Data Aire GPod Manuale di istruzioni

gPod

DX, Air, Water or Glycol Cooled

Ceiling and Floor Mounted

Installation, Operation, & Maintenance

Manual

Data Aire Inc.

230 W. BlueRidge Avenue

Orange, CA 92865

www.dataaire.com

Installation, Operation and Maintenance Manual

Page ii

VERSION HISTORY

Version #

Implemented By

Revision Date

Approved By

Approval

Date

Reason

1.0

A Tran, T Marwitz

06/03/2019

Ted Marwitz

06/07/2019

Initial Release

CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION ENVIRONMENTAL CONTROL SYSTEM. PROPER

ADHERENCE TO THIS INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR THIS EQUIPMENT WILL ENSURE

YEARS OF OPTIMAL PERFORMANCE.

There are separate installation, operation, and maintenance (IOM) manuals for other components of your Data Aire

precision cooling system including dap4 or Mini-dap4, air-cooled condensers, and fluid coolers.

This manual is intended to assist trained service personnel by providing necessary guidelines 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.

Service performed by unauthorized or unqualified technicians may void manufacturers’ warranties and could result

in property damage and/or personal injury.

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

any design without notice.

Installation, Operation and Maintenance Manual

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IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS

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 de

ath.

CAUTION indicates a hazardous

situation

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. Special care

should be given to those areas where these symbols

appear.

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 documentand 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 electric shock can cause injury or death. Disconnect local and

remote electrical power before working within unit.

Customer must provide earth ground to unit, per NEC, CEC and local codes, as

applicable. Before proceeding with installation, read all instructions, verify that

all the parts are included and check the nameplate to be sure the voltage

matches available utility power.

Installation, Operation and Maintenance Manual

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WARNING The Data Aire dap4 or Mini-dap4 microprocessor does not isolate

power from the unit, even in the “Unit Off” mode. Some internal components

require and receive power even during the “Unit Off” mode of Data Aire dap4™

control.

The factory-supplied optional disconnect switch is located inside the unit’s

electrical control panel. The supply voltage side of the disconnect switch

contains live high voltage. The only way to ensure that there is NO voltage inside

the unit is to install and open a remote facility disconnect switch.

WARNING Risk of explosive discharge from high-pressure refrigerant. Can cause

injury or death. This unit contains fluids and gases under high pressure. Relieve

pressure before working with piping.

WARNING Risk of refrigerant system rupture or explosion from over

pressurization can cause equipment damage, injury or death.

WARNING Risk of contact with high-speed moving parts can cause injury or

death. Disconnect all local and remote electric power supplies before working

in the unit. Do not operate unit with any or all cabinet panels removed. Do not

operate up flow units without installing a plenum, ductwork or guard over the

blower opening(s) on the top surface of the unit cabinet. Ductwork must be

connected to the blower(s), or a plenum must be installed on the blower deck

for protection from rotating blower wheel(s) on up flow units.

CAUTION Risk of contact with hot surfaces can cause injury. The compressors,

refrigerant discharge lines, humidifiers and reheats are extremely hot during

unit operation. Allow enough time for them to cool before working within the

unit cabinet. Use extreme caution and wear protective gloves and arm

protection when working on or near hot compressors, discharge lines,

humidifiers and reheats.

CAUTION Risk of handling heavy andlengthy parts can cause personal injury and

equipment damage. Follow relevant OSHA lifting recommendations and

consider using a two-person lift for safe and comfortable removal and

installation of cabinet panels. Only properly trained and qualified personnel

wearing appropriate safety headgear, gloves and shoes should attempt to

remove or install cabinet panels.

NOTICE Risk of clogged or leaking drain lines can cause equipment and building

damage. This unit requires a condensate water drain connection. Drain lines

must be inspected regularly and maintenance must be performed to ensure

that drain water runs freely through the drain system and that lines are clear

Installation, Operation and Maintenance Manual

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and free of obstructions and in good condition with no visible sign of damage or

leaks. Improper installation, application and service practices can 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 damage. Data Aire recommends installing

leak detection equipment for unit and supply lines.

