Emerson XDR Air Conditioner User Manual
Contents
1. Liebert A Liebert XDR A Liebert XDR Liebert XDR A Connection Methods and Points Refer to site specific drawings for general locations of the piping connections For Liebert XDR con nection locations refer also to Figures 14 17 and 21 The assembly and connection means used for piping in the Liebert XD system are the same as those used in conventional refrigeration systems Observe all standard practices during installation and startup to prevent damage and contamination All piping must be ASTM Type ACR copper The Liebert XDR has supply and return piping access on the top of each module Supply piping con nection is 1 2 OD copper pipe and return piping connection is 7 8 OD copper The hard piped Lie bert XDR has a low pressure nitrogen holding charge Both supply and return couplings may be supplied with optional one shot couplings These couplings contain pressurized R 134a refrigerant inside the Liebert XDR For Liebert XDRs with removable couplings the supply piping connection is 1 2 OD and the return piping connection is 7 8 OD Both the Liebert XDR and the Liebert XD Flex Pipe with removable cou plings have a low pressure nitrogen holding charge Insulation To minimize the possibility of condensation insulate all piping between the Liebert XDR and the Lie bert XDP or Liebert XDC Venting the Holding Charge for Hard Piped or Removable Liebert XD Flex Pipe Couplings The Liebert XDR in2. Figure 29 Two adjustable wrenches with a maximum adjustment size of 2 inches Close the service valve in the supply line Ensure there is airflow across the coil Wait two minutes for the refrigerant to flow out of the module Close the service valve in the return line Loosen the Liebert XD Flex Pipe coupling from the header port coupling This requires a wrench Refer to Figure 27 The Liebert XD Flex Pipe coupling must be held stationary while the union nut on the coupling is being loosened Disconnect the coupling Place the protective dust cap on the port Place the protective plug back on the Liebert XD Flex Pipe Repeat Steps 5 through 7 for the remaining Liebert XD Flex Pipe Piping mains without Liebert XD Flex Pipe Dust caps attach here 27 Piping 6 7 7 Disconnecting the Liebert XD Flex Pipe from the Liebert XDR 6 7 8 NOTICE Risk of improper reuse of Liebert XD Flex Pipes with one shot connections Can cause refrigerant leaks Liebert XD Flex Pipes with one shot connections must not be removed from the Liebert XDR unless they are being replaced with Liebert XD Flex Pipes with one shot couplings Do not reuse Liebert XD Flex Pipes with one shot connections Reuse may result in refrigerant leaks Tools Required 1 gut Ge Two adjustable wrenches with a maximum adjustment size of 2 inches Reclaim the refrigerant in the Liebert XD Flex Pipe and in the module by attaching a refrigeran
3. or Liebert user manual NOTE This operation requires two or more people Determine the port location of the supply and return piping overhead Make sure the service valve for each port is closed Remove caps from only the required ports Do not remove caps from the unused ports Remove the pipe plugs that are supplied on the Liebert XD Flex Pipe Inspect both halves of the coupling and remove any foreign contamination from the sealing surfaces and threads before connecting the fittings Determine the coupling size by locating the number scribed on the Liebert XD Flex Pipe coupling See Figure 23 QU Boe gt 23 Piping Figure 23 Coupling size indicator Coupling size indicator Figure 24 Liebert XD prefabricated piping assembly Supply Main Service Valve typical Q all ports Headers Capped Threaded Cap Typical Headers Connected 7 Use mineral oil or polyol ester oil to lubricate the face of the poppet valve and the seal around the poppet valve on the female connector on the Liebert XD Flex Pipe see Figure 25 8 Apply mineral oil or polyol ester oil to the stainless steel delta ring on the male connector header port connector see Figure 25 24 Piping Figure 25 Oil rings on header and Liebert XD Flex Pipe connectors Poppet Valve Face Cil Applicator Spout Rubber Ring Around Poppet Valve Face Stainless Steel Delta
4. a Rr oes or a 12 5 1 Installing the Rack Mounting Kit onto the 12 5 2 Mounting the Liebert on the Rack Mounting Kit 12 5 3 Door Satety 4 aS E e Reit sit aie DE De andes ee ao ie d du ns 13 6 0 PIPING ok GO See Be ana oe Sew 14 6 1 European Union Fluorinated Greenhouse Gas Requirements 14 6 2 System Connection s 14 6 3 Connection Methods and Points 15 6 4 Insulation a aaa a mede n d emt std a e RI ETAT 15 6 5 Venting the Holding Charge for Hard Piped or Removable Liebert XD Flex Pipe Couplings 20 44 ou der sb E E hae een Able E S tM ESSA TIS 15 6 5 1 Brazing Preparations ness bs er e ee dus es dre Be ee ree tid 16 6 5 2 Recommended Piping 16 6 6 Hard Piped Connection Sizes 16 6 6 1 Leak Checking and s 17 6 6 2 sHeader Sy stein stus voe esie Nah eee ed ats De o actae eos we d 17 6 7 7 0 7 1 7 2 8 0 9 0 9 1 10 0 Field Installation of Liebert XD Flex Pipe Kit on Liebert XDR 18 6 7 1 Co
5. Precision Cooling For Business Critical Continuity Liebert XDR User Manual EMERSON Network Power IMPORTANT SAFETY GUIDELINES SAVE THESE INSTRUCTIONS A A A A WARNING Risk of top heavy module falling over Can cause equipment damage personal injury or death Improper handling can cause equipment damage injury or death Read all of the following instructions before attempting to move lift remove packaging from the module or preparing module for installation WARNING Risk of explosive discharge of high pressure refrigerant Can cause personal injury or death This module contains fluids and or gases under high pressure Relieve system pressure before cutting into or disconnecting piping or piping components WARNING Risk of piping and component rupture May cause equipment damage personal injury or death Closing service valves may isolate liquid refrigerant causing high pressure and rupture of piping Do not close valves without following recommended procedures for repair maintenance and replacement of components Install pressure relief valves in field piping that may become isolated by service valves CAUTION Risk of sharp edges splinters and exposed fasteners Can cause personal injury Only properly trained personnel wearing appropriate safety headgear gloves shoes and glasses should attempt to move lift remove packaging from or prepare module for installation C
