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Data Aire DAFC 06, Installation, Operating And Maintenance Manual

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Data Aire DAFC 06 Installation, Operating And Maintenance Manual Download Page 34

AIR-COOLED FLUID COOLER

 

34 

•

 Air-Cooled Condenser Manual 

7.8 

Maintenance Functions 

Monthly

 

Inspect fluid cooler for obstruction to the inlet air side of the coil 

Inspect the motor/fan blade assemblies to ensure the bearings 

are free and the motor mounts and fan(s) are secure 

Bleed air from the system 

Seasonally

 

Inspect electrical components for loose wire connections 

Inspect  contactor  contacts  for  pitting  Check  glycol  solution  level  in  the 
system Inspect fan motor(s) 

In the winter, do not allow snow to accumulate or build-up around 

the sides or underneath the coil 

Bi-Annually

 

Check the glycol solution inhibitors.  Flush as necessary 

Clean the fluid cooler coil of all debris that could restrict airflow 

Annually

 

Check the glycol system for leaks and corrosion 

 

 

 

Summary of Contents for DAFC 06

Page 1: ...1 Air Cooled Condenser Manual ...

Page 2: ... information considered important but may have potential hazard for personal injury or property damage NOTICE This Installation Operation and Maintenance Manual IOM is intended to assist trained service personnel by providing necessary guidelines for this equipment Service to Data Aire units should be done by qualified individuals with an adequate background in areas such as HVAC electrical plumbi...

Page 3: ...me 16 3 5 Freezing Point of Aqueous Solutions 17 3 6 Mixing Glycol and Water 17 4 0 ELECTRICAL CONNECTIONS 18 4 1 General Electrical Field Wiring Guidelines 18 4 2 Electrical Service 19 4 3 Nameplate Ratings 19 4 4 Grounding 20 4 5 Voltage Tolerance 20 4 6 Phase 21 4 7 Remote Heat Exchanger Auxiliary Control Wiring 21 4 8 Disconnect Switch Optional 22 4 9 Wiring Diagrams 23 5 0 CONTROLS 24 5 1 Ele...

Page 4: ...Replacement 30 7 6 Axial Fans with Electronically Commutated Motor 30 7 7 Preventive Maintenance 33 7 8 Maintenance Functions 34 8 0 FREQUENTLY ASKED QUESTIONS FAQ 35 9 0 CONTACT DATA AIRE 37 10 0 REMOTE THERMOSTAT BULB MOUNTING INSTRUCTIONS 38 10 1 TYPICAL SENSING BULB INSTALLATION 38 10 2 NOTES 38 ...

Page 5: ...nnections to be made at the job site All electrical connections and controls are enclosed in an integral weatherproof electrical control section of the fluid cooler The AC motors are thermally protected direct drive type Fan cycling is controlled by ambient thermostats or electronic temperature controller on dry coolers with more than one fan 1 1 Model Identification 1 2 Inspection This Data Aire ...

Page 6: ...ta Aire for proper activation of the unit warranty Failure to do so may cause delays and in some cases void the warranty WARNING This equipment may contain substance that has been deemed harmful to public health and the environment Venting of refrigerants to the atmosphere is illegal Refrigerant recovery devices must be used when installing and or servicing these types of products 1 4 Storage Data...

Page 7: ...f applicable Humidity range 25 to 50 RH High humidity may cause damage to insulation and electrical components Storage in moist air above 50 should be avoided High humidity may cause rust on metal components such as sheave pulley blower housing cabinet parts supports etc Low Humidity may cause brittle conditions to components within the unit At low humidity problems of brittleness or electrical st...

Page 8: ... offering maximum security Where service is easily accessible Areas where public access is available should be avoided Install in an area with adequate airflow Remote heat exchangers should be located in clean areas free from debris or foreign matter that could clog the coil surface Avoid areas with loose dirt or other blowing matter which might clog the coil Avoid areas that contribute to ice and...

