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GForce Ultra Installation, Operation And Maintenance Manual Download Page 11

 

11 

2. 

INSTALLATION 

 

NOTE:

  There  is  no  intent  on  the  part  of  Data  Aire,  Inc.  to  define  local 

codes  or  statutes  which  may  supersede  common  trade  practices.  The 
manufacturer assumes no responsibility for their interpretation.  Consult 
local  building  codes  and  National  Electrical  Code  (NEC)  for  special 
installation requirements. 

During  installation,  operation,  maintenance  or  service,  individuals  may  be  exposed  to  certain 
components  or  conditions  including,  but  not  limited  to:  refrigerants,  oils,  and  materials  under 
pressure,  rotating  components,  and  both  high  and  low  voltage.  Each  of  these  items  has  the 
potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation 
and  responsibility  of  operating/service  personnel  to  identify  and  recognize  these  inherent 
hazards,  protect  themselves,  and  proceed  safely  in  completing  their  tasks.  Failure  to  comply 
with any of these requirements could result in serious damage to the equipment 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  personnel.  It  is 
expected  that  this  individual  possesses  independent  training  that  will  enable  them  to  perform 
their assigned tasks properly and safely. It is essential that, prior to performing any task on this 
equipment, this individual shall  have read and understood this document  and any referenced 
materials. This individual shall also be familiar with and comply with all applicable governmental 
standards and regulations pertaining to the task in question. 

This manual contains important safety instructions that should be followed during the installation 
and  maintenance  of  Data  Aire  equipment.  Read  this  manual  thoroughly  before  attempting  to 
install or operate this unit. 

Only qualified personnel should move, install or service this equipment. Adhere to all warnings, 
cautions and installation, operating and safety instructions on the unit and in this manual. Follow 
all operating and user instructions. 

 

WARNING:

  Risk of handling heavy and lengthy parts, risk of top-heavy 

unit falling over, risk of sharp edges, splinters and exposed fasteners; can 
cause personal injury and equipment damage.  Cabinet doors and panels 
can weigh more than 35lb. (15.9kg) therefore follow relevant OSHA lifting 
recommendations  and  consider  using  a  two-person  lift  for  safe  and 
comfortable removal and installation of cabinet doors and panels. 

Only properly trained and qualified personnel wearing appropriate safety 
headgear, gloves and shoes should attempt to remove or install cabinet 
doors and panels. 

 

 

 

Summary of Contents for Ultra

Page 1: ......

Page 2: ... in areas such as HVAC electrical plumbing and electronics as applicable WARNING Service performed by unauthorized or unqualified technicians may void manufacturers warranties and could result in property damage and or personal injury Safety Alert Symbols and Words for Hazard Alerting Safety DANGER Indicates a hazardous situation which if not avoided will result in serious injury or death WARNING ...

Page 3: ...ocating the Unit 16 2 8 Downflow Units 17 2 9 Upflow Units 18 2 10 Piping 19 2 11 Air Cooled Unit Piping 20 2 12 Discharge Lines 20 2 13 Liquid Lines 22 2 14 Recommended Line Sizing Air Cooled Units 22 2 15 Connection Sizes Air Cooled Units 23 2 16 Field Piping Remote Condenser Above Evaporator 24 2 17 Field Piping Remote Condenser Below Evaporator 25 2 18 Refrigerant Piping Protection 26 2 19 Wat...

Page 4: ...sing Cable Optional 40 3 15 Remote Temperature and Humidity Sensors Optional 40 3 16 Manual Override Switch Board 40 3 17 Plug Fan Current Sensing Switch 41 3 18 Wiring Diagrams 41 3 19 Electronic Expansion Valve 42 3 19 1 Electrical Connection to EEV 42 4 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER 43 5 CHARGING 44 5 1 Triple Evacuation and Dehydration Procedure 44 5 1 1 Tools Needed 44 5 1 2 F...

