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Data Aire gForce Ultra Installation, Operation & Maintenance Manual

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  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........................9 Product Information ..........................9 Model Identification ........................... 10 Inspection ............................10 Paperwork ............................11 Storage.............................. 11 Suggested Reference Storage Room Conditions ............... 11 General Storage Considerations ....................12 Registered Trademarks – Copy Rights – References Section ............12 INSTALLATION ...........................
  • Page 4 TABLE OF CONTENTS ELECTRICAL ..........................37 General Electrical Field Wiring Guidelines ..................38 Electrical Service ..........................39 Nameplate Ratings ..........................39 Grounding ............................39 Voltage Tolerance ..........................39 Three Phase Voltage Tolerance ....................39 Single-Phase Voltage Tolerance ....................40 Heat Exchanger Auxiliary Control Wiring ................... 40 Remote Shutdown ..........................
  • Page 5 Low Pressure Cutout Switch ......................85 Liquid Line Solenoid Valve ......................... 85 Energy Saver Cooling (Optional) ....................... 85 CONTROLS ..........................87 dap4 Microprocessor Controller ......................87 dap4 Factory Settings ........................87 dap4 Universal Security Access: ....................87 gForce Ultra Settings: ......................... 88...
  • Page 6 Plenum Plug Fans ........................... 110 EC Motor Testing ........................111 Current Sensing Switch Adjustment ....................112 MAINTENANCE/INSPECTION CHECKLIST ..............113 Frequently Asked Questions (FAQ) ................. 116 Electrical FAQ Section ........................116 Mechanical FAQ Section ......................... 117 CONTACT DATA AIRE ......................120...
  • Page 7 TABLE OF CONTENTS TABLE OF FIGURES Figure 1 Typical Upper Spring-Loaded Hinge ..................16 Figure 2 Upper Hole for Spring-Loaded Hinge ..................17 Figure 3 Lower Fixed Pin Hinge ......................17 Figure 4 Example of Lifting Method ....................18 Figure 5 Typical Return & Discharge Air Distribution ................20 Figure 6 Typical Check Valve ......................
  • Page 8 TABLE OF CONTENTS LIST OF TABLES Table 1 Line Size Metric Conversion ....................24 Table 2 Hot Gas Lines (Single Circuit Systems) ................. 24 Table 3 Liquid Lines (Single Circuit Systems) ..................24 Table 4 Hot Gas Lines (Dual Circuit Systems) ..................24 Table 5 Liquid Lines (Dual Circuit Systems) ..................

  • Page 9: Introduction

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

  • Page 10: Model Identification

    Ultra IOM Model Identification gForce Ultra Model Number GU X X - XXX X │ │ │ │ │ │ │ │ │ │ │ │ GU - gForce Ultra, Single and Dual Circuit ──── ┘ │ │ │...

  • Page 11: Paperwork

    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 12: General Storage Considerations

    Registered Trademarks – Copy Rights – References Section NOTE: Data Aire Inc. Trademarks Disclaimer: All names, logos, brand, materials and other Registered Trademarks, Trademarks, or Copy Rights...

  • Page 13: Installation

    Ultra IOM 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.

  • Page 14: Recommended Tools For Installation

    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.

  • Page 15: Room Considerations

    Ultra IOM 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. • It is also necessary to consider access requirements for safe operation and maintenance of the unit, and power and control panels.

  • Page 16: Door And Rear Panel Removal

    Ultra IOM Door and Rear Panel Removal 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.

  • Page 17: Rear Panel

    Ultra IOM Figure 2 Upper Hole for Spring-Loaded Hinge Figure 3 Lower Fixed Pin Hinge Rear Panel Remove screws from rear panel to remove rear panel. 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.

  • Page 18: Rigging

    Ultra IOM 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. WARNING: Use care when moving. Improper handling could result in injury.

  • Page 19: Locating The Unit

    Ultra IOM Locating the Unit Verify that the floor is level, solid and appropriate construction to support the unit. When installing the unit, enough space must be allowed for airflow clearance, wiring, plumbing and service access. It is recommended that each side and front have a clearance of at least 36” (914mm) to allow the doors to swing open and for servicing the unit.

