Rack Manifold Requirements and Qualification

Author: Jordan Johnson, Intel (presenting on behalf of Berhanu Wondimu, Edward Kung, and David, Intel) Collection: 2023 Global Summit - Cooling Environments

Summary

This presentation covers the OCP Rack Manifold Requirement and Qualification Guideline, a white paper in final community review at the time of OCP Global Summit 2023. Jordan Johnson (Intel) presents on behalf of the primary authors — Berhanu Wondimu, Edward Kung, and David (all Intel) — with contributions from Intel, CoolIT, Foxconn, Inventec, Wistron, Delta, Chia Cherne, Jabil, CEJN, Supermicro, MGCooling, and SouthCo. The paper is explicitly not a design specification but a knowledge-sharing guideline to homogenize manifold features and enable off-the-shelf compatibility for OEM/ODM customers.

The key motivation is that rack manifold designs are currently highly custom, vary significantly between vendors, and do not interchange well. The paper aims to identify which features can be homogenized across standard 19-inch racks and ORv3 racks, covering design considerations (geometry, CDU connection sizing, server loop connection sizing, safety and control features), material compatibility, operating conditions, testing requirements, manufacturing options, surface treatment, quality control, and assembly considerations. Terminations are addressed using the Universal Quick Disconnect (UQD) and Universal Quick Disconnect Blind Mate (UQD-BM) specifications already published on the OCP contributions portal and with commercial products listed on the OCP marketplace.

A key design challenge highlighted is radial misalignment accommodation for blindmate quick disconnects — the paper provides a design example of a floating mechanism on the server chassis side that can accommodate larger-than-normal misalignment without adding parts. Operating conditions specify 17°C to 75°C operating temperature, -40°C to 75°C shipping temperature, maximum operating pressure (MAWP), and 3× MAWP minimum burst pressure. Testing requirements include 100 PSIG pressure test, 300 PSIG burst pressure, flow resistance measurement, fluid leak at terminations and seals, salt spray corrosion test, and shock/vibration mechanical testing.