Motivair · The CDU is heavy and requires an opening in a raised floor for piping egress DO NOT CUT raised floor cross supports or remove stanchions around CDU for this opening, consult

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INSTALLATION <> OPERATION <> MAINTENANCE GUIDE

Cooling Distribution Unit

Model: MCDU‐75‐6‐60

Motivair Corporation85 Woodridge Drive Amherst, NY 14228 716‐691‐9222 (Ph) 716‐691‐9229 (fax)

CDU IOM Rev1.0

Product Standards and ComplianceAll products conform to industry standards and ratings; contact Motivair for a complete list

and certificates for specific models.

The manufacturer shall not be liable for any damages resulting from misapplication or misuse

of its products.

ATTENTION

Read this page before proceeding

ABOUT THIS DOCUMENT


This document may be updated without notice at any time. Motivair reserves the right to

update and or change product specifications and performance without notice as design

improvements occur. Please contact the factory to ensure that your version is the most up to

date.

Disclaimer

Page 2

Section 1 SAFETY INSTRUCTIONS

General Safety 5

Owners Responsibility 5

Installation / Handling 5

Application 5

Electrical Warning 5

Section 2 GENERAL DESCRIPTIONGeneral Product Description 6

Technical Data 6

Section 3 TECHNICAL DATAElectrical Data 7

Design Capacities 7

Dimensional Drawings 8

P&ID 9Primary Loop 10

Secondary Loop 10

Section 4 INSTALLATIONReceiving and Uncrating 11Floor Preparation 11

Locating and Positioning 12

Electrical 12Piping Connections 12‐15

Cleaning and Flushing 15

Water Quality 16Filling and Venting 17

Section 5 COMMISSIONINGPre‐commissioning Checks 18

Commissioning 19

Description/Sequence of Operation 19‐20

Section 6 OPERATIONPLC Controller HMI Introduction 21PLC Controller Parameter Screens 22

Set Points and Operation 23‐25

Alarm Acknowledgement 26

CDU IOM Rev1.0

CONTENTS


Page 3

Section 7 TROUBLESHOOTING

General 27

Non‐Alarms 27Alarms 28

Section 8 MAINTENANCEScheduled Maintenance 29

Section 9 SPARE PARTSParts List 30‐31

Section 10 DOCUMENTS AND TABLESBMS Table 32‐34

Electrical Schematics 35‐37

Section 11 SUPPORT AND WARRANTYFactory Support Contact Info 38

Notes 39

Section 12 APPENDIX Start Up Report A1‐A2

CDU IOM Rev1.0


Page 4

Section 1

CDU IOM Rev1.0


This unit must only be used in the application for which it was designed. Do not use this

product in any hazardous environment.

Application

Electrical

WARNING – This unit is powered by HIGH VOLTAGE. Serious injury or death can occur. Power

being supplied to the unit must be isolated with an electrical disconnect. Any and all

electrical connections or procedures should only be performed by a certified electrician. All

electrical work or procedures should be in accordance with local, state and national electrical

codes and regulations. NEVER make any electrical connections to this unit unless the power

supply is OFF at the power supply disconnect switch.

This equipment must be installed, maintained and operated by a person or persons qualified

for this equipment. This system contains water circulation equipment and electrical

components. The person most suited to perform any operations or service on this equipment

is a qualified industrial technician and or electrician with experience and qualifications to

work with water systems and electrical systems.

Owner's Responsibility

Installation and operation should always be conducted in compliance with local, state and

national codes and industry best practices. When moving or installing the unit, CAUTION

must be observed at all times to ensure the safety and well being of personnel. Follow all

local, State and national codes for moving equipment. Only appropriate and approved

moving equipment should be used.

Installation

Operation of this equipment involves potentially lethal dangers (HIGH VOLTAGE POWER and

High water Pressures.) Therefore, ALL safety precautions and warnings described in this

manual must be precisely observed. Failure to follow these precautions and warnings can

result in severe or fatal injury

WARNING

Temperature control equipment, pump stations and electrical devices contained in this

system present various electrical, mechanical, sound and vibration hazards. For this reason,

operation and service procedures should only ever be performed by qualified, fully trained

and technically competent personnel.

This equipment contains:

• High pressure water generated by the system

• Electrically energized components

• Hot pipes and heat exchangers

• Rotating parts such as pump impellers, wheels and valves.

General Safety

SAFETY INSTRUCTIONS

Page 5

Section 2

CDU IOM Rev1.0

GENERAL DESCRIPTION


General Product Description

Technical Data

Technical Data such as pump curves, electrical loads and sound data for any specific CDU that

is not included in this general manual may be obtained on the CDU nameplate or from the

product specification or submittal. Consult Motivair with any questions or document requests

The Cooling Distribution Unit (CDU) is designed for use with Motivair Chilled Doors and other

approved distribution systems and equipment in a data center environment. The CDU

includes a plate heat exchanger that creates a divide between customer supplied cold water

(Primary Loop) and a separate cooling loop that feeds Chilled Doors (Secondary Loop). The

Secondary Loop flow and pressure is created by the CDU pumps and valve assemblies. The

Secondary Loop is always controlled to operate above room dew point to avoid condensation

on the Chilled Door coils.

The Primary Loop water system should always have a micron filtration level of less than 500

microns. The water supply can be from various sources such as a chiller plant. Clean and

filtered water and or glycol is the sole responsibility of the user. Large amounts of debris or

particulate can reduce efficiency or plug the CDU heat exchanger.

