Contec CoolTeg Plus XC40 User Manual

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CoolTeg Plus XC40

USER GUIDE

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Page 1 CoolTeg Plus XC40 USER GUIDE...
Page 2 © 2016 CONTEG, spol. s r.o. All rights reserved. Distribution or reproduction of this documentation, or selling or sharing its content is not allowed, unless expressly approved by the owner of the copyright. Regardless of the fact that this User Guide has been created and checked for correctness with maximum care, CONTEG, spol.
Page 3: Table Of Contents
........................17 IFTING AND TRANSPORTATION ..............................17 TORAGE ........................... 18 EMOVAL OF PACKAGING 5. THE PRINCIPLE OF COOLTEG PLUS XC40 ..........19 6. INSTALLATION ..................21 ......................... 21 NSTALLATION OF INTERNAL UNIT ....................... 23 NSTALLATION OF A UNIT ONTEG RACKS ......................
Page 4 INFO ............................48 CIRCUIT INFO ..........................48 COMPRESSOR INFO EVD .............................. 49 INFO ............................. 49 ZONE ..............................51 LARMS 8. USER MENU .................... 52 ............................52 AIN SWITCH ..........................52 EMPERATURE CONTROL ............................52 ANS CONTROL ..........................52 UMIDITY CONTROL ............................
Page 5 ............................62 ONE SETTINGS Address assignment ..........................62 Zone configuration ............................ 63 ........................70 EFAULT PARAMETERS VALUES 12. ALARM LIST .................... 74 13. COMMUNICATIONS VARIABLE LIST ............76 ..........................76 NALOGUE VARIABLES ........................... 78 NTEGER VARIABLES ........................... 80 IGITAL VARIABLES...
Page 6 IMPORTANT! This User Guide, including all other applicable documentation, forms an integral part of the product. All applicable documentation must be handed over to those persons who will install, operate, control or dismount the equipment. The user must carefully read the User Guide and fully understand it prior to installation and commissioning of the device.
Page 7: Safety Instructions
Safety Instructions The symbols used throughout this User Guide: THIS WARNING SIGN INDICATES SERIOUS DANGER WHICH THE DEVICE DANGER MAY CAUSE AND WHICH MAY LEAD TO INJURY OR EVEN DEATH IF SAFETY PRECAUTIONS ARE NOT OBSERVED! THIS SYMBOL DENOTES PROCEDURES WHICH ENTAIL A RISK OF CAUSING WARNING DAMAGE...
Page 8: Coolant Handling
Coolant handling • The CoolTeg Plus XC40 units are intended to be connected with outdoor condenser. Entire refrigerant cycle works with refrigerant R410A. • Coolant handling, and the installation and disposal of cooling units must be made in compliance with the regulations applicable in the country where the unit is installed.
Page 9: Environmental And Safety Requirement
Environmental and safety requirement In accordance with the certificate of compliance, Conteg spol. s r. o., as the manufacturer of the device, declares that CoolTeg Plus cooling units have been manufactured and tested in accordance with the following directives: • EU EMC Directive 2004/108/EC •...
Page 10: Product Identification
2. Product identification Product plate This equipment may be identified by its product plate, which contains basic information on the product. The technical specifications on the plate are related to the rated conditions of operating the cooling equipment. The product plate is located at the bottom of the cooling unit in the rear. Figure 2.1 Production plate...
Page 11 Key to ordering code AC – TXC – 2 – 3 / 4 – 5 7 – 8 9 10 11 12 13 14 15 16 7. Display (D = Door display; W = without disp.) 6. Architecture (O = Open; C = Close – MCL) 5.
Page 12: Basic Description Of The Device
3. Basic description of the device In principle, the CoolTeg Plus unit is an air/coolant heat exchanger, which conducts heat from servers and other IT equipment in the most efficient way. CoolTeg Plus is optimized for placement between server cabinets so as to ensure optimum separation of the hot and cold aisles, or for a closed loop installation (Modular Closed Loop), where the circulating air is completely separated from the ambient space.
