Black Box CRCW-12 User Manual
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Black Box CRCW-12 User Manual

Black Box CRCW-12 User Manual

Cold row chilled water (cw)
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Cold Row
This precision data center air-conditioning system
uses the latest, state-of-the-art control technology.
Customer
Support
Information
Chilled Water (CW) User Manual
™
Order toll-free in the U.S.: Call 877-877-BBOX (outside U.S. call 724-746-5500)
FREE technical support 24 hours a day, 7 days a week: Call 724-746-5500 or fax 724-746-0746
Mailing address: Black Box Corporation, 1000 Park Drive, Lawrence, PA 15055-1018
Web site: www.blackbox.com • E-mail: info@blackbox.com
BLACK BOX
CRCW-12
CRCW-24
®

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Summary of Contents for Black Box CRCW-12

  • Page 1 Order toll-free in the U.S.: Call 877-877-BBOX (outside U.S. call 724-746-5500) Customer FREE technical support 24 hours a day, 7 days a week: Call 724-746-5500 or fax 724-746-0746 Support Mailing address: Black Box Corporation, 1000 Park Drive, Lawrence, PA 15055-1018 Information Web site: www.blackbox.com • E-mail: info@blackbox.com...
  • Page 2 Trademarks Used in this Manual Trademarks Used in this Manual Black Box and the Double Diamond logo are registered trademarks, and Cold Row is a trademark, of BB Technologies, Inc. Schrader is a registered trademark of Schrader-Bridgeport International, Inc. Teflon is a registered trademark of E.I. du Pont de Nemours & Co.
  • Page 3 FCC and IC RFI Statements Federal Communications Commission and Industry Canada Radio Frequency Interference Statements This equipment generates, uses, and can radiate radio-frequency energy, and if not installed and used properly, that is, in strict accordance with the manufacturer’s instructions, may cause inter ference to radio communication. It has been tested and found to comply with the limits for a Class A computing device in accordance with the specifications in Subpart B of Part 15 of FCC rules, which are designed to provide reasonable protection against such interference when the equipment is operated in a commercial environment.

  • Page 4: Instrucciones De Seguridad

    NOM Statement Instrucciones de Seguridad (Normas Oficiales Mexicanas Electrical Safety Statement) 1. Todas las instrucciones de seguridad y operación deberán ser leídas antes de que el aparato eléctrico sea operado. 2. Las instrucciones de seguridad y operación deberán ser guardadas para referencia futura. 3.

  • Page 5: Table Of Contents

    Table of Contents Table of Contents 1. Introduction ..................................10 1.1 General ..................................10 1.2 Product Description ..............................10 1.3 Product Warranty ................................ 12 1.4 Safety ..................................13 1.4.1 General ................................13 1.4.2 Safety Summary............................... 13 1.5 General Design ................................15 1.5.1 Electrical Compartment ...........................
  • Page 6 Table of Contents 2.10.2 EC Fans ................................31 2.10.3 Humidifier Adjustment............................. 31 3. Startup/Commissioning ...............................32 3.1 Initial Operation ................................32 3.2 Step-by-Step Startup Instructions ..........................32 3.3 Microprocessor Controller Programming ........................33 4. E2 Controller ..................................34 4.1 General ..................................34 4.1.1 Features ................................34 4.1.1.1 Field Configurable ..........................34 4.1.1.2 Password Protection ..........................34 4.1.1.3 Restorable Setpoint Parameters ......................34 4.1.1.4 A/C Grouping pLAN Operation ......................34...
  • Page 7 Table of Contents 4.4.4.1.3 Manual Speed Control......................50 4.4.4.2 Static Pressure Control .........................50 4.4.5 Remote On/Off ...............................50 4.4.6 Dual Power Transfer Monitoring ........................50 4.5 Menu Screens ................................50 4.5.1 Main Menu ..............................50 4.5.2 Information Menu Loop ..........................52 4.5.2.1 Operating Conditions .........................52 4.5.2.2 Return Temperature Sensor ........................52 4.5.2.3 Return Humidity Sensor ........................52 4.5.2.4 Remote Supply (RSP) Temperature Sensor ..................52 4.5.2.5 Remote Supply (RSP) Humidity Sensor ....................52...
  • Page 8 Table of Contents 4.5.5.10 Save Configuration ...........................78 4.5.5.11 Factory Menu ............................79 4.6 Communication with the Controller ..........................80 4.6.1 Workgroup Setup ............................80 4.6.1.1 Standby ............................... 81 4.6.1.2 Capacity Assist ............................ 81 4.6.1.3 Unit Rotation ............................81 4.6.1.4 Out of Service ............................. 81 4.6.2 Configuring a Workgroup ..........................
  • Page 9 Table of Contents 5.2 Troubleshooting ................................111 5.3 Field Service ................................113 5.3.1 CW System ..............................113 5.3.2 System Repairs/Component Replacement ..................... 114 5.3.2.1 Humidifier Cylinder Replacement ...................... 114 5.3.2.2 Fan Replacement ..........................116 5.3.2.3 Condensate Pump Replacement ....................... 117 6. Troubleshooting ................................. 119 6.1 Contacting Technical Support ............................

  • Page 10: Introduction

    NOTE: Cold Row systems capture and neutralize heat within close-coupled, rack-based environments. Any use beyond what is described in this manual is deemed to be not intended. Black Box is not liable for any damage resulting from improper use. The functional modes of operation are cooling and dehumidification, which provides localized cooling to offset hot spots in data centers.
  • Page 11 Chapter 1: Introduction Figure 1-1. User interface display. Refer to Chapter 4 for detailed instructions on operating the system controller. Page 11 724-746-5500 | blackbox.com...