NOTICE Risk of a leaking coil due to freezing and/or corrosion can cause

equipment and serious building damage. Cooling and heat rejection coils, heat

exchangers and piping systems that are connected to open cooling towers or

other open water/glycol systems are at high risk for freezing and premature

corrosion. Fluids in these systems must contain the proper antifreeze and

inhibitors to prevent freezing and premature coil corrosion. The water or

water/glycol solution must be analyzed by a competent water treatment

specialist before startup to establish the inhibitor requirement. The water or

water/glycol solution must be analyzed every six months to determine the

pattern of inhibitor depletion. The complexity of water-caused problems and

their correction makes it important to obtain the advice of a water treatment

specialist and follow a regularly scheduled maintenance program.

NOTICE Installation and maintenance must be performed only by qualified

personnel who are familiar with this type of equipment.

WARNING Refrigerant can be harmful if it is inhaled. Refrigerant must be used

and recovered responsibly. Failure to follow this warning may result in personal

injury or death.

CAUTION Do not operate doors when unit is not on a flat surface.

WARNING Pressure-relief line must be vented to the atmosphere per the latest

edition of ASHRAE standard and/or any local building, fire or mechanical codes.

This is for units with shell and tube and units with high pressure relief valve.

NOTICE Maintain a minimum clearance of 36 inches or width of the unit

whichever is larger.

NOTICE Altering, modification or equal of our product may void warranty and

or void regulatory certification(s). Field rearrangement of components are not

recommended.

Installation, Operation and Maintenance Manual

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NOTICE Any installation of an auxiliary device shall not require the cutting,

wiring or the soldering of connections by the installer, and shall not require

cutting, drilling or welding in the electrical enclosure(s) and in other areas where

such operations may damage electrical or refrigeration components and wiring.

CAUTION For replacement of fuses, replace with same size fuse size and type

or equivalent.

NOTICE Data Aire products are strictly for non-residential applications.

NOTICE Using substitute parts or bypassing electrical or refrigeration

components is not recommended and will VOID THE WARRANTY.

NOTICE Using substitute parts or bypassing electrical or refrigeration

components is not recommended and will VOID THE WARRANTY.

NOTICE TO CUSTOMER/CONTRACTOR PROTECT YOUR WARRANTY PRIOR TO

STARTUP.

• Read and follow the Installation & Start-up Instructions provided with this

equipment.

• Storage of this equipment must be on a flat surface and protected from the

weather.

• Protect this equipment from damage, construction dirt, debris, freezing

temperatures and water.

• Make sure all shipping materials have been removed.

• A qualified startup technician must complete the Data Aire “Field start up

test sheet”

Installation, Operation and Maintenance Manual 
 
 
 
