Emerson Liebert XDCF User manual

Emerson Liebert XDCF User manual
Precision Cooling
For Business-Critical Continuity™
Liebert® XDP™ with Liebert® iCOM® Control
User Manual–50-60 Hz; 160kW Nominal Capacity
GENERAL SAFETY GUIDELINES
! WARNING
Risk of electric shock. Can cause injury or death.
Disconnect local and remote power supplies before working within.
Before proceeding with installation of the XDP, read all instructions, verify that all the parts
are included and check the nameplate to be sure the XDP voltage matches the available
utility power.
Follow all applicable codes.
! WARNING
Risk of unit falling over. Can cause death, injury or property damage. The XDP is top-heavy.
Use extreme caution and care when moving and installing this unit.
NOTE
This document is intended to 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.
NOTE
Risk of piping and component rupture. May cause injury or equipment damage.
Do not close service valves without following recommended procedures for repair, maintenance
and replacement of components. Closing service valves may isolate liquid refrigerant, causing
high pressure and rupture of piping. Install pressure relief valves in field piping that may
become isolated by service valves.
Figure i
Model number nomenclature
Example: XDP160RA– –3
XD
P
160
Pumping
unit
Liebert
X-treme heat
Density system
R
A
Pump
Redundancy
160kW
nominal
capacity
–
–
Place holder
A = 460V-3ph-60Hz
(voltage-phase-frequency)
C = 208V-3ph-60Hz
M = 380/415-3ph-50Hz
3
Revision
level
Place holder
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1
1.3.2
1.3.3
Handling With Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal from Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removing Piano Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1
Mechanical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1
2.2
Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.1
2.2.2
2.3
Positioning the Liebert XDP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting High-Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Extra Low Voltage (ELV) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Sensor Installation—Proper Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.1
DIP Switch and Jumper Settings for Remote Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4
Field Connections—Optional for All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.0
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1
European Union Fluorinated Greenhouse Gas Requirements . . . . . . . . . . . . . . . . . . . . . . . 14
3.2
Connection Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.1
Recommended Pipe Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3
Liebert XDP Interconnection with Liebert XD Cooling Modules . . . . . . . . . . . . . . . . . . . . . 15
3.4
Piping Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.1
3.5
Piping Details—Shutoff/Isolation Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.1
3.5.2
3.5.3
3.6
Bypass Flow Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piping Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Piping Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Evacuation and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling the Pumped Circuit—R-134a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6.1
Calculating Refrigerant Charge—Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7
Checklist for Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.0
LIEBERT ICOM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1
Liebert iCOM Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2
Navigating Through the Liebert iCOM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.1
4.2.2
Accessing Menus and Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Entering the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3
Changing Operational Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4
Changing Liebert iCOM’s Display Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
i
4.5
Graphical Data Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6
Liebert iCOM Service Menu Icons and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.0
START THE LIEBERT XDP WITH ICOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1
Checklist for Liebert XDP Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2
Starting the Liebert XDP with iCOM Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.0
OPERATIONAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1
Using Liebert iCOM User Menu Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1.1
6.1.2
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Set Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.0
ALARM DESCRIPTIONS AND SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.1
Alarm Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2
Display Lamp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3
System Shutdown Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.0
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.0
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1
Fluorinated Greenhouse Gas Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.0
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ii
FIGURES
Figure i
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover
Liebert XDP components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tie-down brackets and lag bolts to be removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removing pallet boards for piano jack insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Liebert XDP strapped to piano jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove remaining lag bolts from one runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove runner from pallet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sliding pallet from under Liebert XDP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Piping access points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front view of Liebert XDP and electrical enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical enclosure knockout location for hazardous voltage wiring . . . . . . . . . . . . . . . . . . . . . . . 8
High voltage connections—60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High voltage connections—50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical enclosure knockout locations for Extra Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Suggested remote sensor placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting the remote temperature/humidity sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIP switch and jumper settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Liebert XDP extra low voltage field connections points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piping arrangement for Liebert XDP/Liebert XDC used with Liebert XD cooling modules . . . . 15
Bypass flow controller details, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bypass flow controller arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bypass flow controller piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General piping details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Liebert iCOM display components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Liebert iCOM default home screen, simple display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Entering the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Liebert iCOM User Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Display setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Liebert iCOM Service Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System R-134a liquid level at 160kW load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Set Alarms submenu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Home screen, graphical display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
iii
TABLES
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Liebert XDP dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit piping outlet connection sizes, inches, OD Cu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Supply, return pipe sizes for refrigerant loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bypass flow controllers for a Liebert XDP-based system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System R-134a charge for a Liebert XDP with any model Liebert XDH/Liebert
XDO/Liebert XDV/Liebert XDCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System refrigerant charge for the supply and return mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
R-134a refrigerant charge for hard-piped connector lines to and from any model
Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
R-134a refrigerant charge for Flex Pipe connector lines to and from any model
Liebert XDO/Liebert XDH/Liebert XDV/Liebert XDCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calculating refrigerant charge—example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Worksheet to calculate refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Keyboard icons and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Liebert XDP pump light indicator—208V and 400V units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting the XDP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Liebert XDP160 specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
iv
Product Description
1.0
PRODUCT DESCRIPTION
1.1
General Product Information
1.1.1
Product/System Description
Liebert’s XDP refrigerant distribution unit is an interface between the building chilled water system
and the cooling modules in the Liebert XD system. It is designed to circulate and control refrigerant
to the cooling modules that are in the room with heat-producing equipment. The Liebert XDP consists
of a cabinet that includes a heat exchanger, circulating pump(s), control valve, receiver, controls,
valves and piping.
The Liebert XDP monitors room conditions and prevents coil condensation by maintaining the refrigerant being pumped to the cooling modules at a temperature above the room’s dew point.
All functions, such as switching pumps (if applicable), controlling refrigerant temperature, etc., are
automatic.
The Liebert XDP’s minimum recommended operating load is 30% of system nominal capacity. For
example, a Liebert XDP160 60Hz system’s minimum load would be 32 kW. Loading below this value
can unfavorably affect system operation. Consult factory for any loading below this recommendation.
The Liebert XDP is rated for 160kW (546,000 BTU/H) of cooling.
Figure 1
Liebert XDP components
Liebert XDP Unit
Liebert XD Cooling Modules
Control Valve
Chilled Water
Heat Exchanger
1.2
Receiver Pumps
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.
1
Product Description
1.3
Equipment Handling
! WARNING
Risk of unit falling over. Can cause injury or death.
The Liebert XDP is top-heavy. Use extreme caution and care when moving and installing this
unit.
NOTE
Personnel should be properly trained and certified to move and rig equipment.
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. In
either case, do NOT press on the top edges of the packaging.
• If using a forklift, make sure the forks (if adjustable) are spread to the widest allowable distance
to still 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 by-standing personnel are to be no closer than 20 feet (6m)
from the lift point of the unit.
NOTICE
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. 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 from Skid
Liebert recommends using dual hand trucks or a similar method to remove the Liebert XDP from the
skid. This is to ensure that both ends of the unit are firmly secure and to provide a good means of unit
mobility.
1. Always keep the unit upright, indoors and protected from possible damage.
2. Remove the exterior packaging. Leave the plastic bag over the Liebert XDP until the unit has
been moved to its final location. The bag will protect the painted panels against scuffing.
3. Remove two (2) corner tie-down brackets from one side of the unit, on a non-runner notch side of
the pallet. Remove eight (8) lag bolts from two (2) end deck boards on the same end where the
tie-down brackets were removed (refer to Figure 2).
Figure 2
Tie-down brackets and lag bolts to be removed
Remove these 4 lag bolts
to free deck boards
Remove these 2
tie-down brackets
Remove these 4 lag bolts
to free deck boards
2
Product Description
4. Remove the two (2) end deck boards from one end of the pallet and the attached, notched section
of the center runners (refer to Figure 3).
Figure 3
Removing pallet boards for piano jack insertion
Remove two deck boards ...
... and center runner sections
from one end of pallet.
5. Place a piano jack with its forks snugly against the bottom of the unit and strap the Liebert XDP
securely to the jack (refer to Figure 4).
NOTE
Place a mover’s blanket or other cushioning material between the piano jack and the
unit’s side panels.
Figure 4
Liebert XDP strapped to piano jack
Piano jack
Strap secures the
Liebert XDP to the jack
Place cushioning material
between the forks and the Liebert
XDP to protect unit’s finish
(cushion not shown for clarity)
Piano jack’s forks should be
snug against the Liebert XDP
6. Repeat Steps 2, 4 and 5 for the opposite side of the unit. When these steps have been completed,
the Liebert XDP will be supported by two piano jacks, one on either side.
