Liebert XDK-W User Manual

Precision Cooling For Business-Critical Continuity™

Liebert® XDK-W™ Rack Enclosure With Integrated Liquid Cooling

User Manual–25kW, 50 and 60Hz

CoolTherm

Manual / Bedienungsanleitung

Manual CoolTherm

Server Cabinet with integrated liquid cooling

Effective cooling capacity 12 - 25 / 35 KW

Bedienungsanleitung CoolTherm

Schaltschrank mit integrierter Flüssigkeitskühlung

Nutzkühlleistung 12 -25 / 35 KW

(ab Seite 42)

date / Datum issue / Ausgabe author / erstellt reviewed / geprüft

2007-06-01 01_998_330_0_k Carsten Dietze Heiko Ebermann

CoolTherm 01_998_330_0_k page / Seite 1/83

CoolTherm

Manual / Bedienungsanleitung

Contents

0.

Abstract ......................................................................................................................................... 3

1.

Safety............................................................................................................................................. 3

1.1 Work safety symbols.................................................................................................................... 3

1.2 Safety instructions........................................................................................................................ 4

2.

Operating conditions.................................................................................................................... 5

3.

Description .................................................................................................................................... 6

3.1 General function ........................................................................................................................... 6

3.2 Principle of operation of cooling ................................................................................................. 7

3.3 Dimensions ................................................................................................................................... 8

3.4 Technical data............................................................................................................................. 12

3.5 Control......................................................................................................................................... 15

Storage and transportation ........................................................................................................ 17

4.

Installation and commissioning................................................................................................. 19

5.

5.1 Preparation for installation ........................................................................................................ 19

5.2 Positioning the units................................................................................................................... 20

5.3 Chilled water connection............................................................................................................ 21

5.4 Condensed water connection .................................................................................................... 23

5.5 Electrical connection.................................................................................................................. 24

5.6 Sealing of cabinet ....................................................................................................................... 25

5.7 Automatic door opening............................................................................................................. 25

6.

Servicing and maintenance........................................................................................................ 29

7.

Dismantling and disposal........................................................................................................... 32

8.

Customer service, manufacturer's address.............................................................................. 32

9.

Appendix ..................................................................................................................................... 33

9.1 Quality requirements on the water used in CoolTherm........................................................... 33

9.2 Checklist for unit installation ..................................................................................................... 34

9.3 Commissioning certificate ......................................................................................................... 35

9.4 CoolTherm Diagrams.................................................................................................................. 40

9.5 Control Standard Factory Settings............................................................................................ 41

page

CoolTherm 01_998_330_0_k page / Seite 2/83

CoolTherm

Manual / Bedienungsanleitung

0. Abstract

The CoolTherm platform provides the dissipation of heat loads from 10 up to 22 / 35 kW. The server rack is closed to the installation area, that means no heat load will dissipate to the environment. (see also chapter 2.) The cooling is provided by a closed cooling system via an airto-water heat exchanger. The cooling capacity is adapted to the accruing heat load. 19” hole raster profiles are designed for components as well as rails and shelves. The cable entry is possible via bottom and top cover

1. Safety

1.1 Work safety symbols

The following symbols identify specific hazards or provide information on safe operation.

Attention! Danger! Safety instruction!

Risk of electric shock or danger due to high voltage

Caution! Hot surface

Safety-related instruction

Attention! Identifies possible damage to the unit

Risk of electric shock

Note! Identifies possible hazards for the environment

Caution! Rotating parts / automatic start

CoolTherm 01_998_330_0_k page / Seite 3/83

CoolTherm

Manual / Bedienungsanleitung

Important note, information

1.2 Safety instructions

Our engineers will provide comprehensive support on how to install the CoolTherm. Extensive material, function and quality checks ensure that you fully benefit from product functions and a long service life. Nevertheless, this product can produce hazards if it is used incorrectly by untrained personnel or is not used for the correct purpose.

Prior to commissioning the CoolTherm, read these operating instructions carefully.

