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Summary of Contents for GForce Ultra
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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 micro- processor controller and condenser/condensing unit and fluid cooler.
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.
1.2. Model Identification gForce Ultra Model Number GU X X - XXX X │ │ │ │ │ │ │ │ │ │ │ │ gForce Ultra, Single and Dual Circuit ──── ┘ │ │ │ │ │ Voltage │...
1.4. 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 Installation, Operation, and Maintenance manual.
• Store at non-condensing temperature and humidity conditions. 1.5.2. 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. •...
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 manufacturer assumes no responsibility for their interpretation. Consult local building codes and National Electrical Code (NEC) for special installation requirements.
the unit. A minimum clearance equal to the width of the unit is suggested on one side of the unit for removing the coil or fan assembly. Add dimension of pipe chase, ducts, control and electrical panels, etc. to minimum clearances. Allow additional clearance as required by local and national codes.
Removal of the decorative doors is easily accomplished and may be done when moving equipment. The door hinge is spring loaded and slides down using the catch, for easy removal of the doors. Door hinges allow the door to be lift off. WARNING: When releasing the spring-loaded upped door hinge, be prepared for the weight of the door.
Figure 3 Lower Fixed Pin Hinge 2.5.2. Rear Panel Remove screws from rear panel to remove rear panel. 2.5.3. Moving Unit into Final Location 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.
2.6. Rigging Move the unit in its upright position to the installation site. It is recommended that the unit be protected from damage to the decorative doors during any storage or moving. Removal of the decorative doors is easily accomplished and may be done without moving the equipment. The shipping skid should be left in place if the unit is being moved with a forklift.
to 50mm) of clearance is suggested. For the best air distribution, the unit should be centered against the longest wall, distributing the cold air as close to heat load as possible, unless the unit is ducted. The unit should not be placed near any corner of the room or at the end of a long, narrow room.
There may be additional support required in the form of adjustable jackstands. These are adjustable, threaded leveling rods which support the unit in each of the corners and in the center on longer length units. Tighten the locknuts provided with each jackstand. The base plate can rest on the floor or on vibration pads.
NOTE: Seal openings around piping and electrical connection to prevent air leakage. Failure to do so could reduce the unit’s cooling performance. 2.10. Piping • All refrigerant piping should be is Type L Air Conditioning Refrigeration (ACR) hard drawn copper pipes. Soft copper is unacceptable. •...
Ensure that the tubing surfaces to be brazed are clean and that all burrs have been removed from the ends of the tubes. Ensure that all loose material has been cleaned from inside the tubing before brazing. Keep piping clean and dry, especially on units with R-410A refrigerant. The units may be ordered with top or bottom connections.
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Figure 6 Typical Check Valve NOTE: Picture of the check valve is only intended to show an example of a common check valve installation. It may not represent your specific unit, check valve size, location or orientation. The check valve will prevent flow from the condenser to the compressor during the off cycle. The evaporator section ships with a nitrogen holding charge.
Discharge line pressure drop should not exceed 9 PSI (62 kPa) for R-410A. Recommended gas velocity for proper oil return is 1,000 FPM (5.1 m/sec). Slope horizontal lines downward in the direction of the refrigerant flow. The recommended slope is 1/2” (12 mm) for every ten (10) feet (3 m) of line length.
2.18. Refrigerant Piping Protection The refrigerant in the system(s) is under high-pressure and this pressure can rapidly increase if the refrigerant is unintentionally confined (or trapped) between isolation devices such as service valves, liquid line solenoid valves, expansion valves, etc. If the ambient temperature surrounding the piping system increases, this may cause the contained refrigerant pressure to increase to an unacceptable level.
2.19. Water/Glycol Cooled Unit Piping Water/Glycol-cooled units are factory-charged and tested. Field-supplied and field-installed piping is required from the unit to building water or tower water sources or the fluid cooler (i.e., dry cooler) and pump package. Pipe size will depend on length of run and the maximum water flow required.
recommended to install under-floor leak detection equipment whenever possible. 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.
NOTE: Do not supply steam generating humidifier with softened water. Also, do not use hot water source. 2.27. Leak Testing WARNING: No installation is complete until the entire system has been thoroughly checked for leaks. This includes checking the refrigerant tubing, flare fittings, pressure controls, Schrader fittings and compressor Rotolock service valves.
Installation of the remote temperature and humidity sensors (Optional) should not be placed where they will be directly affected by machines other or equipment which gives off heat or moisture. Prevent exposure to direct sunlight. 2.29. Commissioning Information In general with respect to Data Aire products, the commissioning process is the integration of Data Aire units with your project design system.
