Data Aire DALA 06, DALA 13, DALA 08, DALA 10, DALW 06 Installation, Operation And Maintenance Manual

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LCS

Installation, Operation and Maintenance Manual

6, 8, 10 and 13 ton

Air, Water and Glycol Cooled DX and Chilled Water

Congratulations! You have selected a Data Aire precision control system, one of the ﬁ nest available in

the market today. 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 qualiﬁ ed individuals with an adequate background in areas

such as HVAC, electrical, plumbing and electronics, as applicable.

Service performed by unauthorized or unqualified technicians may void manufacturers’ warranties and could result in property damage and/or personal injury.

Special care should be given to those areas where these symbols appear.

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

product improvement, or to withdraw any design without notice.

Table of Contents

1.0 INSTALLATION ........................................................................................................6

1.1 Room Considerations ....................................................................................................6

1.2 Inspection .......................................................................................................................6

1.3 Locating the Unit .............................................................................................................6

1.3.1 Horizontal Airﬂ ow Units .............................................................................................7

1.3.2 Vertical Airﬂ ow Units ..................................................................................................7

1.4 Paperwork.......................................................................................................................7

1.5 Storage ...........................................................................................................................8

1.6 Model Identiﬁ cation .........................................................................................................8

2.0 PIPING ........................................................................................................................9

2.1 Split Air Cooled Unit Piping .............................................................................................9

2.1.1 Discharge Lines.........................................................................................................9

2.1.2 Liquid Lines ...............................................................................................................9

2.1.3 Suction Lines .............................................................................................................9

2.1.4 Connection Sizes, Air Cooled Units.........................................................................10

2.1.5 Field Piping, Remote Condenser ............................................................................11

2.1.6 Field Piping, Remote Condensing Unit ...................................................................11

2.2 Water/Glycol Cooled Unit Piping ..................................................................................12

2.3 Auxiliary Chilled Water Coil Piping ...............................................................................13

2.4 Condensate Drain Piping ..............................................................................................13

2.5 Humidiﬁ er Piping...........................................................................................................13

2.6 Dry Steam Humidiﬁ er ....................................................................................................13

2.7 Leak Testing ..................................................................................................................14

2.8 Evacuation ....................................................................................................................14

3.0 ELECTRICAL CONNECTIONS ..........................................................................15

3.1 Electrical Service ..........................................................................................................15

3.2 Nameplate Ratings .......................................................................................................15

3.3 Grounding .....................................................................................................................15

3.4 Voltage Tolerance .........................................................................................................15

3.5 Auxiliary Control Wiring ................................................................................................15

3.6 Remote Shutdown ........................................................................................................16

3.7 Remote Alarm Contacts ................................................................................................16

3.8 Remote Sensors ...........................................................................................................16

3.9 Condensate Pumps ......................................................................................................16

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER .............17

4.1 Rigging..........................................................................................................................17

4.2 Leg Assembly ...............................................................................................................17

4.3 Locating the Remote Heat Exchanger ..........................................................................17

4.4 Electrical Service ..........................................................................................................18

Table of Contents, continued

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER - (continued)

4.5 Air Cooled Condensers - Model DARC .............................................................................18

4.5.1 Fan Speed Control .......................................................................................................18

4.5.2 Ambient Thermostats ...................................................................................................18

4.6 Fluid Coolers - Model DAFC ..............................................................................................19

4.6.1 Fluid-Sensing Thermostats ..........................................................................................19

4.6.2 Energy Saver Cooling ..................................................................................................19

5.0 CHARGING ...................................................................................................................20

5.1 Voltage Phase Check ..........................................................................................................20

5.1.1 Evaporator ....................................................................................................................20

5.1.2 Secondary Heat Exchanger .........................................................................................20

5.2 Air Cooled Systems ......................................................................................................20

5.2.1 Split Indoor Air Cooled Systems Charging ...................................................................20

5.2.2 Fan Speed Control System Charging...........................................................................21

5.2.3 Flooded System Charging ............................................................................................21

5.3 Water/Glycol Cooled Systems ......................................................................................22

5.3.1 Water/Glycol Cooled Systems Charging ......................................................................22

5.4 Refrigerant Handling .................................................................................................... 23

5.5 Important Refrigeration Components ...........................................................................23

5.5.1 Expansion Valve ...........................................................................................................23

5.5.2 High Pressure Cutout Switch ......................................................................................24

5.5.3 Low Pressure Cutout Switch ........................................................................................24

6.0 GLYCOL SYSTEMS ...................................................................................................24

6.1 Glycol Concentration .........................................................................................................24

6.2 Internal (Fluid) Volume.......................................................................................................24

6.3 Fluid Cooler Internal Volume .............................................................................................24

6.4 Copper Piping Internal Volume ..........................................................................................25

6.5 Freezing Point of Aqueous Solutions .................................................................................25

7.0 CONTROLS ..................................................................................................................25

7.1 Mini dap4 Controller...........................................................................................................25

7.2 Optional Expanded dap4 Controller...................................................................................25

7.3 Secondary Heat Exchangers .............................................................................................25

7.4 Wiring Diagrams ................................................................................................................26

Table of Contents, continued

8.0 REGULAR MAINTENANCE ITEMS (continued)

8.4 Humidiﬁ er Canisters .........................................................................................................27

8.5 Fuses ................................................................................................................................28

8.6 Heating Elements .............................................................................................................28

8.7 Refrigerant Filter Drier ......................................................................................................28

9.0 WARRANTY ................................................................................................................29

10.0 CONTACT DATA AIRE ...........................................................................................30

Line Sizing Chart .......................................................................................................................31

Monthly Maintenance Inspection Checklist ...............................................................................32

Quarterly Maintenance Inspection Checklist .............................................................................33

Superheat and Suction Pressure Troubleshooting Guide .........................................................34

Temperature Pressure Chart for R-407c and R-410a .................................................................35

INDEX ...............................................................................................................................36-37

1.0 INSTALLATION

There is no intent on the part of Data Aire, Inc. to deﬁ ne 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. However, the room must be built with a proper vapor barrier. A ﬁ lm of polyethylene is often used on walls and ceilings. Walls and ﬂ oors must also be painted with a vapor- seal paint. All doors to the controlled space should be equipped with weather seals to prevent the inﬁ ltration of non-neutral conditioned air from external spaces. Failure to provide a vapor barrier can compromise the ability to control space conditions.

Introduction of outside air into the space should be minimized. Outside air in excess of 5% of the total circulated air volume can have a signiﬁ cant effect on the overall space conditions and result in poor space control. All outside air that is introduced should be conditioned to the humidity and temperature parameters of the computer room air conditioner (CRAC) unit set points to maintain proper room conditions and to prevent the CRAC units from running excessively to maintain the room’s conditions.

1.2 Inspection

This Data Aire 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.

Note any external damage or other transportation damage on the freight carrier’s forms. Inspect the unit itself for internal damage. A claim should be ﬁ led with the shipping company if the equipment is damaged or incomplete.

Loose items such as remote control panels, disconnect switch handles, spare belts and spare ﬁ lters are packed inside the unit. Refer to the manila shipping tag located on the unit panel for details.

Freight damage claims are the responsibility of the purchaser. Action to recover losses should be ﬁ led immediately. Please notify factory personnel of any claims.

1.3 Locating the Unit

The unit is intended for above the ceiling installation and is typically suspended from structural members in the building above the ceiling. Add at least a 50% safety factor to the weight of the unit to determine the necessary strength of the supporting structural members or follow local code.

Appropriate service access above the ceiling is required around all service and electrical access panels. There must be unobstructed clearance below the unit allowing ladder access to enable routine maintenance and service. Consult local building codes and National Electric Code for special installation requirements.

Note: There are many available unit conﬁ gurations for the LCS. Be sure to identify the unit type and style before installing. For instance there may be split condenser/condensing sections requiring separate or shared power.

Note to Installing Contractor: Condensation formation and frequent humidiﬁ er ﬂ ush- ing (when humidiﬁ er is installed) are normal functions of this equipment. Drain connec- tions must be made to ensure proper water removal. Unit will require drain connections for condensate removal and water connections possibly for humidiﬁ er (when installed)

makeup water, condenser water , chilled water and/or hot water . Installation of units above equipment that could sustain water damage should be avoided.