6. 2 4 1 References This document must be used together with site specific documentation and documentation for other parts of the system Pre Installation Checks Check the received materials to be sure all required assemblies and parts have been received If you discover any external damage report it to the shipping company and your local Emerson rep resentative Packing List User manual this document Liebert XDR module Installation Considerations The Liebert XDR is designed for attachment to the rear of computer cabinets in the data center See 4 0 Mechanical Considerations for details Room Preparation The room should be well insulated and must have a sealed vapor barrier The vapor barrier in the ceiling and walls can be a polyethylene film Paint on concrete walls and floors should contain either rubber or plastic NOTE The vapor barrier is the single most important requirement for maintaining environmental control in the conditioned space Outside or fresh air should be kept to a minimum when temperature and humidity must be tightly controlled Outside air adds to the cooling heating dehumidifying and humidifying loads of the site Doors should be properly sealed to minimize leaks and should not contain ventilation grilles General Product Information 3 0 GENERAL PRODUCT INFORMATION 3 1 Product System Description The Liebert XDR 1s a cooling system for high density heat loads that mo
7. Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 FIGURES Liebert XDR component Liebert XDR model number nomenclature Generic piping layout 9 oh eee RE BAe ENS ee NEUE EN E Ea bates Recommended module handling Removing packaging eo wees we Steg ee Ge Ge RI E RE EQ ER Remove Liebert XDR from Overall dimensions with hard piped Overall dimensions with one shot coupling Overall dimensions with removable amp Generic airflow diagram e eens Liebert XDR mounting locations eee s Typical Liebert XDR piping interlaced Typical Liebert XDR piping non interlaced Piping location and connection sizes modules with hard piped connections Hard pipe connection diag
8. Liebert XDC user manual is SL 16671 The user manuals were supplied with the units and are available on the Liebert Web site ww w liebert com 30 Maintenance 9 0 MAINTENANCE Minimal maintenance is required to keep the Liebert XDR operating at optimal levels The module should be cleaned and checked for damage Suggested maintenance includes Cooling fins Clean any dust and debris from the cooling fins taking care not to bend them 9 1 Fluorinated Greenhouse Gas Requirements Stationary air conditioning refrigeration heat pump equipment and stationary fire protection sys tems in the European Community market and operating with fluorinated greenhouse gases f gas such as R407C R134a R410A must comply with the F Gas Regulation EC No 842 2006 F gas The regulation prohibits among other actions venting fluorinated greenhouse gases to the atmo sphere The F Gas Regulation requires operators to use all measures that are technically feasible and do not entail disproportionate cost to prevent leakage of these gases to test for leakage regularly and to recover f gas during equipment service and maintenance and before disposing of equipment Refer to the full regulation for additional details 31 Specifications 10 0 SPECIFICATIONS Table 6 Liebert XDR specifications Models Cooling Capacity Nominal rated at 104 F 40 C EAT amp 2400ft m 68m m XDR20B1 Pre Charged R 134a
9. Ring on Header Port Connector 9 lhread the union nut of the Liebert XD Flex Pipe coupling onto the port coupling to ensure the threads mate properly 10 Using the wrench arrangement shown in Figure 26 torque the couplings to the values in Table 5 NOTICE Risk of twisted or kinked piping Can cause flow restriction or leaks It is imperative that the brass body of the Liebert XD Flex Pipe coupling does not rotate while the couplings are being tightened Failing to do so may damage the female coupling Table 5 Torque for connecting Liebert XD Flex Pipe to prefabricated piping Coupling Crowsfoot Torque Size Size in mm ft lb Nm RF08 1 3 16 30 25 8 30 35 RF12 1 5 8 41 48 0 60 65 RF16 1 31 32 50 62 7 80 85 Figure 26 Wrench arrangement for tightening couplings Crowsfoot Wrench holding brass body of female coupling stationary to prevent it from turning Torque Wrench 25 Piping Figure 27 Detail view of Liebert XD Flex Pipe and prefabricated piping port 0 I Service Valve Note Make sure the valve eR is closed before attaching Tighten with Liebert XD Flex Pipe to the system torque wrench DO NOT OVERTIGHTEN Hold threaded coupler here with a wrench to keep P the brass body on the female connector from rotating while tightening collar with
10. couplings These fittings con tain pressurized R 134a refrigerant inside the Liebert XDR If the module includes the optional factory installed one shot style couplings proceed with 6 7 2 Connect a Liebert XDR with One Shot Couplings to Liebert XD Flex Pipe and see Figure 17 If the module does not include Liebert Flex Pipes refer to 6 5 Venting the Holding Charge for Hard Piped or Removable Liebert XD Flex Pipe Couplings Figure 17 Piping location and connection sizes modules with pre charged modules TOP VIEW 1 5 16 Rear of Cabinet 33mm a Refrigerant 29mm elrigeran Schrader Valve_ Supply Line Return Line Do Not Vent 149mm 23 1 2 597mm 19 Piping 6 7 2 Connect a Liebert with One Shot Couplings to Liebert XD Flex Pipe NOTICE Risk of improper reuse of Liebert XD Flex Pipes with one shot couplings Can cause refrigerant leaks Liebert XD Flex Pipes with one shot couplings must not be removed from the Liebert XDR unless they are being replaced with Liebert XD Flex Pipes with one shot couplings Do not reuse Liebert XD Flex Pipes with one shot couplings Reuse may result in refrigerant leaks Tools Required 1 2 Figure 18 Figure 19 Two adjustable wrenches with a maximum adjustment size of 2 inches One torque wrench half inch drive see Table 2 for sizes Refrigerant oil Check the Liebert XD Flex Pipe for proper length Remove the protector cap and plug fro
