HP (Hewlett-Packard) 403349-003 manual

HP Modular C ooling S y st em Maint enance and Se r v i ce Guide Part Number 403349-003 October 2008 (Third Edition)[...]

© Copyright 2006, 2008 Hewlett- Packard Development Company, L.P. The information contained herein is subject to chan ge without no tice. The only warranties for HP products and services ar e set forth in the express warranty statements accompanying such produc ts and services. Noth ing herein should be construed as constituting an a dditional w a[...]

Contents 3 Con t en t s Customer se lf re pair ...................................................................................................................... 6 Parts only warr anty service .................................................................................................... ..................... 6 Illustrated pa rts cata log [...]

Contents 4 Replacing the heat exchanger unit with couplers ................................................................................ 63 Heat exchanger unit (H EX) with ba ll valve ...................................................................................... ............ 67 Removing the heat exchanger unit with ba ll valves .........[...]

Contents 5 Water qu ality.................................................................................................................. ............ 139 Condensation manage ment ........................................................................................................ .. 139 Frost dam age ..........................................[...]

Customer self repair 6 C us tomer se lf r epair HP products are designed with many Customer Self Repair (CSR) parts to minimi ze repair time and allow for greater flexibility in performing def ective parts re placement. If during the di agnosis period HP (or HP service providers or service partners) iden tifies that the repair can be accomplished b[...]

Customer self repair 7 • Obligatoire - Pièces pour lesquelles la réparation par le client est obligatoire. Si vous demandez à HP de remplacer ces pièces, les coûts de déplac ement et main d'œuvre du service vous seront facturés. • Facultatif - Pièces pour lesquelles la réparation par le client est facultative. Ces pièces sont é[...]

Customer self repair 8 NOTA: alcuni componenti HP non sono progettati per la ri parazione da parte del cl iente. Pe r rispettare la garanzia, HP richiede che queste parti siano sostituite da un c entro di assistenza autorizzato. Tali parti sono identificate da un "No" nel Ca talogo illustrato dei componenti. In base alla disponibilità e [...]

Customer self repair 9 anrufen und sich von einem Mitarbeiter per Telefon helfen lassen. Den Materiali en, die mit einem CSR- Ersatzteil geliefert werden, könn en Sie entnehmen, ob das defekte Teil an HP zurückgeschickt werden muss. Wenn es erforderlich ist, das defe kte Teil an HP zurückzuschicken, müssen Sie dies inn erhalb eines vorgegebenen[...]

Customer self repair 10 Centro de asistencia técnica de HP y reci birá ayu da telefónica por parte de un técnico. Con el envío de materiales para la sustitución de componente s CSR, HP especificará si los comp onentes defectuosos deberán devolverse a HP. En aquellos casos en los que sea necesario devolver algún componente a HP, deberá hac[...]

Customer self repair 11 periode, gewoonlijk vijf (5) werkdagen, retourne ren aan HP. Het defecte onderdeel moet met de bijbehorende documentatie worden geretourneerd in het meeg eleverde verpakkingsmateriaal. Als u het defecte onderdeel niet t erugzendt, kan HP u voor het vervangende onderdeel kosten in rekeni ng brengen. Bij reparatie door de klan[...]

Customer self repair 12 Se r v iço de gar anti a ap enas par a peça s A garantia limitada da HP pode incluir um serviço de garantia apenas para peças. Segundo os termos do serviço de garantia apenas para peças, a HP fo rnece as peças de reposição sem cobrar nenhuma taxa. No caso desse serviço, a substituição de peças CSR é obrigatóri[...]

Customer self repair 13[...]

Customer self repair 14[...]

Customer self repair 15[...]

Customer self repair 16[...]

Illustrated parts catalog 17 Illus tr ated parts catalog Replaceable spare parts The replaceable spare parts for the HP Modular Coo ling System are listed in the following table. Item Description Spare part number Customer self repair 1 SPS–DISPLAY, OPERATOR (" Operator display " on page 88 ) 395774-001 Optiona l 2 2 SPS–HEAT EXCHANGE[...]

Illustrated parts catalog 18 Item Description Spare part number Customer self repair 4 SPS–TRANSFER SWITCH (" AC transfer switch " on page 26 ) 395773-001 Optiona l 2 5 SPS–CONTROLLER, WATER (" Water group controller " on page 97 ) 395771-001 Optiona l 2 6 SPS–SOLENOID, MAGNETIC VALVE (" Magnetic solenoid valve "[...]

Illustrated parts catalog 19 1 Mandatory: Obbligatorie—Parti che devono essere necessariam ente riparate dal cliente. Se il cliente ne affida la riparazione ad HP, deve sostenere le spese di spedi zione e di manodopera per il servizio. 2 Optional: Opzionali—Parti la cui riparazione da parte d el cl iente è facoltativa. Si tratta comunque di co[...]

Illustrated parts catalog 20 Flow meter repair There are two different flow meter types, depending on your MCS mode l. You shou ld be able to discern which type you have, based on the label on the rear door of your MCS unit.[...]

Illustrated parts catalog 21 The Type 1 flow meter has a round body, and is no longer used in current MCS models. The Type 2 flow meter has a square body an d ships installed in all current MCS m odels. There are two scenarios wh en repairing your flow meter: • You currently have a Type 1 flow meter that you wi ll remove and replace with a Type 2[...]

