-FS
CRDX-A-FS-24KW
CRDX-A-FS-12KW
CRDX-G-FS-24KW
CRDX-G-FS-12KW
CRDX-W-FS-24KW
CRDX-W-FS-12KW
Cold Row™ DX User Manual
This precision data center air-conditioning system
uses the latest, state-of-the-art control technology.
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
Customer
Support
Information
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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 interference 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. Operation of this equipment in a residential area is likely to cause interference, in which case the user at his own
expense will be required to take whatever measures may be necessary to correct the interference.
Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to
operate the equipment.
This digital apparatus does not exceed the Class A limits for radio noise emission from digital apparatus set out in the Radio
Interference Regulation of Industry Canada.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de
la classe A prescrites dans le Règlement sur le brouillage radioélectrique publié par Industrie Canada.
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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. Todas las advertencias en el aparato eléctrico y en sus instrucciones de operación deben ser respetadas.
4. Todas las instrucciones de operación y uso deben ser seguidas.
5. El aparato eléctrico no deberá ser usado cerca del agua—por ejemplo, cerca de la tina de baño, lavabo, sótano mojado o cerca
de una alberca, etc.
6. El aparato eléctrico debe ser usado únicamente con carritos o pedestales que sean recomendados por el fabricante.
7. El aparato eléctrico debe ser montado a la pared o al techo sólo como sea recomendado por el fabricante.
8. Servicio—El usuario no debe intentar dar servicio al equipo eléctrico más allá a lo descrito en las instrucciones de operación.
Todo otro servicio deberá ser referido a personal de servicio calificado.
9. El aparato eléctrico debe ser situado de tal manera que su posición no interfiera su uso. La colocación del aparato eléctrico
sobre una cama, sofá, alfombra o superficie similar puede bloquea la ventilación, no se debe colocar en libreros o gabinetes
que impidan el flujo de aire por los orificios de ventilación.
10. El equipo eléctrico deber ser situado fuera del alcance de fuentes de calor como radiadores, registros de calor, estufas u otros
aparatos (incluyendo amplificadores) que producen calor.
11. El aparato eléctrico deberá ser connectado a una fuente de poder sólo del tipo descrito en el instructivo de operación, o como
se indique en el aparato.
12. Precaución debe ser tomada de tal manera que la tierra fisica y la polarización del equipo no sea eliminada.
13. Los cables de la fuente de poder deben ser guiados de tal manera que no sean pisados ni pellizcados por objetos colocados
sobre o contra ellos, poniendo particular atención a los contactos y receptáculos donde salen del aparato.
14. El equipo eléctrico debe ser limpiado únicamente de acuerdo a las recomendaciones del fabricante.
15. En caso de existir, una antena externa deberá ser localizada lejos de las lineas de energia.
16. El cable de corriente deberá ser desconectado del cuando el equipo no sea usado por un largo periodo de tiempo.
17. Cuidado debe ser tomado de tal manera que objectos liquidos no sean derramados sobre la cubierta u orificios de ventilación.
18. Servicio por personal calificado deberá ser provisto cuando:
A: El cable de poder o el contacto ha sido dañado; u
B: Objectos han caído o líquido ha sido derramado dentro del aparato; o
C: El aparato ha sido expuesto a la lluvia; o
D: El aparato parece no operar normalmente o muestra un cambio en su desempeño; o
E: El aparato ha sido tirado o su cubierta ha sido dañada.
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Table of Contents
Table of Contents
1. Introduction ........................................................................................................................................................................10
1.1 General........................................................................................................................................................................10
1.2 Product Description.....................................................................................................................................................10
1.3 Product Warranty ........................................................................................................................................................13
1.4 Safety ........................................................................................................................................................................14
1.4.1 General............................................................................................................................................................14
1.4.2 Safety Summary...............................................................................................................................................14
1.5 General Design............................................................................................................................................................16
1.5.1 Electrical Compartment ................................................................................................................................... 17
1.5.2 Circuit Breakers/Motor Start Protectors ........................................................................................................... 17
1.5.3 Compressor ..................................................................................................................................................... 17
1.5.3.1 Electronic Thermal Expansion Valve .................................................................................................... 17
1.5.3.2 Electronic Hot Gas Bypass .................................................................................................................. 17
1.5.4 Coils................................................................................................................................................................. 17
1.5.5 Condensate Pump ........................................................................................................................................... 17
1.5.6 EC Fans............................................................................................................................................................ 17
1.5.7 Temperature/Humidity Sensors........................................................................................................................18
1.6 Optional Equipment ....................................................................................................................................................18
1.6.1 Remote Mounted Supply Temperature/Humidity Sensor.................................................................................18
1.6.2 Water Detector................................................................................................................................................18
1.6.3 Smoke Detector...............................................................................................................................................18
1.6.4 Firestat.............................................................................................................................................................18
2. Installation ........................................................................................................................................................................19
2.1 Receiving the Equipment.............................................................................................................................................19
2.2 Moving the Equipment................................................................................................................................................19
2.3 Site Preparation ...........................................................................................................................................................19
2.4 Mounting/Placement...................................................................................................................................................20
2.5 Air Distribution............................................................................................................................................................21
2.6 Optional Equipment (Field Installed)............................................................................................................................23
2.6.1 Remote Water Detectors .................................................................................................................................23
2.6.2 Remote Temperature/Humidity Sensor............................................................................................................24
2.6.3 Outdoor Condensers .......................................................................................................................................25
2.7 Water-Water/Glycol Cooled DX...................................................................................................................................25
2.8 Split Air Cooled Systems..............................................................................................................................................29
2.8.1 Refrigerant Piping ............................................................................................................................................29
2.8.1.1 DX Refrigerant Piping Connections .....................................................................................................30
2.8.1.2 Refrigerant Pipe Sizing .........................................................................................................................31
2.8.2 Remote Air-Cooled Condensers.......................................................................................................................31
2.8.3 Condensate Drain Line.....................................................................................................................................32
2.9 Utility Connections ......................................................................................................................................................32
2.9.1 Main Power .....................................................................................................................................................32
2.9.1.1 Single-Phase Units 208/230 V.............................................................................................................34
2.9.1.2 Three-Phase Units...............................................................................................................................34
2.9.2 Optional Equipment.........................................................................................................................................34
2.9.2.1 Remote Water Detector .......................................................................................................................34
2.9.2.2 Remote Temperature/Humidity Sensor................................................................................................34
2.9.2.3 Remote On/Off ...................................................................................................................................34
2.9.3 Outdoor Equipment.........................................................................................................................................34
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Table of Contents
2.9.3.1 Water-Cooled Systems (CRDX-W-FS-12KW, CRDX-W-FS-24KW)........................................................34
2.9.3.2 Glycol-Cooled Systems (CRDX-G-FS-12KW, CRDX-G-FS-24KW) ........................................................35
2.9.3.3 Remote Condenser (CRDX-A-FS-12KW, CRDX-A-FS-24KW)...............................................................35
2.10 System Charging Procedures......................................................................................................................................36
2.10.1 Water-Water/Glycol Cooled Systems ...............................................................................................................36
2.10.2 Remote-Air Cooled Systems ............................................................................................................................36
2.10.2.1 Estimating Refrigerant Charge...........................................................................................................37
2.10.2.2 Preparing System for Charging .........................................................................................................38
2.10.2.3 Refrigerant Charging Procedures ......................................................................................................39
2.10.2.4 -30° F Ambient Applications.............................................................................................................40
2.10.3 Refrigerant Characteristics ...............................................................................................................................41
2.10.3.1 Pressure/Temperature Settings..........................................................................................................41
2.10.3.2 Saturated Refrigerant Pressure.......................................................................................................... 41
2.11 Settings and Adjustments............................................................................................................................................42
2.11.1 Water–Water/Glycol Circuit .............................................................................................................................42
2.11.2 Low-/High-Pressure Limit Switch.....................................................................................................................42
2.11.3 Thermal Expansion Valve.................................................................................................................................42
2.11.4 Hot Gas Bypass................................................................................................................................................42
2.11.5 EC Fans............................................................................................................................................................42
3. Startup/Commissioning.......................................................................................................................................................43
3.1 Initial Operation...........................................................................................................................................................43
3.2 Step-by-Step Startup Instructions ................................................................................................................................43
3.3 Microprocessor Controller Programming.....................................................................................................................43
4. E2 Controller .......................................................................................................................................................................44
4.1 General........................................................................................................................................................................44
4.1.1 Features ...........................................................................................................................................................44
4.1.1.1 Field Configurable................................................................................................................................44
4.1.1.2 Password Protection............................................................................................................................44
4.1.1.3 Restorable Setpoint Parameters...........................................................................................................44
4.1.1.4 A/C Grouping pLAN Operation ..........................................................................................................44
4.1.2 User Interface Display Panel.............................................................................................................................45
4.1.2.1 Function Keys......................................................................................................................................45
4.1.2.2 Contrast Adjustment...........................................................................................................................46
4.1.2.3 Alarms ................................................................................................................................................46
4.1.3 Controller I/O Module .....................................................................................................................................46
4.1.4 BMS Interface..................................................................................................................................................47
4.2 Navigating Controller Display Screens..........................................................................................................................48
4.2.1 Menu Selection ...............................................................................................................................................48
4.2.2 Menus .............................................................................................................................................................48
4.2.3 Display Variables..............................................................................................................................................49
4.2.4 Cursor Position in Screens................................................................................................................................49
4.2.5 Modifiable Variables ........................................................................................................................................50
4.2.6 Password Authorization Levels.........................................................................................................................50
4.2.6.1 Password-Protected Screen ................................................................................................................50
4.2.6.2 Wrong Password................................................................................................................................ 51
4.2.6.3 Setting the Passwords........................................................................................................................ 51
4.3 System Operation........................................................................................................................................................ 51
4.3.1 Setpoint Adjustment........................................................................................................................................52
4.3.1.1 Saving and Restoring Setpoint Parameters..........................................................................................54
4.3.2 Alarms .............................................................................................................................................................54
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4.3.2.1 Summary Alarm..................................................................................................................................54
4.3.2.2 Customer Alarms................................................................................................................................54
4.3.2.3 Custom Alarms...................................................................................................................................54
4.4 Controller Operation....................................................................................................................................................54
4.4.1 Control Signals.................................................................................................................................................55
4.4.4.1 On/Off Digital Control........................................................................................................................55
4.4.4.2 Proportional/Integral (P/I) Control......................................................................................................56
4.4.2 Control Methods .............................................................................................................................................56
4.4.2.1 Temperature/RH Control.....................................................................................................................56
4.4.2.2 Dewpoint Control ..............................................................................................................................56
4.4.3 Operating Configurations ................................................................................................................................57
4.4.3.1 Compressor Operation .......................................................................................................................57
4.4.3.2 Water–W/G Operation.......................................................................................................................58
4.4.3.3 Dehumidifying....................................................................................................................................58
4.4.4 Airlfow/Fan Speed Control ..............................................................................................................................58
4.4.4.1 Independent Fan Speed Control.........................................................................................................59
4.4.4.2 Variance from Average Fan Speed Control.........................................................................................59
4.4.4.3 Temperature Proportionate Speed Control.........................................................................................59
4.4.4.4 Manual Speed Control .......................................................................................................................59
4.4.5 Remote On/Off ...............................................................................................................................................59
4.5 Menu Screens..............................................................................................................................................................59
4.5.1 Main Menu......................................................................................................................................................59
4.5.2 Information Menu Loop ..................................................................................................................................61
4.5.2.1 Operating Conditions .........................................................................................................................61
4.5.2.2 Return Temperature Sensor................................................................................................................61
4.5.2.3 Return Humidity Sensor......................................................................................................................61
4.5.2.4 Temperature Sensors..........................................................................................................................61
4.5.2.5 Remote Supply Temperature/Humidity Sensor ...................................................................................62
4.5.2.6 Discharge Pressure..............................................................................................................................62
4.5.2.7 Setpoint Values...................................................................................................................................62
4.5.2.8 Compressor Status .............................................................................................................................62
4.5.2.9 EEV Status ..........................................................................................................................................62
4.5.2.10 EHGB Status.......................................................................................................................................63
4.5.2.11 Fan Status...........................................................................................................................................63
4.5.2.12 Group Information Menu Screens......................................................................................................63
4.5.2.13 Software Version/Date.......................................................................................................................63
4.5.3 Alarm Log........................................................................................................................................................64
4.5.3.1 Alarms ................................................................................................................................................64
4.5.3.2 Non-Critical Alarms............................................................................................................................64
4.5.3.3 Critical Alarms ....................................................................................................................................64
4.5.3.4 Alarm Screen Messages .....................................................................................................................65
4.5.4 Control Menu Loop.........................................................................................................................................66
4.5.4.1 Setpoint Screens.................................................................................................................................67
4.5.4.2 Alarm Setpoint Screens......................................................................................................................68
4.5.4.3 Clock Screen ......................................................................................................................................70
4.5.5 Service Menu Loop..........................................................................................................................................70
4.5.5.1 Humidity.............................................................................................................................................71
4.5.5.2 Alarms................................................................................................................................................72
4.5.5.3 Sensors...............................................................................................................................................73
4.5.5.4 Blower................................................................................................................................................74
4.5.5.5 Options Menu Loop...........................................................................................................................75
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Table of Contents
4.5.5.6 Digital In.............................................................................................................................................82
4.5.5.7 Run Hours ..........................................................................................................................................82
4.5.5.8 BMS Communication .........................................................................................................................83
4.5.5.9 Save Configruation.............................................................................................................................83
4.5.5.10 Factory Menu.....................................................................................................................................84
4.6 Communication with the Controller............................................................................................................................85
4.6.1 Workgroup Setup............................................................................................................................................85
4.6.1.1 Standby ...............................................................................................................................................86
4.6.1.2 Capacity Assist....................................................................................................................................86
4.6.1.3 Unit Rotation ......................................................................................................................................86
4.6.1.4 Out of Service.....................................................................................................................................86
4.6.2 Configuring a Workgroup................................................................................................................................86
4.6.2.1 Configure the Terminal Address .........................................................................................................87
4.6.2.2 Configure the Controller (I/O Board) pLAN Address ..........................................................................88
4.6.2.3 Assign the Terminal to the Controller.................................................................................................88
4.6.2.4 Fault Messages...................................................................................................................................89
4.6.2.5 Displaying the Network Status and Firmware Version........................................................................89
4.6.2.6 Configure Workgroups.......................................................................................................................90
4.6.2.7 Service>Options>Group Menu Screens .............................................................................................97
4.6.2.8 Group Information Menu Screens......................................................................................................99
4.7 BMS Communications...............................................................................................................................................101
4.7.1 Direct BMS Control........................................................................................................................................102
4.7.2 BMS Communication.....................................................................................................................................102
4.8 Troubleshooting the Control I/O Module ..................................................................................................................103
4.9 BMS Parameters, Version 1.2.....................................................................................................................................104
4.9.1 Signed Values for HTTP, SNMP/Modbus Holdling Registers/Analog Values for BACnet ................................105
4.9.2 Unsigned Values for HTTP, SNMP/Modbus Holdling Registers/Analog Values for BACnet ............................106
4.9.3 Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet ....................................................107
4.9.4 Alarm Packed Bit Variables ............................................................................................................................108
4.9.5 Sensor Failure Packed Bit Variables ............................................................................................................... 109
4.9.6 Digital Input Packed Bit Variables................................................................................................................... 110
4.9.7 Digital Output Packed Bit Variables.................................................................................................................111
4.9.8 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet............................. 112
4.9.9 Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet .................................................... 112
5. Maintenance...................................................................................................................................................................... 113
5.1 Periodic General Maintenance................................................................................................................................... 113
5.1.1 Filters ............................................................................................................................................................. 113
5.1.1.1 Cleanable Filters................................................................................................................................. 113
5.1.1.2 Cartridge Filters................................................................................................................................. 115
5.1.2 EC Fans.......................................................................................................................................................... 115
5.1.3 Coil................................................................................................................................................................ 115
5.1.4 Drain Pans...................................................................................................................................................... 115
5.1.5 Condensate Pump ......................................................................................................................................... 115
5.1.6 A/C System.................................................................................................................................................... 116
5.2 Troubleshooting......................................................................................................................................................... 116
5.3 Field Service............................................................................................................................................................... 119
5.3.1 Water–Water/Glycol System .......................................................................................................................... 119
5.3.2 DX System ..................................................................................................................................................... 119
5.3.2.1 Leak Detection.................................................................................................................................. 119
5.3.2.2 Leak Repair....................................................................................................................................... 119
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5.3.2.3 Refrigerant Piping............................................................................................................................. 120
5.3.3 Refrigeration System Repairs.......................................................................................................................... 120
5.3.3.1 Compressor Failure ........................................................................................................................... 120
5.3.3.2 Standard Cleanout Procedure........................................................................................................... 121
5.3.3.3 Burn-Out/Acidic Cleanup Procedure................................................................................................. 121
5.3.4 Component Replacement.............................................................................................................................. 121
5.3.4.1 Fan Replacement .............................................................................................................................. 121
5.3.4.2 Condensate Pump Replacement ......................................................................................................122
6. Troubleshooting.................................................................................................................................................................123
6.1 Contacting Technical Support....................................................................................................................................123
6.2 Obtaining Warranty Parts..........................................................................................................................................123
6.3 Obtaining Spare/Replacement Parts..........................................................................................................................123
Appendix A. Forms ................................................................................................................................................................. 125
A.1 Checklist for Completed Installation.......................................................................................................................... 125
A.2 Periodic General Maintenance Checks and Service Checklist .................................................................................... 126
Appendix B. Glossary: Definition of Terms and Acronyms ...................................................................................................... 127
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Chapter 1: Introduction
1. Introduction
1.1 General
The Cold Row precision data center air-conditioning system covered by this manual uses the latest, state-of-the-art control
technology. It uses the finest materials available in the industry. The unit will provide years of trouble-free service if installed and
maintained in accordance with this manual. Damage to the unit from improper installation, operation, or maintenance is not cov-
ered by the warranty.
STUDY the instructions contained in this manual. They must be followed to avoid difficulties. Spare parts are available from
Black Box to ensure continuous operation. Using substitute parts or bypassing electrical or refrigeration components to continue
operation is not recommended and will VOID THE WARRANTY. Because of technical advancements, components are subject to
change without notice.
All Cold Row systems are designed to be installed indoors.
1.2 Product Description
Cold Row systems are available in water-cooled, water/glycol-cooled or air-cooled direct expansion (DX) configurations. DX-based
Cold Row systems are designed to operate with R410A refrigerant.
Table 1-1. Available models.
Product Code
Product Name
CRDX-A-FS-24KW
CRDX-A-FS-12KW
CRDX-G-FS-24KW
CRDX-G-FS-12KW
Cold Row DX, Air
Cold Row DX, Air
Cold Row DX, Glycol
Cold Row DX, Glycol
CRDX-W-FS-24KW Cold Row DX, Water
CRDX-W-FS-12KW Cold Row DX, Water
DX-based Cold Row cabinets are 12" wide. The cooling capacity in KW/Hr will depend on the compressor size. Refer to the unit
nameplate to identify the capacity of your system.
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.
The Cold Row system captures high-temperature (hot aisle) discharge air from adjacent rack-based IT equipment and reintroduces
it as conditioned air through the front of the unit (cold aisle).
The system is equipped with highly reliable Electronically Commutated (EC) fans that offer considerable energy cost savings and
long life. Using an electronically commutated permanent magnet DC motor eliminates AC inverter whine. Fan speed is
continuously adjustable via a signal from the system controller without the use of VFDs. EC fans offer energy-efficient, quiet,
low-vibration operation.
An advanced E2 series microprocessor controller is mounted inside the Cold Row electric box. The controller provides the
following features: input/output monitoring status, full integrated control of cooling and dehumidification, multi-unit control, and
remote communication with a Building Management System (BMS). The controller may interface directly to a BMS, so you can
monitor the performance of the air conditioner and adjust operating parameters.
The E2 user interface display panel is typically factory mounted on the front access panel of the unit.
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Chapter 1: Introduction
Figure 1-1. User interface display.
Refer to Chapter 4 for detailed instructions on operating the system controller.
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Chapter 1: Introduction
12-Month Precision A/C Limited Warranty/
24-Month Precision A/C Upgraded Limited Warranty
The 12-Month Precision A/C Limited Warranty applies when Factory-Authorized startup is not purchased at the time of order
entry.
The 24-month Precision A/C Upgraded Limited Warranty applies only if Factory-Authorized startup was purchased at the time of
Order Entry.
The 12-Month Precision A/C Limited Warranty provided by Black Box Network Services warrants your purchase, including
compressors, to be free from defects in material and workmanship. 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. Parts repaired or
replaced under this warranty are shipped FOB Factory, and warranted for the balance of the original warranty period or for 90
days from the date of installation, whichever is greater. If the factory startup form is not returned to Black Box Network Services
within 90 days from the date of equipment shipment, the equipment warranty will be terminated on the 91st day from shipment.
This limited warranty does not include labor, freon, or any other expense required to replace the defective component and bring
the unit back to a working status.
The 24-Month Precision A/C, Upgraded Limited Warranty provided by Black Box Network Services warrants your purchase,
including compressors, to be free from defects in material and workmanship for 24 months. Black Box Network Services’
obligation under this warranty is to repair or replace, at its option, any part or parts which are determined by Black Box Network
Services to be defective for a period of 24 months from the date of startup. This warranty also includes labor needed to perform
any warranty work for a period of 90 days from the date of startup. Parts repaired or replaced under this warranty are shipped
FOB factory ground, and warranted for the balance of the original warranty period or for 90 days from the date of installation,
whichever is greater. If the factory is not allowed to start the equipment within 90 days from the date of shipment, the warranty
will commence on the 91st day from equipment shipment. This limited warranty does not include labor, freon, or any other
expense required to replace the defective component and bring the unit back to a working status.
In the event equipment is shipped to Black Box for temporary storage for 6 months or less, warranty begins and startup checklist
is required to be on file with Black Box Network Services field service within 90 days of shipment to job site for installation.
Black Box Network Services’ warranty does not cover failures caused by improper installation, abuse, misuse, alteration,
misapplication, improper or lack of maintenance, negligence, accident, normal deterioration (including wear and tear), or the use
of improper parts or improper repair.
Purchaser’s remedies are limited to replacement or repair of non-conforming materials in accordance with the written warranty.
This warranty does not include costs for transportation, travel expenses, costs for removal or reinstallation of equipment or labor
for repairs (*except as set forth above) or replacements made in the field.
If any sample was shown to the buyer, such sample was merely to illustrate the general type and quality of the product, and not
to represent that the equipment would necessarily conform to the sample.
This is the only warranty given by the seller, and such warranty is only given to the buyer for commercial or industrial purposes.
The warranty is not enforceable until the invoice(s) is paid in full.
THIS FOREGOING SHALL CONSTITUTE BLACK BOX NETWORK SERVICES’ ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY. IN
NO EVENT SHALL BLACK BOX NETWORK SERVICES BE LIABLE FOR ANY DEFECT, INDIRECT, SPECIAL, INCIDENTAL,
CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF)
ARISING IN ANY WAY OUT OF THE INSTALLATION, USE, OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN LIEU
OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
This warranty supersedes all other previously printed warranties dated
prior to this document in regards to Diagnostic Labor Warranty.
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Chapter 1: Introduction
1.3 Product Warranty
Black Box offers a two-year standard limited warranty as stated on the previous page. An extended warranty may be purchased
on the unit’s compressor. The compressor warranty as stated below will be sent with your unit if the option is purchased. Retain
this for future reference. You may consult Black Box Technical Support at 724-746-5500 or info@blackbox.com to verify if the
extended compressor warranty was purchased for your system.
Cold Row Warranty — Compressor
This warranty applies only when Factory Authorized Start-Up is purchased at the time of order entry.
