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NOTICE: Indicates information considered important but may have potential hazard for personal injury or property damage. Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice.
TABLE OF CONTENTS INTRODUCTION ......................7 Product Information ........................7 Model Identification ........................7 Inspection ............................8 Paperwork ............................. 8 Storage ............................9 Suggested Reference Storage Room Conditions ................. 9 General Storage Considerations ....................9 Registered Trademarks – Copy Rights – References Section ........... 10 INSTALLATION ......................11 Recommended Tools for Installation ..................
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TABLE OF CONTENTS General Electrical Field Wiring Guidelines .................. 36 Electrical Service ......................... 37 Nameplate Ratings ........................37 Grounding ............................ 37 Voltage Tolerance ........................37 Three Phase Voltage Tolerance ..................37 Single-Phase Voltage Tolerance..................38 Heat Exchanger Auxiliary Control Wiring ..................38 Remote Shutdown ........................
The Data Aire CRAC unit provides cooling, reheat, humidification, dehumidification and air filtration. The unit is provided with a Data Aire Mini-dap4 microprocessor controller for precision control. The unit must be operated in a conditioned space within the operating envelope ASHRAE recommends for data centers.
Paperwork Each Data Aire CRAC unit ships with a startup sheet that should be completed during installation. Also included in the paperwork is a warranty/information packet that provides important wiring diagrams, specific component literature, warranty registration cards and other valuable paperwork, including a copy of this Installation, Operation, and Maintenance manual.
It is the responsibility of the customer to submit a monthly log sheet showing the condition of the unit and noting any discrepancies. A copy of the log sheet should be sent to Data Aire. Failure to perform the long-term storage requirements may void the warranty.
Registered Trademarks – Copy Rights – References Section NOTICE: Data Aire Inc. Trademarks Disclaimer: All names, logos, brand, materials and other Registered Trademarks, Trademarks, or Copy Rights seen featured or referred to within documents or our website are explicitly the sole property of their respective and rightful trademark holders or owners.
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 National Electrical Code (NEC) for special installation requirements.
If possible, transport the Data Aire unit with a forklift or pallet jacks. If using a forklift or pallet jack, make sure that the forks (if adjustable) are spread to the widest allowable distance that will fit under the skid.
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.
Equipment Handling and Rigging WARNING: Only properly trained personnel wearing appropriate safety head gear, gloves, shoes, and glasses should attempt to move the unit, lift it, remove packaging or prepare the unit for installation. 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 or panels during any storage or moving.
NOTE: There are many available unit configurations for the Mini-Plus ceiling units, therefore; be sure to identify the unit type and style before installing. For instance there may be split condenser/condensing unit sections requiring separate or shared power. Note to Installing Contractor: Condensation formation and frequent humidifier flushing (when humidifier is installed) are normal functions of this equipment.
Figure 1 Typical Installation Methods NOTES: The unit must be level when installation is complete. Add an additional 4-1/2” for an Energy Saver or Auxiliary Chilled Water coil option. Figure 2 Typical Installation Details...
Indoor Condensers and Condensing Units Although most split air-cooled systems have outdoor condensers or condensing units, indoor condensers and condensing units are occasionally used. These 29 1/2” (750 mm) tall sections are to be mounted in the same manner as the evaporator sections using four (4) threaded rods. Air-cooled condensers or condensing units have factory provided duct collars on the supply and return air openings as appropriate.
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.
During the installation, the lines should be capped off and filled with dry nitrogen at the end of each day’s work or until the system is completed and sealed. 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 buildup on the inside of the joints. Carbon could contaminate the refrigerant and restrict the metering device. Piping must be supported within 18” (457 mm) of the inlet and outlet connections external to the unit. Internal to the unit, the inlet connection is located on the top header of all units.
Table 5 Connection Sizes, Air Cooled Units (Inches OD) Model Number Hot Gas Line Liquid Line Suction Line DAPA-2.5 DAPA-03 DAPA-04 DAPA-05 NOTICE: Units will have a liquid line and either a hot gas or suction line. Field connections at the indoor evaporator and remote condenser will not necessarily be the same as the field pipe size required.
Field Piping, Remote Condenser/Condensing Unit Above Evaporator NOTES: 1. This is the recommended piping. All piping to be per local and/or state code. 2. Condenser to be no more than 60 feet (18.3 meters) above evaporator. 3. For units built after April 2017, the check valves are included internally in the evaporator section.