1.3.1 Horizontal Airﬂ ow Units

All LCS units have horizontal airﬂ ow conﬁ guration with a 29.5” tall evaporator section. Duct collars are factory provided for the supply and return air.

Four threaded support rods must be securely attached to the building structure. Two ﬁ eld provided support channels connect to the pairs of threaded support rod. (See detail on drawing 536-900-100 shown on page 38.) Raise the evaporator section with an appropriate lifting device. Attach washers, nuts and jam nuts to each threaded rod. Tighten the nuts so the weight is supported evenly by the four rods and the unit is level.

1.3.2 Indoor Condensers and Condensing Units

Although most split air cooled systems have outdoor condensers or condensing units, indoor condensers and condensing units are occasionally used. These 29.5” tall sections are to be mounted in the same manner as the evaporator sections using four threaded rods. Air cooled condensers or condensing units have factory provided duct collars on the supply and intake air openings as appropriate.

Typical installations have the condenser or condensing section physically near the evaporator, especially since most have some shared electrical line power. The mounting of these sections is independent of the evaporator mounting. The same service and maintenance clearance requirements apply to these units as well.

1.4 Paperwork

Each Data Aire unit ships with a start-up sheet that must be completed during installation. Also included in the paperwork is a warranty/information packet that provides important wiring diagrams, speciﬁ c component literature, warranty registration card and other valuable paperwork, including a copy of this Installation/Operation and Maintenance manual.

A manila (yellow) tag is attached to the outside panel to indicate articles that may have been packaged and shipped loose within the unit cabinet. Typically this would be a condensate pump and other loose components that are not factory mounted.

It is the responsibility of the installing contractor to return the start-up sheet and warranty registration card to Data Aire for proper activation of the unit warranty. Failure to do so may cause delays in warranty related services and in some cases void the warranty.

1.5 Storage

Your Data Aire equipment comes ready for immediate installation. In some instances it may be necessary to store the equipment for a period of time. If you must store the equipment it should be done in a dry area, out of the weather, in non-freezing temperatures, protected from damage by other equipment in storage or transportation equipment, never stacked, and avoid frequent relocation.

CAUTION: Complete system drain-down cannot be assured for this product. Freezing

system ﬂ uid can rupture piping.

If equipment is stored for longer than 30 days special precautions must be taken to avoid coil damage. All coils should be charged and sealed with a low pressure (1-3 PSIG) 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 veriﬁ es 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.

When equipment is installed after storage caution should be taken to inspect and replace, if required, rubber hoses and belts. All moving parts, such as blowers and motors, should be hand tested to ensure that they are free and clear prior to start-up. Finally, verify that all lubrication is fresh and full.

1.6 Model Identiﬁ cation

LCS UNITS

DAL A 06 3 2 -E -CO D

DATA AIRE LCS D – Dual compressor

UNIT S – Single compressor A ---------Air cooled

W ---- Water cooled P – Package system G ----Glycol cooled C ----Chilled water CO – Split system with outdoor condenser (DARC) Nominal tons 06, 08, 10 and 13 AO – Split system with outdoor condensing unit 3 – Three phase (DRCU)

2 – 208 or 230 volt C – Auxiliary chilled water coil 4 – 460 volt E – Energy Saver 5 – 575 volt

LCS units are not available in air cooled packaged conﬁ guration. CONDENSER – Condenser coil only, no compressor

CONDENSING UNIT – Condenser coil and compressor The order write-up should have the condenser or condensing unit model number.

Refer to applicable condenser or condensing model number identiﬁ cation. Example: DATA AIRE LCS unit, air cooled, 6 ton, 3Ø – 230 volt, split system

with outdoor condenser and dual compressors – Evaporator model: DALA 0632 CO D Condenser model: DARC 0632

2.0 PIPING

2.1 Split Air Cooled Unit Piping

Refer to the attached line sizing chart on page 31 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 greater than this distance, consult ASHRAE or similar references.

Standard piping practice must be used to ensure proper oil return and efﬁ cient operation. The interconnecting lines to the remote air cooled condenser or condensing unit must be installed by a qualiﬁ ed refrigeration mechanic.

2.1.1 Discharge Lines

Discharge lines, also called hot gas lines, should be trapped at the top (inverted) and bottom, as well as every 20 feet of vertical rise. Discharge line check valves are recommended on all installations, especially those where there are long pipe runs or cold climate. Check valves should be installed no less than six feet from the compressor. The discharge, suction and liquid lines need to be refrigerant grade copper and in accordance with local code. All refrigeration piping should be installed with high temperature brazed joints. When brazing, a supply of nitrogen gas needs to be fed through the refrigerant lines. Be sure to open the other end of the refrigerant line to allow the nitrogen to bleed off and not pressurize the piping. Prevailing good refrigeration practices should be employed for piping support, leak testing, dehydration and charging of the refrigerant circuits. During the installation the lines should be capped off and ﬁ lled with dry nitrogen at the end of each day’s work or until the system is completed and sealed.

Data Aire recommends a silver/phosphorus/copper alloy with 5 to 15% silver be used to braze the refrigerant line sets to the indoor and outdoor units. Nitrogen needs to be ﬂ owing through the lines to eliminate carbon deposit buildup on the inside of the joints. Carbon could contaminate the refrigerant and restrict the metering device.

Piping must be supported within 18” of the inlet and outlet connections. The inlet connection is located on the top header of all units. The discharge outlet is located at the bottom of the header.

Discharge line pressure drop should not exceed 6 PSI for R-407c and 9 PSI for R-410a. Recommended gas velocity for proper oil return is 1,000 FPM. Slope horizontal lines downward in the direction of refrigerant ﬂ ow, 1/2” for every ten feet of line length. Discharge lines do not require insulation but due to the high temperatures of the refrigerant inside the line, the pipes may be insulated to protect against burns to individuals near or around the lines.

2.1.2 Liquid Lines

Liquid line size is determined by pressure drop and velocity . The liquid line pressure drop for R-407c should not exceed 5 PSI or 9 PSI for R-410a. The recommended velocity should be between 200 and 300 FPM. To avoid excessive liquid line pressure drop, the air cooled condenser should be located above or at the same level as the evaporator. Condenser installation more than ten feet below the evaporator is not recommended. Insulation of liquid lines is not required but can be useful in preventing condensation from forming and to avoid ﬂ ashing on long pipe runs.

2.1.3 Suction Lines

Some applications call for the compressor(s) to be mounted as part of the condenser, more commonly referred to as a condensing unit. Such cases require ﬁ eld 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.

2.1.4 Connection Sizes Air Cooled Units

Model Circuiting Hot Gas Liquid Suction

DALA 06 Single circuit 1/2” 1/2” 3/4” DALA 08 Single circuit 3/4” 5/8” 1 1/8” DALA 10 Single circuit 3/4” 5/8” 1 1/8” DALA 13 Single circuit 3/4” 5/8” 1 1/8” DALA 06 Dual circuit 1/2” 1/2” 3/4” DALA 08 Dual circuit 1/2” 1/2” 3/4” DALA 10 Dual circuit 1/2” 1/2” 3/4” DALA 13 Dual circuit 1/2” 1/2” 3/4”

Field connections at the indoor evaporator and remote condenser or condensing unit will not necessarily be the same as the ﬁ eld pipe size required. In some cases these sizes will vary signiﬁ cantly.

Water/Glycol Cooled Units

Model Condenser Water In Condenser Water Out

DALW/G 06 1 5/8” 1 5/8” DALW/G 08 1 5/8” 1 5/8” DALW/G 10 1 5/8” 1 5/8” DALW/G 13 1 5/8” 1 5/8”

Chilled Water Units with 3-Way Valves

Model Chilled Water In Valve CV

DALC 06 1” 14.0 DALC 08 1 1/4” 20.0 DALC 10 1 1/4” 20.0 DALC 13 1 1/4” 20.0

2-Way Chilled Water Units

Model Chilled Water In Valve CV

DALC 06 1” 14.0 DALC 08 1 1/4” 20.0 DALC 10 1 1/4” 20.0 DALC 13 1 1/4” 20.0

Fluid Coolers

Fluid Cooler Water IN and OUT Fluid Cooler Water IN and OUT Model Connections, OD Model Connections, OD

DAFC 06 1 5/8” DAFC 17 2 5/8” DAFC 07 1 5/8” DAFC 24 2 5/8” DAFC 09 1 5/8” DAFC 28 2 5/8” DAFC 11 2 1/8” DAFC 30 2 1/8” DAFC 15 2 1/8”

2.1.5 Field Piping, Remote Condenser

2.1.6 Field Piping, Remote Condensing Unit

2.2 Water/Glycol Cooled Unit Piping

The required ﬁ eld installed condenser water pipe sizes may or may not be the same as the connection sizes at the evaporator or ﬂ uid cooler . (Refer to 2.1.4 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. Pipe size will depend on length of run and the maximum water ﬂ ow required.

