Data Aire GForce DX Manuale di istruzioni

CONGRATULATIONS ON THE SELECTION OF A

DATA

AIRE PRECISION

ENVIRONMENTAL CONTROL SYSTEM. PROPER INSTALLATION,

OPERATION

AND

MAINTENANCE OF THIS EQUIPMENT WILL ENSURE YEARS OF OPTIMAL

PERFORMANCE.

There are separate Installation, Operation and Maintenance and User Manuals for other

components of your Data Aire precision environmental cooling system including dap4

micro-processor controller and condenser/condensing unit and fluid cooler.

NOTE: This manual 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, 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: Indicates a hazardous

situation

which, if not avoided,

could

result

in serious injury or

ath.

CAUTION: Indicates a hazardous si

tuation

which, if not avoided,

could result

minor or moderate

injur

NOTICE: Indicates

information

considered

important

but may have

potential hazard for personal injury or property damage.

Data Aire, Inc. reserves the right to make design changes for the purpose

of product improvement or to withdraw any design without notice.

 
3 
TABLE OF CONTENTS 
1.0 INTRODUCTION...........................................................................................................................................7 
 Product Information................................................................................................................................7 
 Model Identification ................................................................................................................................7 
 Inspection...............................................................................................................................................8 
 Paperwork ..............................................................................................................................................8 
 Storage...................................................................................................................................................8 
 Suggested Reference Storage Room Conditions ..................................................................................9 
 General Storage Considerations............................................................................................................9 
 Registered Trademarks –Copy Rights –References Section.............................................................10 
2.0 INSTALLATION............................................................................................................................................11 
 Recommended Tools for Installation....................................................................................................12 
 Pre-Installation .....................................................................................................................................12 
 Installation must be planned so that:....................................................................................................12 
 Room Considerations...........................................................................................................................13 
 Equipment Handling and Rigging.........................................................................................................14 
 Door and Rear Panel Removal .....................................................................................................14 
 Rear Panel....................................................................................................................................15 
 Moving Unit into Final Location.....................................................................................................15 
 Rigging.................................................................................................................................................16 
 Locating the Unit ..................................................................................................................................17 
 Downflow Units.....................................................................................................................................17 
 Upflow Units .........................................................................................................................................18 
 Piping ...................................................................................................................................................19 
 Air Cooled Unit Piping ..........................................................................................................................20 
 Discharge Lines....................................................................................................................................20 
 Liquid Lines..........................................................................................................................................22 
 Recommended Line Sizing, Air Cooled Units ......................................................................................23 
 Hot Gas Lines............................................................................................................................23 
 Liquid Lines ...............................................................................................................................24 
 Suction Lines.............................................................................................................................25 
 Connection Sizes, Air Cooled Units .....................................................................................................26 
 Field Piping, Remote Condenser Above Evaporator............................................................................27 
 Field Piping, Remote Condenser Below Evaporator............................................................................28 
 Refrigerant Piping Protection ...............................................................................................................29 
 Water/Glycol Cooled Unit Piping..........................................................................................................30 
 Field Piping, Water/Glycol System.......................................................................................................31 
 Connection Sizes, Water/Glycol Cooled Units .....................................................................................32 
 Connection Sizes, Fluid Coolers (Dry Coolers)....................................................................................32 
 Auxiliary Chilled Water/Energy Saver Coil Piping ................................................................................32 
 Condensate Drain Piping .....................................................................................................................32 
 Humidifier Piping..................................................................................................................................33 
 Steam Generator Humidifier......................................................................................................33 
 Dry Steam Humidifier ...........................................................................................................................34 
 Leak Testing.........................................................................................................................................34 

