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Black Box Black Box Cold Row DX, CRDX-W-FS-12KW, CRDX-A-FS-24KW, CRDX-G-FS-24KW Maintenance, Page

Models: CRDX-W-FS-12KW Black Box Cold Row DX CRDX-W-FS-24KW CRDX-A-FS-24KW CRDX-A-FS-12KW CRDX-G-FS-12KW CRDX-G-FS-24KW

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Chapter 5: Maintenance

Symptom: Water–water/glycol valve fails to open or close.

Probable Causes/Recommendations:

a. Temperature setpoint too high. Adjust to correct temperature setting.

b. No control power to the valve. Valve actuator is wired incorrectly. Check wiring diagram and rewire if required. c. Actuator failed. Replace actuator.

Symptom: Condenser pressure too high (CRDX-A-FS-12KW, CRDX-A-FS-24KW units).

Probable Causes/Recommendations:

a. Non-condensable gas or air in the system. Recover system, evacuate per Section 2.10.2.2, recharge. Replace drier/strainer. b. Condenser air intake is blocked. Remove debris and clean condenser.

c. Overcharge of refrigerant. Reclaim excess refrigerant from system.

d. Condenser fan not operating. Check pressure/temperature operating switches and motor. Replace as needed.

Symptom: Condenser pressure too high (CRDX-W-FS-12KW, CRDX-W-FS-24KW, CRDX-G-FS-12KW, CRDX-G-FS-24KW units). Probable Causes/Recommendations:

a. Flow of water/glycol too low.

1.Check glycol solution level and concentration.

2.Valves not open or partially open. Repair/replace as needed.

3.Air in system—bleed system.

4.Check all strainers and clean if needed.

b.Water/glycol temperature too high. Check flow and operation of drycooler.

c.Control pressure set too high. Adjust controller to obtain correct pressure.

d.Water/glycol solution not mixed prior to adding to system. Remove solution and premix. Refill system.

Symptom: Condenser pressure too low.

Probable Causes/Recommendations:

a. Loss of refrigerant (indicated by bubbles in sight glass). Locate and repair leak. Recharge system. b. Condenser fan controls not set properly. Adjust or repair controls.

c. Control pressure set too low. R410A—Readjust to 440 psig.

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Black Box Black Box Cold Row DX, CRDX-W-FS-12KW, CRDX-A-FS-24KW, CRDX-G-FS-24KW, CRDX-W-FS-24KW user manual Maintenance, Page

Contents

CRDX-G-FS-24KW CRDX-W-FS-12KW Cold Row DX User ManualCRDX-A-FS-24KW CRDX-G-FS-12KW CRDX-A-FS-12KW CRDX-W-FS-24KW Customer Support InformationPage Trademarks Used in this ManualTrademarks Used in this Manual FCC and IC RFI Statements PageInstrucciones de Seguridad Normas Oficiales Mexicanas Electrical Safety StatementNOM Statement PageTable of Contents Table of ContentsPage Page Table of ContentsWater-Cooled Systems CRDX-W-FS-12KW, CRDX-W-FS-24KW Table of Contents PageTable of Contents PageTable of Contents Page1.2 Product Description Chapter 1 Introduction1. Introduction 1.1 General PagePage Chapter 1 IntroductionFigure 1-1. User interface display Chapter 1 Introduction 12-Month Precision A/C Limited Warranty24-Month Precision A/C Upgraded Limited Warranty PageChapter 1 Introduction 1.3 Product WarrantyCold Row Warranty - Compressor PageChapter 1 Introduction 1.4.2 Safety Summary1.4 Safety 1.4.1 General PageChapter 1 Introduction Never work on electrical equipment unless another person who is familiar with the operation and hazards of the equipment and is competent in administering first aid is nearbyPage Chapter 1 Introduction 1.5 General DesignPage 1.5.3 Compressor 1.5.1 Electrical Compartment1.5.2 Circuit Breakers/Motor Start Protectors 1.5.3.1 Electronic Thermal Expansion Valve1.6 Optional Equipment 1.5.7 Temperature/Humidity Sensors1.6.1 Remote Mounted Supply Temperature/Humidity Sensor 1.6.2 Water Detector2.2 Moving the Equipment Chapter 2 Installation2. Installation 2.1 Receiving the Equipment 2.3 Site PreparationChapter 2 Installation 2.4 Mounting/PlacementConditioned Space PageChapter 2 Installation 2.5 Air DistributionPage Page Chapter 2 InstallationFigure 2-2. Typical air distribution Chapter 2 Installation 2.6 Optional Equipment Field Installed2.6.1 Remote Water Detectors PageChapter 2 Installation 2.6.2 Remote Temperature/Humidity SensorPage Figure 2-7. Typical W/G piping diagram 2.6.3 Outdoor CondensersChapter 2 Installation PageChapter 2 Installation Piping ConnectionsPage Figure 2-8. Top access piping Water-Water/Glycol Supply and Return Piping ConnectionsChapter 2 Installation PagePage Chapter 2 InstallationFigure 2-9. Bottom access piping SCHRADER VALVE MALE PIPE THREADSChapter 2 Installation 2.8 Split Air-Cooled Systems2.8.1 Refrigerant Piping PageChapter 2 Installation 2.8.1.1 DX Refrigerant Piping ConnectionsPage Chapter 2 Installation 2.8.1.2 Refrigerant Pipe Sizing2.8.2 Remote Air-Cooled Condensers PageChapter 2 Installation 2.9 Utility Connections 2.9.1 Main Power2.8.3 Condensate Drain Line PagePage Chapter 2 InstallationFigure 2-12. Sample nameplate 2.9.2.2 Remote Temperature/Humidity Sensor 2.9.1.1 Single-Phase Units 208/2302.9.1.2 Three-Phase Units 2.9.2 Optional EquipmentChapter 2 Installation 2.9.3.2 Glycol-Cooled Systems CRDX-G-FS-12KW, CRDX-G-FS-24KW2.9.3.3 Remote Condenser CRDX-A-FS-12KW, CRDX-A-FS-24KW Page2.10.2 Remote Air-Cooled Systems 2.10 System Charging Procedures2.10.1 Water-Water/Glycol Cooled Systems Chapter 2 InstallationChapter 2 Installation 2.10.2.1 Estimating Refrigerant ChargePage Chapter 2 Installation 2.10.2.2 Preparing System For ChargingEvacuate the System PageInitial System Charge 2.10.2.3 Refrigerant Charging ProceduresFine-Tuning the System Charge Chapter 2 InstallationChapter 2 Installation 2.10.2.4 -30 F Ambient ApplicationsPage Chapter 2 Installation 2.10.3.2 Saturated Refrigerant PressurePage 2.11.3 Thermal Expansion Valve 2.11 Settings and Adjustments 2.11.1 Water-Water/Glycol Circuit2.11.2 Low-/High-Pressure Limit Switch 2.11.4 Hot Gas Bypass3.2 Step-by-Step Startup Instructions Chapter 3 Startup/Commissioning3. Startup/Commissioning 3.1 Initial Operation 3.3 Microprocessor Controller ProgrammingChapter 4 E2 Controller 4.1.1 Features 4.1.1.1 Field Configurable4.1.1.2 Password Protection 4. E2 Controller 4.1 GeneralChapter 4 E2 Controller 4.1.2 User Interface Display Panel4.1.2.1 Function Keys Page4.1.3 Controller I/O Module 4.1.2.2 Contrast Adjustment4.1.2.3 Alarms Controller I/O Module LayoutChapter 4 E2 Controller 4.1.4 BMS InterfacePage Chapter 4 E2 Controller 4.2 Navigating Controller Display Screens 4.2.1 Menu Selection4.2.2 Menus PageChapter 4 E2 Controller 4.2.3 Display Variables4.2.4 Cursor Position in Screens Page4.2.5 Modifiable Variables 4.2.6 Password Authorization Levels4.2.6.1 Password-Protected Screen Chapter 4 E2 Controller4.3 System Operation 4.2.6.2 Wrong Password4.2.6.3 Setting the Passwords Chapter 4 E2 ControllerChapter 4 E2 Controller 4.3.1 Setpoint AdjustmentPage Page Chapter 4 E2 ControllerFigure 4-14. Flashing cursor 4.3.2.2 Customer Alarms 4.3.2 Alarms4.3.2.1 Summary Alarm 4.3.2.3 Custom AlarmsChapter 4 E2 Controller 4.4.1 Control Signals4.4.1.1 On/Off Digital Control Page4.4.2 Control Methods 4.4.2.1 Temperature/RH Control4.4.1.2 Proportional/Integral P/I Control 4.4.2.2 Dewpoint ControlChapter 4 E2 Controller 4.4.3 Operating Configurations4.4.3.1 Compressor Operation Page4.4.4 Airflow/Fan Speed Control 4.4.3.2 Water-W/G Operation4.4.3.3 Dehumidifying Chapter 4 E2 Controller4.4.4.2 Variance from Average Fan Speed Control 4.4.4.3 Temperature Proportionate Speed Control4.4.4.1 Independent Fan Speed Control 4.4.4.4 Manual Speed ControlChapter 4 E2 Controller “Control” allows modification of basic control parameters such as setpoints and clock. Level 1 password is needed to enter this menuPage 4.5.2 Information Menu Loop 4.5.2.2 Return Temperature Sensor4.5.2.4 Temperature Sensors 4.5.2.1 Operating Conditions4.5.2.7 Setpoint Values 4.5.2.5 Remote Supply Temperature/Humidity Sensor4.5.2.6 Discharge Pressure 4.5.2.8 Compressor Status4.5.2.12 Group Information Menu Screens 4.5.2.10 EHGB Status4.5.2.11 Fan Status 4.5.2.13 Software Version/Date4.5.3.2 Non-Critical Alarms 4.5.3 Alarm Log4.5.3.1 Alarms 4.5.3.3 Critical AlarmsChapter 4 E2 Controller 4.5.3.4 Alarm Screen MessagesTable 4-3. Alarm screen messages PageChapter 4 E2 Controller 4.5.4 Control Menu LoopPage Chapter 4 E2 Controller 4.5.4.1 Setpoint ScreensPage Chapter 4 E2 Controller 4.5.4.2 Alarm Setpoint ScreensPage Chapter 4 E2 Controller Figure 4-33. Low humidity alarmPage 4.5.4.3 Clock Screen Dirty Filter Timer4.5.5 Service Menu Loop Chapter 4 E2 ControllerChapter 4 E2 Controller 4.5.5.1 HumidityFigure 4-40. Service menu loop selections PageChapter 4 E2 Controller 4.5.5.2 AlarmsPage Chapter 4 E2 Controller 4.5.5.3 SensorsPage 4.5.5.4 Blower Temp Zone SetupBlower Setup Chapter 4 E2 ControllerChapter 4 E2 Controller 4.5.5.5 Options Menu LoopControl, Startup PageChapter 4 E2 Controller Unit TimersT/H Offset Scaling PageChapter 4 E2 Controller Custom SetupCustomer Alarm Input Optional PageChapter 4 E2 Controller Custom Alarm Setup OptionalPage Chapter 4 E2 Controller Table 4-5. Alarms 9 toTable 4-6. Alarms 17 to PageChapter 4 E2 Controller Table 4-7. Alarms 25 to 32 Sensor failure alarmsTable 4-8. Alarms 33 to 40 Sensor failure alarms PageChapter 4 E2 Controller Workgroup ScreensPage Chapter 4 E2 Controller 4.5.5.6 Digital In4.5.5.7 Run Hours PageChapter 4 E2 Controller 4.5.5.9 Save Configuration4.5.5.8 BMS Communications PageChapter 4 E2 Controller 4.5.5.10 Factory MenuPage Chapter 4 E2 Controller 4.6.1 Workgroup Setup4.6 Communication with the Controller Page4.6.1.1 Standby 4.6.1.4 Out of Service4.6.2 Configuring a Workgroup 4.6.1.2 Capacity AssistChapter 4 E2 Controller 4.6.2.1 Configure the Terminal AddressPage Chapter 4 E2 Controller 4.6.2.2 Configure the Controller I/O Board pLAN Address4.6.2.3 Assign the Terminal to the Controller PageChapter 4 E2 Controller 4.6.2.4 Fault Messages4.6.2.5 Displaying the Network Status and Firmware Version PageChapter 4 E2 Controller 4.6.2.6 Configure WorkgroupsPage Chapter 4 E2 Controller Figure 4-76. FactoryGroupsGroups Config Screen 1. See TableTable 4-12. FactoryGroupsGroups Config Screen 1 parameters PagePage Chapter 4 E2 ControllerTable 4-13. FactoryGroupGroup Rotation Screen 2 parameters Page Chapter 4 E2 ControllerTable 4-15. FactoryGroupCapacity Assist Screen 4 parameters Chapter 4 E2 Controller Table 4-17. Group alarms 1 toTable 4-18. Group alarms 9 to PageChapter 4 E2 Controller Table 4-19. Group alarms 17 toTable 4-20. Group alarms 25 to PageChapter 4 E2 Controller Table 4-21. Group alarms 33 toPage Chapter 4 E2 Controller 4.6.2.7 ServiceOptionsGroup Menu ScreensGroup Setup PageGroup Sensors Capacity AssistCapacity Assist #2 Chapter 4 E2 ControllerChapter 4 E2 Controller Group Averaging4.6.2.8 Group Information Menu Screens PageLead Controller Group Sensors Group AlarmsGroup Sensor Values Group Sensor StatusChapter 4 E2 Controller 4.7 BMS CommunicationsPage Chapter 4 E2 Controller 4.7.1 Direct BMS Control4.7.2 BMS Communication PageChapter 4 E2 Controller 4.8 Troubleshooting the Control I/O Module Signal LEDsTable 4-26. I/O control module signal LEDs PagePage 4.9 BMS Parameters, VersionChapter 4 E2 Controller Table 4-27. BMS parametersChapter 4 E2 Controller PagePage Chapter 4 E2 ControllerType of unit valid numbers 0 to 6 See Page Variable/Value DescriptionsChapter 4 E2 Controller Table 4-30. Variable/Value DescriptionsChapter 4 E2 Controller 4.9.4 Alarm Packed Bit VariablesTable 4-32. Alarm-Packed Bit Variables PagePage 4.9.5 Sensor Failure Packed Bit VariablesChapter 4 E2 Controller Table 4-33. Sensor Failure Packed Bit VariablesPage 4.9.6 Digital Input Packed Bit VariablesChapter 4 E2 Controller Table 4-34. Digital Input Packed Bit VariablesPage 4.9.7 Digital Output Packed Bit VariablesChapter 4 E2 Controller Table 4-35. Digital Output Packed Bit VariablesPage Chapter 4 E2 Controller4.9.8 Unsigned Values for HTTP, SNMP/Modbus Holding Registers/Analog Values for BACnet 5.1.1.1 Cleanable Filters Chapter 5 Maintenance5. Maintenance 5.1 Periodic General Maintenance 5.1.1 FiltersF Fgure 5-1. Cleanable filters Chapter 5 MaintenancePage 5.1.3 Coil 5.1.1.2 Cartridge Filters5.1.2 EC Fans 5.1.4 Drain PansChapter 5 Maintenance 5.2 Troubleshooting5.1.6 A/C System PageSymptom Control is erratic Chapter 5 MaintenancePage Chapter 5 Maintenance PageLeak Detection/Repair 5.3 Field Service5.3.1 Water-Water/Glycol System 5.3.2 DX SystemChapter 5 Maintenance 5.3.2.3 Refrigerant Piping5.3.3 Refrigeration System Repairs 5.3.3.1 Compressor Failure Page5.3.4 Component Replacement 5.3.3.2 Standard Cleanout Procedure5.3.3.3 Burn-Out/Acidic Cleanup Procedure 5.3.4.1 Fan ReplacementChapter 5 Maintenance 5.3.4.2 Condensate Pump ReplacementPage 6.2 Obtaining Warranty Parts Chapter 6 Troubleshooting6. Troubleshooting 6.3 Obtaining Spare/Replacement PartsPage Chapter 6 TroubleshootingQuotes are given for specified listed parts for a specific unit Appendix A. Forms A.1 Checklist for Completed Installation of Cold Row DXAppendix A Forms PagePage Appendix A FormsDate Appendix B. Glossary Definition of Terms and Acronyms Appendix B Glossary Definition of Terms and AcronymsPage Page Appendix B Glossary Definition of Terms and AcronymsVDC Volt, direct current WG Water Glycol Page Page Page Tech support the way it should be Black Box Tech Support FREE! Live. 24/7About Black Box