Ann-1T1-Rittal-LCP

Ann-1T1-Rittal-LCP
Rittal
Liquid Cooling Package Plus
Operating and Maintenance Instructions
Rittal Liquid Cooling Package Plus
Model No. SK 3301.480 (230 / 400 V version)
Rittal Liquid Cooling Package Plus
Foreword
Dear Customer!
We would like to thank you for choosing our Rittal Liquid Cooling Package Plus
(referred to hereafter as "Liquid Cooling Package Plus" or "LCP Plus").
Please take the time to read this documentation carefully.
Please pay particular attention to the safety instructions in the text and to
Chapter 2, "Safety instructions".
This is the prerequisite for:
- secure assembly of the Liquid Cooling Package Plus,
- safe handling and
- the most trouble-free operation possible.
Please keep the complete documentation readily available so that it is always
on hand when needed.
We wish you every success!
Your
Rittal GmbH & Co. KG
Rittal GmbH & Co. KG
Auf dem Stützelberg
35745 Herborn
Germany
Tel.: +49 (0) 27 72/50 5-0
Fax: +49 (0) 27 72/50 5-23 19
E-mail: [email protected]
www.rimatrix5.com
We are always happy to answer any technical questions regarding our entire
range of products.
2
Operating and Maintenance Instructions
Rittal Liquid Cooling Package Plus
Table of contents
3
Foreword ................................................................................. 2
Table of contents ................................................................... 3
1
Identification ........................................................................... 5
1.1
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.3
1.3.1
1.3.2
1.3.3
Manufacturer ........................................................................................ 5
Notes concerning the documentation ................................................... 5
Other applicable documents ................................................................. 5
CE labelling .......................................................................................... 5
Nameplate ............................................................................................ 6
Storing the documents ......................................................................... 6
Legal information concerning the operating instructions .................... 6
Copyright .............................................................................................. 6
Revision ................................................................................................ 6
Product description ............................................................................... 7
Unit components .................................................................................. 7
Proper use ............................................................................................ 8
Precautionary measures ...................................................................... 8
2
Safety instructions ................................................................. 9
2.1
2.2
2.3
2.4
Symbols in these operating instructions ............................................... 9
Important safety instructions ................................................................ 9
Service and technical staff ................................................................. 10
RoHS compliance ............................................................................... 11
3
Transport and handling ....................................................... 12
3.1
3.2
3.3
Scope of delivery of Liquid Cooling Package Plus ............................. 12
Transport ............................................................................................ 12
Unpacking .......................................................................................... 12
4
Design and function ............................................................. 13
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.2
4.3
4.3.1
Design ................................................................................................ 13
Liquid Cooling Package Plus .............................................................. 14
Air/water heat exchanger ................................................................... 16
Fan module ........................................................................................ 16
Water module with cold water connection .......................................... 18
Function .............................................................................................. 19
Air routing inside the enclosure .......................................................... 22
Possibilities for establishing redundancies ......................................... 24
5
Technical specifications ...................................................... 26
6
Installation – "Getting Started" ........................................... 27
6.1
6.2
6.2.1
6.2.2
6.2.3
6.3
6.3.1
6.3.2
6.4
6.4.1
6.4.2
6.4.3
6.5
6.5.1
6.5.2
6.6
6.6.1
6.6.2
6.7
Installation conditions ......................................................................... 27
Assembling the Liquid Cooling Package Plus .................................... 28
Preparatory work on the server enclosure ......................................... 28
Installation and baying of the Liquid Cooling Package ....................... 32
Assembly of the side panel on the Liquid Cooling Package Plus ....... 34
Fan installation ................................................................................... 35
Removing a fan module ..................................................................... 35
Installing a fan module ....................................................................... 38
Connecting the Liquid Cooling Package Plus .................................... 40
Electrical connection .......................................................................... 40
Cooling water connection ................................................................... 45
Condensate discharge connection ..................................................... 48
Cooling operation and control behaviour ............................................ 49
Cooling output .................................................................................... 49
Pressure loss ...................................................................................... 50
Operation ............................................................................................ 51
General ............................................................................................... 51
Operation in stand-alone mode .......................................................... 53
Extended Basic CMC options with network connection ..................... 55
Operating and Maintenance Instructions – Table of contents
Rittal Liquid Cooling Package Plus
6.7.1 Visualisation ....................................................................................... 57
7
Hardware and software ........................................................ 71
7.1
7.1.1
7.2
7.2.1
7.2.2
7.2.3
7.3
7.3.1
Liquid Cooling Package Plus control unit ........................................... 71
Hardware ............................................................................................ 71
Control unit for fan module (RLCP fan) .............................................. 74
Hardware ............................................................................................ 74
Status LED ......................................................................................... 75
Control unit for water module (RLCP water) ...................................... 76
Hardware ............................................................................................ 76
Staus LED .......................................................................................... 77
8
Maintenance ......................................................................... 78
9
Troubleshooting ................................................................... 79
10
Frequently asked questions (FAQ) ..................................... 81
11
Glossary ................................................................................ 85
12
Spare parts ........................................................................... 87
13
Accessories .......................................................................... 88
13.1
13.2
Accessories Liquid Cooling Package ................................................. 88
Accessories from the rack program .................................................... 88
14
Further technical information ............................................. 89
14.1
14.2
14.2.1
14.2.2
14.3
14.4
14.5
Hydrological information ..................................................................... 89
Characteristic curves .......................................................................... 90
Cooling output .................................................................................... 90
Pressure loss ...................................................................................... 91
Overview diagram .............................................................................. 92
Circuit diagram ................................................................................... 94
Water circulation diagram ................................................................... 95
Installation checklist ................................................... 96
Preparation and maintenance of the water in recooling
systems ...................................................................... 100
4
Operating and Maintenance Instructions – Table of contents
Rittal Liquid Cooling Package Plus
1
Identification
1.1
Manufacturer
1.2
Manufacturer
Rittal GmbH & Co. KG
Address:
Auf dem Stützelberg
City:
35745 Herborn
Germany
Telephone:
+49 (0) 27 72/50 5-0
Telefax:
+49 (0) 27 72/50 5-23 19
E-mail:
[email protected]
Internet:
www.rimatrix5.com
Notes concerning the
documentation
1.2.1 Other applicable documents In conjunction with these operating and maintenance instructions, the superordinate system documentation (if available) also applies.
Rittal GmbH & Co. KG is not responsible for any damage which may result from
failure to comply with these operating and maintenance instructions. This also
applies to failure to comply with the valid documentation for accessories used.
1.2.2 CE labelling
With the EU declaration of conformity, Rittal GmbH & Co. KG, the manufacturer,
certifies that the cooling units of the Liquid Cooling Package Plus series are manufactured and tested in accordance with the following directives:
- EU EMC directive 89/336/EEC (annex 92/31EC and 93/68/EC)
- EU Low Voltage Directive 2006/95/EC
- EN 55022
Information technology equipment - Radio disturbance characteristics
- EN 60335-1
Safety for household and similar electrical appliances
Part 1: General requirements
- EN 61000 3-2
Electromagnetic compatibility (EMC)
Part 3-2: Limits - Limits for harmonic current emissions (equipment input current up to and including 16 A per phase)
- EN 61000 6-2
Electromagnetic compatibility (EMC)
Part 6-2: Generic standards - Immunity for industrial environments
- EN 61000 6-3
Electromagnetic compatibility (EMC)
Part 6-3: Generic standards - Emission standard for residential, commercial
and light-industrial environments
The cooling unit bears the following mark.
5
Operating and Maintenance Instructions – 1 Identification
Rittal Liquid Cooling Package Plus
1.2.3 Nameplate
RITTAL
GmbH & Co.KG
Auf dem Stützelberg
35745 Herborn
SK 3301 480
Luft/Wasser-Wärmetauscher
Air/water heat exchanger
Echangeur de temperature air/eau
Lucht/Water-Warmtewisselaar
Luft/vatten vaermevaexlare
Scambiatore di calore ad aria/acqua
Intercambiador de calor aire/agua
Bemessungsspannung
Rated voltage
Bemessungsstrom
Rated current
Vorsicherung T
Pre-fuse T
Nennleistung
Nominal cooling
output
Nutzkühlleistung L35 W15
Volumenstrom L/h
Useful cooling output
: 400V/3~/N/PE 50/60Hz
Kühlmedium
Coolant
POH O
PT H O
TO Air
TS Air
: Wasser (siehe Spezifikation)
Water (see specification)
: 2-5 bar (29-73 psi)
: 10 bar (174 psi)
: +6˚C bis to +35˚C (+43˚F to +95˚F)
: +6˚C bis to +35˚C (+43˚F to +95˚F)
2
2
Geräuschpegel
Noise level
Schutzart
EN 60529
Protective category
Gewicht
Weight
Baujahr
Year of construction
Fabr.-Nr.:
Production No.
Fig. 1:
: 3,5/3,8 A
: 230V/1~ 50/60Hz
10,5/11,5 A
: 10 A
16 A
: 2400/2650 W
2400/2650 W
: 28/28 kW
3600 L/h
28/28 kW
3600 L/h
: 64 dB(A)
: IP40
: 230 kg (507 pounds)
:
WA ----- / ---
Nameplate
1.2.4 Storing the documents
The operating and maintenance instructions as well as all applicable documents are integral components of the product. They must be handed out to those persons who are engaged with the unit and must always be available and
on hand for operating and maintenance personnel.
1.2.5 Legal information
concerning the operating
instructions
We reserve the right to make changes in content. Rittal GmbH & Co. KG is not
responsible for mistakes in this documentation. Liability for indirect damages
which occur through the delivery or use of this documentation is excluded to
the extent allowable by law.
1.2.6 Copyright
The distribution and duplication of this document and the disclosure and use of
its contents are prohibited unless expressly authorised.
Offenders will be liable for damages. All rights created by a patent grant or registration of a utility model or design are reserved.
1.2.7 Revision
Rev. 1 of 19. April 2007
6
Operating and Maintenance Instructions – 1 Identification
Rittal Liquid Cooling Package Plus
1.3
Product description
1.3.1 Unit components
1
2
3
4
5
6
Fig. 2:
1
2
3
4
5
6
7
Liquid Cooling Package Plus (front)
Rack (H x W x D: 2000 mm x 300 mm x 1200 mm)
LCP door
Touch panel
Wall plate (wide) with air outlet
Wall plate (narrow) with air inlet
Levelling foot
Operating and Maintenance Instructions – 1 Identification
Rittal Liquid Cooling Package Plus
1
2
3
4
5
4
6
7
8
Fig. 3:
1
2
3
4
5
6
7
8
1.3.2 Proper use
Liquid Cooling Package Plus - rear
Mains connection
Control unit (Basic CMC)
LCP door
Fan
Fan control unit
Water module control unit
Water module
Levelling foot
The Liquid Cooling Package Plus serves to dissipate high heat losses and for
the effective cooling of devices built into a server enclosure.
The unit is state of the art and built according to recognised safety regulations.
Nevertheless, improper use can present a hazard to life and limb of the user or
third parties, or result in possible impairment of the system and other property.
The unit should thus only be used properly and in technically sound condition.
Any malfunctions which impair safety should be rectified immediately! Follow
the operating instructions!
Intended use also includes following the operating instructions and fulfilling the
inspection and maintenance conditions.
1.3.3 Precautionary measures
Inappropriate use may result in danger. Inappropriate use may include:
- Use of impermissible tools.
- Improper use.
- Improper rectification of malfunctions.
- Use of replacement parts which are not authorised by Rittal GmbH & Co. KG.
8
Operating and Maintenance Instructions – 1 Identification
Rittal Liquid Cooling Package Plus
2
Safety instructions
The Liquid Cooling Packages Plus (LCP Plus) produced by Rittal GmbH & Co.
KG are developed and produced with due regard to all safety precautions. Nevertheless, the unit still causes a number of unavoidable dangers and risks. The
safety instructions provide you with an overview of these dangers and the necessary safety precautions.
In the interest of your safety and the safety of others, please read these safety
instructions carefully before assembly and commissioning of the Liquid Cooling
Package Plus.
Follow the user information found in these instructions and on the unit carefully.
2.1
Symbols in these
operating instructions
These following symbols are found in this documentation:
Danger!
This warning symbol is used to indicate great dangers caused by the
product which may result in injury and even death if the indicated preventative measures are not followed.
Caution!
This warning symbol is used to indicate procedures which may cause
risk of equipment damage or personal injury.
Note:
This instruction symbol indicates information concerning individual procedures, explanations, or tips for simplified approaches.
• This symbol indicates an "Action Point" and shows that you should carry out
an operation/procedure.
2.2
Important safety
instructions
Danger! Electric shock!
Contact with live electrical parts may be deadly.
Before switching on, ensure that it is not possible to come into contact
with live electrical parts.
Danger! Injury caused by fan impellors!
Keep persons and objects away from the fan impellors! Do not remove
covers until the power supply is disconnected and impellors are not
moving! Always use mechanical protection when working! Shut down
the respective fan as much as possible during maintenance work! Tie
long hair back! Do not wear loose clothing!
Fans start up automatically following power disruptions!
Danger! Cut wounds, especially through sharp edges of the fan module
and heat exchanger modules!
Put on protective gloves before beginning assembly or cleaning work!
9
Operating and Maintenance Instructions – 2 Safety instructions
Rittal Liquid Cooling Package Plus
Danger! Injury due to falling loads!
Do not stand under suspended loads when transporting the unit with a
hoist trolley, a forklift, or a crane.
Caution! Risk of malfunction or damage!
Do not modify the unit! Use only original spare parts!
Caution! Risk of malfunction or damage!
Proper and flawless unit operation can only be ensured when it is operated under the intended ambient conditions. As far as possible, be
sure that the ambient conditions for which the unit is designed are complied with, e.g. temperature, humidity, air purity.
Caution! Risk of malfunction or damage!
All media necessary for the control system, e.g. cooling water, must be
available during the entire operating time.
Caution! Risk of malfunction or damage!
In order to avoid frost damage, the minimum permissible input water
temperature of +6 °C must not be undercut at any point in the water cycle!
It is vital that the manufacturers’ consent is obtained before adding
anti-freeze!
Caution! Risk of malfunction or damage!
During storage and transportation below freezing point, the water cycle
should be drained completely using compressed air!
Caution! Risk of malfunction or damage!
Only set the temperature control setpoint as low as is strictly necessary, since the danger of condensation through undercutting the dew
point increases with a falling water inlet temperature!
Ensure that the enclosure is sealed on all sides, particularly at the cable
entry (condensation)!
2.3
10
Service and technical staff
The installation, commissioning, maintenance and repair of this unit may only
be carried out by qualified mechanical and electro-technical trained personnel.
Only properly instructed personnel may carry out service on a unit while in operation.
Operating and Maintenance Instructions – 2 Safety instructions
Rittal Liquid Cooling Package Plus
2.4
RoHS compliance
The Liquid Cooling Package Plus fulfils the requirements of EU directive 2002/
95/EC on the Restriction of Use of Certain Hazardous Substances in Electrical
and Electronic Equipment (RoHS) of 13 February, 2003.
Note:
Corresponding information concerning the RoHS directive is provided by
our firm on the Internet at www.rittal.de/RoHS.
11
Operating and Maintenance Instructions – 2 Safety instructions
Rittal Liquid Cooling Package Plus
3
Transport and handling
3.1
Scope of delivery of Liquid
Cooling Package Plus
The scope of delivery of a Liquid Cooling Package Plus (LCP Plus
Model No. SK 3301.480) includes:
Qty.
Parts
1
Liquid Cooling Package Plus with LCP Plus, ready for connection
Accessories:
1
• Pipe fitting condensate pump
1
• Condensate hose for condensate pump
1
• Condensate hose emergency overflow
1
• Sealing strip
1
• Connection plug
1
• Cable tie and spreading anchor
1
• Jumper for connection plug (strain relief for connection cable)
4
• Eyebolts
1
Tab. 1:
3.2
Transport
Assembly instructions
Scope of delivery of a Liquid Cooling Package Plus
The Liquid Cooling Package Plus is delivered shrink-wrapped on a pallet.
Caution!
Because of its height and small base, the Liquid Cooling Package Plus
is subject to tipping. Risk of toppling, especially after the unit is removed from the pallet!
Caution!