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Table of Contents 
1INTRODUCTION............................................................................................................................................. 1 
 PRODUCT INFORMATION -WHAT IS GPOD? ........................................................................................................ 1 
 MODEL IDENTIFICATION NOMENCLATURE........................................................................................................... 1 
1.2.1 Ceiling Mounted Units....................................................................................................................... 1 
1.2.2 Floor Mounted Units ......................................................................................................................... 1 
 DELIVERY INSPECTION..................................................................................................................................... 2 
 PAPERWORK................................................................................................................................................. 2 
2INSTALLATION............................................................................................................................................... 3 
 RECOMMENDED TOOLS FOR INSTALLATION ......................................................................................................... 3 
 PRE-INSTALLATION......................................................................................................................................... 3 
2.2.1 Room Considerations ........................................................................................................................ 4 
 LOCATING FLOOR UNITS.................................................................................................................................. 4 
2.3.1 Upflow Units ..................................................................................................................................... 6 
2.3.2 Horizontal Airflow Units .................................................................................................................... 7 
2.3.3 Indoor Condensers ............................................................................................................................ 8 
 STORAGE ..................................................................................................................................................... 8 
2.4.1 Suggested Reference Storage Room Conditions ................................................................................. 9 
2.4.2 General Storage Considerations ........................................................................................................ 9 
 FIELD PIPING CONNECTIONS INSTALLATION ........................................................................................................10 
 ELECTRICAL INSTALLATION ..............................................................................................................................10 
 REFRIGERATION SETUP ..................................................................................................................................10 
2.7.1 Leak Test..........................................................................................................................................11 
 SYSTEM CONTROL SETUP................................................................................................................................11 
 POST INSTALLATION ......................................................................................................................................11 
 INSTALLATION OF REMOTE HEAT EXCHANGER.................................................................................................12 
 VOLTAGE PHASE CHECK .............................................................................................................................12 
2.11.1 Evaporator Power Phasing ...........................................................................................................12 
2.11.2 Remote Heat Exchanger...............................................................................................................12 
3PIPING..........................................................................................................................................................13 
 REFRIGERANT PIPING.....................................................................................................................................13 
 SPLIT AIR-COOLED UNIT PIPING.......................................................................................................................15 
3.2.1 Discharge Lines ................................................................................................................................15 
3.2.2 Liquid Lines ......................................................................................................................................16 
3.2.3 Line Traps: .......................................................................................................................................16 
3.2.4 Field Piping, Remote Condenser Above Evaporator...........................................................................17 
3.2.5 Field Piping, Remote Condenser Below Evaporator ...........................................................................18 
3.2.6 Connection Sizes, Air-Cooled Units....................................................................................................18 
 RECOMMENDED LINE SIZING FOR AIR-COOLED SPLIT SYSTEMS ...............................................................................19 
3.3.1 Hot Gas Lines: Single Circuit Units (Up to 200 Equivalent Feet) .........................................................19 
3.3.2 Liquid Lines: Single Circuit Units (Up to 200 Equivalent Feet).............................................................19 

Installation, Operation and Maintenance Manual 
 
 
 
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3.3.3 Total Equivalent Line Length Calculation ..........................................................................................20 
 POST PIPING INSTALLATION ............................................................................................................................20 
 WATER/GLYCOL COOLING UNIT PIPING.............................................................................................................20 
3.5.1 Field Piping, Water/Glycol System....................................................................................................21 
3.5.2 Connection Sizes, Water/Glycol Cooled Units....................................................................................22 
 CO2PIPING.................................................................................................................................................22 
 CONDENSATE DRAIN PIPING ...........................................................................................................................22 
3.7.1 Condensate Trap ..............................................................................................................................23 
 HUMIDIFIER PIPING.......................................................................................................................................24 
 LEAK TESTING ..............................................................................................................................................24 
 EVACUATION...........................................................................................................................................25 
3.10.1 Evacuation Procedures.................................................................................................................25 
4CHARGING ...................................................................................................................................................27 
 AIR COOLED SYSTEMS....................................................................................................................................27 
4.1.1 Packaged Air-Cooled Systems Ceiling Units (2.5 to 5 Ton) .................................................................27 
4.1.2 Split Air-Cooled Systems Charging (Units with Indoor Condenser or Outdoor Condenser) ..................28 
4.1.3 Flooded System Charging .................................................................................................................29 
 REFRIGERANT HANDLING................................................................................................................................31 
5ELECTRICAL CONNECTIONS ..........................................................................................................................32 
 GENERAL ELECTRICAL FIELD WIRING GUIDELINES.................................................................................................33 
 ELECTRICAL SERVICE......................................................................................................................................33 
 NAMEPLATE RATINGS....................................................................................................................................34 
 GROUNDING................................................................................................................................................34 
 VOLTAGE TOLERANCE....................................................................................................................................34 
 STANDARD ELECTRICAL CONNECTIONS ..............................................................................................................35 
 CONTROLLERS..............................................................................................................................................35 
5.7.1 Floor Mounted Units ........................................................................................................................35 
5.7.2 Ceiling Mounted Units......................................................................................................................35 
 AUXILIARY CONTROL WIRING..........................................................................................................................36 
 REMOTE SHUTDOWN ....................................................................................................................................37 
 REMOTE ALARM CONTACTS........................................................................................................................37 
5.10.1 Mini-dap4 Controller....................................................................................................................37 
5.10.2 dap4 Controller............................................................................................................................37 
 REMOTE TEMPERATURE AND HUMIDITY SENSOR.............................................................................................38 
 CONDENSATE PUMP (OPTIONAL).................................................................................................................38 
 CONDENSATE PROBE (STANDARD ON FLOOR UNITS AND OPTIONAL ON CEILING UNITS) ..........................................39 
 FLOAT SWITCH (CEILING UNITS) ..................................................................................................................39 
 UNDER-FLOOR WATER DETECTION CABLE (OPTIONAL).....................................................................................39 
 DISCONNECT SWITCH (OPTIONAL) ...............................................................................................................39 
 MANUAL OVERRIDE SWITCH BOARD (DAP4ONLY)..........................................................................................40 
 WIRING DIAGRAMS ..................................................................................................................................40 
 PLUG FAN “NO AIRFLOW ALARM”CURRENT SENSING SWITCH (PLUG FAN UNIT ONLY) ..........................................41 
5.19.1 "No Airflow" Switch Adjustment...................................................................................................41 

