Data Aire gForce Ultra, Installation, Operation And Maintenance Manual

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Page 2: ...personnel by providing necessary guidelines for this particular equipment Service to Data Aire units should be done by qualified individuals with an adequate background in areas such as HVAC electric...

Page 3: ...2 Discharge Lines 14 2 7 3 Liquid Lines 15 2 7 4 Recommended Line Sizing Air Cooled Units 16 2 7 5 Connection Sizes Air Cooled Units 17 2 7 6 Field Piping Remote Condenser Above Evaporator 17 2 7 7 Fi...

Page 4: ...Probe 28 3 10 Water Sensing Cable Optional 28 3 11 Remote Temperature and Humidity Sensors Optional 28 3 12 Manual Override Switches 29 3 13 Wiring Diagrams 29 3 14 EEV Connection 30 4 INSTALLATION O...

Page 5: ...lenoid Valve 51 6 GLYCOL SYSTEMS 52 6 1 Glycol Concentration 52 6 2 Internal Fluid Volume Downflow Units 52 6 3 Internal Fluid Volume Upflow Units 52 6 4 Internal Fluid Volume Fluid Coolers 53 6 4 1 F...

Page 6: ...er Canisters 60 9 5 Refrigerant Filter Drier 60 9 6 Current Sensing Relay 60 9 7 Plug Fans 61 9 7 1 Electronically Commutated Motors 61 9 7 2 Testing 61 10 MAINTENANCE INSPECTION CHECKLIST 61 11 CONTA...

Page 7: ...ndation of 68 F 20 C DB and 40 RH or minimum WB of 54 F 12 2 C for proper unit operation Operating below this can alter the operating performance and decrease equipment reli ability Refer to ASHRAE s...

Page 8: ...he labeled equipment matches the bill of lading Note any external damage or transportation damage on the freight carrier s forms Inspect the unit itself for internal damage A claim should be filed wit...

Page 9: ...of this User Manual A yellow tag is attached to the outside decorative door to indicate articles that may have been packaged and shipped loose within the unit cabinet Typically this would be jackstan...

Page 10: ...e conditions Introduction of outside air into the space should be minimized Outside air in excess of 5 of the total circulated air volume can have a significant effect on the overall space conditions...

Page 11: ...g of the equipment may result in damage to the decorative doors panels or frame members 2 5 Locating the Unit Verify that the floor is level solid and sufficient to support the unit When installing th...

Page 12: ...ping wiring raceways inadequate floor height and any other restrictions can inhibit proper airflow Care should be taken to avoid restrictions 2 5 2 Upflow Units Upflow units will typically be supporte...

Page 13: ...ing returns from the evaporator should be designed so as not to trap oil and to prevent oil and refrigerant migration back to the compressor during off cycles Piping should be designed with adequate t...

Page 14: ...ischarge Lines Discharge lines also called hot gas lines should be trapped at the top inverted and bottom as well as every 15 to 20 feet 4 6 to 6 1 m of vertical rise Discharge check valves are requir...

Page 15: ...side of the joints Carbon could contaminate the refrigerant and restrict the metering device Piping must be supported within 18 457 mm of the inlet and outlet connections external to the unit Internal...

Page 16: ...oose the longer equivalent length 2 Dual circuit units should use the same line size on both circuits 3 If hot gas line refrigerant flow is upward use VERTICALUP If it is downward use HOR VERTICAL DOW...

Page 17: ...22 mm O D GUA 045 7 8 22 mm O D 7 8 22 mm O D GUA 070 7 8 22 mm O D 7 8 22 mm O D GUA 091 7 8 22 mm O D 7 8 22 mm O D GUA 125 1 1 8 29 mm O D 7 8 22 mm O D NOTE Field connections at the indoor evapora...

Page 18: ...w the unit to be isolated for service Drain fill valves field provided should be located at the lowest point on the connected piping Water glycol cooled units are shipped with plate fin heat exchanger...

Page 19: ...the piping system to purge the air The water glycol system may include a centrifugal pump or pumps for redundancy available from Data Aire as an option along with field provided union s shutoff valves...