Shutoff valves, ﬁ eld provided, should be installed within a few feet of the inlet and outlet connections of the evaporator to allow the unit to be isolated for service. There should be a means of draining the unit for service. Drain/ﬁ ll valves should be located at the lowest point on the connected piping.

All water/glycol units are shipped with plate/ﬁ n heat exchangers as standard equipment. A strainer is shipped loose and is to be ﬁ eld installed in the supply line with shut-off valves, ﬁ eld provided, before and after the strainer. The strainers and water/glycol piping must be cleaned on a periodic basis. If the unit is shipped with an optional shell and tube condenser, stainers are not required nor shipped with the unit.

One of the most common problems in a water/glycol system is the presence of air in the condenser water loop. Air vents must be installed in various locations in the piping system to purge the air.

Glycol system piping may include a centrifugal pump (or pumps for redundancy). Pumps must be primed before operating per the pump manufacturer’s guidelines.

(Field Provided)

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 2.1.4. Units with an Energy Saver cooling coil typically 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. These caps need to be removed before installing the water piping to the unit. Use a tube cutter for smaller pipes and a reciprocating say with a metal cutting blade for larger pipes sizes or if there is a clearance problem. All connections need to be cleaned before connections are brazed together.

2.4 Condensate Drain Piping

The evaporator section is equipped with a 3/4” FPT connection on the bottom for condensate removal. A union is recommended at the ﬁ eld connection which will permit easy disconnection from the unit for cleaning.

A trap should be built into the drain line to prevent air from backing up into the unit. Drain lines should be pitched downward not less than 1/4” for each ten feet of horizontal run. Do not reduce the size of the drain line. Where local codes permit, PVC pipe may be used.

Some applications have no convenient means of allowing a gravity drain. In this case, a condensate pump can be used. These come either factory mounted or shipped loose. Factory mounted condensate pumps do not require a separate power source.

Condensate pumps shipped loose (or ﬁ eld provided) typically require a dedicated 110 volt power source. Field pipe connections must be made to the pump discharge connection. A check valve must be installed to prevent short cycling. See also condensate pump electrical requirements in Section 3.9.

2.5 Humidiﬁ er Piping

The optional humidiﬁ er offered on LCSs is a steam generator type with a disposable cylinder. The humidiﬁ er makeup water should be brought to the humidiﬁ er through the ﬁ eld connection opening using 1/4” copper tubing. A compression ﬁ tting is provided at the humidiﬁ er. A shutoff valve should be provided outside the unit to allow disconnection for service. An in-line water pressure regulator and strainer should be installed. Water pressure should be set between 30 and 80 PSI.

The humidiﬁ er has a drain at the bottom which is factory piped to the main condensate drain line. The dispersion tube also has a drain line. No additional ﬁ eld piping is required.

2.6 Dry Steam Humidiﬁ er

Units with optional dry steam type humidiﬁ ers require a strainer on the inlet steam line. An outlet connection with ﬁ eld provided steam trap is also required. Steam pressure is typically 10-15 psi.

2.7 Leak Testing

No installation is complete until the entire system has been thoroughly checked for leaks. This includes checking refrigerant tubing, ﬂ are ﬁ ttings, pressure controls, shrader ﬁ ttings and compressor rotolock service valves. Check both ﬁ eld and factory connections.

In addition to the refrigeration system, check all condenser water lines, humidiﬁ er makeup lines, condensate lines, condensate pumps, chilled water lines, centrifugal pumps and ﬂ uid coolers as applicable.

When handling and recovering refrigerant, it is not permissible to release refrigerant into the atmosphere. Many leak-test methods recommended in the past are no longer possible. Current standard practices must be used.

Pressurize system circuit to 150 PSIG (1034kPa) by using dry nitrogen with a trace of refrigerant. Check the entire system for leaks with suitable leak ﬁ nder, (per local code) including but not limited to all braze joints, caps and ﬁ ttings, and ﬂ are nuts on both ﬁ eld and factory furnished components. After completion of leak testing, release test pressure and pull a vacuum on the system.

Tightening of ﬁ ttings and valves is the responsibility of the installing contractor.

2.8 Evacuation

Evacuate the refrigerant lines, condenser coil, and evaporator coil to 250 microns or lower (a micron gauge and 2-stage vacuum pump are required). V alve off and turn off the vacuum pump and wait for at least 15 minutes to make sure the micron gauge reading does not go back up above 700 microns. If it does, re-start the vacuum pump and evacuate until the system reaches 250 microns. If the system still does not hold the pressure below 700 microns the system needs to be rechecked for leaks.

After the system has been satisfactorily evacuated the unit(s) can be charged with refrigerant. Connect the pressure gauge manifold set to the high and low ports near the compressor, connect the charging line to the refrigerant tank and set it for liquid feed. Open the refrigerant tank valve and purge the line at the manifold, then open the high side valve on the manifold only, and allow the refrigerant ﬂ ow until the system pressure equalize, at this point the system will have 75 to 80% of the total refrigerant charge. Start the blower and then the compressor checking the operating pressure and temperatures.

Do not apply power to the compressor when in a vacuum.

3.0 ELECTRICAL CONNECTIONS

Before proceeding with the electrical connections, make certain that the volts,

hertz and phase correspond to that speciﬁ ed on the unit electrical nameplate. Use copper conductors only.

3.1 Electrical Service

Check to be sure the service provided by the utility is sufﬁ cient to handle the additional load imposed by this equipment. Units with outdoor secondary heat exchangers will require a separate power source and ﬁ eld-provided, interconnecting control wires as well. Indoor split units typically have a single power source but can also be provided with separate sources. Field-provided, interconnecting control wires are also required. See section 3.5 below.

Remote outdoor condensers and condensing units require one power source. Glycol systems with ﬂ uid coolers and loose pump(s) typically require one power source for the ﬂ uid cooler and will require one additional source for a single pump or two additional sources for dual pumps. Systems where the pump(s) are mounted and piped integral to the ﬂ uid cooler will usually require a single power source.

3.2 Nameplate Ratings

Refer to the unit electrical nameplate for equipment electrical requirements. Minimum Circuit Ampacity (MCA), also known as wire sizing amps, will dictate the minimum required wire gauge. Maximum Overcurrent Protection (MOP) Device amps will dictate the maximum circuit breaker or fuse size.

3.3 Grounding

The unit cabinet must have an uninterrupted true earth ground. An electrical ground wire of adequate size must be connected to the ground lug provided inside the main electrical box.

3.4 Voltage Tolerance

The supply voltage to the unit must be within tolerance; - 5% to +10% for 208-230 voltage; +10% for 460 volts. Phase to phase imbalance must not exceed 3%. The local utility company should be contacted for correction of improper line voltage. Deviation from ratings can cause premature failures and possibly void unit warranty.

3.5 Auxiliary Control Wiring

For secondary heat exchangers (condensers and ﬂ uid coolers) connect two 18 gauge wires from the electrical box of the indoor evaporator to the electrical box of the remote heat exchanger. Refer to the wiring diagrams located in the electrical box control panel of each unit. Follow the wiring diagrams for each piece of equipment. On most remote heat exchangers the terminals will be #39 and #40. All control wiring on Data Aire equipment is 24 VAC.

Condensing units (compressors mounted in condenser) typically require more wires. Refer to wiring diagrams in the unit.

Check the wiring connections in the unit control panel to ensure they are tight.

Screw terminals may become loose in transit. Tightening of wiring connections is the responsibility of the installing contractor.