Heat extracted from the Chilled Doors is transferred to the CDU heat exchanger where the

heat is exchanged to the Primary Loop and removed.

Various set points and alarms can be monitored and controlled within the CDU. These can be

adjusted by the operator via an integrated PLC.

Cooling Distribution Units can be built in various configurations. Make sure to check specific

product specifications and design criteria for each specific CDU. Consult Motivair with any

questions.

Page 6

Section 3

Standard Available Power Options: 460/3/60 ‐ 575/3/60 ‐ 230/3/60 ‐ 208/3/60

inInIn

‐GPMGPMPSID°F°FkWkWkW

V/Ph/HzLbsLbs

FLA: 11.8 Amps MCA: 14.0 Amps MOP: 22.8 Amp

The above sample design specifications are based on maximum design load conditions

Capacity and performance will vary based on Primary flow, temp, and fluid type.

Note:

For your specific design and application refer to your Motivair engineering selection.

CDU IOM Rev1.0

TECHNICAL DATA

CDU‐75‐6‐60 Design Data:

Primary

Estimated Total Fluid Pressure Drop:

72

CDU MAX Cooling Capacity:

185

Unit Height:Unit Width:

39

100% Water

Specifications are subject to change without notice.

Unit Depth:

Fluid Type:Design Fluid Flow:Max Fluid Flow:

Design Fluid Inlet Temp:Design Fluid Outlet Temp:

272272

Approximate Operating Weight:

CDU Design Cooling Capacity:

Secondary


Electrical Data

Total power consumed at design CDU Power supply:Approximate Shipping Weight: 1,170

Power 460/3/60

Design Capacities

7.745°55°

100% Water1201203.275.5°60.0°

31

185

5.5460/3/60

1,300

Page 7

CDU IOM Rev1.0


Page 8

CDU IOM Rev1.0


Page 9

Primary Loop

Secondary Loop

CDU IOM Rev1.0

The Secondary Loop connections are made on the underside of the CDU (bottom connections

for raised floor installation). These connections can be either NPT or sweat connections and

can be specified at the time of order. These Secondary In and Secondary Out connections

typically run to and from a “supply and return header” that can be mounted under the raised

floor by the installer. Connections between the CDU and the “Supply and return header” are

made by the installer. This piping should be self supporting as the CDU is not designed for

any external pipe loads.

The Secondary Loop should be filled with clean softened water. Consult Chilled Door

specification for water details.

Hydraulic

The Primary Loop cold water is supplied from the customer’s building chilled water system

and is outside the scope of this CDU manual. The Primary Loop is connected to the CDU’s

Primary IN and Primary OUT connections via either an NPT connection or a customer

specified connection i.e. sanitary fitting or grooved pipe. This connection type should be

specified at the time of order.

The CDU can be built to accept either top or bottom connections. This should also be

specified at the time of order. The prevailing standard is bottom connections piped up from a

raised floor space. All Primary Loop piping or hosing connected to the CDU must be self

supporting, as the CDU is not designed for any external pipe loads.

All Primary Loop piping should be insulated BY the installer to prevent condensation from

forming.


Page 10

Section 4

Warning:

CDU IOM Rev1.0

INSTALLATION


Receiving and uncrating

The CDU is heavy and requires an opening in a raised floor for piping egress DO NOT CUT

raised floor cross supports or remove stanchions around CDU for this opening, consult your

raised floor contractor or supplier for safe load specs and cutout assistance if necessary.

Floor Preparation

Preparing a raised floor for a CDU:

When a CDU is installed on a raised floor, holes must be made to allow for supply and return

primary and secondary water lines to pass in and out of the CDU. The drawing below shows a

typical bottom view of a CDU. The rectangular cut out is where the water piping enters and

exits the CDU.

The CDU arrives in a specially designed crate. Make sure the crate is on a level and load

bearing floor. Typically, 4 workers will be needed to remove the CDU from its crate. Open

the front “Drawbridge” door to gain access to the CDU. Note, this drawbridge door folds

down and creates a ramp down which the CDU is rolled out of the crate. Once the

drawbridge door is down, carefully remove the CDU from the crate by pulling from the

bottom of the CDU’s front bracket. DO NOT PULL ON UNIT DOORS, THEY ARE NOT DESIGNED

FOR LOAD PULLING OR RIGGING. The CDU has heavy components located high up inside the

structure so the center of gravity is relatively high. Make sure unloading personnel prevent

the CDU from tipping over by guiding it down the draw bridge ramp. Thoroughly INSPECT the

unit, any shipping damage must be reported to Motivair immediately.

Page 11

CDU IOM Rev1.0

Control wiring: The RH% ‐ dew point sensor located below the control panel can be relocated

(wall mount) if CDU is not installed in the conditioned space. Relocating will require

extending a 4 conductor 18ga wire to the space. BMS wiring is also required per options

installed either IP network cable or shielded 3 wire.


Locating and positioning

Position the CDU on a smooth level floor (top Feed units). Bottom feed units typically will

need to be installed on 12” raised floor or higher to allow for pipe connections to be made to

the underside of the CDU. Once in position, there are leveling feet that MUST be adjusted to

ensure a stable, level operating platform. DO NOT LEAVE ON WHEELS. There are openings in

the bottom of the CDU to allow for IN/OUT Primary piping Connections and IN/OUT

secondary piping connections, the floor cutout should be aligned with CDU opening.

Primary CW supply from building loop

Primary CW return

to building loop

Secondary loop

outlet supply to

doors

Electrical:

The CDU electrical panel is equipped with an opening through which the power wires are

installed. All electrical wiring should be performed by a qualified electrician. Wire sizing may

vary based on CDU electrical loads and building power supply.

