Data Aire gPod Installation, Operation & Maintenance Manual Download Page 56

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Installation, Operation and Maintenance Manual

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Summary of Contents for gPod

Page 1: ...gPod DX Air Water or Glycol Cooled Ceiling and Floor Mounted Installation Operation Maintenance Manual Data Aire Inc 230 W BlueRidge Avenue Orange CA 92865 www dataaire com...

Page 2: ...Data Aire precision cooling system including dap4 or Mini dap4 air cooled condensers and fluid coolers This manual is intended to assist trained service personnel by providing necessary guidelines fo...

Page 3: ...and the property in which it is situated as well as severe personal injury or death to themselves and people at the site This document is intended for use by owner authorized operating service personn...

Page 4: ...ithout installing a plenum ductwork or guard over the blower opening s on the top surface of the unit cabinet Ductwork must be connected to the blower s or a plenum must be installed on the blower dec...

Page 5: ...alist before startup to establish the inhibitor requirement The water or water glycol solution must be analyzed every six months to determine the pattern of inhibitor depletion The complexity of water...

Page 6: ...ions NOTICE Using substitute parts or bypassing electrical or refrigeration components is not recommended and will VOID THE WARRANTY NOTICE Using substitute parts or bypassing electrical or refrigerat...

Page 7: ...PIPING CONNECTIONS INSTALLATION 10 ELECTRICAL INSTALLATION 10 REFRIGERATION SETUP 10 2 7 1 Leak Test 11 SYSTEM CONTROL SETUP 11 POST INSTALLATION 11 INSTALLATION OF REMOTE HEAT EXCHANGER 12 VOLTAGE P...

Page 8: ...9 REFRIGERANT HANDLING 31 5 ELECTRICAL CONNECTIONS 32 GENERAL ELECTRICAL FIELD WIRING GUIDELINES 33 ELECTRICAL SERVICE 33 NAMEPLATE RATINGS 34 GROUNDING 34 VOLTAGE TOLERANCE 34 STANDARD ELECTRICAL CON...

Page 9: ...es 48 7 4 3 EC Plug Fan Maintenance 49 UNITS WITH BELT DRIVEN BLOWERS 49 7 5 1 Belts 49 7 5 2 Bearings 49 AIR FILTERS 50 7 6 1 Upflow Unit Air Filter Replacement Procedure 50 7 6 2 Ceiling Unit Air Fi...

Page 10: ...WITH ELECTRONICALLY COMMUTATED EC MOTORS EC 71 SMOKE DETECTOR MAINTENANCE 72 7 27 1 Smoke Detector Testing 72 7 27 2 Cleaning Smoke Detector 73 CONTROLS 73 TEMPERATURE AND HUMIDITY SENSOR MAINTENANCE...

Page 11: ...Grounding Lug 34 Figure 10 Typical Remote Heat Exchanger Interconnection Points 36 Figure 11 Typical Indoor Evaporator Interconnection Points 37 Figure 12 Typical Mini dap4 Remote Alarm Contact Termin...

Page 12: ...ture humidity dehumidification and CO2 control for users to achieve successful yield after yield Floor or ceiling configuration CO2 control Light sensor Web based control on any smart device Temperatu...

Page 13: ...te Loose items such as remote display disconnect switch handles condensate pumps spare belts spare filters etc are packed inside the unit Refer to the manila shipping tag located on the unit panel for...

Page 14: ...ocal building codes and National Electrical Code NEC for special installation requirements Recommended Tools for Installation Wrenches Common sizes Flat tip and Phillip screwdriver Common sizes Wiring...

Page 15: ...to maintain the room s conditions For floor units verify that the floor is level and solid enough to support the unit The equipment must be level to operate properly and prevent damage to the interna...

Page 16: ...s panels or frame members When installing the unit enough space must be allowed for airflow clearance wiring plumbing and service access It is recommended that each side and front have a clearance of...

