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Installation Checklist and System Fill for Startup

29

7.0

I

NSTALLATION

C

HECKLIST

AND

S

YSTEM

F

ILL

FOR

S

TARTUP

7.1

Checklist for Proper Installation

___ 1. Liebert XDR 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.

___ 5. System checked for leakage.
___ 6. 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,

www.liebert.com

).

___ 7. Run system and verify that the Liebert XDP or Liebert XDC 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.

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Summary of Contents for Liebert XDR

Page 1: ...Precision Cooling For Business Critical Continuity Liebert XDR User Manual ...

Page 2: ...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 pressur...

Page 3: ...CHANICAL CONSIDERATIONS 8 4 1 Liebert XDR Dimensions 8 4 2 Determining Placement in the Conditioned Space 10 4 3 Airflow 11 5 0 INSTALLATION 12 5 1 Installing the Rack Mounting Kit onto the Rack 12 5 2 Mounting the Liebert XDR on the Rack Mounting Kit 12 5 3 Door Safety Catch 13 6 0 PIPING 14 6 1 European Union Fluorinated Greenhouse Gas Requirements 14 6 2 System Connection Configuration 14 6 3 C...

Page 4: ...bert XD Cooling Module 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 System 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 7 0 INSTALLATION CHECKLIST AND SYSTEM FILL FOR STARTUP 29 7 1 Checklist for Proper Installation 29 7 2 Charg...

Page 5: ...Flex Pipe Schrader valve location 20 Figure 20 Hex body union nut on one shot coupling 21 Figure 21 Piping location and connection sizes modules with removable couplings 22 Figure 22 Removable couplings 23 Figure 23 Coupling size indicator 24 Figure 24 Liebert XD prefabricated piping assembly 24 Figure 25 Oil rings on header and Liebert XD Flex Pipe connectors 25 Figure 26 Wrench arrangement for t...

Page 6: ...iv ...

Page 7: ...ure 1 Supply Line 2 Door Safety Catch 3 Return Line 4 Evaporator Coils 5 Locking Door Latch 6 Removable Installation Handles 7 Frame 1 2 3 4 5 6 7 XD 20 B 20 Model Size Liebert X treme heat density system Example XDR20B1R R Rear Cooling Module Domestic Packaging E Export Packaging 1 1 Standard B Basic Module Revision level R Hard Piping P Pre Charged One Shot Coupling R Removable Coupling ...

Page 8: ...ar of computer cabinets in the data center See 4 0 Mechanical Considerations for details 2 4 1 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 Outside or fresh air should be kept to a minimum when temperature and hu...

Page 9: ...e 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 Figure 3 Generic piping layout 3 2 Checking and Unpacking Upon arrival of the module and before unpacking it...

Page 10: ...ove 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 than 6 152mm exercise great care and keep all personnel who are not helping move the module at least 20 feet 5m awa...

Page 11: ... top cover from the package 4 Remove the center top brace 5 Remove and set aside the hardware and key package 6 Remove side panels from package 7 Remove top protective foam from the package 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 fr...

Page 12: ...ormation 6 Figure 5 Removing packaging Cut Bands Unbend Tabs Remove the Top Cover Center Top Brace Hardware and Keys Remove Side Panels Remove Foam Protecting Top of Module Step 1 Step 2 Step 3 Steps 4 and 5 Step 6 Step 7 ...

Page 13: ... supporting the module to keep it from falling 4 If the 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 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 supp...

Page 14: ...nd 9 illustrate the module s dimensions and the location of pipes Figure 11 shows the attachment positions of each module Figure 7 Overall dimensions with hard piped connections 1 1 2 38mm 4 102mm 78 3 8 1991mm 82 3 8 2092mm 5 7 8 149mm 1 5 16 33mm 20 1 2 520mm 110deg 23 1 2 597mm 1 1 8 29mm 27 3 8 695mm 6 12 165mm 2 1 8 54mm 25 5 8 651mm 27 3 8 695mm Piping is not load bearing and should never be...

Page 15: ...g pre charged 1 1 2 38mm 1 5 16 34mm 78 3 8 1991mm 5 1 8 130mm 83 1 2 2121mm 5 7 8 149mm 110deg 23 1 2 597mm 27 3 8 695mm 6 1 2 165mm 27 3 8 695mm 20 1 2 520mm 1 1 8 29mm 2 1 8 54mm 25 5 8 651mm Piping is not load bearing and should never be used to lift or move the Liebert XDR ...

Page 16: ...d 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 1 1 2 38mm 1 5 16 33mm 1 1 2 38mm 78 3 8 1991mm 80 2032mm 5 7 8 149mm 20 1 2 520mm 110deg 23 1 2 597mm 7 8 22mm 27 3 8 695mm 6 1 2 165...

Page 17: ...s 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 NOTE Air bypass and recirculation can severely reduce the cooling effectiveness of the Liebert XDR Bl...

Page 18: ...l 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 frame and into the mounting rails 5 Tighten all of the bolts snugly...

Page 19: ... 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 ...

