Data Aire gForce Ultra Installation, Operation & Maintenance Manual Download

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Summary of Contents for gForce Ultra

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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 prope...

Page 3: ...0 Piping 21 Air cooled Unit Piping 22 Discharge Lines 22 Liquid Lines 24 Recommended Line Sizing Air cooled Units 24 Connection Sizes Air cooled Units 25 Field Piping Remote Condenser Above Evaporator...

Page 4: ...rams 45 Electronic Expansion Valve 45 Electrical Connection to EEV 45 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER 46 CHARGING 47 Charging Installation Work Procedures 47 Triple Evacuation and Dehydr...

Page 5: ...Oil Level 74 Variable Frequency Drive VFD 74 Local Control for Charging 75 To View the Drive Alarms 75 VFD Parameter Settings 76 VFD parameter settings Danfoss CDS 803 Drive 22 kW Ultra units 77 VFD...

Page 6: ...ent Procedure 105 Electric Reheat Elements 105 Humidifier 105 Humidifier Canisters 105 Cylinder Spent Fault 106 Replacement Cylinder 106 Removing the Cylinder 106 Coil Drain Pan 107 Condensate Pump 10...

Page 7: ...e 11 Typical Remote Heat Exchanger Interconnection Points 40 Figure 12 Typical Indoor Evaporator Interconnection Points 41 Figure 13 Manual Override Switch Board 44 Figure 14 EEV with Electrical Matin...

Page 8: ...e Multiplier 53 Table 11 Fixed Speed Compressor Pre Charge R 410A 55 Table 12 Refrigerant Charge Values 57 Table 13 Variable Speed Compressor Pre Charge 58 Table 14 Refrigerant Charge Valves 60 Table...

Page 9: ...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 Guide...

Page 10: ...lters 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...

Page 11: ...d 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...

Page 12: ...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 Refrigera...

Page 13: ...endent 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 unders...

Page 14: ...t 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 th...

Page 15: ...apor 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 I...

Page 16: ...nd comfortable removal and installation of doors Only properly trained and qualified personnel wearing appropriate safety headgear gloves and shoes should attempt to remove or install doors Unlock and...

Page 17: ...to which casters with 3 4 35 mm stems can be attached This allows easy movement down halls into elevators and through doorways Improper lifting or moving of equipment may result in damage to decorativ...

Page 18: ...d from damage to the decorative doors during any storage or moving Removal of the decorative doors is easily accomplished and may be done without moving the equipment The shipping skid should be left...

Page 19: ...ondensation formation and frequent humidifier flushing are normal functions of this equipment Proper drain connections must be made to ensure proper removal Unit will require water connections for con...

Page 20: ...ate floor height and any other restrictions can inhibit proper airflow Care should be taken to avoid restrictions Verify that the raised floor has been properly sized for the unit s airflow and the ro...

Page 21: ...do so could reduce the unit s cooling performance Piping All refrigerant piping should be is Type L Air Conditioning Refrigeration ACR hard drawn copper pipes Soft copper is unacceptable When brazing...

Page 22: ...with top or bottom connections Air cooled Unit Piping Air cooled unit piping is crimped and brazed closed from the factory and contains a nitrogen holding charge Each installation requires field suppl...

Page 23: ...to open 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 testi...

Page 24: ...eventing excessive sub cooling or flashing on long exposed pipe runs Recommended Line Sizing Air cooled Units Table 1 Line Size Metric Conversion Inch mm Inch mm 1 2 OD 12 mm 1 1 8 OD 29 mm 5 8 OD 16...

Page 25: ...d use Vertical Up 4 If hot gas line refrigerant flow is downward use Horizontal Vertical Down Connection Sizes Air cooled Units Table 6 Air cooled Units Connection Sizes Model Number Liquid Line Hot G...

Page 26: ...e evaporator 3 For units built after April 2017 the check valves are included internally in the indoor evaporator section 4 Slope horizontal lines downward in the direction of the refrigerant flow 1 2...

Page 27: ...b specific documentation 1 This is recommended piping All piping to be per local and or state codes 2 Condenser to be no more than 15 feet 4 6 m below evaporator 3 Slope horizontal lines downward in t...

