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Data Aire gForce Ultra Installation, Operation And Maintenance Manual

Computer room air conditioner (crac) equipment
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  • 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.

  • 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 ..................10 Rigging ......................11 Locating the Unit ....................11 2.5.1 Downflow Units ...................12 2.5.2 Upflow Units ....................12 Storage ......................13 Piping ........................13 2.7.1...
  • Page 4 Humidifier Piping ....................22 2.9.1 Steam Generator Humidifier ...............22 2.10 Leak Testing ......................23 2.11 Evacuation......................23 ELECTRICAL CONNECTIONS ................25 Electrical Service ....................25 Nameplate Ratings ....................25 Grounding......................25 Voltage Tolerance ....................25 Auxiliary Control Wiring ..................26 Remote Shutdown .....................27 Remote Alarm Contacts ..................27 Condensate Pumps ...................28 Condensate Probe ....................28 3.10 Water Sensing Cable (Optional) ................28 3.11 Remote Temperature and Humidity Sensors (Optional) ........28...
  • Page 5 Water/Glycol System ..................48 Check a Running Compressor ................49 Refrigerant Handling ..................49 Commissioning ....................49 5.10 Important Refrigeration Components ..............50 5.10.1 Variable Capacity Compressor with VFD ............50 5.10.2 Electronic Expansion Valve ................50 5.10.3 High Pressure Cutout Switch ..............50 5.10.4 Low Pressure Cutout Switch...............50 5.10.5 Liquid Line Solenoid Valve ................51 GLYCOL SYSTEMS....................52 Glycol Concentration ..................52...
  • Page 6 9.4.1 Humidifier Canisters ................60 Refrigerant Filter Drier ..................60 Current Sensing Relay ..................60 Plug Fans ......................61 9.7.1 Electronically Commutated Motors ............61 9.7.2 Testing .....................61 MAINTENANCE/INSPECTION CHECKLIST ............61 CONTACT DATA AIRE..................62...

  • Page 7: Introduction

    Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.” The unique feature of the gForce Ultra is the application of variable capacity compressors. 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 8: Model Identification

    Model Identification Inspection This Data Aire CRAC unit has been factory run-tested and has gone through a comprehensive inspec- tion prior to its packaging and shipment to ensure that it arrives in excellent condition. However, ship- ping damage can occur and a visual inspection of the outer crating immediately upon delivery should be performed.

  • Page 9: Paperwork

    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

    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. The manu- facturer assumes no responsibility for their interpretation. Consult local building codes and National Electrical Code (NEC) for special installation requirements.

  • Page 11: Rigging

    The unit may be too tall to fit through a doorway while on the skid. Measure the unit and doorway heights and refer to the installation plans to verify clearances prior to moving the unit. Use care when moving. Improper handling could result in injury. WARNING: Proper care should be taken when uncrating the unit.

  • Page 12: Downflow Units

    2.5.1 Downflow Units Downflow units will typically sit on an elevated flooring system known as a raised floor. The unit dis- charges 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 and local codes permit, the unit can be placed directly on top with cutouts made for the discharge openings.

  • Page 13: 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 neces- sary to store the equipment for a period of time. If you must store the equipment it should be done in a dry area, out of the weather, protected from damage by other equipment in storage or transportation equipment, never stacked, and avoid frequent relocation.

  • Page 14: Air Cooled Unit Piping

    The ultimate responsibility for line size selection is that of the installing contractor or design engineer. Data Aire does not assume this responsibility. The chart covers distances up to 200 equivalent feet (61 m). For installations beyond this distance, consult ASHRAE or similar references.

  • Page 15: Liquid 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 16: Recommended Line Sizing, Air Cooled Units

    2.7.4 Recommended Line Sizing, Air Cooled Units NOTE: 1. If equivalent piping length falls between two columns above, choose the longer equivalent length. 2. Dual circuit units should use the same line size on both circuits. 3. If hot gas line refrigerant flow is upward, use “VERTICALUP”. If it is downward, use “HOR.VERTICAL DOWN”.

  • Page 17: Connection Sizes, Air Cooled Units

    2.7.5 Connection Sizes, Air Cooled Units Liquid Line Model Number Hot Gas Line 5/8” (16 mm) O.D. 5/8” (16 mm) O.D. GUA* 022 7/8” (22 mm) O.D. 7/8” (22 mm) O.D. GUA* 036 GUA* 045 7/8” (22 mm) O.D. 7/8” (22 mm) O.D. GUA* 070 7/8”...

