Data Aire DAPA-2.5 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 and Mini-dap4

microprocessor 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 situation which, if not avoided, could

result in minor or moderate injury.

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.

TABLE OF CONTENTS 
3 
 INTRODUCTION............................................................................................................. 7 
 Product Information.......................................................................................................................7 
 Model Identification .......................................................................................................................7 
 Inspection......................................................................................................................................8 
 Paperwork.....................................................................................................................................8 
 Storage..........................................................................................................................................9 
 Suggested Reference Storage Room Conditions.........................................................................9 
 General Storage Considerations...................................................................................................9 
 Registered Trademarks –Copy Rights –References Section...................................................10 
 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 
 Moving Unit into Final Location...........................................................................................14 
 Rigging........................................................................................................................................14 
 Locating the Unit .........................................................................................................................14 
 Horizontal Airflow Units...............................................................................................................15 
 Installing/Mounting ......................................................................................................................15 
 Vertical Airflow Units ...................................................................................................................15 
 Indoor Condensers and Condensing Units.................................................................................17 
 Piping ..........................................................................................................................................17 
 Split Air-Cooled Unit Piping.........................................................................................................18 
 Discharge Lines ..........................................................................................................................18 
 Liquid Lines .................................................................................................................................20 
 Suction Lines...............................................................................................................................20 
 Recommended Line 
Sizing
........................................................................................................20 
 Hot Gas Lines......................................................................................................................21 
 Liquid Lines.........................................................................................................................21 
 Suction Lines.......................................................................................................................21 
 Connection Sizes, Air Cooled Units............................................................................................22 
 Connection Sizes, Water/Glycol Cooled Units............................................................................22 
 Connection Sizes, Chilled Water Units .......................................................................................22 
 Field Piping, Remote Condenser/Condensing Unit Above Evaporator ......................................23 
 Field Piping, Remote Condenser/ Condensing Unit Below Evaporator......................................24 
 Connection Sizes, Fluid Coolers (Dry Coolers) ..........................................................................25 
 Auxiliary Chilled Water/Energy Saver Coil..................................................................................25 
 Auxiliary Chilled Water/Energy Saver Coil Piping...............................................................25 
 Condensate Drain System ..........................................................................................................26 
 Condensate Trap.................................................................................................................27 
 Condensate Pump Side Mounting Pump (Optional)...........................................................29 
 Humidifier....................................................................................................................................30 
 Steam Generator Humidifier ...............................................................................................30 
 Humidifier Piping.................................................................................................................30 
 Refrigerant Piping Protection......................................................................................................30 
 Water/Glycol Cooled Unit Piping.................................................................................................31 
 Leak Testing................................................................................................................................33 
 Electrical Installation ...................................................................................................................33 
 Commissioning Information.........................................................................................................34 
 ELECTRICAL CONNECTIONS......................................................................................35 

TABLE OF CONTENTS 
4 
 General Electrical Field Wiring Guidelines..................................................................................36 
 Electrical Service.........................................................................................................................37 
 Nameplate Ratings......................................................................................................................37 
 Grounding....................................................................................................................................37 
 Voltage Tolerance.......................................................................................................................37 
 Three Phase Voltage Tolerance .........................................................................................37 
 Single-Phase Voltage Tolerance.........................................................................................38 
 Heat Exchanger Auxiliary Control Wiring....................................................................................38 
 Remote Shutdown.......................................................................................................................39 
 Mini-dap4 Controller....................................................................................................................39 
 Remote Alarm Contacts..............................................................................................................39 
 Remote Sensors .........................................................................................................................40 
 Condensate Pumps.....................................................................................................................40 
 Disconnect Switch (Optional)......................................................................................................40 
 Manual Override Switch Board ...................................................................................................41 
 Wiring Diagrams..........................................................................................................................42 
 INSTALLATIONOF REMOTE OUTDOOR HEAT EXCHANGER....................................42 
 CHARGING....................................................................................................................43 
 Package Air-Cooled Systems .....................................................................................................43 
 Charging/Installation Work Procedures ......................................................................................43 
 Triple Evacuation and Dehydration Procedure ...........................................................................43 
 Tools Needed......................................................................................................................44 
 First Stage Evacuation........................................................................................................44 
 Second Stage Evacuation...................................................................................................45 
 Third Stage Evacuation.......................................................................................................45 
 Final Evacuation Stage .......................................................................................................46 
 General Pre-Charging Guidelines...............................................................................................46 
 Voltage Phase Check..................................................................................................................47 
 Evaporator Power Phase Check.........................................................................................47 
 Fixed Speed Scroll Compressor Phase Check...................................................................47 
 Heat Exchanger Phase Check............................................................................................48 
 GHRC Air-Cooled Heat Exchanger Phase Check..............................................................48 
 DARC Heat Exchangers Phase Check...............................................................................48 
 Line Set Charge Calculations......................................................................................................48 
 Component Functional Test........................................................................................................49 
 Charging Procedures ..................................................................................................................49 
 Refrigerant Handling ...........................................................................................................50 
 Air Cooled Split System Charging.......................................................................................50 
 Charging the Fixed Speed Compressor..............................................................................52 
 Additional Oil .......................................................................................................................54 
 Flooded System Charging (Systems with Low Ambient Receiver Package)......................54 
 Refrigerant Receiver ...........................................................................................................55 
 Applications.........................................................................................................................55 
 Selection Guidelines ...........................................................................................................55 
 Receiver Location................................................................................................................56 
 Safety Relief Devices..........................................................................................................56 
 Receiver Installation............................................................................................................56 
 Charge Fixed Speed Compressor.......................................................................................58 
 Water/Glycol-Cooled System Charging ..............................................................................58 
 Important Refrigeration Components..........................................................................................59 
 Thermal Expansion Valve ...................................................................................................59 
 High Pressure Cutout Switch ..............................................................................................60 