Field Piping, Remote Condenser/ Condensing Unit Below Evaporator NOTES: 1. This is the recommended piping. All piping to be per local and/or state code. 2. Condenser to be no more than 15 feet (4.6 M) below evaporator. 3. Slope horizontal lines downward in the direction of the refrigerant flow, 1/2” (13 mm) for every 10 (3.1 M) feet of line length.
Connection Sizes, Fluid Coolers (Dry Coolers) The information regarding Fluid Cooler (or often referred to as a “dry cooler”) connection sizes can be found in the individual Fluid Cooler User Manuals which should be referred to for more complete details. Auxiliary Chilled Water/Energy Saver Coil In colder climates, the evaporator will often be equipped with an additional free cooling coil to take advantage of the colder ambient temperatures.
NOTE: Mini-Plus ceiling units with optional Energy Saver or Auxiliary Chilled Water coils have a 28-1/2” (724 mm) frame height instead of the standard 24” (610 mm) height. Condensate Drain System Every indoor unit has a 3/4” (19 mm) copper stub provided for condensate removal. A union (field provided) is recommended at the field connection which will permit easy disconnection from the unit for cleaning.
NOTICE: 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.
Figure 4 Recommended Condensate Trap Dimensions Notes: 1. This trap is capable of handling static pressures equal to 4” H O which is the maximum static available for ceiling units. If the unit fans are standard, there is no need to consider different dimensions but if higher total static pressure is expected, more vertical drop is required.
L1 = Minimum 1” (25.4 mm) L2 = Fan static pressure x 1.5 3. Bracket (Data Aire P/N 550-021-006) to be mounted to the unit and stainless-steel tank (Data Aire P/N 550-721-464) are factory provided. 4. Hose, hose clamps, self-drilling sheet metal screws #10 x 3/4", fittings, P-trap and copper...
Humidifier Steam Generator Humidifier The optional humidifier offered on Mini-Plus units is a steam generator type with a disposable cylinder. The humidifier makeup water should be brought to the humidifier through the field connection opening using 1/4” (6.4 mm) copper tubing. A compression fitting is provided at the humidifier. Humidifier Piping A shutoff valve (field provided) should be installed outside the air conditioner to allow disconnection for service.
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 shutoff valves (field provided) before and after the strainer. The strainers and water/glycol piping must be cleaned on a periodic basis.
NOTE: Unless otherwise specified by job specific documentation 1. The expansion tank is a required component of a proper system installation. The tank can be provided by Data Aire or by others. 2. All Water/Glycol field piping must be designed and installed in accordance with ASHRAE standards and local codes.
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. 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).
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. Data Aire can help provide the installation and maintenance support, but the commissioning is normally done as specified by the owner or others unless otherwise specified.
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.
Remove all packing and shipping materials from the unit before installation. WARNING: The Data Aire dap4 controller does not isolate power from the unit, even in the Unit OFF mode. Some internal components require and receive power even during the Unit OFF mode of dap controller.
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 must be provided with a manual fused disconnect switch or HACR type circuit breaker per local and national electrical codes.
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.
Mini-dap4 Controller The Data Aire Computer Room Air Conditioner (CRAC) or Computer Room Air Handler (CRAH) is furnished with a microprocessor-based Mini-dap4 controller. The controller includes unit control functions and display normal functions and service diagnostics with six keys (buttons) for easy programming.
contact, intended to be used in a control circuit not exceeding 5 amps at 24 VAC. Use field supplied Class 1 wiring. These programmable output contacts will close on a failure and remain closed until the alarm is no longer present. The terminal designations for these alarm output contact pairs are: Table 10 Remote Alarm Contacts Terminals Function Remote Alarm (Common)
Manual Override Switch Board NOTICE: The Manual Override Board with switches was previously available on units before April 2021. Units built after April 2021 do not include this board. For testing and during startup each gForce unit is provided with manual override slide switches. There are seven (7) slide switches.
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. 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 secondary heat exchangers).
(Ref: DOT 4BA400 or ABW400) 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.
system must be purged with nitrogen. We recommend using a solenoid magnet tool to hold the liquid line solenoid valve(s) open during this procedure. A deep vacuum gauge capable of registering pressure in microns must be attached to the system on the liquid line service port before TXV and should be at the farthest point in the system for most accurate vacuum readings.
2. Close the Schrader core shutoff valve and turn OFF the vacuum pump. 3. Disconnect the vacuum pump hoses from the vacuum and attached them to your manifold gauges. 4. Connect a vacuum hose from the nitrogen bottle regulator to the manifold gauges vacuum port and carefully break the vacuum with clean dry nitrogen.
