Instruction/ maintenance manual of the product XDP160RC Liebert
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Precision Cooling For Business -Critic al C ontinuity™ Li eber t ® XDP ™ w i th L ieb er t ® iC OM ® Co nt r o l Us er Manual–50-60 Hz; 160kW No minal C apac it y.
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i T ABLE OF CONTENTS I MPORT ANT S AFETY I NSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I NSIDE F RONT C OVER 1.0 P RODUCT D ESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 4.3 Navigating Through the Liebert iCOM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.3.1 Accessing Menus and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii FIGURES Figure 1 Model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Figure 2 Liebert XD P components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv Figure 50 Diagnostics/Service Mode screen, page 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 51 Diagnostics/Service Mode screen, page 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 I MPORT A NT S AFETY I NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual co ntains important safe ty instructions that sh ould be followe d during the installa tion and maintenance of the Liebert XDP. Read this ma nual thoroughly before a ttempting to install or operate this unit.
2 Figure 1 Model number nomenclature R Pump Redundancy XD P 160 – * Pumping unit Revision level Liebert X-treme heat Density system 160kW nominal capacity Place holder Example: XDP160RA– –4 A A .
Product De scription 3 1.0 P RODUCT D ESCRIPTION 1.1 General Product Information 1.1.1 Product/System Description Liebert’s XDP refrigerant dist ribution unit is an interface between the b uilding chilled wa ter system and the cooling modules in the Lieb ert XD system.
Product De scription 4 1.3 Equipment Handling 1.3.1 Handling the Liebert XDP While it is on Skid and Packaged • Always keep the unit upright, in doors and protected from damage. • If possible, tran sport the unit using a forklift truc k. Otherwise use a crane with belts or cables.
Product De scription 5 1.3.2 Unp acking the Liebert XDP 1. Remove the exterior stretch wr ap packaging from the unit, exp osing the prot ective corner and side packagin g planks. 2. Remove and se t aside filter dryer k it. 3. Remove the corner and side pack aging planks fr om the unit, exposing the bag over the unit.
Product De scription 6 Figure 4 Use a forklif t to remove the Liebe rt XDP from the skid 1.3.4 Removing the Unit fro m the Skid using Rigging 1. Use the center of gravity indicato rs on the unit to posi tion the s lings. The sl ings must be equ ally spaced on either side of the cent er of gravity ind icator.
Product De scription 7 Figure 5 Removing the unit from the skid using rigging 1.3.5 Moving the Liebert XDP Using Piano Jack s 1. Elevate the Liebert XDP with a lifting mech anism, such as a forklift or rigging. 2. Position one piano jack at each end of the Liebert XDP.
Product De scription 8 Figure 6 Securing the Liebert XDP to piano jacks 1.3.6 Removing the Unit fro m the Piano Jacks 1. Lower the Liebert XDP as far as the piano jacks will allow.
Installation 9 2.0 I NST ALLATION 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.
Installation 10 Figure 8 Piping access point s 2.2 Electrical Considerations Make sure the actual supply voltage and f requenc y 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.
Installation 11 2.2.1 Connecting High-V oltage Cables 1. Turn the Liebert XDP’s disconnect switch to the Off position (see Figure 9 ). Open the front doors and push down on the encl osure cover latch to open the hazardous vo ltage enclosure cover. Figure 9 Front view of Liebert XDP and electrical enc losure 2.
Installation 12 Figure 10 Electrical enclosure knockout location f or hazardous volt age wiring 3. Route the input hazardous voltage electrical po wer wiring through the top left knockout (see Figure 10 ) to the disconnect switch L1, L2 and L3 (see Figures 11 and 12 ).
Installation 13 Figure 12 High voltage con nections—50Hz 2.2.2 Extra Low V oltage (EL V) 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 damag e this equipment (refer to Figure 13 ).
Installation 14 Figure 14 Connecting the remote temperature/humidity sens ors E1 P22 P38 P39 P53 P52 P54 P51 TB1 P63 P18 P1 1 P12 P13 P7 P32 P8 P4 0 P33 P34 P36 P35 E5 E1 E2 E3 E4 OFF ON 2 1 4 3 6 5 S.
Installation 15 2.2.3 DIP Switch and Jumper Settings for Remote Sensors The Liebert XDP is shipped with jumpers and DI P switch settings for normal operation.
Installation 16 2.3 Field Connections—O ptional for All Units • Connect field wi ring from the opti onal Liebert XD cooling module conden sation detection circuit to terminal strip locations COMM.
Installation 17 2.4 Remote Sensor Inst allation—Prop er Placement Placement of the two remote temp erature/humidity sensors is criti cal to effective cooling of the conditioned space. The remote sensors must be inst alled in areas wh ere conditions are representative of the space conditioned by the Liebert XDP.
