasticbased paint Doors and windows should be properly sealed and a door sweep used to minimize leakage Outside or fresh air should be kept to a minimum as it adds to the cooling load while maintaining the requirement of the Indoor Air Quality IAQ standard Lack of these steps can cause erratic operation unstable room control and excessive maintenance costs 2 4 Mounting Placement The Cold Row precision A C system uses a frame and panel construction for unit rigidity and full service access while the unit is mounted in place NOTE The equipment must be level to operate properly Cold Row cabinets are designed to be installed in a row of servers between the server racks see Figures 2 1 2 3 They have a compact footprint that allows the units to be placed adjacent to the heat producing equipment racks anywhere in the row They provide cool conditioned air through the front grille to the adjacent server modules on the cold aisle side of the row We recommend positioning the unit to obtain optimum air circulation Allow 36 clearance in the front and rear of the cabinet for servicing the unit The optimal placement location is next to highly loaded servers that throw off the most significant heat into the hot aisle side of the row In this arrang
131. orator coil for bent fins 4 Check correct rotation of fans d Low refrigerant indicated by bubbles in sight glass Check for leaks Repair and recharge system e Expansion valve stuck or obstructed short cycling or continuous running Remove valve and clear obstruction or replace valve f Clogged drier strainer feels cold Replace with new drier strainer Symptom System short of capacity CRDX W FS 12KW CRDX W FS 24KW CRDX G FS 12KW CRDX G FS 24KW Probable Causes Recommendations a Low water water glycol flow 1 Check for leaks Repair and recharge system 2 Check for obstructions in supply return lines 3 Check for clogged strainer if applicable b Supply water temperature too high Check chilled water supply 724 746 5500 blackbox com Page 117 Chapter 5 Maintenance Symptom Water water glycol valve fails to open or close Probable Causes Recommendations a Temperature setpoint too high Adjust to correct temperature setting b No control power to the valve Valve actuator is wired incorrectly Check wiring diagram and rewire if required c Actuator failed Replace actuator Symptom Condenser pressure too high CRDX A FS 12KW CRDX A FS 24KW units Probable Causes Recommendations a Non condensable gas or air in the system Recover system evacuate per Section 2 10 2 2 recharge Replace drier strainer b Condenser air intake is blocked Remove debris and clean condenser c Overcharge of refri
132. ored for view from the Service gt Alarms menu This menu displays the last 50 events sequentially numbered in order of occurrence The alarm log is cleared by pressing the Alarm R key while in this menu NOTE If the Alarm R key is pressed when in any of the Service gt Alarms screens all stored alarm messages will be permanently erased from the controller s memory Page 72 724 746 5500 blackbox com Chapter 4 E2 Controller 4 5 5 3 Sensors SERVICE Alarms SENSORS Blower Figure 4 43 Service gt Sensors screen From the Service gt Sensors menu you may access multiple display screens to enter offsets for calibrating the unit s various temperature humidity and pressure sensors Sensor Offsets KS Sensor Offsets Ronn Gr Demp Return Air Humidity Sensor Type 4 20 mA Apply Offset 0 0 Displayed 0 0 Apply Offset 0 0 Displayed 0 0 Sensor Offsets Upper Zone Air Temp Sensor Type Apply Offset Displayed Sensor Offsets Lower Zone Air Temp Sensor Offsets Middle Zone Air Temp Sensor Type NTG Apply Offset 0 0 F Displayed 0 0 F Sensor Offsets Discharge Press Sensor Sensor Type Apply Offset Displayed Apply Offset 0 Displayed 000 psi e Sensor Offsets Ca Sensor Offsets Suction Pressure S1 Suction Temp EEV 52 Apply Offset 0 0psig Apply Offset 0 0 F Displayed 0 0psig Displayed 0 0 F ies Sensor Offsets Suction Temp EHGB S4 Apply Offset 0 0
133. ory allows modification of more advanced control parameters such as sensor scaling startup delays and grouping parameters Level 3 password is needed to enter this menu Entry to the Factory menu is intended for qualified technicians work ing under the guidance of Black Box Technical Support during startup and commissioning of the A C system The password to enter this menu may be obtained by contacting Black Box Technical Support see Chapter 6 of this manual Page 60 724 746 5500 blackbox com Factory INFO QO Alarm Log Press Enter wv Key 01 01 12 DO COSOu GF d i 00 0 F fy Dp 00 0 F Unit ON Press 4 or Key Return Temp Sensor 00 0 F Press 4 or 4 Key Ret Humidity Sensor 00Srh return dewpoint 00 0 F Press 4 or Key Upper Temp Sensor 00 0 F Press 4 or 4 Key Middle Temp Sensor 00 0 F Press 4 or Key Lower Temp Sensor 00 0 F Continued on next page Figure 4 22 Information menu loop part 1 Chapter 4 E2 Controller 4 5 2 Information Menu Loop The Info menu screens may be accessed from the Main screen by simply scrolling with the Up 4 and Down arrow keys The same screens may also be viewed if you enter the Info menu by pressing the Prg key The Info menu displays screens that provide current temperature and relative humidity conditions and shows the modes the A C system is currently operating There are no adjustable pa
134. ote Temperature Humidity Sensor Depending on the type of control selected the temperature humidity T H sensor may be factory mounted or shipped loose for field installation The remote sensor must be located so that it will properly sense the temperature humidity conditions to be controlled The T H sensor should not be mounted near a doorway or an area where it would be exposed to direct sunlight When locating the sensor consider the length of wire to be used The sensor is typically provided with a 20 foot long cable As an option a 75 foot or 150 foot long cable may be provided Follow the steps below to mount the sensor a wa E GF201 d K TEKOOE TGi3 e2R Figure 2 6 Temperature humidity sensor 1 Remove the cover from the base of the sensor by squeezing it at the top and bottom CAUTION Gs Be careful not to damage the exposed temperature humidity sensors on the PC board when removing the cover The sensors can be damaged if handled improperly 2 Place the base temporarily against the mounting surface 3 Level the base Mark and drill mounting holes through at least two of the available slotted holes 4 Run the 3 conductor shielded cable through the opening in the base then secure the base with screws ensuring the word TOP on the PC board is oriented upward 5 Make the wiring connections Refer to Section 2 9 Utility Connections and refer to the wiring diagram supplied with your unit 6 Seal the hole in
135. p Blower Setup Hum Fan Speed 100 Dehum Fan Speed 60 Figure 4 47 Blower setup screen The blower fans will operate at the Dehum Fan Speed setting during dehumidification Dehumidification fan speed is limited to the most restrictive value between the factory preset minimum and maximum the temperature zone minimum and maximum and the speed setting for the operating mode The higher minimum value is the low speed limit and the lower maximum value is the high speed limit Ex If the Dehum Speed is set to 60 in the Blower Setup screen and the maximum speed for the lower temperature zone fan is set to 75 and the factory set maximum fan speed is 90 the fans will run at 60 during dehumidification Page 74 724 746 5500 blackbox com Chapter 4 E2 Controller 25 Zone 75 Zone Minimum Maximum Gr 100 Off 10 Ba 90 Factory Dehum Speed Factory Pre set Setting 60 Pre set Minimum Maximum Figure 4 48 Fans will run at 60 of full speed during dehumidification If the Dehum Speed is set to 80 the lower fan will run at 75 during dehumidification as it is limited by the maximum speed setting for the lower temperature zone 25 Zone 75 Zone Minimum Maximum o td SS EE E ml 10 90 Factory Dehum Speed Factory Pre set Setting 80 Pre set Minimum Maximum Figure 4 49 Lower fan will run at 75 of full speed during dehumiditication limited by the temperature zone maximum 4 5 5 5 Options Menu