Removal and replacement procedures 22 R emo v al and r eplacement pr ocedur es Removal and replacement procedure overview This section provides guida nce for removing and re placing the HP Modular Cooling System (MCS) spare parts. Follow the instructions care fully to ensure proper installation of the n ew spare part. IMPORTANT: As you are removing[...]

Removal and replacement procedures 23 o T-25 Torx driver o Wire cutters • Condensation pump and sensors o T-25 Torx driver o Phillips screwdriver • Fan unit o T-25 Torx driver • Flow meter paddle-wheel sensor o T-25 Torx driver o Wire cutters o Water hose fitting wrench (include d with your original MCS unit) o Counter hold wrench (in cluded [...]

Removal and replacement procedures 24 o 5-mm Allen wrench • Water temperature sensor o T-25 Torx driver o Phillips screwdriver o (2) 18-mm wrench o Wire cutters Safety considerations Before performing service proced ures, review the following safety i nformation. Rack warnings and cautions Before installing a spare kit, be sure that yo u understa[...]

Removal and replacement procedures 25 WARNING: To reduce the risk of electr ic shock or damage to the equipment: • Do not disable the power cord grounding plug. The grounding plug is an important safety feature. • Plug the power cord into a grounded (earthed) ele c tric al outlet that is easily accessible at all times. • Unplug the power cord[...]

Removal and replacement procedures 26 2. Confirm that no water is flowing into the MCS unit. AC transfer switch The AC transfer switch is located at the bottom front of the MCS unit. The following tools are required for in stallation: • T-25 Torx driver • Small Flathead screwdriver Removing the AC transfer switch 1. Power down the MCS unit (&qu[...]

Removal and replacement procedures 27 4. Using a T-25 Torx driver, remove the four Torx scre ws securin g the AC transfer switch chassis to the water group controller chassis. The transf er switch chassis cannot be completely removed yet because the cables are still connect ed. 5. Disconnect the green and yellow ground bond ing wires from the wat e[...]

Removal and replacement procedures 28 a. Disconnect the three large cables, starting from the left and moving to the right, by inserting a small flathead screwdriver in between the cable connection and the latch, and pulling the cable out from the connector. b. Disconnect the three small cables, starting from th e left and moving to the right, by p[...]

Removal and replacement procedures 29 2. Connect the electrical powe r cables from the MCS unit to the AC transfer switch. a. Connect the three small ca bles, starting from the ri ght and moving to the left, by pressing the tab on the bottom of each cable and pushing it into the connector.[...]

Removal and replacement procedures 30 b. Connect the three large ca bles, starting from the right and moving to the left, by pushing the cable into the connector. 3. Using a T-25 Torx driver, secure the AC transfer switch chassis to the water gro up controller chassis by inserting four Torx screws. CAUTION: To prevent damage to the cables and ensur[...]

Removal and replacement procedures 31 4. Slide the metal AC transfer switch box b ack into the MCS unit on the sliding rail s. 5. Complete the operation checkl ist (on page 111 ). Air bleeder valve The air bleeder valve is located inside the MCS unit, center ed at the top of the unit. The following tools are required for in stallation: • T-25 Tor[...]

Removal and replacement procedures 32 4. Reach into the access panel cut-out. 5. Using a pair of pliers, unscrew the air bleeder valve from the che ck valve. 6. Remove the air bleeder valve from the MCS unit. To replace this component, see "Repla cing the air bleeder valve (on page 32 )." Replacing the air bleeder valve 1. Reach into the [...]

Removal and replacement procedures 33 3. Slightly open the top vent of the air bleeder va lve, approximately 3/4 turn, to allow for air flow. 4. Replace the top heat exchanger unit. (" Replacing the heat exchanger unit with couplers " on page 63 ) 5. Replace the top fan unit. (" Replacing the fan unit " on page 52 ) 6. Restore w[...]

Removal and replacement procedures 34 3. Lift the air deflector plate up, tilt it to an angle, and pull it out toward you. To replace this component, see "Repla cing the air deflector plate (on page 34 )." Replacing the air deflector plate 1. Reattach the ground bonding wire s to the air deflector plate. 2. Align the two screw holes on th[...]

Removal and replacement procedures 35 No tools are required for this procedure. Removing the air sealing plate 1. Disconnect the condensation hose from the condensa tion pump by pressing in the plastic collar quick connect on the condensation pump. 2. Loosen the two thumbscrew s securing the air sealing plate to the MCS unit.[...]

Removal and replacement procedures 36 3. Slide the air sealing plate out of the MCS unit. To replace this component, see "Repla cing the air sealing plate (on page 36 )." Replacing the air sealing plate 1. Slide the air sealing plate into the MCS unit.[...]

Removal and replacement procedures 37 2. Secure the air sealing plate to the MCS un it by tightening the two thumbscrews. 3. Connect the condensation hose to the condensation pump by inserting it into the plastic collar quick connect on the condensation pump.[...]