  • Page 18: Field Piping, Remote Condenser Below Evaporator

    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 19: Field Piping, Water/Glycol Cooled Units

    The water/glycol system may include a centrifugal pump (or pumps, for redundancy) available from Data Aire as an option, along with field provided union(s), shutoff valves, check valve(s) and a flow switch (Data Aire option). Pumps must be primed before operating per the pump manufacturer’s guide- lines.

  • Page 20: Connection Sizes, Water/Glycol Cooled Units

    2.7.10 Connection Sizes, Water/Glycol Cooled Units Evaporator Model Water In Connection Water Out Connection GUWX-022XX 1-1/8” (29mm) O.D. 1-1/8” (29mm) O.D. GUGX-022XX GUWX-036XX 1-5/8” (41mm) O.D. 1-5/8” (41mm) O.D. GUGX-036XX GUWX-045XX 1-5/8” (41mm) O.D. 1-5/8” (41mm) O.D. GUGX-045XX GUWX-070XX 1-5/8” (41mm) O.D. 1-5/8”...

  • Page 21: Factory Charge For Water/Glycol Cooled Systems

    2.7.12 Factory Charge for Water/Glycol Cooled System Variable Speed Evaporator Model R-410A Fixed Speed Circuit Circuit GUWX-022XX GUGX-022XX GUWX-036XX GUGX-036XX GUWX-045XX GUGX-045XX GUWX-070XX 16.5 13.5 GUGX-070XX GUWX-091XX 19.8 16.2 GUGX-091XX GUWX-125XX 23.1 18.9 GUGX-125XX 2.7.13 Auxiliary Chilled Water/Energy Saver Coil Piping Units with Auxiliary Chilled Water cooling coil require a separate source of chilled water.

  • Page 22: Humidifier Piping

    NOTE: Condensation formation and frequent humidifier flushing are normal functions of this equipment. Proper drain connections must be made to ensure proper removal. Unit will require water connections for condensate removal and possibly for humidifier makeup water, condenser water, chilled water and/or hot water.

  • Page 23: Leak Testing

    2.10 Leak Testing WARNING: No installation is complete until the entire system has been thor- oughly checked for leaks. This includes checking the refrigerant tubing, flare fittings, pressure controls, Schrader fittings and compressor rotolock service valves. Check both the field and factory connections. In addition to the refrigeration system, check all condenser water lines, humidifier water makeup lines, condensate lines, condensate pumps, chilled water lines, centrifugal pumps and fluid cooler (where applicable).
  • Page 24 Evacuate the refrigerant lines, condenser coil and evaporator coil to 500 microns or lower (a micron gauge and 2-stage vacuum pump are required). Valve off and turn off the vacuum pump and wait at least 15 minutes to make sure the micron gauge reading does not go back above 750 microns. If it does, restart the vacuum pump and evacuate until the system reaches 500 microns.

  • Page 25: Electrical Connections

    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 26: Auxiliary Control Wiring

    Because of the wide variety of indoor evaporators and remote heat exchangers offer by Data Aire, the installing contractor must refer to the schematic which is provided inside the electrical control box of each unit, for the required auxiliary control wiring interconnection terminal points.

  • Page 27: Remote Shutdown

    Remote Shutdown Every gForce Ultra unit has remote shutdown contacts. These are intended for a field supplied dry con- tact 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. The control circuit is 24 VAC and the field provided contact or switch should have a minimum rating of 10 amps.

  • Page 28: Condensate Pumps

    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. 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.

  • Page 29: Manual Override Switches

    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: Water Valve Fan Speed Humidifier Heat 1...

  • Page 30: Eev Connection

    3.14 Electrical Connection to EEV The Electronic Expansion Valve (EEV) uses an electrical cable assembly with a DIN type connector to interface with EEV valve stator. The connector is indexed by one large blade connection so that the connector can only be properly mate one way. When it is necessary to making this electrical connection, this connector can only properly mate in one position as shown in the picture below (See Figure 1): DIN Connector...