Piping 18 3.0 P IPING 3.1 European Union Fluorinated Greenhouse Gas Requirement s Stationary air conditioning, refrigerat ion, heat pump equipment and statio nary fire protection systems in the Europe.
Piping 19 3.3 Liebert XDP Interconnection wit h Liebert XD Cooling Modules All piping must be ASTM (American Society fo r Testing and Materials) Type ACR copper pipe. The Liebert XDP may be connected to Liebert XD cooling modules with either Liebert’s XD prefabricated pipin g assembly or with rigi d, off-the-shelf pipin g.
Piping 20 3.4.2 Piping Mains All refrigeration p iping mains conne cted to the Li ebert XD cooling mo dule, both supply and return, should be installed with a downward pitch towa rd the Liebert XDP of 1-2" for every 20 feet (25.4-51mm per 6m) of pipe run.
Piping 21 Figure 21 Bypass f low controller arrangement Figure 22 Bypass f low controller piping 3.5 Piping Details—Shut off/Isolation V alves Isolation valves mus t be installe d on the Liebert XDP’s refrige rant circuit to permit maint enance on the unit (see Figure 23 ).
Piping 22 Figure 23 General piping det ails 3.5.1 Evacuation and Leak Ch eck—R-134a Pumped Circuit 1. Open all service valves, includ ing those outside the Liebert XDP. 2. Attach a jumper hose from one of the Schrader valve fittings on a pump outlet before the check valve to a Schrader valve fittings after the check valve.
Piping 23 3.6 Filling the Pumped Circuit—R-134a Using a refrigerant pump or cylinder heat er pads will speed th e charging process. 1. Connect a chargin g manifold to the service port of the receiver outlet valve or to the suction and discharge side of the pump.
Piping 24 3.6.1 Calculating Refrigerant Charge—Example Using Tables 6 , 7 , 8 and 9 , calculate the refrigerant charge of the indi vidual sections of your Liebert XD system.
Piping 25 3.7 Checklist for Proper Inst allation ___ 1. Unpack and check received material. ___ 2. Position the Liebert XDP and secure it to the floor. ___ 3. Wire high voltage connections. ___ 4. Wire low voltage connections. ___ 5. Connect the building chilled w ater piping to the Lieb ert XDP.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 26 4.0 L IEBERT I COM C ONTROL —F IRMWARE V ERSION XP1.00.010.STD 4.1 Liebert iCOM Component s and Functions The Liebert iCOM controller layout is shown in Figure 24 ; the keyboard functions are defined in Table 12 .
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 27 4.2 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 runn ing with an active alarm, or if the unit is shut down because of an alarm.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 28 4.3 Navigating Through th e Liebert iCOM Display Liebert iCOM displays icons and text for monitori ng and controlling your Liebert cooling unit. The Liebert iCOM’s home screen is shown in Figure 25 .
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 29 4.3.2 Cooling Module Overview The Liebert iCOM will display an overview of al l connected cooling module s. It does not display a system view, which would include uni ts ot her than the cooling modules.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 30 4.3.3 Entering the Password Most settings in the Liebert iCOM are protected by a factory-set password, 1490. To enter the password: 1. From the home screen, press the Enter key to view the User Me nu (see Figure 29 ).
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 31 4.4 Changing Liebert iCOM’ s Display Settings No password is required to change the way Lieber t iCO M displays data. The Display Setup controls how the unit shows data, such as temperature, date and time.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 32 4.6 Graphical Dat a Record The Graphical Data Record charts the average temperature from Sensor s A and B and the supply refrigerant temperature. The temperature scales can be chan ged to expand or compress the data.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 33 Figure 30 Liebert XDP User Menu screen EVENT LOG °C / °F % R H SET SET 12 3 9 6 SET ALARMS ! ACTI V E ALARMS 1234 h USER MENUS ESC to uns e.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 34 4.8 Liebert iCOM User Menu Screens User menus report general coolin g unit operations and status. User menu screens employ a coding that begins with “ U” and is followed by parameters and information, such a s settings.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 35 Figure 32 Set Alarms screen High Room Air Temperature —Sets the threshold where a high roo m temperature alarm will occur, based on the actual reading from either remote Sensor A or B. The range for the high room air temperature alarm is 33.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 36 Figure 33 Sensor Data scre en, p age 1 of 2 Sensor A Temperature —Displays the temperature of the re mote CAN Temp Humidity sensor designated as Sen sor A. Sensor A Humidity —Displays the humidity of the re mote CA N Temp Humidity sensor designated as Sensor A.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 37 Figure 34 Sensor Data scre en, p age 2 of 2 Daily High Temperature —Shows the highest temperature in a rolling 24 hour period for either remote Sensor A or remote Sensor B.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 38 Figure 35 Display Setup screen Language —Sets the language on the display. Changing this setting changes all menu parameters to the selected language. Date —Sets the internal date of the un it.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 39 Figure 36 Module St atus screen, pa ge 1 of 20 Module Node ID —The location within the CANbus. Each mo dule ’s ID is factory-set to 80 and is automatically changed during setu p; requires no user action.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 40 Figure 38 Liebert XDH Smart Module St atus screen—each bank shown sep arately U904 —Displ ays the temperat ure of the air enteri ng the top of the bank of the Liebert X DH. U905 —Displays the temperature of th e air leaving the Liebert XDH.