  • Page 20: Upflow Units

    Ultra IOM Figure 5 Typical Return & Discharge Air Distribution There may be additional support required in the form of adjustable jack stands. These are adjustable, threaded leveling rods which support the unit in each of the corners and in the center on longer length units.

  • Page 21: Piping

    Ultra IOM recommended that isolation backdraft dampers be installed on the discharge end of the unit or somewhere prior to the common plenum to prevent cold discharge air from entering units that may be on standby. Alternatively, we offer an AireSeal option which keeps the EC fans running at a selectable speed between 20-50% when the unit is in standby to prevent air from entering the units from the common plenum.

  • Page 22: 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 23: Figure 6 Typical Check Valve

    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 24: Liquid Lines

    Ultra IOM 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.

  • Page 25: Connection Sizes, Air-Cooled Units

    Ultra IOM Table 5 Liquid Lines (Dual Circuit Systems) Equivalent Feet (Meters) Unit kW 50 (15.2) 100 (30.5) 150 (45.7) 200 (61.0) 7/8” 7/8” 7/8” 7/8” 7/8” 7/8” 7/8” 7/8” 1-1/8” 1-1/8” 1-1/8” 1-1/8” NOTE: 1. If equivalent piping length falls between two columns above, choose the longer equivalent length.

  • Page 26: Field Piping, Remote Condenser Above Evaporator

    Ultra IOM Field Piping, Remote Condenser Above Evaporator Figure 7 Typical Remote Condenser Above Evaporator Installation NOTES: (Unless otherwise specified by job specific documentation) 1. This is recommended piping. All piping to be per local and/or state codes. 2. Condenser to be no more than 60 feet (18.3 m) above evaporator.

  • Page 27: Field Piping, Remote Condenser Below Evaporator

    Ultra IOM Field Piping, Remote Condenser Below Evaporator Figure 8 Typical Remote Condenser Below Evaporator NOTES: (Unless otherwise specified by job specific documentation) 1. This is recommended piping. All piping to be per local and/or state codes. 2. Condenser to be no more than 15 feet (4.6 m) below evaporator.

  • Page 28: Refrigerant Piping Protection

    Ultra IOM 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.

  • Page 29: Water/Glycol Cooled Unit Piping

    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 30: Factory Charge For Water/Glycol Cooled System

    Ultra IOM Factory Charge for Water/Glycol Cooled System Total R-410A Variable Speed Fixed Speed Evaporator Model Required (lbs.) Circuit (lbs.) Circuit (Lbs.) 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...

  • Page 31: Field Piping, Water/Glycol System

    NOTES: 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.

  • Page 32: Connection Sizes, Fluid Coolers (Dry Coolers)

    Ultra IOM 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.

  • Page 33: Condensate Trap

    Ultra IOM Condensate pumps shipped loose (or field provided) typically require a dedicated 110-volt power source. Field pipe connections must be made to the pump discharge connection. A check valve must be installed to prevent short cycling. See condensate pump electrical requirements in 3.12 Condensate...

  • Page 34: Figure 10 Recommended Condensate Trap Dimensions

    Ultra IOM Therefore, a trap (field supplied and installed) must be fabricated into the unit drain system external of the evaporator section. In order to eliminate air trapping, an air vent must be used to allow air to exit.

  • Page 35: Auxiliary Chilled Water/Energy Saver Coil Piping

    Ultra IOM Auxiliary Chilled Water/Energy Saver Coil Piping Units with Auxiliary Chilled Water-cooling coil require a separate source of chilled water. These chilled water connection sizes will be equal to the condenser water connection sizes shown in the Fluid Cooler Operation, Installation and Maintenance manual.

  • Page 36: Electrical Installation

    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.

  • Page 37: Electrical

    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 38: General Electrical Field Wiring Guidelines

    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.

  • Page 39: Electrical Service

    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.

  • Page 40: Single-Phase Voltage Tolerance

    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 41: Remote Shutdown

    Figure 12 Typical Indoor Evaporator Interconnection Points 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.

