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Data Aire gForce Ultra User Manual

Dx, single and dual circuit 36, 45, 56, 70 and 106 kw
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DX, Single and Dual Circuit
36, 45, 56, 70 and 106 kW
Air and Water/Glycol Cooled

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Summary of Contents for Data Aire gForce Ultra

  • Page 1 User Manual DX, Single and Dual Circuit 36, 45, 56, 70 and 106 kW Air and Water/Glycol Cooled...
  • Page 2 NOTE: Special care should be given to those areas where these symbols appear. Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice. 2 ● gForce Ultra User Manual...

  • Page 3: Table Of Contents

    Table of Contents INTRODUCTION ....................7 Product Information ....................7 Model Identification ....................8 Inspection ......................8 Paperwork ......................9 INSTALLATION ....................10 Installation Checklist ....................10 Room Considerations....................10 Equipment Handling .....................11 Rigging .......................11 Locating the Unit ....................12 2.5.1 Downflow Units ..................12 2.5.2 Upflow Units ..................
  • Page 4 Microprocessor Control Panel ..............53 8.1.1 Control Module ..................53 8.1.2 Display Module ..................54 8.1.3 Buttons ....................54 8.1.4 Accessing Menus/Passwords ..............54 8.1.5 Changing the Service Level Password............. 56 Entering Menu Settings ..................56 4 ● gForce Ultra User Manual 10-2014...
  • Page 5 8.2.1 Menu A – ON/OFF................. 57 8.2.2 Menu B - Setpoints ................58 8.2.3 Menu C – Clock/Scheduler ..............62 8.2.4 Menu D – Input/Output ................. 62 8.2.5 Menu E – Historical Data ............... 62 8.2.6 Menu F – Information ................65 8.2.7 Menu G –...
  • Page 6 11.3 Liquid Lines – Single Circuit Units (Up to 200 Equivalent Feet (61 m)) ....125 11.4 Liquid Lines – Dual Circuit Units (Up to 200 Equivalent Feet (61 m)) ...... 125 CONTACT DATA AIRE .................. 126 MAINTENANCE/INSPECTION CHECKLIST ............127 6 ● gForce Ultra User Manual 10-2014...

  • Page 7: Introduction

    The Data Aire CRAC unit provides cooling, reheat, humidification, dehumidification and air filtration. The unit is provided with a Data Aire dap4™ microprocessor controller for precision control. The unit must be operated in a conditioned space within the operating envelope ASHRAE recommends for data centers.

  • Page 8: Model Identification

    106 kW 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.

  • Page 9: Paperwork

    Action to recover losses should be filed immediately. Please notify factory personnel of any claims. Paperwork Each Data Aire CRAC unit ships with a start-up sheet that should be completed during installation. Also included in the paperwork is a warranty/information packet that provides important wiring diagrams, specific component literature, warranty registration cards and other valuable paperwork, including a copy of this User Manual.

  • Page 10: Installation

    2. INSTALLATION NOTE: There is no intent on the part of Data Aire, Inc. to define local codes or statutes which may supersede common trade practices. manufacturer assumes no responsibility for their interpretation. Consult local building codes and National Electrical Code (NEC) for special installation requirements.

  • Page 11: Equipment Handling

    Equipment Handling WARNING: Only properly trained personnel wearing appropriate safety headgear, gloves, shoes and glasses should attempt to move the unit, lift it, remove packaging or prepare the unit for installation. Move the unit in its upright position to the installation site using a forklift or pallet jack. It is recommended that the unit be protected from damage to the decorative doors during any storage or moving.

  • Page 12: Locating The Unit

    The unit discharges air downward which pressurizes the raised floor and channels upward through perforated floor tiles. Location and quantity of perforated tiles will dictate proper air distribution. If the raised floor is strong enough to support the unit 12 ● gForce Ultra User Manual 10-2014...

  • Page 13: Upflow Units

    and local codes permit, the unit can be placed directly on top with cutouts made for the discharge openings. Verify that the raised floor has been properly sized for the unit’s airflow and the room is free of airflow restrictions. Perforated floor tiles in the raised floor should ensure minimal pressure loss.

  • Page 14: Storage

    Failure to do so could reduce the unit’s cooling performance. 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...

  • Page 15: Air Cooled Unit Piping

    Refer to section RECOMMENDED LINE SIZING charts on page 125 for a guideline on sizing refrigerant lines. The ultimate responsibility for line size selection is that of the installing contractor or project engineer. Data Aire does not assume this responsibility. 10-2014...

  • Page 16: Discharge Lines

    Data Aire recommends a silver/phosphorus/copper alloy with 5 to 15% silver be used to braze the refrigerant line sets to the indoor and outdoor units. Nitrogen needs to be flowing through the lines to eliminate carbon deposit build-up on the inside of the joints.