Installation, Operation and Maintenance Manual 
 
 
 
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6IMPORTANT COMPONENTS.........................................................................................................................44 
 REMOTE HEAT EXCHANGER ............................................................................................................................44 
 REFRIGERATION COMPONENTS........................................................................................................................44 
6.2.1 Expansion Valve ...............................................................................................................................44 
6.2.2 High Pressure Cutout Switch.............................................................................................................44 
6.2.3 Low Pressure Cutout Switch..............................................................................................................44 
 CONTROLS ..................................................................................................................................................44 
6.3.1 Mini-dap4 Controller (Ceiling Units)..................................................................................................44 
6.3.2 dap4 Controller (Floor Units) ............................................................................................................44 
7GENERAL MAINTENANCE REQUIREMENTS ..................................................................................................46 
 DAILY MAINTENANCE ....................................................................................................................................46 
 SCHEDULED MAINTENANCE ............................................................................................................................46 
 REMOVING DOORS AND PANELS FOR MAINTENANCE (FLOOR UNITS).......................................................................47 
 ELECTRONICALLY COMMUTATED (EC) MOTORS (EC MOTORS)...............................................................................48 
7.4.1 EC Plug Fan Manual Test (Units with a dap4 Controller Only) ...........................................................48 
7.4.2 Protective Features ..........................................................................................................................48 
7.4.3 EC Plug Fan Maintenance.................................................................................................................49 
 UNITS WITH BELT DRIVEN BLOWERS.................................................................................................................49 
7.5.1 Belts.................................................................................................................................................49 
7.5.2 Bearings...........................................................................................................................................49 
 AIR FILTERS .................................................................................................................................................50 
7.6.1 Upflow Unit Air Filter Replacement Procedure..................................................................................50 
7.6.2 Ceiling Unit Air Filter Replacement Procedure...................................................................................51 
 HUMIDIFIER.................................................................................................................................................51 
7.7.1 Humidifier Cannisters.......................................................................................................................51 
7.7.2 Cylinder Spent Fault .........................................................................................................................51 
7.7.3 Replacement Cylinder.......................................................................................................................51 
7.7.4 Preparing Humidifier for Extended Shutdown Duration.....................................................................55 
7.7.5 Starting Humidifier after Extended Shutdown...................................................................................55 
 HUMIDIFIER DRAIN PAN.................................................................................................................................56 
 CONDENSATE PUMP......................................................................................................................................56 
 FUSES ....................................................................................................................................................56 
 REHEATING ELEMENTS...............................................................................................................................56 
 REFRIGERANT FILTER DRIER ........................................................................................................................56 
 CABINET.................................................................................................................................................57 
7.13.1 Exterior Cabinet Maintenance- Cleaning ......................................................................................57 
 COILS.....................................................................................................................................................57 
7.14.1 Coil Cleaning ................................................................................................................................57 
 PIPING ...................................................................................................................................................57 
 WATER/GLYCOL COOLED SYSTEM................................................................................................................58 
 STANDARD WATER/GLYCOL FLOW SWITCH REPLACEMENT................................................................................58 
7.17.1 Mounting the Flow Switch............................................................................................................59 
 DX COMPONENT REPAIR OR REPLACEMENT ...................................................................................................59 

