INSTALLATION AND OPERATION MANUAL COOLING DISTRIBUTION UNIT

Transcription

1 INSTALLATION AND OPERATION MANUAL COOLING DISTRIBUTION UNIT For use with Motivair Chilled Doors Motivair Corporation 85 Woodridge Drive Amherst, NY (Ph) (fax)

2 ATTENTION Read this page before proceeding This document may be updated without notice at any time. Motivair reserves the right to update and or change product performance without notice. Please contact the factory to ensure that your version is the most up to date. WARRANTY: This product carries a 1-year Parts Only Warranty. A copy of this warranty is shipped with your Cooling Distribution Unit. An additional copy of your warranty can be attained by contacting Motivair at the address listed on this document. The manufacturer shall not be liable for any damages resulting from the misapplication or misuse of its products. THIS EXPRESS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, OR IMPLIED, OR STATUTORY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE HEREBY EXCLUDED. MOTIVAIR SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSSES FROM ANY CAUSE WHATSOEVER, INCLUDING, WITHOUT LIMITATION, LOSS OF USE, COMMERCIAL PROFITS, OR CUSTOMER GOODWILL, AND ANY OTHER CLAIMS BASED ON CONTRACT OR TORT, WHETHER OR NOT ARISING FROM MOTIVAIR S NEGLIGENCE.

3 Safety Instructions Owners Responsibility: This equipment must be installed, maintained and operated by a person or persons qualified for this equipment. This system contains water circulation equipment and electrical components. The person most suited to perform any operations or service on this equipment is a qualified industrial technician and or electrician with experience and qualifications to work with water systems and electrical systems. WARNING: Operation of this system involves potentially lethal dangers (HIGH VOLTAGE POWER and High water Pressures.) Therefore, ALL safety precautions and warnings described in this manual must be precisely observed. Failure to follow these precautions and warnings can result in severe or fatal injury. Safety Instructions: Temperature control equipment, pump stations and electrical devices contained in this system presents various electrical, mechanical, sound and vibration hazards. For this reason, operation and service procedures should only ever be performed by qualified, fully trained and technically competent personnel. This equipment contains: High pressure water generated by the system Electrically energized components Hot pipes and heat exchangers Rotating parts such as pump impellers, wheels and valves. Installation: Installation and operation should always be conducted in compliance with local, state and national codes and industry best practices. When moving or installing the unit, CAUTION must be observed at all times to ensure the safety and well being of personnel. Follow all local, State and national codes for moving equipment. Only appropriate and approved moving equipment should be used. Application: Unit is only good for indoor use. This unit must only be used in the application for which it was designed. Do not use this product in any hazardous environment. Warranty: Failure to follow any of the manufacturer s installation and operation guidelines may shorten the reliability and life of the product as well as void product warranty. A copy of the full product Warranty is shipped with the unit and a copy is available from Motivair Corp. Electrical Connection: WARNING This unit is powered by HIGH VOLTAGE. Serious injury or death can occur. Power being supplied to the unit must be isolated with an electrical disconnect. Any and all electrical connections or procedures should only be performed by a certified electrician. All electrical work or procedures should be in accordance with local, state and national electrical codes and regulations. NEVER make any electrical connections to this unit unless the power supply is OFF at the power supply disconnect switch.

4 General Product Description The Cooling Distribution Unit (CDU) is designed for use with Motivair Chilled Doors. The CDU includes a plate heat exchanger that creates a divide between customer supplied cold water (Primary Loop) and a separate cooling loop that feeds Chilled Doors (Secondary Loop). The Secondary Loop flow and pressure is created by the CDU pumps and valve assemblies. The Secondary Loop is always controlled to operate above room dew point to avoid condensation on the Chilled Door coils. The Primary Loop water system should always have a micron filtration level of less than 500 microns. The water supply can be from various sources such as a chiller plant. Clean and filtered water and or glycol is the sole responsibility of the user. Large amounts of debris or particulate can reduce efficiency or plug the CDU heat exchanger. Heat extracted from the Chilled Doors is transferred to the CDU heat exchanger where the heat is exchanged to the Primary Loop and removed. Various set points and alarms can be monitored and controlled within the CDU. These can be adjusted by the operator via an integrated PLC. Cooling Distribution Units can be built in various configurations. Make sure to check specific product specifications and design criteria for each specific CDU. Consult Motivair with any questions. Technical Data: Technical Data such as pump curves, electrical loads and sound data may be obtained on the CDU nameplate or from the product specification or submittal. Consult Motivair with any questions.