Unit Model #:
Warranty Start Date:
Warranty End Date:
Compressor 1 Serial #:
Compressor 2 Serial #:
Optional Compressor Summary:
Black Box warrants your purchase to be free from defects in material and workmanship for up to 60 months (original standard is
24 months and purchased additional is 36 months). The Black Box Optional Compressor Limited Warranty may be purchased in
1-year increments, up to a total warranty period of 60 months from the date of startup. Black Box’s obligation under this
warranty is to repair or replace, at its option, free of charge to the customer, any part or parts which are determined by Black Box
to be defective for a period of 60 months from the date of startup. Startup must be completed within the first 90 days from
shipment. The 60-month warranty only covers original compressor(s) that were installed by Black Box or an original equipment
supplier contracted by Black Box to manufacture equipment solely for Black Box.
Compressors replaced under this warranty are shipped FOB Factory ground, and warranted for the balance of the original
warranty period or for 90 days from the date of installation, whichever is greater. If the factory is not allowed to start up the
equipment within 90 days from the date of shipment, the warranty will commence on the 91st day from equipment shipment.
Black Box’s warranty does not cover failures caused by improper installation, abuse, misuse, alteration, misapplication, improper or
lack of maintenance, negligence, accident, normal deterioration (including wear and tear), or the use of improper parts or
improper repair. Purchaser’s remedies are limited to replacement or repair of non-conforming materials in accordance with the
written warranty. This warranty does not include cost for torch charges, reclaim charges, Freon, transportation, travel expenses,
costs for removal or reinstallation of equipment, or labor for repairs or replacements made in the field.
If any sample was shown to the buyer, such sample was merely to illustrate the general type and quality of the product, and not
to represent that the equipment would necessarily conform to the sample.
This is the only warranty given by the seller, and such warranty is only given to buyers for commercial or industrial purposes. The
warranty is not enforceable until the invoice(s) is paid in full.
THIS FOREGOING SHALL CONSTITUTE BLACK BOX’S ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY. IN NO EVENT SHALL
BLACK BOX BE LIABLE FOR ANY DEFECT, INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES,
INCLUDING LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY WAY OUT OF THE INSTALLATION,
USE, OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty supersedes all other previously printed warranties dated prior to this document.
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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. Be especially
careful to read and follow all cautions that apply to your application.
A bold text WARNING safety alert appears with information that is important for protecting you from harm and the equipment
from damage. Pay very close attention to all warnings that apply to your application.
A safety alert symbol
precedes a general WARNING or CAUTION safety statement.
A safety alert symbol
precedes an electrical shock hazard WARNING or CAUTION safety statement.
1.4.2 Safety Summary
The following statements are general guidelines followed by warnings and cautions applicable throughout the manual. Before
performing any installation, operation, maintenance, or troubleshooting procedure, read and understand all instructions,
recommendations, and guidelines contained within this manual.
CAUTION
All maintenance and/or repairs must be performed by a journeyman refrigeration mechanic or air-conditioning technician.
CAUTION
When moving the unit, it should be kept in its normal installed position. If the unit is not kept level and vertical, damage to the
compressors will result.
WARNING
Never operate the unit with any cover, guard, screen panel, etc. removed unless the instructions specifically state
otherwise; then do so with extreme caution to avoid personal injury.
CAUTION
Never lift any component in excess of 35 pounds without help. If a lifting device is used to move a unit, make sure it is capable of
supporting the unit.
CAUTION
When working on electrical equipment, remove all jewelry, watches, rings, etc. Keep one hand away from the equipment to
reduce the hazard of current flowing through vital organs of the body.
CAUTION
Always turn off the service disconnect switch and disconnect the main power supply to the equipment. Follow a lock-out tag-out
procedure to ensure that power is not inadvertently reconnected.
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.
CAUTION
Equipment may contain components subject to electrostatic discharge (ESD). Before attempting to mount or service these
electronic devices, make sure you have no charge built up by touching a ground source. When possible, use a wrist-grounding
strap when working on or near electronic devices.
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Chapter 1: Introduction
CAUTION
Never work on electrical equipment unless another person who is familiar with the operation and hazards of the equipment and
is competent in administering first aid is nearby.
CAUTION
All personnel working on or near equipment should be familiar with hazards associated with electrical maintenance. Safety
placards/stickers are placed on the unit to call attention to all personal and equipment damage hazard areas.
WARNING
Refrigerant (R410A) is used with this equipment. Death or serious injury may result if personnel fail to observe proper
safety precautions. Great care must be exercised to prevent contact of liquid refrigerant or refrigerant gas, discharged
under pressure, with any part of the body. The extremely low temperature resulting from the rapid expansion of
liquid refrigerant or pressurized gas can cause sudden and irreversible tissue damage.
As a minimum, all personnel should wear thermal protective gloves and face-shield/goggles when working with
refrigerant. Application of excessive heat to any component will cause extreme pressure and may result in a rupture.
Exposure of refrigerant to an open flame or a very hot surface will cause a chemical reaction that will form carbonyl
chloride (hydrochloric/hydrofluoric acid); a highly poisonous and corrosive gas commonly referred to as PHOSGENE.
In its natural state, refrigerant is a colorless, odorless vapor with no toxic characteristics. It is heavier than air and will
disperse rapidly in a well-ventilated area. In an unventilated area, it presents a danger as a suffocant.
Always refer to the manufacturer’s Material Safety Data Sheet (MSDS) provided with the unit.
CAUTION
Certain maintenance or cleaning procedures may call for the use and handling of chemicals, solvents, or cleansers. Always refer to
the manufacturer’s MSDS prior to using these materials. Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes
and prolonged exposure of skin to cleaning solvents. Wash exposed skin thoroughly after contact with solvents.
CAUTION
Do not use cleaning solvents near open flame or excessive heat. Wear eye protection when blowing solvent from parts. The
pressure-wash should not exceed 30 psig. Solvent solutions should be disposed of in accordance with local and state regulatory
statutes.
WARNING
When performing brazing or de-brazing operations, make certain the refrigeration system is fully recovered and
purged and dry nitrogen is flowing through the system at the rate of not less than 1–2 CFM (.03–.06 m3/minute).
CAUTION
The air-intake and discharge areas must be free of obstructions. Make sure access panels are secure and latched into position.
CAUTION
Cooling coils (and associated piping circuits) are pressurized and sealed when they leave the factory. Before installing the
interconnecting piping, observe appropriate safety precautions and release the pressure via an available stem valve or Schrader®
valve before uncapping the pipes.
CAUTION
After interconnecting piping is installed, you must clean the piping system. If you use solvents/cleaning solutions, be sure they are
completely flushed from the piping before connecting it to the unit. Failure to do so will result in equipment problems.
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Chapter 1: Introduction
CAUTION
When filling the water/glycol loop, all air must be bled from the piping system.
WARNING
Do not use chloride-based water-conditioning additives in the condensate drain pans. This will cause corrosion to
occur on the coil fins.
1.5 General Design
The Cold Row DX unit is housed in a steel frame type cabinet rated for indoor use. The exterior of the cabinet is coated with a
powder coat finish to protect against corrosion. Removable access panels are located on the front and rear of the cabinet for easy
access to all components. Operator controls are conveniently located on the front of the cabinet.
NOTE: Customer-specified non-standard features or design variations may not be described in this manual. Refer to the installation
and/or electrical drawings supplied with your unit for details of additional feature(s). 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 unit using direct expansion
(DX) refrigerant. The location of some components may vary depending on the cooling configuration selected (water, water/
glycol, or air cooled).
Figure 1-2. Typical internal layout: Cold Row DX.
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Chapter 1: Introduction
1.5.1 Electrical Compartment
The electrical components are protected inside an electric box located behind the rear access panel. The electric box cover is
safety interlocked with the service disconnect switch (See Figure 1-2), preventing the cover from being opened when the switch in
the On position. The switch must be turned Off to gain access to the electrical compartment.
The service disconnect switch may be used to turn the unit off for emergency shutdown or when routine maintenance is
performed. The handle of the switch locks in the “Off” position to prevent unintended operation.
1.5.2 Circuit Breakers/Motor Start Protectors
Cold Row units incorporate state-of-the-art component protection using motor start protectors and circuit breakers. If an overload
occurs, you must manually reset the switches after clearing the overload condition.
1.5.3 Compressor
A scroll compressor is used in DX-based Cold Row systems. With fewer moving parts, scroll compressors have demonstrated
superior durability. The scroll compressor is designed around two identical spirals or scrolls that, when inserted together, form
crescent-shaped pockets. During a compression cycle, one scroll remains stationary while the other scroll orbits around the first.
As this motion occurs, gas is drawn into the scrolls and moved in increasingly smaller pockets toward the center. At this point, the
gas, now compressed to a high pressure, is discharged from a port in the center of the fixed scroll. During each orbit, several
pockets of gas are compressed simultaneously, creating smooth, nearly continuous compression.
1.5.3.1 Electronic Thermal Expansion Valve
An auxiliary control module mounted to the door of the electric box manages the operation of the electronic expansion valve
(EEV). The control module manages the EEV based on input signals from the suction pressure and temperature sensors. It
regulates the amount of refrigerant entering the evaporator to maintain the correct superheat temperature.
1.5.3.2 Electronic Hot Gas Bypass
Used for freeze protection and capacity control, an electronically controlled hot gas bypass valve is managed by the same auxiliary
control module that manages the EEV valve. The hot gas bypass system allows the compressor to run continuously instead of
cycling the compressor on and off for capacity control. The hot gas bypass system manages system capacity based on the suction
temperature. The hot gas regulator valve meters hot gas into the evaporator coil during low load periods or when evaporator
airflow is reduced.
1.5.4 Coils
Cooling coils are constructed of aluminum finned/copper tube. The coils are leak tested and cleaned before installation by the
factory. Condensate drain pans are provided to collect water condensed by the coils. A condensate pump empties the drain pans
and directs the water to a pipe stub located either at the top or the bottom of the A/C unit depending on the piping
configuration (see Section 2.7.1 and 2.8.1.1).
A float switch in the lower condensate pan detects if the water level rises. If the condensate pan fails to drain, the float switch
signals the controller to sound an alarm and turn off the compressor and the fans.
1.5.5 Condensate Pump
A condensate pump is factory installed in the lower drain pan. The pump automatically eliminates condensate water from the
drain pan. The pump has an internal float switch that turns the pump on and off based on the water level.
1.5.6 EC Fans
The unit is equipped with three high-efficiency, Electronically Commutated (EC) fans. EC fans use a brushless motor equipped
with permanent magnets and permanently lubricated ball bearings. The fan impellers are curved backward and attached to the
rotor casing. The fan is balanced and aerodynamically optimized to minimize vibration.
The fans do not use drive belts. Fan speed is variable via a 0- to 10-VDC signal from the system controller. The fan motor is
equipped with integral electronics and does not require the addition of secondary electronics such as thermal protection,
inverters, or filters. The fan will not produce AC inverter whine.
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Chapter 1: Introduction
During startup, the fans begin operating in stages with five-second time delays. The middle fan starts first, then the upper fan,
then the lower fan. The system controller monitors fan operation. If one or two of the fans fails to operate, the controller alerts
the operator with an alarm message and increases the speed of the remaining fan(s) to compensate for the loss of airflow.
Use the system controller to configure the fans for zone temperature control with independently variable fan speeds or with all
three fans operating at the same variable speed (See Section 4.4.4).
1.5.7 Temperature/Humidity Sensors
Control and alarm recognition takes place by means of the controller analyzing signal inputs from the sensors to manage the
operation of the A/C unit consistent with the setpoints entered in the system controller. The system controller monitors three
NTC-type temperature sensors and a 4–20 mA temperature/humidity (T/H) sensor.
The NTC sensors are factory installed in predetermined supply air fan zones inside the cabinet. Each NTC sensor is used by the sys-
tem controller to manage the speed of the fan for that zone to meet the supply air setpoint temperature. The return air is moni-
tored by a temperature/humidity (T/H) sensor that is typically mounted inside the cabinet. As an option, you can remove the
return air T/H sensor from the cabinet and mount it in the hot aisle. View the actual sensor values from the controller user
interface display using the Information menu loop.
1.6 Optional Equipment
1.6.1 Remote Mounted Supply Temperature/Humidity Sensor
As an option, a supply T/H sensor may be provided for field installation (see Section 2.6.2). This is to be mounted in the supply
(cold aisle) space for monitoring or control purposes. Refer to the electrical drawing supplied with your unit for wiring details
specific to your system.
1.6.2 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.
1.6.3 Smoke Detector
Optionally mounted in the return air side of the cabinet, a photo-electric smoke detector senses the presence of smoke and
signals the controller when a smoke alarm condition exists and shuts down the air conditioner.
1.6.4 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.
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Chapter 2: Installation
2. Installation
2.1 Receiving the Equipment
Your Cold Row precision A/C system has been tested and inspected prior to shipment. Carefully remove the protective packaging
and perform a visual inspection of the equipment immediately upon delivery to confirm that your equipment has been received in
excellent condition. Remove the access panels and thoroughly inspect the interior of the unit for any signs of transit-incurred
damage. 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. If any damage is present, notify Black Box Technical Support at 724-746-5500 or info@blackbox.
com prior to attempting any repairs. Refer to Chapter 6 of this manual for instructions.
A unit data package has been sent with your unit. It contains this manual, system drawings, applicable MSDSs, warranty
registration, other component manuals and applicable instructions based on the configuration of your unit. The data package has
been placed in your unit in a clear plastic bag. These documents need to be retained with the unit for future reference. The unit
should always be stored indoors in a dry location before installation.
NOTE: Items that have been shipped loose, such as the controller display panel, temperature/humidity sensors, water detectors,
etc., are shipped inside the air conditioner unless specified otherwise by the customer. Unpack and store these items in a
safe place unless you are using them immediately.
2.2 Moving the Equipment
Cold Row systems are designed to be kept in a vertical position. The cabinet is equipped with shipping support brackets that are
bolted to the skid to facilitate moving the unit before installation. Move the unit on the skid with a suitable device such as a
forklift, pallet jack, or roller bar, and dollies that are capable of handling the weight of the equipment. For reference, a weight
table is provided on the installation drawing. Unbolt the shipping support brackets from the skid, leaving them attached to the
unit during the installation process.
CAUTION
Tipping Danger. Keep the shipping support brackets attached to the front and rear of the cabinet after removing the Cold Row
unit from the skid. These must remain in place to prevent the unit from tipping over when moving and positioning the cabinet. It
is safe to remove the shipping brackets when a server rack is installed on each side of the cabinet.
CAUTION
Position someone on each side of the cabinet to stop it from tipping over if the shipping brackets must be removed before
installing the server racks on each side.
CAUTION
When moving the unit, lift it vertically and keep it in a level position to prevent damage.
2.3 Site Preparation
Removable access panels are located on the front and rear of the Cold Row cabinet for easy service access. For full-service access
to the internal components, do not place any permanent obstructions in front or behind the cabinet.
NOTE: Establish working clearance requirements before mounting the unit. Refer to local and national electrical codes.
CAUTION
Install the unit in the space that will be air conditioned.
CAUTION
Make sure the mounting surface is capable of supporting the weight of the equipment. Before installing the unit, refer to the
weight table provided on the installation drawing.
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Chapter 2: Installation
When determining the installation location, consider how you’ll route the piping and wiring into the cabinet and ensure access is
available (see Sections 2.7.1 and 2.8.1). The Cold Row system is ordered from the factory with pilot holes for piping and wiring in
either the top or the bottom of the cabinet. See the installation drawing provided with your unit for the pilot hole locations.
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. The installer should ensure that the proper insulation
rating is used based on the design of the space, which was the basis for the system selected. The following table lists
recommended minimum R-value (thermal resistance values) for optimum equipment operation.
Table 2-1. Recommended
minimum thermal resistance.
Structure R-Value
Ceiling
Wall
R-38
R-21
R-19
R-5
Floor
Door
The vapor barrier is the single most important requirement for maintaining environmental control in the conditioned space. The
vapor barrier in the ceiling and walls can be a polyethylene film. Concrete walls and floors should be painted with a rubber- or
plastic-based paint. Doors and windows should be properly sealed, and a door sweep used to minimize leakage. Outside or fresh
air should be kept to a minimum (as it adds to the cooling load), while maintaining the requirement of the Indoor Air Quality
(IAQ) standard. Lack of these steps can cause erratic operation, unstable room control, and excessive maintenance costs.
2.4 Mounting/Placement
The Cold Row precision A/C system uses a frame and panel construction for unit rigidity and full-service access while the unit is
mounted in place.
NOTE: The equipment must be level to operate properly.
Cold Row cabinets are designed to be installed in a row of servers between the server racks (see Figures 2-1–2-3). They have a
compact footprint that allows the units to be placed adjacent to the heat-producing equipment racks anywhere in the row. They
provide cool, conditioned air through the front grille to the adjacent server modules on the cold aisle side of the row. We
recommend positioning the unit to obtain optimum air circulation. Allow 36" clearance in the front and rear of the cabinet for
servicing the unit.
The optimal placement location is next to highly loaded servers that throw off the most significant heat into the hot aisle side of
the row. In this arrangement, the Cold Row minimizes hot spots. It is best not to place a Cold Row unit at the end of a row unless
an air barrier is in place to prevent the conditioned air from being drawn around to the hot aisle side, bypassing the front of the
servers. An air barrier must also be present to prevent conditioned air from being drawn over the top of the row into the hot
aisle.
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Chapter 2: Installation
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.
Once the cabinet is removed from the shipping skid, roll it into position on the casters that are mounted to the bottom of the
unit. Do not remove the shipping support brackets unless server racks are installed on each side of the Cold Row cabinet.
The cabinet is equipped with an adjustable foot at each corner to raise the cabinet off the casters after the unit is positioned in its
operating location. The adjustable feet are also used for leveling and overall height correction. To adjust the height, use a
flat-head screwdriver to turn the screws, located at the top of the four caster housings (accessed inside the front and rear corners
of the cabinet per Figure 1-2). Raise or lower each foot until the cabinet is level and even with the adjacent equipment racks (see
Figure 2-1).
2.5 Air Distribution
Air from the hot aisle is drawn into the rear of the Cold Row cabinet and passes through the fins of the cooling coil. The
conditioned supply air discharges through the front of the cabinet (see Figure 2-2).
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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).
\
Figure 2-3. Front-diverted air distribution.
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Chapter 2: Installation
2.6 Optional Equipment (Field Installed)
NOTE: Do not mount any optional equipment on the unit access panels.
2.6.1 Remote Water Detectors
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. Replace the cover and place the water detector(s) on the floor with the metal electrodes facing down. When water is
present, current will flow between the electrodes. The base has a mounting hole in the center that you can use to secure the
water detector in place.
Figure 2-4. Spot-type water detector.
NOTE: Do not place the spot-type water detector on an electrically conductive surface.
Cable-type water detector: Lay the cable water detector flat across the sub-floor where water could collect. Secure the cable
every 12–18 inches with J-clips or cable ties with adhesive mounting pads when installing it in the airstream. Secure it at each turn
of the cable and when routing it around obstructions. Do not tie the water detector cable to a metal floor stand or to pipes.
Figure 2-5. Cable-type water detector.
When a water leak on the floor reaches the cable, current will flow between the cable wires. A two-conductor wire harness is
provided with a quick-connect fitting on the end. The harness mates to the fitting on the water detector and connects it to the
control terminal block inside the electric box as shown in the wiring diagram provided with your unit.
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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. The T/H sensor should not be mounted near a doorway or an area where it would be exposed to direct sunlight.
When locating the sensor, consider the length of wire to be used. The sensor is typically provided with a 20-foot long cable.
As an option, a 75-foot or 150-foot long cable may be provided. Follow the steps below to mount the sensor.
Figure 2-6. Temperature/humidity sensor.
1. Remove the cover from the base of the sensor by squeezing it at the top and bottom.
CAUTION
Be careful not to damage the exposed temperature/humidity sensors on the PC board when removing the cover. The sensors can
be damaged if handled improperly.
2. Place the base temporarily against the mounting surface.
3. Level the base. Mark and drill mounting holes through at least two of the available slotted holes.
4. Run the 3-conductor shielded cable through the opening in the base, then secure the base with screws ensuring the word
“TOP” on the PC board is oriented upward.
5. Make the wiring connections. Refer to Section 2.9, Utility Connections and refer to the wiring diagram supplied with your unit.
6. Seal the hole in the wall behind the sensor.
7. Replace the cover plate on the base.
CAUTION
The sensor can be damaged if handled improperly. Take care not to damage the exposed temperature/humidity sensor on the PC
board. Do not touch the sensor because this will affect its accuracy.
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Chapter 2: Installation
2.6.3 Outdoor Condensers
Referring to the IOM manual provided with the condenser, install the remote condenser in a secure location where it cannot be
tampered with, and the service disconnect switch cannot be inadvertently turned off. Locate the remote condenser where the fan
is not likely to draw dirt and debris into the coil fins. The clearance around the condenser should be at least 1x the unit's width to
ensure adequate airflow to the coil. Secure the condenser to prevent the system from moving during operation. We recommend
installing the remote condenser with vibration mounts to reduce vibration transmitted to the mounting surface.
2.7 Water–Water-/Glycol-Cooled DX (CRDX-W-FS-12W, CRDX-W-FS-24W, CRDX-G-FS-12W, and
CRDX-G-FS-24W models)
The system uses an external source of fluid to provide coolant to the condenser inside the A/C unit. No refrigeration connections
are required for self-contained water- or glycol-cooled systems (see Figure 2-7).
Table 2-2. Pipe connection sizes.
Model #
Water Glycol Inlet/Outlet
Condensate Drain
CRDX-W-FS-12W,
CRDX-W-FS-24W
11⁄4
"
1
⁄
2
"
CRDX-G-FS-12W,
CRDX-G-FS-24W
11⁄4
"
1
⁄
2
"
THERMAL
EXPANSION
VALVE
DISTRIBUTOR BODY
EVAPORATOR COIL
SIGHT
GLASS
REFRIGERANT
DRIER/STRAINER
PT
ASC
PRESSURE
TRANSDUCER
WATER COOLED CONDENSER
ELECTRONIC
HOT GAS
REGULATOR
SCHRADER
VALVE
SCHRADER
VALVE
T
OPTIONAL PIPING
CONNECTION
TEMPERATURE
SENSOR
PT
PRESSURE
TRANSDUCER
LP
WATER REGULATING
VALVE
HIGH PRESSURE
SWITCH LIMIT
HP
LOW PRESSURE
LIMIT SWITCH
COMPRESSOR
IN
OUT
CONDENSER WATER
CONNECTIONS
Figure 2-7. Typical W/G piping diagram.
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Chapter 2: Installation
Piping Connections
CAUTION
The cooling coil (and associated piping circuits) are pressurized (up to 100 psi) and sealed when they leave the factory. Before
installing the interconnecting piping, release the pressure via an available stem valve or Schrader valve prior to uncapping the
pipes.
Fluid supply and return lines are routed to either the top or bottom of the cabinet as specified when the Cold Row system is
ordered (see Figures 2-8 and 2-9). On units that are piped from the top, the supply and return connections are made outside the
cabinet. On units that are piped from the bottom, the supply and return connections are made inside the cabinet.
Pipe connections are threaded NPT connections. The pipes are labeled; i.e. “Supply,” “Return.” When making the connections, a
Teflon® tape thread sealant is recommended to minimize internal fouling of the piping.
Field piping is not necessarily the same size as the unit’s pipe connections. Piping should be sized to match the system pressure
drop and flow capacity, and may require reducing fittings to match the connection size on the air conditioner. An air vent and
several Schrader valves are installed in the precision A/C unit piping. We recommend providing manual shut-off valves for both
the supply and return fluid for isolating the unit when performing routine maintenance or repairs. Refer to the piping diagram
supplied with your unit.
NOTE: Install a 60-mesh strainer in the supply pipe. Make sure the strainer is readily accessible for servicing or replacement.
For pipe connection sizes, refer to the following table:
Table 2-3. Pipe connection sizes.
Model #
Water Glycol Inlet/Outlet
Condensate Drain
CRDX-G-FS-12W,
CRDX-G-FS-24W
11⁄4
"
1
⁄
2
"
CRDX-W-FS-12W,
CRDX-W-FS-24W
11⁄4
"
1
⁄
2
"
NOTE: Use standard refrigeration practices for piping, leak testing, and filling the water glycol circuit.