Removal and replacement procedures 38 Automatic door release The automatic door release kits are locat ed on the fr ont and rear doors of the rack attached to the MCS unit. The following tools are required for in stallation: • 3-mm Allen wrench • T-25 Torx driver • Wire cutters Removing the front automatic door release 1. Unplug the electroma[...]

Removal and replacement procedures 39 2. Using an Allen wrench, remove the two black cap sc rews securing the electr omagnetic lock to the electromagnetic lo ck bracket. 3. Remove the electromagnet ic lock and cable from the rack. To replace this component, see "Repla cing the front automatic door release (on page 39 )." Replacing the fro[...]

Removal and replacement procedures 40 3. Route the magnetic lo ck cable down through front extension channel, across the front of the rack, and plug it into the panel connector on the MCS unit.[...]

Removal and replacement procedures 41 Removing the rear automatic door release 1. Unplug the top and bottom electromagnetic lock cables from the extension lock ca ble. NOTE: Be sure to note the location of the el ectromagnetic brackets prior to removal.[...]

Removal and replacement procedures 42 2. Using a T-25 Torx driver, remove the four screws securing the upper and lower electromagnetic lock brackets to the rack chassis. 3. Using an Allen wrench, remove the two black cap sc rews securing each electrom agnetic lock to its electromagnetic lo ck bracket. 4. Remove the electromagnet ic locks and cables[...]

Removal and replacement procedures 43 2. Using an Allen wrench, insert and tighten two black cap screws to secure ea ch electromagneti c lock to its electromagnetic lock bracket. 3. Install the top electromagnetic lock bracket to th e rack chassis in the location you noted durin g removal. a. Align the electromagnetic lock assembly to the rack cha [...]

Removal and replacement procedures 44 5. Route the magnetic lock cable through the rear extension channel, across the rack , and plug it into the panel connector on the MCS unit. Bottom fan unit The removal and replacement instructions for the botto m fan unit are provided so that you can access other components. If you are replacin g the fan unit,[...]

Removal and replacement procedures 45 3. Loosen the two thumbscrews on the bottom of the fan unit. CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when rem oving and replacing the top fan unit because it might be higher than your shoulders and is heavy and awkward to lift. 4. Pull the fan unit out toward you, and remove it from the [...]

Removal and replacement procedures 46 2. Slide the bottom fan unit inside the MCS unit on the sl iding rails. 3. Tighten the two thumbscrew s to secure the fan unit to the MCS frame.[...]

Removal and replacement procedures 47 4. Using a T-25 Torx driver, secure the horizontal sh ipping bracket to the MCS unit by inserting four Torx screws. Condensation pump and sensors The condensation pump and sensors are components of the water group located at the bottom interior of the MCS unit. The following tools are required for in stallation[...]

Removal and replacement procedures 48 5. Disconnect the AC power cable from the conden sation pump. 6. Disconnect the two sensor connecti ons fr om the condensation pump.[...]

Removal and replacement procedures 49 7. Loosen the thumbscrew on t he bottom of the condensation pump secu ring the condensation pump to the MCS unit (1), and lift the condensation pump from the MCS unit (2). To replace the component, see "Replacing the conde nsation pump and sensors (on page 49 )." Replacing the condensation pump and se[...]

Removal and replacement procedures 50 2. Connect the two sensor connectors to the conden sation pump. 3. Connect the AC power ca ble to the condensation pump. 4. Replace the air sealing plate (" Replacing the air sealing plate " on page 36 ). 5. Relocate the power inlet box back into position (" Relocating the power inlet box back in[...]

Removal and replacement procedures 51 You can replace the fan units during operation. The following tools are required for in stallation: • T-25 Torx driver Removing the fan unit 1. Open the rear MCS door. NOTE: The number of horizontal brackets varies de pending on the position of the fan unit (top, middle, or bottom). 2. Using a T-25 Torx drive[...]

Removal and replacement procedures 52 3. Loosen the two thumbscrews on the bottom of the fan unit. CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when rem oving and replacing the top fan unit because it might be higher than your shoulders and is heavy and awkward to lift. 4. Pull the fan unit out toward you, and remove it from the [...]

Removal and replacement procedures 53 2. Slide the fan unit onto the sliding rails inside the MCS unit. 3. Tighten the two thumbscrew s to secure the fan unit to the MCS frame. NOTE: The number of horizontal brackets varies de pending on the position of the fan unit (top, middle, or bottom).[...]

Removal and replacement procedures 54 4. Using a T-25 Torx driver, secure the horizontal sh ipping bracket to the MCS unit by inserting four Torx screws. 5. Complete the operation checkl ist (on page 111 ). Flow meter sensor The flow meter sensor is a component of the water gr oup located at the bottom interior of the MCS unit. The following tools [...]

Removal and replacement procedures 55 4. Relocate the power inle t box. (" Relocating the power inlet box " on page 93 ) 5. Remove the air sealing plate. (" Removing the air sealing plate " on page 35 ) 6. Remove the air deflector plate. (" Removing the air deflector plate " on page 33 ) 7. Remove the condensation pump[...]

Removal and replacement procedures 56 12. Using the wire cutters, cut the cable connected to the paddle-wheel sensor and remove the sensor from the MCS unit. 13. Disconnect the paddle-wheel sensor cable connector, labeled X14, from the water group controller and pull the cable completely out of the MCS unit. To replace this component, see "Rep[...]

