Liebert Extreme Density Chiller XDC User Manual
Precision Cooling
For Business-Critical Continuity™
Liebert® XDC
User Manual - 50 and 60 Hz, 130 & 160kW Nominal Cooling Capacity
™
GENERAL SAFETY GUIDELINES
Before beginning the installation of the Liebert XDC, read all instructions, verify that all the parts are
included, and check the nameplate to be sure the Liebert XDC voltage matches available utility power.
Follow all local codes.
WARNING
!
Risk of electric shock. Can cause injury or death.
Disconnect all local and remote electric power supplies before working within.
WARNING
!
Risk of unit falling over. Can cause death, injury and equipment damage.
The Liebert XDC is top-heavy. Use extreme caution and care when moving and installing this
unit.
CAUTION
!
Risk of piping and component rupture. Can cause injury or equipment damage. 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.
WARNING
!
Risk of refrigerant system explosion or rupture from overpressurization. Can cause injury,
death or equipment damage.
Installer must install a 400 psig pressure relief valve in each of the two R-407c refrigerant
circuits of the Liebert XDC system. Do not install shutoff valves between the compressors and
the pressure relief valves.
For systems requiring EU CE compliance, the pressure relief valves must be CE-certified by a
notified body to the EU Pressure Equipment Directive.
CAUTION
!
Risk of contact with hot surfaces. Can cause burn injury. The compressors and refrigerant
discharge lines are extremely hot during unit operation. Allow sufficient time for the
compressors and refrigerant discharge lines to cool before working within the unit cabinet.
Use extreme caution and wear protective gloves and arm protection when working on or near
hot compressor and discharge lines.
NOTE
This document shall be used together with site specific documentation and documentation for
other parts of the system (heat rejection devices and cooling modules).
NOTE
Before any action that could cause a disturbance in the XD system’s cooling function is begun,
the facility manager MUST be informed. In addition, after the action is taken and the work is
finished, the facility manager MUST be informed.
Figure i Model number nomenclature
Example: XDC160AA– –1
XD C 160 – 1
Chiller
unit
Liebert
X-treme heat
Density system
Model size Place holder
A
Place holder
(voltage-phase-frequency)
M = 380/415-3ph-50Hz
A
A = 460V-3ph-60Hz
–
Place holder
Revision
level
TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER
1.0 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 General Product Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Product/System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Equipment Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3.1 Handling With Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.2 Removal of Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.3 Removing Piano Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Mechanical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.1 Positioning the Liebert XDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.2 Placing the Liebert XDC on a Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 Positioning the Liebert XDC with Floor Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 High Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5.1 Connecting High-Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Extra Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.0 PIPING AND FILLING WITH REFRIGERANT: R-134A AND R-407C CIRCUITS . . . . . . . . . . . . .16
2.1 European Union Fluorinated Greenhouse Gas Requirements . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Recommended Pipe Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Liebert XDC Interconnection With Liebert XD Cooling Module . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Piping Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Piping Installation—R-134a Pumped Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Filling the Pumped Circuit—R-134a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.1 Calculating Refrigerant Charge—Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.2 Piping for Direct Expansion (DX) Circuit—R-407c Air Cooled Units . . . . . . . . . . . . . . . . . . . 22
2.6 Install Double Discharge Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6.1 Air Cooled Condenser with Lee-Temp “Flooded Condenser” Head Pressure Control
System—R-407c (DX) Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7 Filling the Direct Expansion (DX) Circuit—R-407c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.0 INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.0 CHECKLIST FOR LIEBERT XDC STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 System Refrigerant Charges Over 35 lb. (15.9kg) Require Additional Oil . . . . . . . . . . . . . . 34
5.0 MICROPROCESSOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.1 Feature Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2.1 Feature Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2.2 Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
i