Page 13 Cooling capacity After setting the outlet temperature set point, the control unit adjusts the cooling capacity based on the difference between the measured outlet temperature and the set point. The PID controller assess the speed and direction at which the outlet temperature changes, and then sets the required cooling capacity.
Page 14: Correct Use
Relatice air humidity control Since the sensors at the bottom of the unit are combination of humidity and temperature sensors, they also measure the relative humidity at the inlet and outlet of the cooling unit. If the required relative humidity of inlet air is exceeded, the cooling unit switches to dehumidification mode, i.e.
Page 15: Illegal Use
Conteg, spol. s r.o. is not liable for incorrect functioning of the equipment caused by the non- observance of these conditions. In the event of a breach of these conditions, the user assumes full responsibility for the functionality of the unit. The main air-conditioning functions are as follows: filtration, cooling, dehumidification (as a secondary effect of cooling), humidification (provided that the unit is equipped with a humidifier) and the drainage of condensate (using gravity or a pump).
Page 16: Unpacking And Inspection Upon Delivery
Unpacking and inspection upon delivery Inspection upon delivery Conteg products are supplied directly from the manufacturing plant. Prior to dispatching, all components are inspected one by one and carefully packed. The whole device is tested for functionality before dispatching. After receiving the goods, immediately check the following: •...
Page 17: Lifting And Transportation
Lifting and transportation Danger of heavy load falling The load-bearing capacity of the equipment must correspond to the weight of the cooling unit. The load must be placed evenly to prevent tilting. Avoid negligent and dangerous handling. Do not place any other objects on the air-conditioning unit. Risk of collision between the top of the air-conditioning unit and the building structure Check the dimensions of the unit (particularly its height) and the clear height of...
Page 18: Removal Of Packaging
Removal of packaging • Remove the packaging without damaging the air-conditioning unit. • Remove all documents and components from inside the packaging. • Once the unit is mounted, you can remove the protective display foil. • Keep the original packaging (pallet and protective elements) for any future transport. Use the original packaging to transport the cooling equipment to a different place.
Page 19: The Principle Of Coolteg Plus Xc40
5. The principle of CoolTeg Plus XC40 In principle, CoolTeg Plus XC40 unit is air/refrigerant heat exchanger, which removes heat load from servers by the most efficient way. The cooling is based on direct evaporation principle. Compressore positioned inside the unit Coolteg Plus XC40 compresses overheated vapor of refrigerant and pushes them into the condenser (positioned out of the datacentre room).
Page 20 Elektrobox (Power supply connecton) Evaporator Fans EMC filter Frequency inverter Compressor Oil separator Figure 5.2 Compoonents...
Page 21: Installation
6. Installation Installation of internal unit When installing the outdoor unit, please follow the instructions in the relevant manual. Open units must be installed between two racks. It is recommended not to install units at the end of the row, as it is where the hot and cold air mix. On the other hand, it is recommended to install them near the racks with the highest heat load Conteg Conteg...
Page 22 Check the following: • There is enough space for easy installation and maintenance of the unit. In particular, consider the access to coolant and wiring connections. The minimum recommended clearance from the front and the rear side of the unit for installation and maintenance is 1.5 m.
Page 23: Installation Of A Unit Conteg Racks
Installation of a unit Conteg racks...
Page 30: Connection Of The Cooling Unit
Connection of the cooling unit Ball shut-off valves are installed at the right-rear side of the unit CoolTeg Plus XC40. They are intended for unit connection with refrigerant circuit. Valve dimensions are 16 mm (liquid) and 22 mm (gas). The valves are accessible from rear side of the unit. Rear door with filtres must be removed to entrance.
Page 31: Condenser Above Coolteg Xc40
Condenser above CoolTeg XC40: - S-traps (syphons) on discharge side must be each 4 meters vertically and at the bottom of the circuit. - With respect to possible refrigerant condensation during compressor ssitching off, one-way valve is recommended to be installed. - Keep grading stated above (1%) Figure 6.15 1.