 
4 
 Electrical Installation.............................................................................................................................34 
 Commissioning Information..................................................................................................................35 
3.0 ELECTRICAL CONNECTIONS...................................................................................................................36 
 General Electrical Field Wiring Guidelines...........................................................................................37 
 Electrical Service..................................................................................................................................38 
 Nameplate Ratings...............................................................................................................................38 
 Grounding.............................................................................................................................................38 
 Voltage Tolerance................................................................................................................................38 
 Three Phase Voltage Tolerance ...................................................................................................38 
 Single-Phase Voltage Tolerance...................................................................................................39 
 Heat Exchanger Auxiliary Control Wiring .............................................................................................39 
 Remote Shutdown................................................................................................................................40 
 Remote Alarm Contacts.......................................................................................................................40 
 dap4 Controller.....................................................................................................................................41 
 Disconnect Switch (Optional) ...............................................................................................................41 
 How to Open the Electrical Enclosure Panel........................................................................................41 
 Condensate Pumps (Optional).............................................................................................................42 
 Condensate Probe ...............................................................................................................................42 
 Water Sensing Cable (Optional)...........................................................................................................43 
 Remote Temperature and Humidity Sensors (Optional).......................................................................43 
 Manual Override Switch Board.............................................................................................................43 
 Plug Fan Current Sensing Switch ........................................................................................................44 
 Wiring Diagrams...................................................................................................................................44 
 Electronic Expansion Valve Optional ...................................................................................................44 
 Electrical Connection to EEV.....................................................................................................44 
4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ................................................................45 
5.0 CHARGING.................................................................................................................................................46 
 Charging/Installation Work Procedures................................................................................................46 
 Triple Evacuation and Dehydration Procedure.....................................................................................46 
 Tools Needed................................................................................................................................47 
 First Stage Evacuation..................................................................................................................47 
 Second Stage Evacuation.............................................................................................................48 
 Third Stage Evacuation.................................................................................................................48 
 Final Evacuation Stage.................................................................................................................49 
 General Pre-Charging Guidelines ........................................................................................................49 
 Voltage Phase Check...........................................................................................................................50 
 Evaporator Power Phase Check...................................................................................................50 
 Fixed Speed Scroll Compressor Phase Check.............................................................................50 
 Heat Exchanger Phase Check......................................................................................................51 
 Line Set Charge Calculations...............................................................................................................51 
 Component Functional Test.................................................................................................................52 
 CHARGING PROCEDURES................................................................................................................52 
 Refrigerant Handling.....................................................................................................................52 
 Air Cooled System Charging.........................................................................................................52 

 
5 
 Charging the Fixed Speed Compressor........................................................................................54 
 Additional Oil.................................................................................................................................56 
 Flooded System Charging (Systems with Low Ambient Receiver Package)................................56 
 Receiver Installation......................................................................................................................58 
 Charge Fixed Speed Compressor.................................................................................................59 
 Water/Glycol-Cooled System Charging ........................................................................................60 
 Refrigerant Handling ............................................................................................................................61 
 Important Refrigeration Components ...................................................................................................62 
 Expansion Valves..........................................................................................................................62 
 High Pressure Cutout Switch ........................................................................................................62 
 Low Pressure Cutout Switch .........................................................................................................63 
 Liquid Line Solenoid Valve (Optional)............................................................................................63 
6.0 GLYCOL SYSTEMS....................................................................................................................................64 
 Glycol Concentration............................................................................................................................64 
 Internal (Fluid) Volume –Up and Downflow Evaporators.....................................................................64 
 Brazed-Plate Condensers.............................................................................................................64 
 Internal (Fluid) Volume –Fluid Coolers.................................................................................................66 
 Fluid Cooler Information................................................................................................................66 
7.0 CONTROLS.................................................................................................................................................67 
 dap4™ Microprocessor Control Panel..................................................................................................67 
 Remote Heat Exchangers....................................................................................................................67 
 Electronic Expansion Valve Drive (EDV) ..............................................................................................67 
 Setup Using Display Panel Guide .................................................................................................67 
 Configuration Menu.......................................................................................................................68 
 Regulation Menu ...........................................................................................................................70 
 How to Manually Open and Close an (EEV)..................................................................................70 
 Multiple EEV Configuration ...........................................................................................................71 
8.0 REGULAR MAINTENANCE ITEMS............................................................................................................73 
 Air Filters ..............................................................................................................................................73 
 Fuses....................................................................................................................................................73 
 Electric Reheat.....................................................................................................................................73 
 Humidifier.............................................................................................................................................74 
 Humidifier Canisters......................................................................................................................74 
 Refrigerant Filter Drier..........................................................................................................................74 
 Plenum (Plug) Fans..............................................................................................................................74 
 Electronically Commutated Motors................................................................................................74 
 EC Motor Testing..........................................................................................................................75 
9.0 MAINTENANCE/INSPECTION CHECKLIST...............................................................................................77 
10.0Frequently Asked Questions –FAQ............................................................................................................80 
 Electrical FAQ Section .........................................................................................................................80 
 Mechanical FAQ Section......................................................................................................................81 
11.0CONTACT DATA AIRE...............................................................................................................................83 
 