  • Page 42: Dap4 Controller

    Ultra IOM dap4 Controller This unit is furnished with a microprocessor-based dap4 controller. The controller includes unit control functions and display normal functions and service diagnostics with six keys (buttons) for easy programming. The controller allows recall and display of the high and low temperature, high and low...

  • Page 43: Condensate Probe

    Ultra IOM 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” alarm. The wiring for this must be done in the field on pumps that ship loose.

  • Page 44: Manual Override Switch Board

    Ultra IOM Manual Override Switch Board NOTE: 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 start-up each gForce unit is provided with manual override slide switches. There are seven (7) slide switches.

  • Page 45: Wiring Diagrams

    Ultra IOM 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).

  • Page 46: Installation Of Remote Outdoor Heat Exchanger

    Ultra IOM 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.

  • Page 47: Charging

    (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.

  • Page 48: Tools Needed

    Ultra IOM NOTE: Do not turn OFF vacuum pump when connected to an evacuated system before closing shut-off valve. WARNING: Do not apply power to the compressor when in a vacuum Tools Needed • Refrigerant manifold gauge set NOTICE: This manifold gauge set should not be used for the vacuum procedure.

  • Page 49: Second Stage Evacuation

    Ultra IOM 5. Isolate and hold the nitrogen charge for at least one (20) minutes. 6. Verify there are no nitrogen leaks. 7. Carefully release the nitrogen charge. Watching the gauge until it reads 1 PSIG (7 kPa). Second Stage Evacuation 1.

  • Page 50: Final Evacuation Stage

    Ultra IOM Final Evacuation Stage 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 500 micron or less.

  • Page 51: Voltage Phase Check

    Ultra IOM refrigerant. A liquid charging adapter prevents liquid refrigerant from entering the compressor. • In some cases, the assistance of a refrigerant recovery machine may be necessary to add the initial charge. • Care must be taken to prevent from over charging the system and from liquid entering the compressor and diluting the oil.

  • Page 52: Fixed Speed Scroll Compressor Phase Check

    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.

  • Page 53: Heat Exchanger Phase Check

    Ultra IOM Heat Exchanger Phase Check GHRC Air-Cooled Heat Exchanger Phase Check Air-cooled GHRC condensers and GHRU condensing unit 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 but the rotation of the compressor on GHRU units must be checked.

  • Page 54: Charging Procedures

    EPA certification card. Air-cooled 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.

  • Page 55: Pre-Charge Fixed Speed Compressor

    Ultra IOM Pre-Charge Fixed Speed Compressor 1. After the system has been properly evacuated. Calculate the proper charge for each circuit by following the steps and the data in the tables. 2. Select the model and refrigerant charge for evaporator and condenser in accordance with the following table.

  • Page 56: Charging The Fixed Speed Compressor

    Ultra IOM 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.

  • Page 57: Additional Oil

    Ultra IOM Finish charging the circuit by slowly opening the valve on the refrigerant manifold set to meter liquid refrigerant into the low side of the system. Use a liquid charging adapter to prevent liquid refrigerant from entering the compressor.

  • Page 58: Pre-Charge Variable Speed Compressor

    5.5 Line Set Charge Calculations together and multiply by 80% (0.80) to get the initial starting charge. NOTICE: Some gForce Ultra models have dual compressors (one (1) variable and one (1) fixed speed) circuits. Each compressor circuit must be charge individually.

  • Page 59: Charging The Variable Speed Compressor

    Ultra IOM 6. Add the calculated amount of refrigerant. At this point, there will be approximately 70 to 80% of the total charge in the system. It is likely that more refrigerant will be required to complete the charging procedure during compressor operations.

  • Page 60: Table 14 Refrigerant Charge Valves

    Ultra IOM Finish charging by slowly opening the valve on the refrigerant manifold set to meter liquid refrigerant into the low side of the system, with the compressor operating at maximum speed, make sure to obtain the required sub-cooling and verify superheat shown in the table below. Use a liquid charging adapter to prevent liquid refrigerant from entering the compressor.