ELECTRICAL CONNECTIONS DANGER: Arc flash and electric shock hazard. Risk of electrical shock could result in injury or death. Disconnect local and remote facility power source before working within this equipment. Access should be limited to authorized personnel. Wear appropriate personal protective equipment per NFPA 70E before working within unit.
CAUTION: Check the wiring connections in the unit control panel to ensure they are tight. Screw terminals may become loose in transit. Tightening of wiring connections is the responsibility of the installing contractor. Remove all packing and shipping materials from the unit before installation.
3.2. Electrical Service Before proceeding with the electrical connections, make certain that the volts, hertz, and phase correspond to that specified on the unit electrical nameplate. Check to be sure the electrical service provided by the utility company is enough to handle the additional load imposed by this equipment.
±10% 3.5.2. Single-Phase Voltage Tolerance (Not available for gForce Ultra units) The supply voltage to the unit for single phase operation must have a tolerance per table below. The local utility company should be contacted for correction of improper line voltage. Deviation from ratings can cause premature failures and possibly void unit warranty.
3.7. 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.
low humidity, current percent of capacity and average percent of capacity for chilled water valve, compressor, reheat, humidification, dehumidification, component runtimes for fan motor(s), reheat, humidification, and dehumidification (if applicable). See the separate dap4 User Manual for detailed parameter settings and operating instructions. 3.10.
Condensate pumps which ship loose, normally require a separate source of power. Always check the pump power requirements before connecting power. Condensate pumps are available in various voltages. Factory installed condensate pumps are wired to display a “HIGH CONDENSATE WATER LEVEL”...
For testing and during start-up each gForce unit is provided with manual override slide switches. There are seven (7) slide switches. One for each of the following functions: Figure 12 Manual Override Switch Board All automatic control is disabled but the safety switches remain functional. Simply slide the manual switches to energize the fan, compressor(s), humidification, reheat and other functions (as applicable).
The wiring diagram in the evaporator will indicate field interface terminals to the secondary heat ex- changer. The internal wiring of the secondary heat exchanger is found on a separate diagram which can be found on the inside cover of the heat exchanger electrical box. Both diagram types are also placed inside the shipping/warranty packet secured in the evaporator section.
INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER Air cooled condenser and fluid coolers have individual Installation, Operation and Maintenance Manuals which should be referred to for more complete details regarding remote heat exchangers.
CHARGING 5.1. Triple Evacuation and Dehydration Procedure Data Aire highly recommends a triple evacuation to be carried out on all Data Aire units to ensure the highest quality moisture removal. Moisture prevents the proper operation of both the compressor and the refrigeration system. Non-condensable and moisture reduces service life and increases condensation pressure, which causes abnormally high discharge temperatures that can degrade the lubricating properties of the oil.
NOTE: Two pumps will speed up the procedure. One (1) vacuum pump located normally outside at the condenser or condensing unit and one (1) vacuum pump is located indoors at the evaporator unit. The vacuum pump should be connected to the discharge line after the check valve and the liquid line before the metering device via vacuum rated hoses and Schrader valve core removal tools.
8. Carefully release the nitrogen charge. Watching the gauge until it reads 5 PSIG. 5.1.4. Third Stage Evacuation 1. Move the vacuum hoses back to the vacuum pump and restart the pump. 2. Open the Schrader core shutoff valve and evacuate the refrigerant system from both sides of the system to 1200 micron or less.
Before applying facility power to the unit, the fuses to the WARNING: VFD (if equipped) and the fixed speed compressor(s) must be removed to prevent compressor starting inadvertently/automatically. When ready to start the charging procedures, remove facility power and replace the fuses. 5.2.
5.3.3. Variable Speed Compressor Phase Check The gForce Ultra unit has a Variable Speed Compressor (VS Compressor) with a Variable Frequency Drive (VFD) which is factory wired and run tested to governor the phasing and rotation direction. The wire connections between the VS Compressor and the VFD have very specific connections, and these are shown on the wire diagrams.
Figure 14 Typical VFD to VS Compressor Wiring 5.3.4. Heat Exchanger Phase Check 5.3.4.1. GHRC Air-Cooled Heat Exchanger Phase Check The GHRX air cooled heat exchangers (with axial EC fan motors) are only offered in three phase voltages and the individual EC fan motors will only operate in one direction so no additional phase verification is required.
The fixed speed compressor (2 stage) must be charged before charging the variable speed compressor (1 stage) in an Ultra dual circuit system. NOTE: Prior to refrigerant charging, a system vacuum and moisture removal procedure must have been carried out. Refer to Section...