11. either hard piped configuration or with removable couplings is shipped with a low pressure holding charge about 30 psi of nitrogen to prevent oxidation and moisture This must be vented from the refrigeration circuit before removing the copper cap NOTE This procedure is for modules with hard piped or removable couplings ONLY Do not vent a pre charged Liebert XDR or pre charged Liebert XD Flex Piping To vent the holding charge 1 Findthe Schrader valve that retains the nitrogen holding charge in the Liebert XDR The valve is inside the rear door on the supply line see Figure 14 for hard piped connections and Figure 22 for removable couplings 2 Ventthe holding charge in the circuit by depressing the pin in the Schrader valve on the supply line 3 Replace and secure the cap on the Schrader valve that was opened 15 Piping 6 5 1 6 5 2 Table 1 Brazing Preparations The assembly and connection means used for piping in the Liebert XD system are similar to those used for conventional refrigeration systems All piping should be installed with high temperature brazed joints Soft soldering is not recommended After the holding charge has been vented and before brazing wrap a wet rag around the copper con nections before removing the caps to prevent internal component damage torch can be used to remove the caps over the ends of the supply and return lines During brazing the lines must be filled with flowing dr
12. other sizes Figures 7 8 and 9 illustrate the module s dimensions and the location of pipes Figure 11 shows the attachment positions of each module Figure7 Overall dimensions with hard piped connections Piping is not load bearing and i should never be used to lift or 102mm move the Liebert i l LL 34 5 16 33mm 25 5 8 78 3 8 651mm 1991mm 20 1 2 520mm NJ Lu Y 6 12 n 165mm e 23 1 2 597mm 27 3 8 27 318 695mm 695mm Mechanical Considerations Figure8 Overall dimensions with one shot coupling pre charged Piping is not load bearing and i should never be used to lift or 5 1 8 move the Liebert XDR 130mm i 1 5 16 1 1 8 29mm 2 1 8 i 54mm 25 5 8 651mm 78 3 8 83 1 2 20 1 2 1991mm 2121mm 520mm lt Ex i 27 3 8 695 23 1 2 597mm __ 27 3 8 695mm Mechanical Considerations Figure9 Overall dimensions with removable coupling Piping is not loa
13. AUTION Risk of improper operation and overpressurization Can cause in personal injury or property damage Only personnel properly trained and qualified in HVAC installation or service should install or service this equipment Read all installation operating and safety instructions before proceeding NOTICE Risk of overhead interference Can cause module or structural damage The module may be too tall to fit through a doorway while on the skid Measure the module and doorway heights and verify clearances by referring to the installation plans and other site specific drawings and documents before moving the module Fluorinated Greenhouse Gas Requirements European Union Stationary air conditioning refrigeration heat pump equipments and stationary fire protection systems in the European Community market and operating with fluorinated greenhouse gases f gas such as R407C R134a R410A must comply with the F Gas Regulation EC No 842 2006 F gas The regulation prohibits among other actions venting fluorinated greenhouse gases to the atmosphere The F Gas Regulation also requires operators to use all measures that are technically feasible and do not entail disproportionate cost to prevent leakage of these gases to test for leakage regularly and to recover f gas during equipment service and maintenance and before disposing of equipment Refer to the full regulation for additional details TABLE OF CONTENTS IMPORTANT SA
14. FETY GUIDELINES 0000 cence cece hn INSIDE FRONT COVER 1 0 COMPONENT LOCATIONS AND MODEL NUMBER 1 2 0 INTRODUCTION etu haber Baca nm ea aod Ad e o ca ar ee eta 2 2 1 ta ded eu d AST UE td ah uud e eee aac 2 2 2 PresInstallation Checks 2 d i TEE Sete Aes 2 2 3 Packing laste osse Dur er rh E estu 2 2 4 Installation Considerations 13 a a Deb NCC IL an od E a odd iod a 2 2 4 1 Room Preparation iio cts no bbe esse ee pta send a EC S EY Nc du M ed 2 3 0 GENERAL PRODUCT INFORMATION hihi 3 3 1 Product System Description RR e e e e ne eens 3 3 2 Checking and Unpacking erias apposui M ao Den PRU Pee es 3 3 2 1 Recyclable Packaging euge e Poste ty due qu Pa Loto P dr Toe d 4 9 22 Mod le Haridling ue ertt ERE EAT eget pe qe UAR ET ATE A E ig 4 39 2 8 Unpacking the Module 1 ee rs 5 3 2 Removing the Liebert XDR from the Pallet 7 4 0 MECHANICAL CONSIDERATIONS 8 4 1 Liebert XDR Dimensiotis 59x39 REY Erb ER Ak wg qa vix 8 4 2 Determining Placement in the Conditioned 10 4 8 ii ae RS aru d See eee arenes repas 11 5 0 INSTALLATION ucc hc er a de Ged webs
15. XDR20B1P 20 5 kW 5 8 tons XDR20B1R Conditions 55 F 13 entering fluid temperature 50 F 10 or lower dew point Dimensions inches mm Height Including Pipe Connections 82 3 8 2093 83 1 2 2121 80 2032 Width With Handles Attached 27 3 8 695 Handles Removed 23 1 2 597 Depth 6 1 2 165 Shipping Length 90 2286 Shipping Width 30 1 2 775 Shipping Depth 15 1 2 394 Max Shipping Depth 4 modules 62 1575 Weight Ib kg Module Only 130 59 133 60 130 59 Shipping 225 103 228 104 225 103 Pipe Connections Refrigerant Supply 1 2 OD Type ACR Refrigerant Return 7 8 OD Type ACR Exterior Finish Black Matte Heat Fused Powder Coat Safety CSA CE Approved Referto Figure 2 for the complete part number Table 7 Rack mounting kit Rack Part Knurr Miracel 198163G1 Dell PowerEdge 4210 199050G1 HP 10642 199051G1 APC AR3100 199054G1 Table 8 Liebert XD Flex Pipe one shot assemblies supply and return Liebert P N Liebert P N Minimum Bend Radius Description m Straight Connection 90 Degree in mm Assembly Connection Assembly Supply Return 10 3 0 186566G2 186565G2 i 8 2 5 18656663 18656563 Liebert XD 29 7 178 9 229 Flex Pipe Kit 6 1 8 186566G1 186565G1 4 1 2 186566G4 186565G4 Table 9 Liebert XD Flex Pipe removable as
16. a torque wrench Flex Pipe 11 Repeat Steps 3 through 10 for the remaining Liebert XD Flex Pipe 12 For a Liebert XDR module with removable couplings open the return and then supply service valves If the Liebert XDR is pre charged DO NOT open either of the service valves 13 Refer to the Liebert XDC or Liebert XDP user manual for procedures for evacuation leak check charging and startup If adding a one shot pre charged Liebert XD module with one shot pre charged Liebert XD Flex Pipes to an operational Liebert XD system after connecting to the header system 1 Open the return service valve 2 Open the supply service valve Figure 28 Liebert XD prefabricated piping assembly and Liebert XD Flex Pipe 4 Return Service Valve Make sure valve is open after system leak check Supply Service Valve Make sure valve is open after system leak check Supply Main ae Return Liebert XD Flex Pipe from Liebert XDR __ Supply Liebert XD Flex Pipe from Liebert XDR 26 Piping 6 7 6 Disconnect a Liebert XD Flex Pipe from a Liebert XD System A CAUTION Risk of sudden discharge of pressurized refrigerant Can cause equipment damage or injury Do not disconnect threaded refrigerant couplings at the module cabinet end without relieving system pressure Reclaim any refrigerant during removal of module from system Tools Required OT RS
