Vertiv CoolChip CDU100kW Operation And Maintenance Manual
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Vertiv CoolChip CDU100kW Operation And Maintenance Manual

Vertiv CoolChip CDU100kW Operation And Maintenance Manual

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CoolChip CDU100kW
Operation and Maintenance Guide

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Summary of Contents for Vertiv CoolChip CDU100kW

  • Page 1 CoolChip CDU100kW Operation and Maintenance Guide...
  • Page 2 The products covered by this instruction manual are manufactured and/or sold by Vertiv. This document is the property of Vertiv and contains confidential and proprietary information owned by Vertiv. Any copying, use, or disclosure of it without the written permission of Vertiv is strictly prohibited.

  • Page 3: Table Of Contents

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide TABLE OF CONTENTS 1 Important Safety Instructions 1.1 General 1.2 Installation and Handling 1.3 Application 1.4 Warranty 1.5 Electrical Connection 1.6 Replacement Parts 1.7 Waste Disposal 1.8 Documentation 2 Agency 2.1 Product Standards and Approvals 2.2 RoHS 3 Compliance...
  • Page 4 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 4.7 Temperature Sensor Graph 4.8 Group Control 4.8.1 Group Control—Network Cabling 4.8.2 Group Control—Network Termination Resistors 4.8.3 Group Control—Network Addresses 4.8.4 Group Control—Start Sequence from Power Up 4.8.5 Group Control—Controls 4.8.6 Group Control—Unit Rotation and Standby Units 4.8.7 Group Control—Failure Offset...

  • Page 5: Important Safety Instructions

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 1 Important Safety Instructions Save These Instructions This manual contains important instructions that must be followed during operation and maintenance of the Vertiv™ CoolChip CDU100kW. NOTICE Some control system menus may not be visible if the user is not logged in. Visibility also depends on the log in access level.

  • Page 6: General

    Commissioning Guide SL- 71337 for more information. 1.3 Application This product is to be used indoors only and must be only used for the application it was designed for. As consulted by Vertiv engineering this product must not be used in a hazardous environment.

  • Page 7: Replacement Parts

    Any parts replaced during maintenance or servicing must be the same specification as those being replaced and should only be obtained from Vertiv. The use of incorrect replacement parts may affect the operation or reliability of the unit and invalidate any warranty.
  • Page 8 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 1 Important Safety Instructions...

  • Page 9: Agency

    This product is cULus listed for the appropriate voltage models and certificates will be made available on request (cULus certificate 60335-1 pending). 2.2 RoHS 3 Compliance Vertiv certifies that all products manufactured and supplied by Vertiv are fully RoHS compliant in accordance with EU RoHS Directives EU 2015/863. 2 Agency...
  • Page 10 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 2 Agency...

  • Page 11: Product Description

    The CoolChip CDU100kW contains a secondary closed loop circuit that provides a supply of cooling fluid to IT equipment, either through indirect cooling (such as rack mounted rear door heat exchangers), or direct cooling (such as cold plates at chip level).

  • Page 12: Vertiv™ Coolchip Cdu100Kw Model Number Nomenclature

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 3.2 Vertiv™ CoolChip CDU100kW Model Number Nomenclature Table 3.1 CoolChip CDU100kW Model Number Digit Model Number Table 3.2 CoolChip CDU100kW Model Number Definitions Digit Feature Value Description 1,2,3 Family name Product family 4,5,6...

  • Page 13: Product Views

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 3.3 Product Views Figure 3.1 Front View of CoolChip CDU100kW (Top Cover Panel Removed) Item Description Plate heat exchanger Fill pump Temperature sensors Control board Alarm buzzer Dual Ethernet (RJ45) and USB connections...
  • Page 14 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 3.2 Rear View of Vertiv™ CoolChip CDU100kW (Top Cover Panel Removed) Item Description Cooling fans Pressure relief valve set at 3.5 bar/50 psi Pressure sensors Secondary flow meter Reservoir/secondary circuit vent Reservoir/secondary circuit drain...
  • Page 15 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 3.3 Rear View of Vertiv™ CoolChip CDU100kW (Electrical and Hose Connectiones) Item Description A and B 1-phase IEC—C14 power Inlet connections (factory provided fuses) Secondary circuit supply Connection for external temperature/humidity sensor external leak detection tape RS485 and CANbus communication...
  • Page 16 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 3 Product Description...

