Data Aire MINI CEILING SERIES Manuale utente

MINI CEILING SERIES

Installation, Operation and Maintenance Manual

1, 1.5, 2 and 2.5 ton

Air, Water and Glycol Cooled DX and Chilled Water

CONGRATULATIONS ON THE SELECTION OF ADATAAIRE PRECISION

ENVIRONMENTAL CONTROL SYSTEM. PROPER INSTALLATION, OPERATION

AND MAINTENANCE OF THIS EQUIPMENT WILL ENSURE YEARS OF OPTIMAL

PERFORMANCE.

This manual is intended to assist trained service personnel by providing

necessary guidelines for this particular 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.

Service performed by unauthorized or unqualiﬁed technicians may void

manufacturers’ warranties and could result in property damage and/or

personal injury.

Special care should be given to those areas where these symbols appear.

Data Aire, Inc. reserves the right to make design changes for the purposes of product

improvement, or to withdraw any design without notice.

Table of Contents

1.0 INSTALLATION .........................................................................................................6

1.1 Room Considerations ................................................................................................6

1.2 Inspection...................................................................................................................6

1.3 Locating the Unit ........................................................................................................6

1.3.1 Vertical Airﬂow Units...................................................................................................7

1.3.2 Air Cooled Package Units ..........................................................................................7

1.3.3 Horizontal Airﬂow Units ..............................................................................................8

1.3.4 Indoor Condensers & Condensing Units....................................................................8

1.4 Paperwork..................................................................................................................8

1.5 Storage.......................................................................................................................8

2.0 PIPING .......................................................................................................................10

2.1 Split Air Cooled Unit Piping ......................................................................................10

2.1.1 Discharge Lines........................................................................................................10

2.1.2 Liquid Lines..............................................................................................................10

2.1.3 Suction Lines............................................................................................................10

2.1.4 Connection Sizes, Air Cooled Units..........................................................................10

2.1.5 Field Piping, Remote Condenser ............................................................................. 11

2.1.6 Field Piping, Remote Condensing Unit .................................................................... 11

2.2 Water/Glycol Cooled Unit Piping..............................................................................12

2.2.1 Connection Sizes, Water/Glycol Cooled Units.........................................................13

2.2.2 Connection Sizes, Fluid Coolers..............................................................................13

2.3 Auxiliary Chilled Water Coil Piping...........................................................................13

2.4 Condensate Drain Piping .........................................................................................13

2.5 Humidiﬁer Piping......................................................................................................14

2.6 Leak Testing.............................................................................................................14

2.7 Evacuation................................................................................................................14

3.0 ELECTRICAL CONNECTIONS ...........................................................................15

3.1 Electrical Service......................................................................................................15

3.2 Nameplate Ratings...................................................................................................15

3.3 Grounding.................................................................................................................15

3.4 Voltage Tolerance.....................................................................................................15

3.5 Auxiliary Control Wiring............................................................................................15

3.6 Remote.....................................................................................................................16

3.7 Remote Alarm Contacts ...........................................................................................16

3.7.1 Mini DAP™ II............................................................................................................16

3.7.2 Mini DAP III ..............................................................................................................16

3.8 Remote Sensors.......................................................................................................16

3.8.1 Mini DAP II ...............................................................................................................16

3.8.2 Mini DAP III ..............................................................................................................16

3.9 Condensate Pumps..................................................................................................16

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ..............17

4.1 Rigging.....................................................................................................................17

4.2 Leg Assembly...........................................................................................................17

4.3 Locating the Remote Heat Exchanger .....................................................................17

Table of Contents, continued

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER - Continued

4.4 Electrical Service........................................................................................................... 18

4.5 Air Cooled Condensers - Model DARC......................................................................... 18

4.6 Fluid Coolers - Model DAFC ......................................................................................... 18

4.6.1 Fluid-Sensing Thermostats ........................................................................................... 18

4.6.2 Energy Saver Cooling ...................................................................................................18

5.0 CHARGING ........................................................................................................................19