Removal and replacement procedures 57 Replacing the flow meter paddle-wheel sensor 1. Insert the keyed paddle-wheel sensor into the top of the flow meter. 2. Screw on the plastic screw cap to secure the paddle-wheel sensor to the flow meter.[...]

Removal and replacement procedures 58 3. Replace the plastic lock washer above the paddle-wheel sensor. 4. Route the paddle-wheel sensor cable thro ugh to the front of the MCS unit. 5. Connect the paddle-wheel sensor cable connector to the X14 connector on the water group controller. 6. Replace the AC transfer swi tch (" Replacing the AC trans[...]

Removal and replacement procedures 59 Heat exchanger unit (HEX) with coupler The three heat exchanger units are locate d on the front of the MCS unit. You can replace the HEX units during operation. The following tools are required for in stallation: • T-25 Torx driver • Water hose fitting wrench (include d with your original MCS unit) • Coun[...]

Removal and replacement procedures 60 3. Disconnect the temperature sensor conn ector from the heat exchanger unit. 4. Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to loosen the water hose (both wrenches are included with yo ur original MCS unit), disconnect the In and Out water hoses from the heat ex[...]

Removal and replacement procedures 61 5. Disconnect the condensation hose from the heat exchanger unit. 6. Disconnect the green and yellow ground bonding wi re grounding the heat exchanger unit to the MCS unit. 7. Open the front MCS door. IMPORTANT: Keep the Torx screws sepa rated accord ing to their thread type and note which thread type came from[...]

Removal and replacement procedures 62 c. Remove the heat exchanger unit shippi ng brackets from the MCS unit (3). CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water. Use extra caution when removing and repl acing the top heat exchanger unit bec ause it might be higher than your shoulder s and is heavy an[...]

Removal and replacement procedures 63 9. Pull the heat exchanger unit out toward you. To replace this component, see "Repla cing the heat exchanger unit (" Replacing the heat exchanger unit with couplers " on page 63 )." Replacing the heat exchanger unit with couplers CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with [...]

Removal and replacement procedures 64 1. Insert the new heat exchanger unit into the same position as the heat exchanger unit you removed. IMPORTANT: Keep the Torx screws sepa rated accord ing to their thread type and note which thread type came from which hole lo c ation on the shipping bracket. 2. Install the two heat exchanger unit shipping brac[...]

Removal and replacement procedures 65 c. Using a T-25 Torx driver, secure the two shipping bracke ts to the MCS frame by inserting and tightening four Torx screws (3). 3. Open the rear MCS door.[...]

Removal and replacement procedures 66 4. Connect the green and yellow ground bond ing wire to the heat exchanger unit. 5. Connect the condensation hose to the heat exchanger unit.[...]

Removal and replacement procedures 67 6. Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to tighten the water hose (both wrenches are included with your original MCS unit), connect the In and Out water hoses to the heat exchanger unit. 7. Connect the temperature sensor connector to the heat exchanger uni[...]

Removal and replacement procedures 68 You can replace the HEX units during operation. The following tools are required for in stallation: • T-25 Torx driver • Adjustable wrench or pipe wrench Removing the heat exchanger unit with ball valves NOTE: For this procedure, remove the fan unit se ated directly behind the heat exchanger unit you will r[...]

Removal and replacement procedures 69 4. Disconnect the condensation hose from the HEX unit. 5. Disconnect the green and yellow ground bonding wire grounding the HEX unit to the MCS unit. 6. Close the two ball valves inside the HEX unit.[...]

Removal and replacement procedures 70 7. Close the two ball valves on the hose assemblies attached to the HEX unit. 8. Using and adjustable wrench or a pipe wrench, disc onnect the two ball valve hose assemblies from the HEX unit. 9. Wipe up any excess water from the hose s. 10. Open the front MCS door. IMPORTANT: Keep the Torx screws sepa rated ac[...]

Removal and replacement procedures 71 c. Remove the HEX unit shipping brackets from the MCS unit (3). CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water. Use extra caution when removing and repl acing the top heat exchanger unit bec ause it might be higher than your shoulder s and is heavy and awkward to[...]

Removal and replacement procedures 72 12. Pull the HEX unit out toward you. To replace this component, see "Repla cing the heat exchanger unit with ball valves (on page 72 )." Replacing the heat exchanger unit with ball valves CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the water. Use extra cautio[...]

Removal and replacement procedures 73 1. Insert the new HEX unit into the same position as the HEX unit you removed. IMPORTANT: Keep the Torx screws sepa rated accord ing to their thread type and note which thread type came from which hole lo c ation on the shipping bracket. 2. Install the two HEX unit shipping brackets. a. Align the HEX unit shipp[...]

Removal and replacement procedures 74 c. Using a T-25 Torx driver, secure the two HEX unit shipping brackets to the MCS frame by inserting and tightening four Torx screws (3). 3. Open the rear MCS door.[...]

Removal and replacement procedures 75 4. Connect the green and yellow ground bonding wire to the HEX unit. 5. Connect the condensation hose to the HEX unit.[...]

Removal and replacement procedures 76 6. Using an adjustable wrench or a pipe wrench, co nnect the two ball valve ho se assemblies to the HEX unit. 7. Connect the temperature sensor connector to the HEX unit. 8. Open the ball valves inside the HEX unit.[...]

Removal and replacement procedures 77 9. Open the ball valves on the hose assemblies. 10. Confirm that water is flowing thro ugh the ball valve couplers, by touching the coupler s. The couplers should be cold. 11. Replace the hose insu lation over the couplers. 12. Replace the air deflector plate (" Replacing the air deflector plate " on [...]

Removal and replacement procedures 78 Removing the HEX coupling 1. Shut off the water flowing into the MCS unit. (" Shutting off the water " on page 25 ) 2. Remove the corresponding fan unit. (" Removing the fan unit " on page 51 ) 3. Remove the corresponding air deflector plate. (" Removing the air deflector plate " o[...]

Removal and replacement procedures 79 7. Using a flathead screwdriver, loosen the hose from the HEX coupling. 8. Using a utility knife, carefully trim approxim ately 0.64 cm (0.25 in) off the water hose.[...]

Removal and replacement procedures 80 9. Remove the HEX coupling from the water hose. To replace this component, see "Repla cing the HEX coupling (on page 80 )." Replacing the HEX coupling 1. Insert the HEX coupling into the water hose.[...]

Removal and replacement procedures 81 2. Using a flathead screwdriver, tighten the hose clamp. 3. Connect the HEX coupling to the heat exchanger unit. 4. Using the water hose fitting wrench and the co unter hold wrench, reconnect the appropriate In or Out water hose to the heat exchanger unit. 5. Confirm that the HEX coupling is fully engage d betw[...]

Removal and replacement procedures 82 6. Reconnect the temperature sen sor cable to the heat exchanger unit. 7. Slide the insulation back in place on the In or Out water hose up against the coupling. 8. Replace the air deflector plate (" Replacing the air deflector plate " on page 34 ). 9. Replace the fan unit (" Replacing the fan un[...]

Removal and replacement procedures 83 2. Remove the bottom fan unit (" Removing the bottom fan unit " on page 44 ). 3. Remove the air deflector plate (" Removing the air deflector plate " on page 33 ). 4. Adjust the water hoses connect ed to the rear of th e bottom heat exchanger unit and hold them out of the way to reach the ma[...]

Removal and replacement procedures 84 Replacing the magnetic solenoid valve 1. Using a Phillips screwdriver, connect the electric al connector from the MCS unit to the magnetic solenoid by inserting and tigh tening one Phillips screw. 2. Adjust the water hoses connect ed to the rear of th e bottom heat exchanger unit and hold them out of the way to[...]

Removal and replacement procedures 85 Management module The management module is located on the in side of the front door of the MCS uni t. No tools are required for this procedure. Removing the management module 1. Power down the MCS unit (" Powering down the MCS unit " on page 24 ). 2. Open the front MCS door. 3. Disconnect the electric[...]

Removal and replacement procedures 86 4. Slide the management module off of the mounting brac ket, and remove it from the inside of the front MCS door. To replace this component, see "Repla cing the management module (on page 86 )." Replacing the management module 1. Slide the management module onto the moun ting bracket until it locks in[...]

Removal and replacement procedures 87 2. Connect the electrical cables from the MCS unit to the management module. 3. Power on the management module. 4. Press and hold the C key for five seconds to confir m th e configuration settings. 5. Complete the operation checkl ist (on page 111 ).[...]

Removal and replacement procedures 88 Operator display The operator display is located on the front door of the MCS unit. The following tools are required for in stallation: • 8-mm socket • Small Flathead screwdriver Removing the operator display 1. Power down the MCS unit (" Powering down the MCS unit " on page 24 ). 2. Open the fron[...]

Removal and replacement procedures 89 5. Disconnect the connector between the op erator display and the display button. 6. Disconnect the connector from the management mod u le (1), and pull the cable up through the cable management hose (2). 7. Squeeze the four release tabs on the top and bo ttom of the operator display (1), and push the operator [...]

Removal and replacement procedures 90 8. Remove the display button by squeezing the two release tabs on the sides of the display button (1) and pushing the display button from the back to the front through the front MCS door (2). To replace this component, see "Repla cing the operator display (on page 91 )."[...]

Removal and replacement procedures 91 Replacing the operator display 1. Hold the four release tabs while pushin g the operat or display from the front to the back through the front MCS door. 2. Hold the two release tabs while pushin g the disp lay button from the front to the back through the front MCS door.[...]

Removal and replacement procedures 92 3. Push the cable down through the cable management hose (1), and connect it to the management module connector (2). 4. Connect the connector between th e op erator display and display button. 5. Slide any extra slack in the cable lines up into the operator display rear cover, and secure by inserting the rubber[...]

Removal and replacement procedures 93 6. Using an 8 mm socket or wrench, secure the operator display rear cover to the back of the operator display by inserting three nuts and external star washers. 7. Complete the operation checkl ist (on page 111 ). Power inlet box The power inlet box is not a spare part. The relocation instructions for the power[...]

Removal and replacement procedures 94 b. Lift the right side of the bracket up at a slant, and pull the bracket out of the MCS unit (2). IMPORTANT: Do not disconnect any of the internal electrical connections to the power inlet box. 3. Pull the power inlet box toward you until it stops.[...]

Removal and replacement procedures 95 4. Set the power inlet box aside in the side cavity by li fting the right side of the power inlet box up until the box sits vertically on th e left side of the MCS unit. To replace this component, see "Rel ocating th e power inlet box back into position (on page 95 )." Relocating the power inlet box b[...]

Removal and replacement procedures 96 2. Push the power inlet box back into th e MCS unit until it locks in place. 3. Replace the outer support bracket. a. Lift the right side of the bracket up at a slant, and slide the bracket into the MCS unit. b. Tighten the four thumbscr ews to secure the outer bracket to the MCS unit. 4. Connect the green and [...]

Removal and replacement procedures 97 Water group controller The water group controller is located at the bottom front of the MCS unit. The following tools are required for in stallation: • T-25 Torx driver • Flathead screwdriver • 8-mm socket Removing the water group controller 1. Power down the MCS unit (" Powering down the MCS unit &q[...]

Removal and replacement procedures 98 4. Using an 8 mm socket, remove the two 8 mm nuts an d washers securing the water group controll er bracket to the water group controller chassis. 5. Disconnect the two large el ectrical cables from the back of the water group controller. 6. Disconnect the green and yellow grounding wire se curing the water gro[...]

Removal and replacement procedures 99 7. Remove the water group controller (m ounted on a bracket) from the water gr oup controller chassis. 8. Slide the water group controller off of the mounting bracket. To replace this component, see "Repla cing the water group controller (on page 100 )."[...]

Removal and repla cement procedures 100 Replacing the water group controller 1. Slide the water group controller onto the mounting bracket until it locks in place. 2. Connect the green and yellow grounding wire to secure the water group co ntroller to the water group controller cha ssis. 3. Connect the two large elec trical cables to the back of th[...]

Removal and repla cement procedures 101 4. Place the water group controller (mounted on the bracket) in the water group controller chassis. 5. Using an 8 mm socket, secure the water group cont roller bracket to the water group controller chassis by inserting two washers and two 8 mm nuts.[...]

Removal and repla cement procedures 102 6. Connect the seven electrica l cables to the front of the water group controller. 7. Replace the AC transfer swi tch (" Replacing the AC transfer switch " on page 28 ). 8. Complete the operation checkl ist (on page 111 ). Water inlet coupling The water inlet coupling is located on the inlet water [...]

Removal and repla cement procedures 103 3. Using a pipe wrench, loosen the water inlet coupling and disconnect the water inlet hose from the supply hose. 4. Using an Allen wrench, remove the four Allen nuts and bolts securing the two brackets to the water inlet hose.[...]

Removal and repla cement procedures 104 5. Remove the two brackets from around the water inlet hose. IMPORTANT: Water will drain out of the hose when you remove the coupling. Be prepared to catch excess water drainage in a bucket or floor drain. 6. Remove the water inlet coupling from the water inlet hose. To replace this component, see "Repla[...]

Removal and repla cement procedures 105 Replacing the water inlet coupling 1. Insert the water inlet coupling into the water inlet hose. 2. Align the two brackets arou nd the water inlet hose. 3. Using an Allen wrench, insert and tighten three 40- mm Allen nuts and bolts into three of the four screw holes.[...]

Removal and repla cement procedures 106 4. Using an Allen wrench, insert and tighten one of the original Allen nuts and bolts into the remaining screw hole. Compress completely. 5. One by one, replace the three 40-mm Allen nuts and bo lts with the original Allen nuts and bolts, until the brackets are firmly compress ed around the water inlet hose. [...]

Removal and repla cement procedures 107 Water temperature sensor The water temperature sen sor is a component of the water group located at the bottom interior of the MCS unit. The following tools are required for in stallation: • T-25 Torx driver • Phillips screwdriver • (2) 18-mm wrench • Wire cutters Removing the water temperature sensor[...]

Removal and repla cement procedures 108 9. Using two 18-mm wrenches, loosen the cap nut from the water temperature sensor. 10. Using the wire cutter s, cut the cable connected to the water temperature sensor, and remove the water temperature probe and cable from the MCS unit . 11. Disconnect the appropriate water temperature se nsor cable connector[...]

Removal and repla cement procedures 109 b. Disconnect the X13 cable conne ctor if you are repairing the outlet water temperat ure sensor. To replace this component, see "Repla cin g the water temperature sensor." Replacing the water temperature sensor 1. Insert the new water temperature sensor probe into the appropriate water line. 2. Pla[...]

Removal and repla cement procedures 110 3. Using two 18-mm wrenches, tighten the cap nut over the water temperature sen sor. 4. Route the water temperatur e sensor cable through to the front of the MCS unit. 5. Connect the water temperature sensor cable conne ctor to the water group controller connector labeled either X12 or X13. 6. Replace the AC [...]

Removal and repla cement procedures 111 Operation checklist 1. If you disconnected the pow er, restore power to the MCS unit (" Restoring power to the MCS unit " on page 111 ). 2. If you shut off the water flowing into the MCS, restore water flow to the MCS un it (" Restoring water flow " on page 112 ). 3. Clear all old logs fro[...]