 
6 
TABLE OF FIGURES 
Figure 1 Typical Upper Spring-Loaded Hinge................................................................................................14 
Figure 2 Upper Hole for Spring-Loaded Hinge ..............................................................................................15 
Figure 3 Lower Fixed Pin Hinge.....................................................................................................................15 
Figure 4 Example of Lifting Method ...............................................................................................................16 
Figure 5 Typical Return & Discharge Air Distribution.....................................................................................18 
Figure 6 Typical Check Valve ........................................................................................................................21 
Figure 7 Typical Remote Condenser Above Evaporator Installation .............................................................27 
Figure 8 Typical Remote Condenser Below Evaporator................................................................................28 
Figure 9 Typical Water/Glycol System...........................................................................................................31 
Figure 10 Typical Remote Heat Exchanger Interconnection Points...............................................................40 
Figure 11 Typical Indoor Evaporator Interconnection Points.........................................................................40 
Figure 12 Manual Override Switch Board......................................................................................................43 
Figure 13 EEV with Electrical Mating Connector ...........................................................................................45 
Figure 14 Typical Low Ambient Receiver Package........................................................................................58 
Figure 15 Example Remote EPO Switch Connection....................................................................................81 
 
 

1.0 INTRODUCTION

Product Information

The Data Aire gForce GF environmental control, direct expansion, dual circuit Computer

Room Air Conditioner (CRAC) equipment provides a high sensible cooling, is self-contained,

factory assembled, piped, wired, and factory tested prior to shipment. These units include an

enclosure/cabinet assembly, fan section, filter section, cooling coils, controls, and

interconnecting piping internal to unit.

The Data Aire CRAC unit provides cooling, reheat, humidification, dehumidification and air

filtration. The unit is provided with a Data Aire dap4™ microprocessor controller for precision

control. The unit must be operated in a conditioned space within the operating envelope

ASHRAE recommends for data centers. Operating outside this envelope can alter the

operating performance and decrease equipment reliability. Return air to the unit must be no

cooler than the ASHRAE recommendation 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.”

Model Identification

GF XX-XXX X X - XXX

│ │ │ │ │ │ │

Model Series │ │ │ │ │ │ │

GF - gForce Dual Circuit

────

┘ │ │ │ │ │ │ Auxiliary Coils

│ │ │ │ │ └ ES - EnergySaver

Type of Cooling │ │ │ │ │ ACW - AuxilaryChilled Water

A - Air Cooled │ │ │ │ │

W - Water Cooled

────

┘ │ │ │ │ Voltage

G - Glycol Cooled │ │ │ └

────

2 - 208/230 VAC

│ │ │ 4 - 460 VAC

Configuration │ │ │ 3 - 380/400V - 50Hz

Downflow

────

┘ │ │

Upflow │ │ Phase

│ └

────

3 - Three phase

Model/Capacity in kW │

021 kW │

028 kW │

035 kW

────

┘

046 kW

056 kW

070 kW

091 kW

106 kW

gForce GF Model Number

Inspection

This Data Aire CRAC unit has been factory run-tested and has gone through a comprehensive

inspection prior to its packaging and shipment to ensure that it arrives in excellent condition.