Use vibration isolating supports to isolate the piping. Provide supports (clamps or hangers) as necessary, every 5 to 10 feet along
piping runs to minimize vibration and noise transmission. To reduce vibration transmission and prevent pipe damage, seal
openings in walls using a soft, flexible material to pack around the piping. After the piping is installed, seal the gaps between the
pipes and the entrance holes so air won’t leak around the pipes.
NOTE: Water/glycol lines should be insulated to prevent condensation from forming on the pipes if ambient dew point
temperatures are higher than the fluid temperatures.
CAUTION
After the interconnecting piping is installed, the entire piping circuit must be thoroughly flushed prior to operating the system.
If newly installed supply and return piping is used, we recommend cleaning the piping system before connecting it to the unit. If
you use solvents/cleaning solutions, ensure they are completely flushed from the piping before connecting it to the unit. Failure to
do so could result in equipment problems.
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Chapter 2: Installation
Water-Water/Glycol Supply and Return Piping Connections
CONDENSATE DRAIN—
1
⁄2" FPT
FEMALE PIPE THREADS
SCHRADER VALVE
Figure 2-8. Top access piping.
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SCHRADER VALVE
MALE PIPE THREADS
Figure 2-9. Bottom access piping.
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Chapter 2: Installation
2.8 Split Air-Cooled Systems
Split air-cooled systems with a remote condenser will require field-installed refrigerant piping. All split systems are shipped with a
dry nitrogen charge of 100 psig. Release the pressure via an available stem valve or Schrader valve prior to uncapping the pipes.
Do not release the pressure until the field-installed refrigerant piping is ready to connect. Systems using a remote condenser will
require a copper liquid line and discharge line. See Figure 2-10 and refer to the IOM documentation provided with the condenser.
OPTIONAL COMPONENTS FOR FLOODED HEAD PRESSURE CONTROL
ELECTRONIC
THERMAL
EXPANSION
VALVE
PRESSURE
RELIEF VALVE
DISTRIBUTOR
BODY
SCHRADER
VALVE
(OPTIONAL)
CHECK VALVE
SIGHT
GLASS
REFRIGERANT
FILTER/DRIER
HEAD PRESSURE
CONTROL VALVE
RECEIVER
ASC
ELECTRONIC
HOT GAS
REGULATOR
EVAPORATOR COIL
T
CHECK VALVE
SCHRADER
VALVE
TEMPERATURE
SENSOR
LP
PT
SCHRADER
VALVE
INTERCONNECTING
FIELD PIPING BY OTHERS
LOW PRESSURE
LIMIT SWITCH
PRESSURE
TRANSDUCER
HP
HIGH PRESSURE
LIMIT SWITCH
COMPRESSOR
REMOTE AIR COOLED CONDENSER
Figure 2-10. Typical remote air-cooled DX piping diagram.
2.8.1 Refrigerant Piping
Refrigerant lines for the A/C unit are routed to either the top or bottom of the cabinet as specified when the Cold Row system is
ordered (see Section 2.8.1.1). The connections are made inside the cabinet. The pipe stubs are labeled; i.e. “Discharge,” “Liquid
Line.”
The refrigerant piping should be isolated by using vibration-isolating supports. Provide supports (clamps or hangers) as necessary
every 5 to 10 feet along piping runs to minimize vibration and noise transmission. To reduce vibration transmission and prevent
pipe damage when sealing openings in walls, use a soft flexible material to pack around the piping. After the piping is installed,
seal the gaps between the pipes and the entrance holes in the cabinet so air won’t leak around the pipes.
All refrigeration piping should be installed with high-temperature brazed joints. Use standard refrigeration practices for piping,
leak testing, dehydration, and charging of the refrigeration circuits. For copper-to-copper brazing, phosphorous alloy containing a
minimum of 15% silver is recommended. General-purpose silver brazing alloy with 45% silver is recommended for brazing
dissimilar metals.
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Wrap wet rags around the pipes between the areas to be soldered and any nearby refrigeration components to keep excessive
heat from traveling through the pipe and causing damage. Clear all pipe connections of debris and prep connections for
soldering. Use only “L” or “K” grade refrigerant copper piping. Be careful not to allow solder/piping debris to get inside
refrigerant lines. Dry nitrogen should be flowing through the tubing while soldering at a rate of not less than
1.2 CFM (0.028–0.057 m3/minute).
Table 2-4. Pipe connection sizes.
Model #
Liquid Line Discharge Line Condensate Drain
CRDX-W-FS-12W,
CRDX-W-FS-24W
5
5
5
5
1
⁄
8
"
⁄
8
"
⁄
2
"
CRDX-G-FS-12W,
CRDX-G-FS-24W
1
⁄8
"
⁄8
"
⁄
2
"
2.8.1.1 DX Refrigerant Piping Connections
CONDENSATE DRAIN—
1
⁄2" FPT
SUCTION LINE
LIQUID LINE
LIQUID LINE
SUCTION LINE
BOTTOM-ACCESS PIPING
TOP-ACCESS PIPING
Figure 2-11. DX refrigerant piping connections.
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2.8.1.2 Refrigerant Pipe Sizing
Refrigerant lines for split systems must be sized according to the piping distance between the evaporator and the condenser. Each
valve, fitting, and bend in the refrigerant line must be considered in this calculation. Pipe sizes are given for “equivalent feet,” not
linear feet. Do not confuse the terminologies. For example, a 7⁄8" standard 90° elbow has an equivalent length of 1.5 feet; a 7⁄8
"
branch tee has an equivalent length of 3.5 feet. These corrections must be accounted for when sizing your piping.
NOTE: Refrigerant piping between the Cold Row unit and the remote condenser must not exceed 150 feet (total equivalent
length). The maximum level drop from the Cold Row unit to the condenser must not exceed 20 feet.
NOTE: Consult ASHRAE standards and refer to the Copeland applications data guide for more detailed information regarding
refrigerant line traps and line sizing.
Refer to the following table for standard equivalent lengths, in feet, of straight pipe.
Table 2-5. Equivalent length of straight pipe.
OD (in.) Line Size
Globe Valve
Angle Valve
90° Elbow
45° Elbow
0.4
Tee Line
0.6
Tee Branch
2.0
1
⁄2
9.0
12
15
22
28
5.0
6.0
8.0
12
0.9
1.0
1.5
1.8
2.4
5
⁄8
0.5
0.8
2.5
7
⁄8
0.7
1.0
3.5
11⁄8
13⁄8
0.9
1.5
4.5
15
1.2
1.8
6.0
Oil traps must be included every 20 feet in the vertical risers, and the refrigerant lines must be sloped 1⁄4 inch for every 10 feet in
the horizontal lines to ensure proper oil return to the compressor. An inverted trap is required on the discharge line of the remote
condenser to help prevent oil and liquid from flooding back to the compressor.
2.8.2 Remote Air-Cooled Condensers
Refer to the Recommended Discharge Line and Liquid Line sizing tables below. Systems using air-cooled condensers must not
have a refrigerant line pressure drop over 14 psig across the condenser and the interconnecting piping to the condenser.
NOTE: Ensure proper condenser selection to maintain reasonable sub-cooling temperatures.
Table 2-6. Recommended discharge line sizes.
*Equivalent Length Ft.
Model Number
50 ft.. or less
100 ft. or less 150 ft. or less
5
5
5
CRDX-A-FS-12KW
CRDX-A-FS-24KW
⁄
8
⁄
8
⁄
8
7
7
7
⁄
8
⁄
8
⁄
8
*Equivalent feet accounts for the linear pipe length as well as equivalent length of valves, elbows, and tees as shown in the
previous table.
Table 2-7. Recommended liquid line sizes.
*Equivalent Length Ft.
Model Number
50 ft.. or less
100 ft. or less
150 ft. or less
1
1
1
CRDX-A-FS-12KW
CRDX-A-FS-24KW
⁄
2
⁄
2
⁄
2
5
5
5
⁄
8
⁄
8
⁄
8
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Chapter 2: Installation
Vertical runs are based on a total rise of 30 equivalent feet. For longer rises, make individual calculations. Sizes assume the use of
single risers; double risers may be necessary.
CAUTION
Do not exceed 150-foot maximum liquid line length.
If the condenser is installed above the evaporator, the discharge line should include a p-trap at the lowest point in the piping. The
highest point in the discharge line should be above the condenser coil and should include an inverted trap to help prevent oil and
liquid from flooding back to the compressor during off cycles.
If the condenser is installed below the evaporator, an inverted trap the height of the evaporator coil is required on the liquid line
to help prevent oil and liquid from flooding back to the compressor during off cycles.
2.8.3 Condensate Drain Line
A condensate pump is factory installed. The drain line connection is typically a 1⁄2” FPT fitting. The installer must connect a drain
line (customer supplied) to the drain fitting to remove water from the cabinet.
Access the condensate drain fitting through the top or bottom of the cabinet as configured with the water/glycol or refrigerant
piping connections. Access the drain fitting from outside the cabinet on top-piped units. Access the drain fitting inside the cabinet
behind the front discharge panel on bottom-piped units. An entrance hole for the drain line is provided in the floor of the fan
compartment. See the installation drawing provided with your unit for the location of the condensate drain fitting.
Connect the drain line to the fitting and direct the water to an appropriate place, such as an open building drain with an air gap,
per local and national plumbing codes. After the piping is installed, seal the gap between the drain line and the cabinet entrance
hole so air won’t leak.
CAUTION
Do not use chloride-based water-conditioning additives in the condensate drain pans. This will cause corrosion on the coil fins.
2.9 Utility Connections
2.9.1 Main Power
The Cold Row is available in single- or three-phase variations and a wide range of voltages. Examine the unit nameplate to
determine the operating voltage, frequency, and phase of the system (see Figure 2-12). The nameplate also provides the full load
amps (FLA), the current the unit will draw under full design load, the minimum circuit ampacity (MCA) for wire sizing, and the
maximum fuse or heating, air conditioning, refrigeration (HACR) breaker size (MAX FUSE/CKT BKR) for circuit protection. The
unit’s nameplate is located inside the cabinet within the electrical box.
NOTE: If the nameplate states MAX FUSE/CKT BKR, it is required to use fuses or a HACR-type circuit breaker to protect the
system. Other protection devices are not allowed based upon the product listing.
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Figure 2-12. 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.
NOTE: All wiring must conform to local and national electrical code requirements. Use of copper conductors only is required.
Wiring terminations may become loose during transit of the equipment; verify that all wiring terminations are secure.
WARNING
Verify power is turned off before making connections to the equipment.
It is important to verify that the main power supply coincides with the voltage, phase, and frequency information specified on the
system nameplate. The supply voltage measured at the unit must be within 10% of the voltage specified on the system
nameplate, except for 208/230V single-phase units that have a different tolerance listed below.
A main distribution panel must be provided with a manual fused disconnect switch or HACR-type circuit breaker per local and
national electrical codes for service to the equipment. Do not mount a customer-supplied manual fused disconnect switch or
HACR-type circuit breaker to the surface of the unit.
The unit has main power and control pilot holes for connection of the field-wiring conduit. These pilot holes are located on the
Cold Row unit based on the configuration. The pilot holes are located in the top of the cabinet or in the floor of the cabinet. A
label stating “MAIN POWER INPUT” is placed nearby. See the installation drawing provided with your unit for pilot hole locations.
Terminate the main power wires at the line side of the service disconnect switch, located within the electric box. A
separate equipment ground lug is provided within the electrical box for termination of the ground wire.
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CAUTION
Before operating the unit, you must connect an adequate unit-to-ground to the unit.
2.9.1.1 Single-Phase Units 208/230 V
The supply voltage for units that are designed for 208-V operation must have a tolerance within -5% and +10%. If the measured
supply voltage is 230 V, the unit can operate with a tolerance of 5% if the following change is made. The control transformers
within the system must have the primary wire connected to its respective 240V tap instead of the 208V tap.
2.9.1.2 Three-Phase Units
Three-phase units are designed to have the L1, L2, and L3 supply wires connected to corresponding L1, L2, and L3 line terminals
of the non-fused service switch. The unit will operate correctly if the supply wires are connected in this manner.
CAUTION
Improper wire connections will result in the reverse rotation of the fans/blower motors and compressor and may eventually result
in damage to the compressor. To correct this problem, exchange any two of the incoming main power wires at the main power
service disconnect switch. Do NOT rewire the unit’s individual components.
2.9.2 Optional Equipment
Additional control wires may be required depending on the options that were purchased with your unit. Optional sensors are to
be connected directly to the control terminal board in the Cold Row electric box. You may route the wires through the top or
bottom of the cabinet as preferred using the available knock-outs. Refer to the electrical drawing supplied with your unit to
determine the total number of interconnecting conductors required for your system.
NOTE: All wiring must be provided in accordance with local and National Electrical Code requirements for Class 2 circuits.
NOTE: The control transformer(s) supplied with the equipment have been sized and selected based upon the expected loads for
each system.
CAUTION
Do not connect any additional loads to the system control transformers. Connecting additional loads to the factory-supplied
control transformer(s) may result in overloading of the transformer(s).
2.9.2.1 Remote Water Detector
Refer to Section 2.6.1. Each remote water detector used will require two conductors to be wired to the control terminal block
within the unit electrical box. The wire insulation must be rated at 600 V.
2.9.2.2 Remote Temperature/Humidity Sensor
Refer to Section 2.6.2. The remote temperature/humidity sensor is equipped with a shielded cable. The shield is to be terminated
at the unit electric box. The electric box includes a control terminal block with box-type lugs for wire connections.
2.9.2.3 Remote On/Off
The unit can remotely turn off the air-conditioning system. A normally closed switch is required for this purpose (customer
furnished). Connect two conductors from the normally closed switch to the control terminal block located within the unit electric
box. Refer to the supplied electrical schematic for the specific power rating of the switch and for wiring details.
See Section 4.4.5 for additional information on the remote on/off feature.
2.9.3 Outdoor Equipment
The following sections detail field power wiring required for a typical system. Additional conductors may be required depending
on the options purchased with the equipment. Refer to the electrical drawing supplied with your unit for the appropriate field
wiring terminations required specifically for your system.
2.9.3.1 Water-Cooled Systems (CRDX-W-FS-12KW, CRDX-W-FS-24KW Models)
Systems equipped with an internal water-cooled condenser do not require field wiring to external components other than to
optional sensors as selected (e.g. Flow Sensors, Remote Supply Air T/H sensor, Air Pressure, Customer Alarm Inputs).
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2.9.3.2 Glycol-Cooled Systems (CRDX-G-FS-12KW, CRDX-G-FS-24KW)
Glycol-cooled systems equipped with a pump package require field wiring between the A/C unit and the pump package (see
Figure 2-13). The installer must wire two control conductors from the terminal board within the A/C unit, to the pump package
electrical box. Refer to the electrical drawings supplied with your unit for the number of field wires needed and for the
appropriate wire terminations required for your system.
Figure 2-13. Interconnecting field wiring glycol systems.
2.9.3.3 Remote Condenser (CRDX-A-FS-12KW, CRDX-A-FS-24KW)
For systems equipped with a remote condenser, the installer must provide main power wiring to the main power distribution
block located within the remote condenser electric box. A separate equipment ground lug is provided within the electrical box for
termination of the earth ground wire. Refer to the electrical drawing supplied with your unit and the wiring diagram supplied with
the condenser (typically located in the condenser electric box).
Control wires are not required between the remote condenser and the A/C system (see Figure 2-14). As an option, control wiring
may be installed between the A/C system and the condenser for the system controller to enable condenser operation only when
the compressor is running. You must remove the jumper from the remote condenser terminal board (see the condenser wiring
diagram). Wire 24-VAC control conductors from the terminal board within the A/C unit to the remote condenser terminal board.
If control wires aren’t installed (and the jumper remains in place), the condenser is always enabled and will turn on and off based
on the condenser’s pressure control settings. Refer to the electrical drawing for the correct number of field wires needed and for
the appropriate wire terminations required for your system.
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Figure 2-14. Interconnecting field wiring remote condenser.
2.10 System Charging Procedures
2.10.1 Water–Water/Glycol Cooled Systems
No field refrigerant charging is required for fluid-cooled units. The following precautions must be observed when installing and
filling the water–water/glycol loop:
• The piping system must be cleaned prior to allowing water or water/glycol to flow through the system.
• Glycol must be mixed with water before it is added to the system. Use only water/glycol solution with inhibitors for corrosion
protection.
• When filling the water–water/glycol loop, all air must be bled from the piping system.
1. Open a vent valve at highest point of the system.
2. Fill the system until the solution is discharging from the vent with minimal signs of foaming caused by air in the system.
2.10.2 Remote Air-Cooled Systems
Remote air-cooled systems are provided with a dry nitrogen holding charge that must be removed before piping and charging the
unit. Before charging, check the unit nameplate to confirm the type of refrigerant to use.
NOTE: Refrigerant charging must be performed by a qualified air-conditioning technician.
Cold Row systems use R410A refrigerant. R410A is a blended refrigerant recognized for being safe for the environment.
Refrigerants that are multicomponent blends have component parts with different volatilities that result in a change in
composition and saturation temperature as evaporation and condensation occur. The composition of liquid R410A refrigerant,
however, remains relatively constant.
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CAUTION
POE oil is used in systems with R410A refrigerant. POE oil quickly absorbs moisture when exposed to air. High POE oil moisture
levels react with refrigerant to form acid, which results in system contamination. Keep the entire system sealed as much as
possible and minimize exposure of POE oil to outside air. R410A operates at high pressures, which must be considered when
checking the operating temperatures/pressures while charging or troubleshooting the system. Tables are provided in Section
2.10.3 showing the temperature/pressure characteristics for R410A.
2.10.2.1 Estimating Refrigerant Charge
When charging a system with R410A refrigerant, you must weigh the refrigerant and confirm the charge is correct by checking
the superheat and subcooling temperatures (see Section 2.10.2.3).
You can estimate the amount of refrigerant needed by adding the amount of refrigerant required for the A/C unit (Table 2-8) plus
the condenser (Table 2-9) plus the interconnecting refrigerant piping between the A/C unit and the condenser (Table 2-10). The
values in the tables are the estimated weights for the refrigerant circuit. Table 2-9 shows the estimated charge weights for Black
Box condensers. Depending upon site-specific conditions, refrigerant may need to be added or removed when fine tuning the
charge to obtain the correct superheat and subcooling temperatures.
Table 2-8. Estimated refrigerant charge weight for A/C unit.
A/C Unit Model Number Approximate R410A Charge
CRDX-A-FS-12KW
CRDX-A-FS-24KW
3.9 lb.
5.2 lb.
Table 2-9. Estimated refrigerant charge weight for condensers.
Condenser Model # R410A Charge (less receiver)
R410A Charge (with receiver)
BB-060-SEC,
2.8 lb.
12.2 lb.
BB-060-SSA
BB-096-SEC,
3.6 lb.
15.7 lb.
23.6 lb.
35.9 lb.
BB-096-SSA
BB-120-SEC,
5.4 lb.
BB-120-SSA
BB-192-SEC,
8.2 lb.
BB-192-SSA
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Table 2-10. Weight of R410A refrigerant (lbs./100 ft. of type L tubing).
Line Size O.D.
R410A Charge (less receiver)
R410A Charge (with receiver)
1
⁄
2
5.88
1.27
2.03
4.22
7.20
10.97
5
⁄
8
9.44
7
⁄
8
19.52
33.44
11⁄8
13⁄8
50.95
15⁄8
21⁄8
72.11
15.53
34.09
158.29
Example: Estimate the amount of refrigerant required for a refrigeration circuit in a system using R410A refrigerant consisting of a
CRDX-A-FS-12KW unit connected with a 1⁄2" x 30 foot liquid line and 7⁄8" x 30 foot discharge line to a BB-060-SEC or BB-060-SSA
condenser.
A/C Unit = 3.9 lb.
+ 1⁄2" Liquid Line- 30 x 5.88/100 = 1.764 lb.
+ 7⁄8" Discharge Line- 30 x 4.22/100 = 1.266 lb.
+ Condenser = 2.8 lb.
Estimated Refrigerant Charge = 9.73 lb.
(Round off to nearest 0.1 lb = 9.7 lb.)
2.10.2.2 Preparing System For Charging
1. With all the system piping connections made, perform a dry nitrogen leak detection test on the system. Using dry nitrogen
only, pressurize the system to 150 psig. Ensure all service and solenoid valves are energized open and that no part of the
system is isolated from the pressurized nitrogen.
2. Since there is no refrigerant in the system to detect at this point, leaks may be detected by observing if there’s been a change
in the standing pressure after 12 hours. A significant drop in pressure (>10 psig) indicates a leak in the system that needs to be
repaired. After the system is determined to be free of leaks, you may evacuate the system.
Evacuate the System
CAUTION
A proper vacuum must be drawn on the refrigerant system to remove moisture prior to charging. If this is not done, the
refrigerant charge will combine with moisture in the pipes to form an acid that will eventually lead to compressor failure. A triple
evacuation procedure with dry nitrogen is recommended especially for systems with newly installed refrigerant piping.
NOTE: Use a vacuum pump that is capable of evacuating the entire volume of the A/C system, including newly installed or
existing piping. It is essential to use a well-maintained pump that is in good operating condition. Always ensure it contains
clean, fresh oil. Manufacturers recommend that you change the oil in the pump regularly to maintain its ability to remove
moisture.
NOTE: Use high-quality hoses that are free of defects and don’t leak. We recommend using copper tubing instead of hoses if
possible because of the low vacuum that must be attained when evacuating the system. Using short, large diameter hoses
helps reduce evacuation time.
3. After ensuring there are no leaks, relieve pressure and evacuate the entire system while maintaining all the solenoids open. Pull
an initial vacuum of 1500 microns or lower using the suction and discharge service ports.
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NOTE: When pulling a vacuum, the Schrader valves will unnecessarily restrict the openings, increasing the evacuation time. During
the evacuation process, we recommend that you remove the Schrader valve cores with a Schrader valve removal tool and
draw the vacuum through the port on the removal tool.
4. If you cannot evacuate the system below 1500 microns, close the vacuum pump isolation valve and perform a rate-of-rise test
by observing the standing pressure over time. If the pressure rises slowly (up to 200 microns in 15 minutes), there is moisture in
the system that still needs to be boiled off. Proceed to Step #5. If the pressure rises rapidly up to atmospheric pressure (more
than 50 microns per minute), there is a leak that wasn’t detected during Step #2. In this case, troubleshoot the entire system
for leaks and repair them. Then begin the initial evacuation process again starting at Step #3.
5. If no leaks are detected after the initial vacuum, release the vacuum and pressurize the system with 2–3 pounds of dry
nitrogen. Allow the system to stand for two hours with the dry nitrogen charge. This gives time for the nitrogen molecules to
disperse in the system and absorb moisture.
6. After two hours, release the pressure. Then turn on the vacuum pump and evacuate the system a second time down to 1500
microns or less. Close the vacuum pump isolation valve and pressurize the system again with dry nitrogen and allow the system
to stand for two hours as in Step #5.
7. After two hours, release the pressure. Turn on the vacuum pump and complete the process of evacuating the system, this time
with a goal of achieving a 250-micron vacuum or less. Close the vacuum pump isolation valve. When you can hold the vacuum
at 500 microns or lower for at least 2 hours with no significant rise in pressure, the system is ready to charge.
8. Replace the Schrader valve cores if you removed them during the evacuation steps. You may now introduce the refrigerant
charge through the Schrader valves.
2.10.2.3 Refrigerant Charging Procedures
R410A refrigerant must be weighed in when performing the charge. Referring to Section 2.10.2.1, calculate the estimated amount
of refrigerant needed for your system.
When charging a system using a blended refrigerant, it is essential that the composition of the refrigerant is maintained. To ensure
correct composition, introduce the refrigerant (R410A) into the system in liquid form rather than vapor form. Cylinders that do not
have dip tubes should be inverted to allow only liquid refrigerant to charge the system. Keeping the temperature of the cylinder
below 85° F will help maintain the correct refrigerant composition while the cylinder is emptied.
