Data Aire DAL-06 Gebrauchsanweisung

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 Installation, Operation and Maintenance and User Manuals for other components

of your Data Aire precision environmental cooling system including dap4 and Mini-dap4

microprocessor controller and condenser/condensing unit and fluid cooler.

NOTE: This manual is intended to assist trained service personnel by

providing necessary guidelines for this 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.

WARNING: Service performed by unauthorized or unqualified

technicians may void manufacturers’ warranties and could result in

property damage and/or personal injury.

Safety Alert Symbols and Words for Hazard Alerting Safety

DANGER: Indicates a hazardous situation which, if not avoided, will result

in serious injury or death

WARNING: Indicates a hazardous

situation

which, if not avoided, could

result

in serious injury or

ath.

CAUTION: Indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

NOTICE: Indicates information considered important but may have potential

hazard for personal injury or property damage.

Data Aire, Inc. reserves the right to make design changes for the purpose

of product improvement or to withdraw any design without notice.

TABLE OF CONTENTS 
3 
 INTRODUCTION............................................................................................................. 7 
 Product Information.......................................................................................................................7 
 Model Identification .......................................................................................................................7 
 Inspection......................................................................................................................................8 
 Paperwork.....................................................................................................................................8 
 Storage..........................................................................................................................................8 
 Suggested Reference Storage Room Conditions.........................................................................9 
 General Storage Considerations...................................................................................................9 
 Registered Trademarks –Copy Rights –References Section ...................................................10 
 INSTALLATION.............................................................................................................11 
 Recommended Tools for Installation ..........................................................................................12 
 Pre-Installation ............................................................................................................................12 
 Installation must be planned so that: ..........................................................................................12 
 Room Considerations..................................................................................................................13 
 Equipment Handling and Rigging ...............................................................................................14 
 Moving Unit into Final Location...........................................................................................14 
 Rigging........................................................................................................................................14 
 Locating the Unit .........................................................................................................................14 
 Horizontal Airflow Units...............................................................................................................15 
 Installing/Mounting ......................................................................................................................15 
 Indoor Condensers and Condensing Units.................................................................................17 
 Piping ..........................................................................................................................................17 
 Split Air-Cooled Unit Piping.........................................................................................................18 
 Discharge Lines ..........................................................................................................................18 
 Liquid Lines .................................................................................................................................20 
 Suction Lines...............................................................................................................................20 
 Recommended Line 
Sizing
........................................................................................................20 
 Hot Gas Lines......................................................................................................................21 
 Liquid Lines.........................................................................................................................21 
 Suction Lines.......................................................................................................................22 
 Connection Sizes, Air Cooled Units............................................................................................22 
 Connection Sizes, Water/Glycol Cooled Units............................................................................23 
 Connection Sizes, DX Water/Glycol-Cooled Units 3-Way Chilled Water Valves .......................23 
 Connection Sizes, DX Water/Glycol-Cooled Units 2-Way Chilled Water Valves .......................23 
 Connection Sizes, Chilled Water Units .......................................................................................23 
 Field Piping, Remote Condenser/Condensing Unit Above Evaporator ......................................24 
 Field Piping, Remote Condenser/ Condensing Unit Below Evaporator......................................25 
 Connection Sizes, Fluid Coolers (Dry Coolers) ..........................................................................26 
 Auxiliary Chilled Water/Energy Saver Coil..................................................................................26 
 Auxiliary Chilled Water/Energy Saver Coil Piping...............................................................26 
 Condensate Drain System ..................................................................................................27 
 Condensate Trap.................................................................................................................28 
 Condensate Pump Side Mounting Pump (Optional)Humidifier Piping........................................30 
 Humidifier....................................................................................................................................31 
 Steam Generator Humidifier ...............................................................................................31 
 Humidifier Piping.................................................................................................................31 
 Refrigerant Piping Protection......................................................................................................31 
 Water/Glycol Cooled Unit Piping.................................................................................................32 
 Leak Testing................................................................................................................................34 
 Electrical Installation ...................................................................................................................34 
 Commissioning Information.........................................................................................................35 

