Air Booster 2
Operating instructions
Fan assisted floor tiles for data centers
230/1/50-60
Index IT30I
Issue 10.2018
A I R B O O ST E R 2
ABOUT STULZ GMBH
Since it was founded in 1947, the STULZ company has
evolved into one of the world’s leading system suppliers of
air-conditioning technology.
Since 1974 the group has seen continual international
expansion of its air conditioning technology business, specialising in A/C for data centres and telecommunications
installations.
STULZ has ten production plants (2 in Germany, Italy, the
USA, Great Britain, Spain, 2 in China, Brazil and India) and
twenty subsidiaries (in Germany, France, Italy, Great Britain,
Belgium, Brazil, the Netherlands, New Zealand, Mexico, Austria, Poland, Spain, Singapore, China, India, Indonesia, South
Africa, Sweden, Australia and the USA).
The company also co-operates with sales and service partners in over 140 other countries, and therefore boasts an
international network of air-conditioning specialists.
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STULZ SpA
Via Evangelista Torricelli n.3
37067 Valeggio sul Mincio VR
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A I R B O O ST E R 2
Air Booster 2
Dear customer,
thank you for having chosen Air Booster 2 from STULZ.
It's the result of decades of research and design studies, with a fine search of materials and
technologies to obtain an high quality unit.
The CE mark guarantees that the STULZ products satisfy the requirements of the European
Machinery Directive for safety.
The level of quality is constantly checked at every stage, from design to production, making the
STULZ products synonymous of SAFETY, QUALITY and RELIABILITY.
For further information concerning our products and services visit our website :
www.stulz.com
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A I R B O O ST E R 2
STULZ reserves the right to update the product and the relevant manual without having to update products
and manuals sold previously except under exceptional circumstances.
Contact your local STULZ partner when requesting or receiving any updates of instruction manuals or corrections when which are considered to be integral parts of the manual.
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Table of contents
1..Introduction............................................................................................................6
1.1..Symbols used in this manual..................................................................................................................... 6
1.2..Attachments.................................................................................................................................................... 6
2..Safety directions....................................................................................................7
2.1..Introduction..................................................................................................................................................... 7
2.2..General rules................................................................................................................................................... 7
2.3..Residual hazard.............................................................................................................................................. 8
2.4..Labels................................................................................................................................................................ 8
2.5..Intended and non-intended use.............................................................................................................10
3..Handling and storage...........................................................................................10
3.1..Unit receipt....................................................................................................................................................10
3.1.1.Precautions when handling the unit.............................................................................................11
3.2..Storage...........................................................................................................................................................12
4..Description ..........................................................................................................13
4.1..Coding.............................................................................................................................................................13
4.2..Component lay-out and operating principle......................................................................................13
4.3..Components..................................................................................................................................................15
4.4..Electrical components of protection and control.............................................................................15
5..I/O Controller ......................................................................................................16
5.1..User interface...............................................................................................................................................16
5.1.1.Quick display menu (actual value display)..................................................................................17
5.1.2.Basic display and setpoint..............................................................................................................18
5.1.3.Selection menu...................................................................................................................................19
5.1.4.Lock and unlock the keypad..........................................................................................................19
5.2..Parameters ...................................................................................................................................................20
5.3..Setting the operating mode.....................................................................................................................21
5.3.1.Temperature control.........................................................................................................................22
5.4..System states...............................................................................................................................................22
5.5..Alarms..............................................................................................................................................................23
5.6..Modbus RTU datapoint.............................................................................................................................25
6..Technical data......................................................................................................26
6.1..Application limits..........................................................................................................................................26
6.2..Technical data..............................................................................................................................................26
6.3..Drawings.........................................................................................................................................................27
7..Installation............................................................................................................27
7.1..Adjusting the airflow direction................................................................................................................29
7.2..Electrical Connections...............................................................................................................................30
8..Start-up................................................................................................................31
8.1..Commissioning.............................................................................................................................................31
8.2..Checks after commissioning ..................................................................................................................31
8.3..Switching off.................................................................................................................................................32
9..Maintenance.........................................................................................................32
9.1..Safety instructions......................................................................................................................................32
9.2..Preventive maintenance schedule........................................................................................................33
9.2.1.General cleaning.................................................................................................................................33
10..Troubleshooting.................................................................................................34
11..Uninstalling and disposal of the unit..................................................................34
12..Accessories........................................................................................................35
12.1..Light duty grille - ACTBALDG .............................................................................................................36
12.2..Heavy duty grille - ACTBAHDG...........................................................................................................36
12.3..Installation of the grille ...........................................................................................................................37
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A I R B O O ST E R 2
1. Introduction
This manual reflects the state of the art existing at the time the product is marketed and shall not be
considered unsuitable merely because it has not been updated following developments in design
and manufacturing methods. Air Booster 2 units are meant to supply a suitable flow of cold air to all
servers to ensure their reliability and optimum working conditions.
Air Boosters are a solution for server rooms whose original layout, load distribution or pressure
conditions in the raised floor have been modified, for example, by additional installations. In these
cases, Air Boosters can be used to adapt the air distribution to the new requirements.
These operating instructions are intended for the following authorized personnel:
• USER: he must know and apply the safety directions and the instructions contained in the present
manual, for correct use of the unit.
• INSTALLER: The unit must be installed that the airflow is directed to the server racks. In doing so,
ensure that installation is in compliance with local safety regulations and instructions contained in
the present manual.
• MAINTENANCE TECHNICIAN: he's a technician authorized by the manufacturer for the start-up
of the unit, technical assistance, ordinary and extraordinary maintenance, reparations.
The qualified personnel consists of professional figures authorized by the safety responsible to
do the activities listed above, due to their training, education, experiences, as well as their specific
knowledge of safety work rules and injury prevention.
INFORMATION
The manufacturer is not responsible for an misuse of the unit, as well as for non-authorized
modifications and for the inobservance of instructions on this manual. The occurring of any of
the conditions above immediately invalidates guarantee coverage for the product.
This manual must be kept by the customer and made available to the installation, commissioning,
use and maintenance personnel.
1.1.
1.2.
Symbols used in this manual
DANGER
RISK OF INJURY FOR OPERATOR AND
POSSIBILITY OF DAMAGING THE UNIT
ATTENTION
INFORMATION OR WARNING OF CAUTION
IN CARRYING OUT A PROCEDURE
INFORMATION
IMPORTANT INFORMATION
Attachments
The following document is attached to this manual, as its integral part:
• Use and maintenance manual part 2, which contains the electrical drawing and the conformity
declaration UL/CE of the unit.
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2. Safety directions
These operating instructions contain basic information which is to be complied with for installation,
operation and maintenance. They must therefore be read and complied with by the fitter and the
responsible trained staff/operators before assembly and commissioning. They must be permanently
available at the place where the system is used.
2.1.
Introduction
This Air Booster 2 unit has been designed and built for a professional use according to applicable
regulations. Please check the complete list of applicable regulations in the attached CE and UL
conformity declaration.
The unit is in conformity with the following CE Directives:
• EN61000-6-2 and EN61000-6-3 - Electromagnetic compatibility
• EN60335 Safety of electrical appliances
It's necessary to respect the regulations of the Country where the product is installed.
2.2.
General rules
DANGER
• Works have to be carried out by competent staff only.
• Observance of regulations for accident prevention.
• Stay out of danger when lifting and setting off the unit.
• Safety devices may not be bypassed.
• Respect the corresponding EN and IEC standards for the electric connection of the unit and
observe the conditions of power supply companies.
• Switch off the voltage from the unit when working on it.
ATTENTION
• Observe the national regulations of the country where the unit will be installed.
• For transport, installation, either ordinary or extraordinary maintenance, operators and
maintenance people must wear individual protection devices (i.e. gloves, glasses, helmet,
shoes), according to the indications of safety manager and applicable regulations.
• The unit may only be used to cool according to the STULZ specification.
• Before any maintenance operation, read and follow instructions in the corresponding chapter.
INFORMATION
• Any special opening tools have to be placed in a visible location nearby the unit.
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2.3.
Residual hazard
During transport and installation
Area
Danger
Risk
Preventive measures
Under
the unit
Defective lifting system of the unit
that causes its fall.
Contusions,
traumas
Keep away from dangerous area during handling of the unit.
Electrical
box
Supply cables under voltage.
Electrocution
Check that the power supply of the electrical box has been
insulated. Remain electrically insulated from the ground. Wear PPE.
During start-up and operation
Area
Danger
Risk
Preventive measures
Near the unit
Launch of tools and various hardware (nuts,
screws, etc.) that can accidentally fall on the
fans blades.
Contusions,
traumas
In the installation phase, be sure to remove
tools and other installation materials. Wear PPE.
Near the unit
Aspiration and following expulsion from the
fans of objects, dusts and substances present
on the installation site.
Contusions,
traumas,
inhalation of dusts
Clean installation area. Wear PPE.
In contact with
the unit
Electrical connection against regulations and
missing ground connection.
Electrocution
Remain electrically insulated from the ground.
Wear PPE.
Near the unit
(electrical box,
supply cables)
Short circuit; wrong dimensioning of the
cables or of the general breaker.
Electrocution, fire,
forming of acid
vapours
Check the fixing of cables in the terminals:
select adequately supply cables and main
switch. Wear PPE.
During maintenance
Area
Danger
Risk
Preventive measures
Electrical box
Powered line even if the switch
of the machine is on OFF.
Electrocution
Check the insulation of the power supply from the
electrical panel. Be sure that the main switch will not be
re-activated during maintenance.
Operation of the fans
during maintenance
Contact with moving surfaces.
Cuts, abrasions,
bruises
Be sure to remove power during maintenance and wait the
stop of the moving parts. Wear PPE.
Hot components
Contact with hot surfaces.
Burns
Wear PPE
During uninstalling
2.4.
8
Area
Danger
Risk
Preventive measures
Electrical
box
Powered line even if the switch
of the machine is on OFF.
Electrocution
Check the insulation of the power supply from the electrical panel.
Be sure that the main switch will not re-activated during maintenance
Labels
DANGER: MOVING
COMPONENTS
DANGER: HIGH VOLTAGE
DANGER: HOT COMPONENTS
LIFT THE UNIT USING
THESE HANDLES
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Technical name-plate
The unit can be correctly identified by the technical name-plate. The name-plate is located on the
external casing of the unit, on the side.
Unit type
Serial no.
Unit type
Serial no.
ATTENTION
For any assistance or information concerning the unit described in this manual, knowledge of its
serial number is essential.
Labels on the packaging of the unit, on both sides
CE marked
UL marked
Maximum 5
units one above
the other
Keep dry
Position
Fragile
Do not step
Lift cart here
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A I R B O O ST E R 2
2.5.
Intended and non-intended use
Intended use
The Air-Booster2 is used to control airflow and is designed for indoor installation.
Any use beyond this is not deemed to be use as intended. STULZ is not liable for any damage
resulting from such misuse. The operator alone bears the risk.
INFORMATION
The use of Air Booster 2 for hotspot cooling requires that the airflow provided by the air
conditioners is sufficient for the entire room. To make this sure we recommend the use of a
raised floor pressure management.
DANGER
The units may not be used or transported in a position other than that for which they have been
designed. STULZ declines all liability deriving from failure to observe the above.
Non-intended use
The unit cannot be installed in the following areas:
• With strong heat radiation;
• With strong magnetic fields;
• With free flames;
• With fire risk;
• With inflammable products;
• With explosive atmosphere;
• With saline atmosphere;
• With aggressive atmosphere.
For any doubt, please consult the manufacturer.
3. Handling and storage
3.1.
Unit receipt
STULZ products are delivered ex-works. All units have been individually inspected in all their
components and been carefully packaged before the delivery. Immediately inspect the unit upon
receipt of the goods.
• The delivery note can be found on the A/C unit when delivered.
• The shipment is make ex works, in case of shipment damages, please assert your claim towards
the carrier.
• Hidden damage, that are verified after removal the packing, must always be notified to the shipper
by registered letter within 8 days of receipt of the goods.
• Before throwing the packaging away check that it does not contain any documents or parts of the
machine.
INFORMAZIONI
When delivery is accepted, the unit is to be checked against the delivery note for completeness
and checked for external damage which is to be recorded on the consignment note in the
presence of the freight forwarder.
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If installation of the product is not required immediately or the product needs to be forwarded to
its final destination, replace it in its packing, after inspecting it, and store it in a safe place. As an
environmental concern, we recommend to recycle the packing cartons and to separate them from
any plastic.
INFORMATION
With ex-works delivery conditions, carrier is the sole responsible for any damage caused during
transport. STULZ is not responsible for damages to the goods caused by the carrier, but will do
everything in its power to assist clients on those situations.
This product cannot be returned without prior approval of STULZ. For any assistance, please
consult your local STULZ partner.
3.1.1. Precautions when handling the unit
Handle these units, when they are packaged and complete of pallet, using a fork lift. When they are
not packaged, use a hoisting machine equipped with cables or chains suited for supporting their
weight or use the handles inside the unit (the grill has to be removed to access the handles).
ATTENTION
Risk of personal injuries during materials handling
Material handling and unpacking must be done only by trained personnel with suitable individual
protection devices (i.e. gloves, glasses, helmet, shoes)
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A I R B O O ST E R 2
LIFTING AND TRANSPORT
DANGER
Capacity of lifting device must be appropriate for the weight of the unit.
Load must be balanced to avoid tilting.
Avoid offhanded or rough manoeuvres.
Don’t lay other objects upon the unit.
When removing the grill take care of avoid pinching under its weight
ATTENTION
Risk of unit deformation
Don’t move the unit on rolls, or with forklift after removing the pallet, to avoid any structural
deformation.
3.2.
Storage
INFORMATION
Standard packing doesn't protect the unit from rain and bad weather
Standard packing is not suitable for seafreight
Standard packing is not suitable for airfreight
If the unit is stored before the installation, comply with the following instructions:
• Don't expose to direct solar radiations;
• Store the unit with its original packaging.
Please see the ambiental condition for storage in paragraph "Application limits".
Removal of packing
• Remove packing without damaging the unit: remove the box and the pallet under the unit;
• Recover any document or component inside the packing;
• Keep original packing (pallet and protections) for future shipments.
ATTENTION
Use original packing to ship the unit to any other destination
If packing disposal is necessary, we remind to dispose different materials suitably
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4. Description
4.1.
Coding
Product type
Size
Configuration
Type of control
Application
Power supply
Grille
BAF 60 F D 2 20 -LD
HD= Heavy duty
LD = Light Duty
20 = 230V/1ph/50-60 Hz
2 = For floor mounting
D = With control inside
N = No control inside (must be connected to ACTPCMP)
F = Fan + Air deflector
600x600 mm
Booster Air Fan
4.2.
Component lay-out and operating principle
In conventional raised-floor systems, the cold air required to cool the servers flows in front of the
server racks via perforated plates from the raised floor. The air volume depends on the pressure in
the raised floor and the degree of perforation of the floor tile.
If this system can not deliver the airflow required by the servers to where it is needed, the floor tile
can be replaced by an Air Booster 2. The reasons for an adjustment of the air supply can be caused
for example by changes in the configuration of the rack (conversion to high density racks) or by
changes in the raised floor which lead to pressure drops which were originally not calculated.
Air Booster 2 delivers exactly the required amount of cold air to the server rack using variable-speed
EC fans. The air stream can be adjusted to two zones per server rack by means of the manually
adjustable air conduction fins. An Air Booster 2 consists of a fan module and a grille. Information
about the different grilles can be found in the chapter grilles.
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A I R B O O ST E R 2
Components lay-out
Damper
Main switch
Keypad
Electrical box
Connections interface
Fan
Operating methods
Temperature control
For Air Booster 2 with their own control (type BAF60FD220), the control of the fan speed depends
on the measured temperatures. Three temperature sensors have to be installed in the high part, the
middle and in the lower part of the rack. The fan speed of the Air Booster 2 is proportional to the
average temperature of the three temperature sensors of the rack, or is proportional to the maximum
temperature detected from the sensors, according to the controller settings. According to this
working mode, the unit has to have the control inside and it works according to the basic principle
that the air delivered to the rack is directly proportional to the desired set point. The controller
ensures smooth transition of fan speed with reference to the set point. Air Booster 2 floods the cold
aisle on the front of the server rack with sufficient cold air as desired.
Pressure control (optional)
To enable the pressure control mode is an external pressure control module (option ACTPCMP)
in combination with an Air Booster 2 without own control (type BAF60FN220) required. The fan
speed is proportional to the difference between the pressure set point and the value measured by
the module and it's controlled by the accessory ACTPCMP. The server temperature management
requires constant pressure conditions in the data centre. In the best of cases, the air is conveyed
from the cold aisle exclusively by the server fans through the rack and not by a pressure difference
between cold aisle and warm aisle.
The pressure control is a pressure limitation, to protect the fans integrated in the servers against
overpressure.
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4.3.
Components
Structure
These machines are built using self-supporting panels made of painted galvanised sheet metal
to guarantee good corrosion resistance (not suitable for corrosive and saline environments). The
internal components of the unit can be accessed by simply removing the upper grill.
Fan
The fan is an infinitely variable axial fan with EC drive and PP coated sheet steel blades.
The bearings of the fans are lifetime lubricated and do not need maintenance.
4.4.
Electrical components of protection and control
Contactors
They control the motors by operating with auxiliary voltage. They refer to IEC947-4-1 standards.
Automatic circuit breakers
They protect against short circuits and excessive motor current. They have adjustable thermal and
magnetic triggering devices.
Main switch
A main switch is located on the top of the unit, under the grille. It's used to disconnect main power
supply to the unit. When switched off, it interrupts power supply to the unit circuits from it downstream.
Temperature probes
Three NTC temperature probes are connected to analogue inputs of electronic controller for units
with controller on board and they have to be positioned in the lower part, in the middle and in the
high part of the rack.
Temperature probe 1
Temperature probe 2
Temperature probe 3
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A I R B O O ST E R 2
5. I/O Controller
Air Booster 2 of type BAF60FD220 are equipped with the controller described in the following.
In the factory setting, Air Booster 2 operates on temperature control. Once the system is in
"System ON" mode, the unit controls fan speed automatically, in dependence of the measured
temperature values. If the measured value exceeds the set point, the fan speed increase, if the
temperature difference between set point and measured value decreases, the fan speed is reduced
proportionally up to the minimum speed. For units with controller on board, the microprocessorbased electronic board is equipped with a set of terminals which are necessary to connect the
board to the controlled devices (e.g. the fan). Software with working logic and parameter settings
are safely stored in the EEPROM so that they remain permanently in case of power failure. The
controller is housed inside the electrical box. A keypad is connected to display information about
working conditions, status of the unit and alarms, if any. The controller has an RS485 interface for
communication with a building management system. The used protocol is ModBus RTU.
Technical data of the controller:
• Power Supply: 230 Vac ±10% - 50/60 Hz
• Power consumption: 10 VA max
• Communication protocol: Modbus – RTU
• Data storage on non-volatile memory (EEPROM)
• Operating temperature: -20 ÷ 60°C
• Storage temperature: -40 ÷ 90°C
• Relative humidity < 90%
5.1.
User interface
Display
ON/OFF
Turns the unit on and off
SET
View / Edit the set point.
It selects a parameter or
confirms a value.
Function key UP
• To scroll through the parameters or
increase their value.
• Quick menu access
Function key DOWN
• To scroll through the parameters or
decrease their value.
Technical data of the user interface:
• Dimensions 75x36 mm; depth 23 mm;
• Protection rating IP20;
• Front protection rating IP65;
• Display: 3 keys, blue LED and height 14,2 mm.
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Key Combinations
+
+
+
Meaning of combinations
Lock / Unlock the keypad. See paragraph "5.1.4. Lock and unlock the keypad".
• To go into programming mode.
• In parameter programming mode: Pr2 level ("Selection menu") is used to change the visibility of the
displayed parameter in level Pr1 (first menu level).
• If the decimal point is on while the parameter’s label is displayed, this means that the parameter is visible in
programming level Pr1 (first menu level).
Exit from programming mode.
Display - The values of the parameters and the operating mode are shown on the display
LED
MODE
MEANING
LED
MODE
ON
MEANING
ON
The unit is in ‘System ON’
Cooling is requested, the unit operates according to the set parameters.
ON
An alarm occurred
Flashing
During delay upon start-up (ton) and delay upon shutdown (toF)
ON
Unit of measurement
Flashing
Programming
Unit of measurement
The instrument allows you to set the unit of measurement for the display and settings.
Label
Description
Range
°C/°F (appears on the display)
Celsius, Fahrenheit
°C(0) - °F(1)
rES
Resolution (only for temperature in °C):
decimal , integer
dE(0) - in(1)
PMU (doesn’t appear on the display)
Unit of measurement of the Pressure
Bar(0) - PA(1)
Display probe selection by default
b1 = probe P1 (upper temperature)
b2 = probe P2 (middle temperature)
b3 = probe P3 (lower temperature)
b4 = air pressure probe
Avr = average temperature of the enabled probes
MAu = Max temperature value of the enabled probes
Lod
5.1.1. Quick display menu (actual value display)
The quick display menu is used to display actual values of the following inputs:
1. Probe B1 value (upper temperature)
2. Probe B2 value (middle temperature)
3. Probe B3 value (lower temperature)
4. Temperature probe average value (Avr)
5. Temperature probe max value (MAu)
6. Probe B4 value (air pressure probe)
7. Analogue output value AO1 (1st Analogue Output) and AO2 (2nd Analogue Output)
8. Digital input value In1 (1st Digital Input) and In2 (2nd Digital Input)
Starting from the main screen press function key UP to enter the quick display menu, from there
follow the procedure below:
1. To go through the list, press UP and DOWN;
2. Press SET to display the corresponding value of the resource. When it's displayed the value of the
parameter in the quick display menu, it's not possible to do other operations.
3. Press SET to go back to the list.
4. Press SET + UP to go back to the main screen.
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INFORMATION
• The temperature values (B1, B2, B3) are expressed in Celsius or Fahrenheit degrees;
• The pressure value (B4) is expressed in Bar or PA;
• Flashing “Err” label indicates that there is a probe failure;
• “nu” (not used) label indicates that the probe is not enabled or that the analogue output / digital
input is not used by any function;
• A value from 0% to 100% expresses the output value of the resource, for analogue outputs
AO1 and AO2;
• “OFF” label indicates that the digital input (In1, In2) is not enabled, while “ON” indicates that the
digital input (In1, In2) is enabled.
5.1.2. Basic display and setpoint
The temperature (SPt) or pressure (SPb) setpoint is displayed according to the type of control,
temperature or pressure control. If there is no operation for at least 30 seconds, the display of the
controller returns automatically to basic display.
5.1.2.1. Controller logic and main parameters
Fan Speed
UAF %
LAF %
SPt - HL SPt
SPt + HY
UAF
Maximum fan speed (100%)
LAF
Minimum fan speed (20%)
SPt
Temperature setpoint (25°C)
HL
Temperature switch-off hysteresis (3°C)
HY
Temperature proportional band (10°C)
tIP
Calculated temperature
tIP
The factory setting and the complete parameter list is provided in chapter 5.2.
5.1.2.2. Changing the setpoint
Make sure that the keypad is not locked (see paragraph 5.1.4). To modify the setpoint, follow the
procedure below:
1. Press SET;
2. The temperature (SPt) or pressure (SPb) setpoint is displayed and °C/°F led starts to flash;
3. To change the value, press UP and DOWN keys;
4. To save new setpoint and return to the standard display, press SET or wait 30 seconds to exit the
programming.
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5.1.2.3. Changing the value of a parameter
Make sure that the keypad is not locked (see paragraph 5.1.4). To change the value of a parameter
proceed as follows:
1. To access the programming mode, hold down SET + DOWN key for few seconds (°C/°F led
flashes);
2. Select the desired parameter;
3. Press SET to display the value;
4. Change it with UP and DOWN keys;
5. Press SET to save the new value and go to the next parameter.
6. To exit, press SET + UP key when a parameter is displayed, or wait 30 seconds without pressing
any key.
INFORMATION
The new set value is saved even when you exit without pressing SET.
5.1.3. Selection menu
Via the selection menu, you can navigate to the parameters which you want to read, change or
transfer to the quick display menu.
Access to the hidden menu (Pr2)
To access to the hidden menu, proceed as follows:
1. Access to programming by pressing SET + DOWN key for 3 seconds (°C/°F led flashes);
2. When a parameter is displayed, hold down SET + DOWN key for more than 7 seconds. ‘Pr2’
message will appear immediately on the display, followed by temperature proportional band
parameter (HY). You are now in the hidden menu;
3. Select the desired parameter;
4. Press SET to display the value;
5. Change it with UP and DOWN keys;
6. Press SET to save the new value and go to the next parameter.
7. To exit, press SET + UP key when a parameter is displayed, or wait 15 seconds without pressing
any key.
INFORMATION
After 30 seconds, the new set value is saved even when you exit without pressing SET.
Move a parameter from the hidden menu on the first level and vice versa.
Each parameter in the hidden menu can be removed or entered into the first menu level (Pr1) by
pressing SET + DOWN key. If a parameter is in the first menu level (Pr1), when you are in the hidden
menu the decimal point is on.
5.1.4. Lock and unlock the keypad
To lock the keypad proceed as follows:
1. Hold down UP and DOWN keys for few seconds, until “POF” starts to flash. Press SET to finish
setting.
2. At this point, the keypad is locked. When the keypad is locked, the quick display menu is shown, but
it's not possible to make modifications. With the key SET you can switch between the display of
the actual value and the setpoint even in the locked mode.
3. If a key (not up arrow) is pressed for more than 3 seconds, “POF” appears.
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To unlock the keypad: hold down UP and DOWN keys for few seconds, until “POn” starts to flash.
Manual reset after locking alarms
If the unit is locked, press DOWN key for 3 seconds to reset the unit. It allows MANUAL UNLOCK
function (manual reset of alarms) when the unit is locked due to:
• FAN BLOCKED alarm (at least 4 events in 4 hours)
• DAMPER BLOCKED alarm
• MOTOR BLOCKED alarm
• HIGH PRESSURE alarm
5.2.
20
Parameters
Label
Description
Range
Preset
value
SPt
Temperature setpoint (Type 1)
[LS ÷ US]
25°C
SPb
Pressure setpoint (Type 2)
[LSb ÷ USb]
20 Pa
LS
Temperature setpoint lower limit
°C [-40,0 ÷ SPt] °F [-40 ÷ SPt]
5°C
US
Temperature setpoint upper limit
°C [SPt ÷ 110,0] °F [SPt ÷ 230]
50°C
LSb
Pressure setpoint lower limit
Bar [0 ÷ SPb] PA [0 ÷ SPb]
10 Pa
USb
Pressure setpoint upper limit
Bar [SPb ÷ 50,0] PA [SPb ÷ 725]
80 Pa
Ctr
Type of control tPr÷ PrS
tPr (temperature control) ÷ PrS (pressure control)
tPr
CMt
Temperature control mode
BAF (Air Booster Fan) ÷ BAM (Air Booster Modulator)
BAF
CF
Temperature unit of measurement: Celsius, Fahrenheit
°C(0) - °F(1)
°C
rES
Resolution (only for T in °C): decimal , integer
dE(0) - in(1)
dE
PMU
Unit of measurement of the Pressure
Bar(0) - PA(1)
PA
Lod
Display probe selection by default
b1 = probe P1 (upper temp)
b2 = probe P2 (middle temp) / b3 = probe P3 (lower temp)
Avr = average temperature of the enabled probes
MAu = Maximum temperature value of the enabled probes
Avr
tIP
Calculated temperature
b1 = probe P1 (upper temp)
b2 = probe P2 (middle temp) / b3 = probe P3 (lower temp)
Avr = average temperature of the enabled probes
MAu = Maximum temperature value of the enabled probes
Avr
HY
Temperature proportional band
°C [0,1÷ 25,5] °F [1 ÷ 45]
10°C
Int
Integral time for the temperature adjustment
0 ÷ 999 (seconds)
0 sec
HL
Temperature switch-off hysteresis
°C [0,1÷ 25,5]
3°C
HP
Pressure switch-off hysteresis
Bar [0,1÷1,0] Pa [1 ÷ 10]
30 Pa
LAF
Minimum speed with CMt = BAF
0 ÷ UAF
20%
UAF
Maximum speed with CMt = BAF
LAF ÷ 100
100%
LAM
Lower operating limit with CMt = BAM
0 ÷ UAM
10%
UAM
Upper operating limit with CMt = BAM
LAM ÷ 100
100%
bPb
Pressure proportional band
Bar [0,1 ÷ 25,5] PA [1 ÷ 360]
20 Pa
Inb
Pressure integral time
0 ÷ 999 (seconds)
0 sec
Lab
Lower operating limit with Ctr = PrS
0÷UAb
10%
UAb
Upper operating limit with Ctr = PrS
LAb ÷100
100%
ton
Delay upon start-up
0 to 255 seconds
0 sec
toF
Delay upon shutdown
0 to 255 seconds
0 sec
ALL
Low temperature alarm
°C [-40,0 ÷ ALU] °F [-40 ÷ ALU]
5°C
ALU
High temperature alarm
°C [ALL ÷ 110,0] °F [ALL ÷ 230]
50°C
HLA
Low temperature alarm hysteresis
(differential for low temp alarm to be restored)
°C [0.1 ÷ 25,5] °F [1 ÷ 45]
2°C
HHA
High temperature alarm hysteresis
(differential for high temp alarm to be restored)
°C [0.1 ÷ 25,5] °F [1 ÷ 45]
2°C
ALd
Temperature alarm delay (in normal mode)
0 to 255 seconds
20 sec
dAo
Temperature alarm exclusion at power on
0 to 255 seconds
60 sec
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A I R B O O ST E R 2
ALP
High pressure alarm
0,1 ÷ 50 Bar; 0 ÷ 725 PA
300 Pa
HPA
High pressure alarm hysteresis
(differential for high pressure alarm to be restored)
0,1 ÷ 25,5 Bar; 1 ÷ 360 PA
10 Pa
dAP
Pressure alarm delay (in normal mode)
0 to 255 seconds
20 sec
b1
Presence of Probe P1 (Upper temperature)
n (no) - y (yes)
yes
OF1
Calibration probe (ntc) P1
°C [-12,0 ÷ 12,0] °F [-21 ÷ 21]
0°C
b2
Presence of probe P2 (Middle temperature)
n (no) - y (yes)
yes
OF2
Calibration probe (ntc) P2
°C [-12,0 ÷ 12,0] °F [-21 ÷ 21]
0°C
b3
Presence of probe (ntc) P3 (Lower temperature)
n (no) - y (yes)
yes
OF3
Probe P3 calibration
°C [-12,0 ÷ 12,0] °F [-21 ÷ 21]
0°C
b4
Presence of probe (mA) P4 (Air Pressure)
n (no) - y (yes)
no
OF4
Calibration probe P4
Bar [-12,0 ÷ 12,0] PA [-21 ÷ 21]
0 Pa
LCi
Pressure probe scale start
[-1,0 Bar] [-15 PA] ÷ UCi
0 Pa
UCi
Pressure probe scale end
LCi ÷ [50 Bar] [725 PA]
250 Pa
i1F
Digital input 1 function
nu(0) - OFF(1) where ‘nu’= not used
nu
i1P
Digital input 1 polarity
OP(0) - CL(1)
CL
i2F
Digital input 2 function
nu = Disabled
Fan = Fan Blocked Alarm (Ctr = tPr/ CMt = BAF)
dMP = Damper Blocked Alarm (Ctr = tPr/ CMt = BAM)
Mtr = Motor Blocked Alarm (Ctr = PrS)
Fan
i2P
Digital input 2 polarity
OP(0) - CL(1)
OP
t2d
Digital input 2 alarm delay
0 to 255 seconds
10 sec
AdP
Analogue output percentage for damper alarm
LAM ÷ UAM
20%
OPC
ON-OFF key enabling
no(0) - yes(1)
yes
AOP
Alarm output polarity
OP(0) - CL(1)
OP
tbA
Silencing the Alarm
no(0) - yes(1)
no
Adr
Serial Address
1 ÷ 247
1
br
Baud Rate selection
96(0) - 192(1)
9600
rEL
Firmware release code
read only
Ptb
EEPROM map identification
read only
INFORMATION
Marked parameters of the list above are not used on BAF units.
5.3.
Setting the operating mode
The controller can use 2 different types of input, mutually exclusive and that are selected with
parameter Ctr, Control type.
• Ctr = tPr: Temperature control, with up to 3 temperature probes, NTC 10K type at 25°C;
• Ctr = PrS: Pressure control, with an input of 4-20mA type, connected to the pressure transducer.
INFORMATION
When the control type is selected, only the sensors assigned to it are taken into account. For
example, a connected pressure probe is not considered in the temperature control mode.
The probe value is displayed only if the probe is connected. If the probe is not used and not
connected, “nu” (not used) label appears on the display.
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5.3.1. Temperature control
The parameters involved for temperature control are: SPt, LS, US.
After the selection of temperature control, select the type of application via parameter CMt.
• CMt = BAF: Air Booster Fan -> Fan Mode
Fan Mode
The parameters involved for fan mode of temperature control are: SPt, tIP, HY, int, HL, LAF, UAF.
• The control must command an electronic fan.
• The associated digital output will be K1 and it will be enabled when the controller is set to ON,
after the delay upon start-up (ton).
• The associated analogue output will be equivalent on both outputs AO1 and AO2 and will be
enabled after the delay upon start-up (ton).
• The control signal depends on the setting of temperature calculation parameter (tIP).
Proportional adjustment
SWITCH-ON:
• The analogue output will be 0 if: tIP ≤ SPt - HL + 1
• The analogue output will be at the minimum speed value (LAF) with: SPt - HL + 1≤ tIP ≤ SPt
• The analogue output will be at the maximum speed value (UAF) with: tIP ≥ SPt + HY
• The intermediate values will be calculated based on the two extreme values reported above
SWITCH-OFF:
• The analogue output will be 0 if: tIP ≤ SPt - HL
• The analogue output will be at the minimum speed value (LAF) with: SPt - HL ≤ tIP ≤ SPt
• The analogue output will be at the maximum speed value (UAF) with: tIP ≥ SPt + HY
INFORMATION
If HL=0 (temperature switch-off hysteresis equal to zero), activation and deactivation on
temperature setpoint (SPt) occurs; the minimum value for the required operation to be
attributed to parameter HL is 0,5 °C.
Adjustment PI
The analogue output will modulate between minimum (LAF) and maximum (UAF) speed value, in order
to reset the error between temperature calculation (tIP) and temperature setpoint (SPt), considering
the temperature proportional band (HY) as a proportional component and integral time for temperature
adjustment (int) for the calculation of the integral part. With an integral type of adjustment, the steadystate system can always reach the setpoint if the load conditions are constant.
5.4.
System states
The parameters involved are: ton, toF, OPC.
Switch-on adjustment delay
Upon switch-on, in “System ON” state, the controller will wait for the delay upon start-up time (ton)
before starting to regulate. This not only applies to the switch-on, but also when switching from
“System OFF” to “System Stand By” or to “System ON”.
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Shutdown adjustment delay
Upon shutdown of the controller from the keypad or remotely, therefore “System OFF” or “System
Stand By”, the controller will continue to work throughout the delay upon shut-down time (toF).
• Switch from “System ON” to “System OFF” and vice versa by pressing ON/OFF button on the
keypad.
• Switch from “System ON” to “System Stand By” and vice versa by switching the signal on the
digital input DI1, if configured as Remote Enable.
INFORMATION
The ON/OFF button on the keypad will have priority on the remote contact, therefore if the
button is pressed when in “System Stand By” it will go to “System OFF”.
5.5.
System state
Behaviour
System ON
Normal operation of the controller
System OFF
All the disabled outputs and inputs, when alarm output polarity (AoP) = oP,
K4 alarm relay will normally remain energised
System Stand-by
All the disabled outputs and inputs, when alarm output polarity (AoP) = oP,
K4 alarm relay will normally remain energised
Alarms
• All alarms will switch K4 alarm
• The output of K4 alarm relay can be configured from parameter AoP =OP / CL
• The alarm relay only changes when the unit is in alarm state
• All alarms give an error code on the display
• The manually reset of alarms can be done from the keypad; see the procedures for each alarm
when the state changes or from Modbus.
Alarm
Parameters
involved
Enabling conditions
Disabling conditions
High
temperature
Ctr, ALU,
HHA, ALd,
dAo, tIP
Alarm conditions occur when:
Ctr = tPr (temp control) and
tIP > ALU. Alarm is signalled
if the delays have elapsed:
dAo / ALd
Normal operating condition is restored
when: tIP < ALU - HHA.
Low
temperature
Ctr, ALL,
HLA, ALd,
dAo, tIP
Alarm conditions occur when:
Ctr = tPr (temp control) and
tIP < ALL. Alarm is signalled
if the delays have elapsed:
dAo / ALd
Normal operating condition is restored
when: tIP > ALL + HLA.
Ctr, ALP,
HPA, dAP
Alarm conditions occur when:
Ctr = PrS (pressure control)
and B4 > ALP
Alarm is signalled if the delay
dAP has elapsed.
High
pressure
Fan blocked
Ctr, CMt,
i2F, i2P,
t2d, ton
Alarm conditions occur when:
-- Ctr = tPr (temp control)
-- CMt = BAF
-- i2F = Fan
-- ton > t2d
Alarm is signalled after dig-in
2 alarm delay (t2d), after the
digital input is activated.
© STULZ SpA . – all rights reserved EN/10.2018/IT30I
Normal operating condition is restored
when:
• B4 < ALP - HPA
• Press DOWN key for 3 sec
Reset
Actions and display
Automatic
Alarm is not signalled.
During the alarm, “HA”
message appears on the
display alternated with
standard display.
Automatic
Alarm is not signalled.
During the alarm, “LA”
message appears on the
display alternated with the
standard display.
Manual
The alarm is also disabled by:
a. Instrument restart shutdown
b.Cycle of Stand-by/Off followed by restart.
High pressure alarm will
open K1 relay and bring
An-out AO1 and AO2 to 0 V.
Automatic disabling: as soon as the dig-in
is disabled, if max 3 activations occur within
4 hours. Manual disabling: it switches from
automatic to manual if 4 activations occur
within 4 hours.
Normal operating condition is restored
when:
- Dig-in is deactivated
- Press DOWN key for 3 sec
- ton < t2d
The alarm is also disabled by:
a. Instrument restart shutdown
b.Cycle of Stand-by/Off followed by restart.
During the alarm, “HP”
message appears on the
display alternated with the
standard display.
Automatic
Manual
With automatic reset,
“Fan” appears on the
display alternated with the
standard display.
With manual reset, “Fnb”
appears on the display
alternated with the standard
display.
Fan blocked alarm will open
K1 relay and bring An-out
AO1 and AO2 to 0 V.
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A I R B O O ST E R 2
i2F, i2P,
t2d
Motor
blocked
Alarm conditions occur when:
-- Ctr = PrS (pressure
control)
-- i2F = Mtr
Alarm is signalled if Dig-in 2
(DI2) is active for a time ≥ t2d
Normal operating condition is restored
when:
-- Dig-in is deactivated
-- Press the DOWN key for 3 sec
Manual
The alarm is also disabled by:
a. Instrument restart shutdown
b. Cycle of Stand-by/Off followed by restart.
“Mtr” message appears on
the display alternated with
standard display.
Motor blocked alarm will
open K1 relay and bring
An-out AO1 and AO2 to 0 V.
Faulty “Upper
Temperature”
probe B1
Ctr, tIP
There will be the probe alarm
if configured: b1 = y.
Alarm is signalled after
approx 10 seconds.
Automatic
Fault probe alarm will bring
An-out AO1 and AO2 to 0
V if Ctr = tPr (temp control)
and tIP = b1 or Avr or MAu.
Faulty
“Middle
Temperature”
probe B2
Ctr, tIP
There will be the probe alarm
if configured: b2 = y.
Alarm is signalled after
approx 10 seconds.
Automatic
Fault probe alarm will bring
An-out AO1 and AO2 to 0
V if Ctr = tPr (temp control)
and tIP = b2 or Avr or MAu.
Faulty “Lower
Temperature”
probe B3
Ctr, tIP
There will be the probe alarm
if configured: b3 = y.
Alarm is signalled after
approx 10 seconds.
Automatic
Fault probe alarm will bring
An-out AO1 and AO2 to 0
V if Ctr = tPr (temp control)
and tIP = b3 or Avr or MAu.
Faulty
pressure
probe
Ctr
There will be the probe alarm
if configured: b4 = y.
Alarm is signalled after
approx 10 seconds.
Automatic
Fault probe alarm will bring
An-out bring AO1 and
AO2 to 0 V if Ctr = PrS
(pressure control)
Find below the table with the list of alarm messages:
Label
Meaning
Mode
b1
Probe B1 alarm
Flashing
b2
Probe B2 alarm
Alternated with temperature
b3
Probe B3 alarm
Alternated with temperature
b4
Probe B4 alarm
Alternated with temperature
HA
High temperature alarm
Alternated with temperature
LA
Low temperature alarm
Alternated with temperature
HP
High pressure alarm, manual reset
Alternated with temperature
Fan
Automatically reset “Fan Blocked” alarm
Alternated with temperature
Fnb
Manually reset “Fan Blocked” alarm
Alternated with temperature
dMP
Manually reset “Damper Blocked”
Alternated with temperature
Mtr
Manually reset “Motor Blocked” alarm
Alternated with temperature
OFF
Off state from key display
Only message
Stb
Stand-by state from digital input 1 display
Only message
noL
No communication between keypad and base
Only message
nu
Trying to view a probe that is declared missing
Only message
The activation of any alarm involves:
• The activation of the buzzer and the activation of the alarm output;
• The display of the relative notification alarm (in flashing mode), on a rotating basis together with
existing alarms alternated with displayed probe by default (Lod). If the display also shows faulty
probe alarm, the display will show the alarms on a rotating basis.
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5.6.
Modbus RTU datapoint
Digital data point
Modbus Address (hex)
ModbusDescription
Address (Dec)
Modbus
range
Mapped
meaning
BMSAccess
ModbusFunction
210
528
High Pressure
0/1
ok/error
r
1
211
529
Fan Block
0/1
off/on
r
1
212
530
Fan Block serious alarm
0/1
no alarm / alarm
r
1
213
531
Damper Block
0/1
off/on
r
1
214
532
Motor Block
0/1
off/on
r
1
200
512
Device ON
FF00 (65280)
on
w
5
200
512
Device OFF
0000 (0)
off
w
5
203
515
Keyboard LOCK
FF00 (65280)
locked (on)
w
5
203
515
Keyboard UNLOCK
0000 (0)
unlocked (off)
w
5
204
516
Alarm mute
FF00 (65280)
muted (on)
w
5
Analog data point
Modbus Address (hex)
ModbusAddress (Dec)
Description
Mapped meaning
BMS-Access
Modbus- Function
100
256
Probe 1
°C/°F
r
3
101
257
Probe 2
°C/°F
r
3
102
258
Probe 3
°C/°F
r
3
103
259
Average Active Probe Value
°C/°F
r
3
104
260
Max active probe value
°C/°F
r
3
105
261
Probe 4
bar/Pa
r
3
106
262
Fan speed
%
r
3
107
263
Damper position
%
r
3
110
272
Min Fan Speed
%
r
3
111
273
Max Fan Speed
%
r
3
112
274
Min Damper Value
%
r
3
113
275
Max Damper Value
%
r
3
114
276
Device On
h
r
3
300
768
SetPoint Temperature
°C/°F
rw
(3)6
301
769
SetPoint Pressure
bar/Pa
rw
(3)6
BMS-Access:
r= read
w= write
Modbus- Function:
01: Read Coil (Digital Output Registers)
02: Read Digital Input Status Function
03: Read Holding Registers
04: Read Input Registers
05: Write Single Coil
06: Write Single Holding Register
The following parameters may have to be adjusted on the controller of the unit:
• Modbus-Address: Adr
• Baud Rate selection: br
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6. Technical data
6.1.
Application limits
Operation limits
Operating Temperature
Min
-10 °C
Max
+ 40 °C
Air humidity range
0-90%
Nominal power supply
230 V / 1ph / 50-60 Hz
Voltage tolerance
± 10%
Frequency tolerance
± 2%
Storage limits
Temperature
Humidity
Min
- 20 °C
Max
+ 50 °C
Max
90%
INFORMATION
Other limits not specified in this table can be found in the rest of this manual
6.2.
Technical data
NOTES ON TECHNICAL DATA:
* Operating at nominal fan speed
** Measured at 2m distance from unit, in a free field, unit operating at nominal conditions.
According to ISO 9614.
This information must be made known to all personnel operating this unit and in the proximity
thereof.
Model
Nominal Airflow
m /h
Maximum Airflow
2880
3
m /h
5200
kW
0,075
A
2
Maximum operating current (FLA)
A
2,2
Raised floor overpressure*
Pa
25
dB(A)
64
Power consumption*
Operating current (OA)*
External sound pressure level**
26
Air Booster2
3
Weight
kg
25
Height x Width x Depth
mm
598 x 598 x 260
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A I R B O O ST E R 2
6.3.
Drawings
7. Installation
Unpack the unit taking care to not damage its exposed parts. Before discarding the packaging,
make sure no parts or documents have been left inside. Check that the supply voltage is as
designated.
The installation and handling of the units may be hazardous as they form a system with electric
components. Only skilled personnel may repair, inspect or maintain the units. The installation of
an Air Booster 2 is similar as fixing an air diffusion grill on the false floor. It's necessary a minimum
space of 150 mm under the unit to guarantee the correct operation of the fan. Please follow the
indications below.
1. Select the location of the unit on the false floor, in a position that can allow a suitable flow of cold air
to all servers;
2. Remove the floor tile where Air Booster 2 unit will be positioned;
3. Insert the unit in the false floor using the internal handles of the unit;
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A I R B O O ST E R 2
Internal handles
4. Position the unit as shown in the following picture;
5. In order to make the unit walkable, install the upper grille, supplied as an accessory (ACTBAHDG
(heavy duty grille) or ACTBALDG (light duty grille)). The grille has to be place above the unit
using 4 grains that can be regulated in order to correspond with the height of the floor. For more
information please refer to chapter "Accessories".
4 x adhesive protection
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A I R B O O ST E R 2
6. If the unit is equipped with control inside, mount the three sensors on predefined locations which
are at 1/3rd, 2/3rd and 3/3rd of the height of rack, as shown in the picture on paragraph
"Electrical components of protection and control". Any deviation from the specified locations of
the sensors may result into wrong behaviour of the system and an optimum air-conditioning of
the racks may not be obtained.
7. A power supply should be provided near the Air Booster 2 which will help to easily rig up the
system connections. Connect the power supply, as shown in paragraph "Electrical Connections"
and the Air Booster 2 is ready to use.
8. If the unit is without control, it's necessary to connect it to Air Booster Remote Control
(ACTPCMP). For the connection of ACTPCMP please refers to its specific manual. Note that
units without control are supplied with wiring that manages alarms and signals.
7.1.
Adjusting the airflow direction
To adjust the airflow direction, according to the needs of the room, follow the procedure below:
1. Take out the grille exploiting the lifting handle provided.
2. Unlock the guide vanes by pulling the black buttons. The guide vanes are divided into two
sections which can be adjusted separately.
3. Rotate the guide vanes until the desired position of the fins is reached.
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A I R B O O ST E R 2
4. Push the guide vanes back in their position so that the fins are locked in the desired position.
5. Restore the grille to its original position
7.2.
Electrical Connections
DANGER
It's absolutely necessary, before making any connections, to use a suitable tester to check the
supply voltage. This must be the same as the voltage indicated on the technical data plate.
The user must furnish and install, upstream from the unit, an isolating switch with pre-fuse and
capacity as specified on the technical plate in order to be able to perform maintenance on the
unit in the absence of electricity.
The ON/OFF-key on the unit is only used for the unit stand-by. It must therefore not be
considered as a safety element to perform maintenance on the unit. Maintenance must be done
after disconnecting the power supply of the unit (see note above).
Electrical connections may only be performed by authorised technicians.
The system must be connected to an efficient earth circuit.
The unit must be electrically connected in compliance with the regulations at paragraph
"Introduction" and national regulations for technical systems.
• Check that supply voltage and frequency are compatible with those for the unit.
• Interrupt both main power and auxiliary power before working on the system.
• Select connection cables (not supplied) according to EN60204-1 Standards.
• Open the electrical box by undoing its fastening screws.
• Check that power cables are installed with a sufficient distance from alarm cables, communication
and monitoring cables.
• On the main power supply line, install an omnipolar circuit breaker, please refer to the electric
diagram on part 2 manual. Size of main switch must be determined according to the maximum
current consumption of the components.
• To make electrical connection of power supply, use cables with section suitable to the power
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absorbed by the users (check manual part 2). These cables must be compliant with current
standards.
DANGER
The inobservance of these points can provoke damages or malfunction of components and
warranty shall become forthwith void.
For use of leakage-current (FI) circuit breakers, EN 50178 5.2.11.2 must be taken into
account. Only type B pulse-current FI circuit breakers are permitted. FI circuit breakers do not
provide protection against bodily harm during operation of the unit or frequency converters.
Connections of Air Booster 2 unit
Connections for general alarm, remote control, modbus management
Connection for main power supply
Connection for temperature probes
8. Start-up
8.1.
Commissioning
Before performing initial start-up, install and connect the system as described in chapter
"Installation".
• Make sure that the general switch is turned off and that the system is not live.
• Check that all the power switches and control fuses in the electrical system are off.
• Check that the power cable and terminals, including the PE terminals, are correctly connected.
• Check the contactors move freely.
• Switch on the unit with the general switch.
• At this point the electronic board is powered and individual components can be enabled to check
they work properly. The main operations that can be performed during installation are described in
the controller manual.
• Press the ON-OFF button near the display to start the unit.
8.2.
Checks after commissioning
• Check the current absorption of the fan and compare it with the values indicated in the technical
data.
• Check the electrical absorption of all the components.
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A I R B O O ST E R 2
• Once the system is working at full power:
1. Check that no alarms have occurred;
2. Check that the fans work properly;
3. Check, while the unit is running, that the supply voltage remains within the values indicated on
the technical name-plate;
4. Check that the unit works according to the set logic.
8.3.
Switching off
To switch off the unit, turn off all the power supplies.
DANGER
The ON-OFF button on the display is only used to put the unit on stand-by. It must therefore not
be considered as a safety device for switching off the unit prior to maintenance operations.
9. Maintenance
9.1.
Safety instructions
Installation and intervention on units must be made in full compliance with specific national
regulations for accident prevention, with particular reference on electric and refrigerant equipment.
Failure to comply with these regulations might be dangerous to people and environment.
Before any intervention on the unit, refer to instructions on this manual, check data on the nameplate and take any other precaution in order to guarantee optimal safety.
Safety procedures
DANGER
Cut off the power supply to the unit before making any maintenance operation. A “DO NOT
SWITCH ON” warning sign must be clearly visible. ON-OFF key on the unit is only used to put the
unit in stand-by.