5.3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.1 Viewing or Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.2 SETPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.3 STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.4 ACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.5 ALARM HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.6 TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.7 DATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.8 SETUP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3.9 SETPT PASSWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.10 SETUP PASSWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.11 CALIBRATE SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.12 ALARM ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.13 ALARM TIME DELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3.14 COM ALARM ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3.15 CUSTOM ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3.16 CUSTOM TEXT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.17 DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.0 ALARM DESCRIPTIONS AND SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.1 Alarm Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Red and Green Lamp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3 Enable / Disable Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4 Alarm Time Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5 View Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.6 View Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7 System Shutdown Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
8.1 Fluorinated Greenhouse Gas Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2 Air Cooled Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.3 Water/Glycol Floor Stand Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3.1 Shell and Tube Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3.2 Regulating Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3.3 Glycol Solution Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.0 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
ii
FIGURES
Figure 1 Liebert XDC components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 2 Moving Liebert XDC with forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 3 Remove tie-down brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 4 Remove pallet, insert piano jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 5 Dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 6 Piping locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 7 Water/glycol Liebert XDC on a floor stand—positioning and piping connections. . . . . . . . . . . . . . 7
Figure 8 Piping locations—floor stand and valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 9 Dimensions and clearances for Liebert XDC on floor stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 10 Front view of Liebert XDC and electrical enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 11 Electrical enclosure knockout locations for field wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 12 60Hz models, high voltage connections—primary disconnect switch . . . . . . . . . . . . . . . . . . . . . . 11
Figure 13 50Hz models high voltage connections—primary disconnect switch . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 14 60Hz models high voltage connections—secondary disconnect switch . . . . . . . . . . . . . . . . . . . . . 12
Figure 15 50Hz models high voltage connections—secondary disconnect switch . . . . . . . . . . . . . . . . . . . . . 13
Figure 16 Liebert XDC heat rejection connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 17 Electrical enclosure knockout locations for Extra Low Voltage connections . . . . . . . . . . . . . . . . . 14
Figure 18 Extra Low Voltage field connections points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 19 Liebert XD system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 20 Bypass flow controller details, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 21 Bypass flow controller arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 22 Bypass flow controller piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 23 Double discharge riser layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 24 Installation data—Lee-Temp, one-circuit, four-fan model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 25 Installation data—Lee-Temp, one-circuit, high ambient six-fan model . . . . . . . . . . . . . . . . . . . . 25
Figure 26 Liebert XDC piping schematic and Lee-Temp heater pad wiring . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 27 General arrangement air cooled Liebert XDC Lee-Temp Control . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 28 DCSL616 piping connections—two refrigerant circuits connected for parallel flow. . . . . . . . . . . 28
Figure 29 CSL616 piping connections—two refrigerant circuits connected for parallel refrigerant
flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 30 Additional oil requirements for refrigerant charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 31 System R-134a liquid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 32 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 33 Outdoor fan/condenser configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
iii
TABLES
Table 1 Liebert XDC dimensions, weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 2 Liebert XDC piping connection sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 3 Liebert XDC water/glycol piping connection Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 4 Supply, return pipe sizes for Liebert XD refrigerant loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 5 Bypass flow controllers for a Liebert XDC-based system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 6 System R-134a charge for a Liebert XDC with any model Liebert XDH/Liebert
XDO/Liebert XDV/Liebert XDCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 7 System refrigerant charge for the supply and return mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 8 R-134a refrigerant charge for hard-piped connector lines to and from any model
Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 9 R-134a refrigerant charge for Liebert XD Flex Pipe connector lines to and from any
model Liebert XDO/Liebert XDH/Liebert XDV/Liebert XDCF . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 10 Calculating refrigerant charge—example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 11 Worksheet to calculate refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 12 Recommended refrigerant line sizes, DX R-407c, OD copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 13 Recommended refrigerant line sizes for DCSL616 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 14 Indoor unit refrigerant charge—R-407c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 15 Outdoor air condenser charge—R-407c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 16 Air cooled systems - liquid line charge - R-407c refrigerant per 100 ft (30 m)
of Type "L" copper tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 17 Indoor water/glycol cooled module – R-407C refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 18 Liebert XDC pump light indicator *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 19 Compressor oil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 20 User interface keypad functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 21 Setpoint functions, default values and allowable ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 22 Setup operation functions default values and allowable ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 23 Liebert XDC DIP switches and factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 24 Liebert XDC troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 25 Liebert XDC specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table 26 Floor stand specifications—water-cooled Liebert XDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 27 Floor stand specifications—Liebert XDC with 40% propylene glycol . . . . . . . . . . . . . . . . . . . . . . 55
Table 28 Floor stand specifications—Liebert XDC with 40% ethylene glycol . . . . . . . . . . . . . . . . . . . . . . . 56
iv
1.0 PRODUCT DESCRIPTION
1.1 General Product Information
1.1.1 Product/System Description
The Liebert XDC™ (eXtreme Density Chiller) is self-contained refrigeration distribution unit
designed to cool rooms with high heat producing equipment. There are two distinct circuits, each utilizing different refrigerants and mechanical parts. The R-134a circuit is the “pumped” circuit containing redundant circulating pumps, a brazed plate heat exchanger along with valves and piping. The
R-407c circuit is the dual direct expansion circuit containing scroll compressors, expansion valves,
brazed plate heat exchanger, and piping. Heat removal is accomplished by using condensers connected to the dual direct expansion circuit. Heat rejection is available in two options: an outdoor air
cooled condenser and a water/glycol condenser. See Figure 1 below.
The Liebert XDC monitors room conditions and prevents coil condensation by maintaining the coolant
being pumped to the cooling modules at a temperature above the room dew point. All functions, such
as temperature control, switching pumps (if necessary), etc., are automatic.
The Liebert XDC’s minimum recommended operating load is 40% of system nominal capacity. For
example, a Liebert XDC160 60Hz system’s minimum load would be 64 kW. Loading below this value
can unfavorably affect system operation. Consult factory for any loading below this recommendation.
See Table 25 for the Liebert XDC160 rated cooling capacity.
Product Description
Figure 1 Liebert XDC components
Liebert XDC
Condenser
Unit
Heat Exchanger
1.2 Equipment Inspection
When the unit is delivered, inspect all items for visible and concealed damage. Damage should be
immediately reported to the carrier and a damage claim filed with a copy sent to Liebert or to your
sales representative.
Compressor
Receiver
Liebert XD Cooling Modules
Pumps
1.3 Equipment Handling
WARNING
!
Risk of unit falling over. Can cause death, injury and equipment damage.
The Liebert XDC is top-heavy. Use extreme caution and care when moving and installing this
unit.
1
1.3.1 Handling With Skid
• Always keep the unit upright, indoors and protected from damage.
• If possible transport the unit using a forklift truck; otherwise use a crane with belts or cables.
When using a crane, apply spreader bars to avoiding pressing on the top edges of the packaging.
• Personnel should be properly certified and trained to move and rig equipment.
• If using a forklift truck, make sure that the forks (if adjustable) are spread to the widest allowable
distance that will fit under the skid.
• When moving the skidded unit with a forklift truck, do not lift the unit any higher than
6" (152mm) off the ground. If circumstances require the unit to be lifted higher than 6" (152mm),
great care must be exercised, and all personnel not directly involved in raising the unit must be
no closer than 20 feet (5m) from the lift point of the unit.
CAUTION
!
Risk of structural interference. Can cause equipment or building damage.
While on the skid, the unit is too tall (83" [2108mm] overall height) to fit through a standard
doorway 83" [2108mm]. Any attempt to move the unit, while skidded, through a standard
doorway will cause damage to the unit and to the building.
1.3.2 Removal of Skid
For skid removal, Emerson Network Power recommends using pallet jack or similar operation. This is
to ensure that both ends of the unit are firmly secure, and provides a good means of unit mobility.
Product Description
Always keep the unit upright, indoors and protected from damage.