Page 32: Condenser Under Coolteg Xc40
Condenser under CoolTeg XC40: - S-straps are not requires. Only the above grading is required. 1. Cooling unit CoolTeg XC40 (Conteg) 2. Shut-off valve in front of condenser 3. Schrader valve 4. Condenser (Conteg) 5. Check-way valve 6. Safety valve for refrigerant R410A 7.
Page 33: Communication Cable Between Indoor And Outdoor Unit
Communication cable between indoor and outdoor unit Indoor unit XC40 must be connected with outdoor unit (condenser) via 6 – core cable (6x1,5mm ) to ensure fan speed control via signal 0-10V (terminal 7.1 and 7.2 on controller), outdoor unit signalization (terminal 8.1 and 8.2), and working permission of outdoor unit (terminal 6.1 and 6.2, option).
Page 34: Table Of Recommended Condensers
ØD Figure 6.17 Condensers dimensions Design of recommended liquid receiver Follow these steps to design proper liquid receiver size and refrigerant amount: A. Indoor unit CoolTeg Plus XC40 �� = 2,96 �� B. Condenser AC-CONDx-xx-xx Multiply condenser volume V [dm ] by coefficient 0,61 and get refrigerant weight in the condenser.
Page 35: Amount Of Refrigerant
E. E = 2,96 + 7,686 + 7,2 + (0,2 x 38,2) = 25,5 kg Thanks to the variable refrigerant flow it is necessary to add the liquid receiver into the piping assembly. Liquid receiver is not part of Coolteg Plus XC40. Proper design significantly affects operation and maintenance. Pay extra attention to it.
Page 36: Coolteg Plus Xc40 Connection With Other Components
1mm. Make sure the piping is clear and without and harmful impurities as sulfur compounds, oxides, burrs or dust. Take care proper location of piping inside the cooling unit CoolTeg Plus XC40 with respect to other components, its control and future maintenance. Body of closing valve must be cooled down during the welding.
Page 37: Refrigerant Circuit Tightness Check
Overpressure test - Nitrogen, dry air or helium could be used. The CoolTeg Plus XC40 unit is filled with nitrogen at the end of the production process (approx. 2 bar). Before opening the ball valves, check the overpressure in the supplied equipment.
Page 38: Vacuum Test
- By checking the overpressure in the enclosed indoor unit, check for tightness. The unit was exhausted and pressurized with nitrogen at the factory. - Open the ball valves on the indoor unit. - Remove the solenoid valve coil and use the service magnet to open the solenoid valve. - Make sure the entire circuit is clear and no other valves (condenser, coolant collector, etc.) are closed.
Page 39: Oil Filling And Refill
Oil filling and refill The compressor in the CoolTeg Plus XC40 unit is filled with 2,51 liters of Emkarate RL 32 CF oil. Oil separator has capacity of 3 liters and it is filled with 1,5 liters.
Page 40: Oil Type
When refilling, observe the amount of oil in the TraxOil sight glass unit. Oil type The type of oil used to lubricate the compressor in the CoolTeg Plus XC40 is EMKARATE RL 32 CF. Oil specification: Figure 6.2 Oil specification...
Page 41: Coolant R410A Filling
Coolant R410A filling The CoolTeg Plus XC40 is supplied without a R410A refrigerant charge. The correct amount of refrigerant must be completed at the installation site by a certified installer. The amount of refrigerant in the system must be calculated according to the volume of the indoor and outdoor unit, the coolant collector and the connecting pipe.
Page 42 end user, whereas the recommended values are 18°C for setpoint and in minimum 3K for hysteresis. • If there was any problem during the filling or testing, please don’t hesitate to contact us on cooling@conteg.com Figure 6.3 Coolant sight glass...
Page 43: Condensed Water
Condensed water Each unit has to be deployed horizontally and connected to condensate outlet. Condensate gathered at the most bottom part of condensate pan will be rejected either by gravity or condensate pump through the syphon (not Conteg delivery) into the drainage. Drainage outlet has outer thread G 3/8”...