Page 17: ...ugh the unit s microprocessor controller Data Alarm Processor 4 dap4 Other fan speed control options are available and some require optional hardware to facilitate the optional control See the dap4 op...

Page 18: ...lable installation options One method is to hang the ceiling mounted units by means of a cradle type installation This method requires four 4 field supplied threaded hanging support rods which must be...

Page 19: ...rage NOTICE Important This storage section is not intended to be a comprehensive guide for all possible issues associated with construction conditions construction stage and indoor environment how int...

Page 20: ...nning but recommend the unit be set level for 24 hours prior to final installation Store at non condensing temperature and humidity conditions 2 4 2 General Storage Considerations All equipment shall...

Page 21: ...low for expansion and contraction changes for piping connections this will prevent stresses which may buckle and rupture the copper piping or joints During the installation the lines should be capped...

Page 22: ...oth field and factory furnished components After completion of leak testing release test pressure and pull a vacuum on the system NOTICE Because fitting may loosen during transit tightening of fitting...

Page 23: ...oller or use compressor Manual control Mode in menu I if using the Mini dap4 controller Observe the compressor operation for a short period of time then slide the switch back to the OFF position An ou...

Page 24: ...ing design should comply with required codes law and regulations that apply at the site of the installation Examples Mechanical Refrigeration Code CSA B52 Building Code Plumbing Code ASHRAE 15 Municip...

Page 25: ...of flow at approximately 1 2 inch 12 7 mm per 10 feet 3 1 m or 1 inch 25 mm per 20 feet 6 1 m ASHRAE Standard 15 and ASME Standard B31 5 should be used as guides for safe practice because they are th...

Page 26: ...lver phosphorus copper alloy with 5 to 15 silver be used to braze the refrigerant line sets to the indoor and outdoor units Nitrogen needs to be flowing through the lines to eliminate carbon deposit b...

Page 27: ...External field piping must be supported within 18 of the inlet and outlet connections 3 2 2 Liquid Lines Liquid line size is determined by the recommended allowable pressure drop and velocity The liq...

Page 28: ...r must install mid rise trap s every 15 feet or evenly spaced points along the vertical lift 4 An inverted trap is required at the top of the vertical rise and no greater than 3 feet horizontal distan...

Page 29: ...Condenser Below Evaporator 3 2 6 Connection Sizes Air Cooled Units CEILING MOUNTED UNITS Model Number Hot Gas Discharge Line Liquid Line GPAX 2 5 1 2 O D 1 2 O D GPAX 03 1 2 O D 1 2 O D GPAX 04 1 2 O...

Page 30: ...will not necessarily be the same as the field pipe size required In some cases these sizes will vary significantly Recommended Line Sizing for Air Cooled Split Systems 3 3 1 Hot Gas Lines Single Circu...

Page 31: ...size will depend on the length of pipe and the calculated pressure drop of peripheral components Shutoff valves field provided should be installed within a few feet of the inlet and outlet connections...

Page 32: ...Installation Operation and Maintenance Manual Page 21 of 100 3 5 1 Field Piping Water Glycol System Figure 7 Typical Water Glycol System...

Page 33: ...ndensate Drain Piping To properly drain the condensate from the evaporator condensate pan the evaporator section is equipped with a 3 4 FPT connection on the bottom of the unit for condensate removal...

Page 34: ...commended dimensions for fabricating a proper trap when required to be field fabricated Figure 8 Recommended Condensate Trap Dimensions Notes 1 This trap is capable of handling static pressures equal...

Page 35: ...ompression fitting is provided at the humidifier A field provided shut off valve should be installed outside the unit to allow disconnection of service A field provided in line water pressure regulato...

Page 36: ...the system both liquidline solenoid valve and Rotolock type service valves if the compressor is equipped with them need to remain open during the vacuum process and the system must be purged of nitro...

Page 37: ...high and low ports near the compressor connect the charging line to the refrigerant tank and set it for liquid feed Open the refrigerant tank valve and purge the line at the manifold then open the hi...

Page 38: ...e 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...