7. Remove all of the remaining lag bolts from one (1) of the pallet’s outside runners (see Figure 5).
Figure 5
Remove remaining lag bolts from one runner
Remaining 6 lag bolts
to remove
3
Product Description
8. Remove the runner from which all lag bolts have been removed (refer to Figure 6).
Figure 6
Remove runner from pallet
Slide this runner away
from the Liebert XDP
9. Using the pallet jacks, raise the secured unit to the highest point that the piano jacks will allow.
Once the unit has been raised, slide the remainder of the pallet from under the Liebert XDP (see
Figure 7). Lower the Liebert XDP so that its base is approximately 1" (25.4mm) off the ground.
Figure 7
Sliding pallet from under Liebert XDP
Slide the remaining part of the pallet
from under the Liebert XDP so the unit
may be moved on the piano jacks.
1.3.3
Removing Piano Jacks
Once the unit has been moved to the installation location, Emerson Network Power recommends the
following method to remove the piano jacks:
1.
2.
3.
4.
Lower the unit as far as the piano jacks will allow.
Undo all strapping holding the piano jacks to the unit.
Remove all cushioning material used to protect the unit from the straps and the piano jacks.
Use a pry bar or other lever to lift one side of the Liebert XDP enough to allow removal of the
piano jack.
5. Repeat Step 4 to remove the piano jack on the opposite side.
6. Remove the plastic bag.
4
Installation
2.0
INSTALLATION
2.1
Mechanical Considerations
2.1.1
Positioning the Liebert XDP
Install the Liebert XDP according to the site specific documentation and secure the unit to the floor.
The Liebert XDP can be installed near a wall or another Liebert XDP. However, there must be at
least 3 feet (92cm) clearance in front of the Liebert XDP as service access for components in the unit.
For additional technical information, refer to the System Design and Configuration Document for the
Liebert XD™ System, SL-16655. The document is available in electronic format at Liebert’s Web site,
www.liebert.com, as well as from your local Emerson Network Power representative.
Figure 8
Dimensions
A
Overall
B
Overall
C
Side Panel
78"
(1981mm)
E
D
5"
(127mm)
1" (25mm)
2-3/8"
(60mm)
11"
(279mm)
Floor Cutout Dimensions
D
Unit Base
E
Unit Base
Unit Dimensional Data
Table 1
The shaded area indicates
a recommended clearance
of 36" (914mm) for component
access.
DPN001598
Pg. 2, Rev. 1
Liebert XDP dimensions
Dimensional Data, inches (mm)
Shipping Weight, lb (kg)
Model
50/60Hz
A
B*
C
D
E
Domestic
Export
XDP160
38 (965)
34 (864)
33-1/8 (841)
33 (838)
36 (914)
990 (449)
1067 (484)
* The dimension does not include the bezel of the disconnect switch.
5
Installation
Figure 9
Piping access points
To first cooling module or
bypass flow controller **
Install replaceable filter dryer assembly
in liquid supply line B.
Close this
valve during
normal
operation
Orientation
defined by
installer. *
A - Return from cooling modules
B - Supply to cooling modules
17-1/4"
(438mm)
Liebert recommends field-installation
of shutoff valves at these points to permit
isolating the Liebert XDP for maintenance.
16-1/8" (409.6mm)
10" (254mm)
Dimensions are approximate and
subject to change without notice
19" (483mm)
* 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 XDP and
the first bypass flow controller or the
first cooling module.
D - Chilled water return
to chilled water source
Table 2
C - Chilled water supply
from chilled water source
DPN001598
Pg. 3, Rev 0
Unit piping outlet connection sizes, inches, OD Cu
Model
Pipe Connection Point
50/60 Hz
A
B
C
D
XDP160
2-1/8
1-1/8
2-5/8
2-5/8
6
Installation
2.2
Electrical Considerations
Make sure the actual supply voltage and frequency correspond to the voltage and frequency indicated
on the Liebert XDP’s rating plate. The unit must be installed in accordance with national wiring regulations.
Connect cables for high voltage supply to the electrical box in the Liebert XDP according to Figure 12
and make sure that the phases are correctly connected.
! WARNING
Risk of electric shock. Can cause injury or death.
Disconnect all local and remote electric power before working within the unit.
! CAUTION
Risk of sharp edges and heavy parts. Can cause injury or equipment damage.
Wear gloves to prevent injury to hands.
Damage to wiring or components may 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.
2.2.1
Connecting High-Voltage Cables
1. Turn the Liebert XDP’s 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 XDP and electrical enclosure
Disconnect
Switch
iCOM
User
Interface
Enclosure Cover
Latch
Hazardous Voltage
Enclosure Cover
Front of Liebert XDP
DPN001598
7
Installation
2. Determine which knockouts in the electrical enclosure will be used and remove them (see
Figure 11).
Figure 11
Electrical enclosure knockout location for hazardous voltage wiring
XDP Input Power
Knockout
Enclosure cover
not shown for clarity
3. Route the input hazardous voltage electrical power wiring through the top left knockout (see
Figure 11) to the disconnect switch L1, L2 and L3 (see Figures 12 and 13). Observe proper
phasing.
4. Connect the ground wire to the ground lug (see Figures 12 and 13), which is in the middle left of
the enclosure.
Figure 12 High voltage connections—60Hz
Transformer 2
(supplied on 460V
units only)
Customer Power
Connection
Ground Lug
Power Block
Disconnect Switch
Transformer 6
Pump Fuse
Blocks
Fuse Blocks
Transformer 1
Pump Contactors
8
Installation
Figure 13 High voltage connections—50Hz
Customer Power
Connection
Ground Lug
Transformer 2
Disconnect Switch
Power Block
Pump Circuit
Breakers
Transformer 6
Busbar
Fuse Blocks
Transformer 1
Pump Contactors
2.2.2
Extra Low Voltage (ELV) Connections
Extra Low Voltage 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 (refer to Figure 14).
2. Route low voltage electrical connections through the appropriate knockouts as indicated below.
Figure 14 Electrical enclosure knockout locations for Extra Low Voltage
Knockouts for low voltage
field wiring connections
(remote sensors, optional
condensate detection,
remote alarms, etc.)
Enclosure Cover Not Shown for Clarity
9
Installation
2.3
Remote Sensor Installation—Proper Placement
Placement of the two remote temperature/humidity sensors is critical to effective cooling of the conditioned space.
The remote sensors must be installed in areas where conditions are representative of the space conditioned by the Liebert XDP. Emerson recommends installing the sensors in different areas near the
cooling modules served by the Liebert XDP. If the return air side of the primary air mover, such as a
Liebert DS, represents the conditions where the Liebert XD cooling modules are located, one sensor
could be placed there. Emerson suggests placing the other sensor on the wall opposite the heat load
area (see Figure 15 for guidance).
Do not install the sensors where ambient air might cause false readings, for example, near unsealed
doors or windows, or areas with stagnant air.
1. Unpack the two remote temperature/humidity sensors and cables.
One sensor is labeled Sensor A and the other Sensor B. The sensor cables are interchangeable;
each bears labels indicating Sensor End and Unit End.
2. Connect the Sensor End of one of the supplied sensor cables to P66 on Sensor A (see Figure 16).
3. Connect the Unit End of the sensor cable to P67 on the Liebert iCOM input/output board inside
the Liebert XDP. Secure the ring terminal on the cable shield to the electric box adjacent to P67
(see Figure 16).
4. Connect the Sensor End of the second sensor cable to P66 on Sensor B (see Figure 16).
5. Connect the Unit End of the cable to P67 on the Liebert iCOM display (see Figure 16). Secure the
ring terminal on the cable shield to the grounding screw adjacent to P67.
Figure 15 Suggested remote sensor placement
10
Installation
Figure 16 Connecting the remote temperature/humidity sensors
Ribbon
Cables
Liebert IntelliSlot
Power Supply
P2
Liebert
IntelliSlot 1
P1
Two Liebert IntelliSlots
for optional OCWEB-LBDS Card
or OC485-LBDS Card
Liebert
IntelliSlot 2
P65
Red Crossover
Ethernet Cable
Cable A
77 78
Cable B
Not
Used
See Note 1
P61
P18
CAN
Cable
P63
E5
P64
P65
P32
P40
P66 P67
P3
P12
P11
P8
P7 P13
P33
P34
Liebert iCOM Microprocessor
and I/O Board
Crossover
Coupler
SW2
P39
P53
P52
P51
E1 E2 E3 E4
P43
TB1
OFF O
N
38
6
5
P54
P22P
4
3
P35
P36
See Table for
Plug Assignments
2
1
P68
P4
P64 P66 P67
P4
E1
P43
P44
Control
Fuse Board
P24
Unit Display
(Rear View)
P41
T1 Unit Control
T6 Isolation
Transformer
Transformer
24VAC Nominal
P66 P67
NOTE 1
Cables A and B are provided with each unit—Only one cable is used.
One is for communication using the Liebert IntelliSlot cards;
the other is for communication that does not use a Liebert IntelliSlot card.
LIEBERT INTELLISLOT-BASED COMMUNICATION—Cable A is
connected at the factory to P65 on the I/O board and to P65
on the Liebert IntelliSlot power supply.
