Vertiv Liebert XDU 060 Installation and maintenance instructions

Liebert® XDU™
Liquid to Air Heat Exchanger for Chip Cooling
Installer/User Guide
600-mm Wide

Vertiv | XDU™ Liquid to Air Heat Exchanger for Chip Cooling
Technical Support Site
If you encounter any installation or operational issues with your product, check the pertinent section of this
manual to see if the issue can be resolved by following outlined procedures.
Visit https://www.Vertiv.com/en-us/support/ for additional assistance.
The information contained in this document is subject to change without notice
and may not be suitable for all applications. While every precaution has been
taken to ensure the accuracy and completeness of this document, Vertiv
assumes no responsibility and disclaims all liability for damages resulting from
use of this information or for any errors or omissions. Refer to other local
practices or building codes as applicable for the correct methods, tools, and
materials to be used in performing procedures not specifically described in this
document.
The products covered by this instruction manual are manufactured and/or sold
by Vertiv. This document is the property of Vertiv and contains confidential
and proprietary information owned by Vertiv. Any copying, use or disclosure of
it without the written permission of Vertiv is strictly prohibited.
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TABLE OF CONTENTS
1 Important Safety Instructions 1
2 Nomenclature and Components 7
2.1 Model Number Nomenclature 7
2.2 Component Location 8
2.3 Cooling Configuration 9
3 Pre-installation PreparationandGuidelines 11
3.1 Planning Dimensions 11
3.2 Unit Weights 11
3.3 Implementing a Hot Aisle/Cold Aisle Equipment Layout 12
4 Equipment Inspection and Handling 15
4.1 Storing Before Installation 15
4.2 Packaging Material 16
4.3 Handling the Unit while Packaged 16
4.4 Unpacking the Export Shipped Unit 16
4.5 Unpacking the Domestic Shipped Unit 18
4.6 Removing Units from the Pallet 19
5 Installing in Enclosure Row 23
5.1 Adjusting Base Supports/Leveling Feet 23
6 Piping Requirements 25
6.1 Fluid Volume for Unit and Connection Piping 25
6.2 Water Quality Requirements 26
6.3 Connecting the Closed Loop System 28
6.4 Leak Check before Commission and Operation 29
6.5 Filling the System 30
6.5.1 Fluid Fill Source 31
6.5.2 Flushing the Cooling System 32
6.5.3 Filling the Complete System 32
6.5.4 Draining the System 33
7 Electrical Connections 35
7.1 Power Supply Cable Connection Guidelines 35
7.2 Wiring Connection Guidelines 35
7.3 Electrical Field Connections 36
7.4 Protective Features of the Electronically Commutated (EC) Fans—All Models 36
8 XDU Start up 37
8.1 Checks to Perform after Startup 37
9 Troubleshooting 39
10 Maintenance 41
10.1 Safety Instructions 41
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10.2 Fluid and Piping Maintenance 42
10.3 Spare Parts 42
10.4 Maintenance Schedule 42
10.5 Fan Replacement 43
10.5.1 Replacing a Fan in 600-mm (24-Inch) Models 43
10.6 Checking and Cleaning the Strainer 45
10.7 Flow Sensor 46
11 Preventive Maintenance Worksheet 49
Appendices 53
Appendix A: Technical Support and Contacts 53
Appendix B: Performance Curves 55
Appendix C: Technical Specifications 57
Appendix D: Submittal Drawings 59
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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®XDU. 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.
Any operation that requires opening doors or equipment panels must be carried out only by properly trained and qualified
personnel.
To identify the unit model and serial number for assistance or spare parts, locate the identification label on the unit. The
label is inside of the display of the door.
WARNING! Arc flash and electric shock hazard. Open all local and remote electric power supply disconnect
switches, verify with a voltmeter that power is Off, and wear appropriate, OSHA approved personal protective
equipment (PPE) per NFPA 70E before working within the electric control enclosure. Failure to comply can
cause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC, and local codes,
as applicable. Before proceeding with installation, read all instructions, verify that all the parts are included,
and check the nameplate to be sure the voltage matches available utility power. The Liebert® controller does
not isolate power from the unit, even in the Unit Off mode. Some internal components require and receive
power even during the Unit Off mode of the controller. The factory supplied, optional disconnect switch is
inside the unit. The line side of this switch contains live high voltage. The only way to ensure that there is NO
voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic.
Follow all local codes.
WARNING! Risk of electric shock. Can cause equipment damage, injury, or death. Open all local and remote
electric power supply disconnect switches and verify with a voltmeter that power is off before working within
any electric connection enclosures. Service and maintenance work must be performed only by properly
trained and qualified personnel and in accordance with applicable regulations and manufacturers’
specifications. Opening or removing the covers to any equipment may expose personnel to lethal voltages
within the unit even when it is apparently not operating and the input wiring is disconnected from the
electrical source.
WARNING! Risk of electric shock. Can cause serious injury or death. The Liebert® iCOM microprocessor does
not isolate power from the unit, even in the Unit Off mode. Some internal components require and receive
power even during the Unit Off mode of the Liebert® iCOM control. Open all local and remote electric power
disconnect switches and verify with a voltmeter that power is Off before working on any component of the
system.
1