  • Page 17: Liquid Lines

    mm) for every ten (10) feet (3 m) of line length. Discharge lines do not require insulation but due to the high temperatures of the refrigerant inside the line, the pipes may be insulated to protect against burns to individuals near or around the lines. 2.7.3 Liquid Lines Liquid line size is determined by pressure drop and velocity.

  • Page 18: Field Piping, Remote Condenser

    Shutoff valves (field provided) should be installed within a few feet of the inlet and outlet connections of the evaporator to allow the unit to be isolated for service. 18 ● gForce Ultra User Manual 10-2014...
  • Page 19 Water/glycol cooled units are shipped with plate/fin heat exchangers as standard equipment. A strainer (Data Aire provided) is shipped loose and is to be field installed in the supply line with shut-off valves (field provided) before and after the strainer. The strainers and water/glycol piping must be cleaned on a periodic basis.

  • Page 20: Field Piping, Water/Glycol System

    2.7.7 Field Piping, Water/Glycol System 20 ● gForce Ultra User Manual 10-2014...

  • Page 21: Connection Sizes, Water/Glycol Cooled Units

    2.7.8 Connection Sizes, Water/Glycol Cooled Units Model Number Water In Water Out GUW or G* 036 2-1/8” (54 mm) O.D. 2-1/8” (54 mm) O.D. GUW or G* 045 2-1/8” (54 mm) O.D. 2-1/8” (54 mm) O.D. GUW or G* 056 2-5/8”...
  • Page 22 The lines must be clear and free of obstructions and in good condition with no visible sign of damage or leaks. 22 ● gForce Ultra User Manual 10-2014...

  • Page 23: Humidifier Piping

    This unit also requires an external water supply to the humidifier. Improper installation, application and service may 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.

  • Page 24: Evacuation

    Good evacuation processes include frequent vacuum pump oil changes and large diameter, short hose connections to both high and low sides of the system preferably using copper tubing or braided hose. If the compressor has 24 ● gForce Ultra User Manual 10-2014...
  • Page 25 service valves, they should remain closed. A deep vacuum gauge capable of registering pressure in microns should be attached to the system for pressure readings. A shut-off valve between the gauge connection and vacuum pump should be provided to allow the system pressure to be checked after evacuation.

  • Page 26: Electrical Connections

    3. ELECTRICAL CONNECTIONS WARNING: The Data Aire cooling unit must be connected by a licensed and qualified electrician. Risk of electrical shock could result in injury or death. Disconnect all remote electrical power supplies prior to working on the unit. Follow all local codes.

  • Page 27: Grounding

    (refer to unit wiring diagrams). Remote Shutdown Every gForce Ultra unit has remote shutdown contacts. These are intended for a field supplied dry contact or switch to be wired across two terminals. When the contactor or switch opens, the control circuit power is interrupted and the unit shuts down, including the control panel.

  • Page 28: Remote Alarm Contacts

    Remote Alarm 4 (Normally Closed) # 50 Remote Alarm 4 (Normally Open) Condensate Pumps A condensate pump is optional. Factory mounted pumps are pre-wired. While no outside power source is required, field piping is still a requirement. 28 ● gForce Ultra User Manual 10-2014...

  • Page 29: Condensate Probe

    WARNING: The condensate drain MUST be connected to an external drain line (provided by others) before unit start up. Without field piping condensate water will damage internal components. Condensate pumps which ship loose, normally require a separate source of power. Always check the pump power requirements before connecting power.

  • Page 30: Remote Temperature And Humidity Sensors (Optional)

    3.12 Manual Override Switches For testing and during start-up each gForce Ultra unit is provided with manual override slide switches. There are seven (7) slide switches. One for each of the following functions:...

  • Page 31: Wiring Diagrams

    OFF position when completing testing and/or start-up. An alarm will be activated if units are left in the ON position. 3.13 Wiring Diagrams Every Data Aire evaporator, condenser, condensing unit or fluid cooler comes with a wiring diagram. These diagrams are ladder type schematics intended for service personnel.

  • Page 32: Installation Of Remote Outdoor Heat Exchanger

    (if available) on the evaporator section of dual circuit units by momentarily energizing the COOL 2 (constant speed compressor) switch on the Manual Override Module located next to the 32 ● gForce Ultra User Manual 10-2014...

  • Page 33: Secondary Heat Exchanger

    The gForce Ultra unit has a variable capacity compressor and an out of phase compressor will not turn ON and the VFD will show an error message. On the Manual...