5 Installation Physical Removal and Locating The CDU arrives in a specially designed crate. Make sure the crate is on a level and load bearing floor. Typically, 4 workers will be needed to remove the CDU from its crate. Open the front draw bridge door to gain access to the CDU. Note, this Draw Bridge door folds down and creates a ramp down which the CDU is rolled out of the crate. Once the Draw Bridge door is down, carefully remove the CDU form the crate by pulling from the bottom of the CDU s front bracket. DO NOT PULL ON UNIT DOORS, THEY ARE NOT DESIGNED FOR LOAD PULLING OR RIGGING. The CDU has heavy components located high up inside the structure so the center of gravity is relatively high. Make sure unloading personnel prevent the CDU from tipping over by guiding it down the draw bridge ramp. Positioning the CDU Position the CDU on a smooth level floor. Typically this will need to be 12 raised floor or higher to allow for pipe connections to be made to the underside of the CDU. Once in position, there are leveling feet that can be adjusted to ensure a stable, level operating platform. There are openings in the bottom of the CDU to allow for IN/OUT Primary piping Connections and IN/OUT secondary piping connections. A floor cut out template can be requested from Motivair if needed. Electrical: The CDU has an electrical panel with an opening through which the power wires are installed. All electrical wiring should be performed by a qualified electrician. Wire sizing may vary based on CDU electrical loads and building power supply. The CDU can be supplied with A/B power feed option allowing for 2 different power sources to be fed to the CDU. If only 1 power source is available, that power can be fed to both the A and B power terminals. Standard Available Power Options: 460/3/60-575/3/60-230/3/60-208/3/60 Piping connections: Piping connection arrangement: S-in: Secondary loop inlet Return from doors S-out: Secondary loop outlet supply to doors P-in: Primary CW supply from building loop P-out: Primary CW return to building loop P-in S-in P-out S-out

6 Hydraulic: Primary Loop The Primary Loop cold water is supplied from the customer s building and it outside the scope of the CDU. The Primary Loop is connected to the CDU s Primary IN and Primary OUT connections via either an NPT connection or a brazed sweat connection. This connection type can be specified at the time of order. The CDU can be built to accept either top or bottom connections. This is specified at the time of order. The prevailing standard is bottom connections. All Primary Loop piping or hosing connected to the CDU must be self supporting, as the CDU is not designed for any external pipe loads. All Primary Loop piping should be insulated BY the installer to prevent condensation from forming. Secondary Loop The Secondary Loop connections are made on the underside of the CDU (bottom connections for raised floor installation). These connections can be either NPT or sweat connections and can be specified at the time of order. These Secondary In and Secondary Out connections typically run to and from a supply and return header that can be mounted under the raised floor by the installer. Connections between the CDU and the Supply and return header are made by the installer. This piping should be self supporting as the CDU is not designed for any external pipe loads. The Secondary Loop should be filled with clean softened water. Consult Chilled Door specification for water details. Filling and Venting: Standard industry best practices should be used for filling and venting of the primary & secondary Loop. Make sure all air is vented from both loops before starting the system.

7 Cooling Fluids: The CDU Primary Loop should be supplied with clean, particulate free water or glycol. Note that increased glycol concentrations reduce CDU efficiency and cooling capacity. It is the responsibility of the owner to ensure that the Primary Loop supply has less than 500 microns of particulate. The CDU Secondary Loop should be filled with clean, particulate-free, softened water with suitable corrosion inhibitors and biocides. Motivair Water Quality Recommended Mineral Limit Chloride < 25 ppm Calcium < 15 ppm Magnesium < 15 ppm Total Water Hardness <30 ppm Sulfate < 25 ppm ph softened water should be used Preparing a raised floor for a CDU: When a CDU is installed on a raised floor, holes must be made to allow for supply and return primary and secondary water lines to pass in and out of the CDU. The drawing below shows a typical bottom view of a CDU. The rectangular cut out is where the water piping enters and exists the CDU.