5.1 Air Cooled Systems.............................................................................................................19

5.1.1 Package Air Cooled Systems.........................................................................................19

5.1.2 Split Indoor Air Cooled Systems Charging.....................................................................19

5.1.3 Fan Speed Control System Charging.............................................................................20

5.1.4 Flooded System Charging..............................................................................................21

5.2 Water/Glycol Cooled Systems........................................................................................22

5.2.1 Water/Glycol Cooled Systems Charging........................................................................22

5.2.2 Factory Charge for Water/Glycol Cooled Systems.........................................................22

5.3 Refrigerant Handling ......................................................................................................22

5.4 Important Refrigeration Component...............................................................................23

5.4.1 Expansion Valve.............................................................................................................23

5.4.2 High Pressure Cutout Switch ........................................................................................23

5.4.3 Low Pressure Cutout Switch..........................................................................................23

6.0 GLYCOL SYSTEMS ...........................................................................................................24

6.1 Glycol Concentration......................................................................................................24

6.2 Internal (Fluid) Volume...................................................................................................24

6.3 Fluid Cooler Internal Volume..........................................................................................24

6.4 Copper Piping Internal Volume.......................................................................................24

6.5 Freezing Point of Aqueous Solutions .............................................................................24

7.0 CONTROLS ........................................................................................................................25

7.1 Standard Thermostat......................................................................................................25

7.2 Optional Programmable Thermostat..............................................................................25

7.3 Optional Mini DAP II Microprocessor Control Panel.......................................................25

7.4 Optional DAP II Microprocessor Control Panel..............................................................25

7.5 Secondary Heat Exchangers..........................................................................................25

7.6 Wiring Diagrams.............................................................................................................26

8.0 REGULAR MAINTENANCE ITEMS

8.1 Air Filters........................................................................................................................27

8.2 Belts ...............................................................................................................................27

8.3 Bearings.........................................................................................................................27

8.4 Humidiﬁer Canisters.......................................................................................................27

8.5 Fuses..............................................................................................................................27

8.6 Heating Elements...........................................................................................................27

8.7 Refrigerant Filter Drier....................................................................................................28

Table of Contents, continued

9.0 WARRANTY .......................................................................................................................29

10.0 CONTACT DATA AIRE .......................................................................................................30

LINE SIZING CHART ....................................................................................................................31

Monthly Maintenance Inspection Checklist ..............................................................................32

Quarterly Maintenance Inspection Checklist ............................................................................33

Superheat and Suction Pressure Troubleshooting Guide .......................................................34

Temperature Pressure Chart ......................................................................................................35

INDEX .......................................................................................................................................36,37

1.0 INSTALLATION

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

may supercede common trade practices. The manufacturer assumes no responsibility

for their interpretation. Consult local building codes and the National Electrical Code

for special installation requirements.

1.1 Room Considerations

Precision air conditioning equipment is designed to control spaces within close tolerances of

temperature and humidity. However, the room must be built with a proper vapor barrier. A ﬁlm of

polyethylene is often used onwalls and ceilings or wallsand ﬂoors must also be painted with a vapor-

seal paint. All doors to the controlled space should be equipped with weather seals to prevent the

inﬁltration of non-neutral conditioned air from entering the space. Failure to provide a vapor barrier

can compromise the ability to control space conditions.

Introduction of outside air into the controlled 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 conditions and

result in poor space control. All outside air that is introduced should be conditioned to the humidity

and temperature parameters of the computer room air conditioner (CRAC) unit set points to maintain

proper room conditions and to prevent the CRAC units from running excessively to maintain the

room’s conditions.

1.2 Inspection

This Data Aire 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, shipping

damage can occur and a visual inspection of the outer crating immediately upon delivery should be

performed.

Note any external damage or other 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.

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

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

Freight damage claims are the responsibility of the purchaser. Action to recover losses

should be ﬁled immediately. Please notify factory personnel of any claims.