17. d bearing and 41 1 2 should never be used to lift or 388mm move the Liebert XDR i Rn 1 l 1 5 16 7 8 i 33mm M 2 1 8 54mm F 25 5 8 78 3 8 80 651 1991 2032mm 110d g 20 1 2 520mm ES J Y Y s 5 7 8 o mam 6 1 2 149mm O1 165mm e Lp 27 3 8 695mm I 23 1 2 597mm 27 3 8 695mm 4 2 Determining Placement in the Conditioned Space Refer to site specific drawings for exact placement Efficient cooling of the rack equipment depends on proper placement of equipment proper use of blanking plates in any voids in the rack and good cable management The Liebert XDR is engineered to fit the rear of computer enclosure cabinets Figures 7 8 and 9 illustrate the module s dimensions and the location of pipes Ensure that there is 25 6 649mm clearance in the rear to allow the door to open fully 10 Mechanical Considerations 4 3 Airflow The server fans draw air into the equipment enclosure After heated the air the server fans force the air across the Liebert XDR s two coils The Liebert XDR has a low air side pressure drop similar to a rack with perforated doors The server fans with
18. e Wrench Sizes Coupling in mm Torque Union Nut Size Only ft Ib Nm Union Nut 10 Supply 1 5 16 34 35 45 13 5 6 2 12 Return 1 3 8 35 50 60 67 8 88 1 If a torque wrench is not available continue with the steps below 6 Tighten the union nut on the Liebert XD Flex Pipe the coupling on the module with the proper sized wrench until a definite resistance is felt metal to metal contact Use a marker or pen to draw a line lengthwise across the module coupling to the Liebert XD Flex Pipe The line should parallel the Liebert XD Flex Pipe Tighten the nuts an additional one 1 wrench flat 60 judging the amount by the mark drawn in Step 7 21 Piping 6 7 3 Connection Methods Removable Couplings The assembly and connection means used for piping in the Liebert XD system are the same as those used in conventional refrigeration systems Observe all standard practices during installation and startup to prevent damage and contamination Both supply and return fittings may be supplied with optional removable couplings Figure 21 Piping location and connection sizes modules with removable couplings TOP VIEW 1 5 16 Rear of Cabinet 718 33mm Refrigerant Refrigerant 22mm Return Line Schrader Valve Supply Line 1 1 2 2 gn 38mm S 5 7 8 149mm mm 2 1 8 54mm 23 1 2 597mm 6 7 4 Connect Liebert XD Fl
19. emove Foam General Product Information Figure6 Remove Liebert from pallet Two people are required to remove the module from the pallet and remove the bag A WARNING Risk of 130 pound 59 kg module falling Can cause equipment damage personal injury or death Do not leave a Liebert XDR standing unattended on its side or its end without adequate support to prevent it from falling over The Liebert XDR must be supported at all times or laid flat on protective material until it is installed Two properly trained and qualified people are required to move the module 3 2 4 Removing the Liebert from the Pallet 1 Unfold the module bag to expose the Liebert XDR 2 Compare the serial tag information on the Liebert XDR to the bill of lading information If the information does not match the product specified contact your local sales representative 3 Atleast two properly trained and qualified personnel may lift the Liebert XDR off the pallet using the four handles and stand it upright supporting the module to keep it from falling 4 Ifthe Liebert XDR will not be installed immediately lay a piece of protective material the length of the module on a flat surface and lay the Liebert XDR on it Mechanical Considerations 4 0 MECHANICAL CONSIDERATIONS 4 1 Liebert XDR Dimensions The Liebert XDR is engineered to fit on the rear of a rack enclosure measuring approximately 24 x 42U Consult the factory for
20. ert XDR Liebert XDV or Liebert XDP Pumped Refrigerant R134a Checking and Unpacking Upon arrival of the module and before unpacking it verify that the labeled equipment matches the bill of lading Inspect all items for either visible or concealed damage Damage should be immediately reported to the carrier and a damage claim filed with a copy sent to Emerson or to your sales representative If you later find any concealed damage report it to both the shipping company and your local Emerson representative Check to be sure all required assemblies and parts have been received The Liebert XDR 1s shipped in protective packaging and secured to a pallet see Figure 5 Do not remove these protective items from the Liebert XDR before it is at the installation location When unpacking and handling the Liebert XDR exercise extra care to prevent damage General Product Information 3 2 1 Recyclable Packaging LAY or dispose of the material appropriately All material used to package this module is recyclable Please save for future use Vy A CAUTION Risk of sharp edges splinters and exposed fasteners Can cause personal injury Only properly trained personnel wearing appropriate safety headgear gloves shoes and glasses should attempt to move lift remove packaging from or prepare module for installation NOTICE Risk of improper storage Can cause module damage Keep the module indoors and pro
21. ex Pipe with Removable Coupling to a Liebert XD Cooling Module Tools Required One adjustable wrench with a maximum adjustment size of 2 inches One torque wrench half inch drive see Table 3 for sizes Check the Liebert XD Flex Pipe for proper length Remove the protector plugs from the Liebert XD Flex Pipe Remove the protector cap from the couplings on the module Wipe the fittings and threaded surfaces clean of particles and other foreign substances Verify the O ring is in place on the module coupling Should additional O rings be required refer to Table 4 6 Place the Liebert Flex Pipe assembly so that the flat face of the flange on the Liebert XD Flex Pipe coupling comes into contact with the O ring on the module coupling 7 Thread the coupling halves together by hand to ensure that the threads mate properly If a torque wrench is not available continue with the steps below Table 3 Torque and wrench sizes for connecting Liebert Flex Pipe to the Liebert XDR with removable couplings Wrench Size in Coupling mm Torque Union Nut Size in Only ft Ib Nm Union Nut 1 2 Supply 15 16 24 40 55 1 Return 1 5 8 41 110 150 8 Hold the Liebert XD Flex Pipe so that 1s does not rotate and use the torque wrench to tighten the union nut to the proper value shown in Table 3 9 Tighten the union nut on the Liebert XD Flex Pipe to the coupling on the module with the adjustable wrench until a de
