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HP 403349-003 Maintenance And Service Manual

Modular cooling system
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Table of Contents
HP Modular Cooling System
Maintenance and Service Guide
Part Number 403349-003
October 2008 (Third Edition)

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  Summary of Contents for HP 403349-003

  • Page 1 HP Modular Cooling System Maintenance and Service Guide Part Number 403349-003 October 2008 (Third Edition)
  • Page 2 The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein.

  • Page 3: Table Of Contents

    Removing the rear automatic door release ... 41 Replacing the rear automatic door release ... 42 Bottom fan unit... 44 Removing the bottom fan unit ... 44 Replacing the bottom fan unit ... 45 Condensation pump and sensors... 47 Removing the condensation pump and sensors ... 47 Replacing the condensation pump and sensors...
  • Page 4 Replacing the heat exchanger unit with couplers... 63 Heat exchanger unit (HEX) with ball valve ... 67 Removing the heat exchanger unit with ball valves... 68 Replacing the heat exchanger unit with ball valves... 72 HEX coupling... 77 Removing the HEX coupling ... 78 Replacing the HEX coupling ...
  • Page 5 Water quality... 139 Condensation management ... 139 Frost damage... 139 Diagnostic tools ... 140 Troubleshooting ... 141 HP Modular Cooling System troubleshooting... 141 Specifications ... 142 MCS specifications... 142 Thermal and air flow performance ... 143 Environmental specifications ... 143 HP 10642 G2 Rack specifications...

  • Page 6: Customer Self Repair

    HP specifies in the materials shipped with a replacement CSR part whether a defective part must be returned to HP. In cases where it is required to return the defective part to HP, you must ship the defective part back to HP within a defined period of time, normally five (5) business days.
  • Page 7 HP sono realizzati con numerosi componenti che possono essere riparati direttamente dal cliente (CSR, Customer Self Repair). Se in fase di diagnostica HP (o un centro di servizi o di assistenza HP) identifica il guasto come riparabile mediante un ricambio CSR, HP lo spedirà direttamente al cliente per la sostituzione.
  • Page 8 La mancata restituzione del componente può comportare la fatturazione del ricambio da parte di HP. Nel caso di riparazione da parte del cliente, HP sostiene tutte le spese di spedizione e resa e sceglie il corriere/vettore da utilizzare.
  • Page 9 Dokumentation in der Verpackung zurückgeschickt werden, die im Lieferumfang enthalten ist. Wenn Sie das defekte Teil nicht zurückschicken, kann HP Ihnen das Ersatzteil in Rechnung stellen. Im Falle von Customer Self Repair kommt HP für alle Kosten für die Lieferung und Rücksendung auf und bestimmt den Kurier-/Frachtdienst.
  • Page 10 Si no enviara el componente defectuoso requerido, HP podrá cobrarle por el de sustitución. En el caso de todas sustituciones que lleve a cabo el cliente, HP se hará cargo de todos los gastos de envío y devolución de componentes y escogerá la empresa de transporte que se utilice para dicho servicio.
  • Page 11 Opcional – Peças cujo reparo feito pelo cliente é opcional. Essas peças também são projetadas para o reparo feito pelo cliente. No entanto, se desejar que a HP as substitua, pode haver ou não a cobrança de taxa adicional, dependendo do tipo de serviço de garantia destinado ao produto.
  • Page 12 HP fornece as peças de reposição sem cobrar nenhuma taxa. No caso desse serviço, a substituição de peças CSR é obrigatória. Se desejar que a HP substitua essas peças, serão cobradas as despesas de transporte e mão-de-obra do serviço.
  • Page 13 Customer self repair 13...
  • Page 14 Customer self repair 14...
  • Page 15 Customer self repair 15...
  • Page 16 Customer self repair 16...

  • Page 17: Illustrated Parts Catalog

    Illustrated parts catalog Replaceable spare parts The replaceable spare parts for the HP Modular Cooling System are listed in the following table. Item Description SPS–DISPLAY, OPERATOR display" on page 88) SPS–HEAT EXCHANGER unit (HEX) with coupler" on page 59) SPS–MCS, MGMT, MODULE ("Management...
  • Page 18 Optional—Parts for which customer self repair is optional. These parts are also designed for customer self repair. If, however, you require that HP replace them for you, there may or may not be additional charges, depending on the type of warranty service designated for your product.
  • Page 19 Optional: Opcional—Peças cujo reparo feito pelo cliente é opcional. Essas peças também são projetadas para o reparo feito pelo cliente. No entanto, se desejar que a HP as substitua, pode haver ou não a cobrança de taxa adicional, dependendo do tipo de serviço de garantia destinado ao produto.

  • Page 20: Flow Meter Repair

    Flow meter repair There are two different flow meter types, depending on your MCS model. You should be able to discern which type you have, based on the label on the rear door of your MCS unit. Illustrated parts catalog 20...
  • Page 21 The Type 1 flow meter has a round body, and is no longer used in current MCS models. The Type 2 flow meter has a square body and ships installed in all current MCS models. There are two scenarios when repairing your flow meter: •...