However, ship- ping damage can occur and a visual inspection of the outer crating immediately

upon delivery should be performed. Upon arrival of the unit and before unpacking it, verify that

the labeled equipment matches the bill of lading.

Loose items such as remote-control panels, disconnect switch handles, and spare air filters

are packed inside the unit. Refer to the yellow shipping tag located on the unit door for details.

NOTICE: 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.

NOTICE: Freight damage claims are the responsibility of the purchaser.

Action to recover losses should be filed immediately. Please notify factory

personnel of any claims.

Paperwork

Each Data Aire CRAC unit ships with a start-up sheet that should be completed during

installation. Also included in the paperwork is a warranty/information packet that provides

important wiring diagrams, specific component literature, warranty registration cards and other

valuable paperwork, including a copy of this Installation, Operation, and Maintenance manual.

A yellow tag is attached to the outside decorative door to indicate articles that may have been

packaged and shipped loose within the unit cabinet. Typically this would be jackstands,

condensate pumps and other loose components that are not factory mounted.

WARNING: It is the responsibility of the installing contractor to return

the start- up sheet and warranty registration card to Data Aire for proper

activation of the unit warranty. Failure to do so may cause delays and

some cases void the warranty

Storage

Short-term storage is considered 60 days or less from shipment date. Long-term storage is

considered any period beyond 60 days from date of shipment. It is mandatory that a detailed

record be maintained during this long-term period, such as, but not limited to: proper sealing of

the cabinet, rotation of the blowers and bearings, and protection of all motors from moisture.

Check the fan rotation monthly, 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 unit and noting any discrepancies. A copy of the log sheet should be sent to Data Aire.

Failure to perform the long-term storage requirements may void the warranty.

Suggested Reference Storage Room Conditions

•Dry bulb temperature range: 65°F to 85°F.

•Effects of high temperatures may dry out components or may damage electrical

components.

•Effects of low temperatures may cause freezing damage to coil, compressor, system

components, electrical components, etc. Freezing temperatures must be avoided.

•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 static might arise for the equipment.

•Level with floor.

•Units with compressor maximum tilt angle is 30° (compressor not running) but

recommend the unit be set level for 24 hours prior to final installation.

•Store at non-condensing temperature and humidity conditions.

General Storage Considerations

•All equipment shall be stored for safety of occupants. Per OSHA codes and codes

applicable to your installation.

•Maintain clearance from working space and traffic areas.

•Our indoor products are not designed or intended to be stored outdoors or exposed to

outdoor conditions.

•Components sealed in plastic shrink-wrap are not exempt from this requirement.

Moisture will collect inside the plastic, resulting in corrosion of the cabinet, the electronic

components and or other water sensitive components.

•Provide proper fire protection per local and national codes.

•Protect from all water or fluid sources. Equipment should be protected from possible

water damage, such as from leaks, fire-sprinkler discharge, and flooding.

•The storage space should be filtered to remove dust, cleansed of gaseous

contaminants, if present, and controlled to the desired relative humidity and

temperature.

•Isolate this equipment from pressure testing of water, steam, gas and air piping.

•Isolate this equipment from temporary building power.

•The unit must also be protected from damage 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 connections capped or closed tight to prevent

foreign materials and liquids from gaining entrance during the storage period.

When equipment is installed after storage, caution should be taken to inspect and replace, if

required, any components that may have deteriorated during storage. All moving parts, such

as fans and motors, should be hand tested to ensure that they are free and clear prior to start-

up.

Registered Trademarks –Copy Rights –References Section

NOTICE: Data Aire Inc. Trademarks Disclaimer: All names, logos, brand,

materials and other Registered Trademarks, Trademarks, or Copy Rights

seen featured or referred to within documents or our website are explicitly

the sole property of their respective and rightful trademark holders or owners.

This disclaimer shall not be construed or manipulated from hereafter. Said

trademarks or copy rights are only used to directly or indirectly familiarize,

reference, identify and describe the services.

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