22. finite resistance is felt 10 Use a marker or pen to draw a line lengthwise across the module coupling to the Liebert XD Flex Pipe The line should parallel the Liebert XD Flex Pipe 11 Tighten the nuts an additional quarter turn judging the amount by the mark drawn in Step 10 22 Piping Figure 22 Removable couplings On the Liebert Flex Pipe Removable Female Coupling on the end of Liebert XD Flex Pipe O Ring On the Liebert XD Module Table 4 O ring part number Liebert Part Size in Fitting 192917P1 1 2 FD57 1224 08 10 192917P2 5 8 FD57 1224 10 11 192917P3 7 8 FD57 1224 14 12 6 7 5 Connect a Liebert with Liebert XD Flex Pipe to a Liebert XD System NOTE Check the entire system for leaks before connecting the Liebert XDR with Liebert XD Flex Pipe to the prefabricated piping mains Read all instructions before beginning installation NOTICE Risk of refrigerant loss Can cause environmental pollution and equipment malfunction Before connecting the Liebert XDR with Liebert XD Flex Pipe to the prefabricated piping mains check the whole system for leaks Check the Liebert XDR to ensure that the module has no refrigerant leaks Read all instructions before beginning installation Tools Required One adjustable wrench with a maximum adjustment size of 2 inches One torque wrench half inch drive Crowsfoot supplied with Liebert and Liebert XDC Liebert
23. frame and into the mounting rails 5 Tighten all of the bolts snugly with a 10mm wrench Figure 11 Liebert XDR mounting locations Keyhole Slot p biles TT WRIT 1 Keyhole Slot One on Each Side on Each Side Piping is not load bearing and should never be used to lift or move the Liebert XDR Bolt Holes 3 on Each Side Bolt Holes 3 on Each Side 12 Installation 5 3 Door Safety Catch The door safety catch prevents the door from opening beyond 110 When the door is fully open the safety catch will hold door in place To release the door push up on the door catch and close the door 13 Piping 6 0 PiPING Refer to site specific drawings for general locations of the piping connections The drawings should specify where the piping connects to the Liebert XDR 6 1 European Union Fluorinated Greenhouse Gas Requirements Stationary air conditioning refrigeration heat pump equipment and stationary fire protection sys tems in the European Community market and operating with fluorinated greenhouse gases f gas such as R407C R 134a R410A must comply with the F Gas Regulation EC No 842 2006 F gas The regulation prohibits among other actions venting fluorinated greenhouse gases to the atmo sphere The F Gas Regulation requires operators to use all measures that are technically feasible and do not entail disproportionate cost to prevent leakage of these gases t
24. han 6 152mm exercise great care and keep all personnel who are not helping move the module at least 20 feet 5m away from the module Do not use module piping to lift or move the Liebert XDR General Product Information 3 2 3 Unpacking the Module A WARNING Risk of 130 pound 59 kg module falling Can cause equipment damage personal injury or death Do not leave a Liebert XDR standing unattended on its side or its end without adequate support to prevent it from falling over The Liebert XDR must be supported at all times or laid flat on protective material until it is installed Two properly trained and qualified people are required to move the module Do not unpack the Liebert XDR before moving it to the installation location Once at the installation point 1 2 SI SON os 00 Cut the banding and place all packaged modules on the floor for unpacking Unbend all metal tabs as shown in Figure 5 Use any of these tools to unbend the tabs flat blade screwdriver claw hammer pliers or crowbar Remove the top cover from the package Remove the center top brace Remove and set aside the hardware and key package Remove side panels from package Remove top protective foam from the package General Product Information Removing packaging Figure 5 Step 2 Unbend Tabs Step 1 and Keys Steps 4 and 5 Remove the Top Cover Step 7 Protecting Top 22 R
25. he return piping for the circuit is 7 8 OD copper The Liebert XDR modules that are intended for hard piping connections will have copper caps sol dered in place and a holding charge of nitrogen Figure 14 Piping location and connection sizes modules with hard piped connections 1 5 16 TOP VIEW 1 1 8 33mm Rear of Cabinet Refrigerant 29mm Refrigerant Schrader Valve Supply Line Return Line 23 1 2 597mm 16 Piping Figure 15 Hard pipe connection diagram Refer to Table 1 for details 6 6 1 6 6 2 Return Main seen from end 2 1 8 O D or 2 5 8 d Acceptable a Arc Recommended Arc Supply Main seen from end 1 1 8 O D or 1 3 8 O D 7 8 Refrigerant Grade E Full Port Ball Valve Field Supplied and Field Installed 1 2 Refrigerant Grade Full Port Ball Valve Field Supplied and Field Installed Copper Tubing Total length of each line from Liebert XDR to Main not to exceed 72 1829 mm Top of Return from Liebert XDR Cooling Module and Supply to Cooling Equipment Module Rack Leak Checking and Evacuation Refer to the Liebert XDC or Liebert XDP user manual for procedures for evacuation leak check charging and startup Header System The Liebert XDR module system with optional flexible piping requires use of the Liebert XD prefabri cated piping assembly The prefabricated piping is compatible
26. i ES Mese E a Ne Ie EO pot dete LCS ted Det Torque and wrench sizes for connecting Liebert Flex Pipe to the Liebert XDR with removable co plings 5 2124 nes a WG em m Hee ve ea NEP vs er O ring part number Ve ERE Vetere aute Aedes eere OD SIS e ue Se ees Torque for connecting Liebert XD Flex Pipe to prefabricated piping Liebert XDR specifications Rack mounting gt READ RN EE eae SE EE PNEU ENSE TRE E PE Liebert XD Flex Pipe one shot assemblies supply and return Liebert XD Flex Pipe removable assemblies supply and iii Component Locations and Model Number Nomenclature 1 0 COMPONENT LOCATIONS AND MODEL NUMBER NOMENCLATURE Figure1 Liebert component locations Supply Line Door Safety Catch Return Line Evaporator Coils Locking Door Latch Removable Installation Handles Frame m g NOORWON LIC Figure2 Liebert model number nomenclature Example XDR20B1R XD R 20 B 1 R Liebert 20 Model Size 1 Standard Domestic Packaging X treme E Export Packaging heat density system Rear Cooling Module B Basic Module Hard Piping Revision P Pre Charged One Shot level Coupling R Removable Coupling Introduction 2 0 INTRODUCTION 2 1 2 2 2 3 2 4