  • Page 12: Product Warranty

    Black Box Network Services’ obligation under this warranty is to repair or replace, at its option, any part or parts that are determined by Black Box Network Services to be defective for a period of 12 months from the date of shipment when an accurately completed Precision Cooling Limited Warranty Registration and Startup Checklist Form has been submitted to Black Box Network Services, within 90 days from shipment.

  • Page 13: Safety

    Chapter 1: Introduction 1.4 Safety 1.4.1 General This manual uses NOTES along with CAUTION and WARNING symbols to draw your attention to important operational and safety information. A NOTE marks a short message in the information to alert you to an important detail. A CAUTION safety alert appears with information that is important for protecting your equipment and performance.
  • Page 14 Chapter 1: Introduction WARNING This unit is fed by incoming power wires. Even with the service disconnect switch in the “Off” position, power may still be “live” between the switch and the main power source. When performing service, always ensure that main power is disconnected from the unit.

  • Page 15: General Design

    In some cases, an addendum to this manual may also be included to further describe the feature(s). Figure 1-2 depicts a typical internal layout and identifies the major components of a typical Cold Row CW (CRCW-12) unit. The location of some components may vary.

  • Page 16: Electrical Compartment

    Chapter 1: Introduction Figure 1-3 depicts a typical internal layout and identifies the major components of a typical Cold Row CW (CRCW-24) unit. The location of some components may vary. Supply/return pipe transition plate Disconnect switch Humidifier EC fan (3) CW valve Humidifier Electric box...

  • Page 17: Condensate Pump

    1.6.3 Water Detector As an option, Black Box offers spot-type or strip-/cable-type water detectors (see Section 2.6.1). Upon sensing a leak, the water detector control circuit will signal the system controller of the alarm condition. The system controller is programmed to shut down the compressor and the fans when a leak is detected.

  • Page 18: Firestat

    Chapter 1: Introduction 1.6.5 Firestat Optionally mounted in the return air side of the cabinet, a fire detector senses high return air temperature and signals the controller when a fire alarm condition exists and shuts down the air conditioner. 1.6.6 Dual Power Auto Transfer Switching An automatic transfer, main power switching system is available for critical operations.

  • Page 19: Installation

    If there is shipping damage, it must be noted on the freight carrier’s delivery forms BEFORE signing for the equipment. Any freight claims MUST be done through the freight carrier. Black Box ships all equipment FOB. We can assist in the claim filing process with the freight carrier.

  • Page 20: Mounting/Placement

    Chapter 2: Installation Conditioned Space Take certain steps to minimize the effects of the environment surrounding the conditioned space. This is especially important for critical/precision room preparation (computer data centers) that require close tolerance control of temperature and humidity. The conditioned space should be well-insulated and include a vapor barrier.

  • Page 21: Air Distribution

    Chapter 2: Installation Server racks Cold Row CW units Figure 2-1. Recommended installation. NOTE: Placement of air barriers between the cold aisle/hot aisle is important. If the supply discharge is too close to the hot aisle, the conditioned supply air will be recirculated back to the intake in the hot aisle side of the cabinet before it has circulated through the equipment to be cooled.
  • Page 22 Chapter 2: Installation Figure 2-2. Typical air distribution. The front discharge panel directs the supply air out of the Cold Row unit where it will be drawn into the front of the server racks. An optional front-diverted air discharge panel is also available. This directs the supply air sideways out of the Cold Row unit and directly into the front of the server racks (see Figure 2-3).

  • Page 23: Optional Equipment (Field Installed)

    The remote water detector is normally placed on the sub-floor or in a field-supplied auxiliary drain pan located beneath the unit. Black Box provides two types of water detectors: Spot-type water detector: Remove the protective cover and connect two control wires to the terminals on the base. Run the control wires into the electric box and connect them to the control terminal block as shown in the wiring diagram provided with your unit.

  • Page 24: Remote Temperature/Humidity Sensor

    Chapter 2: Installation 2.6.2 Remote Temperature/Humidity Sensor Depending on the type of control selected, the temperature/humidity (T/H) sensor may be factory-mounted or shipped loose for field installation. The remote sensor must be located so that it will properly sense the temperature/humidity conditions to be controlled.

  • Page 25: Chilled Water (Cw) Cooling

    Chapter 2: Installation 2.7 Chilled Water (CW) Cooling The system uses a chilled water source to provide coolant to the cooling coil in the A/C unit. When the hot aisle air temperature rises to the CW cut-in setpoint plus dead band, the controller opens the modulating CW control valve proportionally to the demand for cooling (see Figure 2-7).

  • Page 26: Cw Supply And Return Piping Connections-12" Cabinets

    2.7.1.1 CW Supply and Return Piping Connections—12" Cabinets Bottom access piping Top access piping Female pipe threads Schrader valve Schrader valve Condensate drain ⁄ " FPT Pump Male pipe threads Figure 2-8. Top and bottom access piping for the CRCW-12. 724-746-5500 | blackbox.com Page 26...

  • Page 27: Cw Supply And Return Piping Connections-24" Cabinets

    Chapter 2: Installation 2.7.1.2 CW Supply and Return Piping Connections—24" Cabinets Top access piping Bottom access piping Schrader Female pipe valves threads Schrader Condensate drain valve ⁄ " FPT Condensate drain ⁄ " FPT Pump Pump Male pipe threads Figure 2-9. Top and bottom access piping for the CRCW-24. 724-746-5500 | blackbox.com Page 27...

  • Page 28: Condensate Drain Line

    Chapter 2: Installation 2.7.2 Condensate Drain Line A condensate pump is factory-installed. The drain line connection is typically a ⁄ " FPT fitting that is accessed through the top or bottom of the cabinet as configured with the chilled water pipes. The installer must connect a drain line (customer supplied) to the end of the drain fitting to remove water from the cabinet.
  • Page 29 Chapter 2: Installation Figure 2-10. Sample nameplate. The unit is provided with terminals for all required field wiring. Refer to the electrical drawing supplied with the unit for all power and control field wiring. It is important to identify the options that were purchased with the unit to confirm which field connections are required.

