ENVIRONMENTAL PROTECTION
RackCooler
INSTALLATION MANUAL
8 kW Nominal
Capacity
TABLE OF CONTENTS
Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.0
PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General RackCooler System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0
PRE-INSTALLATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parts Included With RackCooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.0
CABINET DOOR MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.0
INSTALLING THE RACKCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.0
ADDING A RACKCOOLER MODULE TO AN EXISTING SYSTEM . . . . . . . . . . . . 7
FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
RackCooler overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RackCooler model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door cutout detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line cord bushing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose connection to RackCooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RackCooler mounting detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose connections to CDU supply and return ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
4
5
5
6
7
7
WARNINGS AND CAUTIONS
!
CAUTION
System contains hazardous electrical voltage. Disconnect all
power before working within.
Sharp edges and heavy parts may cause personal injury. Wear
protective gloves. Two people may be required for some
installation operations.
Before proceeding with installation of RackCooler, read all
instructions, verify that all the parts are included, and check the
nameplate to be sure the RackCooler voltage matches available
utility power.
Follow all local codes.
!
!
!
CAUTION
Drilling and cutting doors for required modifications may leave
sharp edges. To protect personnel and equipment, remove burrs
or cover metal edges after finishing door modifications.
CAUTION
Unit is heavy—over 60 lbs (27 kg)—and may cause injury if
dropped. Obtain assistance before lifting or installing this unit
CAUTION
Tip Hazard—Cabinet may become top-heavy after installation.
Use caution when opening doors of lightly loaded cabinets.
1
1.0
PRODUCT DESCRIPTION
1.1
General RackCooler System Description
The RackCooler is a cooling system for high-density heat loads. The RackCooler system includes
cooling modules that are mounted on a door of each cabinet containing heat-producing equipment.
Chilled water circulates through the module. Four fans in the RackCooler draw heat out of the
cabinet, through a heat exchanger and return it to the critical space at nearly room temperature.
Figure 1
A Coolant Distribution Unit (CDU) (sold separately) provides an isolated source of chilled
water for the RackCooler modules. It controls
temperature to ensure maximum heat removal
with no reduction in room humidity.
RackCooler
ER MOUNTED
mounted
on cabinet
Coolant is distributed through piping run under T
the flooring between the CDU and the area
where the RackCooler modules are to be
installed. Flexible hoses and double-shutoff,
quick-connect couplers provide easy, reliable
connection of the RackCooler modules to the
under-floor coolant distribution ports (see
Figure 1.
The Coolant Distribution Unit (CDU) controls
the fluid temperature for up to 12 RackCooler
modules, preventing the water temperature
from causing coil condensation. Each CDU is
rated for 100kw (341,300 BTUHs) of cooling,
and each RackCooler is rated for 8kw (27,300
BTUHs).
RackCooler overall view
R
Raised floor
Cooling
portsCOO
CDU supply
and return
lines
The control on the CDU monitors room conditions and controls the temperature water leaving the CDU and entering the RackCooler,
keeping it above above the room dew point to
prevent coil condensation. An internal purge system pumps fluid to a drain if a leak is detected.
Refer to the CDU installation and operation manual for more information.
Figure 2
RackCooler model number nomenclature
R
C
08
C
–
K
RC = RackCooler
0 = Revision level
= 8 kw nominal capacity
C = Chilled water
2
Product Description
0
K = 120V-1ph-50/60hz
S = 200V/220V-1ph-50/60hz
Place holder
2.0
PRE-INSTALLATION CHECKS
Before beginning installation of the RackCooler, read all the instructions and verify that all parts
are included.
2.1
Parts Included With RackCooler
•
•
•
•
1.
2.
3.
4.
Installation manual (this document)
RackCooler module
Supply and return hoses—two total
Parts bag including:
• four bolts 5/16"-18 x 1-1/4"
• two nuts 5/16"-18
• one snap bushing 2"
Verify that the RackCooler unit voltage matches the available utility power. The nameplate
with this information is located on the bottom of the cooling module, adjacent to the hose
connections.
Installation of the RackCooler requires physical modification to the door of the equipment
cabinet. Your cabinet supplier may be able to provide doors with pre-cut holes and openings.
Check with your supplier.
Pre-cut doors are available for Liebert Foundation and Framework products. Contact your
Liebert representative or Liebert Technical Support at 1-800-222-5877. Please have the serial
number of your Foundation or Framework product available when you call.