COMMUNICATION NOT BASED ON LIEBERT INTELLISLOT— Cable B
is connected at the factory to terminals 77 and 78 but must be exchanged
with Cable A at P65 on the I/O board.
11
Remote T/H
Sensor A
P66 P67
Remote T/H
Sensor B
192252
Rev. 01
Installation
2.3.1
DIP Switch and Jumper Settings for Remote Sensors
The Liebert XDP is shipped with jumpers and DIP switch settings for normal operation. See
Figure 17.
Figure 17 DIP switch and jumper settings
MICROPROCESSOR AND I/O BOARD
OFF ON
Jumpers
1
3
4
2
5
6
7
8
P78
3
OFF ON
1
2
3
4
5
6
7
8
9
10
SW2
Jumpers
P78
3
P68
2
1
4
3
6
5
SW3
DIP switches
(numerals show
switch location;
example shows
all switches Off)
SW1
6
7
8
OFF
1
2
3
4
OFF
5
ON
2
ON
5
REMOTE SENSOR “B”
1
REMOTE SENSOR “A”
6
7
8
1
2
2
3
4
DIP switches
(numerals show
switch location;
example shows
switches 2,5,6,7
and 8 Off)
UNIT DISPLAY
1
SW1
P3
1 2 3
Jumpers for Sensor A
and Sensor B
12
DIP switches
(numerals show
switch location;
example shows
switches 2 and 5 On)
Installation
2.4
Field Connections—Optional for All Units
• Connect field wiring from the optional Liebert XD cooling module condensation detection circuit
to terminal strip locations COMM. (24) and H2O (51).
• Connect optional field wiring from remote devices to remote alarm device, common alarm outputs,
site monitor and remote shutdown, if applicable. See terminal strip descriptions in Figure 18.
Figure 18 Liebert XDP extra low voltage field connections points
TO REMOTE T/H SENSOR B
COMMON WARNING OUTPUT
TO REMOTE T/H SENSOR A
FOR CONTACTS INDICATING AN
ALARM CONDITION.
(MAX) 1.0AMP @ 24V
K11
K11
K11NO K11COM K11NC
TO REMOTE ALARM
CIRCUIT BY OTHERS
INPUT: REMOTE ALARM DEVICE
FOR INDICATION OF ALARM, WIRE
N.O. CONTACTS FROM REMOTE
ALARM DEVICE AS SHOWN.
24
50
N.O. CONTACT BY OTHERS
UNIT DISPLAY (REAR VIEW)
TS-3
TS-4
K11COM
K11NO
K11NCL
FACTORY-WIRED
TEMPERATURE
SENSOR(S)
INPUT: CONDENSATION
DETECTION
ALARM WHEN CLOSED.
24
51
N.O. CONTACTS REQUIRED
INPUT: FAN BREAKER STATUS
ALARM WHEN CLOSED.
54
24
Powered 24 VAC (24)
RAD (50)
H2O (51)
FAN (54)
K3COM
K3NO
K3NCL
37
38
N.O. CONTACTS REQUIRED
COMMON ALARM OUTPUT
FOR CONTACTS INDICATING AN
ALARM CONDITION.
(MAX) 1.0AMP @ 24V
K3NO
K3
K3
K3COM K3NC
TO REMOTE ALARM
CIRCUIT BY OTHERS
INPUT: REMOTE SHUTDOWN
NOTES:
1.
CONTROL WIRING MUST BE CLASS 2 AND INSTALLED IN
ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (NEC).
2.
REQUIRES SHIELDED CABLE.
FOR SHUTDOWN OF CONTROL
CIRCUIT, REMOVE JUMPER
BETWEEN TERMINALS 37 & 38
AND REPLACE WITH N.C. CONTACT
37
38
N.C. CONTACTS BY OTHERS
LIEBERT SITE MONITOR
FOR DIGITAL COMMUNICATIONS
WITH LIEBERT SITE MONITORS
ONLY. CONNECT 2 WIRE TWISTED
PAIR TO 77 & 78. ALSO SEE SITE
MONITOR INSTALLATION MANUAL.
(-)
77
BK
REFER TO SL-16655, LIEBERT XD SYSTEM DESIGN MANUAL FOR ADDITIONAL DETAIL.
13
78
(+)
R or W
DPN001598
Pg. 6 Rev. 0
Piping
3.0
PIPING
3.1
European Union Fluorinated Greenhouse Gas Requirements
Stationary air conditioning, refrigeration, heat pump equipment and stationary fire protection systems in the European Community market and operating with fluorinated greenhouse gases (f-gas),
such as R407C, R134a, R410A, must comply with the F-Gas Regulation: (EC) No. 842/2006 (F-gas).
The regulation prohibits, among other actions, venting fluorinated greenhouse gases to the atmosphere.
The F-Gas Regulation requires operators to use all measures that are technically feasible and do not
entail disproportionate cost to prevent leakage of these gases, to test for leakage regularly and to
recover f-gas before disposing of equipment, as well as during service and maintenance.
Refer to the full regulation for additional details.
3.2
Connection Sizes
The copper pipe connections on the Liebert XDP are:
3.2.1
Building Chilled Water Supply
2-5/8" OD
Building Chilled Water Return
2-5/8" OD
Refrigerant Supply
1-1/8" OD
Refrigerant Return
2-1/8" OD
Recommended Pipe Size
Connect the main pipes between the Liebert XDP and the Liebert XD cooling modules according to
site specific documentation and the configuration guide for the Liebert XD system.
Elbows and restrictions must be minimized to get good fluid flow.
Table 3
Supply, return pipe sizes for refrigerant loop
Pipe Function
Size / Equivalent Pipe Length
Liebert XDP supply line, from Liebert XDP supply
to farthest Liebert XD cooling module
1-1/8" OD for lengths up to 60 feet
1-3/8" OD for lengths over 60 but less than 175 feet
Liebert XDP return line, from farthest Liebert XD cooling 2-1/8" OD for lengths up to 60 feet
module to Liebert XDP return
2-5/8" OD for lengths over 60 but less than 175 feet
From any model Liebert XDO/Liebert XDH supply
to supply line of Liebert XDP
1/2" OD for lengths up to 10 feet
From any model Liebert XDO/Liebert XDH return
to return line of Liebert XDP
7/8" OD for lengths up to 10 feet
From any model Liebert XDV/Liebert XDCF supply
to supply line of Liebert XDP
1/2" OD for lengths up to 10 feet
From any model Liebert XDV/Liebert XDCF return
to return line of Liebert XDP
5/8" OD for lengths up to 10 feet
14
7/8" OD for lengths over 10 but less than 25 feet
1-1/8" OD for lengths over 10 but less than 25 feet
5/8" OD for lengths over 10 but less than 35 feet
7/8" OD for lengths over 10 but less than 35 feet
Piping
3.3
Liebert XDP Interconnection with Liebert XD Cooling Modules
All piping must be ASTM (American Society for Testing and Materials) Type L copper pipe.
The Liebert XDP may be connected to Liebert XD cooling modules with either Liebert’s XD prefabricated piping assembly or with rigid, off-the-shelf piping. In either setup, piping for the Liebert XD
system is arranged in a manner similar to piping for a chilled water system. Liebert XD cooling modules are connected in parallel between main return and supply pipes going to and from the Liebert
XDP/Liebert XDC. For piping details, refer to Liebert’s XD System Design Manual, SL-16655. The
guidelines provided for pipe size must be strictly followed. Failure to size the main lines
and connection lines adequately may result in reduced cooling capacity. The critical aspects
of pipe sizing are related to refrigerant volume and pressure drop. Both must be minimized.
Figure 19 Piping arrangement for Liebert XDP/Liebert XDC used with Liebert XD cooling modules
Liebert XD
Cooling
Modules
Liebert XDP/
Liebert XDC
3.4
Liebert XD
Cooling
Modules
Liebert XD
Cooling
Modules
Liebert XD
Cooling
Modules
Liebert XD
Cooling
Modules
All supply and
return mains
must be level with
or above the top
of all Liebert
XD modules
SLOPE—The main supply and return lines to and from the Liebert XDP/Liebert XDC
must be sloped downward toward the Liebert XDP/Liebert XDC at a rate of 1-2" per
20 feet (25.4-51mm per 6m) of pipe run.
Piping Installation Method
The assembly and connection means used for piping in the Liebert XD system are similar to that of
conventional refrigeration systems. All piping should be installed with high-temperature brazed
joints. Brazing material may be used, but soft soldering is not recommended. If brazing material is
used, the lines being brazed MUST be filled with flowing dry nitrogen during brazing to prevent
excessive oxidation and scale formation inside the piping. Prevailing good refrigeration practices
should be employed for piping supports, leak testing, dehydration and charging.
Insulate all piping lines to prevent condensation in applications where the dew point approaches the
R-134a refrigerant temperature.