1. Remove the exterior packaging.
2. Align forklift with either the front or rear of the unit. Ensure the forks are locked at the widest
position that will fit under pallet (see Figure 2).
Figure 2 Moving Liebert XDC with forklift
Spread forks as far apart as possible and
drive forklift against the Liebert XDC
CAUTION
!
Risk of unit damage. Ensure the forklift tines are level and not angled in an upward direction.
Improper positioning may cause damage to the bottom of the unit. Ensure the forks are
positioned in a manner as to have the Center of Gravity label, located on the unit, centered
between the tines. Ensure the tines extend beyond the opposite side of the unit.
3. Drive the forklift forward, sliding the forks under the base of the unit (see Figure 2).
2
4. Move the Liebert XDC to its installation location.
WARNING
!
Risk of unit falling over. Can cause death, injury and equipment damage.
The Liebert XDC is top-heavy. Use extreme caution and care when moving and installing this
unit.
5. Remove all lag bolts from the four (4) corner tie-down brackets. Remove the tie-down brackets
from the unit. (see Figure 3).
Figure 3 Remove tie-down brackets
Unscrew lag bolts and
remove brackets to release
the XDC from the pallet.
There are four brackets, one
bracket on each corner.
Product Description
6. Lift the Liebert XDC about an inch and remove the shipping pallet.
Figure 4 Remove pallet, insert piano jacks
7. Place piano jacks at either end of the Liebert XDC and lower it until it is supported by the piano
jacks. Secure the Liebert XDC to the jacks (see Figure 4 for arrangement).
CAUTION
!
8. Back the forklift away from the Liebert XDC until the forks are no longer under the unit.
9. Using the piano jacks, maneuver the Liebert XDC into its installation position—this requires at
Risk of overtightening securing strips. Can cause damage to panels.
Place a protective material between the straps of the piano jacks and the unit.
Ensure that the straps are not tightened to a point of damaging panels.
least two people.
3
1.3.3 Removing Piano Jacks
Once the unit has been moved to the installation location, Emerson Network Power recommends
using the following method to remove the piano jacks.
1. Lower the unit as far as the piano jacks will allow.
2. Undo all strapping holding the piano jacks to the unit.
3. Remove all cushioning material that might have been used to protect the unit panels from the
strapping and/or the piano jacks.
4. Use a pry bar or similar device on one side of the unit, lift unit just enough to allow for the
removal of the piano jack.
5. Repeat the previous step to remove the piano jack on the opposite side.
6. Remove the plastic bag.
1.4 Mechanical Considerations
1.4.1 Positioning the Liebert XDC
Install the Liebert XDC according to the site specific documentation and secure the unit to the floor.
The Liebert XDC can be installed near a wall or another Liebert XDC. However, there must be at
least 3 feet (92cm) clearance in front of the Liebert XDC as service access for components in the unit.
NOTE
During installation of the Liebert XDC, the top, bottom, front and left side of the unit
must be accessible.
Product Description
Figure 5 Dimensional data
A
Overall
C
D
Unit
Base
Overall
E
Unit Base
Unit Dimensional Data
Table 1 Liebert XDC dimensions, weight
Air Cooled
Model Dimensional Data, inches (mm) Shipping Weight, lb (kg)
50/60Hz A B * C D E Domestic Export
XDC160 74 (1880) 34 (864) 33-1/8 (841) 33 (838) 72 (1829) 1945 (882) 2093 (949)
* Dimension does not include the bezel of the disconnect switch.
B
78"
1981mm
1"
(25.4mm)
Shaded areas indicate a
recommended clearance
of 34" (864mm) for
component access.
D
17"
(432mm)
2"
(51mm)
Recommended
Minimum Hot Gas
Supply & Liquid Return
5"
(127mm)
Piping Opening
Floor Cutout Dimensions
DPN000768
Page 2, Rev. 6
4
Figure 6 Piping locations
(584.2mm)
Dimensions are
approximate and
subject to change
without notice.