  • Page 34: Fan Speed Control System

    5.2.3 Fan Speed Control System The standard air cooled condenser provided with Data Aire gForce Ultra equipment has modulating Fan Speed Control (FSC) on the all motors. The modulation speed of the fans is directly proportional to the compressor head pressure.
  • Page 35 Function R-410A Conditions Discharge Pressure 340 to 415 PSIG (2344 to 2861 kPa) Suction Pressure 104 to 121 PSIG (717 to 834 kPa) Superheat 6 to 12°F (3.33 to 6.67°C) Differential 8 to 10°F (4.44 to 5.55°C) Differential Sub-Cooling Depending on ambient conditions Measure the superheat at the compressor suction line at least 6 inches (152 mm) away from the compressor.
  • Page 36 When done charging, press the “Auto on” key on the VFD local display to return to normal operation controlled by the dap4™ controller. Also adjust the fan speed potentiometer back to the original position and set the slide switches OFF on the Manual Override Module. 36 ● gForce Ultra User Manual 10-2014...

  • Page 37: Flooded System Charging

    Note: Charging to a full liquid line sight glass should never be the sole means of determining the correct refrigerant charge. Other parameters such as superheat, suction pressure, head pressure, sub-cooling and ambient temperature are also important. A system charged to a clear sight glass is often overcharged.
  • Page 38 Other parameters such as superheat, suction pressure, head pressure, sub-cooling and ambient temperature are also important. A system charged to a clear sight glass is often overcharged. 38 ● gForce Ultra User Manual 10-2014...
  • Page 39 5.3.2.2 Variable Capacity Compressor At this point, the unit and compressor will need to be started. Use the VFD “Hand on” key (7.5.1 Local Control for Charging) of the VFD controller to adjust the speed of the compressor to minimum frequency. Make sure to set the airflow of the unit to its full capacity.
  • Page 40 When done charging, press the “Auto on” key on the VFD local display to return to normal operation controlled by the dap4™ controller. Also adjust the fan speed potentiometer back to the original position and set the slide switches OFF on the Manual Override Module. 40 ● gForce Ultra User Manual 10-2014...

  • Page 41: Water/Glycol System

    Water/Glycol System 5.4.1 Water/Glycol Cooled System Charging All water/glycol cooled units are factory charged with refrigerant. The water regulating valve should be adjusted to maintain the required conditions. Field charging, if required, of water/glycol systems should be done by referring to the unit’s electrical nameplate.

  • Page 42: Check A Running Compressor

    Refrigerant purchasers must be certified technicians and have a valid EPA certification card. 42 ● gForce Ultra User Manual 10-2014...

  • Page 43: Commissioning

     No abnormal vibration or noise Important Refrigeration Components 5.8.1 Variable Capacity Compressor with VFD The unique feature of the gForce Ultra is the application of variable capacity compressor. The quest for greater energy efficiency is continuous; efficiency benchmarks are always moving up. That's why Data Aire is moving toward variable capacity compressor technology for quieter, more energy-saving performance.

  • Page 44: Electronic Expansion Valve

    Liquid line solenoid valve(s) (LLVS) are a standard feature on this unit. The LLSV are direct acting, NC (normally closed; i.e. closed when de-energized) solenoid operated valve(s). This has the advantage that the valve is closed when the system is not 44 ● gForce Ultra User Manual 10-2014...
  • Page 45 running and when the solenoid valve is not energized. For this reason, an electrical power failure does not lead to any problems with the refrigeration system. The primary purpose of a solenoid valve in a refrigerant liquid line is to helps prevent refrigerant migration (i.e., flow into the evaporator) during the OFF cycle.

  • Page 46: Glycol Systems

    Gallons (Liters) Gallons (Liters) GUGU 036 7.9 (30.0) 9.2 (34.8) GUGU 045 9.5 (35.9) 9.2 (34.8) GUGU 056 9.9 (37.4) 15.9 (60.2) GUGU 070 12.2 (46.1) 16.3 (61.7) GUGU 106 16.2 (61.3) 23.1 (87.4) 46 ● gForce Ultra User Manual 10-2014...

  • Page 47: Internal (Fluid) Volume - Fluid Coolers

    Note: Risk of a leaking coil due to freezing and/or corrosion. Can cause equipment and serious building damage. Note: Risk of corrosion can cause equipment damage. Contact a water consultant about water quality, corrosion freeze protection requirements. Water chemistry varies greatly by location, as do the required additives, called inhibitors that reduce the corrosive effect of the fluids on the piping systems and components.

  • Page 48: Variable Speed Compressor

    A cooling solution optimized for energy consumption and for power grid requirements. Thanks to a 4:1 modulation ratio, the gForce Ultra can cycle from 25 to 100 RPS to provide greater savings. Match exactly your cooling requirements to control temperature and humidity, critical for the best process as well as product quality.

  • Page 49: Oil Level

    compressor is idle, the oil temperature in the sump of the compressor must be maintained at no lower than the 10⁰ F above the saturation temperature of the refrigerant on the low pressure side. This ensures that liquid refrigerant is not accumulating in the sump.