1.3 Locating the Unit

The unit is intended for above the ceiling installation and is typically suspended from structural

members in the building above the ceiling. Add a 50% safety factor to the weight of the unit to

determine the strength of the supporting structural members.

Appropriate service access above the ceiling is required around all service and electrical access

panels. There must be unobstructed clearance below the unit allowing ladder access to enable

routine maintenance and service.

Note there are many available unit conﬁgurations for Mini Ceiling systems. Be sure to

identifytheunittype andstyle beforeinstalling. Forinstancetheremay besplitcondenser/

condensing sections requiring separate or shared power.

Note to Installing Contractor: Condensation formation and frequent humidiﬁer ﬂush-

ing are normal functions of this equipment. Proper drain connections must be made

to ensure proper removal. Unit will require water connections for condensate removal

and possibly for humidiﬁer make-up water, condenser water, chilled water and/or hot

water. Installation of units above equipment that could sustain water damage should

be avoided.

1.3.1 Vertical Airﬂow Units

The evaporator (cooling) section is typically mounted over a standard 2’ x 4’ T-bar ceiling grid,

supportedby four threadedrods. Theevaporator (cooling) sectionwillbereferred to astheevaporator

section from here on even though the coil on chilled water units is not a true evaporator coil.

Fourthreadedsupportrodsmustbesecurelyattachedtothebuildingstructure. Raisetheevaporator

section with an appropriate lifting device. Attach washers, nuts and jam nuts to each threaded rod.

Tighten the nuts so the weight is supported evenly by the four rods and the unit is level. Be sure

to allow for the depth of the Supply/Return air plenum when calculating the height of the unit above

the ceiling.

The5” tall vertical Supply/Return plenum assemblyisattachedtothe bottom of the evaporator section

after the evaporator section has been hung. Six screws fasten the plenum to the evaporator section.

The Supply/Return air grilles should be temporarily removed for access. The plenum mounts ﬂush

to the ceiling grid.

1.3.2 Air Cooled Packaged Units

Air cooled package units require an additional condenser fan section to be mounted to the end of

the evaporator section at the condenser coil. Place a gasket around the perimeter of the condenser

coil opening. Connect the female motor plug from the condenser blower section to the male plug

inside the evaporator section. Attach the condenser blower section using four (4) self-drilling #10

self drilling sheet metal screws.

Most applications will allow for the condenser discharge air to blow out into the ceiling space and no

ducting is required. The ceiling space must be large enough to dissipate the rejected heat. Plenum

space temperature should not exceed 95oF. If ducting is required the additional static imposed by

ductwork on the air intake and/or discharge should not exceed 0.3”. In some applications a factory

provided low ambient damper is used at the condenser air intake. The air intake is modiﬁed from its

normal grilled openings to a single 15” x 17” duct collar.

1.3.3 Horizontal Airﬂow Units

Ductwork is connected to factory provided duct collars on the supply and return air openings. Four

threaded support rods must be securely attached to the building structure. Raise the evaporator

section with an appropriate lifting device. Attach washers, nuts and jam nuts to each threaded rod.

Tighten the nuts so the weight is supported evenly by the four rods and the unit is level.

Note some options call for a combination of vertical and horizontal airﬂow conﬁguration.

In that case, the 5” plenum assembly described above is necessary.

1.3.4 Indoor Condensers and Condensing Units

These sections are to be mounted in the same manner as the evaporator sections using four

threaded rods. Air cooled condensers or condensing units have factory provided duct collars on the

supply and intake air openings as appropriate. Water cooled condensing sections have no airﬂow

connections.

Typical installations have the condenser or condensing section physically near the evaporator,

especiallysincemosthave sharedelectrical linepower. Themountingof thesesectionsisindependent

of the evaporator mounting. The same service and maintenance clearance requirements apply to

these units as well.

1.4 Paperwork

Each Data Aire 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 registrations cards and other valuable paperwork, including

a copy of this Installation/Operation and Maintenance manual.

A yellow tag is attached to the outside panel to indicate articles that may have been packaged and

shipped loose within the unit cabinet. Typically this would be a condensate pump and other loose

components that are not factory mounted.

