Data Aire GHFC Series Installation, Operating And Maintenance Manual
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Data Aire GHFC Series Installation, Operating And Maintenance Manual

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1 • Air-Cooled Condenser Manual

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Summary of Contents for Data Aire GHFC Series

  • Page 1 1 • Air-Cooled Condenser Manual...
  • Page 2 Special care should be given to those areas where these symbols appear. Data Aire, Inc. reserves the right to make design and component changes for the purpose of product improvement or to withdraw any design without notice. 2 • Air-Cooled Condenser Manual...

  • Page 3: Table Of Contents

    AIR-COOLED FLUID COOLER TABLE OF CONTENTS INTRODUCTION ......................5 Model Identification..........................5 Inspection .............................. 5 Paperwork ............................. 6 Storage ..............................6 Locating the Remote Heat Exchanger ....................8 Leg Assembly ............................10 Rigging ..............................10 Installation ............................11 PIPING ........................13 GLYCOL SYSTEMS ....................
  • Page 4 Axial Fans with Electronically Commutated Motor ................30 Preventive Maintenance ........................33 Maintenance Functions ........................34 FREQUENTLY ASKED QUESTIONS (FAQ) ............. 35 CONTACT DATA AIRE ....................37 10.0 REMOTE THERMOSTAT BULB MOUNTING INSTRUCTIONS ......38 10.1 TYPICAL SENSING BULB INSTALLATION ..................38 10.2...

  • Page 5: Introduction

    3 - Three phase Inspection This Data Aire unit has been factory run tested and has passed a comprehensive inspection prior to packaging and shipment ensuring 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 6: Paperwork

    Paperwork Each Data Aire unit ships with paperwork which includes a start-up sheet that should be completed during installation. Return the completed Start-Up Sheets to the factory to validate the warranty. Also included in the paperwork is a warranty/information packet that provides...
  • Page 7 It will be the responsibility of the customer to submit a monthly log sheet showing the condition of the unit and noting any discrepancies. A copy of the log sheet should be sent to Data Aire. Failure to perform the long-term storage requirements may void the warranty.

  • Page 8: Locating The Remote Heat Exchanger

    AIR-COOLED FLUID COOLER • Isolate this equipment from pressure testing of water, steam, gas and air piping. • Isolate this equipment from temporary building power. • The unit must also be protected from damage to the exterior of the cabinet or coil connections by construction vehicles and personnel.
  • Page 9 (from the building) water lines. • Dual wide heat exchangers are field mounted side by side (see drawing 600-000- 881). • Consult the Data Aire Service department before installing heat exchangers outside of these conditions. 9 • Air-Cooled Condenser Manual...

  • Page 10: Leg Assembly

    AIR-COOLED FLUID COOLER Leg Assembly The legs must be unbolted from their collapsed shipping position and extended prior to placing the unit on its pad. Each leg extends down approximately 18 inches (457 mm) and reattaches using the same bolts. NOTICE: Failure to extend the legs will result in poor air distribution over the cooling coil resulting in significant capacity reduction and system failure.

  • Page 11: Installation

    AIR-COOLED FLUID COOLER Figure 2 Typical Lifting Method Installation NOTICE: 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 the National Electrical Code (NEC) for special installation requirements.
  • Page 12 AIR-COOLED FLUID COOLER As a precaution, review the following checklist to ensure proper operation. Failure to meet the following conditions could result in voiding the warranty: • Only qualified and experienced service technicians should perform installation and maintenance on this product. •...

  • Page 13: Piping

    AIR-COOLED FLUID COOLER PIPING Tightly drawn Teflon tape should be used on threaded pipe joints where needed. Glycol piping requires no insulation except when fluid temperature will be below ambient dew point temperatures. Fluid coolers typically produce around 70°F (21.1°C) or higher fluid temperatures.
  • Page 14 1. - - - - - - - Indicates Field Piping - Provided by the installing contractor. 2. The expansion tank is a required component of a proper system installation. The tank can be provided by Data Aire as an option. 3. All water/glycol field piping must be designed and installed in accordance with ASHRAE standards and local codes.

  • Page 15: Glycol Systems

    AIR-COOLED FLUID COOLER GLYCOL SYSTEMS Glycol Concentration The system must be filled with water and the appropriate amount of antifreeze (ethylene or propylene glycol) making an aqueous solution which protects against winter freezing. In order to achieve the approximate glycol concentration, it is necessary to know the total system volume.