  • Page 17: Operation

    4.1 Controller Overview The Vertiv™ CoolChip CDU100kW controller is designed to monitor and control the supply of cooling fluid to IT equipment in unattended data center environments. Secondary circuit cooling fluid is closely controlled to a defined temperature and at a controlled differential pressure (or flow rate) for optimum heat management.
  • Page 18 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide NOTE: Some control system menus may not be visible if the user is not logged in. Visibility will also depend on the login access level used. The touchscreen display is intuitive and easily navigable. The touchscreen display has been designed to be intuitive and for easy navigation.

  • Page 19: Status Screen

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 4.2.3 Status Screen The Status screen displays comprehensive view only information on the operating condition of the Vertiv™ CoolChip CDU100kW unit. NOTE: Information is not given for options that have not been configured.
  • Page 20 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.1 Status Screen - Page 1 (continued) Item Value __°C __°C Secondary Return Temperature T4 __°C Table 4.2 Status Screen - Page 2 Item Value Primary Supply Temperature T1 __°C Primary Return Temperature T5 __°C...

  • Page 21: Data Curves Screen (Real Time Update)

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.4 Status Screen - Page 4 (continued) Item Value Controller Firmware Version 2.1b5 Serial Number CTCN_____ Controller Hardware Revision 5.xB SD Card Detect Present SD Card File System Status SD Card Used Space _.__%...

  • Page 22: Alarm Screen

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 4.4 Control System Data Curves Screen 4.2.5 Alarm Screen The Alarm screen can be used to view new or active alarms and to acknowledge these events. Refer to Troubleshooting Alarms on page 43 for a full list of alarms and further information.

  • Page 23: Login Screen

    Code xxxx (+Engineer Level) enter after Engineer Level code for Factory Setup. Figure 4.6 Control System Login Screen Login codes are available on request from the Vertiv. Entering an invalid code results in an Access Denied Message. 4 Operation Proprietary and Confidential ©2024 Vertiv Group Corp.

  • Page 24: Setup Screen

    Figure 4.7 Setup Screen NOTE: Information under Factory Configuration can be viewed with the service and engineer access codes. A separate code from Vertiv is required to change items under Factory Configuration. Table 4.6 Setup Screen - Factory Configuration Title...
  • Page 25 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.7 Setup Screen - Date and Time (Page 1) (continued) Title Description Default Range Unit P024 NTP Server IP Address IP address of the NTP Server 0.0.0.0 P025 Time Zone Offset Level Sensor response time,...
  • Page 26 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.11 Setup Screen - IP Connectivity (Interface A) (continued) Title Description Default Range Unit P054 Default Gateway Set gateway address 0.0.0.0 Configurable P055 Preferred DNS Server Set DNS address 0.0.0.0 Configurable P056...

  • Page 27: Configuration Screen

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.16 Setup Screen - Group Control Title Description Default Range Unit P081 CDU Address Unit address 1 to 4 P082 Number of CDUs in Group Number of CDUs in group 1 to 4...
  • Page 28 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.17 Configuration Screen - Filling Title Description Default Range Unit P101 Fill Pressure Start threshold for fill pump 0.3 to 1.0 P102 Fill Hysteresis Stop hysteresis for fill pump 0.1 to 0.5...
  • Page 29 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.20 Configuration Screen - Temperature Control (Page 1) Title Description Default Range Unit Temperature P301 Set required secondary temperature setpoint 45.0 10.0 to 55.0 °C Setpoint Select from Fixed Setpoint or fixed setpoint with dewpoint...
  • Page 30 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.22 Configuration - Primary Title Description Default Range Unit P401 Primary Flow Delay Time delay prior to low flow alarm 1 to 120 Seconds Primary Low P402 Temperature Low temp alarm threshold 2 to 40 °C...
  • Page 31 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.25 Configuration - Sensors Title Description Default Range Unit Secondary T2 P701 Temperature Alarm threshold T2a/b/c temperature differential 0.1 to 10 °C Differential Secondary T2 P702 Time delay before T2a/b/c differential alarm...