  • Page 50: Vfd Drive

     Start, stop, and control speed when in local control mode  Display operational data, status, warnings and cautions  Programming frequency converter functions  Manually reset the frequency converter after a fault when auto-reset is inactive 50 ● gForce Ultra User Manual 10-2014...

  • Page 51: Local Control For Charging

    7.5.1 Local Control for Charging  Press the “Hand on” button. The display will show Hand Local Running.  Use the  and  keys to move the cursor to the desired digit position, then use the and  keys to increase or decrease the desired RPM setting. As you change the value, the compressor will increase or decrease in speed.

  • Page 52: View Drive Alarms

     See example display below: When done, press the Auto on key to return to normal operation controlled by the dap4™ controller. Note: If more information is required, see the full operating manual for the drive system. 52 ● gForce Ultra User Manual 10-2014...

  • Page 53: Controls

    8. CONTROLS dap4™ Microprocessor Control Panel The standard controller on all gForce Ultra units is the dap4™ microprocessor control panel. The unit is shipped with factory default settings. The settings can be changed to meet the controlled space criteria. The dap4™ consists of two main components: the control module and the display panel.

  • Page 54: Display Module

    To access any Menu, a numerical password is required. To enter the menu and Sub-Menu screens, press the MENU key on the display panel. A password will be requested. The password is a four digit entry (including 0). Units are 54 ● gForce Ultra User Manual 10-2014...
  • Page 55 shipped from the factory with the password requirement bypassed to accommodate start-up and set-up. The display screen will have following message: The Service Level Password setting from the factory is: 0000 The cursor will be flashing by the Security Access message at the top of the screen. Press the ENTER key to move the cursor.

  • Page 56: Changing The Service Level Password

    Entering Menu Settings NOTE: The dap4™ control panel is used on a variety of Data Aire equipment types including the gForce Ultra. Some Menus and Menu screens will appear that are not applicable to the gForce Ultra.

  • Page 57: Menu A - On/Off

    8.2.1 Menu A – ON/OFF Menu A allows the unit power to be switched from ON to OFF and from OFF to ON (the Service level password is required). Enter Menu A by pressing the MENU key. Use the UP or DOWN keys to scroll through the menus.

  • Page 58: Menu B - Setpoints

    Use the UP or DOWN key to scroll through the screens. Menu B has two screens. The following screen will appear: This is for the cooling temperature setpoint settings (to control the chilled water valve or compressor capacity): 58 ● gForce Ultra User Manual 10-2014...
  • Page 59 NOTE: The Temp Setpoint range is from 45.0°F to 105.0°F (factory setting is 72.0°F). The Temp Deadband range is from 2.0°F to 5.0°F (factory setting is 2.0°F). Superheat setpoint range is from 5.0°F to 15.0°F (factory setting is 6.0°F). To change the values press the ENTER key to move the cursor to the desired input (Temp Setpoint).
  • Page 60 The following will appear on the first Menu B screen (values are for reference only): To see the next screen, press the DOWN key. The following will appear on the first Menu B screen (values are for reference only): 60 ● gForce Ultra User Manual 10-2014...
  • Page 61 NOTE: The Hum Setpoint range is from 25% to 70% (factory setting is 50%). The Hum Deadband range is from 1% to 15% (factory setting is 2%). Follow the same steps as detailed for Temperature Setpoints to make any desired changes.

  • Page 62: Menu C - Clock/Scheduler

    Disregard this Menu – it is not applicable to in-row cooling units. 8.2.4 Menu D – Input/Output This is a view only menu. The values are factory set and only if instructed by Data Aire Engineering or Technical Service personnel should these be changed.
  • Page 63 NOTE: This screen and the subsequent two screens will have information not applicable to gForce Ultra cooling units. With the cursor flashing on the title, press the DOWN key to view the next screen The following will appear on the second Menu E screen (values are for reference only): 10-2014 gForce User Manual ●...
  • Page 64 ENTER key. With the cursor flashing on the title, press the DOWN key to view the next screen The following will appear on the third Menu E screen (values are for reference only): 64 ● gForce Ultra User Manual 10-2014...

  • Page 65: Menu F - Information

    There are three screens – two with information detailing the processor version and data. The third screen details unit information including model number, serial number and Data Aire job number. To view the screens, press the DOWN key. The cursor will not move as this is a view only screen.
  • Page 66 The following protocols are available:  MODBUS  MODBUS EXT (future use)  LON  BACnet TCP/IP  BACnet MSTP The following screen will appear when MODBUS protocol is selected: 66 ● gForce Ultra User Manual 10-2014...
  • Page 67 The following screen will appear when LON protocol selected: The following screen will appear when BACnet TCP/IP protocol is selected: The following screen will appear when BACnet MSTP protocol is selected: 10-2014 gForce User Manual ● 67...