** To first cooling module
or bypass flow controller
F - Return From Cooling Units
47"
(1193.8mm)
(1117.6mm)
6" (152mm)
23"
Product Description
Install replaceable filter dryer
assembly in liquid supply line G
* Orientation determined
by installer.
G - Supply to Cooling Units
44"
A - Hot Gas
Refrigerant Lines
B - Liquid
Refrigerant Lines
* Allow 8" (204mm) of clearance for filter replacement
** To ensure all refrigerant flow is filtered, install the filter dryer assembly
between the discharge line of the Liebert XDC and the first bypass flow controller
or the first cooling module.
Table 2 Liebert XDC piping connection sizes
Air Cooled Model Piping Outlet Connection Sizes, OD Cu, inches
50/60Hz A B C D E F G
XDC160 1-3/8 7/8 - - - 2-1/8 1-1/8
DPN000768
Page 3, Rev. 6
5
1.4.2 Placing the Liebert XDC on a Floor Stand
WARNING
!
Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or
death.
Read all of the following instructions before attempting to move, lift, remove packaging from
or preparing unit for installation.
CAUTION
!
Only properly trained and qualified personnel wearing appropriate safety headgear, gloves,
shoes and glasses should attempt to move, lift, remove packaging from or prepare unit for
installation.
The water/glycol floor stand can be located beneath the XDC unit or can be installed nearby.
NOTE
Consult the factory if the XDC is not installed on the water/glycol condenser floor stand to
prevent exceeding maximum the piping distances.
Refer to the floor stand installation sheet shipped inside the water regulating valve package.
1. Move the floor stand assembly to its installation area and uncrate the unit.
2. Position the floor stand in its final location.
3. Insert leveler pads into each floor stand leg.
4. Level the top of the floor stand to the specified height with the flanged adjusting nut.
5. Tighten jam nuts on all legs against flanged adjusting nuts.
6. Using an appropriate lifting device or method, raise the Liebert XDC and move it above the floor
stand.
7. Align the welded tabs on top of the floor stand with the inside of the unit frame base (see Detail A
in Figure 7).
8. Maintaining the alignment of the Liebert XDC and the floor stand, lower the Liebert XDC onto
the floor stand.
9. Connect the hot gas refrigerant lines from the Liebert XDC to the floor stand with 1-3/8" tubing
(see Figures 7 and 8).
10. Connect the liquid refrigerant lines as shown from the Liebert XDC unit to the floor stand with
7/8" tubing (see Figures 7 and 8).
11. Connect the water lines as shown with the provided valving (see Figures 7 and 8).
12. Connect capillary lines from each water regulating valve to condensers in the floor stand (see
Figures 7 and 8).
Capillary length is limited to 48" (1219mm).
13. Check the pipes for leaks and evacuate air from all pipes.
14. Insulate all water/glycol lines.
15. Charge each condenser loop with R-407c (see Table 17).
Product Description
6
Product Description
Figure 7 Water/glycol Liebert XDC on a floor stand—positioning and piping connections
A - Return from
Cooling Units
B - Supply to
Cooling Units
(1194mm)
6"
(153mm)
23"
(584mm)
47"
44"
(1118mm)
Welded Tab
C - Hot Gas
Refrigerant Lines
D - Liquid
Refrigerant Lines
E - Threaded
Female
Connections
Customer
Water
Return
Customer Provided Piping
Table 3 Liebert XDC water/glycol piping connection Sizes
Model Piping Outlet Connection Sizes, OD Cu, inches
50/60Hz A B C D E* F**
XDC160 2-1/8 1-1/8 1-3/8 7/8 2-1/2 2-1/8 or 2-5/8
* Threaded Female Conection
** 2-1/8" for 1" WRV, 2-5/8" for 1-1/4" WRV
A
DETAIL A
Customer
Water
Supply
F - Cup Fitting
Capillary Lines are 48" (1220mm)
Limit Valve Distance from Condensers
DPN001419
Pg. 01, Rev. 01
7
Figure 8 Piping locations—floor stand and valve assembly
Product Description
TOP VIEW OF FLOOR STAND
Hot Gas 1
Hot Gas 2
Outlet
24" Nominal
(609mm)
Liquid 1
Liquid 2
72"
(1,828mm)
33"
(838mm)
Shaded areas indicate a recommended
clearance of 36" (915mm) for component
access and water/glycol piping.