WARNING
If refrigerant gas is released in an enclosed area, it may accumulate in low areas and near the floor, displacing
available oxygen. If a major leak occurs, there is a risk of asphyxiation. In such case, the area should be immediately
evacuated and ventilated. Personnel should remain away from the area until it is determined to be safe.
Initial System Charge
Follow the step-by-step instructions below to charge systems using R410A refrigerant. The initial charge will be performed by
introducing liquid refrigerant to the discharge side of the compressor or an available liquid line port with the A/C unit turned Off.
1. Bleed air from hoses and break the vacuum by supplying liquid refrigerant (R410A) to the discharge port near the compressor
until the pressure is equalized. This holding charge allows the low pressure switch to “hold,” enabling the compressor to
operate throughout the process of charging the system.
Fine-Tuning the System Charge
Once the initial charge is completed, refrigerant will need to be added with the unit running.
CAUTION
An adequate heat load must be supplied to ensure a proper charge.
2. Disconnect the refrigerant cylinder from the discharge side of the compressor and connect it to the suction side.
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3. Referring to Chapter 3, start the A/C system and use the system controller to lower the room temperature setpoint 3–5° F
below actual room temperature to ensure that cooling remains on as the unit is charged.
When fine tuning the charge on cool days, it may be necessary to restrict the airflow across the condenser coil to raise the pres-
sure. The fan closest to the header must be running. When fine tuning the charge, ensure the pressures are correct for the type
of refrigerant used. Refer to the tables in Section 2.10.3 for the operating temperature and pressure ranges for R410A refrigerant.
4. Block off a portion of the intake air to the condenser until a constant discharge pressure can be obtained. This will lower the
possibility of overcharging. Allow the discharge pressure to rise to 445–480 psig and hold it constant.
5. Slowly meter liquid refrigerant through the suction side while watching the pressure gauges and monitoring superheat and
sub-cooling temperatures.
CAUTION
Add liquid refrigerant slowly to prevent the refrigerant oil from “washing out” of the compressor.
6. Take a superheat temperature reading near the feeler bulb from the auxiliary control module with the temperature measuring
device well insulated. The ideal superheat temperature is 12–15° F. Maximum allowable superheat temperature is 20° F.
CAUTION
Do not exceed 20° F superheat. Exceeding this temperature may cause failure of the compressor.
7. While monitoring the pressure, take a sub-cooling temperature reading on the output side of the condenser. The sub-cooling
temperature should be 10–20° F.
8. If necessary, (slowly) add liquid refrigerant to the suction side to achieve the correct sub-cooling temperature.
CAUTION
Remove the blockage from the air intake of the condenser.
9. Fill out the applicable sections of the Warranty Registration and Start-Up Checklist.
2.10.2.4 -30° F Ambient Applications
NOTE: For units designed for -30° F operation, a receiver is used to store the refrigerant during the time the condenser is not
using the extra refrigerant charge.
1. Follow Steps 1–8 in Section 2.10.2.3. Once superheat and sub-cooling temperatures are stabilized, add more refrigerant to the
receiver.
NOTE: Do not exceed 80% of the total condenser and receiver volume to allow room for expansion.
2. A refrigerant level sight glass is located on the side of the receiver to assist the service technician in charging the
air-conditioning system. Determine the proper charge by viewing the level of refrigerant in the receiver while the unit is running
at an elevated discharge pressure.
3. Keep the air intake to the condenser blocked and maintain the discharge pressure at 445 psig and hold it constant. The
condenser fan nearest the condenser header should be operating continuously. All other fans, if additional fans exist, should be
off during this time.
4. Add additional refrigerant charge to the receiver as needed until the refrigerant level rises to the center of the sight glass,
indicating that the receiver is 80% filled.
When the refrigerant in the receiver reaches the sight glass, the unit is fully charged.
CAUTION
Remove the blockage to the air intake of the condenser.
5. Fill out the applicable sections of the Warranty Registration and Start-Up Checklist.
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Chapter 2: Installation
2.10.3 Refrigerant Characteristics
2.10.3.1 Pressure/Temperature Settings
The following table is provided to assist with the normal settings of the system for R410A refrigerant. Where applicable, minimum
and maximum settings are given along with normal operating pressures.
Table 2-11. R410A refrigerant pressure/temperature settings.
Normal
Min.
Max.
Sub-cooling °F
Superheat °F
10
5
20
15
10
20
Design Condensing Temp. @ 95°F
Ambient
125
140
105
Suction Pressure (psig)
130
440
440
140
480
—
105
330
—
Fan Cycling Control—Fan On (psig)
Fan Speed Control (psig)
2.10.3.2 Saturated Refrigerant Pressure
The following refrigerant temperature/pressure table is provided for reference for R410A refrigerant.
Table 2-12. R410A refrigerant pressures.
Temperature (°F)
Pressure (psig)
Temperature (°F) Pressure (psig)
20
78.4
75
80
85
90
218
236
255
274
22
24
26
81.9
85.5
89.2
28
30
32
34
36
38
40
42
44
46
48
50
55
60
65
70
93.1
97.0
101
105
109
114
118
123
128
133
137
143
155
170
185
201
95
295
318
341
365
391
418
446
477
508
541
—
100
105
110
115
120
125
130
135
140
—
—
—
—
—
—
—
—
—
—
—
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Chapter 2: Installation
2.11 Settings and Adjustments
2.11.1 Water–Water/Glycol Circuit
Condensing temperature is maintained by liquid flowing through a regulating valve and then into the condenser. The regulating
valve opens to increase the liquid flow as the refrigerant pressure rises (or closes as the refrigerant pressure falls). The system
controller monitors a signal from a pressure transducer to determine how far to open the valve. The controller automatically
changes the control valve position to maintain head pressure based on the difference between the setpoint value and the actual
measured value. The controller transmits a proportional 0– to 10–VDC signal to the regulating valve with 10 VDC corresponding
to the valve opening 100%.
The system controller is factory set for the correct condensing pressure; however, it can be adjusted to increase or decrease the
pressure. To adjust the pressure, enter the Factory menu in the E2 controller. Contact Black Box Technical Support at
724-746-5500 or info@blackbox.com for a password to enter the Factory menu and for technical assistance if adjustment is
necessary.
Make adjustments in small increments. Allow adequate time between adjustments for the valve to fully respond to the control
signal so you can observe the changes in system operation.
2.11.2 Low-/High-Pressure Limit Switch
Air-conditioning systems using DX refrigerant are equipped with hermetically sealed high-pressure and low-pressure switches.
These switches are pre-set by the manufacturer and cannot be adjusted. The high-pressure switch opens at 630 psig and has a
manual reset. The low-pressure switch opens at 65 psig ( 10) and closes at 105 psig ( 10) and has an automatic reset.
2.11.3 Thermal Expansion Valve
An electronically controlled expansion valve (EEV) maintains constant superheat of the refrigerant vapor at the outlet of the
evaporator by metering the flow of refrigerant into the evaporator. Superheat is the difference between the refrigerant vapor
temperature and its saturation temperature at a given suction pressure. By controlling superheat, the EEV keeps nearly the entire
evaporator surface active while preventing liquid refrigerant from returning to the compressor. As a standard, superheat is factory
set at 12–15° F and should not need adjustment. The superheat temperature is monitored and controlled by the auxiliary control
module (EVD Driver) mounted on the door of the electric box. We recommend that you contact Black Box Technical Support if
adjustment is required.
CAUTION
Do not exceed 20° F superheat. Exceeding this temperature may cause failure of the compressor.
2.11.4 Hot Gas Bypass
A electronic hot gas bypass system is provided for freeze protection and capacity control. The auxiliary control module (EVD
Driver) mounted on the door of the electric box manages operation of the hot gas valve. The hot gas regulator valve allows
refrigerant to flow from the discharge line directly to the evaporator through an auxiliary connection downstream of the thermal
expansion valve. This is used to maintain the evaporator at a minimum constant pressure as the heating load varies.
The hot gas (discharge) regulating valve is set to prevent the surface temperature of the evaporator coil from dropping below
35° F. The bypass temperature is factory set and no adjustment should be necessary. Contact Black Box Technical Support at
724-746-5500 or info@blackbox.com if adjustment is required.
2.11.5 EC Fans
The speed of the EC fans is controlled via a 0– to 10–VDC signal from the system controller. The controller is preset by the
factory for the correct fan speed configuration and should not require adjustment. 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.
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Chapter 3: Startup/Commissioning
3. Startup/Commissioning
3.1 Initial Operation
For new installations, make sure the unit is ready to operate by going through the Checklist for Completed Installation, located in
Appendix A, before startup.
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.
Startup must be performed by a journeyman refrigeration mechanic or an air-conditioning technician.
3.2 Step-by-Step Startup Instructions
1. Replace all equipment removed before performing the startup checks.
2. Turn the system on with the service disconnect switch. Upon applying power to the controller, it begins an initialization
sequence, conducting internal diagnostics to confirm functionality (see Section 4.3).
3. After about 30 seconds the Main screen is displayed (see Figure 3-1). At the bottom of the screen a status message “Unit On”
appears.
Figure 3-1. Main display screen.
NOTE: You may turn the A/C unit on and off at any time by pressing and holding the Enter key for 3 seconds.
4. After “Unit On” appears, the fans begin operating in 5-second, time-delayed stages (adjustable). The middle fan is turned on
first, then the upper fan, then the lower fan. The Black Box logo in the display is replaced with a blower symbol.
5. A 45-second time delay is allowed after the first fan turns on before the controller polls the air proving switch. If adequate
airflow is detected, the controller enables its outputs. If the actual room conditions are not within the range of the
programmed setpoints, the system will begin operating in the mode(s) needed (cooling, dehumidifying) to reach the setpoints.
Symbols appear in the display to indicate the active operating modes (see Section 4.3).
6. Temperature and humidity alarms are masked out for 30 minutes to allow for conditions to stabilize without triggering nuisance
alarms.
7. Ensure that all fans are rotating correctly and freely without any unusual noise.
8. Test cooling operation by decreasing the temperature setpoint (see Section 4.5.4.1) to create a demand for cooling. The
compressor will turn on and the supply air should feel cooler than the return air.
In all cases, 1 to 6 hours might be required to see the desired temperature and humidity level in the conditioned space. Once
room conditions have been programmed or set, a repeat visit to the conditioned space may be required to ensure the system is
meeting the room’s requirements.
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. More advanced parameter adjustments may be made through the user interface display (see Figure 4-1).
Operating instructions for the E2 controller are provided in Chapter 4.
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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. The controller is completely programmed at the factory and most applications will require no field setup.
However, you can easily view and adjust the default setpoints and their ranges from the user interface display. The program and
operating parameters are permanently stored on Flash memory in case of power failure.
The E2 Series controller is designed to manage temperature and humidity levels to user-defined setpoints via control output
signals to the A/C system. Control parameters have variable outputs from 0 to 100% of the full rated capacity. The controller
continually receives inputs for the measurable control conditions (temperature and relative humidity) via sensors installed in the
cabinet. The internal logic determines if the conditions require cooling or dehumidification. Control setpoints are established to
maintain the room's designed conditions. The controller responds accordingly to changes and controls the output(s) to the
air-conditioning system so temperature/humidity conditions reach the user-defined control setpoints.
4.1.1 Features
4.1.1.1 Field Configurable
The program for the E2 Series controller is field configurable, ao the operator can select control parameters and setpoints specific
to the application. Operator interface for the E2 controller is provided via an attractive, door-mounted user interface display panel.
The display panel has a backlit LCD graphical display and function keys, giving the user complete control and monitoring capability
of the precision cooling system. The menu driven interface provides users with the ability to scroll through and enter various menu
loops. Monitoring of room conditions and A/C system operation is allowed without entering a password. Modifications to the
control setpoints require the use of a password.
4.1.1.2 Password Protection
You can access the Info menu and Alarms log without a password. The controller recognizes predetermined security levels before
allowing access to display screens containing critical variables. Three secured menu levels (Control, Service, and Factory) support
unique passwords that must be entered to access the menu screens so only authorized personnel may perform modifications to
the settings.
4.1.1.3 Restorable Setpoint Parameters
Upon initial startup, the A/C system operates using the setpoints programmed by the factory. The customer may enter new
operating parameters in the Control and Service menus and the system will then operate accordingly. The new setpoints may be
stored as Customer Default setpoints. The primary setpoints entered by the factory still remain stored in the controllers' memory
as Factory setpoints. The setpoints for the system may be re-adjusted in the Control menu at any time. If it becomes necessary,
the customer may restore the setpoints back to the Customer Default setpoint values or to the original Factory (primary) setpoint
values in the Service menu (See Section 4.5.5.9).
4.1.1.4 A/C Grouping pLAN Operation
Multiple A/C system controllers can be connected (grouped) to a Private LAN (pLAN) local network, allowing the communication
of data and information from each controller to a central control terminal or lead controller. Use the lead controller display screens
to monitor and adjust group control variables for the individual system controllers. Each E2 controller connected to the pLAN
network must be identified with its own unique address.
Multiple A/C units consisting of up to eight (8) precision air conditioners equipped with like controllers may be controlled and
monitored via the E2 series controller. With multiple A/C units each unit can selectively be configured as "Active" to operate as a
primary A/C, “Capacity Assist” for staged operation, or as “Standby” to come on-line in case of a failed air-conditioning unit to
ensure continuous availability. The controller may also be configured to rotate units with timed duty cycling to promote equal
run-time and ensure that each A/C unit within the rotating group is operationally exercised on a periodic timed basis.
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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. The screens that appear on the user interface display panel present data that originates from the controller I/O
module (Figure 4-1). The controller is operated via a 6-key, menu-driven loop structure and offers an alarm log plus four different
interface menu levels to the operator: Information, Control, Service, and Factory. These menus permit the user to easily view,
control, and configure operating parameters for the A/C unit. (See Menu Selections, Figure 4-6.)
4.1.2.1 Function Keys
Table 4-1. Function keys.
Key
Function
Accesses the active alarm screen(s).
Silences audible alarms.
Resets active alarms in the alarm menu.
Accesses the main menu.
Prg Illuminates yellow when unit is on.
Returns to the previous menu level.
Cancels a changed entry.
Steps to the next screen in the display menu.
Increases the value of a modifiable numeric field.
Starts/Stops system operation.
Accepts current value of a modifiable field.
Advances the cursor to the next active alarm screen.
Steps back to the previous screen in display menu.
Decreases the value of a modifiable numeric field.
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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. An alarm is acknowledged by pressing the alarm key. This calls up alarm display screen(s)
that provide a text message detailing the alarm condition(s). After an alarm condition is corrected, the alarm can be cleared by
pressing the alarm key.
4.1.3 Controller I/O Module
The controller is a microprocessor-based I/O module mounted inside the A/C system electric box (see Figure 4-2). The controller
I/O module contains the software that manages the operating parameters of the A/C system.
1
2
7
6
5
4
3
Figure 4-2. Controller I/O module.
Controller I/O Module Layout
The controller I/O module contains the logic and input/output terminals. See Figure 4-2 for details of the controller I/O module
layout. The item numbers that follow coincide with the call-outs in Figure 4-2.
1. Connection (J10) for interface display panel
2. Connection for pLAN (J11)
3. Hatch for BMS or network card
4. Power on LED (Yellow)
5. Signal LEDs (Red, Yellow, Green)
6. Hatch for expansion I/O module(s)
7. Power connector (J1)
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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. A controller intaced to a network must be configured for BMS
communication.
Figure 4-3. BACnet MS/TP BMS interface port.
Figure 4-4. Modbus RTU BMS interface port.
Figure 4-5. BACnet IP, BACnet Ethernet, HTTP, SNMP, and Modbus IP BMS interface port.
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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
allowed to scroll between adjacent menu selections within the Main Menu by using the up and down
key. You are then
arrow keys. When
the desired menu is centered in the screen with bold capital letters and an arrow symbol is pointing towards the Enter
you may press the Enter key to access that menu loop. The user can access the menu loop screens located within the
designated menu selection using the up and down arrow keys. Access to some menus may be protected by a built-in
key,
security protocol and may require the use of a password to gain access.
4.2.2 Menus
From the Main screen, you may press the Program (Prg) key to select from among the five menus shown in Figure 4-6.
Figure 4-6. Menu selections.
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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.
• Word Variables have a unique text message for each of the variable's possible choices.
4.2.4 Cursor Position in Screens
The following display screen is shown as an example after accessing a new menu loop display screen using the function keys.
The name of the menu loop is the line in the upper-most field of the screen. A flashing window also appears in the left of the
uppermost field, indicating that you're in the top level of that menu loop.
Figure 4-7. Flashing window.
From this position, the Up
menu.
and Down
arrow keys may be used to access additional selections within the current display
Each screen supports a specific functional requirement. Pressing the Enter
key allows you access to the selected display screens
to adjust any of the modifiable fields. If a screen with modifiable values is accessed, you may use the Enter key to insert a flashing
cursor in the modifiable fields within that screen.
Figure 4-8. Flashing cursor.
If the flashing cursor is located in a modifiable field, the value of the field will be changed using the up
keys. Press the Enter
screen, press the Enter
the upper-most field of the current screen. To get to the next adjacent menu loop screen, press the up
Press the Enter
and down
key to move the cursor to the next modifiable field. After entering the last modifiable field within a
key to remove the cursor and the enable the flashing window to reappear in the left-hand corner of
or down arrow key.
key successively to advance the cursor through the various modifiable fields of the display screen,
arrow
eventually returning to the first field.
Values that are already correct may simply be skipped over by using the Enter
key without modification of the variable. The
current value, if not changed, will be retained after pressing the Enter key. Values for fields being adjusted will automatically
wrap when adjusted beyond the high or low limit established for that field.
Whenever the flashing cursor is located in a modifiable field, press the Escape (Esc) key one time to return the user to the next
menu up. Each successive use of the Escape key returns you to the next menu level up until the Main screen is reached.
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Chapter 4: E2 Controller
4.2.5 Modifiable Variables
Figure 4-9. Modifiable variable.
Pressing the Enter key accepts the value displayed and advances the cursor to the next modifiable field. You can use the Up or
Down key to modify the values of these fields.
If the modifiable field is a positive (+) number, the positive value is indicated by the absence of a (+) or (-) symbol. The (-) negative
symbol will be displayed to the left of the first digit for negative numbers.
4.2.6 Password Authorization Levels
You can request access to a menu loop from the main menu. Modifiable control screens have variables that affect system
performance. Improper settings may result in erratic operation and possible system failure or damage. Anyone is allowed direct
access to the Info and Alarm log display menus with no security password.
Only authorized personnel who possess a thorough understanding of the system operation should perform modifications to
secured menu settings (Control, Service, and Factory). These menus are configured with password protection, requiring a higher
level of authority to access them. The screens must have accurate variables entered otherwise erratic operation may occur.
4.2.6.1 Password-Protected Screen
When you first attempt to select a secure menu in a given session, the "Enter Password” screen will be displayed. This screen
displays the current security level authorized.
Figure 4-10. Enter password screen.
A session is defined as from the time access is gained to a secure menu until 60 seconds elapses with no key activity. Security
access will be terminated at this point and you will have to re-enter the password to gain access. The menus that may be
password-protected by the user are the Control and Service menus. The factory-level menu screens are also password-protected;
however, the password is set at the factory to limit access.
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” screen is needed when contacting Technical Support to determine the correct
factory menu password for your specific controller.
The level of authority is established by entering the proper password for a given security level. The controller is shipped from the
factory with preset passwords for all the security levels.
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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. For example, if the entered password allows access to Level 2 and the Control menu (Level 1) is requested, access will be
allowed. If the entered password authority level is lower than the level requested, the words “WRONG PASSWORD” will appear
for several seconds at the bottom of the screen.
4.2.6.2 Wrong Password
Figure 4-11. Wrong password.
The “WRONG PASSWORD” message is displayed any time an incorrect password has been entered and the Enter
key has
been pressed. If the “Wrong Password” message appears, pressing the Enter
Password” field.
key will return the operator to the “Enter
A requested menu screen is displayed any time a valid password has been entered and the Enter key is pressed.
NOTE: If you request the Control menu and enter the Service menu password, you are granted access to both.
4.2.6.3 Setting the Passwords
The initial passwords are set by the factory to 0001 for the Control menu (Level 1) and to 0002 for the Service menu (Level 2).
Upon entering the Service>Save Cfg menu, the operator can change the passwords for the menus. If changed, from that point
on, only personnel who know the password can access that menu.
4.3 System Operation
CAUTION
Ensure all system hookups to the air conditioner(s) are completed and that power is available.
1. Turn the main power disconnect switch for the A/C unit to “On.” Upon applying control power, the controller display function
keys illuminate, and the controller begins conducting internal diagnostics to confirm functionality. The controller monitors the
alarm inputs and alarm logic to determine if it’s safe to start the unit. After an initialization period of about 30 seconds, the
Main screen is displayed.
The Main Screen is a status screen displaying the current date and time. It displays the current control temperature and relative
humidity and the current temperature and dew point as calculated from the T/H sensor. It also displays the current system
operating mode(s).
2. If the controller is configured for Automatic On operation (standard), a status message “Unit On” then appears in the display.
Figure 4-12. Main screen.
3. If the status message “OFF–Manual Restart Req” appears instead of “Unit On,” the Automatic On feature may not be enabled.
In this case, turn the air conditioner on by pressing the Enter key.
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NOTE: You may turn the A/C unit on and off at any time by pressing and holding the Enter key for 3 seconds.
Other status messages that may appear at the bottom of the screen are:
“OFF by remote shutdown” indicates the Remote Start/Stop feature is enabled and requires a remote start switch to be turned
On.
“OFF by Network” indicates the unit is part of a group and is off because of a grouping priority command such as a compressor
alarm or loss of airflow, or the BMS communication feature is enabled and the unit received a network signal to pause operation.
“OFF by Internal Alarm” indicates that the unit is off because of a group alarm condition. (Only active with grouped units.)
“Unit on CL Lockout” indicates cooling has been locked out while there is a demand for dehumidification because the
temperature is below the minimum temperature allowable for dehumidification (factory default setting is 4° F below setpoint).
4. After the initialization period expires, the controller enables the control output to the fluid control valve (CRDX-W-FS-12KW,
CRDX-W-FS-24KW, CRDX-G-FS-12KW, CRDX-G-FS-24W) and 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. The middle fan starts first, then the upper fan, then the lower fan.
6. Following a 45-second time delay (after the first fan turns on), the controller polls the air proving switch. If adequate airflow is
detected, the controller enables the compressor to turn on if there is a demand for cooling or dehumidification as defined by
the control setpoints.
Figure 4-13. Controller polls screen.
7. The controller records the date and time power is reinitialized in the alarm history log.
8. If the actual room conditions are not within the range of the programmed setpoints, the system will begin operating in the
mode(s) needed to reach the setpoints (cooling or dehumidifying). Symbols appear to indicate the active operating modes.
= Blower On
= Call For Cooling
= Dehumidifying
9. Temperature and humidity alarms are masked out for 30 minutes to allow conditions to stabilize without triggering nuisance
alarms.
10. Operator interface to the menu loops is available from the Main screen by pressing the Program (Prg) key. The controller starts
a timer whenever a key sequence is initiated. Every time a button is pressed, the timer is reset. If there is no key activity for 60
seconds, the controller will return to the Main screen unless the Screen Lock feature is enabled in the Information menu loop
(see Section 4.5.2).
4.3.1 Setpoint Adjustment
1. From the Main screen, access the Main Menu screen by pressing the program
2. Scroll through the Main Menu selections with the Up and Down arrow keys and select the Control menu by pressing the
key when “CONTROL” appears in bold letters in the center of the screen. A password entry screen will be displayed.
key.
Enter
3. To access the Control menu, press the Enter
key twice to insert a flashing cursor in the “Enter Password” field.
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Figure 4-14. Flashing cursor.
Change the "0" to "1" (or to the current Control menu password if it was changed in the Service menu) with the Up
key and then press the Enter key to accept the password. Press the Enter key again to access the Control menu screens.
arrow
4. From the Control menu, select Setpoints by scrolling through the menu selections with the Up
pressing the Enter key when “SET” appears in bold capital letters in the center of the screen.
and Down arrow keys and
Figure 4-15. Set screen.