The CDU can be supplied with A/B power feed option allowing for 2 different power sources

to be fed to the CDU. If only 1 power source is available, that power can be fed to both the A

and B power terminals. Consult CDU Model name plate for proper supply voltage and power

for your unit.

Piping Connections

Secondary loop

inlet Return from

doors

Page 12

CDU IOM Rev1.0


Bottom Feed Top View piping layout position

Bottom Feed Side View

Piping Layout

Page 13

CDU IOM Rev1.0

Piping Layout cont.…

Top Feed Top View piping layout position

Top Feed Side View


Page 14

CDU IOM Rev1.0

16 Port Distribution Header

All piping should only be performed by qualified piping contractors and all industry standard

best practices and plumbing codes must be followed. The piping connections are standard

2.5" female NPT (unless ordered alternate connection option) and may be attached to the

building's primary chilled water loop by any acceptable piping material and connection

method, i.e. flex hose, copper, sch 80 PVC, carbon steel pipe, Grooved (Vic) etc. The piping

must be supported completely as to not stress the CDU piping or components. Primary piping

should be insulated to avoid condensation issues. The secondary loop of the CDU will be

piped per above requirements and will connect the temperature controlled loop to the

chilled doors via a Motivair header assembly (per below) or a site provided

header/distribution system. All field piping must be pressure tested not to exceed 100 psi on

any Motivair supplied components.

Cleaning and Flushing

Cleaning and flushing of any field installed piping that may be required must be completed

before connecting to any Motivair equipment. Motivair supplied Chilled Doors, CDU's,

Underfloor Distribution Headers, and all hoses are shipped clean and new, these require no

cleaning or flushing.


Piping

Page 15

CDU IOM Rev1.0

To insure long term reliability and operation of the sealing components of the Motivair CDU

and coolant loop distribution components clean water with a low to no suspended solids level

is required for closed loop systems.

Suspended Particles can damage O‐rings, mechanical pump seals and cartridge valve seals

and operation. Excessive suspended solids will leave deposits in system piping, including

critical sealing and heat transfer surfaces. The following recommendations are a minimum for

and closed loop distribution system utilizing the Motivair Chilled door, CDU or header

distribution system.



Good installation practice must include Initial system flushing


before connecting to any Motivair equipment. Motivair supplied ChilledDoor®, CDU's,



Minimum Water Quality Standard for Motivair Equipment

A water treatment professional should be consulted regarding the testing and proper

chemical treatment for a closed loop system’s composition and fluid requirements. Proper

levels of all loop and makeup water must be maintained per industry standards and best

practices. Proper levels of pH, Alkalinity, Chlorides, Nitrite, and Conductivity, along with other

chemicals and metals in the system must be tested for and monitored. A treatment program

should be implemented at the time of initial system commissioning to provide long term

system reliability. This testing is outside this documents scope.

Water testing and filtration must employed to ensure a system is filtered to <50 microns

(High limit of a closed loop system per industry standards) The recommendation by Motivair

is to utilize a 5 micron or less bag/cartage type filter in the closed loop or other suitable

method of removing suspended solids to a minimum 5 microns or less. Iron levels less than

<2.0 ppm ‐ Copper levels less than <0.1 ppm ‐ Suspended solids <1 mg/L.

The following table is a guide

for initial fill water for all

closed loop system using

Motivair Chilled Doors and

components. Potable water is

a good source and starting

point for initial filling.

Motivair Water Quality

Mineral Recommended Limit

Chloride < 25 ppm

Calcium < 15 ppm

Magnesium < 15 ppm

Total Water Hardness <30 ppm

Sulfate < 25 ppmpH 7.3‐8.3softened water should be used

Page 15 1/2

CDU IOM Rev1.0

Water Quality cont…

The CDU Primary Loop should be supplied with clean, particulate free water or glycol. Note

that increased glycol concentrations reduce CDU efficiency and cooling capacity. It is the

responsibility of the owner to ensure that the Primary Loop supply has less than 500 microns

of particulate.

TIP: The flow path for purging air is from the fill in CDU pump return pipe through the pump

and exchanger to the header supply and zone valves through the chilled door coil and back to

the header check valve inlet. Removing the quick connect hose at the header check valve and

purging into a suitable container will force the air out at the low point. Final purging is done

at the chilled door coil air vents and CDU auto vents.

The CDU Secondary Loop should be filled with clean, particulate‐free, softened water with

suitable corrosion inhibitors and biocides. Consult a water treatment service provider if you

need assistance.


The secondary loop should be filled slowly using a hose and transfer pump or suitable

municipal water supply at the drain and fill valve located on the suction inlet piping of the

CDU pumps. The Bottom feed CDU has auto vents at the high points to purge the air from

both the primary and secondary water loops. The auto vents are to be open during filling,

venting, and start‐up. The auto vent manual isolation valves should be closed following the

completion of the commissioning process. Top feed CDUs may be filled in the same manner,

but air venting and purging must be provided at the highest point of elevation in the building

piping system.

A CDU connected to a Motivair under floor distribution header and to Chilled Doors will

require venting at both the CDU per above and at the chilled door coil vent ports. (refer to

the Chilled Door Manual for installation and venting information). The under floor

distribution header contains manual isolation valves, actuator valves, and one way check

valves. These valves/circuits should be open and purged one at a time to ensure all air is

removed.

Fill & Vent Note: The flow path is stopped at the check valves on the header.

