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Data Aire gForce Ultra User Manual

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133 pages
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User Manual
DX, Single and Dual Circuit
36, 45, 56, 70 and 106 kW
Air and Water/Glycol Cooled

Table of Contents

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Data Aire gForce Ultra Specifications

General IconGeneral
RefrigerantR-410A
Compressor TypeScroll
Control SystemMicroprocessor-based
EfficiencyHigh efficiency
Voltage Options208/230/460V, 3-phase
ApplicationData center cooling
Heating CapacityOptional electric or hot gas reheat

Summary

1. Introduction

1.1 Product Information

Details the Data Aire gForce Ultra CRAC equipment features, including its cooling, reheat, humidification, and dehumidification capabilities.

1.2 Model Identification

Explains the structure of the gForce Ultra model number for clear identification of unit specifications and features.

1.3 Inspection

Provides guidelines for inspecting the unit upon delivery to check for any external damage before unpacking.

1.4 Paperwork

Lists the essential documents included with the unit, such as startup sheets and warranty information.

2. Installation

2.1 Installation Checklist

A pre-installation checklist to ensure all necessary steps are reviewed for proper unit operation.

2.2 Room Considerations

Guidelines for preparing the installation space, including vapor barriers and minimizing outside air.

2.3 Equipment Handling

Safe procedures for moving, lifting, and preparing the unit for installation.

2.4 Rigging

Instructions for rigging and moving the unit safely, including skid and spreader bar usage.

2.5 Locating the Unit

Guidance on optimal unit placement for airflow, service access, and heat load proximity.

2.6 Storage

Procedures and precautions for storing the unit before installation to prevent damage.

2.7 Piping

General practices for proper piping installation, including oil return and vibration control.

2.8 Condensate Drain Piping

Instructions for installing the condensate drain line, including trap requirements and slope.

2.9 Humidifier Piping

Details on connecting the water supply to the humidifier unit.

2.10 Leak Testing

Procedures for thoroughly checking the refrigeration system for leaks before charging.

2.11 Evacuation

Steps for evacuating the system to remove moisture and air for optimal operation.

3. Electrical Connections

3.1 Electrical Service

Guidance on verifying the adequacy of the electrical service supply for the unit.

3.2 Nameplate Ratings

How to read and understand the unit's electrical specifications on the nameplate.

3.3 Grounding

Requirements for ensuring proper and continuous earth ground connection for the unit.

3.4 Voltage Tolerance

Specifies acceptable voltage supply variations and phase imbalance limits.

3.5 Auxiliary Control Wiring

Instructions for wiring remote components like condensers and fluid coolers.

3.6 Remote Shutdown

Connecting external dry contacts or switches for remote unit shutdown.

3.7 Remote Alarm Contacts

Details on accessing and utilizing the control panel's remote alarm output contacts.

3.8 Condensate Pumps

Information on optional condensate pumps, including factory-mounted and loose configurations.

3.9 Condensate Probe

Instructions for installing the standard condensate probe for water detection.

3.10 Water Sensing Cable (Optional)

Details on the optional water detection cable for sensing moisture.

3.11 Remote Temperature and Humidity Sensors (Optional)

Information regarding the installation of optional remote sensors for environmental monitoring.

3.12 Manual Override Switches

Using manual slide switches for testing and startup of unit components.

3.13 Wiring Diagrams

Locating and understanding the ladder-type schematics for electrical troubleshooting.

4. Installation of Remote Outdoor Heat Exchanger

5. Charging

5.1 General Charging Guidelines

Fundamental principles for safely and accurately charging the system with refrigerant.

5.2 Voltage Phase Check

Procedure to verify correct voltage phasing for unit components like compressors and fans.

5.3 Air Cooled Systems

Specific guidelines and procedures for charging air-cooled refrigeration systems.

5.4 Water/Glycol System

Instructions for charging water or glycol-cooled systems, referring to unit nameplate.

5.5 Check a Running Compressor

Methods for checking compressor operation, oil level, and vibration post-charging.

5.6 Refrigerant Handling

Regulations and practices for safe recovery, recycling, and handling of refrigerants.

5.7 Commissioning

Monitoring system operation after initial startup to ensure correct performance characteristics.

5.8 Important Refrigeration Components

Overview of key refrigeration system components and their functions.

6. Glycol Systems

6.1 Glycol Concentration

Importance of proper glycol concentration for freeze protection and corrosion prevention.

