Vertiv Liebert DCD35 Installation and maintenance instructions

Liebert®
DCD™
Installer/User Guide

Vertiv | Liebert® DCD™Installer/User Guide
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TABLE OF CONTENTS
1 Important Safety Instructions 5
2 Nomenclature and Components 9
2.1 Model Number Nomenclature 9
2.2 Component Locations 10
3 General Product Information 13
3.1 Product/System Description 13
3.1.1 Cooling Principle 14
3.2 DCD Active with Fan Module 16
4 Pre-installation Preparation and Guidelines 19
4.1 Planning Dimensions 19
4.2 UnitWeights 19
4.3 Room Preparation 19
4.4 Air-flow Considerations 20
4.5 Water-supply Considerations 20
4.5.1 Water Quality Requirements 21
4.5.2 Water Temperature Requirements 22
5 Equipment Inspection and Handling 23
5.1 Storing the Unit 24
5.2 Packaging Material 24
5.3 Handling the Unit while Packaged 24
5.4 Unpacking the Module 25
6 Installation 29
6.1 DCD Frame Preparation 29
6.2 Installing the DCD Frame on a DCM Rack 30
6.2.1 Required Tools 30
6.3 Installing the DCD Door 34
6.4 Installing the DCD Swivel-joint Covers 40
6.5 Reversing the Door Handle 44
6.6 Installing the Active Fan Module 44
6.6.1 Mounting the Active Fan Module on DCD 45
6.6.2 Connecting Supply Power and Sensors 47
7 Piping Considerations and Connections 49
7.1 System Connection Configuration 49
7.1.1 Using Chilled-water Distribution Units 51
7.1.2 Using Open-loop Chilled-water Systems 51
7.2 Connection Methods and Points 51
7.3 Floor Cut-out Dimensions for Units with Bottom Connections 52
7.4 Insulate Piping 52
7.5 Recommended Pipe Sizes 52
7.6 Chilled-water Connection Components 53
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7.6.1 Strainer 53
7.6.2 Service Valves 53
7.6.3 Balancing Valves 53
7.6.4 Flexible Pipes 54
7.7 Leak Checking 55
7.8 Filling the Unit 55
7.8.1 Bleeding Air from the DCD 56
8 Installation Checklist andSystemFillforStart-up 57
9 Using the DCD Active TFT Display 61
9.1 Main Screen 61
9.1.1 Viewing Fan Status Detail 62
9.1.2 Viewing Exhaust-air Sensor Status 63
9.1.3 Viewing Cabinet Temperature-sensor Status 64
9.2 Settings Menu 65
9.2.1 Temperature Sensors Menu 66
9.2.2 Differential-pressure Regulation 66
9.2.3 Set-up Menu 67
10 Maintenance 69
10.1 General Maintenance 69
Appendices 71
Appendix A: Technical Support and Contacts 71
Appendix B: Specifications 73
Appendix C: Submittal Drawings 83
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1 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important safety instructions that should be followed during the installation and
maintenance of the Liebert®DCD. Read this manual thoroughly before attempting to install or operate
this unit.
Only qualified personnel should move, install or service this equipment.
Adhere to all warnings, cautions, notices and installation, operating and safety instructions on the unit
and in this manual. Follow all installation, operation and maintenance instructions and all applicable
national and local building, electrical and plumbing codes.
WARNING! Arc flash and electric shock hazard. Open all local and remote electric power
disconnect switches, verify with a voltmeter that power is Off and wear personal protective
equipment (PPE) per NFPA 70E before working with the module. Failure to comply can cause
serious injury or death. Follow all local codes.
WARNING! Risk of heavy module falling. Can cause equipment damage, injury and death. Two
properly-trained and qualified people are required to move and install the module. The DCD™
weighs in excess of 210lb(95kg). Do not leave a DCD™ standing unattended on its side or its
end without adequate support to prevent it from falling over. The module must be supported at
all times or laid flat on protective material until it is installed. Read all instructions before
attempting to move, lift, remove packaging from, or prepare the module for installation. See
Table 4.2 on page19, for unit weights based on model.
WARNING! Risk of improper operation and overpressurization. Can cause equipment or other
property damage, injury and death. Only personnel properly trained and qualified in HVAC
installation or service should install or service this equipment
WARNING! Risk of contact with high-speed, rotating fan impeller blades. Can cause injury or
death. Open all local and remote electric power-supply disconnect switches, verify with a
voltmeter that power is off, and verify that all fan impellers have stopped rotating before
working in the unit cabinet.
CAUTION: Risk of contact with sharp edges, splinters, and exposed fasteners. Can cause
injury. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE
should attempt to move, lift, remove packaging from or prepare the unit for installation.
1 Important Safety Instructions 5