  • Page 61: Flooded System Charging (Systems With Low Ambient Receiver Package)

    Ultra IOM 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 62: Low Ambient Receiver Package

    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...
  • Page 63 Ultra IOM a receiver over temperature condition. The fusible plug allows refrigerant to release at a controlled rate and relieves an over temperature/pressure condition in the receiver. See section 2.18 Refrigerant Piping Protection for additional information regarding piping and receiver over pressure protection.

  • Page 64: Figure 16 Typical Low Ambient Receiver Package

    Ultra IOM Figure 16 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.

  • Page 65: Table 15 Refrigerant Receiver Charging Chart

    Ultra IOM Use approximately 2 lbs. per nominal ton and using a “liquid charging adapter” to 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.

  • Page 66: Table 17 Packaged Units Without Receivers

    Ultra IOM 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. After the system stabilize, verification of a few key measurements should be noted.

  • Page 67: Additional Oil

    Ultra IOM 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.

  • Page 68: Glycol Systems

    Ultra IOM GLYCOL SYSTEMS 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.

  • Page 69: Brazed-Plate Fin Condensers

    Ultra IOM Brazed-Plate Fin 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.

  • Page 70: Cleaning

    Ultra IOM Cleaning Although cleaning of in situ condensers is a difficult process, it may be necessary in extreme circumstances. Fouling of a condenser can be corrected by chemical cleaning, reverse flushing or a combination of both. Both procedures will require temporarily disconnecting the condenser on the water side and preforming these procedures.

  • Page 71: Type L Copper Tubing Internal Volume

    Ultra IOM Type L Copper Tubing Internal Volume Table 21 Type L Copper Tubing Internal Volume Volume per Foot Volume per 100 Feet Nominal Tubing Tubing OD Size of Tubing, of Tubing, Inches (mm) Inches (mm) Gallons (Liters) Gallons (Liters) 1/2 (12.7)
  • Page 72 Ultra IOM CAUTION: Risk of using the wrong type of glycol can cause piping damage, coolant fluid leaks, and catastrophic and expensive building and equipment damage. Do not use automotive antifreeze as it contains chemicals that can damage the piping system.

  • Page 73: Important Refrigeration Components

    Interior Permanent Magnet (IPM) design to provide higher efficiency. 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.

  • Page 74: Oil Level

    Ultra IOM 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.

  • Page 75: Local Control For Charging

    Ultra IOM 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 ...

  • Page 76: Vfd Parameter Settings

    Ultra IOM • 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. VFD Parameter Settings The VFD parameters can be setup from the Local Control Panel (LCP) on the face of the VFD.

  • Page 77: Vfd Parameter Settings - Danfoss Cds-803 Drive (22 Kw Ultra Units)

    Ultra IOM VFD parameter settings - Danfoss CDS-803 Drive (22 kW Ultra units) Figure 17 CDS-803 Drive P/N 101-260-230 or 460-VFD (22 kW Ultra units) Menu ID Description Setting 3.** Reference / Ramps 3.0* Reference Limits 3-02 Minimum Reference 30 Hz 3.4* Ramp 1...

  • Page 78: Vfd Parameter Settings - Danfoss Cds-303 Drive (36 To 125 Kw Ultra Units)

    Ultra IOM VFD parameter settings - Danfoss CDS-303 Drive (36 to 125 kW Ultra units) Figure 18 CDS-303 Drive P/N Various (36 to 125 kW Ultra units) Menu ID Description Setting 3.** Reference / Ramps 3.4* Ramp 1 3-41...