Page 39: ...pressor Check the liquid line sight glass to get a feel for the approximate charge Bubbles in the sight glass are not unusual at this point and can be caused by flashing from liquid line pressure drop...

Page 40: ...stored in the receiver Flooded systems require more refrigerant than fan speed control systems Connect the pressure gauge manifold set to the high and low ports near the compressor Connect the chargin...

Page 41: ...ser fan must be de energized to maintain head pressure Observe the sight glass on the receiver Add refrigerant through the suction line until the level of liquid in the receiver is approximately 1 3 f...

Page 42: ...tremely small releases of refrigerant such as what occurs when disconnecting service hoses a technician who knowingly releases or vents refrigerant to the atmosphere is in violation of this regulation...

Page 43: ...ional loads to the system control transformers Connecting additional loads to the factory supplied control transformer may result in overloading of the transformer WARNING Improper wire connections wi...

Page 44: ...following specifications Control wires only a Conductors AWG stranded copper b Twisted pair minimum eight twists per foot c Braided shield or foil shield d UL approved temperature rated to 105 C e UL...

Page 45: ...installing contactor to be compliant with the product UL listing The facility main distribution panel which provides electrical service to the Data Aire equipment must be provided with a manual fused...

Page 46: ...controller includes the unit control and displays operating functional information and service diagnostics The controller allows recall and display of the high and low temperature high and low humidit...

Page 47: ...requires the connection of two 2 18 gauge wires for installations up to 150 feet 45 m or 16 gauge wires for installations from 151 feet 46 m up to 200 feet 61 m from the electrical control panel of th...

Page 48: ...to verify these points see electrical diagrams supplied with each unit to verify the exact TB designation The unit is shipped with a factory installed jumper bar that connects TB1 1 and TB1 2 Remove t...

Page 49: ...already connected to a predetermined length of multi conductor cable and a remote wall mounted enclosure When ordered the remote temperature and humidity sensor is shipped with a 35 foot 11 m cable a...

Page 50: ...and wired condensate pan overflow detection float switch located in the condensate drain pan If needed an optional flow switch can be ordered to be used as a secondary condensate drain pan alarm Cons...

Page 51: ...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 position Wiring Diagrams Every...

Page 52: ...ronically commutated EC motor i e plug fan use a current sensing switch CT as a safety to alarm when the air flow is unusually low or no air flow Figure 14 Current Sensing Switch shows the CT used to...

Page 53: ...ack to normal operation 3 Move to Menu Analog Output 3 and adjust the fan speed to the desired low limit operating point In this example the low limit is 30 Change the Mode to Manual and Manual Value...

Page 54: ...reen TRIP OFF LED indicates the current is above the adjustable trip point When the Green TRIP OFF LED is lite the fan s are operating in a normal current range and the No Airflow Alarm message will d...

Page 55: ...tch with automatic reset The switch is located near the compressor The fixed pressure setting for R 410A systems is 20 PSIG 138 kPa Controls 6 3 1 Mini dap4 Controller Ceiling Units The Mini dap4 cont...

Page 56: ...Installation Operation and Maintenance Manual Page 45 of 100...

Page 57: ...ily by the operator customer Please note that the units are not generally user serviceable and no attempt should be made to rectify faults or problems found during daily checks unless competent and eq...

Page 58: ...OFF the optional disconnect switch and or disconnect all power sources to the units before opening any door or panel 3 Unlock and open the door by using a flat blade screwdriver or other tool to turn...

Page 59: ...ually test the EC plug fans turn ON the Blower slide switch and the Fan Speed slide switch on the Manual Override Switch Board This will enable a temporary analog fan control signal to the maximum val...

Page 60: ...l 7 4 3 EC Plug Fan Maintenance Maintenance is not required on EC motor plug fan modules The motors are sealed have maintenance free ball bearings and permanent lubrication The only acceptable service...

Page 61: ...r filter pressure differential pressure switch for proper adjustment temporarily cover approximately 75 of the return air opening using heavy cardboard or similar material The alarm should energize wh...