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WARNING: Pressure relief lines(s) must be vented to the atmosphere per the latest edition of ASHRAE Standard 15 and/or any local building, fire or mechanical codes. This applies to all units with either shell and tube condensers or high-pressure relief valve options. 5.7.1.1.
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NOTE: A quick and easy way to run the fans and compressor is by using the dap4, MENU I – MANUAL CONTROL (Service Level). See dap4 IOM instructions for details. All automatic control is disabled but safety switches will remain functional. 5.7.1.2.
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Function R-410A Conditions Liquid Line Pressure 290 to 390 PSIG (2000 to 2687 kPa) Liquid Line Temperature 85 to 100 PSIG (586 to 690 kPa) Suction Pressure 103 to 130 PSIG (710 kPa to 896 kPa) Suction Saturated Temperature 33 to 45°F (0.56 to 7.22°C) Subcooling 8 to 15°F (-13.33 to -9.44°C) Differential Temperature - Depending on ambient conditions,...
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Weight of Refrigerant in Evaporator plus Condenser for VS Compressors Model Starting Charge (lbs.) GUAX-022XX GUAX-036XX GUAX-045XX 32.5 GUAX-070XX GUAX-091XX 32.5 GUAX-125XX 37.5 2. Add the amount of refrigerant needed for the evaporator and condenser plus the line-set volume 5.4 Line Set Charge Calculations then multiply by 0.80.
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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 the pressure cutout, make sure to add more refrigerant per recommended charge calculation shown above.
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The fixed speed compressor (2 stage) must be charged before charging the variable speed compressor (1 stage) in an Ultra dual circuit system. NOTE: Prior to refrigerant charging, a system vacuum and moisture removal procedure must have been carried out. Refer to 5.1 Triple...
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Flooded systems are supplied with an optional liquid receiver and head pressure control valve. When the ambient temperature falls during cold weather, the head pressure control valve will regulate the flow of refrigerant to ensure minimum receiver pressure. The sub-cooling at times will fluctuate.
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Function R-410A Conditions Discharge Pressure 322 PSIG (2220 kPa) minimum Suction Pressure 104 PSIG (717 kPa) or greater Subcooling 8 to 15°F (-13.33 to -9.44°C) Differential Temperature - Depending on ambient conditions Superheat 8 to 18°F (-13.33 to -7.78°C) Differential Temperature 5.7.2.2.
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Table 2 - Packaged Units with Receivers Acceptable parameters range for water/glycol packaged units with receivers, with return air temperature of 65°F to 85°F and entering water/glycol temp of 65 - 85°F (110°F for Glycol) Suction Liquid Line Liquid Line Suction Subcooling Superheat...
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for future inspections. • Short cycling protection is provided in the VFD. It is factory preset “Enabled” with default parameters. The minimum run time is set to ensure long enough running time at start up in order to create enough refrigerant flow velocity in the system to recover the oil to the compressor sump.
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GLYCOL SYSTEMS 6.1. Glycol Concentration The system must be filled with water and the appropriate amount of glycol (either ethylene or propylene) 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.
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NOTE: Risk of corrosion can cause equipment damage. Contact a water consultant about water quality, corrosion and 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.
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It delivers efficiency across a wider range. 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.
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7.4. Oil Level When the compressor is running under stable conditions the oil level must be visible in the sight glass. The presence of foam filling the sight glass indicates large concentration of refrigerant in the oil and/or presence of liquid returning to the compressor. The oil level can also be checked a few minutes after the compressor is shut down, the level must be between ¼...
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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.
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• 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 Danfoss VFD drive system. 7.6. High Pressure Cutout Switch Each refrigerant circuit is protected by a high-pressure cutout switch with manual reset button.
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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. NOTE: Charging to a full liquid line sight glass should never be the sole means of determining the correct refrigerant charge.
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90°F (32°C) per ASHRAE Standard 15-78. Includes within Data Aire’ Product Selector Guide, the low ambient receiver package has already sized and selected for each Ultra model size. It is essential that the maximum operating charge be determined, e.g., winter charge in air cooled condenser having flooded head pressure control, this being much greater than the normal summer charge.
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point of a water-sensing thermostat in the evaporator (typically about 50°F or 10C), energy saver cooling becomes available. Systems with an Energy Saver Coil should have at least one fluid-sensing thermostat on the fluid cooler set lower to take advantage of colder ambient temperatures. The desired fluid temperature for energy saver cooling is 45°F (7.2C).
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Maintenance 9.1. Service vs. Maintenance There is a noteworthy distinction between the activities of “maintenance” on one hand and “service” on the other. Maintenance is a partial or total renewal of an item. Maintenance reduces the physical age of an item or can even “zero time” the item by rejuvenating some or all of its components.
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out on a regular basis by a suitably qualified Service Technician. It should be noted that the interval necessary between each ‘minor’ and ‘major’ service can vary depending on, for instance, application, site conditions and expected operating schedule. Normally a ‘minor’ service should be carried out every three to six months and a ‘major’...
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In general on Data Aire gForce floor units, the filters are removable from the front of the unit unless otherwise specified. NOTE: Replace the air filters with same filter size and type. Any new filters manufacturer must be U.L.
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9.6. Humidifier Some units are provided with a self-contained, microprocessor-controlled steam generator type humidifier as standard equipment and others, as an option. The steam generating humidifier uses a disposable cylinder with electronic controls. The humidifier discharges pure steam with no material dust carry-over and has a self-regulating automatic flush cycle. Cylinders are disposable and do not requiring cleaning or maintenance.
• When completely drained, push the On/Off/Drain switch to the “Off” position. • Turn OFF the disconnect switch to all remote electric facility power to the unit with the external disconnect. The inside of the humidifier’s cabinet contains high voltage DANGER: components and wiring.
condensate drain pan. Look for any moisture or signs of previous wetness or dripping inside the cabinet. • Look for and replace damaged insulating material. • Check door and panel gasket for wear or damage. Repair or replace, as needed. •...
• Check the glycol level. • Check glycol concentration to job site requirement. • Check water quality to your design requirements and to your local and national codes. • Check flow rate. • Check water regulating valve and other water components for leaks or damage. Repair as needed.
9.16. Plug Fans with Electronically Commutated Motor Plug fan(s) with Electronically Commutated (EC) motors are standard equipment on all gForce units. Plug fan(s) with EC motors are maintenance free and only require visual inspection. The motors are sealed, have maintenance free ball bearings and permanent lubrication. The only...
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If one of the fan internal safeties are triggered, the motor will stop (via electronic controls) and an alarm (FAN FAILURE) will be indicated on the unit’s dap4 display controller screen. Once the fan is stopped via internal controls, the motor will not restart automatically. The internal electronic controller must be reset, by cycling the main electrical power supply.
MAINTENANCE/INSPECTION CHECKLIST MAINTENANCE/INSPECTION CHECKLIST (NOTE: Maintenance/inspection items are monthly unless otherwise specified.) 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 ☐...
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MAINTENANCE/INSPECTION CHECKLIST (NOTE: Maintenance/inspection items are monthly unless otherwise specified.) ☐ Inspect element (and clean if required) ☐ Check for lines (leaks/lines secure) ☐ Check wiring ☐ Check capillary lines ☐ Record amps Condensers (Water-Cooled) ☐ Check for leaks ☐ Entering/leaving water temperatures: Entering T °F Leaving T °F Compressor (Monthly)
Frequently Asked Questions – FAQ NOTE: 1. This Frequent Asked Questions Section applies only to the standard units unless specified. 2. This Frequent Asked Questions Section does not apply to units with special options or special design. This is based on factory settings. 3.
Figure 16 Example Remote EPO Switch Connection Question 10: What is a time delay fuse? Answer: Time delay fuses are used in general on circuits with induction load that have initial surges of electrical power when the motor starts. Induction loads may be motor, pump, etc. Question 11: What is a fast-acting fuse? Answer: Fast acting delay fuses are used in general on circuits with resistance load that have initial surges of electrical power when the resistance load starts.
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Data Aire unit. To determine the model number, locate the product description label on the Nortec humidifier. Match the model number to the table below to determine the amount of steam generated. All humidifiers can be adjusted within the range minimum to 100%. Factory setting is 60% of capacity.
CONTACT DATA AIRE Address: Data Aire, Inc. 230 West Blueridge Avenue Orange, CA 92865 Telephone: 714-921-6000 800-347-AIRE (2473) Toll Free E-mail: Service@dataaire.com Engineering@dataaire.com Sales@dataaire.com Fax: 714-921-6010 Main 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:...
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APPENDIX: Additional Oil Required (Oz) Additional Oil Required (Oz) NOTE: Additional oil is only needed if pipe run is longer than 66 feet. (20 m) Total Refrigerant Danfoss Variable Danfoss Fixed Speed Weight (lbs.) Speed Compressor Compressor...
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INDEX Air 3, 4, 5, 6, 7, 17, 18, 19, 21, 22, 26, 35, 41, 45, 46, 47, Glycol system ..............35 48, 68, 76, 77, 80 Grounding ..............4, 35 air discharge plenum ............. 18 air distribution plenum ........... 18 Air filter ................
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Questions and answers