Page 44 Main power supply connection process: 1. Make sure the power supply is interrupted. Main switch must be in OFF position) 2. Unfasten handlers bolt and dismantle the handle. 3. Unscrew top cover of electro-box. 4. Connect main power supply’s terminals 2T1, 4T2, 6T3, N – (free blue terminal) and PE (free yellow-green terminal) 5.
Page 45: Control
7. Control The system is controlled via service display pGD . Terminal description: Key Alarm Key Nahoru Key Prg Key Enter Key Dolů Key Esc Key functions Alarm: alarm service Prg: menu parameters settings Esc: according to actual level back to the user menu, service menu or main screen Enter: set value or confirmation, move to the next value Up, down: according to a cursor position changing of the set value, moving with menu items or toggling between screens...
Page 46: Changing Displayed Controller
Changing displayed controller The terminal is shared with all units via pLAN. The address of currently selected unit is shown in the upper left corner at all screens. To show another unit on the terminal, push ESC and Down keys together. Display of pLAN network status It is possible to find out the status of pLAN communication via pGD1 terminal.
Page 47: Operating Information
Operating information On the first screen, there is information about inlet humidity, eventually about pressure difference (if the unit has connected a pressure difference sensor). Aditionally information about operation status of master and slave units. Satus information is stated in next part of the screen: : unit’s operation is not permitted (input U10 on expansion box) : unit is switched off : unit is switched on...
Page 48: Info Humidity
INFO humidity This screen show an information about inlet and outlet air relative humidity. Calculated limits of inlet humidity are shown according required outlet relative humidity. INFO circuit Refrigerant circuit information is shown in this screen. Upper part shows condenser’s information: : Condenser’s fan is switched off : Condenser’s fan is switched on : Condenser’s fan in failure...
Page 49: Info Evd
compressor speed and power (read from frequency driver) are shown. If lubrication is active, you will see symbol INFO EVD Next screens show EVD operation information and values from individual sensors (inputs U1 – U4). INFO zone This screen is to be shown only on Master unit. Units total: Total number of units Active units: Total active units (with the operation requirements)
Page 51: Alarms
Alarms A new alarm in the system is indicated by flashing the diode below the Alarm key - . At the same time the corresponding alarm screen is displayed and the fault signal blinks. After the alarm is cleared, the fault indication stays on permanently until the alarm is cleared. Active alarm screens can be several, each alarm has its own screen.
Page 52: User Menu
8. User menu You can access the user menu by pressing the Prg key. Move the cursor with the Up or Down keys, press Enter to move to the desired setting. Main switch From this screen, you can turn off the unit permanently. The "ON"...
Page 53: Clock Settings
Clock settings This screen is for setting the date and time in the controller. DST set On this screen is the daylight saving time setting. On the first line, the Daylight Saving function can be disabled, the next line is the setting of the shift size and the beginning and end of the summer time period.
Page 54: High Discharge Temperature
High discharge temperature Set emergency discharge temperature. Temperature warning Setting the upper air outlet temperature limit. If the outlet air temperature reaches the set limit, a warning is issued. The high temperature warning ends when the exhaust air temperature reaches the set value of the differential alarm warning. Humidity warning Setting limits for non-compliance with moisture output.
Page 55: Unit Operation
Unit operation Remote off delay: After switching the order of the units in the zone, the units are switched off in operation for the time set here so that the newly switched units can reach the operating parameters. Operating hours limit: Set the unit's operating hours limit. Upon exceeding this limit, a warning is issued.
Page 56: Humidity Control
Setpoint dT MAX, MIN: Limitation of the maximum and minimum of the requested difference. Setpoint dP MAX, MIN: Maximum and minimum pressure drop requirements. At the bottom of the screens is the setting of the fan speed controller parameters. Humidity control On this screen, there is the setting of humidity control parameters: Setpoint MAX, MIN: Maximum and minimum required output...