3.6 Remote Shutdown

Every Data Aire evaporator has remote shutdown contacts points available. This is intended for a ﬁ eld 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 ﬁ eld provided contact or switch should have a minimum rating of 10 amps. A minimum wire size of 18 gauge wire is recommended. Check wiring diagram for location of the terminals.

3.7 Remote Alarm Contacts

The Mini dap4 microprocessor control panel has, a remote alarm output contact that can be ﬁ eld accessed on terminals #14, #15 and #16 of terminal block TB1. This is a Normally Open, Close on Alarm, dry contact, intended to be used in a control circuit not exceeding 2 amps at 250 VAC. This output contact will reverse position on a failure and remain reversed until the alarm is no longer present.

3.8 Remote Sensors

The Mini dap4 panel comes with remote mounted sensors for ﬁ eld installation. The sensors are attached to 35 feet of cable and come mounted in a remote sensor enclosure. The temperature and humidity sensors require a total of four wires. This should be a twisted, shielded cable.

3.9 Condensate Pumps

Condensate pumps which ship loose normally require a separate source of 110 volt power . Always check the pump power requirements before connecting power. Condensate pumps are available in other voltages.

Condensate pumps may also come unit mounted and wired in the unit as a factory option. While no outside power source is required, ﬁ eld piping is still a requirement.

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER

Air cooled condensers and ﬂ uid coolers have individual Installation, Operation and Maintenance manuals which should be referred to for more complete details.

4.1 Rigging

This section covers outdoor condensers/condensing units and ﬂ uid coolers. Outdoor heat exchangers should be moved to their (typically rooftop) mounting location using a crane or fork lift. Each fan section has supports with lifting holes at the top.

Do not lift with a choke sling around the unit. Spreader bars are recommended for lifting multiple fan units. Under no circumstances should the coil headers or piping be used for lifting the unit. Ideally, the unit should be kept in its shipping crate until it is ready to be set in place.

4.2 Leg Assembly

The legs of remote heat exchanger are shipped with the unit and need to be lowered during the rigging process. The legs must be unbolted from their collapsed position and extended prior to placing the unit on its pad. Each leg extends down 18 inches and reattached using the same bolts. The bolts are placed through the lower set of holes on the bracket. Multiple fan units have leg supports between each fan section.

Model number DARC-03 and DARC-05 do not have legs and are ready for installation.

Note: Failure to extend the legs will result in poor air distribution over the cooling coil resulting in signiﬁ cant capacity reduction.

Concrete pads or a rail system are often used to provide support for the heat exchanger. Bolt holes in the bottom of each leg can be used to anchor the unit.

4.3 Locating the Remote Heat Exchanger

The remote heat exchanger must be located in an area that will ensure free air ﬂ ow into and out of the heat exchanger plus adequate service access clearance. Short circuiting of the air ﬂ ow or the intake of warmer air from another unit will seriously degrade the performance of the air cooled heat exchanger.

Do not locate the heat exchanger in a location that is bordered by tall obstructions (i.e., higher than 10 feet) on no more than two sides. See ﬁ gure on next page for minimum clearance from obstructions and between units. With proper clearance on all sides, two units can be placed side by side. Additional units should be placed at least 48 inches apart.

Noise factors should be also 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. Mounting the remote heat exchanger (condenser or condensing unit) more than 10 feet below the evaporator is not recommended. Excessive liquid line pressure drop can cause poor evaporator performance.

Piping must be supported within 18 inches of the inlet and outlet connections. The inlet connection is located on the top header on all remote heat exchangers and the outlet connection is located on the bottom header of all units.

Air cooled condensers should be placed at a level that is above the level of the indoor evaporator. Mounting a condenser or condensing unit more than ten feet below the evaporator is not recommended. Excessive liquid line pressure drop can cause poor evaporator performance.

4.4 Electrical Service

Refer to Sections 3.1 to 3.5 for information regarding line voltage and control voltage wiring details.

4.5 Air Cooled Condensers - Model DARC

4.5.1 Fan Speed Control

Standard outdoor air cooled condensers have a fan speed controller on the ﬁ rst fan. On single- fan condensers this is the only means of control. A variable speed controller modulates the motor speed based on system head pressure. The fan speed controller will normally not require ﬁ eld adjustment.

4.5.2 Ambient Thermostats

Additional motors (subsequent to the fan speed control operated motor) on multi-fan condensers are cycled by ambient-sensing thermostats. These thermostats have a capillary tube with a remote sensing bulb. They will function best if the sensing bulbs are mounted below the coil, away from exposure to direct sunlight, with the bulb in a vertical position. An instruction set comes as part of a mounting kit that includes a sheet metal bracket, mounting clamp(s) and TEK screws. This includes directions for ﬁ eld mounting and adjusting the thermostat bulbs. Desired head pressure should be maintained at approximately 250 psi.

Typical settings for the ambient thermostats are as follows:

Number of fans Header fan Fan 2 Fan 3 Fan 4 Fan 5

2 FSC 65° 3 FSC 75° 65° 4 FSC 75° 85° 65° 5 FSC 65° 85° 75° 50°

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 ﬁ rst fan motor will only have a thermostat if the unit has an energy saver coil. Without the optional energy saver coil, the ﬁ rst fan motor runs whenever there is a call for cooling via an auxiliary signal sent by the indoor evaporator (see also Section 3.5).

The water-sensing thermostats have adjustable setpoints which are typically staggered to maintain water temperature in the 85 to 105° F range. This is generally the desired range for glycol cooled systems.

A surge tank is standard with all ﬂ uid coolers. This is sufﬁ cient for most applications. However, an expansion tank should be installed at the highest point in the system and the point of least pressure.

4.6.2 Energy Saver Cooling

In colder climates, the evaporator will often be equipped with an additional free cooling coil to take advantage of the colder ambient temperatures. When incoming ﬂ uid falls below the setpoint of a water-sensing thermostat in the evaporator (typically about 50° F), energy saver cooling becomes available.

Systems with an energy saver coil should have at least one ﬂ uid-sensing thermostat on the ﬂ uid cooler set lower to take advantage of colder ambient temperatures. The desired ﬂ uid temperature for energy saver cooling is 45° F. Field adjustment of ﬂ uid-sensing thermostats is not unusual.

It is desirable to use the energy saver mode as much as possible. However, ﬂ uid temperature that is too cold can cause excessive dehumidiﬁ cation and coil sweating. Fluid temperature that is too high can also cause the indoor space temperature to rise. This could cause the evaporator’s microprocessor control to lock out the energy saver mode for one hour while it reverts back to compressor (mechanical) cooling. Adjust the setpoints of the thermostats to allow the maximum free cooling time. Over cooling or under cooling the ﬂ uid should be avoided

Every application will have a different ambient temperature and indoor heat load/ air distribution proﬁ le. Therefore it is not possible to dictate the exact water-sensing thermostat setpoints. Field adjustments are typical to allow ﬁ ne-tuning to speciﬁ c

conditions.

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. 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 ﬁ eld connection point to change the blower rotation.

Although the scroll compressor is phase dependent, units shipped from the factory are run tested, ensuring the compressor rotation is consistent with the evaporator fan motor. However , a ﬁ eld change- out of the compressor may require checking proper phase. An out-of-phase compressor will draw relatively low amps and both suction and discharge pressures will remain nearly equal.

5.1.2 Secondary Heat Exchanger

The secondary heat exchanger may be ordered as three phase but the individual fan motors are single phase and will only run in one direction. Check operation by placing a momentary jumper across low voltage ﬁ eld terminals #39 and #40. (Disconnect pumps on glycol systems unless already ﬁ lled with water/glycol solution.) This will energize the control circuit. Fans may not run because: 1) the thermostat setpoint is above the current ambient, or 2) the #1 fan on air cooled condensers with fan speed control react to head pressure. The fan will not run until the head pressure is well over 200

psi.

5.2 Air Cooled Systems

5.2.1 Split Indoor Air Cooled Systems Charging

After the ﬁ eld refrigerant piping is properly completed, connect the refrigerant drum to the low side and charge with vapor. Charge with approximately three lbs. per nominal ton.

For example, a model DALA 0834-COS is a nominal 8 ton single circuit unit. Charge with about 24 lbs. of refrigerant to begin. It is likely that more refrigerant will be required to complete the charging procedure. Make sure all hoses are properly purged. Review the model number carefully because LCS units are available with either single or dual compressors.