The electrical equipment complies with the applicable VDE and accident prevention regulations. Hazardous voltages (higher than 50 V AC or higher than 100 V DC) are present: → behind the server cabinet doors → on the power supply in the unit's housing → behind the fan cover

Use only original fuses with the stipulated rating. Immediately shut down the unit if there are problems with the supply of electrical power or supply of cold water.

Risk of electric shock Repair and cleaning work should only

be performed by qualified personnel. The personnel must ensure that the unit is electrically isolated whilst it is serviced and cleaned. For this reason shut down the unit before starting work.

Risk due to incorrect work on the unit. Cleaning and servicing is only allowed to be performed by

qualified personnel. To ensure that the unit remains safe to use and has a long service life, it is imperative

that you observe the maintenance and cleaning intervals.

Only operate the CoolTherm correctly within the stipulated ratings and with approved equipment.

CoolTherm 01_998_330_0_k page / Seite 4/83

CoolTherm

Manual / Bedienungsanleitung

During all work on and with the unit, observe:

• The related applicable regulations (e. g. VDE regulations or other applicable national regulations)

• The applicable accident prevention instructions (BGV)

• The applicable rules

• The applicable laws on the protection of the environment

Only operate the unit if it is in correct working condition. On the occurrence of malfunctions or faults, you must shut down the unit immediately and inform the responsible member of staff in the operating organisation. You are only allowed to use the unit again after its correct function has been reestablished.

Caution hot surface Faulty fans, power supplies, control circuit boards can run hot.

Prior to starting work, let these cool down.

2. Operating conditions

The unit is a server cabinet cooling device and is only used for the

removal of heat from server cabinets to protect temperature sensitive components. The cooling system in the cabinet is thermally

Ambient temperature: 10°C / 50°F to 35°C / 95°F

Absolute humidity in the installation location: 8 g H

Water temperature, feed: 12°C / 53°F (other temperatures upon request)

Water temperature, return: 18°C / 64.4°F (other temperatures upon request)

Correct use

independent of the room air. Total heat load of the installed equipment is taken out of the room using the chilled water circuit. Note: Under special conditions a very small amount can dissipate to the room (approx. 05, kW)

For reliable function of the CoolTherm, chilled water must be available in the correct amount, and at the correct temperature and pressure. Observe water quality as per VGB-R 455 P. (see Appendix)

(other temperatures upon request)

Temperatures on use of RMS with temperature-dependent alarm: 20°C / 68°F to 25°C / 77°F

O/ kg air maximum

2

CoolTherm 01_998_330_0_k page / Seite 5/83

CoolTherm

Manual / Bedienungsanleitung

Temperature spread, water: 6K

Use of anti-freeze in the chilled water: upon request

Water connection: from below

Condensed water connection: from below

Nominal voltage at cooling capacity: 12 KW, 17 KW, 25 KW 200V to 264V / 50Hz / 60 Hz

Max. operating pressure: 10 bar / 145 PSI

3. Description

3.1 General function

CoolTherm complies with the conditions of EN 60950 The modular design facilitates the installation of all 19“ equipment of varying depth. Heat produced by installed equipment (e. g. servers) is reliably removed using the cold water system integrated into the server cabinet. The cooling system is inherently safe because water cannot reach the server area. The cooling system comprises a high-performance air/water heat exchanger, fans with fan control unit (fan-speed according to heat load) for the ducted supply of air and cold water connection. The air circuit is closed such that no heat (thermal load) is emitted to the environment.

Attention! CoolTherm only works if cold server feed air

and heated server outlet air are fully separated.

Height units not in use have to be sealed using blanking panels.

Top view

WARM

Air duct

Luftkanal

Server

KALT

Air separation

COLD

WARM

Lufttrennung

CoolTherm 01_998_330_0_k page / Seite 6/83

CoolTherm

Manual / Bedienungsanleitung

3.2 Principle of operation of cooling

Air that has been heated by the servers (to 35°C/95°F, e.g.) is fed to a specially designed air/water heat exchanger using high-performance fans. There the air is cooled to approx. 20-25°C / 68-77°F, and fed to the front of the server. The server fans can draw in the air and feed it over internal equipment.