136. perature screen Pressing the Enter key places the flashing cursor in the setpoint value field Increase or decrease the Temperature Setpoint with the Up 4 and Down arrow keys until the desired temperature value is shown Press the Enter Y key again to accept the setpoint this removes the cursor from the field 6 From the Temperature setpoint screen select the Humidity Setpoint screen by scrolling with the Up or Down arrow key When the word Humidity appears in the field at the top of the screen press the Enter Y key to move the cursor into the setpoint value field Setpoint M 45 03 STATUS Hum ADS PS Set 45 03 Dew 51 9 F Figure 4 17 Humidity screen Increase or decrease the Humidity Setpoint with the Up and Down arrow keys until the desired humidity value is shown Press the Enter XY key again to accept the setpoint and then press the Escape key to return to the Setpoints SET Control menu screen 7 Press the Escape Esc key twice to exit the Control gt Setpoints screens and return to the Main Menu screen 724 746 5500 blackbox com Page 53 Chapter 4 E2 Controller 8 Observe the indicator symbols in the Main screen to determine if the unit is operating in the required mode s 9 One to six hours may be required to see the desired temperature humidity level in the conditioned space Once room conditions have been programmed or set a repeat visit to the conditioned site may be requir
137. point the gas now compressed to a high pressure is discharged from a port in the center of the fixed scroll During each orbit several pockets of gas are compressed simultaneously creating smooth nearly continuous compression 1 5 3 1 Electronic Thermal Expansion Valve An auxiliary control module mounted to the door of the electric box manages the operation of the electronic expansion valve EEV The control module manages the EEV based on input signals trom the suction pressure and temperature sensors It regulates the amount of refrigerant entering the evaporator to maintain the correct superheat temperature 1 5 3 2 Electronic Hot Gas Bypass Used for freeze protection and capacity control an electronically controlled hot gas bypass valve is managed by the same auxiliary control module that manages the EEV valve The hot gas bypass system allows the compressor to run continuously instead of cycling the compressor on and off for capacity control The hot gas bypass system manages system capacity based on the suction temperature The hot gas regulator valve meters hot gas into the evaporator coil during low load periods or when evaporator airflow is reduced 1 5 4 Coils Cooling coils are constructed of aluminum finned copper tube The coils are leak tested and cleaned before installation by the factory Condensate drain pans are provided to collect water condensed by the coils A condensate pump empties the drain pans and directs the water to
138. possibility of overcharging Allow the discharge pressure to rise to 445 480 psig and hold it constant 5 Slowly meter liquid refrigerant through the suction side while watching the pressure gauges and monitoring superheat and sub cooling temperatures CAUTION AP Add liquid refrigerant slowly to prevent the refrigerant oil from washing out of the compressor 6 Take a superheat temperature reading near the feeler bulb from the auxiliary control module with the temperature measuring device well insulated The ideal superheat temperature is 12 15 F Maximum allowable superheat temperature is 20 F CAUTION IN Do not exceed 20 F superheat Exceeding this temperature may cause failure of the compressor 7 While monitoring the pressure take a sub cooling temperature reading on the output side of the condenser The sub cooling temperature should be 10 20 F 8 If necessary slowly add liquid refrigerant to the suction side to achieve the correct sub cooling temperature CAUTION AP Remove the blockage from the air intake of the condenser 9 Fill out the applicable sections of the Warranty Registration and Start Up Checklist 2 10 2 4 30 F Ambient Applications NOTE For units designed for 30 F operation a receiver is used to store the refrigerant during the time the condenser is not using the extra refrigerant charge 1 Follow Steps 1 8 in Section 2 10 2 3 Once superheat and sub cooling temperatures are stabilize
139. pply air temperature sensors and the return air T H sensor or optional remote mounted supply T H sensor The E2 controller may be configured for temperature relative humidity control standard or dewpoint control optional for cooling dehumidification and humidification functions The control method selected in the Factory menu determines which sensors the controller uses to manage operation of the A C system You may view the method selected in the Control gt Set menu see Section 4 5 4 1 Table 4 2 Control method sensor selection Control Method Control Sensor Selection Supply air sensors Temperature control 2 Return T H sensor UJ Remote supply T H sensors o 1 Return T H sensor Humidity control N Remote supply T H sensors l Return T H sensor Dewpoint control 2 Remote supply T H sensor 4 4 2 1 Temperature RH Control When enabled for temperature RH control the controller continuously monitors the selected combination of air temperature sensors and return T H sensor or optional remote supply T H sensor as configured by the factory to manage system operation 4 4 2 2 Dewpoint Control When enabled for dewpoint control the controller logically examines the combination of temperature and relative humidity dewpoint and determines the proper control of cooling humidification and dehumidification to move the actual conditions to within the boundaries of the dewpoint setpoints as they
140. pter 4 E2 Controller Factory gt Group gt Group Status Screen 8 provides an overview of the current duty status for all the A C units combined in the group Table 4 23 Factory gt Group gt Group Status Screen 8 parameters Display Description Description Running Display indicates how many units in the group are currently operating Active Display indicates how many units in the group are currently active Standby Display indicates how many units in the group are currently in standby Assist Display indicates how many units in the group are currently operating in the capacity assist mode Online Display indicates how many units in the group are currently available to operate Out of Service Display indicates how many units in the group are not available to operate Variables Default Oto 8 0 0 to 8 0 0 to 8 0 0 to 8 0 0 to 8 0 The final step to configure a workgroup Is to access the Service gt Options gt Group Setup screens used to configure parameters that apply to how individual A C units interact in the workgroup see Section 4 6 2 7 LS t Cimning Lead UNTE Plan timer Plan present Figure 4 84 Factory gt Group gt Plan timing Screen 9 Table 4 24 Factory gt Group gt Plan timing Screen 9 parameters Display Description Description Variables Lead unit Display indicates which unit is currently the lead 0 to 8 plan tinier Display indicates the time delay in seconds between the detection of gt ER a commu
141. r connectado a una fuente de poder s lo del tipo descrito en el instructivo de operaci n o como se indique en el aparato Precauci n debe ser tomada de tal manera que la tierra fisica y la polarizaci n del equipo no sea eliminada Los cables de la fuente de poder deben ser guiados de tal manera que no sean pisados ni pellizcados por objetos colocados sobre o contra ellos poniendo particular atenci n a los contactos y recept culos donde salen del aparato El equipo el ctrico debe ser limpiado nicamente de acuerdo a las recomendaciones del fabricante En caso de existir una antena externa deber ser localizada lejos de las lineas de energia El cable de corriente deber ser desconectado del cuando el equipo no sea usado por un largo periodo de tiempo Cuidado debe ser tomado de tal manera que objectos liquidos no sean derramados sobre la cubierta u orificios de ventilaci n Servicio por personal calificado deber ser provisto cuando El cable de poder o el contacto ha sido da ado u Objectos han ca do o l quido ha sido derramado dentro del aparato o El aparato ha sido expuesto a la lluvia o El aparato parece no operar normalmente o muestra un cambio en su desempe o o El aparato ha sido tirado o su cubierta ha sido da ada TUNT ge 4 724 746 5500 blackbox com Table of Contents Table of Contents k AMEN MN ORN e E esc E E oe eee per casas see ete esol eee 10 A CTE EE 10 Te PROG CS GOON E E A sere tees see AAE