  • Page 68: Menu H - Calibrate Sensors

    Menu H allows calibration of the installed unit sensors (if required). The service level password is required for entry. Press the ENTER key The following screens will be displayed (values are for reference only): 68 ● gForce Ultra User Manual 10-2014...
  • Page 69 10-2014 gForce User Manual ● 69...
  • Page 70 With cursor on the title, Press the DOWN key to advance to the next screen. Press the MENU key to exit Menu H – Calibrate Sensors Press the ENTER to advance to Menu I – Manual Control 70 ● gForce Ultra User Manual 10-2014...

  • Page 71: Menu I - Manual Control

    8.2.9 Menu I – Manual Control Menu I allows manually running different unit components (the Service Level password is required). This menu should be used during service of the unit. Press the ENTER key. The following screen will be displayed (values are for reference only): NOTE: The “Return to Auto”...
  • Page 72 Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the DOWN key. The following screen will be displayed (values are for reference only): 72 ● gForce Ultra User Manual 10-2014...
  • Page 73 Each component can be manually tested. Press the ENTER key to move the cursor to the selected component. To change from Auto (automatic) to Man (manual) press the DOWN key. To change from OFF to ON press the DOWN key. Move the cursor to the title block by pressing the ENTER key stepping through all the inputs.
  • Page 74 Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the DOWN key. The following screen will be displayed (values are for reference only): 74 ● gForce Ultra User Manual 10-2014...

  • Page 75: Menu J - Factory Settings

    Press the DOWN key to advance to Menu J – Factory Settings 8.2.10 Menu J – Factory Settings Menu J is for setting the control to the type equipment and options ordered. This requires the Factory Level password and entry should be limited to Data Aire factory and service personnel. 10-2014...
  • Page 76 Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the DOWN key. The following screen will be displayed (values are for reference only): 76 ● gForce Ultra User Manual 10-2014...
  • Page 77 CW Mode: This is the fan control settings for the unit when a chilled water valve is used. There are 6 different modes. DX Mode: This is the fan control settings for the unit when a compressor runs. There are 6 different modes: ...
  • Page 78 The Fan Rack Settings screen will be displayed (values are for reference only): Ramp step rate: The rate at which the fan will change its speed in any modulation mode. The default rate is 0.5% per second and ranges from 0.1% per second to 5% 78 ● gForce Ultra User Manual 10-2014...
  • Page 79 Type: Selectable compressor types are Variable & Fixed Speed for dual circuit units or Sngl Variable for single circuit unit. The other types (Sngl Primary, Singl Pri w/UnLdr, Dual Primary, Dual Pri w/UnLdr) are not applicable for gForce Ultra. See section 9.2 for control logic details.
  • Page 80 Do not select this in gForce Ultra units. It is only applicable for fixed speed compressor units. Electronic Valve: Single or Dual, depending on how many circuits are in the system.
  • Page 81 Band: Band has the same unit as the setpoint and is tunable in the dap4™ controller. Increasing the band makes the system more stable and increases the steady state error. A good start for tuning the band is half of the setpoint. The default value is 18⁰F. Integration Time: (Ti) Increasing Ti decreases the steady state error;...
  • Page 82 C2 On Delay: Compressor 2 will not run until compressor 1 has run for at least this amount of time and other conditions. Default value is 60 seconds, and selectable from 0 to 999 seconds. 82 ● gForce Ultra User Manual 10-2014...
  • Page 83 C2 Off Delay: Compressor 2 will continue to run for this amount of time before turning off, with other conditions applied. Default value is 5 seconds, and selectable from 0 to 999 seconds. Move the cursor to the title block by pressing the ENTER key stepping through all the inputs.
  • Page 84 To return to the main Menu press the ESC key or to view the following screen press the DOWN key. The screen Humidity Settings will be displayed (values are for reference only): 84 ● gForce Ultra User Manual 10-2014...
  • Page 85 Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the DOWN key. The following screen will be displayed (values are for reference only): Temp Sensors Used: Up to 32 rack temperature sensors may be used.
  • Page 86 Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the DOWN key. The following screen will be displayed (values are for reference only): 86 ● gForce Ultra User Manual 10-2014...
  • Page 87 NOTE: This screen only appears when the “Electronic Valve” is selected as “One” or “Two” in “Compressor Settings” screen. Super Heat: The current value of refrigerant super heat Suction Temp: The current value of refrigerant suction temperature Suction Pres: The current value of refrigerant suction pressure Move the cursor to the title block by pressing the ENTER key stepping through all the inputs.