Removal and repla cement procedures 112 3. Connect the two AC power cables to the power connector s on th e power inlet box. 4. Open the front MCS door. 5. Turn on the AC1 breaker on the AC transfer swit ch. 6. Turn on the AC2 breaker on the AC transfer swit ch. Restoring water flow If water was disconnected, restor e water flow to the MCS unit at [...]

Technician repair remova l and replacement procedures 113 T ec hnic ian r epair r emo v al and r eplacement pr ocedur es WARNING: You must follow the removal and replac ement instructions listed in the site preparation guide, the user guide, and the ma intenance and service guide. Failure to follow the instructions list ed in these guides ca n void[...]

Technician repair remova l and replacement procedures 114 *Only the diaphragm and spring are shown, though the entire magnetic valv e ships in the kit. **The removal and replacement instructions for this component are not included in this document. Technician repair required tools The following tools are requ ired for the removal and replacement in[...]

Technician repair remova l and replacement procedures 115 NOTE: This procedure is speci fically for the removal of the Type 1 flow meter. 1. Power down the MCS unit (" Powering down the MCS unit " on page 24 ). 2. Shut off the water flowing into the MCS unit (" Shutting off the water " on page 25 ). 3. Remove the bottom fan unit[...]

Technician repair remova l and replacement procedures 116 10. Remove the flow meter from the water line. 11. Remove the two fiber gaskets on eith er side of the water line.[...]

Technician repair remova l and replacement procedures 117 12. Disconnect the threaded pick-up at the top of the flow meter and pull the flow meter out of the MCS unit. 13. Remove the threaded pick-up and cable from the MCS unit, and disconnect from the c onnector labeled X14 on the water group controller. To replace this component, see "Repla [...]

Technician repair remova l and replacement procedures 118 9. Replace the condensation pump and sensors (" Replacing the condensation pum p and sensors " on page 49 ). 10. Relocate the power inlet box back into position (" Relocating the power inlet box back into position " on page 95 ). 11. Replace the bottom fan unit (" Re[...]

Technician repair remova l and replacement procedures 119 6. Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to loosen the water hose (both wrenches included with your o riginal MCS unit), disconnect t he In and Out water hoses from the bottom heat exchanger unit. 7. Remove the magnetic sol enoid valve ([...]

Technician repair remova l and replacement procedures 120 9. Remove the cover from the magnetic valve. 10. Remove the diaphragm and spring from the magnetic valve. To replace this component, see "Repla cing th e magnetic valve diaphragm and spring (on page 120 )." Replacing the magnetic valve diaphragm and spring NOTE: When you replace th[...]

Technician repair remova l and replacement procedures 121 1. Place the diaphragm and spring on the magnetic valve. 2. Place the cover on the magnetic valve.[...]

Technician repair remova l and replacement procedures 122 3. Using an 8 mm Allen wrench, secure the cover to the magnetic valve by inserting and tightening four socket screws. 4. Replace the magnetic sol enoid valve (" Replacing the magnetic solenoid valve " on page 84 ). 5. Using the counter hold wrench to hold the fitting in place and t[...]

Upgrading procedures 123 Upgr ading pr ocedur es Viewing the upgrade procedures video Because of the difficulty of removing and replac ing spare parts, HP recommends watching the HP Modular Cooling System Spare Replacement video. This video provides further ex planation and detail of replacement strategies and techniques that might be helpful when [...]

Upgrading procedures 124 5. Using a T-25 Torx driver, remove the three scre ws on each side of the bottom cover plate and remove the bottom cover plate from the HEX unit. 6. Using a flathead screwdriver, push in the tabs of the white electrical connector of the temperatu re sensor and push the connector into the HEX unit.[...]

Upgrading procedures 125 7. Using a flathead screwdriver, loosen the hose clam ps attaching the condensation drain hose to the quick disconnect on the HEX unit face plate. NOTE: You might need to cut the condensation drain hose to remove it from the barbs. 8. Remove the condensation drain hose from both barbs. NOTE: Depending on the style of the ho[...]

Upgrading procedures 126 10. Using a small pipe wrench, loosen the nut attachin g the HEX unit copper pipe to each of the ball valve assemblies. 11. Using a T-25 Torx driver, remove the four screws se curing the coupler face p late to the HEX unit.[...]

Upgrading procedures 127 12. Remove the coupler faceplate and hose couplers as a single assembly. 13. Remove the O-ring from each pipe an d verify that the pipe is clean. To replace this component, see "Repla cing the HEX coupler (on page 128 )."[...]

Upgrading procedures 128 Replacing the HEX coupler 1. Install one O-ring on to each HEX unit pipe. 2. Install each ball valve assembly to the HEX unit tubing, positioning the handles d own. 3. Loosely attach the HEX unit pipe nut to the ball valve assembly, barely connecting the threads.[...]

Upgrading procedures 129 4. Align the first faceplate (faceplate with eight side holes) to the ball valve assemblies, and slide t he faceplate over the ball valve assemblies. 5. Align the second faceplate (faceplate with round holes) to the ball valve assemblies and slide the faceplate over the ball valve assemblies.[...]