142. r fan alarm Reserved 8 Fire smoke Reserved 9 Lower fan alarm Reserved 10 Dual power input A Reserved 11 Dual power input B Reserved 12 Circuit 1 low pressure Reserved 13 Circuit 1 high pressure Reserved 14 Pump alarm Reserved 15 Humidifier lockout Reserved 724 746 5500 blackbox com 4 9 7 Digital Output Packed Bit Variables Table 4 35 Digital Output Packed Bit Variables Bit Digital Outputs 1 Digital Outputs 2 0 Global alarm Reserved 1 Custom alarm 1 Reserved 2 Master fan enable Reserved 3 DX1 enable Reserved 4 DX1 liquid line solenoid Reserved 5 Humidifier enable Reserved 6 Dual power output A Reserved 7 Dual power output B Reserved 8 Pump enable Reserved 9 Custom alarm 2 Reserved 10 Custom alarm 3 Reserved 11 Reserved Reserved 12 Reserved Reserved 13 Reserved Reserved 14 Reserved Reserved 15 Reserved Reserved Chapter 4 E2 Controller The R W BMS variables fall into two categories Variables like the temperature setpoint are permanent As permanent variables they retain their value regardless of power loss or BMS communications failure The controller s flash memory is limited to one million write cycles for permanent variables The other category is the integer and digital variables that start with BMS These are expected to be changed frequently and require that the BMS is active when changing them All BMS variables require that the BMS keep alive parameter Variable 100 changes between 1 and 2 within a 10 minu
143. r pressing the Enter S key Values for fields being adjusted will automatically wrap when adjusted beyond the high or low limit established for that field Whenever the flashing cursor is located in a modifiable field press the Escape Esc key one time to return the user to the next menu up Each successive use of the Escape key returns you to the next menu level up until the Main screen is reached 724 746 5500 blackbox com Page 49 Chapter 4 E2 Controller 4 2 5 Modifiable Variables SET CLOCK Time 00 00 Modifiable Variable Date 00 00 0000 Day XXXXXXX Figure 4 9 Modifiable variable Pressing the Enter key accepts the value displayed and advances the cursor to the next modifiable field You can use the Up or Down key to modify the values of these fields If the modifiable field is a positive number the positive value is indicated by the absence of a or symbol The negative symbol will be displayed to the left of the first digit for negative numbers 4 2 6 Password Authorization Levels You can request access to a menu loop trom the main menu Modifiable control screens have variables that affect system performance Improper settings may result in erratic operation and possible system failure or damage Anyone is allowed direct access to the Info and Alarm log display menus with no security password Only authorized personnel who possess a thorough understanding of the system operation should perform mo
144. rameters in this loop From the Info loop you may view the following display screens as they apply to the unit configuration 4 5 2 1 Operating Conditions The first Info screen displays the current date and time and provides state of operation icons The actual control temperature F and relative Humidity rh is always displayed and dewpoint Dp will appear as derived from the control T H sensor selection The values displayed are used by the controller to develop control output signals for managing system operations 4 5 2 2 Return Temperature Sensor Displays relative humidity as measured by the return temperature humidity T H sensor inputs The return T H sensor is typically factory mounted inside the cabinet As an option the return T H sensor may be removed from the cabinet and remotely mounted in the hot aisle 4 5 2 3 Return Humidity Sensor Displays relative humidity as measured by the return T H sensor inputs Return dewpoint is calculated by the controller based on the return T H sensor inputs and then shown at the bottom of the display screen 4 5 2 4 Temperature Sensors The temperature screens display the supply air temperature as measured by sensors located in the cold aisle side of the Cold Row cabinet The sensors are located within the cabinet in upper middle and lower zones as called out in the display Values measured by the sensors may be used to individually control the speeds of the fans see Section 4 4 4 1
145. removing all paint dirt and oily film Use a wire brush sandcloth or sandpaper and wipe the area with clean dry cloths Protect nearby parts from heat damage by wrapping with watersoaked cloths For copper to copper piping repairs use a phosphorus copper brazing alloy with 15 silver Use general purpose silver brazing alloy with 45 silver for copper to brass or copper to steel repairs When repairs are completed remove all traces of flux and flush the system After any repair pressurize the system to check for leaks before recharging the system 5 3 2 DX System You might need to perform repairs on the refrigeration system H field repairs are necessary the following procedures apply 5 3 2 1 Leak Detection Several methods can be used to detect a leak in the refrigeration system The most modern and easiest method is to use an electronic leak detector Follow the manufacturer s directions to quickly locate any leak A second method is to use soap bubbles Apply a solution of soapy water with a brush or sponge to the joints and connections in the refrigeration lines A leak in the lines will cause bubbles to form 5 3 2 2 Leak Repair When a leak is located properly reclaim the remaining refrigerant charge before beginning repairs Adjacent piping must be thoroughly cleaned by removing all paint dirt and oily film Use a wire brush sandcloth or sandpaper and wipe the area with clean dry cloths Protect nearby parts trom heat damag
146. rm Optional Temp Low Alarm High Head Pressure Low Suction Pressure EVD Driver Offline Description of Alarm Conditiion Air temperature is above user defined alarm setpoint Air temperature is below user defined alarm setpoint Humidity is above user defined alarm setpoint Humidity is below user defined alarm setpoint Sensor is disconnected or faulty The failed sensor is identified External and or internal communication lost BMS or pLAN Full Water level in condensate pan is reaching an unsafe level Water sensed by any combination of a leak detector or condensate pan level switch Upper middle and or lower fan failure Filter replacement time interval elapsed filter needs to be replaced Insufficient airflow per air proving switch An alarm condition detected by the smoke detector or firestat Temperature is above alarm threshold user configurable Temperature is below alarm threshold user configurable Head pressure is above user configured alarm threshold Suction pressure is below user configured alarm threshold EEV and EHGB control driver error 724 746 5500 blackbox com Page 65 Chapter 4 E2 Controller Alarm Log CONTROL QO Service Press 4 Key CONTROL Version SET 9 Alarm Set Press 4 or 4 Key CONTROL Press 4 or 4 Key CONTROL Alarm Set CLOCK CR Version Press 4 or 4 Key CONTROL Clock Key VERSION Set Press 4 Key Figur
147. rminal associated with the controller Using the up arrow T and down arrow 4 keys enter the address 25 32 of the terminal assigned to the controller I O board In Figure 4 41 Address 31 has been entered for the first A C unit added to the group 7 The Priv Shared column indicates the type of terminal The workgroup is setup using private terminals Do not change the value Pr Press the Enter Y key to move to the last field Page 88 724 746 5500 blackbox com Chapter 4 E2 Controller 8 Enter the field Ok No choose Yes using the up arrow 4 and down arrow keys and confirm by pressing Enter Ste save the data and exit the group setup procedure 9 Referring to the wiring diagram provided with your A C units interconnect the units together with the pLAN cable s provided 4 6 2 4 Fault Messages If the terminal detects the status of the I O board it is associated with is off line the display shows the message I O Board xx fault If this appears check the Signal LEDs on the control I O module Figure 4 2 for an error signal See Section 4 8 for guidelines on analyzing the signal LEDs On the other hand if the terminal receives no signal from the network the display shows the following message NO LINK If this appears check the pLAN cables and ensure they are connected properly 4 6 2 5 Displaying the Network Status and Firmware Version Once each A C unit is configured with its new controller an