Filling and Venting

Warning: Do not use deionized water (DIW) in chilled door closed loop systems as

DIW is corrosive to certain metals.

The use of Propylene and Ethylene glycol mixtures and water treatment additives that are

compatible with the piping and wetted materials used in the coolant distribution system are

acceptable. A qualified water treatment contractor should be consulted for

recommendations and water analysis testing that meet your specific requirements.

Page 16

Section 5

CDU IOM Rev1.0

COMMISSIONING


7. Check secondary loop pressure gauges on CDU have a minimum pressure to start.

components, controls, valves, pipes, vents, auto bleeders and heat exchangers before beginning commissioning. Safety is no accident.

Commissioning

Pre‐commissioning checks

1. Visual inspection of unit to confirm all components and panels are in place.

2. Check all water piping to CDU and system are properly supported and insulated

3. Check primary loop water supply is open and within pressure limit of CDU.

4. Check all electrical connection's tightness and proper routing.

5. Check site electrical supply power matches nameplate voltage on CDU 6. Confirm the fuse or circuit breaker and wire size are correct for the unit

The CDU will alarm on low pressure below 5 psi operating pressure after 90 seconds 8. "Know the system". Take another look at the complete hydronic loop and all

2. Apply power to the CDU by closing the A/B disconnects on the front panel. The HMI

display will be visible in about 30 seconds and will display the main screen showing pump

pressures and "Off by Keyboard" message.

3. Check the display screen and note the pump supply and return static pressures. The initial

static charge should be between 15 ‐ 30 psi. Do not operate pumps "dry".

4. Navigate the PLC to command the unit “ON” via the user interface. (See controls section

for description and navigation of screens). Open the front door of the CDU and locate the

operating pump and check that rotation matches the directional arrow on pump. The CDU's

are factory wired and phased ABC for proper rotation. If rotation is reversed, stop unit, open

disconnects and correct phasing.

5. The Pumps will operate at a speed to maintain a differential pressure as per set point

(default = 25 psi). The auto vent air bleeders should remain open to remove any entrained

air in the system. The minimum pump return pressure operating at 60 hz is 10 psi. Add fluid

as necessary to maintain pressure.

1. If Motivair or one of its agents was not contracted for commissioning assistance, please

notify Motivair before commencing start up

6. Navigate to pump rotation screen, switch lead pump and continue above checks.

7. Navigate to the Temperature I/O screen and note the Primary and secondary loop temps.

The HXP In temp should be below 60°F and the HXS Out temp should be at set point (default

= 65°F). The "Main Outputs" screen will display the signal (0‐10v) output to the temperature

control actuator valve and the pump VFD. Check all HX temperatures are reading as

expected.

Page 17

Section 6

CDU IOM Rev1.0

1. The PLC set to "ON" and sensing the leaving secondary loop temperature, sends a 0‐10 volt

output signal to the motorized actuator valve on the inlet building supply. The valve

modulates to maintain secondary loop temperature to the Chilled Doors at set point.

2. The PLC set to "ON" and monitoring the lead pump supply and return pressure differential

sends a 0‐10 volt output signal to the VFD to maintain secondary loop flow volume at set

point per the current system demand.

3. Secondary loop pump pressures and outlet temperature are displayed on the HMI home

screen.

4. Entering & leaving primary & secondary loop temperatures are displayed on the

Temperature I/O screen.

5. Chilled doors (CDU heat load) are fitted with their own load‐based modulating control

valves. Therefore secondary pump pressure will vary based on the number of Chilled Doors

in service and/or the actual heat load applied to the Chilled Doors. Secondary pump pressure

is monitored by a pressure transducer in the pump discharge header and constant design

pump pressure is maintained by the VFD connected to the operating pump.

6. Triple duty valves on the discharge of each pump provide:

A. Final adjustment of operating pump head pressure, if needed, to balance pumps on full

load to design head pressure.

B. Check valve to prevent backflow for automatic pump changeover.

C. Isolation of pump for removal.

Description/Sequence of Operation

Commissioning Cont.

8. Following a suitable period of time to be sure all air has been removed from the closed

loops, close the auto vent safety caps and valves to prevent accidental leaks.

10. Record all measurements and readings and complete the "Start up Report" located in

the documents section of this manual.

9. The Optional leak detection system sensor should be located in the lowest appropriate

area (floor level or under floor) to detect moisture present. Make sure water detection LED

(green) is lit on WDS module, test alarm with water on sensor.


OPERATION

Page 18

CDU IOM Rev1.0

Description/Sequence of Operation cont.

7. Closed diaphragm expansion tank allows for hydraulic expansion of water in closed loop

during temperature changes that may occur between filling time, operation and shut‐down.

8. The relative humidity sensor monitors data center humidity to ensure secondary water

loop temperature remains above the dew point. This is necessary to prevent condensation

on the coils inside the Chilled doors. In the event the data center humidity reaches a dew

point within 3°F of the leaving secondary water loop temperature, the dew point warning is

activated and the PLC throttles the primary water control valve to reduce the cooling effect

on the secondary loop. The CDU will automatically adjust outlet secondary water

temperature to stay 3°F above room dew point.

9. Check communication of all selected PLC points to master control or BMS via BacNet, LON

or Modbus.

10. CDU is set‐up to accept A/B power supply check/test switch over (if option is connected)

by opening A disconnect switch.