WARNING! Risk of improper moving, lifting, or handling of the unit. Can cause equipment damage, injury, or
death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the
weight of the unit before attempting to move, lift, remove packaging from, or prepare the unit for installation.
See Table 3.2 on page11, for weights.
WARNING! Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment damage,
serious injury, or death. Installation and service of this equipment should be done only by qualified personnel
who have been specially trained in the installation of air conditioning equipment and who are wearing
appropriate, OSHA approved PPE.
WARNING! Risk of improper wire sizing/rating and loose electrical connections. Can cause overheated wire
and electrical connection terminals resulting in smoke, fire, equipment and building damage, injury, or death.
Use correctly sized copper wire only and verify that all electrical connections are tight before turning power
On. Check all electrical connections periodically and tighten as necessary.
WARNING! Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury, or
death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the
weight of the unit before attempting to move, lift, remove packaging from, or prepare the unit for installation.
WARNING! Risk of unsecured unit rolling off of pallet. Can cause equipment damage, injury, or death. The
unit is on casters. Ensure that the unit and pallet are located on a flat surface before loosening the hardware
securing the unit to its shipping pallet.
WARNING! Risk of hair, clothing, and jewelry entanglement with high speed rotating fan blades. Can cause
equipment damage, serious injury, or death. Keep hair, jewelry, and loose clothing secured and away from
rotating fan blades during unit operation.
WARNING! Risk of contact with high speed rotating fan blades. Can cause serious 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 blades have stopped rotating before working in the unit cabinet or on the fan assembly. If
control voltage is applied, the fan motor can restart without warning after a power failure. Do not operate the
unit with any or all cabinet panels removed.
CAUTION: Risk of contact with extremely hot and/or cold surfaces. Can cause injury. Verify that all
components have reached a temperature that is safe for human contact or wear appropriate, OSHA approved
PPE before working within the electric connection enclosures or unit cabinet. Perform maintenance only
when the system is de-energized and component temperatures have become safe for human contact.
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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.
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: backup 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 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 3

NOTICE
Risk of frozen pipes and corrosion from improper coolant mixture. Can cause water leaks resulting in
equipment and building damage.
When the cooling unit or piping may be exposed to freezing temperatures, charge the system with the proper
percentage of glycol and water for the coldest design ambient temperature. Automotive antifreeze is
unacceptable and must NOT be used in any glycol fluid system. Use only HVAC glycol solution that meets the
requirements of recommended industry practices. Do not use galvanized pipe.
NOTICE
Risk of no-flow condition. Can cause equipment damage.
Do not leave the water/coolant fluid supply circuit in a no-flow condition. Idle fluid allows the collection of
sediment that prevents the formation of a protective oxide layer on the inside of tubes. Keep unit switched On
and water/coolant fluid supply circuit system operating continuously.
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 of doorway/hallway interference. Can cause unit and/or structure damage. The unit may be too large to fit
through a doorway or hallway while on 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. Can cause unit damage.
Keep the unit upright, indoors, and protected from dampness, freezing temperatures, and contact damage.
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Agency Listed
Standard 60-Hz units are CSA Certified to the harmonized U.S. and Canadian product safety standard CSA C22.2 No
236/UL 1995 for “Heating and Cooling Equipment” and are marked with the CSA c-us logo.
1 Important Safety Instructions 5