Before starting a compressor, the crankcase heater should be energized for a minimum

of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize

the crankcase heater could result in compressor damage.

Start the evaporator fan and compressor. Check the liquid line sight glass to get a feel for the approximate charge. Bubbles in the sight glass are not unusual at this point and can be caused by ﬂ ashing from liquid line pressure drop, low sub-cooling or low charge. It is likely that more refrigerant will be required to complete the charging procedure.

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.

A properly charged system operating at typical parameters will have a head pressure of 240 - 295 psi for R 407C and 340 - 415 psi for R 410A. Suction temperature should be 58 psi or greater for R 407C and 104 - 121 psi for R 410A. The superheat at the compressor suction line at least 6 inches away from the compressor should be 8 - 15°.

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 parameters. A system charged to a clear sight glass is often overcharged.

5.2.2. Fan Speed Control System Charging

The standard outdoor air cooled condenser for Data Aire equipment is a Fan Speed Control system. After the ﬁ eld refrigerant piping is properly completed, connect the refrigerant drum to the low side and charge with vapor. Charge with approximately three lbs. per nominal ton.

For example, a model DALA 0834-COD is a nominal 8 ton unit but has two nominal four ton circuits. Charge each circuit with about 12 lbs. of refrigerant to begin. It is likely that more refrigerant will be required to complete the charging procedure. Make sure all hoses are properly purged. From a vacuum feed liquid refrigerant into the high side of the system until the pressure equalizes. At this point there will be about 70 - 80% of the total charge in the system.

Before starting a compressor, the crankcase heater should be energized for a minimum of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize the crankcase heater could result in compressor damage.

If the system is charged from a vacuum, the preheating of the compressor is not necessary. Start the system and allow the system to stabilize to room temperature. Bubbles in the sight glass are not unusual at this point and can be caused by ﬂ ashing from liquid line pressure drop, low sub- cooling or low charge. It is likely that more refrigerant will be required to complete the charging procedure. Adjust the refrigerant charge until the sub-cooling is between 8 - 10° F and the superheat is between 8 - 15° F. There may be ﬂ ashing and/or bubbles in the sight glass when the system is properly charged.

The unit should be allowed to stabilize for several minutes before meaningful measurements can be taken. After the system is allowed to stabilize, veriﬁ cation of a few key measurements should be noted. The discharge should be between 1 10 - 125° F condensing temperature and the sub-cooling should be between 8 - 10° F depending on ambient conditions. Suction temperature should be 58 PSI or greater. Measure the superheat at the compressor suction line a least 6 inches away from the compressor. The superheat should be between 8 - 15° F for units that are water/glycol cooled and air-cooled units with air-cooled condensers. Units with remote condensing unit should have a superheat between 20 - 25° F at the compressor. The sub-cooling will be the same 8 - 10° F.

5.2.3. Flooded System Charging

Flooded systems are units having refrigerant circuits with an optional liquid receiver and head pressure control valve. When the ambient temperature falls during cold weather, the head pressure control valve will regulate the ﬂ ow of refrigerant to ensure nearly constant receiver pressure. The condenser is partially ﬂ ooded with liquid in cold weather. In warm weather the extra refrigerant is stored in the receiver.

Flooded systems require more refrigerant than fan speed control systems. Connect the pressure gauge manifold set to the high and low ports near the compressor. Connect the charging line to

the refrigerant tank and set it for liquid feed. Open the refrigerant tank valve and purge the line a the manifold. Open the high side valve on the manifold only and allow the refrigerant to ﬂ ow until the system pressure equalizes. At this point the system will have 78 - 85% of the total refrigerant charge. Start the (evaporator) blower. Start the compressor 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 microprocessor. Switch the blower and compressor manual switches to the “ON” position. All automatic control is disabled but safety switches will remain functional.

Before starting a compressor, the crankcase heaters should be energized for a minimum

of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize crankcase heaters could result in compressor damage.

Start the evaporator fan and verify the fan rotation. Start the compressor. Check the liquid line sight glass to get a feel for the approximate charge. Bubbles in the sight glass are not unusual at this point and can be caused by ﬂ ashing from liquid pressure drop, low sub-cooling or low charge. It is likely that more refrigerant will be required to complete the charging procedure.

If the receiver (head) pressure is below 230 PSI, block part of the condenser coil surface until the pressure rises to 230 PSI or higher. During extremely cold weather all the condenser fans may have to be de-energized to maintain 230 PSI.

Observe the sight glass on the receiver. Add refrigerant through the suction line until the level of liquid in the receiver is approximately 1/3 from the bottom (the leveling ball in the receiver will start to ﬂ oat) of the sight glass. At this point the receiver is 80% full. Observing the receiver sight glass becomes difﬁ cult when they are remote mounted near the condenser. The unit should be allowed to stabilize for several minutes before meaningful measurements can be taken.

After the system is allowed to stabilize, the superheat at the compressor suction line (reading from at least 6 inched from the compressor) should be 8 - 15°F. Unit with remote condensing units (DRCU) the superheat should be 20 - 25°F at the compressor. The sub-cooling will be the same 8 - 10°F as a standard. Remove any block that may have been used on the condenser coil. If the ambient temperature while charging is below 60°F , some of the refrigerant will be backed up in the condenser coil causing the liquid level in the receiver to drop, this is normal.

5.3 Water/Glycol Cooled Systems

5.3.1. Water/Glycol Cooled Systems Charging

All water/glycol cooled units are factory charged with refrigerant. The water regulating valve should be adjusted to maintain condensing temperature of 105 - 119° F. Saturated suction temperature

should be 33° F or higher. The superheat at the compressor suction line at least 6 inches away from the compressor should be 8-15° F.

Field charging water/glycol systems should be done by referring to the unit electrical nameplate for the factory charge. Although this ﬁ gure represents the original factory charge, it is still necessary to measure and note proper unit operation including superheat, head and suction pressure. Some adjustment to charge may be required.

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 sensing transducer is connected to a shrader ﬁ tting on the discharge line and water is regulated into the condenser coil. Condenser coils may be plate ﬁ n or coaxial type.

Before starting a compressor, the crankcase heaters should be energized for a minimum of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize crankcase heaters could result in compressor damage.

5.4 Refrigerant Handling

The use of recovery/recycling units is required by U.S. Environmental Protection Agency (EPA) regulations. Technicians who service and dispose of air conditioning and refrigeration equipment must recover the refrigerant instead of venting to atmosphere.

Except for extremely small releases of refrigerant such as what occurs when disconnecting service hoses (diminutive release), a technician who knowingly releases or vents refrigerant to the atmosphere is in violation of these regulations. Freon purchasers must be certiﬁ ed technicians and have a valid EPA certiﬁ cation card.

Warning! Pressure relief lines(s) must be vented to the atmosphere per the latest edition of ASHRAE Standard 15 and/or any local building, ﬁ re or mechanical codes.

This applies to all units with either sell and tube condensers or high pressure relief valve options.

5.5 Important Refrigeration Components

5.5.1. Expansion Valve

Each refrigerant circuit has an adjustable thermo-expansion valve (TXV). These are factory adjusted to their nominal rating. Any ﬁ eld adjustment should be to ﬁ ne tune a system that has stabilized and already has acceptable operating parameters.

5.5.2. High Pressure Cutout Switch

Each refrigerant circuit is protected by a high head pressure cutout switch with a manual reset button. The cutout pressure rating for refrigerant R-407c is 400 psi. Physical location is near the compressor which may be either in the evaporator or the condensing section.

5.5.3. Low Pressure Cutout Switch

Each circuit also contains a low suction pressure cutout switch with automatic reset. The cutout pressure rating for this switch is 30 psi. Physical location is near the compressor which can be either in the evaporator or the condensing section.

6.0 GLYCOL SYSTEMS

6.1 Glycol Concentration

The system must be ﬁ lled with water and the appropriate amount of ethylene or propylene glycol to protect against winter freeze-up. To achieve the approximate glycol concentration, it is necessary to know the total system volume. This consists of the sum of the ﬂ uid cooler volume, the evaporator unit volume, and the volume of the interconnecting piping.

