Rittal 3311.493 Assembly And Operating Manual

Brand: Rittal

Model: 3311.493

Category: Split-system air conditioners

Type: Assembly And Operating Manual

This manual is also suitable for

LCUDX

Assembly and operating instructions

3311.490

3311.491

3311.492

3311.493

Foreword

2 Rittal LCU DX

Foreword

Dear Customer,

Thank you for choosing a Rittal Liquid Cooling Unit DX

(also referred to hereafter as "LCU DX").

This documentation applies to the following devices in

the LCU DX series (DX = Direct Expansion):

– LCU DX 3 kW single

–LCU DX 3 kW redundant

– LCU DX 6.5 kW single

– LCU DX 6.5 kW redundant

Those sections where information only applies to one of

the units are labelled accordingly in the documentation.

Please take the time to read this documentation carefully

and pay particular attention to the safety instructions in

the text and to section 2 "Safety instructions".

This is the prerequisite for:

– secure assembly of the LCU DX

– safe handling and

– the most trouble-free operation possible.

Please keep the complete documentation readily availa-

ble so that it is always on hand when needed.

We wish you every success!

Your,

Rittal GmbH & Co. KG

Auf dem Stützelberg

35745 Herborn

Germany

Tel.: +49(0)2772 505-0

Fax: +49(0)2772 505-2319

E-mail: info@rittal.de

www.rimatrix5.com

www.rimatrix5.de

We are always happy to answer any technical questions

regarding our entire range of products.

Rittal LCU DX 3

Contents

1 Notes on documentation .................. 4

1.1 CE label ........................................................ 4

1.2 Information on electromagnetic compatibility . 4

1.3 Storing the documents .................................. 4

1.4 Symbols in these operating instructions ........ 4

1.5 Associated documents ................................. 4

1.6 Normative instructions .................................. 4

1.6.1 Legal information concerning the operating

instructions ........................................................... 4

1.6.2 Copyright ............................................................. 4

1.6.3 Revision ................................................................ 4

2 Safety instructions ............................ 5

2.1 Important safety instructions: ........................ 5

2.2 Service and technical staff ............................ 6

2.2.1 Personal safety equipment ................................... 6

2.3 Operator requirements .................................. 6

2.3.1 Abbreviated instructions ....................................... 6

2.3.2 System log ........................................................... 6

2.3.3 F-gas regulation ................................................... 7

2.3.4 Chemicals – Climate Protection Ordinance ........... 7

2.4 RoHS compliance ......................................... 7

3 Device description ............................ 8

3.1 General functional description ....................... 8

3.2 Air routing ..................................................... 8

3.3 Device assembly ........................................... 8

3.3.1 Internal unit (evaporator coil) ................................. 8

3.3.2 External unit (inverter-controlled cooling unit) ........ 9

3.3.3 Refrigerant lines and electrical pilot wires .............. 9

3.4 Proper and improper usage .......................... 9

3.5 Scope of supply for the LCU DX ................. 10

4 Transport and handling .................. 11

4.1 Transport .................................................... 11

4.2 Unpacking .................................................. 11

5 Assembly and siting ....................... 12

5.1 General ....................................................... 12

5.1.1 Siting location requirements ................................ 12

5.1.2 Relative positioning of the internal unit to the

external unit ........................................................ 12

5.1.3 Supply connections required at the installation

site ..................................................................... 12

5.1.4 Electromagnetic interference .............................. 12

5.2 Assembly procedure ................................... 12

5.2.1 Preparatory tasks ............................................... 12

5.2.2 Mounting the internal unit ................................... 13

5.2.3 Mounting the internal unit accessories ................ 13

5.2.4 Mounting the external unit .................................. 14

6 Installation ...................................... 16

6.1 General information ..................................... 16

6.2 Notes on pipework ...................................... 16

6.3 Connecting the condensate discharge ........ 18

6.4 Electrical connection ................................... 18

6.4.1 General .............................................................. 18

6.4.2 Connecting the external unit ............................... 19

6.4.3 Connecting the internal unit ................................ 19

6.5 Checking the entire system prior to

commissioning ........................................... 19

6.6 Installing the server .................................... 20

7 Operation ....................................... 22

7.1 Control and display devices ....................... 22

7.2 Switching the LCU DX on and off ............... 22

7.2.1 Switching on the internal and external units ........ 22

7.2.2 Switching off the internal and external units ........ 22

7.2.3 Switching off in an emergency ............................ 22

7.3 Setting the setpoint temperature ................ 22

8 Troubleshooting ............................. 24

8.1 General ...................................................... 24

8.2 List of error messages ................................ 24

9 Inspection and maintenance ........... 25

10 Storage and disposal ...................... 26

11 Technical specifications .................. 27

11.1 LCU DX 3 kW ............................................. 27

11.2 LCU DX 6.5kW ........................................... 28

11.3 Information about the refrigerant ................ 29

11.4 Cooling output ........................................... 29

11.4.1 LCU DX 3 kW ..................................................... 30

11.4.2 LCU DX 6.5 kW .................................................. 31

11.5 Overview drawings ..................................... 32

11.5.1 Internal unit LCU DX 3 kW and 6.5 kW ............... 32

11.5.2 Dimensions of internal unit LCU DX 3 kW and

6.5 kW ............................................................... 33

11.6 RI flow chart LCU DX ................................. 34

11.7 Circuit diagram ........................................... 35

11.7.1 Functional diagram, internal unit ......................... 35

11.7.2 Connection internal unit – external unit, external

interfaces ........................................................... 36

11.7.3 Circuit diagram, external unit .............................. 37

12 Spare parts .................................... 38

13 Accessories .................................... 39

14 Glossary ......................................... 40

15 Customer service addresses .......... 41

1 Notes on documentation

4 Rittal LCU DX

1 Notes on documentation

1.1 CE label

The declaration of conformity has been issued by the

company Hannich GmbH and is included with the sup-

ply of the LCU DX.

The cooling unit bears the following mark:

1.2 Information on electromagnetic com-

patibility

The LCU DX is a class A device as defined by EN 55022.