Page 28: ...the refrigerant to expanded freely or eliminate pressure increases the installing contractor must field supply pressure relief devices Additionally the installing contractor must consult local buildi...

Page 29: ...Aire 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 o...

Page 30: ...36 19 8 16 2 GUWX 125XX GUGX 125XX 42 23 1 18 9 Connection Sizes Water Glycol Cooled Units Table 7 Water Glycol Cooled Units Connection Sizes Evaporator Model Water In Connection Water Out Connection...

Page 31: ...ion 1 The expansion tank is a required component of a proper system installation The tank can be provided by Data Aire or by others 2 All Water Glycol field piping must be designed and installed in ac...

Page 32: ...ned before connections are brazed together Condensate Drain System Every indoor unit has a 3 4 19 mm copper stub provided for condensate removal A union field provided is recommended at the field conn...

Page 33: ...MUST be connected to an external drain line provided by others before unit start up NOTICE Clogged or leaking drain lines can cause damage to the equipment and building Drain lines must be inspected r...

Page 34: ...ed to as a P trap is capable of handling static pressures equal to 4 200 mm H2O which is the maximum static available for wall units If the unit fans are standard there is no need to consider differen...

Page 35: ...ressure regulator field provided and strainer field provided should be installed Water pressure should be set between 20 and 80 PSI 128 and 552 kPa The humidifier has a drain at the bottom which is fa...

Page 36: ...double check all wiring connections including the factory terminals Factory connections can vibrate loose during shipment Installation of the remote temperature and humidity sensors Optional should no...

Page 37: ...nsed 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 an...

Page 38: ...se 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 veri...

Page 39: ...imum 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 Heat...

Page 40: ...arts department for detailed information In this case the installing contractor must follow the applicable electrical codes to determine the required wire gauge Condensing units i e where the compress...

Page 41: ...mper clip prior to installing the field wires Remote Alarm Contacts The dap4 microprocessor control panel provides four 4 remote alarm output contacts that can be field accessed The contacts include a...

Page 42: ...transit and installation It is the installing contactors responsibility to install these components as part of the installation process How to Open the Electrical Enclosure Disconnect all remote elec...

Page 43: ...t and can result in a nuisance water detected alarm Remove disconnect the probe if it is not to be used Water Sensing Cable Optional Some units may be equipped with an optional water detection cable i...

Page 44: ...the Electronically Commutated EC plug fan motor can be adjusted from 0 to 10 volts DC by adjusting the potentiometer at the left of the Fan Speed switch The fan speed will increase 10 of the fan base...

Page 45: ...e standard Thermal Expansion Valve EEV The EEV controls superheat through the dap4 controls by actively measuring suction pressure via a transducer attached to the suction line and suction temperature...

Page 46: ...ATION OF 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 regar...

Page 47: ...abnormally high discharge temperatures that can degrade the lubricating properties of the oil The risk of acid formation is also increased by non condensable and moisture and this condition can also...

Page 48: ...the leaving side of the check valve and on the liquid line before the expansion valve attach your Schrader valve core removal tools and hoses here A micron gauge should be fitted to the system at the...

Page 49: ...least one 10 minutes 7 Verify there are no nitrogen leaks 8 Carefully release the nitrogen charge Watching the gauge until it reads 1 PSIG 7 kPa Third Stage Evacuation 1 Move the vacuum hoses back to...

Page 50: ...be charged with refrigerant 9 Make sure all service and field installed ball valve are open and remain open for charging 10 Ensure all valve cores and caps are re installed on the Schrader port and o...

Page 51: ...le speed compressor is running at low speed Heat load is required when adjusting charge use load banks to offset the cooling load Suction pressure should be equal to 33 F 0 56 C saturated temperature...

Page 52: ...pressor rotation is consistent with evaporator fan motor However a field change out of a compressor may require checking proper phase Variable Speed Compressor Phase Check The gForce Ultra unit has a...

Page 53: ...check procedures 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 ca...

Page 54: ...cycling units is required by U S Environmental Protection Agency EPA regulations Technicians who service and dispose of air conditioning and refrigeration equipment must recover the refrigerant instea...