TABLE OF CONTENTS 
4 
 ELECTRICAL CONNECTIONS......................................................................................36 
 General Electrical Field Wiring Guidelines..................................................................................37 
 Electrical Service.........................................................................................................................38 
 Nameplate Ratings......................................................................................................................38 
 Grounding....................................................................................................................................38 
 Voltage Tolerance.......................................................................................................................38 
 Three Phase Voltage Tolerance .........................................................................................38 
 Single-Phase Voltage Tolerance.........................................................................................39 
 Heat Exchanger Auxiliary Control Wiring....................................................................................39 
 Remote Shutdown.......................................................................................................................40 
 Mini-dap4 Controller....................................................................................................................40 
 Remote Alarm Contacts..............................................................................................................40 
 Remote Sensors .........................................................................................................................41 
 Condensate Pump ......................................................................................................................41 
 Disconnect Switch (Optional)......................................................................................................41 
 Manual Override Switch Board ...................................................................................................42 
 Wiring Diagrams..........................................................................................................................43 
 INSTALLATIONOF REMOTE OUTDOOR HEAT EXCHANGER....................................43 
 CHARGING....................................................................................................................44 
 Charging/Installation Work Procedures ......................................................................................44 
 Triple Evacuation and Dehydration Procedure ...........................................................................44 
 Tools Needed......................................................................................................................45 
 First Stage Evacuation........................................................................................................45 
 Second Stage Evacuation...................................................................................................46 
 Third Stage Evacuation.......................................................................................................46 
 Final Evacuation Stage .......................................................................................................47 
 General Pre-Charging Guidelines...............................................................................................47 
 Voltage Phase Check..................................................................................................................48 
 Evaporator Power Phase Check.........................................................................................48 
 Fixed Speed Scroll Compressor Phase Check...................................................................49 
 Heat Exchanger Phase Check............................................................................................49 
 GHRC Air-Cooled Heat Exchanger Phase Check ..............................................................49 
 DARC Heat Exchangers Phase Check...............................................................................49 
 Line Set Charge Calculations......................................................................................................49 
 Component Functional Test........................................................................................................50 
 Charging Procedures ..................................................................................................................50 
 Refrigerant Handling ...........................................................................................................51 
 Air Cooled Split-System Charging.......................................................................................51 
 Charging the Fixed Speed Compressor..............................................................................54 
 Additional Oil .......................................................................................................................55 
 Flooded System Charging (Systems with Low Ambient Receiver Package)......................56 
 Refrigerant Receiver ...........................................................................................................57 
 Applications.........................................................................................................................57 
 Selection Guidelines ...........................................................................................................57 
 Receiver Location................................................................................................................57 
 Safety Relief Devices..........................................................................................................58 
 Receiver Installation............................................................................................................58 
 Charge Fixed Speed Compressor.......................................................................................60 
 Water/Glycol-Cooled System Charging ..............................................................................60 
 Important Refrigeration Components..........................................................................................62 
 Thermal Expansion Valve ...................................................................................................62 