  • Page 31: Installation Of Remote Outdoor Heat Exchanger

    INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER Air cooled condenser and fluid coolers have individual User Manuals which should be referred to for more complete details. CHARGING WARNING: Before starting a compressor, the crankcase heater should be energized for a minimum of 12 hours to reduce the possibility of liquid slug- ging on start-up.

  • Page 32: Triple Evacuation

    Triple Evacuation Data Aire highly recommends a triple evacuation to be carried out on all Data Aire units, to insure the highest quality vacuum. Moisture prevents the proper operation of both the compressor and the re- frigeration system.

  • Page 33: Voltage Phase Check

    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 Override Module located next to the microprocessor control module, slide the Cool 1 switch to the ON position, observe the VFD for an error message then slide the switch back to the OFF position.

  • Page 34: Variable Capacity Compressor

    After Charging and verifying Subcooling and oil level, close the valve on the refrigerant manifold gauge set, switch “Cool 2” and “Blower” slide switches to the OFF position on manual bypass board, and close the service valve on the refrigerant tank and disconnect the refrigerant manifold gauge set. 5.4.2 Variable Capacity Compressor NOTE: Prior to refrigerant charging, a system vacuum and moisture removal procedure must have been carried out.
  • Page 35 After the system has been properly evacuated. Calculate the proper charge by following the steps of the tables below. Add the amount of refrigerant needed for the evaporator & condenser + the line-set then multiply by .80. Step 1: Select the model and refrigerant charge for evaporator and condenser. Weight of Refrigerant in Evap + Condenser Model Starting Charge (lbs.)
  • Page 36 At this point there will be approximately 70-80% of the total charge in the system. It is likely that more refrigerant will be required to complete the charging procedure. Close the valve on the refrigerant manifold gauge set. Before starting a compressor, the crankcase heater should be WARNING: energized for a minimum of 12 hours to reduce the possibility of liquid slug- ging on start-up.
  • Page 37 When the compressor starts, monitor closely the suction pressure, head pressure, compressor VFD display and the EEV. Watch for any alarms that you might see. During startup, you might see some alarms such as: “C1 Low Pressure”: If suction pressure is below 50 psi, make sure to add more refrigerant per recommended charge calculation shown above “Compressor VFD Alarm”: This alarm shows up when the compressor is called upon for cooling requirement, but either the VFD has stopped the compressor, or the...

  • Page 38: Flooded System Charging

    When charging is complete, close the valve on the refrigerant manifold set and close the service valve on the refrigerant tank. Then go back into menu “H. Calibrate Sensors” and set either the “Return Air Temp Sensor” or “Discharge Air Temp Sensor” menu offset values back to 0. If a cali- bration offset value has been determined in the field that is different from 0 bring the offset num- ber back to this value.
  • Page 39 Measure the superheat at the compressor suction line at least 6 inches (152 mm) away from the com- pressor. Compare suction pressure and temperature reading between the dap4 and the manifolds. If the difference between the manifold reading and dap4 reading is more than 5%, check for the EEV wir- ing and any possible alarms on dap4, or EEV driver.
  • Page 40 Example: If the liquid line of an R-410A system is 150ft of 1-1/8” pipe, then multiply 150 * 0.38 = 57lbs Step 3: Add refrigerant weights from step 1 and 2 together and multiply by .80 to get the starting charge. Example: model GUAX-125XX (37.5 + 57 lbs.) *.80 = 75.6 lbs.
  • Page 41 Add the amount of refrigerant needed for the evaporator & condenser + the line-set then multiply by .80. Step 1: Select the model and refrigerant charge for evaporator and condenser. Weight of Refrigerant in Evap + Condenser Model Starting Charge (lbs.) GUAX-022XX GUAX-036XX GUAX-045XX...
  • Page 42 Step 4: Add refrigerant weights from step 1 through 3 together and multiply by .80 to get the starting charge. Example: model GUAX-125XX (37.5 + 57 lbs. + 55) *.80 = 119.6 lbs. Next connect the refrigerant tank to the refrigerant manifold gauge set and make sure the manifold gauge set is properly purged Then from a vacuum, slowly open the high side liquid line valve on the refrigerant manifold gauge to feed liquid refrigerant through the high side.
  • Page 43 Observe the sight glass on the receiver. Meter refrigerant through the suction line until the level of liquid in the receiver is approximately 1/3 from the bottom (the leveling ball in the receiver will start to float) of the sight glass. The unit should be allowed to stabilize for 15 to 20 minutes to verify key measurements in the table below.