TABLE OF CONTENTS 
5 
 Low Pressure Cutout Switch...............................................................................................60 
 Liquid Line Solenoid Valve (Optional)..................................................................................61 
 GLYCOL SYSTEMS ......................................................................................................62 
 Glycol Concentration...................................................................................................................62 
 Internal (Fluid) Volume................................................................................................................62 
 Fluid Cooler Internal Volume...............................................................................................62 
Fluid coolers have individual Installation, Operation and Maintenance Manuals which should be 
referred to for more complete details regarding remote heat exchangers..........................................62 
 Brazed-Plate Condensers...................................................................................................62 
 Water Treatment..................................................................................................................63 
 Fluid Cooler.................................................................................................................................64 
 Type L Copper Tubing Internal Volume......................................................................................64 
 Freezing Point of Aqueous Solutions..........................................................................................65 
 Mixing Glycol and Water .............................................................................................................65 
 CONTROLS...................................................................................................................66 
 Mini-dap4 Microprocessor Control Controller .............................................................................66 
 Optional Expanded dap4 Microprocessor Controller..........................................................66 
 Optional Thermostat............................................................................................................66 
 Remote Heat Exchangers...........................................................................................................66 
 REGULAR MAINTENANCE ITEMS...............................................................................67 
 Air Filters.....................................................................................................................................67 
 Belts ............................................................................................................................................67 
 Bearings......................................................................................................................................67 
 Fuses...........................................................................................................................................68 
 Electric Reheat............................................................................................................................68 
 Humidifier....................................................................................................................................68 
 Humidifier Canisters............................................................................................................68 
 Refrigerant Filter Drier.................................................................................................................68 
 EC Plenum (Plug) Fans ..............................................................................................................69 
 Electronically Commutated Motors......................................................................................69 
 EC Motor Testing ................................................................................................................70 
 MAINTENANCE/INSPECTION CHECKLIST.................................................................71 
 Frequently Asked Questions –FAQ............................................................................74 
 Electrical FAQ Section ................................................................................................................74 
 Mechanical FAQ Section.............................................................................................................75 
 Contact Data Aire .........................................................................................................78 
TABLE OF FIGURES 
Figure 1 Typical Installation Methods........................................................................................16 
Figure 2 Typical Installation Details...........................................................................................16 
Figure 3 Typical Discharge Check Valve...................................................................................19 
Figure 4 Recommended Condensate Trap Dimensions............................................................28 
Figure 5 Typical Side Pump Mounting.......................................................................................29 
Figure 6 Typical Water/Glycol System ......................................................................................32 
Figure 7 Typical Remote Heat Exchanger Interconnection Points.............................................39 
Figure 8 Typical Indoor Evaporator Interconnection Points .......................................................39 
Figure 9 Manual Override Switch Board....................................................................................41 
Figure 10 Typical Low Ambient Receiver Package ...................................................................57 
Figure 11 Example Remote EPO Switch Connection................................................................75 