148. rons close the vacuum pump isolation valve and perform a rate of rise test by observing the standing pressure over time If the pressure rises slowly up to 200 microns in 15 minutes there is moisture in the system that still needs to be boiled off Proceed to Step 5 If the pressure rises rapidly up to atmospheric pressure more than 50 microns per minute there is a leak that wasn t detected during Step 2 In this case troubleshoot the entire system for leaks and repair them Then begin the initial evacuation process again starting at Step 3 5 If no leaks are detected after the initial vacuum release the vacuum and pressurize the system with 2 3 pounds of dry nitrogen Allow the system to stand for two hours with the dry nitrogen charge This gives time for the nitrogen molecules to disperse in the system and absorb moisture 6 After two hours release the pressure Then turn on the vacuum pump and evacuate the system a second time down to 1500 microns or less Close the vacuum pump isolation valve and pressurize the system again with dry nitrogen and allow the system to stand for two hours as in Step 5 7 After two hours release the pressure Turn on the vacuum pump and complete the process of evacuating the system this time with a goal of achieving a 250 micron vacuum or less Close the vacuum pump isolation valve When you can hold the vacuum at 500 microns or lower for at least 2 hours with no significant rise in pressure the system
149. roup Averaging Upe Unit Sensors wien in Gamelle Or EES for Group Averaging Temp Hum Sensors Yes Static Pr Sensors Yes Figure 4 80 Factory gt Group gt Group Averaging Screen 5 Table 4 16 Factory gt Group gt Group Averaging Screen 5 parameters Display Description Description Variables Default 0 No Temp Hum Sensors l l l l Yes Enter Yes for the unit to respond to its local sensors to enable Standby or Capacity Assist 1 Yes operation Enter No for unit to respond to the Group sensors 0 No Static Pr Sensor Yes 1 Yes Group Alarm Setup i 000 9 16 000 17 24 000 25832 000 33 40 000 Figure 4 81 Factory gt Group gt Group Alarm Setup Screen 6 This screen may be accessed on the controller for each unit to be grouped You may enter bitmask numbers to establish which alarm conditions for that particular unit will initiate a group internal alarm The group alarms may be set before the A C units are wired together When a group alarm condition is detected by a unit it causes that unit to temporarily switch over from Active to Off and if another unit is available in the group it may rotate into its place A status massage Off by internal alarm will appear in the Main screen of the unit that detected the group alarm and switched off See Section 4 5 5 5 for an overview of how to select alarms using bitmask values The Group Alarms bitmask values are shown in the Tables 4 17 4 21 The settings may be viewed
150. rranty given by the seller and such warranty is only given to buyers for commercial or industrial purposes The warranty is not enforceable until the invoice s is paid in full THIS FOREGOING SHALL CONSTITUTE BLACK BOX S ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY IN NO EVENT SHALL BLACK BOX BE LIABLE FOR ANY DEFECT INDIRECT SPECIAL INCIDENTAL CONSEQUENTIAL OR EXEMPLARY DAMAGES INCLUDING LOST PROFITS EVEN IF ADVISED OF THE POSSIBILITY THEREOF ARISING IN ANY WAY OUT OF THE INSTALLATION USE OR MAINTENANCE OF THE EQUIPMENT THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty supersedes all other previously printed warranties dated prior to this document 724 746 5500 blackbox com Page 13 Chapter 1 Introduction 1 4 Safety 1 4 1 General This manual uses NOTES along with CAUTION and WARNING symbols to draw your attention to important operational and safety information A NOTE marks a short message in the information to alert you to an important detail A CAUTION safety alert appears with information that is important for protecting your equipment and performance Be especially careful to read and follow all cautions that apply to your application A bold text WARNING safety alert appears with information that is important for protecting you trom harm and the equipment trom damage Pay very close attention to all warnings
151. s The 24 Month Precision A C Upgraded Limited Warranty provided by Black Box Network Services warrants your purchase including compressors to be free from defects in material and workmanship for 24 months Black Box Network Services obligation under this warranty Is to repair or replace at its option any part or parts which are determined by Black Box Network Services to be defective for a period of 24 months from the date of startup This warranty also includes labor needed to perform any warranty work for a period of 90 days from the date of startup Parts repaired or replaced under this warranty are shipped FOB factory ground and warranted for the balance of the original warranty period or tor 90 days trom the date of installation whichever is greater If the factory is not allowed to start the equipment within 90 days from the date of shipment the warranty will commence on the 91st day from equipment shipment This limited warranty does not include labor freon or any other expense required to replace the defective component and bring the unit back to a working status In the event equipment is shipped to Black Box for temporary storage for 6 months or less warranty begins and startup checklist is required to be on file with Black Box Network Services field service within 90 days of shipment to job site for installation Black Box Network Services warranty does not cover failures caused by improper installation abuse misuse alteration
152. s Use of copper conductors only is required Wiring terminations may become loose during transit of the equipment verify that all wiring terminations are secure WARNING E Verify power is turned off before making connections to the equipment It is important to verify that the main power supply coincides with the voltage phase and frequency information specified on the system nameplate The supply voltage measured at the unit must be within 10 of the voltage specified on the system nameplate except for 208 230V single phase units that have a different tolerance listed below A main distribution panel must be provided with a manual fused disconnect switch or HACR type circuit breaker per local and national electrical codes for service to the equipment Do not mount a customer supplied manual fused disconnect switch or HACR type circuit breaker to the surface of the unit The unit has main power and control pilot holes for connection of the field wiring conduit These pilot holes are located on the Cold Row unit based on the configuration The pilot holes are located in the top of the cabinet or in the floor of the cabinet A label stating MAIN POWER INPUT is placed nearby See the installation drawing provided with your unit for pilot hole locations Terminate the main power wires at the line side of the service disconnect switch located within the electric box A separate equipment ground lug is provided within the electrical box for term
153. s established by entering the proper password for a given security level The controller is shipped from the factory with preset passwords for all the security levels Page 50 724 746 5500 blackbox com Chapter 4 E2 Controller Operators who are allowed access to the Service menu Level 2 for example must know the password to enter that level If the entered password equals or exceeds the level requested during a given session the operator is allowed to access the requested loop For example if the entered password allows access to Level 2 and the Control menu Level 1 is requested access will be allowed If the entered password authority level is lower than the level requested the words WRONG PASSWORD will appear for several seconds at the bottom of the screen 4 2 6 2 Wrong Password Ea Reset No Enter Password JID Level 0 xx WRONG PASSWORD Figure 4 11 Wrong password The WRONG PASSWORD message is displayed any time an incorrect password has been entered and the Enter ball key has been pressed If the Wrong Password message appears pressing the Enter key will return the operator to the Enter Password field A requested menu screen is displayed any time a valid password has been entered and the Enter key is pressed NOTE If you request the Control menu and enter the Service menu password you are granted access to both 4 2 6 3 Setting the Passwords The initial passwords are set by t
154. select the network sensor values to be the Lead Average Min or Max values The selections made in this screen will affect all the controllers in the workgroup no matter which controller you access the screen from Group Averaging Group Averaging Use unit sensors when im Standby or Assist For Group Averaging Temp Hum Sensors Yes LEaLLG Er sensors es Figure 4 89 Group averaging screen Each unit in the group may be individually set to allow the lead controller to include its sensors for determining the group average value when it is configured for Standby or Capacity Assist operation If set to no the lead controller will not poll that unt sensors when calculating the averaged values 4 6 2 8 Group Information Menu Screens The following display screens are available in the Information menu loop Section 4 5 2 if two or more units are wired together as a group They display key operating parameters for grouped A C units 724 746 5500 blackbox com Page 99 Chapter 4 E2 Controller Net T H Sensors 00 0 F T H Sensor Value Local Unit 0 of 0 Lead J Press 4 or 4 Key Group Alarm Setup dea 000 Sc 000 17 24 000 25 327 000 33 40 000 See manual for details Press 4 or 4 Key Group T H Sensors Avg 000 0 F 000 0 Min 000 0 F 000 0 Max 000 0 F 000 0 Min Temp 0 Min Hum Max Temp 0 Max Hum OO oP OO Sie Press 4 or 4 Key Group Sensor Starus Unitl 15 Lead Unit I CET 0 Un