Chilled water is provided by a chiller made available on site. Below the heat exchanger there is a condensed water tray with a 5/8“ outlet.

When the cooling system fails to prevent a build up of heat in the cabinet. In this case the heat load is dissipated into the room where the unit is located.

When the CoolTherm fans fail

to prevent a build up of heat in the housing. In this case the heat is emitted into the room where the unit is installed as a thermal load.

If the rear door (with fans) is opened, the front door

must be opened.

, the unit doors have to be opened

, the unit doors are to be opened

CoolTherm 01_998_330_0_k page / Seite 7/83

CoolTherm

Manual / Bedienungsanleitung

If the front door is opened, it is not necessary to open the rear door.

3.3 Dimensions

1 Multifunction door (rear) with embedded redundant fans, air duct and sealing 2 Heat exchanger with condensate tray, condensate connection 3 recirculation deflector 4 Side panel 5 Glass door (front)

Bottom plate with cutouts

4

front

23

1

3

1

45

rear

2

CoolTherm 01_998_330_0_k page / Seite 8/83

CoolTherm

Manual / Bedienungsanleitung

legend:

1 sealed cable cutout 2 cutout for chilled water pipes 3 cable entry (network cable) 4 cutouts for condensed water

rear side

standard dimension

front side

cover dimensions with cable entries 12- 17 - 25 / 35 kW plan view)

Cable and pipe openings are to be sealed air-tight on completion of work.

CoolTherm 01_998_330_0_k page / Seite 9/83

CoolTherm

Manual / Bedienungsanleitung

Dimensions bottom plate / cut outs / connections 12- 17 - 25 / 35 kW

CoolTherm 01_998_330_0_k page / Seite 10/83

CoolTherm

Manual / Bedienungsanleitung

Useable space for server

CoolTherm 01_998_330_0_k page / Seite 11/83

CoolTherm

Manual / Bedienungsanleitung

3.4 Technical data

Housing material: Aluminium sheet, sheet steel, galvanized

and coated

Operating Temperature range: 10 °C to 35 °C / 50°F to 95°F

abs. atmospheric humidity: 8g / kg maximum

Air outlet to heat exchanger: 20 to 25°C / 68 to 77°F according to ASHRAE

Temperature difference across server: approx. 15K

Noise level: 55 dB(A) sound pressure at a distance

of 1 m

Useful load 1.000 kg / 2204 pounds

Chilled water

Effective cooling capacity depending on type: 12 KW to 25 / 35)* KW

Feed temperature: 12°C / 54°F (other temp. upon consultation)

Return temperature: 18°C / 64°F

)*21°C/ 69,8°F at 35 kW (Blade application) (other temp. upon consultation)

Max. operating pressure: 10 bar / 145 PSI

Feed/return supply connection: 1“

CoolTherm 01_998_330_0_k page / Seite 12/83

CoolTherm

Manual / Bedienungsanleitung

Data overview CoolTherm Table A

General data

Spread chilled water: 12 / 18°C (nominal conditions) Maximum operation pressure heat exchanger: 10 bar Air temperature to server: 22°C Maximum absolute humidity on site : 8g/kg Connection heat exchanger: 1“ female threat Colour code for standard colours: x = 8 = RAL 7021 (black grey) Connection condensate tray: 5/8“ condensed water hose connection x = 1 = RAL 7035 (light grey)

Electrical connection data

Item

no.