  • Page 79: Program Danfoss Cds-303 Vfd For Modbus Communication

    Ultra IOM Figure 19 Danfoss Model CDS-803 Modbus Point List for dap4 Index/Selection # Danfoss Settings Point Description [0][7] 16-03 Status Word [1][8] 16-05 Main Actual Value [2][14] 16-14 Motor Current [3][6] 16-02 Reference (%) [4][10] 16-10 Power (KW)

  • Page 80: Programming Cds303 Vfds With Mcb105 Relay Card

    Programming CDS303 VFDs with MCB105 Relay Card Instructions to cover the programming for the Danfoss CDS303 series VFDs with MCB105 Relay Cards installed for gForce Ultra units. NOTE: The CDS803 VFDs for the 22kW products do NOT need to be programmed because they are already default programmed to these parameters.
  • Page 81 Ultra IOM • Press the main menu button on the VFD display to bring up the menu options. • Navigate to Menu 5, titled “Digital In/Out” and press Enter.
  • Page 82 Ultra IOM • Scroll down to Option 5-4, titled “Relays” and press Enter. • Scroll down to “Optional relay 7” and press Enter. • Program Option 5-40, titled “Function Relay” to “[9] Alarm” and press Enter.

  • Page 83: Setting Pcoe And C.pcoe Expansion Modules

    Ultra IOM Setting pCOe and c.pCOe Expansion Modules The Carel pCOe or C.pCOe expansion modules has two sets of DIPs switches used to set the Serial Protocol and Address. When received, the Carel factory default position for all DIP switches is OFF (Up) position.

  • Page 84: C.pcoe Expansion Module P/N 160-700-016

    Ultra IOM c.pCOe Expansion Module P/N 160-700-016 Make sure Ext- Baud- Port DIP switches are all in OFF (Up) position, if they are not, change them to Up position as shown in picture below. Next, set all the Address DIP switches to the ON (Down) position as shown in picture below for address...

  • Page 85: Remote Heat Exchangers

    Ultra IOM Remote Heat Exchangers Most of the controls on remote condensers, condensing units or fluid coolers consist of basic electromechanical type components. Remote heat exchangers have a separate User Manual which gives complete details on adjusting thermostat settings, etc. Also refer to section 3.6 Heat Exchanger...
  • Page 86 Ultra IOM It is desirable to use the energy saver mode as much as possible. However, fluid temperature that is too cold can cause excessive dehumidification and coil sweating. Fluid temperature that is too high can also cause the indoor space temperature to rise. This could cause the evaporator’s microprocessor control to lock out the energy saver mode for one hour while it reverts to compressor (mechanical) cooling.

  • Page 87: Controls

    CONTROLS dap4 Microprocessor Controller The standard controller on all gForce Ultra GU equipment is the dap4 microprocessor controller. The controller includes a main microprocessor controller and a unit mounted display. Normal functions and service diagnostics is accessed by the unit mounted graphic touch display (dap4Touch). The controller...

  • Page 88: Gforce Ultra Settings

    Ultra IOM gForce Ultra Settings: dap4 Settings for Ultra Units Must enter Universal Security Access password 1739 to adjust these parameters Data Aire Settings: Enter Model: Ultra gForce Start-up Charging: 22kW 36-45kW 70, 91, 125kW VFD Type: CDS-803 CDS-303...
  • Page 89 Ultra IOM dap4 Settings for Ultra Units Variable Compressor 1: Band: 18.0F (Default) Integration Time: 1000s (Default) Derivative: 0 (Default) C1 Offset: 2.0F (Default) C1 Off Delay: 60s (Default) Minimum Speed: 1500 RPM Maximum Speed: 6000 RPM NOTE: When Analog Output Config: Optional Output #2 is changed, these speeds must be changed proportionally.
  • Page 90 Ultra IOM dap4 Settings for Ultra Units h. Water Valve Settings: Water Valve: None (Default) E-Saver Assist: Aux Chill Wtr or Engy Svg Cool Wtr Vlv Action: Direct (Default) Wtr Vlv Voltage: 0-10 E/S Startup Time: 0s (Default) E/S Lockout Time:...
  • Page 91 Ultra IOM dap4 Settings for Ultra Units Number of Fans: (Default) Fan K-Factor: (Default) Minimum Flow: 2000 CFM (Default) Maximum Flow: 32000 CFM (Default) Set Point: 15000 CFM (Default) Fan Flow Tuning PID - This screen will display if Display Airflow is selected...
  • Page 92 Ultra IOM dap4 Settings for Ultra Units Comp Envelope Alarm: Envelope Protect: Yes (Default) (Air-cooled Only) Start-Up Delay: 100s (Default) Run Outside Delay: 1s (Default) Max Number Alarms: 3 (Default) In 1 (Default) day, to Lock-out Pump-Down Alarm: Failed PD Alarm:...
  • Page 93 Ultra IOM dap4 Settings for Ultra Units h. Digital Input: Dirty Filter Switch Channel: ID8 (Default) Action: Closed (Default) Delay: 5s (Default) Status: Open Info Only Based on Sw State Digital Input: Humidifier Fault Sw Channel: ID9 (Default) Action:...
  • Page 94 Ultra IOM dap4 Settings for Ultra Units Digital Input: Manual Override Channel: ID18 (Default) Action: Closed (Default) Delay: 5s (Default) Status: Open Info Only Based on Sw State Analog Input: Humidity Sensor: Enable: On (Default) Channel: U01 (Default) Normal:...
  • Page 95 Ultra IOM dap4 Settings for Ultra Units Optional Sensor #2: Choose Name: Enable: Off (Default) Channel: U03 (Default) Normal: 4-20mA (Default) Minimum: 0.0 (Default) Maximum: 1000 (Default) Offset: 0.0F (Default) Value: 0.0F (Reading, not a setting) aa. Optional Sensor #3:...