8. Verify no that there are nitrogen leaks. 9. Carefully release the nitrogen charge. Watching the gauge until it reads 1 PSIG (7 kPa). Final Evacuation Stage 1. Move the vacuum hoses back to the vacuum pump and restart the pump. 2.
• If the TXV is in the close position, use a liquid charging adapter to break the vacuum at the compressor suction and discharge Rotolock service valves with 90 PSIG (621 kPa) of liquid refrigerant. A liquid charging adapter prevents liquid refrigerant from entering the compressor.
An out of phase fixed speed scroll compressor will draw relatively low amps and both suction and discharge pressures will remain nearly equal. If necessary, reverse any two of the three input line voltage wires at the line voltage field connection point to change the compressor rotation. Units shipped from the factory are run tested to ensure the compressor rotation is consistent with evaporator fan motor.
This applies to all units with either shell and tube condensers or high-pressure relief valve options. Air Cooled Split System Charging Air-cooled condensers provided with Data Aire equipment have integral fan speed controls. The fan speed control is programmed at the factory to start the fan at a specific head pressure and increase speed (i.e., airflow) when enough head pressure is developed, the fan will run at full speed.
Table 14 DAPA Starting Charge R-410A Weight of Refrigerant in Evaporator and Condenser Evaporator Starting Condensing Unit Model Model Charge (lbs.) DAPA-2.5XX GHRC-011XX or DARC-03XX GHRC-018XX or DARC-05XX (Option) GHRC-025XX or DARC-07XX (Option) DAPA-03XX GHRC-011XX or DARC-03XX GHRC-018XX or DARC-05XX (Option) GHRC-025XX or DARC-07XX (Option) GHRC-039XX or DARC-11XX (Option) DAPA-04XX...
4. Next, connect the refrigerant tank to the refrigerant manifold gauge set on circuit 1 and make sure the manifold gauge set is properly purged. 5. Then from a vacuum, add the amount of refrigerant weight per the above calculations by slowly opening the high side liquid line valve on the refrigerant manifold gauge to feed liquid refrigerant through the high side.
Use the Temp Setpoint under Menu B – Setpoints to force the circuit 1 compressor to start in the normal operating mode. A call for cooling can artificially be created from the controller by setting the Temp Setpoint to a value lower than the current ambient temperature in the space. Example: Existing return air temperature (RAT) is 75F (23.9C), set the controller Temperature Setpoint to 65F (18.3C).
Additional Oil When charging is complete, add the correct amount of oil to each circuit. In installations with good oil return and line runs up to 50 ft (15 m), no additional oil is required. If installation lines exceed 50 ft (15 m), additional oil needs to be added.
Receiver storage capacities are based on the liquid occupying no more than 90% of the internal volume when the temperature of the refrigerant is 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.
Safety Relief Devices Data Aire’s low ambient receiver(s) include a suitable fusible plug safety relief device installed on the receiver housing. The fusible plug is a onetime discharge device and must be replaced in the event of a receiver over temperature condition.
Figure 10 Typical Low Ambient Receiver Package NOTES: 1. Install the Low Ambient Control (LAC) valve remote sensing bulb on a smooth flat part of the liquid line for optimal surface contact and insulate the bulb after mounting. 2. Keep the LAC away from the hot gas inlet. 3.
Use two (2) lbs. per nominal ton and using a “liquid charging adapter” add the calculated system charge at the condenser through the liquid line and discharge line with liquid refrigerant. A “liquid charging adapter” is needed so liquid refrigerant doesn’t enter the compressor. At this point the receiver(s) are pre-charged.
nameplate. Although this figure represents the initial factory charge, it is still necessary to measure and note proper unit operation including superheat, head and suction pressure. Some adjustment of charge may be required. Adjust the refrigerant charge until the sight glass has sparse bubbles. The system should be allowed to stabilize for 15 to 20 minutes before meaningful measurements can be taken.
The refrigerant circuit has an adjustable Thermal Expansion Valve (TXV). The TXV is factory adjusted to their normal rating. Any field adjustment should be to “fine tune” a system that has stabilized and already has acceptable operating parameters. Adjusting a TXV to produce large swings in superheat is not recommended.
Liquid Line Solenoid Valve (Optional) 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. The Liquid Line Solenoid Valve (LLVS) is a direct acting, NC (normally closed; i.e. closed when deenergized) solenoid operated valve. The advantage is the valve is closed when the system is not running and when the solenoid valve is not energized.
Brazed-Plate Condensers Data Aire water cooled units use brazed-plate condensers as a standard. Brazed-plate condensers are constructed of plates brazed together to form an assembly of separate channels. Refrigerant is confined to the space between the welded plates and is exposed to gaskets only at the ports. Such condensers have a higher range of capacity.