Page 19

“Alarm “ – press to view current alarm & clear alarms

“Program” – press to enter the programming menu screen

“Escape” – press to go back one screen or one space

“Down arrow” – press to scroll down or lower a setting

“Up arrow” – press to scroll up or raise a setting

CDU IOM Rev1.0

The above Display is the main screen or “Home Screen” it displays the controlled points and

the state of the PLC i.e. "Unit off By Keyboard"

HMI Screen Navigation

The Human Machine Interface (HMI) is a 6 button Remote panel mount display screen The 6

button functions on left and right sides as follows:

The HMI screens are a scrolling menu style the up and down arrows will scroll through all

available screens in a sub menu, i.e. press alarm, and scroll through all active alarms.

“Enter” – press to navigate to changeable parameters and confirm/save changes

PLC control HMI introduction


Page 20

CDU IOM Rev1.0


The home screen is displayed when you

press the ESC key or after a few minutes

of inactivity. The home screen displays

the temperature reading of the CDU. The

"I" Icon for information is a reminder to

scroll down for additional info screens.

Pressing the DOWN ARROW key will

scroll to the next information screen.

First is the Temperature I/O display

showing the actual reading of each input

and is used for monitoring and alarm

functions.

The next info screen shown by pressing

the DOWN ARROW key contains the

actual outputs to the VFD and the chilled

water valve. Also the power source for

dual power feed option and an hour

count down timer to next pump

rotation.

The next Info screen is for configuration

of the pump rotation, and allows for

manual switching and rotation by hours

or a specific day and time each week for

predictable change times. Also shown is

the current operating lead pump.

The last Info screen in this menu series is

the pump hours, counters, and reset of

counter function.


Page 21

CDU IOM Rev1.0

Highlight “Client Settings” press ENTER

for “User Password “ screen. Press

ENTER to highlight the first digit and use

the UP ARROW to enter the PW (Default

PW=1234).

Press ENTER to move to the second digit

to insert “2‐3‐4”. Press ENTER etc…


Press the "PRG" key for access to the

programming menu. The programming

menu contains three sub menus as

shown. Use the UP & DOWN ARROW

keys to highlight your selection then

press the ENTER key to confirm your

selection.

Pressing the ENTER key enters the

“On/Off Unit” screen as shown. Press

ENTER key to highlight “SWITCH OFF”

then press the UP or DOWN ARROW key

to change to “SWITCH ON”. Press ENTER

key to confirm your selection. The CDU

is now On.

On "Main Menu" (above) Highlight

“Manufacturer setup” press ENTER for

“Manufacturer Password “ screen. Press

ENTER to highlight the PW number 0000 ‐

Contact Motivair for password to this

area of the menu.


Client Settings Screen

The following Client setup screens are provided to allow the client/end‐user to make

adjustments and changes to the default settings if necessary to facilitate an operating

parameter or site specific condition. Set points for loop temp and differential pump pressure

and all alarm thresholds are available on the following screens.

Page 22

CDU IOM Rev1.0


Client Setup The Set‐point/alarm setting screens are

accessed with the UP/DOWN ARROW

keys. The first screen (shown) is the

pump set‐point screen. Press ENTER to

highlight the parameter to change and

use the UP/DOWN ARROW to change

setting then press ENTER to confirm

change.

The HXS outlet temperature set point is

a PID loop setup (default). The set point

and other parameters can be adjusted

on this screen. The Regulation type can

also be changed form PID to P

(Proportional only) if desired. (Factory

defaults shown)

The next set of screens are ALARM

setup. The High HXS out temp alarm is a

differential setting from set point i.e. the

set point (above) of 65°F + the ° above

setpt 10°F = 75°F alarm point temp

delayed 60 sec. The Low HXS alarm °

below setpt ‐ 10°F = 55°F

The High HXP (Primary HX) Inlet

temperature alarm set point of 65°F

(default) may need to be adjusted per

your site requirements and actual

secondary loop set point and design

conditions.

The water detection system (WDS) alarm

setup is a On/Off parameter to enable

the alarm function or not and to choose

the action the pump should take upon

an alarm condition. Both are defaulted

to "Yes".

Page 23

CDU IOM Rev1.0


Client Setup

The Supervisor settings setup is a safety

layer screen to prevent accidental

On/Off by a BMS system or the digital

I/O contacts. To use these functions they

must be set to "Yes".

The BMS set‐up is to select your protocol

BacNet ‐ Modbus ‐ Lon based on your

selected communication option. The

Baud rate is fixed based on protocol

selected. The BMS address is for Modbus

only.

Also in client settings are the probe

calibration screens for service.

The probe calibration screens are for

adding an offset to exact a probe reading

max offset is 9.9°F.

Date and time input screen is to set the

current date and time to display on the

"Home screen" and history logs. Note:

This screen is not a clock screen. Only a

set up page and will not display the

correct time or date.

Page 24

CDU IOM Rev1.0

The Manufacturer setup area of the

menu is password protected and should

only be accessed with Motivair

permission. All parameters in this section

are preset per the specified CDU and

should rarely need change. The first

screen shows the program version.

Setup screen for background options

installed and enabled.


Manufacturer Setup

Unit of Measure change over to degrees

Celsius screen.

Factory default Pump flow alarm time

delays are set in this screen.

Factory default parameter reboot screen

to reboot the PLC to factory default

conditions.

Page 25

CDU IOM Rev1.0


Alarms and warning

The "ALARM" warning screen appears

when any alarm is triggered. This screen

along with a buzzer is to alert of an

alarm condition.

Pressing the "bell" alarm key 1 time will

silence the alarm buzzer and display the

current alarm. Pressing the alarm button

a second time will acknowledge and

clear the alarm if the condition has

cleared.