5. After entering the Setpoints screens, select the Temperature setpoint screen by scrolling the menu selections with the Up
and Down arrow keys until the word “Temperature” appears in the field at the top of the screen.
Figure 4-16. Temperature screen.
Pressing the Enter
key places the flashing cursor in the setpoint value field. Increase or decrease the Temperature Setpoint with
the Up
and Down arrow keys until the desired temperature value is shown.
Press the Enter
key again to accept the setpoint (this removes the cursor from the field).
6. From the Temperature setpoint screen, select the Humidity Setpoint screen by scrolling with the Up
or Down
arrow key.
When the word “Humidity” appears in the field at the top of the screen, press the Enter
setpoint value field.
key to move the cursor into the
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
screen.
key again to accept the setpoint and then press the Escape key to return to the Setpoints (SET) Control menu
7. Press the Escape
key twice to exit the Control>Setpoints screens and return to the Main Menu screen.
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8. Observe the indicator symbols in the Main screen to determine if the unit is operating in the required mode(s).
9. One to six hours may be required to see the desired temperature/humidity level in the conditioned space. Once room
conditions have been programmed or set, a repeat visit to the conditioned site may be required to ensure the air conditioner is
meeting the room's requirements.
Saving and Restoring Setpoint Parameters
Upon initial startup, the A/C system operates using the setpoints programmed by the factory (primary setpoints) as the operating
setpoints. As described in Section 4.3.1, the user may enter new operating parameters in the Control menu anytime and the
system will then operate accordingly. The user may store the new setpoints in the Service menu if it is intended to save them.
Once stored, the user setpoints now become the operating setpoints. The primary setpoints entered by the factory still remain
stored in the controller’s memory as the factory setpoints.
At any time, setpoints for the system may be re-adjusted to any value and the system will operate accordingly. If necessary, the
customer may enter the Service menu and restore the setpoints to the stored user operating setpoint values. The original Factory
(primary) setpoint values may also be restored from the Service menu. Whichever setpoints are restored (Factory or User) become
the current operating setpoints.
4.3.2 Alarms
As programmed into the system controller, an alarm condition activates the summary alarm logic, which illuminates the alarm key
and energizes an audible alarm. Some alarms are programmed by the factory to automatically shut down the A/C unit until the
alarm condition is remedied and the alarm is cleared by pressing the alarm key. Some of the alarms that may be enabled by the
factory are listed in Section 4.5.3.
4.3.2.1 Summary Alarm
A summary alarm will activate when the controller senses any programmed alarm condition. This illuminates the alarm key and if
the option is selected, a N.O./N.C. summary alarm contact may be energized for remote monitoring of alarm conditions. If certain
critical summary alarm conditions are detected, they will cause the A/C unit to shut down.
4.3.2.2 Customer Alarms
A customer-provided digital (on/off switching) alarm sensor may be connected to terminals provided in the electric box. This alarm
input may be for any site-specific alarm condition the user wishes to monitor that may or may not be provided in the standard
controller alarms menu; that is, Gas Detection, Intrusion Alarm, etc. Upon detection of a customer alarm, the controller will
activate the summary alarm contact and display a screen message indicating a customer alarm message. The screen message
“Customer Alarm 1” (default) will appear in the controller display, or the user may reconfigure the controller to display any
alphanumeric message desired, up to 20 characters long, in the Service>Options>Custom menu loop (see Section 4.5.5.5.).
4.3.2.3 Custom Alarms
A custom (user configured) alarm is activated upon detection of one or more programmed alarm conditions as set by the
operator in the Service>Options>Custom menu loop (see Section 4.5.5.5). When a custom alarm condition is detected, a
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. That way, you are alerted before the filters are so badly clogged that airflow is reduced to a point where a
“Loss of airflow” alarm is activated.
4.4 Controller Operation
The E2 Series controller is designed to control an air-conditioning system in a space or process application to temperature and
humidity levels as defined by the user. Conditioned air is supplied to the space as needed to maintain the temperature/humidity
control setpoints.
The controller I/O module includes inputs and outputs as depicted in Figure 4-18. Not all the inputs and outputs shown below are
used; therefore, only the inputs/outputs needed for the specific A/C system type and application are enabled.
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Figure 4-18. Control inputs and outputs.
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. The controller also monitors a temperature/humidity (T/H) sensor that is mounted in the return (hot
aisle) side of the cabinet.
A remote, mounted supply air T/H sensor may also be provided as an option. The controller may be configured by the factory to
manage system operation based on the remote T/H sensor inputs that are to be field installed in the supply (cold aisle) space.
4.4.1 Control Signals
Control output signals and alarm recognition takes place by means of the controller analyzing signal inputs from the sensor(s) and
developing the appropriate digital or proportional response.
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).
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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. Signals representing temperature and humidity are each compared by the controller
as a percentage value to the maximum control setpoint value resulting in control output values that are directly proportional to
the input signal.
The integral value is used to gradually adjust the proportional output when the calculated output does not move the process
variable closer to setpoint in a given period of time. Decreasing the integral value decreases the interval for the output corrections
(speeding the rate of adjustment). Increasing the integral value increases the interval for corrections (slowing the rate of
adjustment).
4.4.2 Control Methods
System operation depends on the controller's programmed operating configuration. Control takes place by means of the
controller analyzing signal inputs from the supply air temperature sensors and the return air T/H sensor or optional remote
mounted supply T/H sensor. The E2 controller may be configured for temperature/relative humidity control (standard) or
dewpoint control (optional) for cooling, dehumidification, and humidification functions.
The control method, selected in the Factory menu, determines which sensors the controller uses to manage operation of the A/C
system. You may view the method selected in the Control>Set menu, see Section 4.5.4.1.
Table 4-2. Control method sensor selection.
Control Method
Control Sensor Selection
1. Supply air sensors.
Temperature control
2. Return T/H sensor.
3. Remote supply T/H sensors.
1. Return T/H sensor.
Humidity control
Dewpoint control
2. Remote supply T/H sensors.
1. Return T/H sensor.
2. Remote supply T/H sensor.
4.4.2.1 Temperature/RH Control
When enabled for temperature/RH control, the controller continuously monitors the selected combination of air temperature
sensors and return T/H sensor or optional remote supply T/H sensor, as configured by the factory, to manage system operation.
4.4.2.2 Dewpoint Control
When enabled for dewpoint control, the controller logically examines the combination of temperature and relative humidity
(dewpoint) and determines the proper control of cooling, humidification, and dehumidification to move the actual conditions to
within the boundaries of the dewpoint setpoints as they would appear on a psychrometric chart (see Figure 4-19). It avoids
scenarios where the A/C unit might both cool and humidify the supply air when cooling alone will achieve the desired result.
The controller calculates dewpoint using the control inputs from the return air T/H sensor or optional remote, mounted supply T/H
sensor as configured by the factory. The calculated dewpoint property is used to manage system operation, resulting in higher
operational efficiency and shorter component run times.
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Figure 4-19. Dewpoint control.
4.4.3 Operating Configurations
The operating configuration for the controller depends on what type of air conditioner is being controlled (that is, AR, CW, W/G)
and what features are selected. The operating configuration is preset by the factory according to the application. If certain
features discussed in this manual are not factory enabled, no screens for that feature will appear in the controller user interface
display.
4.4.3.1 Compressor Operation
The controller cycles the compressor on when it is determined that cooling is called for. The compressor is turned on based upon
the controller’s cooling response to temperature and humidity inputs from the air sensors. The compressor is enabled following a
time delay, once the programmed “Cooling Stage Enable” setpoint value is reached (see Figure 4-20).
Minimum
Run Time
Start
1
Stop 1
Dehum
Min Temp
Cut-out
1
Cut-in
1
Set
Point
Figure 4-20. Compressor on/off cycle.
The compressor runs at a constant speed and an electronic hot gas bypass system manages capacity in accordance with the
demand for cooling. The compressor is turned off when the control cut-out setpoint is achieved, provided the minimum run time
is expired. Operating setpoints for the compressor are programmed by the factory, and no adjustment should be necessary. If
adjustment is required, contact Black Box Technical Support at 724-746-5500 or info@blackbox.com.
The cooling cut-in and cut-out setpoints are set with a minimum span of 2.0° F.
NOTE: If the compressor cut-in/cut-out setpoints are set too closely together when adjusting setpoints, the compressor could run
below the setpoint temperature during periods of light heat loads because of the minimum run time cycle.
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4.4.3.2 Water–W/G Operation
When the system is turned on, the controller activates the fluid supply control valve with a proportional/integral (P/I), 0–10 VDC
signal. The valve opens proportionally based on head pressure. The control parameters are adjustable in the Factory menu. If
adjustment is required, contact Black Box Technical Support at 724-746-5500 or info@blackbox.com.
The control valve changes position to adjust coolant flow to keep the head pressure to the control setpoint and maintain it. If the
head pressure rises, the valve position continues to modulate open as needed, up to 100% (fully open), to maintain the control
setpoint.
The control output signal is matched to the valve. If the valve typically opens at 2.5 VDC, the control I/O module will generate the
appropriate voltage for opening the valve starting at the minimum voltage of 2.5 VDC. From there the signal increases as needed
until the valve position reaches 100% open.
4.4.3.3 Dehumidifying
When dehumidification is called for, the blower speed automatically changes to the dehumidification fan speed setting. The
controller will operate the system in the cooling mode at full output to strip moisture from the air. The system will remain in the
cooling mode until the actual relative humidity (or dewpoint) reaches the control setpoint plus the dehumidification cut-out offset.
If the control temperature drops below the low temperature cutout setpoint for the dehumidification mode (temperature setpoint
minus 4° F default), cooling operations will stop.
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. The maximum fan speed setting is used during times when the A/C unit is cooling. A dehumidification fan speed setting
is used when the system is in the dehumidification mode. The speed settings are adjustable in the Service>Blower>Blower Set Up
menu loop (see Section 4.5.5.4).
EC fan speed is automatically varied based on temperature. There are mechanisms to trade off the control valve opening versus
fan speed. When the system enters the dehumidification mode, the fan speed automatically changes to the dehumidification
speed setting.
The E2 controller's software is equipped with an operational fail-safe mode. Upon sensing a temperature sensor failure, the
controller signals an alarm. It continues to develop the fan control outputs by calculating the averaged value of the remaining
sensors to replace the input value of the failed sensor. If all the temperature sensors fail, the controller develops the control
outputs based on the entered temperature setpoint value minus a 3° F temperature offset. This allows the Cold Row system to
continue operating while the cause of the problem is corrected.
The controller continually monitors fan operation. Cold Row DX units are equipped with a pneumatic air proving system connect-
ed to a flow switch that detects the loss of airflow when a fan fails to operate.
If one of the fans fails to operate, the controller alerts the operator with an alarm message and increases the speed of the
remaining two fans to 99.9% to compensate for the loss of airflow. If the fault does not clear, the fans shut down for 5 seconds
and then restart. If the fault continues, the fans reset a second time. If the fault does not clear after the second reset, the fan(s)
that generated the fault are shut down and the remaining fans continue operation at 99.9% speed.
If the BMS monitoring/control signal fails, the E2 controller will default to local operation at the current setpoints for the fans. The
local sensors have priority over the BMS system.
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4.4.4.1 Independent Fan Speed Control
The system controller may be configured for independent, variable fan speed control for managing upper, middle, and lower zone
cooling. The controller continually monitors the actual cold aisle supply air conditions for each fan zone (upper, middle, and lower)
as determined by temperature sensors mounted locally to each zone inside the Cold Row cabinet, and it adjusts the speed of each
fan to meet the supply air temperature setpoint for that zone. The operator may select from three independent fan speed
temperature control methods in the Control> Set>Fan Control menu loop (Section 4.5.4.1). Minimum and maximum fan speed
settings for each fan are user adjustable in the Service>Blower>Temp Zone Set Up menu loop (see Section 4.5.5.4). The fans will
not run at speeds outside of the envelope established in that menu loop.
4.4.4.2 Variance from Average Fan Speed Control
When configured for variance from average fan speed control, each fan operates independently. The controller manages the
speed of each fan by comparing the variance of the fan’s local zone temperature sensor to the overall average temperature
measured by the sensors for all three fan zones. The controller adjusts the speed of each fan as necessary to meet the supply air
temperature setpoint for that zone.
4.4.4.3 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.
4.4.4.4 Manual Speed Control
The controller continually controls the speed of each fan to values manually entered in the system controller Control>Set>Fan
Control menu loop (Section 4.5.4.1) without regard to the temperature setpoint.
4.4.5 Remote On/Off
For Remote On/Off operation, terminal positions are provided to connect a remotely located, On/Off switching control device. If
the A/C unit is turned on and the E2 controller receives a remote input signal to turn off the A/C unit, the controller disables all
control outputs and a message “Off by Remote Shutdown” appears in the main display screen. The A/C system will automatically
be reenabled when the remote On/Off signal calls for the A/C unit to turn back on.
The control device may be an On/Off switch, thermostat, or a humidistat. If customer provided, the remote On/Off control
contacts must be sized appropriately. The Remote On/Off contacts must have a minimal rating of 24 VAC. Refer to the electrical
drawing included with the A/C unit for the electrical specifications and for wiring details.
4.5 Menu Screens
4.5.1 Main Menu
Figure 4-21. Main menu.
The Main Menu is accessed from the Main screen by pressing the
key. The Main Menu screen provides a complete listing of
the menu loops that are available. You may scroll through the menu categories using the Up
the Main Menu screen, you may select from among the following standard menus:
and Down
arrow keys. From
“Info” displays basic read-only status information. Allows you to monitor system operational parameters. No password is needed
at this level.
“Alarm Log” displays all alarms and “power-ups” in sequential order with a time and date stamp. No password is needed at this
level.
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“Control” allows modification of basic control parameters such as setpoints and clock. Level 1 password is needed to enter this
menu.
“Service” allows modification of advanced control parameters such as offsets, blower speed, and BMS setup, and permits the
user to save customer parameters and reset the controller to the customer or factory default values. Level 2 password is needed
to enter this menu.
“Factory” allows modification of more advanced control parameters such as sensor scaling, startup delays, and grouping
parameters. Level 3 password is needed to enter this menu. Entry to the Factory menu is intended for qualified technicians work-
ing 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).
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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. There
are no adjustable parameters in this loop. From the Info loop, you may view
the following display screens as they apply to the unit configuration:
4.5.2.1 Operating Conditions
The first Info screen displays the current date and time, and provides state of
operation icons.
The actual control temperature (° F) and relative Humidity (rh) is always
displayed, and dewpoint (Dp) will appear as derived from the control T/H
sensor selection. The values displayed are used by the controller to develop
control output signals for managing system operations.
4.5.2.2 Return Temperature Sensor
Displays relative humidity as measured by the return temperature/humidity
(T/H) sensor inputs. The return T/H sensor is typically factory mounted inside
the cabinet. As an option, the return T/H sensor may be removed from the
cabinet and remotely mounted in the hot aisle.
4.5.2.3 Return Humidity Sensor
Displays relative humidity as measured by the return T/H sensor inputs. Return
dewpoint is calculated by the controller based on the return T/H sensor inputs
and then shown at the bottom of the display screen.
4.5.2.4 Temperature Sensors
The temperature screens display the supply air temperature as measured by
sensors located in the cold aisle side of the Cold Row cabinet. The sensors are
located within the cabinet in upper, middle, and lower zones as called out in
the display. Values measured by the sensors may be used to individually control
the speeds of the fans (see Section 4.4.4.1).
Figure 4-22. Information menu loop, part 1.
Screen Lock Feature
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You may lock any of the status display screens, bypassing the display screen
time-out function. This is sometimes useful to maintain visibility to a specific
screen when testing, making adjustments, or troubleshooting the system.
Simultaneously press the program
approximately 3 seconds to turn the screen lock feature On or Off. When a
screen is locked, it remains displayed unless you press the Up or Down
key and Enter
key for
arrow keys to select a different screen within the menu loop. A symbol (
appears in the upper right corner indicating the screen lock feature is On.
)
4.5.2.5 Remote Supply Temperature/Humidity Sensor
The remote temperature and humidity screens appear if your unit is configured
for a remote supply T/H sensor. The screens display the supply air temperature
and humidity as measured by the sensor that is to be customer installed in the
cold aisle. Remote dewpoint is calculated by the controller based on the
remote supply T/H sensor inputs and shown at the bottom of the display
screen. Values measured by the sensor may be used to control the
temperature and humidity.
4.5.2.6 Discharge Pressure
The Discharge Pressure Status screen only appears if your unit is a water- or
water/glycol-cooled DX system. It displays the current operating head pressure.
Discharge pressure is managed by the system controller based on the input of
the head pressure transducer.
4.5.2.7 Setpoint Values
Displays the current operating temperature and humidity setpoints and control
method. If configured for dewpoint control, the controller displays the
calculated dewpoint setpoints for dehumidification and humidification as
derived from the operating temperature and humidity setpoints.
4.5.2.8 Compressor Status
Displays the status icon (On or Off) for the system compressor and shows the
status of the high pressure and low pressure switches (Open or Closed). It also
shows the current status (On or Off) of the compressor and indicates “Min
On” if the compressor minimum off time has elapsed. If the minimum off time
has not elapsed, the display will show “Min Off,” and the actual minimum off
time will appear next to it.
4.5.2.9 EEV Status
Displays the current operating position of the electronic expansion valve. The
current suction pressure and temperature and the superheat temperature
appear below. The bar gauge next to the valve icon provides a visual
representation of the output signal controlling the valve position.
Figure 4-22. Information menu loop, part 2.
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4.5.2.10 EHGB Status
Displays the current operating position of the electronic hot gas bypass valve.
The current suction temperature appears below. The bar gauge next to the
valve icon provides a visual representation of the output signal controlling the
valve position.
4.5.2.11 Fan Status
The Fan Status screen displays symbols indicating the operating status of the
upper, middle, and lower fans. The symbols are animated when the fans are
running. If a fan is not running, the
symbol will appear instead. The value
of the proportional output signal (0 to 100%) that controls each fan appears in
the field to the right of each symbol. The animated icons are linked together
indicating the three fans are being controlled to the same fan speed setting
(default). The controller also displays the temperature value for the sensor from
each fan zone. The fans may be linked or unlinked in any combination for
individual zone temperature control (see Section 4.5.4.1).
The message “Var from Avg” or “Temp Prop” appears indicating the speed
control configuration (see Section 4.4.4.1). The message in the field is replaced
with “Dehum” when the system is in the dehumidification mode. In the
dehumidification mode, the animated icons are always linked together
indicating that the three fans are being controlled to the same
(dehumidification) fan speed setting.
4.5.2.12 Group Information Menu Screens
The Group Information menu screens only appear if the controller is set up to
operate multiple A/C unit work groups. See Section 4.6.2.8 for a more detailed
description of these screens.
4.5.2.13 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.
Figure 4-22. Information menu loop, part 3.
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4.5.3 Alarm Log
Figure 4-23. Alarm Log screen.
No password is required to view alarm display messages. If an alarm condition occurs, the first active alarm may be displayed by
pressing the key. The alarm screen display text message will remain unchanged until the alarm condition is cleared.
If the alarm log is entered from the main menu, any other active alarm message(s) may be viewed by using the Up
arrow keys to scroll through alarm messages.
and Down
4.5.3.1 Alarms
The red LED backlight within the alarm key will illuminate any time an alarm condition is present or previous alarms existed
without having been reset or cleared. An audible alarm will also activate when an alarm condition occurs. The audible alarm may
be enabled or disabled in the Service>Options menu loop. The first active alarm screen may be displayed by pressing the Alarm
key. The Alarm display provides you with a text message describing the abnormal operating condition. Use the Up
and
Down arrow keys to scroll for any additional alarm messages. Only active alarm screens will be displayed when the Alarm key is
pressed. The alarm screen display will remain unchanged until the alarm condition is corrected and the alarm
again to clear the alarm.
key is pressed
When access is gained to the Alarm Log loop, use the Up
and Down
arrow keys to scroll through the log for a history of
alarm messages. The alarms log may be cleared in the Service>Alarm log menu loop.
The application software supports two types of alarms: “Non-Critical” and “Critical.” Any alarm may be programmed to activate
the “Custom” (user-configured) alarm relay contacts.
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:
• High Temperature
• Low Temperature
• High Humidity
• Moisture Detection
• Change Filter
• Sensor Failure
• Low Humidity
• Communication Failure
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.
Some examples of critical alarms are:
• No Airflow (Air-Proving Switch)
• Fire/Smoke Detection
• High Head Pressure
• Low Suction Pressure
• Off by Internal Alarm (Only for grouped systems)
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4.5.3.4 Alarm Screen Messages
Table 4-3. Alarm screen messages.
Alarm Release
Description of Alarm Conditiion
High Temperature
Air temperature is above user-defined alarm setpoint.
Low Temperature
High Humidity
Low Humidity
Air temperature is below user-defined alarm setpoint.
Humidity is above user-defined alarm setpoint.
Humidity is below user-defined alarm setpoint.
Sensor Failure
Sensor is disconnected or faulty. (The failed sensor is identified.)
External and/or internal communication lost (BMS or pLAN).
Full. Water level in condensate pan is reaching an unsafe level.
Communication Failure
Condensate Pan
Moisture
Water sensed by any combination of a leak detector or condensate pan level switch.
Upper, middle, and/or lower fan failure.
Fan Failure
Change Filter
Filter replacement time interval elapsed; filter needs to be replaced.
No Airflow
Insufficient airflow per air-proving switch.
Smoke/Fire
An alarm condition detected by the smoke detector or firestat.
Temperature is above alarm threshold (user configurable).
Temperature is below alarm threshold (user configurable).
Head pressure is above user-configured alarm threshold.
Suction pressure is below user-configured alarm threshold.
EEV and EHGB control driver error.
Optional Temp High Alarm
Optional Temp Low Alarm
High Head Pressure
Low Suction Pressure
EVD Driver Offline
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4.5.4 Control Menu Loop
From the Control Menu, you may select from four screen menus: Setpoints,
Alarm Setpoints, Clock, and Version. The controller may be programmed by
the user to require Level 1 password authorization to enter this menu loop
(see Section 4.2.6). Once password access is granted, you may select and
adjust the setpoints controlling the performance of the unit, enable alarms
and determine their setpoints, and set the clock.
The Setpoints (SET) screens allow you to view and adjust the temperature
and humidity setpoint control parameters and compare them to system level
operating data derived from the various sensor/transmitter inputs. See
Section 4.5.4.1.
The Alarm Setpoints (ALARM SET) screens allow you to enable and adjust
the high and low temperature and humidity alarm setpoints and offsets, and
compare them to the control setpoints and to the system level operating
data derived from the sensor/transmitter inputs. See Section 4.5.4.2.
From the Clock screens you may view and adjust the current time, date and
day, and set up operating schedule(s) and setpoints for the 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 Support if you need help.
Figure 4-24. Control menu loop.
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4.5.4.1 Setpoint Screens
Figure 4-25. Set screen.
The Setpoints (SET) screens below may be accessed from the Control menu.
Figure 4-26. 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.
Figure 4-27. Fan Control screens, 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. The linked zones use the average of the linked temperature sensors to control fan
speed. Link bars appear to the left of the fan icons indicating which fan zones have been linked.
Figure 4-28. Fan Control screens, not linked.
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When fans are not linked, the controller adjusts the speed of each fan as necessary for that zone to meet the supply air
temperature setpoint. When the system is in the dehumidification mode, the fan speeds are automatically linked and controlled to
the same speed.
4.5.4.2 Alarm Setpoint Screens
Figure 4-29. Alarm Set screen.
You can access the Alarm Setpoints screens from the Control menu. These screens enable the high and low temperature and
humidity alarms, adjust their setpoints, and compare them to the control setpoints and to the current system-level operating data
derived from the sensor inputs.
Figure 4-30. High temperature alarm.
Figure 4-31. Low temperature alarm.
Figure 4-32. High humidity alarm.
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Figure 4-33. Low humidity alarm.