Page 55: ...anifold gauge set on circuit 2 always the fixed speed compressor on Ultra units and make sure the manifold gauge set is properly purged 5 Then from a vacuum add the amount of refrigerant weight per th...

Page 56: ...troller may be turned ON or OFF by pressing the Power icon at the bottom left corner of the main screen The icon is green when the unit is ON and red when unit is OFF Once controller is turned ON ther...

Page 57: ...56 to 7 22 C Subcooling 8 to 15 F 13 33 to 9 44 C Differential Temperature Depending on ambient conditions at compressor s maximum speed Superheat 8 to 18 F 13 33 to 7 78 C Differential Temperature Me...

Page 58: ...ant charge for evaporator and condenser in accordance with the following table Table 13 Variable Speed Compressor Pre Charge Weight of Refrigerant in Evaporator plus Condenser for VS Compressors Model...

Page 59: ...ngs are aligned with EEV reading For dual circuit units remove the fixed speed compressor s fuses to prevent it from starting If the unit is in OFFbyKEY position hold the Esc key for 5 seconds to star...

Page 60: ...2 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 f...

Page 61: ...Dehydration Procedure 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 oper...

Page 62: ...stem increase installation time and increase the refrigerant charge The loss of subcooling should be recognized If a flooded system is required consult the Data Aire prior to installation Applications...

Page 63: ...er coil The receiver package s is typically mounted outdoors near the condenser If the receiver package s are installed indoors a check valve is required on the liquid line at the condenser outlet and...

Page 64: ...or Connect the charging line to the refrigerant tank and set for liquid feed Open the refrigerant tank valve and purge the line Use a liquid charging adapter to break the vacuum with 90 PSIG 621 kPa o...

Page 65: ...Discharge Head Pressure Refrigerant Head Pressure R 410A 380 PSIG 2620 kPa or higher While charging during the summer meter refrigerant through the suction line until the level of liquid in the recei...

Page 66: ...to 45 0 56 to 7 2 0 to 3 17 8 to 16 1 12 to 18 11 1 to 7 8 Measure the superheat at the compressor suction line at least 6 inches 152 mm away from the compressor All water glycol cooled units have a w...

Page 67: ...rheat to reduce risk of slugging Observe the oil level in compressor sump at startup and during operation to confirm that the oil level remains visible and indicating proper oil return Excess foaming...

Page 68: ...ntervals to ensure freeze protection Internal Fluid Volume Table 19 Ultra Downflow Unit Internal Fluid Volume Evaporator Model Standard Unit Volume In Gallons Liters Energy Saver Unit Volume In Gallon...

Page 69: ...HRAE Handbook HVAC Applications covers water treatment in more detail Specific recommendations on water treatment can be obtained from water treatment suppliers Scale Treatment In daily use scale accu...

Page 70: ...pH must be maintained between 6 and 8 Hydrochloric acid should never be used to clean the exchangers NOTICE Risk of corrosion can cause equipment damage Contact a water consultant about water quality...

Page 71: ...3 76 2 3 125 79 4 0 354 1 34 35 4 134 Freezing Point of Aqueous Solutions Table 22 Freezing Point of Aqueous Solutions Ethylene Glycol by Volume Freezing Point Degrees F C Propylene Glycol by Volume F...

Page 72: ...al inhibited formula ethylene glycol and propylene glycol are supplied with corrosion inhibitors and do not contain a silicone anti leak formula Commercial ethylene glycol and propylene glycol when pu...

Page 73: ...immediate 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 Oil Management...

Page 74: ...s energy saving 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 t...

Page 75: ...keys to 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 ret...

Page 76: ...ired see the full operating manual for the Danfoss VFD drive system VFD Parameter Settings The VFD parameters can be setup from the Local Control Panel LCP on the face of the VFD Figure 1 Local Contro...

Page 77: ...umber indicate the month and year of manufacture 468 46th week of 2018 5 12 Terminal 27 Digital Input 2 Coast Inverse VFDs built before 7 2017 last 3 digits of serial number indicate the month and yea...