Following the acknowledgement of the

alarm (2nd press), the "No active alarms"

screen will appear and direct you to the

alarm history log. If the alarm condition

has not been cleared (i.e. overload not

reset) the alarm screen will re‐trigger

another alarm.

Press "Enter" while on the above screen

to enter the alarm log area. The alarm

log entry is recorded at every alarm and

will store each alarm. The log records the

alarm number sequence 001, 2, 3…,

Time, date, and the alarm description.

Alarms and warnings are to signal a problem or issue with the CDU or the system the CDU is

connected refer to the Troubleshooting section for information on alarm causes and system

checks

Page 26

Section 7

CDU IOM Rev1.0

Display active ‐ press alarm key &

read alarmSee "troubleshooting alarms"

Alarm high HXS Out

temp

Secondary HX outlet

temp exceeded set

point by amount = to

"High HXS out temp"

diff alarm set point ‐

default 10°F (Example

65°F + 10°F = 75°F)

{3} Check pump pressures and flow both primary and

secondary loops

TROUBLESHOOTING

No display ‐ No power

TROUBLESHOOTING ‐ Alarms

Current alarm

conditionAlarm trigger event Check/Corrective action

WDS alarm (water

detection sensor)

Water on sensor or

open sensor circuit

{1} Check for leak or wet sensor strip.

{2} check for open circuit wire or end resistor.

Clock board alarm Failed clock board

{1} Check building power supply and CDU disconnects are ON

No display ‐ with power

{1} Check display network cable is plugged in at PLC and HMI

{2} Check Fuses F1, F2, F3, F4, F7, F8,

{3} Check transformer for 24v secondary voltage

Check/Corrective action

CDU Pumps not operating {1} Unit "Off by keyboard" Switch unit "On"


TROUBLESHOOTING ‐ General

High Voltage Warning:

Serious injury or death could result from High voltage present in this equipment.

Disconnect (open) all electrical safety switches and disconnects before attempting to open,

troubleshoot, test or repair any components in this unit .

Troubleshooting of electrical/mechanical equipment must be performed only by qualified and

trained service technicians. Factory technical support is available please refer to "support"

section of this manual.

TROUBLESHOOTING ‐ Non Alarms

Problem

Replace PLC

{1} Check primary HXP inlet temp is below 55°F

{2} Check cooling valve actuator is open (10vdc signal to

actuator)

Page 27

{2} Building chilled water pump/flow stopped

{3} Primary 2 way valve closed for extended time

CDU IOM Rev1.0

Alarm high HXP In

temp

Heat exchanger primary

inlet water temperature

exceeded High HXP

alarm set point ‐ Default

65°F

Alarm VFD A Alarm originating in

VFD and opening

alarm contacts.

{1} Check VFD screen alarm code or history

Alarm VFD B

{3} Check probe B3 calibration/accuracy

Alarm low HXS out

temp

Secondary HX outlet

temp below set point by

amount = to "Low HXS

out temp" diff alarm set

point ‐ default 10°F

(Example 65°F ‐ 10°F =

55°F)

Pump 1 or 2 overload The VFD alarm was

triggered

{1} Same as VFD alarm

triggered at the same time.

{2} Check for failed open actuator/cooling valve

B6 Probe HXP InAll probe alarms are

triggered by a failed

or disconnected

probe (electrically

open or shorted).

B7 Probe Rm DB

B3 Probe HXS Out {1} Check probe connection to PLC connector

B4 probe HXS in

{2} Follow up with VFD trouble shooting manual


Pressure differential

across pump dropped

50 % below set point

and exceeded time

delay of 10 sec during

running mode

{1} Check VFD screen for power/display or alarm

Low flow Pump B

Alarm

{1} Check valve minimum position setting at 0% (default

= 0%)

{3} If none of above remedy issue replace PLC

{1} Check for loss of pressure/leak/air in system Alarm Low Suction

Pressure

Suction pressure fell

below alarm set point 5

psi for 90 sec {2} Check closed suction isolation valve.

(2) Check pump/VFD overload switch

{3} Check pumps rotation direction and operation

{4} Check for loop flow blockage/all valves closed

{5} Check for loss of pressure/leak/air in system

High Dew Point Temp

warning

{1} Building primary chilled water supply too warm

Current alarm

conditionAlarm trigger event

TROUBLESHOOTING ‐ Alarms

Check/Corrective action

Room dew point has

increased to within 2°F

of set point

{1} Set point will be reset + 3°F above dew point

{2} Lower room Humidity levels ‐ vapor barrier

Low Flow Pump A

Alarm

{2} Replace Probe

B5 probe HXP out

B8 probe Rm RH %

B1 Pressure Probe

alarmPressure transducer

failed out of range or

disconnected

{1} check probe connection to PLC connector and

connection at the transducer

B2 Pressure Probe

alarm

{2} Replace Probe with known good transducer

Page 28

Section 8

1. Visual inspection of all piping and components for leaks.2. Visual inspection of all components for integrity. 3. Check and tighten all electrical connections.4. Check auto vents stop valves are closed.

5. Check latches and hinges lubricate as necessary.6. Check floor levelers are down and secure.7. Check and record any alarm history since last maintenance.8. Check all set points and record.9. Check all temperature probes and calibrate as necessary.10. Check all pressure transducers and calibrate as necessary.11. Check system pressures and record.12. Check pump rotation settings and hour counters for even run times.13. Check PLC clock time and date are correct, adjust if necessary and record.14. Check WDS sensor location and integrity.15. Check actuator valve stem is tight and aligned.16. Check VFD parameters and alarm log record any alarms. 17. Check for dual power feed. If present test failover relay. 18. Obtain both loop water samples and lab test (once per year).19. Manual switch pumps and check same.20. Wipe clean all surfaces and close all panels.

