Data Aire gForce Ultra Manual de usuario
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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 User Manuals for other components of your Data Aire precision
environmental cooling system including dap4™, condenser/condensing unit and uid cooler.
NOTE: This manual is intended to assist trained service personnel by providing
necessary guidelines for this particular equipment. Service to Data Aire units
should be done by qualied individuals with an adequate background in areas
such as HVAC, electrical, plumbing and electronics, as applicable.
WARNING: Service performed by unauthorized or unqualied technicians may
void manufacturers’ warranties and could result in property damage and/or per-
sonal injury.
NOTE: Special care should be given to those areas where
these symbols appear.
Data Aire, Inc. reserves the right to make design changes for the purpose of product
improvement or to withdraw any design without notice.
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Table of Contents
1. INTRODUCTION.......................................................................................................7
1.1 Product Information.............................................................................................7
1.2 Model Identication .............................................................................................8
1.3 Inspection............................................................................................................8
1.4 Paperwork ...........................................................................................................9
2. INSTALLATION ......................................................................................................10
2.1 Installation Checklist..........................................................................................10
2.2 Room Considerations........................................................................................10
2.3 Equipment Handling..........................................................................................10
2.4 Rigging ..............................................................................................................11
2.5 Locating the Unit ............................................................................................... 11
2.5.1 Downow Units...........................................................................................12
2.5.2 Upow Units................................................................................................12
2.6 Storage..............................................................................................................13
2.7 Piping ................................................................................................................13
2.7.1 Air Cooled Unit Piping.................................................................................14
2.7.2 Discharge Lines..........................................................................................14
2.7.3 Liquid Lines.................................................................................................15
2.7.4 Recommended Line Sizing, Air Cooled Units .............................................16
2.7.5 Connection Sizes, Air Cooled Units ............................................................17
2.7.6 Field Piping, Remote Condenser Above Evaporator ..................................17
2.7.7 Field Piping, Remote Condenser Below Evaporator ..................................18
2.7.8 Water/Glycol Cooled Unit Piping ................................................................18
2.7.9 Field Piping, Water/Glycol Cooled Units…………………………………… .19
2.7.10 Connection Sizes, Water/Glycol Cooled Units…………………………… …20
2.7.11 Conection Sizes, Fluid Coolers…………………………………………………20
2.7.12 Factory Charge for Water/Glycol Cooled Systems………………………….21
2.7.13 Auxiliary Chilled Water/Energy Save Coil Piping…………………………….21
2.8 Condensate Drain Piping ..................................................................................21
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2.9 Humidier Piping ...............................................................................................22
2.9.1 Steam Generator Humidier.......................................................................22
2.10 Leak Testing ......................................................................................................23
2.11 Evacuation.........................................................................................................23
3. ELECTRICAL CONNECTIONS ..............................................................................25
3.1 Electrical Service...............................................................................................25
3.2 Nameplate Ratings............................................................................................25
3.3 Grounding..........................................................................................................25
3.4 Voltage Tolerance..............................................................................................25
3.5 Auxiliary Control Wiring.....................................................................................26
3.6 Remote Shutdown.............................................................................................27
3.7 Remote Alarm Contacts ....................................................................................27
3.8 Condensate Pumps...........................................................................................28
3.9 Condensate Probe ............................................................................................28
3.10 Water Sensing Cable (Optional)........................................................................28
3.11 Remote Temperature and Humidity Sensors (Optional)....................................28
3.12 Manual Override Switches ................................................................................29
3.13 Wiring Diagrams................................................................................................29
3.14 EEV Connection................................................................................................30
4. INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ..........................31
5. CHARGING.............................................................................................................31
5.1 General Charging Guidelines............................................................................31
5.2 Triple Evacuation...............................................................................................32
5.3 Voltage Phase Check ........................................................................................33
5.4 Air Cooled System Charging.............................................................................33
5.4.1 Constant Speed Compressor .....................................................................33
5.4.2 Variable Capacity Compressor ...................................................................34
5.5 Flooded System Charging.................................................................................38
5.5.1 Constant Speed Compressor .....................................................................38
5.5.2 Variable Capacity Compressor ...................................................................44
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5.6 Water/Glycol System.........................................................................................48
5.7 Check a Running Compressor ..........................................................................49
5.8 Refrigerant Handling .........................................................................................49
5.9 Commissioning..................................................................................................49
5.10 Important Refrigeration Components ................................................................50
5.10.1 Variable Capacity Compressor with VFD....................................................50
5.10.2 Electronic Expansion Valve ........................................................................50
5.10.3 High Pressure Cutout Switch......................................................................50
5.10.4 Low Pressure Cutout Switch.......................................................................50
5.10.5 Liquid Line Solenoid Valve..........................................................................51
6. GLYCOL SYSTEMS................................................................................................52
6.1 Glycol Concentration.........................................................................................52
6.2 Internal (Fluid) Volume – Downow Units .........................................................52
6.3 Internal (Fluid) Volume – Upow Units ..............................................................52
6.4 Internal (Fluid) Volume – Fluid Coolers .............................................................53
6.4.1 Fluid Cooler Information .............................................................................53
7. VARIABLE SPEED COMPRESSOR ......................................................................54
7.1 Features ............................................................................................................54
7.2 Oil Management................................................................................................54
7.3 Crankcase Heaters............................................................................................54
7.4 Oil Level ............................................................................................................54
7.5 VFD Drive..........................................................................................................54
7.5.1 Local Control for Charging..........................................................................56
7.5.2 View Drive Alarms.......................................................................................57
8. CONTROLS ............................................................................................................58
9. REGULAR MAINTENANCE ITEMS ....................................................................59
9.1 Air Filters ...........................................................................................................59
9.2 Fuses.................................................................................................................60
9.3 Electric Reheat..................................................................................................60
9.4 Humidier ..........................................................................................................60
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9.4.1 Humidier Canisters ................................................................................60
9.5 Refrigerant Filter Drier.......................................................................................60
9.6 Current Sensing Relay ......................................................................................60
9.7 Plug Fans ..........................................................................................................61
9.7.1 Electronically Commutated Motors..........................................................61
9.7.2 Testing .....................................................................................................61
10. MAINTENANCE/INSPECTION CHECKLIST ......................................................61
11. CONTACT DATA AIRE.........................................................................................62
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1. INTRODUCTION
1.1 Product Information
The Data Aire gForce Ultra environmental control, direct expansion, single and dual circuit Computer
Room Air Conditioner (CRAC) equipment provides a high sensible cooling, is self-contained, factory
assembled, piped, wired, and factory tested prior to shipment. These units include an enclosure/cabinet
assembly, fan section, lter section, cooling coil, controls, and interconnecting piping internal to unit.