27. in the rack create sufficient airflow to move the air Figure 10 Generic airflow diagram Enclosure Rack Shown from Side Refrigerant Connections Liebert XDR Critical Equipment Front Rear of of Rack Rack NOTE Q Air bypass and recirculation can severely reduce the cooling effectiveness of the Liebert XDR Blanking plates must be installed in any voids in the rack to prevent air bypass and air recirculation Contact the factory for further information Refer to the user manual supplied with the rack the Liebert XDR is mounted on Efficient cooling of rack equipment depends on proper use of blanking plates in any voids in the rack and good cable management Keep the Liebert XDR s coils clear of any obstructions that may block the airflow Each of the Liebert XDR s coils removes approximately half the load For even cooling in partially filled racks servers should be evenly spaced and blanking plates should be installed on unused rack spaces to prevent recirculation of heated air 11 Installation 5 0 INSTALLATION 5 4 Installing the Rack Mounting Kit onto the Rack The Liebert XDR module mounts on the rear of the rack using a mounting kit The mounting kit secures the Liebert XDR s frame to the rack Two rails are attached to the rear of the rack with M6 x 12 bolts The number of bolts can vary depending on the rack Before beginning to attach the rack mounting brackets to the rack remove the rear door from
28. m the connections and carefully wipe the couplings and threaded surfaces clean Use a small applicator brush saturated with refrigerant oil to lubricate the entire surface of the diaphragm and the O ring Refer to Figure 18 Male coupling on Liebert XD cooling module Oil Rubber Seal and Face of Diaphragm If refrigerant oil is not used an alternate lubricant for this application is a refrigerant compatible silicone grease product such as Dow Corning DC200 60 000 cst Thread the coupling halves together by hand to ensure that the threads mate properly Ensure that the Schrader valve is oriented so that it is accessible for service Female one shot coupling Liebert Flex Pipe Schrader valve location Coupling Size 27 Marking Lip of Couplin Schrader pg Valve 20 Piping Figure 20 Hex body union nut on one shot coupling 5 y Union Nut EU Hex Body NOTICE Risk of improper tightening Can cause equipment damage Itis imperative that the brass body on the Liebert XD Flex Pipe coupling does not rotate while the union nut is being tightened If the brass body rotates it may damage the Liebert XD Flex Pipe Hold the brass body of the Liebert XD Flex Pipe with a wrench so that it does not rotate and use the torque wrench to tighten the union nut to the proper value shown in Table 2 Table 2 Torque and wrench size for connecting Liebert XDR with one shot couplings to Liebert XD Flex Pip
29. modules are securely attached to the cabinet and aligned properly with the rack ___ 2 Check to ensure there are no obstructions that prevent the Liebert XDR from opening ___ 3 Piping from Liebert XDP or Liebert XDC with isolation valves is properly connected to each Liebert XDR module 4 Liebert XD Flex Pipe couplings to prefabricated header assembly are secure and according to specifications _ System checked for leakage EN Check the R 134a refrigerant charge see the user manual for either the Liebert XDP SL 16671 or the Liebert XDC SL 16644 each is available on the Liebert Web site ww w liebert com ___ 7 Run system and verify that the Liebert XDP or Liebert and the Liebert XDR modules operate properly 8 Piping is insulated 7 2 Charging with Refrigerant The Liebert XD system must be completely installed before it is charged with refrigerant After installation is complete refer to the Liebert XDP or Liebert XDC user manual for instructions on charging Liebert XD modules with refrigerant and the starting of the system The complete Liebert XD system includes all Liebert XD cooling modules a Liebert XDC or Liebert XDP and any other con nected equipment 29 Starting the Liebert XD System 8 0 STARTING THE LIEBERT XD SYSTEM Refer to the user manual for the refrigerant supply unit either a Liebert XDP or Liebert XDC for details on starting the system The Liebert XDP user manual is SL 16644 and the
30. nnecting Methods One Shot Couplings for Pre Charged Refrigerant Option 19 6 7 2 Connect a Liebert XDR with One Shot Couplings to Liebert XD Flex Pipe 20 6 7 8 Connection Methods Removable 22 6 7 4 Connect Liebert XD Flex Pipe with Removable Coupling to a Liebert XD Cooling Modulen RES SAT e a he ead A eed e ug 22 6 7 5 Connect a Liebert XDR with Liebert XD Flex Pipe to a Liebert XD System 23 6 7 6 Disconnect a Liebert XD Flex Pipe from a Liebert XD 27 6 7 7 Disconnecting the Liebert XD Flex Pipe from the Liebert XDR 28 6 7 8 Removing the Liebert XDR from a Cabinet 28 INSTALLATION CHECKLIST AND SYSTEM FILL FOR STARTUP 29 Checklist for Proper 29 Charging with Refrigerant 0 0 ee ee lr 29 STARTING THE LIEBERT XD 30 MAINTENANCE e Oe ope at rr us pe pata perd Fas wr cR E 31 Fluorinated Greenhouse Gas 31 SPECIFICATIONS ie dre eR xa Or NE ou ee wee See 32 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11
31. o test for leakage regularly and to recover f gas before disposing of equipment as well as during service and maintenance Refer to the full regulation for additional details 6 2 System Connection Configuration If possible connect the Liebert XDR modules to Liebert XDPs or Liebert XDCs in an interlaced configuration see Figure 12 In an interlaced configuration half the cooling modules in an aisle are connected to one Liebert XDP or Liebert XDC and the other half in that aisle are connected to another Liebert XDP or Liebert XDC Interlacing the connection piping will keep half the Liebert XDR modules operating and maintain cooling in the conditioned space should one of the Liebert XDP or Liebert XDC units fail However if this is not possible connect the Liebert XDR modules in a non interlaced configuration see Figure 13 Figure 12 Typical Liebert XDR piping interlaced connections TOP VIEW DRAWING IS NOT TO SCALE Liebert Liebert Liebert XDR A XDR B XDR A Liebert XDP Liebert XDC A e Supply Return ae oco ee 4 0 Liebert XDP Liebert XDC B NOTE Line size does NOT indicate pipe size difference 14 Piping Figure 13 Typical Liebert XDR piping non interlaced connection 6 3 6 4 6 5 DRAWING IS NOT TO SCALE TOP VIEW ss Return 4 Supply Liebert XDP Liebert XDC A