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2 NOMENCLATURE AND COMPONENTS
This section describes the model number for Liebert® XDU units and components.
2.1 Model Number Nomenclature
Table 2.2 below describes each digit of the 25-digitconfigurationnumber. The 14-digit model number consists of the first
10 digits and last four digits of the configuration number.
Model # Part 1 Model Details Model # Part 2
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
X D U 0 6 0 A C W - - 1 D - - - - - - - - A - - -
Table 2.1 Liebert XDU Model Number Example
Digit Description
Digits 1, 2, = The base unit
XD = Extreme Heat Density System
Digit 3 = System Type
U = Coolant distribution unit
Digit 4, 5, 6 = Nominal Capacity
060 = 60kW
Digit 7 = Heat Rejection
A = Air (fin-type heat exchanger)
Digit 8 = Supply Power
C = 208V / 3ph / 60Hz
Digit 9 = Coolant Fluid Type
W = Water
Digit 10 = Pump Configuration
- = Placeholder
Digit 11 = Pump Hp
- = Placeholder
Digit 12 = Fan Redundancy
1 = N
Digit 13 = Packaging
D = Domestic
E = Seaworthy (Export)
Table 2.2 Model Number Digit Definitions for Liebert XDU
2 Nomenclature and Components 7

Digit Description
Digit 14 = Agency
- = Placeholder
Digit 15 = Coil
- = Placeholder
Digit 16 = Placeholder
- = Placeholder
Digit 17 = Placeholder
- = Placeholder
Digit 18 = Placeholder
- = Placeholder
Digit 19 = Placeholder
- = Placeholder
Digit 20 = Placeholder
- = Placeholder
Digit 21 = Placeholder
- = Placeholder
Digit 22 = Special Feature Application Configuration
A = Standard configuration
S = SFA
Digit 23, 24, 35 = Factory Configuration
- = Placeholder
Table 2.2 Model Number Digit Definitions for Liebert XDU (continued)
2.2 Component Location
The unit component locations are described in the submittal documents included in the Submittal Drawings on page59.
The following table lists the relevant documents by number and title.
Document Number Title
DPN004931 Component Location Diagram Liquid to Air 60 kW, 600 mm (24 in.) Model
Table 2.3 Component Location Drawings
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2.3 Cooling Configuration
Figure 2.1 Liquid to Air Cooling System Overview
Item Description
1 XDU
2 Heat load
3 Pump
4 Heat exchanger
2 Nomenclature and Components 9

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3 PRE-INSTALLATION PREPARATIONANDGUIDELINES
NOTE: Before installing unit, determine whether any building alterations are required to run piping, wiring, and duct
work. Follow all unit dimensional drawings and refer to the submittal engineering dimensional drawings of individual
units for proper clearances.
Refer to Model Number Nomenclature on page7 and the appropriate submittal drawings to determine the type of system
being installed and anticipate building alterations, piping, and duct work needed.
The unit dimensions, pipe connection locations, and piping schematics are described in the submittal documents included
in the Submittal Drawings on page59.
•Verify that the floor is level, solid, and sufficient to support the unit. See Table 3.2 below, for unit weights.
•Confirm that the room is properly insulated and has a sealed vapor barrier.
•For proper humidity control, keep outside or fresh air to an absolute minimum (less than 5% of total air
circulated in the room).
•Install the units as close as possible to the largest heat load.
•Allow at least the minimum recommended clearances for maintenance and service. See the appropriate
submittal drawings for dimensions.
•We recommend installing an under floor leak detection system. Contact your Vertiv representative for
information.
3.1 Planning Dimensions
The unit and floor stand dimensions are described in the submittal documents included in the Submittal Drawings on
page59.
The following table lists the relevant documents by number and title.
Document Number Title
XDU
DPN004930 Cabinet Dimensional Data Liquid to Air 60kW, 600 mm (24 in.) Model
Floor Stand
DPN004933 Floorstand Dimensional Data 600 mm (24 in.) Model
Table 3.1 Dimension Planning Drawings
3.2 Unit Weights
Domestic Packaging Export Packaging
Dry Weight, lb(kg)
Ship Weight, lb(kg) Shipping Dimensions, in.(mm) Ship Weight, lb(kg) Shipping Dimensions, in.(mm)
825 (374) 90x128x 97 (2286x3251x 2464) 915 (415) 90.5x 128.5x99 (2299x3264x2515) 700 (318)
Table 3.2 XDU Shipping Dimensions and Unit Weights
3 Pre-installation PreparationandGuidelines 11