Page 20: ...g 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...

Page 21: ...d the Liebert XD Flex Pipe with removable cou plings have a low pressure nitrogen holding charge 6 4 Insulation To minimize the possibility of condensation insulate all piping between the Liebert XDR and the Lie bert XDP or Liebert XDC 6 5 Venting the Holding Charge for Hard Piped or Removable Liebert XD Flex Pipe Couplings The Liebert XDR in either hard piped configuration or with removable coupl...

Page 22: ...inimized to ensure good fluid flow See Table 1 below for recommended pipe sizes and Figure 3 for piping segment locations See Figure 14 for piping recommendations for hard piping between the Liebert XDR and the header system 6 6 Hard Piped Connection Sizes The supply piping for the refrigeration circuit is 1 2 OD copper pipe The return piping for the circuit is 7 8 OD copper The Liebert XDR module...

Page 23: ...tion 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 Top of Liebert XDR and Equipment Rack Return Main seen from end 2 1 8 O D or 2 5 8 O D Recommended Arc Acceptable Arc Copper Tubing Total length of each line from Liebert XDR to Main not to exceed 72 1829mm 7 8 Refrigerant Grad...

Page 24: ...nnection 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 Connection to Prefabricated Piping as...

Page 25: ...tional 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 CAUTION Risk o...

Page 26: ... Pipe for proper length 2 Remove the protector cap and plug from the connections and carefully wipe the couplings and threaded surfaces clean 3 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 Figure 18 Male coupling on Liebert XD cooling module If refrigerant oil is not used an alternate lubricant for th...

Page 27: ...able continue with the steps below 6 Tighten the union nut on the Liebert XD Flex Pipe to the coupling on the module with the proper sized wrench until a definite resistance is felt metal to metal contact 7 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 8 Tighten the nuts an additional one 1 wre...

Page 28: ... 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 8 Hold the Liebert XD Flex Pipe so that is does not rotate and use the torque wrench...

Page 29: ...he service valve for each port is closed 3 Remove caps from only the required ports Do not remove caps from the unused ports 4 Remove the pipe plugs that are supplied on the Liebert XD Flex Pipe 5 Inspect both halves of the coupling and remove any foreign contamination from the sealing surfaces and threads before connecting the fittings 6 Determine the coupling size by locating the number scribed ...

Page 30: ...lve 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 Coupling size indicator Threaded Cap Typical Supply Main Service Valve typical all ports Return Main Headers Capped Headers Connected ...

Page 31: ...t XD Flex Pipe coupling does not rotate while the couplings are being tightened Failing to do so may damage the female coupling Figure 26 Wrench arrangement for tightening couplings Table 5 Torque for connecting Liebert XD Flex Pipe to prefabricated piping Coupling Size Crowsfoot Size in mm Torque 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 Stainless Stee...

Page 32: ...tional 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 Tighten with torque wrench DO NOT OVERTIGHTEN Service Valve Note Make sure the valve is closed before attaching Liebert XD Flex Pipe to the system Hold threaded coupler here with a wrench to keep t...

Page 33: ... Figure 27 The Liebert XD Flex Pipe coupling must be held stationary while the union nut on the coupling is being loosened 6 Disconnect the coupling 7 Place the protective dust cap on the port 8 Place the protective plug back on the Liebert XD Flex Pipe 9 Repeat Steps 5 through 7 for the remaining Liebert XD Flex Pipe Figure 29 Piping mains without Liebert XD Flex Pipe CAUTION Risk of sudden disch...

Page 34: ...ionally hold the brass body of the cou pling so it does not rotate while loosening the couplings Failing to do so may cause damage 3 Loosen the Liebert XD Flex Pipe coupling from the module with a wrench 4 Replace the dust plug on the Liebert XD Flex Pipe 5 Replace the dust cap on the Liebert XD module 6 Lay the Liebert XD Flex Pipe with removable couplings aside where it will not be damaged Disca...

Page 35: ...tem checked for leakage ___ 6 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 www liebert com ___ 7 Run system and verify that the Liebert XDP or Liebert XDC and the Liebert XDR modules operate properly ___ 8 Piping is insulated 7 2 Charging with Refrigerant The Liebert XD system must ...

Page 36: ...al 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 Liebert XDC user manual is SL 16671 The user manuals were supplied with the units and are available on the Liebert Web site www liebert com ...

Page 37: ...n 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 dispropo...

Page 38: ...rior Finish Black Matte Heat Fused Powder Coat Safety CSA CE Approved Refer to 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 Description Length ft m Liebert P N Straight Connection Assembly Liebert P N 90 Degree Con...

Page 39: ......

Page 40: ...ive owners Technical Support Service Web Site www liebert com Monitoring liebert monitoring emerson com 800 222 5877 Outside North America 00800 1155 4499 Single Phase UPS Server Cabinets liebert upstech emerson com 800 222 5877 Outside North America 00800 1155 4499 Three Phase UPS Power Systems 800 543 2378 Outside North America 614 841 6598 Environmental Systems 800 543 2778 Outside the United S...

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