  • Page 32: Service Screen

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.27 Configuration - Miscellaneous (Page 1) (continued) Title Description Default Range Unit 0—60 Seconds Data Logging 1—30 Seconds P905 time interval between loggings Interval 2—10 Seconds 3—5 Seconds Temperature Alarm P906 Delay set to Alarms...
  • Page 33 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.29 Service - Fill Pump Request Screen Prompt Explanation This fill function is used at commissioning only and will allow the fill pump to run without any time limit. Fill pump will still switch off automatically when unit reaches required static pressure.
  • Page 34 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.34 Service - SD Card Title Description Default Range Unit File System Status Shows the status of the system Card Detect Shows the cards presence Present Used Space Shows the amount of space used by SD Card 0.59...

  • Page 35: Diagnostic Screen

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 4.2.10 Diagnostic Screen NOTE: This screen is only available after you are logged in. The Diagnostic Screen provides raw information and conversion factors for all Universal Inputs, Resistive Inputs, Digital Inputs, Digital Outputs, and Analog Outputs.
  • Page 36 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.38 I/O Diagnostics - Universal Inputs 9 to 14 (continued) Description ADC Value Electrical Processed UI12 Secondary Flow Rate 0.00 UI13 Control Valve Feedback 0.00 0.00 UI14 Primary Return Temperature T5 Ohms 0.00...

  • Page 37: Calibration Screen

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 4.2.11 Calibration Screen The touchscreen will enter calibration mode if the screen is pressed 20 times within a 4 second interval. To complete calibration follow the on screen instructions. Figure 4.11 Control System Calibration Screen 4.3 Automatic Operation...

  • Page 38: Secondary Circuit Operation

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 4.3.1 Secondary Circuit Operation When the ON button is pressed, the Start/Stop icon on the Home screen changes from red to green. When the fluid level and static pressure are healthy, either the pump starts to increase in speed, arrows are displayed on the Home screen for primary and secondary circuits to signify that the unit is operational.

  • Page 39: Static Pressure

    A16 - Insufficient fluid Level alarm will be triggered. This is a latched alarm and the system will not restart the unit until the event has been manually cleared. The system pressure at the Vertiv™ CoolChip CDU100kW inlet (PS1) is continuously monitored to ensure that the system is always pressurized. See Status Screen - Page 3 on page 16.
  • Page 40 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 4.15 Vertiv™ CoolChip CDU100kW Pressure and Level Flow Chart (Initial Startup) Proprietary and Confidential ©2024 Vertiv Group Corp. 4 Operation...
  • Page 41 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 4.16 Vertiv™ CoolChip CDU100kW Fill Pressure and Level Flow Charge (When Running) 4 Operation Proprietary and Confidential ©2024 Vertiv Group Corp.

  • Page 42: Flow Control

    DP control Monitors secondary differential pressure with sensors on the supply and return connections of CoolChip CDU100kW. During startup, the control loop increases the pump speed in stages until the DP matches the DP setpoint.
  • Page 43 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide • If any of the T2 temp. sensors go open circuit, then an A02 (A03 or A04) - T2a (T2b or T2c) Secondary Temperature Sensor Fault alarm will be raised (no time delay) and the controller will only read and average the two remaining healthy sensors.