Page 5: ...ase Heaters 63 7 4 Oil Level 64 7 5 Variable Frequency Drive 64 7 5 1 Local Control for Charging 65 7 5 2 To View the Drive Alarms 65 7 6 High Pressure Cutout Switch 66 7 7 Low Pressure Cutout Switch 66 7 8 Liquid Line Solenoid Valve 66 7 9 Low Ambient Receiver Package 67 7 9 1 Refrigerant Receiver 67 7 9 2 Applications 68 7 9 3 Selection Guidelines 68 7 9 4 Receiver Location 68 7 9 5 Safety Relie...

Page 6: ...TACT DATAAIRE 85 Table of Figures Figure 1 Typical Upper Spring Loaded Hinge 16 Figure 2 Upper Hole for Spring Loaded Hinge 16 Figure 3 Lower Fixed Pin Hinge 17 Figure 4 Example of Lifting Method 18 Figure 5 Typical Return Discharge Air Distribution 20 Figure 6 Typical Remote Condenser Above Evaporator Installation 26 Figure 7 Typical Remote Condenser Below Evaporator 27 Figure 8 Typical Water Gly...

Page 7: ...commendation 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 reliability Refer to ASHRAE s publication Thermal Guidelines for Data Processing Environments The unique feature of the gForce Ultra is the application of variable capacity compressors The quest for greater energy efficiency i...

Page 8: ...ir filters are packed inside the unit Refer to the yellow shipping tag located on the unit door for details 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 with the shipping company if the equipment is damaged or incomplete NOTE Freight damage claims are the responsibility of the purchaser Action t...

Page 9: ...onthly the fan and motor should be rotated several times to replenish the bearing surfaces with fresh grease as needed and to prevent flat spots of the fan shaft The fan impeller should be left at approximately 180 from that of the previous month to prevent the belts from taking a set position It will be the responsibility of the customer to submit a monthly log sheet showing the condition of the ...

Page 10: ...age to the exterior of the cabinet or coil connections by construction vehicles and personnel Isolate from vibration sources Isolate from direct sun light Isolate from storage of hazardous materials and substances Refrigerant coils have been evacuated and pre charged with slight nitrogen holding charge DO NOT damage or disturb these coils and connections Water coils must have all inlet and outlet ...

Page 11: ...training that will enable them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood this document and any referenced materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question This manua...

Page 12: ...forklift or pallet jacks If using a forklift or pallet jack make sure that the forks if adjustable are spread to the widest allowable distance that will fit under the skid Ensure the fork length is suitable for the unit length Keep tines of the forklift level and at a height suitable to fit below the skid and or unit to prevent exterior and or underside damage When moving the packaged Data Aire un...

Page 13: ...be built with a proper vapor barrier A film of polyethylene is often used on walls and ceilings Walls and floors must also be painted with vapor seal paint Failure to provide a vapor barrier can compromise space 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 c...

Page 14: ...oors Only properly trained and qualified personnel wearing appropriate safety headgear gloves and shoes should attempt to remove or install doors Unlock and open the door by using a flat blade screwdriver or other tool to turn the door latch 90 degrees to unlock the door Most doors on larger floor mounted units will have a door latch at the top and bottom of each door Unplug the dap display connec...

Page 15: ...nd tube connections are protected to prevent any damage Keep tines of the forklift level and at a height suitable to fit below the skid and or unit to prevent exterior and or underside damage Make sure the forks are spread to their widest allowable width for proper balance Do not lift the unit any higher than 4 inches 100mm off the ground If necessary to lift higher than the suggested 4 inches 100...

Page 16: ... elevators and through doorways If clearance is a problem the casters may be inserted directly into the bottom of the 1 25mm tubular steel corner posts at the bottom of the unit WARNING Improper lifting or moving of the equipment may result in damage to the decorative doors panels or frame members 2 7 Locating the Unit Verify that the floor is level solid and appropriate construction to support th...

Page 17: ...units above equipment that could sustain water damage should be avoided 2 8 Downflow Units Downflow units will typically sit on an elevated flooring system known as a raised floor The unit dis charges air downward which pressurizes the raised floor and channels upward through perforated floor tiles Location and quantity of perforated tiles will dictate proper air distribution If the raised floor i...