Page 20: ...ow 2 7 11 Connection Sizes Fluid Coolers Dry Coolers Evaporator Model Fluid Cooler Model Water In Connection Water Out Connection GUWX 022XX GUGX 022XX GHFC 053 2 1 8 2 1 8 GHFC 074 2 1 8 2 1 8 GHFC 1...

Page 21: ...nnections are brazed together 2 8 Condensate Drain Piping Every indoor unit has a 3 4 19 mm copper stub provided for condensate removal A union field pro vided is recommended at the field connection w...

Page 22: ...esult in water leakage from the unit Water leakage can result in severe property damage and loss of critical data center equipment Do not locate unit directly above any equipment that could sustain wa...

Page 23: ...on critical equipment A water drain connection is required Units with optional steam generator humidifiers will require an external potable water supply Water leakage can result from improper installa...

Page 24: ...ks After the system has been satisfactorily evacuated the lines can be charged with refrigerant Connect the pressure gauge manifold set to the high and low ports near the compressor Connect the charg...

Page 25: ...luid cooler and will require one additional source for single pump or two additional sources for dual pumps Systems where the pump s are mounted and piped integral to the fluid cooler will usually req...

Page 26: ...the electrical control box of the remote heat exchanger Condensing units i e where the compressor s are mounted in the remote heat exchanger will typically require 4 or more wiring connection points...

Page 27: ...arm Contacts The dap4 microprocessor control panel provides four 4 remote alarm output contacts that can be field accessed The contacts include a Normally Open NO or Normally Closed NC on Alarm dry co...

Page 28: ...th of standard hookup wire may be used if required WARNING Failure to remove the condensate probe from the plastic bag and uncoil the length of wire attached to the probe will leave the unit unprotect...

Page 29: ...ull speed WARNING Do not leave the unit in manual override Slide the switches to the OFF position when completing testing and or start up An alarm will be activated if units are left in the ON positio...

Page 30: ...e large blade connection so that the connector can only be properly mate one way When it is necessary to making this electrical connection this connector can only properly mate in one position as show...

Page 31: ...er must be OFF and prevented from start ing inadvertently automatically NOTE Prior to refrigerant charging a system vacuum and moisture re moval procedure must have been carried out Refer to Section _...

Page 32: ...es if the compressor is equipped with them need to remain open during the vacuum process and the system must be purged of nitrogen We recommend using a solenoid magnet tool to hold the liquid line sol...

Page 33: ...D will show an error message On the Manual Override Module located next to the microprocessor control module slide the Cool 1 switch to the ON position observe the VFD for an error message then slide...

Page 34: ...e tables below Add the amount of refrigerant needed for the evaporator condenser the line set then multiply by 80 Step 1 Select the model and refrigerant charge for evaporator and condenser Weight of...

Page 35: ...line size by the correct multiplier to get the refrigerant weight needed for the Line set 1 Weight of Refrigerant in Liquid Line lbs ft Liquid Line OD inches Multiplier 1 2 067 5 8 107 3 4 160 7 8 223...

Page 36: ...suction pressure head pressure sub cooling and ambient temperature are also important A system charged to a clear sight glass is often overcharged Manually start the system by first sliding the Blower...

Page 37: ...IG 2344 to 2861 kPa Suction Pressure 104 to 165 PSIG 717 to 1138 kPa Superheat 10 to 12 F 5 56 to 6 67 C Differential Sub Cooling 10 to 12 F 5 56 to 6 67 C Differential Depending on ambient conditions...

Page 38: ...looded System Charging WARNING The constant speed compressor must be charged before charg ing the variable speed compressor in a dual circuit system Flooded systems are supplied with optional liquid r...

Page 39: ...m or 66ft This procedure must be conducted with the system running at high load compressor at full speed ALWAYS use original Danfoss POE oil 160SZ from new cans Oil addition is calculated based on ref...

Page 40: ...ust be active while charging the compressor In order to ensure this manual bypass switches on the Manual Override Board MUST NOT be used Instead the unit must be started in the normal operating mode b...