6.2 Internal (Fluid) Volume – Downflow Units

Table detailing the internal fluid volume for downflow evaporator units.

6.3 Internal (Fluid) Volume – Upflow Units

Table detailing the internal fluid volume for upflow evaporator units.

7. Variable Speed Compressor

7.1 Features

Highlights the benefits of variable capacity compressor technology for efficiency and quiet operation.

7.2 Oil Management

Procedures and system functions to ensure adequate oil return to the compressor.

7.3 Crankcase Heaters

Explains the role of crankcase heaters in preventing refrigerant migration.

7.4 Oil Level

Guidance on checking and maintaining the correct oil level in the compressor sight glass.

7.5 VFD Drive

Overview of the Variable Frequency Drive (VFD) and its energy-saving advantages.

8. Controls

8.1 dap4™ Microprocessor Control Panel

Introduction to the dap4™ control panel, its components, and basic operation.

8.1.1 Control Module

Details about the control module, a main component of the dap4™ system.

8.1.2 Display Module

Details about the display module, featuring an LCD screen for unit status.

8.1.3 Buttons

Description of the six keys on the display panel used for navigation and input.

8.1.4 Accessing Menus/Passwords

Procedure for entering menus and the initial service level password.

8.1.5 Changing the Service Level Password

Step-by-step instructions on how to modify the unit's service level password.

8.2 Entering Menu Settings

General notes on navigating menu screens and applicability to the gForce Ultra unit.

8.2.1 Menu A – ON/OFF

Instructions for powering the unit ON or OFF using the control panel menu.

8.2.2 Menu B - Setpoints

How to view and adjust temperature, humidity, and superheat setpoints.

8.2.5 Menu E – Historical Data

Accessing logs for alarms, component runtime hours, and resetting runtimes.

8.2.6 Menu F – Information

Viewing unit identification details, processor version, and data.

8.2.7 Menu G – Network Config

Configuring network communication protocols like MODBUS and BACnet.

8.2.8 Menu H – Calibrate Sensors

Procedure for calibrating installed unit sensors for accurate readings.

8.2.9 Menu I – Manual Control

Operating individual unit components manually for service and testing.

8.2.10 Menu J – Factory Settings

Accessing factory-configured settings, typically for qualified personnel only.

8.2.11 Menu K – Alarms & Limits

Configuring control alarms, operational limits, and alarm messages.

8.2.12 Menu L – Configure I/O

Setting up unit inputs and outputs, requiring factory password access.

8.2.13 Zone Master

Information regarding the optional Zone Master control system.

8.3 Secondary Heat Exchangers

Overview of controls for secondary heat exchangers and related components.

9. Control Logic

9.1 Fan Control Logic

Describes the six different fan speed control modes available in DX logic.

9.2 Compressor

Details the compressor control modes based on return air or discharge air temperature.

9.3 Safeties and Alarms

Explanation of safety features and alarm conditions for the variable speed compressor.

9.4 Dehumidification Mode

Overview of the dehumidification modes and control strategies.

10. Regular Maintenance Items

10.1 Air Filters

Guidance on inspecting, cleaning, and replacing air filters for optimal unit performance.

10.2 Fuses

Information on troubleshooting and replacing fuses, especially during voltage inconsistencies.

10.3 Electric Reheat

Maintenance recommendations for the electric reheat elements.

10.4 Humidifier

Maintenance overview for the steam generator type humidifier.

10.5 Refrigerant Filter Drier

Guidance on when to replace the refrigerant filter drier.

10.6 Current Sensing Relay

Adjustment and function of the current sensing relay for detecting airflow.

10.7 Plug Fans

Maintenance information for Electronically Commutated (EC) motors and plug fans.

11. Recommended Line Sizing

11.1 Hot Gas Lines – Single Circuit Units (Up To 200 Equivalent Feet (61 m))

Table providing recommended line sizes for hot gas lines on single circuit units.

11.2 Hot Gas Lines – Dual Circuit Units (Up To 200 Equivalent Feet (61 m))

Table providing recommended line sizes for hot gas lines on dual circuit units.

11.3 Liquid Lines – Single Circuit Units (Up to 200 Equivalent Feet (61 m))

Table providing recommended line sizes for liquid lines on single circuit units.

11.4 Liquid Lines – Dual Circuit Units (Up to 200 Equivalent Feet (61 m))

Table providing recommended line sizes for liquid lines on dual circuit units.

13. Maintenance/Inspection Checklist

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