DATA AIRE SERIES Operation and Maintenance Manual DX 6-30 ton Air and Water/Glycol Cooled
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. 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 qualified individuals with an adequate background in areas such as HVAC, electrical, plumbing and electronics, as applicable.
Table of Contents 1.0 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.5 1.6 INSTALLATION .................................................................................................. 6 Room Considerations ............................................................................................ 6 Inspection .............................................................................................................. 6 Rigging ............................................................................................
Table of Contents, cont’d 4 4.0 4.1 4.2 4.3 4.4 4.5 4.5.1 4.5.2 4.6 4.6.1 4.6.2 INSTALLATION OF REMOTE HEAT EXCHANGER ......................................... 18 Rigging ................................................................................................................ 18 Leg Assembly ...................................................................................................... 18 Locating the Remote Heat Exchanger ................................................................
Table of Contents, cont’d 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 REGULAR MAINTENANCE ITEMS .................................................................. 28 Filters................................................................................................................... 28 Belts .................................................................................................................... 28 Bearings ................................................................................................
1.0 INSTALLATION 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 the National Electrical Code for special installation requirements. 1.1 Room Considerations Precision air conditioning equipment is designed to control spaces within close tolerances of temperature and humidity.
the casters may be inserted directly into the bottom of the 1” tubular steel corner posts at the bottom of the unit. Warning: Improper lifting or moving of equipment may result in damage to decorative doors, panels or frame members. 1.4 Locating the Unit When installing the unit, sufficient space must be allowed for airflow clearance, wiring, plumbing, and service access.
1.4.2 Upflow Units Upflow units will typically be supported by vibration isolation pads and/or floorstands which may also include leveling screws. An air discharge plenum may be factory provided which ships loose and must be attached at the top of the unit frame. Alternately, an air distribution plenum must be field fabricated with supply grilles to distribute the air. Units are shipped with a drive package to overcome external static pressure.
2.0 PIPING 2.1 Air Cooled Unit Piping Refer to the attached line sizing chart on page 32 for a guideline for sizing refrigerant lines. The ultimate responsibility for line size selection is that of the installing contractor or project engineer. Data Aire does not assume this responsibility. The chart covers distances up to 200 equivalent feet. For installations beyond this distance, consult ASHRAE or similar references.
2.1.3 Suction lines Some applications call for the compressor(s) to be mounted as part of condenser (more commonly referred to as a condensing unit). Condensing units require field piping of liquid and suction lines. Suction lines are trapped similarly to discharge lines. Common practice for suction line selection and installation should be followed. Suction line should always be insulated. 2.1.
2.1.6 Field Piping, Remote Condensing Unit One Circuit Shown 2.2 Water/Glycol Cooled Unit Piping The required filed installed fluid cooler pipe sizes may or may not be the same as the connection sizes at the fluid cooler. (Refer to 2.2.2 and 2.2.3 for connection sizing). This will depend on the length of pipe and the calculated pressure drop of peripheral components. Water cooled units may also be connected to building water or tower water sources.
2.2.1 Field Piping, Glycol System (Field Provided) 2.2.
2.3 Auxiliary Chilled Water Coil Piping Units with an 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 on the chart in Section 2.2.2. Units with an Energy Saver cooling coil have shared piping with the condenser supply and therefore do not require a separate water source. All chilled water pipes have a cap installed on the end of the pipe for pressure testing the system.
2.6 Leak Testing No installation is complete until the entire system has been thoroughly checked for leaks. This includes checking refrigerant tubing, flare fittings, pressure controls, Shrader fittings and compressor rota-lock service valves. In addition to the refrigeration system, check all condenser water lines, humidifier makeup lines, condensate lines, condensate pumps, chilled water lines, centrifugal pumps, and fluid coolers as applicable.
3.0 ELECTRICAL CONNECTIONS Before proceeding with the electrical connections, make certain that the volts, hertz, and phase correspond to that specified on the unit electrical nameplate. Use copper conductors only. 3.1 Electrical Service Check to be sure the service provided by the utility is sufficient to handle the additional load imposed by this equipment. Most units with secondary heat exchangers will require a separate power source and field-provided, interconnecting control wires. See section 3.
3.6 Remote Shutdown Every Data Aire evaporator has remote shutdown contacts. These are intended for a field supplied dry contact or switch to be wired across two terminals. When the contact or switch opens, the control circuit power is interrupted and the unit shuts down, including the control panel. The control circuit is 24 VAC and the field provided contact or switch should have a minimum rating of 10 amps.
3.10 Condensate Probe A condensate probe for sensing under floor water is included with this unit. This comes in a plastic bag, with about 15 feet of coiled-up wire. The probe is a flat plate that is typically placed below the unit in a location where water is likely to accumulate. Place the probe flat on the floor on top of a thin layer of non conductive silicone. Secure the attached wires where necessary. A longer length of wire may be used if required.