Water Treatment If impurities are not controlled, they can cause sludge or biological fouling. Simple blowdown (discharging a small portion of the recirculating water to a drain) may be adequate to control scale and corrosion on sites with good quality makeup water, but it does not control biological contaminants such as Legionella.
6.2.3.5 Corrosion protection Stainless steel has a high resistance to most chemicals but is sensitive to chloride ion concentration so this must be limited to 280ppm or less in systems operating at less than 131°F (55°C). The copper used in the brazing process is mainly sensitive to strong acid and ammonia so the pH must be maintained between 6 and 8.
Freezing Point of Aqueous Solutions Table 25 Freezing Point of Aqueous Solutions Ethylene Glycol, Freezing Point, Propylene Glycol, Freezing Point % by Volume Degrees F (C) % by Volume Degree F (C) 32 (0) 32 (0) 24 (-4.4) 27 (-2.8) 15 (-9.4) 18 (-7.8) 4 (-15.6)
CONTROLS Mini-dap4 Microprocessor Control Controller The standard controller on all DAP equipment is the Mini-dap4 microprocessor controller. The controller includes unit controller and a remote display. Normal functions and service diagnostics is accessed by the remote graphic touch display (dap4Touch). The controller allows recall and display of the high and low temperature for the last 24 hours, high and low humidity for the last 24 hours, current percent of capacity and average percent of capacity for the last hour of operation for compressor, reheat, humidification, dehumidification, component runtimes (if applicable) for fan motor(s), reheat,...
REGULAR MAINTENANCE ITEMS Air Filters The air filter section is an integral part of the environmental control system, designed within the unit for easy front accessibility. An initial set of filters are factory installed in the unit. The filters are 2-inch (50 mm) deep, disposable, pleated design, extended surface, nonwoven, reinforced cotton fabric;...
Fuses 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 1) amperage, 2) voltage, and 3) speed. For instance, motors are inductive loads which require time delay fuses.
EC Plenum (Plug) Fans NOTICE: Electronically Commutated (EC) motors with backward curved plenum (plug) fans are a special optional on some Mini-Plus units. Maintenance is not required on electronically commutated (EC) motor/plenum fan modules. The motors are sealed, have maintenance free ball bearings and permanent lubrication. The only acceptable service is replacement.
EC motors have an under-voltage protection. If the power supply voltage falls below 150 VAC/3Ø (for 230-volt motors) 290 VAC/3Ø (for 460 motors) for a minimum of five (5) seconds, the motor will automatically switch off and an alarm condition (NO AIRFLOW) will be energized and displayed. If the power supply voltage returns to the correct values, the motor will automatically restart.
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 ☐...
MAINTENANCE/INSPECTION CHECKLIST (NOTE: Maintenance/inspection items are monthly unless otherwise specified.) Humidifier (Steam Generator) is equipped: ☐ Inspect drain valve/trap/drain line ☐ Check for leaks (makeup water/hoses) ☐ Check humidifier canister (replace if needed) ☐ Check and clean fill strainer ☐ Check operation Record humidifier amp draw A L2 A L3...
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MAINTENANCE/INSPECTION CHECKLIST (NOTE: Maintenance/inspection items are monthly unless otherwise specified.) Air Cooled Condenser, Condensing Unit, Fluid Cooler (if applicable) ☐ Inspect coil/clean if required or Fluid Cooler (if applicable) ☐ Inspect coil/clean if required ☐ Inspect motor/motor mounts ☐ Inspect motor/motor mounts ☐...
Question 5: Will all units operate at 50 or 60 hertz power? Answer: No. This depends on the model and options selected. Consult with Data Aire for details. Question 6: Does the unit require an electrical ground? Answer: Yes. All units require a true earth ground.
Question 2: How much clearance around my Data Aire unit is required for servicing? Answer: Data Aire recommends a minimum of 36” on two sides of ceiling mounted units. Units with EC motor and plug fans require 40” on the front and two sides.
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The amount of steam generated depends on the model of humidifier you have in your 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.
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2. Poor air distribution 3. Poor refrigerant distribution 4. Improper compressor-evaporator balance 5. Evaporator oil logged 6. Flow from one TXV affecting another’s bulb NOTE: Data Aire has ensured that TXVs are sized properly as the unit ships from the factory.
Telephone: 714-921-6000 or 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: Evaporator Model Number: Evaporator Serial Number: Condenser Model Number: Condenser Serial Number: Date Installed: Installing Contractor:...