Transport of the Liquid Cooling Package Plus without a pallet:
- Use only suitable and technically sound lifting gear and load-bearing
devices with sufficient load capacity.
3.3
Unpacking
• Remove the unit's packaging materials.
Note
After unpacking, the packaging materials must be disposed of in an environmentally friendly way. They may consist of the following materials:
- Wood,
- Polyethylene film (PE film),
- Strap,
- Edge protectors.
• Check the unit for damages occurring in transport.
Note
Damage and other faults, e.g. incomplete delivery, should immediately be
reported to the shipping company and to Rittal GmbH & Co. KG in writing.
• Place the unit in its intended location.
12
Operating and Maintenance Instructions – 3 Transport and handling
Rittal Liquid Cooling Package Plus
4
Design and function
4.1
Design
The schematic design is seen in the following illustration:
1
2
3
4
5
8
6
7
9
Fig. 4:
1
2
3
4
5
6
7
8
9
Schematic design of a Liquid Cooling Package Plus
Control unit Basic CMC)
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Air/water heat exchanger
Water module
The Liquid Cooling Package Plus consists of a superordinate control unit (Basic
CMC), a water module, a heat exchanger, and six fan modules. Fans, in groups
of two, and the water module contain their own electronic controls (3 x RLCP
fan and 1 x RLCP water), which are connected to one another over an I2C bus.
13
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
4.1.1 Liquid Cooling Package Plus
1
2
3
4
5
6
Fig. 5:
1
2
3
4
5
6
14
Liquid Cooling Package Plus (front)
Rack (H x W x D: 2000 mm x 300 mm x 1200 mm)
LCP door
Touch panel
Wall plate (wide) with air outlet
Wall plate (narrow) with air inlet
Levelling foot
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
1
2
3
4
5
4
6
7
8
Fig. 6:
1
2
3
4
5
6
7
8
Liquid Cooling Package Plus - rear
Mains connection
Control unit (Basic CMC)
LCP door
Fan
Fan control unit
Water module control unit
Water module
Levelling foot
The Liquid Cooling Package Plus consists of a solid welded frame in which the
heat exchanger, fan modules, and the water module are installed. The frame
stands on four levelling feet, which may be used to align the unit with the bayed
server enclosure. One wide and one narrow wall plate are mounted on both the
left and right sides. A vertical divider plate is positioned at the joint of the two
plates, which separates the Liquid Cooling Package Plus into warm and cold
air sections.
The wide wall plates on the front right and left sides of the device form the cold
air section together with the divider plate and the built-in air/water heat exchanger. The wall plates have been punched with air outlet openings along
their entire length in the front and rear to ensure cold air supply to the server
and rejected hot air supply to the heat exchanger.
The narrower wall plates close off the rear of the device and form the warm air
section together with the divider plate. The wall plates have been punched with
air inlet openings along their entire height and width to ensure the removal of
warm air from the server.
Eight shelves are positioned between the wall plates that divide the Liquid Cooling Package Plus into five installation spaces of differing heights. The control
unit (Basic CMC) sits on the top shelf. Installation spaces for the fans and control units for the six fan modules are located below. All components of the cooling water supply and condensate management are integrated into the water
module on the floor of the Liquid Cooling Package Plus.
15
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
The front door completely seals the Liquid Cooling Package Plus. The graphical display (touchscreen) for operation in stand-alone mode is located on the
front. Behind the display is a partitioning plate that closes off the cold air section
to the front. The door on the rear side of the device only seals off the Liquid Cooling Package Plus in the upper section of the device. The lower section is covered with a U-shaped plate. The possible connection line to the cold water
network and the condensate discharge hoses are run out of the Liquid Cooling
Package Plus through the resulting opening.
4.1.2 Air/water heat exchanger
The air/water heat exchanger is installed in the front section of the Liquid Cooling Package Plus between both of the front wall plates. The heat exchanger is
covered with a spray eliminator on the air outlet side that catches any occurring
condensate and directs it to the condensate collecting tray in the Liquid Cooling Package Plus. Three temperature sensors are mounted on the front side of
the spray eliminator at the level of the fan modules. The sensors record the temperature of the cold air that is blown in (server-in temperature) and transfer it to
the control.
4.1.3 Fan module
1
4
2
3
Fig. 7:
1
2
3
4
Fan module
Fan
Rack-mounted shelf
Control unit for fan module (RLCP fan)
T handle
A fan module consists essentially of one fan that is mounted an angle bracket.
One control unit (RLCP fan) controls two fan modules. The fans may be operated at four output levels and are activated by four relays. (Both fans always operate at the same output level.)
The fan modules are installed on rack-mounted shelves in the rear section of
the Liquid Cooling Package Plus with the control unit in between. Each shelf
has slide rails on the longitudinal sides. The angle brackets with the fans are
inserted into and held in the rails.
16
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
1
2
3
Fig. 8:
1
2
3
Fan module
Fan
Angle bracket
Connector for power supply and control cable
The angle bracket consists of two long plate pieces. The longer of the two forms
the base plate and the shorter (vertical) one supports the fan and the connector
for the power supply and the control cable. The air outlet vent of the fan projects
forward from a circular opening on the vertical plate piece. When the fan module is installed, the air outlet vent extends into the cold air section of the device
and facilitates a trouble-free and direct routing of the air from the fan module to
the air/water heat exchanger.
Because the individual fan modules are located on separate angle brackets, it
is possible to remove a single fan module and replace it easily during operation
by opening the T handle (hot pluggable). It takes about 30 seconds to replace
a fan module (see chapter 6.3, "Fan Installation").
17
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
4.1.4 Water module with cold
water connection
1
8
Fig. 9:
1
2
3
4
5
6
7
8
7
2
3
6 5
4
Water module with cold water connection
Two-way control valve
Leakage sensor
Cooling water flow with temperature sensor
Cooling water return with temperature sensor
Condensate pump
Condensate sensor (floating switch)
Flow sensor
Condensate collecting tray
A significant component of the water module is the stainless steel condensate
collecting tray, on which a level sensor, a condensate pump, and a condensate
overflow are located.
A hose line leads the condensate from the condensate pump out of the Liquid
Cooling Package Plus through the rear. Additionally, the condensate tray is
equipped with a no pressure condensate overflow in case either the level sensor or the condensate pump should malfunction. This is located underneath the
condensate pump and also leads the condensate to the rear, out of the Liquid
Cooling Package Plus. Both hoses should be connected to either a collecting
device or an external drain.
The pipework for the Liquid Cooling Package's Plus cooling water connection
(inlet and return) runs on the side, above the condensate collecting tray. The
lines connect the rear-mounted cooling water connection with the air/water heat
exchanger that is built into the front of the device. The lines are insulated to avoid the formation of condensation. A motor-operated control valve is located in
the cooling water return line. This control valve can control the cooling water
flow.
The control unit of the water module is mounted with a holder on a separate
mounting plate directly behind the rear door of the Liquid Cooling Package
Plus, above the water module at the level of the lower fan module.
The cooling water connection is connected to the main connections of the cooling water return by two 1" externally threaded pipes. The connecting pieces of
both pipes are composed of T pieces, to allow for the option of connecting from
the rear or through the raised floor.
The cooling water connection to the cold water network can be made by either
rigid pipework or flexible hoses, which are available from the Rittal accessory
range (Model No. SK 3301.351).
18
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
4.2
Function
The Liquid Cooling Package Plus (LCP Plus) is essentially an air/water heat exchanger. It serves to dissipate high heat losses from server enclosures or for
the effective cooling of devices built into a server enclosure.
The Liquid Cooling Package Plus may, as desired, be bayed on the right or left
of a server enclosure.
Fig. 10: Liquid Cooling Package Plus on a server enclosure
The Liquid Cooling Package Plus may also be bayed between two server enclosures.
Fig. 11: Liquid Cooling Package Plus between two server enclosures
Together with the bayed server enclosures, the Liquid Cooling Package Plus
forms an airtight cooling system with horizontal air routing. It places no additional demands on the room's climate control system.
The air routing in the LCP Plus supports the "front to back" cooling principle of
the devices built into the server enclosure. The fan modules draw the warm air
exhausted from the devices in the server enclosure in the entire height of the
rear area into the Liquid Cooling Package Plus, which is bayed to the side, and
then into the heat exchanger module.
In the heat exchanger module, the heated air is directed through an air/water
heat exchanger, and its thermal energy (heat losses from the server) is transferred to a cold water system. Through this, the air is cooled to a freely selec-
19
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
table temperature and then routed in front of the 482.6 mm (19") level in the
server enclosure.
1
5
2
3
6
4
Fig. 12: Air routing on the Liquid Cooling Package Plus (top view)
1
2
3
4
5
6
Fan module
Air inlet
Heat exchanger
Air outlet
2nd air inlet (optional)
2nd air outlet (optional)
The temperature control of the cold air which is blown in takes place through
constant comparison of the actual temperature with the setpoint temperature
set on the Liquid Cooling Package Plus' control unit (default is +20 °C).
If the setpoint temperature is exceeded, the control valve in the cooling water
system opens, and the heat exchanger is provided with cold water. The control
valve is infinitely variable (can open from 0 to 100%). In addition, the temperature differential between the cold air that is blown in and the warm air that is
drawn is used to determine and set the fan speed. The control attempts to keep
the air temperature constant in front of the 482.6 mm (19") level by activating
the control valve.
Any condensate which may develop is collected in the condensate collecting
tray that is integrated in the water module of the Liquid Cooling Package Plus.
Upon reaching a defined condensate level in the collecting tray, the level sensor activates the condensate pump. The pump leads the condensate out of the
Liquid Cooling Package Plus. Further, a condensate overflow hose leads from
the tray to the exterior, so that, if necessary, (e.g. in the event of a defective level
sensor or a defective condensate pump) liquid is led away.
Note:
The water flow temperature should always be set so that the temperature never falls below the dew point (cf. Fig. 13).
20
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
Rel. humidity
En
th
al
py
Temperature
Water
Mollier h-x diagram for humid air - pressure 0.950 bar (537.000 m / 10.000 °C / 80.000 %rF)
Fig. 13: Mollier h-x diagram for humid air
21
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
4.3
Air routing inside the
enclosure
The targeted air routing in the server enclosure has a primary implication on the
heat loss to be dissipated.
In order to achieve sufficient cooling in the server enclosure, it must be ensured
that the cooling air must pass through the interior of the built-in units and may
not flow to the side.
1
2
Fig. 14: Air routing of a bayed server enclosure (top view)
1
2
Liquid Cooling Package Plus
Server enclosure
1
2
Fig. 15: Air routing of two bayed server enclosures (top view)
1
2
1
Server enclosure
Liquid Cooling Package Plus
In addition, the system consisting of the Liquid Cooling Package Plus and the
server enclosure should be sealed as well as possible in order to prevent a loss
of the cooling air. To accomplish this, the enclosure is equipped with side panels, roof and gland plates. Any existing cable entries should be sealed with,
22
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
e.g. brush strips.
Whilst the system is in operation, both the front and the rear doors should be
kept completely shut.
Note:
However, the system does not need to be completely airtight. This is not necessary due to the high, coordinated air throughput of the server fans and
LCP Plus fans.
In fact, a small amount of ambient air is desirable, since this can prevent the
cooling air from becoming too dry.
In order to ensure the targeted air routing in the system, the server enclosure is
divided into warm air and cold air sections. The division is accomplished in the
front section of the server assembly to the left and right of the 482.6 mm (19")
level through foam strips, which, depending on the enclosure width and the
number of server enclosures to be cooled, can be ordered as an accessory
(see Chapter 13, "Accessories").
If devices which require sideways air throughput are built into the server enclosure (e.g. switches, router, etc.), these may be cooled through targeted placement of the foam strips.
Note:
The 482.6 mm (19") level must likewise be completely sealed. This is already
the case in a fully equipped server enclosure. If the server enclosure is partially equipped, the open height units (U) of the 482.6 mm (19") level must
be sealed with blanking plates, which are available from the Rittal accessory
range (see Chapter 13, "Accessories").
As more devices are installed in the server enclosure, it becomes even more
important to follow this specification.
23
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
4.3.1 Possibilities for establishing It is simple to establish cooling redundancies through the baying possibilities
described above. The separation of the server enclosure from the Liquid Cooredundancies
ling Package Plus makes it possible to achieve differing levels of redundancy.
1
2
1
4
3
Fig. 16: Redundant or double cooling with two Liquid Cooling Packages Plus
1
2
3
4
Liquid Cooling Package Plus
Server enclosure
Inlet cold water system
Return cold water system
Two server enclosures may be cooled with 3 Liquid Cooling Packages Plus.
Depending on the cooling output, the device bayed in the middle, between the
server enclosures, forms the redundancy for the respective left and right server
enclosure.
24
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
1
2
1
2
1
4
3
Fig. 17: Redundant cooling with three Liquid Cooling Packages Plus
1
2
3
4
1
2
1
2
Liquid Cooling Package Plus
Server enclosure
Inlet cold water system
Return cold water system
1
2
1
2
6
1
5
4
3
Fig. 18: Redundant cooling and doubled, alternating water supply
1
2
3
4
5
6
25
Liquid Cooling Package Plus
Server enclosure
Inlet cold water system 1
Return cold water system 1
Inlet cold water system 2
Return cold water system 2
Operating and Maintenance Instructions – 4 Design and function
Rittal Liquid Cooling Package Plus
5
Technical
specifications
Technical specifications
Liquid Cooling Package Plus
Model No. SK
3301.480
Rated voltage (V, Hz)
230/1~ 50/60
400/3~/N/PE
50/60
Rated current (A/Hz)
10.5/50
11.5/60
3.5/50
3.8/60
16.0
10.0
Pre-fuse T (A)
Duty cycle (%)
100
Capacity (W/Hz)
2400/50
2650/60
Useful cooling output L37W15 (kW/Hz)
(at 15 °C inlet temperature and a volumetric flow
of 60 l/min)
Air throughput of fans
((m3/h)/Hz)
max. 5000
Coolant
Water/glycol mixture
(up to 30%)
Coolant inlet temperature (°C)
Permissible operating pressure pmax (bar)
Ambient temperature range (°C)
+6 to +20 (ideally +15)
5
+6 to +35
Noise level (dB(A))
(Open air above reflective flooring, distance 1 m)
64
Width (mm)
300
Height (mm)
2000
Depth (mm)
1200
Weight (kg)
max. 230
Fill quantity (l)
Tab. 2:
26
28/50
28/60
9
Technical specifications
Operating and Maintenance Instructions – 5 Technical specifications
Rittal Liquid Cooling Package Plus
6
Installation – "Getting
Started"
6.1
Installation conditions
In order to ensure problem-free operation of the Liquid Cooling Package Plus,
the following conditions for the installation location should be observed:
Supply connections required at the installation site
Type of connection
Connection description:
Power connection:
- 230 V 50/60 Hz
with connection cable DK 7856.026
16 A, 1~, CEE connector, 3-pole
- 400 V, 3~, N, PE, 50/60 Hz
with connection cable DK 7856.025
16 A, 3~, CEE connector, 5-pole
Cooling water connection:
- +6 °C to +20 °C inlet temperature
- 5 bar permissible operating pressure
- Volumetric flow: depending on design
(cf. Chapter 6.5.1, "Cooling output")
- 1" threaded pipe connection
Tab. 3:
Supply connections required at the installation site
Note:
Please see the notes and data regarding the cold water connection in
Chapter 6.4.2, "Cooling water connection" and in Chapter 14.1, "Hydrological information".
Recommendation:
To keep the Liquid Cooling Package Plus easy to service, maintain a distance of min. 1 m between the front and rear of the device and the nearest
wall.
Floor conditions
- The floor of the installation space should be rigid and level.
- Choose the installation site so that the unit is not situated on a step, unlevel
location, etc.
Climatic conditions
- The room temperature must be between +6 °C and +40 °C
- The relative air humidity must be below 80%.
Recommendation:
Room temperature + 22 °C at 50% relative air humidity, according to ASHRAE guidelines.
Electromagnetic interference
- Interfering electrical installations (high frequency) should be avoided.
27
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.2
Assembling the Liquid
Cooling Package Plus
6.2.1 Preparatory work on the
server enclosure
Before the Liquid Cooling Package Plus can be bayed onto the server enclosure, the following work should be carried out.
- Dismantle the side panels,
- Seal the server enclosure and
- Dismantle the server enclosure door.