Following the alarm enable screens are the alarm offset screens. From these screens, you may adjust offsets for the high and low
alarm setpoints at which the alarm will be cancelled. The entered offset applies to both the upper and lower values entered in the
alarm setpoints screens. The offset is subtracted when it's applied to the high alarm setpoint and it is added when it’s applied to
the low alarm setpoint.
EXAMPLE 1: Temperature Alarm Offset
Figure 4-34. 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)
or,
80.0° F - 5.0° F = 75.0° F
The High Temperature Alarm will cancel at 75° F.
Conversely, the low temperature alarm will cancel when the actual temperature rises to the Low Temperature Alarm setpoint
(60.0° F) + the Offset (5.0° F)
or,
60.0° F + 5.0° F = 65.0° F
The Low Temperature Alarm will clear at 65.0° F.
EXAMPLE 2: Humidity Alarm Offset
Figure 4-35. Humidity alarm screen.
If the offset for the humidity alarm is set at 5% (default), the high humidity alarm will cancel when the actual humidity drops to
the High Humidity Alarm setpoint (70.0%) - the Offset (5.0%)
or,
70.0% - 5.0% = 65.0%
The High Humidity Alarm will cancel at 65%.
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Dirty Filter Timer
Figure 4-36. Dirty filter timer.
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.
4.5.4.3 Clock Screen
Figure 4-37. Clock screen.
The Clock screens may be accessed from the Control menu. From this screen, you may set the time, date, and day.
Figure 4-38. Set Clock screen.
The Set Clock screen allows you to set and/or adjust the current time, date, and day.
4.5.5 Service Menu Loop
Figure 4-39. Service Menu Loop screen.
The service screens enable the user to enter cut-in and cut-out values, calibrate the system control sensor(s), save and restore
parameters, and view the event log. The Service menu may be entered and programmed by the user via the password menu
(requires Level 2 password). Once password access is granted, the user may access the service screens.
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Figure 4-40. Service menu loop selections.
4.5.5.1 Humidity
The cut-in/cut-out offsets for the Dehumidification modes may be adjusted from the Service>Humid menu.
Figure 4-41. Humidity screens.
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4.5.5.2 Alarms
Figure 4-42. 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.
key is pressed when in any of the Service>Alarms screens, all stored alarm messages will be permanently
NOTE: If the Alarm
erased from the controller's memory.
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4.5.5.3 Sensors
Figure 4-43. Service>Sensors screen.
From the Service>Sensors menu, you may access multiple display screens to enter offsets for calibrating the unit’s various
temperature, humidity, and pressure sensors.
Figure 4-44. Display screens.
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.
NOTE: When calibrating sensors, an offset at one extreme may produce an error at the other extreme. Always verify that any
offset is valid over the entire range of the sensor.
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4.5.5.4 Blower
Figure 4-45. Blower screen.
From the Service>Blower menu, you may access screens to view and adjust the blower speed parameters.
Temp Zone Setup
Figure 4-46. Temperature zone setup screen.
If your unit is configured for zone temperature control, Blower>Temp Zone display screens are available for the upper, middle, and
lower fan. These screens allow you to adjust minimum and maximum fan speed settings and modify the fan speed proportional/
integral (PI) control response parameters. The variable dampening value, used with Variance From Average fan speed control (see
Section 4.4.4.1), adjusts the effect of the variance on the final fan speed.
Blower Setup
Figure 4-47. Blower setup screen.
The blower fans will operate at the Dehum Fan Speed setting during dehumidification. Dehumidification fan speed is limited to
the most restrictive value between the factory preset minimum and maximum, the temperature zone minimum and maximum,
and the speed setting for the operating mode. The higher minimum value is the low speed limit and the lower maximum value is
the high speed limit.
Ex: If the Dehum Speed is set to 60% in the Blower Setup screen and the maximum speed for the lower temperature zone fan is
set to 75% and the factory-set maximum fan speed is 90%, the fans will run at 60% during dehumidification.
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Figure 4-48. Fans will run at 60% of full speed during dehumidification.
If the Dehum Speed is set to 80%, the lower fan will run at 75% during dehumidification as it is limited by the maximum speed
setting for the lower temperature zone.
Figure 4-49. Lower fan will run at 75% of full speed during dehumidification (limited by the temperature zone maximum).
4.5.5.5 Options Menu Loop
Figure 4-50. Options Menu Loop screen.
From the Service>Options menu, you may press the Enter
various options.
key to access a menu loop with screens used to set up and adjust
Control, Startup
Figure 4-51. Control, Startup screen.
The Service>Options>Control, Startup screen allows you to select the control method.
Standard = Temperature/Humidity Control
Dewpoint = Dewpoint Control
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<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.
“Auto on remote” If set to On, the A/C unit may be turned on via a remote On/Off switch.
“EPO Option” (Emergency Power Off)-—If set to On, the off delay timers are bypassed so compressors, blowers, etc. stop
operating immediately when the unit is turned off by a remote on/off signal or a critical alarm.
“Suppress Buzzer” allows you to enable or disable the alarm signal buzzer.
Unit Timers
Figure 4-52. Unit Timers screen.
The Service>Options>Unit Timers screen allows you to adjust the unit timers controlling various startup or shutdown delay
periods.
“Startup delay”—Time delay before blower(s) begin operating after pushing the Enter (
remote on command.
) key after turning the unit on with a
“Airflow delay”—Time delay for allowing the blowers to reach adequate speed before the air-proving sensor actively monitors an
airflow alarm condition.
“Shutdown delay” — Time delay before unit stops operating after pressing the Enter (
it off with a “remote off” command.
) key for three seconds or after turning
“Recovery time” — Time period after startup that temperature and humidity alarms are masked from signaling nuisance high or
low temperature and humidity alarms.
T/H Offset Scaling
Figure 4-53. T/H Offset Scaling screen.
The Service>Options>T/H Offset Multiplier screen allows you to enter a multiplier to apply to scale both the temperature and
humidity cut-in/cut-out offsets. The multipliers are factored to the system offset values set by the factory (shown below).
Default Cut-in/Cut-out Offsets
Temp. Cut-in Offset= 2.0° F; Cut-out Offset= 0.3° F
Humidity Cut-in Offset= -5.0%; Cut-out Offset= -2.0%
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EXAMPLE 1: Temperature Offset Multiplier
With the default cut-in offset for temperature at 2.0° F, a multiplier of 1.0 x 2° F = 2° F. This means the unit will begin operating
in the cooling mode at 74.0° F (Setpoint 72.0° F + Offset 2° F).
Conversely, with the default cut-out offset at 0.3° F, the cooling mode will turn off at 72.3° F.
EXAMPLE 2: Temperature Offset Multiplier
If 2.0 is entered, the offset for temperature is multiplied by 2.0. (2.0 x 2° F= 4° F). This means the unit will begin operating in the
cooling mode at 76.0° F (Setpoint 72.0° F + Offset 4° F).
Conversely, the cooling mode will turn off at 72.6° F.
(Setpoint 72.0°F + [2.0 x Cut-out Offset 0.3°F]).
72.0° F + 0.6° F = 72.6° F
EXAMPLE 3: Humidity Offset Multiplier
If 1.3 is entered, the offset for humidity is multiplied by 1.3. (1.3 x -5%= -6.5%). This means the unit will begin operating in the
dehumidification mode at 38.5% (Setpoint 45.0% + Offset -6.5%).
Conversely, the dehumidification mode will turn off at 42.4%.
(Setpoint 45.0% + [1.3 x Cut-out Offset -2.0%])
45.0% + (-2.6%) = 42.4%
Custom Setup
Figure 4-54. 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.
Customer Alarm Input (Optional)
If enabled, a customer provided alarm input may be used to activate the Summary Alarm relay and show a specific Customer
Alarm message in the alarm display screen. A Customer Alarm message may simply be displayed as “CUSTOMER ALARM 1” as
shown below, or you may press Enter
and use the up
and down
arrow keys to construct a specific alpha/numeric
message in the field stating the specific alarm condition in your own terms; that is, “GAS DETECTION,” “INTRUSION ALARM,”
etc. The Customer Alarm message may be set up on one line with up to 20 characters.
Figure 4-55. Customer Alarm screen.
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NOTE: Display screens shown with a dashed border
appear only if the application feature is enabled.
Custom Alarm Setup (Optional)
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.
Figure 4-56. Custom Alarm Setup screen.
NOTE: Custom alarm display screens may appear even if the feature is not enabled. In this case, changes made to these screens
will have no effect.
You can select any mix of the 48 alarm variables as shown in the tables that follow. As an example, for a custom alarm based
only on the occurrence of moisture alarm, fire/smoke, condensate pan, failure of the return humidity sensor, you would enter the
following bitmask values for the applicable alarm numbers and enter 0 for the rest:
Custom Alarm number 1–8...............Moisture alarm (No. 4) = 8
Custom Alarm number 9–16.............Fire/smoke (No. 10) + Condensate pan (No. 12) = 10 (2+8)
Custom Alarm number 25–32............Return humidity sensor (No. 29) = 16
The custom alarms are set up by entering the bitmask totals developed from the tables shown next.
Table 4-4. Alarms 1 to 8.
Number
Description
Bitmask
Default
1
Upper fan alarm
1
1
2
3
4
5
6
7
8
Lower fan alarm
Middle fan alarm
Moisture alarm
Emergency shutdown
Remote shutdown
Customer alarm
2
2
4
4
8
8
16
32
64
128
16
32
0
Airflow alarm
128
191
Factory Default Bitmask Total
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Table 4-5. Alarms 9 to 16.
Number
Description
Bitmask
Default
9
Filter alarm
1
0
10
11
12
13
14
15
16
Fire/smoke alarm
2
2
Water detection alarm
Condensate pan alarm
Circuit low pressure alarm
4
4
8
8
16
32
64
128
16
32
0
Circuit high pressure
alarm
Dual power Input A alarm
Dual power Input B alarm
0
Factory Default Bitmask Total
62
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. Only the enabled sensors can generate an alarm. To enable an additional custom alarm, add the alarm
bitmask number to the factory default total and enter the new total for the applicable alarm numbers in the Custom Alarm
Setup screen. If an alarm condition appearing in the following tables is detected, it needs to be reset at the interface
display panel or via the BMS.
Table 4-6. Alarms 17 to 24.
Number
Description
Bitmask
Default
17
Humidifier alarm
1
1
18
19
20
21
22
23
24
High temperature alarm
Low temperature alarm
High humidity alarm
2
0
4
0
8
0
Low humidity alarm
16
32
64
128
0
High water temperature CW1
Low water temperature CW1
Loss of power
0
0
128
129
Factory Default Bitmask Total
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Table 4-7. Alarms 25 to 32 (Sensor failure alarms).
Number
Description
Bitmask
Default
25
Lower temperature sensor fail
1
1
26
27
28
29
30
31
32
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
2
2
4
4
8
8
16
32
64
128
16
32
64
128
255
Factory Default Bitmask Total
Table 4-8. Alarms 33 to 40 (Sensor failure alarms).
Number
Description
Bitmask
Default
33
DX1 suction temp sensor fail
1
1
34
35
36
37
38
39
40
Custom sensor 1 fail
Reserved
2
2
0
0
0
0
0
0
3
4
Reserved
8
Reserved
16
32
64
128
Reserved
Reserved
Reserved
Factory Default Bitmask Total
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Table 4-9. Alarms 41 to 48.
Number
Description
Bitmask
Default
41
System Off
1
0
0
0
0
0
0
0
0
0
42
43
44
45
46
47
48
BMS keep alive off
Customer alarm 2
Customer alarm 3
Flow switch alarm
Reserved
2
4
8
16
32
64
128
Reserved
Reserved
Factory Default Bitmask Total
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.
Figure 4-57. Workgroup screens.
See Section 4.6 for a detailed description of how workgroups are set up and for information on setting the operating parameters
available in these screens.
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4.5.5.6 Digital In
Figure 4-58. Digiral 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).
4.5.5.7 Run Hours
Figure 4-59. Run hours screens.
From the Service>Run Hours menu, you may access a loop consisting of the component run hours display screens applicable to
your unit using the Up and Down arrow keys. Each screen displays the number of run hours and number of starts logged for the
component (i.e. compressor, fans, air filter changes, etc.). The run hours and start values may be reset to 0 from the display
screens. The values displayed in each screen are the values logged since the last time the screen was reset.
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4.5.5.8 BMS Communications
Figure 4-60. BMS Communcations 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.
4.5.5.9 Save Configuration
Figure 4-61. Save Configuration screen.
The default setpoints may be restored and passwords may be changed from the Service>Save Cfg menu.
Figure 4-62. Customer Save screen.
The first Service>Save Cfg menu screen allows you to save any adjustments made in service level menu screens as the new
“Customer” parameters or, restore the controller to the previously saved “Customer” parameters. The user may also restore the
controller to the original factory default parameter values shown in Table 4-10.
Use the Enter key to move the flashing cursor to the field you wish to confirm and press the Up or Down arrow key. The word
“No” will momentarily change to “Yes,” indicating the command has been accepted. Then press the Enter key sequentially until
the flashing cursor returns to the top left corner of the screen.
The table that follows are the factory default parameters.
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Table 4-10. Factory default setpoints.
Parameter
Default Value
Temperature Setpoint
72° F
Compressor Cut- in
Compressor Cut- out
Minimum Fan Speed
74° F
72.3° F
40%
Maximum Fan Speed
Dehumidification Fan Speed
Humidity Setpoint
100%
60%
45% RH
Dehumidify Cut-in
Dehumidify Cut-out
50% RH
47% RH
Figure 4-63. Set Passwords screen.
The second Service>Save Cfg menu screen allows you to set new passwords for entering the Control and Service menus.
4.5.5.10 Factory Menu
Figure 4-64. Factory Menu screen.
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.
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4.6 Communication with the Controller
It is possible for the E2 controller to communicate in multiple ways. The controller may be set up to use a pLAN network to link
with additional E2 controllers to create a workgroup consisting of multiple A/C units (see Section 4.6.1).
Using an expansion card, the unit may also be connected to a BMS for monitoring and control of data points using a variety of
different serial communication protocols (see Section 4.7).
Figure 4-65. Configuring multiple A/C units.
4.6.1 Workgroup Setup
The controller may be networked with a group of A/C unit controllers to manage their outputs as a system in an N+M (M =
number of standby units) group. The controllers from up to seven additional A/C units may be tied to a lead controller. The
number of units to be assigned as 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.”
The main screen of each unit in the workgroup will indicate that unit's duty assignment in the bottom field. If the controller is the
group Lead, it will be indicated in the bottom field also.
Figure 4-66. Multiple unit display screen.
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One controller may be designated as the workgroup lead and networked with the controllers from a series of up to 7 additional
A/C units. If configured for multi-unit operation, the workgroup lead controller display panel allows access to the same data and
group control sensor choices that are available from networked system controller display panels.
4.6.1.1 Standby
If the lead controller in the workgroup loses a signal acknowledgement from an active A/C unit in the group, that A/C unit is
deemed as failed or taken out of service. The failed unit will be replaced with the first available standby unit from the workgroup.
The standby unit is cycled on and designated as the new active unit.
4.6.1.2 Capacity Assist
The Capacity Assist option can be used to maximize efficiency for conservation of energy and to more precisely control capacity
at low demand. This feature enables Active A/C units to handle the demand up to a certain temperature/humidity setpoint and
then enables additional units to begin operating as needed. If the Active A/C units are running and unable to satisfy the demand,
Capacity Assist A/C unit(s) may be programmed to turn on to assist the Active units.
Each Capacity Assist unit may set to control operation based on its local temperature/humidity sensor values or control operation
based on network sensor values transmitted from the lead controller. Multiple Capacity Assist units are typically set with each unit
in the group assigned incrementally increasing/decreasing offsets for cooling, humidifying, and dehumidifying so they will turn on
one at a time only if the unit(s) currently operating are unable to satisfy the demand. They should incrementally turn off as each
unit reaches its cut-out setpoint, while active A/C unit(s) continue to maintain room conditions at the desired level.
4.6.1.3 Unit Rotation
In this mode, the lead controller will rotate duty between the grouped A/C units to promote equal run time and will rotate the
role of group lead. When set up for unit rotation, the A/C units will rotate duty in order of their group addresses. Active, Capacity
Assist, and Standby units are all in the rotation cycle, so even a standby unit will be cycled into active duty on a scheduled basis.
A/C units in the group may have their duty assignments locked so they do not join the rotation cycle (and cannot take the lead).
In this case, the message “No_Rot” appears after the duty assignment displayed in the main screen.
Figure 4-67. Unit rotation screen.
An Active_No_Rot unit is always On therefore, it will not rotate out. An Active_No_Rot unit will still be able to take the role as
lead controller during a rotation. 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. Call Black Box Technical
Support for assistance when accessing the Factory menu.
4.6.1.4 Out of Service
A unit may be removed from the group entirely by placing it Out of Service. In this mode, the unit will not operate. A unit may be
placed in this mode as a safety measure to prevent it from unexpectedly starting when performing maintenance or repairs.
4.6.2 Configuring a Workgroup
A workgroup can consist of up to 8 controllers (I/O boards) with pLAN addresses 1 to 8. Their corresponding display terminals will
be assigned pLAN addresses from 32 down to 25. The E2 controller program is defaulted with the controller address set to 1 and
its terminal (display) address set to 32. As such, a normal standalone controller does not need any changes made to either the
controller or the terminal address. The method to setting up workgroups is to retain the first (group lead) controller’s pLAN
address as #1 and terminal address as #32 so that the sum of the addresses equals 33. The first controller added to the group is
assigned pLAN address #2 and its terminal is assigned address #31, the sum of which again equals 33.
NOTE: The sum of the controller and terminal address numbers must always equal 33.
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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)
1
2
3
4
5
6
7
8
Display Terminal
32
31
30
29
28
27
26
25
You must assign the terminal and controller I/O board addresses for each controller to be grouped. Review Sections 4.6.2.1 to
4.6.2.3 first, before turning power on and assigning addresses. Do not interconnect the controllers together before assigning their
terminal and I/O board pLAN addresses.
The first step is to change the terminal address of each controller to 0, referring to Section 4.6.2.1 below. You must set the
terminal address to 0 before you can assign the controller (I/O board) address.
NOTE: If the terminal remains inactive (no key is pressed) for more than 30 seconds, the group setup procedure is exited
automatically, without saving any changes.
4.6.2.1 Configure the Terminal Address
The address of the terminal (display) can only be configured if its telephone jack is connected to the I/O control module in the
electric box and power is turned on. The factory default value for the display terminal address is 32. To reassign the terminal
address, press and hold the (up-arrow ( ), down-arrow (
) and Enter (
) keys simultaneously for five seconds until the
Address Configuration screen shown below appears with the flashing cursor in the top left corner:
Figure 4-68. Terminal (Display) Address screen.
1. To change the address of the terminal (Display address setting), press the Enter
address field (nn).
key once. The cursor will move to the
2. Use the up
and down
arrow keys to select the desired value (0), and confirm by pressing Enter
again.
Figure 4-69. Display Address screen.
The Display Address Changed screen will appear, indicating the display address selected is not the same as the one saved
previously and the new value will be saved to the permanent memory.
3. Once the terminal address is set to zero, cycle the power to the unit Off and then back On.
NOTE: If the “Display address setting:__" field is set to 0, the terminal will communicate with the controller (I/O board) using
point-to-point protocol (not pLAN). The display field “I/O Board address:__” will disappear as it has no meaning until you
set the controller (I/O board) pLAN address.
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4.6.2.2 Configure the Controller (I/O Board) pLAN Address
Immediately after turning power back on, press and hold the Alarm
seconds. First you will see a display message “self test please wait” then the pLAN Address Configuration screen shown below
will appear. Don’t press the Enter key; the cursor is already in the modifiable field.
and the up-arrow
keys simultaneously for 10 to 15
Figure 4-70. pLAN Address screen.
key to set the pLAN address (1–8) for the controller (I/O board). The pLAN Address 1 is already assigned by
default to the first (lead) controller in the group. Address 2 is to be assigned to the first controller added to the group (Address 3
Press the up-arrow
is to be assigned to the second controller added and so on). Then press the Enter
“NO LINK” will appear.
key to confirm your selection. A message
Next, press the up-arrow , down-arrow , and Enter
keys simultaneously. Reconfigure the terminal address following the
steps in Section 4.6.2 again. This time set the terminal address to match the corresponding controller (I/O board) address. If the
controller is assigned Address 2, then the corresponding terminal address should be set to 31 as shown in Table 4-11. If the next
controller is assigned Address 3, the corresponding terminal should be set to 30.
After setting the correct terminal address, press the Enter
key once to confirm your selection. A message “NO LINK” will
appear. At this point, the terminal has been set with the correct address for the controller, and the controller has been set for the
terminal—but now they need to be assigned to each other.
4.6.2.3 Assign the Terminal to the Controller
1. Access the Terminal Address Configuration screen again using the up-arrow , down-arrow , and Enter
keys.
2. Press the Enter
3. Using the up
4. Press the Enter
key until the cursor moves to the field “I/O board address:__”.
and down-arrow keys, enter the address (1–8) for the controller I/O board.
key twice to display the Terminal Configuration screen shown below.
Figure 4-71. Terminal Configuration screen.
5. Here, too, the Enter
key moves the cursor from one field to the next, and the up-arrow
and down-arrow
keys
change the value of the current field. The field “P:0_” depicts the pLAN address (1–8) assigned to the I/O board. In the
example shown, the controller has been assigned address 2.
6. Press the Enter (
) key to move to the field “Trm1 xx”. The field represents the address of the terminal associated with the
and down-arrow keys, enter the address (25–32) of the terminal assigned to the controller
controller. Using the up-arrow
(I/O board). In Figure 4-41, Address 31 has been entered for the first A/C unit added to the group.
7. The Priv/Shared column indicates the type of terminal. The workgroup is setup using private terminals. Do not change the value
(“Pr”). Press the Enter
key to move to the last field.
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8. Enter the field “Ok?No,” choose ”Yes“ using the up-arrow
save the data and exit the group setup procedure.
and down-arrow
keys and confirm by pressing Enter
to
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.” If this appears, check the Signal LEDs on the control I/O module (Figure 4-2) for an error signal. See Section 4.8 for
guidelines on analyzing the signal LEDs.
On the other hand, if the terminal receives no signal from the network, the display shows the following message: “NO LINK.” If
this appears, check the pLAN cables and ensure they are connected properly.
4.6.2.5 Displaying the Network Status and Firmware Version
Once each A/C unit is configured with its new controller and terminal pLAN address, you can examine the entire network setup.
Press the group setup keys up-arrow , down-arrow , and Enter
together as done to access the Address Configuration
screen, but continue holding after the Address Configuration screen appears for at least 5 seconds until the “Network Status”
screen appears.
The Network Status screen, shown below, provides overview of the pLAN group indicating which and how many devices are
connected and the corresponding pLAN addresses.
Figure 4-72. Network Status screen.
Key:
: Controllers (I/O Boards) active in network
: Terminals active in network
: No device connected
The example shown represents:
Controllers active in network, addresses: 1, 2, 3
Terminals active in network, addresses: 30, 31, 32.
The terminal for Controller 1 is always addressed 32; the terminal for Controller 2 is always addressed 31, and so on such that the
sum of the controller address number and the terminal address number always equals 33. Therefore, when viewing controller
number 1, its terminal address will be 32. When viewing Controller 2, its terminal address will be 31, and so on.
Press an up-arrow
terminal.
or down-arrow
key to display the next screen showing the version of the firmware residing in the
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Chapter 4: E2 Controller
Figure 4-73. Firmware version.
To exit the Network Status loop, press Enter
.
The next step is to access the Factory>Group screens used to configure the workgroup parameters (Section 4.6.2.6).
4.6.2.6 Configure Workgroups
The Factory>Group menu screens only appear when multiple A/C units are grouped. These menu screens allow you to define
grouping parameters (duty, rotation, offsets, etc.) for the A/C units in the workgroup. These screens should be accessed after
setting up the workgroups (Section 4.6.2). The Factory>Group menu screens may be accessed from the main screen by pressing
the Prg
key and scrolling through the menu selections until the word Factory appears in the center of the screen.