CDU IOM Rev1.0

MAINTENANCE

If underfloor distribution header option is present this should also be inspected during the

CDU maintenance service visit.

A copy of all maintenance check lists and documentation should be left on site with the

owner.

Other site specific maintenance may be required which is outside the scope of this manual,

be sure to consult with the proper personnel.


Bi‐annual scheduled maintenance

The scheduled maintenance recommended is two times per year and should include the

following checks as a minimum.

Scheduled Maintenance

The CDU should be inspected and maintained at regular intervals to provide reliable long

term operation.

Service and maintenance of electrical/mechanical equipment must be performed only by

qualified and properly trained service technicians.

Page 29

Section 9

2. Valve Actuator

3. Air Vent

4. Expansion Tank

5. Pressure Gauge

5. Triple Duty Valve

6. Suction Diffuser

7. Pump

8. (12) 2.5" Gasket

9. Leveling Caster

CDU IOM Rev1.0

SPARE PARTS


10. Door Handle &

Latch assy

Recommended spare parts are based on an individual site tolerance for down time,

geographic location and site access requirements. Most of the CDU components are

redundant.

The following list of spare parts and recommended quantities is a minimum for any

application. This is not a complete list of all parts used or required. Please contact your local

distributor or Motivair for a full list of your model's spare parts and pricing.

Spare Parts

1. Heat Exchanger

Page 30

1 1 PLC - PCO3 - Medium Board1 PGD1 - HMI Remote Display1 WDS Leak Detection Control Module1 Main Pump 7.5hp, 3/60/230/460v,1 1 Belimo Actuator for Control Valve1 WDS Dew Point Sensor (wall remote mount)2 1 SPK. 316L Transducer,100 Psi1 SPKC00 - Transducer 6.5 Feet Cable4 2 Temperature Probe1 CM009107 - Water Detection Sensor Ribbon Kit1 Disconnect 25A Non fused1 Overload Motor Protector 6.3-10A1 1 Phase Monitor Relay1 150VA Transformer 460-120-244 4 1.5A CC Fuse2 2 1A Midget Fuse2 2 5A Midget Fuse1 460V 7.5HP Variable Speed Drive (VFD)1 Cabinet Cooling Fan

CDU IOM Rev1.0

Item DescriptionTotal Used

Qty Recommend

ed


Spare Parts

Page 31

Section 10

CDU IOM Rev1.0


DOCUMENTS & TABLES

Page 32

CDU IOM Rev1.0


Page 33

CDU IOM Rev1.0


Page 34

CDU IOM Rev1.0


Electrical Schematics

Page 35

CDU IOM Rev1.0



Page 36

CDU IOM Rev1.0



Page 37

Section 11

CDU IOM Rev1.0


SUPPORT & WARRANTY

Support <> Contact <> Warranty Information

Factory Service & Support:

www.motivaircorp.com

Additional information on this product may be found at

www.chilleddoor.com

Motivair Corporation

85 Woodridge Drive

Amherst, New York, 14228

716‐691‐9222 Phone

716‐691‐9229 Fax

Parts <> Service <> Technical support Email

www.motivaircorp.supportsystem.com also available through our web site link at

www.motivaircorp.com/service‐support

https://motivaircorp.supportsystem.com/account.php?do=create to create an account.

Once an account is created you can create support tickets from your email account using

[email protected]

A service support portal is available at the following link

Visit the Motivair service portal at

WARRANTY: This product carries a 1‐year Parts Only Warranty. A copy of this warranty is

shipped with your Cooling Distribution Unit. An additional copy of your warranty can be

obtained by contacting Motivair at the address listed on this document. The manufacturer

shall not be liable for any damages resulting from the misapplication or misuse of its

products. THIS EXPRESS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES, EXPRESS,

OR IMPLIED, OR STATUTORY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY

AND FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE HEREBY EXCLUDED. MOTIVAIR SHALL

NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSSES FROM

ANY CAUSE WHATSOEVER, INCLUDING, WITHOUT LIMITATION, LOSS OF USE, COMMERCIAL

PROFITS, OR CUSTOMER GOODWILL, AND ANY OTHER CLAIMS BASED ON CONTRACT OR

TORT, WHETHER OR NOT ARISING FROM MOTIVAIR’S NEGLIGENCE.

Page 38

Section 12

CDU IOM Rev1.0


APPENDIX

NOTES:

Page 39

CDU IOM Rev1.0

To insure long term reliability and operation of the sealing components of the Motivair CDU

and coolant loop distribution components clean water with a low to no suspended solids level

is required for closed loop systems.

Suspended Particles can damage O‐rings, mechanical pump seals and cartridge valve seals

and operation. Excessive suspended solids will leave deposits in system piping, including

critical sealing and heat transfer surfaces. The following recommendations are a minimum for

and closed loop distribution system utilizing the Motivair Chilled door, CDU or header

distribution system.



Good installation practice must include Initial system flushing


before connecting to any Motivair equipment. Motivair supplied ChilledDoor®, CDU's,



Minimum Water Quality Standard for Motivair Equipment

A water treatment professional should be consulted regarding the testing and proper

chemical treatment for a closed loop system’s composition and fluid requirements. Proper

levels of all loop and makeup water must be maintained per industry standards and best

practices. Proper levels of pH, Alkalinity, Chlorides, Nitrite, and Conductivity, along with other

chemicals and metals in the system must be tested for and monitored. A treatment program

should be implemented at the time of initial system commissioning to provide long term

system reliability. This testing is outside this documents scope.