Page 57: Discharge Temperature
Discharge temperature Setting the operating temperature limit on the discharge side. If the compressor temperature exceeds this temperature, the compressor performance is limited. Compressor Setting the compressor operation parameters: Minimum on time, off time: Minimum compressor running and idle time. Control delay: Delay of activation of limiting regulators.
Page 58: Manual Control
Manual control These screens allow you to manually control each component of the unit. Alarm counters The controller calculates the occurrence of individual alarms. The screens are the number of individual alarms since the last reset. When you press the Enter key, the reset screen for all alarms appears.
Page 59: Outputs
Offset: Input value shift (constant over the entire range). Probe type: Type of sensor used. Only the type of sensor that can read the input can be entered. Range: Measuring range of sensor used (not shown in passive sensors). Alarm delay: Sensor alarm delay. Mode: Each input can be converted into manual mode (for example, in case of a sensor failure).
Page 60 1. Modbus Slave 2. CAREL 3. pCO Manager (For service purposes only) 4. Modbus Master BMS adresa: Controller address for BMS systems. pLAN adresa: Controller address in pLAN. Each controller in the pLAN network must have its unique address in the range 1 .. 16. The controller with address 1 has the Mater function, it controls the operation of the units in each zone.
Page 61: Communication Options
Communication options The following table shows the relationship between the set communication protocol in the software, the communication card used and the communication protocol on the BMS: BMS protocol Communication card Settings in the controller software OPC server PCOS004850 CAREL WEB server PCO1000WB0 CAREL...
Page 62: Information Evo
Information EVO This screen shows information about the built-in driver. Initialisation This screen is used to restore the default parameter settings. After changing "NO" to "YES" and confirming with Enter, the parameters are set to the default values. The default parameter values table is listed below.
Page 63: Zone Configuration
Zone configuration Total units: Total number of units in the zone. It is an information value. The total number of units in the zone is calculated by units with a nonzero address. Active units: The number of units in the zone that are currently in use.
Page 64 Operating group 5 Operating group 6 Total units:6 Active units: 2 Skip groups: YES Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Operating group 1 Operating group 2 Operating group 3 Operating group 4 Operating group 5 Operating group 6...
Page 65 Total units:6 Active units: 3 Skip groups: YES Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Operating group 1 Operating group 2 Operating group 3 Operating group 4 Operating group 5 Operating group 6 The Skip groups parameter can be used if we want to keep the same number of inactive units among the active units.
Page 66 Zone 1 - operating group 2 + 5 Adresa Adresa Adresa Adresa Adresa Adresa Unit 1 Unit 3 Unit 5 Unit 2 Unit 4 Unit 6 Zone 1 - operating group 3 + 6 Adresa Adresa Adresa Adresa Adresa Adresa Unit 1 Unit 3 Unit 5...
Page 67 Opositelly, when you set Skip groups: NO, the zone will work as follows: Zone 1 - operating group 1 Adresa Adresa Adresa Adresa Adresa Adresa Unit 1 Unit 3 Unit 5 Unit 2 Unit 4 Unit 6 Zone 1 - operating group 2 Adresa Adresa Adresa...
Page 68 Zone 1 - operating group 5 Adresa Adresa Adresa Adresa Adresa Adresa Unit 1 Unit 3 Unit 5 Unit 2 Unit 4 Unit 6 Zone 1 - operating group 6 Adresa Adresa Adresa Adresa Adresa Adresa Unit 1 Unit 3 Unit 5 Unit 2 Unit 4...
Page 69 Zone 1 - operating group 2 +4 + 6 Adresa Adresa Adresa Adresa Adresa Adresa Unit 1 Unit 4 Unit 2 Unit 5 Unit 3 Unit 6 In this set zone, there will always be half active and half in reserve (Total unit = 6, Active units = 3).
Page 70: Default Parameters Values
Default parameters values Description Data type DefaultValue U.M. DefMinLim DefMaxLim Band condenser control Analog 20.0 999.9 Band discharge pressure control Analog 10.0 3276.7 Band fans control by dP Analog 30.0 999.9 Band fans control by dT Analog 30.0 999.9 Band humidity control Analog 30.0 999.9...