TABLE OF CONTENTS 
5 
 High Pressure Cutout Switch ..............................................................................................62 
 Low Pressure Cutout Switch ...............................................................................................62 
 Liquid Line Solenoid Valve (Optional)..................................................................................63 
 GLYCOL SYSTEMS ......................................................................................................64 
 Glycol Concentration...................................................................................................................64 
 Internal (Fluid) Volume................................................................................................................64 
 Fluid Cooler Internal Volume...............................................................................................64 
 Brazed-Plate Condensers...................................................................................................64 
 Water Treatment..................................................................................................................65 
 Type L Copper Tubing Internal Volume......................................................................................66 
 Freezing Point of Aqueous Solutions..........................................................................................67 
 Mixing Glycol and Water .............................................................................................................67 
 CONTROLS...................................................................................................................68 
 Mini-dap4 Microprocessor Control Controller .............................................................................68 
 Optional Expanded dap4 Microprocessor Controller..................................................................68 
 Remote Heat Exchangers...........................................................................................................68 
 REGULAR MAINTENANCE ITEMS...............................................................................69 
 Air Filters.....................................................................................................................................69 
 Belts ............................................................................................................................................69 
 Bearings......................................................................................................................................69 
 Fuses...........................................................................................................................................70 
 Electric Reheat............................................................................................................................70 
 Humidifier....................................................................................................................................70 
 Humidifier Canisters............................................................................................................70 
 Refrigerant Filter Drier.................................................................................................................70 
 EC Plenum (Plug) Fans ..............................................................................................................71 
 Electronically Commutated Motors......................................................................................71 
 EC Motor Testing ................................................................................................................72 
 MAINTENANCE/INSPECTION CHECKLIST .................................................................73 
 Frequently Asked Questions –FAQ............................................................................76 
 Electrical FAQ Section ................................................................................................................76 
 Mechanical FAQ Section.............................................................................................................77 
 Contact Data Aire .........................................................................................................80 
TABLE OF FIGURES 
Figure 1 Typical Installation Methods............................................................................16
Figure 2 Typical Installation Details...............................................................................16 
Figure 3 Typical Discharge Check Valve.......................................................................19 
Figure 4 Recommended Condensate Trap Dimensions................................................29
Figure 5 Typical Side Pump Mounting...........................................................................30
Figure 6 Typical Water/Glycol System ..........................................................................33
Figure 7 Typical Remote Heat Exchanger Interconnection Points................................40
Figure 8 Typical Indoor Evaporator Interconnection Points...........................................40
Figure 9 Manual Override Switch Board........................................................................42
Figure 10 Typical Low Ambient Receiver Package.......................................................59
Figure 11 Example Remote EPO Switch Connection....................................................77
 

TABLE OF CONTENTS 
6 
LIST OF TABLES 
Table 1 Line Size Metric Conversion.............................................................................20
Table 2 Hot Gas Lines (Inches OD) (Single Circuit Systems).......................................21
Table 3 Hot Gas Lines (Inches OD) (Dual Circuit Systems)..........................................21
Table 4 Liquid Lines (Inches OD) (Single Circuit Systems)...........................................21 
Table 5 Liquid Lines (Inches OD) (Dual Circuit Systems) .............................................21
Table 6 Suction Lines (Inches OD) (Single Circuit Systems) ........................................22
Table 7 Suction Lines (Inches OD) (Dual Circuit Systems)...........................................22 
Table 8 Connection Sizes, Air Cooled Units (Inches OD) .............................................22
Table 9 Connection Sizes, Water/Glycol Cooled Units (Inches OD) .............................23
Table 10 Connection Sizes (Inches OD), Water/Glycol-Cooled Units 3-Way CW Valve23
Table 11 Connection Sizes (Inches OD), Water/Glycol-Cooled Units 2-Way CW Valve23
Table 12 Connection Sizes, Chilled Water Units (Inches OD).......................................23
Table 13 Three Phase Voltage Tolerance.....................................................................39
Table 14 Remote Alarm Contacts Terminals.................................................................41 
Table 15 Liquid Line Multiplier.......................................................................................49
Table 16 Liquid Line Multiplier for R-410A at Various Line Lengths..............................50 
Table 17 Liquid Line Multiplier for R-407C at Various Line Lengths..............................50
Table 18 Large Ceiling System Units R-410A...............................................................52 
Table 19 Large Ceiling System Units R-407C...............................................................53
Table 20 Refrigerant Charge Values.............................................................................55 
Table 21 Refrigerant Receiver Charging Chart.............................................................60
Table 22 Discharge Head Pressure ..............................................................................60
Table 23 Packaged Units without Receivers.................................................................61 
Table 24 Packaged Units with Receivers......................................................................61
Table 25 High Pressure Cutout Switch Setting .............................................................62
Table 26 Low Pressure Cutout Switch Setting ..............................................................62 
Table 24 LCS Internal (Fluid) Volume ...........................................................................64
Table 28 Type L Copper Tubing Internal Volume..........................................................66
Table 29 Freezing Point of Aqueous Solutions .............................................................67
 
 
 

INTRODUCTION

Product Information

The Data Aire Large Ceiling System (LCS) environmental control, direct expansion, single or 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, filter section, cooling coils, controls, and interconnecting

piping internal to unit. This unit is normally mounted above the ceiling tiles.

The Data Aire CRAC unit provides cooling, reheat, humidification, dehumidification and air filtration.

The unit is provided with a Data Aire Mini-dap4 microprocessor controller for precision control. The unit

must be operated in a conditioned space within the operating envelope ASHRAE recommends for data

centers. Operating outside this envelope can alter the operating performance and decrease equipment

reliability. Return air to the unit must be no cooler than the ASHRAE recommendation for proper unit

operation. Operating below this can alter the operating performance and decrease equipment reliability.

Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.”

Model Identification

DAL X - XX X X - X - XX - X

06 Tons

08 Tons

10 Tons

13 Tons

5 - 575V - 60Hz

Phase

3 - Three phase

Model Series

DAL (Single or Dual Circuit)

Type of Cooling

A - Air Cooled

W - Water Cooled

G - Glycol Cooled

Model/Capacity in Tons

E - EnergySaver (Water/Glycol Cooled Units)

D - Dual Compressor

S - Single Compressor

Voltage

2 - 208/230 VAC

4 - 460 VAC

Large Ceiling System (LCS) Model Number

P - Package System

(Not available in air-cooled packaged configuration)

CO - Split System withoutdoor condenser

AO - Split System withoutdoor condensing unit

Auxiliary Coils

C - AuxilaryChilled Water (Air or Water Cooled Units)

Inspection

This Data Aire CRAC unit has been factory run tested and has gone through a comprehensive

inspection prior to its packaging and shipment to ensure that it arrives in excellent condition. However,

shipping 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, verify that the labeled equipment

matches the bill of lading.

Loose items such as remote-control panels, disconnect switch handles, and spare air filters are packed

inside the unit. Refer to the yellow shipping tag located on the unit door for details.

NOTICE: Any external damage or transportation damage on the freight

carrier’s forms. Inspect the unit itself for internal damage. A claim should be

filed with the shipping company if the equipment is damaged or incomplete.

NOTICE: Freight damage claims are the responsibility of the purchaser.

Action to recover losses should be filed immediately. Please notify factory

personnel of any claims.

Paperwork

Each Data Aire CRAC unit ships with a startup sheet that should be completed during installation. Also

included in the paperwork is a warranty/information packet that provides important wiring diagrams,

specific component literature, warranty registration cards and other valuable paperwork, including a

copy of this Installation, Operation, and Maintenance manual.

A yellow tag isattached to the outside decorative door to indicate articles that mayhave 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

startup 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 warranty

Storage

Short-term storage is considered 60 days or less from shipment date. Long-term storage is considered

any period beyond 60 days from date of shipment.

It is mandatory that a detailed record be maintained during this long-term storage period, such as, but

not limited to proper sealing of the cabinet, rotation of the blowers and bearings, and protection of all

motors from moisture. Check the fan rotation monthly, the fan and motor should be rotated several

times to replenish the bearing surfaces with fresh grease as needed and to prevent flat spots of the fan

shaft. The fan impeller should be left at approximately 180° from that of the previous month to prevent

the belts from taking a set position.

If equipment is stored for longer than 60 days special precautions must be taken to avoid coil damage.

All coils should be charged and sealed with a low pressure 1 to 3 PSIG (6.9 to 20.7 kPa) inert gas,

such as nitrogen. This prevents contaminates from entering the coils; then when the seal is broken at

installation, the rush of escaping gas verifies the coil is still leak free. If coils are not charged and sealed,

condensation mixes with air pollutants forming a weak acid and over time can cause pin hole leaks to

develop in the coil tubes.

It is the responsibility of the customer to submit a monthly log sheet showing the condition of the unit

and noting any discrepancies. A copy of the log sheet should be sent to Data Aire. Failure to perform

the long-term storage requirements may void the warranty.

CAUTION: A complete system drain-down after factory functional testing

cannot be assured for this product. Therefore, if exposed to freezing

conditions, rupture piping and component may occur.

Suggested Reference Storage Room Conditions

•Dry bulb temperature range: 65°F to 85°F (18.3C) to 85°F (29.4C).

•Effects of high temperatures may dry out components or may damage electrical components.

•Effects of low temperatures may cause freezing damage to coil, compressor, system

components, electrical components, etc. Freezing temperatures must be avoided.

•Humidity range: 25 to 50% RH.

•High humidity may cause damage to insulation and electrical components. Storage in moist

air, above 50%, should be avoided. High humidity may cause rust on metal components such

as sheave, pulley, blower housing, cabinet parts, supports, etc.

•Low Humidity may cause brittle conditions to components within the unit. At low humidity,

problems of brittleness or electrical static might arise for the equipment.

•Level with floor.

•Units with compressor maximum tilt angle is 30° (compressor not running) but recommend

the unit be set level for 24 hours prior to final installation.

•Store at non-condensing temperature and humidity conditions.

General Storage Considerations

•All equipment shall be stored for safety of occupants. Per OSHA codes and codes applicable

to your installation.

•Maintain clearance from working space and traffic areas.

•Our indoor products are not designed or intended to be stored outdoors or exposed to

outdoor conditions.

•Components sealed in plastic shrink-wrap are not exempt from this requirement. Moisture

will collect inside the plastic, resulting in corrosion of the cabinet, the electronic components

and or other water sensitive components.

•Provide proper fire protection per local and national codes.

•Protect from all water or fluid sources. Equipment should be protected from possible water

damage, such as from leaks, fire sprinkler discharge, and flooding.

•The storage space should be filtered to remove dust, cleansed of gaseous contaminants, if

present, and controlled to the desired relative humidity and temperature.

•Isolate this equipment from pressure testing of water, steam, gas and air piping.

•Isolate this equipment from temporary building power.

•The unit must also be protected from damage to the exterior of the cabinet or coil connections

by construction vehicles and personnel.

•Isolate from vibration sources.

•Isolate from direct sun light.

•Isolate from storage of hazardous materials and substances.

•Refrigerant coils have been evacuated and pre-charged with slight 1 to 3 PSIG (6.9 to 20.7

kPa) nitrogen holding charge. DO NOT damage or disturb these coils and connections.

•Water coils must have all inlet and outlet connections capped or closed tight to prevent

foreign materials and liquids from gaining entrance during the storage period.

When equipment is installed after storage, caution should be taken to inspect and replace, if required,

any components that may have deteriorated during storage. All moving parts, such as fans and motors,

should be hand tested to ensure that they are free and clear prior to startup.

Registered Trademarks –Copy Rights –References Section

NOTICE: Data Aire Inc. Trademarks Disclaimer: All names, logos, brand,

materials and other Registered Trademarks, Trademarks, or Copy Rights

seen featured or referred to within documents or our website are explicitly

the sole property of their respective and rightful trademark holders or owners.

This disclaimer shall not be construed or manipulated from hereafter. Said

trademarks or copy rights are only used to directly or indirectly familiarize,

reference, identify and describe the services.

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