Dismantle the side panels
Note:
It is only necessary to dismantle the side panels when the Liquid Cooling
package is to be bayed onto a previously erected server enclosure.
Otherwise, this work is not necessary.
Proceed as follows to dismantle the side panels:
• Loosen and remove the 8 assembly screws found on each side panel of the
server enclosure.
• Remove all side panel securing elements from the side of the server enclosure onto which the Liquid Cooling Package Plus is to be bayed.
• Dismantle both side panel mountings from the upper mounting rail of the
server enclosure. Use an appropriate lever to do this.
• Loosen and remove the screws on both of the side panel mounting brackets
(upper and lower) in the middle of the mounting rail.
• Loosen and remove the screws from the 6 side panel holders on the side
mounting rails.
Caution! Risk of injury!
The side panel holders have sharp-edged teeth, which allow for an earthing of the server enclosure's side panel.
Seal the server enclosure
In order to ensure the targeted air routing in the system, the server enclosure is
horizontally divided into warm air and cold air sections by sealing the 482.6 mm
(19") level.
Proceed as follows to seal the 482.6 mm (19") level:
• If the server enclosure is only partially configured, seal the open sections of
the 482.6 mm (19") level using blanking plates. Screw these tightly into the
server rack from the front side.
Note:
The blanking plates are available in various heights (U) from the Rittal accessory range.
• Fasten the broader (Model No. SK 3301.370/3301.320) of the two foam strips
from the Liquid Cooling Package Plus accessories from outside onto one of
the front supports of the server rack (cf. Fig. 19). Make sure to install this strip
on the side of the server enclosure onto which the Liquid Cooling Package
Plus is to be bayed.
• Fasten the smaller (Model No. SK 3301.380/3301.390) of the two foam strips
from the Liquid Cooling Package Plus accessories from outside onto one of
the front supports of the server rack (cf. Fig. 19). Make sure to install this strip
on the side of the server enclosure which will again be sealed by a side panel.
28
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
1
2
Fig. 19: Foam strip on a server rack support
1
2
Foam strip
Server rack
• If devices which require cooling via sideways air throughput (e.g. switches,
router, etc.) are built into the server enclosure, cut-outs must be incorporated
into the foam strips.
• To do this, cut out a piece of the foam strip with a sharp knife.
• If several devices which require sideways air throughput are included, cut
out several pieces of the foam strip, as is appropriate, so that, ultimately,
there is a cut-out in the foam to the left or right in the height of each such
device in the server rack. Ensure that there are no gaps on the warm air side
of the device (Fig. 20, item 3).
• Cut additional pieces from the foam strips with a sharp knife that are at least
as long as the height of the built-in devices.
• Attach the foam strips to the cold air side of the devices facing backward
(Fig. 20, item 4). Ensure that you attach the strips such that all fans built into
the devices can draw air and that none of them are blocked.
Note:
The foam strips can be attached between the front and rear supports of the
server rack along the entire depth of the devices with air throughput at the
sides (Fig. 20, item 5).
29
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
5
5
4
3
1
2
Fig. 20: Placement of foam strips for devices with sideways air throughput - top view
1
2
3
4
5
Liquid Cooling Package Plus
Server enclosure
Foam strips on warm air side
Foam strips on cold air side
Area in which the foam strips can be positioned
• If there is any remaining length of the foam strip on the server rack, cut it off
at the top edge of the rack.
Note:
The Liquid Cooling Package Plus can, as desired, be bayed onto a server
enclosure with a width of either 600 mm or 800 mm. Thus, the Liquid Cooling
Package Plus accessories include a total of four foam strips with differing dimensions.
The foam strips for a 600 mm wide server enclosure may be ordered with the
following numbers from the Rittal accessory range:
- Model No. SK 3301.370 for the LCP side
- Model No. SK 3301.380 for the side with the side panel
The foam strips for a 800 mm wide server enclosure may be ordered with the
following numbers from the Rittal accessory range:
- Model No. SK 3301.320 for the LCP side
- Model No. SK 3301.390 for the side with the side panel
• On the side of the server enclosure opposite the Liquid Cooling Packing Plus,
mount a side panel on the two side panel mountings. Align it with the front and
rear side of the enclosure.
• Using the 8 assembly screws, screw the side panel firmly onto the side panel
holders and the side panel mounting brackets.
• Seal off any cable entries which may be present with corresponding brush
strips or similar.
Dismantle the server enclosure door
Before baying a Liquid Cooling Package Plus, one or both of the server enclosure doors must be dismantled so that the attachment points for the baying
connectors are accessible and are not covered by a door edge.
30
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Note:
It is only necessary to dismantle a server enclosure door when the Liquid
Cooling Package Plus is to be bayed onto a previously erected server enclosure.
Otherwise, this work is not necessary.
If the Liquid Cooling Package Plus is to be set up with a new server enclosure, proceed according to the enclosure's assembly instructions and bay
the Liquid Cooling Package Plus onto the server enclosure before assembling the server enclosure doors.
Proceed as follows to dismantle a server enclosure door:
• Remove the sealing bungs from the four door hinges with an appropriate tool
(e.g. screwdriver).
• Release and open the server enclosure door.
• Loosen the hinge bolts from the four door hinges by raising them with an appropriate tool (e.g. screwdriver). Pull the bolts out of the hinge bolt holding fixture up to the catch (see Fig. 21, Step A).
Begin with the lowest door hinge.
A
1
3
2
B
4
1
A
Fig. 21: Door hinge – dismantling
1
2
3
4
Door hinges
Hinge bolt holding fixture
Hinge joint
Server enclosure door
Note:
Support the server enclosure door so that it will not fall as the door hinges
are loosened. If needed, work with a second person.
• Remove the server enclosure door (see Fig. 21, Step B).
31
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.2.2 Installation and baying of the
Liquid Cooling Package
1
3
4
3
2
4
Fig. 22: Liquid Cooling Package Plus - rear
1
2
3
4
Enclosure door
Cover
Assembly screws
Mounting hole
• Position the Liquid Cooling Package Plus on the side of the server enclosure
to which it is to be bayed.
• Align the Liquid Cooling Package Plus with the server enclosure using the levelling feet. Ensure that the Liquid Cooling Package Plus is aligned levelly
and that both enclosures are adjusted to the same height and are vertically
aligned to each other.
• Dismantle the door of the Liquid Cooling Package Plus whose hinges are on
the side on which the server enclosure is to be bayed. Proceed as described
in Chapter 6.2.1, "Preparatory work on the server enclosure".
Note:
If the Liquid Cooling Package Plus is to be bayed between two server enclosures, both doors of the LCP Plus must be dismantled before the baying
connector is installed and the cover must be removed from the lower section
of the rear so that the attachment points for the baying connector are accessible.
• Loosen both assembly screws from the cover (Fig. 22, item 3) and remove
the cover (Fig. 22, item 2).
• Using assembly screws, fasten three baying connectors each (Fig. 23,
item 3) onto the intended attachment points in the frame on the front and rear
sides of the Liquid Cooling Package Plus (Fig. 23, item 1).
32
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
1
3
2
3
3
Fig. 23: Liquid Cooling Package Plus on a server enclosure - rear
1
2
3
Liquid Cooling Package Plus
Server enclosure
Baying connector
• Using the corresponding assembly screws, fasten the baying connectors
(Fig. 23, item 3) onto the intended attachment points in the frame on the front
and rear sides of the server enclosure (Fig. 23, item 2). As needed, press the
Liquid Cooling Package Plus lightly against the server enclosure in order to
bring the baying connectors into alignment with the attachment points.
• Then, check the stability of the Liquid Cooling Package Plus once more and
adjust the levelling feet if necessary.
33
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.2.3 Assembly of the side panel
on the Liquid Cooling
Package Plus
If the Liquid Cooling Package Plus is not bayed between two server enclosures,
close it off with a side panel. Proceed as follows to assemble the side panel:
• Remove the various assembly components from the optional side panel package (Model. No. SK 8100.235) or use those from a server enclosure which
has already been dismantled.
• Using the assembly screws, mount the assembly components (2 side panel
mountings, 2 side panel mounting brackets, 6 side panel holders) onto the
side of the Liquid Cooling Package Plus which is opposite to the server enclosure.
• Place both side panel mountings (Fig. 24, item 1) as symmetrically as possible onto the upper mounting rail of the LCP Plus and, using your hand,
press them firmly in place.
• Screw down the two side panel mounting brackets (Fig. 24, item 2) above
and below in the middle of the mounting rail using one screw each.
• Screw down 3 side panel holders (Fig. 24, item 3) onto each of the two side
assembly rails with one screw each.
Caution! Risk of injury!
The side panel holders have sharp-edged teeth, which allow for an earthing of the side panel through the Liquid Cooling Package Plus.
1
2
1
3
3
2
Fig. 24: Assembly components for the side panel
1
2
3
Side panel mounting
Side panel mounting bracket
Side panel holder
• Mount a side panel onto the two side panel mountings of the Liquid Cooling
Package Plus and align them to the front and rear sides of the unit.
• Using the 8 assembly screws, screw the side panel firmly onto the side panel
holders and the side panel mounting brackets.
34
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.3
Fan installation
6.3.1 Removing a fan module
As delivered, the Liquid Cooling Package Plus contains six fan modules. If a fan
module is defective, it can be replaced during operation without tools - quickly
and easily.
Proceed as follows to remove a fan module:
• Open the rear door of the Liquid Cooling Package Plus.
1
3
2
Fig. 25: Fan plug-in unit
1
2
3
Fan plug-in unit
T handle
Handle
• Open the fan module lock by turning the T handle (fig. 25, item 2) anticlockwise a quarter of a rotation. (Fig. 25, item 2).
Fig. 26: Opening the T handle
35
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
• Using the handle (Fig. 25, item 3), pull the fan module completely out of the
fan plug-in unit.
Fig. 27: Pulling out the fan module
Caution! Risk of injury!
Only pull on the handle when removing the fan module. There is a danger of trapping between the main carrier of the fan module and the
edges of the gaps in the floor of the fan plug-in unit.
Caution! Risk of injury! Risk of damage!
While pulling the fan module out of the fan plug-in unit, support it from
below. It cannot be held by the handle alone.
36
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Removing the lower fan module
As delivered, the fan module in the lower fan plug-in unit is covered by the vertically installed control unit of the water module (RLCP water). For this reason,
you must remove the control unit of the water module before you can remove
the lower fan module. Proceed as follows:
• Open the rear door of the Liquid Cooling Package Plus.
1
2
4
3
4
Fig. 28: Water module control unit
1
2
3
4
Water module control unit (RLCP water)
Mounting plate
Control unit holder
Thumb screw
• Loosen both thumb screws (Fig. 28, item 4) from the control unit holder
(Fig. 28, item 3) and completely unscrew them.
• Remove the control unit together with the holder (Fig. 28, item 1 and item 3)
from the mounting plate (Fig. 28, item 2) and set it down outside the Liquid
Cooling Package Plus.
•
Note:
There is no need to seperate any conductors from the water module control
unit (RLCP water) to remove the fan module.
• Open the fan module lock by turning the T handle (fig. 25, item 2) anticlockwise a quarter of a rotation. (Fig. 25, item 2).
• Using the handle (Fig. 25, item 3), pull the fan module completely out of the
fan plug-in unit.
Caution! Risk of injury!
Only pull on the handle when removing the fan module. There is a danger of trapping between the main carrier of the fan module and the
edges of the gaps in the floor of the fan plug-in unit.
Caution! Risk of injury! Risk of damage!
While pulling the fan module out of the fan plug-in unit, support it from
below. It cannot be held by the handle alone.
37
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.3.2 Installing a fan module
Proceed as follows to install a fan module:
1
2
3
3
Fig. 29: Fan plug-in unit
1
2
3
Fan plug-in unit
T handle
Slide rails
• Place the fan module onto the slide rails (Fig. 29, item 3) of the fan plug-in unit
and push it in until it reaches the stop position.
Fig. 30: Plugging in the fan module
38
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
• Close the fan module lock by turning the T handle (Fig. 29, item 2) clockwise
a quarter of a rotation.
Fig. 31: Closing the T handle
Inserting the lower fan module
After you have installed the lower fan module as described above, you must
then install the water module control unit. Proceed as follows:
1
2
4
3
4
Fig. 32: Water module control unit
1
2
3
4
Water module control unit (RLCP water)
Mounting plate
Control unit holder
Thumb screw
• Place the control unit together with the holder (Fig. 32, item 1 and item 3) onto
the mounting plate (Fig. 32, item 2) in the Liquid Cooling Package Plus.
• Insert both thumb screws (Fig. 32, item 4) and tighten them.
39
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.4
Connecting the
Liquid Cooling Package
Plus
6.4.1 Electrical connection
6.4.1.1 General
Note:
Please keep this electrical documentation readily available so that it is always on hand when needed. This is the only documentation which is authoritative for the unit.
Caution!
Work on electrical systems or equipment may only be carried out by an
electrician or by trained personnel guided and supervised by an electrician. All work must be carried out in accordance with electrical engineering regulations.
The unit may only be connected after the above-named personnel have
read this information.
Use insulated tools.
The connection regulations of the appropriate power company are to be
followed.
The voltage values shown in the wiring plan or on the rating plate must
match the mains voltage.
The pre-fuse specified in the wiring plan or on the rating plate should
be provided as power protection. The unit must be individually fused.
The unit must be connected to the mains via an isolating device which
ensures at least 3 mm contact opening when switched off.
The mains connection may only be made using the connection cable
which extends from the unit.
No additional control equipment may be connected upstream of the device at the supply end.
The Liquid Cooling Package Plus' power supply is made over either a separate
3-pole or 5-pole supply, as desired. The device is always delivered with a 5pole mains connection socket so that the user can attach a connection cable
with a mains plug (3-pole or 5-pole) that corresponds to local requirements. Relevant connection cables available from Rittal accessories (Model No. DK
7856.025 or DK 7856.026).
Two of fan modules installed in the Liquid Cooling Package Plus are on a separate phase.
If the Liquid Cooling Package Plus is connected to the mains using a 3-pole,
single-phase, 230 V connection cable (L, N, PE; DK 7856.026), one of the phases must be bridged to the other two. This is already implemented in the 5-pole
plug.
40
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
If the Liquid Cooling Package Plus is connected to the mains using a 5-pole
connection cable (400 V, 3~, N, PE; DK 7856.025), three separate phases (L1,
L2, and L3) are available.
In this way, if one connection phase fails, four fan modules will still be supplied
with power and the Liquid Cooling Package Plus will continue to function (redundancy).
Note:
The cross section and the fusing of the connection cable may be found in
Chapter 14.4, "Circuit diagram".
Danger!
Take outmost care not to short-circuit one of the phases with the zero
conductor or the earth conductor. Otherwise, there is a risk of damage
or injury.
6.4.1.2 Electrical connection with the
included 5-pole plug
5-pole, 3-phase connection
To connect the Liquid Cooling Package Plus to the mains using a 5-pole, 3-phase connection cable, proceed as follows:
• Remove approximately 45 mm from the rubber cover of the sheathed flexible
cable.
• Trim the neutral conductor (N) and the three phase conductors (L1, L2, and
L3) to a length of approximately 35 mm. Leave the length of the PE conductor
at approximately 45 mm.
• Remove approximately 9 mm from the insulation of all conductors with a suitable tool.
45
9
9
Fig. 33: Dimensions for removing the rubber cover and insulation
• Attach wire end ferrules without insulating collars to the ends of the conductors. To crimp the wire end ferrules, use a suitable crimping tool with an integral lock to prevent the tool from opening prematurely.
• Connect all conductors to the connection plug (X-Com plug).
• Insert a screwdriver into an activation opening (Fig. 34, item 1) and open
the screw terminal clamping point of the conductor entry (Fig. 34, item 2).
• Insert the conductor completely into the conductor entry and then remove
the screw driver to close the screw terminal clamping point.
41
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
1
2
Fig. 34: Connection plug - rear
1
2
Activation opening of the screw terminal clamping point for the conductor
entry
Conductor entry
Note:
The configuration of the Connection plug may be found in Chapter 14.4,
"Circuit diagram".
Danger!
Take upmost care not to short-circuit one of the phases with the zero
conductor or the earth conductor. Otherwise, there is a risk of damage
and injury.
• Press the bottom piece of the strain relief housing from below onto the connection plug.