  • Page 16: Ghfc/Dafc Fluid Cooler Internal Volume

    AIR-COOLED FLUID COOLER GHFC/DAFC Fluid Cooler Internal Volume Model Volume, Gallons Model Volume, Gallons GHFC 021/ DAFC 06 GHFC 130/ DAFC 37 13.0 GHFC 025/ DAFC 07 GHFC 141/ DAFC 40 16.3 GHFC 032/ DAFC 09 GHFC 155/ DAFC 44 16.2 GHFC 039/ DAFC 11 GHFC 176/ DAFC 50...

  • Page 17: Freezing Point Of Aqueous Solutions

    AIR-COOLED FLUID COOLER Freezing Point of Aqueous Solutions ETHYLENE GLYCOL FREEZING POINT PROPYLENE GLYCOL FREEZING POINT F (C) F (C) % by VOLUME % by VOLUME 32 (0) 32 (0) 20 (-6.6) 27 (-2.8) 15 (-9.4) 18 (-8.8) 4 (-15.6) 8 (-13.3) -13 (-25) -6 (-21.1)

  • Page 18: Electrical Connections

    WARNING: Data Aire equipment must be connected by a licensed and qualified electrician. Risk of electrical shock could result in injury or death. Disconnect all remote electrical facility power prior to working on the unit.

  • Page 19: Electrical Service

    Heating, Air Conditioning, and Refrigeration (HACR) type circuit breaker. Other protection devices are not allowed based upon the product UL listing. The facility main distribution panel which provides electrical service to the Data Aire equipment 19 • Air-Cooled Condenser Manual...

  • Page 20: Grounding

    AIR-COOLED FLUID COOLER must be provided with a manual fused disconnect switch or HACR type circuit breaker per local and national electrical codes. Grounding The equipment frame must have an uninterrupted true earth ground. The facility earth ground wire of adequate size must be connected to the ground lug provided inside the main electrical box.

  • Page 21: Phase

    All control wiring on Data Aire equipment is 24 VAC or less. Refer to the wiring diagrams. Check all wiring connections in the unit control panel to ensure they are tight. Screw terminals may become loose in transit.

  • Page 22: Disconnect Switch (Optional)

    AIR-COOLED FLUID COOLER Figure 3 Typical Remote Heat Exchanger Interconnection Points Figure 4 Typical Indoor Evaporator Interconnection Points Disconnect Switch (Optional) A thru-door locking disconnect switch is an optional feature which includes a non-automatic disconnect switch mounted in the high voltage section of the electrical control box. The operating mechanism prevents access to the high voltage electrical components until switched to the "OFF"...

  • Page 23: Wiring Diagrams

    AIR-COOLED FLUID COOLER Wiring Diagrams Every Data Aire fluid cooler comes with a wiring diagram. These diagrams are ladder type schematics intended for service personnel. The intent is to allow the technician to understand the wiring details associated with the electrical components and how they interface with the controls as well as peripheral equipment (including remote heat exchangers).

  • Page 24: Controls

    AIR-COOLED FLUID COOLER CONTROLS Electronically Commutated (EC) Axial Fan Motors (Optional) Fluid coolers with Electronically Commutated (EC) axial fan motor(s) will modulate the fan motor(s) from minimum speed (approximately 20%) to full fan speed (i.e., throttling range – proportional band) by means of an electronic proportional fluid temperature sensing controller. All fan motor(s) are modulated equally over the throttling range.
  • Page 25 AIR-COOLED FLUID COOLER default setpoint for Energy Saver operation is 45°F (7.2°C) with a modulation (throttling) range up to 50°F (10°C). Field adjustment 5.3.2 Systems with PSC Fan Motor(s) Systems with PSC fan motor(s) and the optional Energy Saver coil will have the first fan motor (closest to the electrical enclosure) controlled by a fluid sensing thermostat set to take advantage of the colder ambient temperatures.

  • Page 26: Warranty

    If damage or a system failure occurs due to improper maintenance during the warranty period, Data Aire shall not be liable for costs incurred to return the unit to satisfactory condition. See Data Aire warranty for additional details.

  • Page 27: Cabinet

    Normally a ‘minor’ service should be carried out every three to six (6) months and a ‘major’ service once a year. It is recommended that Data Aire Service Department be contacted for recommendations for individual sites.

  • Page 28: Coils

    AIR-COOLED FLUID COOLER 7.3 Coils • Coils should be inspected semi-annually and cleaned as required. • Check for bent or damaged coil fins and repair as necessary. Use a coil fin comb if the coil fin is bent or deformed and is repairable. •...