CAUTION: Risk of improper repair and maintenance. Can cause reduced unit performance,
equipment damage and injury.
All maintenance and repair jobs must be performed by properly trained and qualified personnel.
All actions must be in accordance with regulations and the manufacturer’s instructions. Use
only Vertiv-approved tools and parts for maintenance and repair.
NOTICE
Risk of improper power-supply connection. Can cause equipment damage and loss of warranty
coverage.
Prior to connecting any equipment to a main or alternate power source (for example: back-up
generator systems) for start-up, commissioning, testing, or normal operation, ensure that these
sources are correctly adjusted to the nameplate voltage and frequency of all equipment to be
connected. In general, power-source voltages should be stabilized and regulated to within
±10% of the load nameplate nominal voltage. Also, ensure that no three-phase sources are
single-phased at any time.
NOTICE
Risk of passageway interference. Can cause unit and/or structure damage. The unit may be
too large to fit through a passageway while on or off the skid. Measure the unit and passageway
dimensions, and refer to the installation plans prior to moving the unit to verify clearances.
NOTICE
Risk of damage from forklift. Can cause unit damage. Keep tines of the forklift level and at a
height suitable to fit below the skid and/or unit to prevent exterior and/or underside damage.
NOTICE
Risk of improper storage. Keep the unit upright, indoors and protected from dampness,
freezing temperatures and contact damage.
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NOTICE
Risk of piping-system corrosion and freezing fluids. Can cause leaks resulting in equipment
and very expensive building damage. Cooling coils and piping systems are at high risk of
freezing and premature corrosion. Fluids in these systems must contain the proper antifreeze
and inhibitors to prevent freezing and premature coil and piping corrosion. The water or
water/glycol solution must be analyzed by a competent local water treatment specialist before
start up to establish the inhibitor and antifreeze solution requirement and at regularly
scheduled intervals throughout the life of the system to determine the pattern of inhibitor
depletion.
The complexity of water/glycol solution condition problems and the variations of required
treatment programs make it extremely important to obtain the advice of a competent and
experienced water treatment specialist and follow a regularly scheduled coolant fluid system
maintenance program.
Water chemistry varies greatly by location, as do the required additives, called inhibitors, that
reduce the corrosive effect of the fluids on the piping systems and components. The chemistry
of the water used must be considered, because water from some sources may contain corrosive
elements that reduce the effectiveness of the inhibited formulation. Sediment deposits prevent
the formation of a protective oxide layer on the inside of the coolant system components and
piping. The water/coolant fluid must be treated and circulating through the system
continuously to prevent the buildup of sediment deposits and or growth of sulfate reducing
bacteria.
Proper inhibitor maintenance must be performed in order to prevent corrosion of the system.
Consult glycol manufacturer for testing and maintenance of inhibitors.
Commercial ethylene glycol, when pure, is generally less corrosive to the common metals of
construction than water itself. It will, however, assume the corrosivity of the water from which it
is prepared and may become increasingly corrosive with use if not properly inhibited.
We recommend installing a monitored fluid-detection system that is wired to activate the
automatic-closure of field-installed coolant-fluid supply and return shut-off valves to reduce
the amount of coolant-fluid leakage and consequential equipment and building damage. The
shut-off valves must be sized to close-off against the maximum coolant-fluid system pressure
in case of a catastrophic fluid leak.
1 Important Safety Instructions 7

