Precision Cooling For Business-Critical Continuity™ Liebert® XDR™ User Manual
IMPORTANT SAFETY GUIDELINES SAVE THESE INSTRUCTIONS ! 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.
TABLE OF CONTENTS IMPORTANT SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER 1.0 COMPONENT LOCATIONS AND MODEL NUMBER NOMENCLATURE. . . . . . . . . . . . . . . . . . . . .1 2.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2.1 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Field Installation of Liebert XD Flex Pipe Kit on Liebert XDR . . . . . . . . . . . . . . . . . . . . . . 18 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.7.6 6.7.7 6.7.8 Connecting Methods—One-Shot Couplings for Pre-Charged Refrigerant Option . . . . . . . . . Connect a Liebert XDR with One-Shot Couplings to Liebert XD Flex Pipe . . . . . . . . . . . . . . Connection Methods—Removable Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 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 Liebert XDR component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Liebert XDR model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . .
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Component Locations and Model Number Nomenclature 1.0 COMPONENT LOCATIONS AND MODEL NUMBER NOMENCLATURE Figure 1 Liebert XDR component locations 3 2 1 7 4 6 5 1. Supply Line 2. Door Safety Catch 3. Return Line 4. Evaporator Coils 5. Locking Door Latch 6. Removable Installation Handles 7.
Introduction 2.0 INTRODUCTION 2.1 References This document must be used together with site specific documentation and documentation for other parts of the system. 2.2 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 representative. 2.3 Packing List • User manual (this document) • Liebert XDR module 2.
General Product Information 3.0 GENERAL PRODUCT INFORMATION 3.1 Product/System Description The Liebert XDR is a cooling system for high-density heat loads that mounts 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.
General Product Information 3.2.1 Recyclable Packaging All material used to package this module is recyclable. Please save for future use or dispose of the material appropriately. R ! 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.
General Product Information 3.2.3 Unpacking the Module ! 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.
General Product Information Figure 5 Removing packaging Step 1 Cut Bands Step 2 Unbend Tabs Hardware and Keys Step 3 Steps 4, and 5 Remove the Top Cover Center Top Brace Step 7 Remove Foam Protecting Top of Module Step 6 Remove Side Panels 6
General Product Information Figure 6 Remove Liebert XDR from pallet Two people are required to remove the module from the pallet and remove the bag ! 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.
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 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. Figure 7 Overall dimensions with hard-piped connections Piping is not load-bearing and should never be used to lift or move the Liebert XDR.
Mechanical Considerations Figure 8 Overall dimensions with one-shot coupling (pre-charged) Piping is not load-bearing and should never be used to lift or move the Liebert XDR.
Mechanical Considerations Figure 9 Overall dimensions with removable coupling Piping is not load-bearing and should never be used to lift or move the Liebert XDR. 1-1/2" (38mm) 1-5/16" (33mm) 7/8" (22mm) 2-1/8" (54mm) 1-1/2" (38mm) 25-5/8" (651mm) 80" (2032mm) 78-3/8" (1991mm) 110deg 20-1/2" (520mm) 5-7/8" (149mm) 6-1/2" (165mm) 27-3/8" (695mm) 23-1/2" (597mm) 27-3/8" (695mm) 4.2 Determining Placement in the Conditioned Space Refer to site-specific drawings for exact placement.
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 within the rack create sufficient airflow to move the air.
Installation 5.0 INSTALLATION 5.1 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 the rack. Refer to the rack’s installation manual for details. 1.
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.
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 systems 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.
Piping Figure 13 Typical Liebert XDR piping—non-interlaced connection DRAWING IS NOT TO SCALE TOP VIEW Return Supply Liebert XDP / Liebert XDC A Liebert XDR A Liebert XDR A 6.3 Liebert XDR A Liebert XDR A Connection Methods and Points Refer to site specific drawings for general locations of the piping connections. For Liebert XDR connection locations, refer also to Figures 14, 17 and 21.
Piping 6.5.1 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 connections before removing the caps to prevent internal component damage.
Piping Figure 15 Hard pipe connection diagram Return Main (seen from end ) 2-1/8" O.D. or 2-5/8" O.D. Recommended Arc Acceptable Arc Supply Main (seen from end ) 1-1/8" O.D. or 1-3/8" O.D. 7/8” Refrigerant -Grade Full-Port Ball Valve Field-Supplied and Field-Installed 1/2” Refrigerant -Grade Full-Port Ball Valve Field-Supplied and Field- Installed Refer to Table 1 for details.
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 couplings.
Piping 6.7.1 Connecting Methods—One-Shot Couplings for Pre-Charged Refrigerant Option ! 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 is 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.
Piping 6.7.2 Connect a Liebert XDR 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.
Piping Figure 20 Hex body, union nut on one-shot coupling Union Nut Hex Body NOTICE Risk of improper tightening. Can cause equipment damage. It is 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. 5.
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.
Piping Figure 22 Removable couplings Flange On the Liebert Flex Pipe On the Liebert XD Module Removable Female Coupling on the end of Liebert XD Flex Pipe Table 4 6.7.5 O-Ring O-ring part number Liebert Part # Size, in.
Piping Figure 23 Coupling size indicator Coupling size indicator Figure 24 Liebert XD prefabricated piping assembly Return Main Supply Main Service Valve, typical (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.
Piping Figure 25 Oil rings on header and Liebert XD Flex Pipe connectors Poppet Valve Face Oil Applicator Spout Rubber Ring Around Poppet Valve Face Stainless Steel Delta Ring on Header Port Connector 9. Thread 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.
Piping Figure 27 Detail view of Liebert XD Flex Pipe and prefabricated piping port Tighten with torque wrench. DO NOT OVERTIGHTEN! Flex Pipe 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 the brass body on the female connector from rotating while tightening collar with a torque wrench. 11. Repeat Steps 3 through 10 for the remaining Liebert XD Flex Pipe. 12.
Piping 6.7.6 Disconnect a Liebert XD Flex Pipe from a Liebert XD System ! 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 • 1. 2. 3. 4. 5. 6. 7. 8. 9. Two adjustable wrenches with a maximum adjustment size of 2 inches Close the service valve in the supply line.
Piping 6.7.7 Disconnecting the Liebert XD Flex Pipe from the Liebert XDR 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.
Installation Checklist and System Fill for Startup 7.0 INSTALLATION CHECKLIST AND SYSTEM FILL FOR STARTUP 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.
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 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.
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.
Specifications 10.0 SPECIFICATIONS Table 6 Liebert XDR specifications XDR20B1- * Models Cooling Capacity, Nominal, rated at 104ºF (40°C) EAT & 2400ft3/m (68m3/m) XDR20B1P * (Pre-Charged R-134a) XDR20B1R * 20.5 kW (5.
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