33" (838mm)
Circuit 1
Inlet
FLOOR STAND CONNECTIONS
Circuit 2
12-5/16"
(313mm)
26-15/16" (684mm)
LEFT SIDE OF CABINET
20-1/4"
(514mm)
10-1/2"
(267mm)
6-1/2"
(165mm)
2-1/4" - 5-1/4"
(57 - 133 mm)
DPN001419
Pg. 2 , Rev. 01
8
1.4.3 Positioning the Liebert XDC with Floor Stand
Install the Liebert XDC according to the site-specific documentation and secure the unit to the floor.
The Liebert XDC can be installed near a wall or another Liebert XDC. There must be at least 3 feet
(914mm) clearance in front of the Liebert XDC for service access. When the Liebert XDC is combined
with the optional water/glycol floor stand, Liebert recommends leaving 3 feet (914mm) of clearance on
the left side of the unit.
A Liebert XDC on a floor stand is 102 inches (2591 mm) high (see Figure 9). The unit can be raised or
lowered 1.5 inches (38.1 mm) with the leveling feet.
Figure 9 Dimensions and clearances for Liebert XDC on floor stand
Product Description
78"
(1981mm)
102"
(2591mm)
24" Nominal
610 mm
Shaded areas indicate a recommended
cleareance of 36" (914mm) for component
access and water/glycol piping.
9
1.5 High Voltage Connections
Make sure the actual supply voltage and frequency correspond to the voltage and frequency indicated
on the Liebert XDC’s rating plate.
Connect cables for high voltage supply to the electrical box in the Liebert XDC according to
Figures 5, 11 and 12 and make sure that the phases are correctly connected.
WARNING
!
Risk of electric shock. Can cause death or injury.
Disconnect all local and electric remote power supplies before working within.
CAUTION
!
Risk of sharp edges and heavy parts. May cause personal injury or equipment damage.
Wear gloves to prevent injury to hands.
Damage to wiring or components can make unit unsafe to operate.
Use caution when installing wiring to prevent damage to factory wiring.
Install protective bushings in wiring knockouts as required
Do not disturb factory wiring or route field-installed wiring over electrical terminals.
Use NEC Class 1 wiring for all hazardous voltage electrical power supplies.
Check and retighten all wiring connections before starting the unit.
NOTE
Before beginning to install the Liebert XDC, read all instructions, verify that all the parts are
included and check the nameplate to be sure the Liebert XDC voltage matches available utility
power.
Product Description
Follow all local codes.
1.5.1 Connecting High-Voltage Cables
1. Turn the Liebert XDC’s primary disconnect switch to the Off position (see Figure 10). Open the
front doors and push down on the enclosure cover latch to open the hazardous voltage enclosure
cover.
Figure 10 Front view of Liebert XDC and electrical enclosures
Primary Disconnect
Switch
Enclosure Cover La tch
Secondary Disconnect
Switch
Status Lamp s
Us er Interface
Enclosure Cove r La tc h
Hazardous Voltage
Enclosure Cover
PRIMARY
ELECTRICAL ENCLOSURE
COMPRESSOR SECTION
Hazardous Voltage
Enclosure Cover
SECONDARY
ELECTRICAL ENCLOSURE
PUMP SECTION
10
2. Determine which knockouts in the electrical enclosure will be used and remove them (see
Figure 11).