Upgrading procedures 130 6. Using a T-25 Torx driver, install four screws to secure the fac eplate. NOTE: Do not overtighten the fittings. The gasket ne eds only a slight compression to seal the fitting. 7. Using a small pipe wrench, tighten the fitting that connects the HEX unit copper pipe to the ball valve.[...]

Upgrading procedures 131 8. Using an adjustable wrench, insert the quick disc onnect for the drain hose in to the HEX unit. TIP: Use a light lubrication spray to ease insta llation of the hose barbs and hose clamps to hold the condensation drain line in place while working. 9. Connect the condensation drain line between the qu ick disconnect hose b[...]

Upgrading procedures 132 12. Using a T-25 Torx driver, insert and tighten three screws on each side of the bottom cover plate. 13. Turn the HEX unit right-side up , so it is sitting on the bottom cover plate. 14. Replace the heat exchanger unit (" Replacing the heat exchanger unit with couplers " on page 63 ). 15. Replace the air deflecto[...]

Upgrading procedures 133 2. Insert the washer inside the hose union fitt ing of the hose assembly. 3. Hand-tighten the union fitting on the assembly, al igning the compression washer to the HEX unit . NOTE: Do not overtighten the fittings. The gasket ne eds only a slight compression to seal the fitting.[...]

Upgrading procedures 134 4. Using an adjustable wrench, tighten the union fitting 1/ 8 flat. 5. Insert the HEX unit in to the MCS unit.[...]

Upgrading procedures 135 6. Connect the right-side ball valve hose to t he left-side MCS return hose. Connect the left-sid e ball valve hose to the right-side MCS return h ose. The hoses create a criss- cross pattern. 7. Cut the hose attached to the old coupler the same length of the repla cement hose, and insert the hose barb from the HEX unit int[...]

Upgrading procedures 136 11. Insert the barbed-end of the hose from the new ball valve assembly attached to the HEX unit into the hose you clamped in step 10. 12. Tighten the hose clamp. 13. Slide the insulation back over the hose and secure w ith tie wraps. 14. Repeat steps 7 through 13 for the other HEX unit hose. 15. Open the valves inside the H[...]

Upgrading procedures 137 c. Using a T-25 Torx driver, insert and tighte n four Torx screws to the MCS frame (3). 17. Connect the green and yellow ground bonding wire to the HEX unit.[...]

Upgrading procedures 138 18. Connect the condensation hose to the HEX unit. 19. Connect the temperature sensor cabl e to the HEX unit. 20. Replace the air deflector plate (" Replacing the air deflector plate " on page 34 ). 21. Replace the fan unit (" Replacing the fan unit " on page 52 ). 22. Complete the operation checkl ist ([...]

Maintenance 139 Maintenance Maintenance and service For information on maintenance and service, refer to the HP website ( http://www.hp.com ). Air and water heat exchanger maintenance The air and water heat exchanger requires no mainte nance. If particulates are present in the cooling water, a filter must be fitted. Check the function in g of the c[...]

Maintenance 140 Before storage or transportation at sub-zero temper atures, the water cycle must be drained completely using compressed air. Avoi d setting the target temper atur e low er than is ne cess ary because the danger of falling below the dew point increases as water temper ature decreases (condensation buildup). Ensure that the enclosure [...]

Troubleshooting 141 T r oubleshooting HP Modular Cooling System troubleshooting Issue Resolution The water flow is low or not flowing. For more information, see the "Temperature Control settings" section in the HP Modular Cooling System Web Interface User Guide located on the Documentation CD included with this product. The fan speed is t[...]

Specifications 142 Sp e c i fica t io n s MCS specifications Item Specification Voltage 208–240 VAC +/- 10%, 50–60 Hz Maximum Height (including the rack) 200 cm (78.7 i n) Maximum Width (including the rack) 90.9 cm (35.8 in) maximum Maximum Depth (including the rack and rack handle) 127 cm (50 in) Maximum Shipping Height (on skid) 224.8 cm (88.[...]

Specifications 143 Thermal and air flow performance Maximum thermal and air flow performance parameters Specifications Air temperature—inlet to rack-m ounted components 25ºC (68ºF) Chilled water temperature 7º–10 ° C (45º–50 ° F) Total rack-mounted component air flow 2,60 0 cfm or less at 0 or more pressure drop across the rack-mounted [...]

Acronyms and abbreviations 144 A c r on y ms and a bbr e v i ations CSR Customer Self Repair HEX heat exchanger MCS modular cooling system SPS spare part[...]

Index 145 A AC transfer switch 26, 28 air bleeder valve 31, 32 air deflector plate 33, 34 air sealing plate 34, 35, 36 automatic door release 38, 39, 41, 42 C condensation pump 47, 49 CSR (customer self repair) 6 customer self repair (CS R) 6 D diagnostic tools 140, 141 E environmental specifications 143 F fan unit 44, 45, 50, 51, 52 flow meter 114[...]

Index 146 replacing the front automatic door release 39 replacing the HEX coupling 80 Replacing the HEX unit with ball valve 72 Replacing the HEX unit with coupler 63 replacing the magnetic solenoid valve 84 replacing the magnetic valve diaphragm and spring 120 replacing the management module 86 replacing the operator display 91 replacing the rear [...]