  • Page 88: Menu K - Alarms & Limits

    Requires Service level password. Press the DOWN key to advance to Menu K – Alarms and Limits The following screen will be displayed (values are for reference only): 88 ● gForce Ultra User Manual 10-2014...
  • Page 89 Press the ENTER key to move through the alarm/message inputs. Press the UP or DOWN keys to change the alarm/message. The following selections are available: Audio Mode: None (factory setting) Full On Long Beep Short Beep Pwr-Up: Auto, No Alarm (factory setting) Auto, With Alarm Man, Clr Alarm...
  • Page 90 No Water Flow Action: Turn Compressors Off Alarm Only (factory setting) Wtr Flow Alm Dly: 5 to 190 seconds (5 - factory setting) Air Flow Alm Dly: 5 to 180 seconds (5 – factory setting) 90 ● gForce Ultra User Manual 10-2014...
  • Page 91 Once the selections have been made, with the cursor on the title line, Press the DOWN key to advance to the next screen. The following screen will be displayed (values are for reference only): Press the ENTER key to move through the alarm/message inputs. Press the UP or DOWN keys to change the alarm/message.
  • Page 92 If No is selected for the Hi or Low Humidity, the setpoint will not be displayed. Once the selections have been made, with the cursor on the title line, Press the DOWN key to advance to the next screen. 92 ● gForce Ultra User Manual 10-2014...
  • Page 93 The following screen will be displayed (values are for reference only): Press the ENTER key to move through the alarm/message inputs. Press the UP or DOWN keys to change the alarm/message. The following selections are available: Alarm # 1 SEE TAG INSIDE DOOR CHECK HUMIDIFIER CYL REHEAT INHIBITED FAN MOTOR OVERLOAD...
  • Page 94 FAN MOTOR OVERLOAD HUMIDIFIER INHIBITED CUSTOM MESSAGE REHEAT & HUM INHIBIT POWER A OPERATING UNIT IN STBY POWER B OPERATING UPS ON-CHK MAIN PWR POWER A AVAILABLE STANDBY PUMP ON POWER B AVAILABLE 94 ● gForce Ultra User Manual 10-2014...
  • Page 95 Alarm # 4 SEE TAG INSIDE DOOR CHECK HUMIDIFIER CYL REHEAT INHIBITED FAN MOTOR OVERLOAD HUMIDIFIER INHIBITED CUSTOM MESSAGE REHEAT & HUM INHIBIT POWER A OPERATING UNIT IN STBY POWER B OPERATING UPS ON-CHK MAIN PWR POWER A AVAILABLE STANDBY PUMP ON POWER B AVAILABLE Once the selections have been made, with the cursor on the title line, Press the DOWN key to advance to the next screen.
  • Page 96 Yes or No Yes or No Yes or No Yes or No Once the selections have been made, with the cursor on the title line, Press the DOWN key to advance to the next screen. 96 ● gForce Ultra User Manual 10-2014...
  • Page 97 The following screen will be displayed (values are for reference only): Alarm Output Function 6 Alarm 1 Alarm 2 Alarm 3 Alarm 4 Unit Stdby Yes or No Yes or No Yes or No Yes or No UPS is On Yes or No Yes or No Yes or No...
  • Page 98 The following screen will be displayed (values are for reference only): Once the selections have been made, with the cursor on the title line, Press the DOWN key to advance to the next screen. 98 ● gForce Ultra User Manual 10-2014...

  • Page 99: Menu L - Configure I/O

    See the dap4™ Operation Manual for details – available on the Data Aire website (dataaire.com). 8.2.13 Zone Master The gForce Ultra units with optional Zone Master control will be shipped with a supplemental manual detailing programming and individual screens on the dap4™ controller.

  • Page 100: Fan Control Logic

    9. Control Logic The following describes the implementation of the gForce Ultra logic with dap4™ controller. Fan Control Logic There are six (6) different fan speed mode in DX logic:  Fan Speed Modulation to Rack Temperature (Mod to Rack) ...

  • Page 101: Fan Speed Modulation Proportional To Cooling Demand (Mod To Comp)

    9.1.2 Fan Speed Modulation Proportional to Cooling Demand (Mod to Comp): Proportional fan speed control is based on the cooling demand. The fan speed ranges from 70% to 100% of fans total capacity. When the fans start, they operate at the minimum fan speed.

  • Page 102: Constant Fan Speed (Const Speed)

    Proportional band is the same as deadband. The Integral band is programmed in Factory settings menu. In most cases there is no need to change the P and I value as the result of temperature control fluctuation. 102 ● gForce Ultra User Manual 10-2014...
  • Page 103 Return air temperature is dropping (Off cycle):  As the return air temperature reaches setpoint, the compressor will ramp down to its minimum speed. (Note: If variable speed compressor runs at the minimum speed for a long period of time, it will automatically ramp up to the maximum speed for one minute to maintain the minimum compressor oil level.
  • Page 104  If the temperature is consistently rising, then the valve will be opened wider. Likewise, if the temperature is consistently falling, then the valve will be close gradually. However, if temperature movement changes directions, then it must 104 ● gForce Ultra User Manual 10-2014...
  • Page 105 change the amount of the deadband before the valve will be repositioned. The temperature can be slowly drifting back and forth within a deadband window at any point in the adjustment period and no valve position changes will be made. ...
  • Page 106 Compressors off cycle  Fixed speed compressor C2 cycles off at Temperature Setpoint + 2ºF, variable speed compressor C1 continues to run at 100%. For instance: SP=72⁰F, the C2 compressor goes off at 74⁰F. 106 ● gForce Ultra User Manual 10-2014...