  • Page 22: Removal And Replacement Procedures

    Removal and replacement procedures Removal and replacement procedure overview This section provides guidance for removing and replacing the HP Modular Cooling System (MCS) spare parts. Follow the instructions carefully to ensure proper installation of the new spare part. IMPORTANT: retain the screws in a safe place and separate them according to their type.
  • Page 23 T-25 Torx driver Wire cutters • Condensation pump and sensors T-25 Torx driver Phillips screwdriver • Fan unit T-25 Torx driver • Flow meter paddle-wheel sensor T-25 Torx driver Wire cutters Water hose fitting wrench (included with your original MCS unit) Counter hold wrench (included with your original MCS unit) •...

  • Page 24: Safety Considerations

    5-mm Allen wrench • Water temperature sensor T-25 Torx driver Phillips screwdriver (2) 18-mm wrench Wire cutters Safety considerations Before performing service procedures, review the following safety information. Rack warnings and cautions Before installing a spare kit, be sure that you understand the following warnings and cautions. WARNING: preparation guide, the user guide, and the maintenance and service guide.

  • Page 25: Shutting Off The Water

    WARNING: Do not disable the power cord grounding plug. The grounding plug is an important safety • feature. Plug the power cord into a grounded (earthed) electrical outlet that is easily accessible at all • times. • Unplug the power cord from the power supply to disconnect power to the equipment. Do not route the power cord where it can be walked on or pinched by items placed against •...

  • Page 26: Ac Transfer Switch

    Confirm that no water is flowing into the MCS unit. AC transfer switch The AC transfer switch is located at the bottom front of the MCS unit. The following tools are required for installation: • T-25 Torx driver • Small Flathead screwdriver Removing the AC transfer switch Power down the MCS unit Open the front MCS door.
  • Page 27 Using a T-25 Torx driver, remove the four Torx screws securing the AC transfer switch chassis to the water group controller chassis. The transfer switch chassis cannot be completely removed yet because the cables are still connected. Disconnect the green and yellow ground bonding wires from the water group controller. Disconnect the electrical power cables from the rear of the AC transfer switch.

  • Page 28: Replacing The Ac Transfer Switch

    Disconnect the three large cables, starting from the left and moving to the right, by inserting a small flathead screwdriver in between the cable connection and the latch, and pulling the cable out from the connector. Disconnect the three small cables, starting from the left and moving to the right, by pressing the small tab on the bottom of each small cable and pulling it out from the connector.
  • Page 29 Connect the electrical power cables from the MCS unit to the AC transfer switch. Connect the three small cables, starting from the right and moving to the left, by pressing the tab on the bottom of each cable and pushing it into the connector. Removal and replacement procedures 29...
  • Page 30 Connect the three large cables, starting from the right and moving to the left, by pushing the cable into the connector. Using a T-25 Torx driver, secure the AC transfer switch chassis to the water group controller chassis by inserting four Torx screws. CAUTION: To prevent damage to the cables and ensure proper fit of the transfer switch chassis, be sure to route all cables through the U-shaped opening in the rear of the chassis.

  • Page 31: Air Bleeder Valve

    Counter hold wrench (included with your original MCS unit) Removing the air bleeder valve Shut off the water flowing into the MCS unit. Remove the top fan unit. Remove the top heat exchanger unit. ("Shutting off the ("Removing the fan unit"...

  • Page 32: Replacing The Air Bleeder Valve

    Reach into the access panel cut-out. Using a pair of pliers, unscrew the air bleeder valve from the check valve. Remove the air bleeder valve from the MCS unit. To replace this component, see "Replacing the air bleeder valve (on page 32)." Replacing the air bleeder valve Reach into the access panel cut-out and align the air bleeder valve to the check valve.

  • Page 33: Air Deflector Plate

    Slightly open the top vent of the air bleeder valve, approximately 3/4 turn, to allow for air flow. Replace the top heat exchanger unit. Replace the top fan unit. Restore water flow to the MCS unit. Complete the operation checklist (on page 111).

  • Page 34: Replacing The Air Deflector Plate

    Lift the air deflector plate up, tilt it to an angle, and pull it out toward you. To replace this component, see "Replacing the air deflector plate (on page 34)." Replacing the air deflector plate Reattach the ground bonding wires to the air deflector plate. Align the two screw holes on the air deflector plate to the two screw holes inside the MCS unit.

  • Page 35: Removing The Air Sealing Plate

    No tools are required for this procedure. Removing the air sealing plate Disconnect the condensation hose from the condensation pump by pressing in the plastic collar quick connect on the condensation pump. Loosen the two thumbscrews securing the air sealing plate to the MCS unit. Removal and replacement procedures 35...

  • Page 36: Replacing The Air Sealing Plate

    Slide the air sealing plate out of the MCS unit. To replace this component, see "Replacing the air sealing plate (on page 36)." Replacing the air sealing plate Slide the air sealing plate into the MCS unit. Removal and replacement procedures 36...
  • Page 37 Secure the air sealing plate to the MCS unit by tightening the two thumbscrews. Connect the condensation hose to the condensation pump by inserting it into the plastic collar quick connect on the condensation pump. Removal and replacement procedures 37...