3.3 Implementing a Hot Aisle/Cold Aisle Equipment Layout
Best practice is to place equipment racks in alternating rows of cold aisles and hot aisles. This is best accomplished when
planning the layout of the file server farm area. It is more difficult to accomplish when the computer room is already
populated with operating hardware.
In the cold aisle, the equipment racks are arranged face-to-face so the cooling air discharged from the cooling unit is
discharged up through perforated floor tiles, drawn into the face of the computer hardware and exhausted out the back of
the equipment rack into the adjacent hot aisles. Hot aisles are literally hot because the alternating cold and hot-aisle design
separates the source of cooling air from hot air discharge, which returns to the computer room cooling unit. No perforated
tiles should be placed in the hot aisles, which mixes hot and cold air, lowering the temperature of the air returning to the
cooling units and reducing usable capacity.
Figure 3.1 XDU Layout in Hot/Cold Aisle Application
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Item Description
1 Aisle pitch, 7tiles, 14ft. (4.3m)
2 Cold aisle
3 Hot aisle
4 Front aisle, 4ft. (1.2m)
5 Rack, 42in. (1067mm)
6 Back aisle, 3ft. (0.91 m)
7 XDU
8 Heat load
3 Pre-installation PreparationandGuidelines 13

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4 EQUIPMENT INSPECTION AND HANDLING
WARNING! Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury, or
death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the
weight of the unit before attempting to move, lift, remove packaging from, or prepare the unit for installation.
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.
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.
Upon arrival of the unit and before unpacking:
•Verify that the labeled equipment matches the bill of lading.
•Carefully inspect all items for visible or concealed damage.
•Report damage immediately to the carrier and file a damage claim with a copy sent to Vertiv or to your sales
representative
Equipment Recommended for Handling the Unit:
•Forklift
•Pallet jack
•Piano jacks
4.1 Storing Before Installation
If storing the unit for long periods before installation:
•Keep the packaging on the unit and allow proper clearance around the unit to perform periodic inspections and
maintenance.
•Inspect the unit periodically for condensation inside the unit or other signs of other effects of the storage
environment.
•Rotate the fans and motor shaft by hand periodically for several revolutions. Look for signs of lubrication
problem or obstructions. Failure to regularly rotate fans on a stored unit will result in premature fan failure. This
type of failure is not covered by warranty.
4 Equipment Inspection and Handling 15

•If storing at low temperatures, trapped moisture can collect on walls and electrical components.
•We recommend routine inspections and, if needed, install electric heaters near the unit to prevent
condensation.
4.2 Packaging Material
All material used to package this unit is recyclable. Please save for future use or dispose of the material appropriately.
4.3 Handling the Unit while Packaged
Transport the unit with a forklift or pallet jack.
When using a forklift or pallet jack:
•Make sure that the forks (if adjustable) are spread to the widest allowable distance that will fit under the skid.
•Make sure the fork length is suitable for the skid length. Skid length is 60inches (1524mm).
•When moving the packaged unit, do not lift the unit any higher than 2to4inches (51to102 mm). All personnel
except those moving the unit must be kept 12feet (3.7m) or more from the unit while it is being moved.
•If the unit must be lifted higher than 4inches (102 mm), all personnel not directly involved in moving the unit
must be 20feet (5m) or farther from the unit.
4.4 Unpacking the Export Shipped Unit
1. Remove the metal clips (12 places typical) that secure the top panel of the crate to the side panels, see Figure
4.1 on the facing page.
2. Use a Phillips head screwdriver to remove all the wood screws (34 places typical) that secure the side panels
together and to the pallet, see Figure 4.1 on the facing page.
3. To remove the remaining packaging, start with Step 1, of Unpacking the Domestic Shipped Unit on page18.
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