Page 71 Humidification On Time Integer 10 min Humidifier fault delay Integer Temperature hysteresis Analog 3.0 GradC Change group daily Digital Group change day Integer Group change hour Integer Interval between writes of the counter to permanent memory Integer Oil distribution off time Integer 120 min Oil distribution on time...
Page 72 Discharge pressure operating maximum Analog 30.0 BAR 99.9 Suction pressure operating minimum Analog 4.0 BAR 10.0 Humidity setpoint high Analog 65.0 PercH 99.9 Humidity setpoint low Analog 35.0 PercH 99.9 Humidity setpoint MAX Analog 70.0 PercH 99.9 Humidity setpoint MIN Analog 30.0 PercH 99.9...
Page 73 Weight inlet top Analog 50.0 Perc 100.0 12.0 °C/°F MOP: thresold inhibition valve A Analog 15.0 °C/°F MOP: threshold high temperature evaporation Analog -29.0 °C/°F LOP: threshold for low temperature of evaporation Analog LowSH: threshold low superheat Analog 5.0 K Oil protection speed limit Analog 25.0 %...
Page 74: Alarm List
Alarm list The following table lists all the alarms that may occur in the system. Alarm text code Cause Shuts down Probe Bnn ALAnn Fault of any of the sensors. The sensor is marked with Nothing. Incorrect sensor data may the appropriate terminal.
Page 75 Circuit LP ALB01 The pressure on the suction sensor dropped below the The whole unit. set limit. Circuit HP ALB02 The pressure on the discharge exceeded the set limit. The whole unit. Circuit HT ALB03 The discharge temperature exceeded the set limit. The whole unit.
Page 76: Communications Variable List
Communications variable list Analogue variables Description Read/Write Address Suction pressure -99.9 99.9 °C Suction temperature -99.9 99.9 Discharge pressure -99.9 99.9 °C Discharge temperature -999.9 999.9 rH Inlet 999.9 °C Temperature inlet top -99.9 99.9 °C Temperature inlet bottom -99.9 99.9 °C External temperature...
Page 77 °C Temperature differential setpoint 30.0 Pressure differential setpoint -10.0 10.0 Fan speed MAX 100.0 Fan speed MIN 100.0 Humidity setpoint high 99.9 Humidity setpoint low 99.9 Humidifier power MAX 100.0 Humidifier power MIM 100.0 °C Temperature for cooling request 50.0 °C Cooling request temperature differential °C...
Page 78: Integer Variables
Integer variables Description Direction Address Position valve steps 9999 Cooling capacity Dehumidification On Time Dehumidification Off Time Humidification On Time Humidification Off Time Operating hours (thousands) h*1000 Operating hours (units) Operating hours total (thousands) h*1000 Operating hours total (units) Maximum number of operating hours (thousands) Maximum number of operating hours (units) Address Unit 1 Address Unit 2...
Page 79 Unit Off Delay 9999 EVD Evolution OnBoard regulation status Compressor status Compressor RPM Compressor real RPM New day New month New year New hour New minute Current day Current month Current year Current hour Current minute...
Page 80: Digital Variables
Digital variables Description Direction Address Alarm filter Alarm float Alarm condensate pump Alarm Humidifier Alarm compressor Alarm condenser Alarm fan 1 Alarm fan 2 Alarm fan 3 Alarm LP Alarm HP Alarm HT Alarm CoolTop Alarm inverter Alarm temperature high Alarm humidity high Alarm humidity low LowSH (low super heat) alarm EVO...
Page 81 Warning Emergency Off Alarm reset System ON Set default values Change group daily Configuration fault Skip Groups Address assignment error Dehumidification Humidification Oil protection active Warnig operating hours Fans on Stand-by Humidifier installed Temperature selection MAX Common setpoints Config dP Sensor Fans by dT Fans by dP Request to copy NEW_DAY into DAY...
Page 82 Notes...
Page 83 Verze 9801...