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 41 Figure 40 T ot al Run Hours screen The parameter shows the actual hours Pump 1 an d Pump 2 have operated and the maximum time Pump 1 can op erate before the next ma intenance.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 42 Figure 42 Liebert XDP Service Menu screen 4.10 Liebert iCOM Service Menu Screens Service menus allow custo mized settings for site op erations. Service Menu s creens employ a coding that begins with “S” and is followed by para meter s and informatio n, such as settings.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 43 Min Room Temperature Setpoint —Sets the minimum room temperat ure the unit will attempt to maintain. If the temperature falls below this point, unit will raise the refrigerant tempera ture to reduce the amount of cooling.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 44 Figure 44 Maintenance—Basic Settings scre en, p age 1 of 7 Maintenance Frequenc y Per Year —Sets the number of expected ma intenance visits in a one year time span. Max Bonus —Increases the time until the next requir ed ma intenance.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 45 Figure 45 Maintenance—Pump 1 Sett ings screen, p age 2 of 7 Number of Starts —Shows the number of star ts for the unit’s Pump 1. Run Hours —Shows the number of run hours for the unit’s Pump 1.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 46 Figure 46 Maintenance—Pump 2 Sett ings screen, p age 3 of 7 Number of Starts —Shows the number of star ts for the unit’s Pump 2. Run Hours —Shows the number of run hours for the unit’s Pump 2.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 47 Figure 48 Diagnostics/Service Mode screen, p age 1 of 6 Page 1 applie s to the Liebert XDC only . No Liebert XDP parameters are present. Figure 49 Diagnostics/Service Mode screen, p age 2 of 6 Manual Mode —Used to place the Lieber t iCOM control in manual mode.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 48 Figure 50 Diagnostics/Service Mode screen, p age 3 of 6 Page 3 applie s to the Liebert XDC only . No Liebert XDP parameters are present. Figure 51 Diagnostics/Service Mode screen, p age 4 of 6 Manual Mode Control Type —Not currently used.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 49 Figure 52 Diagnostics/Service Mode screen, p age 5 of 6 Status Remote Shutdown —Displays the status of the unit’s remote shutdown input . Status Fan Failure —Displays the status of the dry contact to communicate fan failure at a module.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 50 Figure 54 Set Alarms screen, p age 1 of 7 High Room Air Temperature —Sets the threshold for a high room air temperature al arm. The range for the high room air temperature alarm is from 33.8 to 95°F (1 to 35° C); the default is 80°F (26.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 51 Figure 55 Set Alarms screen, p age 2 of 7 Customer Input 1 —Selects the device and o peration of the customer input.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 52 Figure 56 Set Alarms screen, p age 3 of 7 HIGH TEMP SENSOR A —Enables or disables the High Temperature Sensor A event, which occurs when the reading from Sensor A is above the user-specified alarm setpoint.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 53 Figure 57 Set Alarms screen, p age 4 of 7 HIGH REFRIGER ANT TEMP —Ena bles or disables the High Refrigerant Temp event, which occurs when the reading from supply refrigerant tempe rature sensor is above the user-specified alarm setpoint.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 54 Figure 58 Set Alarms screens, p ages 5 and 6 Pages 5 and 6 apply to the Liebert XDC only. No Liebert XDP parameters are pr esent.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 55 WATER UNDER FLOOR —Enables or disables the Water Unde r Floor event, which occurs when the Customer Input 1 is configured for “Water Unde r Floor” and 24VAC is applied to the input. Sets how the event is reported: as an alarm, a warning or a message.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 56 Humidity Sensor B —Adjusts the humidity reading from the actual remote sens or designated as Sensor B to compensate for any error of the sensor or to match other sensors in the room.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 57 Supply Refrigerant Sensor 0% —Allows the sensor reading to be ca librated at the lowest reading of the sensor.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 58 Figure 64 System/Network Setup screen—Sys tem, p age 2 of 2 IP Address —Contains the network addres s of the displa y. This address must be unique on the network. The factory default is 192.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 59 Figure 65 System/Network Setup screen—Unit, p age 1 of 2 Monitoring Address —Sets the address u sed by the Liebert Intell iSlot ® ca rds . Th is is s et t o 3 at t he factory and should not be change d.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 60 Figure 66 System/Network Setup screen—Unit, p age 2 of 2 Monitoring Protocol —Sel ects the monit oring protoco l. Velocity V4 is the factory default which will provide communications to the Liebert IntelliSlot ho using.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 61 Figure 67 Options Setup screen, p age 1 of 2 Autorestart Enabled —Restarts the unit after a power cycle wh en set to Yes. When this par ameter is set to No, the unit will not restart after a power cycle.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 62 Figure 68 Options Setup screen, p age 2 of 2 Valve Start Open —Sets position of the valv e when the unit starts. Valve Start TD —Sets a time interval for the unit to co mplete startup and enter into normal operation.