3.4.1
Bypass Flow Controller
Some installations require one or more bypass flow controller(s) to ensure that the Liebert XDP’s
pumps operate within the optimum range. These devices are added to the field piping and simulate
the flow of additional cooling modules.
Each bypass flow controller should be installed with one shutoff valve to allow the controller to be disabled when cooling modules are added to a Liebert XD system.
If bypass flow controllers are required, they should be connected between the main supply and the
main return lines of the field piping. The connection points to the main supply and return lines should
be in a convenient and accessible location between the Liebert XDP and the first Liebert XD module
in the circuit. See Figures 20 and 21 for piping details of the bypass flow controller.
Refer to Table 4 to determine the number of bypass flow controllers needed, based on the total nominal cooling capacity of the cooling modules in each Liebert XD system.
Table 4
Bypass flow controllers for a Liebert XDP-based system
Cooling Modules Cumulative Model Size, kW
32 to 63
64 to 95
96 to 127
128 to 160
Required Number
of Bypass Flow Controllers
Liebert XDP
3
2
1
0
15
Piping
Figure 20 Bypass flow controller details, dimensions
4”
(102mm)
7/8”
(22mm) ID
Figure 21 Bypass flow controller arrangement
7/8" Refrigerant Grade
Full Port Ball Valve
Field-Supplied and Field-Installed
Flow Direction
Bypass Flow Controller
(Field-Installed)
Supply
Main
Figure 22 Bypass flow controller piping
Liebert XD
Cooling
Module #1
Bypass Flow
Controllers
Coolant
Supply
Coolant
Return
Filter Dryer
Assembly
Liebert XDP
or
Liebert XDC
16
Liebert XD
Cooling
Module #2
Return
Main
Piping
3.5
Piping Details—Shutoff/Isolation Valves
To allow for maintenance of the Liebert XDP, isolation valves must be installed on the chilled water
circuit (see Figure 23).
Figure 23 General piping details
Return
Supply
Return
Liebert recommends field-installation
of shutoff valves at these points
to permit isolating the Liebert XDP
for maintenance.
Supply
Liebert
XDP A
Liebert
XDP B
Floor
Isolation
valves
Isolation
valves
Building Chilled Water Supply
Building Chilled Water Return
3.5.1
Piping Installation Method
All piping should be installed with high temperature brazed joints. Prevailing good refrigeration practices should be employed for piping supports, leak testing, dehydration and charging. Emerson Network Power highly recommends venting the pressure relief of the Liebert XDP (located at the top of
the receiver) outside of the conditioned space where it is open to the atmosphere.
3.5.2
Piping Mains
All refrigeration piping mains, both supply and return, should be installed with a downward pitch
toward the Liebert XDP of 1-2" for every 20 feet (25.4-51mm per 6m) of pipe run.
Install a 20-40 mesh strainer on the chilled water supply to the Liebert XDP. The strainer is needed
to prevent particles in the chilled water from entering the heat exchanger of the Liebert XDP.
3.5.3
Evacuation and Leak Check
1. Open all service valves, including those located outside of the Liebert XDP.
2. Place 150 psig (1034kPa; 10.34 bars) of dry nitrogen with a tracer of R-134a in the system.
NOTICE
3.
4.
5.
6.
Risk of overpressurization. Can cause equipment damage.
Do not exceed 150 psig (1034 kPa; 10.34 bars) in the R-134a circuit.
Check the system for leaks with a suitable leak finder
After completion of the leak testing, release the test pressure (per local code) and connect to
vacuum pump(s) at the Schrader valves.
After four hours of pulling a deep vacuum, check the vacuum level and if it has not changed,
break the vacuum with dry nitrogen.
Pull a second vacuum to 250 microns or less. Recheck the vacuum level after 2 hours.
17
Piping
3.6
Filling the Pumped Circuit—R-134a
Using a refrigerant pump or cylinder heater pads will speed the charging process.
1. Connect a charging manifold to the service port of the receiver outlet valve or to the suction and
discharge side of the pump.
2. Purge the hoses.
3. Calculate the amount of R-134a refrigerant needed to charge the system, using the values in
Tables 5, 6, 7 and 8; for assistance, refer to 3.6.1 - Calculating Refrigerant Charge—
Example. The section includes a worksheet to calculate system refrigerant charge requirements.
4. Weigh in the calculated charge.
5. After adding the calculated charge, allow the system to sit 15 to 30 minutes to reach equilibrium.
Observe the refrigerant level through the sight glasses of the receiver. The level should be above
the second sight glass at a minimum when the Liebert XDP is off.
6. If the refrigerant level is improper, the charge must be adjusted.
If the level is too high or too low, recalculate the required charge and reduce or increase the
amount as needed to reach the proper level.
NOTE
All lengths in Tables 5, 6 and 7 are actual pipe lengths, not equivalent pipe lengths.
NOTE
System refrigerant volume calculations derived from Tables 5, 6, 7 and 8 are based on a fully
loaded system. Additional charge may be required for lightly loaded systems.
Table 5
System R-134a charge for a Liebert XDP with any model Liebert XDH/Liebert
XDO/Liebert XDV/Liebert XDCF
Refrigerant Charge,
lb (kg)
Per Liebert XD Unit
(Excludes Connector Lines
to and from Liebert XD Cooling Module)
157 lb. (71.2kg)
Liebert XDP
3.55 lb. (1.61kg)
Liebert XDO
2.32 lb. (1.05kg)
Liebert XDV
5.32 lb. (2.41kg)
Liebert XDH
1.41 lb. (0.64kg)
Liebert XDCF
Table 6
System refrigerant charge for the supply and return mains
Refrigerant Charge,
lb/foot (kg/m)
Supply/Return Main Length and Diameter
0.45 (0.67)
Main supply actual length per 1-1/8" OD copper tubing
0.68 (1.01)
Main supply actual length per 1-3/8" OD copper tubing
0.28 (0.42)
Main return actual length per 2-1/8" OD copper tubing
0.43 (0.64)
Main return actual length per 2-5/8" OD copper tubing
18
Piping
Before beginning, verify that the system is not equipped with pre-charged flex pipe.
Table 7
R-134a refrigerant charge for hard-piped connector lines to and from any model
Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF
Refrigerant Charge,
lb/foot (kg/m)
Hard-Piped Connector Length and Diameter
0.08 (0.12)
1/2" OD Liebert XDO/Liebert XDH/Liebert XDV/Liebert XDCF supply connector actual
length
0.13 (0.19)
5/8" OD copper tubing Liebert XDV/Liebert XDCF supply connector actual length
0.26 (0.39)
7/8" OD Liebert XDO/Liebert XDH supply connector actual length
0.02 (0.03)
5/8" OD copper tubing Liebert XDV/Liebert XDCF return connector actual length
0.04 (0.06)
7/8" OD copper tubing Liebert XDV/Liebert XDCF return connector actual length
0.04 (0.06)
7/8" OD copper tubing Liebert XDH/Liebert XDO return connector actual length
0.07 (0.1)
1-1/8" OD copper tubing Liebert XDH/Liebert XDO return connector actual length
Table 8
R-134a refrigerant charge for Flex Pipe connector lines to and from any model
Liebert XDO/Liebert XDH/Liebert XDV/Liebert XDCF
Refrigerant Charge, lb. (kg)
Metal Flex Pipe Connector Length
Supply Line Diameter 1/2"
0.3 lb. (0.14)
4 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
0.5 lb. (0.23)
6 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
0.7 lb. (0.32)
8 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
0.8 lb. (0.36)
10 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
Return Line Diameter 5/8"
0.01 lb. (0.01)
4 ft. Flex Pipe existing Liebert XDV systems
0.02 lb. (0.01)
6 ft. Flex Pipe existing Liebert XDV systems
0.03 lb. (0.01)
8 ft. Flex Pipe existing Liebert XDV systems
0.03 lb. (0.01)
10 ft. Flex Pipe existing Liebert XDV systems
Return Line Diameter 1"
0.13 lb. (0.06)
4 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
0.2 lb. (0.09)
6 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
0.27 lb. (0.12)
8 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
0.33 lb. (0.15)
10 ft. Flex Pipe Liebert XDH/Liebert XDO/Liebert XDV/Liebert XDCF supply
19
Piping
3.6.1
Calculating Refrigerant Charge—Example
Using Tables 5, 6, 7 and 8, calculate the refrigerant charge of the individual sections of your Liebert
XD system. Add the calculated charge amounts to determine the amount of R-134a refrigerant
required for one system combining a Liebert XDP with Liebert XD cooling modules (Liebert XDCF,
Liebert XDH, Liebert XDO and Liebert XDV). The example below combines one Liebert XDP with 20
Liebert XDV8 cooling modules.