• Guide the conductors in the strain relief housing, as displayed in Fig. 35, and
secure the sheathed flexible cable to the strain relief housing with a cable
clamp.
1
2
Fig. 35: Connection plug with strain relief housing
1
2
Strain relief for conductors with Ø > 12 mm
Strain relief for conductors with Ø < 2 mm
Note:
To provide adequate strain relief for cables with a diameter of <12 mm as
well, it is necessary to install a second cable clamp underneath the cable
(Fig. 35, item 2).
42
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
• Close the strain relief housing by pressing the top piece of the housing from
above onto the bottom piece (Fig. 36).
Fig. 36: Closing the strain relief housing
3-pole, single-phase connection
To connect the Liquid Cooling Package Plus to the mains using a 3-pole, single-phase connection cable, proceed as follows:
• Remove approximately 45 mm from the rubber cover of the sheathed flexible
cable.
• Trim the neutral conductor (N) and the phase conductor (L) to a length of approximately 35 mm. Leave the length of the PE conductor at approximately 45
mm.
• Remove approximately 9 mm from the insulation of all conductors with a suitable tool.
45
9
9
Fig. 37: Dimensions for removing the rubber cover and insulation
• Attach wire end ferrules without insulating collars to the ends of the conductors. To crimp the wire end ferrules, use a suitable crimping tool with an integral lock to prevent the tool from opening prematurely.
• Bypass the phase connections on the connection plug using the two included
bridges (Fig. 38, item 1).:Place one bridge between phase conductors L1
and L2 and one bridge between phase conductors L2 and L3.
43
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
1
2
3
4
Fig. 38: Schematic diagram of the connection plug with strain relief housing
1
2
3
4
Bridge for bridging the phase conductors
Phase conductor (L)
Neutral conductor (N)
PE conductor
• To connect the connection plug, proceed as described in the section "5-pole,
3-phase connection".
Fastening the connection cable
The connection cable must be fastened for the electrical connection of the Liquid Cooling Package Plus. Proceed as follows:
• Insert the cable tie and spreading anchor from the accessories into the provided hole on the top of the Liquid Cooling Package Plus.
• Lay the connection cable and connect it to the connection socket.
Note:
The following bending radii must not be exceeded for a fixed installation of
the connection cable.
5-pole connection cable: 4 x external diameter
3-pole connection cable: 3 x external diameter
• Fasten the connection cable with the cable tie.
44
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.4.2 Cooling water connection
The Liquid Cooling Package Plus is connected to the cold water network via
two 1" threaded pipe connections (external thread) on the inlet and return, located on the lower rear side of the unit. The connecting pieces of both pipes
are composed of T pieces, to allow for the option of connecting from the rear or
through the raised floor.
Note:
As much as possible, use armoured hoses for the cooling water hoses.
The water connection may be made in a fixed manner using solid pipes as
well. This may be done locally by the appropriate qualified person.
Note:
When tightening the coupling connection, use an appropriate tool to provide
counter-support on the primary connection to ensure over-tightening is not
performed (on the Liquid Cooling Package Plus and on the building services).
1
2
Fig. 39: Cold water network connection:
1
2
Cooling water return (outlet) with1" external thread
Cooling water flow (inlet) with 1" external thread
Note:
To ensure proper functioning of the control valve, a bypass or a water hammer arrestor should be provided.
Caution!
When installing, observe the applicable specifications concerning water quality and water pressure.
45
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Optionally, the cooling water connection may be made from below through the
raised floor. This may be done through a built-in T piece.
1
(45)
2
(297)
206
(45,5)
150
3
Fig. 40: Mounting hole for the cooling water connection through the raised floor
1
2
3
Cooling water flow
Cooling water return
Liquid Cooling Package Plus rack
In case of a low water inlet temperature (<12 °C), the inlet and return lines
should be appropriately insulated. If this is not done, condensate may form on
the supply lines.
Note:
It is possible to test the flow of the water cycle immediately after connection
on the graphical display (touchscreen). In addition, you must first check
whether the control valve is completely open (see Chapter 6.6.2, "Operation
in stand-alone mode"). If the control valve is closed or only partially open, it
can be opened in manual mode over a network connection using the setup
screen (see Chapter 6.7.1, "Visualisation", page 68).
Note:
The building-side piping should be designed according to the Tichelmann
Principle in order to maintain a hydraulically balanced system.
If this is not the case, the flow volume of each Liquid Cooling Package Plus
must be assured by using a flow quantity regulator.
Ideally, the Liquid Cooling Package Plus is connected to the cooling water
system using a water/water heat exchanger.
Advantage:
• Reduction of water volumes in the secondary circuit,
• Setting of a defined water quality,
• Setting of a defined input temperature and
• Setting of a defined volumetric flow.
46
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Notes on water quality
For safe operation, it is vital that the VBG guidelines on cooling water are observed (VGB R 455P). Cooling water must not contain any limescale deposits
or loose debris, and it should have a low level of hardness, particularly a low
level of carbonate hardness. For recooling within the plant, the carbonate hardness should not be too high. On the other hand, however, the water should not
be so soft that it attacks the operating materials. When recooling the cooling
water, the salt content should not rise too high as the result of evaporation of
large quantities of water, since electrical conductivity increases as the concentration of dissolved substances rises, and the water thereby becomes more
corrosive. For this reason, it is not only always necessary to add a corresponding quantity of fresh water, but also to remove part of the enriched water. Gypsiferous water is unsuitable for cooling purposes because it has a tendency to
form boiler scale, which is particularly difficult to remove. Furthermore, cooling
water should be free from iron and manganese, because deposits may occur
which settle in the pipes and block them. At best, organic substances should
only be present in small quantities, because otherwise sludge deposits and microbiological contamination may occur.
Note:
To avoid frost and corrosion damage as well as biological contaminants, Rittal GmbH & Co. recommends that a water/glycol mixture be used up to max.
30% glycol.
Note:
The Liquid Cooling Package Plus is secured against excess pressure as regards a maximum permissible pressure (PS) of 8 bar if no cooling medium
liquid is trapped. If shut-off valves that could cause cooling medium liquid
getting trapped are installed on site, pressure relief vessels with safety valves (8 bar blowing-off pressure) must be built into the coolant circuit of the
recooling system.
Note:
Before operation with water is started, all supply lines must be adequately
flushed.
Rittal GmbH & Co. KG also recommends the implementation of a magnetic
filter in the cooling water flow for each Liquid Cooling Package or a central
magnetic filter to avoid devices becoming contaminated with suspended
matter and impurities containing ferrite.
Note:
To avoid the loss of fluids due to diffusion (open and closed systems) or evaporation (open systems), it is recommended to employ automatic filling.
47
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.4.3 Condensate discharge
connection
Any condensate which may develop is collected in the condensate collecting
tray in the water module of the Liquid Cooling Package Plus.
3
4
1
2
Fig. 41: Water module
1
2
3
4
Cooling water flow (inlet)
Condensate discharge (from condensate pump)
Condensate discharge (outlet)
Condensate overflow (no pressure), emergency overflow
Upon reaching a defined condensate level in the collecting tray, a float actuated switch activates a pump, which pumps off the condensate. The condensate
that is pumped out is guided out of the Liquid Cooling Package Plus through a
discharge hose (dimensions: external Ø = 8 mm, internal Ø = 6 mm) to an external drain.
In addition, the Liquid Cooling Package Plus is equipped with a condensate
overflow hose that guides any condensate out of the Liquid Cooling Package
Plus without pressure into an external drain, if the condensate pump or floatactuated switch fails.
Both the condensate discharge hose and the condensate overflow hose are to
be connected to a drain equipped with a siphon trap.
Note:
In order to ensure safe condensate discharge, the following points should
be observed:
- Lay the discharge hose without kinks
- Do not constrict the hose cross section
- Lay the condensate overflow hose with a gradient
Note:
In order to avoid increased condensation and to reduce energy use, the
cooling water temperature should be adapted to match the required cooling
output.
48
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.5
Cooling operation and
control behaviour
If the LCP Plus is provided with power, the control valve controls the cooling water flow according to the established setpoint temperature. For more detailed
explanations, please refer to Chapter 4.2, "Function".
6.5.1 Cooling output
The following diagrams show the cooling output of the Liquid Cooling Package
Plus in [kW], depending on the cooling water flow [l/min] and the air inlet temperature [°C] for various flow temperatures. They are meant to assist the operator in the planning phase to determine the water circuit necessary for the
system.
35
Cooling output [Watt]
30
25
20
15
10
10
15
20
25
30
35
40
45
Inlet temperature [°C]
Air admittance 20˚C
Air admittance 25˚C
Fig. 42: Cooling output of the Liquid Cooling Package Plus, with flow temperature 10 °C
49
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
35,00
Cooling output [Watt]
30,00
25,00
20,00
15,00
10,00
20,0
25,0
30,0
35,0
40,0
45,0
50,0
55,0
60,0
65,0
Inlet temperature [°C]
Air admittance 20˚C
Air admittance 22˚C
Air admittance 25˚C
Fig. 43: Cooling output of the Liquid Cooling Package Plus, with flow temperature 15 °C
6.5.2 Pressure loss
The following diagram shows the pressure loss of the Liquid CoolingPackage
Plus in [bar], depending on the volumetric flow [l/min]. It is meant to assist the
operator in the planning phase to determine the water pressure of the cold water supply system necessary for the system.
1,6
1,4
Pressure loss [bar]
1,2
1
0,8
0,6
0,4
0,2
0
0
10
20
30
40
50
60
70
80
Volumetric flow [l/min]
Fig. 44: Pressure loss in the Liquid Cooling Package Plus
50
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.6
Operation
6.6.1 General
A Basic CMC forms the control unit of the Liquid Cooling Package Plus. Its jobs
are to:
- Retrieve all measurements over the I2C bus from the fan modules and the water module (temperature, speed, flow, etc.).
- Evaluate all measurements and generate alarm and warning signals.
- Calculate the thermal output of the flow and return temperature as well as determine the water flow volume.
- Control air temperature in the server enclosure by regulating the fan speed
and the water volume through the heat exchanger.
- Set the setpoint temperature for the cold air blown in (factory setting 20 °C).
- Control a graphical display (touchscreen) over a RS-232 interface.
- Display the measurements and settings of parameters and setpoints over the
web interface of the CMC.
- Poll the sensor and setting values over SNMP.
Note:
Further explanations concerning the various setting options and features are
available in the CMC-TC system documentation.
C
!
IOIOI
CMC - TC
Basic CMC
1
2
3
4
Fig. 45: Control unit Liquid Cooling Package (Basic CMC) – front
1
2
3
4
Button "C"
Status LED (alarms and warnings)
Status LED (network status)
Hyperterminal
The control unit polls all measurements from the connected fan modules and
water module. This communication takes place over the I2C bus. The control
unit thus serves as the master and polls the measurements from the slave units
or returns the setting data.
The measurements which are delivered from the individual modules are evaluated by the control unit and possible warning and alarm signals are generated.
If a new warning or alarm occurs, the internal beeper communicates this. At the
same time, the alarm relay is switched. This acoustic alarm may be cleared by
pressing down the clear button "C" briefly. At the same time, the alarm relay is
reset. The exact cause of malfunction can be displayed in plain text on the connected graphical display (touchscreen). The following messages can be displayed:
Warning messages
- Fan speed of fan 1 or 2 from fan unit 1 faulty
- Fan speed of fan 1 or 2 from fan unit 2 faulty
- Fan speed of fan 1 or 2 from fan unit 3 faulty
- Flow faulty
- Control valve faulty
51
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Alarm messages
- Temperature sensor of fan unit 1 (server-in/server-out temperature) faulty
- Temperature sensor of fan unit 2 (server-in/server-out temperature) faulty
- Temperature sensor of fan unit 3 (server-in/server-out temperature) faulty
- Low temperature sensor faulty
- Return temperature sensor faulty
- Water module not present
- Leakage message
- No fan module detected
Note:
After turning on for the first time or after repair work, it is possible that the
Liquid Cooling Package Plus will operate in emergency operation mode.
In order to switch the unit to normal operation (control operation), press
down the "C" button (Fig. 45, item 1) once quickly.
Design of the temperature control circuit
The actual temperature values of the cold air on the air input side (server-in
temperature) delivered by the three temperature sensors on the heat exchanger are used to control the air which is blown into the server enclosure. The
average value is determined from the actual temperature values. The control
unit constantly compares this (average) actual temperature with the setpoint
temperature. If the setpoint temperature is exceeded, the control unit attempts
to maintain a constant temperature by opening and closing the control valve.
Only when the actual temperature falls below the value of "setpoint temperature" is the control valve kept closed, i.e. no cold water flows through the heat exchanger. Additionally, the necessary fan speed is determined and controlled
through determining the temperature difference between the inlet and the outlet
air (server-out temperature / also, in this case, an average value is determined
through the fan modules.) The respective setpoint speed for the fans and the
setting of the control valve is sent to the connected control units over the I2C
bus.
Power
2
4
1
3
1
24 VDC
max. 2,5A
1
2
P-I C
IOIOI
2
3 4
5
6
Fig. 46: Control unit of the Liquid Cooling Package Plus (Basic CMC) - rear
1
2
3
4
5
6
Sockets for additional sensors
I2C socket socket
Socket for controlling the graphical display
Alarm relay sockets
Network connection
Power supply
Four additional standard sensors can be connected to the control unit (Basic
CMC) to monitor additional physical parameters of the Liquid Cooling Package
Plus. The sensors must simply be connected to one of the four sockets on the
rear of the control unit (Fig. 46, item 1) and configured via the Basic CMC.
52
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
The following standard sensors can be connected in addition:
Model No.
DK
Max.
Quantity
Temperature sensor
7320.500
4
Humidity sensor
7320.510
4
Analogue sensor input module "4 - 20 mA"
7320.520
4
Access sensor
7320.530
4
Vandalism sensor
7320.540
4x5
Airflow sensor
7320.550
4
Smoke alarm
7320.560
4
Motion sensor
7320.570
4
Digital input module
7320.580
4
Digital relay output module
7320.590
4
Voltage monitor
7320.600
4
Voltage monitor with switch output
7320.610
4
48 V voltage monitor
7320.620
4
Leakage sensor
7320.630
4
Sensor
Tab. 4:
List of standard sensors
Note:
Further explanations concerning the various setting options and features are
available in the CMC-TC system documentation.
6.6.2 Operation in stand-alone
mode
In stand-alone mode, the Liquid Cooling Package Plus is operated via the
touchscreen of the graphical display on the front door.
The user interface of the touchscreen allows the user to navigate between the
individual menu options of the Liquid Cooling Package Plus controller using
software-controlled buttons (MENU, NEXT, BACK).
Fig. 47: Touchscreen
The following menu options can be accessed:
53
Menu option
Explanation
Server-in
temperature
Display of the average of the three server-in temperatures from the
sensors on the heat exchanger.
Alarms /
Warnings
Display of the alarm and warning message in plain text (cf.
Chapter 6.6.1, "General").
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Menu option
Explanation
Air
temperatures
Display of the six air temperatures (3 x server-in, 3 x server-out)
determined by the temperature sensors.
Fan speed
Display of the fan speeds.
Water system
Display of
- the water flow and water return temperatures,
- the setpoint and actual position of the control valve,
- the flow in [l/min] and the cooling output determined from the water temperature and the flow volume.
Setpoint
Display and entry of the setpoint for the server-in temperature.
IP-Adress /
Softwareversion
Display of the current IP address and software version of the Basic
CMC.
Tab. 5:
Menu options of the Liquid Cooling Package Plus controller
Setting the setpoint for the server-in temperature
• Press the [NEXT] or [BACK] buttons repeatedly until the graphical display
displays the menu option "Setpoint".
• Open entry mode for the setpoint by pressing the [EDIT] button.
• Enter the setpoint by pressing the [+] and [-] buttons. The value can be set
between 10 °C and 40 °C.
• To increase the setpoint, press the [+] button until the desired setpoint has
been reached.
• To decrease the setpoint, press the [-] button until the desired setpoint has
been reached.
• Confirm the entry by pressing the [ENTER] button.
• To cancel the entry of the setpoint, press the [ESC] button.
Note:
The input mode for the setpoint for the server-in temperature could be locked, to avoid access by unauthorised personel. Further explanations are
available in Chapter 6.7, "Extended Basic CMC options with network
connection".