The RackCooler is intended for use on doors at least 22 inches wide. Installation on doors less
than 22 inches wide may prevent the doors from being fully opened.
The top of the door on which the RackCooler will be mounted should be at least 66 inches
above the floor. Using a shorter door may cause difficulty in routing hoses.
NOTE
:The RackCooler is designed to mount on cabinet doors hinged on the left
side. The RackCooler can also be mounted on a door hinged on the right
using the right-hand mounting kit.
Pre-Installation Checks
3
3.0
CABINET DOOR MODIFICATIONS
!
Caution
Drilling and cutting doors for required modifications may leave
sharp edges. To protect personnel and equipment, remove burrs
or cover metal edges after finishing door modifications.
1. Decide which door—front or rear—the RackCooler will be mounted on. This will be where the
cabinet discharges heat. Typically the rear door is chosen.
NOTE
When modifying more than one door, mark or number the doors and
cabinets to ensure the doors are placed back on their original cabinets.
Figure 3
Door cutout detail
11 "
11"
11
2. Remove the door from the cabinet.
Place the door on a flat surface where it
7/16"
7/16 "
7/16"""
7/16
7/16
can be marked for cutting or drilling.
3/42-3/4"
"
-3/4"
3. Refer to Figure 3 for specific cutout
and hole dimensions. Carefully and
accurately mark where the door cutout,
Door
Door
DOOR CU
CU
DOOR
six mounting holes and power cord hole
cutout
cutout
are to be located. The six mounting
holes are most critical and must line up
correctly with RackCooler mounting
24""
24
24
holes. Use the guidelines below for
placing cutouts and holes on the door.
RackCooler
RackCooler
All measurements are made facing the
RACKCO
RACKCO
outline
outline
outside of the door.
48"
48"
48
48
""
4. The door cutout should be placed 2
inches below the top of the door.
5. The RackCooler should be centered left
to right on the door if possible. Follow
Steps a through d below to accomplish
24"""
this.
24
24
2-3/4"
2 3/4
3/4 ""
a. Measure the door width.
22-3/4"
2-1/2"
2 1/2 "
b. Subtract 15 inches.
c. Divide this number by 2.
d. Add 2-1/2 inches. This is the
Mounting
Mounting
distance needed from the left edge R CORD
holes
3/8"
MOUNTI
CORD HOLE
HOLE
MOUNTI
holes 3/8"
of the door to the left edge of the
Typically
O
O Power
2 " cord
1-3/4"
1
3/4
1
3/4
"
hole 2"
door cutout for the RackCooler to be
6Typically
places TY
TY
6 places
centered left-to-right on the door.
6. Check for interference with the door
handle. If the handle on the door swings to the center rather than to the outside of the door, it
may interfere with mounting the RackCooler. Measure the distance from the left edge of the
door cutout to the most inward part of the handle. This distance must be at least 12-1/2
inches. If this is less than 12-1/2 inches, then the door cutout must be moved to the left to
eliminate interference with the door handle.
7. After the door cutout is placed and marked, the remaining holes can be placed and marked.
Refer to Figure 3 for detail placement of the power cord hole and the mounting holes relative
to the door cutout. Carefully mark the placement of these holes on the door.
8. Recheck all measurements and hole and cutout placements before modifying the door.
9. Cut or drill the holes in the door. Remove any burrs from around the openings.
10. Place the modified door back on the cabinet.
4
Cabinet Door Modifications
4.0
INSTALLING THE RACKCOOLER
1. Complete the required door modifications detailed in 3.0 - Cabinet Door Modifications.
2. Place the 2" snap bushing in the 2" power cord hole from the outside as shown in Figure 4.
3. Push the door closed but do not latch it.
!
!
CAUTION
Heavy (over 60 lbs/27 kg.) May cause injury if dropped. Obtain
assistance before lifting or installing this unit
WARNING
TIP HAZARD—CABINET MAY BECOME TOP-HEAVY AFTER
INSTALLATION. USE CAUTION WHEN OPENING DOORS OF
LIGHTLY LOADED CABINETS.
Figure 4 Line cord bushing installation
4. Ensure that the two studs protruding from the
RackCooler are fully extended.