Table 9
Calculating refrigerant charge—example
Number of Units
or Piping Length,
feet
Pounds Per
Component
1
157
157
Liebert XDV8 Cooling Modules
20
2.32
46.4
Supply Main, 1-1/8"
100
0.45
45
Return Main, 2-1/8"
100
0.28
28
Liebert XDV 1/2" supply Liebert XD Flex Pipes
20
0.8
16
Liebert XDV 5/8" return Liebert XD Flex Pipes
20
0.03
Components
Liebert XDP
0.6
Total
Table 10
Number of Units
or Piping Length
Pounds Per
Component
Total
Checklist for Proper Installation
___ 1.
___ 2.
___ 3.
___ 4.
___ 5.
___ 6.
___ 7.
___ 8.
___ 9.
___ 10.
293
Worksheet to calculate refrigerant charge
Components
3.7
Total, lb.
Unpack and check received material.
Position the Liebert XDP and secure it to the floor.
Wire high voltage connections.
Wire low voltage connections.
Connect the building chilled water piping to the Liebert XDP.
Connect the Liebert XD cooling module piping to the Liebert XDP with slope.
Check the system for leaks.
Hold a vacuum on the system.
Charge the system with refrigerant.
Make sure that all piping has proper insulation.
20
Total
Liebert iCOM Control
4.0
LIEBERT ICOM CONTROL
4.1
Liebert iCOM Components and Functions
The Liebert iCOM controller layout is shown in Figure 24; the keyboard functions are defined in
Table 11.
Figure 24 Liebert iCOM display components
Liquid Crystal
Display screen
LED Status Indicators
(top LED is red or flashing
red; bottom LED is green
or amber)
Keypad
LEDs
(see Table 11 for
meanings)
Alarm Key
Up Arrow Key
?
On/Off Key
Help Key
Left Arrow Key
Enter Key
ESC
Escape Key
Down Arrow Key
21
Right Arrow Key
Liebert iCOM Control
Table 11
Icon
?
ESC
Keyboard icons and functions
Key Name
Function
On/Off Key
Controls the operational state of the cooling unit.
Alarm Key
Silences an alarm.
Help Key
Accesses integrated Help menus.
ESCape Key
Returns to the previous display view.
Enter Key
Confirms all selections and selects icons or text.
Increase Key
(Up Arrow)
Moves upward in a menu or increases the value of a selected parameter.
Decrease Key
(Down Arrow)
Moves downward in a menu or reduces the value of a selected parameter.
Left and Right
Arrow Keys
Navigates through text and sections of the display.
Blinking Red—Active, unacknowledged alarm exists
Upper LED
Solid Red—Active, acknowledged alarm exists
Amber—Power is available to the unit; unit is NOT operating
Lower LED
Green—Unit is operating with no alarms
22
Liebert iCOM Control
4.2
Navigating Through the Liebert iCOM Display
Liebert iCOM displays icons and text for monitoring and controlling your Liebert cooling unit. The
Liebert iCOM’s home screen may be either simple, graphical (with bar graphs), simple comma (with
decimal) or graphical comma (as in Figure 32). The default for the Liebert XDP is simple display (see
Figure 25).
Figure 25 Liebert iCOM default home screen, simple display
UNIT 1
Cooling
Status
Air Temperature
Room
Temperature
(average of
Sensor A and
Sensor B)
72
°F
Pump
Cooling
Maintenance
Pump
Status
On
Light
7/7/2008 09 :18:07
UNIT ON
7/3/2008 11 :50 (01) RST General Alarm
7/3/2008 11 :48 (01) ALM LOSS OF FLOW PUMP 1
Alarm
History
Navigation
Prompts
4.2.1
08/2008
Next
Scheduled
Maintenance
for next/previous unit
ESC
for previous screen
for menu
for system view
? for help
Accessing Menus and Settings
Viewing Data
No password is required to view data or settings.
To view data:
1.
2.
3.
4.
From the home screen, press the Enter key to view the User Menu (see Figure 27).
Press Enter again to highlight the first icon.
Use the keyboard’s arrow keys to move to the icon for the data you wish to view.
Once that icon is highlighted, press Enter again to open that menu.
• If a password is required, see 4.2.2 - Entering the Password.
• If a menu has more than one screen, the Liebert iCOM display will have text at the top similar to this: (page 1 of 2).
5. Press Enter to select the first line of data.
6. Use the Up and Down arrow keys to scroll to the desired data point.
7. Press ESC to move back to higher level menus.
23
Liebert iCOM Control
4.2.2
Entering the Password
Most settings in the Liebert iCOM are protected by a factory-set password, 1490. To enter the password:
1.
2.
3.
4.
5.
6.
7.
From the home screen, press the Enter key to view the User Menu (see Figure 27).
Press Enter again to highlight the first icon.
Use the keyboard’s arrow keys to move to the icon for the data you wish to change.
Once that icon is highlighted, press Enter again to open that menu.
Press Enter to highlight the Password line.
With the Password line highlighted, press Enter to highlight the first digit in the password
Enter the password, 1490.
Use the Up and Down arrow keys to select a numeral for the first digit of the password.
Move to the next digit of the password with the Right arrow key.
Select the numerals for all four digits with the same process.
8. After all four digits of the password have been entered, press the Enter key.
NOTE
Do not press the ESC key or the Liebert iCOM will move to the previous screen and the
password must be re-entered before changes may be made.
Figure 26 Entering the password
After highlighting the Password command line, press
Enter again to highlight the first digit. Use the Up and
Down arrow keys to change the first digit. Move to the
next digit in the Password with the right arrow.
Password command line—highlight
by pressing Enter
UNIT 01
SETPOINTS
U101 PASSWORD (Actual Level 0)
U102 Min Room Temperature Setpoint
U103
U104
U105
U106
U107
U108
U109
U110
U111
????
68.0°F
to select parameter
to confirm
for next/previous unit
then
to change parameter
24
Liebert iCOM Control
4.3
Changing Operational Settings
Changes to the Liebert XDP’s operation settings in the Set Alarms and Setpoints menus require a
password.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
From the home screen, press the Enter key to view the User Menu (see Figure 27).
Press Enter again to highlight the first icon.
Use the keyboard’s arrow keys to move to the icon for the data you wish to change.
Once that icon is highlighted, press Enter again to open that menu.
• If a password is required, see 4.2.2 - Entering the Password.
After entering the password, use the Up and Down arrow keys to scroll to and highlight the
operational setting to be changed.
Press Enter to highlight the values for that setting.
Use the Up and Down arrow keys to change the value.
Press Enter to accept the change. (The value will no longer be highlighted.)
Press ESC to deselect the operational setting. (The setting will no longer be highlighted.)
Press ESC again to move to previous screens.
Figure 27 Liebert iCOM User Menu icons
°C / °F
% RH
SET
Setpoints
View and change
operational
setpoints
EVENT
LOG
Spare Parts List
Contains spare
parts available on
site
Event Log
Lists last 400
events and
alarms
View Only
!
ACTIVE
ALARMS
Sensor Data
Shows readings
of sensors; View
Only
Active Alarms
Lists all current
alarms; View Only
SET
ALARMS
Graphic Data Record
Displays average room
air temperature and
supply refrigerant
temperature graphs;
Data is View Only;
Display scale is
adjustable
View Network
Shows status of
all connected
units; View Only
Set Alarms
Allows user to
change settings for
alarms
12
9
SET
3
1234h
6
Display Setup
Total Run Hours
Change settings Records the run time of
for display:
all components and
language, time, allows setting of limits on
simple or graphic
run time; View Only
display
Service
Contacts
Contains key
contact information
for service
NOTE
Menu shows icons only; text is explanatory and does not appear on the Liebert iCOM display.
25
Liebert iCOM Control
4.4
Changing Liebert iCOM’s Display Settings
No password is required to change the way Liebert iCOM displays data. The Display Setup controls
how the unit shows data, such as temperature, date and time.
To change the display settings:
1.
2.
3.
4.
5.
6.
7.
8.
9.
From the home screen, press the Enter key to view the User Menu (see Figure 27).
Press Enter again to highlight the first icon.
Use the keyboard’s arrow keys to move to the Display Setup icon.
Once that icon is highlighted, press Enter again to open that menu.
Press the Enter key to select the first setting.
Either change that setting or navigate to another setting with the Up and Down arrow keys.
Once the desired setting is highlighted, press the Enter key to access that parameter’s display
setting options.
Use the Up and Down arrow keys to make changes.
Press the Enter key to accept the changes.
Press the ESC key twice to return to Liebert iCOM’s user menu.
Figure 28 Display setup screen
DISPLAY SETUP
Highlight the
setting to be
changed by
pressing Enter.
U401
U402
U403
U404
U405
U406
U407
U408
U409
U410
U411
SYSTEM
for next/previous unit
then
to change parameter
4.5
ENGLISH (US)
7/7/2008
09:24:17
°C
50
Off/ 50
5 min
Simple
ACT+SET
Normal
mm/dd/yyyy
Language
Date
Time
Temperature Indication
Display Contrast
Buzzer Frequency
Backlite Off after
Screen
Display Shows
Display Colors
Date Format
to select parameter
to confirm
Graphical Data Record
The Graphical Data Record charts the average temperature from Sensors A and B and the supply
refrigerant temperature.
The temperature scales can be changed to expand or compress the data.
The time scale also can be altered to any of several selectable values.
NOTE
Changing the time scale eliminates all previous graphical data and the unit will begin
recording new data.
26
Liebert iCOM Control
4.6
Liebert iCOM Service Menu Icons and Legend
Figure 29 Liebert iCOM Service Menu icons
°C / °F
% RH
SET
SET
ALARMS
WELLNESS
Setpoints
View and change
operational
setpoints
Unit Diary
Shows all program
changes and
maintenance
performed,
Maintenance/
Wellness
Settings
Shows all maintenance records, calculates next
maintenance date
NETWORK
Network
Setup or alter
network setting.
Diagnostics/
Set Alarms
Service Mode
Change settings for
Enter Diagnostics/
alarms
Service Mode for
troubleshooting
and repair
SET
UP
+/Sensor
Calibration/Setup
Setup and calibrate
sensors for site
SERVICE
Options Setup
Enter specific
settings for various
options
Service Contacts
Contains key
contact information
for service
NOTE
Menu shows icons only; text is explanatory and does not appear on the Liebert iCOM display.
27
Start the Liebert XDP with iCOM
5.0
START THE LIEBERT XDP WITH ICOM
5.1
Checklist for Liebert XDP Startup
NOTICE
Risk of piping and component rupture. May 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.
NOTE
Before any action that could cause a disturbance in the Liebert 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
1. Verify that bypass flow controllers were installed (if applicable), see Table 4.
2. Check all isolation ball valves in the Liebert XDP and Liebert XD cooling module and verify that
all are open.
3. Check rotation of the Liebert XDP’s pumps.
On 460V units only—Hold the rotation device provided against the pump housing at the inspection screw prior to energizing the pumps. Counterclockwise indicates proper rotation; clockwise
indicates incorrect rotation.
On 208V and 400V units only, view the LED indicator on the pump. Green indicates proper
rotation; Green and Red indicate incorrect rotation.
Table 12
Liebert XDP pump light indicator—208V and 400V units
Indicator Lights
Description
Green
Red
Off
Off
The electricity supply has been switched Off or the pump has
been cut out by the thermal switch.
On
Off
The electricity supply has been switched On. Normal operation.
On
On
The electricity supply has been switched On. The direction of
rotation is wrong.
4. Check rotation of fans on Liebert XD cooling module units.
5. Verify that air is being discharged into the cold aisle.
6. Confirm that the total calculated refrigerant R-134a amount has been properly charged into the
system (see 3.6 - Filling the Pumped Circuit—R-134a).
7. Confirm that the remote temperature/humidity sensors provided have been installed in optimal
locations (see 2.3 - Remote Sensor Installation—Proper Placement)
The Liebert XDP system is now ready to be turned ON.
28
Start the Liebert XDP with iCOM
5.2
Starting the Liebert XDP with iCOM Controller
The Liebert XDP is started, stopped and controlled through the Liebert iCOM controller. Figure 24
shows the Liebert iCOM keypad.
1. Turn On the fans of all the connected Liebert XD cooling modules.
2. Switch on power to the Liebert XDP with the main disconnect switch on the upper left corner of
the unit.
3. Turn the On Liebert iCOM controller by pressing it’s I/O switch (see (Figure 24).
Allow the system to attempt to start for at least 5 minutes.
If the Liebert XDP pump cannot maintain flow and continues to switch over due to starting difficulties, refer to 8.0 - Troubleshooting. After remedying the problem, proceed to Step 4.
4. If constant flow is established, wait until the Liebert XDP has been operating for 10-15 minutes,
then verify that the refrigerant level in the receiver sight glass is between the second and third
level (see Figure 30). Add or remove charge, if necessary.
5. Check pressure differential functionality:
The Liebert XDP system should be On. If it is Off:
a. Turn On the Liebert XD cooling module fans
b. Turn the Liebert XDP On with its I/O button.
If there is no “Loss of Flow” alarm present—This suggests that there is flow. Test the
pressure differential by closing the ball valve on either the suction line or discharge line to
stop the flow.
This should prompt an alarm for “loss of flow on P1.” This alarm confirms that the switch has
opened on low pressure (below 6 psi; 41kPa; 0.41 bars).
If there is a “Loss of Flow” alarm present—This suggests that there is no flow. Verify
that this is correctly annunciated by looking at the sight glass in the receiver. If a true no-flow
condition exists, the level will not move.
However, if there is flow, but the differential reading is faulty, the level will slowly
drop, indicating flow, while the loss of flow alarm is annunciated.
Check the pressure differential physically by making sure that the electrical connections are
properly connected. Then check the pressure differential electrically by making sure that the
unit has 24VAC across it.
Figure 30 System R-134a liquid level at 160kW load
Operation above sight glass #3 can
make the system operate erratically
and reduce cooling capacity. Reduce
charge to recommended level.
Recommended operating level
Acceptable operating level
Operation below sight glass #1 may
cause loss of flow or cooling. Add
charge to reach recommended level.
Sight Glasses 1, 2 & 3
29
For lightly loaded systems,
the recommended operating
level is sight glass #2.
Operational Settings
6.0
OPERATIONAL SETTINGS
The Liebert XDP with Liebert iCOM controller is configured at the factory with default values for various settings. Some may be altered for specific sites.
6.1
Using Liebert iCOM User Menu Icons
The User Menu includes the following submenus, some of which may only be viewed and some which
have settings that may be changed (see Figure 27 to view the icons on the User Menu).
Setpoints
The Liebert XDP’s setpoints menu may be used to change one setting, the Min Room Temperature
Setpoint.
The setting is intended to keep the room temperature above the setpoint. Without a proper setpoint,
the Liebert XDP can lower the room temperature too much, depending on the room dew point and
load. This setpoint will reduce the cooling to keep the room temperature above this desired temperature.
NOTE
This is not a true room temperature setpoint. The Liebert XDP has no heaters; it will try to cool
as much as possible. If it is able to cool the room to this setpoint, it will reduce its cooling action
to try to keep the room temperature at or above this setpoint.
The default setting is 72°F (22°C). The range is 50-80°F (10-27°C).
For optimal cooling performance, the minimum temperature setpoint should be at least 1-2° below the
expected temperature at the remote sensors, which may affect placement of the remote sensors. If the
minimum temperature setpoint is set above the typical remote temperature sensor reading, it will
reduce the Liebert XD cooling output and, in extreme cases, cause erratic Liebert XD performance.
6.1.1
Spare Parts List
Spare parts available on site for the Liebert XDP may be recorded in this submenu. To enter the spare
parts, navigate to the submenu and use the UP and Down arrow keys to select letters or numbers
identifying the parts.
6.1.2
Set Alarms
The Set Alarms submenu permits setting alarms that are activated when conditions exceed settings
for high and low room temperature, high room dew point, high refrigerant temperature and high
chilled water temperature (see Figure 31). This submenu is accessible only by entering the password
(see 4.2.2 - Entering the Password).
High Room Air Temperature—This is the setpoint at which the HIGH TEMP SENSOR A and
HIGH TEMP SENSOR B alarms will be activated. The range for the high room air temperature
alarms is 33.8-95°F (1-35°C); the default is 80°F (26.6°C).
Low Room Air Temperature—This is the setpoint at which the LOW TEMP SENSOR A and LOW
TEMP SENSOR B alarms will be activated. The range for the low room air temperature alarms is
33.8-95°F (1-35°C); the default is 55°F (12.7°C).
High Room Dew Point—This is the setpoint at which the HIGH DEW POINT alarm will be activated. The range for the high room dew point setpoint is 33.8-95°F (1-35°C); the default is 65°F
(18.3°C).
High Refrigerant Temperature—This is the setpoint at which the HIGH REFRIGERANT TEMPERATURE alarm will be activated. The range for the high refrigerant temperature setpoint is 33.895°F (1-35°C); the default is 80°F (26°C).
High Chilled Water Temperature—This is the setpoint at which the HIGH CHILLED WATER
TEMP alarm will be activated. The range for the high chilled water temperature setpoint is 33.8-95°F
(1-35°C); the default is 60°F (15.5°C).
30
Operational Settings
Figure 31 Set Alarms submenu
SET ALARMS (page 1 of 1)
U201
U202
U203
U204
U205
U206
U207
U208
U209
U210
U211
UNIT 01
PASSWORD (Actual Level 0)
High Room Air Temperature
Low Room Air Temperature
High Room Dewpoint
High Refrigerant Temperature
????
80.0°F
55.0°F
65.0°F
80.0°F
High Chilled Water Temperature
60.0°F
to select parameter
to confirm
for next/previous unit
to change parameter
then
Display Setup
The appearance of the Liebert iCOM display may be changed through the Display Setup submenu of
the User Menu. The submenu permits choosing the language used by the display, the time format,
whether data is shown in the simple (default) or graphical version. Changing these settings does not
require entering a password. Figure 28 shows the choices available.
The user can check the status of the temperature of the room at each sensor, the dew point at each
sensor, the refrigerant setpoint, cooling/pump operation and maintenance schedule. This requires
using the graphical display setting, found in Display Setup option in the User Menu (see Figure 32).
Figure 32 Home screen, graphical display
Temperature
Sensor B
Dew Point
Sensor A
Refrigerant Setpoint
Dew Point
Sensor B
Temperature
Sensor A
UNIT 1
A
49.3°F
B 49.5°F
70.5
°F
1
SET
53.4°F
Actual
Refrigerant
Temperature
72.5 53.1
°F
°F
ACT
32%
Chilled water
valve open
position
percentage
Next Scheduled
Maintenance
11/2008
7/7/2008 09 :18:07
UNIT ON
7/3/2008 11 :50 (01) RST General Alarm
7/3/2008 11 :48 (01) ALM LOSS OF FLOW PUMP 1
for system view
? for help
for next/previous unit
ESC
for previous screen
for menu
31
See 4.4 - Changing
Liebert iCOM’s
Display Settings to
change the home
screen to the
graphical display.
Alarm Descriptions and Solutions
7.0
ALARM DESCRIPTIONS AND SOLUTIONS
7.1
Alarm Descriptions
NOTE
Alarms must be acknowledged before they can be reset. To acknowledge or silence an alarm,
press the ALARM key one time. This will silence the alarm; the red LED will remain
illuminated until the alarm is reset.
• HIGH TEMP SENSOR A—Activated when the remote temperature/humidity sensor designated
as Sensor A detects that the temperature exceeds the setpoint. The alarm will reset itself when
the room temperature drops below the setpoint.
• HIGH TEMP SENSOR B—Activated when the remote temperature/humidity sensor designated
as Sensor B detects that the temperature exceeds the setpoint. The alarm will reset itself when
the room temperature drops below the setpoint.
• LOW TEMP SENSOR A—Activated when the remote temperature/humidity sensor designated
as Sensor A detects that the temperature has dropped below the setpoint. The alarm will reset
itself when the room temperature returns to or exceeds the setpoint.
• LOW TEMP SENSOR B—Activated when the remote temperature/humidity sensor designated
as Sensor B detects that the temperature has dropped below the setpoint. The alarm will reset
itself when the room temperature returns to or exceeds the setpoint.
• HIGH DEW POINT—Activated when the dew point exceeds the setpoint. The alarm will reset
itself when the dew point drops below the setpoint.
• SENSOR A FAILURE—Activated when the control stops receiving a signal from Sensor A. The
alarm will reset itself when the sensor signal is re-established.
• SENSOR B FAILURE—Activated when the control stops receiving a signal from Sensor A. The
alarm will reset itself when the sensor signal is re-established.
• HIGH CW TEMP—Activated when entering chilled water temperature exceeds the setpoint. The
alarm will reset itself when the entering chilled water temperature drops below the setpoint.
• SUPPLY CW SENSOR FAILURE—Activated when the control stops receiving a signal from
the Supply CW Sensor. The alarm will reset itself when the sensor signal is re-established.
• HIGH REFRIGERANT TEMP—Activated when the refrigerant temperature exceeds the setpoint. The alarm will reset itself when the refrigerant temperature drops below the setpoint.
• LOW REFRIGERANT TEMP—Activated when the refrigerant temperature drops below the
higher of the two calculated room dew points. The alarm will reset when the refrigerant temperature returns to a temperature above both of the calculated room dew points.
• SUPPLY REFRIGERANT SENSOR FAULURE—Activated when the control stops receiving a
signal from the Supply Refrigerant Sensor. This alarm will shut down the Liebert XDP. The main
power (disconnect switch) must be turned Off, then back On to clear this alarm.
• LOSS OF FLOW PUMP 1—Activated when Pump 1 is commanded to run and the differential
pressure switch does not sense differential pressure (set at 6 psi; 41kPa; 0.41 bars). After attempting to start Pump 1 three times, the Liebert XDP will automatically switch to the other pump to
establish flow.
• LOSS OF FLOW PUMP 2—Activated when Pump 2 is commanded to run and the differential
pressure switch does not sense differential pressure (set at 6 psi; 41kPa; 0.41 bars). After attempting to start Pump 2 three times, the Liebert XDP will automatically switch to the other pump to
establish flow.
• PUMP SHORT CYCLE—Activated when the Liebert XDP is trying to establish flow (differential pressure) and is unable to do so. The Liebert XDP will attempt three times to establish flow
on a pump before trying the other pump. The control will keep cycling three times on one pump,
then three times on the other pump until it is able to establish flow (differential pressure). If this
cycling occurs for 30 minutes and the Liebert XDP still does not establish flow, a PUMP SHORT
CYCLE alarm will be present. This alarm will shut down the Liebert XDP. Main power (disconnect switch) must be turned Off, then back On to clear this alarm. The cycling time for the PUMP
SHORT CYCLE alarm can be adjusted from the default of 30 minutes; the range is 10 minutes to
60 minutes.
32
Alarm Descriptions and Solutions
• CONTROL VALVE FAILURE—Activated when the chilled water control valve has been commanded by the control to open or close and no change is detected from the valve-position signal.
The control will close the valve and then try to control the control valve based on its travel time.
Main power (disconnect switch) must be turned Off, then back On to clear this alarm.
• CONDENSATION DETECTED (optional)—Activated when water is detected at the Liebert
XD cooling module (24VAC is applied to the condensation input on the control). When this alarm
is active, the control will raise its refrigerant control point by 4°F (2.2°C). Alarm will reset when
the 24VAC signal stops being sent.
• FAN FAILURE (optional)—Activated when a 24VAC signal is applied to the fan failure input
on the control board. This alarm will reset when the 24VAC signal stops being sent.
• CUSTOMER INPUT 1—Activated when a 24VAC signal is applied to the customer alarm input
on the control board. This alarm will reset when the 24VAC signal ends. WATER UNDER
FLOOR and SMOKE DETECTED are possible designations for this alarm; they are set with the
Unit Code.
• SMOKE DETECTED—Activated when sensors detect smoke in the vicinity of the Liebert XDP.
NOTE
This is not a room smoke detector and is not intended to replace external smoke detectors.
• WATER UNDER FLOOR—Activated when sensors detect water under the raised floor under
the Liebert XDP.
• UNIT X DISCONNECTED—Activated when a unit has been disconnected from the network.
• LOSS OF POWER—Activated when the unit is On and operational and 24VAC power to the control is lost. This alarm will be emitted when power is restored to the control. The Liebert XDP will
restart at a user-defined time delay after power is restored. The alarm will reset itself after 30
seconds of run time.
7.2
Display Lamp Indicators
• The Green lamp will be On only when the Liebert XDP is On and running with no alarms.
• The Red lamp will be On if the unit is On and running with an active alarm, or if the unit is shut
down because of a certain alarm.
• The Red lamp will flash while an alarm is being annunciated. The Red lamp will stop flashing and
the beeper in the display will stop beeping when the ALARM SILENCE / ? key is pressed.
• The Amber lamp will be On if the Liebert XDP has been shut down at the I/O switch or if the unit
has been shut down by an alarm condition.
7.3
System Shutdown Causes
Unit Is Off By Refrig Sens Fail
The control has lost its signal from the refrigerant temperature sensor. The control has no way of controlling the refrigerant temperature, so the unit is shut off. Main power (disconnect switch) must be
turned Off, then back On to clear this alarm.
Unit Is Off By High CW Temp
The entering chilled water temperature is too high to keep the refrigerant pump(s) running normally. If
a HIGH CW TEMP alarm occurs and the refrigerant pump loses flow (differential pressure), then the
Liebert XDP will go into a pre-chill mode. The Liebert XDP can attempt to start again only if the entering chilled water temperature drops below the HIGH CW TEMP setpoint.
Unit Is Off By Pump Short Cycle
The control was unable to get a pump started upon startup or after a loss of differential pressure. The
control looks at the SHORT CYCLE time delay. If it cannot establish differential pressure within that
amount of time, the unit is shut down. Main power (disconnect switch) must be turned Off, then back
On to clear this alarm.
Unit Is Off By Low Refrig Temp
The control was unable to raise the refrigerant temperature to the calculated refrigerant temperature
control point. The unit is shut down because if the control cannot raise the refrigerant temperature to
the calculated refrigerant temperature control point, water may condense on the refrigerant piping and
receiving coils. Main power (disconnect switch) must be turned Off, then back On to clear this alarm.