  • Page 30: Single-Phase Units 120 V

    Chapter 2: Installation CAUTION Before operating the unit, you must connect an adequate unit-to-ground to the unit. 2.8.1.1 Single-Phase Units 120 V Single-phase units require the hot leg of power to be connected to terminal L1 and the neutral wire to terminal L3 of the main power non-fused service switch.

  • Page 31: Chilled Water System Preparation

    If the airflow needs to be adjusted, this may be done using the controller’s programming menu selections. Refer to Section 4.4.4 for instructions on adjusting airflow using the system controller. Contact Black Box Technical Support at 724-746-5500 or info@blackbox.com when initially making adjustments to the controller.

  • Page 32: Startup/Commissioning

    NOTE: A Warranty Registration and Startup Checklist is provided in the unit data package. Complete it during startup and send it to Black Box Technical Support. This checklist should be used as a guideline for items that need to be confirmed during startup.

  • Page 33: Microprocessor Controller Programming

    Chapter 3: Startup/Commissioning 3.3 Microprocessor Controller Programming The E2 microprocessor controller is factory-programmed based on the features selected with the system. A user-provided Building Management System (BMS) may be used to directly interface to the E2 controller. The operator may view all the available menu screens through a BMS, however, changes may be made only to basic parameters such as adjusting setpoints and setting and acknowledging alarms.

  • Page 34: E2 Controller

    Chapter 4: E2 Controller 4. E2 Controller 4.1 General The advanced microprocessor-based E2 Series controller is a highly versatile and flexible A/C system controller. It is designed primarily for precision air conditioners. The controller is equipped with flexible software capable of meeting the specific needs of the application.

  • Page 35: User Interface Display Panel

    Chapter 4: E2 Controller 4.1.2 User Interface Display Panel Your unit is equipped with an interface display panel typically mounted on the front panel of the A/C unit. Figure 4-1. User interface display panel. The user interface display panel features an easy-to-read, backlit liquid-crystal alphanumeric display equipped with LED illuminated function keys.

  • Page 36: Contrast Adjustment

    Chapter 4: E2 Controller 4.1.2.2 Contrast Adjustment Press and hold the Alarm ( ) and Prg ( ) keys, then use the Up and Down keys to adjust the contrast. 4.1.2.3 Alarms Alarm conditions activate a red LED indicator that backlights the alarm function key. As an option, an alarm condition may also be enunciated by an audible alarm signal.

  • Page 37: Bms Interface

    Chapter 4: E2 Controller 4.1.4 BMS Interface The E2 series controller may incorporate a Building Management System (BMS) network card equipped with a communication port (Figure 4-3). This can be field-connected through a serial interface to a Building Management System via Modbus, BACnet, SNMP, or HTTP protocol as configured by the factory.

  • Page 38: Navigating Controller Display Screens

    Chapter 4: E2 Controller 4.2 Navigating Controller Display Screens 4.2.1 Menu Selection The E2 Series controller provides five user-selectable menus needed to view operating data and enter setpoints for the system (see Figure 4-6). These menus may be accessed from a scrolling Main Menu screen by pressing the Program key.

  • Page 39: Display Variables

    Chapter 4: E2 Controller 4.2.3 Display Variables The user interface display panel provides screens with three different forms of both the read-only and the modifiable variables: • Numbers are displayed as positive (+) or negative (-) integers. • Dual-State can be toggled between two (2) values, i.e., On/Off, Yes/No. •...

  • Page 40: Modifiable Variables

    Access to the Factory menu screens will only be granted while the user is working with the guidance of Black Box Technical Support (see Chapter 6), because incorrect settings made at that level could unintentionally damage the equipment. The Access ID Code in the bottom left of the “Enter Password”...

  • Page 41: Wrong Password

    Chapter 4: E2 Controller Operators who are allowed access to the Service menu (Level 2), for example, must know the password to enter that level. If the entered password equals or exceeds the level requested during a given session, the operator is allowed to access the requested loop.
  • Page 42 Following a 45-second time delay (to allow the valve to fully open) the fans are allowed to begin operating. 5. The Black Box logo in the display is replaced with a blower symbol. The fans begin operating in stages with five-second time delays.

  • Page 43: Setpoint Adjustment

    Chapter 4: E2 Controller 4.3.1 Setpoint Adjustment 1. From the Main screen, access the Main Menu screen by pressing the program key. 2. Scroll through the Main Menu selections with the Up and Down arrow keys and select the Control menu by pressing the Enter key when “CONTROL”...

  • Page 44: Alarms

    Chapter 4: E2 Controller Figure 4-17. Humidity screen. Increase or decrease the Humidity Setpoint with the Up and Down arrow keys until the desired humidity value is shown. Press the Enter key again to accept the setpoint and then press the Escape key to return to the Setpoints (SET) Control menu screen.

  • Page 45: Controller Operation

    Chapter 4: E2 Controller summary alarm is signaled and a designated set of N.O. & N.C. Custom Alarm relay contacts may be energized to provide remote indication of the specific alarm condition(s). For example, you may want to be notified when a change filter alarm is annunciated, notifying that the air filters need to be cleaned or replaced.

  • Page 46: Control Signals

    Chapter 4: E2 Controller The E2 controller continually analyzes the demand for cooling, humidifying, and dehumidifying against the control setpoints and determines the appropriate response (control output signals) to operate the A/C system. The controller is equipped with analog input positions for monitoring temperature and humidity sensor(s). The controller monitors the actual cold aisle supply air conditions for three fan zones (upper, middle, and lower) as measured by temperature sensors mounted locally to each zone inside the Cold Row cabinet.