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11 COMMISSIONING CHECKS 1. Check complete unit to make sure all components are in place & undamaged. 2. Check all water piping connections for tightness. 3. Check building water pressure is within maximum CDU rated pressure 4. Confirm primary water filter/strainer is installed if required 5. Check all electrical connections for tightness 6. Make sure electrical power supply matches the nameplate data 7. Confirm main fuse sizing is correct for CDU nameplate data 8. Check all underfloor manifold water connections 9. Check all secondary water connections from headers to Chilled doors via flexible hydraulic hoses. COMMISSIONING 1. If Motivair was not contracted for startup supervision, notify Motivair service before commencing startup. 2. Slowly fill primary loop from building system and make sure all air is vented from loop 3. Slowly fill secondary loop with particulate-free, pre-softened water to the specified standards and vent air from loop using automatic vents provided. Loosen safety caps on vents for this purpose. 4. Check slowly & carefully for any water leaks & carefully tighten fittings where necessary, using a backup wrench to avoid damage. 5. Apply power to CDU and turn on A/B disconnect switches. 6. Bump start pump 1 and observe rotation is correct per direction arrow on pump casing. Change phase connections if required 7. Repeat rotation check of pump 2 as above. 8. CDU is now ready to commence startup operation 9. Set flow (triple duty valve) See description/sequence of operation DESCRIPTION/SEQUENCE OF OPERATION 1. Navigate the PLC to command the unit ON via the user interface. See controls section for description of screens. 2. The PLC will go through an initialization process for approximately 30 seconds. 3. The PLC, sensing the leaving secondary loop temperature, sends a 0-10 ma output signal to the motorized valve on the inlet building supply and the valve modulates to maintain secondary loop temperature to the Chilled Doors. 4. Entering & leaving primary & secondary loop temperatures are displayed on the home screen 5. Chilled doors (CDU heat load) are fitted with their own load-based modulating control valves. Therefore secondary pump pressure will vary based on the number of Chilled Doors in service and/or the actual heat load applied to the Chilled Doors. Secondary pump pressure is monitored by a pressure transducer in the

12 pump discharge header and constant design pump pressure is maintained by the VFD connected to the operating pump. 6. Triple duty valves on the discharge of each pump provide: A. Final adjustment of operating pump head pressure, if needed, to balance pumps on full load to design head pressure. B. Check valve to prevent backflow for automatic pump changeover C. Isolation of pump for removal. 7. After 5 minutes of operation carefully check vents on primary & secondary circuits to remove all air. Entrained air can take some time to each the vent points so this can be repeated again after 30 minutes of operation. When all air is removed, tighten safety caps on vents to prevent accidental leaks. 8. Observe CDU operation and monitor primary & secondary loop temperatures & pressures. 9. Measure the pump running amps & verify compliance with pump data plate amps. 10. Pumps automatically rotate on a factory default schedule. a. With pump 1 running, switch off manual overload. After a short delay, pump failed alarm will operate and pump 2 should start. b. Silence/acknowledge alarm and turn on Pump 1 manual overload. c. Turn off pump 2 overload. Alarm will sound and pump 1 will start. d. Contact Motivair service for assistance if pumps do not rotate as described during test. 11. Closed diaphragm expansion tank allows for hydraulic expansion of water in closed loop during temperature changes that may occur between filling time, operation and shut-down. 12. Humidity sensor monitors data center humidity to ensure secondary water loop temperature remains above the dew point. This is necessary to prevent condensation on the coils inside the Chilled doors. In the event the data center humidity reaches within 3F of the leaving secondary water loop temperature, the humidity alarm is activated and the PLC throttles the primary water control valve to reduce the cooling effect on the secondary loop. The CDU will automatically adjust outlet secondary water temperature to stay 3F above room dew point. 13. OPTIONAL Leak Prevention System a. Check operation of water detection system as follows: A. Make sure water detection LED (green) is lit on PLC. B. Take a small amount of water (1/2 cup) and pour it under the detector. The alarm should sound within 5 seconds. Acknowledge/silence alarm. C. Contact Motivair if alarm is not present. 14. Check communication of all selected PLC points to master control or BMS via BacNet, LON or ModBus. 15. Remove strainer on both suction guides after 24hrs of run time.

13 SECTION 4 CDU Start-up and operation HMI Screen Navigation The Human Machine Interface (HMI) is a 6 button Remote panel mount display screen. The 6 buttons on left and right sides as follows: Alarm press to view current alarm & clear alarms Program press to enter the programming menu screen Escape press to go back one screen or one space Down arrow press to scroll down or lower a setting Up arrow press to scroll up or raise a setting Enter press to navigate to changeable parameters and to confirm changes The HMI screens are a scrolling menu style the up and down arrows will scroll through all available screens in a sub menu i.e. press alarm and scroll through all active alarms. This is the main screen or Home Screen

14 The home screen is displayed when you press the ESC key or after a few minutes of inactivity. The home screen displays all the temperature reading of the CDU. Pressing the DOWN ARROW key will scroll to the next two information screens the first is the Temperature I/O display showing the actual reading of each input and is used for monitoring and alarm functions. The next information screen shown by pressing the DOWN ARROW key contains the actual outputs to the VFD s and the chilled water valve. Also shown is the power source for dual power feed option. Press the PROGRAM key for access to the programming menu. The programming menu contains three sub menus as shown use the UP & DOWN ARROW keys to highlight your selection then press the ENTER key to confirm your selection. Switching the unit On and Off Pressing the ENTER key on the previous screen enters the On/Off Unit screen as shown. Pressing ENTER key will highlight any changeable settings on the screen. Press ENTER key to highlight SWITCH OFF then press the UP or DOWN ARROW key to change to SWITCH ON Press ENTER key to confirm your selection. The CDU is now On.