08.006.001.x

08.006.002.x

08.006.003.x

08.006.006.x

08.006.007.x

08.006.008.x 12 38 2200 700 1300

08.006.012.x

08.006.013.x

08.006.014.x

08.006.022.x

08.006.023.x

08.006.024.x

08.006.033.x

08.006.034.x

08.006.043.x

Effective

cooling

capacity U (useable)

Height

Width

Depth [D]

Useable depth

[d]

Weight

Recirculated

kW mm mm mm mm kg m³/h

12 29 12 33 12 38

12 29 12 33

17 35 17 40 17 44

25(35) 37

25 (35) 42

25 (35) 37

1800 700 1200 2000 700 1200 740 290 2.000 200 to 264 / 7 / 1000 2200 700 1200

1800 700 1300 2000 700 1300 840 295 2.000 200 to 264 / 7 / 1000

2000 800 1200 2200 800 1200 740 310 3.100 200 to 264 / 8 / 1400 2400 800 1200

2000 800 1300 2200 800 1300 840 320 3.100 200 to 264 / 8 / 1400 2400 800 1300

2200 800 1200 740 340 4.500 200 to 264 / 8 / 1800 2400 800 1200

2200 800 1300 840 350 4.500 200 to 264 / 8 / 1800

voltage / currency / power

air flow rate in

cabinet

08.006.044.x 25 (35) 42 2400 800 1300

V / A / Watt

frequency

Hz

50 / 60

Fuse / supply

A / mm²

16 / 3 x 2,5

CoolTherm 01_998_330_0_k page / Seite 13/83

CoolTherm

Manual / Bedienungsanleitung

Data overview CoolTherm Table B (Hydraulic Data)

effective

cooling

capacity

kw

12

17

25

35

total cooling

capacity (at normal operation)

kw kw l m³/h bar K K

12,5 13,0 5,9 1,79 0,41 6 6,2

17,8 18,4 7,9 2,55 0,62 6 6,2

26 26,8 9,9 3,72 0,58 6 6,2

36 36,8 9,9 3,72 0,58 8,1 8,51

total cooling

capacity

(at full speed

operation /

emergency)

water

content

water flow

rate

pressure

loss

cabinet

water

temperature

rise (at normal operation)

water

temperature

rise

(at full speed

operation /

emergency)

CoolTherm 01_998_330_0_k page / Seite 14/83

CoolTherm

Manual / Bedienungsanleitung

3.5 Control

The server cabinet temperature is controlled by the fan control board VR 2.2. A air temperature sensor continuously measures the temperature of the server cabinet (server feed air). The air circulation flow rate is controlled by the fan speed according to the current thermal load. At temperatures lower than 20°C / 68°F fans rotate at 75% of maximum speed. Between 20°C / 68°F and 23°C / 73,4°F speed increases proportional to the temperature up to 96% of maximum speed. The failure of the temperature sensor set the fans to maximum speed.

PDU – Box*)

*) by 12 kW rack under the roof

CoolTherm front view

The water flow rate is controlled by a three-way valve depending on thermal load. (distribution flow control) Before all a undertemperature at part load operation can be avoided. By using a blind sieve in the bypass a hydraulic volume control could be achieved (two way valve function).

In case of failure the valve opens and the all the chilled water flows through the heat exchanger.

From 16°C / 60,8°F to 19°C / 66,2°F the three-way valve controls the water flow rate from 0% to 100% of the nominal flow rate.

Air temperature sensor

Status LED:

Green System OK

Yellow fault controller cooling/fans or rear door open

Red fault controller cooling/fans and rear door open

Fuses for each fan and switching power supply

Space for optional equipment

Service socket and fuse

CoolTherm 01_998_330_0_k page / Seite 15/83

CoolTherm

Manual / Bedienungsanleitung

valve actuator

Three way valve

Bypass (flow direction)

CoolTherm Heat Exchanger (rear view)

The programming of the control is factory preset and password protected.

The failure of the temperature sensor or one of the fans set an alarm using a potential free contact. Following alarms can be also provided to potential free contacts:

- sensor error

- fan malfunction

- high temperature (two levels)

The fans are automatically shut down if the server cabinet rear door is opened.

Start at 20°C

fan control characteristic (factory setting)

CoolTherm 01_998_330_0_k page / Seite 16/83

CoolTherm

Manual / Bedienungsanleitung

Start at 16°C

air inlet temperature

three- way valve control characteristic (factory setting)

4. Storage and transportation

• Cover open pallets with tarpaulins and protect the components from soiling (e. g. sand, rain, dust, etc.).