Page 18: ...ads and or floorstands which may also include leveling legs An air discharge plenum may be factory provided which ships loose and must be attached at the top of the unit frame For in room applications with supply and return grilles several feet of clearance must be maintained at the intake and discharge of the unit Alternately an air distribution plenum must be field fabricated with supply grilles...

Page 19: ... evaporator See section 2 14 Recommended Line Sizing Air Cooled Units for more information on line sizes Tubing 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 compressor off cycles Piping should be designed with adequate three dimensional flexibility It should not be in contact with the surrounding str...

Page 20: ...lar references NOTE Standard piping practice must be used to ensure proper oil return and efficient operation The interconnecting lines to the remote air cooled condenser or condensing unit must be installed by a qualified refrigeration mechanic 2 12 Discharge 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 ...

Page 21: ...n the other end of the refrigerant line to allow the nitrogen to bleed off and not pressurize the piping Prevailing good refrigeration practices should be employed for piping support leak testing dehydration and charging the refrigerant circuits During the installation the lines should be capped off and filled with dry nitrogen at the end of each day s work or until the system is completed and sea...

Page 22: ... avoid excessive liquid line pressure drop the air cooled condenser should be located above or at the same level as the evaporator Condenser installations more than 15 feet below the evaporator are not recommended Insulation of liquid lines is not required but can be useful in preventing excessive sub cooling or flashing on long exposed pipe runs 2 14 Recommended Line Sizing Air Cooled Units Hot G...

Page 23: ...8 1 1 8 1 1 8 NOTE 1 If equivalent piping length falls between two columns above choose 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 Vertical Up 4 If hot gas line refrigerant flow is downward use Horizontal Vertical Down 2 15 Connection Sizes Air Cooled Units Model Number Liquid Line Hot Gas Line G...

Page 24: ...24 2 16 Field Piping Remote Condenser Above Evaporator Figure 7 Typical Remote Condenser Above Evaporator Installation ...

Page 25: ...25 2 17 Field Piping Remote Condenser Below Evaporator Figure 8 Typical Remote Condenser Below Evaporator ...

Page 26: ...refrigerant to expanded freely or eliminate pressure increases the installing contractor must field supply pressure relief devices Additionally the installing contractor must consult local building and piping codes regarding installing pressure safety devices in the required areas of the piping system s that could be unintentionally isolated during field installation maintenance or repairs of the ...

Page 27: ...provided is shipped loose and is to be field installed in the supply line with shut off valves field provided before and after the strainer The strainers and water glycol piping must be cleaned on a periodic basis If the unit is shipped with optional shell and tube condensers strainers are not required and not shipped with the unit All water pipes have a cap installed on the end of the pipe prior ...

Page 28: ...28 2 20 Field Piping Water Glycol System Figure 9 Typical Water Glycol System ...

Page 29: ...2 22 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 GHFC 130 GHFC 060 2 1 8 2 5 8 2 1 8 2 1 8 2 5 8 2 1 8 GUGX 036XX GHFC 074 GHFC 141 2 1 8 2 5 8 2 1 8 2 5 8 GUWX 045XX GUGX 045XX GHFC 074 2 1 8 2 1 8 GHFC 106 GHFC 176 GHFC 084 GHFC 106 GHFC 176 GHFC 141 GHFC 176 GHFC 310 2...

Page 30: ... is a clearance problem All connections need to be cleaned before connections are brazed together 2 25 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 which will permit easy disconnection from the unit for cleaning A trap should be built into the drain line to prevent air from backi...

Page 31: ...ternal water supply to the humidifier Improper installation application and service may result 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 water dam age It is recommended to install leak detection equipment for unit and supply lines 2 26 Humidifier Pip...

Page 32: ...on of leak testing release test pressure and pull a vacuum on the system WARNING Tightening of fittings and valves is the responsibility of the installing contractor WARNING With any fluid connection there is risk of leakage Water leak age could result in property damage to mission critical equipment A water drain connection is required Units with optional steam generator humidifiers will require ...