  • Page 96: Electronic Expansion Valve Drive (Edv)

    This guide is not intended to be used as a means of altering the values which are set at the factory. Any changes made must be first discussed with a Data Aire trained technician. Figure 22 Typical EVD Display View...

  • Page 97: Configuration Menu

    Ultra IOM Configuration Menu WARNING: These menu screens are factory settings and are intended to be viewed only, not to be changed. If any values are different than shown here, please consult with Data Aire’s Service Department. Configuration Menus...

  • Page 98: Regulation Menu

    Ultra IOM Configuration Menus Regulation Menu Regulation Menus Valve position In stand-by and at start-up varies based on cooling type: Air-Cooled units Valve opened In stand-by * = 0 Air-Cooled units Valve position In stand-by ** = 0% Air-Cooled units Valve position at start-up *** = 50%...
  • Page 99 Ultra model: • For GUXX-022XX and GIXX-022XX units, the MOP is set to 67.0°F For all other gForce Ultra units (GUXX- 036XX, -045XX, -070XX, -091XX and - 125XX) the MOP is set to 59.0°F Only used for Manual control...

  • Page 100: Manually Open And Close The Eev

    Ultra IOM Manually Open and Close the EEV Follow the previous screens to the Regulation Menu screen. Change “Enable manual valve position” from 0 to 1 and “Manual valve position from 0stp to a desired step value. There are 480 steps total for the EEV. So, if you would like the valve to open 62.5%, enter “300stp”...

  • Page 101: Multiple Eev Configuration

    Ultra IOM Multiple EEV Configuration For single circuit units, there will be one EEV and it will be shown as valve A. The letter “A” will be displayed on the top right corner of the EVD display screen, near the “ON” status. For a dual circuit unit, there will be two EEVs and the second valve will be displayed as valve B.

  • Page 102: Regular Maintenance Items

    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. The operating life of the equipment can be extended by following a simple preventive maintenance schedule.

  • Page 103: Daily Maintenance

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

  • Page 104: Downflow Unit Filter Replacement Procedure

    All side panels must remain closed when determining if an adjustment is necessary. In general on Data Aire gForce floor units, the filters are removable from the front of the unit unless otherwise specified.

  • Page 105: Upflow Unit Filter Replacement Procedure

    Ultra IOM Upflow Unit Filter Replacement Procedure • Turn OFF the disconnect switch to all remote electric facility power to the unit with the external disconnect. • Open the front access door(s) and remove the filters by lifting them up and maneuvering the filter downward and out of the unit.

  • Page 106: Cylinder Spent Fault

    Failure to replace the cylinder at the end of cylinder life will result in improper operation and may result in damage to the humidifier. Data Aire is not responsible for any damages resulting from, or attributed to, the failure to replace a spent cylinder.