Page 78: ...he MCT 10 Local Control Panel LCP of the compressor VFD for Modbus communication with the dap4 controller to display the VFD operating data NOTE There are two different types of compressor VFDs The CD...

Page 79: ...wh Counter 15 3 15 02 Kwh Counter Program Danfoss CDS 303 VFD for Modbus Communication Use the LCP and the Up Down and OK keys press the Main Menu key of the VFD then move to Parameter 8 Communication...

Page 80: ...15 02 KWh Counter 12 15 01 Running Hours 13 16 66 Digital Output Bin Programming CDS303 VFDs with MCB105 Relay Card Instructions to cover the programming for the Danfoss CDS303 series VFDs with MCB10...

Page 81: ...gForce Ultra IOM 81 Press the main menu button on the VFD display to bring up the menu options Navigate to Menu 5 titled Digital In Out and press Enter...

Page 82: ...gForce Ultra IOM 82 Scroll down to Option 5 4 titled Relays and press Enter Scroll down to Optional relay 7 and press Enter Program Option 5 40 titled Function Relay to 9 Alarm and press Enter...

Page 83: ...e to connect and communicate with the dap4 controller the Serial Protocol DIP switches must remain in the OFF position Up and the Serial DIP Address switches need to be changed to ON Position Down for...

Page 84: ...160 700 016 Make sure Ext Baud Port DIP switches are all in OFF Up position if they are not change them to Up position as shown in picture below Next set all the Address DIP switches to the ON Down po...

Page 85: ...45 kPa Cut in Close 90 PSI 621 kPa Liquid Line Solenoid Valve Liquid line solenoid valve s LLVS are a standard feature on this unit The LLSV are direct acting NC normally closed i e closed when de ene...

Page 86: ...fferent 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 f...

Page 87: ...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 dap4 controller settings are established...

Page 88: ...3 Default 3 Menu G Network Config a BMS Port 1 Protocol Detect Heartbeat Heartbeat Ok N A Default Yes Default No Default b pLAN Address 1 Notice Do not change this setting without following Zone Cont...

Page 89: ...1 0 F Default 60s Default 60s Default 60s Default 90s Default e Variable Compressor 3 22kW 36 45kW 70 91 125kW Suction Pr Cut Out SP Differential Delay C1 Start Maximum PD Time SH PD Cut In Not requi...

Page 90: ...rs if fan speed assist is selected to yes k Rack Settings Temp Sensors Used Optional RackSense module required 0 Default l Unit Identification Model Serial Number Job Number GUXX 022XX XX 20XX XXXX X...

Page 91: ...ault No Default b Alarm Settings Comp Short Cycle Floor Water Alarm Action Reset Alarm Log Alarm Screen Contact Yes Default Alarm Only Default No Default No Contact Message Default c Flow Alarms No Wa...

Page 92: ...nput C1 Hi Pressure Sw Channel Action Delay Status ID1 Default Open Default 5s Default Open Info Only Based on Sw State b Digital Input C1 Low Pressure Sw Channel Action Delay Status ID2 Default Open...

Page 93: ...Action Delay Status ID12 Default Open When Ziehl Abegg fans are used Closed When ebm papst fans are used 5s Default Open Info Only Based on Sw State m Digital Input Opt Alarm 1 Switch Channel Action...

Page 94: ...l Normal Min 1 1000 H2O Max 1 1000 H2O Offset Air Press Off Default U07 Default 0 10VDC Default 0 Default 5000 Default 000 Default 0 000 Wtr Reading not a setting v Analog Input Discharge Air Pressure...

Page 95: ...Default U08 Default NTC Default 0 0 F Default 0 0 F Reading not a setting cc Optional Sensor 5 Cond Sup Temp Enable Channel pCOe Module Offset Value Off Default B2 Default NTC Default 0 0 F Default 0...

Page 96: ...V to a fixed position The suction temperature suction pressure and super heat values can be viewed on our dap4 display The dap4 reads this information from the Electronic Valve Driver EVD and allows t...

Page 97: ...ration Menu WARNING These menu screens are factory settings and are intended to be viewed only not to be changed If any values are different than shown here please consult with Data Aire s Service Dep...