  • Page 107: Discharge Air Temperature Control Mode

     Variable speed compressor C1 starts to ramp down to minimum speed when return temperature reaches setpoint + 1⁰F.  Variable speed compressor cycles off at Temperature Setpoint.  CW Valve will close 10% for every 0.1⁰F below the setpoint plus 1⁰F and completely close at setpoint.
  • Page 108 Compressor/Factory settings menu.  Once fixed compressor C2 started, the variable speed compressor C1 will operate at minimum speed for duration of Delay Modulation. Delay modulation is programmed in Compressor/factory settings menu. 108 ● gForce Ultra User Manual 10-2014...
  • Page 109 Discharge air temperature is dropping (Off cycle):  Fixed speed compressor C2 turns off when discharge air temperature drops to the temperature setpoint – C2 offset.  Variable speed compressor C1 turns off when discharge air temperature drops to temperature setpoint – C1 offset. 9.2.2.3 Energy saver/ auxiliary cooling without DX cooling assist in discharge temperature control.

  • Page 110: Safeties And Alarms

    * This applies on dual compressor system. Safeties and Alarms NOTE: All suction safeties are only applied to the variable speed compressor, not the fixed speed compressor. 110 ● gForce Ultra User Manual 10-2014...
  • Page 111 Monitor the variable speed compressor’s suction temperature using EVD drive communication. Add compressor high suction temperature alarm limits and default to F (the range is 80 to 95 F). Also add a suction temperature deadband (1 to 5 ⁰ ⁰ When C1 has been running for 3 minutes and suction temperature is higher than ...

  • Page 112: Dehumidification Mode

    None, 1C in Limit and 1C No Limit.  There are five dehumidification control modes for dual compressors unit.  Reheat is required for dehumidification.  Dehumidification cooling can be controlled by relative humidity and/or dew point. 112 ● gForce Ultra User Manual 10-2014...

  • Page 113: Relative Humidity Control Mode

     If dehumidification is programmed for “1C in Limit” or “2C in Limit” the dehumidification cooling will be inhibited by reheat if the return air temperature drops below Temperature Setpoint - Temperature DB - 2⁰F. Dehumidification will be inhibited until the return air temperature rises above the Temperature Setpoint.
  • Page 114 Temperature Control Cooling Mode. Dehumidification cycles off  When humidity drops, fixed speed compressor C2 (NO3) will turn off when humidity = Humidity Setpoint +1%. 114 ● gForce Ultra User Manual 10-2014...

  • Page 115: Dewpoint Control Mode

     Variable speed compressor C1 starts to ramp down in 0.1 % RH decrement when Humidity drops to Humidity Setpoint + 1% (decreasing 10% speed for every 0.1%RH).  C1 compressor will run at its minimum speed when humidity = Humidity SP. ...
  • Page 116 9.4.2.3 High Relative humidity Limit in dewpoint control  If high relative humidity condition occurs while humidity control mode is set to Dewpoint Control then Dewpoint Control has priority over the Relative Humidity Control. 116 ● gForce Ultra User Manual 10-2014...
  • Page 117  If high dewpoint setpoint satisfies but relative humidity rises to relative humidity setpoint, the dehumidification control will be as follows: 9.4.2.3.1 Single Variable speed compressor system Dehumidification cycles on: If unit is not in cooling mode, the variable speed compressor turns on when humidity is at Humidity Setpoint (HSP) - 1%.

  • Page 118: Regular Maintenance Items

    Fuses may occasionally require changing especially with installations where the voltage is not consistent. Drops in voltage can create brief periods of high amp draw, causing fuses to blow. Always replace fuses with those of the equivalent rating with regard to: 118 ● gForce Ultra User Manual 10-2014...

  • Page 119: Electric Reheat

    1) amperage, 2) voltage, and 3) speed. For instance motors are inductive loads which require time delay fuses. Electric reheat and humidifiers are resistive loads requiring fast acting fuses. 10.3 Electric Reheat The electric reheat is a finned enclosed, sheath type, fabricated of stainless steel core sheath with plated fins to withstand moist conditions.

  • Page 120: Current Sensing Relay

    When the green LED is on, the “No Airflow Alarm” message will appear. When the red LED is on, the “No Airflow Alarm” message will disappear. Figure 1: "No Airflow Alarm" Current Sensing Relay 120 ● gForce Ultra User Manual 10-2014...
  • Page 121 The following steps indicate how to use the dap4™ controller to adjust the plug fan speed to temporarily reduce the plug fan current to set the current sensing relay. Press the MENU key and enter either Service or Factory Level password. Go to Menu I: Manual Control Adjust the “Return to Auto”...