Figure 4-74. Factory>Group screen.
key twice and you’ll be prompted to enter the password for the Factory level (contact Black Box Technical
Press the Enter
Support for the password).
Once the factory-level password is entered, press Enter
to call up the menu screens. From here, you may press the up-arrow
or down-arrow
keys to scroll through the Factory menu selections.
Figure 4-75. Group screen.
When the word GROUP appears in the center of the screen, press the Enter
key to access the Factory>Group menu screens.
From here, you may use the up-arrow
or down-arrow
keys to scroll through the Factory>Group menu selections.
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Figure 4-76. Factory>Groups>Groups Config (Screen 1). (See Table 4-12.)
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
1
4= Active_No_Rot
5= Standby_No_Rot
6= Assist_No_Rot
Total in Network
Enter the total number of A/C units in the group.
0 to 9
0 to 9
1
1
Min Number Active Enter the total number of active A/C units in the group.
0= No
1= Yes
Enb lead override
Lead Unit
If set to yes, you may manually assign the lead unit in the following field.
No
1
Lead Unit Identifies which A/C unit controller is currently the lead unit in the group.
If "Enb lead override" is set to yes, you may select which unit is lead.
1 to 8
Figure 4-77. Factory>Group>Group Rotation (Screen 2).
From this screen, you may set the schedule to rotate operation of the A/C units to promote equal run times.
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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 ( ) it initiates
a manual rotation cycle to rotate duty between active and standby units. It also rotates
the role of lead controller. The fi eld will disappear after the role of Lead is rotated to
the next A/C unit.
0= Off
Force Rotation
0
1= On 0
Number of Days
Hour of Day
Enter the number of days between rotating active units.
Enter the hour of day for unit rotation to occur.
0 to 999
0 to 23
0
0
Cur Lead
Next lead
Rot Unit
Identifies which A/C unit controller is currently the lead unit in the group.
Identifies which A/C unit controller is designated to be the next lead unit.
Identifies which A/C unit is designated to be the next unit to rotate duty.
1 to 8
1 to 8
1 to 8
0
0
0
Identifies the duty of the A/C unit by displaying the variable number assigned in
Factory>Group screen.
Value
0 to 6
0
1 (0=Out of Service, 1=Active, 2=Standby, etc.).
Figure 4-78. Factory>Group> Capacity Assist (Screen 3).
Each A/C unit in the group may be assigned local cut-in and cut-out setpoints for its capacity assist operation. The values entered
are offsets that are applied to the control setpoints established at the lead controller. Each unit in the group should be assigned
incrementally increasing/decreasing offsets for cooling, humidifying, and dehumidifying so they will turn on one at a time only if
the unit(s) currently operating are unable to satisfy the demand.
Table 4-14. Factory>Group> Capacity Assist (Screen 3) parameters.
Display
Description
Description
Variables
Default
Assist Time
Enter the delay period for capacity assist unit(s) to begin operating.
0 to 999
300
Cooling Cut in
Cut out
Enter a temperature setpoint offset for cooling capacity assist operation to begin.
Enter a temperature setpoint offset for cooling capacity assist operation to stop.
-99.9 to 99.9
-99.9 to 99.9
1.0
0.0
Figure 4-79. Factory>Group>Capacity Assist (Screen 4).
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Table 4-15. Factory>Group>Capacity Assist (Screen 4) parameters.
Display
Description
Description
Variables
Default
Humid Cut in
Cut out
Enter relative humidity setpoint offset for humidifying capacity assist operation to begin.
Enter relative humidity setpoint offset for humidifying capacity assist operation to stop.
Enter relative humidity setpoint offset for dehumidifying capacity assist operation to begin.
Enter relative humidity setpoint offset for dehumidifying capacity assist operation to stop.
-99.9 to 99.9
-99.9 to 99.9
-99.9 to 99.9
-99.9 to 99.9
-4.0
0.0
4.0
0.0
Dehum Cut in
Cut out
Figure 4-80. Factory>Group>Group Averaging (Screen 5).
Table 4-16. Factory>Group>Group Averaging (Screen 5) parameters.
Display
Description
Description
Variables
Default
0 = No
1= Yes
Temp/Hum Sensors
Static Pr Sensor
Yes
Enter Yes for the unit to respond to its local sensors to enable Standby or Capacity Assist
operation. Enter No for unit to respond to the Group sensors.
0 = No
1= Yes
Yes
Figure 4-81. Factory>Group>Group Alarm Setup (Screen 6).
This screen may be accessed on the controller for each unit to be grouped. You may enter bitmask numbers to establish which
alarm conditions for that particular unit will initiate a group internal alarm. The group alarms may be set before the A/C units are
wired together. When a group alarm condition is detected by a unit, it causes that unit to temporarily switch over from “Active”
to “Off” and if another unit is available in the group, it may rotate into its place. A status massage “Off by internal alarm” will
appear in the Main screen of the unit that detected the group alarm and switched off.
See Section 4.5.5.5 for an overview of how to select alarms using bitmask values. The Group Alarms bitmask values are shown in
the Tables 4-17–4-21. The settings may be viewed at the Info level following the network sensors screen. If an alarm condition
appearing in the following tables is detected, it needs to be reset at the unit's display terminal or via the BMS for the unit to
return to “Active” and resume operation.
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Table 4-17. Group alarms 1 to 8.
Number
Description
Bitmask
Default
1
Humidifier
1
0
2
3
4
5
6
7
8
Pump
2
0
0
0
0
0
0
0
Customer alarm 1
Circuit 1 high pressure
Circuit 1 low pressure
DX lockout
4
8
16
32
64
128
Humidifier lockout
FC/AWS lockout
Table 4-18. Group alarms 9 to 16.
Number
Description
Bitmask
Default
9
Upper fan alarm
Middle fan alarm
Lower fan alarm
Water detection
Condensate pan
Moisture
1
0
10
11
12
13
14
15
16
2
0
0
0
0
0
0
0
4
8
16
32
64
128
Filter
Reserved
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Table 4-19. Group alarms 17 to 24.
Number
Description
Bitmask
Default
17
High temperature
Low temperature
High humidity
1
0
18
19
20
21
22
23
24
2
0
0
0
0
0
0
0
4
Low humidity
8
High water temperature CW1
Low water temperature CW1
Reserved
16
32
64
128
Reserved
Table 4-20. Group alarms 25 to 32.
Number
Description
Bitmask
Default
25
26
27
28
29
30
31
32
Upper temperature sensor
Middle temperature sensor
Lower temperature sensor
Return humidity sensor
0
0
0
0
0
0
0
0
1
2
4
8
Optional temperature sensor
Circuit 1 discharge pressure
Circuit 1 suction pressure
Circuit 1 suction temperature
16
32
64
128
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Table 4-21. Group alarms 33 to 40.
Number
Description
Bitmask
Default
33
Static air pressure
Differential air pressure
Dewpoint
0
1
34
35
36
37
38
39
40
2
0
0
0
0
0
0
0
4
Airspeed
8
Reserved
16
32
64
128
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
compressors or all CW valves), or loss of airflow.
Figure 4-82. Factory>Group>Group Status (Screen 7).
The Factory>Group Screen 7, provides an overview of pLAN workgroup.
Table 4-22. Factory>Group>Group Status (Screen 7) parameters.
Display Description Description
Variables
0= On
Default
Group Status
Indicates if multiple A/C unit grouping is enabled.
0
1= Off
C 1 2 3 4 5 6 7 8
Indicates the address (1-8) of each controller in the pLAN.
1
Indicates the address (25–32) of the terminal for each controller in the
pLAN. The terminal address numbers range from 25 to 32 but only the
last digit appears in the screen.
T 5 6 7 8 9 0 1 2
32
Figure 4-83. Factory>Group>Group Status (Screen 8).
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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
Active
Display indicates how many units in the group are currently operating.
0 to 8
0
Display indicates how many units in the group are currently active.
0 to 8
0
Standby
Assist
Display indicates how many units in the group are currently in standby.
0 to 8
0 to 8
0 to 8
0
0
0
Display indicates how many units in the group are currently operating in the capacity assist mode.
Display indicates how many units in the group are currently available to operate.
Display indicates how many units in the group are not available to operate.
Online
Out of Service
The final step to configure a workgroup is to access the Service>Options>Group Setup screens used to configure parameters that
apply to how individual A/C units interact in the workgroup (see Section 4.6.2.7).
Figure 4-84. Factory>Group>Plan timing (Screen 9).
Table 4-24. Factory>Group>Plan timing (Screen 9) parameters.
Display Description Description
Variables
Default
Lead unit
Plan timer
Display indicates which unit is currently the lead.
0
0 to 8
Display indicates the time delay (in seconds) between the detection of
a communication failure and the annunciation of a Comm alarm.
0 to 60
30
0 = No
1 = Yes
pLAN present
Display indicates if a pLAN is detected by the controller.
No
4.6.2.7 Service>Options>Group Menu Screens
Accessed in the Service menu, the Service>Options>Group Setup screens only appear if two or more units are wired together as
a workgroup.
Group Setup
Figure 4-85. Group setup screen.
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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.
The screen also displays a status message indicating which A/C unit you are accessing and which unit is currently the lead unit in
the group.
Capacity Assist
Figure 4-86. Capacity Assist screen.
The first Service>Options>Capacity Assist screen allows you to enter the delay period for the unit to begin operating if it is in the
capacity assist mode. Also each A/C unit in the group may be assigned local cut-in and cut-out setpoints for its capacity assist
operation. The values entered are offsets, which are applied to the control setpoints.
Each unit in the group should be assigned incrementally increasing/decreasing offsets for cooling, humidifying, and dehumidifying
so they will turn on one at a time only if the unit(s) currently operating are unable to satisfy the demand.
Capacity Assist #2
Figure 4-87. Capacity Assist #2 screen.
The second Service>Options>Capacity Assist screen allows you to adjust local capacity assist humidification and dehumidification
setpoints.
Group Sensors
Figure 4-88. Group Sensors screen.
The lead controller polls the controllers from all the A/C units in the workgroup and calculates the averaged value of their
temperature sensors and humidity sensors. It also determines the minimum (lowest) temperature sensor value and the lowest
humidity sensor value in the A/C group and conversely, determines the maximum (highest) temperature sensor value and
maximum humidity sensor value in the A/C group.
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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. You may select the network sensor values to be the Lead, Average, Min, or Max values. The selections made in this
screen will affect all the controllers in the workgroup no matter which controller you access the screen from.
Group Averaging
Figure 4-89. Group averaging screen.
Each unit in the group may be individually set to allow the lead controller to include its sensors for determining the group average
value when it is configured for Standby or Capacity Assist operation. If set to no, the lead controller will not poll that unit’s
sensors when calculating the averaged values.
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.
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Group Sensor Values
This displays the current group temperature and humidity control values transmitted from
the Lead controller. The field below displays the selected control T/H sensor arrangement
(lead, avg, min, max, local) depending upon how the group is set up. See Service>Options
screens, Section 4.6.2.7. The last field shows the unit group address assigned to the
controller within the group and the address of the current lead controller.
Group Alarms
This screen only appears when the controller is wired with additional A/C unit controllers. It
displays bitmask values indicating the alarm conditions that will initiate a group internal
alarm causing the unit to switch over from “Active" to "Unit Off.” See Factory>Group
(Group Alarm Setup) in Section 4.6.2.6.
Lead Controller Group Sensors
This screen appears only in the display of the controller that is designated as the lead in a
multi-unit workgroup. The lead controller polls the temperature and humidity sensors from
all the A/C units in the work group and displays the averaged values. It also displays the
value of the minimum (lowest) temperature sensor and the value of the minimum humidity
sensor in the A/C group and, conversely, displays the value of the maximum (highest)
temperature sensor and maximum humidity sensor in the A/C group. The fields at the
bottom are the addresses of the controllers in the group that have the min. (lowest) and
max. (highest) temperature and humidity sensor readings.
Group Sensor Status
This screen appears only in the display of the controller that is designated as the Lead in a
multi-unit workgroup. It shows what sensors exist on each A/C unit for the lead controller
to perform the group sensor averaging calculation. The numbers are the sums of index
values assigned to the sensors as shown in the following key:
1 = Supply Temperature Sensor
2 = Return Humidity Sensor
4 = Remote Supply Temperature Sensor
8 = Remote Supply Humidity Sensor
16 = Static Pressure Sensor
Figure 4-90. Group screens.
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.
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The number shown for Unit 2 is three, the result of adding 1 + 2. This confirms that Unit 2's supply temperature and return
humidity sensors are detected by the lead controller. If a one appeared instead for Unit 2, it would indicate the signal for the
return humidity sensor is not present. That sensor is either not enabled or it has failed.
4.7 BMS Communications
When BMS communication are used, the controller must be equipped with an optional expansion card designed for one of a
variety of serial communications protocols available (see Section 4.1.4). A communications port on the expansion card allows the
controller to be field connected to a central Building Management System (BMS) for monitoring and control of data points.
An RS-485 serial port is available for Modbus or BACnet MS/TP protocols and a 10BASE-T port is available for TCP/IP based
protocols such as BACnet over IP, BACnet over Ethernet, SNMP, or HTTP.
Table 4-25. BMS communications parameters.
Supported Protocols
Media
Connection
BACnet over IP
10BASE-T
RJ-45 direct
BACnet over Ethernet
HTTP
10BASE-T
10BASE-T
10BASE-T
10BASE-T
Twisted pair
Twisted pair
RJ-45 direct
RJ-45 direct
RJ-45 direct
RJ-45 direct
Daisychain
Daisychain
SNMP V1, V2c
Modbus over IP
BACnet MS/TP
Modbus RTU
Direct Connection
Daisychain Connection
Figure 4-91. Direct connection vs. daisychain connection.
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).
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4.7.1 Direct BMS Control
The controller may be configured to accept proportional analog signals that mimic a sensor. The controller will act on that signal
whether it comes from a real sensor or a BMS analog output. Refer to Section 4.9 for the E2 controller's BMS parameters.
4.7.2 BMS Communication
Figure 4-92. BMS Comm screen #1.
The Service>BMS Comm menu is used to set up the parameters to allow a BMS (BAS) interface for monitoring controller opera-
tion for the serial-based networks such as BACnet MS/TP. Units using the BACnet over IP, BACnet over Ethernet, or HTTP proto-
cols do not need to change anything in this menu loop.
Figure 4-93. BMS Comm screen #2.
The BMS address and baud rate have meaning only on RS-485 networks and with the serial protocols of Modem, Modbus RTU,
Commission, and Carel. The baud rate is fixed for BACnet. Systems using a 10BASE-T interface should use the defaults of address
1, baud rate 19200, and protocol BACnet.
Certain Integer and Digital variables that start with BMS (see Sections 4.9.7–4.9.9) require that the BMS “keep alive” parameter
changes between 1 and 2 within a 10-minute span. The general procedure is to set up variables like the BMS low fan speed and
then write a 1 to the BMS “keep alive” address.
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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). The signal LEDs may be used for diagnostic purposes if a problem arises with the controller.
Key:
LED off
LED on
LED flashing
Table 4-26. I/O control module signal LEDs.
Red LED
Yellow LED
Green LED
Description
Application with error or no pLAN table.
Application with error or no pLAN table. Controller connected to ONLY one terminal.
Application with correct pLAN table.
Correct operation in pLAN.
Awaiting communication with WinLoad (factory configuration software). Check address.
(LED flashing alternately) Communication with WinLoad not valid. No power supply or wrong
driver.
/
/
Communicating with WinLoad (in low-level operation).
Communication with WinLoad on hold.
WinLoad not suitable or incorrect software protection password.
Communicating with WinLoad (in normal operation).
Controller supervisor protocol (slave) active on serial 0.
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4.9 BMS Parameters, Version 1.2
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
HTTP
10 Mbps
10 Mbps
10BASE-T
10BASE-T
RJ-45 direct unit connection
RJ-45 direct unit connection
Uses BMS addresses
Uses BMS addresses
SNMP V1, V2c
Modbus over IP
BACnet MS/TP
Modbus RTU
10 Mbps
10BASE-T
RJ-45 direct unit connection
RJ-45 direct unit connection
Daisychain connection
Uses BMS addresses
Uses Modbus addresses
Uses BMS addresses
Uses Modbus addresses
10 Mbps
10BASE-T
19200 baud
19200 baud
Twisted pair
Twisted pair
Daisychain connection
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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.
BMS
Address
Modbus
Address
BACnet
Address
Description
Default
Read/Write
1
2
002
003
1
2
Temperature setpoint
72.0
R/W
Humidity setpoint
45.0
0.0
R/Ws
R
3
4
5
004
005
006
3
4
5
Average supply temperature display value
Return humidity sensor current value
0.0
0.0
R
R
Dewpoint of return temperature and humidity
6
7
007
008
6
7
Dewpoint of remote temperature and humidity
Middle fan speed
0.0
0.0
R
R
8
009
010
011
012
013
014
015
016
017
018
019
020
021
101
102
103
104
105
106
8
Upper fan speed
0.0
R
9
9
Lower fan speed
0.0
R
10
10
Middle fan manual speed
0.0
R/W
R/W
R/W
R
11
11
Upper fan manual speed
0.0
12
12
Lower fan manual speed
0.0
13
13
Static pressure sensor current value
C1 discharge pressure sensor current value
C1 suction pressure sensor current value
C1 suction temperature sensor current value
Return temperature display value
Remote temperature display value
Entering water temperature display value
Leaving water temperature display value
High air temperature alarm limit
Low temperature alarm limit
High humidity alarm limit
0.0
14
14
0.0
R
15
15
0.0
R
16
16
0.0
R
17
17
0.0
R
18
18
0.0
R
19
19
0.0
R
20
100
101
102
103
104
105
20
100
101
102
103
104
105
0.0
R
80.0
60.0
70.0
30.0
60.0
40.0
R/W
R/W
R/W
R/W
R/W
R/W
Low humidity alarm limit
High water temperature limit
Low water temperature alarm limit
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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.
BMS
Address
Modbus
Address
BACnet
Address
Description
Default
Read/Write
1
2
130
131
1001
1002
Cooling analog output
0
R
Middle fan Speed analog output
0
R
3
4
5
6
7
132
133
134
135
136
1003
1004
1005
1006
1007
Upper fan analog control value
Lower Fan analog control value
Packed bit for BMS - alarms
Packed bit for BMS - alarms
Packed bit for BMS - alarms
0
0
0
0
0
R
R
R
R
R
8
137
138
139
140
141
142
144
145
229
230
231
232
233
234
235
236
237
239
240
241
252
253
254
255
256
1008
1009
1010
1011
1012
1013
1015
1016
1100
1101
1102
1103
1104
1105
1106
1107
1108
1110
1111
1112
1123
1124
1125
1126
1127
Packed bit for BMS - sensor fails
Packed bit for BMS - sensor fails
Packed bit for BMS - digital inputs
Packed bit for BMS - digital inputs
Packed bit for BMS - digital outputs
Packed bit for BMS - digital outputs
Prop humidifier control output
Head pressure control output
BMS keep alive parameter
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
R
9
R
10
R
11
R
12
R
13
R
15
R
16
R
100
101
102
103
104
105
106
107
108
110
111
112
123
124
125
126
127
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
BMS low fan speed for CW units
BMS run fan speed for CW units
BMS dehumidifier fan speed for CW units
Fan link control (0 to 4) See 4.9.2.1
Control mode of dewpoint, hybrid, standard
Temperature control sensor selection
Humidity control sensor selection
Type of unit (valid numbers 0 to 6) See 4.9.2.1
Lower fan speed control (0 to 2) See 4.9.2.1
Middle fan speed control (0 to 2) See 4.9.2.1
Upper fan speed control (0 to 2) See 4.9.2.1
Current day
Current month
Current year
Current hour
Current minute
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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 & middle
Upper & lower
Middle & lower
All
—
—
[X] fan speed
control
Temperature
proportionate
Variance from
average
Manual
—
—
—
—
Type of unit
Not selected
CW-12"
CW-24"
AR-12"
AR-24"
W/G-12"
W/G-24"
4.9.3 Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet
Table 4-31. Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet.
BMS
Address
Modbus
Address
BACnet
Address
Description
Default Direction
1
002
003
004
005
006
007
101
102
103
104
105
106
107
1
Global alarm output
0
0
0
0
0
0
0
0
0
0
0
0
0
R
r
2
System on status
R
3
3
Airflow has been proven
R
4
4
Call for cooling
R
5
5
Call for humidification
R
6
6
Call for dehumidification
R
100
101
102
103
104
105
106
100
101
102
103
104
105
106
BMS value to pause the unit
BMS value to reset alarms
Force rotation of units in group manual or BMS
BMS value to switch CW sources
BMS value to switch dual power primary
BMS value to activate lockout function
Reset dirty filter alarm
R/W
R/W
R/W
R/W
R/W
R/W
R/W
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Chapter 4: E2 Controller
4.9.4 Alarm Packed Bit Variables
Table 4-32. Alarm-Packed Bit Variables.
Bit
Alarms 1
Alarms 2
Alarms 3
0
Emergency shutdown
Remote shutdown
Customer Alarm 1
Airflow
Middle fan alarm
Reserved
1
Upper fan alarm
Lower fan alarm
High temperature
Low temperature
High humidity
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
2
3
4
Filter
5
Fire/Smoke
6
Water detection
Condensate pan
Moisture
Low humidity
7
High water temp CW1
Low water temp CW1
Customer Alarm 2
Customer Alarm 3
Flow alarm (temp sensors)
Flow alarm (flow switch)
Reserved
8
9
Circuit 1 low pressure
Circuit 1 high pressure
Pump
10
11
12
13
14
15
Dual power input A
Dual power input B
Humidifier
Reserved
Loss of power
Reserved
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Chapter 4: E2 Controller
4.9.5 Sensor Failure Packed Bit Variables
Table 4-33. Sensor Failure Packed Bit Variables.
Sensor
Bit
Sensor Failures 1
Failures 2
0
Middle temperature
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
1
Upper temperature
Lower temperature
Return temperature
Return humidity
2
3
4
5
Static air pressure
Suction pressure
6
7
Suction temperature
Discharge pressure
Discharge temperature
Remote temperature
Remote humidity
Entering water temperature
Leaving water temperature
Reserved
8
9
10
11
12
13
14
15
Reserved
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Chapter 4: E2 Controller
4.9.6 Digital Input Packed Bit Variables
Table 4-34. Digital Input Packed Bit Variables.
Bit
Digital Inputs 1
Digital Inputs 2
0
Remote shutdown
Customer alarm 2
1
Customer alarm 1
Water
Customer alarm 3
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
2
3
Condensate pan
Humidifier
4
5
Moisture
6
Middle fan alarm
Upper fan alarm
Fire/smoke
7
8
9
Lower fan alarm
Dual power input A
Dual power input B
Circuit 1 low pressure
Circuit 1 high pressure
Pump alarm
10
11
12
13
14
15
Humidifier lockout
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Chapter 4: E2 Controller
4.9.7 Digital Output Packed Bit Variables
Table 4-35. Digital Output Packed Bit Variables.
Bit
Digital Outputs 1
Digital Outputs 2
0
Global alarm
Reserved
1
Custom alarm 1
Master fan enable
DX1 enable
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
2
3
4
DX1 liquid line solenoid
Humidifier enable
Dual power output A
Dual power output B
Pump enable
5
6
7
8
9
Custom alarm 2
Custom alarm 3
Reserved
10
11
12
13
14
15
Reserved
Reserved
Reserved
Reserved
The R/W BMS variables fall into two categories. Variables like the temperature setpoint are permanent. As permanent variables,
they retain their value regardless of power loss or BMS communications failure. The controller‘s flash memory is limited to one
million write cycles for permanent variables. The other category is the integer and digital variables that start with “BMS.” These
are expected to be changed frequently and require that the BMS is active when changing them. All BMS variables require that the
BMS “keep alive” parameter (Variable 100) changes between 1 and 2 within a 10-minute span. The general procedure is to set
up variables like the BMS low fan speed and then write a 1 to the BMS “keep alive” address. If the controller does not see a 2
written to the BMS “keep alive” address within 10 minutes, all the BMS variables will revert to their previous values.