32. ram 1 eee ra Liebert XD Flex Pipe dimensions straight and 90 degree Piping location and connection sizes modules with pre charged modules Male coupling on Liebert XD cooling module Female one shot coupling Liebert Flex Pipe Schrader valve location Hex body union nut on one shot Piping location and connection sizes modules with removable couplings sss Removable couplings 4 nva eR eet rac ade wok eae c vmi a Nec Coupling sizendieatoro are sos acu t esos n eh enh ena Liebert XD prefabricated piping assembly Oil rings on header and Liebert XD Flex Pipe 8 Wrench arrangement for tightening Detail view of Liebert XD Flex Pipe and prefabricated piping port Liebert XD prefabricated piping assembly and Liebert XD Flex 1 Piping mains without Liebert XD Flex TABLES Branch piping sizes for pumped refrigerant Torque and wrench size for connecting Liebert XDR with one shot couplings to Liebert XD Flex Pipes rruti ia
33. rom greater IT system availability operational flexibility and reduced capital equipment and operating costs 39 0499719111 While every precaution has been taken to ensure the accuracy Fax 39 049 5841 257 and completeness of this literature Liebert Corporation assumes no Asia responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions 29 F The Orient Square Building 2009 Liebert Corporation F Ortigas Jr Road Ortigas Center All rights reserved throughout the world Specifications subject to change Pasig City 1605 without notice Philippi Liebert is a registered trademark of Liebert Corporation Hippines All names referred to are trademarks 63 2687 6615 or registered trademarks of their respective owners Fax 63 2 730 9572 1 16935 REVO2 06 10 Emerson Network Power The global leader in enabling Business Critical Continuity EmersonNetworkPower com E AC Power Embedded Computing I3 Outside Plant Racks amp Integrated Cabinets H Connectivity Embedded Power IE Power Switching amp Controls Services Infrastructure Management amp Monitoring I Precision Cooling Surge Protection Emerson Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks of Emerson Electric Co or one of its affiliated companies 2009 Emerson Electric Co
34. semblies supply and return keith Liebert P N Liebert P N Minimum Bend Radius Description ft m Straight Connection 90 Degree Connection in mm Assembly Assembly Supply Return 10 3 0 187865G2 187864G2 i 8 2 5 18786563 18786463 Liebert 2 5 7 178 9 229 Flex Pipe Kit 6 1 8 187865G1 187864G1 4 1 2 187865G4 187864G4 32 Ensuring The High Availability Of Mission Critical Data And Applications Emerson Network Power the global leader in enabling business critical Technical Support Service continuity ensures network resiliency and adaptability through Web Site a family of technologies including Liebert power and cooling www liebert com technologies that protect and support business critical systems Monitoring Liebert solutions employ an adaptive architecture that responds liebert monitoring emerson com 800 222 5877 Outside North America 00800 1155 4499 Single Phase UPS amp Server Cabinets liebert upstech emerson com 800 222 5877 Outside North America 00800 1155 4499 Three Phase UPS amp Power Systems 800 543 2378 Outside North America 614 841 6598 Environmental Systems 800 543 2778 Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy to changes in criticality density and capacity Enterprises benefit f
35. t reclaim device to the Schrader valve For help finding the Schrader valve see Figures 14 17 and 21 Hold the Liebert XD Flex Pipe so it does not rotate For the Liebert XD Flex Pipe with one shot couplings additionally hold the brass body of the cou pling so it does not rotate while loosening the couplings Failing to do so may cause damage Loosen the Liebert XD Flex Pipe coupling from the module with a wrench Replace the dust plug on the Liebert XD Flex Pipe Replace the dust cap on the Liebert XD module Lay the Liebert XD Flex Pipe with removable couplings aside where it will not be damaged Discard or recycle the one shot Liebert XD Flex Pipes NOTICE Risk of permanent damage to the Liebert XD Flex Pipes Do not fold or bend pipe tightly Removing the Liebert XDR from a Cabinet A WARNING Risk of 130 pound 59 kg module falling Can cause equipment damage personal injury or death Removing a Liebert XDR from above a cabinet will require two properly trained and qualified people Read all instructions before beginning Reinstall the four removable installation handles Loosen the bolts holding the Liebert XDR on the cabinet With the help of another person lift the Liebert XDR from the cabinet or hanging bracket onto a stable surface 28 Installation Checklist and System Fill for Startup 7 0 INSTALLATION CHECKLIST AND SYSTEM FILL FOR STARTUP 71 Checklist for Proper Installation ___ 1 Liebert XDR
36. tected from dampness freezing temperatures and contact damage NOTICE Risk of damage from forklift Can cause exterior and or underside damage Keep tines of the forklift level and at a height suitable to fit below the skid Figure 4 Recommended module handling equipment Pallet Jack Forklift 3 2 2 Module Handling A WARNING Risk of 130 pound 59 kg module falling Can cause equipment damage personal injury or death Do not leave a Liebert XDR standing unattended on its side or its end without adequate support to prevent it from falling over The Liebert XDR must be supported at all times or laid flat on protective material until it is installed Two properly trained and qualified people are required to move the module When unpacking and handling the module exercise extra care to prevent damage Use a forklift or pallet jack to move the Liebert XDR If multiple Liebert XDR modules are delivered they will be shipped on a pallet with up to four modules A pallet jack will be required to move these modules to the installation location If using a forklift or pallet jack ensure that the fork tine length is suitable to safely move the packaged module Keep the module in the protective packaging until it has been moved to the installation site When handling and unpacking the module exercise great care to prevent damage Do not lift the module any higher than 6 152mm while moving it If it must be lifted higher t
