Data Cool
Installation, Operation and Maintenance Manual
2 and 3 ton
Air, Water and Glycol Cooled DX and Chilled Water
Page 1: ...Data Cool Installation Operation and Maintenance Manual 2 and 3 ton Air Water and Glycol Cooled DX and Chilled Water ...
Page 2: ...ng necessary guidelines for this particular equipment Installation and service to Data Aire units should be done by qualified individuals with an adequate background in areas such as HVAC electrical plumbing and electronics as applicable Service performed by unauthorized or unqualified technicians may void manufacturers warranties and could result in property damage and or personal injury Special ...
Page 3: ...ng 10 2 2 1 Liquid Lines 10 2 2 2 Suction Lines 10 2 2 3 Connection Sizes Water Glycol Cooled Units 11 2 2 4 Connection Sizes Fluid Coolers 11 2 3 Chilled Water Piping 11 2 4 Condensate Drain Piping 11 2 5 Humidifier Piping 12 2 6 Leak Testing 12 2 7 Evacuation 12 3 0 ELECTRICAL CONNECTIONS 13 3 1 Electrical Service 13 3 2 Nameplate Ratings 13 3 3 Grounding 13 3 4 Voltage Tolerance 13 3 5 Auxiliar...
Page 4: ... 18 5 5 2 High Pressure Cutout Switch 18 5 5 3 Low Pressure Cutout Switch 18 6 0 CONTROLS 18 6 1 Standard Thermostat 18 6 2 Optional Programmable Thermostat 19 6 3 Optional Mini DAP II Microprocessor Control Panel 19 6 4 Optional DAP II Microprocessor Control Panel 19 6 5 Wiring Diagrams 19 7 0 REGULAR MAINTENANCE ITEMS 20 7 1 Air Filters 20 7 2 Bearings 20 7 3 Humidifier Canisters 20 7 4 Fuses 20...
Page 5: ...5 Model Identification ...
Page 6: ...the CRAC units from running excessively to maintain the room conditions 1 2 Inspection This DataAire unit has been factory run tested and has gone through a comprehensive inspection prior to its packaging and shipment to ensure that it arrives in excellent condition However shipping damage can occur and a visual inspection of the outer crating immediately upon delivery should be performed Note any...
Page 7: ...it cabinet This could be the thermostat or other optional control devices that are not factory mounted It is the responsibility of the installing contractor to return the start up sheet and warranty registration card to Data Aire for proper activation of the unit warranty Failure to do so may cause delays in warranty related services and in some cases void the warranty 1 6 Storage Your DataAire eq...
Page 8: ...n the other end of the refrigerant line allowing the nitrogen to bleed off and not cause excess pressure buildup Data Aire recommends a silver phosphorus copper alloy with between 5 and 15 silver be used to braze refrigerant line set to the indoor and outdoor units Nitrogen needs to be flowing through the lines to eliminate carbon deposit buildup on the inside of the joints which could contaminate...
Page 9: ...Liquid Line and DACU 03 1 2 3 4 Suction Line DACU 04 1 2 3 4 DACU 05 1 2 3 4 Field connections at the indoor evaporator and remote condensing unit will not necessarily be the same as the field pipe size required In some cases these sizes will vary significantly 2 1 4 Field Piping Remote Condensing Unit ...
Page 10: ...r should be field installed on the inlet water pipe Strainers must be cleaned periodically 2 2 1 Liquid Lines Liquid line size is determined by pressure drop and velocity The liquid line pressure drop should not exceed 5 PSI The recommended velocity should be between 200 and 300 FPM To avoid excessive liquid line pressure drop the air cooled condensing unit should be located above or at the same l...
Page 11: ...sy disconnection from the unit for cleaning A trap should be built into the drain line to prevent air from backing up into the unit Drain lines should be pitched downward not less than 1 4 for each ten feet of horizontal run Do not reduce the size of the drain line Where local codes permit PVC pipe may be used Some applications have no convenient means of allowing a gravity drain In this case a co...
Page 12: ... release refrigerant into the atmosphere Many leak test methods recommended in the past are no longer possible Current standard practices must be used One acceptable method of leak testing air cooled systems does not involve the use of refrigerant Prior to charging pressurize the system to 150 psi with dry nitrogen with all refrigerant valves open Place a gauge on the line and allow at least four ...
Page 13: ... wire gauge Maximum Overcurrent Protection Device amps will dictate the maximum circuit breaker or fuse size 3 3 Grounding The unit cabinet must have an uninterrupted true earth ground An electrical ground wire of adequate size must be connected to the ground lug provided inside the main electrical box 3 4 Voltage Tolerance The supply voltage to the unit must be within tolerance of 5 10 for 208 23...
Page 14: ...vaporator Mounting a condensing unit more than ten feet below the evaporator is not recommended Excessive liquid line pressure drop can cause poor evaporator performance See dimensional drawings for the following 1 Location of refrigeration and electrical connections 2 Recommended clearances 3 Direction of condenser airflow 4 Mounting base dimensions Place unit on level base strong enough to suppo...
Page 15: ...may require checking proper phase An out of phase compressor will draw relatively low amps and both suction and discharge pressures will remain nearly equal 5 1 2 Secondary Heat Exchanger The secondary heat exchanger may be ordered as three phase but the individual fan motors are single phase and will only run in one direction 5 2 Air Cooled Systems Before starting a compressor the crankcase heate...