33
Troubleshooting
8.0
TROUBLESHOOTING
Table 13
Troubleshooting the XDP
Symptom
Pump will not energize
Pump will not start or run
Pump will not start
Pump noisy
Liebert XDP (Pump)
suddenly stops
Clogged filter/dryer
and/or impeller
Pipe rattle
Possible Cause
Check or Remedy
No main power
Check L1, L2 and L3 for rated voltage.
Loose electrical connections
Tighten connections.
Overloads tripped
Tripped circuit breaker
Allow pump to cool. Check amp draw.
Check circuit breaker to pump(s).
Incorrect phase wiring
See Table 12.
No chilled water
Check and verify that there is supply chilled water to the
Liebert XDP.
Isolation valve(s) on pump suction
and/or discharge is closed.
Open all isolation valves completely during normal operation.
Supply chilled water is too high
Check and verify that the chilled water temperature setpoint is
at 50°F (10°C) or lower and that there is flow on the chilled
water side.
Liebert XD cooling modules are Off
Check Liebert XD cooling modules to make sure that they are
On prior to starting the Liebert XDP.
Low Refrigerant Temperature
(high dew point)
Check alarm(s) history on Liebert XDP. The Liebert XDP was
operating below the dew point for a significant amount of time.
Check humidity in conditioned space, lower humidity if
necessary to allow Liebert XDP to operate at a lower
temperature. (Disconnect must be switched to Off then back
On to allow Liebert XDP to reset itself).
Pressure switch not making contact
Check both differential pressure settings. If not within 6 psi, ± 1
psi (41kPa, ±7kPa; 0.41 bars, ±0.07bars) then manually
change accordingly.
Not enough charge
See 5.1 - Checklist for Liebert XDP Startup.
Chilled water valve not closing
completely.
Wait at least 10 minutes before calibrating. Access the
Advanced Menu>Factory Settings>Calibrate Actuator.
Contact Liebert Services for assistance, 1-800-543-2778.
Cavitation due to vapor in pump
Check for adequate charge in system, refer to the User's
Manual. 5.1 - Checklist for Liebert XDP Startup
Worn motor bearings
Replace pump
Low Refrigerant Temperature
1. Check humidity of the room along with the location of
remote sensors. Make sure that the sensors are not in a cold
area where there is insufficient air flow for accurate,
representative readings.
2. Chilled Water temperature is too cold.
3. Load is too light.
Low Chilled Water Temperature
Alarm and Loss of Flow Pump X
Alarm
Check supply chilled water temperature.
Supply Refrigerant Sensor Failure
Alarm
Check wiring.
Call service.
Debris or other contaminants in
refrigerant
Loose pipe connections
Replace.
Check pipe connections.
No 24 VAC power to motor
Check linkage for adjustment and be sure that it is tight on the
valve.
Check for 24 VAC between P52-1 and P52-4.
No signal from control
Check 24 VAC at P22-1 (close) or P22-3 (open).
Motor not operating
Unplug P22 from the board. Jumper P22-5 to P52-4 for
grounding, then jumper P22-1 to P52-1 to drive close. Remove
jumper to close and then jumper P22-3 to P52-1 to drive open.
If motor fails to work, replace it.
Motor operates but valve won't open
Chilled water valve not
working
Motor burnout
Main 24 VAC fuse trips
Unstable pump
operation
Check control panel for welded
contactor contacts or welded
overload contacts
Shorts or loose connections
Replace defective components.
Check the wiring connections of the 24 VAC circuit.
Faulty circuit board
Replace the circuit board.
R-134a pump loop overcharged
While pump is running R-134a receiver level must be within
recommended levels (see Figure 30).
34
Maintenance
9.0
MAINTENANCE
The Liebert XD system components require little maintenance when proper fluid levels are maintained and proper startup and operation procedures are followed. The following tasks should be performed at the intervals stated:
1. Clean or replace chilled water strainer annually. Adjust accordingly based on purity of chilled
water.
2. Check sight glass level of receiver every 4-6 weeks. During normal operation, the level should be
at or above the second sight glass.
3. Check system for leaks every 4-6 weeks.
9.1
Fluorinated Greenhouse Gas Requirements
Stationary air conditioning, refrigeration, heat pump equipment and stationary fire protection systems in the European Community market and operating with fluorinated greenhouse gases (f-gas),
such as R407C, R134a, R410A, must comply with the F-Gas Regulation: (EC) No. 842/2006 (F-gas).
The regulation prohibits, among other actions, venting fluorinated greenhouse gases to the atmosphere.
The F-Gas Regulation requires operators to use all measures that are technically feasible and do not
entail disproportionate cost to prevent leakage of these gases, to test for leakage regularly and to
recover f-gas during equipment service and maintenance and before disposing of equipment.
Refer to the full regulation for additional details.
35
Specifications
10.0 SPECIFICATIONS
Table 14
Liebert XDP160 specifications
Models
XDP160RC--3
XDP160RA--3
160kW / 46 Tons, 60Hz
XDP160RM--3
140kW / 40 Tons, 50Hz
Each capacity is based on 45ºF (7ºC) entering water temperature and
140gpm (530lpm) water flow rate. Capacity is reduced when glycol mixtures
are used in place of 100% water.
Cooling Capacity, Nominal
The Liebert XDP’s minimum recommended operating load is 20% of system
nominal capacity. For example, a Liebert XDP160 60Hz system’s minimum
load would be 32 kW. Loading below this value can unfavorably affect system
operation. Consult factory for any loading below this recommendation.
Minimum Load
Electrical Requirements
Input
Full Load Amps
208V/3ph/60Hz
460V/3/ph60Hz
380/415V/3ph/50Hz
4A
2.1A
2.3A
Dimensions, inches (mm)
Height – Unit only
78 (1981)
Height – As shipped
83 (2108)
Width
38 (965)
Depth
34 (864)
Unit only
821 (372)
Weight, lb (kg)
Shipping weight
Domestic: 990 (449); Export: 1067 (484)
Installed, with refrigerant and
chilled water
1038 (471)
Pipe Connections
Refrigerant supply to Liebert XD
cooling module
1-1/8" OD, Cu
Refrigerant return from Liebert XD
cooling module
2-1/8" OD, Cu
Chilled water supply and return
2-5/8" OD, Cu
2-way, 2" nominal; 35 PSIG close off pressure rating; 150 PSIG maximum
allowable pressure
Control valve
Pressure Drop – Chilled Water
Side
20 psig (137kPa, 1.38bar), with 140 gpm (530lpm) water flow rate,
control valve fully open
Temperature Rise – Chilled
Water Side at rated flow, °F (°C)
8.0 (4.4)
6.9 (3.8)
Number of Liebert XD cooling units connected, maximum (minimum)
Liebert XDCF10
16 (4)
Liebert XDH20
8 (2)
Liebert XDH32
5 (1)
Liebert XDV8
20 (4)
Liebert XDV10
16 (4)
Liebert XDO16
10 (2)
Liebert XDO20
8 (2)
Cabinet Exterior Finish
Black, matte finish, heat-fused powder coat
Operating Ambient
Temperature, Maximum, °F (°C)
86 (30)
Agency
Approvals
CSA 60Hz
36
CE 50Hz
Ensuring The High Availability
Of Mission-Critical Data And Applications.
Emerson Network Power, the global leader in enabling business-critical
continuity, ensures network resiliency and adaptability through
a family of technologies—including Liebert power and cooling
technologies—that protect and support business-critical systems.
Liebert solutions employ an adaptive architecture that responds
to changes in criticality, density and capacity. Enterprises benefit
from greater IT system availability, operational flexibility and
reduced capital equipment and operating costs.
Technical Support / Service
Web Site
www.liebert.com
Monitoring
800-222-5877
[email protected]
Outside the US: 614-841-6755
Single-Phase UPS
800-222-5877
[email protected]
Outside the US: 614-841-6755
Three-Phase UPS
800-543-2378
[email protected]
Environmental Systems
800-543-2778
Outside the United States
614-888-0246
Locations
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
Europe
Via Leonardo Da Vinci 8
Zona Industriale Tognana
35028 Piove Di Sacco (PD) Italy
+39 049 9719 111
Fax: +39 049 5841 257
Asia
7/F, Dah Sing Financial Centre
108 Gloucester Road, Wanchai
Hong Kong
852 2572220
Fax: 852 28029250
While every precaution has been taken to ensure the accuracy
and completeness of this literature, Liebert Corporation assumes no
responsibility and disclaims all liability for damages resulting from use of
this information or for any errors or omissions.
© 2008 Liebert Corporation
All rights reserved throughout the world. Specifications subject to change
without notice.
® Liebert is a registered trademark of Liebert Corporation.
All names referred to are trademarks
or registered trademarks of their respective owners.
SL-16644_REV0_12-08
Emerson Network Power.
The global leader in enabling Business-Critical Continuity.
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Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co.
©2008 Emerson Electric Co.
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