Data Aire gForce Ultra - 6. Glycol Systems; 6.1 Glycol Concentration; 6.2 Internal (Fluid) Volume - Downflow Units; 6.3 Internal (Fluid) Volume - Upflow Units

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gForce 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.

Main Page

Table of Contents3
Introduction9
Product Information9
Model Identification10
Inspection10
Paperwork11
Storage11
Suggested Reference Storage Room Conditions11
General Storage Considerations12
Registered Trademarks - Copy Rights - References Section12
Installation13
Recommended Tools for Installation14
Pre-Installation14
Installation Must be Planned so that14
Room Considerations15
Equipment Handling and Rigging15
Door and Rear Panel Removal16
Figure 1 Typical Upper Spring-Loaded Hinge16
Rear Panel17
Moving Unit into Final Location17
Figure 2 Upper Hole for Spring-Loaded Hinge17
Figure 3 Lower Fixed Pin Hinge17
Rigging18
Figure 4 Example of Lifting Method18
Locating the Unit19
Downflow Units19
Upflow Units20
Figure 5 Typical Return & Discharge Air Distribution20
Piping21
Air-Cooled Unit Piping22
Discharge Lines22
Figure 6 Typical Check Valve23
Liquid Lines24
Recommended Line Sizing, Air-Cooled Units24
Table 1 Line Size Metric Conversion24
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
Connection Sizes, Air-Cooled Units25
Table 5 Liquid Lines (Dual Circuit Systems)25
Table 6 Air-Cooled Units Connection Sizes25
Field Piping, Remote Condenser above Evaporator26
Figure 7 Typical Remote Condenser above Evaporator Installation26
Field Piping, Remote Condenser below Evaporator27
Figure 8 Typical Remote Condenser below Evaporator27
Refrigerant Piping Protection28
Water/Glycol Cooled Unit Piping29
Factory Charge for Water/Glycol Cooled System30
Connection Sizes, Water/Glycol Cooled Units30
Table 7 Water/Glycol Cooled Units Connection Sizes30
Field Piping, Water/Glycol System31
Figure 9 Typical Water/Glycol System31
Connection Sizes, Fluid Coolers (Dry Coolers)32
Auxiliary Chilled Water/Energy Saver Coil Piping32
Condensate Drain System32
Condensate Trap33
Figure 10 Recommended Condensate Trap Dimensions34
Auxiliary Chilled Water/Energy Saver Coil Piping35
Humidifier Piping35
Steam Generator Humidifier35
Leak Testing35
Electrical Installation36
Commissioning Information36
Electrical37
General Electrical Field Wiring Guidelines38
Electrical Service39
Nameplate Ratings39
Grounding39
Voltage Tolerance39
Three Phase Voltage Tolerance39
Single-Phase Voltage Tolerance40
Heat Exchanger Auxiliary Control Wiring40
Figure 11 Typical Remote Heat Exchanger Interconnection Points40
Table 8 Three Phase Voltage Tolerance40
Remote Shutdown41
Remote Alarm Contacts41
Figure 12 Typical Indoor Evaporator Interconnection Points41
Table 9 Remote Alarm Contacts Terminals41
Dap4 Controller42
Disconnect Switch (Optional)42
How to Open the Electrical Enclosure42
Condensate Pumps (Optional)42
Condensate Probe43
Water Sensing Cable (Optional)43
Remote Temperature and Humidity Sensors (Optional)43
Manual Override Switch Board44
Plug Fan Current Sensing Switch44
Figure 13 Manual Override Switch Board44
Wiring Diagrams45
Electronic Expansion Valve45
Electrical Connection to EEV45
Figure 14 EEV with Electrical Mating Connector45
Installation of Remote Outdoor Heat Exchanger46
Charging47
Charging/Installation Work Procedures47
Triple Evacuation and Dehydration Procedure47
Tools Needed48
First Stage Evacuation48
Second Stage Evacuation49
Third Stage Evacuation49
Final Evacuation Stage50
General Pre-Charging Guidelines50
Voltage Phase Check51
Evaporator Phase Check51
Fixed Speed Scroll Compressor Phase Check52
Variable Speed Compressor Phase Check52
Figure 15 Typical VFD to VS Compressor Wiring52
Heat Exchanger Phase Check53
Line Set Charge Calculations53
Component Functional Test53
Table 10 Liquid Line Multiplier53
Charging Procedures54
Refrigerant Handling54
Air-Cooled System Charging54
Pre-Charge Fixed Speed Compressor55
