A/C UNITS

Air Booster
230/1/50-60

Index FFAB-03
Issue 2.2014

AIR CONDITIONING
AIR BOOSTER for COMPUTER ROOMS

Original instructions

OPERATING INSTRUCTIONS
© STULZ GmbH, Hamburg
 Contents
1. Safety............................................................................................................................3
1.1 Marking...............................................................................................................................................3
1.2 Safety instructions..............................................................................................................................3
2. Components and operating principle........................................................................5
2.1 Intended Use:.....................................................................................................................................7
3. Unpacking and inspection..........................................................................................8
4. Installation and controller operation.........................................................................9
4.1 Controller programming....................................................................................................................11
4.2 Controller logic and operation..........................................................................................................12
4.3 Wiring diagram.................................................................................................................................13
5. Maintenance procedures..........................................................................................14
6. Technical data ...........................................................................................................15
7. Dimensions................................................................................................................15
8. Option - Pressure Transmitter Module.....................................................................16

Subject to technical modifications.

EN/02.2014/FFAB-03/2
1. Safety
1.1 Marking

Danger - threatening danger, grievous bodily harm and death

Attention - dangerous situation, light bodily injury and material damage

Information - important information and application notice

ESD note - risk of damaging electronical components

1.2 Safety instructions

General
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.

- Works have to be carried out by competent staff only

- Observance of the regulations for accident prevention
- Safety devices may not be bypassed.
- Respect the corresponding VDE-, EN- and IEC standards for the electrical connection of the unit
and observe the conditions of the power supply companies
- Switch off the voltage from the unit when working on it.

- Observe the national regulations of the country where the unit will be installed
- The unit may only be used to cool air according to the Stulz specification.

Independent conversion and manufacture of replacement parts

The system may only be converted or modified after consultation with STULZ. Original replacement parts and re-
placement parts/accessories authorised by STULZ are an aid to safety.

Unacceptable operating methods

The operating safety of the system is only guaranteed when it is used as intended. The limit values stipulated in the
technical data must not be exceeded under any circumstances.

EN/02.2014/FFAB-03/3
 Type plate
The type plate is located at the side of the Air Booster / Air Modulator.

IMPORTANT
These operating instructions are to be read carefully and complied with before
installing and operating the A/C unit.

Keep this manual for the whole life period of the unit, inside the shelter or together with
any other literature concerning the equipment, which utilizes the product, provided it is a dry
and clean place.

This manual reflects the state of the art existing at the time the product is marketed and
shall not be deemed to be inadequate for the sole reason that it has not been updated
despite of any new experience.

STULZ GmbH reserves the right to update the product and relevant
manual without being required to update previous products and manuals other than in
exceptional circumstances.

To require or receive any updates of the instructions manual or amendments thereto,

which shall be deemed to be an integral part of the manual, please contact your local
STULZ partner.

It is absolutely essential to comply with the measures listed in the chapter giving
safety instructions.

EN/02.2014/FFAB-03/4
2. Components and operating principle
The Air Booster is designed keeping in mind the basic principle of hot aisle and cold aisle arrangement where cold
air is delivered in front of the racks to enable servers to absorb and reject heat at the rear of the rack. Many times it
has been observed that the CRAC (Computer Room Air-Conditioning) unit is not able to deliver the right amount of
cold air as desired by the user in front of the rack. The standard air diffusion system cannot deliver the capacity as
required due to various reasons such as high density computing equipment and either less or uneven air distribu-
tion which may be due to the CRAC positioning or high velocity effects under the floor. The result is that the hot air
exhausted from the servers tend to often recycle in the cold aisle and destabilize the steady operation of the data
center or the rack.

The Air Booster exist in two variants:

1. Air Booster
2. Air Booster Pro
In contrast to the Air Booster the Air Booster Pro is equipped with adjustable vanes at the outlet which allow to direct
the air flow towards the CRAC unit whereas the air flow out of the Air Booster rises vertically.

Rack front

Sensor 1

Sensor 2

Air booster

Air Booster Pro:

Adjustable Vanes

Moving
direction

EN/02.2014/FFAB-03/5
 Sensor 1

Sensor 2

Air Booster

Power supply

The Air Booster works on basic science where the air delivered to the rack is directly proportional to the desired
set point. The sensors installed at 1/3rd and 2/3rd of the rack height from the bottom as reference ensures that the
air delivered has the right temperature and also the fan speed is proportional to the average temperature of the
temperature sensors 1 and 2. The fan speed is controlled by pwm (pulse width modulation) algorithm and it ensures
smooth transition of fan speed with reference to the set point. The idea of the Air Booster is to flood the cold aisle or
the front of the server rack with sufficient cold air as desired.

EN/02.2014/FFAB-03/6
2.1 Intended Use:
This A/C unit is used to control room temperature. The A/C unit 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 ope-
rator alone bears the risk.

Bottom view

Installation example:

Floor support

Power supply box

*Floor supports and power supply box are not delivered with the air booster, but must be provided by the customer.

EN/02.2014/FFAB-03/7
 3. Unpacking and inspection
STULZ products are shipped ex-works. All units have been individually inspected in all their parts and carefully
packaged.
Immediately inspect the unit upon receipt, making sure it has been shipped in its proper position. Note improper
shipment on the shipping document. We recommend you accepting merchandise subject to inspection.

Check presence of all items written on shipping document.

Check for damage and if damages have been detected, note this on the shipping document. Remove packing and
make sure that there are no scratches, marks or any signs of impact on the exterior casing. Before throwing the
packaging away check that it does not contain any documents or parts of the machine.

Any damage that is encountered must be notified to the carrier by registered letter within 8 days from receipt. The
carrier is responsible for any damage caused during shipment. STULZ is not responsible for damage caused to the
merchandise by the shipper but will do everything in its power to assist customers in these situations.

This product may not be returned without prior written approval by STULZ. For any assistance
please contact your local STULZ partner.

If delivery terms are not EX WORKS, in case of damage, please follow the instructions on the ship-
ping documents or on web site www.stulz.com

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.

EN/02.2014/FFAB-03/8
4. Installation and controller operation
The installation of an Air Booster system is very simple and does not require any special techniques or expertise.
The fitment of an Air Booster is not different from fixing an air diffusion grill on the false floor. Decide for the location
and connect the power supply and the Air Booster is ready to use. Both sensors need to be mounted on predefined
locations which are at 1/3rd and 2/3rd of the height of rack. Any deviation from the specified locations of the sensors
may result into erratic behaviour of the system and an optimum air-conditioning of the racks may not be obtained.

A power supply, preferably from the UPS power chain should be provided adjacent to the Air Booster which will help
to easily rig up the system connections. The power rating of the air booster system is 5A and also requires a plug, a
socket, a switch (230 V P+N+E). An Air Booster comes with a flexible cord with a length of max. 1.5 m.

A UPS power supply is recommended for the Air Booster as it stays powered during shutdown of the mains. Since
the heat intensity in the aisle is higher than in a normal situation during power cut off, this feature helps maintaining
temperature in the cold aisle and prevents the server racks from temperature peaks. The Air Booster uses thermal
inertia of the air and keeps the temperature of the room by adjusting the air volume delivery. This helps keeping the
data center free from hot spots during the critical down time.

For the system setup please refer to page 7 of this manual. It is understood that the application of this Air Booster
requires a stable power supply to guarantee the efficiency and reliability of the system.

Adjusting the airflow direction -

Special instructions for the Air Booster Pro:
1. Take the Air Booster Pro out of the raised floor.
2. Remove the screws which fix the top plate to the
housing (two on each side, see arrow).
3. Remove the top plate from the housing.
4. Loosen the two M6 Allen bolts which fix the guide
vanes.
5. Adjust the air flow direction with the help of the guide
vanes which are mounted in parallel so that all vanes
will be inclined with the same angle.
6. Retighten the two M6 Allen bolts.
7. Replace the top plate and fix it with the eight bolts.
8. Place the Booster in the raised floor.

The required Allen keys are delivered with the unit.

Fixing screws
Housing

2 x M6 Allen bolts for guide vane locking Detail: M6 Allen bolt

EN/02.2014/FFAB-03/9
 Assembly procedure for installing the corner brackets

Eight corner brackets in two different heights (4 brackets each) are provided with each Air Booster (Pro) / Air Modu-
lator to adapt the unit to the thickness of the raised floor tiles.
These corner brackets will only be required when there is no horizontal railing of the raised floor stands.

4 height adjusting brackets

Top surface of the double side adhesive

tape should be bonded to the bottom
of the Air Booster/Pro/ Air Modulator
as shown.

EN/02.2014/FFAB-03/10
4.1 Controller programming

Controller
Up arrow
PWR
ON/OFF key
TC 1

TC 2
PRS Set key
O/P
Down arrow
Display
Programming key

LED Indication
PWR Presence of voltage
TC1 Temp. sensor 1 connected
TC2 Temp. sensor 2 connected
PRS Pressure sens. connected
O/P Unit working

1. When switch is ON, the LCD will display rack temperature in

controller OFF mode

2. To enter the programming mode press programming key (i.e. DOWN

arrow key) for 5 sec.

Press key for 5 seconds. P2 will start blinking.

Press SET key.

Change the parameter.

Press SET key to confirm.

Select the next parameter P3.

or

select the menu item EP and press SET to exit the program-
ming mode. EP

EN/02.2014/FFAB-03/11
 Parameter overview for temperature control

These parameters are not Display Code Explanation Text Min Max Default Values
effective for temperature
control and will be explai- P2 Temperature Setpoint 5 50 25°C
ned with the option "Pres- P3 Temp. difference, high side 1 10 10 K
sure transmitter box"
P4 Temp. difference, low side 1 5 3K
P5 Pressure Setpoint 20 60 30 Pa
P6 Press. difference, high side 10 50 30 Pa
P7 Press. difference, low side 5 30 20 Pa
P8 O/P Refresh Delay 3 90 15 sec
P9 Temp. sensor fail speed 30 90 50%
C1 Temp. sensor 1 offset -5 +5 0°C
C2 Temp. sensor 2 offset -5 +5 0°C
C3 Pressure I/P calibration -9 +9 0 Pa
S1 Min speed - temp. mode 0 40 10%
S2 Maximum Speed 50 99 99%
S3 Min speed - pressure mode 0 40 10%
T1 Temp./Pressure mode 0 1 0 = temp. mode
td Toggle Display Value A/2 0 1 0*
LP Lock parameters 0 1 0**
FS Default Factory Reset 0 1 0 = disabled
EP Exit Programming ----***
* The display will switch between two values when parameter is set to "1".
** 0 means parameters can be changed. 1 means parameters can not be changed.
***press SET key to exit programming mode.
NOTE:
If you have not pressed any key in the programming mode for 30 seconds the controller commutes to info mode.
Above default values will be saved in the memory. The settings can be changed whenever required and the same
will be stored in the memory even if the power is switched off.

4.2 Controller logic and operation

The different control parameters may be changed by entering in the programming mode as described in previous
section and changed using UP or DOWN keys.
At a temperature below the setpoint reduced by the low side differential (P2-P4) the fan will stop operating.
From P2-P4 to the temperature setpoint P2 the fan speed is kept at minimum speed S1. From the setpoint to P2+P3
the fan speed is raised proportionally from S1 to maximum speed S2. Above P2+P3 fan speed is kept at S2.
When a temperature of 0°C is measured, the tempe-
rature sensor is supposed to be broken. In this case Speed
the fan speed set with P9 is applied.

S2 (%)
P2 = Setpoint (°C)
P3 = High Side Differential (K)
P4 = Low Side Differential (K)
S1 = Minimum Fan Speed (%)
S2 = Maximum Fan Speed (%)

S1 (%)
Temperature Temperature

EN/02.2014/FFAB-03/12
4.3 Wiring diagram

EN/02.2014/FFAB-03/13
 5. Maintenance procedures
Moving parts are fully automatic and highly reliable which helps to reduce ordinary maintenance to a great extent. This
maintenance, however, must be performed at the prescribed intervals. Failure to perform maintenance compromises
fan operation and durability and invalidates the warranty coverage.

Interrupt the electrical supply before performing any work on the unit.

Preventive Maintenance Schedule

Check that air openings are clean and dirt particles are not preventing the passage of air. Make sure that there is no
abnormal noise and the system operation is smooth and quiet. Spare parts can be ordered from the STULZ GmbH
Service Department.

Every year
Check that fan motor and other components do not show abnormal vibrations or show any signs of overheating.

More frequent cleanings must be done if the unit works in particularly dirty environments or if they
are required according to experience.

Cleaning / replacement of components

We recommend to replace the fans every 12, 000 operating hours (MTBF [Mean Time Between Failure] calculated
at 30°C working temperature).
The metal casing of the unit can be cleaned using a liquid detergent as long as the liquid is compatible with: PVC,
polyethylene, silicone and polyester coating. Be careful not to wet the electrical connections inside the unit.

General Safety Provisions

All staff responsible for testing, operating and servicing this unit, must be familiar with the following safety provisi-
ons:
• Hazards tags and notices must be readily visible in any potential hazard areas.
• A monitoring service must be arranged in such hazard areas.
• Supervisors must keep in constant touch with monitors.
• Transit areas, doorways and stairways, in the proximity of the unit must be kept clear.
• Emergency exits must be kept clear at all times.
• Slippery areas, which represent a hazard to the staff, must be covered with anti-slip material.
• For any specific activity, specific tools and procedures must be used.
• Testing tools and equipment must be kept in good working condition.
• Staff must have a thorough knowledge of methods and procedures used in the event of a fire (make fire
extinguishers readily accessible).
• The following steps must be taken in case of a fire:
- turn off the electric power supply from the part affected by fire
- increase ventilation capacity to evacuate combustion gases
- inform appropriate department.

Hazards arising from the product coming into contact with things or persons
• Danger arises from the fan rotation. The fan‘s protective grille prevents passage of particles with a diameter
larger than 10 mm.

Failure to comply with the above mentioned conditions invalidates the warranty and STULZ GmbH will not
accept any resposibility for any damage or losses if they occur due to wrong application of the product.

The service must be exclusively performed by STULZ GmbH or their authorized representatives. Any unau-
thorized repairs will void the warranty.

The liability of STULZ GmbH is limited to the product and excludes claims for consequential damage, lost
profit and other financial losses incurred by the customer.

EN/02.2014/FFAB-03/14
6. Technical data
AirBooster AirBoosterPro Application limits
Airflow 2650 m³/h 2500 m³/h Operating Temperature 10 - 55 ± 5°C
Maximum Speed 1526 rpm Humidity Range 0 - 90 % r.h.
Sound power level Lw 68,9 dB(A) Nominal Voltage 230 VAC
Current consumption 1.4 A Frequency 50/60 Hz
Power consumption 171 W UDL on the grid 2780 kg/m²
Total surface of top plate 0.302 m² Point load on the stringer 250 kg
Free surface 0.146 m² 0.151 m² UDL: uniformly distributed load
Length 600 mm
Width 600 mm
Depth 200 mm
Weight 20 kg
Model Name & No : Air Booster SAB-EC-600-TP (Air Booster Pro SAB P-EC-600-TP)
Controller Model : SFCB - 230 V
Color : Top - RAL 7015 (white), Bottom Box - RAL 9017 (black)
Plug/Socket/MCB : 6 amps AC3 duty C curve (customer supplied)
Cable : 1.5 mm2 - R/B/G
Protection Class : IP22

7. Dimensions

Stringers
Stringers

(protective fan grille)

Fig. Air Booster

EN/02.2014/FFAB-03/15
 8. Option - Pressure Transmitter Module
The pressure control by the pressure transmitter module is based on the temperature management integrated in every
server which measures the temperature of each processor and adapts the server fan speed to the thermal load.
The server temperature management requires constant pressure conditions in the data center. 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 provides cold air up to an adjustable pressure difference limit.

Technical Data
Length 200 mm
Pressure transmitter
Width 120 mm
Depth 75 mm
Weight 1 kg
Response time 1s
Output signal 0-10 VDC

Color : white
Connection : 6 mm hose pipe
Cable : 1.5 mm2 - R/B/G
Protection Class : IP22

Application limits
Operating Temperature : 0 - 50° C
Humidity Range : 0 - 95 % r.h.
Nominal Voltage : 230 VAC
Frequency : 50/60 Hz 24 VDC power supply
Maximum load : 500 Ohm
Pressure medium : Air and non-aggressive gas

Pressure hoses

EN/02.2014/FFAB-03/16
Position of the connector box

Connect the signal line (length ap-

prox. 1 m) coming from the pressure
transmitter module with the short
line at the connector box. Both lines
are equipped with connectors which
fit to each other.

When several air boosters are con-

nected to one pressure transmitter
module these connectors can not
be used. The wiring must be carried
out according to the wiring scheme
on page 20.

EN/02.2014/FFAB-03/17
 Placing the pressure hoses
The PTM is delivered with two pressure hoses with a length of 1 m each. These hoses are indicated by (+) and (-).
For a proper function the open end of the (+) hose must be conducted to the outlet area of the AirBooster. The open
end of the (-) hose can be placed where warm air from the servers is exhausted to measure the ambient pressure.
See the illustration for a better understanding.

(-) (+)
PTM

Controller Display
The display shows the average value of the two temperature sensors. By pressing the DOWN arrow key, the LED
PRS is illuminated and the pressure is indicated in Pa. The display range is from 0 to 99 Pa.

EN/02.2014/FFAB-03/18
Pressure Control
With the connection of the pressure transmitter module (PTM) pressure control is enabled. The pressure control serves
as a pressure limitation as a high pressure difference between warm aisle and cold aisle can damage server equip-
ment. The exclusive pressure control which is described below can be enabled by setting parameter T1 to "1".
At a pressure below the pressure setpoint P5 reduced by the low side differential (P5-P7) the fan speed is kept at S2
(maximum speed). From P5-P7 to the setpoint the fan speed is reduced proportionally from S2 to minimum speed
S3. From the pressure setpoint P5 to P5+P6 the fan speed is kept at minimum speed S3. Above P5+P6 the fan will
stop operating.
When a pressure of 0 Pa is measured, the pressure sensor is supposed to be broken. In this case the fan speed
goes to 50%.