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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.
BMS
Address
Modbus
Address
BACnet
Address
Description
Default
Direction
100
101
229
230
1100
1101
BMS keep alive parameter
0
R/W
BMS low fan speed for CW units
0
R/W
102
103
231
232
1102
1103
BMS run fan speed for CW units
0
0
R/W
R/W
BMS dehum fan speed for CW units
4.9.9 Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet
Table 4-37. Boolean Values for HTTP, SNMP/Modbus Coils/Binary Values for BACnet.
BMS
Address
Modbus
Address
BACnet
Address
Description
Default
Direction
100
101
101
102
1100
1101
BMS value to pause the unit
0
R/W
BMS value to reset alarms
0
R/W
102
103
104
103
104
105
1102
1103
1104
Force rotation of units in group manual or BMS 0
BMS value to switch CW sources
0
0
0
R/W
R/W
R/W
BMS value to switch dual power primary
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Chapter 5: Maintenance
5. Maintenance
5.1 Periodic General Maintenance
Systematic, periodic general maintenance of the Cold Row unit is required for optimum system performance. General
maintenance should include, but is not limited to the following: replacing filters, tightening electrical connections, checking the
condensate pans and drain line to ensure they are free of debris, cleaning the interior of the unit, inspecting the units’
components visually, checking level of refrigerant, and ensuring no moisture is in the refrigerant IF APPLICABLE.
Use copies of the Periodic General Maintenance Checklist in this manual (see Appendix A.2) to record periodic general mainte-
nance inspections. For assistance, contact Black Box Technical Support. Ensure adherence to all safety statements while perform-
ing any type of maintenance.
WARNING
This equipment should be serviced and repaired by a journeyman or a qualified refrigeration technician only.
WARNING
This unit uses high-voltage equipment with rotating components. Exercise extreme care to avoid accidents and
ensure proper operation.
Hazardous voltage will still be present inside the electric box at the motor start protectors and circuit breakers, even with the unit
turned off at the microprocessor controller. To isolate the unit for maintenance, turn off power at the main power disconnect
switch. Always disconnect main power prior to performing any service or repairs.
WARNING
Turn off power to the unit unless you are performing tests that require power. With power and controls energized,
the unit could begin operating automatically at any time. To prevent personal injury, stay clear of rotating
components as automatic controls may start them unexpectedly.
5.1.1 Filters
The filter is usually the most neglected item in an air-conditioning system. To maintain efficient operation, check the filter every 3
to 6 months and clean or replace it as required.
NOTE: Conditions of spaces vary. Extremely dusty environments may require more frequent filter maintenance.
The air filters are located behind the air intake grille at the rear of the cabinet. To access the filters, unlatch the rear access panel
at the top and remove it from the cabinet.
5.1.1.1 Cleanable Filters
Cleanable filters are spring loaded in the holding trays in the access panel. Using a flat-head screwdriver, gently push the filters to
one side and remove the old filters from the trays (Figure 5-1).
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Chapter 5: Maintenance
F
Fgure 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.
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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. Slide the new filters into the tray and replace the end cap. Ensure the four screws are fully
tightened.
REAR ACCESS PANEL
(4) SCREWS
END CAP
Figure 5-2. Cartridge filters.
5.1.2 EC Fans
Periodic checks of the EC fans should include checking the wiring, fan motor mounts, housing, and impeller wheel. Ensure all
electrical connections are tight. Check that all mounting fasteners are secure and the impeller wheel is tightly mounted. The
impeller blades must be kept free of debris.
5.1.3 Coil
The coil should be inspected semi-annually and cleaned as required, following standard coil cleaning practices. Using a brush,
clean the coil fins of all debris that will inhibit airflow. This can also be done with compressed air or with a commercial coil
cleaner. Check for bent or damaged coil fins and repair as necessary. Check all refrigerant lines and capillaries for vibration
isolation and support as necessary. Check all piping for signs of leaks.
5.1.4 Drain Pans
To ensure proper drainage, inspect the drain pans regularly. Make sure the drain pan outlets are always free of debris so they
empty readily and ensure the drain pans do not leak.
WARNING
Do not use chloride-based water-conditioning additives in the condensate drain pans. This will cause corrosion to
occur on the coil fins.
5.1.5 Condensate Pump
The condensate pump should be inspected semi-annually and cleaned. Remove the pump as described in Section 5.3.4.2. Inspect
the water-level switch and ensure that the float works freely. Wipe the float with a wet cloth and detergent to remove dirt. Check
that the discharge line is open and water can pass through it freely.
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Chapter 5: Maintenance
5.1.6 A/C System
Check the refrigerant sight glass on a monthly basis while the unit is running and ensure it is free of bubbles. Bubbles in the sight
glass indicate a low refrigerant charge or a clogged filter-drier. Check for humidity in the refrigerant by viewing the color of the
indicator in the center of the sight glass and comparing it to the color scale on the outer ring. If humidity is present, the system
must be evacuated and recharged.
Check the superheat and sub-cooling temperatures semi-annually and ensure they are within the range shown in the refrigerant
pressure/temperature table (Tables 2-9–2-11) in Section 2.10.3. If necessary, adjust the refrigerant charge to achieve the correct
values. If the
refrigerant level is low, check the system for leaks.
5.2 Troubleshooting
Turn off all power to the unit before conducting any troubleshooting procedures, unless the procedure specifically requires the
system to operate. For troubleshooting purposes, the system may be operated with the doors open by using a pair of channel
lock pliers to turn the shaft of the main power disconnect switch to the “On” position. When the switch is turned on, high
voltage will be present inside the cabinet. Exercise caution to prevent injury. Keep hands, clothing, and tools clear of the electrical
terminals and rotating components. Ensure that your footing is stable at all times.
Symptom: Airflow too low.
Probable Cause: Dirty air filters (reduced airflow).
Recommendation: Clean/replace filters.
Symptom: EC fan(s) fail to start.
Probable Causes/Recommendations:
a. Power failure. Check main voltage power source input cable.
b. Motor starter protector tripped. Reset motor starter protector and check amperage of motor.
c. Control transformer circuit breaker tripped. Check for short circuit or ground fault; if none, reset circuit breaker.
d. Condensate overflow switch open.
1. Ensure unit is level.
2. Check that condensate pan is draining.
e. Defective contactor. Repair or replace.
f. No control signal to fan(s). Check the control I/O board for a 0-10 VDC control signal to the fan(s). Refer to the electric
drawing to determine the correct I/O board terminal numbers. This must done within 15 seconds of turning the disconnect
switch “On” or the controller will go into “Air Proving Alarm” mode.
g. EC fan’s internal overheat protection. Determine the cause of the interruption and correct. Possible causes are:
1. Blocked rotor.
2. Low supply voltage > 5 seconds.
3. Loss of phase > 5 seconds.
After causes 1, 2, and 3 are corrected, the motor will automatically reset.
After the causes below are corrected, the fan(s) must be manually reset by turning off power for 20 seconds:
4. Over temperature of electronics.
5. Over temperature of motor.
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Chapter 5: Maintenance
Symptom: Control is erratic.
Probable Cause: Wiring improperly connected or broken.
Recommendation: Check wiring against electrical drawing.
Symptom: Compressor fails to start
Probable Causes/Recommendations:
a. Temperature setpoint too high. Adjust to desired temperature.
b. Compressor internal overload protector is open. Check compressor for short circuit or ground.
c. Complete loss of refrigerant charge (low pressure safety switch tripped). Locate and repair leak. Recharge system.
d. Condenser pressure too high (high pressure safety switch tripped). Check condenser for obstructions.
e. Minimum off time has not expired. Wait for time to expire.
Symptom: System short of capacity.
Probable Causes/Recommendations:
a. Temperature setting too high. Increase temperature setpoint.
b. Discharge air short cycling back to return. Check air barrier between hot/cold aisles.
c. Low airflow.
1. Check filters. Replace as needed.
2. Check for and clear any obstructions across or in the (supply) discharge air stream. Clear coil fins of debris.
3. Check evaporator coil for bent fins.
4. Check correct rotation of fans.
d. Low refrigerant (indicated by bubbles in sight glass). Check for leaks. Repair and recharge system.
e. Expansion valve stuck or obstructed (short cycling or continuous running). Remove valve and clear obstruction or replace valve.
f. Clogged drier/strainer (feels cold). Replace with new drier/ strainer.
Symptom: System short of capacity (CRDX-W-FS-12KW, CRDX-W-FS-24KW, CRDX-G-FS-12KW, CRDX-G-FS-24KW).
Probable Causes/Recommendations:
a. Low water–water/glycol flow.
1. Check for leaks. Repair and recharge system.
2. Check for obstructions in supply/return lines.
3. Check for clogged strainer (if applicable).
b. Supply water temperature too high. Check chilled water supply.
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Chapter 5: Maintenance
Symptom: Water–water/glycol valve fails to open or close.
Probable Causes/Recommendations:
a. Temperature setpoint too high. Adjust to correct temperature setting.
b. No control power to the valve. Valve actuator is wired incorrectly. Check wiring diagram and rewire if required.
c. Actuator failed. Replace actuator.
Symptom: Condenser pressure too high (CRDX-A-FS-12KW, CRDX-A-FS-24KW units).
Probable Causes/Recommendations:
a. Non-condensable gas or air in the system. Recover system, evacuate per Section 2.10.2.2, recharge. Replace drier/strainer.
b. Condenser air intake is blocked. Remove debris and clean condenser.
c. Overcharge of refrigerant. Reclaim excess refrigerant from system.
d. Condenser fan not operating. Check pressure/temperature operating switches and motor. Replace as needed.
Symptom: Condenser pressure too high (CRDX-W-FS-12KW, CRDX-W-FS-24KW, CRDX-G-FS-12KW, CRDX-G-FS-24KW units).
Probable Causes/Recommendations:
a. Flow of water/glycol too low.
1. Check glycol solution level and concentration.
2. Valves not open or partially open. Repair/replace as needed.
3. Air in system—bleed system.
4. Check all strainers and clean if needed.
b. Water/glycol temperature too high. Check flow and operation of drycooler.
c. Control pressure set too high. Adjust controller to obtain correct pressure.
d. Water/glycol solution not mixed prior to adding to system. Remove solution and premix. Refill system.
Symptom: Condenser pressure too low.
Probable Causes/Recommendations:
a. Loss of refrigerant (indicated by bubbles in sight glass). Locate and repair leak. Recharge system.
b. Condenser fan controls not set properly. Adjust or repair controls.
c. Control pressure set too low. R410A—Readjust to 440 psig.
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Chapter 5: Maintenance
Symptom: Noisy compressor.
Probable Causes/Recommendations:
a. Expansion valve stuck in open position (abnormally cold suction line). Ensure feeder bulb is tight on suction line. Check
operation and superheat.
b. Broken compressor valve (compressor knocking, suction pressure rises faster than 2 lb./min. after shutdown). Replace
compressor.
c. Worn or scarred compressor bearings. Replace compressor.
d. Liquid slugging. System overcharged. Reclaim excess refrigerant.
e. Scroll compressor not properly phased. Phase correctly at main power source. DO NOT REWIRE COMPRESSOR.
5.3 Field Service
Repairs must be performed by a journeyman refrigeration mechanic or air-conditioning technician. Turn off power to unit at the
main power disconnect switch before attempting to make repairs.
NOTE: Do not attempt to make repairs without the proper tools.
5.3.1 Water–Water/Glycol System
If the water or water/glycol system isn’t cooling or if cooling is reduced, check for fluid leaks in the system. Check for clogged
water lines. If filters are installed in the fluid lines, check the condition of the filters. Clean or replace the filters if necessary.
In situations where scaling could be heavy, untreated water in the unit cooling coils may cause, over a period of time, a loss of
heat exchange capacity from a mineral deposit build-up inside the coil. Only a qualified service mechanic should clean dirty coils.
Leak Detection/Repair
A leak in a fluid cooling system will usually form a puddle of fluid beneath the unit that can be easily seen. Visually trace the leak
up from the puddle to the area on the unit where fluid may be seen dripping.
When a leak is detected, turn off the fluid supply before attempting repairs. Adjacent piping must be thoroughly cleaned by
removing all paint, dirt and oily film. Use a wire brush, sandcloth, or sandpaper and wipe the area with clean, dry cloths. Protect
nearby parts from heat damage by wrapping with watersoaked cloths.
For copper-to-copper (piping) repairs, use a phosphorus copper brazing alloy with 15% silver. Use general-purpose silver brazing
alloy with 45% silver for copper-to-brass or copper-to steel repairs.
When repairs are completed, remove all traces of flux and flush the system. After any repair, pressurize the system to check for
leaks before recharging the system.
5.3.2 DX System
You might need to perform repairs on the refrigeration system. If field repairs are necessary, the following procedures apply:
5.3.2.1 Leak Detection
Several methods can be used to detect a leak in the refrigeration system. The most modern and easiest method is to use an
electronic leak detector. Follow the manufacturer’s directions to quickly locate any leak. A second method is to use soap bubbles.
Apply a solution of soapy water with a brush or sponge to the joints and connections in the refrigeration lines. A leak in the lines
will cause bubbles to form.
5.3.2.2 Leak Repair
When a leak is located, properly reclaim the remaining refrigerant charge before beginning repairs. Adjacent piping must be
thoroughly cleaned by removing all paint, dirt, and oily film. Use a wire brush, sandcloth, or sandpaper and wipe the area with
clean, dry cloths. Protect nearby parts from heat damage by wrapping with water-soaked cloths.
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Chapter 5: Maintenance
5.3.2.3 Refrigerant Piping
When replacing components within the cabinet of the unit, the following consumable materials are recommended: When brazing
copper-to-copper connections (piping liquid line or suction line), use a phosphorus copper brazing alloy with 15% silver.
Use general-purpose silver brazing alloy with 45% silver for copper-to-brass or copper-to steel. For liquid line repairs at the drier,
strainer, sight glass, or expansion valve, use a 95% tin to 5% antimony solder with flux.
When component replacement is complete, remove all traces of flux. After any repair, pressure check the system to ensure there
are no leaks prior to recharging the system.
5.3.3 Refrigeration System Repairs
5.3.3.1 Compressor Failure
The compressor is the most important component of the air conditioner. Numerous safety devices are provided to protect the
compressor from failing.
If a compressor failure occurs, determine whether it is an electrical or a mechanical failure. An electrical failure will be indicated by
the distinct pungent odor once the system has been opened. If a burnout has occurred, the oil will be black and acidic. A
mechanical failure will have no burned odor and the motor will attempt to run; an abnormal or excessive noise may be present.
An analysis of the oil is the only way to determine the proper procedure for cleaning the refrigerant system. Acid test kits are
available from several manufacturers for measuring the acid level in the oil. These are capable of making accurate acid
measurements, but if they are not available, a check of the oil by sight and smell can give a quick indication if contamination
remains in the system.
CAUTION
Avoid touching or contacting the gas and oil with exposed skin. Severe burns will result. Use long rubber gloves in handling
contaminated parts.
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.
If there is acid in the oil, there has been an electrical failure that has caused the compressor motor to burn out. The acid diffuses
throughout the refrigeration system and must be removed by using a burnout filter kit before a new compressor is placed in
service. Not only must the compressor be replaced, but also the entire refrigeration circuit must be cleaned of the harmful
contaminants left by the burnout. See Section 5.3.3.3 (Burn-Out/Acidic Cleanup) for the proper procedure.
If there is no acid in the oil, there has been a mechanical failure. See Section 5.3.3.2 (Standard Cleanout) for the proper cleaning
procedure.
CAUTION
Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty.
This will VOID THE COMPRESSOR WARRANTY. Always consult Black Box Technical Support before replacing the compressor.
CAUTION
POE oil is used in systems with R410A refrigerant. If a replacement compressor is provided, ensure that it is filled with POE oil
before installing.
NOTE: Cleaning operations must be performed by a journeyman refrigeration mechanic or air-conditioning technician.
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Chapter 5: Maintenance
5.3.3.2 Standard Cleanout Procedure
1. Turn off power to unit at the main power disconnect switch.
2. Remove the old compressor and install the new compressor.
3. Remove the liquid line drier and install an oversized liquid line filter-drier (one size larger than the normal selection size).
4. Evacuate the system according to standard procedures. Normally, this will include the use of a high-vacuum pump and a low-
vacuum micron gauge for measuring the vacuum obtained.
5. Recharge the system.
6. Turn on the power at the main power disconnect switch and start the system.
5.3.3.3 Burn-Out/Acidic Cleanup Procedure
1. These systems should be cleaned using the suction line filter-drier method.
2. Turn off power to the unit at the main power disconnect switch.
3. Remove the burned-out compressor and install the new compressor.
4. Install a suction line filter-drier designed for acid removal.
5. Remove the liquid line drier and install an oversized liquid line filter-drier (one size larger than the normal selection size).
6. Check the expansion valve, sight glass, and other controls to see if cleaning or replacement is required.
7. Evacuate the system according to standard procedures. Normally this will include the use of a high-vacuum pump and a
low-vacuum micron gauge for measuring the vacuum obtained.
8. Recharge the system through the access valve on the suction line filter-drier.
9. Turn on power at the main power disconnect switch and start the system.
10. A permanently installed suction line filter-drier permits small-system cleanup to be completed in one service call. The pressure
drop across the suction line filter-drier should be measured during the first hour of operation. If the pressure drop becomes
excessive, the suction line filter-drier should be replaced (See Sporlan Bulletin 40-10, for the maximum recommended pressure
drop [PSI] for the suction line filter drier).
11. In 24 hours, take an oil sample. Observe the color and test for acidity. If the oil is dirty or acidic, replace the suction line
filter-drier.
12. In two weeks, examine oil to determine if another suction line filter-drier change is necessary.
5.3.4 Component Replacement
Check all electrical connections 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. Turn off power to the unit at the main power disconnect switch.
2. Remove the old component and install the new one.
3. Turn on power at the main power disconnect switch and start the system.
5.3.4.1 Fan Replacement
The EC Fans are located behind the front access panel. The panel must be removed to access the fans. The fans are equipped
with quick connect fittings for the power and control cables to make swap-out easy. Lift the retaining latch on top of the power
and control cable connector housings to unplug the cables. Cut the wire-ties holding the cable bundle in the 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. Bolt the new fan assembly (together with the inlet ring) into the cabinet and plug the power and control cables into the
connectors.
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Chapter 5: Maintenance
INLET RING
FAN
INLET RING
M6 HEX BOLTS—
TWO PER SIDE
M5 HEX BOLTS—
TWO PER SIDE
POWER/CONTROL
CONNECTORS
Figure 5-3. Fan.
5.3.4.2 Condensate Pump Replacement
The condensate pump is located behind the lower cabinet fan assembly. To access the pump, the lower fan must be removed as
described in Section 5.3.4.1.
CABLE LOOP
PUMP
RETAINING
CLIP
DISCHARGE
LINE
WIRE TIE
Figure 5-4. Condensate pump.
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. Maneuver the pump into the fan opening with the cable still attached and remove the cover to
expose the wire terminals. Remove the wires from the pump and remove the pump from the cabinet. Install the replacement
pump in the same manner that the old pump was removed, reversing the procedure.
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Chapter 6: Troubleshooting
6. Troubleshooting
Black Box provides its customers with Technical Support that not only provides technical support and parts but also the following
additional services, as requested:
• Performance Evaluations
• Start-up Assistance
• Training
6.1 Technical Support
If a problem develops that cannot be resolved using this manual, contact Black Box Technical Support at 724-746-5500 or
info@blackbox.com.
When calling for Tech Support, it is important to have the following information readily available, (information is found on the
unit’s nameplate):
• Unit Model Number
• Black Box Sales Order Number
• Black Box Item Number
• Unit Serial Number
• Description of Problem
6.2 Obtaining Warranty Parts
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.
A written (or faxed) purchase order is required on warranty parts. The purchase order must contain the following items:
• Purchase Order Number
• Unit Model No., Serial No. and Black Box Item No.
• Date of Order
• Black Box Stated Part Price
• Customer Billing Address
• Shipping Address
• Customer’s Telephone and Fax Numbers
• Contact Name
The customer is responsible for the shipping cost incurred for returning the defective part(s) back to Black Box. Return of defective
part(s) must be within 30 days, at which time an evaluation of the part(s) is conducted and if the part is found to have a
manufacturing defect a credit will be issued.
When returning defective part(s), complete the Return Material Authorization Tag and the address label received with the
replacement part.
See the Black Box Standard Warranty located in Chapter 1 of this manual.
6.3 Obtaining Spare/Replacement Parts
Spare and replacement parts requests are to be made through Black Box Technical Support. Contact us at 724-746-5500 or
info@blackbox.com.
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Chapter 6: Troubleshooting
Quotes are given for specified listed parts for a specific unit.
A 25% minimum restocking charge will be applied on returned stocked parts that were sold as spare/replacement parts. If the
returned part is not a stocked item, a 50% restocking charge may be applied. Additionally, a Return Material Authorization
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.
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Appendix A: Forms
Appendix A. Forms
A.1 Checklist for Completed Installation of Cold Row DX
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. Condensate drain line connected.
6. Water supply line connected to humidifier (if applicable). If manual cut-off valve is installed, open valve.
7. Humidifier “On/Off/Drain” switch is in “On” position.
8. Filters installed.
9. Incoming line voltage matches equipment nominal nameplated rating tolerances.
10. Main power wiring connections to the equipment, including ground, have been properly installed.
11. Customer-supplied main power circuit breaker (HACR type) or fuses have proper ratings for equipment installed.
12. All wiring connections are tight.
13. Foreign materials have been removed from inside and around all equipment installed (shipping materials, construction
materials, tools, etc.).
14. Inspect all piping connections for leaks during initial operation.
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Appendix A: Forms
A.2 Periodic General Maintenance Checks and Services Checklist for Cold Row DX
Date: ____________________________
Prepared By: ___________________________
Serial Number: __________________________
Model Number: ____________________________
Item Number: ____________________________
Monthly
Filters:
Cleanliness.
Blower Section:
Blower turns.
Condensate Drain:
Drain is open.
Condensate pan safety switch
operates freely.
Miscellaneous:
Check water/glycol or chilled water circuit for air (bleed as required).
Humidifier and controls operate properly.
Semi-Annually
Check refrigerant charge (bubbles in sight-glass).
Check suction and discharge pressure.
Tighten electrical connections.
Check contacts on contactors for pitting.
Clean the unit as necessary.
Check glycol solution concentration in system.
Clean coils.
Test the glycol solution inhibiters
(flush if necesary).
Clean condensate pump.
Annually
Chilled water systems:
Inspect water glycol system for leaks and corrosion.
Conduct a complete check of all services listed above and clean unit’s interior.
NOTES: ____________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
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. ***
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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
HP: Horsepower
Hz: Hertz
IAQ: Indoor air quality
KVA: Kilo Volt Amps
kW: Kilowatt
LRA: Locked rotor amps
MAX CKT BKR: Maximum circuit breaker
MAX FUSE: Maximum fuse
MCA: Minimum circuit ampacity
m.i.w.g.: Milli-inches of water gauge
MSDS: Material Safety Data Sheet
NEC: National Electric Code
NFPA: National Fire Protection Agency
PH: Phase
PI: Proportional/integral (control)
PSIG: Pounds per square inch gauge
R410A: Refrigerant
RLA: Run load amps
R-Value: Thermal resistance
SPDT: Single pole, double throw
TEV: Thermostatic expansion valve
V: Volt
VAC: Volt, alternating current
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Appendix B: Glossary: Definition of Terms and Acronyms
VDC: Volt, direct current
WG: Water Glycol
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NOTES
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NOTES
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NOTES
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Black Box Tech Support: FREE! Live. 24/7.
Tech support the
way it should be.
Great tech support is just 30 seconds away at 724-746-5500 or blackbox.com.
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.
© Copyright 2013. Black Box Corporation. All rights reserved.
CRDX-A-FS-24KW, version 1
BB-OWR0129-; Dec., 2012
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