  • Page 47: On/Off Digital Control

    Chapter 4: E2 Controller 4.4.1.1 On/Off Digital Control Based on control inputs, the controller provides an on/off output signal to activate certain modes of operation for the air conditioner (i.e. humidifier, fans, or annunciate an operating condition status, that is, alarm condition). 4.4.1.2 Proportional/Integral (P/I) Control The controller calculates proportional control output signal(s) based on the analysis of input signals and then determines the air conditioner’s required mode(s) of operation.

  • Page 48: Operating Configurations

    The valve opens proportionally to the demand for cooling based on air temperature. The control settings include a setpoint and a control dead band. The cooling band is adjustable from 0–10° F in the Factory menu. Contact Black Box Technical Support at 724-746-5500 or info@blackbox.com for guidance if adjustment is needed.

  • Page 49: Airlfow/Fan Speed Control

    Chapter 4: E2 Controller 4.4.4 Airflow/Fan Speed Control The E2 controller treats each EC fan as a variable speed fan. The controller manages the speed of each fan from a factory-set minimum up to a factory-set maximum speed. The minimum fan speed is used whenever the A/C unit has no cooling operations running.

  • Page 50: Variance From Average Fan Speed Control

    Chapter 4: E2 Controller 4.4.4.1.2 Temperature Proportionate Speed Control The controller adjusts the speed of each fan proportionally for that zone to meet the supply air temperature setpoint. The controller compares the variance of each temperature zone to the temperature setpoint and develops a proportional control output to modulate the speed of each fan to meet the supply air temperature setpoint for that zone.
  • Page 51 Level 3 password is needed to enter this menu. Entry to the Factory menu is intended for qualified technicians working under the guidance of Black Box Technical Support during startup and commissioning of the A/C system. The password to enter this menu may be obtained by contacting Black Box Technical Support (see Chapter 6 of this manual).

  • Page 52: Information Menu Loop

    Chapter 4: E2 Controller 4.5.2 Information Menu Loop The Info menu screens may be accessed from the Main screen by simply scrolling with the Up and Down arrow keys. The same screens may also be viewed if you enter the Info menu by pressing the “Prg” key. The Info menu displays screens that provide current temperature and relative humidity conditions and shows the modes the A/C system is currently operating.

  • Page 53: Temperature Sensors

    Chapter 4: E2 Controller Screen Lock Feature You may lock any of the status display screens, bypassing the display screen time-out function. This is sometimes useful for maintaining visibility to a specific screen when testing, making adjustments, or troubleshooting the system. Simultaneously press the program key and Enter key for approximately...

  • Page 54: Cw Valve Status

    Chapter 4: E2 Controller Confinued from previous page 4.5.2.10 CW Valve Status This screen displays “Req,” the value of the analog output signal (0 to 100%) that controls the position of the CW valve and it displays “Act,” the approximate position (0 to 100%) of the valve. The bar gauge provides a visual representation of the output signal and the valve position.

  • Page 55: Dual Power

    (or back up) power source is to be connected to power source “B” disconnect switch (Q81). 4.5.2.14 Software Version/Date Displays the type of A/C system the controller is configured for (W/G, AR), and the Black Box software version and its release date. 4.5.3 Alarm Log Figure 4-21 (Continued). Information menu loop.

  • Page 56: Non-Critical Alarms

    Chapter 4: E2 Controller 4.5.3.2 Non-Critical Alarms A non-critical alarm will activate the alarm screen that it is associated with. These alarms are programmed to activate the “Summary Fault” alarm and close the “Summary Fault” relay contacts without stopping unit operation. Some examples of the factory-programmed, non-critical alarms are: •...

  • Page 57: Critical Alarms

    Chapter 4: E2 Controller 4.5.3.3 Critical Alarms Critical alarms will coincide with automatic shutdown of the A/C unit(s) equipment as needed to prevent possible system damage. The A/C unit(s) equipment will remain shut down until the alarm condition(s) are no longer sensed and the controller has been reset.

  • Page 58: Control Menu Loop

    A/C system. See Section 4.5.4.3. Two Version screens are provided for information only. They show controller hardware and software details that are useful to Black Box Technical Figure 4-23. Control menu loop. Support if you need help.

  • Page 59: Setpoint Screens

    Chapter 4: E2 Controller 4.5.4.1 Setpoint Screens Figure 4-24. Set screen. The Setpoints (SET) screens below may be accessed from the Control menu. Figure 4-25. Temperature/Humidity Setpoint screens. The Temperature and Humidity Setpoint screens enable you to view and adjust the control setpoints and compare them to system level operating data derived from the various sensor/transmitter inputs.

  • Page 60: Alarm Setpoint Screens

    Chapter 4: E2 Controller Figure 4-27. Fan Control screen, linked. The Fan Control screen enables you to select a fan-speed control method (Variance from Average, Temperature Proportional, or Manual, see Section 4.4.4.1) for each of the three fans. You may also link the fan temperature zones together in any combination, so selected fans operate at the same speed.
  • Page 61 Chapter 4: E2 Controller Figure 4-31. High humidity alarm. Figure 4-32. Low humidity alarm. The following two screens appear only if your unit is factory-configured to use an optional entering water temperature (EWT) sensor input. Figure 4-33. High Entering Water Temperature Alarm. Figure 4-34.
  • Page 62 Chapter 4: E2 Controller EXAMPLE 1: Temperature Alarm Offset Figure 4-35. Temperature alarm offset. If the offset for the temperature alarm is set at 5.0° F (default), the high temperature alarm will cancel when the actual temperature drops to the High Temperature Alarm setpoint (80.0° F) - the Offset (5.0° F) 80.0°...