Page 33: ...d by the owner or others unless otherwise specified Startup service assistance maybe available from our Service Department Contact Data Aire Service Department for details The commissioning includes pre startup inspections of installed components subsystems and systems and the execution of the verification and functional performance testing and related system controls The commissioning field work ...

Page 34: ...sed 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 performance NOTE Single or dual Dis...

Page 35: ...aceway or chase as high voltage wiring Upon arrival of the unit inspect all wiring and electrical components for damage either visible or concealed before installation Use correctly sized copper wire only and verify that all electrical connections are tight before turning power ON Check all electrical connections periodically and tighten as necessary All field supplied cable shall have the followi...

Page 36: ...e Maximum Overcurrent Protection MOP device amps indicates the maximum circuit breaker or fuse size required to protect the system Max Fuse or Max CKT BKR indicates the maximum breaker or fuse size and this information is used to size the appropriate fuses or a Heating Air Conditioning and Refrigeration HACR type circuit breaker Other protection devices are not allowed based upon the product UL li...

Page 37: ... remote heat exchangers condensers and fluid coolers 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 box of the indoor evaporator to the electrical control box of the remote heat exchanger Condensing units i e where the compressor s are mounted in the remote ...

Page 38: ...nclude a Normally Open NO or Normally Closed NC on Alarm dry contact intended to be used in a control circuit not exceeding 5 amps at 24 VAC Use field supplied Class 1 wiring These programmable output contacts will close on a failure and remain closed until the alarm is no longer present The terminal designations for these alarm output contact pairs are Remote Alarm Contacts Terminals TB1 Function...

Page 39: ...el Disconnect all remote electric facility power before servicing unit Turn OFF the disconnect switches if equipped Open the cabinet outer door in front of the electrical enclosure Pushing down on both spring latches on electrical enclosure panel Open electrical control panel CAUTION Verify all power is OFF using a voltmeter 3 12 Condensate Pumps Optional If a gravity drain is not available a cond...

Page 40: ... 3 14 Water Sensing Cable Optional Some units may be equipped with an optional water detection cable in addition to or in lieu of the condensate probe The cable can sense moisture anywhere along its length It is typically placed below the unit in a rectangular pattern that matches the perimeter of the unit The cable is connected to the terminal board and ready for installation Cable lengths will v...

Page 41: ...RNING 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 position 3 17 Plug Fan Current Sensing Switch Unit with backward curve plenum fans with electronically commutated EC motor plug fan use a current sensing relay CT as a safety to alarm when the air flow is unusually low ...

Page 42: ...l transducer strapped to the suction line The EEV actively adjusts the orifice size and resulting mass flow of refrigerant to maintain the superheat setpoint The EEV maintains more stable system balance and is more energy efficient With variable capacity systems an electronic expansion valve is the solution to handle refrigerant mass flow variations 3 19 1 Electrical Connection to EEV The Electric...

Page 43: ...F REMOTE OUTDOOR HEAT EXCHANGER Air cooled condenser and fluid coolers have individual Installation Operation and Maintenance Manuals which should be referred to for more complete details regarding remote heat exchangers ...

Page 44: ...e system all refrigerant lines suction line discharge line and liquid line preferably using copper tubing vacuum rated or braided hose All valves in the system solenoid valves electronic expansion valves ball valves and service valves if the compressor is equipped need to remain open during the vacuum procedures and the system must be purged with nitrogen We recommend using a solenoid magnet tool ...

Page 45: ...r less 2 Close the Schrader core shutoff valve and turn OFF the vacuum pump 3 Disconnect the vacuum pump hoses from the vacuum and attached them to your manifold gauges 4 Connect a vacuum hose from the nitrogen bottle regulator to the manifold gauges vacuum port and carefully break the vacuum with clean dry nitrogen Slowly raise the pressure to approximately 5 PSIG without contaminating the system...