Figure 11 Electrical enclosure knockout locations for field wiring
Knockout for
Input Power
Product Description
Enclosure Cover
Not Shown for Clarity
3. Route the input hazardous voltage electrical power wiring through the top right knockout on the
primary electrical enclosure (see Figure 11) to the disconnect switch L1, L2 and L3 (see
Figure 12). Observe proper phasing.
4. Connect the ground wire to the ground lug (see Figures 12 and 14 for 60Hz models and
Figures 13 and 15 for 50Hz models).
Figure 12 60Hz models, high voltage connections—primary disconnect switch
Transformer Fuse Block
Compressor Fuse Blocks
Customer Power Connection
Primary Power Block
Ground
Lug
Primary
Disconnect
Switch
Compressor Contactors
Transformer 3
11
Relay
Electronic Hot Gas
Bypass Controllers
Figure 13 50Hz models high voltage connections—primary disconnect switch
Product Description
Compressor
Circuit Breakers
Busbar
Primary Power Block
Customer
Power
Connection
Wire
Raceway
Compressor
Transformer 3
Contactors
Figure 14 60Hz models high voltage connections—secondary disconnect switch
Relay
Electronic Hot Gas
Bypass Controllers
Ground
Lug
Primary
Disconnect
Switch
Power Connection
From Primary
Power Block
Ground Lug
Secondary Disconnect Switch
Pump Fuse Blocks
Pump Contactors
Transformer 2
Secondary Power Block
Transformer Fuse Block
Transformer 1
12
Figure 15 50Hz models high voltage connections—secondary disconnect switch
Power Connection
From Primary
Power Block
Product Description
Secondary
Ground Lug
Disconnect
Switch
Pump Circuit
Breakers
Busbar
Pump Contactors
1.6 Extra Low Voltage Connections
Extra Low Voltage (ELV) power output is 30V and 100VA or less.
1. Turn off all unit power before connecting cables or wires. Failure to do so may damage this
equipment.
2. Route low voltage electrical connections through the appropriate knockouts as shown in
Figure 17.
3. User interface and temperature/humidity sensor wire is NEC Class 2. All electrical installation
must comply with all national, state and local requirements.
Figure 16 Liebert XDC heat rejection connection points
Transformer 2
Power Block
Fuse Blocks
Transformer 1
HEAT REJECTION CONNECTION
Field-supplied 24V. Class 1 wiring
to interlock heat rejection from pigtails:
70A and 71A - Compressor 1 circuit
70B and 71B - Compressor 2 circuit
70C and 71C - Dual Source relay (optional)
Electrical handy box,
factory-installed with cover
13
Figure 17 Electrical enclosure knockout locations for Extra Low Voltage connections
Product Description
User Interface
(Wall Box) Wiring
Temperature/Humidity
Sensor Wiring
Enclosure Cover Not Shown for Clarity
Liebert XD Module Condensate
Connections (optional;
depends on features
supplied with Liebert XD Module)
Alternate Knockout
for Temperature/Humidity
Sensor Wiring
Field Connections—All Units
• Connect the control display panel cable to terminal block TB3 terminals 1 through 4 on the Liebert XDC control board as shown (refer to Figure 18). The display panel must always be installed
in the conditioned space. The display panel may be mounted on the Liebert XDC’s front right door
if the Liebert XDC is located in the area that it conditions.
• Place the sensor in the higher-temperature portion of the cold aisle where the XD modules are
located. Alternatively, it may be placed on the return air side of the primary air mover (e.g., Liebert Deluxe System/3
ules are located. Do not install the sensor where ambient air might cause false readings, for
example, near unsealed doors, windows and similar areas..
™
) in the room if it represents the conditions where all the XD cooling mod-
Field Connections—Optional for All Units
• Connect optional field wiring from remote devices to Remote Alarm Device, Common Alarm Output, IGM and Remote Shutdown, if applicable. See terminal strip descriptions in Figure 18.
Field Connections—Air Cooled Units only
Connect field wiring to heat rejection connection terminals on the handy box as shown in Figure 16.
14
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