  • Page 63: Clock Screen

    Chapter 4: E2 Controller This screen allows you to enable the dirty filter notification timer, which provides an alarm indication when it’s time to clean or change the air filter. The filter change period is adjustable and should be set according to the conditions at the site. Extremely dusty environments may require more frequent filter changes.

  • Page 64: Cool

    Chapter 4: E2 Controller Figure 4-41. Service menu loop selections. 4.5.5.1 Cool The Service>Cool menu screens below apply to your unit that’s configured for CW operation. Figure 4-42. Cool menu. CW Cooling Status Figure 4-43. Cooling status. 724-746-5500 | blackbox.com Page 64...

  • Page 65: Humidity

    Chapter 4: E2 Controller You can view the cooling band from the Service>Cool menu. The “CW Prop Band” establishes the number of degrees for the proportional control output band. The “CW Int Time” is the integral factor used to adjust the proportional output response. The “CW Dead Band”...

  • Page 66: Alarms

    Chapter 4: E2 Controller 4.5.5.3 Alarms Figure 4-45. Alarms screens. A log of events is stored for view from the Service>Alarms menu. This menu displays the last 50 events sequentially numbered in order of occurrence. The alarm log is cleared by pressing the Alarm key while in this menu.

  • Page 67: Blower

    Chapter 4: E2 Controller Figure 4-47. Calibration screens. A Static Pressure Offset screen only appears if your unit is configured for static pressure control. Figure 4-48. Static Presure Offset screen. Additional sensor offset screens are available for optional sensors if enabled at the factory such as Remote Supply Air Temp and Remote Supply Air Humidity.

  • Page 68: Static Pressure Pi Status

    Chapter 4: E2 Controller 4.5.5.5.1 Static Pressure PI Status Figure 4-50. PI status screen. The Static Pressure PI Status screen only appears if your unit is configured for static pressure control. From this screen you may view the static pressure setpoint and dead band and you may view the proportional and integral values controlling fan speed. The current operating static pressure and proportional fan control output signal are displayed at the bottom of the screen.

  • Page 69: Options Menu Loop

    Chapter 4: E2 Controller The blower fans will operate at the Hum Fan Speed setting during humidification, and the Dehum Fan Speed setting during dehumidification. Humidification and dehumidification fan speeds are limited to the most restrictive value between the factory preset minimum and maximum, the Temp Zone minimum and maximum, and the speed setting for the operating mode.

  • Page 70: Control, Startup

    Chapter 4: E2 Controller 4.5.5.6.1 Control, Startup Figure 4-56. Control, Startup screen. The Service>Options>Control, Startup screen allows you to select the control method. Standard = Temperature/Humidity Control Dewpoint = Dewpoint Control <Reserved> = For future use. DO NOT select this control method. “Auto on powerup”—If set to On, the A/C unit turns on automatically when main power is applied.

  • Page 71: T/H Offset Scaling

    Chapter 4: E2 Controller 4.5.5.6.3 T/H Offset Scaling Figure 4-58. T/H Offset Scaling screen. The Service>Options>T/H Offset Multiplier screen allows you to enter a multiplier to scale both the temperature and humidity cut- in/cut-out offsets. The multipliers are factored to the system offset values set in the Service menu (Sections 4.5.5.1 and 4.5.5.2). Default Cut-in/Cut-out Offsets Temp.

  • Page 72: Custom Setup

    Chapter 4: E2 Controller Figure 4-59. Auto flush cycle. 4.5.5.6.5 Custom Setup Figure 4-60. Custom Setup screen. From the Service>Options>Custom Setup screen, press the Enter key to access a menu loop to set up custom alarm features. Any controller alarm or signal failure will activate the summary alarm output. Upon receiving an alarm indication, press the alarm key to call up alarm screen messages.

  • Page 73: Custom Alarm Setup

    Chapter 4: E2 Controller 4.5.5.6.7 Custom Alarm Setup The E2 controller may be enabled to activate a Custom Alarm output and energize a designated N.O./N.C. relay. A custom alarm output is set up by adding the binary bitmask numbers assigned to the specific alarms and signal failures you wish to monitor via the relay and then entering them in the Custom Alarm Setup screen.
  • Page 74 Chapter 4: E2 Controller Table 4-5. Alarms 9 to 16. Number Description Bitmask Default Filter alarm Fire/smoke alarm Water detection alarm Condensate pan alarm Circuit low pressure alarm Circuit high pressure alarm Dual power Input A alarm Dual power Input B alarm Factory Default Bitmask Total NOTE: The default values (shown in bold italics) are factory set to generate a custom alarm output on any of the major alarms and any sensor failure.
  • Page 75 Chapter 4: E2 Controller Table 4-7. Alarms 25 to 32 (Sensor failure alarms). Number Description Bitmask Default Lower temperature sensor fail Middle temperature sensor fail Optional temperature sensor fail Upper temperature sensor fail Return humidity sensor fail DX1 discharge pressure fail Static air pressure sensor fail DX1 suction press sensor fail Factory Default Bitmask Total...

  • Page 76: Workgroup Screens

    Chapter 4: E2 Controller Table 4-9. Alarms 41 to 48. Number Description Bitmask Default System Off BMS keep alive off Customer alarm 2 Customer alarm 3 Flow switch alarm Reserved Reserved Reserved Factory Default Bitmask Total 4.5.5.6.8 Workgroup Screens The Service>Group display screens shown below only appear if two or more units are wired together as a group. They allow you to configure parameters that apply to how the A/C units interact in the workgroup.

  • Page 77: Digital In

    Chapter 4: E2 Controller 4.5.5.7 Digital In Figure 4-64. Digital In screens. The Service>Digital In screen is provided for information only. It shows the state of each digital input as either Closed (+24 V) or Open (Gnd). 4.5.5.8 Run Hours Figure 4-65.