Page 9: ...nstall heat exchangers in a pit See Figure 1 or minimum clearance from obstructions and between units Noise factors should be considered when locating an air cooled heat exchanger Proximity to windows walls and surrounding structures can cause objections by the occupants An acoustical expert should be consulted when noise is of a concern Avoid installing heat exchangers near occupied spaces above ...

Page 10: ...d practices and in accordance with local codes should be followed in either instance 1 7 Rigging Outdoor heat exchangers should be moved to their mounting location typically rooftop using a crane or forklift Each fan section has heavy gage steel leg supports with lifting holes at the top of the legs Do not lift with a choke sling around the unit or coil Spreader bars are recommended for lifting mu...

Page 11: ...e NEC for special installation requirements 1 8 1 Installation Checklist WARNING When preparing the equipment proper care should be taken when uncrating the unit The packaging has wrapping bands with sharp edges that are under tension crating has staples and splinters Proper Protective Equipment PPE should be worn by qualified personnel Remove the metal strapping bands Remove the wooden crating Rem...

Page 12: ...ities when installed in accordance with industry standards System piping must be installed following industry standards for good piping practices System must be thoroughly leak checked before initial charging System power supply must meet Voltage Tolerance see section 4 5 All controls and safety devices properly connected per wiring diagram Factory installed wiring must not be changed without writ...

Page 13: ...quired at all high points in the piping in order to bleed air when filling the system Gates valves field provided by others are recommended to be installed on both sides of the pump to prevent loss of fluid during repair or replacement Shut off valves field provided by others are also recommended at the fluid cooler in the event the evaporator is to be moved or maintenance is required for the cool...

Page 14: ...k can be provided by Data Aire as an option 3 All water glycol field piping must be designed and installed in accordance with ASHRAE standards and local codes 4 Centrifugal pumps and components are optional A flow switch is required with dual pump application 5 Variable pump flow control or a bypass system are the responsibility of the installing contractor when a 2 way valve is specified in the e...

Page 15: ...se the product safely The installing contractor must read understand and comply with the information on the product packaging and in the current Material Safety Data Sheets This information also must be available to anyone responsible for operation maintenance and repair of the fluid cooler and related equipment Because government regulations and use conditions are subject to change it is the end ...

Page 16: ...039 DAFC 11 3 3 GHFC 176 DAFC 50 20 3 GHFC 053 DAFC 15 4 9 GHFC 201 DAFC 57 24 6 GHFC 060 DAFC 17 6 6 GHFC 215 DAFC 61 19 6 GHFC 074 DAFC 21 7 4 GHFC 264 DAFC 75 26 0 GHFC 084 DAFC 24 9 8 GHFC 281 DAFC 80 32 6 GHFC 099 DAFC 28 12 3 GHFC 310 DAFC 88 32 4 GHFC 106 DAFC 30 9 8 GHFC 352 DAFC 100 40 6 3 3 Copper Piping Internal Volume Pipe Diameter Inches Volume per 100 Feet of Pipe Gallons 5 8 1 2 3 4...

Page 17: ...ygen Oxygen is extremely undesirable in a closed loop system NOTICE Risk of using the wrong type of glycol Can cause piping damage coolant fluid leaks and catastrophic and expensive building and equipment damage Do not use automotive antifreeze as it contains chemicals that can damage the piping system Typical inhibited formula ethylene glycol and propylene glycol are supplied with corrosion inhib...

Page 18: ...nt must be connected by a licensed and qualified electrician Risk of electrical shock could result in injury or death Disconnect all remote electrical facility power prior to working on the unit All wiring must conform to local and national electrical code requirements Seal openings around piping and electrical connection to prevent air leakage Failure to do so could reduce the unit s cooling perf...

Page 19: ... to that specified on the unit electrical nameplate Check to be sure the electrical service provided by the utility company is enough to handle the additional load imposed by this equipment Remote fluid coolers will typically require one power source Glycol systems with fluid coolers and loose pump s typically require one power source for the fluid cooler and will require one additional source for...