Page 62: ...humidifier assembly is capacity field adjustable and includes a high water probe Drain duration and drain interval are also field adjustable See the humidifier manufacturer s literature for more deta...

Page 63: ...OFF position 6 Turn OFF all electrical input power to the unit with the external disconnect The inside of the humidifier s cabinet contains high voltage components and wiring Access should be limited...

Page 64: ...ose Pull hose from drain valve Lift the drain valve from the drain pan 5 Unsnap red coil cap on solenoid and remove the solenoid from the valve 6 Loosen brass nut holding actuator to plastic housing w...

Page 65: ...eration and Maintenance Manual Page 54 of 100 CAUTION Be sure to reattach the green ground wire to reduce the risk of electrical shock Figure 20 Typical Humidifier Drain Valve Figure 21 Typical Drain...

Page 66: ...age to the humidifier It is recommended to keep a replacement cylinder in stock throughout the humidification season This will prevent possible downtime when the humidifier reports cylinder end of lif...

Page 67: ...structions in gravity lines leading to condensate pump 5 Check operation of float s for free movement 6 Inspect and clear clogs in discharge check valve and float mechanism 7 Reassemble and check for...

Page 68: ...d support as necessary 3 Check all piping for signs of leaks 4 Check for condensation water spot piping insulation damage frost or other visual sign of wear or damage Periodic inspection of the coil f...

Page 69: ...ow Switch Replacement NOTICE Must refer to document ship with the flow switch for instructions for installing the paddle 1 Disconnect all remote electric power source to unit before maintenance or ser...

Page 70: ...furnished Using terminal screws other than those provided will void the warranty and may damage the switch 8 To adjust the setting of the flow switch Disconnect electrical power source before making...

Page 71: ...g personnel who are using the equipment to see if there have been any reports of abnormal or erratic operation Install a temporary test gauge set and check the compressor suction and discharge pressur...

Page 72: ...ation voltage refrigerant type etc Also may vary due to product improvement or due to special job specifications This does not apply to field supplied compressor special order compressors tandem or va...

Page 73: ...es to ensure that the compressor oil is completely degassed 12 Do not hammer the compressor suction and discharge tube fittings flat and braze them closed These fittings must remain undamaged so the c...

Page 74: ...g upon the phasing of the input power b Verification of proper rotational direction must be made by observing that the suction pressure drops and the discharge pressure rises when the compressor is en...

Page 75: ...ion as the original part with Sil Fos or equivalent silver copper phosphorus composition brazing material No soldering allowed NOTICE The area should be vented thoroughly to prevent formation of dange...

Page 76: ...s an extra precaution a wet cloth may be wrapped around the body and element during brazing operation 12 Evacuate and charge the system with the specified quantity of refrigerant 13 Adjust refrigerant...

Page 77: ...the connection during the brazing operation Overheating can also be minimized by directing the flame away from the valve body 4 When valve body has cooled to room ambient temperature then reinstall v...

Page 78: ...ns 4 Contactors should be kept clean and free from dust and other accumulated deposits Dust can be removed from the contactor by blowing with dry air that is free from lubricants 5 Check for hairline...

Page 79: ...dic cleaning is recommended 7 22 1 Electric Reheat Element Checklist 1 Check wire connections inside reheat box 2 Check reheat wires for wear or damage Repair as needed 3 Check for any physical damage...

Page 80: ...The physical size and shape may vary The new capacitor must have the same identical performance properties as the original one d Make sure to purchase the replacement capacitor with rubber boot Capaci...

Page 81: ...damage Repair or replace as needed 9 Remove all mounting screws from original the contactor 10 Using the existing fasteners mount the new contactor to the original surface using all contactor mounting...

Page 82: ...HE FIRST 5 MINUTES AFTER DISCONNECTING OF ALL ELECTRICAL POWER If one of the fan internal safeties are triggered the motor will stop via electronic controls and an FAN FAILURE alarm will be indicated...