15 Program Revision 43.4 Pump rotation supplement CDU pump rotation timed Timed by hours from hrs. is actual pump run time. In most cases this is actual calendar time as the pump is rarely turned off. However if the pump is stopped or the controller is stopped for maintenance the hr. counter stops counting until run is resumed. This means 24 = 1 day is true but can be off by any hours the unit is stopped this is actual pump run hours. The run hours can also be reduced from 0 2 hrs. by a power down of the controller; this is due to memory recording intervals. The Weekly rotation option was added to the program for applications where the exact day and time of rotation would always occur every week. This weekly rotation is not dependent on pump hours or power off situations. The Day of the week and the hour and minute are settable to provide a predictable changeover rotation point. To manually switch the current lead running pump set type to Manual and press the up or down arrow to switch between the pumps.

16 Press the PROGRAM key to go to the programming menus as shown above scroll down and Highlight Client Settings press ENTER key to confirm. The next screen will be the User Password screen. Press ENTER to highlight the first digit and us the UP ARROW to change the number. (Default PW=1234) Press ENTER to confirm and move to the second digit and scroll UP ARROW to insert Press ENTER etc The Client/User programming submenus contain all the Setpoint/alarm setting screens accessed by scrolling with the UP/DOWN ARROW keys. The first screen (shown) is the pump set-point screen. Press ENTER to highlight the parameter to change and use the UP/DOWN ARROW to change setting then press ENTER to confirm change. Scrolling down will show the other set-point and alarm screens. The Alarm screen shown is used to set high and low heat exchanger alarm time delays and alarm temperature thresholds. Water outlet temperature set point screen Other screens available in the submenu are the Date/Time setting screen.

17 The BMS setup screen is also available to set the desired communications protocol and stating address. The following screens shown here are accessible through the Manufacturer Setup and should not need to be accessed unless a specific change requirement is necessary. Contact Motivair for access and more information if changes in this menu section are required. Unit of Measure screen. Default reboot screen. Pressing the ALARM key will display the screen shown if no alarms are present. Press ENTER to view the alarm log history.

18 Example of the alarm log history showing the date/time of Pump A overload fault. The screen shown is displayed if an alarm is present and active. Press the ALARM key once to display the actual alarm press the ALARM key 2 x to clear non active alarms. Pressing the ALARM key once displays the active alarm.

19 CDU Supervisor parameters table Analog variables ModBus BMS Description Defau UOM Min Max Dire Variable name Register 2 HxS Temp set point (supply) 0 C/ F R/W Setpt_HXS_Out HxS Water Out Control band 0 C/ F R/W SetDiff_HXS_Out v output to the Valve 0 V R Valve_output_signal Calibrate B1 Supply pressure probe 0 PSI R/W Calibrate_B Calibrate B3 Hxs Out probe 0 C/ F R/W Calibrate_B Calibrate B2 Return pressure probe 0 PSI R/W Calibrate_B High secondary xchanger out temp alarm threshold 0 C/ F R/W SetAlm_HighHXS_Out Low Secondary Exchanger out temp alarm 0 C/ F R/W SetAlm_LowHXS_Out Calibrate B4 HxS In probe 0 C/ F R/W Calibrate_B Exchanger secondary outlet temp (supply) 0 C/ F R HXS_Out Exchanger secondary inlet temp (return) 0 C/ F R HXS_In Calibrate B5 HXP_out probe 0 C/ F R/W Calibrate_B Exchanger Primary inlet temp (supply) 0 C/ F R HXP_In Calibrate B6 HXP_In probe 0 C/ F R/W Calibrate_B Calibrate B7 Rm DB Temp probe 0 C/ F R/W Calibrate_B Room Dry Bulb Temp 0 C/ F R Rm_DB_Temp Calibrate B8 Rm RH% probe 0 %rh R/W Calibrate_B Room RH% output 0 %rh R Rm_RelHumd Exchanger Primary outlet temp (Return) 0 C/ F R HXP_Out High secondary xchanger in temp alarm set point 0 C/ F R/W SetAlm_HighHXP_In Room Dry Bulb Temp in C 0 C/ F R Rm_DB_Temp_C Pump Pressure Supply 0 PSI R Pressure_Supply Pump Pressure Return 0 PSI R Pressure_Return B1 transducer low range limit 0 PSI R/W B1_xducer_low_Limit B1 transducer High range limit 0 PSI R/W B1_xducer_High_Limit B2 transducer low range limit 0 PSI R/W B2_xducer_low_Limit Pump differential pressure output 0 PSI R Pump_DeltaP Delta P Control set point 0 PSI R/W SetPt_Pump_VFD Control band VFD 0 PSI R/W Setpt_VFDControlBand VFD output 0-10v 0 V R VFD_Out10v DewPoint Temp 0 C/ F R DewPoint B2 transducer High range limit 0 PSI R/W B2_xducer_low_Limit 4043