Liebert iCOM Control—Firmw are Version XP1.00.010.STD 63 This screen sele cts the operatio n of an activ e alar m for each smart module. Each event can be enabled or disabled and can be set to operate as a n alarm, a warning or a m essage. The delay is th e time the control waits before reporting the event.
Start the Liebert XDP with Liebert iCOM 64 5.0 S TA R T THE L IEBERT XDP WITH L IEBERT I COM 5.1 Checklist for Liebert XDP St artup 1. Verify that bypass f low controllers were instal led (if a pplicable), see Table 5 . 2. Verify that the minimum load level of 48kW (163,800BTU/H) is present.
Start the Liebert XDP with Liebert iCOM 65 5.2 St arting the Liebert XDP wi th Liebert iCOM Controller The Liebert XDP is started, stopped and cont rolled through the Liebert iCOM controller. Fi gure 24 shows the Liebert iCOM keypad. 1. Turn the Liebert XDP On with the user interface (I/O bu tton).
Alarm Descriptions and Solutions 66 6.0 A LARM D ESCRIPTIONS AND S OLUTIONS 6.1 Alarm Descriptions CALL SERVICE —Activated when Customer Input 1 is configured for “Call Service” and 24VAC is applied to the input. This alarm is reset when the 24VAC is removed.
Alarm Descriptions and Solutions 67 LOW MEMORY —Activated when the control board is low in memory resources. This alarm rests automatically as soon as memory co nsumption falls below the threshold.
Alarm Descriptions and Solutions 68 SMOKE DETECTED —Activated when the Custom er Input 1 is configured for “Smoke” and 24 VAC is applied to the input. This alarm is reset when the 24VAC is removed. SUPPLY CW SENSOR FAILURE —Activated when the con trol no lo nger senses a signal from the Supply CW sensor.
Trou bleshoot ing 69 7.0 T ROUBLESHOOTING T able 14 T roubleshooting the Liebe rt XDP Symptom Possible Cause Check or Remedy Pump Will Not Energize No main power Check L1, L2 and L3 for rated voltage. Loose electrical conne ctions Tighten connections.
Trou bleshoot ing 70 Motor Burnout Check control panel for wel ded contactor contacts or we lded overload cont acts Replace defective components. Main 24VAC Fuse Trips Shorts or loose connectio ns Check the wiring connect ions of the 24 VAC circuit. Faulty circuit board Replace the circuit boa rd.
Maintenance 71 8.0 M AINTENANCE The Liebert XD system componen ts require little mainten ance when prope r fluid levels are maintained and prop er startup and operati on proced ures are followed. The fo llowing tasks should be performed at the intervals stated: 1.
Specifications 72 9.0 S PECIFICATIONS T able 15 Liebert XDP160 specifications Models XDP160RC-- 4 XDP160RA--4 XDP160RM--4 Cooling Capacity, Nominal 160kW / 46 Tons, 60Hz 140kW / 4 0 Tons, 50Hz Each capacity is based on 45ºF (7ºC) ente ring water temperature and 140gpm (530lpm) wa ter flow rate.
C OMPLIANCE WITH E UROPEAN U NION D IRECTIVES Il Produttore dichiara che, se m unito di marchio CE, il prodotto è co nforme alle direttive dell'Unione europea: The Manufacturer hereby declares t.
Ensuring The Hi gh A vai lab ilit y Of Mission-Critic al Dat a And App lic ations. Emerson Net work P ow er , a business of Emerson (NYSE:EMR), is the global leader in enabling Business-Critic a l C ontinuity ™ from grid to chip f or telecommunication networks, data centers, health care and industrial facilities.
An important point after buying a device Liebert XDP160RC (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Liebert XDP160RC yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Liebert XDP160RC - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Liebert XDP160RC you will learn all the available features of the product, as well as information on its operation. The information that you get Liebert XDP160RC will certainly help you make a decision on the purchase.
If you already are a holder of Liebert XDP160RC, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Liebert XDP160RC.
However, one of the most important roles played by the user manual is to help in solving problems with Liebert XDP160RC. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Liebert XDP160RC along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