The following tables can be used for arriving at an approximate system volume. After installation, the glycol percentage should be checked. The glycol percentage should also be checked at regular intervals to ensure freeze protection.

6.2 Internal (Fluid) Volume

Evaporator Without With Internal Volume Energy Saver Coil Energy Saver Coil* Model Volume, Gallons Volume, Gallons

DALG 06, single circuit 3.0 11.5 DALG 08, single circuit 3.0 11.5 DALG 10, single circuit 4.0 10.5 DALG 13, single circuit 4.0 10.5 DALG 06, dual circuit 4.0 12.5 DALG 08, dual circuit 4.0 12.5 DALG 10, dual circuit 5.0 11.5 DALG 13, dual circuit 5.0 11.5

6.3 Fluid Cooler Internal Volume

Fluid Cooler Internal Fluid Cooler Internal Model Volume, Gallons Model Volume, Gallons DAFC 06 2.5 DAFC 17 6.6

DAFC 07 3.4 DAFC 21 7.4 DAFC 09 4.2 DAFC 24 9.8 DAFC 11 3.3 DAFC 28 12.3 DAFC 15 4.9 DAFC 30 9.8

* 6 and 8 ton units use a 4 row energy save coil

10 and 13 ton units use a 3 row energy saver coil.

6.4 Copper Piping Internal Volume

Pipe Diameter, Volume per 100 Feet inches of Pipe, Gallons 5/8 1.2

3/4 1.8 7/8 2.5 1-1/8 2.5 1-5/8 4.3 2-1/8 9.2

6.5 Freezing Point of Aqueous Solutions Ethylene Glycol, Freezing Point Propylene Glycol, Freezing Point

% by Volume Degrees F % by Volume Degree F 0 32 0 32

10 24 10 27 20 15 20 18 30 4 30 8 40 -13 40 -6 50 -33 50 -2

7.0 CONTROLS

7.1 Mini dap®4 Microprocessor Controller

The Mini dap4 microprocessor controller is the standard controller on the LCS equipment. There is a separate manual that goes into extensive detail regarding functions, features, programming and troubleshooting.

The Mini dap4 microprocessor controller has an entire manual dedicated to its use and operation. This manual must be referenced to complete a thorough unit installation. Start-up is not complete until the Mini dap4 controller settings are established.

7.2 Optional Expanded dap4 Microprocessor Controller

The Expanded dap4 microprocessor controller is available as an upgrade from the Mini dap4 and offers additional features.

The dap4 microprocessor controller panel has an entire manual dedicated to its use and operation. This manual must be referenced to complete a thorough unit installation. Start-up is not complete until the dap4 control panel settings are established.

7.3 Secondary Heat Exchangers

Most of the controls on remote condensers, condensing unit and ﬂ uid coolers consist of basic electromechanical type components. Secondary heat exchangers have separate installation and operation manuals which give complete details on adjusting thermostat settings, etc. Refer also to details in Section 3.5 within this manual.

7.4 Wiring Diagrams

Every Data Aire evaporator , condenser , condensing unit or ﬂ uid cooler comes with a wiring diagram. These diagrams are ‘ladder”- type schematics intended for service personnel. The intent is to allow the technician to understand the wiring details associated with the electrical components and how they interface with the controls as well as peripheral equipment, including secondary heat exchangers.

The wiring diagram in the evaporator will indicate ﬁ eld interface terminals to the secondary heat exchanger. The internal wiring of the heat exchanger is found on a separate diagram which can be found on the inside cover of the heat exchanger electrical box. Both diagram types are also placed inside the shipping/warranty packet that is placed inside the evaporator.

Evaporator wiring diagrams will have a drawing number which starts out with the three letter designation, “DAL”. An example of a typical diagram is DAL-S-908. Wiring diagrams for condensers or condensing units start out with the three letter designation, “DRC”. An example of a typical diagram is DRC-S-001. Wiring diagrams for ﬂ uid coolers start out with the three letter designation, “DFC”. An example of a typical diagram is DFC-S-001

8.0 REGULAR MAINTENANCE ITEMS

8.1 Air Filters

Air ﬁ lters should be checked on a regular basis and changed when they become dirty. This will ensure efﬁ cient operation of the unit. Spare air ﬁ lters should be kept in stock as these tend to be a frequently replaced maintenance item. Air ﬁ lters may require changing as often as monthly. Note also that construction dust on new installations will quickly clog new ﬁ lters.

The Mini dap4 control panel can monitor air ﬁ lters status with an optional dirty air ﬁ lter sensor. Although the unit may have a dirty ﬁ lter alarm, this should not be relied on as the only determinant for replacing air ﬁ lters. A mis-adjusted air ﬁ lter differential pressure switch may not give a proper indication of a clogged air ﬁ lter .

T o check the air ﬁ lter differential pressure switch for proper adjustment, temporarily cover about 75% of the return air opening using heavy cardboard or similar material. The alarm should energize when 75% of the air is blocked, simulating dirty ﬁ lters. If the alarm energizes prematurely or does not energize at all, the pressure switch should be adjusted. Panels must remain closed when determining if an adjustment is necessary.

Air ﬁ lters that require changing can restrict airﬂ ow and create problems such as coil

icing or poor air distribution.

8.2 Belts

Belt tension should be checked regularly (monthly) to ensure proper tension. If tightening is required, loosen the four motor mounting bolts. Turn the adjustment screw on the end of the motor mounting channel until the proper belt tension is attained. Retighten the four mounting bolts. Damage can occur to belts that are overtightened. The amount of play in a typical driveset should be 1/2 inch. When tightening the belts make sure the pulley alignment is true. If the belts are over tightened or if the pulleys are misaligned the bearing and belt life can be signiﬁ cantly shortened.

8.3 Bearings

LCS units with either one (1) and two (2) HP motors have permanent lubricated bearings. Motors of three (3) HP and above have a pillow block bearing that must be greased quarterly, or as needed.

Some motors have zirk type grease ﬁ ttings on the bearings. If so the motor should be greased at least annually. Use NLGI grade 2 lithium or lithium complex grease. Care should be taken to avoid over-greasing. Only one or two pumps from a manual gun are required.

8.4 Humidiﬁ er Canisters

The optional steam generator type humidiﬁ er does not require maintenance other than to replace the canister as required. This frequency will depend on usage and water type. A set of manufacturer’s instructions for the humidiﬁ er is sent as part of the paperwork placed inside the unit when it ships.

8.5 Fuses

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 humidiﬁ ers are resistive loads requiring fast acting fuses.

8.6 Heating Elements

Heating elements do not normally require maintenance. However sometimes they may accumulate a ﬁ lm of dust or dirt when unused for extended periods of time. When energized, the burning debris can create smoke or unpleasant odor. To help avoid this, periodic cleaning is recommended.

8.7 Refrigerant Filter Drier

Factory installed refrigerant ﬁ lter driers do not normally require maintenance. When replacing compressors or other repairs that open the refrigeration system to atmosphere, it is advisable to replace the ﬁ lter drier. The equivalent type and size should be used.

9.0 Warranty Policy

Seller warrants its equipment to Buyer to be free from defects in material and workmanship for a period of eighteen (18) months from date of shipment, as long as equipment is utilized under normal conditions and service and is properly installed; however, the warranty shall not be applicable to any of the following items: refrigerant, belts, ﬁ lters, humidiﬁ er, heaters not regularly cleaned, light bulbs, and any other items either consumed or worn out by normal wear and tear, or by conditions beyond Seller’s control, including (without limitation as to generally) polluted or contaminated air or water.

The Seller’s obligation under this warranty is limited solely to the repair or replacement, at Seller ’s options, of any part or parts thereof which shall, within eighteen (18) months from date of shipment of the equipment to the original purchaser be returned to the factory , transportation charges prepaid, which upon examination shall disclose to the Seller’s satisfaction to have been defective under normal use and service. This agreement to repair or replace defective parts is expressly in lieu of all other warranties, expressed or implied and all other obligations or liabilities on the part of Seller and Seller neither assumes nor authorizes any other person to assume for it any liability or obligation in connection with the sales or service of its equipment, except said repair or replacement of defective parts set forth above.