Under certain circumstances, the device may cause ra-

dio interference in domestic environments. In such cas-

es, the operator may be asked to implement appropriate

measures.

1.3 Storing the documents

The assembly and operating instructions as well as all

other applicable documents are an integral part of the

product. They must be passed to those persons who

are engaged with the unit and must always be available

and on hand for the operating and maintenance person-

nel.

1.4 Symbols in these operating instructions

The following symbols are used in this documentation:



This symbol indicates an "Action Point" and shows

that you should perform an operation/procedure.

1.5 Associated documents

The general plant documentation for the room where the

equipment is situated (construction specifications for the

ventilation system) also applies in conjunction with these

assembly and operating instructions.

1.6 Normative instructions

1.6.1 Legal information concerning the operating

instructions

We reserve the right to make changes in content. Rittal

GmbH & Co. KG and/or Hannich GmbH are not respon-

sible for any damage which may result from failure to

comply with these assembly and operating instructions.

The same applies to failure to comply with the valid doc-

umentation for any accessories used.

1.6.2 Copyright

The distribution and duplication of this document and

the disclosure and use of its contents are prohibited un-

less expressly authorised.

Offenders will be liable for damages. All rights created by

a patent grant or registration of a utility model or design

are reserved.

1.6.3 Revision

Rev. 0A of 25/01/2016

Danger!

Hazardous situation which will result in

death or serious injury if the instructions

are not followed.

Warning!

Hazardous situation which may lead to

death or serious injury if the instructions

are not followed.

Caution!

Hazardous situation which may lead to

(minor) injuries if the instructions are not

followed.

Note:

Information concerning individual proce-

dures, explanations, or tips for simplified ap-

proaches. Also indicates situations which

may result in material damage.

Rittal LCU DX 5

2 Safety instructions

The devices in the LCU DX series from Rittal GmbH &

Co. KG are developed and manufactured with due re-

gard for all safety precautions. Nevertheless, the unit still

poses a number of unavoidable dangers and residual

risks. These safety instructions provide an overview of

these dangers and the necessary safety precautions.

In the interests of your own safety and the safety of oth-

ers, please read these safety instructions carefully be-

fore assembling and commissioning the LCU DX!

Follow the user information found in these instructions

and on the unit carefully.

2.1 Important safety instructions:

Danger! Electric shock!

Contact with live electrical parts may re-

sult in fatal injury.

Before switching on, ensure that there is

no possibility of accidental contact with

live electrical parts.

The unit has a high discharge current.

Before connecting to the supply circuit,

therefore, it is essential to make a 6 mm²

earth connection (see section 11.7 "Cir-

cuit diagram").

Danger! Injury caused by fan impellers.

Keep persons and objects away from

the fan impellers. Do not remove covers

until the power supply is disconnected

and impellers are immobilised. Always

use mechanical protection when work-

ing. Shut down the respective fan during

maintenance work, if possible. Tie long

hair back. Do not wear loose clothing.

The fans will start up again automatically

following a power disruption.

Danger! Hot components may cause in-

jury!

The external unit and the pipelines are

hot during operation, and may cause

burns on direct contact.

Danger! Risk of poisoning from refriger-

ant gases created under the influence of

heat.

When carrying out welding and solder-

ing work, shortness of breath or asphyx-

iation may occur.

The refrigerant is heavier than air, and in

high concentrations may cause short-

ness of breath and asphyxiation, by dis-

placing the oxygen.

Danger! Risk of poisoning from refriger-

ant gases created under the influence of

heat.

When carrying out welding and solder-

ing work on the refrigerant circuit, use

protective gloves and breathing appara-

tus with a filter.

Even a very low concentration of refrig-

erant may cause the refrigerant to de-

compose in combination with a naked

flame, and cause acute shortness of

breath.

Danger! Risk of injury from incorrect in-

stallation.

Installation of the refrigerant lines and

other media connections must only be

carried out by qualified plumbers or

cooling technology specialists.

Danger! Threat to the environment from

escaping refrigerant!

Never allow the refrigerant to escape

into the environment if at all possible

(see section 2.3.3 "F-gas regulation").

Danger! Injury due to falling loads!

Do not stand under suspended loads

when transporting the unit with a hoist

trolley, a forklift, or a crane.

Warning! Danger of cut injuries, espe-

cially from the sharp edges of the fan

module and heat exchanger module.

Put on protective gloves before begin-

ning assembly or cleaning work.

2 Safety instructions

6 Rittal LCU DX

As a general requirement, please observe the following

five safety rules to DIN EN 50110-1 (VDE 0105-1) when

working in and on the LCU DX, in order to avoid acci-

dents:

1. Switch off!

Switch off the on-site power supply to the LCU DX.

2. Secure against reactivation.

3. Ensure that all poles are de-energised.

4. Earth and short-circuit.

5. Cover or shield adjacent, live parts.

2.2 Service and technical staff

The installation, commissioning, maintenance and repair

of this unit may only be carried out by trained, qualified

mechanical, electro-technical and refrigeration engi-

neering specialists.

Only properly instructed personnel may service a unit

while in operation.

2.2.1 Personal safety equipment

Personal safety equipment, which should as a minimum

include thermally insulated gloves and protective gog-

gles, is to be worn during any work on this unit when

personnel might come into contact with refrigerant (see

section 11.3 "Information about the refrigerant").

Additionally, in the event of fire, airtight respiratory

masks must be worn.

2.3 Operator requirements

In accordance with EU Regulation 842/2006, for a total

refrigerant fill volume of more than 2.5 kg (R410A), the

operator must carry out a leak test at least once a year.

This fill volume is achieved or exceeded with a pipe

length of > 28 m.

Any leaks that are detected must be repaired immedi-

ately.

2.3.1 Abbreviated instructions

The operator must ensure that abbreviated instructions

containing the following information are available in a

readily accessible location on the LCU DX:

1. Name, address and telephone number of the instal-

lation company, its customer service department, or

the customer service department of the owner/op-

erator, or as a minimum requirement, the individual

responsible for the cooling system, together with the

address and telephone number of the fire brigade,

police, hospitals and burn victims centres.

2. Type of refrigerant: R410A, comprising 50% di-

fluoromethane R32 (CH

) and 50% R125 penta-

fluoroethane (C

);

3. Instructions for switching off the cooling system in

an emergency (see section 7.2.3 "Switching off in an

emergency");

4. The maximum permissible pressures (see sec-

tion11 "Technical specifications").

2.3.2 System log

Under DIN EN 378, the operator is required to keep a

system log and ensure that it is regularly updated. The

system log should contain the following information:

1. Details of all repair work

2. Quantity and type (new, reused or recycled) of refrig-

erant added, quantity of refrigerant removed

Warning! Injuries from escaping refriger-

ant.

Escaping gas may freeze the skin. Be-

fore working on the cooling circuit, put

on protective gloves and goggles.

Caution! Risk of malfunction or damage!

Do not modify the unit. Use only original

spare parts.

Caution! Risk of malfunction or damage!

Proper operation can only be ensured if

the unit is operated under the intended

ambient conditions. As far as possible,

observe the ambient conditions for

which the unit was designed, e.g. tem-

perature, humidity, air purity.

Caution! Risk of malfunction or damage!

All media required for the control sys-

tem, such as the correct fill volume of re-

frigerant, must be available throughout

the entire operating period of the device.

Caution! Risk of malfunction or damage!

Installation, and in particular the laying

of the refrigerant pipework between the

internal and external unit, must only be

carried out by trained, qualified and ac-

credited cooling system specialists.

Caution! Risk of malfunction or damage!

In order to prevent EMC-related mal-

functions during operation, and to allow

access for servicing purposes, cross-

wiring through the LCU DX to the bayed

racks is prohibited.

Note:

Rittal offers leak testing of the device as a

service.

Rittal LCU DX 7

2 Safety instructions

3. Outcome of any analysis of reused refrigerant, if

available

4. Origin of reused refrigerant

5. Amendments to and replacement of system com-

ponents

6. Results of all regular routine checks and

7. Any significant shutdowns

2.3.3 F-gas regulation

Regulation (EC) No. 842/2006 of the European Parlia-

ment and of the Council of 17 May 2006 on certain fluor-

inated greenhouse gases entered into force on 4 July

2006. The Regulation regulates the reduction of emis-

sions, the use, recovery and destruction of certain fluor-

inated greenhouse gases, and the labelling and disposal

of products and equipment containing such gases.

Leak test pursuant to Article 3 (containment)

– 3kg – 30kg at 12-month intervals (or 6 kg in hermet-

ically sealed systems),

– 30 kg – 300 kg at 6-month intervals,

– more than 300 kg at 3-month intervals.

2.3.4 Chemicals – Climate Protection Ordinance

This Ordinance applies in addition to the aforementioned

Regulation (EC) No. 842/2006 of the European Parlia-

ment and of the Council of 17 May 2006 on certain fluor-

inated greenhouse gases.

2.4 RoHS compliance

The LCU DX fulfils the requirements of EU Directive

2011/65/EC on the Restriction of Use of Certain Hazard-

ous Substances in Electrical and Electronic Equipment

(RoHS) of 8 June 2011.

Note:

Corresponding information about the RoHS

Directive may be found on our website at

www.rittal.com/RoHS.

3 Device description

8 Rittal LCU DX

3 Device description

3.1 General functional description

The Liquid Cooling Unit DX (DX = Direct Expansion) is

essentially a split cooling unit used to dissipate heat

losses from server enclosures or for the effective cooling

of devices built into a server enclosure.

The air routing in the LCP DX supports the "front to

back" cooling principle of the devices built into the server

enclosure. The hot air expelled by the devices in the

server enclosure is drawn in by the fans at the rear di-

rectly from the server enclosure or Micro Data Center

and then routed through the heat exchanger module.

In the heat exchanger module, the heated air is directed

through a heat exchanger (refrigerant evaporator), and

its thermal energy (heat loss from the server enclosure)

is removed from the refrigerant via evaporation. This pro-

cess cools the air to a freely selectable temperature, and

it is then routed directly in front of the 482.6 mm (19")

level in the server enclosure or Micro Data Center.

The setpoint (outlet temperature from the cooling unit or

server air intake temperature) may be set in the range

+18°C to +28°C.

Fig. 1: Air routing on the LCU DX – Top view

Key

1 Installed equipment in the server

2 Server enclosure/Micro Data Center

3Air outlet

4 Heat exchanger

5Fan

6 Air inlet

In the LCU DX, the temperature of the incoming cold air

(server air intake) is controlled by continuously compar-

ing the actual temperature with the setpoint temperature

(preset to +22°C).

If the actual temperature exceeds the setpoint tempera-

ture, the speed of the compressor is automatically in-

creased, providing a greater cooling output from the

heat exchanger, until the setpoint temperature is

reached.

In the LCU DX, the measured temperature of the extract-

ed warm air is used to determine and control the re-

quired fan speed.

Any condensate incurred is collected in the integral con-

densate collecting tray below the heat exchanger, and

from there is routed outside via a condensate discharge

hose.

3.2 Air routing

In order to achieve sufficient cooling in the server enclo-

sure, it is important to ensure that the cooling air passes

through the interior of the built-in devices rather than

flowing past at the sides.

Targeted air routing inside the server enclosure has a

major effect on the thermal output to be dissipated.

In order to ensure targeted air routing in the system, the

server enclosure should be divided vertically into warm

air and cold air sections. Essentially, this is already en-

sured by the 482.6 mm (19") arrangement and the in-

stallation of "front to back" vented servers. Consistent

sub-division is achieved with additional plastic foam

strips and air baffle plates on the left and right of the

482.6 mm (19") level (see section 13 "Accessories").

If the LCU DX is used to cool a TS IT server enclosure, it

is important that this is sealed, by fitting the enclosure

with side panels, roof and gland plates. Any existing ca-

ble entries should be sealed e.g. using suitable brush

strips. Whilst the system is in operation, both the front

and the rear doors should be kept completely shut. No

slotted doors should be used.

When using in the Micro Data Center, the LCU DX is in-

serted in a sealed safe structure for application-related

reasons.

3.3 Device assembly

3.3.1 Internal unit (evaporator coil)

The internal unit of the LCU DX may be bayed either on

the right or left of a server enclosure or Micro Data

Center. To this end, the internal unit is mounted directly

Note:

The 482.6 mm (19") level must likewise be

completely sealed. This is already the case in

a fully configured server enclosure. With a

partially configured server enclosure, the

open height units (U) of the 482.6 mm (19")

level must be sealed with blanking plates,

which are available as Rittal accessories (see

section 13 "Accessories").

Rittal LCU DX 9

3 Device description

on fixing brackets on the rear wall of the evaporator coil.

The evaporator coil has two condensate collecting trays

to enable installation on the left or right of the enclosure.

The bottom condensate discharge in each case remains

unused.

The internal unit is comprised of the following compo-

nents:

– Housing of powder-coated sheet steel.

– Two condensate collecting trays in the enclosure (bot-

tom/top) so that the evaporator coil can be used in

two installation positions. The discharge connection of

the condensate tray has a diameter of 12 mm.

– Direct refrigerant evaporator coil of inner-grooved

copper core pipes with aluminium membranes. The

evaporator coil is pressurised with exhaust air from the

server in order to ensure heat absorption (heat dissi-

pation) via the refrigerant flowing into the copper

pipes.

– Evaporator coil fan as linear controlled EC fan.

– Full electronic control of all components in the internal

unit, for evaporator coil fan speed control, server in-

take air temperature control, and power demand from

the external unit. The controller has temperature sen-

sors built into the intake and exhaust side of the inter-

nal unit, as well as on the evaporator coil itself.

– Additional temperature sensor in the server front.

3.3.2 External unit (inverter-controlled cooling

unit)

The external unit is comprised of the following compo-

nents:

– Housing of weather-proof, stove-enamelled sheet

steel.

– Compressor for compressing and circulating the re-

frigerant from the low-pressure side (internal unit) to

the high-pressure side (external unit). The motor is ac-

tivated by an external inverter, which controls the

speed of the compressor and therefore allows the

cooling output to be precisely adapted to the actual

cooling requirement.

– Full electronic control of all components and measure-

ment devices on the external unit, including various

sensors and pressure measuring devices.

– Condenser for condensing the compressed refriger-

ant so that it can be returned to the evaporator coil via

the expansion valve in liquid form. The condenser is

comprised of copper core pipes with aluminium mem-

branes and a DC fan motor, which is speed-controlled

to adjust the output.

– Electronic expansion valve to supply the evaporator

coil with the required volume of refrigerant, so as to

ensure the corresponding optimum thermal absorp-

tion capacity to suit the current output requirements.

The expansion valve is electronically regulated via the

pilot wire from the evaporator coil.

3.3.3 Refrigerant lines and electrical pilot wires

The medium connection lines between the internal unit

and the external unit are comprised of the following

components:

– Pair of refrigerant lines as a refrigerant suction line (re-

turn) and refrigerant liquid line (inlet), including conden-

sate insulation. Refrigerator-quality copper pipes

should be cleaned and dried (to DIN EN 12735-1/DIN

1786) and sealed before use.

– Electrical and pilot wire lines between the internal unit

and the external unit in a UV-resistant design.

3.4 Proper and improper usage

The LCU DX is used to dissipate low to medium heat

losses and for the effective cooling of devices built into a

server enclosure/Micro Data Center. The unit is de-

signed solely for static use in sealed rooms.

The unit is state of the art and built according to recog-

nised safety regulations. Nevertheless, improper use

can pose a threat to the life and limb of the user or third

parties, or result in possible damage to the system and

other property.

Consequently, the unit must only be used properly and

in a technically sound condition!

Any malfunctions which impair safety should be rectified

immediately.

Proper usage also includes following the operating in-

structions and fulfilling the inspection and maintenance

conditions.

Inappropriate use can be dangerous. Examples of inap-

propriate use include:

– Use of another external unit

– Improper operation

– Use of a refrigerant other than R410A

– Use of a refrigerant fill volume other than that specified

– Installation of the external unit in an unsuitable position

– Improper rectification of malfunctions

– Use of replacement parts which are not authorised by

Rittal GmbH & Co. KG

– Non-static use, e.g. on moving or vibrating machines

3 Device description

10 Rittal LCU DX

3.5 Scope of supply for the LCU DX

The supply of an LCU DX in the "single" variant includes

the following:

The supply of an LCU DX in the "redundant" variant in-

cludes the following:

Qty. Parts

LCU DX

, ready to connect, consisting of:

1 Internal unit

1 Remote control/operating unit

1 Holder for operating unit (482.6 mm (19") con-

sole, 3 U)

1 Temperature sensor, server front

1 Condensate discharge hose with copper si-

phon

1 External unit

1 Set of accessories for mounting the internal

unit and for the air block panel

1 Assembly and operating instructions

Tab. 1: Scope of supply of an LCU DX, "single" variant

Qty. Parts

LCU DX

, ready to connect, consisting of:

1 Internal unit

2 Remote control/operating unit

1 Holder for operating unit (482.6 mm (19") con-

sole, 3 U)

2 Temperature sensor, server front

1 Condensate discharge

2 External unit

1 Set of accessories for mounting the internal

unit and for the air block panel

1 Assembly and operating instructions

Tab. 2: Scope of supply of an LCU DX, "redundant" variant

Rittal LCU DX 11

4 Transport and handling

4.1 Transport

The LCU DX is delivered shrink-wrapped on a pallet.

4.2 Unpacking



Remove the packaging materials from the unit.



Check the unit for any damage that may have oc-

curred during transport.



Place the unit in its intended location.

Caution!

Because of its height and narrow base,

the LCU DX is liable to tip over. Risk of

toppling, especially after the unit is re-

moved from the pallet!

Caution!

Transportation of the LCU DX without a

pallet:

Use only suitable and technically sound

lifting gear and load-bearing devices

with sufficient load capacity.

Note:

After unpacking, the packaging materials

must be disposed of in an environmentally

friendly way. They consist of the following

materials:

Wood, polyethylene film (PE film), strap, edge

protectors.

Note:

Damage and other faults, e.g. incomplete de-

livery, should be reported immediately, in

writing, to the shipping company and to Rittal

GmbH & Co. KG.

5 Assembly and siting

12 Rittal LCU DX

5 Assembly and siting

5.1 General

5.1.1 Siting location requirements

To ensure proper functioning of the LCU DX, the follow-

ing conditions for the siting location of the device must

be observed.

Climatic conditions



When choosing a siting location for the internal unit

and external unit, please observe the values pre-

scribed in section 11 "Technical specifications" for the

ambient temperature, dewpoint and air purity.

According to ASHRAE Directive TC 9.9, a maximum

room temperature of 30°C at 50% relative humidity must

be observed at the internal unit's siting location. This

equates to a dew point of 19°C. If these limits are ex-

ceeded, there is a risk of condensation forming on the air

outlet of the internal unit.

Floor conditions

– The floor of the installation space should be rigid and

level.

– Choose the location carefully so that the unit is not sit-

uated on a step or uneven surface, etc.

Minimum required thermal output in the enclosure

In order to achieve continuous operation of the LCU DX,

a heat load of at least 1 kW (3 kW version) or 3 kW

(6.5 kW version) respectively must be installed in the en-

closure. Otherwise, intermittent operation of the system

may occur.

5.1.2 Relative positioning of the internal unit to

the external unit

The internal unit and the external unit must be connect-

ed with a suitable copper pipe connection to DIN EN

378-2. The entire system must then be filled with refrig-

erant (cf. section 6.2 "Notes on pipework").

The following distances and geodetic height differences

must not be exceeded when installing the internal unit

and external unit:

5.1.3 Supply connections required at the installa-

tion site

Power is usually supplied to the external unit.

LCU DX 3 kW

LCU DX 6.5 kW

5.1.4 Electromagnetic interference

– Interfering electrical installations (high frequency) are

to be avoided.

5.2 Assembly procedure

5.2.1 Preparatory tasks

The internal unit may be mounted both on the right and

on the left of the TS IT server enclosure.

Before the internal unit of the LCU DX can be installed in

a TS IT server enclosure, the following work should be

carried out.



Slide the 482.6 mm (19") mounting angles 50 mm

away from you.

Recommendation:

Where necessary, these values should be

achieved by installing an additional room air-

conditioning system.

Position Distance

Maximum equivalent pipeline

length

LCU DX 3 kW: 30 m

LCU DX 6.5 kW: 50 m

Of which maximum height

difference

12 m

Tab. 3: Distances and height differences

Connection type Connection description

Electrical connection

LCU DX 3 kW

230 V, 1~, N, PE, 50 Hz

Electrical fuse provid-

ed by the customer

16 A, miniature circuit-breaker

with C characteristic

Refrigerant connec-

tion

Copper pipework

Tab. 4: Supply connections for the LCU DX 3 kW

Connection type Connection description

Electrical connection

LCU DX 6.5 kW

230 V, 1~, N, PE, 50 Hz

Electrical fuse provid-

ed by the customer

20 A, miniature circuit-breaker

with C characteristic

Refrigerant connec-

tion

Copper pipework

Tab. 5: Supply connections for the LCU DX 6.5 kW

Note:

Installation in a Micro Data Center is de-

scribed in the assembly instructions for the

Micro Data Center. The assembly parts re-

quired for the internal unit are included with

the supply of the Micro Data Center.

Note:

The LCU DX may only be operated in combi-

nation with 482.6 mm (19") mounting angles.

Installation with a 482.6 mm (19") mounting

frame is not possible.

Rittal LCU DX 13

5 Assembly and siting

Fig. 2: Move the 482.6 mm (19") level sideways



Ensure that the front distance from the 482.6 mm (19")

mounting angle to the front edge of the TS frame is at

least 100 mm.

Fig. 3: Move the 482.6 mm (19") level in the depth



Position the punched section with mounting flange as

shown in the assembly drawing (Fig. 18) and attach it

to the inner level of the TS frame (mounting side).



Remember to maintain a distance of at least 15 cm

between the roof plate and the top edge of the internal

unit.



Locate the two mounting devices supplied loose for

installing the internal unit into the lower punched sec-

tion with mounting flange.

Fig. 4: Arrangement of the internal unit

Key

1 Internal unit

2 Rear wall of internal unit

3 Mounting device

4 Punched section with mounting flange

5 Assembly screw

5.2.2 Mounting the internal unit



Position the internal unit on the mounting devices in

such a way that the air outlet opening is on the opera-

tor side of the server enclosure, and the fans are in the

rear section.

The end face of the internal unit must be flush with the

front edge of the TS frame.



Align the internal unit horizontally.



In this position, screw the internal unit to the punched

section with mounting flange using the attachment

points provided (at the top and bottom of the rear pan-

el).

5.2.3 Mounting the internal unit accessories



Install the remote control (3U trim panel) with the built-

in operating units at the top of the 482.6 mm (19") lev-

el, on the maintenance side of the rack.

Fig. 5: Mounting the internal unit accessories

Key

1 Remote control (3U trim panel)

2 Control and display device 1

3 Control and display device 2

4 Second control and display device 1 for "redundant" ver-

sion



For the "single" version, fit the external temperature

sensor included with the supply in a suitable position

in front of the server installations.

5 Assembly and siting

14 Rittal LCU DX



For the "redundant" version, fit the second external

temperature sensor included with the supply, likewise

in a suitable position in front of the server installations.

5.2.4 Mounting the external unit

The external unit may be secured to a solid wall or onto

a flat roof or concrete surface using wall brackets (ac-

cessory, not included with the supply).

Please observe the following instructions regarding the

installation site:

– The external unit is weather-resistant and may there-

fore be installed completely in the open air, with no

need for a weather protection canopy etc.

– For continuous operation, the base surface must rise

above the snow zone.

– It is also important to ensure that foreign bodies such

as leaves cannot be drawn into the external unit.

– The external unit must not be exposed to extreme

wind conditions, otherwise the heat exchanger could

be excessively under-cooled, or the fan would need to

work against the wind and be unable to move the re-

quired volume of air.

– If necessary, a wind break should be installed at a dis-

tance of 1 m from the device.

– If the unit is installed underneath a canopy, there must

be a distance of at least 2 m between the floor and the

canopy.

The following distances should be observed for mainte-

nance purposes:

Fig. 6: Distances from external unit

Key

1 Air inlet

2Distance > 300mm

3 Clearance for maintenance: Distance > 600 mm

4Air outlet

5Distance > 200mm

6 External unit

7Distance > 600mm

8 Roof area/foundations

9 Strip foundation

10 Assembly screws/vibration dampers



The installation site of the external unit must be care-

fully selected to ensure an adequate supply and distri-

bution of the airflow, even in unfavourable conditions.



Install the external unit on brackets, remembering to

observe the required minimum distance from the wall.



Attach the external unit to the base plate to avoid the

risk of tipping over.

Fig. 7: Attachment points for external unit

Key

1 4 x M10 plugs per external unit

2Distance > 600mm

1 1

Rittal LCU DX 15

5 Assembly and siting

Fig. 8: Top view of attachment points

Key

1 For 3 kW unit: 550 mm

For 6.5 kW unit: 560 mm

2 Distance 1000 mm

3 For 3 kW unit: 325 mm

For 6.5 kW unit: 335 mm

4 12 x 20 mm elliptical drilled holes

1 12

6 Installation

16 Rittal LCU DX

6 Installation

6.1 General information

The internal unit and the external unit must be connect-

ed with suitable copper pipework. With the TS IT server

enclosure, this pipework can either be inserted into the

enclosure from above or from below.

When using in a Micro Data Center, a cable duct is pro-

vided and this must be used for inserting the pipework

into the safe.

In its delivered state, the internal unit is filled with 1.5 bar

nitrogen. It is therefore crucial that the following steps

are carried out in the order shown.

6.2 Notes on pipework

The following basic rules should be observed when con-

necting the internal unit and external unit.

General information

1. The pipes may only be made from special copper

piping that has been cleaned on the inside and

sealed at both ends. The material of the copper

pipework must comply with the specifications out-

lined in EN 12735-1 / EN 12735-2 and DIN 8964-3.

2. The external diameters of the copper pipes for the

intake gas line from the internal unit to the external

unit, as well as the liquid line from the external unit to

the internal unit, must comply with the values given

in section 11 "Technical specifications".

In order to ensure the correct spatial arrangement of the

pipework, particular consideration should be given to

the position of the individual pipes, the flow conditions

(two-phase flow, oil transportation in part-load opera-

tion), condensation processes, thermal expansion, vi-

bration, and good accessibility.

As a general rule, pipelines should be laid in such a way

as to prevent damage associated with routine activities.

For safety reasons, and in order to protect the environ-

ment, the following aspects should be taken into ac-

count when laying pipework:

1. There must not be any threat to human safety, i.e.

escape and emergency vehicle routes must not be

obstructed or restricted in any way. No detachable

connections or fittings must be positioned in publicly

accessible areas.

2. Pipework should be protected from the thermal in-

fluence of hot lines and heat sources by means of

spatial separation.

3. Refrigerant lines must be protected or covered if

there is a risk of damage.

4. Flexible connecting parts such as connection lines

between indoor and outdoor devices that could be-

come displaced during regular work operations

must be protected against mechanical damage.

5. The maximum distance between the supports of the

copper pipes is 1 m for pipelines with 1/4" to 3/8",

1.25 m for pipelines with 1/2" to 5/8" and 2 m for

pipelines with 3/4" to 7/8".

Laying the pipework

1. The equivalent length of the overall line between the

internal unit and the external unit must not exceed

the maximum length as set out in section 11 "Tech-

nical specifications". To calculate the equivalent

length, in addition to the actual length of the pipeline,

you should also make allowance for the equivalent

length of curves and valves.

2. The number of curves should be kept to a bare min-

imum so as to avoid pressure losses. Where curves

are unavoidable, the radius chosen should be as

large as possible.

3. Generally speaking, the lines between the internal

unit and external unit should take the shortest pos-

sible route. Exceptions are only admissible to avoid

unnecessary bends or circumvent extreme heat

sources.

4. Where possible, refrigerant lines should not be rout-

ed through rooms where people spend a lot of time,

such as offices or meeting rooms.

5. The intake gas line must be laid with an incline of 1%

in the direction of flow of the refrigerant.

6. When laying refrigerant lines, please ensure that

there is no overarching of liquid lines and no dipping

of gas lines (intake gas line). Oil could collect here, or

in the case of the liquid line, gas bubbles could form.

Caution! Risk of malfunction or damage!

Installation work, particularly the laying

of the refrigerant pipework between the

internal and external unit of the LCU DX,

must only be carried out by trained,

qualified and accredited cooling system

specialists.

Note:

Installation of the pipework, creation of a vac-

uum and filling with refrigerant must only be

carried out by qualified, accredited special-

ists in accordance with the valid technical

regulations.

Furthermore, when carrying out the installa-

tion, it is important to observe all the pipe-

work instructions in section 6.2.

Note:

Routing and support of the pipework has a

significant influence on a cooling system's

operational reliability and service-friendliness.

Rittal LCU DX 17

6 Installation

7. For intake gas lines laid vertically with the direction of

flow pointing upwards (external unit is above the in-

ternal unit), an oil elevation arc should be provided at

least every 3 m of line length. The pre-insulated pairs

of lines may be laid with no distance between them.

Protecting the pipework

1. Suitable precautions should be taken to prevent ex-

cessive vibrations or pulsations. In particular, care

should be taken to prevent the direct transmission of

noise or vibrations onto or through the supporting

structure and the connected devices.

2. Safety devices, pipework and fittings should be pro-

tected from unfavourable environmental influences

as far as possible. Due consideration should be giv-

en to unfavourable environmental influences, such

as the risk of water collecting, relief lines freezing, or

dirt and waste accumulating.

3. With long pipelines, adequate precautions should be

taken with regard to expansion and contraction.

4. The pipelines of cooling systems should be de-

signed and laid in such a way that the system cannot

be damaged by liquid slugging (hydraulic shock).

5. Pipelines with detachable connections must not be

positioned in public thoroughfares, vestibules, stair-

wells, steps, entrances, exits or in ducts or shafts

with unsecured openings to such areas, unless pro-

tected against disconnection.

6. Pipelines without detachable connections, valves,

control and regulatory devices that are protected

against accidental damage may be positioned in

public thoroughfares, stairwells or vestibules, pro-

vided they are situated at least 2.2 m above the

ground.

Pipe supports

1. Both horizontal and vertical lines must be laid with vi-

bration-damping elements (such as rubber seals).

These must be used at a spacing of at least 2 m.

2. Take care to ensure that the first pipe support be-

hind the internal unit and in front of the external unit

does not exert any mechanical pressure (via the

pipe) on the component. Pipe supports must not be

located too close to bends, to give the lines space

to expand.

Create the pipework system

1. To create the refrigerant pipework system, open the

ends of the lines on the internal unit. Upon opening,

gas should flow out audibly (from the nitrogen filling

provided in the factory) as an indication that there

are no leaks in the cooling circuit.

2. Only cut pipes to length using a pipe cutter.

3. Never saw pipes, as this could create swarf.

4. Only solder pipes under nitrogen or helium! To this

end, allow dry inert gas to flow into the pipe at one

end of the pipeline which has already been created.

Before starting, introduce a powerful current, reduce

this to a minimum when you start soldering, and

maintain this weak flow of protective gas throughout

the entire soldering process.

5. Before soldering the final connection, loosen the

screw connection on the external unit, or leave it un-

tightened throughout, so that overpressure cannot

build up in the pipeline system. Immediately after

soldering, tighten the screw connection.

6. The pipelines may only be connected to the external

unit with flares. However, flare connections should

be restricted to soft pipes! After cutting the pipes to

length, adjust to the correct internal diameter with

light flaring. The flares must be tightened with the

prescribed torque using a torque wrench.

Low-temperature insulation of the liquid line and

intake gas line

1. Both lines outside and inside the building should be

equipped with low-temperature insulation to DIN

4140 made from UV-resistant HT/Armaflex or an

equivalent material.

2. We recommend a wall thickness of 9 mm

Leak test / conducting the leak test

The system must undergo leak testing as a complete

system. A test should also be carried out on site once

the installation is complete.

Multiple techniques may be used to test for leaks, de-

pending on the manufacturing conditions, such as pres-

surisation with inert gas, or leak detection using radioac-

tive gas. In order to avoid emissions of hazardous sub-

stances, the pressure test may be carried out with inert

gas such as nitrogen, helium or carbon dioxide. Oxy-

acetylene and hydrocarbons must not be used for safety

reasons. Air and gas mixtures are to be avoided, since

certain mixtures may be hazardous.

The manufacturer must select a test method which al-

lows suitable results to be achieved in accordance with

the requirements outlined below.

Note:

Vibrations and pulsations should be as-

sessed with the system operational at maxi-

mum condensation temperature and when

switching the system on and off, which has

unfavourable impacts on the pipework.

Note:

The internal unit is pressurised (filled with pro-

tective gas)!

6 Installation

18 Rittal LCU DX

Connections must be checked with a detector or using

a technique with a detection sensitivity as described in

EN 1779 with a bubble test (application of liquid) if the

test pressure is 1 x PS.

The manufacturer must verify that the test method used

complies with the aforementioned requirements.

EN 1779:1999 may be used as a basis for this test.

The detector must be calibrated at regular intervals as

per the manufacturer's instructions.

Any leak detected must be repaired and subjected to a

further leak test.

1. Systems with dry nitrogen should be tested at a

maximum overpressure of 28 bar. When doing so,

the shut-off valves on the external unit should remain

closed. The external unit is pre-filled with refrigerant

and this must not be allowed to escape.

2. Check the complete pipe network and the system

parts for leaks. We recommend using Nekal spray to

check every connection, including screw connec-

tions, for leak-proofness.

Evacuating

1. After checking for leaks, remove the air from the sys-

tem. To do so, connect a vacuum pump and evac-

uate to a pressure of < 0.3 mbar (absolute pressure).

2. Break the vacuum at least twice, refill the system

with nitrogen, and evacuate again. Where possible,

implement double-sided evacuation of the suction

side and the pressure side of the compressor, to

which end a test/measurement connection must be

made in the liquid line.

Filling with refrigerant

1. The external unit is prefilled in the factory, the fill vol-

ume is adequate for a 5 m line pair. For longer pipe

lengths, additional refrigerant should be added in

accordance with section 11 "Technical specifica-

tions".

2. The system must only be filled gravimetrically (i.e. by

weight) using refrigerant as the liquid in the liquid

line. Only liquid R410A should be added. After-

wards, switch on the device and whilst it is running,

continue carefully restricted filling via the intake side

of the external unit until the required fill volume has

been added.

3. The set volume of refrigerant is determined by

weighing the refrigerant bottle during the filling pro-

cess.

4. The additional fill volume or the new total fill volume

should be noted on the rating plate and operating

manual.

6.3 Connecting the condensate discharge

Any condensate which may develop is collected in the

condensate collecting tray of the internal unit. For univer-

sal use, the internal unit has two condensate collecting

trays which may be fitted on the left or right of the enclo-

sure, depending on the installation position.



Connect the discharge hose supplied loose (internal

diameter 12 mm) at the bottom connection (external

diameter 12 mm).

The tray at the top is not used.



Route the discharge hose to a drain with odour seal

provided by the customer, so that any condensate

can be discharged from the device.

6.4 Electrical connection

6.4.1 General

The electrical connection can only be made on the ex-

ternal unit. The internal unit is supplied with power via

the external unit. A 3-wire power cable should be used

for this purpose. The corresponding pilot wires from the

internal unit to the external unit should be laid with the re-

frigerant lines in accordance with section 11.7 "Circuit

diagram".

Note:

Lower test pressures are admissible, provid-

ed there is an equivalent detection sensitivity.

Note:

In order to ensure safe condensate dis-

charge, the following points should be ob-

served:

– Lay the discharge hose so that it always

runs downhill and without any kinks.