Page 16: ...lete the charging procedure Make sure all hoses are properly purged Before starting a compressor if the system has a refrigerant holding charge the crankcase heater should be energized for a minimum of 12 hours to reduce the possibility of liquid slugging on start up Failure to energize the crankcase heater could result in compressor damage If the system is charged and started from a vacuum the pr...
Page 17: ...llowed to stabilize for several minutes before meaningful measurements can be taken A properly charged system operating at typical parameters will have a head pressure of 225 to 275 psi Suction pressure should be 58 psi or greater The superheat at the compressor suction line at least 6 inches away from the compressor should be 8 15 Note Charging to a full liquid line sight glass should never be th...
Page 18: ...cutout switch with a manual reset button The cutout pressure rating for refrigerant R 22 is 400 psi Physical location is near the compressor which may be either in the evaporator or the condensing section 5 5 3 Low Pressure Cutout Switch Each circuit also contains a low suction pressure cutout switch with automatic reset The cutout pressure rating for this switch is 30 psi Physical location is nea...
Page 19: ...oubleshooting The Mini DAP II microprocessor control panel has an entire manual dedicated to its use and operation This manual must be referenced to complete a thorough unit installation Start up is not complete until the Mini DAP II control panel settings are established 6 4 Optional DAP II Microprocessor Control Panel The DAP II microprocessor control panel is available as an upgrade to the Mini...
Page 20: ...ations will quickly clog new filters Air filters that require changing can restrict airflow and create problems such as coil icing or poor air distribution 7 2 Bearings Blower bearings used on Data Cool units are permanently lubricated and do not require maintenance 7 3 Humidifier Canisters The optional steam generator type humidifier does not require maintenance other than to replace the canister...
Page 21: ...lled refrigerant filter driers do not normally require maintenance When replacing compressors or other repairs that open the refrigeration system to atmosphere it is advisable to replace the filter drier The equivalent type and size should be used ...
Page 22: ...f a freeze up are also excluded These warranties cannot be transferred or assigned by you and shall run only in favor of the original owner user of the DataAire Inc unit Prior written authorization by DataAire Inc is required for the return of any parts which are deemed to be defective These warranties shall not apply to the replacement of air filters belts refrigerant customer provided parts heat...
Page 23: ...ch_support dataaire com Technical Support engineering dataaire comEngineering sales dataaire com Sales Web site www dataaire com Job Information Data Aire Job Number _________________________________________ Evaporator Serial Number ______________________________________ Evaporator Model Number _____________________________________ Condensing Unit Fluid Cooler Serial Number _______________________...
Page 24: ...per EQUIVALENT FEET Tonnage Circuit 50 100 150 200 2 2 3 8 1 2 1 2 1 2 3 3 1 2 1 2 1 2 1 2 SUCTIONLINES SINGLE CIRCUIT SYSTEMS EQUIVALENT FEET Unit Tons per 50 100 150 200 Tonnage Circuit HOR VER HOR VER HOR VER HOR VER 2 2 7 8 7 8 7 8 7 8 7 8 7 8 1 1 8 7 8 3 3 7 8 7 8 1 1 8 7 8 1 1 8 7 8 1 1 8 7 8 HOR HORIZONTAL VERT VERTICAL ...
Page 25: ... Water regulating valve function ___ Check for water glycol leaks piping area Glycol Pump s if applicable ___ Glycol leaks pump area ___ Pump operation ___ Auto air vent clean of mineral deposits Condensate Drain and Pump if applicable ___ Check for water leaks ___ Check for restricted air flow ___ Pump operation Steam Generating Humidifier if applicable ___ Check canister for deposits and water l...
Page 26: ...tch operational Glycol Pump s if applicable ____ Glycol leaks pump area ____ Pump operation ____ Auto air vent clean of mineral deposits Condensate Drain and Pump if applicable ____ Check for water leaks and restricted flow ____ Pump operation Steam Generating Humidifier if applicable ____ Check canister for deposits and water level ____ Check condition of steam hose and clamps ____ Check drain an...
Page 27: ...27 ...
Page 28: ...er 12 20 I Inspection 6 Installation 6 Internal Volume see Volume A Air Cooled Systems 7 8 9 12 14 24 25 Air Filters 15 20 Air Vents 10 Ambient Thermostats 6 7 18 19 Auxiliary Control Wiring 15 B Bearings 20 C Charging Air Cooled Fan Speed Systems 12 16 Air Cooled Split Systems 15 Water Glycol Systems 17 Coils Condenser 7 17 18 Compressors 8 10 12 15 16 17 18 20 21 Crankcase Heaters 15 17 Fan Moto...
Page 29: ...2 R Recovery 18 Refrigerant 8 12 15 16 17 18 Charge see Charging Handling 18 Recovery 18 Reheat Elements 20 Electric 20 Remote Condensing Units 7 11 13 14 15 20 Fluid Coolers 10 11 12 13 14 19 20 Rigging 14 S Sight Glass 16 17 Start Up Sheet 7 Storage 7 Strainer 10 12 Subcooling 16 Suction Lines 8 9 10 16 17 24 Superheat 16 17 T Thermo expansion Valve TXV 18 Thermostats Ambient 6 7 18 Programmable...
Page 30: ...________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ___________________...
Page 31: ......
Page 32: ...ww dataaire com e mail sales dataaire com A Member of the CS Group of Companies 2011 Data Aire Inc Data Aire Inc reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice DACU IOM 0807 Rev A ...