TABLE OF CONTENTS 
6 
LIST OF TABLES 
Table 1 Line Size Metric Conversion.........................................................................................20 
Table 2 Hot Gas Lines (Inches OD) ..........................................................................................21 
Table 3 Liquid Lines (Inches OD)).............................................................................................21 
Table 4 Suction Lines (Inches OD)............................................................................................21 
Table 5 Connection Sizes, Air Cooled Units (Inches OD)..........................................................22 
Table 6 Connection Sizes, Water/Glycol Cooled Units (Inches OD)..........................................22 
Table 7 Connection Sizes, Chilled Water Units (Inches OD).....................................................22 
Table 8 Three Phase Voltage Tolerance...................................................................................38 
Table 9 Single Phase Voltage Tolerance..................................................................................38 
Table 10 Remote Alarm Contacts Terminals.............................................................................40 
Table 11 Liquid Line Multiplier...................................................................................................48 
Table 12 Liquid Line Multiplier for R-410A at Various Line Lengths...........................................49 
Table 13 Liquid Line Multiplier for R-407C at Various Line Lengths ..........................................49 
Table 14 DAPA Starting Charge R-410A...................................................................................51 
Table 15 DAPA Starting Charge R-407C ..................................................................................51 
Table 16 Refrigerant Charge Values.........................................................................................53 
Table 17 Refrigerant Receiver Charging Chart..........................................................................58 
Table 18 Discharge Head Pressure ..........................................................................................58 
Table 19 Packaged Units without Receivers.............................................................................59 
Table 20 Packaged Units with Receivers..................................................................................59 
Table 21 High Pressure Cutout Switch Setting..........................................................................60 
Table 22 Low Pressure Cutout Switch Setting...........................................................................60 
Table 23 Mini-DAP Ceiling Unit Internal (Fluid) Volume ............................................................62 
Table 24 Type L Copper Tubing Internal Volume......................................................................64 
Table 25 Freezing Point of Aqueous Solutions..........................................................................65 
 
 
 

INTRODUCTION

Product Information

The Data Aire Mini-Plus (DAP) environmental control, direct expansion, single circuit or chilled water-

cooled 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. This unit is normally mounted above the ceiling tiles.

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

The unit is provided with a Data Aire Mini-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 decreaseequipment reliability.

Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.”

Model Identification

DAP X - XX X X - X - XX

Mini-Plus Ceiling System (DAP) Model Number

2.5 Tons

03 Tons

04 Tons

05 Tons

Auxiliary Coils

Voltage

Phase

P - Package System (Not available in air-cooled packaged configuration)

Fluid cooler identificationmaybe required forglycol-cooled

units (GHFC or DAFC)

CO - Split System withoutdoor condenser (GHRC or DARC)

CI- Split system with indoor condenser (DAIC)

AO - Split System withoutdoor condensing unit (GHCU or DACU)

DAP Data Aire Mini-Plus

Ceiling System

A - Air Cooled

W - Water Cooled

G - Glycol Cooled

Model/Capacity in Tons

2 - 208/230 VAC

4 - 460 VAC

5 - 575V - 60Hz

AI- Split System with indoor condensing unit (DAAC)

WS - Split System with water-cooled

indoor condensing unit (DAWC)

1 - Single phase

3 - Three phase

C - AuxiliaryChilled Water (Air or Water Cooled Units)

E - EnergySaver (Water/Glycol Cooled Units)

Type of Cooling

Model Series

CW- Chilled Water

MODEL NUMBER NOTES:

1. CONDENSER - Condenser coil only, no compressor

2. CONDENSING UNIT - Condenser coil and compressor

3. The order write-up should have the condenser or condensing unit model number. Refer to applicable condenser or

condensing unit model number identification.

EXAMPLE: Data Aire Mini-Plus, air-cooled, 5-Ton, single phase 230V, package system with outdoor condensing

unit: Evaporator Model: DAPA 0512-AO

Condensing Unit Model: GHCU 0512 or DACU-0512

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,

shipping 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, 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 startup 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 isattached to the outside decorative doorto indicate articles that mayhave 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

startup 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 storage 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.

If equipment is stored for longer than 60 days special precautions must be taken to avoid coil damage.

All coils should be charged and sealed with a low pressure 1 to 3 PSIG (6.9 to 20.7 kPa) inert gas, such

as 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.

It is 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.

CAUTION: A complete system drain-down after factory functional testing

cannot be assured for this product. Therefore, if exposed to freezing

conditions, rupture piping and component may occur.

Suggested Reference Storage Room Conditions

•Dry bulb temperature range: 65°F to 85°F(18.3C) to 85°F (29.4C) .

•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 1 to 3 PSIG (6.9 to 20.7

kPa) 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 startup.

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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