Note:
Connect the Basic CMC to a network for extended setting options (cf.
Chapter 6.7, "Extended Basic CMC options with network connection").
54
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.7
Extended Basic CMC
options with network
connection
By connecting the Liquid Cooling Package Plus control unit (Basic CMC) to a
network, you are able to call up various measurements and warning or alarm
messages. These may then be further processed (e.g. via a Web browser,
SNMP, etc.). Furthermore, various values can be set over the network and then
sent to the control unit. If the control unit is connected to a network, the status
LED (Fig. 45, item 3) flashes when the unit is polled over the network via the
Ethernet interface.
The following values can be called up and processed over the network in the
browser window of the Basic CMC software:
- Actual temperature
(average value of the cold air temperature, as determined by the control unit,
which is used to regulate)
- Cooling output
(calculated thermal output which is removed from the server enclosure)
- Alarm and warning messages
(messages which give further information concerning the cause of a warning
or an alarm)
- Setpoint fan speed/control valve
(the fan speed set by the control unit for the fan modules as well as the position of the control valve (open/closed))
- Actual temperature/fan speeds
(temperature level measured behind the heat exchanger (cold air temperature) as well as the actual fan speeds of the fans for each fan module)
- Flow/return temperature/flow volume
(the values of the flow and return temperatures as reported by the heat exchanger module as well as the flow volume in l/min)
The following values can be edited in the browser window of the Basic CMC
software and then sent to the control unit.
- Setpoint temperature
(from the control unit to regulate the setpoint used)
To connect the Liquid Cooling Package Plus to a network, connect one of the
network ports on the Liquid Cooling Package Plus control unit (Fig. 49, item 5)
to a network access port using a category 5 patch cable.
C
!
IOIOI
CMC - TC
Basic CMC
1
2
3
4
Fig. 48: Control unit Liquid Cooling Package Plus (Basic CMC) – front
1
2
3
4
55
Button "C"
Status LED (alarms and warnings)
Status LED (network status)
IO connection
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Power
1
3
2
4
2
P-I C
1
IOIOI
24 VDC
max. 2,5A
1
2
3 4
5
Fig. 49: Control unit Liquid Cooling Package Plus (Basic CMC) – rear
1
2
3
4
5
6
56
6
Sockets for additional sensors
I2C socket
Socket for controlling the graphical display
Alarm relay sockets
Network connection
Power supply
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
6.7.1 Visualisation
Setting and changing the values which are delivered from the Liquid Cooling
Package Plus control unit are explained in the examples presented below.
Note:
This documentation refers to the Basic CMC software with the provisional
version 6.02. Further explanations concerning the operation and various setting options and features are available in the separate Basic CMC documentation.
Firmware updates for the Basic CMC software are available under
www.rimatrix5.com.
Status screen
1
2
3
Fig. 50: Status screen of a CMC
1
2
3
Information display
Status window
Navigation display
Fig. 50 shows the status screen of the browser window of a CMC. The screen
is divided into three areas.
At the left edge of the screen, under the Rittal logo, there is a navigation display
which shows the current screen menu.
The header of the screen contains an information display. This contains details
of the connected units (Name/Liquid Cooling Package Plus), the location of the
unit (Location), and the responsible contact person (Contact).
57
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
1
2
3
4
Fig. 51: Status window
1
2
3
4
LCP-Overview
Graphical overview
Sensors
Status line
LCP-Overview
The following values are displayed in the LCP-Overview area:
Setting
values
Explanation
Server-in temperature
Displays the average of the three server-in temperatures from the
fan modules.
Server-out
temperature
Displays the average of the three server-out temperatures from the
fan modules.
Cooling capacity
Displays the calculated cooling output of the Liquid Cooling
Package Plus. The output is calculated from the flow and return
temperatures as well as from the flow values of the cooling water
circuit (the value is calculated over approximately one to two minutes).
Setpoint
Displays the current setpoint for the server-in temperature. This
setpoint is used to control the server-in temperature using the flow
volume of the control valve.
Operating
mode
Displays the current operating mode (automatic or manual) in
which the LCP Plus is operating.
Fanspeed
Displays the currently set fan speed (0 = off / 1 to 4 = speed 1 to
4).
Control valve
Displays the current setpoint for the position of the control valve in
[%]:
- 0% = valve closed,
- 100% = valve open.
Cycles cond.
pump
Displays how often the condensate pump has been switched on.
Leakage sensor
Status of the Leakage sensor.
Tab. 6:
58
Displays in the LCP-Overview display area
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Graphical overview
The following values are displayed in the graphical overview in an illustrated
depiction of the Liquid Cooling Package Plus:
Setting
values
Server-in temperature (3x)
Explanation
Displays the actual temperature and the status of each temperature sensor on the cold air side of the LCP Plus.
The temperatures are displayed in real values in [°C]. The status of
the temperature sensors displayed in terms of colour:
- green = sensor o.k.
- red = sensor defective
Server-out
temperature
(3x)
Displays the actual temperature and the status of each temperature sensor on the warm air side of the LCP Plus.
The temperatures are displayed in real values in [°C]. The status of
the temperature sensors displayed in terms of colour:
- green = sensor o.k.
- red = sensor defective
Fanspeed (3x)
Displays the actual speed and the status of each fan.
The temperatures are displayed in real values in [rpm]. The status
of the temperature sensors displayed in terms of colour:
- green = sensor o.k.
- orange = speed is minor to 400 rpm
The arrangement and the numbering of the fan at the monitor is
equivalent to the real arrangement and numbering at the Liquid
Cooling Package Plus (fan 1, top/fan 6 bottom).
Flow rate
Displays the actual flow rate of the cooling medium in real values in
[l/min]. The status of the temperature sensors displayed in terms of
colour:
- green = sensor o.k.
- orange = sensor defective
Control valve
Displays the current setpoint for the position of the control valve in
[%]:
- 0% = valve closed,
- 100% = valve open.
Water temperature
Displays the actual temperature and the status of the temperature
sensor at the cooling water inlet and outlet.
The temperatures are displayed in real values in [°C]. The status of
the temperature sensors displayed in terms of colour:
- green = sensor o.k.
- red = sensor defective
Tab. 7:
Measurements and display values in the graphical overview
Sensors
Four additional standard sensors can be connected to the control unit (Basic
CMC) to monitor additional physical parameters of the Liquid Cooling Package
Plus. The status of these sensors is displayed in this window.
Note:
Further explanations concerning the various setting options and features are
available in the CMC-TC system documentation.
Status line
The status line displays whether or not the unit is functioning problem-free or if
a warning or alarm message is present. The following displays are possible:
- No Alarm (green background)
- Warning (orange background)
- Alarm (red background)
59
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
1
Fig. 52: Status screen with warning message
1
Warning message
A warning message is displayed in the status line of the status window in
Fig. 52. In this case, the control valve is open (74%), but there is no flow (0 l/
min).
1
Fig. 53: Status screen with alarm message
1
Alarm message
An alarm message is displayed in the status line of the status window in Fig. 53.
In this case, temperature sensor 1 on the warm air side of the LCP Plus (serverout temperature) is faulty.
You can acknowledge alarm and warning messages as well as the message
"Configuration Change" by pressing the "Clear" button.
60
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Setup screen
1
2
3
Fig. 54: Setup window for the actual temperature
1
2
3
Information display
Status window
Navigation display
Fig. 54 shows the setup screen of the browser window of a CMC. The screen is
divided into three areas.
Note:
The layout of the left edge of the screen and the header corresponds to that
of the status screen.
In the setup screen, the setup window is located underneath the header. The
values which are to be set are shown and entered in this window.
Beneath the setup window there are also two buttons, "Accept" and "Reset".
These are used to either accept or reject the entries, which have been made.
- The "Accept" button is used to accept the changed values.
- The "Reset" button is used to clear the changed values.
Fig. 54 shows the setup window for the server-in temperature. Either the following values are displayed or the following settings may be made in this screen:
61
Setpoint
Explanation
Unit name:
Name of the RLCP unit (max. 10 characters)
Type:
Message type
Sensor status:
Temperature and status of the message are displayed in colour.
Message text:
Text message which appears in the status window
(may be edited).
Setpoint high:
This setpoint may be used to generate and forward an alarm message in case of overheating (temperature sensor).
Setpoint
warning:
This setpoint may be used to generate and forward a warning
message.
Setpoint low:
This setpoint may be used to generate and forward an alarm message in case of overcooling (temperature sensor).
Alarm relay:
Serves to switch the PU's alarm relay on and off.
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Setpoint
Explanation
Alarm beeper:
Serves to switch the PU's alarm beeper on and off.
Alarm reset:
Setting to determine whether triggered alarms are cleared automatically or require manual confirmation.
Trap receiver:
Choice as to which receiver a trap is sent when status is changed.
Scheduled
alarm off:
This point may be used to determine that no alarm should be
reported for one or more timers. The time for the timer must be set
in the timer menu.
Tab. 8:
Setup value for the server-in temperature
Fig. 55: Setup screen for cooling capacity setpoint.
Fig. 55 shows the setup screen for the cooling capacity setpoint. This shows
how much cooling output is being delivered by the recooling systems to the
system at the moment.
The temperatures for the following setpoints may be changed in the lower part
of the window:
- Setpoint server-in temperature
62
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Fig. 56: Setup Screen for alarm messages
Fig. 56 shows the setup screen for alarm messages. Either the following values
are displayed or the following settings may be made in this screen:
Setpoints
Explanation
Unit name:
Name of the RLCP unit (max. 10 characters)
Type:
Message type
Sensor status:
Status of the message (displayed in colour).
Message text:
Text message which appears in the status window (may be edited).
Alarm relay:
Switches the PU's alarm relay on and off.
Alarm beeper:
Switches the PU's alarm beeper on and off.
Alarm reset:
Setting to determine whether triggered alarms are cleared automatically or require manual confirmation.
Trap receiver:
Choice as to which receiver a trap is sent when status is changed.
Scheduled
alarm off:
This point may be used to determine that no alarm should be
reported for one or more timers. The time setting for the timer must
be entered in the timer menu.
Tab. 9:
Setup value for alarm messages
Additionally, the exact cause of the alarm message is displayed in plain text
(more than one cause can be displayed).
- Temperature sensor of fan unit 1 (server-in/server-out temperature) faulty
- Temperature sensor of fan unit 2 (server-in/server-out temperature) faulty
- Temperature sensor of fan unit 3 (server-in/server-out temperature) faulty
- Inlet temperature sensor faulty
- Return temperature sensor faulty
- Water module not available
- Leakage message
- Fan module not available
63
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Fig. 57: Setup screen for warning messages
Fig. 57 shows the setup screen for warning messages. Either the following values are displayed or the following settings may be made in this screen.:
Setpoints
Explanation
Unit name:
Name of the RLCP unit (max. 10 characters)
Type:
Message type
Sensor status:
Status of the message (displayed in colour).
Message text:
Text message which appears in the status window (may be edited).
Alarm relay:
Switches the PU's alarm relay on and off.
Alarm beeper:
Switches the PU's alarm beeper on and off.
Alarm reset:
Setting to determine whether triggered alarms are cleared automatically or require manual confirmation.
Trap receiver:
Choice as to which receiver a trap is sent when status is changed.
Scheduled
alarm off:
This point may be used to determine that no alarm should be
reported for one or more timers. The time for the timer must be set
in the timer menu.
Tab. 10: Setup value for warning messages
Additionally, the exact cause of the warning message is displayed in plain text
(more than one cause can be displayed).
- Fan speed of fan 1 or 2 faulty
- Fan speed of fan 3 or 4 faulty
- Fan speed of fan 4 or 5 faulty
- Flow faulty
- Control valve faulty
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Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Fig. 58: Login window
You must enter a password to call up the setup window for the operation data.
This is done in the login window depicted in Fig. 58.
Note:
Password: RittalLcp+XXXXX
The five-digit number (XXXXX) is the serial number of the Basic CMC (see
page 69, table 13, “General settings for Liquid Cooling Package Plus” ).
Caution!
Never refer the password to unauthorised personnel.
The setup mode only serves for service purpose. Setting up of basic
operating parameters should be exclusively carried out by Rittal service personnel.
If nothing is entered or confirmed in the login window for more than 10 minutes,
the password is reset and it must be entered again to call up the setup window
for operation data.
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Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Fig. 59: Setup screen for operation parameters - "Automatic Mode"
Fig. 59 shows the setup screen for the operating parameters of the Liquid Cooling Package Plus for the functions in automatic mode. The following are parameters that are displayed or settings that may be made on this screen:
Displays
Explanation
Operating
mode
Selection of the Liquid Cooling Package Plus operating mode.
Here, automatic mode is selected.
Automatic
mode
Pull-down menu for setting the control of the fans and the control
valve of the Liquid Cooling Package Plus.
Fig. 60: Setting options
- Full:
In this mode, the fan speed and the position of the control valve
are controlled automatically.
- Fan only:
In this mode, only the fan speed is controlled automatically. The
position of the control valve can be set to a fixed position using
the function for manual operation. This position is saved and used
again after the system is restarted.
- Valve only:
In this mode, only the position of the control valve is controlled automatically. The fan speed can be set to a fixed speed using the
function for manual operation. This speed is saved and used
again after the system is restarted.
66
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Displays
Explanation
Fan control
mode
Pull-down menu for setting the calculation mode for automatic control of the fan speeds.
The required fan speed for automatic control is determined from
the difference of the server-out temperature and the setpoint for the
server-in temperature (dT = server-out temperature - server-in temperature) and controlled linearly between speeds 1 and 4.
The following modes can be selected:
Fig. 61: Setting options
- Average temperature:
In this mode, the average value of the server-out temperatures is
used to calculate the required fan speed.
- Maximum temperature:
In this mode, the highest value of the server-out temperatures is
used to calculate the required fan speed.
In addition, the automatic control of the fan speeds can be controlled using the values dT [min. fan speed] and dT [max. fan
speed].
dT [min.
fanspeed]
The fan operates at the lowest fan speed beneath this temperature
difference.
dT [max.
fanspeed]
The fan operates at the highest fan speed above this temperature
difference.
Sampling time
Setting of the control interval for the control valve. In this interval,
the actual temperature (average from the measurements of the
three fan modules/server-out temperature) is compared with the
setpoint (server-in temperature).
This is set in seconds [s] between 10 and 60 s (preset to 30 s).
PID
componenets
Values for setting the PID control algorithm integrated in the LCP
software. The following settings can be made here:
- P amount:
Parameter for setting the proportional amount. This is set as a percentage [%] between 0 and 30% (preset to 10%).
- I amount:
Parameter for setting the integral amount. This is set in seconds
[s] between 20 and 150 s (preset to 80 s).
- D amount:
Parameter for setting the differential amount. This is set in amount
per second [1/s] between 0 and 50/s (preset to 0/s).
Cw value
Specific thermal capacity of the cooling liquid used.
Setpoint by
display
Release options for the setpoint entry of the server-in temperature
using the graphical display (touchscreen) of the Liquid Cooling
Package Plus:
- Enable:
Setpoint entry is possible.
- Disable:
Setpoint entry is locked.
Tab. 11: Operating parameters for automatic mode
Caution!
The preset values for the parameters "Sampling time" and "PID components" are determined experimentally. Only change this values based
cases to enhance the type of control.
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Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Fig. 62: Setup screen for operation parameters - "Manual Mode"
Fig. 62 shows the setup screen for the operating parameters of the Liquid Cooling Package Plus for the functions in manual mode.
The following are parameters that are displayed or settings that may be made
on this screen in addition to the functions in automatic mode:
Setpoints
Explanation
Operating
mode
Selection of the Liquid Cooling Package Plus operating mode.
Here, manual mode is selected.
Fanspeed
Fan speed setting (0 = off / 1 to 4 = speed 1 to 4).
The last setting that was made is saved and used again after the
system is restarted if the setting "Valve only" is selected in automatic mode. Otherwise, the fan modules are controlled automatically.
Enable fans
Switch off individual fan modules for testing.
This function is only possible in manual mode. In automatic mode,
all fan modules are activated.
Valve
Setting of the opening position of the control valve. This is set as a
percentage [%] between 0 and 100%.
The last setting that was made is saved and used again after the
system is restarted if the setting value "Fan only" is selected in
automatic mode. Otherwise, the control valve is controlled automatically.