This warranty does not include any labor charges for work done outside of the factory for replacement of parts, adjustments, repairs, or any other work. Seller’s liability does not include any resulting damage to persons, property , equipment, goods or merchandise arising out of any defect in or failure of any equipment of its manufacture and Buyer hereby waives any claim against Seller arising out of such claim. This warranty shall not cover the repair or replacement of any equipment which has been repaired or altered outside of the factory in any way or which has been subject to negligence, misuse, or abuse, or to pressures in excess of stated limits.

This warranty applies only to the original purchaser of the equipment and does not extend, expressly or by implication, to the third parties or others without the speciﬁ c written approval and acknowledgment of Seller. Buyer’s exclusive remedy and Seller’s maximum liability for any and all loss, injury , damage, costs, or expense arising from any defect covered by this warranty shall be limited to the repair or replacement, but not the installation of any defective material, F .O.B., Seller’s plant; provided however , that Seller shall not be required to replace any part or component (a) which can be repaired, or (b) unless Buyer has given Seller immediate written notice that replacement or repair. In addition, Seller shall not be liable for any cost or expense of replacement or repair contracted for by Buyer with any third person, unless, and then only to the extent that Seller authorizes in writing, such costs or expense.

Seller shall not be liable for any direct, indirect incidental, consequential, or other form of loss, injury , damage, cost, or expense, whether caused by delay, failure, or performance, breach of warranty, or by any cause whatsoever.

Seller’s obligation under this warranty shall be void if Buyer fails: (a) without legal justiﬁ cation to pay Seller, when due, the full purchase price for the equipment sold hereunder; or (b) to have the equipment sold hereunder installed, maintained, and serviced by competent personnel and in accordance with Seller’s instructions.

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

Fax: 714-921-6010 Main 714-921-6011 Engineering

E-mail: tech_support@dataaire.com Technical Support engineering@dataaire.com Engineering sales@dataaire.com Sales

Web site: www.dataaire.com

Job Information: Data Aire Job Number: ________________________________________ Evaporator Serial Number: _____________________________________ Evaporator Model Number: _____________________________________

Condenser/Condensing Unit/ Fluid Cooler Serial Number: _________________________________

Condenser/Condensing Unit Fluid Cooler Model Number: _________________________________

RECOMMENDED LINE SIZING FOR AIR COOLED SPLIT SYSTEMS

UP TO 200 EQUIVALENT FEET

HOT GAS LINES

SINGLE CIRCUIT SYSTEMS DUAL CIRCUIT SYSTEMS

Unit Tons per EQUIVALENT FEET Unit Tons per EQUIVALENT FEET Tonnage Circuit 50 100 150 200 Tonnage Circuit 50 100 150 200

6 6 7/8 1-1/8 1-1/8 1-1/8 6 3 7/8 7/8 7/8 7/8 8 8 1-1/8 1-1/8 1-3/8 1-3/8 8 4 7/8 7/8 7/8 1-1/8 10 10 1-1/8 1-1/8 1-3/8 1-3/8 10 5 7/8 1-1/8 1-1/8 1-1/8 13 13 1-1/8 1-3/8 1-3/8 1-3/8 13 6.5 7/8 1-1/8 1-1/8 1-1/8

LIQUID LINES

SINGLE CIRCUIT SYSTEMS DUAL CIRCUIT SYSTEMS

Unit Tons per EQUIVALENT FEET Unit Tons per EQUIVALENT FEET

Tonnage Circuit 50 100 150 200 Tonnage Circuit 50 100 150 200 6 6 1/2 5/8 5/8 5/8 6 3 1/2 1/2 1/2 1/2

8 8 5/8 7/8 7/8 7/8 8 4 1/2 5/8 5/8 5/8

10 10 5/8 7/8 7/8 7/8 10 5 1/2 5/8 5/8 5/8

13 13 7/8 7/8 7/8 7/8 13 6.5 1/2 5/8 5/8 5/8

SUCTION LINES

SINGLE CIRCUIT SYSTEMS

EQUIVALENT FEET

Unit Tons per 50 100 150 200 Tonnage Circuit HOR VER HOR VER HOR VER HOR VER

6 6 1-1/8 1-1/8 1-3/8 1-1/8 1-3/8 1-1/8 1-5/8 1-3/8 8 8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-3/8 10 10 1-3/8 1-3/8 1-5/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 13 13 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-5/8

SUCTION LINES

DUAL CIRCUIT SYSTEMS

EQUIVALENT FEET

Unit Tons per 50 100 150 200 Tonnage Circuit HOR VER HOR VER HOR VER HOR VER

6 3 7/8 7/8 1-1/8 7/8 1-1/8 7/8 1-1/8 7/8 8 4 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-1/8 10 5 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-1/8 1-3/8 1-1/8 13 6.5 1-1/8 1-1/8 1-3/8 1-1/8 1-3/8 1-1/8 1-5/8 1-3/8

HOR = HORIZONTAL VERT = VERTICAL

Data Aire, Inc.

Monthly Maintenance Inspection Checklist

Model No. __________________ Serial No. ____________________ Prepared by: _______________ Date: ___ / ___/ 201__

Air Filters

___Check for restricted air ﬂ ow

Blower Section

___Blower wheel free of debris moves freely ___Check belt tension and condition ___Bearings in good condition ___Check pulleys and motor mounts

Air Distribution Section

___Check for restriction in grille(s)

Compressor(s)

___Check for leaks

Refrigeration Cycle/Section

___Check crank case temperature Air Cooled Condenser (if applicable)

___Condenser coil clean ___Motor mounts tight ___Motor fan bearings in good condition ___Refrigeration lines properly supported

Water/Glycol Fluid Cooler (if applicable) ___Water regulating valve function ___ Check for water/glycol leaks (piping area)

Glycol Pump(s) (if applicable) ___Glycol leaks (pump area) ___Pump operation ___Auto air vent clean of mineral deposits

Steam Generating Humidiﬁ er (if applicable) ___ Check canister for deposits and water level ___ Check condition of steam hose and clamps

Electrical Panel ___Check contactor operation ___Mini dap4 controller operations

Equipment Runtimes

Blower _________ hrs Condenser _________ hrs Compressor(s) _________ hrs Reheat _________ hrs Humidiﬁ er _________ hrs Dehumidiﬁ cation _________ hrs Energy Saver _________ hrs

___ Reset all to read zero runtimes Temperature/Humidity set at: ___° ___% RH Notes: ______________________________

_____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________

Condensate Drain and Pump (if applicable) ___Check for water leaks ___Check for restricted air ﬂ ow ___Pump operation

Data Aire, Inc.

Quarterly Maintenance Inspection Checklist

Model No. _______________________ Serial No. ___________________________ Prepared by: _____________________ Date: ___ / ___/ 201__

Air Filters

____ Check for restricted air ﬂ ow ____ Check ﬁ lter differential switch ____ Wipe ﬁ lter rack section clean

Blower Section

____ Blower wheel free of debris and moves freely ____ Check belt tension and condition ____ Bearings in good condition ____ Check air ﬂ ow safety switch operation ____ Check pulleys and motor mounts

Air Distribution Section

____ Check for restriction in grille(s)

Compressor(s)

____ Check for leaks

Refrigeration Cycle/Section

____ Check for moisture (site glass) ____ Check suction pressure ____ Check discharge pressure ____ Check hot gas bypass valve operation ____ Check thermostatic expansion valve operation ____ Check solenoid valve operation

Steam Generating Humidiﬁ er (if applicable) ____ Check canister for deposits and water level ____ Check condition of steam hose and clamps ____ Check drain and ﬁ ll valve for deposits

Reheat (if applicable) ____ Check reheat element(s) for dust

____ Check high limit switch operation

Electrical Panel ____ Check fuses

____ Check contactor operation ____ Check all electrical connections ____ Check operation sequence ____ Check calibration of change over thermostat (Energy Saver System Only)

Equipment Runtimes

Blower ____________ hrs Condenser ____________ hrs Compressor(s) ____________ hrs Reheat ____________ hrs Humidiﬁ er ____________ hrs Dehumidiﬁ cation ____________ hrs Energy Saver ____________ hrs

Air Cooled Condenser (if applicable) ____ Condenser coil clean ____ Motor mounts tight ____ Motor fan bearings in good condition ____ Refrigeration lines properly supported ____ Heated receiver site