20 Integer variables ModBus Modbus BMS Description Defau UOM Min Max Dire Variable name Register TCP/IP 4 Time for PI Valve control 0 s R/W Intergral_Time_Valve Minimum valve opening % 10 % R/W Min_Valve_Open High HXS Out temp alarm delay 0 s R/W SetDelay_HighHXS_Out Low HXS temp alarm delay 0 s R/W SetDelay_LowHXS_Out High Coil Inlet temp alarm delay 0 s R/W SetDelay_HighCoil_In High HXP In temp alarm delay 0 s R/W SetDelay_HighHXP_In Flow alarm delay start 30 s R/W Delay_Startup_Flow_Alarm_ Flow alarm delay run 30 s R/W Delay_Run_Flow_Alarm_ Rotation time 1 s R/W Rot_Time_hh_ Number of pumps R/W N_Pumps Pump A Run Hours Hi Integer --- Hrs R P1_Hrs_H Pump A Run Hours Lo Integer --- Hrs R P1_Hrs_L Pump B Run Hours Hi Integer --- Hrs R P2_Hrs_H Pump B Run Hours Lo Integer --- Hrs R P2_Hrs_L Clock Day R BMS_Day Clock Month R BMS_Month Clock Year R BMS_Year Clock Hour R BMS_Hour Clock Minute R BMS_Minute Time Next Rotation 0 Hrs R Rot_countdown * Note on TCP/IP: Interger registers are reallocated to and above with PcoWeb interfaces 1.5 version. The older Version 1.4 or below subtract 1 from the register address i.e = Digital variables ModBus BMS Description Defau UOM Min Max Dire Variable name Register 12 Select P or P+I Valve R/W Enable_PI_Valve On-Off unit state (0: Off; 1: On) R Sys_On Water valve present R/W Valve_Enable Enable WDS alarm input R/W Enable_WDS_alarm Alarm Reset by BMS R/W Reset_Alarm_BMS WDS alarm input R Alarm_WDS_In General alarm output R General_Alarm Clock board alarm R Al_Clock Alarm high HXS Out temp R Alarm_highHXS_Out Alarm low HXS out temp R Alarm_lowHXS_Out Alarm B6 Probe R Al_Probe_ Alarm B7 Probe R Al_Probe_ Alarm B3 Probe R Al_Probe_ Enable motivair logo splash screen R/W LogoMA_Enable Alarm high HXP In temp R Alarm_highHXP_In B1 Pressure Probe alarm R B1_Probe_alarm B2 Pressure Probe alarm R B2_Probe_alarm Alarm VFD A R VFD_A_Alarm Alarm VFD B R/W VFD_B_Alarm Low Flow Pump A warning R Warning_Pump1_ Low flow Pump B warning R Warning_Pump2_ Manual pump select R/W Pump_select enable VFD A alarm R/W VFD_A_Alm_Enable enable VFD B alarm R/W VFD_B_Alm_Enable High DewPoint Temp warning R DewPoint_Warning Digital input On-Off R/W Dig_In_OnOff Pump A Status R Pump_A_Status Pump B Status R Pump_B_Status Low Flow Pump A Alarm R Alarm_Pump1_ Low flow Pump B Alarm R Alarm_Pump2_ Hrs counter reset pump A R/W Reset_A Hrs counter reset pump B R/W Reset_B 10060

21 Factory Service & Support: Motivair Corporation 85 Woodridge Drive Amherst, New York, Phone Fax This product is covered by Motivair s Limited Product Warranty. A copy of this warranty is available by calling the factory number listed above. Additional information on this product may be found at NOTES: