Digital Vision Network

5000 Series

Storage, Shipping, and

Environmental Guidelines

October, 2009
24-10520-22 Revision –
 Copyright 2009
Johnson Controls, Inc.
All Rights Reserved
(805) 522-5555
www.johnsoncontrols.com
No part of this document may be reproduced without the prior permission of Johnson Controls, Inc.

These instructions are supplemental. Often they are supplemental to other manufacturer’s
documentation. Never discard other manufacturer’s documentation. Publications from Johnson
Controls, Inc. are not intended to duplicate nor replace other manufacturer’s documentation.

If this document is translated from the original English version by Johnson Controls, Inc., all
reasonable endeavors will be used to ensure the accuracy of translation. Johnson Controls, Inc. shall
not be liable for any translation errors contained herein or for incidental or consequential damages in
connection with the furnishing or use of this translated material.

Federal Communication Commission Notice

This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause interference to radio communications. It has been
tested and found to comply with the limits for a Class A computing device pursuant to Part 15 of FCC
Rules, which are designed to provide reasonable protection against such interference when operated in
a commercial environment. Operation of this equipment in a residential area is likely to cause
interference, in which case the user at his own expense will be required to take whatever measures may
be required to correct the interference.

Canadian Notice

This Class A digital apparatus complies with Canadian ICES-003.

Cet numérique de la classe A est conforme à la norme NMB-003 du Canada.

Declaration of Conformity
This product complies with the requirements of the European Council Electromagnetic Compatibility
Directive 2004/108/EEC and the Low Voltage Directive 2006/95/EEC.
This equipment must not be modified for any reason and it must be installed as stated in the
Manufacturer’s instruction.
If this shipment (or any part thereof) is supplied as second-hand equipment, equipment for sale
outside the European Economic Area or as spare parts for either a single unit or system, it is not
covered by the Directives.
DVN 5000 STORAGE, SHIPPING, AND
ENVIRONMENTAL GUIDELINES

INTRODUCTION
The DVN 5000 Series server contains delicate electronic components that can be damaged
under harsh conditions, such as excessive heat or humidity, or during shipment due to
improper packaging. If not properly checked, these conditions can lead to equipment failure,
which may void an existing warranty, add unnecessarily to a customer’s costs, and
potentially fail to track a security breach at the building where the unit is installed. Follow
the best practice guidelines in this document to help prevent these situations.

Contact Information
If you require technical support assistance, contact the Johnson Controls Product
Sales Team at 1-800-ASK-JNSN (1-800-275-5676) for 24-hour assistance in the
USA, Technical Support at 805-582-3117 (menu option 5) in the USA, or one of the
following numbers for Europe:
 +49 20 12 40 04 50
 +33 6 72 99 49 66

PACKAGING AND SHIPPING GUIDELINES

When you need to ship a DVN 5000 Series server to Johnson Controls for repair, follow the
packing and shipping guidelines in this section prior to shipment.

Anti-static Handling and Electrostatic Discharge (ESD)

ESD can damage static-sensitive components, such as circuit boards and other
electronic devices.
Before handling static-sensitive electronic components, discharge any static
electricity from yourself. Touch a grounded object such as a grounded, metal
enclosure and use anti-static protection equipment.
While handling static-sensitive components, protect them by using anti-static
gloves or similar types of protection, such as anti-static wrist bands and/or floor
mats.

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General Guidelines and Disclaimers

 Johnson Controls, Inc. shall not be responsible for loss or damage during
shipment.
 Write your Return Material Authorization (RMA) number on the outside of
the box in bold print. You must have a RMA from Johnson Controls, Inc.
prior to shipping defective equipment for replacement. Retain a record of
your RMA number for any future inquiries.
 We recommend that you use a carrier with tracking capability in case proof
delivery is required.
 Use the original packaging when possible.
 A DVN chassis with a torn warranty seal may void the unit’s warranty.

Packaging DVN 5000 Equipment

 Credit for RMA shipments will not be issued if the disk drives are missing
upon receipt of the returned package(s). Any DVN product that arrives
damaged in shipment due to improper packaging voids the equipment’s
warranty.
 If you wish to keep your current data drives, purchase new data drives and
ship the new ones back with the RMA.
 External DVN 5000 disk drives must be removed from the chassis prior to
shipping.
 Enclose each drive separately in an ESD-protective bag for shipment.
 Wrap each drive separately in 2-inch foam rubber or thick bubble wrap. Wrap
the unit chassis in 3-inch foam rubber or two layers of bubble wrap on all six
sides (be sure to wrap around corners when using bubble wrap). Avoid using
foam packing pellets, cloth, or newspaper, since they will not support the
drive(s) in all directions during transit, and the contents will tend to settle to
the bottom of the box.
 You are responsible for saving or backing up data contained in the returned
disk drive(s). Johnson Controls, Inc. shall not be responsible for any loss of
data while the disk drives are in the company’s possession.
 If shipping more than one drive in a carton, confirm that the drives are not
touching each other and the DVN chassis.
 Use an outer carton made of a durable corrugated cardboard.
 For RMA shipments, return all accessories, such as the cables and mouse,
with the DVN server and disk drive(s).

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Preparing the DVN for Shipment

Before shipping the DVN 5000 equipment, perform the following series of
preparatory steps.

 To prepare the DVN for shipment:

1. Verify that all cables (coax, USB, network, audio, etc.) are properly labeled,
as you will need to disconnect them and then reconnect them once the DVN
is returned to you from the repair center.
2. Write down the current network settings, which you may have to
reconfigure once the DVN is returned to you from the factory. See page 4.
3. Export the DVN configuration settings. See page 5.
4. Save existing video, unless you are shipping new drives with the RMA, by
exporting video to one or more DVDs. For more information on exporting
video, refer to the DVN 5000 Series Software Installation and
Configuration Manual, which can be downloaded from the following site:
ftp://cardkey:cardkey2000@ftp2.johnsoncontrols.com/cardkey-out/
DVN_Software/5000.v2.9/
5. Shut down the DVN 5000 server. Wait 20 seconds after shutdown for the
drives to stop rotating.
6. Disengage and remove the drives in each Redundant Array of Independent
Disks (RAID) slot from the drive chassis.

Figure 1: Removing a RAID Drive (Rackmount 4-Bay Drive Chassis Shown)

To disengage a drive from the Rackmount drive chassis, press the drive
slot’s release button and pull the handle until the drive is no longer fully
secured in the drive chassis.
To disengage a drive from the Desktop drive chassis, move the locking
switch to the right and pull the handle until the drive is no longer fully
secured in the drive chassis. See Figure 2.

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LOCKING SWITCH
Left (Locked)/Right (Unlocked)

DRIVE BAY

Figure 2: Removing the Hard Disk Drive (DVN 5000 Desktop)

7. Disconnect all cables from the chassis.

8. Package the equipment according to the guidelines previously described.

Viewing the DVN’s Current Network Settings

Since you may need to manually reconfigure the DVN’s network settings once the
DVN is returned to you from the repair center, we recommend writing down the
DVN’s current network settings as a reference.

 To view the DVN’s current network settings:

1. At the Main screen, click Setup. The Setup window appears.
2. Under General Settings, click System. The System Configuration screen
appears.
3. Click Network Cards next to Incoming Connections. The Network
Settings screen appears.

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4. Write down the DVN 5000 server’s current network settings (IP address,
Net Mask, and Gateway).
The Gateway address is located on the Gateways tab.
5. Click Ok.

Exporting the DVN Configuration Settings

Export (save) the DVN configuration settings to a USB flash drive, so that they can
be uploaded (imported), if necessary, once the DVN is returned to you from the
repair center. If you do not export the system configuration, you may have to
manually re-configure the settings.

NOTE
The configuration settings are exported into a single .txt file on a USB
flash drive.

 To export the DVN system configuration:

1. Insert the USB flash drive into one of the DVN’s available USB ports.
2. On the Main screen, click Setup.
3. On the Setup screen, click System.
4. Click Export next to Configuration Settings.

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The Export Configuration screen appears.

5. Enter a descriptive name for the configuration file, so the DVN

configuration can be easily identified amongst other DVN configuration
files.
6. Save the configuration file to your USB flash drive.
7. Click Ok. The Select the sections screen appears.

8. Verify that all of the check boxes are selected. The System check box
cannot be selected – it is disabled.
9. Click Ok.

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Environmental Guidelines DVN 5000

REQUIRED ENVIRONMENTAL CONDITIONS FOR STORAGE

AND INSTALLATION

General Guidelines
 Do not store or install the DVN 5000 in a dusty environment, which could
affect the operation of the server. Clean the filter every year.
 Ideally, mount the DVNs at the bottom of the 19-inch rack just above the
Uninterruptible Power Supply (UPS). Mount the unit in an appropriate server
rack using the rack manufacturer’s specific mounting hardware or on a fixed
shelf or tray – use the front rackmount wings to keep the DVN stationary in
the rack (not for support). Leave 1 inch between each DVN for air flow.
 Do not place the DVN 5000 in a location where the unit’s vents will be
obstructed, as this may cause the unit to overheat. Leave room at the back and
right side (on newer cases) of the DVN, since these areas are the hot air exits.
 Since the 19-inch rack has a high concentration of heat in a small space, the
air temperature entering the front of the DVN must be less than 75F (24C).
For every 18F (10C) reduction in temperature, the reliability of any
electronic circuit doubles. Control the room and rack temperature to keep the
DVN within normal operating and storage limits and help prevent the unit(s)
from overheating. See “Controlling the Temperature Inside DVN 5000
Equipment Racks” on page 8 for more information.

DVN 5000 Rackmount

The exhaust temperature out of the back of the DVN 5000 Rackmount Series server
must be within an environment that conforms to the following specifications:

Table 1: DVN 5000 Rackmount Series Environmental Specifications

Environmental Condition Specification

Operating Temperature 41 to 95F (5 to 35C)

Storage Temperature 14 to 140F (-10 to 60C)

Relative Humidity 10 to 85%, non-condensing

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DVN 5000 Desktop

The exhaust temperature out of the back of the DVN 5000 Desktop Series server
must be within in an environment that conforms to the following specifications:

Table 2: DVN 5000 Desktop Series Environmental Specifications

Environmental Condition Specification

Operating Temperature 32 to 95F (0 to 35C)

Storage Temperature 14 to 140F (-10 to 60C)

Relative Humidity 10 to 85%, non-condensing

DVN 5000 Temperature Alarms

If the DVN 5000 RAID controller detects excessive heat, such as a temperature at or
greater than 113ºF (45ºC) at the front air intake, the unit generates a loud,
high-pitched audible alarm signal. Excessive heat can cause the RAID drives to fail.
When a RAID drive fails, the DVN 5000 displays a message in the system log that
the RAID drive is critical or offline. To view the system log, navigate to the
Setup>System Log screen using RemoteControl.
To determine if a drive has failed:
1. Check the system log for a critical or offline RAID drive message.
2. Open the front panel and monitor the status Light-Emitting Diode (LED) of
each RAID drive.
A red LED indicates the drive has failed and must be replaced. For
information on replacing RAID drives, refer to the DVN 5000 Rackmount
Series RAID Management Guide (Part Number 24-10177-3).
The DVN 5000 can also be configured to send specific alarms during certain events
(e.g. broken disk detected, camera disconnected, etc.). For more information on
configuring DVN 5000 alarms, refer to the DVN 5000 Software Installation and
Configuration Manual (Part Number 24-10248-5).

CONTROLLING THE TEMPERATURE INSIDE DVN 5000

EQUIPMENT RACKS

NOTE
The information in the following sections contains excerpts from the
document “Controlling the Temperature Inside Equipment Racks” from
Middle Atlantic Products™, Inc. For the complete document, go to
http://www.middleatlantic.com.

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NOTE
The enclosure diagrams in the following sections are protected by
copyright and are the sole property of Middle Atlantic Products, Inc
("Middle Atlantic Products").

Maintaining a proper temperature inside equipment racks is critical to the proper

functioning and survival of the DVN equipment operating within it. To effectively control
the temperature, take a system (integrated) approach to thermal management.

Thermal design of equipment racks and enclosures is essential for the continued functioning
of DVN equipment when subjected to the surrounding environment. The most robust designs
for thermal management, for instance, occur in the telecommunications industry, where
equipment reliability can literally be a matter of life and death. People expect an immediate
dial tone when they lift the receiver, even during a power failure.

Figure 3: Sample Equipment Racks (Middle Atlantic DRK and WRK Series Models Shown)

Definitions
Baffle – An object, such as a plate, used to direct or control the movement of air
within a confined area
BTU/Hr. – British Thermal Units per Hour (of heat); 12,000 BTU/Hr. = 1 Ton of air
conditioning
CFM – Cubic Feet per Minute (of airflow)
Chimney Effect – The natural process of heat flowing upwards
Convection – The process of air passing over a hot object and carrying the heat away
HVAC – Heating, Ventilation, and Air-conditioning

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Rack – Enclosure, cabinet

Thermal Gradient – The rate of temperature change in a given direction
Ton – One Ton of air conditioning = 400 CFM (on most units)
Watt – One Watt of current draw (Volts RMS X Amps) = 3.413 BTU/Hr.

Objective
Use the following information to calculate and understand when and how to vent a
rack using natural convection, and when to force the air using fans.
When using fans, you will be able to calculate the required amount of airflow (CFM)
and know where to place the vents.
Fan choices, filtering, and environmental variables are discussed, along with a range
of real-world application diagrams and helpful charts on how you can achieve
proper thermal management.

Thermal Design Guidelines

To avoid common mistakes, use the following guidelines when considering the
thermal design of equipment racks and enclosures for use with the DVN 5000
product.

Important Considerations
 Consider how the room will exhaust hot air out and draw cool air in.
 Keep the room temperature within the DVN’s operating temperature range.
See Table 1 on page 7.
 Provide a separate zone in the HVAC system to ensure consistent air flow and
proper room temperature.
 Use wide racks for passive convection (no fan) applications.
 A fan near the top of the enclosure can move air through a cabinet from
bottom to top.
 Verify the fan’s CFM rating is at least the sum of the CFM ratings of all the
equipment when using forced air applications. Use the following equation:
(CFM rating for 1 DVN) X (# of DVNs) = Minimum CFM rating of
enclosure fan(s)
 When utilizing a rear fan door, choose one that directs air upwards towards a
return air duct (especially important in hot isle/cold aisle rack arrangements).
 Use vented shelf surfaces that overhang the internal natural rise of heat. See
“Vented Shelves” on page 23.

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 Use fans if you choose a vented front door with less than 68% open area,
except when the equipment has high static pressure front-intake fans built in
(which is rare). The DVN 5000 has front-intake fans, but they are not high
static pressure fans.
 Use a blower rather than a fan in situations with inlet restrictions.
 Use inlet air filters in environments with a high level of airborne particles or
dust to extend the service life of the equipment.
 Install gasketed and sealed NEMA®-rated racks in harsh environments where
filters quickly become clogged. For more information on NEMA ratings and
standards, visit the following sites:
http://www.cdynamics.com/nema-4.html
http://www.nema.org/stds/250.cfm

Avoid
 Installing the DVN 5000 rack inside an enclosed area with little or no
ventilation.
 Allowing the temperature in the room to exceed recommended temperature
levels. A room that is too hot results in DVN drive failures. A room that is too
cold can generate condensation, damaging the DVN’s internal components.
 Locating the racks directly under supply ductwork.
 Using more than one DVN/DVR in a rack in a passive convection
application.
 Selecting an enclosure with venting built-in to the top face when top-mount
fans are required.
 Downward airflows (fans blowing down), since they create mixed convection
(a mixture of forced air and convection).
 The common belief that an equipment fan working in conjunction with a rack
fan will increase the airflow. It provides greater static pressure, but does not
increase the airflow.

Thermal System
This thermal system consists of two types of airflow: how the heat travels through
the rack and how the air moves throughout the room. The interactions between these
two airflows are important and must be considered when taking a systems approach.
All heat (BTU/Hr.) generated by equipment must first be removed from the rack,
and then the room itself must have the ability to remove the total heat from all racks.
Many installations do not have the luxury of an air-conditioned environment.
Consider how the room itself will vent.

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If the equipment room does not have the ability to remove the heat generated by the
rack(s), then all of the following calculations will have little meaning. Whatever
heat is removed from the rack should not raise the room temperature by more than
3F.
For digital equipment, the room itself should be no hotter than 75ºF (24ºC). This
gives a 10ºF (5ºC) temperature difference between the room and the recommended
85ºF (29ºC) internal rack temperature for optimum equipment life.
The cooler the room (as long as the room temperature is above the dew point so
condensation does not occur), the fewer vents or fan CFMs will be needed.
All necessary information is included within this document to calculate the total
BTU/Hr. that will need to be removed.

Rack Placement
Heat generated by equipment in racks needs to be removed. The hot air from the
enclosure must be replaced with cooler room air. In general, it is more effective to
work with natural convection and remove the heated air from the top of the rack
while letting cooler room air enter at or near the bottom. Several examples are
shown later in this document.
Since fan noise is often not welcome in a work area, equipment racks are housed in
closets. Ambient (or room) temperature will be much higher in closets, and heat
should be exhausted out when the ambient air inside the closet exceeds 75°F (24ºC).
When using a single rack in a non-air-conditioned closet, use a fully louvered closet
door and monitor the temperature at the front of the DVN.
In an air-conditioned room (without a raised computer floor), have the supply ducts
and diffusers in front of the racks, and the return ductwork and registers in the rear
of the room.
Avoid locating the racks directly under supply ductwork. Cold air falls, and the flow
of the hot air that rises from the top of the rack should have no impediments on its
way back to the return air (intake) duct. See Figure 4.
When supplying cool air to a dedicated rack room or closet, it is always best to
provide a separate zone in the HVAC system, along with properly placed supply and
return ducts, to ensure consistent air flow and proper room temperature.

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Figure 4: Proper Air Conditioning Airflow and Rack Placement

Enclosure Designs
For passive convection (no fan) applications, wider racks are beneficial; spacious
sides around mounted equipment create a good chimney effect by effectively
drawing heat upward. See Figure 5.
In forced-air applications, a narrower cabinet can be selected to save space.

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For racks in the middle of a multi-bay installation, there are no exposed sides;
therefore, the only way to introduce air is through the front of the rack. Additionally,
incorporating a fan top is the best way to exhaust the air.
When top-mount fans are required, select an enclosure without venting built-in to
the top face. This helps prevent air from short-circuiting (see “Forced Air (Fans)” on
page 24).
Many enclosure manufacturers do not take proper thermal engineering into
consideration, so select your enclosure carefully.

Figure 5: Chimney Effect on Front Air Intake

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Equipment
Nowadays, microprocessors emit greater heat from equipment than ever before, and
as the speed of these clocks increases, the heat continues to rise. Couple that with the
continuing miniaturization of electronics, and you can quickly see that the trend is
for more and more heat to be generated per rackspace of equipment. This is also
known as increased heat density.
Heat has been proven to substantially reduce the service life of most equipment,
which makes it vital to engineer the removal of this heat.
85ºF (29ºC) is the maximum recommended constant operating temperature for most
equipment; keeping the temperature within the allowable operating temperature
range helps provide a long service life for the equipment inside an enclosure.
Both the performance reliability and life expectancy of electrical equipment are
inversely related to the component temperature of the equipment.

Radiated Dissipation
Non-vented solid areas of all racks dissipate internal heat to the outside by radiation.
As the internal temperature rises, so does the temperature of the sheet metal
enclosure. This heat is then radiated to the ambient environment.
This is an important consideration for environments where the cabinet must be
sealed airtight.

NOTE
This document covers only passive convective venting and forced-air
cooling, where the dissipated heat by radiation is negligible in the
calculations of these scenarios.

BTU/Hr. Calculations
100% of the power consumed by communications equipment and computer products
is converted to heat.
Calculating BTU/Hr. output for non-amplifier equipment is simple: the more current
it draws, the more BTU/Hr. will be produced. At 117 volts, each ampere of current
drawn produces exactly 400 BTU/Hr. of heat output.

Planning Airflow Inside the Rack

Proper planning of the cooling air path inside a rack helps prevent hot-spots and
enables the waste heat to be effectively removed.
The most common airflow found in higher current draw equipment is that which
pulls cooler air in from the front and exhausts the heated air towards the rear or sides
(referred to in this document as front-intake equipment).

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Simulations and real-world testing show that moving air through a cabinet from
bottom to top results in the lowest internal cabinet temperatures.
During normal operation and in the event of fan failure, downward airflows are not
recommended, since they create mixed convection (a mixture of forced air and
convection).
Some equipment use internal fans that draw air in through the rear (or sides) and
exhaust out the sides (or rear), which re-circulates the cabinet air. Care should be
taken as to the placement of this type of equipment so the natural convective rise of
heat is not disturbed. For example, do not place this type of rack tightly against a
wall.
Hot air rises. The hotter it gets, the more CFM flow occurs by natural convection.
The friction of all vents gets in the way of the flow; more open area, in the form of
slots or perforations, is always better.

Planning Airflow: Passive Convection

At normal room temperature, a rack can dissipate 300 to 500 watts (only 1 DVN per
rack) of heat through natural convection (no fan assist). This requires adequate vent
openings at the bottom and top of the unit (none in the middle for effective chimney
flow), and an unimpeded airflow inside the rack.

When using passive convection, limit the number of DVN 5000 units in a
rack to 1. Installing additional DVNs or DVRs in the same rack with
passive convection cooling will cause the DVN to overheat, resulting in
drive failures.

The main advantage of natural convection is its intrinsic reliability. Air movement in
a properly configured cabinet is generated by thermal gradients. Proper
configuration most importantly includes optimization of component placement.
Hotter equipment located lower in the rack provides a better natural airflow.
Calculating airflows in a passive convection enclosure is complicated. The slow
speed of airflow makes it nearly impossible to measure, and smoke tests show air
can enter and exit from the same vent.
Equipment that passively vents (without fans) sometimes has intake vents on the
bottom or vents on the top, so take care not to block these with equipment stacked
directly on top of each other; otherwise, it is acceptable to stack equipment directly
on top of each other.
Many times installers simply put vents between each piece of equipment without
regard to the re-circulation of hot air. This can short-circuit the airflow because the
vents are placed too close to fans or heat sources.
Good airflow strategies break the temperature stratification areas, which cause
hot-spots. In some cases you may have to re-arrange the vents and equipment.

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For equipment with front-intake, you can save rackspace by stacking equipment
directly on top of each other as long as the equipment has no vents on the top or
bottom of its chassis.
The following diagrams show this arrangement with passive convection. As with
any passive convection scheme, the more venting up top, the better. Choose racks
that have vents built into the top face for optimum performance, and ensure that a
fully vented top has been installed.
Installing a vented rear door in a passive cooling scenario is not required; this is
dependent on the total BTU/Hr. produced within the rack. For clarification, consult
the nomograph on page 38.

Figure 6: Incorrect Use of Passive Convection with Front Intake on Equipment

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Figure 7: Correct Use of Passive Convection with Front Intake on Equipment

Planning Airflow: Forced Air (Active Thermal Management)

In certain cases when there is too much heat (BTU/Hr.) for natural convection to
properly perform this task, it is essential to force the heated air from the rack. Active
thermal management involves the use of fans and an engineered airflow to
effectively remove heat from an equipment rack.
In these cases where forced air (fans) are required, it is acceptable (but not essential)
to put vents between equipment with front-intakes.

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Most front-intake equipment exhausts between 50 and 150 CFM. If a fan is required
for the top of the rack, ensure that this fan’s CFM rating is at least the sum of the
CFM ratings of all the equipment. With proper fan placement, hot air will not
short-circuit and re-circulate between equipment, as the fan will draw air from all
openings. A solid rear door is recommended in this situation to control airflow from
front to rear. However, adequate (6” minimum) clearance needs to be between the
rear door and rear exhaust outlets of the equipment.
It is important to note that Fan CFM is a maximum rating, as if you mounted it in
free air. As soon as you connect it to an enclosure, the flow rate decreases because of
bends and turns that slow the air flow.
Note that Figure 9 on page 20 (Correct Use of Forced Air with Front Intake on
Equipment) shows no vents in the upper rack face, no vents in the upper rear door,
and no vents in the upper 6 spaces of the rack. This will prevent the short-circuiting
of air at the top of the rack.

Figure 8: Incorrect Use of Forced Air with Front Intake on Equipment

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Figure 9: Correct Use of Forced Air with Front Intake on Equipment

A high-performance alternative method for forced air heat removal in thermally

dense installations can be achieved through the use of a high CFM rear door. These
doors typically provide significantly greater CFM than top mounted fans. When
utilizing a rear fan door, choose one that directs air upwards towards a return air duct
(especially important in hot isle/cold aisle rack arrangements).

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Figure 10: Correct Use of Forced Air on Raised Floor and Vented Floor Grate with High
Density Servers, Network Video Recorders (NVRs), and Switches

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Figure 11: Proper Air Conditioning Airflow and Rack Placement When Utilizing a High
CFM Rear Door

Vent Sizing For Forced Air (Fans)

To avoid “starving” the forced airflow, provide an adequate intake venting area. The
following are minimum recommendations on the number of rackspaces of venting
needed – more venting is better, if properly placed. See the diagrams elsewhere in
this document for proper (and improper) vent placement.
Assumptions:
1. Rackmounted vents have 68% of open area.
2. Does not include equipment with front-intake (less venting is required if
“series” conditions are present from the front-intake fans in equipment; see
“Vents, Fans, And Equipment Layout” on page 26 for more information).
3. 4-inch fans deliver 95 CFM.
4. 10-inch fans deliver 550 CFM.
5. H10-inch (High-output) fans deliver 825 CFM.

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Table 3: Minimum Number of Vented Rackspaces for Forced Air (Fans)

Fan Qty. Fan Size (Inches) Minimum Number of Vented Rackspaces
1 4 2 spaces
2 4 3 spaces
3 4 4 spaces
4 4 5 spaces
1 10 6 spaces
1 H10 8 spaces

If the rack has a vented rear door (bottom-only is proper for top mounted fans), less
rackmount venting is required. Visual approximation is adequate for determining
how many vented rackspaces are required in this situation.

NOTE
The overall vented area must not be less than specified in Table 3.

Figure 12: Sample Rack Fans (Middle Atlantic Products Models Shown)

Vented Shelves
Shelves are an important component of the internal airflow planning process. Shelf
surfaces that overhang the internal natural rise of heat should be vented.
Any obstruction to airflow raises the temperature in the lower portion of the rack,
possibly creating a stratification zone (or heat layer), and should be avoided if
possible.

Figure 13: Sample Vented Shelf (Middle Atlantic Products Model U317 Shown)

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Forced Air (Fans)

Fans substantially reduce interior operating temperatures with correct intake vent
placement, size, and airflow. Fans, however, add little value over good convection
designs if air short-circuiting occurs from having intake points close to the fan.
Venting in the wrong places can also cause hot spots where air does not flow. Proper
fan/vent placement forces more air disturbance inside a rack, breaking up these hot
spots. Additionally, fans help reduce condensation in colder ambient environments.
Condensation increases equipment downtime.
The ideal spot for fan placement (in clean environments) is in the top of the rack,
where the hotter air needs to be removed. This also aids the natural force of the hot
air rising. Rack mounting fans is recommended where there is a likelihood of
contaminants falling into the rack from above.
Baffles can be installed in difficult situations as a solution to maintain proper
airflow. A baffle channels air across a problem location, such as in an excessive heat
spot or an isolated area.
If using multiple fans mounted next to each other, check them regularly for proper
operation. When one fan fails, it acts as a vent near a fan and will not remove heat
from the enclosure effectively (see Figure 14). Confirm the fans are operating
properly to avoid a re-circulation of heated enclosure air.

Figure 14: Using Multiple Fans (One not Operating)

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Figure 15: Using Multiple Fans (Both Operating)

Fan Life
Of the many types of fans available, ball-bearing fans outlast sleeve-bearing fans by
about 50%. At 90ºF (32ºC) a ball-bearing fan lasts approximately 55,000 hours,
while a sleeve-bearing fan quickly becomes inoperable at this temperature.
Because of the necessary bearings inside fan assemblies, fans are more susceptible
to failure than any other component. Since fans wear out faster at higher speeds, the
most practical way to extend fan life is to use a proportional speed thermostatic fan
control circuit, which extends equipment life and reduces service calls by varying
fan speed based upon temperature. A temperature probe triggers fans when an
enclosure’s internal temperature reaches a pre-set level.
Variable speed fans are also self-adaptive; they take into account changes in ambient
temperature and the varying power dissipated by equipment. Even if you employ
filters, the more unnecessary air that is forced through the rack deposits dust inside
the electronics, reducing its thermal transfer. Slowing the airflow down to the
required amount reduces the deposited dust.

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Vents, Fans, And Equipment Layout

The optimum configurations presented in this document were derived using both
thermal modeling and actual temperature measurements.
In most cases the installation of front doors has an effect on airflow. A fully
perforated front door (68% open area) does not impede a fan’s performance; the
paths of air inside the rack and temperatures are not changed. A vented plexiglas
front door’s performance varies from inadequate to adequate based on the design of
the door.
As a general rule, if you choose a vented front door with less than 68% open area,
fans should be used, except when the equipment has high static pressure front-intake
fans built in (which is rare).
In all other cases, using a fan in the top of the rack in series with the equipment’s
built-in fans increases the static pressure (decreases the air system’s impedance), so
air can be pulled through the vented door more effectively. In this arrangement, both
the rack fan and equipment fans work together, increasing the cooling effectiveness,
but not the airflow.
It is a common misconception that the equipment fan working in conjunction with a
rack fan will increase the airflow. As you can see from the “Parallel vs. Series Fans”
chart (Figure 17 on page 27), all this provides is a greater static pressure. It does not
increase the airflow. The only way to increase airflow is to add a fan in parallel, or
obtain a fan with a greater CFM rating.

Static Pressure
Airflow Rate and Static Pressure are terms typically used to describe fan
performance. Airflow rate is the volume of air moved per unit of time, commonly
expressed as cubic feet of air per minute (CFM). Static pressure (S.P.) is the pressure
or suction the fan is capable of developing. In a rack, it is the measurement of
resistance to airflow.
System impedance is associated with forced-air cooling. As air travels through
intake vents and filters, the air pressure drops. The system impedance is the sum of
all pressure drops. The fan selected must be capable of operating at this static
pressure, or the airflow will drop.
All fans have performance curves, which show how much airflow will be delivered
at various static pressures. All diagrams and fans referred to in this document
operate within the proper range.
In situations with inlet restrictions, use a blower rather than a fan. Blowers are
typically capable of generating a higher static pressure.
By definition, a fan is an axial device in which the air moves straight through. A
blower’s air intake is 90 degrees to the discharge outlet. Blowers also produce a
more concentrated airflow than fans and can lead to more audible noise. See
Figure 16.

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Figure 16: Typical Performance Curves: Fans and Blowers

Figure 17: Parallel and Series Fans Performance Chart

Filters
Rack filters, which can be mounted over fans or used as a filtered vent panel, help
protect digital and other sensitive equipment from hygroscopic dust failure (i.e.
when dust absorbs moisture and deposits itself on circuit boards, causing an
equipment failure). This problem occurs in humid environments (generally 65%
relative humidity or higher). Computers and other digital equipment utilizing rapid
clock rates are most affected by this problem.

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Inlet air filters are highly recommended and extend the service life of digital
equipment, as most switchers, routers, hubs, and other processing equipment have
their power supply fans in the rear, without any filtered front air intake.
Filters are especially important in environments with a high level of airborne
particles or dust. For example, the filters must be cleaned after the drywall is
installed, since drywall dust effectively blocks the filter.
Filter loading and subsequent maintenance requirements can be greatly reduced with
the use of a proportional thermostatic fan speed control circuit, since the overall
volume of air is lower when not required.
Good filters have a long service life and low static pressure drop. To avoid clogging,
regularly maintain and/or replace filters, as needed. Refer to the filter
manufacturer’s documentation for maintenance recommendations.
Also consider using a heat exchanger for keeping contaminants out of the enclosure
in very dusty environments or when maintenance is questionable.

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Figure 18: Correct Use of Forced Air Filtered without Front Intakes on Equipment

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Figure 19: Correct Use of Forced Air Filtered with and without Front Intakes on Equipment

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Pressurizing Racks
Pressurizing the rack (rather than sucking the air out of the top) is the best solution
for dusty or dirty environments where filters need to be changed regularly.
Although less thermally efficient, pressurizing helps clean air escape through cracks
and openings, rather than allowing dirty air to enter.

Figure 20: Correct Use of Pressuring a Filtered Rack without Front Intakes

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Heat Exchangers and Air Conditioning Units

In harsh environments, such as dirty factory floors, filters quickly become clogged
and heat inside the rack builds rapidly. In these applications, gasketed and sealed
racks rated by the National Electrical Manufacturers Association (NEMA®) should
be installed.
Heat exchangers and air conditioning units (mostly installed in NEMA-rated racks)
do not allow the ambient dirty air to mix with the enclosure interior air, which helps
the interior rack air stay clean.
These devices (either water-coil or refrigerant-compressed) are also the only way to
make the temperature inside the rack cooler than the ambient air. However, avoid
condensation when cooling the rack with an air conditioning unit. To prevent
condensation, keep the temperature above the dew point.

Figure 21: Correct use of Simplified Heat Exchangers and Air Conditioners

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Data Centers and Raised Computer Room Floors

Data center installations require careful airflow design by a professional engineer
skilled in the HVAC trades.
Use a total system approach, and take into account the thermal loads along with the
minimum static pressure required inside the cabinet.
Provide selective openings in the raised floor instead of allowing air to leak out
where not required. If excess air enters some enclosures, other enclosures will not
get the required airflow and equipment may overheat.
Airflow under the computer floor must be directed and managed, which can only be
accomplished by measuring the CFM and static pressures inside the enclosures.
Consider the following to control the static pressure inside the cabinet:
 The amount of air let into the bottom
 The design of the rear door
 The careful placement of blank panels
For extremely high heat densities, or large variances between heat densities in
adjacent enclosures, additional spot cooling may be required. This can be
accomplished by utilizing a variety of solutions, one of which is an
enclosure-mounted cooling system. For higher BTU/Hr., popular types of these
systems use flexible hoses and liquid-to-air heat exchangers.

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Figure 22: Incorrect Use of Forced Air on a Raised Floor with a Floor Grate and
High-Density Servers

A balanced system uses cool air effectively by not allowing it to re-circulate back to
the HVAC unit without removing heat.
In a data center system designed for airflow, the total cabinet fan CFMs should not
exceed the CFM of the room’s HVAC unit. If this situation occurs, the required
static pressure drops and some cabinets will be in need of essential CFMs of airflow,
possibly resulting in overheated equipment.

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Figure 23: Correct Use of Forced Air on a Raised Floor and Front Grill with 1-Space
Servers

To introduce cool air into enclosures on a raised computer floor, provide an air
outlet grate in front of the rack (recommended) (see Figure 23) or have the air enter
through the bottom of the rack. Both methods work well, as long as proper airflow is
engineered into the system and adequate air is provided to equipment intakes.

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The downside to using a totally perforated cabinet and cold air-cooling in a data
center is uneven cooling and short-circuiting of airflow. If the air is too cold,
condensation can occur, and energy costs for the facility will be high.
Older data centers were mostly designed for equipment racks with less heat output
per rack footprint, so pay special attention to any equipment changes or additions.
The optimum layout for high heat density racks is an arrangement in rows of two to
produce both hot and cold aisles (see Figure 24). The front of the racks face each
other in the cold aisle, with air grating down the center for cold air supply. The rear
of the racks face each other in the hot aisles, with return grills overhead for optimum
utilization of the air conditioning system.

Figure 24: Optimum Arrangement of High Heat Density Racks

How to Calculate Ventilation Required to Provide an Interior

Rack Temperature of 85°F (29ºC)
The nomograph on page 38 shows the minimum ventilation (active or passive)
required to provide an interior rack temperature of 85ºF (29ºC).

 To calculate total waste heat (column B):

1. Obtain total waste heat output by combining the published waste heat
BTU/Hr. of all DVNs in the rack.
DVN 5000 Rackmount Series BTU/Hr.: Typical: 655; Maximum: 706
2. Add up total measured amperage draw from all other equipment and
multiply by 400 (total amperage x 400 = total BTU/Hr. @117V).

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3. Combine BTU/Hr. totals from steps 1 and 2 to obtain total for all
equipment. Mark total in column B.

 To obtain minimum ventilation requirements:

1. Mark ambient room temperature in column C, and connect points in B and
C with a straight-edge.
2. The minimum cooling required providing an interior rack temperature of
85ºF (29ºC) is shown in column A, where the straightedge intersects the
minimum cooling requirements column.
System Requirements:
 For passive and active ventilation, verify adequate intake vents are installed.
 No short-circuiting of air should occur (See previous diagrams).

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Figure 25: Nomograph for Calculating Required Ventilation

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Thermal Solutions
Careful placement of vent blockers, as part of your proper thermal management
planning, helps prevent the short-circuiting of airflow in rack enclosures. Vent
blockers magnetized on one side help force the heated enclosure air out through
top-mounted exhaust fans.

Upper Inside Side Panel Upper Inside Rear Door

Enclosure Upper Faces

Figure 26: Vent Blockers

Vibration
Hard drives are very sensitive to vibration from other drives and nearby fans. This
causes the read/write head to stop momentarily, which slows the system, or can even
cause a head crash. Mounting DVNs near the top of the rack causes more vibration
and early disk drive failures. The three year life is reduced to two years in actual
cases observed.

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Future Planning
When designing racks and thermal loading, consider future expansion and possible
changes. Adding equipment to a rack can compromise the proper thermal design.
Identify and correct these problems if the interior rack temperature exceeds 85°F
(29ºC).
On some enclosure manufacturers’ tops, knockouts are provided for adding
additional fans once all equipment has been installed.
As stated earlier, the room needs to exhaust all the heat produced by the equipment,
so it is important that the facility be able to handle future expansion.

Troubleshooting Tip
When airflow is inadequate, equipment can fail. For a quick, short-term fix, open the
rear door and place a floor fan facing the rear to lower the rack’s temperature. Do
not use this method as a long-term fix; however, it may keep heat-sensitive
equipment working while you obtain a replacement.

Standards
Some current standards relating to thermal management, heat release, and
temperature requirements are found in the Network Equipment-Building System
(NEBS) standards.
The Telcordia® GR-63-CORE standard has been found to be unclear in many
respects, so the GR-3028-CORE (Thermal Management in Telecommunications
Central Offices) standard was recently released. This includes the results of
advanced computer modeling techniques for thermal management.
For more information, access the Telcordia website at: http://www.telcordia.com/

PREVENTATIVE MAINTENANCE
This section describes the specific tasks for properly maintaining the DVN 5000 equipment
and its accessories. When servicing equipment, follow all manufacturer’s guidelines and
instructions.

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DVN 5000 Server

Perform the following tasks after the drywall dust has cleared and every 6 months
thereafter:

Task Description Date Performed

1. Visually inspect all cable terminations (BNC, network, SCSI

device, etc.). Tighten mounting screws.

2. Inspect the DVN for infiltration of dust or moisture.

3. Remove the filters and drives and clean with a vacuum or

compressed air.

4. If possible, restart system and ensure correct start-up and

operation.

5. Check for noisy drives and fans in the DVN and rack.

6. Perform full unit test of operational functions, including

recording and playback.

7. Check the RAID drive LEDs for any data drives that may be
in a critical state or that have failed. The log file will show
critical RAID drives. Replace these drives.

8. Review the log file for specific errors.

9. Check for viruses and run a cleanup tool.

10. Check the air temperature of the DVN server’s exhaust.

Exhaust temperature must be less than 95ºF (35ºC). The
audible alarm will sound if too hot.

11. Check the storage settings for any issues.

12. Back up the DVN’s configuration settings onto a Flash drive

and leave it at the site.

13. Replace all 4 data drives and the system drive every
3 years.

Cameras

Task Description Date Performed

1. Visually inspect the Camera Assembly Exterior. It should be

sound and have no signs of water infiltration or damage.

2. Inspect the Mounting Bracket, if applicable. Operate the

Pan and Tilt Unit. Check condition of all mounting points.

3. Secure all relevant cable entry locations and verify they are
free from foreign objects.

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Task Description Date Performed

4. Visually inspect Termination Box, checking for corrosion.

The door should be operational and any seals should be
checked. If applicable, confirm the lock operates properly.

5. Remove any obstructions, such as natural foliage, from the

camera’s field of view. This is most applicable when Video
Motion Detection is employed. Report all clearance
requirements to the customer.

6. Remove enclosure cover and verify there is no infiltration of

foreign materials, insects, or vermin.

7. Clean the enclosure glass front with a lint-free cloth

moistened with a non-alcohol-based glass cleaner.

8. Inspect and verify via a continuity test that all earth-bonding

points are connected to the incoming earth termination
point. Where circuits are outfitted with ground fault
detection, test to ensure correct tripping and reset.

9. Where present, inspect the lens wiper blade and ensure

correct operation over the complete area to be wiped.

10. If present, check operation of infrared lamps.

11. Complete all applicable forms.

CCTV Switcher, Multiplexer, Control, and Monitoring

Equipment

Task Description Date Performed

1. Visually inspect all controls and verify operation of all

functions. Ensure all indicators and displays are
operational.

2. Inspect for contaminants or dust. Clean according to

manufacturer’s specifications, if required.

3. Clean all monitor screens with antistatic spray.

4. Where control equipment is presented in rack format or in a

console, ensure any system cooling fans are operational.
Also ensure the interior is free from contaminants and dust.

5. Perform a full inspection and check the terminations of all

system cables. Re-terminate where necessary. Inspect
condition of plug terminators and replace where necessary.
Replace any cables where necessary.

6. Measure the incoming video signals and ensure a proper

peak-to-peak signal voltage is present.

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Task Description Date Performed

7. Observe display pictures at high contrast and ensure there

is no “blooming” of peak white levels.

8. Check the operation of all controller push buttons and

keypads. Replace any switches or buttons in accordance
with the manufacturer’s handbook.

9. Check remote control panels and line drivers. Clean all

surfaces with a non-abrasive solvent.

10. Return unit to normal operational mode.

11. Carry out a full operational test of the unit and full
configuration backup.

12. Inspect and clean system configuration backup device in

accordance with manufacturer’s specifications.

13. Complete all applicable forms.

Computer Workstations

Task Description Date Performed

1. Visually and physically inspect all cable connectors.

2. Visually inspect unit for damage or contamination.

3. If applicable, clean floppy drive using drive cleaning disk.

4. Clean optical drive using drive cleaning CD or cotton swap

and alcohol.

5. Inspect computer power supply vents for accumulation of

dust and debris. Clean filters with compressed air.

6. Remove cover and inspect for dust and debris.

7. Inspect processor, memory, system board, and hard drive

for dust and debris. If present, remove using appropriate
computer servicing tools.

8. Check monitor contrast, brightness control, and ensure

screen is readable.

9. Check Keyboard operation/ Key identification. Ensure all

Keys are operational and legends are readable.

10. Check file system (i.e. defragment, scan disk, etc.). Check
for viruses and run a cleanup tool.

11. Check operation of mouse.

12. Check operation of keyboard and clean.

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Task Description Date Performed

13. Complete all applicable forms.

14. If applicable, back up the SiteManager configuration

settings.

Uninterruptible Power Supplies (UPS)

Task Description Date Performed

1. Visually inspect cable entry and mounting points.

2. Check for infiltration of dust.

3. Inspect all terminations.

4. Confirm that the power supply is operating in accordance

with operational specifications.

5. Check for correct battery venting and air flow.

6. Bypass the main’s input direct to load.

7. Measure battery charge voltage.

8. Isolate the main’s input and check output voltage.

9. Visually inspect unit battery; check date of installation.

10. Clean battery terminals. Apply non-conductive protective

agent.

11. Return unit to on-line status and isolate main’s input.

12. Check for continued load support.

13. Perform any required corrective actions and clean outer

casing as necessary.

14. Complete all applicable forms.

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