The Data Aire CRAC unit provides cooling, reheat, humidication, dehumidication and air ltration.
The unit is provided with a Data Aire dap4™ microprocessor controller for precision control. The unit
must be operated in a conditioned space within the operating envelope ASHRAE recommends for data
centers. Maximum dew point is 59°F (15°C). Operating outside this envelope can alter the operat-
ing performance and decrease equipment reliability. Return air to the unit must be no cooler than the
ASHRAE recommendation of 68°F (20°C) DB and 40% RH or minimum WB of 54°F (12.2°C) for proper
unit operation. Operating below this can alter the operating performance and decrease equipment reli-
ability. 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 eciency is continuous; eciency benchmarks are always moving up. That’s why
Data Aire is moving toward variable capacity compressor technology for quieter, more energy-saving
performance. Conventional compressors are designed to run at constant speed to handle a given
capacity requirement. But in data center applications, the capacity requirement varies. In these situ-
ations, a constant speed compressor uses various capacity-regulation techniques and can be less ef-
cient than a compressor utilizing variable capacity technology. A variable capacity compressor (VCC),
on the other hand, saves energy and operates more quietly by varying speed to match the workload.
Tests with VCC compressors have shown an immediate energy savings and sound level reductions.
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1.2 Model Identication
1.3 Inspection
This Data Aire CRAC unit has been factory run-tested and has gone through a comprehensive inspec-
tion prior to its packaging and shipment to ensure that it arrives in excellent condition. However, ship-
ping damage can occur and a visual inspection of the outer crating immediately upon delivery should be
performed. Upon arrival of the unit and before unpacking it, verify that the labeled equipment matches
the bill of lading.
Note: any external damage or transportation damage on the freight carrier’s
forms. Inspect the unit itself for internal damage. A claim should be led with
the shipping company if the equipment is damaged or incomplete.
Loose items such as remote control panels, disconnect switch handles, and spare air lters are packed
inside the unit. Refer to the yellow shipping tag located on the unit door for details.
NOTE: Freight damage claims are the responsibility of the purchaser. Action
to recover losses should be led immediately. Please notify factory personnel
of any claims.
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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,
specic component literature, warranty registration cards and other valuable paperwork, including a
copy of this User Manual.
A yellow tag is attached to the outside decorative door to indicate articles that may have been packaged
and shipped loose within the unit cabinet. Typically this would be jackstands, condensate pumps and
other loose components that are not factory mounted.
WARNING: It is the responsibility of the installing contractor to return the start-
up sheet and warranty registration card to Data Aire for proper activation of the
unit warranty. Failure to do so may cause delays and some cases void the war-
ranty.
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2. INSTALLATION
NOTE: There is no intent on the part of Data Aire, Inc. to dene local codes
or statutes which may supersede common trade practices. The manu-
facturer assumes no responsibility for their interpretation. Consult local
building codes and National Electrical Code (NEC) for special installation
requirements.
2.1 Installation Checklist
As a precaution, review the following checklist to ensure proper operation:
Check for any damage
Check all wiring connections
Filters are properly positioned in air intake
WARNING: Before removing from the packaging inspect the unit for any
damage. Report any damage to the carrier and le a damage claim.
2.2 Room Considerations
Precision air conditioning equipment is designed to control spaces within close tolerances of tempera-
ture and humidity. However, the room must be built with a proper vapor barrier. A lm of polyethylene
is often used on walls and ceilings. Walls and oors must also be painted with vapor-seal paint. Fail-
ure to provide a vapor barrier can compromise space conditions.
Introduction of outside air into the space should be minimized. Outside air in excess of 5% of the total
circulated air volume can have a signicant eect on the overall space conditions and result in poor
space control.
Install the units as close as possible to the largest heat load.
2.3 Equipment Handling
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.
Move the unit in its upright position to the installation site using a forklift or pallet jack. It is recom-
mended that the unit be protected from damage to the decorative doors during any storage or moving.
Keep tines of the forklift level and at a height suitable to t below the skid and/or unit to prevent exterior
and/or underside damage. Make sure the forks are spread to their widest allowable width for proper
balance. Do not lift the unit any higher than 4 inches (100mm) o the ground. If necessary to lift high-
er than the suggested 4 inches (100mm), exercise great care to ensure proper handling of the unit.
Personnel not involved with the lifting of the unit should keep a safe distance from the unit.
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