155. split systems are shipped with a dry nitrogen charge of 100 psig Release the pressure via an available stem valve or Schrader valve prior to uncapping the pipes Do not release the pressure until the field installed refrigerant piping is ready to connect Systems using a remote condenser will require a copper liquid line and discharge line See Figure 2 10 and refer to the IOM documentation provided with the condenser OPTIONAL COMPONENTS FOR FLOODED HEAD PRESSURE CONTROL ELECTRONIC a ehh CS THERMAL PRESSURE EXPANSION RELIEF VALVE eeneg VALVE DISTRIBUTOR CHECK VALVE OPTIONAL REFRIGERANT SIGHT VAINE BODY e A FILTER DRIER a h CN SE CD D e S hd PEELE EL EL D W CONTROL VALVE RECEIVER ASC Hea CITT HOT GAS T REGULATOR a DOT EE l i CHECK VALVE I i re SCHRADER TEMPERATURE S VALVE SENSOR I KE LOW PRESSURE PRESSURE LIMIT SWITCH TRANSDUCER INTERCONNECTING SE Ch FIELD PIPING BY OTHERS HIGH PRESSURE LIMIT SWITCH COMPRESSOR REMOTE AIR COOLED CONDENSER Figure 2 10 Typical remote air cooled DX piping diagram 2 8 1 Refrigerant Piping Refrigerant lines for the A C unit are routed to either the top or bottom of the cabinet as specified when the Cold Row system is ordered see Section 2 8 1 1 The connections are made inside the cabinet The pipe stubs are labeled i e Discharge Liquid Line The refrigerant piping should be
156. startup Startup must be completed within the first 90 days trom shipment The 60 month warranty only covers original compressor s that were installed by Black Box or an original equipment supplier contracted by Black Box to manufacture equipment solely for Black Box Compressors replaced under this warranty are shipped FOB Factory ground and warranted for the balance of the original warranty period or tor 90 days trom the date of installation whichever is greater If the factory is not allowed to start up the equipment within 90 days from the date of shipment the warranty will commence on the 91st day from equipment shipment Black Box s warranty does not cover failures caused by improper installation abuse misuse alteration misapplication improper or lack of maintenance negligence accident normal deterioration including wear and tear or the use of improper parts or improper repair Purchaser s remedies are limited to replacement or repair of non conforming materials in accordance with the written warranty This warranty does not include cost for torch charges reclaim charges Freon transportation travel expenses costs tor removal or reinstallation of equipment or labor for repairs or replacements made in the field If any sample was shown to the buyer such sample was merely to illustrate the general type and quality of the product and not to represent that the equipment would necessarily conform to the sample This is the only wa
157. t provide information on the operation of the control module and status of the connection to the pLAN These signal LEDs are positioned adjacent to the yellow Power On LED see Figure 4 2 The signal LEDs may be used for diagnostic purposes if a problem arises with the controller Key LED off O LED on LED flashing Table 4 26 I O control module signal LEDs Red LED Yellow LED Green LED O e e CG e ee ee e O OG Geo Go OO oO GGG Ge eo OO Description Application with error or no pLAN table Application with error or no pLAN table Controller connected to ONLY one terminal Application with correct pLAN table Correct operation in pLAN Awaiting communication with WinLoad factory configuration software Check address LED flashing alternately Communication with WinLoad not valid No power supply or wrong driver Communicating with WinLoad in low level operation Communication with WinLoad on hold WinLoad not suitable or incorrect software protection password Communicating with WinLoad in normal operation Controller supervisor protocol slave active on serial O 724 746 5500 blackbox com Page 103 Chapter 4 E2 Controller 4 9 BMS Parameters Version 1 2 Supported Protocols BACnet over IP BACnet over Ethernet HTTP SNMP V1 V2c Modbus over IP BACnet MS TP Modbus RTU Page 104 Speed 10 Mbps 10 Mbps 10 Mbps 10 Mbps 10 Mbps 19200 baud 19200 bau
158. t system Acid test kits are available from several manufacturers for measuring the acid level in the oil These are capable of making accurate acid measurements but if they are not available a check of the oil by sight and smell can give a quick indication if contamination remains in the system A CAUTION Avoid touching or contacting the gas and oil with exposed skin Severe burns will result Use long rubber gloves in handling contaminated parts All electrical connections should be checked to ensure they are tight and properly made Check all circuit breakers contactors and wiring The contactors should be examined and replaced if contacts are worn or pitted If there is acid in the oil there has been an electrical failure that has caused the compressor motor to burn out The acid diffuses throughout the refrigeration system and must be removed by using a burnout filter kit before a new compressor is placed in service Not only must the compressor be replaced but also the entire refrigeration circuit must be cleaned of the harmful contaminants left by the burnout See Section 5 3 3 3 Burn Out Acidic Cleanup for the proper procedure If there is no acid in the oil there has been a mechanical failure See Section 5 3 3 2 Standard Cleanout for the proper cleaning procedure K CAUTION Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty This will VOID THE COMPRESSOR
159. t the Network Status loop press Enter The next step is to access the Factory gt Group screens used to configure the workgroup parameters Section 4 6 2 6 4 6 2 6 Configure Workgroups The Factory gt Group menu screens only appear when multiple A C units are grouped These menu screens allow you to define grouping parameters duty rotation offsets etc for the A C units in the workgroup These screens should be accessed after setting up the workgroups Section 4 6 2 The Factory gt Group menu screens may be accessed from the main screen by pressing the Prg Prg key and scrolling through the menu selections until the word Factory appears in the center of the screen MAIN MENU Service FACTORY O Into Figure 4 74 Factory gt Group screen Press the Enter XY key twice and you ll be prompted to enter the password for the Factory level contact Black Box Technical Support for the password Once the factory level password is entered press Enter t0 call up the menu screens From here you may press the up arrow or down arrow keys to scroll through the Factory menu selections FACTORY MENU Modbus GROUP CH Check Cfg Figure 4 75 Group screen When the word GROUP appears in the center of the screen press the Enter key to access the Factory gt Group menu screens From here you may use the up arrow or down arrow keys to scroll through the Factory gt Group menu selections Page 90 724 746 5500 blackbox com
160. te span The general procedure is to set up variables like the BMS low fan speed and then write a 1 to the BMS keep alive address If the controller does not see a 2 written to the BMS keep alive address within 10 minutes all the BMS variables will revert to their previous values 724 746 5500 blackbox com Page 111 Chapter 4 E2 Controller 4 9 8 Unsigned Values for HTTP SNMP Modbus Holding Registers Analog Values for BACnet Table 4 36 Unsigned Values for HTTP SNMP Modbus Holding Registers Analog Values for BACnet BMS Modbus BACnet Address Address Address Description Default Direction 100 229 1100 BMS keep alive parameter O R W 101 230 1101 BMS low fan speed for CW units 0 R W 102 Ss 1102 BMS run fan speed for CW units 0 R W 103 232 1103 BMS dehum fan speed for CW units 0 R W 4 9 9 Boolean Values for HTTP SNMP Modbus Coils Binary Values for BACnet Table 4 37 Boolean Values for HTTP SNMP Modbus Coils Binary Values tor BACnet BMS Modbus BACnet Address Address Address Description Default Direction 100 101 1100 BMS value to pause the unit 0 R W 101 102 1101 BMS value to reset alarms 0 R W 102 103 1102 Force rotation of units in group manual or BMS O 0 R W 103 104 1103 BMS value to switch CW sources 0 R W 104 105 1104 BMS value to switch dual power primary 0 R W Page 112 724 746 5500 blackbox com Chapter 5 Maintenance 5 Maintenance 5 1 Periodic General Maintenance Systematic periodic general main