Page 46: ...o the vacuum pump and restart the pump 2 Open the Schrader core shutoff valve and evacuate the refrigerant system from both sides of the system to 500 micron or less 3 Close the Schrader core shutoff valve and turn OFF the vacuum pump 4 Conduct a rise test by waiting at least 30 minutes to make sure the micron gauge reading does not go above 500 microns 5 Conduct a second rise test by waiting at l...

Page 47: ...a refrigerant recovery machine may be necessary to add the initial charge Care must be taken to prevent from over charging the system and from liquid entering the compressor and diluting the oil The return air temperature to the unit being charged must be stable and must be maintained greater than 65 F 18 C If this is not possible due to lack of heat load then load banks must be used to offset the...

Page 48: ...n nearly equal If necessary reverse any two of the three input line voltage wires at the line voltage field connection point to change the compressor rotation Although fixed speed scroll compressors are phase dependent units shipped from the factory are run tested ensuring the compressor rotation is consistent with evaporator fan motor However a field change out of a compressor may require checkin...

Page 49: ...intenance Manual for proper phase check procedures 5 4 Line Set Charge Calculations 1 Since most of the refrigerant weight is in liquid form in the liquid line refrigerant in the hot gas line and suction line is ignored in the charging calculation 2 Calculate the total of the liquid line run then multiply the equivalent feet of line based on the line size by the correct multiplier to get the refri...

Page 50: ...ration The below system refrigerant charge procedure is strongly recommended to reduce these risks 5 6 1 Air Cooled System Charging WARNING The fixed speed compressor 2nd stage must be charged before charging the variable speed compressor 1st stage in an Ultra dual circuit system NOTE Prior to refrigerant charging a system vacuum and moisture removal procedure must have been carried out Refer to S...

Page 51: ...r the evaporator and condenser plus the line set volume 5 4 Line Set Charge Calculations then multiply by 0 80 3 Next connect the refrigerant tank to the refrigerant manifold gauge set and make sure the manifold gauge set is properly purged 4 From a vacuum slowly open the high side liquid line valve on the refrigerant manifold gauge to feed liquid refrigerant through the high side 5 Add the calcul...

Page 52: ...peed compressor Start the system by using the setpoint under Menu B Setpoints The unit must be started in the normal operating mode based on a call for cooling required by the dap4 controller once an initial charge has been added to the circuit Before starting the system make sure pressure gauges and suction line temperature sensor are hooked up and refrigerant readings are aligned with EEV readin...

Page 53: ... exceeds longer than 66 feet 20 m This procedure must be conducted with the system running at high load compressor at full speed See APPENDIX Additional Oil Required Oz for proper amount of oil to add ALWAYS use clean original Danfoss POE oil 160SZ or equivalent from new cans After charging verifying Sub cooling and Oil Level close the valve on the refrigerant manifold gauge set and close the serv...

Page 54: ...ilure to energize the crankcase heater could result in compressor damage If the system is charged from a vacuum the preheating of the compressor is not necessary 5 7 1 4 Charge Variable Speed Compressor The variable speed compressor requires a little more care while charging All unit safeties must be active while charging the compressor Start the system by changing the Temperature Setpoint under M...

Page 55: ... verify superheat shown in the table below Use a liquid charging adapter to prevent liquid refrigerant from entering the compressor The unit should be allowed to stabilize for 15 to 20 minutes to verify key measurements Function R 410A Conditions Liquid Line Pressure 290 to 390 PSIG 2000 to 2687 kPa Liquid Line Temperature 85 to 100 PSIG 586 to 690 kPa Suction Pressure 103 to 130 PSIG 710 kPa to 8...

Page 56: ...out Refer to 5 1 Triple Evacuation and Dehydration Procedure for a triple evacuation prior to charging the system NOTE Improper charging procedure could cause compressor damage in several ways excessive Low High Pressure differences liquid slugging or vacuum operation The below system refrigerant charge procedure is strongly recommended to reduce these risks WARNING The compressor power must be OF...