Tab. 12: Operating parameters for manual mode
Note:
After the Liquid Cooling Package Plus is connected to the mains or restarted, the controller is always in automatic mode.
68
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Fig. 63: Setup screen „General Setup“
The setup screen "General Setup" is depicted in Fig. 63. All settings are made
for the Liquid Cooling Package Plus here:
Setpoints
Explanation
Name
Name of the LCP Plus unit (max. 40 characters)
Location
Location of the LCP Plus unit (max. 40 characters)
Contact
Responsible contact person (max. 40 characters)
Revision /
Serialnr.
Revisions and serial numbers of the LCP Plus unit
- SW: Software revision
- HW: Hardware revision
- SN: Serial number
Temperature
unit
Default setting for the unit of temperature:
- Degrees Celsius [°C]
- Degrees Fahrenheit [°F]
Measurement
unit
Default setting for the unit of flow:
- Litres per minute [l/min]
- Gallons per minute [US-Gallons/min]
Beeper
Used to switch the Basis-CMC' alarm beeper on and off.
Quit alarm
relay
Used to switch the Basis-CMC' alarm relay on and off.
Alarm relay
options
Used to set the switching position that generates an alarm message.
- Open: Message is generated when the relay opens
- Close: Message is generated when the relay closes
Web access
Used to set the network access to the LCP Plus:
- Full: Full access
- View only: Only view access
- No Access: No access
Actual date
Actual Date
Actual time
Current time
Tab. 13: General settings for Liquid Cooling Package Plus
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Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
Note:
Further explanations concerning the various setting options and features are
available in the CMC-TC system documentation.
70
Operating and Maintenance Instructions – 6 Installation – "Getting Started"
Rittal Liquid Cooling Package Plus
7
Hardware and
software
7.1
Liquid Cooling Package
Plus control unit
7.1.1 Hardware
A Basic CMC forms the control unit of the Liquid Cooling Package Plus. Its job
is to use the I2C bus to poll the measurements (such the three server-in temperatures, three server-out temperatures, six fan speeds, flow rate, control valve
position, flow and return temperatures of the cooling water) from the six fan modules, the sensors on the heat exchanger, and from the water module, to perform control functions, and to transfer the setpoints (such as the fan speed) to
the individual units.
C
IOIOI
!
CMC - TC
Basic CMC
1
2
3
4
Fig. 64: Control unit Liquid Cooling Package (Basic CMC) – front
1
2
3
4
Button "C"
Status LED (alarms and warnings)
Status LED (network status)
Hyperterminal
The control circuit board is built into a standard CMC plastic housing. The following components are on the front side of the unit:
Control
component
71
Explanation
Button "C"
Use this button to confirm warnings and alarms as well as to set
the setpoint for the desired cold air temperature.
Status LED:
(alarms and
warnings)
Displays the internal status of the control unit through a duo LED
(red/green). The various alarm and warning conditions can be
shown via this LED.
Status LED:
(network
status)
Displays the status of the network connection.
Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
Power
2
4
1
3
1
24 VDC
max. 2,5A
1
2
P-I C
IOIOI
2
3 4
5
6
Fig. 65: Control unit of the Liquid Cooling Package Plus (Basic CMC) - rear
1
2
3
4
5
6
Sockets for additional sensors
I2C socket socket (X 22)
Socket for controlling the graphical display (X 24)
Alarm relay sockets
Network connection (X 23)
Power supply (X 21)
Various sockets are found on the rear side of the control unit.
Pin assignment of the sockets for additional sensors:
1 24 V DC
2 Gnd
3 Sensor ID 1
4 Sensor ID 2
5 Analogue input
6 Digital input/output
The 8-pole connector X22 contains the so-called Power-I2C bus.
Assignment of the I2C bus:
1 - N/C
2 - N/C
3 - N/C
4 - N/C
5 - Gnd
6 - + 24 V DC
7 - P-SDA
8 - P-SCL
The graphical display on the front door is controlled via an RS-232 connection
with the RJ12 socket X24.
X24 pin assignment:
1 24 V DC
2 Gnd
3 TxD
4 RxD
5 RTS
6 CTS
Alarm relay socket pin assignment:
1 24 v DC
2 Gnd- Relay COMMON
3 N/C
4 Relay normally closed
5 Relay common
6 Relay normally open
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Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
The RJ45 socket X23 is used to make an optional Ethernet connection to a network.
1 Tx+
2 Tx3 Rx+
4 n.c.
5 n.c.
6 Rx7 n.c.
8 n.c.
Power supply pin assignment:
1 24 V DC
2 Gnd
The control unit is supplied with power via a separate power pack (DK
7320.425) and a Kycon socket. All modules are supplied with 24 V DC and are
fed together with the I2C bus.
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Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
7.2
Control unit for fan module
(RLCP fan)
7.2.1 Hardware
1
X3 AC in
(max. 230V/6A)
2
3
F5
F6
Fuse max. 2,5 A T
X4 Fan 1 out
X5 Fan 2 out
4
5
Fig. 66: Control unit fan module – front
1
2
3
4
5
Power supply (X3)
Fuse (2.5 A)
Fuse (2.5 A)
Power supply for fan 1 (X4)
Power supply for fan 2 (X5)
1
X26
I2C
2
3
4
5
X8 X9
X6
X7
Air 1 Air 2 Speed 1 Speed 2
6
Fig. 67: Control unit fan module – rear
1
2
3
4
5
6
Socket for control cable (X26)
Socket for air outlet temperature sensor (X8)
Socket for air inlet temperature sensor (X9)
Socket for tachometer Fan 1 (X6)
Socket for tachometer Fan 2 (X7)
Status LED
One control unit (RLCP fan) is assigned to two fan modules. It controls their individual components. The control voltage is +24V and is fed together with the
I2C bus through connector X26 of the control unit (Basic CMC).
X26 pin assignment:
1 Address signal (TTL Level)
2 Gnd
3 Address signal (TTL Level)
4 Address signal (TTL Level)
5 Gnd
6 + 24 V DC
7 I2C (data)
8 I2C (clock)
The address signals can address up to six fan modules
74
Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
The fans have four speeds. Four relays control two fans. Both fans that belong
to a control unit run with the same speed and are connected to the control unit
(RLCP fan) via a 5-pole cable using a connector. The fans are equipped with
an echo sensor, which reports the speed signal to the control unit (sockets X6
and X7).
X6/X7 pin assignment:
1 + 5 V DC
2 Gnd
3 Echo sensor
Furthermore, the control unit has two sockets (X8 and X9) for connecting temperature sensors. One of these sensors is inside the fan module and one is on
the front of the heat exchanger. The air temperature in front of the fans (that is,
the temperature of the air drawn in from the server enclosure, X9) and the temperature behind the heat exchanger (that is, the temperature of the cold air supplied to the server enclosure, X8) are measured.
X8/X9 pin assignment:
1 NTC (5 V/max. 0.5 mA)
2 Gnd
X3 pin assignment (power supply):
1 L
2 N
X4/X5 pin assignment (power supply of the fan modules):
1 L (Speed 1)
2 L (Speed 2)
3 L (Speed 3)
4 L (Speed 4)
5 N
7.2.2 Status LED
The control unit includes an LED which displays the internal status.
The control unit's software continuously reads the analogue values from the
temperature sensors via the analogue channel and establishes an average value for each sensor. Next, it reads the temperature value in °C from a table and
writes this in the I2C transmission buffer.
Furthermore, the software counts the speed pulses of both connected fans and
also writes this into the I2C transmission buffer.
The fan set speed determined by the control unit is evaluated and the appropriate fan speed is set on the fans via relays. An LED on the fan module shows
an error code, which is indicated by short flash pulses.
0 No error (LED constantly on). The I2C data traffic is indicated as the LED is
briefly extinguished when a data packet is requested.
1 Temperature sensor defect
2 Fan speed error fan 1
3 Fan speed error fan 2
4 I2C timeout (approx. 20 s)
75
Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
7.2.3 Control unit for water module
(RLCP water)
7.3
Hardware
Fuse max. 0. A
X10 AC in
1
Fig. 68: Control unit – water module (front)
1
2
3
2
3
Fuse (0.5 A)
Power supply (X10)
Power supply for condensate pump (X11)
I2C
X18
Motor
Valve
X19
Water
Out
In
X13 X12
1
2
3 4
Fig. 69: Control unit – water module - rear
1
2
3
4
5
6
7
8
9
X11 Cond.pump
Valve
X15
5
Flow
X14
6
Leak Cond.
X16 X17
7
8
9
Socket for control cable (X18)
Socket for control valve (X19)
Status LED
Socket for temperature sensor of cooling water return (X13)
Socket for temperature sensor of cooling water flow (X12)
Socket for magnetic valve (optional)
Socket for flow sensor (X14)
Socket for leakage sensor (X16)
Socket for condensate sensor (X17)
The water unit also contains a control unit (RLCP water). The control voltage is
+24 V and is fed together with the I2C bus through connector X18 of the control
unit (RLCP water).
X18 pin assignment:
1 Address signal (TTL Level)
2 Gnd
3 N/C:
4 Gnd
5 Gnd
6 + 24 V DC
7 I2C (Data)
8 I2C (Clock)
The control unit has two sockets (X12 and X13) for connecting two temperature
sensors. Both of these sensors are used to measure the flow and return water
temperature.
X12/X13 pin assignment:
1 NTC (5 V/max. 0.5 mA)
2 Gnd
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Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
The water flow can be opened or closed via a control valve (+24 V DC). This
valve is controlled via socket X19.
X19 pin assignment:
1 Gnd
2 + 24 V DC (100 mA)
3 2 ... 10 V DC (0.1 mA)
4 2 ... 10 V DC (0.1 mA)
The water flow is measured by a flow sensor. This sensor is equipped with an
echo sensor. It is connected to socket X14.
X14 pin assignment:
1 +5V
2 Gnd
3 Input signal (TTL Level)
Furthermore, input X16 of the control unit (RLCP water) evaluates the signal
from a leakage detector. X16 pin assignment:
1 +5V
2 Gnd
3 Input signal (TTL Level)
The condensate level in the condensate collecting tray is measured using a level sensor (float-actuated switch). This sensor is connected to socket X17.
X17 pin assignment:
1 +5V
2 Gnd
3 Input signal (TTL Level)
X10 pin assignment (power supply):
1 N (max. 250 V AC/0.5 A)
2 L (max. 250 V AC/0.5 A)
X11 pin assignment (power supply for condensate pump):
1 N
2 L
7.3.1 Staus LED
The control unit includes an LED which displays the internal status.
The water module's software continuously reads the analogue values from the
two temperature sensors for the inlet and return of the cooling water system via
the analogue channel of the CPU and establishes an average value for each
sensor. Next, it reads the temperature value in °C from a table and writes this
in the I2C transmission buffer.
Furthermore, the software counts the pulses from the flow meter, reads the leakage sensor and the digital input, and also writes these values to the I2C transmission buffer. The position of the ball valve (opened/closed) is determined by
the control unit. An LED on the water module shows an error code, which is indicated by short flash pulses.
0 No error (LED constantly on). The I2C data traffic is indicated as the LED is
briefly extinguished when a data packet is requested.
1 Leakage
2 Inlet temperature sensor faulty
3 Return temperature sensor faulty
4 I2C timeout (approx. 20 s)
77
Operating and Maintenance Instructions – 7 Hardware and software
Rittal Liquid Cooling Package Plus
8
Maintenance
The Liquid Cooling Package Plus is maintenance-free. An additional external
filter should be used if the cooling water is contaminated. This should be cleaned regularly.
- The condensate discharge device should be checked regularly for proper
function.
- Visually inspect for leaks regularly (annual cycle).
Note:
At an ambient temperature of 40 °C, the nominal service life of the built-in
fan is 40,000 operating hours.
Fan module malfunctions are displayed on the graphical display or on the
status screen of the Basic CMC (if the Basic CMC is connected to a network). Furthermore, the built-in control that is responsible for two fan modules compensates fully in the event of a fan module failure.
78
Operating and Maintenance Instructions – 8 Maintenance
Rittal Liquid Cooling Package Plus
9
Troubleshooting
Malfunction
location
Control valve
Malfunction
Cause of malfunction
Effect
Remedy
The Basic
CMC displays flow
even though
the control
valve is displayed as
closed.
The control valve is dirty
The flow meter displays a
value. There is a ΔT.
Use the Basic CMC to open
and close the control valve
several times; contaminants
may be loosened.
It is highly recommended that a
filter be installed in the system
to ensure the required water
quality.
Flow meter is dirty
The flow meter displays no
value, even when the control
valve is open and there is a ΔT.
Switch the complete LCP Plus
off and restart. Also disconnect
any existing network connections by removing the network
connector of the Basic CMC
from the LCP Plus.
Flow meter
Electronics/
Software
The electronics/software
do not
respond
The system is hung up, e.g.
through loose connection or
incorrect operation
No response, display and control via the Basic CMC do not
work correctly.
Disconnect power to the complete LCP Plus and restart. Also
disconnect any existing network connections by removing
the control unit network connector from the LCP Plus.
Liquid Cooling
Package Plus
The LCP Plus
is not regulating
temperature
and is operating in emergency mode.
After a power supply interruption or upon first installation, the
LCP Plus may operate in emergency mode because of an
alarm, e.g. because there is no
water pressure.
The ball valve is open and the
fans operate at full speed.
Press the ”C” button on the
LCP Plus control unit. The system will then enter regulating
mode if all is properly connected and the unit is supplied with
electricity and cold water.
The unit is not
providing the
required cooling output.
Air in the system
If there is air in the system, the
water cannot circulate properly
in the heat exchanger. Thus, it
cannot remove heat.
Bleeding the air from the heat
exchanger.
Increased pressure loss on the
piping network side, e.g.
through a clogged filter or
incorrectly set flow limiter.
The external pumps are not
able to pump enough cold
water through the LCP Plus.
Clean the filter, set the flow limiter correctly.
Air routing not correct
The cooled air passes through
unsealed openings past the
equipment to the back of the
enclosure.
Unused height units in the
482.6 mm (19") level as well as
side slots and openings must
be sealed using blanking plates or foam strips. Both are
available as accessories.
Server
enclosure
79
Overheating
of individual
equipment in
the server
enclosure
Operating and Maintenance Instructions – 9 Troubleshooting
Rittal Liquid Cooling Package Plus
Malfunction
location
Cold water
system
80
Malfunction
Cause of malfunction
Effect
Remedy
Corrosion and
contaminants
in the cold
water system
Insufficient cleaning after a new
installation
Unclean and aggressive water
leads to a weakening of the
material and to improper function. The function of components such as the ball valve and
the flow meter is strongly
impaired through contaminants.
During initial installation, the
pipe network and the system
parts should be flushed out
before the installation of the
LCP Plus.
Improper treatment of the water
with corrosion protection additives.
Rittal GmbH & Co. KG recommends the installation of filters
and the treatment of the water
with appropriate corrosion and,
if needed, antifreeze additives.
The recommended notes
regarding water quality are
found in Chapter 14.1, "Hydrological information".
Older systems with existing
contaminants
Upon integration in existing
cold water networks, the use of
a water/water heat exchanger
is recommended. This forms a
second water cycle.
Operating and Maintenance Instructions – 9 Troubleshooting
Rittal Liquid Cooling Package Plus
10
Frequently asked
questions (FAQ)
Note:
This chapter contains only a selection of the frequently asked questions
(FAQ). Further FAQs may be found on our website: www.rimatrix5.com
In what output ranges is the
Rittal Liquid Cooling Package
available?
The cooling output of an air/water heat exchanger is basically dependent on the
inlet temperature and volumetric flow of the water as well as the air throughput
achieved by the fans which are used. Up to 30 kW of cooling output is possible.
In correctly assessing the information, it is important to note at what ΔT (at what
temperature differential between server air inlet and server air outlet) these values were reported. Modern servers such as 1 U Dual CPU systems or blade
servers can have a ΔT of up to 25 °C. Please note the recommendations of the
server manufacturer.
Are special components
All components that follow the "front to back" cooling principle (99% of IT equiprequired for use with the Liquid ment) may be used without restriction in connection with the Liquid Cooling
Cooling Package?
Package. Every Rittal server rack which was previously cooled conventionally
may be cooled with a Liquid Cooling Package after changing to sealed doors.