• Keep storage temperatures between –30 °C and +50 °C / -22°F and 104°F.

• The heat exchanger must be completely drained (to prevent the risk of

frost damage)

• When stored for more than 1 year, check the the fan bearings prior to

installation. (⇒ Turn fans by hand.)

• CoolTherm can be transported using a forklift truck or crane. For transport using a crane, straps must be used. The CoolTherm weighs, depending on the version, up to 340 kg / 749 lbs. (net weight)

• Avoid twisting the housing or other damage.

• Use suitable tools during installation, e. g. approved scaffolding.

• Prior to lifting the CoolTherm using a crane or forklift truck, close all doors.

• Do not stand under suspended loads.

• Hooks attached to the load must be be of appropriate tensile strength.

• CoolTherm must not be lifted at an angle using a crane.

• All packaging is to be removed prior to commissioning CoolTherm.

CoolTherm 01_998_330_0_k page / Seite 17/83

CoolTherm

Manual / Bedienungsanleitung

Safety instruction for crane transport:

> 680 kg > 1000 kg

< 680 kg

Eyebolts M 12 according to standard DIN 580!

CoolTherm 01_998_330_0_k page / Seite 18/83

CoolTherm

Manual / Bedienungsanleitung

5. Installation and commissioning

5.1 Preparation for installation

Before you install the unit, you have to check a number of points. These checks are for safety and to ensure the correct function of the

server cabinet. Take care when performing these checks to ensure that the unit functions correctly.

Check unit for transport damage:

The packaging for the CoolTherm must not show signs of transport damage on delivery. Any damage on the packaging indicates possible transport damage. In the worst case this damage may result in the loss of function.

Returning the unit in case of transport damage:

If the unit is not returned in the original packaging, the packaging used for return must comply with following criteria: There must be at least 30 mm space between the unit and the packaging.

As an installation aid, there is a checklist in the appendix, that you should complete prior to commissioning.

The commissioning also can be carried out by approved staff. Use the commissioning certificate included in the appendix for this purpose.

CoolTherm must be installed on a level surface.

For this reason, check the horizontal alignment with a spirit level prior to starting installation.

Note that the floor must be able to support a rack load of

1.500 kg/m² (with installed equipment per CoolTherm).

there is no packaging material or other equipment that could hinder

To achieve good air circulation, ensure that

• in the area of the equipment

• in the area of the heat exchanger

• in the air inlet

• in the air outlet

or prevent air circulation

CoolTherm 01_998_330_0_k page / Seite 19/83

CoolTherm

Manual / Bedienungsanleitung

5.2 Positioning the units

After positioning, the feet on the CoolTherm are to be set such that the cabinet is vertical. When positioned the doors must close easily. The feet are adjusted using a spanner (spanner width 65mm). Watch the length of the thread.

As an option it is possible to connect the cabinets together. There for remove the plugs from the side panels and connect with hex screw, item no. 4000 1411.

Distance

W700 D1200

W800 D1200

W800 D1300

Adjustable Feet

Remove recirculation air duct transport lock

After positioning remove the transport lock screws at the sides of the recirculation air duct. The recirculation air duct can be pulled out to remove items which possibly had felt into the head exchanger tray.

feets

B1

(mm)

600 1114

700 1114

700 1214

T1

(mm)

CoolTherm 01_998_330_0_k page / Seite 20/83

CoolTherm

Manual / Bedienungsanleitung

Remove both screws

5.3 Chilled water connection

The heat exchanger can be pulled out for servicing Chilled water pipes should be connected so that the heat exchanger can be pulled out when the connection is undone. If the heat exchanger is connected to the chilled water network using threaded fittings, the pipe fitting must be supported on tightening. Prior to commissioning the server cabinet, the pipe connections should be checked for leaks.