Page 20: ...one or several phases which in turn leads to overheating and possible damage The local utility company should be contacted for correction of improper line voltage Deviation from ratings can cause premature failures and possibly void unit warranty For three phase units only three power wires and an earth ground are required A neutral is not required at the unit input connections Three Phase Voltage...

Page 21: ...rical control box of the indoor evaporator to the electrical control box of the remote heat exchanger Follow the wiring diagrams for each of these pieces of equipment NOTICE For installation more than 100 feet 30 meters and up to 200 feet 61 meters from the electrical control box of the indoor evaporator to the electrical control box of the remote heat exchanger require heavier gauge wire and a sp...

Page 22: ...ess to the high voltage electrical components until switched to the OFF position The operating mechanism protrudes through the exterior door and is lockable in the OFF position NOTICE The optional disconnect switch extension shaft and locking handle are shipped loose to prevent damage during transit and installation It is the installing contactors responsibility to install these components as part...

Page 23: ...e electrical components and how they interface with the controls as well as peripheral equipment including remote heat exchangers The wiring diagram in the evaporator will indicate field interface terminals to the remote heat exchanger The internal wiring of the remote heat exchanger is found on a separate diagram which can be found on the inside cover of the heat exchanger electrical box Both dia...

Page 24: ...r there is a call for cooling via an auxiliary signal sent from the indoor evaporator section The thermostat sensing bulbs are strapped to the leaving fluid header The fluid sensing thermostats have adjustable setpoints which are staggered to maintain fluid temperature in the 85 F to 105 F 29 4 C to 40 6 C range This is generally the desired range for glycol cooled systems These setpoints are fact...

Page 25: ...al NOTICE Every application will have a different ambient temperature and indoor heat load air distribution profile Therefore it is not possible to dictate the exact fluid temperature setpoint Field adjustments are typical to allow fine tuning to specific conditions It is desirable to use the Energy Saver mode as much as possible However fluid temperature that is cold can cause excessive dehumidif...

Page 26: ... section Data Aire units have been designed to operate continuously provided they are regularly maintained and operated within the limitations given in this manual Each unit should be included in a routine schedule of daily maintenance checks by the operator customer backed up by regular service inspection and maintenance visits by a suitably qualified Service Technician Good maintenance practices...

Page 27: ...e carried out every three to six 6 months and a major service once a year It is recommended that Data Aire Service Department be contacted for recommendations for individual sites CAUTION Personal Protective Equipment is to be used for maintaining and servicing equipment Some operations when servicing or maintaining the unit may require additional assistance regarding manual handling This requirem...

Page 28: ... pushed further in Be sure to carefully read and follow the cleaning fluid manufacturer s recommendations before using any cleaning fluid Using a brush non metallic clean the coil fins of all debris that will inhibit airflow This can also be done with compressed air or with a commercial coil cleaner CAUTION Caution should be exercised in selecting the cleaning solution as well as the cleaning equi...

Page 29: ...l thoroughly Any residue left on the coil can act as a magnet to dirt Reinstall and secure the fan blades and fan guards after the cleaning is finished Last reconnect the power supply to the unit 7 4 Electrical Control Enclosure DANGER The inside of the electrical control enclosure contains high voltage components and wiring Access should be limited to authorized personnel Arc flash and electric s...

Page 30: ...e end with end of fuse holder clips Turn ON power and verify that operation has been restored 7 6 Axial Fans with Electronically Commutated Motor Axial fan s with Electronically Commutated EC motors are standard equipment on all gForce GHRC and GHCU condensers Axial fan s with EC motors are maintenance free and only require visual inspection The motors are sealed have maintenance free ball bearing...

Page 31: ...ION Do not attempt to remove any obstruction without first disconnecting the power to the motor Once the obstruction is removed the motor will start if powered Disconnect AC power to the motor determine if the blade will spin and rotate freely Any blockage or rubbing will cause the motor to stop operation until the obstruction is removed 7 6 4 Confirm to Following The unit does not have any visible...