NOTICE
Risk of clogged or leaking drain lines and leaking water-supply lines. Can cause equipment and
building damage.
This unit requires a water drain connection. Drain lines must be inspected at start-up and
periodically, and maintenance must be performed to ensure that drain water runs freely
through the drain system and that lines are clear and free of obstructions and in good
condition with no visible sign of damage or leaks. This unit may also require an external water
supply to operate.
Improper installation, application and service practices can result in water leakage from the
unit. Water leakage can result in catastrophic and expensive building and equipment damage
and loss of critical data center equipment.
Do not locate unit directly above any equipment that could sustain water damage.
We recommend installing a monitored fluid-detection system to immediately discover and
report coolant-fluid system and condensate drain-line leaks.
NOTICE
Risk coil and piping rupture. Can cause equipment damage and major fluid leaks resulting in
serious building damage, expensive repair costs and costly system down time.
Thermal expansion of the cooling fluid without means of expansion can cause the coil and
piping to rupture, spilling cooling fluid in the conditioned space. This can be caused, among
other ways, by closing the ball valves on both the supply and the return pipes. Always allow for
thermal expansion either by leaving at least one of the valves open or by opening the DCD™
bleed valve.
NOTE: This document is intended to be used together with site-specific documentation and
documentation for other parts of the system.
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2 NOMENCLATURE AND COMPONENTS
This section describes the model number for Liebert® DCD units and components.
2.1 Model Number Nomenclature
Table 2.2 on the next page describes each digit of the model number.
Model Number Digits 1 to 10 Model Details Model Number Digits 11 to 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
D C D 3 5 A 6 0 3 0 0 0 0 0 0 G 0 0 0 0 S A 0 0 2
Table 2.1 Liebert DCD Model-number Example
Digit Description
Digits 1, 2, 3 = the base unit
DCD = Data Center Door
Digit 4, 5 = Nominal Capacity
35 = 35kW
50 = 50kW
Digit 6 = Rack Height
A = 42U, 78-6/8 in. (2000mm)
Digit 7 = Rack Width
6 = 23-5/8 in. (600mm), only available on 35 models.
8 - 32-1/2 in. (800mm)
Digit 8 = Cabinet Type
0 = No aluminum frame
Digit 9 = Chilled-water Connection/Hinge Position
1 = Top connection/Hinges left
3 = Bottom connection/Hinges left
Digit 10 = Options
0 = None
Digits 11 to 15 = Not Used
0 = No options
Digit 16 = Color
G = RAL 7021 (dark gray)
Table 2.2 Model-number Digit Definitions for Liebert DCD
2 Nomenclature and Components 9

Digit Description
Digits 17 to 20 = Not Used
0 = No options
Digit 21 = Packaging Type
S = Seaworthy (air freight), Long distance (wooden crate)
Digit 22 = SFA (Special Features)
A = Standard, no SFA
X = SFA(s) included
Digits 23 to 25 = Revision Identifier
Table 2.2 Model-number Digit Definitions for Liebert DCD (continued)
2.2 Component Locations
Figure 2.1 Liebert DCD Component locations
Item Description
1 Upper and Lower swivel joints
2 Door handle
3 Door
4 Upper piping
5 DCD frame
6 Lower Piping
7 Aluminum profile
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Item Description
8 Condensate tray
9 Condensate drain plug
10 Chilled-water outlet
11 Chilled-water inlet
12 Condensate-hose adapter (on the bottom of the unit)
2 Nomenclature and Components 11