  • Page 78: Bms Communications

    Chapter 4: E2 Controller 4.5.5.9 BMS Communications Figure 4-66. BMS Communications screens. The Service>BMS Comm menu is used to set up parameters to allow a BMS (BAS) to interface with the controller. See Section 4.7.2 for a description of this screen and instructions for setting up BMS communication. 4.5.5.10 Save Configuration Figure 4-67.

  • Page 79: Factory Menu

    The Factory Menu loop may be accessed from the Service>Factory screen. You must enter the factory-level password to gain access to the loop. Contact Black Box Tech Support for the password and for guidance when adjustments must be made at this level.

  • Page 80: Communication With The Controller

    Active, Capacity Assist, or Standby duty is configured by the factory; however, you can configure this field with the help of Black Box Technical Support. A unit may also be designated as “Out of Service.”...

  • Page 81: Standby

    Units designated as “Out of Service” do not rotate nor can they be used as lead units. The rotation time period is typically 1 week, however it may be set by the user via the Factory menu. Contact Black Box Technical Support at 724-746-5500 or info@blackbox.com for assistance when accessing the Factory menu.

  • Page 82: Configure The Terminal Address

    Chapter 4: E2 Controller A workgroup should ALWAYS start with controller address 1 and go up from there. DO NOT skip over controller addresses. The list of suitable controller/display terminal address pairs is shown below: Table 4-11. Corresponding Controller to Terminal pLAN Addresses. Controller (I/O board) Display Terminal You must assign the terminal and controller I/O board addresses for each controller to be grouped.

  • Page 83: Configure The Controller (I/O Board) Plan Address

    Chapter 4: E2 Controller 4.6.2.2 Configure the Controller (I/O Board) pLAN Address Immediately after turning power back on, press and hold the Alarm and the up-arrow keys simultaneously for 10 to 15 seconds. First you will see a display message “self test please wait” then the pLAN Address Configuration screen shown below will appear.

  • Page 84: Fault Messages

    Chapter 4: E2 Controller 8. Enter the field “Ok?No,” choose ”Yes“ using the up-arrow and down-arrow keys and confirm by pressing Enter save the data and exit the group setup procedure. 9. Referring to the wiring diagram provided with your A/C units, interconnect the units together with the pLAN cable(s) provided. 4.6.2.4 Fault Messages If the terminal detects the status of the I/O board it is associated with is off-line, the display shows the message: “I/O Board xx fault.”...

  • Page 85: Configure Workgroups

    Factory appears in the center of the screen. Figure 4-80. Factory>Group screen. Press the Enter key twice and you’ll be prompted to enter the password for the Factory level (contact Black Box Technical Support for the password). Once the factory-level password is entered, press Enter to call up the menu screens.
  • Page 86 Chapter 4: E2 Controller Table 4-12. Factory>Groups>Groups Config (Screen 1) parameters. Display Description Description Variables Default 0= Out of Service 1= Active Assign the duty of the A/C unit within the group. 2= Standby Unit The duty must be assigned for each A/C unit at its local display terminal. 3= Assist 4= Active_No_Rot 5= Standby_No_Rot...
  • Page 87 Chapter 4: E2 Controller Table 4-13. Factory>Group>Group Rotation (Screen 2) parameters. Display Description Description Variables Default This field only appears on the lead controller. If you select “On” and press “Enter,” it 0= Off initiates a manual rotation cycle to rotate duty between active and standby units. It also Force Rotation rotates the role of lead controller.
  • Page 88 Chapter 4: E2 Controller Table 4-15. Factory>Group>Capacity Assist (Screen 4) parameters. Display Description Description Variables Default Humid Cut in Enter relative humidity setpoint offset for humidifying capacity assist operation to begin. -99.9 to 99.9 -4.0 Cut out Enter relative humidity setpoint offset for humidifying capacity assist operation to stop. -99.9 to 99.9 Dehum Cut in Enter relative humidity setpoint offset for dehumidifying capacity assist operation to begin.
  • Page 89 Chapter 4: E2 Controller Table 4-17. Group alarms 1 to 8. Number Description Bitmask Default Humidifier Pump Customer alarm 1 Circuit 1 high pressure Circuit 1 low pressure DX lockout Humidifier lockout FC/AWS lockout Table 4-18. Group alarms 9 to 16. Number Description Bitmask...
  • Page 90 Chapter 4: E2 Controller Table 4-19. Group alarms 17 to 24. Number Description Bitmask Default High temperature Low temperature High humidity Low humidity High water temperature CW1 Low water temperature CW1 Reserved Reserved Table 4-20. Group alarms 25 to 32. Number Description Bitmask...
  • Page 91 Chapter 4: E2 Controller Table 4-21. Group alarms 33 to 40. Number Description Bitmask Default Static air pressure Differential air pressure Dewpoint Airspeed Reserved Reserved Reserved Reserved There are several automatic crossover signals that will cause a switchover from Unit Active to Unit Off. They are the occurrence of a remote shutdown command, unit shutdown from a group alarm or BMS command, fire/smoke detection, loss of all cooling (all CW valves), or loss of airflow.

  • Page 92: Service>Options>Group Menu Screens

    Chapter 4: E2 Controller Factory>Group>Group Status (Screen 8) provides an overview of the current duty status for all the A/C units combined in the group. Table 4-23. Factory>Group>Group Status (Screen 8) parameters. Display Description Description Variables Default Running Display indicates how many units in the group are currently operating. 0 to 8 Active Display indicates how many units in the group are currently active.

  • Page 93: Capacity Assist

    Chapter 4: E2 Controller The Service>Options>Group Setup screen allows you to select the workgroup duty assignment for the A/C unit. The duty must be assigned for each grouped A/C unit at its local display terminal. Enter the number of days between rotating active units. Enter the hour of day for unit rotation to occur.