161. te the Summary Alarm relay and show a specific Customer Alarm message in the alarm display screen A Customer Alarm message may simply be displayed as CUSTOMER ALARM 1 as shown below or you may press Enter Y and use the up 4 and down arrow keys to construct a specific aloha numeric message in the field stating the specific alarm condition in your own terms that is GAS DETECTION INTRUSION ALARM etc The Customer Alarm message may be set up on one line with up to 20 characters Customer Alarm I Text CUSTOMER ALARM 1 GESSEN Figure 4 55 Customer Alarm screen 724 746 5500 blackbox com Page 77 Chapter 4 E2 Controller r em em 4 NOTE Display screens shown with a dashed border Ge appear only if the application feature is enabled Custom Alarm Setup Optional The E2 controller may be enabled to activate a Custom Alarm output and energize a designated N O N C relay A custom alarm output is set up by adding the binary bitmask numbers assigned to the specific alarms and signal failures you wish to monitor via the relay and then entering them in the Custom Alarm Setup screen 1 8 8 9 16 10 17 24 0 25 32 16 i aiiai O 41 48 Gi SEH Figure 4 56 Custom Alarm Setup screen NOTE Custom alarm display screens may appear even if the feature is not enabled In this case changes made to these screens will have no effect You can select any mix of the 48 alarm variables as shown in the tables th
162. tective cover and connect two control wires to the terminals on the base Run the control wires into the electric box and connect them to the control terminal block as shown in the wiring diagram provided with your unit Replace the cover and place the water detector s on the floor with the metal electrodes facing down When water is present current will flow between the electrodes The base has a mounting hole in the center that you can use to secure the water detector in place Figure 2 4 Spot type water detector NOTE Do not place the spot type water detector on an electrically conductive surface Cable type water detector Lay the cable water detector flat across the sub floor where water could collect Secure the cable every 12 18 inches with J clips or cable ties with adhesive mounting pads when installing it in the airstream Secure it at each turn of the cable and when routing it around obstructions Do not tie the water detector cable to a metal floor stand or to pipes Figure 2 5 Cable type water detector When a water leak on the floor reaches the cable current will flow between the cable wires A two conductor wire harness is provided with a quick connect fitting on the end The harness mates to the fitting on the water detector and connects it to the control terminal block inside the electric box as shown in the wiring diagram provided with your unit 724 746 5500 blackbox com Page 23 Chapter 2 Installation 2 6 2 Rem
163. tenance of the Cold Row unit is required for optimum system performance General maintenance should include but is not limited to the following replacing filters tightening electrical connections checking the condensate pans and drain line to ensure they are free of debris cleaning the interior of the unit inspecting the units components visually checking level of refrigerant and ensuring no moisture is in the refrigerant IF APPLICABLE Use copies of the Periodic General Maintenance Checklist in this manual see Appendix A 2 to record periodic general mainte nance inspections For assistance contact Black Box Technical Support Ensure adherence to all safety statements while perform ing any type of maintenance Le WARNING This equipment should be serviced and repaired by a journeyman or a qualified refrigeration technician only WARNING This unit uses high voltage equipment with rotating components Exercise extreme care to avoid accidents and ensure proper operation Hazardous voltage will still be present inside the electric box at the motor start protectors and circuit breakers even with the unit turned off at the microprocessor controller To isolate the unit for maintenance turn off power at the main power disconnect switch Always disconnect main power prior to performing any service or repairs Le WARNING Turn off power to the unit unless you are performing tests that require power With power and controls energized
164. the terminal remains inactive no key is pressed for more than 30 seconds the group setup procedure is exited automatically without saving any changes 4 6 2 1 Configure the Terminal Address The address of the terminal display can only be configured If its telephone jack is connected to the I O control module in the electric box and power is turned on The factory default value for the display terminal address is 32 To reassign the terminal address press and hold the up arrow A down arrow Vv and Enter lt keys simultaneously for five seconds until the Address Configuration screen shown below appears with the flashing cursor in the top left corner Display address setting I O Board address xx Figure 4 68 Terminal Display Address screen 1 To change the address of the terminal Display address setting press the Enter key once The cursor will move to the address field nn 2 Use the up and down arrow keys to select the desired value 0 and confirm by pressing Enter again Display address changed Figure 4 69 Display Address screen The Display Address Changed screen will appear indicating the display address selected is not the same as the one saved previously and the new value will be saved to the permanent memory 3 Once the terminal address is set to zero cycle the power to the unit Off and then back On NOTE If the Display address setting __ field is set to O the terminal will c
165. the top or bottom of the cabinet as preferred using the available knock outs Refer to the electrical drawing supplied with your unit to determine the total number of interconnecting conductors required for your system NOTE All wiring must be provided in accordance with local and National Electrical Code requirements for Class 2 circuits NOTE The control transformer s supplied with the equipment have been sized and selected based upon the expected loads for each system CAUTION A Do not connect any additional loads to the system control transformers Connecting additional loads to the factory supplied control transformer s may result in overloading of the transformer s 2 9 2 1 Remote Water Detector Refer to Section 2 6 1 Each remote water detector used will require two conductors to be wired to the control terminal block within the unit electrical box The wire insulation must be rated at 600 V 2 9 2 2 Remote Temperature Humidity Sensor Refer to Section 2 6 2 The remote temperature humidity sensor is equipped with a shielded cable The shield is to be terminated at the unit electric box The electric box includes a control terminal block with box type lugs for wire connections 2 9 2 3 Remote On Off The unit can remotely turn off the air conditioning system A normally closed switch is required for this purpose customer furnished Connect two conductors from the normally closed switch to the control terminal block located wit
166. the unit could begin operating automatically at any time To prevent personal injury stay clear of rotating components as automatic controls may start them unexpectedly 5 1 1 Filters The filter is usually the most neglected item in an air conditioning system To maintain efficient operation check the filter every 3 to 6 months and clean or replace it as required NOTE Conditions of spaces vary Extremely dusty environments may require more frequent filter maintenance The air filters are located behind the air intake grille at the rear of the cabinet To access the filters unlatch the rear access panel at the top and remove it from the cabinet 5 1 1 1 Cleanable Filters Cleanable filters are spring loaded in the holding trays in the access panel Using a flat head screwdriver gently push the filters to one side and remove the old filters trom the trays Figure 5 1 724 746 5500 blackbox com Page 113 Chapter 5 Maintenance SSS A J reg e Ors C A f a Ge E ke T r a Fgure 5 1 Cleanable filters Clean the filter media using a vacuum cleaner low pressure compressed air or rinse with water A mild detergent such as dishwashing liquid may be used DO NOT use solvents or cleaning agents Replace the filters every 2 to 3 years when they become too flimsy 724 746 5500 blackbox com Page 114 Chapter 5 Maintenance 5 1 1 2 Cartridge Filters Replaceable cartridge filters are held in place by an end cap i