Page 57: ...arging adapter should be used to prevent liquid refrigerant from entering the compressor Measure the superheat at the compressor suction line at least 6 inches 152 mm away from the compressor Compare suction pressure and temperature reading between the dap4 and the manifolds If the difference between the manifold reading and dap4 reading is more than 5 check for the EEV wiring and any possible ala...

Page 58: ...y charged with refrigerant The water regulating valve should be adjusted to maintain the required conditions Field charging if required of water glycol systems should be done by referring to the unit s electrical nameplate The factory charge is indicated on the nameplate Although this figure represents the initial factory charge it is still necessary to measure and note proper unit operation inclu...

Page 59: ...0 minutes to ensure proper operating characteristics such as Check the current draw of compressor is within acceptable values Check the suction and discharge pressures are within acceptable levels Check for proper EEV operation and desired superheat readings Check the superheat to reduce risk of slugging Observe the oil level in compressor sump at startup and during operation to confirm that the o...

Page 60: ...provided in the VFD It is factory preset Enabled with default parameters The minimum run time is set to ensure long enough running time at start up in order to create enough refrigerant flow velocity in the system to recover the oil to the compressor sump ...

Page 61: ...lume Downflow Units Evaporator Model Standard Unit Volume In Gallons Liters Energy Saver Unit Volume In Gallons Liters GUWX 022XX GUGX 022XX 2 5 9 46 5 0 18 92 GUWX 036XX GUGX 036XX 7 9 30 0 10 1 38 2 GUWX 045XX GUGX 045XX 9 5 35 9 10 6 40 1 GUWX 070XX GUGX 070XX 9 9 37 4 16 3 61 7 GUWX 091XX GUGX 091XX 12 2 46 1 18 8 71 2 GUWX 125XX GUGX 125XX 16 2 61 3 6 9 86 7 6 3 Internal Fluid Volume Upflow U...

Page 62: ...per inhibitor maintenance must be performed to prevent corrosion of system components Consult glycol manufacturer for testing and maintenance of inhibitors Commercial ethylene glycol when pure is generally less corrosive to the common metals of construction than water itself It will however assume the corrosively of the water from which it is prepared and may become increasingly corrosive with use...

Page 63: ...ate energy savings and sound level reductions Match exactly your cooling requirements to control temperature and humidity critical for the best process as well as product quality 7 2 Oil Management Insufficient oil level can be the result of oil depositing itself in pipes and heat exchangers The oil deposit can be returned to the crankcase by increasing velocity for short periods at regular time i...

Page 64: ...ving and application advantages available by applying a Variable Frequency Drive VFD drive to compressor cooling Variable speed control offers the ability to match the cooling capacity to the actual need Costs are reduced through direct energy savings of operating at a lower speed The drive can operate a variable capacity compressor over a wider range Other advantages of the VFD are limiting the n...

Page 65: ... increase or decrease the desired RPM setting As you change the value the compressor will increase or decrease in speed See example display below When done charging press the Auto on key to return to normal operation controlled by the dap4 controller 7 5 2 To View the Drive Alarms Press the Alarm log key Use the and keys to move the cursor through the various alarms See example display below ...

Page 66: ...SI 3965 kPa Cut in Close Manual Reset 7 7 Low Pressure Cutout Switch Each refrigerant circuit has a low pressure cutout switch which features SPST open low switch action and automatic reset The switch is typically located in the evaporator near the compressor The low pressure switch rating is R 410A Refrigerant Setting Cut out Open 50 PSI 345 kPa Cut in Close 90 PSI 621 kPa 7 8 Liquid Line Solenoi...

Page 67: ...ssure head pressure sub cooling and ambient temperature are also important A system charged to a clear sight glass is often overcharged 7 9 Low Ambient Receiver Package Figure 15 Typical Low Ambient Receiver Package 7 9 1 Refrigerant Receiver The function of a Liquid Refrigerant Receiver is to store liquid refrigerant to provide continuous flow of liquid refrigerant to the expansion device and to ...