37. the rack Refer to the rack s installation manual for details 1 Insert and screw in the M6 x 12mm bolts that shipped with the Rack Connecting Bracket 2 Tighten the bolts with a 10mm wrench 5 2 Mounting the Liebert on the Rack Mounting Kit A WARNING Risk of 130 pound 59 kg module falling or causing cabinet to tip over Can cause equipment damage personal injury or death Read all instructions before beginning Usecaution when installing the Liebert XDR on an equipment cabinet particularly a cabi net with little equipment installed Lack of weight in the cabinet could cause it to tip while the Liebert XDR 1s being installed Two properly trained and qualified people are required to handle the Liebert Do not move a cabinet with a Liebert XDR installed on it The rack mounting brackets must be mounted on the rack before the Liebert XDR can be installed 1 Thread one of the provided M6x12 bolts into the top threaded hole of each rail attached to the rack 2 Use fingers or a 10mm wrench to tighten the bolts leaving a 1 8 8 4mm gap between the bolt heads and the rail This gap is necessary to allow the door to fit over the bolts and hang safely on the rack 3 With another person lift the Liebert XDR by the handles on the sides match the two keyhole slots near the top of the Liebert XDR frame to the bolts and hang the Liebert XDR on the rack 4 Thread the remaining bolts through the holes in the
38. to Liebert XD Connection to Liebert XD Cooling Module Cooling Module DPNO000780 18 Piping 6 7 1 Connecting Methods One Shot Couplings for Pre Charged Refrigerant Option A CAUTION Risk of sudden refrigerant discharge Can cause loss of charge and minor injury If the optional pre charged option is chosen the Liebert XDR 1s shipped with a full charge of R 134a refrigerant under pressure Do not remove the pipe caps or plugs before the module is ready for connection to Liebert XD Piping Supply and return fittings on the pre charged Liebert XDR modules are one shot couplings Do not disconnect one shot couplings after they have been connected Disconnection will release pressurized R 134a refrigerant from the Liebert XDR Liebert XDRs with the pre charged option are equipped with one shot couplings on the supply and return fittings These contain a charge of R 134a refrigerant under pressure within the module This charge must not be vented Do not remove the pipe caps or plugs before the module is ready for connection to Liebert XD Piping Do not disconnect one shot Liebert XD Flex Pipes after they have been connected The assembly and connection means used for piping in the Liebert XD system are the same as those used in conventional refrigeration systems Observe all standard practices during installation and startup to prevent damage and contamination Both supply and return fittings may be supplied with optional one shot
39. unts on the rear of a 24 x 42U rack for other sizes consult the factory and maintains access to the back of the server rack Room air is drawn in through the front of the rack and picks up heat from the servers The coil captures that heat cooling the air which is expelled through the rear of the rack The Liebert XDR relies on the rack equipment s fans to move air across the micro channel coil Ca tured heat is carried away through pumped R 134a refrigerant supplied by either a Liebert Liebert The complete cooling System may include other Liebert XD cooling modules such as the Liebert Liebert Liebert Liebert XDA or Liebert see Figure 3 and Liebert XD Flex Piping The Liebert XDR is not expected to produce any condensation because of its location usually in the data center condensate pan is provided as a precaution It does not have a drain fitting or other means of being emptied Four handles to ease carrying the Liebert XDR are attached at the factory These should be removed after the module is attached to the rear of the enclosure Leaving the handles attached would require space between the racks The handles should be retained for use if the Liebert XDR is removed from the enclosure Figure3 Generic piping layout 3 2 XD Cooling Module Supply Lines qmm m Return Lines Cooling Module Liebert XDCF Liebert XDH Liebert XDO Lieb
40. with the Liebert XD Flex Pipe required to attach to the Liebert XDR modules For the details on piping connection locations see Figure 14 For additional information refer to the Liebert X treme Density System Design Manual SL 16655 available at the Liebert Web site www liebert com 17 Piping 6 7 Field Installation of Liebert XD Flex Pipe Kit on Liebert XDR If you are not performing a service installation or a field retrofit skip this section and proceed with the instructions in 6 7 2 Connect a Liebert XDR with One Shot Couplings to Liebert XD Flex Pipe Liebert XD Flex Pipe kits are available in lengths of 4 6 8 and 10 feet 1 2 1 8 2 4 and 3 meters Connection style to the module end may be straight or 90 degrees with one shot or removable cou plings Connection to the prefab piping assembly is a threaded coupling For data on acquiring the correct kit for your installation see Table 8 The Liebert XD Flex Pipe should be connected to the Liebert XD module then to the header system to ease installation and prevent twisting the flex pipe Figure 16 Liebert XD Flex Pipe dimensions straight and 90 degree connections 2 Connection to Prefabricated Piping assembly Connection to Prefabricated Piping assembly 90 Degree Connection 4 6 8 or 10 feet 1 2 1 8 2 4 or 3 meters 4 6 8 or 10 feet 1 2 1 8 2 4 or 3 meters Straight Connection 90 Connection
41. y nitrogen to prevent excessive oxidation and scale formation inside the piping Prevailing good refrigeration practices must be employed for piping supports leak testing dehydration and charging Failure to use good system practices may result in damage to the system Refer to the ASHRAE refrigeration handbook for general good practice refrigeration Recommended Piping Size Connect the main pipes between the Liebert XDR branch piping and the Liebert XDP or Liebert XDC according to Table 1 Elbows and restrictions must be minimized to ensure good fluid flow See Table 1 below for recommended pipe sizes and Figure 3 for piping segment locations Branch piping sizes for pumped refrigerant loop From Liebert XDR supply to supply line of 1 2 OD 0 430 ID for lengths up to 10 feet 3m Liebert XDP Liebert XDC 7 8 OD 0 545 ID for lengths over 10 feet but less than 25 feet 3 7 6m Pipe Function Size Equivalent Pipe Length 6 6 From Liebert XDR return to return line of 7 8 OD 0 545 ID for lengths up to 10 feet 3m Liebert XDP Liebert XDC 1 1 8 OD 1 025 ID for lengths over 10 but less than 25 feet 3 7 6m To minimize the amount of pumped refrigerant required do NOT oversize the piping See Figure 14 for piping recommendations for hard piping between the Liebert XDR and the header system Hard Piped Connection Sizes The supply piping for the refrigeration circuit is 1 2 OD copper pipe T
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