Table 11 Fixed Speed Compressor Pre-Charge R-410A55
Charging the Fixed Speed Compressor56
Additional Oil57
Table 12 Refrigerant Charge Values57
Pre-Charge Variable Speed Compressor58
Table 13 Variable Speed Compressor Pre-Charge58
Charging the Variable Speed Compressor59
Table 14 Refrigerant Charge Valves60
Flooded System Charging (Systems with Low Ambient Receiver Package)61
Low Ambient Receiver Package62
Figure 16 Typical Low Ambient Receiver Package64
Table 15 Refrigerant Receiver Charging Chart65
Table 16 Discharge Head Pressure65
Table 17 Packaged Units Without Receivers66
Table 18 Packaged Units with Receivers66
Additional Oil67
Commissioning a Running Compressor67
Glycol Systems68
Glycol Concentration68
Internal (Fluid) Volume68
Table 19 Ultra Downflow Unit Internal (Fluid) Volume68
Table 20 Ultra Upflow Unit Internal (Fluid) Volume68
Brazed-Plate Fin Condensers69
Water Treatment69
Scale Treatment69
Undissolved Solids (Turbid Water)69
Dissolved Products69
Cleaning70
Corrosion Protection70
Fluid Cooler70
Type L Copper Tubing Internal Volume71
Freezing Point of Aqueous Solutions71
Mixing Glycol and Water71
Table 21 Type L Copper Tubing Internal Volume71
Table 22 Freezing Point of Aqueous Solutions71
Important Refrigeration Components73
Variable Speed Compressor (VSC) Features73
Oil Management73
Crankcase Heaters73
Oil Level74
Variable Frequency Drive (VFD)74
Local Control for Charging75
To View the Drive Alarms75
VFD Parameter Settings76
VFD Parameter Settings - Danfoss CDS-803 Drive (22 Kw Ultra Units)77
Figure 17 CDS-803 Drive P/N 101-260-230 or 460-VFD (22 Kw Ultra Units)77
VFD Parameter Settings - Danfoss CDS-303 Drive (36 to 125 Kw Ultra Units)78
Programing the VFD for Modbus Communications78
Program Danfoss CDS-803 VFD for Modbus Communication78
Figure 18 CDS-303 Drive P/N Various (36 to 125 Kw Ultra Units)78
Program Danfoss CDS-303 VFD for Modbus Communication79
Figure 19 Danfoss Model CDS-803 Modbus Point List for Dap479
Programming CDS303 Vfds with MCB105 Relay Card80
Figure 20 Danfoss Model CDS-303 Modbus Point List for Dap480
Figure 21 Danfoss VFD MCB105 Relay Card80
Setting Pcoe and C.pcoe Expansion Modules83
Pcoe Expansion Module P/N 160-700-00883
C.pcoe Expansion Module P/N 160-700-01684
Remote Heat Exchangers85
High Pressure Cutout Switch85
Low Pressure Cutout Switch85
Liquid Line Solenoid Valve85
Energy Saver Cooling (Optional)85
Table 23 High Pressure Cutout Switch Setting85
Table 24 Low Pressure Cutout Switch Setting85
Controls87
Dap4 Microprocessor Controller87
Dap4 Factory Settings87
Dap4 Universal Security Access87
Gforce Ultra Settings88
Electronic Expansion Valve Drive (EDV)96
Setup Using Display Panel Guide96
Figure 22 Typical EVD Display View96
Configuration Menu97
Regulation Menu98
Manually Open and Close the EEV100
Multiple EEV Configuration101
Regular Maintenance Items102
Service Vs. Maintenance102
General Maintenance Requirements102
Daily Maintenance103
Maintenance/Inspection Checklist103
Air Filters103
Downflow Unit Filter Replacement Procedure104
Upflow Unit Filter Replacement Procedure105
Electric Reheat Elements105
Humidifier105
Humidifier Canisters105
Cylinder Spent Fault106
Replacement Cylinder106
Removing the Cylinder106
Coil Drain Pan107
Condensate Pump107
Cabinet107
Exterior Cabinet Maintenance Cleaning107
Coils108
Coil Cleaning108
Piping108
Water/Glycol Cooled System108
Refrigerant Filter Drier109
Electrical Control Enclosure109
Fuses110
Fuse Replacement110
Plenum Plug Fans110
EC Motor Testing111
Current Sensing Switch Adjustment112
Maintenance/Inspection Checklist113
Frequently Asked Questions (FAQ)116
Electrical FAQ Section116
Mechanical FAQ Section117
Figure 23 Example Remote EPO Switch Connection117
Contact Data Aire120

Data Aire gForce Ultra - 6. Glycol Systems; 6.1 Glycol Concentration; 6.2 Internal (Fluid) Volume - Downflow Units; 6.3 Internal (Fluid) Volume - Upflow Units

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