DATA TEMP AND MODULAR DATA TEMP Operation and Maintenance Manual 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 1.7 INSTALLATION .................................................................................................. 6 Room Considerations ............................................................................................ 6 Inspection .............................................................................................................. 6 Rigging ........................................................................................
Table of Contents, cont’d 4 4.0 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.3 4.3.1 4.3.2 4.4 4.5 4.5.1 4.5.2 4.5.3 CHARGING ........................................................................................................ 18 Voltage Phase Check .......................................................................................... 18 Evaporator ........................................................................................................... 18 Secondary Heat Exchanger .........................
Table of Contents, cont’d RECOMMENDED LINE SIZING CHART for AIR COOLED SPLIT SYSTEMS ................... 30 TEMPERATURE PRESSURE CHART................................................................................ 31 SUPERHEAT and SUCTION PRESSURE TROUBLE SHOOTING GUIDE ....................... 32 MAINTENANCE INSPECTION CHECKLIST ...................................................................... 33 NOTES ...................................................................................................
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 (NEC) for special installation requirements. 1.1 Room Considerations Precision air conditioning equipment is designed to control spaces within close tolerances of temperature and humidity.
problem, 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 (optional) air discharge plenum may be factory provided. The plenum ships loose and must be field 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 the external static pressure (ESP).
1.
2.0 PIPING 2.1 Split Air Cooled Unit Piping Refer to the attached line sizing chart on page 30 for a guideline for sizing refrigerant lines. The ultimate responsibility for line sizing selection is that of the installing contractor or the project engineer. Data Aire does not assume this responsibility. The chart covers distances up to 200 equivalent feet. For installations greater than this distance, consult ASHRAE or similar references.
2.1.3 Suction Lines Some applications call for the compressor to be mounted as part of the condenser, more commonly referred to as a condensing unit. Such 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 lines should always be insulated. 2.1.
2.1.6 Field Piping, Remote Condensing Unit 2.2 Water/Glycol Unit Piping The required field installed condenser water pipe sizes may or may not be the same as the connections at the evaporator section or fluid cooler (refer to Sections 2.2.2 and 2.2.3 for connection sizes). Water pipe sizes will depend on the length of pipe required and the calculated pressure drop of peripheral components. Water cooled units may be connected to building water or tower water sources.
Water/glycol system piping may include a centrifugal pumps (or pumps for redundancy). Pumps must be primed before operating per the pump manufacturer’s guidelines. 2.2.1 Field Piping, Glycol System 2.2.2 Connection Sizes, Water/Glycol Cooled Units Evaporator Model DTW/G-02 DTW/G-03 DTW/G-04 DTW/G-05 Water IN and Out Connections, O.D. 3/4” 3/4” 1-1/8” 1-1/8” Evaporator Model DTW/G-08 DTW/G-10 DTW/G-13 Water IN and Out Connections O. D. 1-5/8” 1-5/8” 1-5/8” 2.2.
NOTE: Models DAFC-57 and larger are double-wide units. Although the header connection for each section is 2-5/8” O.D., each unit comes with a factory provided manifold kit with 3-1/8” O.D. field connections. 2.3 Auxiliary Chilled Water Coil Piping Units with optional auxiliary chilled water cooling coil require a separate source of chilled water. The chilled water connection sizes will be the same as those listed for the condenser water (see Section 2.2.3).
2.5.2 Dry Steam Humidifier Units with optional dry steam humidifiers require a strainer on the inlet steam line. An outlet connection with a field provided steam trap is also required. Steam pressure is typically 10 to 15 PSI. 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, shraeder fittings and compressor rotolock service valves. Check both field and factory connections.
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 wires (see Section 3.5).
the control panel). The control circuit is 24 VAC and the field provided contact or switch should have a minimum rating of 10 amps. The remote shutdown contacts are always terminals #1 and #2 on the terminal block designated TB2. The unit will ship with a factory wired metal jumper clip (bridge) that connects terminal #1 to terminal #2. Remove the clip prior to installing the field wires. 3.
4.0 CHARGING 4.1 Voltage Phase Check 4.1.1 Evaporator Prior to charging, the correct voltage phasing should be checked on the indoor evaporator. Check blower direction on the evaporator by momentarily energizing the fan motor. Reverse any two of the three line voltage wires at the line voltage field connection point to change the blower rotation.
Adjust the refrigerant charge until to a sub-cooling of 8 to 10° F and has sparse bubbles. The unit should be allowed to stabilize for several minutes before meaningful measurements can be taken.
If the receiver (head) pressure is below 322 PSIG for R-410A (230 PSIG for R-407C), block part of the condenser coil surface until the pressures rises to 322 PSIG for R-410A (230 PSIG for R-407C) or greater. During extremely cold weather all the condenser fans may have to be de-energized to maintain 322 PSIG for R-410A (230 PSIG for R-407C). Observe the sight-glass on the receiver.
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. 4.3.
4.5.3 Low Pressure Cutout Switch Each circuit includes a low pressure cutout switch with automatic reset. The switch is located near the compressor section. The pressure rating for R-407C systems is 30 PSIG, cut in at 50 PSIG. The pressure rating for R-410A systems is 34 PSIG, cut in at 68 PSIG.
5.0 GLYCOL SYSTEMS 5.1 Glycol Concentration The system must be filled with water and the appropriate amount of ethylene or propylene glycol to protect against winter freezing. To achieve the approximate glycol concentration, it is necessary to know the total system volume. The total system volume consists of the fluid cooler volume, the evaporator unit volume and the volume of the inter-connecting piping. The following tables can be used for arriving at an approximate system volume.
5.2 Fluid Cooler Internal Volume Fluid Cooler DAFC-06 DAFC-07 DAFC-09 DAFC-11 DAFC-15 DAFC-17 DAFC-21 DAFC-24 DAFC-28 DAFC-30 5.3 Volume (gallons) 2.5 3.4 4.2 3.3 4.9 6.6 7.4 9.8 12.3 9.8 Volume per 100 feet of Pipe (gallons) 1.2 1.8 2.5 2.5 4.3 16.1 24.8 35.4 62.2 Freezing Point of Aqueous Solutions Ethylene Glycol % by Volume 0 10 20 30 40 50 24 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 O.D.
6.0 CONTROLS 6.1 Microprocessor Control Panel Each Data Temp and Modular Data Temp unit is shipped with a DAP-III microprocessor control panel. This state-of-the art control panel has a separate manual that goes into extensive detail regarding its operation, 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.
7.0 REGULAR MAINTENANCE ITEMS 7.1 Air Filters Air filters should be checked on a regular basis and changed when they become dirty. This will ensure efficient operation of the unit. Spare air filters should be kept in stock as these tend to be a frequently replaced maintenance item. Air filters may require changing as often as monthly dependent on room or space conditions. New installations with construction dust will quickly clog filters requiring new filters.
7.5 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 regard to: 1) amperage, 2) voltage and 3) speed. For instance – compressors are and motors are inductive loads which require time delay fuses where electric reheat and humidifiers are resistive loads requiring fast acting fuses. 7.
8.
9.0 CONTACT DATA AIRE Address: Data Aire, Inc. 230 West Blueridge Avenue Orange, CA 92865 Telephone: 714-921-6000 800-347-AIRE (2473) Toll Free E-mail: Service@dataaire.com Tech_Support@dataaire.com Engineering@dataaire.com Sales@dataaire.com Fax: 714-921-6010 714-921-6011 714-921-6022 Main Engineering Parts Sales Web Site: www.dataaire.
RECOMMENDED LINE SIZING for AIR COOLED SPLIT SYSTEMS HOT GAS LINES – SINGLE CIRCUIT UNITS (Up To 200 Equivalent Feet) Tonnage 2.5 3 4 5 8 10 13 Tons/ Circuit 2.5 3 4 5 8 10 13 50 feet 5/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 100 feet 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 150 feet 7/8 7/8 7/8 1-1/8 1-3/8 1-3/8 1-3/8 200 feet 7/8 7/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 LIQUID LINES – SINGLE CIRCUIT UNITS (Up to 200 Equivalent Feet) Tonnage 2.5 3 4 5 8 10 13 Tons/ Circuit 2.
TEMPERATURE-PRESSURE CHART R-407C R-410A TEMPERATURE (°F) PRESSURE (PSIG) PRESSURE (PSIG) 26 43.6 89.7 27 44.7 91.6 28 45.9 93.5 29 47.1 95.5 30 48.4 97.5 31 49.6 99.5 32 50.9 101.6 33 52.1 103.6 34 53.4 105.7 35 54.8 107.9 36 56.2 110.0 37 57.5 112.2 38 58.9 114.4 39 60.3 116.7 40 61.7 118.9 41 63.1 121.2 42 64.6 123.6 43 66.1 125.9 44 67.6 128.3 45 69.1 130.7 46 70.6 133.2 47 72.2 135.6 48 73.8 138.2 49 75.4 140.7 50 77.1 143.
Superheat and Suction Pressure Troubleshooting Guide Low Suction Pressure and High Superheat 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Moisture, wax, dirt in system 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.
Data Aire, Inc. Maintenance/Inspection Checklist Evaporator Model No. _____________ Technician: ______________________ Evaporator Serial No.
Notes __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________
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 © 2011 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.