5. Route the power cord through the snap
bushing from outside to inside. Ensure the
power cord is not pinched between the
RackCooler and the door. Refer to Figure 6.
6. Lift the RackCooler using the handles
provided. Place the two studs through the
lower two mounting holes in the door. Ensure
that the studs are completely through the
holes.
7. While holding the door and RackCooler
module securely, carefully open the door
slightly. Thread one 5/16" bolt into each of the upper two mounting holes until they are finger
tight
8. Install one 5/16" bolt into the RackCooler through each of the two remaining mounting holes.
Tighten all four of the bolts.
9. Thread one 5/16" nut onto each of the two studs.Tighten the nuts.
Figure 5 Hose connection to RackCooler
10. Remove the protective caps from the fittings
on the bottom of the RackCooler. Connect the
hoses to the fittings (refer to Figure 5).
Tighten to 55 ft.-lb. torque. If a torque
measuring device is not available, hand
tighten the connection, then tighten an
additional 1/2 flat (1/12 turn).
11. Plug power cord into utility power of the
appropriate voltage: 120 VAC or 230 VAC, 50
or 60 Hz. The RackCooler should be powered
from the same power source as the critical
equipment in the cabinet to which the
RackCooler is attached. Verify that the fans
are running.
Installation of the RackCooler to the door is now complete. The RackCooler must now be connected to a Liebert CDU. If this is a new RackCooler/CDU installation, refer to the CDU startup
procedure in the Liebert CDU operation manual. If this RackCooler is being added to an existing,
operating CDU, refer to the instructions in 5.0 - Adding a RackCooler Module to an Existing
System.
Installing the RackCooler
5
Figure 6
RackCooler mounting detail
FIGURE 3 RACKCOOLER MOUNTING DETAIL
6
Installing the RackCooler
5.0
ADDING A RACKCOOLER MODULE TO AN EXISTING SYSTEM
NOTE
:Shutdown of the CDU is NOT required to connect additional RackCooler
modules.
Figure 7 Hose connections to
CDU supply and return ports
1. If the CDU is equipped with the optional Fluid
Management System (FMS), this system must be
temporarily disabled before connecting the RackCooler.
Refer to the CDU operation manual for specific
instructions on disabling the FMS.
2. Connect the hose marked CDU SUPPLY to the underfloor cooling port labeled CDU SUPPLY. Refer to
Figure 7.
3. Refer to Figure 8 for the next two steps. Remove the cap
Supply
Supply
from the CDU SUPPLY vent port on the top of the
RackCooler. Depress the valve pin to release air.
Continue releasing air until a small amount of water is
discharged. Replace the vent cap.
Figure 8 Vent locations
4. Remove the cap from the CDU
PPLY AIR
VENT
CDU
supply air vent
RETURN vent port on the top of the
RackCooler. Depress the valve pin to
release air. Continue releasing air until
a small amount of water is discharged.
AIR
VENT
CDU
return air vent
Replace the vent cap.
5. Carefully depress the plunger inside
the quick-connect coupler, on the end of
the hose labeled CDU RETURN, to
release trapped air. Continue releasing
air until a small amount of water is
discharged.
6. Refer to Figure 7. Connect the hose
marked CDU RETURN to an underfloor cooling port labeled CDU
RETURN.
7. When connection of all RackCooler
modules is completed, re-enable the
optional Fluid Management System
(refer to the CDU operation manual).
Return
Return
OSE CONNECTIONS
Installation and startup of the RackCooler is now complete. Keep these instructions for reference.
Please take a moment to complete the enclosed startup survey card.
Thank you for selecting the Liebert RackCooler for your high-density cooling needs!
Adding a RackCooler Module to an Existing System
7
8
Adding a RackCooler Module to an Existing System
9
ENVIRONMENTAL PROTECTION
RackCooler
INSTALLATION MANUAL
The Company Behind the Products
Technical Support
With over a million installations around the globe,
Liebert is the world leader in computer protection
systems. Since its founding in 1965, Liebert has
developed a complete range of support and
protection systems for sensitive electronics:
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
1-800-222-5877
Outside the United States
+614-888-0246
•
•
•
•
•
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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.
© 1994 Liebert Corporation
All rights reserved throughout the world.
Specifications subject to change without notice.
® Liebert and the Liebert logo are registered
trademarks of Liebert Corporation. All names
referred to are trademarks or registered
trademarks of their respective owners.
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