  • Page 122: Plug Fans

    Maintenance is not required on EC motor/plug fan modules. The motors are sealed, have maintenance free ball bearings and permanent lubrication. The only acceptable service is replacement. 10.7.1 Electronically Commutated Motors Electronically Commutated (EC) motors with “plug fans” are standard on all gForce units. 122 ● gForce Ultra User Manual 10-2014...
  • Page 123 NOTE: The plug fan modules are powered by high voltage input line power (i.e. 208-230V/3PH/50-60HZ or 380-460V/3PH/50-60HZ). EC motors have built in protective features that include the following: Over-Temperature protection of the (motor) electronics, Over-Temperature protection of the motor, Locked rotor protection, Phase failure protection, Under voltage detection, Short circuit protection.

  • Page 124: Testing

    To test the plug fan modules in manual mode, use the manual override slide switch Fan Speed and adjust the potentiometer up and down to vary the fan speed to check proper response. 124 ● gForce Ultra User Manual 10-2014...

  • Page 125: Recommended Line Sizing

    RECOMMENDED LINE SIZING 11.1 Hot Gas Lines – Single Circuit Units (Up To 200 Equivalent Feet (61 m)) 50 Feet 100 Feet 150 Feet 200 Feet (Tonnage) (15.2 m) (30.5 m) (45.7 m) (61.0 m) 36 (10.2) 1-1/8 (29) 1-1/8 (29) 1-3/8 (35) 1-3/8 (35) 45 (12.2) 1-1/8 (29) 1-1/8 (29) 1-3/8 (35) 1-3/8 (35) 11.2 Hot Gas Lines –...

  • Page 126: Contact Data Aire

    Data Aire Job Number: ___________________________________ Evaporator Serial Number: ________________________________ Evaporator Model Number: ________________________________ Condenser/Fluid Cooler Serial Number: ______________________ Condenser/Fluid Cooler Model Number: ______________________ Date installed: _______ / _____ / 20_____ Installing Contractor: ____________________________________ 126 ● gForce Ultra User Manual 10-2014...

  • Page 127: Maintenance/Inspection Checklist

    MAINTENANCE/INSPECTION CHECKLIST NOTE: Maintenance/inspection items are monthly unless otherwise specified. MAINTENANCE/INSPECTION CHECKLIST Evaporator Model No.: Evaporator Serial No.: Technician: Date: Temperature/Humidity set at _______ °F _______ % RH Air Filters Air Distribution Section Inspect and replace (if required) Check restriction of grilles and discharge Inspect grille area and ensure louvers unrestricted...
  • Page 128 ___ Check low pressure cut-in ______ PSIG ______ PSIG ___ Check low pressure cut-out ______ PSIG ___ Record compressor amp draw ______ L1 ______ L1 ______ L2 ______ L2 ______ L3 ______ L3 128 ● gForce Ultra User Manual 10-2014...
  • Page 129 MAINTENANCE/INSPECTION CHECKLIST Condensate Pan and Pump (if equipped) Air Cooled Condenser (if applicable) ___ Check for leaks ___ Inspect coil/clean if required ___ Check for debris ___ Inspect motor/motor mounts ___ Inspect/check float operation ___ Inspect fan blade(s) ___ Check pump operation ___ Check wiring ___ Inspect piping for leaks Dry Cooler (if applicable)
  • Page 130 Hot gas lines ........16 dap4™ Microprocessor Control Panel .. 53 Humidifier ........119 Discharge Lines ........ 16 Humidifier canisters ......119 Disconnect switch ......9, 26 Drain/fill valves ......... 19 Inspection .......... 8 130 ● gForce Ultra User Manual 10-2014...
  • Page 131 Installation ........10 Interconnecting lines ......16 Raised floor ........12 Receiver ........... 37 Recommended gas velocity ....16 Jackstands ........13 Recovery .......... 42 Refrigerant grade copper ....16 Refrigerant handling ......42 Refrigerant lines ....... 15 Leak testing ........23 Remote alarm contacts ......
  • Page 132 Variable Frequency Drive (VFD) ..48 Wiring ..........31 VFD Drive ......... 50 Wiring diagrams ........9 Vibration pads ........13 Voltage ....... 27, 29, 118, 123 Zone Master ........99 Warranty ..........9 132 ● gForce Ultra User Manual 10-2014...
  • Page 133 DataAire.com 800-347-2473 sales DataAire.com ISO 9001-2008 Certified 230 W. BlueRidge Ave. A member of the CS Group of Companies Orange, CA 92865 Creating Products That Make Buildings Better...

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