4.0 INSTALLATION OF REMOTE HEAT EXCHANGER Air cooled condensers and fluid coolers have individual Selection Guide/Operation and Maintenance manuals which should be referred to for more complete details. 4.1 Rigging Secondary heat exchangers matched with evaporators of this size are typically remote, outdoor type. The heat exchanger should be moved to its (typically rooftop) mounting location using a crane or fork lift. Each fan section has heavy, steel leg supports with lifting holes at the top.
Noise factors should also be considered when locating an air cooled heat exchanger. Proximity to windows, walls and surrounding structures can cause objections by the occupants. An acoustical expert should be consulted when noise is of a particular concern. Air cooled heat exchangers should be placed at a level that is higher than the indoor evaporator. The mounting of the remote heat exchanger more than 10 feet below the evaporator is not recommended.
4.6 Fluid Coolers - Model DAFC 4.6.1 Fluid-Sensing Thermostats Fluid cooler fan motors are cycled on and off by individual water-sensing thermostats strapped to the leaving water header. The first fan motor will only have a thermostat if the unit has an Energy Saver Coil. Without the optional Energy Saver Coil, the first fan motor runs whenever there is a call for cooling via an auxiliary signal sent by the indoor evaporator (see Section 3.5).
5.0 CHARGING 5.1 Voltage Phase Check 5.1.1 Evaporator Prior to charging, the correct voltage phasing should be checked on the indoor evaporator. It is easiest to check the blower direction on the evaporator with standard poly-phase motors by momentarily moving the blower manual bypass switch located in the DAP-III control module to the ON position, then back to the OFF position (there is a Power ON/OFF switch above the blower bypass switch that must in the ON position before running the blower).
5.3 Air Cooled Systems 5.3.1 Fan Speed Control System Charging The standard air cooled condenser provided with Data Aire equipment has fan speed control on the lead motor (nearest the header). After the field refrigerant piping is properly completed connect the refrigerant drum to the low side and charge with vapor. (Refer to Section 2.6 LEAK TESTING and Section 2.7 EVACUATION prior to charging the system.
Open the high side valve on the manifold only and allow the refrigerant to flow until the system pressure equalizes. At this point the system will have 78-85% of the total refrigerant charge. Start the (evaporator) motor(s). Start the compressor(s) and check the operating pressures and temperatures. A quick and easy way to run the blower and compressor is using the manual switches on the unit’s microprocessor. Switch the blower and compressor manual switches to the ON position.
Adjust the refrigerant charge until the sight glass clears or has only sparse bubbles. The unit should be allowed to stabilize for several minutes before meaningful measurements can be taken and the conditioned room should be at or near the temperature setpoint. All water/glycol cooled units have a water regulating valve. A head pressure transducer is connected to a shraeder fitting on the discharge line and water is regulated into the condenser coil. Plate fin condensers are standard.
6.2 Internal (Fluid) Volume - Downflow Models Evaporator Model DAGD 06 DAGD 08 DAGD 10 DAGD 13 DAGD 16 DAGD 20 DAGD 26 DAGD 30 Without Energy Saver Coil Volume, Gallons 4.0 4.5 5.0 5.5 7.5 8.0 10.0 12.0 With Energy Saver Coil Volume, Gallons 9.1 9.6 10.1 10.6 16.3 16.8 18.8 22.9 6.3 Internal (Fluid) Volume - Upflow Models Evaporator Model DAGU 06 DAGU 08 DAGU 10 DAGU 13 DAGU 16 DAGU 20 DAGU 26 DAGU 30 Without Energy Saver Coil Volume, Gallons 4.0 4.5 5.0 5.5 7.5 8.0 10.0 12.
Fluid Cooler Model DAFC 37 DAFC 40 DAFC 44 DAFC 50 DAFC 57 DAFC 61 DAFC 75 DAFC 80 DAFC 88 DAFC 100 6.5 Internal Volume Volume, Gallons 13.0 16.3 16.2 20.3 24.6 19.6 26.0 32.6 32.4 40.6 Copper Piping Internal Volume Pipe Diameter inches 5/8 3/4 7/8 1-1/8 1-5/8 2-1/8 2-5/8 3-1/8 4-1/8 6.6 Freezing Point of Aqueous Solutions Ethylene Glycol % by Volume 0 10 20 30 40 50 26 Volume per 100 Feet of Pipe, Gallons 1.2 1.8 2.5 4.3 9.2 16.1 24.8 35.4 62.