– Do not constrict the hose cross-section.

Note:

Please keep the wiring plan readily available

so that it is always on hand when needed.

This is the only authoritative documentation

for this unit.

Caution!

Work on electrical systems or equip-

ment may only be carried out by an elec-

trician or by trained personnel under the

guidance and supervision of an electri-

cian. All work must be carried out in ac-

cordance with electrical engineering

regulations.

Contact with live electrical parts may re-

sult in fatal injury.

The unit may only be connected after the

aforementioned personnel have read

this information!

Use only insulated tools.

Rittal LCU DX 19

6 Installation

6.4.2 Connecting the external unit

Power is supplied to the external unit via a 3-wire con-

nection cable (230–240 V, 1~, N, PE). As external units

are generally sited outdoors, a UV-resistant cable should

be used.



Strip approximately 45 mm from the rubber sheathing

of the connection cable.



Trim the neutral conductor (N) and the phase conduc-

tor (L) to a length of approximately 35 mm. Leave the

length of the PE conductor at approximately 45 mm.



Remove approximately 9 mm from the insulation of all

conductors with a suitable tool.

Fig. 9: Dimensions for removing the rubber sheathing and in-

sulation



Attach wire end ferrules without insulating collar to the

ends of the cables, using a four-jaw pressing tool.



Insert the cable into the connection box in the device

from below.



Attach the cooling unit to the strain relief provided.



Connect the cable in the connection box as shown in

the circuit diagram in section 11.7 "Circuit diagram" to

the correspondingly labelled terminals (PE, L1, N).



Connect the external units using an all-pole isolating

device as described in DIN EN 60335-2-40. This dis-

connector device must ensure at least 3 mm contact

opening when switched off.



The customer should provide a pre-fuse in the supply

line to the external unit, as specified on the rating plate

of the device.

6.4.3 Connecting the internal unit

Connecting the internal unit simply entails connecting

the cables routed from the external unit, which comprise

a data line and a 230 V pilot wire as described in

section 11.7 "Circuit diagram".

The fault signals may be picked off at the internal unit

(floating contacts).



Should you wish to switch the internal unit on and off

via a remote switch (e.g. for an external fire shutoff),

connect a remote contact (normally open contact) in

the electronic box to terminals L1 and 11 for the "sin-

gle" version and terminals L1 and 11 as well as L2 and

23 ("remote" or "ON/OFF") for the "redundant" version

(see section 11.7.3 "Circuit diagram, external unit"). In

the closed state, the system is then deactivated.

If both terminals are jumpered, the status message

"– –" will appear in the display.

6.5 Checking the entire system prior to

commissioning

Before operating the cooling system, the entire system,

including the complete cooling system, must be

checked for conformity with the relevant diagrams, sys-

tem flow charts and piping and instrumentation dia-

grams, and wiring plans.

Cooling systems must be checked by a trained plant in-

spector (as defined in EN 13313) and should include a

review of the following points:

1. Inspect the documents.

2. Check the safety switchgear for pressure limiting to

ensure that the safety switchgear for pressure limit-

ing is operational and correctly installed.

3. Check selected hard solder connections on pipe-

work for compliance with EN 14276-2.

Caution!

Follow the connection regulations of the

appropriate electrical power company.

The voltage specified in the wiring plan

or on the rating plate must match the

mains voltage.

The unit has a high discharge current.

Before connecting to the supply circuit,

therefore, it is essential to make a 6 mm²

earth connection (see section 11.7 "Cir-

cuit diagram").

The pre-fuse specified in the wiring

plan / rating plate should be provided to

protect the cable and equipment from

short-circuits. The unit must be individu-

ally fused.

The unit must be connected to the mains

using an all-pole red/yellow isolating de-

vice as described in DIN EN 60335-2-40,

which ensures at least 3 mm contact

opening when switched off.

No additional control equipment may be

connected upstream of the device at the

supply end.

Danger!

Take utmost care not to short-circuit the

phase conductor with the zero conduc-

tor or the earth conductor. Otherwise,

there is a risk of damage or injury.

6 Installation

20 Rittal LCU DX

4. Check the refrigerant pipelines.

5. Inspect the report on the cooling system leak test.

6. Visually inspect the cooling system.

7. Check the labels.

This inspection must be documented; see EN 378-2,

section 6.4.3. No cooling system may be operated with-

out the correct documentation.

The installer must document the fact that the system

was installed in accordance with the construction re-

quirements and state the safety and control device set-

tings, if adjustable, following commissioning. This docu-

mentation must be kept by the installer and presented

upon request.

6.6 Installing the server

As a general rule, the cooling system is designed for

"front to back" cooling – in other words, the devices in-

stalled in the enclosure must likewise follow this air rout-

ing. To this end, the area in front of the 482.6 mm (19")

level is supplied completely with cold air. The servers

draw the cooling air they require from this area, and ex-

pel the warm air downwards or sideways. The area at

the rear may reach a high temperature. This is intention-

al, since it increases the transmission performance of

the heat exchanger in the internal unit.



Distribute the equipment you wish to install evenly

across the 482.6 mm (19") level.



Close any areas you do not require with 482.6 mm

(19") blanking plates.



Cover the side opposite the internal unit in the enclo-

sure with an air baffle plate (see section 13 "Accesso-

ries").

Fig. 10: Air baffle plate on the side opposite the LCU internal

unit

Key

1 Air baffle plate



Exchange the brush strip of the standard air baffle

plate in the TS IT server enclosure for the brush strip

with shorter brushes included with the supply of the

LCU DX.

The brush strip is included with the supply in two

parts.



Remove the top corner of the air baffle plate near the

TS frame using an angle grinder or other suitable tool.

Fig. 11: Cut-out in the air baffle plate

Key

1TS frame

2 Cut-out for TS frame

3 Air baffle plate

Fig. 12: Dimensions of the cut-out



Partition the remaining gap between the 482.6 mm

(19") level and the internal unit, as well as above and

below the internal unit, using the foamed plastic sup-

plied loose with the LCU DX.



Cut the foamed plastic to the required size.

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Rittal 3311.493 Assembly And Operating Manual

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