Page 68: ...eady sized and selected for each Ultra model size It is essential that the maximum operating charge be determined e g winter charge in air cooled condenser having flooded head pressure control this being much greater than the normal summer charge 7 9 4 Receiver Location The low ambient receiver package can be ordered as a unit mounted system or as a shipped loose system If the low ambient receiver...

Page 69: ...s of the thermostats to allow the maximum free cooling time Over cooling or under cooling the fluid should be avoided Every application will have a different ambient temperature and indoor heat load air distribution profile Therefore it is not possible to dictate the exact water sensing thermostat set points Field adjustments are typical to allow fi ne tuning to specific conditions With an Energy ...

Page 70: ...life It is entirely the responsibility of the owner or personnel to provide for these regular maintenance requirements and or enter into a maintenance agreement with a Data Aire Authorized Service Company to protect the operation of the unit Data Aire recommends the use of trained and authorized service personnel extended service contracts and factory specified replacement parts Contact Data Aire ...

Page 71: ...d and bonded to welded wire grid enclosed in cardboard frame design rated not less than MERV 8 per ASHRAE Std 52 2 A filter differential switch for alarm activation is included on some units and optional on other units Air filters should be checked on a regular basis and changed when they become dirty This will ensure efficient operation of the unit Air filters that that are not maintained and req...

Page 72: ...ntial pressure setpoint Turn ON the electrical facility power to the unit After the controller completes the self checks the fan or blowers will start Temporarily cover approximately 75 of the return air opening using heavy cardboard or similar material to adjust the filter differential switch Adjust the switch setpoint if necessary 9 5 2 Upflow Unit Filter Replacement Procedure Turn OFF the disco...

Page 73: ...on the cylinder is completely spent the MES2 will stop operating and the yellow LED will flash in a repeating pattern of 4 flashes At this time the cylinder must be replaced The steam cylinder is disposable and must be replaced at end of cylinder life Cylinder life is dependent on water supply conditions and humidifier usage Failure to replace the cylinder at the end of cylinder life will result i...

Page 74: ...egarding removing the humidifier cylinder Drain valve cleaning Installing the new cylinder Preparing humidifier for extended shutdown duration Starting humidifier after an extended shutdown 9 7 Coil Drain Pan To ensure proper drainage inspect the drain pan regularly Make sure the drain pan outlet is always free of debris and ensure the drain pan does not leak Check and clean P trap as needed for p...

Page 75: ...ing insulation damage frost or other visual sign of wear or damage Periodic inspection of the coil for signs of corrosion and for leaks is recommended Repair and replacement of the coil and the connecting piping valves etc should be performed by a qualified individual s 9 10 1 Coil Cleaning Comply with EPA and OSHA regulations when cleaning Clean the coil in the direction of the airflow so that fo...

Page 76: ...ctric shock hazard Risk of electrical shock could result in injury or death Disconnect local and remote facility power source before working within this equipment Wear appropriate personal protective equipment per NFPA 70E before working within unit Use voltmeter to make sure facility electrical power is turned OFF before making any electrical connections Failure to comply can cause injury or deat...

Page 77: ...ll new fuse into fuse holder Align fuse end with end of fuse holder clips Turn ON power and verify that operation has been restored 9 15 Electric Reheat Elements The electric reheat element is a finned enclosed sheath type fabricated of stainless steel core sheath with plated fins to withstand moist conditions The reheat is installed on the air discharge side of the cooling coil and has three 3 st...

Page 78: ...umidification will stop until the alarm is cleared EC motors have an under voltage protection If the electrical power supply voltage falls below 150 VAC 3Ø for 208 230 VAC volt motors 290 VAC 3Ø for 380 480 VAC motors for a minimum of five 5 seconds the motor will automatically switch off and an alarm condition NO AIRFLOW will be energized and displayed If the electrical power supply voltage retur...

