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Choose liquid cooling by starting with the exact AI server platform, then proving that the rack system, coolant distribution unit (CDU), facility water loop and heat-rejection plant work together under your real workload and ambient conditions. Rack density alone is not a sufficient selection rule.
For most deployments, the practical decision is among direct-to-chip cold plates, immersion cooling and rear-door heat exchangers. Each can be appropriate, but they differ in server compatibility, components cooled, facility modifications, fluids, maintenance and failure modes. The right design is the one whose interfaces, capacity, reliability and operating procedures are documented for your equipment and site.
What liquid cooling for AI servers actually includes
Liquid cooling is not a single device installed beside a server. It is a chain that captures heat at the IT equipment, moves it through a technology cooling system (TCS), transfers it to the facility water system (FWS), and rejects or reuses that heat. The chain normally includes server-level cold plates or a rack heat exchanger, manifolds and quick disconnects, pumps, controls, leak detection, a CDU, facility supply and return piping, and a heat-rejection plant.
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Open Compute Project (OCP) workstreams group the main equipment approaches as cold plate, immersion and door heat exchanger cooling. A CDU is the intermediate system between the equipment loop and the facility loop. ASHRAE guidance describes the CDU as a means to separate the two water-quality domains, transfer heat between them, and circulate and control TCS coolant.
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This separation matters because the facility loop and the IT loop may need different temperatures, filtration and chemistry. A properly specified CDU can help keep TCS coolant above room dew point, reducing condensation risk, while allowing its chemistry to differ from the facility water. The CDU itself must still be compatible with both loops and with every wetted material.
Compare the three main approaches
| Approach | Where heat is captured | Server and rack implications | Facility and operating implications |
|---|---|---|---|
| Direct-to-chip cold plate | Liquid cold plates mounted on selected high-power components, usually processors or accelerators | Requires server models designed or approved for liquid interfaces; components without plates may remain air-cooled | Needs a TCS with manifolds, tubing, quick disconnects and a CDU; service procedures must address liquid connections |
| Immersion cooling | Server boards and components are placed in a dielectric cooling fluid | Requires equipment, seals, materials and service methods approved for the immersion fluid; standard rack practices may change | Introduces tanks, fluid handling, filtration and different maintenance and safety procedures; facility integration is site-specific |
| Rear-door heat exchanger | Liquid heat exchanger removes heat from the rack’s exhaust air | Can cool a broader set of air-cooled servers, but depends on rack format, airflow and door compatibility | Captures heat at rack level; validate door interfaces, condensate and the facility’s ability to accept the resulting liquid heat load |
Direct-to-chip or cold-plate cooling
Cold plates transfer heat directly from selected high-power devices into a liquid loop. OCP’s cold-plate work covers requirements for plates, tubing, manifolds, quick disconnects and CDUs. This approach is usually the most straightforward when the server manufacturer offers a supported liquid configuration and the operator can run a controlled TCS.
Do not assume that a CPU or GPU plate makes the whole server liquid-cooled. Memory, storage, voltage-regulation components, network adapters and other devices may still depend on air. Obtain a component-by-component cooling map and determine the residual air load that the room or rack airflow system must remove.
Ask the server vendor for approved coolant, supply and return temperatures, flow range, pressure drop, connector type, allowable pressure and connection sequence. A cold plate that fits physically but operates outside those limits can underperform, cause alarms or void support.
Immersion cooling
Immersion places the IT equipment in a cooling fluid, making the fluid, tank, pump, filtration and service process part of the computing platform. OCP treats immersion as a separate area covering thermal management, energy and water consumption, operational efficiency and sustainability.
Evaluate immersion against the exact server design, fluid compatibility, component materials, warranty terms, lifting and draining procedures, contamination control and technician training. Maintenance is not simply a matter of opening a rack: technicians may need fluid-management equipment and a defined method for removing and servicing wet hardware.
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There is no universally applicable cost or efficiency ranking that makes immersion the automatic choice for every AI deployment. Require bidders to state fluid life, filtration, replacement handling, energy assumptions and service intervals on the same basis as other proposals.