  • Page 38: Automatic Door Release

    Automatic door release The automatic door release kits are located on the front and rear doors of the rack attached to the MCS unit. The following tools are required for installation: • 3-mm Allen wrench • T-25 Torx driver • Wire cutters Removing the front automatic door release Unplug the electromagnetic lock cable from the panel connector on the MCS unit.

  • Page 39: Replacing The Front Automatic Door Release

    Using an Allen wrench, remove the two black cap screws securing the electromagnetic lock to the electromagnetic lock bracket. Remove the electromagnetic lock and cable from the rack. To replace this component, see "Replacing the front automatic door release (on page 39)." Replacing the front automatic door release Align the electromagnetic lock to the electromagnetic lock bracket.
  • Page 40 Route the magnetic lock cable down through front extension channel, across the front of the rack, and plug it into the panel connector on the MCS unit. Removal and replacement procedures 40...

  • Page 41: Removing The Rear Automatic Door Release

    Removing the rear automatic door release Unplug the top and bottom electromagnetic lock cables from the extension lock cable. NOTE: Be sure to note the location of the electromagnetic brackets prior to removal. Removal and replacement procedures 41...

  • Page 42: Replacing The Rear Automatic Door Release

    Using a T-25 Torx driver, remove the four screws securing the upper and lower electromagnetic lock brackets to the rack chassis. Using an Allen wrench, remove the two black cap screws securing each electromagnetic lock to its electromagnetic lock bracket. Remove the electromagnetic locks and cables from the rack.
  • Page 43 Using an Allen wrench, insert and tighten two black cap screws to secure each electromagnetic lock to its electromagnetic lock bracket. Install the top electromagnetic lock bracket to the rack chassis in the location you noted during removal. Align the electromagnetic lock assembly to the rack chassis in the location you noted during removal.

  • Page 44: Bottom Fan Unit

    MCS unit. Bottom fan unit The removal and replacement instructions for the bottom fan unit are provided so that you can access other components. If you are replacing the fan unit, see Fan unit (on page 50).

  • Page 45: Replacing The Bottom Fan Unit

    CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when removing and replacing the top fan unit because it might be higher than your shoulders and is heavy and awkward to lift. Pull the fan unit out toward you, and remove it from the MCS unit.
  • Page 46 Slide the bottom fan unit inside the MCS unit on the sliding rails. Tighten the two thumbscrews to secure the fan unit to the MCS frame. Removal and replacement procedures 46...

  • Page 47: Condensation Pump And Sensors

    T-25 Torx driver • Phillips screwdriver Removing the condensation pump and sensors Power down the MCS unit Remove the bottom fan unit Relocate the power inlet box Remove the air sealing plate ("Powering down the MCS unit" on page 24).
  • Page 48 Disconnect the AC power cable from the condensation pump. Disconnect the two sensor connections from the condensation pump. Removal and replacement procedures 48...

  • Page 49: Replacing The Condensation Pump And Sensors

    Loosen the thumbscrew on the bottom of the condensation pump securing the condensation pump to the MCS unit (1), and lift the condensation pump from the MCS unit (2). To replace the component, see "Replacing the condensation pump and sensors (on page 49)." Replacing the condensation pump and sensors Align the condensation pump thumbscrew to the hole inside the MCS unit (1), and tighten the thumbscrew on the bottom of the condensation pump to secure it to the MCS unit (2).

  • Page 50: Fan Unit

    Replace the bottom fan unit Complete the operation checklist (on page 111). Fan unit The three fan units are located at the rear of the MCS unit. ("Replacing the air sealing plate" on page 36). ("Relocating the power inlet box back into ("Replacing the bottom fan...

  • Page 51: Removing The Fan Unit

    Open the rear MCS door. NOTE: The number of horizontal brackets varies depending on the position of the fan unit (top, middle, or bottom). Using a T-25 Torx driver, remove the four Torx screws securing the horizontal shipping bracket to the MCS frame.

  • Page 52: Replacing The Fan Unit

    CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when removing and replacing the top fan unit because it might be higher than your shoulders and is heavy and awkward to lift. Pull the fan unit out toward you, and remove it from the MCS unit.
  • Page 53 Slide the fan unit onto the sliding rails inside the MCS unit. Tighten the two thumbscrews to secure the fan unit to the MCS frame. NOTE: The number of horizontal brackets varies depending on the position of the fan unit (top, middle, or bottom). Removal and replacement procedures 53...

  • Page 54: Flow Meter Sensor

    Counter hold wrench (included with your original MCS Unit) Removing the flow meter paddle-wheel sensor Power down the MCS unit. Shut off the water flowing into the MCS unit. Remove the bottom fan unit. ("Powering down the MCS unit" on page 24) ("Shutting off the ("Removing the bottom fan...
  • Page 55 Relocate the power inlet box. Remove the air sealing plate. Remove the air deflector plate. Remove the condensation pump and sensors. page 47) Remove the AC transfer switch. Remove the plastic lock washer from above the paddle-wheel sensor. Unscrew the plastic screw cap securing the paddle-wheel sensor to the flow meter. Lift the paddle-wheel sensor up and off the flow meter.
  • Page 56 Using the wire cutters, cut the cable connected to the paddle-wheel sensor and remove the sensor from the MCS unit. Disconnect the paddle-wheel sensor cable connector, labeled X14, from the water group controller and pull the cable completely out of the MCS unit. To replace this component, see "Replacing the flow meter paddle-wheel sensor (on page 57)."...