Water/Glycol Fluid Cooler (if applicable) ____ Water regulating valve function ____ Check solution _____% ____ Check for water/glycol leaks (piping area) ____ Water/Glycol ﬂ ow switch operational

Glycol Pump(s) (if applicable) ____ Glycol leaks (pump area) ____ Pump operation ____ Auto air vent clean of mineral deposits

Condensate Drain and Pump (if applicable) ____ Check for water leaks and restricted ﬂ ow ____ Pump operation

____Reset all to read zero runtimes Temperature/Humidity set at: _____° _____% RH Notes: _____________________________________

____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________

Superheat and Suction Pressure

Trouble Shooting Guide

Low Suction Pressure and High Superheat

1. Moisture, dirt, wax

2. Undersized valve*

3. High superheat adjustment

4. Gas charge condensation

5. Dead thermostatic element charge

6. Wrong thermostatic charge

7. Evaporator pressure drop - no external equalizer

8. External equalizer location

9. Restricted or capped external equalizer

10. Low refrigerant charge

11. Liquid line vapor a. Vertical lift b. High friction loss c. Long or small line d. Plugged drier or strainer

12. Low pressure drop across valve a. Same as #11 above b. Undersized distributor nozzle or circuits c. Low condensing temperature

High Suction Pressure - Low Superheat

1. Oversized valve*

2. TXV seat leak

3. Low superheat adjustment

4. Bulb installation a. Poor thermal contact b. Warm location

5. Wrong thermostatic charge

6. Bad compressor - low capacity

7. Moisture, dirt, wax

8. Incorrectly located external equalizer

Low Suction Pressure - Low Superheat

1. Low load

a. Not enough air b. Dirty air ﬁ lters c. Coil icing

2. Poor air distribution

3. Poor refrigerant distribution

4. Improper compressor-evaporator balance

5. Evaporator oil logged

6. Flow from one TXV affecting another’s bulb

* Data Aire has ensured that valves are sized properly as the unit ships from the factory.

Temperature Pressure Chart

Temperature (°F) R-407c R-410a 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 53.2 110.0 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 75.1 140.7 50 77.1 143.3 55 106.0 156.6 60 116.2 170.7 65 127.0 185.7 70 138.5 201.5 75 150.6 218.2 80 163.5 235.9 85 177.0 254.6 90 191.3 274.3 95 206.4 295.0 100 222.3 316.9 105 239.0 339.9 110 256.5 364.1 115 274.9 389.6 120 294.2 416.4 125 314.5 444.5 130 335.7 474.0 135 357.8 505.0 140 380.9 537.6 145 405.1 571.7 150 430.3 607.6

Air Cooled Systems ..............7, 14, 20, 21

Air Filters ..............................................27

Air Vents ...............................................12

Ambient Thermostats .....................18, 19

Auxiliary Control Wiring ...........................15

Bearings ..................................................27

Belts.........................................................27

Charging

Air Cooled Fan Speed Systems .........20

Air Cooled Flooded Systems..............21

Air Cooled Split Systems....................20

Flooded Systems ...............................21

Water/Glycol Systems ........................22

Coils

Auxiliary Chilled Water .......................13

Condenser......................................... 22

Evaporator.................................... 11, 12

Fluid Cooler ..................... 14, 15, 19, 24

Volume see Volume Compressors

Crankcase Heaters ......................22, 23

Fan Motor .............................................7

Condensate Pumps ..................7, 13,14, 16

Condensers ... 10 ,11, 15, 17, 18, 20, 21, 26 Condensing Units ... 7, 10, 11, 15, 17, 18 25 Connection Sizes

Air Cooled Units .................................10

Fluid Coolers ......................................10

Water/Glycol Cooled Units .................10

Contact Data Aire ....................................30

Controls

Mini dap4 Contoller ............................25

dap4 Controller.................................. 25

Wiring Diagrams .................................26

Crankcase Heaters ............... 20, 21, 22, 23

dap4 Controller ........................................25

Differential Pressure Switch ....................27

Discharge Lines ............................. 9, 11, 31

Ducting ......................................................7

Electrical

Evaporator....................................15, 16

Outdoor Heat Exchanger .............15, 17

Energy Saver ...............................13, 19, 25

Expansion Valve ..........................11, 12, 24

Expansion Tank .......................................12

Evaporator 9, 12, 13, 15, 16, 18, 19, 20, 24

Fan Speed Control Systems..............18, 21

Field Piping

Air Cooled ..........................................10

Auxiliary Chilled Water .......................13

Condensate ........................................13

Condenser.......................................... 11

Condensing Unit.................................11

Fluid Cooler ..................................12, 25

Glycol Cooled ...............................12, 25

Steam Generator Humidiﬁ er ..............13

Water Cooled .....................................12

Field Wiring

Remote Alarm Contacts .....................16

Remote Condenser ............................15

Remote Condensing Unit ...................15

Remote Fluid Cooler ..........................15

Remote Sensors ................................16

Remote Shutdown..............................16

Filter

Air .......................................................27

Drier ...................................................28

Differential Pressure Switch ...............27

Flooded Systems .....................................21

Flow Switch .............................................12

Fluid Coolers .........................12, 14, 15, 19

Fluid Sensing Thermostats ......................19

Freezing Point, Aqueous Solutions..........25

Fuses .......................................................28

Glycol Concentration ...............................24

Glycol Systems ................12, 15, 19, 20, 23

Grounding ................................................15

Head Pressure.....17, 18, 20, 21, 22, 23, 24

Control Valve ......................................21

Cutout Switch .....................................24

Heat

Crankcase ....................... 20, 21 ,22, 23

Electric ...............................................28

Reheat Elements................................28

High Pressure Cutout Switch...................24

Horizontal Units .........................................8

Humidiﬁ er

Canister ........................................13, 27

Steam Generator Humidiﬁ er ........13, 27

Inspection ..................................................6

Installation .................................................6

Internal Volume see Volume

Liquid Lines ....................................... 11, 31

Locating

Evaporator............................................6

Secondary Heat Exchanger ...............17

Low Pressure Cutout Switch ...................24

Maintenance

Bearings .............................................27

Belts ...................................................27

Filters .................................................27

Fuses .................................................28

Heating Elements ...............................28

Humidiﬁ er Canisters ...........................28

Refrigerant Filter Drier........................28

Model Identiﬁ cation....................................8

Paperwork .................................................7

Piping See Field Piping Pumps

Centrifugal ....................................12, 14

Condensate ........................7, 13, 14, 16

Receivers................................................. 21

Recovery .................................................23

Refrigerant .................14, 20, 21, 22, 23, 35

Charge see Charging

Handling .............................................23

Recovery ............................................23

Reheat

Elements ............................................28

Remote

Alarm Contacts...................................16

Condensers .................. 7, 11, 15, 18, 21

Condensing Units ..................... 7, 11, 15

Fluid Coolers ........12, 13, 14, 15, 17, 19

Sensors ..............................................16

Shutdown ...........................................16

Rigging ....................................................17

Sight Glass ......................19, 20, 21, 22, 23

Start Up Sheet ...........................................7

Storage ......................................................8

Strainer ....................................................12

Subcooling .............................20, 21, 22, 23

Suction Lines ..............................11, 12, 31

Superheat ........................20, 21, 22, 23, 34

Thermo-expansion Valve (TXV) 11, 12, 24, 34 Thermostats

Ambient ........................................18, 19

Fluid Sensing .....................................19

Traps ........................................... 11, 12, 13

Valves

Head Pressure Control.......................21

Humidiﬁ er Makeup Water ...................13

Shutoff ................................................12

Water Regulating ...............................23

Voltage

Phase Check ......................................15

Volume

Copper Piping ....................................25

Fluid Coolers ......................................24

Internal Fluid ......................................24

Warranty ....................................7, 8, 27, 29

Wiring ..........................................15, 16, 26

Zirk Fittings ..............................................28

www.dataaire.com e-mail: sales@dataaire.com

Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice.

DALAIOM-1209 Rev D

230 W. BlueRidge Avenue

Orange, CA 92865

800-347-2473

A Member of the CS Group of Companies

Data Aire DALA 06, DALA 13, DALA 08, DALA 10, DALW 06 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual