Chapter 5: Maintenance

5.3.2.3 Refrigerant Piping

When replacing components within the cabinet of the unit, the following consumable materials are recommended: When brazing copper-to-copper connections (piping liquid line or suction line), use a phosphorus copper brazing alloy with 15% silver.

Use general-purpose silver brazing alloy with 45% silver for copper-to-brass or copper-to steel. For liquid line repairs at the drier, strainer, sight glass, or expansion valve, use a 95% tin to 5% antimony solder with flux.

When component replacement is complete, remove all traces of flux. After any repair, pressure check the system to ensure there are no leaks prior to recharging the system.

5.3.3Refrigeration System Repairs 5.3.3.1 Compressor Failure

The compressor is the most important component of the air conditioner. Numerous safety devices are provided to protect the compressor from failing.

If a compressor failure occurs, determine whether it is an electrical or a mechanical failure. An electrical failure will be indicated by the distinct pungent odor once the system has been opened. If a burnout has occurred, the oil will be black and acidic. A mechanical failure will have no burned odor and the motor will attempt to run; an abnormal or excessive noise may be present.

An analysis of the oil is the only way to determine the proper procedure for cleaning the refrigerant system. Acid test kits are available from several manufacturers for measuring the acid level in the oil. These are capable of making accurate acid measurements, but if they are not available, a check of the oil by sight and smell can give a quick indication if contamination remains in the system.

CAUTION

Avoid touching or contacting the gas and oil with exposed skin. Severe burns will result. Use long rubber gloves in handling contaminated parts.

All electrical connections should be checked to ensure they are tight and properly made. Check all circuit breakers, contactors, and wiring. The contactors should be examined and replaced if contacts are worn or pitted.

If there is acid in the oil, there has been an electrical failure that has caused the compressor motor to burn out. The acid diffuses throughout the refrigeration system and must be removed by using a burnout filter kit before a new compressor is placed in service. Not only must the compressor be replaced, but also the entire refrigeration circuit must be cleaned of the harmful contaminants left by the burnout. See Section 5.3.3.3 (Burn-Out/Acidic Cleanup) for the proper procedure.

If there is no acid in the oil, there has been a mechanical failure. See Section 5.3.3.2 (Standard Cleanout) for the proper cleaning procedure.

CAUTION

Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty. This will VOID THE COMPRESSOR WARRANTY. Always consult Black Box Technical Support before replacing the compressor.

CAUTION

POE oil is used in systems with R410A refrigerant. If a replacement compressor is provided, ensure that it is filled with POE oil before installing.

NOTE: Cleaning operations must be performed by a journeyman refrigeration mechanic or air-conditioning technician.

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Black Box CRDX-A-FS-24KW, CRDX-W-FS-12KW Refrigerant Piping, Refrigeration System Repairs 5.3.3.1 Compressor Failure
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CRDX-W-FS-12KW, Black Box Cold Row DX, CRDX-W-FS-24KW, CRDX-A-FS-24KW, CRDX-A-FS-12KW specifications

The Black Box CRDX series consists of high-performance cooling solutions designed to maintain optimal temperature conditions in data centers and server rooms. Key models in this series include the CRDX-W-FS-12KW, CRDX-W-FS-24KW, CRDX-G-FS-12KW, and CRDX-A-FS-24KW. These units are engineered to provide efficient cooling while addressing the rising demands of modern IT infrastructure.

One of the standout features of the CRDX series is its cold row design. This configuration enables targeted cooling delivery directly to the equipment, enhancing efficiency and reducing energy consumption. The airflow management in these models ensures that cooled air is directed where it is needed most, minimizing hotspots and maximizing cooling performance.

Both the CRDX-W-FS-12KW and CRDX-W-FS-24KW models utilize advanced refrigerant-based cooling technology. These units are equipped with electronically commutated (EC) fans, which are highly efficient and quieter than traditional fan technologies. This innovation not only lowers operational costs but also creates a more comfortable environment within the data center.

The CRDX-G-FS-12KW model stands out for its hybrid capabilities, offering both chilled water and direct expansion cooling options. This versatility allows facility managers to choose the best cooling approach based on their specific requirements and current infrastructure. The hybrid system can optimize energy consumption and enhance cooling efficiency, contributing to lower operating costs.

Another noteworthy feature across these models is their intelligent controls and monitoring capabilities. Equipped with sophisticated sensors and control systems, operators can gain real-time insights into temperature fluctuations, humidity levels, and unit performance. This data aids in proactive maintenance and ensures that cooling systems are operating at peak efficiency.

The CRDX-A-FS-24KW, on the other hand, is designed with a focus on adaptability and scalability. This model can be integrated easily into existing network setups, making it an excellent choice for facilities that anticipate future growth or need to adapt to changing cooling demands.

Overall, the Black Box CRDX series exemplifies the latest advancements in cooling technology, offering innovative features designed to support high-density computing environments. With their efficient cooling capabilities, intelligent controls, and flexible design options, these models provide reliable solutions for data centers looking to enhance their cooling systems while reducing operating costs.
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