Rear-door heat exchangers
A rear-door heat exchanger (RDHx) removes heat from rack exhaust air through a liquid heat exchanger. It can be useful when the server population is largely air-cooled but rack exhaust temperatures exceed what the room air system can handle.
OCP’s door heat-exchanger work, including integration with Open Rack V3, identifies interfaces, rack compatibility, fluid compatibility, operating parameters and heat extraction as key design areas. Confirm the rack dimensions, door weight, hinge and cable clearances, airflow path and whether the heat exchanger is passive or fan-assisted.
RDHx does not eliminate the need for a facility liquid loop. It moves the heat-capture point to the rack boundary, so the facility must still provide the required supply and return conditions and reject the captured heat. Validate the remaining room load and the consequences of a door or pump outage.
Use this selection process before choosing a vendor
- Freeze the server configuration. List the exact server and accelerator models, quantities per rack, supported liquid options, component coverage and any air-cooled residual load. Obtain the manufacturer’s thermal design and coolant-interface documentation.
- Define the operating envelope. Record expected utilization, accelerator power, inlet-air temperature and humidity, supply and return temperatures, flow, pressure and allowable pressure drop. Require a guaranteed range rather than a single peak number.
- Map the facility loops. Document FWS temperature, flow, pressure, water quality, heat-rejection capacity, pump redundancy, pipe routes, available power, floor loading, drainage and maintenance access. Identify what is new construction and what is a retrofit.
- Select the heat-capture point. Use cold plates when supported components and a TCS are available; consider immersion when the organization can operate tanks and fluid processes; consider RDHx when rack-level air heat capture fits the existing server fleet. Treat these as engineering hypotheses until interfaces and capacity are verified.
- Choose CDU architecture and location. Decide between an in-rack CDU serving one rack and a floor-standing or external CDU serving several racks. Compare the resulting hose lengths, failure domains, service clearances, pump redundancy, controls and expansion path.
- Check fluids and materials. Trace every wetted material from facility piping through the CDU, manifolds, quick disconnects and server hardware. Confirm approved chemistry, filtration, corrosion control, pressure ratings and sampling responsibilities for each loop.
- Design reliability and isolation. Specify redundant pumps or CDUs where the availability target requires them, isolation valves, bypasses, leak sensors, alarms, automatic or manual shutoff behavior, spare parts and a procedure for replacing a failed component without a broad shutdown.
- Validate with a witnessed test. Require the supplier to demonstrate flow, temperature control, pressure drop, leak response and capacity at representative workload and ambient conditions. Accept the design only when the test data and operating limits match the contract.
How to size a CDU and verify capacity
CDU sizing must follow the actual server and rack workload, not a marketplace headline. Active heat-exchange capacity changes with external ambient temperature and IT workload. Ask for a capacity curve or operating table showing inlet conditions, TCS supply temperature, flow, pressure drop, pump operating point and maximum workload.
Separate three values that are often conflated:
- IT heat load: the heat generated by the supported equipment at the stated utilization and power condition.
- Heat-exchange capacity: the amount the CDU and facility loop can transfer at specified temperatures and flows.
- Installed margin: additional capacity for growth, fouling, degraded pumps, warmer ambient conditions or a failed redundant module.
OCP’s marketplace listing for the OCP–Deschutes 5 In-Row CDU describes up to 2 MW of thermal cooling capacity and names Cooler Master as the solution provider. That is a current listing claim, not an independent comparative test or a guarantee for every configuration. Verify the exact model, conditions, redundancy and controls directly with the provider.
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Have the supplier state whether capacity is continuous or temporary, whether it includes pump power, what water temperatures are assumed, and how performance changes when one module is offline. A design that meets a short-duration peak but not sustained workload can still throttle accelerators or overheat the room.
Condensation, water quality and controls
Keep coolant above dew point
Cold surfaces below room dew point can condense water. Ask how the CDU controls TCS supply temperature relative to measured room temperature and humidity, what alarm limits are used, and what happens if a sensor fails. The design should identify the coldest wetted surface, not merely the nominal supply temperature.