  • Page 44: Temperature Control Loop Adjustment

    Primary flow rate is monitored with a calorimetric flow meter at the primary inlet to the CDU. The flow can be read on the Home screen or on page 2 of the Status screen. NOTE: The flow meter only reads the total primary flow through the Vertiv™ CoolChip CDU100kW unit. It does not monitor the flow rate through the heat exchanger.

  • Page 45: Pi Control

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 2. Increase the Proportional Band (Configuration - Temperature Control screen P308) to a higher value from the default of 12 °C (54 °F) to 20 °C (68 °F). 3. Check that the secondary supply temperature (T2) stabilizes.
  • Page 46 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 4.18 Control Screen Alarm Indication Figure 4.19 Control Screen Active Alarms The alarm descriptions may be accessed by selecting the vertical columns where the alarms appear (as shown in Figure 4.20 on the facing page).

  • Page 47: Troubleshooting Alarms

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 4.20 Control Screen Alarm identification Access the alarm descriptions by selecting the columns where the alarms appear. Some alarms self-clear if the condition is transient. For example, a temperature goes over an alarm threshold then comes back to a healthy condition or when a fault has been rectified such as when a faulty sensor has been replaced.
  • Page 48 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.42 Code Severity Classifications Code Description Sev. Self-clear Latching Shutdown Delay No display Detail Display not illuminated. Power failure on display board or controller I/O board. Action Open upper electrical panel door to check that 24 VDC is available at controller I/O board. If there are no LEDs showing on processor board then check I/O board 24 V fuse FS1.
  • Page 49 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.42 Code Severity Classifications (continued) Code Description Sev. Self-clear Latching Shutdown Delay PS2 Secondary Pressure Sensor Fault ü Detail Reading from Secondary supply pressure sensor PS3 is outside the normal range of -1 to 8 bar (-15 to 116 psi) and min/max values only will be displayed NOTE: For DP control, if system differential pressure PS1-PS2 is not valid, then pump speed will remain at last known demand.
  • Page 50 Action Check operation of control valve. Check chilled water supply flow rate. Ensure system heat load does not exceed the CoolChip CDU100kW capacity. Check that Primary flow is sufficient for heat load - refer to Vertiv™ CoolChip CDU100kW Application and Planning Guide SL- 71339.
  • Page 51 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.42 Code Severity Classifications (continued) Code Description Sev. Self-clear Latching Shutdown Delay Detail Leak tape in unit drip tray has detected a substantial water leak. Event may be set for Alarm Only (default), or Alarm + Unit Shutdown.
  • Page 52 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Table 4.42 Code Severity Classifications (continued) Code Description Sev. Self-clear Latching Shutdown Delay Level Sensor - No Water Detected ü Detail While Unit is Running only - if level sensor is open circuit for more than 1 second then this alarm will be raised, providing flow or DP (depending on control function set) is >50% of flow/DP setpoint.

  • Page 53: Temperature Sensor Graph

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide 4.7 Temperature Sensor Graph Figure 4.21 below may be used to check the validity of any of the temperature sensors used in the unit or the remote room sensor. Figure 4.21 Temperature Sensor Resistance Graph 4 Operation Proprietary and Confidential ©2024 Vertiv Group Corp.

  • Page 54: Group Control

    2 signal wires (CAN Hand CAN L) and a 1 signal return path. The CoolChip CDU100kW provides 2 CAN H, 2 CAN L and two ground terminals on sockets SK9, 1, 2 and 3 for In and terminals 4, 5 and 6 for Out.

  • Page 55: Group Control-Network Termination Resistors

    The CoolChip CDU100kW controller includes an onboard 120 ohm resistor which can be activated by fitting a hardware jumper. If only one CoolChip CDU100kW unit is installed, the resistor does not require activation. For a two unit installation, both units should have the termination resistors enabled. For three units and above, units 1 and n should have the termination resistors enabled, while units between should be disabled.
  • Page 56 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 4.25 CANbus Network Termination Resistors Item Description Units with termination enabled Units with termination disabled Figure 4.26 CANbus Network Termination Resistors Item Description Jumper fitted = Termination resistor activated Jumper not fitted = Termination resistor not activated Proprietary and Confidential ©2024 Vertiv Group Corp.