Itistheresponsibility of the installing contractor to return the start-up sheet andwarranty

registration card to DataAire for proper activation of the unit warranty. Failure to do so

may cause delays and in some cases void the warranty.

1.5 Storage

Your Data Aire equipment comes ready for immediate installation. In some instances it may be

necessary to store the equipment for a period of time. If you must store the equipment it should be

done in a dry area, out of the weather, protected from freezing temperatures, protected from damage

by other equipment in storage or transportation equipment, never stacked, and avoid frequent

relocation.

Ifequipment is stored for longer than 30daysspecialprecautionsmustbe taken to avoid coil damage.

Allcoilsshouldbechargedandsealedwithalowpressure(1-3psig)inertgas,suchas nitrogen. This

prevents contaminates from entering the coils; then when the seal is broken at installation, the rush

of escaping gas veriﬁes the coil is still leak free. If coils are not charged and sealed condensation

mixes with air pollutants forming a weak acid and over time can cause pin hole leaks to develop in

the coil tubes.

Whenequipmentis installed after storage caution should betaken to inspect and replace,if required,

rubberhosesandbelts. All movingparts,suchasblowers andmotors,shouldbehand testedtoensure

that they are free and clear prior to start-up. Finally, verify that all lubrication is fresh and full.

Itis the responsibility of the installingcontractortoreturnthe start-up sheet and warranty

registration card to DataAire for proper activation of the unit warranty. Failure to do so

may cause delays and in some cases void the warranty.

2.0 PIPING

2.1 Split Air Cooled Unit Piping

Refer to the attached Line Sizing chart on page 31 for a guideline for sizing refrigerant lines. The

ultimate responsibility for line size selection is that of the installing contractor or project engineer.

DataAire does not assume this responsibility. The chart covers distances up to 200 equivalent feet.

For installations beyond this distance, consult ASHRAE or similar references.

StandardPiping practice must be used to ensure proper oil return and efﬁcient operation.

The interconnecting lines to the remote air cooled condenser must be installed by a

qualiﬁed refrigeration mechanic.

2.1.1 Discharge Lines

Dischargelines,alsocalled Hot Gas lines, should be trapped atthe top (inverted) and bottom, as well

as every 20 feet of vertical rise. Discharge line check valves are recommended on all installations,

especially those where there are long pipe runs or cold climate. Check valves should be installed

six feet from the compressor.

Discharge line pressure drop should not exceed 6 PSI. Recommended gas velocity for proper oil

return is 1,000 FPM. Slope horizontal lines downward in the direction of refrigerant ﬂow 1/2” for

every ten feet of line length.

2.1.2 Liquid Lines

Liquid line size is determined by pressure drop and velocity. The liquid line pressure drop should be

not exceed 5 PSI. The recommended velocity should be between 200 and 300 FPM.

To avoid excessive liquid line pressure drop, the air cooled condenser should be located above or at

the same level as the evaporator. Condenser installation more than ten feet below the evaporator

should be avoided.

2.1.3 Suction Lines

Some applications call for the compressor to be mounted in the outdoor condenser, or condensing

unit. Such cases require ﬁeld piping of liquid and suction lines. Suction lines are trapped similarly

to discharge lines except for the inverted trap at the top of the suction line and the line needs to be

insulatedwith a minimum 1/2”thickinsulationor per code. Common practiceforsuctionline selection,

see page 31, and installation should be followed.

2.1.4 Connection Sizes, Air Cooled Units

Model Hot Gas Liquid Suction

DAMA 0112 1/2” 1/2” 3/4” Note: Unit will have a Liquid Line and

DAMA 1.512 1/2” 1/2” 3/4” either a Hot Gas or Suction Line

DAMA 0212 1/2” 1/2” 3/4”

DAMA 2.512 1/2” 1/2” 3/4”

Field connections at the indoor evaporator and remote condenser or condensing unit will

not necessarily be the same as the ﬁeld pipe size required. In some cases these will

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