Water testing and filtration must employed to ensure a system is filtered to <50 microns

(High limit of a closed loop system per industry standards) The recommendation by Motivair

is to utilize a 5 micron or less bag/cartage type filter in the closed loop or other suitable

method of removing suspended solids to a minimum 5 microns or less. Iron levels less than

<2.0 ppm ‐ Copper levels less than <0.1 ppm ‐ Suspended solids <1 mg/L.

The following table is a guide

for initial fill water for all

closed loop system using

Motivair Chilled Doors and

components. Potable water is

a good source and starting

point for initial filling.

Motivair Water Quality

Mineral Recommended Limit

Chloride < 25 ppm

Calcium < 15 ppm

Magnesium < 15 ppm

Total Water Hardness <30 ppm

Sulfate < 25 ppmpH 7.3‐8.3softened water should be used

Page 40

Motivair CDU Start‐up Report

DATE:

NAME

NAME COMPANY

SITE NAME

CONTRACTOR REP

CONTRACTOR CONTACT INFO

SERIAL No.

CDU'S ON SITE No.

SITE ADDRESS

SITE INFORMATION

JOB W/O No.

MODEL No.

OWNER/REP NAME

ADDRESS

CITY, STATE & ZIP

SITE CONTACT INFO

OFFICE PHONE

COMPANY NAME

ADDRESS

CITY, STATE & ZIP

OFFICE PHONE

CELL PHONE

EMAIL

INSTALLING CONTRACTOR

CELL PHONE

EMAIL

OTHER SITE CONTACTS

PHONE#

ENGINEERS

COMMISSIONING AGENT

CONTROLS CONTRACTOR

START‐UP TECHNICIAN

START‐UP TECHNICIAN


CDU LOCATION

DEW POINT SENSOR LOCATION RELATIVE OR DISABLED

SERVICE ACCESS OK IF NO DESCRIBE:

PIPING COMPLETE Check all if complete

FILLED, AIR BLED, & READY TO START Notes:

PROBES AND WDS SENSOR INSTALLED

ISOLATION VALVES AT INLET & OUTLET OF CDU

AUTO BLEEDERS CLOSED BEFORE LEAVING SITE

HEADER ASSEMBLY OPTION INSTALLED

CHECK CALIBRATION ALL PRESSURE TRANSDUCERS

CHECK CALIBRATION ALL TEMPERATURE PROBES

ELECTRICAL CONNECTIONS CHECKED

VFD PARAMETERS CHECKED AND SET

VISIBLE LEAK CHECK

FIELD POWER WIRING COMPLETE

PLC CONTROLLER PARAMETERS CHECKED

Type

IF "NO" CUSTOMER APPROVAL IS REQUIRED

(water, PG, EG, other)

GLYCOL % %

GLYCOL SPECTROMETER TEST °F

static Psig Outlet Psig

AMBIENT TEMPERATURE °F VOLTAGE READING V

CONTROL VOLTAGE V CDU AMPS TOTAL A

PUMP 1 CURRENT A 60 Hz PUMP 2 CURRENT A 60 Hz

PUMP DIFFERENTIAL SET POINT PSI PUMP SUPPLY PRESSURE PSI

PSI PUMP RETURN PRESSURE PSI

SEC PUMP DIFFERENTIAL PSI

WATER TEMP OUT SET POINT F HXS OUT TEMP F

WATER CONTROL BAND F HXS IN TEMP F

SEC HXP IN TEMP F

RH% HXP OUT TEMP F

Notes:

OWNER TRAINING COMPLETE & DOCUMENTED

VISUAL DAMAGE TO UNIT IF YES COMPLETE DAMAGE REPORTDOOR INSTALLATION

SITE INSTALLATION

PUMP PRESSURES

TRIPLE DUTY VALVE OPEN 100%

CLOCK SET AND ALARM LOG CLEARED

Run @ 60 Hz: Inlet

STOP PUMPS ON WDS ALARM ENABLED

DOOR KEYS ONSITE

UNIT LEFT RUNNING

FINAL INSPECTION

O & M MANUAL 0N SITE

COMMUNICATIONS CARD INSTALLED

WATER TIME BAND

ROOM RH%

PUMP TIME BAND

PUMP CONTROL BAND

START‐UP INFO

SITE SETUP AND OPERATING INFO

FLUID INFO

TYPE OF FLUID IN SYSTEM

START‐UP AND COMMISSIONING COMPLETE


DATE:

OWNER OR OWNERS REP NAME

OWNER OR OWNERS REP SIGNATURE

DATE

COMMISSIONING AGENT NAME

COMMISSIONING AGENT SIGNATURE

DATE

START‐UP TECHNICIANS NAME

START‐UP TECHNICIANS SIGNATURE

DATE

SITE ADDRESS

SITE NAME

START‐UP AND COMMISSIONING ACCEPTANCE

SITE INFORMATION

JOB W/O No.

MODEL No.

SERIAL No.

No. UNITS ON SITE

ADDRESS

CITY, STATE & ZIP

ACCEPTANCE

Documents

Motivair · The CDU is heavy and requires an opening in a raised floor for piping egress DO NOT CUT raised floor cross supports or remove stanchions around CDU for this opening, consult