Page 98: ...up varies based on cooling type Air Cooled units Valve opened In stand by 0 Air Cooled units Valve position In stand by 0 Air Cooled units Valve position at start up 50 Water Glycol units Valve opened...

Page 99: ...protection threshold F varies depending on gForce Ultra model For GUXX 022XX and GIXX 022XX units the MOP is set to 67 0 F For all other gForce Ultra units GUXX 036XX 045XX 070XX 091XX and 125XX the...

Page 100: ...position from 0stp to a desired step value There are 480 steps total for the EEV So if you would like the valve to open 62 5 enter 300stp such as below Once all the changes are done press ESC to retu...

Page 101: ...e second valve will be displayed as valve B Set up for valve A does not affect settings for valve B therefore when the unit has two EEVs set up for valve B is required To setup valve B for circuit 2 p...

Page 102: ...s by a suitably qualified Service Technician Good maintenance practices are essential to minimizing operation costs and maximizing product life It is entirely the responsibility of the owner or person...

Page 103: ...ntaining and servicing equipment Some operations when servicing or maintaining the unit may require additional assistance regarding manual handling This requirement is down to the discretion of the Se...

Page 104: ...lace the air filters with same filter size and type Any new filters manufacturer must be U L and CSA approved Classified WARNING Air filters that require changing can restrict airflow and create probl...

Page 105: ...r electric resistance heating Heating elements do not normally require maintenance However they may accumulate a film of dust or dirt when unused for extended periods of time When energized the burnin...

Page 106: ...Serial number and voltage are located on the specification label on the left side of the humidifier Contact Data Aire Parts Department for replacement humidifier cylinder Removing the Cylinder Check t...

Page 107: ...brush and flush with water Check that the discharge line is clear and water can pass through it freely Check and clear obstructions in gravity lines leading to condensate pump Check operation of float...

Page 108: ...than 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 deb...

Page 109: ...in unit Use voltmeter to make sure facility electrical power is turned OFF before making any electrical connections Failure to comply can cause injury or death Inspect electrical control panel box eac...

Page 110: ...r throw Install new fuse into fuse holder Align fuse end with end of fuse holder clips Turn ON power and verify that operation has been restored Plenum Plug Fans Plug fan s with Electronically Commuta...

Page 111: ...automatically restart when powered ON If there is an alarm condition indicated as NO AIRFLOW all active functions cooling heating and humidification will stop until the alarm is cleared EC motors hav...

Page 112: ...set at the factory and does not normally require adjustment in the field If the unit speed operating mode is change in the field the current sensing switch may require the no airflow alarm to be adju...

Page 113: ...change 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...

Page 114: ...densers Water Cooled Check for water glycol leaks in the piping area Water regulating valve function Entering leaving water temperatures Entering T F Leaving F Compressor Monthly Check for oil leaks C...

Page 115: ...Check wiring Inspect piping for leaks Glycol Pump Monthly if applicable Glycol leaks pump area Pump operation Auto air vent clean of mineral deposits Glycol Pump Quarterly if applicable Record pump pr...

Page 116: ...rotection 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 Ques...

Page 117: ...electrical rating for the unit Answer The electrical ratings are located on the unit serial name plate label Question 15 What is the SCCR rating for the unit Answer SCCR is short circuit current ratin...

Page 118: ...w much steam is generated by the Condair previously known as Nortec humidifier Can it be adjusted Answer The amount of steam generated depends on the model of humidifier you have in your unit To deter...

Page 119: ...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...

Page 120: ...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...

Page 121: ...ntrol Enclosure 109 Electrical Control Enclosure 42 Electrical FAQ 116 Electronic Expansion Valve EEV 45 96 Electronically Commutated EC 21 44 110 Energy Saver 85 Equipment Runtimes 115 Evacuation 48...

Page 122: ...39 Remote EPO Switch 117 Remote Heat Exchanger 85 Remote Shutdown Contacts 116 Remote Temperature and Humidity Sensors 43 Return Air Plenum 20 Rigging 15 18 Safety Relief Devices 62 Service Access 15...

Page 123: ...gForceUltraIOM_11 2022 docx...

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