By parameter P8 you can stabilize the con- Speed

trol. Every 5 seconds a pressure value is
transmitted to the controller. A refresh cycle
(P8) of 30 seconds means that every 6th 99%
S2 (%)
value is taken for the control. The minimum
refresh cycle is 15 seconds.

P5 = Pressure Setpoint (Pa)

P6 = Press. difference high side (Pa)
10% S3 (%)
P7 = Press. difference low side (Pa)
S2 = Maximum Fan Speed (%)
S3 = Minimum Fan Speed (%) 10 60 Pressure
P5–P7 30 P5+P6 [Pa]
P5

Display Code Explanation Text Min Max Default Values

P2 Temperature Setpoint 5 50 25°C
P3 Temp. difference, high side 1 10 10 K
P4 Temp. difference, low side 1 5 3K
P5 Pressure Setpoint 20 60 30 Pa
P6 Press. difference, high side 10 50 30 Pa
P7 Press. difference, low side 5 30 20 Pa
P8 O/P Refresh Delay 3 90 15 sec
P9 Temp. sensor fail speed 30 90 50%
C1 Temp. sensor 1 offset -5 +5 0°C
C2 Temp. sensor 2 offset -5 +5 0°C
C3 Pressure I/P calibration -9 +9 0 Pa
S1 Min speed - temp. mode 0 40 10%
S2 Maximum Speed 50 99 99%
S3 Min speed - pressure mode 0 40 10%
T1 Temp./Pressure mode 0 1 0 = temp. mode
td Toggle Display Value A/2 0 1 0*
LP Lock parameters 0 1 0**
These parameters are
FS Default Factory Reset 0 1 0 = disabled
not effective for pressure
control. EP Exit Programming ----***

Function of parameters td, LP, FS and EP as for temperature control, see page 12.

EN/02.2014/FFAB-03/19
 Installation example

One pressure transmitter box can control

up to six air boosters/modulators.

0-10 VDC (+)

GND (-)

2 wire 0.5 mm²

0-10 VDC signal,
connected in parallel at
the pressure transmitter

EN/02.2014/FFAB-03/20
Konformitätserklärung
Declaration of Conformity
Der Unterzeichnete
The undersigned
STULZ GmbH
Klimatechnik
Holsteiner Chaussee 283
D - 22457 Hamburg

bestätigt hiermit, dass das nachfolgend bezeichnete Gerät in der von uns in Verkehr gebrachten
Ausführung die Anforderungen der harmonisierten EG-Richtlinien und EN-Sicherheitsstandards erfüllt.

hereby confirms that the units listed below, in the version marketed by us, fulfil the requirements of the
harmonized EC Directives and EC Safety Standards listed below.

Bei einer nicht mit uns abgestimmten Änderung des Gerätes verliert diese Erklärung ihre Gültigkeit.

In the case of a modification of the equipment not co-ordinated with us this declaration loses its validity.

Klimagerät / AC unit

AirBooster SAB-EC-600-TP

EG-Richtlinien EC-Directives
EG Maschinenrichtlinie: 2006/42/EG EC machinery directive: 2006/42/EC
EG Niederspannungsrichtlinie: 2006/95/EWG EC directive for low voltage: 2006/95/EC
EG EMV- Richtlinie: 2004/108/EWG EC EMC directive: 2004/108/EC

Harmonisierte EN Harmonized EN
EN ISO 12100 -1/2 EN ISO 12100 -1/2
EN ISO 13857 EN ISO 13857
EN 60204 -1 EN 60204 -1
EN 55011 EN 55011

EN 60335-1 EN 60335-1
EN 60335-2-40 EN 60335-2-40
EN 61000-4-2 EN 61000-4-2
EN 61000-4-3 EN 61000-4-3
EN 61000-4-4 EN 61000-4-4
EN 61000-4-5 EN 61000-4-5
EN 61000-4-6 EN 61000-4-6
EN 61000-4-11 EN 61000-4-11
EN 61000-6-2 EN 61000-6-2
EN 61000-6-4 EN 61000-6-4

Nationale Vorschrift National regulations

BGV D4 BGV D4
BGV A3 BGV A3

Hamburg, 01.01.2011 ppa.

Ort, Datum Werksleitung: Herr Panknin
Place, date Works Management: Mr. Panknin

2011 Konformität AirBooster deutsch englisch.doc