  • Page 44: Variable Capacity Compressor

    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 45 At this point there will be approximately 70-80% of the total charge in the system. It is likely that more refrigerant will be required to complete the charging procedure. Close the valve on the refriger- ant manifold gauge set. WARNING: Before starting a compressor, the crankcase heater should be energized for a minimum of 12 hours to reduce the possibility of liquid slug- ging on start-up.
  • Page 46 Measure the superheat at the compressor suction line at least 6 inches (152 mm) away from the com- pressor. Compare suction pressure and temperature reading between the dap4 and the manifolds. If the difference between the manifold reading and dap4 reading is more than 5%, check for the EEV wir- ing and any possible alarms on dap4, or EEV driver.
  • Page 47 Step 2: Since the majority of refrigerant weight is in liquid form in the liquid line, refrigerant in the hot gas line and suction line is ignored in the charging calculation. Calculate the total of the liquid line run, then multiply the equivalent feet of line based on line size by the correct multiplier to get the refrigerant weight needed for the Line-set.

  • Page 48: Water/Glycol System

    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 49: Check A Running Compressor

    Check a Running Compressor • Check current draw and voltage. • Check suction superheat to reduce risk of slugging. • Observe the oil level at start and during operation to confirm that the oil level remains visible. • Excess foaming in oil sight glass indicates refrigerant on the sump. •...

  • Page 50: Important Refrigeration Components

    Important Refrigeration Components 5.10.1 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 perfor- mance.

  • Page 51: Liquid Line Solenoid Valve

    5.10.5 Liquid Line Solenoid 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 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.

  • Page 52: Glycol Systems

    GLYCOL SYSTEMS Glycol Concentration The system must be filled with water and the appropriate amount of glycol (either ethylene or pro- pylene) inhibitors to protect against winter freeze-up and premature coil corrosion. To achieve the approximate glycol concentration, it is necessary to know the total system volume. This consists of the sum of the fluid cooler volume, the evaporator unit volume and the volume of the inter-connecting piping.

  • Page 53: Internal (Fluid) Volume - Fluid Coolers

    GUWX-070XX 9.9 (37.4) 15.9 (60.2) GUGX-070XX GUWX-091XX 12.2 (46.1) 16.3 (61.7) GUGX-091XX GUWX-125XX 16.2 (61.3) 23.1 (87.4) GUGX-125XX 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 and freeze protection requirements.

  • Page 54: Variable Speed Compressor

    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 pro- cess as well as product quality.
  • Page 55 to compressor cooling. Variable speed control offers the ability to match the cooling capacity to the actual need. Costs are reduced through direct energy savings of operating at a lower speed. The drive can operate a variable capacity compressor over a wider range. Other advantages of the VFD are limiting the number starts and reduced start system shock thus reducing peak energy demand and system wear.

  • Page 56: 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 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 57: View Drive Alarms

    7.5.2 View Drive Alarms • Press the Alarm log key • Use the keys to move the cursor through the various alarms. • See example display below: When done, press the Auto on key to return to normal operation controlled by the dap4™ controller.

  • Page 58: Controls

    CONTROLS Refer to dap4 IOM for controls and control logic...

  • Page 59: Regular Maintenance Items

    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 louvers Inspect grille area and ensure unre- stricted...

  • Page 60: Fuses

    MAINTENANCE/INSPECTION CHECKLIST Humidifier (Steam Generator) is equipped ___ Inspect drain valve/trap/drain line ___ Check for leaks (make-up water/hoses) ___ Check humidifier canister (replace if needed) ___ Check and clean fill strainer ___ Check operation ___ Record humidifier amp draw L1_____ L2 _____ L3 _____ Reheat...
  • Page 61 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 62 714-921-6011 Engineering 714-921-6022 Parts Sales Web Site: www.dataaire.com Job/Unit Information: Data Aire Job Number: ___________________________________ Evaporator Serial Number: ________________________________ Evaporator Model Number: ________________________________ Condenser/Fluid Cooler Serial Number: ______________________ Condenser/Fluid Cooler Model Number: ______________________ Date installed: _______ / _____ / 20_____...
  • Page 64 gFUltra_IOM 09/2020...

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