Live electric components have to be switched to de-energized and checked to ensure that they
are in the de-energized state.
Some verifications must be effected with the unit in operation (measuring current, pressures,
temperatures). In such a case, the unit must only be switched on at the master switch after all
mechanical connections have been carried out. The unit must be switched off immediately after
the measuring procedure.
The electric box might be hot.
Maintenance operations may only be performed by authorised and qualified technicians.
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A I R B O O ST E R 2
9.2.
Preventive maintenance schedule
ATTENTION
Very little routine maintenance is necessary to keep the unit in reliable operating order and protect
its moving parts. This maintenance, however, must be performed at the prescribed maintenance
intervals. Failure to perform maintenance, in addition to affecting the unit durability and operation,
invalidates the warranty.
If the unit works in particularly dirty environment or if experience shows that a more frequent
maintenance is needed, this must be made as necessary.
Interval
Every year
Operation
Check that fan motor and other components do not show abnormal vibrations or show any signs of overheating.
Fan
The bearings of the fan are lifetime lubricated and do not need maintenance. Check the operation
current. An increased operation current indicates either a higher air resistance by a clogged prefilter or a winding short circuit in the fan motor.
Replacement of components
We recommend to replace the fans every 40, 000 operating hours (L10 life calculated at 40°C
working temperature).
9.2.1. General cleaning
The metal casing of the unit can be cleaned using a liquid detergent as long as this liquid is
compatible with: PVC, polyethylene, silicone and polyester coating. Be careful not to wet the
electrical connections inside the unit.
ATTENTION
Use of an unsuitable detergent might cause damage to the unit. Do not use either acid or caustic
substances or solvents to clean any part of the unit.
Remove dust with a vacuum cleaner. Clean the internal parts with a liquid detergent and compressed
air not greater than 4 bar, with the unit suitably earthed.
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A I R B O O ST E R 2
10. Troubleshooting
Please consider the safety considerations at chapter "Safety directions". All the operations
described below have to be done by authorized and qualified personal.
Problem
Possible cause
Possible solution
GENERAL
1. The controller and the
rest of the unit don't
work
2. Controller is working
but display is not
working
3. Controller is working
but the rest of the unit
is not working
Main power supply missing
Restore power supply
Main switch open
Close main switch
Power supply to the controller is missing
Check voltage on power supply cables. Repair the
broken cable or restore the missing connection
Controller faulty
Contact STULZ service
Cable between controller and display disconnected
Reconnect the cable
Cable between controller and display broken
Replace the cable
Display faulty
Contact STULZ service
Faults blocking the unit
Look for alarms on the display (see below).
Contact STULZ service
Controller faulty
Contact STULZ service
ALARMS ON THE DISPLAY
4. Component x thermic
5. Fan blocked
6. Air flow
7. LAN failure
Anomalous absorbed current by component x
Contact STULZ service
Defective protection
Contact STULZ service
Fan broken
Contact STULZ service
Fan cables disconnected
Contact STULZ service
Wrong configuration of controller
Contact STULZ service
Fan broken
Contact STULZ service
Fan cables disconnected
Contact STULZ service
Wrong setting of air flow
Contact STULZ service
Missing LAN cable
Connect units in LAN with a suitable cable
LAN cable is not pin-to-pin
Replace it with a pin-to-pin cable
Controller is damaged
Contact STULZ service
11. Uninstalling and disposal of the
unit
This unit must be uninstalled by specialized and authorized persons.
DANGER
Before starting to dismantle the unit check that it has been disconnected from electric power
supply and secure it against being switched on again.
The following are the instructions for proper disposal of the unit during the various phases of its life.
For further clarification or additional information, please contact info@stulz.it.
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A I R B O O ST E R 2
INFORMATION
To ensure proper and safe disposal activities, operator must equip themselves with the
necessary PPE including: anti-cut gloves, oil resistant gloves, heat resistant gloves, safety
footwear, safety eye-wear against liquid and gas splashes.
The context in which the unit is located may require the use of additional PPE, thus it is mandatory
to inquire with the relevant staff of the area before starting operation.
Once the materials have been separated as shown below, they should be assigned EWC codes and
then sent for disposal in accordance with the national legislation.
Disposal related to the unit purchased occurs in three stages:
1. Disposal of packaging
The packaging of the unit must be disposed of ensuring separation of the following materials:
• Paper and Cardboard
• Wood Packing – Packing materials are not chemically treated unless they are declared to be
“fumigate”
• Plastic pallets – high- density polyethylene HDPE
• Plastic Film – polyethylene PE
• Polystyrene – expanded polystyrene EPS 6
2. Disposal at the end of life of the unit
The unit must be disposed of ensuring separation of the following materials:
• Metals
• Insulation and sound-absorbing materials
• Electric and electronic components
• Cables and wiring
• Plastic Parts – Plastic parts that are important in terms of weight are the following:
Identified Substance
CAS Number
acrylonitrile butadiene styrene terpolymer
9003-56-9
polystyrene homopolymer
9003-53-6
polycarbonatefrom bisphenol A
103598-77-2
12. Accessories
A grille is used in order to make the unit walkable. For the purpose of adaptation to the local
conditions, the grilles are available in two versions. The Light Duty version is more handy and the
airflow can be distributed over a larger area of the server rack front with the air conduction fins. The
Heavy Duty version is designed for a higher point load, and is preferable when the area in front of the
racks is for instance loaded by the wheels of transport trolleys.
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A I R B O O ST E R 2
12.1. Light duty grille - ACTBALDG
Technical data
Weight
12,1 kg
Thickness
20 mm
Height adjustment
23 ÷ 44 mm
Concentrated load over 25 mm x 25 mm
1,5 kN
Width
598 mm
Height
598 mm
Threaded pins
M8x30 or M8x20 (for different height regulation)
Colour
RAL 7047
Material
Steel
Floor grille structural class
EN 13264:2001
12.2. Heavy duty grille - ACTBAHDG
Technical data
36
Weight
18,9 kg
Thickness
30 mm
Height adjustment
33 ÷ 44mm
Concentrated load over 25 mm x 25 mm
4,5 kN
Width
598 mm
Height
598 mm
Threaded pins
M8x20
Colour
RAL 7047
Material
Steel
Floor grille structural class
EN 13264:2001
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A I R B O O ST E R 2
1.
12.3. Installation of the grille
The grille has to be installed above the Air Booster 2 unit, using 4 threaded pins, that can be regulated
using an hexagonal 4 mm Allen key in order to correspond with the height of the floor.
Apply 4 adhesive protection in the bottom side of the grille to protect the unit.
INFORMATION
In order to maintain the by the "guide vanes" intended air direction, the grille must be oriented so
that the bearing bars are 90° rotated to the "guide vanes". Otherwise, the supply air will rise up
vertically and not directed to the intended zones in front of the rack.
The grille has to be positioned on Air Booster 2 units as shown in the pictures below.
ACTBALDG
© STULZ SpA . – all rights reserved EN/10.2018/IT30I
ACTBAHDG
37
A I R B O O ST E R 2
1. Take the lifting key/keys
2. Hook the lifting key/keys to the grille (picture number 1).
3. Lift and move the grille (picture number 2).
4. Put the grille on the floor (picture number 3).
INFORMATION
Inside the packaging of the fan module, one lifting key is present.
1 - ACTBALDG
2
38
1 - ACTBAHDG
3
EN/10.2018/IT30I © STULZ SpA – all rights reserved
EN
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