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3 GENERAL PRODUCT INFORMATION
3.1 Product/System Description
The Liebert® DCD™ is an air-water heat exchanger that is integrated into the rear door of a server rack.
The DCD™ meets the requirements of the EN 60950 standard. The design allows installation on the back
of a server cabinet and maintains access to the back of the servers while the chilled water connections
remain stationary. The DCD35 is suitable for absorbing up to 35-kW heat loads from server racks 24in.
(600mm) x 42U. The DCD50 is suitable for absorbing up to 50-kW heat loads from server racks 31.5in.
(800mm) x 42U. It can be configured so that no heat is released in the installation area with proper
cabinet sealing.
Heat produced by internal components (for example, servers), is reliably removed by the door with a built-
in chilled water system or a chilled-water distribution unit, such as the Liebert® DCP™ (see Figure 3.1
below). A chilled-water distribution unit provides these benefits:
•Isolates the building’s chilled-water circuit from the chilled-water circuit in the data center. The
DCP circulates chilled water to DCD while preventing condensation by maintaining the water
temperature above the room dew point.
•Ensures the proper flow rate to the DCD. This is critical to achieve and maintaining the needed
capacity.
•Minimizes the possibility of a leak within the data center by separating the data center from
the building chilled-water circuit. Should a leak occur within the data center, the volume of
water is limited to the amount in the secondary piping system instead of the amount in the
entire-building chilled-water system.
Figure 3.1 Generic piping layout
Room air is drawn in through the front of the rack and picks up heat from the servers. Cooling occurs
when the server exhaust air passes through the DCD™ heat exchanger (see Figure 3.2 on the next
page). The air is moved through the heat exchanger by the server fans.
3 General Product Information 13

The DCD™ is not expected to produce any condensation because of its location within the conditioned
space and connected to a Liebert® DCP or if the chilled-water temperature is maintained above the dew
point, A condensate pan is provided as a precaution. It has a drain fitting to allow any condensate to be
emptied.
Figure 3.2 Top view of air flow and cooling of rack with Liebert DCD
Item Description
1 DCD unit
2 Server
3 Warm air
4 Air barrier
5 Cold air
6 Recirculation prevented
3.1.1 Cooling Principle
The server fans force air heated by the rack equipment through the unit’s air-water heat exchanger
where it is cooled. The air-side pressure-drop flow-rate dependency curve is shown in Figure B.7 on
page77.
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Figure 3.3 Cooling principle shown in side-view diagram of rack/DCD
Item Description
1 Air intake
2 Air outlet
3 Air barrier
4 Cold air
5 Warm air
6 Top cooling-water connections
7 DCD unit
8 Bottom cooling-water connections
NOTE: Before using the DCD™, check the system and rack equipment and make sure that they match
hydraulically. In particular, the server fans must be able to generate sufficient pressure to drive the air
through the DCD™.
NOTE: Cooling-water supply and return connections are supplied at each end of the DCD™, but
connections must be made at only one end, either the top or the bottom of the DCD™.
NOTE: In case of chilled-water supply-system failure, the cooling is provided either by adjacent DCD™
modules and/or the room cooling system. In this example, the equipment waste heat is released into
the room.
3 General Product Information 15