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7.18.1 Compressor Checklist ...................................................................................................................60 
7.18.2 Fixed Speed Scroll Compressor Replacement ................................................................................61 
7.18.3 Refrigerant Filter Drier .................................................................................................................63 
7.18.4 Thermostatic Expansion Valve (TXV) Replacement .......................................................................64 
7.18.5 Refrigerant Liquid Line Solenoid Valve (LLSV) Replacement ..........................................................65 
 ELECTRICAL COMPONENT MAINTENANCE/REPLACEMENT..................................................................................66 
 ELECTRICAL CONTROL PANEL ......................................................................................................................67 
 FUSES ....................................................................................................................................................67 
7.21.1 Fuse Replacement........................................................................................................................67 
 ELECTRIC REHEAT WITH MODULATING SCR CONTROL (SPECIAL OPTION) .............................................................68 
7.22.1 Electric Reheat Element Checklist .................................................................................................68 
 RUN OR START CAPACITOR REPLACEMENT .....................................................................................................68 
 DEFINITE AND GENERAL PURPOSE CONTACTOR REPLACEMENT...........................................................................70 
 CONTROL AND ISOLATION TRANSFORMER REPLACEMENT..................................................................................70 
 PLUG FANS WITH ELECTRONICALLY COMMUTATED (EC) MOTORS (EC)................................................................71 
 SMOKE DETECTOR MAINTENANCE ...............................................................................................................72 
7.27.1 Smoke Detector Testing ...............................................................................................................72 
7.27.2 Cleaning Smoke Detector .............................................................................................................73 
 CONTROLS ..............................................................................................................................................73 
 TEMPERATURE AND HUMIDITY SENSOR MAINTENANCE ....................................................................................74 
7.29.1 Disposal of Temperature and Humidity Sensor .............................................................................74 
 MINI-DAP4OR DAP4CONTROLLER REPLACEMENT...........................................................................................74 
8LOW AMBIENT RECEIVER PACKAGE .............................................................................................................75 
 REFRIGERANT RECEIVER .................................................................................................................................76 
 APPLICATIONS..............................................................................................................................................76 
 SELECTION GUIDELINES..................................................................................................................................76 
 SAFETY RELIEF DEVICES..................................................................................................................................77 
 REFRIGERANT RECEIVER INSTALLATION..............................................................................................................77 
 HEAD PRESSURE CONTROL .............................................................................................................................77 
 RECEIVER LEVELS ..........................................................................................................................................77 
 RECEIVER HEATERS .......................................................................................................................................78 
 RECEIVER HEATER ELECTRICAL WIRING..............................................................................................................78 
9GPOD ADDITIONAL FEATURES .....................................................................................................................79 
 DAY/NIGHT CONTROL ...................................................................................................................................79 
 CO2CONTROL .............................................................................................................................................79 
10 WARRANTY POLICY......................................................................................................................................80 
11 CONTACT DATA AIRE ...................................................................................................................................81 
12 SUPERHEAT AND SUCTION PRESSURE TROUBLESHOOTING GUIDE..............................................................82 
 LOW SUCTION PRESSURE AND HIGH SUPERHEAT .............................................................................................82 
 HIGH SUCTION PRESSURE AND LOW SUPERHEAT.............................................................................................82 
 LOW SUCTION PRESSURE AND LOW SUPERHEAT..............................................................................................82 