Page 32: ...otor terminals Confirm that the correct AC voltage is present on all three phases at the fan terminals including a good ground connection Check for damage or any short in the power leads to the motor To simplify troubleshooting all the control wiring at KL3 and alarm relay wiring KL2 should be labeled capped or taped and removed from the motor This will prevent any external issues from effecting th...

Page 33: ...or using a multimeter confirm the proper voltage is present at the input of the motor by measuring at the spring contact on the motor at the terminal block Confirm that the PWM or 4 20mA signal is correct using the appropriate measuring instrument If the motor still does not operate remove and replaced Typically problems can be found and corrected by following the listed guidelines If the module wil...

Page 34: ...air from the system Seasonally Inspect electrical components for loose wire connections Inspect contactor contacts for pitting Check glycol solution level in the system Inspect fan motor s In the winter do not allow snow to accumulate or build up around the sides or underneath the coil Bi Annually Check the glycol solution inhibitors Flush as necessary Clean the fluid cooler coil of all debris tha...

Page 35: ...etup matters QUESTIONS ANSWERS Electrical FAQ Section 1 What is FLA Full load Amps Represents the amount of current a motor is designed to draw at the rated horsepower 2 What is MCA Minimum circuit ampacity This is used to help determine the wire size 3 What is MOP Maximum Overcurrent Protection device This is to help determine the maximum protective device 4 What is the input voltage tolerance In...

Page 36: ...ve initial surges of electrical power when the resistance load starts Resistance loads may be electric heat humidifier etc 10 Where is the unit wiring diagram Each unit is shipped with wiring diagram inside the electrical control enclosure Contact Service Department for replacement wiring diagram if necessary 11 What is the electrical rating for the unit The electrical ratings are located on the u...

Page 37: ...92865 Telephone 714 921 6000 800 347 2473 E mail Service dataaire com Engineering dataaire com Sales dataaire com Fax 714 921 6010 Main 714 921 6011 Engineering 714 921 6022 Parts Sales Web Site www dataaire com Job Unit Information Data Aire Job Number Condenser Model Number Condenser Serial Number Date Installed Installing Contractor ...

Page 38: ... a zip tie to position the sensing bulbs in place on the header 3 Secure the sensing bulbs with two 2 copper straps and a Tek screw 4 Apply thermal mastic paste evenly to the contact points of each bulb and the leaving water header to increase the heat conductivity 5 Install insulation tape around the sensing bulbs as shown in the picture 6 Set the thermostats controllers located inside the electr...

Page 39: ...AIR COOLED FLUID COOLER 39 Air Cooled Condenser Manual Figure 5 Fan Thermostat Controller Temperature Setpoints ...

Page 40: ...AIR COOLED FLUID COOLER 40 Air Cooled Condenser Manual Figure 6 Fluid Temperature Sensor Bulbs ...

Page 41: ...AIR COOLED FLUID COOLER 41 Air Cooled Condenser Manual Figure 7 Half Insulated Applying Thermal Mastic and Insulation Tape ...

Page 42: ...AIR COOLED FLUID COOLER 42 Air Cooled Condenser Manual Figure 8 Fully Insulated Bulbs ...

Page 43: ...hanger 8 Inspect 5 8 Inspection 5 Installation Operation and Maintenance Manual IOM 2 6 Internal Damage 5 Locating 8 Loose Items 6 Maintenance 26 35 Maintenance Inspection Checklist 27 Maximum Overcurrent Protection MOP 19 35 Minimum Circuit Ampacity MCA 19 35 Multimeter 31 National Electrical Code NEC 11 Obstruction 8 Paperwork 6 Personal Protective Equipment PPE 11 18 27 29 Piping 8 9 12 18 28 P...

Page 44: ...NOTES 44 Air Cooled Condenser Manual ...

Page 45: ...Publication Fluid Cooler IOM FluidCoolerIOM 03 2022 docx Date 03 2022 ...

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