  • Page 57: Group Control-Network Addresses

    This can be changed to the differential pressure over all CoolChip CDU100kW in the group in Seh1p/Group Control/P094 regardless if they are running. All CoolChip CDU100kW units work in parallel and set their pump speeds to be identical with that of the lead CoolChip CDU100kW.

  • Page 58: Group Control-Failure Offset

    4.8.7 Group Control—Failure Offset Failure mode enable standby pumps to start in 75 ms and a 2 second ramp up when a CoolChip CDU100kW in the group is taken offline. This is to seamlessly maintain system differential pressure if a unit is lost without over/undershoots.
  • Page 59 In the event of a sensor failure, all sensors related to control (PS1, PS2 and T2) are redundant at the Vertiv™ CoolChip CDU100kW level, so a single sensor failure will not impact the operation or the status of the CoolChip CDU100kW. So, if the lead CoolChip CDU100kW does have a sensor failure it will not result in a change of lead.
  • Page 60 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 4 Operation...

  • Page 61: Maintenance

    Primary circuit The CoolChip CDU100kW is designed for use with a facility supply of plain water or up to 20% glycol/water. A 20% glycol concentration will give protection to approx. -9 °C (16 °F). If a higher concentration of glycol is used, then the cooling capacity of the unit may have to be de-rated (contact manufacturer for advice).

  • Page 62: Secondary Filter Service

    Take coolant sample and have tested for correct levels of inhibitors and biocides, if applicable Planned Maintenance services first 6 months (in addition to 3 month maintenance) • Simulate the CoolChip CDU100kW switch off, using backup CoolChip CDU100kW or parallel operation to meet the performance requirement •...

  • Page 63: Spare Parts

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Figure 5.1 Servicing Secondary Filter Item Description Secondary circuit vent point Secondary circuit drain point Remove retaining screws and withdraw filter from side of unit for cleaning NOTE: This will require sufficient flexibility in the primary and secondary hoses connections (valves or QCs) will need to be isolated and disconnected first.
  • Page 64 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 5 Maintenance...

  • Page 65: Appendices

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Appendices Appendix A: Technical Support and Contacts A.1 Technical Support/Service in the United States Vertiv Group Corporation 24x7 dispatch of technicians for all products. 1-800-543-2378 Liebert® Thermal Management Products 1-800-543-2378 Liebert® Channel Products 1-800-222-5877 Liebert®...
  • Page 66 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. Appendices...

  • Page 67: Appendix B: Piping Schematic

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Appendix B: Piping Schematic Figure B.1 Piping Schematic Proprietary and Confidential ©2024 Vertiv Group Corp.
  • Page 68 Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp.

  • Page 69: Appendix C: Notes

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Appendix C: Notes Proprietary and Confidential ©2024 Vertiv Group Corp.

  • Page 70: Appendix D: Disposal Information

    Vertiv™ CoolChip CDU100kW Operation and Maintenance Guide Appendix D: Disposal Information NOTE: Waste materials must be disposed of in a responsible manner in line with environmental regulations. Decommissioning and disposal of this product should be undertaken by qualified personnel in adherence to local and national safety regulations, particularly for protection of lungs, eyes, and skin from chemicals, dust.
  • Page 72 Vertiv.com | Vertiv Headquarters, 505 N Cleveland Ave, Westerville, OH 43082 USA ©2024 Vertiv Group Corp. All rights reserved. Vertiv™ and the Vertiv logo are trademarks or registered trademarks of Vertiv Group Corp. All other names and logos referred to are trade names, trademarks or registered trademarks of their respective owners. While every precaution has been taken to ensure accuracy and completeness here, Vertiv Group Corp.

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