  • Page 57: Replacing The Flow Meter Paddle-Wheel Sensor

    Replacing the flow meter paddle-wheel sensor Insert the keyed paddle-wheel sensor into the top of the flow meter. Screw on the plastic screw cap to secure the paddle-wheel sensor to the flow meter. Removal and replacement procedures 57...
  • Page 58 Replace the AC transfer switch Replace the condensation pump and sensors page 49). Replace the air deflector plate Replace the bottom fan unit ("Replacing the bottom fan Restore water flow to the MCS unit Complete the operation checklist (on page 111).

  • Page 59: Heat Exchanger Unit (Hex) With Coupler

    Counter hold wrench (included with your original MCS unit) Removing the heat exchanger unit with couplers NOTE: For this procedure, remove the fan unit seated directly behind the heat exchanger unit you will remove. Remove the fan unit Remove the air deflector plate NOTE: The heat exchanger units are deep-seated within the MCS unit.
  • Page 60 Disconnect the temperature sensor connector from the heat exchanger unit. Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to loosen the water hose (both wrenches are included with your original MCS unit), disconnect the In and Out water hoses from the heat exchanger unit.
  • Page 61 Disconnect the condensation hose from the heat exchanger unit. Disconnect the green and yellow ground bonding wire grounding the heat exchanger unit to the MCS unit. Open the front MCS door. Keep the Torx screws separated according to their thread type and note which IMPORTANT: thread type came from which hole location on the shipping bracket.
  • Page 62 Remove the heat exchanger unit shipping brackets from the MCS unit (3). CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water. Use extra caution when removing and replacing the top heat exchanger unit because it might be higher than your shoulders and is heavy and awkward to lift.

  • Page 63: Replacing The Heat Exchanger Unit With Couplers

    Pull the heat exchanger unit out toward you. To replace this component, see "Replacing the heat exchanger unit with couplers" on page 63)." Replacing the heat exchanger unit with couplers CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water.
  • Page 64 Insert the new heat exchanger unit into the same position as the heat exchanger unit you removed. IMPORTANT: Keep the Torx screws separated according to their thread type and note which thread type came from which hole location on the shipping bracket. Install the two heat exchanger unit shipping brackets.
  • Page 65 Using a T-25 Torx driver, secure the two shipping brackets to the MCS frame by inserting and tightening four Torx screws (3). Open the rear MCS door. Removal and replacement procedures 65...
  • Page 66 Connect the green and yellow ground bonding wire to the heat exchanger unit. Connect the condensation hose to the heat exchanger unit. Removal and replacement procedures 66...

  • Page 67: Heat Exchanger Unit (Hex) With Ball Valve

    Connect the temperature sensor connector to the heat exchanger unit. Replace the air deflector plate Replace the fan unit Complete the operation checklist (on page 111). Heat exchanger unit (HEX) with ball valve The three heat exchanger units are located on the front of the MCS unit.

  • Page 68: Removing The Heat Exchanger Unit With Ball Valves

    Adjustable wrench or pipe wrench Removing the heat exchanger unit with ball valves NOTE: For this procedure, remove the fan unit seated directly behind the heat exchanger unit you will remove. Remove the fan unit Remove the air deflector plate NOTE: The heat exchanger units are deep-seated within the MCS unit.
  • Page 69 Disconnect the condensation hose from the HEX unit. Disconnect the green and yellow ground bonding wire grounding the HEX unit to the MCS unit. Close the two ball valves inside the HEX unit. Removal and replacement procedures 69...
  • Page 70 Close the two ball valves on the hose assemblies attached to the HEX unit. Using and adjustable wrench or a pipe wrench, disconnect the two ball valve hose assemblies from the HEX unit. Wipe up any excess water from the hoses. Open the front MCS door.
  • Page 71 Remove the HEX unit shipping brackets from the MCS unit (3). CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water. Use extra caution when removing and replacing the top heat exchanger unit because it might be higher than your shoulders and is heavy and awkward to lift.

  • Page 72: Replacing The Heat Exchanger Unit With Ball Valves

    Pull the HEX unit out toward you. To replace this component, see "Replacing the heat exchanger unit with ball valves (on page 72)." Replacing the heat exchanger unit with ball valves CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water.
  • Page 73 Insert the new HEX unit into the same position as the HEX unit you removed. IMPORTANT: Keep the Torx screws separated according to their thread type and note which thread type came from which hole location on the shipping bracket. Install the two HEX unit shipping brackets.
  • Page 74 Using a T-25 Torx driver, secure the two HEX unit shipping brackets to the MCS frame by inserting and tightening four Torx screws (3). Open the rear MCS door. Removal and replacement procedures 74...
  • Page 75 Connect the green and yellow ground bonding wire to the HEX unit. Connect the condensation hose to the HEX unit. Removal and replacement procedures 75...
  • Page 76 Using an adjustable wrench or a pipe wrench, connect the two ball valve hose assemblies to the HEX unit. Connect the temperature sensor connector to the HEX unit. Open the ball valves inside the HEX unit. Removal and replacement procedures 76...