  • Page 94: Group Averaging

    Chapter 4: E2 Controller The Service>Options>Group Sensors screen allows you to select whether to control the A/C workgroup using the T/H sensors connected to individual A/C units (Local) or control the workgroup using network sensor values transmitted from the lead controller.

  • Page 95: Group Information Menu Screens

    Chapter 4: E2 Controller 4.6.2.8 Group Information Menu Screens The following display screens are available in the Information menu loop (Section 4.5.2) if two or more units are wired together as a group. They display key operating parameters for grouped A/C units. 4.6.2.8.1 Group Sensor Values This displays the current group temperature and humidity control values transmitted from the Lead controller.

  • Page 96: Bms Communications

    Chapter 4: E2 Controller To determine which sensors are enabled and operable for each unit, simply determine which index numbers, derived from the key above, will produce the number shown in the screen. In the example shown, the number for the lead unit is 15. This results from adding 1 Supply Temperature + 2 Return Humidity + 4 Remote Supply Temperature + 8 Remote Supply Humidity together, confirming those sensors are operable.

  • Page 97: Direct Bms Control

    If multiple A/C units are grouped together, each controller added to the group must be configured with a CPU address for BMS communication. For complete details on using BMS control, contact Black Box Technical Support (see Chapter 6). 4.7.1 Direct BMS Control The controller may be configured to accept proportional analog signals that mimic a sensor.

  • Page 98: Troubleshooting The Control I/O Module

    Chapter 4: E2 Controller 4.8 Troubleshooting the Control I/O Module Signal LEDs The E2 control I/O module includes three signal LEDs (red, yellow, and green) that provide information on the operation of the control module and status of the connection to the pLAN. These signal LEDs are positioned adjacent to the yellow “Power On” LED (see Figure 4-2).

  • Page 99: Bms Modbus Parameters, Version 1.1

    Chapter 4: E2 Controller 4.9 BMS Parameters, Version 1.1 Table 4-27. BMS parameters. Supported Protocols Speed Media Connection Notes BACnet over IP 10 Mbps 10BASE-T RJ-45 direct unit connection Uses BMS addresses BACnet over Ethernet 10 Mbps 10BASE-T RJ-45 direct unit connection Uses BMS addresses HTTP 10 Mbps...

  • Page 100: Signed Values For Http, Snmp/Modbus Holdling Registers/Analog Values For Bacnet

    Chapter 4: E2 Controller 4.9.1 Signed Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet Table 4-28. Signed Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet. Modbus BACnet Address Address Address Description Default Read/Write Temperature setpoint 72.0 Humidity setpoint 45.0 R/Ws Average supply temperature display value...

  • Page 101: Unsigned Values For Http, Snmp/Modbus Holdling Registers/Analog Values For Bacnet

    Chapter 4: E2 Controller 4.9.2 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet Table 4-29. Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet. Modbus BACnet Address Address Address Description Default Read/Write 1001 Cooling analog output 1002 Middle fan speed analog output 1003 Upper fan analog control value...

  • Page 102: Boolean Values For Http, Snmp/Modbus Coils/Binary Values For Bacnet

    Chapter 4: E2 Controller Variable/Value Descriptions Table 4-30. Variable/Value Descriptions. Variable Description for Description for Description for Description for Description for Description for Description for Description Value 0 Value 1 Value 2 Value 3 Value 4 Value 5 Value 6 Fan link control None Upper &...

  • Page 103: Alarm-Packed Bit Variables

    Chapter 4: E2 Controller 4.9.4 Alarm-Packed Bit Variables Table 4-32. Alarm-Packed Bit Variables. Alarms 1 Alarms 2 Alarms 3 Emergency shutdown Middle fan alarm Reserved Remote shutdown Upper fan alarm Reserved Customer Alarm 1 Lower fan alarm Reserved Airflow High temperature Reserved Filter Low temperature...

  • Page 104: Sensor Failure Packed Bit Variables

    Chapter 4: E2 Controller 4.9.5 Sensor Failure Packed Bit Variables Table 4-33. Sensor Failure Packed Bit Variables. Sensor Sensor Failures 1 Failures 2 Middle temperature Reserved Upper temperature Reserved Lower temperature Reserved Return temperature Reserved Return humidity Reserved Static air pressure Reserved Suction pressure Reserved...

  • Page 105: Digital Input Packed Bit Variables

    Chapter 4: E2 Controller 4.9.6 Digital Input Packed Bit Variables Table 4-34. Digital Input Packed Bit Variables. Digital Inputs 1 Digital Inputs 2 Remote shutdown Customer alarm 2 Customer alarm 1 Customer alarm 3 Water Reserved Condensate pan Reserved Humidifier Reserved Moisture Reserved...

  • Page 106: Digital Output Packed Bit Variables

    Chapter 4: E2 Controller 4.9.7 Digital Output Packed Bit Variables Table 4-35. Digital Output Packed Bit Variables. Digital Outputs 1 Digital Outputs 2 Global alarm Reserved Custom alarm 1 Reserved Master fan enable Reserved DX1 enable Reserved DX1 liquid line solenoid Reserved Humidifier enable Reserved...

  • Page 107: Unsigned Values For Http, Snmp/Modbus Holding Registers/Analog Values For Bacnet

    Chapter 4: E2 Controller 4.9.8 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet Table 4-36. Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet. Modbus BACnet Address Address Address Description Default Direction 1100 BMS keep alive parameter 1101 BMS low fan speed for CW units 1102...

  • Page 108: Maintenance

    Use copies of the Periodic General Maintenance Checklist in this manual (see Appendix A.2) to record periodic general maintenance inspections. For assistance, contact Black Box Technical Support. Ensure adherence to all safety statements while performing any type of maintenance.
  • Page 109 Chapter 5: Maintenance Figure 5-1. Cleanable filters. Clean the filter media using a vacuum cleaner, low-pressure compressed air, or rinse with water. A mild detergent such as dishwashing liquid may be used. DO NOT use solvents or cleaning agents. Replace the filters every 2 to 3 years when they become too flimsy.