  • Page 107: Coil Drain Pan

    Ultra IOM See the humidifier manufacturer’s instructions is included with the paperwork placed inside the unit when it ships for: • Further information regarding removing the humidifier cylinder. • Drain valve cleaning • Installing the new cylinder • Preparing humidifier for extended shutdown duration •...

  • Page 108: Coils

    Ultra IOM 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 109: Refrigerant Filter Drier

    Ultra IOM Refrigerant Filter Drier Factory installed refrigerant filter driers do not normally require maintenance. When replacing compressors or other repairs that open the refrigeration system to atmosphere, it is advisable to replace the filter drier. The equivalent type and size should be used.

  • Page 110: Fuses

    Ultra IOM 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 regarding 1) amperage, 2) voltage, and 3) speed.

  • Page 111: Ec Motor Testing

    Ultra IOM WARNING: The plug fan modules are powered by high voltage input line power (i.e. 208-230V/3PH/60HZ or 460V/3PH/60HZ). Do not carry out any work on electrically live parts. Even after disconnection, the de-link circuit is still live. Always wait at least 3 minutes.

  • Page 112: Current Sensing Switch Adjustment

    The current sensing relay is set at the factory and does not normally require adjustment in the field. If the unit speed operating mode is change in the field, the current sensing switch may require the no airflow alarm to be adjusted. Contact Data Aire Service for instructions regarding current sensor adjustment.

  • Page 113: Maintenance/Inspection Checklist

    Ultra IOM 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) ☐...
  • Page 114 Ultra IOM 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 Condensate Pan and Pump (if equipped) ☐...
  • Page 115 Ultra IOM MAINTENANCE/INSPECTION CHECKLIST (NOTE: Maintenance/inspection items are monthly unless otherwise specified.) Air-Cooled Condenser, Condensing Unit, or Fluid Cooler (Dry Cooler) (if applicable) Fluid Cooler (if applicable) ☐ Inspect coil/clean if required ☐ Inspect coil/clean if required ☐ Inspect motor/motor mounts ☐...

  • Page 116: Frequently Asked Questions (Faq)

    Answer: In general it is +/- 10% but refer to Electrical Section for more details. 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.

  • Page 117: Mechanical Faq Section

    Question 2: How much clearance around my Data Aire unit is required for servicing? Answer: Data Aire recommends a minimum of 36” on the front and two sides of floor-mounted units. Units with EC motor and plug fans require 40” on the front and two sides.
  • Page 118 Ultra IOM Answer: Yes, trapping is required on both the discharge and/or suction lines. See section 2.11 Air- cooled Unit Piping. for more information. Question 4: How much steam is generated by the Condair (previously known as Nortec) humidifier? Can it be adjusted? Answer: The amount of steam generated depends on the model of humidifier you have in your unit.
  • Page 119 Ultra IOM All electrode steam humidifier can be adjusted. The capacity adjustment potentiometer can adjust the capacity of the humidifier between 100% and 20% of its rated output. The factory default setting is 60% of capacity. Question 5: Is an air vent valve required in the piping when an expansion tank is used? Answer: Yes, air vents must be installed in various locations in the piping system to purge air and are required at the highest point in the piping system.

  • Page 120: Contact Data Aire

    Ultra IOM CONTACT DATA AIRE Address: Data Aire, Inc. 230 West Blueridge Avenue Orange, CA 92865 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:...
  • Page 121 Condensate Pump ....32, 34, 42, 107 Humidifier ........105, 113, 115 Condensate Trap .......... 33 Humidifier Piping ........... 35 Contact Data Aire ....36, 102, 106, 112 Inspection ............10 Controls............113 Installation ....... 14, 19, 21, 26, 33, 36 Corrosion Protection ........
  • Page 122 INDEX Out of Envelope Alarm ........59 Return Air Plenum ......... 20 Outside Air ............ 15 Rigging ............ 15, 18 Paperwork ............. 11 Safety Relief Devices ........62 Password ............87 Service Access ........15, 19 Phase Check ..........51 Short Circuit Current Rating (SCCR) ...
  • Page 123 gForceUltraIOM_11-2022.docx...

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