167. the wall behind the sensor 7 Replace the cover plate on the base CAUTION N The sensor can be damaged if handled improperly Take care not to damage the exposed temperature humidity sensor on the PC board Do not touch the sensor because this will affect its accuracy Page 24 724 746 5500 blackbox com Chapter 2 Installation 2 6 3 Outdoor Condensers Referring to the IOM manual provided with the condenser install the remote condenser in a secure location where it cannot be tampered with and the service disconnect switch cannot be inadvertently turned off Locate the remote condenser where the fan is not likely to draw dirt and debris into the coil fins The clearance around the condenser should be at least 1x the unit s width to ensure adequate airflow to the coil Secure the condenser to prevent the system from moving during operation We recommend installing the remote condenser with vibration mounts to reduce vibration transmitted to the mounting surface 2 7 Water Water Glycol Cooled DX CRDX W FS 12W CRDX W FS 24W CRDX G FS 12W and CRDX G FS 24W models The system uses an external source of fluid to provide coolant to the condenser inside the A C unit No refrigeration connections are required for self contained water or glycol cooled systems see Figure 2 7 Table 2 2 Pipe connection sizes Model Water Glycol Inlet Outlet Condensate Drain CRDX W FS 12W ayy y CRDX W FS 24W 2 CRDX G FS 12W i CRDX G FS
168. tics for R410A 2 10 2 1 Estimating Refrigerant Charge When charging a system with R410A refrigerant you must weigh the refrigerant and confirm the charge is correct by checking the superheat and subcooling temperatures see Section 2 10 2 3 You can estimate the amount of refrigerant needed by adding the amount of refrigerant required for the A C unit Table 2 8 plus the condenser Table 2 9 plus the interconnecting refrigerant piping between the A C unit and the condenser Table 2 10 The values in the tables are the estimated weights for the refrigerant circuit Table 2 9 shows the estimated charge weights for Black Box condensers Depending upon site specific conditions refrigerant may need to be added or removed when fine tuning the charge to obtain the correct superheat and subcooling temperatures Table 2 8 Estimated refrigerant charge weight for A C unit A C Unit Model Number Approximate R410A Charge CRDX A FS 12KW SCH CRDX A FS 24KW 5 2 lb Table 2 9 Estimated refrigerant charge weight for condensers Condenser Model R410A Charge less receiver R410A Charge with receiver GE 2 8 Ib 12 2 Ib GE 3 6 lb 15 7 Ib GREEN 5 4 Ib 23 6 Ib BB 192 SSA 8 2 Ib 35 9 Ib 724 746 5500 blackbox com Page 37 Chapter 2 Installation Table 2 10 Weight of R410A refrigerant lbs 100 ft of type L tubing Line Size O D R410A Charge less receiver R410A Charge with receiver Ya 5 88 1 27 9 44 2 03 K 19 52 4 22
169. tion 4 3 3 After about 30 seconds the Main screen is displayed see Figure 3 1 At the bottom of the screen a status message Unit On appears Figure 3 1 Main display screen NOTE You may turn the A C unit on and off at any time by pressing and holding the Enter key for 3 seconds 4 After Unit On appears the fans begin operating in 5 second time delayed stages adjustable The middle fan is turned on first then the upper fan then the lower fan The Black Box logo in the display is replaced with a blower symbol 5 A 45 second time delay is allowed after the first fan turns on before the controller polls the air proving switch If adequate airflow is detected the controller enables its outputs If the actual room conditions are not within the range of the programmed setpoints the system will begin operating in the mode s needed cooling dehumiditying to reach the setpoints Symbols appear in the display to indicate the active operating modes see Section 4 3 6 Temperature and humidity alarms are masked out for 30 minutes to allow for conditions to stabilize without triggering nuisance alarms 7 Ensure that all fans are rotating correctly and freely without any unusual noise 8 Test cooling operation by decreasing the temperature setpoint see Section 4 5 4 1 to create a demand for cooling The compressor will turn on and the supply air should feel cooler than the return air In all cases 1 to 6 hours might b
170. tion when blowing solvent from parts The pressure wash should not exceed 30 psig Solvent solutions should be disposed of in accordance with local and state regulatory Statutes WARNING When performing brazing or de brazing operations make certain the refrigeration system is fully recovered and purged and dry nitrogen is flowing through the system at the rate of not less than 1 2 CFM 03 06 m minute CAUTION J The air intake and discharge areas must be free of obstructions Make sure access panels are secure and latched into position CAUTION J Cooling coils and associated piping circuits are pressurized and sealed when they leave the factory Before installing the interconnecting piping observe appropriate safety precautions and release the pressure via an available stem valve or Schrader valve before uncapping the pipes CAUTION J After interconnecting piping is installed you must clean the piping system If you use solvents cleaning solutions be sure they are completely flushed from the piping before connecting it to the unit Failure to do so will result in equipment problems 724 746 5500 blackbox com Page 15 Chapter 1 Introduction CAUTION A When filling the water glycol loop all air must be bled from the piping system WARNING Do not use chloride based water conditioning additives in the condensate drain pans This will cause corrosion to occur on the coil fins 1 5 General Design The Cold Row D
171. troller Use the lead controller display screens to monitor and adjust group control variables for the individual system controllers Each E2 controller connected to the pLAN network must be identified with its own unique address Multiple A C units consisting of up to eight 8 precision air conditioners equipped with like controllers may be controlled and monitored via the E2 series controller With multiple A C units each unit can selectively be configured as Active to operate as a primary A C Capacity Assist for staged operation or as Standby to come on line in case of a failed air conditioning unit to ensure continuous availability The controller may also be configured to rotate units with timed duty cycling to promote equal run time and ensure that each A C unit within the rotating group is operationally exercised on a periodic timed basis Page 44 724 746 5500 blackbox com 4 1 2 User Interface Display Panel Chapter 4 E2 Controller Your unit is equipped with an interface display panel typically mounted on the front panel of the A C unit BLACK BOX www blackbox cam Figure 4 1 User interface display panel The user interface display panel features an easy to read backlit liquid crystal alohanumeric display equipped with LED illuminated function keys The screens that appear on the user interface display panel present data that originates from the controller I O module Figure 4 1 The controller is operated via
172. uit 1 suction temperature 128 0 724 746 5500 blackbox com Page 95 Chapter 4 E2 Controller Table 4 21 Group alarms 33 to 40 Number Description Bitmask Default 33 Static air pressure 1 0 34 Differential air pressure 2 0 35 Dewpoint 4 0 36 Airspeed 8 0 a7 Reserved 16 0 38 Reserved 32 0 39 Reserved 64 0 40 Reserved 128 0 There are several automatic crossover signals that will cause a switchover from Unit Active to Unit Off They are the occurrence of a remote shutdown command unit shutdown trom a group alarm or BMS command fire smoke detection loss of all cooling all compressors or all CW valves or loss of airflow GLOUP gt CACO Figure 4 82 Factory gt Group gt Group Status Screen 7 The Factory gt Group Screen 7 provides an overview of pLAN workgroup Display Description Group Status C12345678 156789012 Page 96 Table 4 22 Factory gt Group gt Group Status Screen 7 parameters Description Variables Default l l ete O On Indicates if multiple A C unit grouping is enabled ier O Indicates the address 1 8 of each controller in the pLAN 1 Indicates the address 25 32 of the terminal for each controller in the oLAN The terminal address numbers range from 25 to 32 but only the 32 last digit appears in the screen GEOUDIT tactus Running ACLS Standby Assist Online Qut Or service Figure 4 83 Factory gt Group gt Group Status Screen 8 724 746 5500 blackbox com Cha