Preparing heat exchanger for initial commissioning:

- Check the mechanical installation and the supply pipe connection.

Remove this air duct for bleeding, draining the

CoolTherm 01_998_330_0_k page / Seite 21/83

heat exchanger and checking the valve

CoolTherm

Manual / Bedienungsanleitung

- Carefully bleed heat exchanger when filling the system.

- Open the air bleed valve until the coming out water is bubble free.

- Close this valve after bleeding carefully.

Air bleed valve

Chilled water return

Drain valve

Chilled water feed

- If necessary, re-tighten threaded fittings.

- After an extended period without use, and particularly in case of risk of

frost, the heat exchanger and the supply pipe are to be completely drained.

- Drain completely by blowing out with compressed air and remove all bleed and drain plugs.

CoolTherm 01_998_330_0_k page / Seite 22/83

CoolTherm

Manual / Bedienungsanleitung

Heat exchanger connection

Chilled water feed

The chilled water pipes should be insulated against condensation and losses using a waterproof insulation.

Insulation thickness : „F“ (9 - 12mm) λ = 0,037 W/mK (10°C)

Chilled water return

5.4 Condensed water connection

If the CoolTherm is operated below dew point, condensed water may occur. As standard there is a water connection, 5/8“ diameter, in the condensed water tray for drainage.

Preparations for connecting:

Step 1): Remove air duct

Condensat connection

Step 2.) Remove cap

Step 3.) Connect the nipple with a drain hose

”

Step 4.) Move and click the nipple with hose into the hole

CoolTherm 01_998_330_0_k page / Seite 23/83

CoolTherm

Manual / Bedienungsanleitung

When connecting to the condensed water tray, ensure that the condensed water pipe is connected to a self-filling siphon with return protection and that the condensed water pipe has a drop. The height of the siphon must be designed for an under or overpressure of 800 Pa so that air is not drawn in or blown out of the waste pipe.

5.5 Electrical connection

The wiring diagram is enclosed in the unit.

Make sure the server cabinet is electrically disconnected during installation. Prior to beginning installation work shut down the server cabinet, disconnect it and secure it against unauthorised switch on.

As soon as all preparations for installation have been made, you can start electrical installation.

The unit should only be connected by appropriately qualified personnel (electrician). The personnel must ensure that the server cabinet is electrically isolated for the duration of the connection work and is secured against unauthorised switch on.

Check whether voltage and frequency at installation site as well as fuse ratings match the specifications on the rating plate.

Power supply connection is done by a terminal block.

To connect the unit to the power supply:

• Correctly shut down the server cabinet.

• See the wiring diagram for information on the connections to be made.

• Connect the supply cable in the computer room.

• Check the secure connection of the earth wire.

To put the server cabinet correctly back in operation: Switch on the fuse protected power supply. The unit's fans will rotate clockwise. The status indicator on the RMS viewer will go green if running.

CoolTherm 01_998_330_0_k page / Seite 24/83

CoolTherm

Manual / Bedienungsanleitung

5.6 Sealing of cabinet

The air tightness of the housing corresponds to RAL 652

To ensure the optimal cooling function the cabinet must be sealed:

- Pipe entries should be cut into the foam and properly closed with a extra foam if required.

- Cable entries should be closed with the pivoting plate and foamed material

- Air flows on the warm and cold sides of the cabinet must be separated from each other

5.7 Automatic door opening

gas pressure springs

Upper cable entry (standard)

upper magnet

retaining plate

Cover CoolTherm with automatic door opening

Function

Front and rear door are kept closed with two electromagnets.

The door will be pushed off smoothly by a gas pressure spring, if the power supply of the electromagnets breaks.

The electric door opening can prevent damages through overtemperature in the rack as well as occurring humidity.

If the doors are opened the thermal load can disappear to the room. There is no overheating of the servers.

The suck in of air with water droplets can also be prevented (Door opening due to humidity alarm).

When the rear door is opened, the fans will be shut down.

CoolTherm 01_998_330_0_k page / Seite 25/83