In other words, it is possible to retrofit standard racks and bay them onto the
Liquid Cooling Package. The server enclosure remains unaffected by the side
installation of the Liquid Cooling Package. All height units remain fully usable in
their complete depth. Further, by locating the foam strips appropriately, sufficient cooling is also possible for devices which require sideways air throughput
(e.g. switches).
81
Is the ambient air heated by
additional heat coming out of
these enclosures?
The cooling system in the enclosure works completely independently of the ambient air. All waste heat is transferred externally through the cooling water circuit.
May the quantity of heat
removed be controlled
dependent on the heat loss?
The controlled variable for the Liquid Cooling Package is the temperature of the
air blown in in front of the 482.6 mm (19") level. The values to be used here are
available in the manufacturer's instruction manual. Upon installation, the desired setpoint temperature is set once on the Liquid Cooling Package. This value will be kept constant, irrespective of the cooling output demands. This
occurs through the corresponding automatic opening and closing of the ball
valve. Additionally, the necessary fan output is adjusted based on the air inlet
and exhaust temperatures of the server. In this manner, the Liquid Cooling
Package always cools only as much as is necessary without wasting energy.
Further, this avoids problems arising from condensation and desiccation which
results from overcooling.
How is the airflow in the
enclosure achieved and what
advantages does this have?
As a general rule, the "front to back" principle is used in server enclosures. Cold
air is supplied to the front of the enclosure. The units built into the enclosure
have their own fans, which draw in this air and use it internally for cooling. Thus
heated, it is exhausted to the rear. The special horizontal air routing of the Liquid Cooling Package, which is adapted especially to this widespread cooling
principle, evenly supplies cooled air to the complete height of the server enclosure. That means that all units, independent of their installation position in the
enclosure and their charge state, receive sufficient cold air. Temperature gradients are avoided, so that an extremely high cooling output can be achieved
for each enclosure.
Operating and Maintenance Instructions – 10 Frequently asked questions (FAQ)
Rittal Liquid Cooling Package Plus
Can the Liquid Cooling
Package be operated when
the doors are opened?
The response of the Liquid Cooling Package upon operation with opened doors
depends chiefly upon the prevailing ambient conditions. If a front door is
opened, the cool air is mixed marginally with the ambient air. Thus, no cooling
problems are expected in air conditioned rooms. Overall, no heat is carried into
the room. The back door should only be opened for a short while during operation, since this breaks the cooling air circuit, resulting that the waste heat is
carried into the room. However, this does not influence the cooling of the units
in the enclosure.
Why is the Liquid Cooling
Package, as an air/water heat
exchanger, installed on the
side panel?
It was important to develop a high performance cooling system which would
also meet the requirements of the coming years. This could only be achieved
by routing the cooling air in a manner which was tailored to the needs of the
devices. The chief problem encountered when cooling with air from the raised
floor, or with roof or floor heat exchangers is the air flow. Cold air which is fed
into the enclosure from below or above changes its temperature greatly because of recirculation. Temperature differentials of up to 20 °C were measured
from "below" to "above" in enclosures found in data centres. Thus, a server installed "below" in an enclosure may have temperature conditions of up to 20 °C
"better" than one installed "above" in an enclosure. Because of this, in order to
achieve sufficient cooling of all systems in the enclosure when using this sort of
cooling, a significantly lower air temperature must be used. When cooling air is
provided from the side, this problem does not arise. Cooling is more effective
and more exact because the air supplied to the units can be held within 1-2 °C.
Because the system is built as its own enclosure, the system is protected
against the risk of leaks. All water-carrying parts are located outside the actual
server enclosure. Connection to the cooling water network is made in the floor.
Further, Rittal has many years of experience in the field of air/water heat exchangers. All of this experience is incorporated into the construction of the Liquid Cooling Package. Because of these precautionary measures, even in the
very unlikely event of a leak, water cannot find its way into the area for electronic
components. Because of its "thin" profile of just 300 mm, the pattern achieved
in the data centre is not interrupted. Because the depth of the enclosures is not
increased, the full width of the walkways in the data centre is maintained.
How is water connected to the For easy installation, connection to the building or recooling system is made, as
Liquid Cooling Package?
desired, from below or from the rear with 1" threaded connections. Of course,
these may be exchanged with quick-release couplings.
82
Can both air-cooled and watercooled server enclosures
operate side-by-side in a data
centre?
Of course. There must only be a water installation available for the water-cooled
enclosures. The advantage of this is that the existing room air conditioning is
not further burdened. Thereby, Liquid Cooling Package Systems can be used
to intercept "hotspots" in the data centre without requiring the expansion of the
air conditioning system.
Which dimensions are usable
for the Liquid Cooling
Package?
The Liquid Cooling Package itself has the dimensions W x H x D 300 x 2000 x
1200 mm. Every Rittal enclosure with the dimensions H x D 2000 x 1200 mm,
independent of width, can be bayed. Other sizes available on request.
Does the Liquid Cooling
Package require
maintenance?
The Liquid Cooling Package is maintenance free. All components are designed
with an extremely long lifespan. In case of a malfunction a message is generated through the alarm output of the control unit or through the Basic CMC.
What advantages does a
water-cooled solution have
over an air-cooled solution in a
data centre?
The use of water-cooled enclosures allows for controlled, efficient and costsaving cooling of heat losses, which was not possible with conventional air conditioning. Thus, it is possible to fully use the space, which is physically available
in the enclosures, instead of being forced to erect half-empty enclosures because of air conditioning problems. This achieves considerable savings in the
investment and operating costs of a data centre.
Operating and Maintenance Instructions – 10 Frequently asked questions (FAQ)
Rittal Liquid Cooling Package Plus
Is a raised floor necessary for A raised floor is not required for routing the cooling water pipes. In principle,
installation? If yes, what height the pipes can also be laid in channels in the floor. A main cooling pipe requires
is required?
approx. 150 mm headroom in a raised floor; an enclosure supply line approx.
50 mm. With high-quality composite pipes, such as those used in underfloor
heating, an extremely flexible routing of the cooling water pipelines is possible.
Can LCP-cooled enclosures
also be bayed with one
another?
Basically, the Liquid Cooling Package is just a "small" enclosure. That means
that all accessories for baying may be used. Thus, LCP-cooled systems may
be bayed without limitation.
How is condensate formation Condensation can only occur when air is significantly cooled below the ambient
prevented in the Liquid Cooling temperature. Thus, its capacity to absorb or "hold" water is reduced. In the
Package?
norm, the Liquid Cooling Package works with water temperatures above the
dewpoint. Condensate formation is thus excluded. If it is operated with lower
temperatures, the control minimises condensate formation. Any arising condensate is effectively hindered from leaving the Liquid Cooling Package
through design measures. These measures include suitable air routing, wipeoff grids and active condensate management.
How does the Liquid Cooling At the same time that air is cooled, it is also dehumidified. Because of cable enPackage prevent desiccation? try points, the system is not 100% sealed off from its surroundings. This small
amount of exchange with external air is sufficient to hold the air's relative humidity above 30% and thus non-critical. At no time is there the danger of static
charges arising in the enclosure.
Can the Liquid Cooling
A combination of direct CPU cooling with water and the Liquid Cooling PackPackage be operated together age is always possible. Depending on the computer system, only up to 70% of
with the CPU cooling solution? the total heat loss is removed through the water heatsinks with direct CPU cooling. In cases of high cooling output requirements, this means that a combination of systems is even necessary. Please request our documentation for
individual projects separately.
In case a pipe should break or Because the components are carefully chosen, it is practically impossible for a
burst, how is water entry into pipe to break. The base unit of each LCP module serves as a water collecting
the server rack avoided?
tray. These are connected to one another, so that any water arising is immediately led away through the condensate discharge. Through the physical separation of the Liquid Cooling Package from the server enclosure, it is always
ensured that no water can enter into the server area. Additionally, the integrated
leakage sensor reports even the smallest leak volumes to allow for a rapid response.
83
Why does the Liquid Cooling
Package allow for the
possibility of cooling one or two
enclosures?
The most important design principle was a flexible cooling system which would
correspond to the enormous volume of air required by a modern server. Because of the horizontal cooling possibility, options for "right", left" or "both-sided"
cooling arise in combination with the chosen fans. Cooling a server rack with
two Liquid Cooling Packages has the advantage of complete system redundancy without further removal of 482,6 mm (19") equipment. See also
Chapter 4.3.1, "Possibilities for establishing redundancies".
In which applications and
situations should an air/water
heat exchanger system be
used?
Whenever the cooling output of the room air conditioning system is not sufficient to handle the heat loads of current high performance servers. With an optimal design in a newly planned data centre, this limit is at about 1,000 –
1,200 W/m²; in older data centres, it is often significantly below that. At best, a
maximum of 4 kW per rack needs to be removed. By contrast, racks which are
filled with blade servers reach up to 17 kW. But the Liquid Cooling Package
represents a possible solution even in applications where there is no existing
air conditioning system. In combination with Rittal recooling systems, even climate control solutions for high performance cluster systems can be created.
What additional infrastructure
is required to operate the
system?
In addition to the Liquid Cooling Package, pipes to the individual enclosures
and a system for generating the cooling water are required. With single enclosures, a direct connection with the cooling water is sufficient. With multiple enclosures, a cooling water distribution system, similar to a central heating
distribution system, should be provided. To a great degree, this infrastructure
corresponds to that which is already used in a conventionally air conditioned
Operating and Maintenance Instructions – 10 Frequently asked questions (FAQ)
Rittal Liquid Cooling Package Plus
data centre. The "cold" water is provided by water chillers (with adequate redundancy, especially in regard to the pumps). The water is distributed over a
cooling water network in the data centre to fan coil or ceiling cooling units.
What key disadvantages of
The chief problem of conventional cooling involves directing large amounts of
today's air-cooled solutions are cool air through raised floors, suspended ceilings and within the room. Often,
remedied by water cooling?
because of complex flow conditions, the cold air does not reach the servers in
sufficient quantities. There is actually enough cold produced; often, the cooling
output from raised floor systems lies far above the electrically connected load
of the unit, which needs to be cooled. In spite of this, the cooling is insufficient.
This effect is explained by the fact that the cooling air is already warmed too
much through recirculation on its way to the server. By using water to remove
the heat out of the enclosure, an excellent separation between cold air and removed thermal energy is achieved. Because of its material characteristics, water can transport thermal energy almost 4,000 times "better" than air. Small
pipes are capable of transporting very large quantities of heat.
Can accessories and other
equipment from 482.6 mm
(19") enclosures be used in
conjunction with the Liquid
Cooling Package?
The Liquid Cooling Package and the accompanying server enclosure are standard products within the Rittal family of enclosures. All components and accessory parts can be used without limitation.
Up to what depth may servers Modern server systems may be up to 800 mm deep. Because of that, it is recbe installed?
ommended that the 482.6 mm (19") level in the enclosure be installed so that
the same distance remains to the door in front and in back. In combination with
the space on the side between the 482.6 mm (19") level and the Liquid Cooling
Package, sufficient room for the air which is fed or emitted is achieved. The side
openings do not need to be completely open throughout their depth.
How does the Liquid Cooling
Package respond to an
elevated ambient temperature
or fire?
Because the closed design seals the system to the outside, even greatly increased ambient air temperatures are not a problem – as long as the cold water
supply is functioning. This represents an effective protection against the effects
of fire in case of a fire in the room. Smoke, corrosive gases, water steam and
fire-fighting water are securely kept away. Only extremely high temperatures or
direct exposure to flames would be critical, but the consequences of fire in the
area or in the adjacent room are in any case restrained.
Does the maximum depth
Almost the entire depth of the enclosure can be used for installed equipment.
available for installed
No other space for installed mechanical equipment, e.g. fans, is required.
equipment correspond with the
enclosure's depth?
84
Operating and Maintenance Instructions – 10 Frequently asked questions (FAQ)
Rittal Liquid Cooling Package Plus
11
Glossary
1 U server:
1 U servers are very flat and deep, modern high performance servers, whose
height corresponds to one height unit (1 U = 44.54 mm, the smallest standard
height division). Typical dimensions are (W x D x H) 19" (482.6 mm) x 800 mm
x 1 U.
These systems normally include 2 CPUs, many GB RAM and hard drives, so
that they require up to 100 m3/h cooling air at a maximum of 32°C.
482.6 mm (19") level:
The front sides of the devices built into the server enclosure form the 19"
(482.6 mm) level.
Blade server:
By orienting dual CPU systems vertically and placing up to 14 units on a common backplane to provide for signal routing and power supply, one has a socalled blade server.
Blade servers can "generate" up to 4.5 kW heat loss per 7 U and 700 mm depth.
"Front to back" cooling
principle:
The devices built into the server enclosure are normally cooled according to the
"front to back" cooling principle.
Under this cooling principle, cold air supplied by external air conditioning is
blown to the front of the server enclosure. The fans in the devices built into the
server enclosure direct this air horizontally through the server enclosure. The
air is warmed through this process and is exhausted out the rear side of the enclosure.
Fig. 70: "Front to back" cooling principle as an example in a 1 U server
85
Hotspot:
A hotspot is the concentration of thermal energy in a small area.
Hot spots normally lead to local overheating and can cause system malfunctions.
Air/water heat exchanger:
Air/water heat exchangers operate according to the same principle as automobile radiators. A liquid (water) flows through the heat exchanger, while, at the
same time, air is blown over its surface area (which is as large as possible), facilitating energy exchange.
Depending on the temperature of the circulating liquid (water), an air/water
heat exchanger may either heat or cool the circulated air.
Recooling system:
As an initial comparison, a recooling system is like a refrigerator – through an
active cooling circuit, unlike a household refrigerator, a recooling system produces cold water. The thermal energy which is removed from the water is dissipated to the outside by fans. Because of this, it is normally advisable to locate
recooling systems outside of buildings.
Recooling systems and air/water heat exchangers form a normal cooling combination.
Operating and Maintenance Instructions – 11 Glossary
Rittal Liquid Cooling Package Plus
Switch:
86
Multiple servers normally communicate with one another and in the network
using switches.
Because as many inputs as possible are located on the front side of switches,
they frequently have an airflow from the side, not "front to back" cooling.
Operating and Maintenance Instructions – 11 Glossary
Rittal Liquid Cooling Package Plus
12
Spare parts
Model No.
SK
Item
Qty./Pack
Circuit board, water unit, complete
1
Circuit board, control unit, complete
1
Circuit board, fan unit, complete
1
Fan
1
Fan module, complete
1
Display
1
Heat exchanger
Sensor condensate pump
1
Float-actuated switch
1
Leakage sensor
1
Control valve
1
Flow meter
1
Condensate pump
1
Automatic bleeding valve
1
Cold air temperature sensor
1
Warm air temperature sensor
1
Temperature sensor water flow
1
Temperature sensor water return
1
Tab. 14: Spare parts list – Liquid Cooling Package Plus
87
Operating and Maintenance Instructions – 12 Spare parts
Rittal Liquid Cooling Package Plus
13
Accessories
13.1 Accessories
Liquid Cooling Package
Model No.
SK
Qty./Pack
Vertical shielding (foam strips)
for enclosure width 600 mm, for mounting side
panel
3301.380
1
Vertical shielding (foam strips)
for enclosure width 600 mm, for mounting LCP
Plus
3301.370
1
Vertical shielding (foam strips)
for enclosure width 800 mm, for mounting side
panel
3301.390
1
Vertical shielding (foam strips)
for enclosure width 800 mm, for mounting LCP
Plus
3301.320
1
Covers to close off unused air entry and exhaust
openings on Liquid Cooling Package
3301.310
2
Add-on cover
3301.421
1
Connection hose
3301.351
2
Connection cable, single-phase
7856.025
1
EU-Type
Connection cable, three-phase
7856.026
1
CEE plug 230 V
Item
Comments
Tab. 15: Accessories list – Liquid Cooling Package Plus
13.2 Accessories from the rack
program
Item
Model No.
Qty./Pack
Blanking plates, 1U
7151.035
2
Side panel package/side panel, screw-fastened
2000 mm x 1000 mm
8102.235
2
Comments
also available in other heights!
Tab. 16: Accessories list – rack program
88
Operating and Maintenance Instructions – 13 Accessories
Rittal Liquid Cooling Package Plus
14
Further technical information
14.1 Hydrological information
To avoid system damage and to ensure safe operation, Rittal GmbH & Co KG
recommends the use of system water or an additive whose composition does
not differ from that presented in the following summary:
pH value
7 – 8.5%
Carbon hardness
> 3 < 8 °dH
Free carbonic acid
8 – 15 mg/dm3
Accompanying carbonic acid
8 – 15 mg/dm3
Corrosive carbonic acid
0 mg/dm3
Sulphides
Free
Oxygen
<10 mg/dm3
Chloride ions
< 50 mg/dm3
Sulphate ions
< 250 mg/dm3
Nitrates and nitrites
< 10 mg/dm3
COD
< 7 mg/dm3
Ammonia
< 5 mg/dm3
Iron
< 0.2 mg/dm3
Manganese
< 0.2 mg/dm3
Conductivity
< 2200 µS/cm
Residue on evapouration
< 500 mg/dm3
Potassium permanganate consumption
< 25 mg/dm3
Suspended matter
< 3 mg/dm3
> 3 < 15 mg/dm3 Partial current purification
recommended
> 15 mg/dm3 Continuous purification recommended
Tab. 17: Hydrological data
89
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
14.2 Characteristic curves
14.2.1 Cooling output
35
Cooling output [Watt]
30
25
20
15
10
10
15
20
25
30
35
40
45
Inlet temperature [°C]
Air admittance 20˚C
Air admittance 25˚C
Fig. 71: Cooling output of the Liquid Cooling Package Plus, with flow temperature 10 °C
35,00
Cooling output [Watt]
30,00
25,00
20,00
15,00
10,00
20,0
25,0
30,0
35,0
40,0
45,0
50,0
55,0
60,0
65,0
Inlet temperature [°C]
Air admittance 20˚C
Air admittance 22˚C
Air admittance 25˚C
Fig. 72: Cooling output of the Liquid Cooling Package Plus, with flow temperature 15 °C
90
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
14.2.2 Pressure loss
1,6
1,4
Pressure loss [bar]
1,2
1
0,8
0,6
0,4
0,2
0
0
10
20
30
40
50
60
70
80
Volumetric flow [l/min]
Fig. 73: Pressure loss in the Liquid Cooling Package Plus
91
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
14.3 Overview diagram
View without side panel right front/back
Heat exchanger
Front left side panel
Back left side panel
Fig. 74: Overview diagram – Liquid Cooling Package Plus (front, side and rear views)
Connector
Fan mounting plate (6x)
Fan slide rail (6x)
Front partition
Fan partition
Fan slide rail connector cover (3x)
Fig. 75: Overview diagram – Liquid Cooling Package Plus (detail B and C)
92
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
Fig. 76: Overview diagram – Liquid Cooling Package Plus (isometry)
93
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
14.4 Circuit diagram
= LCP-Steuerplatine
= LCP control board
= Display
= Display
= Netzteil 24 V DC
= Power pack 24 V DC
Display on front door
= Wasserplatine
X25
= Water board
= Lüfterplatine
A2
= Fan board
= Temperaturfühler Wasservorlauf
= Temperature sensor water inlet
= Temperaturfühler Wasserrücklauf
F1...F3
Netzfilter / Line filter
= Temperature sensor water reflow
Mains input
Fuses 3 x 6A
3 x 10A
= Durchflußmesser
L3
= Flow meter
L2
Z1
= Leckagefühler
L1
= Leakage level sensor
N
= Kondensatfühler
PE
= Condensate level sensor
X1
= Temperaturfühler HEX-1
= Temperature sensor HEX-1
PE
PE PE
= Temperaturfühler Lüfter-1
= Temperature sensor fan-1
= Sicherung 6A
= Fuse 6A
= Sicherung 0,5A
= Fuse 0.5A
= Sicherung 2,5A
= Fuse 2.5A
= Pumpe
= Pump
Temp. sensor HEX-1
2 x 0,34qmm
= Lüftermotor 4stufig
= Fan motor 4 speeds
= Eingangsstecker
B6
= Input connector
= Klemmleiste
= Terminal strip
= AC Eingang Lüfter
= AC input fan
= Anschluss AC zum Lüfter
= Connector AC to fan
= Anschluss AC zum Lüfter
= Connector AC to fan
= Lüfter Drehzahlgeber
= Fan speed sensor
= Lüfter Drehzahlgeber
= Fan speed sensor
= Temperaturfühler Ausblasluft
= Temperature sensor extracted air
= Temperaturfühler Ansaugluft
= Temperature sensor air intake
= AC Wasserkontroller
= AC water controller
= Kondensatpumpe
= Condensate pump
Temp. sensor HEX-2
2 x 0,34qmm
= Temperaturfühler Wasservorlauf
= Temperature sensor water inlet
= Temperaturfühler Wasserrücklauf
B6
= Temperature sensor water reflow
= Durchflussmesser
= Flow meter
= Leckagefühler
= Leakage level sensor
= Kondensatfühler
= Condensate level sensor
= Anschluss DC Eingang Wasser
= DC input water
= Motorventil
= Motor valve
= Anschluss DC Eingang CMC
= Connector DC input CMC
= Anschluss Steuerkabel CMC
= Connector cable CMC
= Anschluss Ethernet
= Connector Ethernet
= Anschluss CMC / Display
= Connector CMC / display
= Anschluss Display
= Connector display
Temp. sensor HEX-3
2 x 0,34qmm
= Anschluss DC Eingang Lüfter
= Connector DC input fan
= Blind-Mating zur Lüftereinheit
B6
= Blind mating to fan unit
3 x 1,0qmm
= Blind-Mating Kabel
= Blind mating cable
= Blind-Mating Lüfter
= Blind mating fan
= Anschluss Lüfter
= Connector fan
= Lüfter Sensor Hall IC
= Fan sensor Hall IC
X10
Fuse 0,5 A
= IEC 320 Anschluss an Netzteil A2 Condensate pump
F4
= IEC 320 connection to power pack A2
PE
3 x 1,0qmm
= Netzfilter, 4 polig
X11
A4
= Line filter, 4 poles
PE
= Ferritkern
PE
M1
= Ferrite core
Übersicht Kabelbaum "LCP - Plus" / Overview cable harness "LCP Plus"
M
Water group controller
Z2
X24
RS232 (IOIOI)
X21
Power 24 VDC
X22
P-I2C
RJ12
X32
A3
Kycon KPP-3P
24VDC Supply
RJ45
L1
L2
L3
N
PE
Ethernet
CMC-TC/Basic
X23
RJ45
A1
Ethernet cable Kat. 5
X2
RJ45
Molex (Blind mating)
X30
X27
X29
X31
X6
X4
PE
X9
X8
Temp. sensor FAN-1
B7
M2
F5
Fuse 2,5 A
Fan
Controller 1
A5
X30
4 x 0,25qmm
DC & Signal cable harness
3 x 1,0qmm
M
X26
Schirm / shield
X3
PE
X7
PE
F6
Fuse 2,5 A
X5
3 x 1,0qmm
AC cable harness
A1
A1
A2
A2
A3
A3
A4
A4
A5
A5
B1
B1
B2
B2
B3
B3
B4
B4
B5
B5
B6
B6
B7
B7
F1-3
F1-3
F4
F4
F5-6
F5-6
M1
M1
M2
M2
X1
X1
X2
X2
X3
X3
X4
X4
X5
X5
X6
X6
X7
X7
X8
X8
X9
X9
X10
X10
X11
X11
X12
X12
X13
X13
X14
X14
X16
X16
X17
X17
X18
X18
X19
X19
X21
X21
X22
X22
X23
X23
X24
X24
X25
X25
X26
X26
X27
X27
X28
X28
X29
X29
X30
X30
X31
X31
X32
X32
Z1
Z1
Z2
Z2
X28
X29
X31
Molex (Blind mating)
M
M2
Molex (Blind mating)
X30
X27
X29
X31
X6
X4
PE
X9
X8
Temp. sensor FAN-2
B7
M
Fuse 2,5 A
Fan
Controller 2
X26
Schirm / shield
X3
PE
X7
PE
F6
Fuse 2,5 A
X5
3 x 1,0qmm
M2
F5
A5
X30
X28
X29
X31
Molex (Blind mating)
Molex (Blind mating)
X27
X29
X6
X4
PE
X9
X8
B7
M
M2
F5
Fuse 2,5 A
Fan
Controller 3
X26
Schirm / shield
X3
PE
X7
PE
F6
Fuse 2,5 A
X5
3 x 1,0qmm
M2
X30
X31
Temp. sensor FAN-3
M
A5
X30
X18
X12
X13
X14
X19
X16
X17
X28
B1 Temp. sensor (water inlet)
B2 Temp. sensor (water outlet)
B3 Flow meter
Y1 Motor valve
B4 Level sensor (leakage)
B5 Level sensor (condensate)
Molex (Blind mating)
X29
X31
M
M2
Sensor signals
Legende / Legend:
Wechselstrom-Kabelbaun 230V AC / AC cable harness 230 V AC
Gleichstrom und Kommunikationssiganel / DC and communication signals
Sensorsignal / Sensor signals
K 04434 01 SK 23
Fig. 77: Circuit diagram
94
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
14.5 Water circulation diagram
9
10
11
1
8
7
2
3
6 5
4
Fig. 78: Water circulation diagram
1
2
3
4
5
6
7
8
9
10
11
95
Two-way control valve
Leakage sensor
Cooling water flow
Cooling water return
Condensate pump
Condensate sensor (float-actuated switch)
Flow meter
Condensate collecting tray
Fan module 1 (top)
Fan module 2 (middle)
Fan module 3 (bottom)
Operating and Maintenance Instructions – 14 Further technical information
Rittal Liquid Cooling Package Plus
Appendix 1
Installation checklist
Rittal GmbH & Co. KG hopes that this checklist will help its customers and cooperation partners install and operate the products of the Liquid Cooling Package family successfully.
Before the installation:
Are shut-off valves installed in These valves serve to facilitate exchange or maintenance of the Liquid Cooling
the flow and return?
Package without requiring that the entire cold water supply is shut off.
Is a tacho setter installed in the The tacho setter ensures a constant volumetric flow and helps to maintain the
return of each Liquid Cooling hydraulic balance of the system, especially when operating with other types of
Package?
units, such as convectors.
Note:
If the pipework for the Liquid Cooling Package is carried out according to
the Tichelmann principle, a tacho setter is not necessary.
Is a magnetic filter installed in Rittal GmbH & Co. KG recommends that the flow of each Liquid Cooling Pathe flow of each Liquid Cooling ckage be equipped with a magnetic filter in order to protect the parts of the device from malfunction due to contamination from the water system. It is
Package?
recommended to install the filter as close to the Liquid Cooling Package as possible.
Is the water supply area
insulation carried out cleanly?
Proper insulation protects against condensate formation, especially on the
parts of the cooling water flow.
Photo Amacell
96
Operating and Maintenance Instructions – Installation checklist
Rittal Liquid Cooling Package Plus
Are the allowable bend radii of The hoses may not be kinked too strongly, otherwise the flow volume may be
the hoses adhered to?
impaired and the materials may fatigue prematurely.
Is there a good water supply
available which meets the
quality requirements?
Water quality determines the lasting reliability of the system. It ensures that no
undesirable corrosion or harmful deposits will occur. The exact manufacturer's
recommendations regarding water quality are found in Chapter 14.1, "Hydrological information" in the operating and maintenance instructions of your Liquid
Cooling Package. The recommended water quality should be ensured even after the installation.
Photo Honeywell
97
Was the pipework sufficiently
flushed before the Liquid
Cooling Package was
connected?
It is important to clean or flush the water circuits appropriately, especially for
new installations. Experience has shown that there are often remnants of sealants, lubricants, and even metal chips in new systems, which may lead to a premature failure of the Liquid Cooling Package. Cleaning the cold water system
carefully before connecting the Liquid Cooling Package ensures sure operation
later.
If the water quality of the
primary cold water supply is
inadequate, was a separate
water circuit with a water/water
heat exchanger installed?
If the cold water supply is strongly contaminated, it may make sense to install
a second, high quality cold water circuit which is connected to the primary circuit via a water/water heat exchanger. Even in this case, the water circuit on the
Liquid Cooling Package side must be carefully cleaned before connecting the
device. Our recommendations regarding water quality in Chapter 14.1, "Hydrological information" in the operating and maintenance instructions of your Liquid Cooling Package apply in this case as well.
Operating and Maintenance Instructions – Installation checklist
Rittal Liquid Cooling Package Plus
Was the water prepared/
treated with the appropriate
additives?
In addition to our recommendations regarding water quality, we recommend
that the water be enriched with corrosion inhibitor and/or antifreeze. Also, a
treatment to prevent algae and biofilms may be expedient in some cases.
Photo Clariant
Are unused height units in the
bayed server enclosures
sealed through vertical
blanking plates, and are the
side vertical foam strips
installed?
In order to prevent undesired air short circuits and circulation patterns inside
the server enclosure, all unused height units of the 482.6 mm (19") level should
be closed off with blanking plates. Thus, the air will only enter the rear side of
the server enclosure through the server itself, where it is drawn off by the Liquid
Cooling Package. The blanking plates are available in various heights, e.g. Model No. SK 1931.200 for one height unit. The vertical foam sealing strips, which
are installed on the side in the server enclosure, ensure that the cooled air does
not flow on the sides, past the 482.6 mm (19") level. Sealing strips are available
for 2 applications and 2 enclosure widths. The respective model numbers are
found in Chapter 13, "Accessories" in the operating and maintenance instructions of your Liquid Cooling Package
Are all electrical, water, and
power connections correctly
made?
Before water is admitted, and, ideally before the ball valves are opened, be
sure to check that all connections are properly made. Pay special attention to
check that all quick release fasteners are fully snapped into place.
Is the TS/PS server enclosure Both the Liquid Cooling Package Standard and the Liquid Cooling Package
equipped with the appropriate Plus function with a sealed air circuit. Thus, the cooled server enclosure must
door?
largely be hermetically sealed and equipped with unperforated steel or glass
doors on the front and rear sides.
Exception when using the Liquid Cooling Package Extend:
The front of the server enclosure must, in this case, be fully air permeable.
After admitting cold water:
98
Are all parts and connections
water tight?
Please check to be sure that all parts and connections which carry water are
water tight. The Liquid Cooling Package is subject to an individual, comprehensive factory test, which also includes checking for leaks. This additional check
serves to locate problems, such as possible transport damage, and to prevent
greater damage.
Venting of the Liquid Cooling
Package Plus
The Liquid Cooling Package Plus has an automatic vent. This has been closed
in the factory and must be opened for venting purposes during initial startup.
Close the vent again after startup. To gain access to the vent, the top fan must
be removed.
Operating and Maintenance Instructions – Installation checklist
Rittal Liquid Cooling Package Plus
After installation:
We recommend that the following selected parameters be gathered and documented within a short time after installation.
- Inlet temperature
- Return temperature
- Volumetric flow with opened magnetic valve
Note:
Documenting these parameters helps with error analysis if, during operation, malfunctions occur.
Please feel free to contact Rittal if you have further questions or
problems:
For malfunctions and repairs
Rittal Service Department
Tel.: +49 (0) 27 72/50 5-18 55
E-mail: [email protected]
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Operating and Maintenance Instructions – Installation checklist
Rittal Liquid Cooling Package Plus
Appendix 2
Preparation and
maintenance of the water in
recooling systems
Depending on the type of installation to be cooled, certain purity requirements
are placed on the cooling water in a recooling system. According to the level of
contamination and the size and design of the recooling systems, a suitable process is used to prepare and/or maintain the water. The most common types of
contamination and frequently used techniques to eliminate them in industrial
cooling are:
Type of impurity
Procedure
Mechanical contamination
Filter the water using:
Mesh filter, sand filter, cartridge filter, precoated
filter, magnetic filter
Excessive hardness
Soften the water via ion exchange
Moderate content of mechanical contaminants and hardeners
Treat the water with stabilisers and/or dispersing
agents
Moderate content of chemical
contaminants
Treat the water with passivators and/or inhibitors
Biological contaminants, slime
bacteria and algae
Treat the water with biocides
Tab. 18: Cooling water contaminants and treatment procedures
Note:
For the proper operation of a recooling system that uses water on at least
one side, the composition of any additive used or system water should not
deviate substantially from hydrological data presented in Chapter 14.1, "Hydrological information".
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Operating and Maintenance Instructions – Preparation and maintenance of the water in recooling systems
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