7.0 CONTROLS 7.1 DAP© III Microprocessor Control Panel The standard controls on all Data Aire Series equipment is the DAP III microprocessor control panel. This state-of-the-art control panel has a separate manual that goes into extensive detail regarding functions, features, programming, and troubleshooting. The DAP III microprocessor control panel has an entire manual dedicated to its use and operation. This manual must be referenced to complete a thorough unit installation.
8.0 REGULAR MAINTENANCE ITEMS 8.1 Filters Filters should be checked on a regular basis and changed when they become dirty. This will ensure efficient operation of the unit. Although the unit has a dirty filter alarm, this should not be relied on as the only determinant for replacing filters. A maladjusted filter differential pressure switch may not give a proper indication of a clogged filter.
8.5 Fuses Fuses will 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 compressors and motors are inductive loads which require time delay fuses. Electric reheat and humidifiers are resistive loads requiring fast acting fuses. 8.
9.0 Warranty Policy Data Aire Inc. warrants your Data Aire environmental control unit to be free from defects in material and workmanship under normal use and service for a period of (18) eighteen months from date of shipment. Our obligation under this warranty shall be limited to repairing or replacing any part or parts, (F.O.B. Orange, California), of your Data Aire unit, which, in our judgment, shows evidence of defect within the period of time heretofore set forth.
10.0 Contact Data Aire Address: Data Aire Inc. 230 W. BlueRidge Avenue Orange, CA 92865 Phone 714-921-6000 800-347-AIRE (2473) Toll Free 714-921-6010 714-921-6011 714-921-6022 Main Engineering Part Sales Fax: E-mail: tech_support@dataaire.com engineering@dataaire.com sales@dataaire.com Technical Support Engineering Sales Web site: www.dataaire.
RECOMMENDED LINE SIZING FOR AIR COOLED SPLIT SYSTEMS UP TO 200 EQUIVALENT FEET HOT GAS LINES SINGLE CIRCUIT SYSTEMS Tons per EQUIVALENT FEET Unit Tonnage 1 1.5 2 2.5 3 4 5 6 8 10 13 Circuit 50 1 5/8 1.5 5/8 2 5/8 2.5 5/8 3 7/8 4 7/8 5 7/8 6 7/8 8 1-1/8 10 1-1/8 13 1-1/8 100 5/8 5/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 150 5/8 7/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 DUAL CIRCUIT SYSTEMS EQUIVALENT FEET Unit Tons per Tonnage Circuit 6 3 8 4 10 5 13 6.
Data Aire, Inc. Monthly Maintenance Inspection Checklist Model No.__________________ Prepared by: _______________ Air Filters ___ Check for restricted air flow Serial No.
Data Aire, Inc. Quarterly Maintenance Inspection Checklist Model No.
Superheat and Suction Pressure Trouble Shooting Guide Low Suction Pressure and High Superheat 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Moisture, dirt, wax Undersized valve* High superheat adjustment Gas charge condensation Dead thermostatic element charge Wrong thermostatic charge Evaporator pressure drop - no external equalizer External equalizer location Restricted or capped external equalizer Low refrigerant charge Liquid line vapor a. Vertical lift b. High friction loss c. Long or small line d.
Temperature Pressure Chart Temperature (°F) 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 36 R-22 50.0 51.2 52.4 53.7 54.9 56.2 57.5 58.8 60.2 61.5 62.9 64.3 65.7 67.1 68.6 70.0 71.5 73 74.5 76.1 77.6 79.2 80.8 82.4 84.1 92.6 101.6 111.3 121.5 132.2 143.7 115.7 168.4 181.9 196.0 210.8 226.4 242.8 260.0 278.1 297.0 316.7 337.4 359.1 381.7 R-407C 43.6 44.7 45.9 47.1 48.4 49.6 50.9 52.1 53.4 54.8 53.2 57.5 58.
Correction Factor for Superheat Measurement 6 Expected Error Degrees F 5.5 5 4.5 4 3.5 3 2.
- A Air Cooled Systems ...........9, 10, 18-22 Air Filters .......................................... 28 Air Vents ........................................... 11 Ambient Thermostats ....................... 19 Auxiliary Wiring ................................. 14 - B Bearings ........................................... 28 Belts .................................................. 28 - C Cable, Water Sensing ....................... 17 Charging ...........................................
Heat Crankcase ................................ 22, 23 Electric ........................................... 29 Reheat Elements............................ 29 High Pressure Cutout Switch............... 21 Humidifier ...................................... 13, 28 Canister .......................................... 28 Dry Steam Humidifier ..................... 13 Steam Generator Humidifier .... 13, 28 - I Inspection .............................................. 6 Installation ..............................
230 W. BlueRidge Avenue Orange, CA 92865 800-347-2473 www.dataaire.com e-mail: sales@dataaire.com A Member of the CS Group of Companies © 2010 Data Aire, Inc. Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice.