173. ur of Day Cur Lead Next lead Rot Unit Value Table 4 13 Factory gt Group gt Group Rotation Screen 2 parameters Description This field only appears on the lead controller If you select On and press it initiates a manual rotation cycle to rotate duty between active and standby units It also rotates the role of lead controller The fi eld will disappear after the role of Lead is rotated to the next A C unit Enter the number of days between rotating active units Enter the hour of day for unit rotation to occur Identifies which A C unit controller is currently the lead unit in the group Identifies which A C unit controller is designated to be the next lead unit Identifies which A C unit is designated to be the next unit to rotate duty Identities the duty of the A C unit by displaying the variable number assigned in Factory gt Group screen 1 0 Out of Service 1 Active 2 Standby etc Capacity Assist Assist Time 300s Cooling Cit 1n 1 0 F Cie out 00 F Variables O Off 1 On 0 O to 999 O to 23 1 to 8 1 to 8 1 to 8 Oto 6 Figure 4 78 Factory gt Group gt Capacity Assist Screen 3 Default Each A C unit in the group may be assigned local cut in and cut out setpoints for its capacity assist operation The values entered are offsets that are applied to the control setpoints established at the lead controller Each unit in the group should be assigned incrementally incr
174. ure sensor current value 0 0 R 16 017 16 C1 suction temperature sensor current value 0 0 R 17 018 17 Return temperature display value 0 0 R 18 019 18 Remote temperature display value 0 0 R 19 020 19 Entering water temperature display value 0 0 R 20 021 20 Leaving water temperature display value 0 0 R 100 101 100 High air temperature alarm limit 80 0 R W 101 102 101 Low temperature alarm limit 60 0 R W 102 103 102 High humidity alarm limit 70 0 R W 103 104 103 Low humidity alarm limit 30 0 R W 104 105 104 High water temperature limit 60 0 R W 105 106 105 Low water temperature alarm limit 40 0 R W 724 746 5500 blackbox com Page 105 Chapter 4 E2 Controller 4 9 2 Unsigned Values for HTTP SNMP Modbus Holding Registers Analog Values for BACnet Table 4 29 Unsigned Values for HTTP SNMP Modbus Holding Registers Analog Values for BACnet BMS Modbus BACnet Address Address Address Description Default Read Write 1 130 1001 Cooling analog output 0 R 2 131 1002 Middle fan Speed analog output 0 R 3 132 1003 Upper fan analog control value 0 R 4 133 1004 Lower Fan analog control value 0 R 5 134 1005 Packed bit for BMS alarms 0 R 6 135 1006 Packed bit for BMS alarms 0 R 7 136 1007 Packed bit for BMS alarms O R 8 137 1008 Packed bit for BMS sensor fails 0 R 9 138 1009 Packed bit for BMS sensor fails 0 R 10 139 1010 Packed bit for BMS digital inputs 0 R 11 140 1011 Packed bit for BMS digital inputs 0 R 12 141 1012 Packed
175. ustomer Alarm 1 E2 Controller Air Proving Switch gt UC Module CIX Fan s Enable Fire Smoke Detector gt Humidifier Enable Moisture Alarm Detection Leak Condensate Pan Full gt DX1 Compressor Enable DX1 Low Pressure CI ce gt DX1 Liquid Line Solenoid DX1 High Pressure gt gt gt D ee Auxiliary EVD Driver Supply Additional E Voltage Controller s Serial Communications Figure 4 18 Control inputs and outputs The E2 controller continually analyzes the demand for cooling humiditying and dehumiditying against the control setpoints and determines the appropriate response control output signals to operate the A C system The controller is equipped with analog input positions for monitoring temperature and humidity sensor s The controller monitors the actual cold aisle supply air conditions for three fan zones upper middle and lower as measured by temperature sensors mounted locally to each zone inside the Cold Row cabinet The controller also monitors a temperature humidity T H sensor that is mounted in the return hot aisle side of the cabinet A remote mounted supply air T H sensor may also be provided as an option The controller may be configured by the factory to manage system operation based on the remote T H sensor inputs that are to be field installed in the supply cold aisle space 4 4 1 Control Signals Control output signals and alarm recognition takes place by means of the controller
176. water temp CW1 Reserved 9 Circuit 1 low pressure Customer Alarm 2 Reserved 10 Circuit 1 high pressure Customer Alarm 3 Reserved 11 Pump Flow alarm temp sensors Reserved 12 Dual power input A Flow alarm flow switch Reserved 13 Dual power input B Reserved Reserved 14 Humidifier Reserved Reserved 15 Loss of power Reserved Reserved 724 746 5500 blackbox com 4 9 5 Sensor Failure Packed Bit Variables Table 4 33 Sensor Failure Packed Bit Variables Bit 724 746 5500 blackbox com Sensor Failures 1 Middle temperature Upper temperature Lower temperature Return temperature Return humidity Static air pressure Suction pressure Suction temperature Discharge pressure Discharge temperature Remote temperature Remote humidity Entering water temperature Leaving water temperature Reserved Reserved Sensor Failures 2 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Chapter 4 E2 Controller Page 109 Chapter 4 E2 Controller 4 9 6 Digital Input Packed Bit Variables Table 4 34 Digital Inout Packed Bit Variables Bit Digital Inputs 1 Digital Inputs 2 Page 110 0 Remote shutdown Customer alarm 2 1 Customer alarm 1 Customer alarm 3 2 Water Reserved 3 Condensate pan Reserved 4 Humidifier Reserved 5 Moisture Reserved 6 Middle fan alarm Reserved 7 Uppe
177. would appear on a psychrometric chart see Figure 4 19 It avoids scenarios where the A C unit might both cool and humidity the supply air when cooling alone will achieve the desired result The controller calculates dewpoint using the control inputs from the return air T H sensor or optional remote mounted supply T H sensor as configured by the factory The calculated dewpoint property is used to manage system operation resulting in higher operational efficiency and shorter component run times Page 56 724 746 5500 blackbox com Chapter 4 E2 Controller Psychrometric Chart Figure 4 19 Dewpoint control 4 4 3 Operating Configurations The operating configuration for the controller depends on what type of air conditioner is being controlled that is AR CW W G and what features are selected The operating configuration is preset by the factory according to the application If certain features discussed in this manual are not factory enabled no screens for that feature will appear in the controller user interface display 4 4 3 1 Compressor Operation The controller cycles the compressor on when it is determined that cooling is called for The compressor is turned on based upon the controller s cooling response to temperature and humidity inputs from the air sensors The compressor is enabled following a time delay once the programmed Cooling Stage Enable setpoint value is reached see Figure 4 20 Minimum Ru
178. y be networked with a group of A C unit controllers to manage their outputs as a system in an N M M number of standby units group The controllers from up to seven additional A C units may be tied to a lead controller The number of units to be assigned as Active Capacity Assist or Standby duty is configured by the factory however you can configure this field with the help of Black Box Technical Support A unit may also be designated as Out of Service The main screen of each unit in the workgroup will indicate that unit s duty assignment in the bottom field If the controller is the group Lead it will be indicated in the bottom field also 01 01 09 00 00 00 i 00 0 Figure 4 66 Multiple unit display screen 724 746 5500 blackbox com Page 85 Chapter 4 E2 Controller One controller may be designated as the workgroup lead and networked with the controllers trom a series of up to 7 additional A C units If configured for multi unit operation the workgroup lead controller display panel allows access to the same data and group control sensor choices that are available from networked system controller display panels 4 6 1 1 Standby If the lead controller in the workgroup loses a signal acknowledgement from an active A C unit in the group that A C unit is deemed as failed or taken out of service The failed unit will be replaced with the first available standby unit from the workgroup The standby unit is cycled on and designate

Black Box Network Hardware Cold Row DX User's Manual

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