  • Page 29: Electrical Control Enclosure

    AIR-COOLED FLUID COOLER cleaner be used. Acid-type cleaners can be aggressive to the coil fins as well as surrounding areas. Many sites do not allow the use of acidic cleaners for environmental reasons. 7.3.4 How to Clean • The absolute best way to clean coils is from the inside out. This requires disconnecting the power supply before working on the unit.

  • Page 30: Fuse Replacement

    AIR-COOLED FLUID COOLER flaking of insulation and/or metal parts. Pitting or melting of connecting surfaces is a sign of arcing due to a loose or otherwise poor connection. Parts which show evidence of overheating or looseness should be replaced if damaged. Tighten screws or bolts and nuts to component manufacturer’s torque specifications.
  • Page 31 Do not power up any module (EC motor/fan blade) that has external damage. The module should be replaced (contact Data Aire Technical Service at 800-347-2473). • The unit has not stopped due to operating in temperatures above the recommended operating range.
  • Page 32 AIR-COOLED FLUID COOLER 7.6.5 If the motor does not operate, proceed to next steps • Confirm there has been no damage due to water or excessive moisture into the module’s terminal box. • Check for signs of water penetration into the motor’s terminal box. Typically, this can be confirmed by the presence of a white, powdery residue on the inside or under the terminal box or around the cable gland or threads in any one of the three ports.

  • Page 33: Preventive Maintenance

    AIR-COOLED FLUID COOLER • If the motor does not operate there probably is a defect internal to the motor (the module needs to be replaced). • If the unit operates normally in these tests, then the likely cause for the motor not operating is in the control scheme and should be further investigated.

  • Page 34: Maintenance Functions

    AIR-COOLED FLUID COOLER Maintenance Functions Monthly Inspect fluid cooler for obstruction to the inlet air side of the coil Inspect the motor/fan blade assemblies to ensure the bearings are free and the motor mounts and fan(s) are secure Bleed air from the system Seasonally Inspect electrical components for loose wire connections Inspect contactor contacts for pitting Check glycol solution level in the...

  • Page 35: Frequently Asked Questions (Faq)

    Electrical section for more details. Will all units operate at 50 or 60 hertz No. This depends on the model and power? options selected. Consult with Data Aire for details. Does the unit require an electrical Yes. All units require a true earth ground.
  • Page 36 AIR-COOLED FLUID COOLER QUESTIONS ANSWERS What is a time delay fuse? 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. What is a fast-acting fuse? Fast acting delay fuses are used in general on circuits with resistance load that have...

  • Page 37: Contact Data Aire

    800-347-2473 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: Condenser Model Number: Condenser Serial Number: Date Installed: Installing Contractor: 37 • Air-Cooled Condenser Manual...

  • Page 38: Remote Thermostat Bulb Mounting Instructions

    AIR-COOLED FLUID COOLER 10.0 REMOTE THERMOSTAT BULB MOUNTING INSTRUCTIONS The water-sensing thermostats used on the fluid cooler each consist of a capillary tube connected to a sensing bulb. The thermostat sensing bulbs are to be strapped to the leaving water header of the fluid cooler coil and insulated with insulation tape. Follow the instructions below for the proper installation of the sensing bulbs.
  • Page 39 AIR-COOLED FLUID COOLER Figure 5 Fan Thermostat Controller Temperature Setpoints 39 • Air-Cooled Condenser Manual...
  • Page 40 AIR-COOLED FLUID COOLER Figure 6 Fluid Temperature Sensor Bulbs 40 • Air-Cooled Condenser Manual...
  • Page 41 AIR-COOLED FLUID COOLER Figure 7 Half Insulated - Applying Thermal Mastic and Insulation Tape 41 • Air-Cooled Condenser Manual...
  • Page 42 AIR-COOLED FLUID COOLER Figure 8 Fully Insulated Bulbs 42 • Air-Cooled Condenser Manual...
  • Page 43 Coil Cleaning Solution ......... 28 Personal Protective Equipment (PPE)... 11, 18, Concrete Pads ..........10 27, 29 Contact Data Aire ........26, 37 Piping........8, 9, 12, 18, 28 Disconnect Switch ....6, 18, 20, 22, 27 Preventive Maintenance Schedule ....27 Electrical .............
  • Page 44 NOTES 44 • Air-Cooled Condenser Manual...
  • Page 45 Publication: Fluid Cooler IOM FluidCoolerIOM-03-2022.docx Date: 03-2022...

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