3.2 DCD Active with Fan Module
The DCD Active is an option which includes a fan module to be attached to the DCD cooling coil. See
Table 3.1 on the facing page, for the physical and environmental data and requirements of the module.
The active-fan module operates by measuring pressure differential between ambient pressure and the
pressure inside the cabinet and modulating fan speed to reach a predefined pressure setpoint. The
default setpoint is 0-Pa pressure differential. There are two versions of active-fan module:
•Standard—actively maintains a 0-Pa pressure differential by modulating fan speed, and
indicates operating status via a green "operating"LED and a red "disturbance" LED.
•TFT—includes a touch-screen display and temperature sensors for precise control of the
pressure differential and fan speed based on pressure and temperature readings. See Using
the DCD Active TFT Display on page61, for details.
Item Specification
Power Supply Single 110/230V A/B 230V A/B 110V
Operating voltage 95 - 264 V, 47 - 63 Hz 190 - 264 V, 47 - 63 Hz 95 - 264 V, 47 - 63 Hz
Rated current 5/11 A (110/230 V) 5A 11A
Fuses 10/12A T 10AT 12AT
External Temperature Sensors
Output voltage 5 V
Output current maximum 5mA
Communication type OneWire
Usable types Liebert® SN-T
Maxim DS28EA00, DS18B20
IP Interface
Communication type RS-485, 3.3V
Data rate 9600 baud
Physical Data
Dimensions (LxWxH) DCD35, in. (mm) 76.9 x16.5x4.9 (1954 x 420 x 125)
Dimensions (LxWxH) DCD50, in. (mm) 76.9x 22.8X4.9 (1954 x 579 x 125)
Weight DCD35, lb (kg) 77 (35)
Weight DCD50, lb (kg) 88.2 (40)
Degree of protection IP20
Degree of containment 2
Ambient Conditions
Operating temperature 50 to 104°F (10 to 40°C)
Storage temperature –13 to 176°F (–25 to 80°C)
Relative humidity 0 to 95% non-condensing
Table 3.1 DCD Active Specifications
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Item Specification
Altitude above sea level, ft (m) maximum 6,562 (2000)
Pressure Connection
Operating pressure, –1.005 to 1.005 inAq (–250 to 250Pa)
Maximum pressure permitted ± 14.5psi (1bar)
Tolerance 3% of the measured value ± 0.0008 inAq (0.2Pa)
Working gases Air, Nitrogen
Hose—outer diameter, in. (mm) 0.24 (6)
Table 3.1 DCD Active Specifications (continued)
3 General Product Information 17

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4 PRE-INSTALLATION PREPARATION AND GUIDELINES
The Liebert DCD attaches to the rear of a computer cabinet with side panels. See the dimensional-data
drawings in the Submittal Drawings on page83.
NOTE: The cooling with Liebert DCD works only if a strict air separation exists between server cold air
intake and server warm air outlet. Unused rack spaces must be blocked with blanking plates. All
bushings (network cables, piping, etc.) must be sealed to prevent air leakage. Racks must have side
panels. The tops and bottoms of the racks must be sealed.
4.1 Planning Dimensions
Refer to site-specific drawings for exact placement. Efficient cooling depends on proper equipment
placement, proper use of plates in any voids in the rack and good cable management.
Ensure that there is 25.6-in.(649mm) clearance in the rear to allow the door to open fully.
The unit dimensions are described in the submittal documents included in the Submittal Drawings on
page83.
The following table lists the relevant documents by number and title.
Document Number Title
DPN004112 Dimensional Data, DCD35
DPN004113 Dimensional Data, DCD50
Table 4.1 Dimension Planning Drawings
4.2 UnitWeights
Model Number Weight, lb (kg)
DCD35 210 (95)
DCD50 230 (104)
Table 4.2 Liebert DCD unit weights
4.3 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 most important factor in 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 site’s cooling, heating, dehumidifying and humidifying loads. Doors
must be properly sealed to minimize leaks and must not contain ventilation grilles.
4 Pre-installation Preparation and Guidelines 19

4.4 Air-flow Considerations
The server fans draw air into the rack where the equipment heats it. The server fans force the heated air
across the DCD™ coil. The DCD™ has a low air-side pressure drop, similar to a rack with perforated doors.
Figure 4.1 Generic airflow diagram—enclosure/rack shown from side
Item Description
1 Front of rack
2 Rear of rack
3 DCD
4 Cooling water connections
5 Critical equipment
NOTE: To provide optimal cooling, strict separation between the hot and cold air must exist within the
rack and all the bushings (network cables, piping, etc.) must be sealed to prevent air leakage. Air
bypass and recirculation can severely reduce the cooling effectiveness of the DCD™. Install blanking
plates in any voids in the rack to prevent air bypass and air recirculation. Keep the coils clear of any
obstructions that may block the airflow. Contact the factory for further information. Refer to the user
manual supplied with the rack on which the DCD™ is mounted.
4.5 Water-supply Considerations
For reliable function of the DCD™, chilled water must be available in an appropriate amount, of the
required quality, and at the appropriate temperature and pressure.
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