Page 79: ...e over thermostat Energy Saver system only Controls Check unit control operation Check operation of the following High water alarm Pressure differential switch Fan current sensing switch EC Plug Fan Section Check plug fan wheel movement to be free and clear of any debris Record motor voltage Record motor amp draw Fan 1 L1 V L2 V L3 V L1 A L2 A L3 A Fan 2 L1 V L2 V L3 V L1 A L2 A L3 A Fan 3 L1 V L2...

Page 80: ...onnection Compressor Quarterly Compressor 1 Compressor 2 Record suction pressure PSIG PSIG Record discharge pressure PSIG PSIG Record superheat F F Record sub cooling F F Check high pressure cut out PSIG PSIG Check low pressure cut in PSIG PSIG Check low pressure cut out PSIG Record compressor amp draw L1 A L1 A L2 A L2 A L3 A L3 A Condensate Pan and Pump if equipped Check for leaks Check for debr...

Page 81: ...n blade s Check wiring Inspect piping for leaks Glycol Pump if applicable Glycol leaks pump area Pump operation Auto air vent clean of mineral deposits Equipment Runtimes Blower hours Compressor 1 hours Compressor 2 hours Condenser hours Reheat 1 if equipped hours Reheat 2 if equipped hours Reheat 3 if equipped hours Humidifier if equipped hours Dehumidification hours Energy Saver if equipped hour...

Page 82: ...ion device This is to help determine the maximum protective device Question 4 What is the input voltage tolerance Answer In general it is 10 but refer to Electrical Section for more details Question 5 Will all units operate at 50 or 60 hertz power Answer No This depends on the model and options selected Consult with Data Aire for details Question 6 Does the unit require an electrical ground Answer...

Page 83: ... SCCR is short circuit current rating Unless specified the SCCR rating is 10 kA root mean square symmetrical 600 volts maximum 11 2 Mechanical FAQ Section Question 1 What piping sizes should be used to connect split air cooled Data Aire units Answer The best way to get this information is to review the Installation Operations and Maintenance manual that comes with the unit If you cannot locate the...

Page 84: ...f capacity Question 5 Is an air vent valve required in the piping when an expansion tank is used Answer Yes air vents must be installed in various locations in the piping system to purge air and are required at the highest point in the piping system One of the most common problems in water glycol systems is the presence of air in the condenser loop In addition an expansion tank is recommended on g...

Page 85: ...ataaire 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 Evaporator Serial Number Evaporator Model Number Condenser Fluid Cooler Serial Number Condenser Fluid Cooler Model Number Date installed 20 Installing Contractor ...

Page 86: ...20 m Total Refrigerant Weight lbs Danfoss Variable Speed Compressor Danfoss Fixed Speed Compressor 20 12 6 30 18 9 40 25 12 50 31 15 60 37 18 70 43 21 80 49 25 90 55 28 100 61 31 110 67 34 120 74 37 130 80 40 140 86 43 150 92 46 160 98 49 170 104 52 180 110 55 190 117 58 200 123 61 210 129 64 220 135 67 230 141 71 240 147 74 250 153 77 ...

Page 87: ... 5 40 Electronically Commutated 6 18 40 74 Elements 6 74 Energy Saver 65 Evacuation 4 42 43 44 48 51 54 F FAQ 79 Filter 5 6 69 72 Flooded system 54 64 Frequently Asked Questions 79 Fuse 35 73 G Glycol system 35 Grounding 4 35 H Head pressure 50 53 Heat 4 6 36 45 47 Humidifier 3 5 30 70 76 78 I Inspection 3 5 8 67 Installation 3 6 9 12 17 19 23 26 29 30 31 32 35 41 47 59 80 L Liquid line 21 63 Liqu...

Page 88: ...lters 68 Storage 3 9 Subcooling 50 53 55 56 Superheat 50 53 55 56 V Variable Frequency Drive 5 46 50 61 Variable Speed Compressor 4 5 46 50 51 52 55 60 VFD 5 6 44 46 47 50 52 53 57 60 61 Voltage 4 35 36 46 49 W Water glycol cooled 26 Wiring 4 6 12 34 36 40 47 ...

Page 89: ...INDEX gForceUltraIOM_12 2021 docx ...

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