  • Page 110: Cartridge Filters

    Chapter 5: Maintenance 5.1.1.2 Cartridge Filters Replaceable cartridge filters are held in place by an end cap in the bottom of the rear access panel. Lay the access panel down on a piece of cardboard and remove the four screws holding the end cap in place. Remove the end cap and slide the old filters out of the tray as shown in Figure 5-2.

  • Page 111: Humidifier

    Chapter 5: Maintenance 5.1.6 Humidifier The steam cylinder has a limited lifetime and must be replaced periodically. Because water conditions and humidifier usage rates vary greatly, it is difficult to establish intervals for changing the cylinder. Individual maintenance schedules must be determined for each location, based upon periodic examination of the humidifier.
  • Page 112 Chapter 5: Maintenance Symptom (continued): System short of capacity. Probable Causes/Recommendations (continued): c. Supply water temperature is too high. Check chilled water supply. d. Temperature setting is too high. Increase temperature setpoint. e. Discharge air short cycling back to return. Check the air barrier between hot/cold aisles. Symptom: EC fan(s) fail to start.

  • Page 113: Field Service

    Chapter 5: Maintenance Symptom: System short of capacity. Probable Causes/Recommendations: a. Low chilled water flow. Check for leaks. Repair and recharge system. b. Supply water temperature is too high. Check the chilled water supply. c. Reduced airflow. Check filters. d. Dirty coil. Clear coil fins of debris. Symptom: Humidifier inoperative.

  • Page 114: System Repairs/Component Replacement

    Chapter 5: Maintenance 5.3.2 System Repairs/Component Replacement All electrical connections should be checked to ensure they are tight and properly made. Check all circuit breakers, contactors, and wiring. The contactors should be examined and replaced if contacts are worn or pitted. 1.
  • Page 115 Chapter 5: Maintenance 4. Fashion a jumper wire and install it across the terminals on the Air Flow Switch (F40). Figure 5-4. Jumper wire installed. 5. Using a pair of vise grips, turn the shaft of the main power switch to the “On” position to provide power for the humidifier drain solenoid.

  • Page 116: Fan Replacement

    Chapter 5: Maintenance Humidifier Drain Pump Replacement The humidifier drain pump is located on a shelf beneath the humidifier assembly. To access the pump, the rear access panel must be removed as described in Section 5.3.2.1. Cut the wire-ties holding the clear plastic discharge line (reference Section 5.3.2.4). Remove the discharge line from the barbed stub fitting.

  • Page 117: Condensate Pump Replacement

    Chapter 5: Maintenance M6 hex bolts (two per side) Power/control connectors Figure 5-6. 24" cabinet. Remove the four hex-bolts holding the inlet ring then remove the four hex-bolts holding the fan mounting bracket. Remove the fan assembly together with the inlet ring from the cabinet. Remove the mounting bracket from the old fan and install it on the new fan.
  • Page 118 Chapter 5: Maintenance Reach inside the fan opening to grasp the pump. Tilt the pump up and cut the wire-ties holding the clear plastic discharge line. Remove the discharge line from the barbed stub fitting. Release the cable retaining clip on the side of the pump and cut the wire- ties holding the cable loop.

  • Page 119: Troubleshooting

    Warranty inquiries are to be made through Black Box Technical Support at 724-746-5500 or info@blackbox.com. A service technician at Black Box will troubleshoot the system over the telephone with a field service technician to determine the defect of the part. If it is determined that the part may be defective, a replacement part will be sent.
  • Page 120 Number is required when returning parts. To receive credit for returned repair/replacement parts, the parts must be returned to Black Box within 30 days of the purchase date. Spare part sales over 30 days old will be considered final and the parts will remain the sole property of the ordering party.

  • Page 121: Appendix A. Forms

    Appendix A: Forms Appendix A. Forms A.1 Checklist for Completed Installation of Cold Row CW 1. Proper clearances for service access have been maintained around equipment. 2. Equipment is level and mounting fasteners are tight. 3. Field-installed piping completed. 4. All field installed piping leaks tested. 5.

  • Page 122: Periodic General Maintenance Checks And Service Checklist

    ___________________________________________________________________________________________________ Signature: _______________________________ *** If factory assistance is required for any reason, provide the model number, serial number, and Black Box item number found on the unit nameplate. This will speed the process and ensure accuracy of information. *** 724-746-5500 | blackbox.com...

  • Page 123: Appendix B. Glossary: Definition Of Terms And Acronyms

    Appendix B: Glossary: Definition of Terms and Acronyms Appendix B. Glossary: Definition of Terms and Acronyms BTU/Hr: British Thermal Units per hour CFM: Cubic feet per minute CNDCT: Conductor CW: Chilled water DX: Direct expansion ESD: Electrostatic discharge ° F: Degrees Fahrenheit FLA: Full load Amps FOB: Freight on Board HACR: Heating, air conditioning, refrigeration...
  • Page 124 Appendix B: Glossary: Definition of Terms and Acronyms VDC: Volt, direct current WG: Water Glycol 724-746-5500 | blackbox.com Page 124...
  • Page 125 NOTES 724-746-5500 | blackbox.com Page 125...
  • Page 126 NOTES 724-746-5500 | blackbox.com Page 126...
  • Page 127 NOTES 724-746-5500 | blackbox.com Page 127...
  • Page 128 About Black Box Black Box provides an extensive range of networking and infrastructure products. You’ll find everything from cabinets and racks and power and surge protection products to media converters and Ethernet switches all supported by free, live 24/7 Tech support available in 30 seconds or less.

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