Page 83: ...dergoing maintenance and will temporarily be out of service Disable the zone or system undergoing maintenance to prevent unwanted alarms Detectors must be tested as part of periodic maintenance Check...

Page 84: ...r screen assembly by pulling it straight out 7 Use a vacuum cleaner or compressed air to remove dust and debris from the sensing chamber 8 Reinstall the chamber cover screen assembly by sliding the ed...

Page 85: ...e new controller is in place and operational 1 Turn OFF all remote electric power source to unit before maintenance or servicing 2 Use lock out tag out protection 3 Record all connection to the Mini d...

Page 86: ...roller is in place and operational Refer to dap4 or Mini dap4 User Manual for programming details 18 Check all sensors and options are operating correctly 8 Low Ambient Receiver Package NOTICE The pre...

Page 87: ...ing head pressure control in cold climates but they increase initial cost add complexity to the refrigeration system increase installation time and increase the refrigerant charge The loss of sub cool...

Page 88: ...device after such an occurrence Refrigerant Receiver Installation 1 Install the liquid refrigerant receiver after the condenser and before the liquid line filter drier 2 An NPT fitting is provided on...

Page 89: ...l refrigerant temperature during cold ambient outdoor conditions The heaters are wired single phase and powered by the condenser power source Receiver Heater Electrical Wiring 1 Wire per the condenser...

Page 90: ...temperature and humidity setpoints for day and night operation CO2 Control The CO2 option allows the gPod unit to control monitor and display alarms for CO2 levels The package includes a CO2 sensor a...

Page 91: ...and Maintenance Manual Page 80 of 100 10 Warranty Policy See the hardcopy Warranty Statement which is provided in the warranty information packet which is located inside the electrical control panel...

Page 92: ...one 714 921 6000 800 347 AIRE 2473 Toll Free E mail Service dataaire com Engineering dataaire com Sales dataaire com Website www dataaire com Fax 714 921 6010 Main 714 921 6022 Parts Sales Job Unit In...

Page 93: ...friction loss c Long or small line d Plugged drier or strainer 11 Low pressure across valve a Vertical lift b Undersized distributor nozzle or circuits c Low condensing temperature High Suction Press...

Page 94: ...contractor operation dap4 or Mini dap4 controller operations Compressor Check for leaks Equipment Runtimes Condenser ___________ hours Refrigeration Cycle Section Compressor ___________ hours Check cr...

Page 95: ...n Air Distribution Section Check for restriction in grille s Compressor Check for leaks Refrigeration Cycle Section Check for moisture site glass Electrical Panel Check suction pressure Check fuses Ch...

Page 96: ...ndensate pump 22 37 55 Condensate trap 22 Contact Data Aire 45 51 60 73 80 Control and Isolation Transformer Replacement 69 Controller 34 43 47 73 Controls 43 72 D dap4 ii 1 4 21 29 39 43 46 47 48 49...

Page 97: ...cannisters 50 Humidifier cylinder 54 I Indoor condensers 7 L Leak test 10 13 14 Leak testing 23 Light sensor 1 Line traps 15 Liquid line 15 16 81 Liquid Line Solenoid valve LLSV 65 Locating 4 5 Loose...

Page 98: ...y Maintenance Inspection Checklist 83 R Receiver 28 29 61 75 76 77 Recommended gas velocity 15 Recommended tools 3 Refrigerant handling 30 Refrigerant Receiver Internal Volumes 76 Reheat 55 67 Remote...

Page 99: ...7 73 Thermostatic Expansion Valve TXV 63 U Under Floor water detection cable 38 Upflow 5 User Manual 78 V Version history ii Voltage 33 W Warranty 79 Water glycol cooled 19 57 Weather 75 Website 80 Wi...

Page 100: ...com 714 921 6000 gPod IOM Manual_09 2020 gPod DX Air Water or Glycol Cooled Installation Operation MaintenanceManual Ceiling and Floor Mounted Data Aire Inc 230 W BlueRidge Avenue Orange CA 92865 www...

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