Page 41: ...run then multiply the equivalent feet of line based on line size by the correct multiplier to get the refrigerant weight needed for the Line set Weight of Refrigerant in Liquid Line lbs ft Liquid Lin...

Page 42: ...ary NOTE A quick and easy way to run the fans and compressor is by using the manual slide switches provided by the Manual Override Module Exclu sively for floor mounted units Ceiling mounted units are...

Page 43: ...olds If the difference between the manifold reading and dap4 reading is more than 5 check for the EEV wiring and any possible alarms on dap4 or EEV driver Measure sub cooling at the liquid line When c...

Page 44: ...5 2 Variable Capacity Compressor NOTE Prior to refrigerant charging a system vacuum and moisture removal procedure must have been carried out Refer to Section 5 2 for evacuation procedures prior to c...

Page 45: ...ilizing the arrow keys scroll up or down to menu H Calibrate Sensors and press ENTER If the system is being con trolled from the return air temperature sensors simply scroll down to the Return Air Tem...

Page 46: ...m or 66ft This procedure must be conducted with the system running at high load compressor at full speed ALWAYS use original Danfoss POE oil 160SZ from new cans Oil addition is calculated based on ref...

Page 47: ...iver based on condenser size and circuit type Weight of Refrigerant per Standard Liquid Receiver lbs Receiver Type Condenser Circuit type Lbs of Refrigerant GHRC 011 039 Single 29 GHRC 053 074 Single...

Page 48: ...figure represents the initial factory charge it is still necessary to measure and note proper unit operation including superheat head and suction pressure Some adjustment of charge may be required Adj...

Page 49: ...en disconnecting service hoses a technician who knowingly releases or vents refrigerant to the atmosphere is in violation of this regulation Refrigerant purchasers must be certified technicians and ha...

Page 50: ...his high efficiency feature provides an EEV in place of the standard Thermal Expansion Valve EEV The EEV controls superheat through the dap4 controls by actively measuring suction pressure via a trans...

Page 51: ...lectrical power failure does not lead to any problems with the refrigeration system The primary purpose of a solenoid valve in a refrigerant liquid line is to helps prevent refrigerant migra tion i e...

Page 52: ...ge should be checked The glycol percentage should also be checked at regular intervals to ensure freeze protection 6 2 Internal Fluid Volume Downflow Units Evaporator Model Standard Unit Volume In Gal...

Page 53: ...lation Preferably surface waters that are classified as soft and are low in chloride and sulfate ion content should be employed Proper inhibitor maintenance must be performed to prevent corrosion of s...

Page 54: ...eters This boost is performed at programmable fixed time intervals or if the compressor speed has been less than 3000 RPM 50 rps for too long which is again a programmable parameter whichever comes fi...

Page 55: ...thus reducing peak energy demand and system wear Below is a figure showing the VFD control display and some general instructions required to charge the unit and monitor any alarms The local control p...

Page 56: ...move the cursor to the desired digit position then use the and keys to increase or decrease the desired RPM setting As you change the value the compressor will increase or decrease in speed See examp...

Page 57: ...keys to move the cursor through the various alarms See example display below When done press the Auto on key to return to normal operation controlled by the dap4 controller NOTE If more information i...

Page 58: ...58 8 CONTROLS Refer to dap4 IOM for controls and control logic...

Page 59: ...__ Inspect contactor operation ___ Check operation sequence ___ Check calibration of change over thermostat Energy Saver system only Controls ___ Check unit control operation Check operation of the fo...

Page 60: ...nes Condensers Water Cooled ___ Check for leaks ___ Entering leaving water temperatures ENT ____ F LVG ____ F Compressor Monthly ___ Check for oil leaks ___ Check compressor mounting ___ Inspect wire...

Page 61: ...il clean if required ___ Inspect motor motor mounts ___ Inspect fan blade s ___ Check wiring ___ Inspect piping for leaks Glycol Pump if applicable ___ Glycol leaks pump area ___ Pump operation ___ Au...

Page 62: ...714 921 6022 Parts Sales Web Site www dataaire com Job Unit Information Data Aire Job Number ___________________________________ Evaporator Serial Number ________________________________ Evaporator Mo...

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