  • Page 77: Hex Coupling

    Replace the hose insulation over the couplers. Replace the air deflector plate Replace the fan unit Complete the operation checklist (on page 111). HEX coupling The three HEX couplings are located at the rear of each HEX unit iinside the MCS unit.

  • Page 78: Removing The Hex Coupling

    Removing the HEX coupling Shut off the water flowing into the MCS unit. Remove the corresponding fan unit. Remove the corresponding air deflector plate. Disconnect the temperature sensor cable from the heat exchanger unit. Slide back the insulation on either the In or Out water hose.
  • Page 79 Using a flathead screwdriver, loosen the hose from the HEX coupling. Using a utility knife, carefully trim approximately 0.64 cm (0.25 in) off the water hose. Removal and replacement procedures 79...

  • Page 80: Replacing The Hex Coupling

    Remove the HEX coupling from the water hose. To replace this component, see "Replacing the HEX coupling (on page 80)." Replacing the HEX coupling Insert the HEX coupling into the water hose. Removal and replacement procedures 80...
  • Page 81 Using a flathead screwdriver, tighten the hose clamp. Connect the HEX coupling to the heat exchanger unit. Using the water hose fitting wrench and the counter hold wrench, reconnect the appropriate In or Out water hose to the heat exchanger unit. Confirm that the HEX coupling is fully engaged between the heat exchanger bulkhead and the coupling nut.

  • Page 82: Magnetic Solenoid Valve

    Slide the insulation back in place on the In or Out water hose up against the coupling. Replace the air deflector plate Replace the fan unit Restore water flow to the MCS unit Complete the operation checklist (on page 111).
  • Page 83 Remove the bottom fan unit ("Removing the bottom fan Remove the air deflector plate Adjust the water hoses connected to the rear of the bottom heat exchanger unit and hold them out of the way to reach the magnetic solenoid on the valve. This process can be difficult. If you struggle excessively, disconnect the In and Out water hoses on the back of the bottom heat exchanger unit using the counter hold wrench and the water hose fitting wrench.

  • Page 84: Replacing The Magnetic Solenoid Valve

    Place the magnetic solenoid back on the valve post (1), and press down until the silver retainer tab locks the magnetic solenoid in place on the valve (2). Replace the air deflector plate Replace the bottom fan unit Complete the operation checklist (on page 111). ("Replacing the air deflector plate"...

  • Page 85: Management Module

    Management module The management module is located on the inside of the front door of the MCS unit. No tools are required for this procedure. Removing the management module Power down the MCS unit Open the front MCS door. Disconnect the electrical cables from the management module. ("Powering down the MCS unit"...

  • Page 86: Replacing The Management Module

    Slide the management module off of the mounting bracket, and remove it from the inside of the front MCS door. To replace this component, see "Replacing the management module (on page 86)." Replacing the management module Slide the management module onto the mounting bracket until it locks in place. CAUTION: To avoid damage to the management module connectors, do not allow the cables to pull on the management module connectors.
  • Page 87 Connect the electrical cables from the MCS unit to the management module. Power on the management module. Press and hold the C key for five seconds to confirm the configuration settings. Complete the operation checklist (on page 111). Removal and replacement procedures 87...

  • Page 88: Operator Display

    Operator display The operator display is located on the front door of the MCS unit. The following tools are required for installation: • 8-mm socket • Small Flathead screwdriver Removing the operator display Power down the MCS unit Open the front MCS door. Using an 8 mm socket or wrench, remove the three nuts and external star washers securing the operator display rear cover to the back of the front MCS door.
  • Page 89 Disconnect the connector between the operator display and the display button. Disconnect the connector from the management module (1), and pull the cable up through the cable management hose (2). Squeeze the four release tabs on the top and bottom of the operator display (1), and push the operator display from the back to the front through the front MCS door (2).
  • Page 90 Remove the display button by squeezing the two release tabs on the sides of the display button (1) and pushing the display button from the back to the front through the front MCS door (2). To replace this component, see "Replacing the operator display (on page 91)." Removal and replacement procedures 90...

  • Page 91: Replacing The Operator Display

    Replacing the operator display Hold the four release tabs while pushing the operator display from the front to the back through the front MCS door. Hold the two release tabs while pushing the display button from the front to the back through the front MCS door.
  • Page 92 Push the cable down through the cable management hose (1), and connect it to the management module connector (2). Connect the connector between the operator display and display button. Slide any extra slack in the cable lines up into the operator display rear cover, and secure by inserting the rubber grommet into the designated notch on the operator display rear cover.

  • Page 93: Power Inlet Box

    Using an 8 mm socket or wrench, secure the operator display rear cover to the back of the operator display by inserting three nuts and external star washers. Complete the operation checklist (on page 111). Power inlet box The power inlet box is not a spare part. The relocation instructions for the power inlet box are provided so that you can access other components.
  • Page 94 Lift the right side of the bracket up at a slant, and pull the bracket out of the MCS unit (2). IMPORTANT: Do not disconnect any of the internal electrical connections to the power inlet box. Pull the power inlet box toward you until it stops. Removal and replacement procedures 94...

  • Page 95: Relocating The Power Inlet Box Back Into Position

    Set the power inlet box aside in the side cavity by lifting the right side of the power inlet box up until the box sits vertically on the left side of the MCS unit. To replace this component, see "Relocating the power inlet box back into position (on page 95)." Relocating the power inlet box back into position Lower the right side of the power inlet box until it is back into the horizontal position.
  • Page 96 Push the power inlet box back into the MCS unit until it locks in place. Replace the outer support bracket. Lift the right side of the bracket up at a slant, and slide the bracket into the MCS unit. Tighten the four thumbscrews to secure the outer bracket to the MCS unit. Connect the green and yellow ground bonding wire to ground the outer support bracket to the MCS unit.

  • Page 97: Water Group Controller

    Water group controller The water group controller is located at the bottom front of the MCS unit. The following tools are required for installation: • T-25 Torx driver • Flathead screwdriver • 8-mm socket Removing the water group controller Power down the MCS unit Remove the AC transfer switch Disconnect the seven electrical cables in the front of the water group controller.
  • Page 98 Using an 8 mm socket, remove the two 8 mm nuts and washers securing the water group controller bracket to the water group controller chassis. Disconnect the two large electrical cables from the back of the water group controller. Disconnect the green and yellow grounding wire securing the water group controller to the water group controller chassis.
  • Page 99 Remove the water group controller (mounted on a bracket) from the water group controller chassis. Slide the water group controller off of the mounting bracket. To replace this component, see "Replacing the water group controller (on page 100)." Removal and replacement procedures 99...

  • Page 100: Replacing The Water Group Controller

    Replacing the water group controller Slide the water group controller onto the mounting bracket until it locks in place. Connect the green and yellow grounding wire to secure the water group controller to the water group controller chassis. Connect the two large electrical cables to the back of the water group controller. Removal and replacement procedures 100...
  • Page 101 Place the water group controller (mounted on the bracket) in the water group controller chassis. Using an 8 mm socket, secure the water group controller bracket to the water group controller chassis by inserting two washers and two 8 mm nuts. Removal and replacement procedures 101...

  • Page 102: Water Inlet Coupling

    Connect the seven electrical cables to the front of the water group controller. Replace the AC transfer switch Complete the operation checklist (on page 111). Water inlet coupling The water inlet coupling is located on the inlet water hose connected to the MCS unit. The following tools are required for installation: •...
  • Page 103 Using a pipe wrench, loosen the water inlet coupling and disconnect the water inlet hose from the supply hose. Using an Allen wrench, remove the four Allen nuts and bolts securing the two brackets to the water inlet hose. Removal and replacement procedures 103...
  • Page 104 Remove the two brackets from around the water inlet hose. IMPORTANT: Water will drain out of the hose when you remove the coupling. Be prepared to catch excess water drainage in a bucket or floor drain. Remove the water inlet coupling from the water inlet hose. To replace this component, see "Replacing the water inlet coupling (on page 105)."...

  • Page 105: Replacing The Water Inlet Coupling

    Replacing the water inlet coupling Insert the water inlet coupling into the water inlet hose. Align the two brackets around the water inlet hose. Using an Allen wrench, insert and tighten three 40-mm Allen nuts and bolts into three of the four screw holes.
  • Page 106 Using an Allen wrench, insert and tighten one of the original Allen nuts and bolts into the remaining screw hole. Compress completely. One by one, replace the three 40-mm Allen nuts and bolts with the original Allen nuts and bolts, until the brackets are firmly compressed around the water inlet hose.

  • Page 107: Water Temperature Sensor

    47) Remove the AC transfer switch. NOTE: HP recommends removing the In and Out water hoses and all cables to the bottom heat exchanger unit in order to gain greater access. ("Powering down the MCS unit" on page 24) ("Shutting off the...
  • Page 108 Using two 18-mm wrenches, loosen the cap nut from the water temperature sensor. Using the wire cutters, cut the cable connected to the water temperature sensor, and remove the water temperature probe and cable from the MCS unit. Disconnect the appropriate water temperature sensor cable connector from the water group controller and pull the cable completely out of the MCS unit.

  • Page 109: Replacing The Water Temperature Sensor

    Disconnect the X13 cable connector if you are repairing the outlet water temperature sensor. To replace this component, see "Replacing the water temperature sensor." Replacing the water temperature sensor Insert the new water temperature sensor probe into the appropriate water line. Place the cap nut over the water temperature sensor.
  • Page 110 Replace the air deflector plate Replace the air sealing plate Relocate the power inlet box back into position on page 95). Replace the bottom fan unit ("Replacing the bottom fan Restore water flow to the MCS unit Complete the operation checklist (on page 111).

  • Page 111: Operation Checklist

    Operation checklist If you disconnected the power, restore power to the MCS unit page 111). If you shut off the water flowing into the MCS, restore water flow to the MCS unit flow" on page 112). Clear all old logs from the web interface to ensure that any additional alarms are current. Confirm that no additional warning or alarm messages have been detected by looking at the operator display.

  • Page 112: Restoring Water Flow

    Connect the two AC power cables to the power connectors on the power inlet box. Open the front MCS door. Turn on the AC1 breaker on the AC transfer switch. Turn on the AC2 breaker on the AC transfer switch. Restoring water flow If water was disconnected, restore water flow to the MCS unit at the facility-side valve.

  • Page 113: Technician Repair Removal And Replacement Procedures

    The customer can order the miscellaneous hardware kit, but it will be delivered by a trained HP service technician, who will then install the new spare kit by following the removal and replacement instructions in this chapter.

  • Page 114: Technician Repair Required Tools

    *Only the diaphragm and spring are shown, though the entire magnetic valve ships in the kit. **The removal and replacement instructions for this component are not included in this document. Technician repair required tools The following tools are required for the removal and replacement instructions for each component included in the miscellaneous hardware kit: •...
  • Page 115 This procedure is specifically for the removal of the Type 1 flow meter. Power down the MCS unit ("Powering down the MCS Shut off the water flowing into the MCS unit Remove the bottom fan unit ("Removing the bottom fan Relocate the power inlet box Remove the condensation pump and sensors page 47).
  • Page 116 Remove the flow meter from the water line. Remove the two fiber gaskets on either side of the water line. Technician repair removal and replacement procedures 116...

  • Page 117: Replacing The Flow Meter

    Disconnect the threaded pick-up at the top of the flow meter and pull the flow meter out of the MCS unit. Remove the threaded pick-up and cable from the MCS unit, and disconnect from the connector labeled X14 on the water group controller. To replace this component, see "Replacing the flow meter (on page 117)."...

  • Page 118: Magnetic Valve

    Replace the condensation pump and sensors page 49). Relocate the power inlet box back into position on page 95). Replace the bottom fan unit Restore water flow to the MCS unit Complete the operation checklist (on page 111). Magnetic valve The magnetic valve is a component of the water group located at the bottom interior of the MCS unit.
  • Page 119 Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to loosen the water hose (both wrenches included with your original MCS unit), disconnect the In and Out water hoses from the bottom heat exchanger unit. Remove the magnetic solenoid valve Using an 8 mm Allen wrench, remove the four socket screws securing the cover of the magnetic valve.

  • Page 120: Replacing The Magnetic Valve Diaphragm And Spring

    Remove the cover from the magnetic valve. Remove the diaphragm and spring from the magnetic valve. To replace this component, see "Replacing the magnetic valve diaphragm and spring (on page 120)." Replacing the magnetic valve diaphragm and spring NOTE: When you replace the diaphragm inside the magnetic valve, be sure to line up the tab of the diaphragm with the indentation of the magnetic valve.
  • Page 121 Place the diaphragm and spring on the magnetic valve. Place the cover on the magnetic valve. Technician repair removal and replacement procedures 121...
  • Page 122 Replace the air deflector plate Relocate the power inlet box back into position on page 95). Replace the bottom fan unit ("Replacing the bottom fan Reconnect the main water lines. Complete the operation checklist (on page 111).

  • Page 123: Upgrading Procedures

    Upgrading procedures Viewing the upgrade procedures video Because of the difficulty of removing and replacing spare parts, HP recommends watching the HP Modular Cooling System Spare Replacement video. This video provides further explanation and detail of replacement strategies and techniques that might be helpful when attempting to remove and replace spare parts.
  • Page 124 Using a T-25 Torx driver, remove the three screws on each side of the bottom cover plate and remove the bottom cover plate from the HEX unit. Using a flathead screwdriver, push in the tabs of the white electrical connector of the temperature sensor and push the connector into the HEX unit.
  • Page 125 Using a flathead screwdriver, loosen the hose clamps attaching the condensation drain hose to the quick disconnect on the HEX unit face plate. NOTE: You might need to cut the condensation drain hose to remove it from the barbs. Remove the condensation drain hose from both barbs. NOTE: Depending on the style of the hose barb, you might need to remove the hose barb before you remove the quick disconnect.
  • Page 126 Using a small pipe wrench, loosen the nut attaching the HEX unit copper pipe to each of the ball valve assemblies. Using a T-25 Torx driver, remove the four screws securing the coupler face plate to the HEX unit. Upgrading procedures 126...
  • Page 127 Remove the coupler faceplate and hose couplers as a single assembly. Remove the O-ring from each pipe and verify that the pipe is clean. To replace this component, see "Replacing the HEX coupler (on page 128)." Upgrading procedures 127...

  • Page 128: Replacing The Hex Coupler

    Replacing the HEX coupler Install one O-ring on to each HEX unit pipe. Install each ball valve assembly to the HEX unit tubing, positioning the handles down. Loosely attach the HEX unit pipe nut to the ball valve assembly, barely connecting the threads. Upgrading procedures 128...
  • Page 129 Align the first faceplate (faceplate with eight side holes) to the ball valve assemblies, and slide the faceplate over the ball valve assemblies. Align the second faceplate (faceplate with round holes) to the ball valve assemblies and slide the faceplate over the ball valve assemblies. Upgrading procedures 129...
  • Page 130 Using a T-25 Torx driver, install four screws to secure the faceplate. NOTE: Do not overtighten the fittings. The gasket needs only a slight compression to seal the fitting. Using a small pipe wrench, tighten the fitting that connects the HEX unit copper pipe to the ball valve.
  • Page 131 Using an adjustable wrench, insert the quick disconnect for the drain hose in to the HEX unit. TIP: Use a light lubrication spray to ease installation of the hose barbs and hose clamps to hold the condensation drain line in place while working. Connect the condensation drain line between the quick disconnect hose barb and the HEX unit hose barb.

  • Page 132: Upgrading The Hex Hose Coupler

    • T-25 Torx driver Removing the HEX hose coupler NOTE: For this procedure, remove the fan unit seated directly behind the heat exchanger unit you will remove. Remove the fan unit Remove the air deflector plate Remove the heat exchanger unit...
  • Page 133 Insert the washer inside the hose union fitting of the hose assembly. Hand-tighten the union fitting on the assembly, aligning the compression washer to the HEX unit. NOTE: Do not overtighten the fittings. The gasket needs only a slight compression to seal the fitting.
  • Page 134 Using an adjustable wrench, tighten the union fitting 1/8 flat. Insert the HEX unit in to the MCS unit. Upgrading procedures 134...
  • Page 135 Connect the right-side ball valve hose to the left-side MCS return hose. Connect the left-side ball valve hose to the right-side MCS return hose. The hoses create a criss-cross pattern. Cut the hose attached to the old coupler the same length of the replacement hose, and insert the hose barb from the HEX unit into the hose.
  • Page 136 Insert the barbed-end of the hose from the new ball valve assembly attached to the HEX unit into the hose you clamped in step 10. Tighten the hose clamp. Slide the insulation back over the hose and secure with tie wraps. Repeat steps 7 through 13 for the other HEX unit hose.
  • Page 137 Using a T-25 Torx driver, insert and tighten four Torx screws to the MCS frame (3). Connect the green and yellow ground bonding wire to the HEX unit. Upgrading procedures 137...
  • Page 138 Connect the condensation hose to the HEX unit. Connect the temperature sensor cable to the HEX unit. Replace the air deflector plate Replace the fan unit ("Replacing the fan Complete the operation checklist (on page 111). ("Replacing the air deflector plate"...

  • Page 139: Maintenance

    CAUTION: Damage caused by water that does not meet the HP Modular Cooling System water quality requirements is not covered by MCS warranty. For specific guidelines concerning water quality, see the HP Modular Cooling System Site Preparation Guide. Condensation management Any condensation that forms is collected in each individual cooling module and is taken through a discharge tube to a condensation tray integrated in the base assembly.

  • Page 140: Diagnostic Tools

    (condensation formation). Diagnostic tools For a complete list of the warning and alarm messages displayed on the operator display and the web interface, see the HP Modular Cooling System User Guide, included with your original MCS unit. Maintenance 140...

  • Page 141: Troubleshooting

    Resolution For more information, see the "Temperature Control settings" section in the HP Modular Cooling System Web Interface User Guide located on the Documentation CD included with this product. For more information, see the "Cooling performance parameters" section in the HP Modular Cooling System Web Interface User Guide located on the Documentation CD included with this product.

  • Page 142: Specifications

    Specifications MCS specifications Item Voltage Maximum Height (including the rack) Maximum Width (including the rack) Maximum Depth (including the rack and rack handle) Maximum Shipping Height (on skid) Maximum Shipping Width (on skid) Maximum Shipping Depth (on skid) Maximum Depth with Rear Extension Kit installed Net Weight (including...

  • Page 143: Thermal And Air Flow Performance

    Non-operating temperature Transit temperature Storage temperature Operating humidity Non-operating humidity Operating altitude Non-operating altitude HP 10642 G2 Rack specifications U height Width 600 mm (23.82 in) Specifications 25ºC (68ºF) 7º–10°C (45º–50°F) 2,600 cfm or less at 0 or more pressure drop...

  • Page 144: Acronyms And Abbreviations

    Acronyms and abbreviations Customer Self Repair heat exchanger modular cooling system spare part Acronyms and abbreviations 144...

  • Page 145: Index

    CSR (customer self repair) 6 customer self repair (CSR) 6 diagnostic tools 140, 141 environmental specifications 143 fan unit 44, 45, 50, 51, 52 flow meter 114 flow meter sensor 54, 57 HEX coupler 123 HEX coupling 77, 78, 80...
  • Page 146 replacing the front automatic door release 39 replacing the HEX coupling 80 Replacing the HEX unit with ball valve 72 Replacing the HEX unit with coupler 63 replacing the magnetic solenoid valve 84 replacing the magnetic valve diaphragm and spring 120 replacing the management module 86 replacing the operator display 91 replacing the rear automatic door release 42...

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