Separate chemistry responsibilities
FWS and TCS may use different water-quality controls. Define who supplies and treats each loop, acceptable conductivity and particulate limits, filtration locations, sampling frequency, corrosion monitoring and the process for adding or replacing fluid. Do not accept a generic statement that the system is “water compatible” without a materials and chemistry schedule.
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Specify connector gender, drip-free behavior, connection and disconnection sequence, hose bend radius, labeling, maximum pressure and inspection points. Quick disconnects reduce service time only when technicians can reach them safely and when isolation valves prevent draining an entire loop.
Reliability and serviceability requirements
Liquid adds pumps, valves, hoses, seals and sensors to the failure chain. Compare designs by how a single failure affects IT load and how quickly technicians can isolate and repair it.
- Redundancy: Identify whether redundancy is at pump, heat-exchanger, CDU, power-feed or facility-plant level. Confirm the capacity remaining after one element is unavailable.
- Leak detection: Place sensors where liquid can collect, define alarm thresholds and specify whether detection triggers notification, valve closure, workload migration or shutdown.
- Isolation: Provide valves that let technicians isolate one rack, manifold, CDU or tank without draining unrelated equipment.
- Service access: Preserve clearance for removing servers, disconnecting hoses, replacing filters and lifting heavy doors or tanks. Include spill containment and a documented cleanup method.
- Spare parts: Stock compatible pumps, sensors, seals, quick disconnects, filters and control modules for the expected support period.
- Operations: Train staff on sampling, pressure checks, leak response, fluid handling, lockout procedures and restart verification.
One JD.COM design described two CDUs, each capable of the maximum system cooling load and normally operated at 50%, with leak detection. Treat that as a case-specific architecture, not a universal requirement. Your redundancy level should follow the uptime target, maintenance windows and workload-restart capability.
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Facility readiness for a new build or retrofit
Before ordering equipment, verify that the building can deliver and return the required fluid at design conditions. A liquid-cooled rack can fail operationally even when the rack hardware is correct if the facility pump cannot maintain flow, the heat-rejection plant is undersized or the piping route adds excessive pressure drop.
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Check these physical and electrical items
- Supply and return pipe size, pressure, temperature and available flow at the rack or CDU location
- Heat-rejection capacity at the site’s design ambient, including chiller, dry cooler, cooling tower or other plant limits
- Floor loading and point loads for CDUs, tanks, manifolds and filled hoses
- Power feeds, breaker capacity, generator or UPS coverage and control-panel requirements
- Pipe routing, expansion joints, isolation points, drains, spill containment and access for lifting equipment
- Room humidity control and dew-point monitoring where cold surfaces are present
- Network and building-management integration for temperatures, flow, pressure, leak alarms and device status
For a retrofit, map every change to an outage plan. Determine whether doors, aisles, raised-floor panels, cable trays or fire-protection systems must be modified. OCP and ASHRAE announced on October 13, 2025 that their collaboration roadmap addresses facility readiness and integration of liquid loops into existing data centers.
Economics, water use and heat reuse
Compare proposals using the same boundary. Include the liquid hardware, CDU pumps, controls, facility distribution, heat rejection, electrical work, construction, commissioning, maintenance contracts, fluid treatment, replacement parts and expected downtime exposure.
Ask each bidder to itemize energy use for pumps, fans, chillers and controls; water consumption or treatment; staffing and training; and expansion cost. Published material does not establish a universally comparable total-cost or efficiency ranking among cold plate, immersion and RDHx systems, so a low purchase price can hide facility or operating costs.
Heat reuse can improve the business case when a nearby process or building has a dependable demand at a useful temperature. OCP treats heat reuse as a separate workstream covering technical reference designs, economics and policy. Treat reuse as a site-specific opportunity: identify the customer, seasonal demand, required temperature, distance, backup heat-rejection path and metering before assigning it financial value.
Decision examples
New AI cluster with supported liquid servers
A new cluster whose server maker supplies cold-plate manifolds and documented coolant limits is usually a strong candidate for direct-to-chip cooling. Concentrate the design effort on component coverage, CDU placement, residual air load, redundancy and facility loop chemistry.
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Mixed fleet of existing air-cooled racks
If replacing servers is impractical, RDHx may capture rack exhaust heat while preserving more of the existing IT hardware. Confirm that every rack fits the door solution and that the facility can support the added liquid distribution. Keep room airflow and failure-mode analysis in the design.
Purpose-built facility with fluid operations capability
Immersion can be considered when the organization accepts tank infrastructure, fluid handling, specialized maintenance and different hardware logistics. Require a complete service, safety and lifecycle plan before treating thermal performance as an advantage.
Common selection mistakes and their fixes
- Choosing by rack-density number alone: Replace the headline with a guaranteed capacity at your workload, ambient and inlet conditions.
- Assuming every server component is liquid-cooled: Obtain a coverage diagram and calculate the remaining air heat load.
- Using one fluid specification for both loops: Require separate FWS and TCS chemistry, filtration and materials schedules.
- Ignoring dew point: Tie supply-temperature control to measured room conditions and define sensor-failure behavior.
- Putting a CDU where technicians cannot reach it: Review hose routing, valve access, filter replacement and spill response during a physical walk-through.
- Treating redundancy as a marketing label: Model the actual heat load after each pump, CDU, power feed or heat-rejection component fails.
- Comparing prices with different boundaries: Normalize facility work, controls, commissioning, service, energy and water assumptions.
- Assuming heat reuse is automatic: Secure a real heat sink and retain a conventional rejection path for periods when reuse is unavailable.
What to require in a vendor proposal
Give every bidder the same data sheet and require a response in the same units. At minimum, request:
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- Supported server and component list, including parts that remain air-cooled
- Approved coolant, materials, chemistry, filtration and sampling requirements
- Supply and return temperature range, flow range, pressure drop and connection details
- Capacity curves for expected workload, utilization and facility ambient conditions
- CDU architecture, location, pump configuration, controls and communications interfaces
- Redundancy and degraded-mode performance after a single component failure
- Leak-detection locations, alarm actions, isolation sequence and spill-containment method
- Maintenance clearances, filter and fluid service intervals, spare-parts list and technician qualifications
- Facility utility requirements, heat-rejection assumptions, power draw and retrofit scope
- Commissioning test plan, acceptance criteria, warranty boundaries and operating documentation
Require the provider to identify every assumption. A proposal should state whether its capacity is measured, calculated or listed by the manufacturer, and under which temperature, flow, workload and redundancy conditions it applies.
Standards and further engineering reference
OCP publishes specifications and guidance for cold plates, manifolds, quick disconnects, CDUs and door heat exchangers. ASHRAE’s publication update page lists Liquid Cooling Guidelines for Datacom Equipment Centers, second edition, with an update date of September 11, 2014; verify the current edition and availability before relying on it for a project.
The Open Compute Project Foundation’s October 13, 2025 announcement describes the relationship this way: “As the power and thermal management requirements of AI systems reshape data center IT equipment and the facilities that house it, the OCP Community’s innovative open data center specifications and ASHRAE’s cooling standards intersect in areas from the facilities—technology cooling system (TCS) and facility water system (FWS) coolant loops—to the IT equipment—direct-to-chip or immersion cooling—and various interconnecting technologies and intermediate systems like in-row or in-rack coolant distribution units (CDUs).”
Use these materials to establish terminology and interface requirements, then have a qualified data-center engineer and the exact server and facility vendors validate the final design. They do not replace project-specific hydraulic, structural, electrical, controls and operations analysis.
Make the final choice
Select the cooling method that your server platform supports, your facility can supply and reject, and your operations team can safely maintain. Cold plates are often the direct path for purpose-built liquid servers; RDHx can extend liquid heat capture to compatible air-cooled racks; immersion is a distinct operating model that requires fluid and service readiness. In every case, approve the design only after the CDU, loops, interfaces, reliability features and capacity have been demonstrated against the actual workload and site conditions.
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