Data Aire DAMA 0112, DAMA 1.512, DAMA 0212, DAMA 2.512, DAFC 06 Installation, Operation And Maintenance Manual

...

MINI CEILING SERIES

Installation, Operation and Maintenance Manual

1, 1.5, 2 and 2.5 ton

Air, Water and Glycol Cooled DX and Chilled Water

CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION ENVIRONMENTAL CONTROL SYSTEM. PROPER INSTALLATION, OPERATION AND MAINTENANCE OF THIS EQUIPMENT WILL ENSURE YEARS OF OPTIMAL PERFORMANCE.

This manual is intended to assist trained service personnel by providing necessary guidelines for this particular equipment. Service to Data Aire units should be done by qualiﬁ ed individuals with an adequate background in areas such as HVAC, electrical, plumbing and electronics, as applicable.

Service performed by unauthorized or unqualiﬁ ed 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 Vertical Airﬂ ow Units ...................................................................................................7

1.3.2 Air Cooled Package Units ..........................................................................................7

1.3.3 Horizontal Airﬂ ow Units ..............................................................................................8

1.3.4 Indoor Condensers & Condensing Units ....................................................................8

1.4 Paperwork ..................................................................................................................8

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

2.0 PIPING .......................................................................................................................10

2.1 Split Air Cooled Unit Piping ......................................................................................10

2.1.1 Discharge Lines........................................................................................................10

2.1.2 Liquid Lines ..............................................................................................................10

2.1.3 Suction Lines ............................................................................................................10

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

2.2.1 Connection Sizes, Water/Glycol Cooled Units .........................................................13

2.2.2 Connection Sizes, Fluid Coolers ..............................................................................13

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

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

2.5 Humidiﬁ er Piping ......................................................................................................14

2.6 Leak Testing .............................................................................................................14

2.7 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 .....................................................................................................................16

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

3.7.1 Mini DAP™ II ............................................................................................................16

3.7.2 Mini DAP III ..............................................................................................................16

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

3.8.1 Mini DAP II ...............................................................................................................16

3.8.2 Mini DAP III ..............................................................................................................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

Table of Contents, continued

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER - Continued

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

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

4.6 Fluid Coolers - Model DAFC ......................................................................................... 18

4.6.1 Fluid-Sensing Thermostats ........................................................................................... 18

4.6.2 Energy Saver Cooling ...................................................................................................18

5.0 CHARGING ........................................................................................................................19

5.1 Air Cooled Systems .............................................................................................................19

5.1.1 Package Air Cooled Systems .........................................................................................19

5.1.2 Split Indoor Air Cooled Systems Charging .....................................................................19

5.1.3 Fan Speed Control System Charging.............................................................................20

5.1.4 Flooded System Charging ..............................................................................................21

5.2 Water/Glycol Cooled Systems ........................................................................................22

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

5.2.2 Factory Charge for Water/Glycol Cooled Systems .........................................................22

5.3 Refrigerant Handling ......................................................................................................22

5.4 Important Refrigeration Component ...............................................................................23

5.4.1 Expansion Valve .............................................................................................................23

5.4.2 High Pressure Cutout Switch ........................................................................................23

5.4.3 Low Pressure Cutout Switch ..........................................................................................23

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.......................................................................................24

6.5 Freezing Point of Aqueous Solutions .............................................................................24

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

7.1 Standard Thermostat ......................................................................................................25

7.2 Optional Programmable Thermostat ..............................................................................25

7.3 Optional Mini DAP II Microprocessor Control Panel .......................................................25

7.4 Optional DAP II Microprocessor Control Panel ..............................................................25

7.5 Secondary Heat Exchangers..........................................................................................25

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

8.0 REGULAR MAINTENANCE ITEMS

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

8.2 Belts ...............................................................................................................................27

8.3 Bearings .........................................................................................................................27

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

8.5 Fuses ..............................................................................................................................27

8.6 Heating Elements ...........................................................................................................27

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

Table of Contents, continued

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 ......................................................................................................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 supercede 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 or 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 entering the space. Failure to provide a vapor barrier can compromise the ability to control space conditions.

Introduction of outside air into the controlled 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 yellow shipping tag located on the unit door 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 a 50% safety factor to the weight of the unit to determine the strength of the supporting structural members.

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.

Note there are many available unit conﬁ gurations for Mini Ceiling systems. 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 are normal functions of this equipment. Proper drain connections must be made to ensure proper removal. Unit will require water connections for condensate removal

and possibly for humidiﬁ er make-up 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 Vertical Airﬂ ow Units

The evaporator (cooling) section is typically mounted over a standard 2’ x 4’ T-bar ceiling grid, supported by four threaded rods. The evaporator (cooling) section will be referred to as the evaporator section from here on even though the coil on chilled water units is not a true evaporator coil.

Four threaded support rods must be securely attached to the building structure. 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. Be sure to allow for the depth of the Supply/Return air plenum when calculating the height of the unit above the ceiling.

The 5” tall vertical Supply/Return plenum assembly is attached to the bottom of the evaporator section after the evaporator section has been hung. Six screws fasten the plenum to the evaporator section. The Supply/Return air grilles should be temporarily removed for access. The plenum mounts ﬂ ush to the ceiling grid.

1.3.2 Air Cooled Packaged Units

Air cooled package units require an additional condenser fan section to be mounted to the end of the evaporator section at the condenser coil. Place a gasket around the perimeter of the condenser coil opening. Connect the female motor plug from the condenser blower section to the male plug inside the evaporator section. Attach the condenser blower section using four (4) self-drilling #10 self drilling sheet metal screws.

Most applications will allow for the condenser discharge air to blow out into the ceiling space and no ducting is required. The ceiling space must be large enough to dissipate the rejected heat. Plenum space temperature should not exceed 95o F. If ducting is required the additional static imposed by ductwork on the air intake and/or discharge should not exceed 0.3”. In some applications a factory provided low ambient damper is used at the condenser air intake. The air intake is modiﬁ ed from its normal grilled openings to a single 15” x 17” duct collar.

1.3.3 Horizontal Airﬂ ow Units

Ductwork is connected to factory provided duct collars on the supply and return air openings. Four threaded support rods must be securely attached to the building structure. 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.

Note some options call for a combination of vertical and horizontal airﬂ ow conﬁ guration. In that case, the 5” plenum assembly described above is necessary.

1.3.4 Indoor Condensers and Condensing Units

These 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. Water cooled condensing sections have no airﬂ ow connections.

Typical installations have the condenser or condensing section physically near the evaporator, especially since most have 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 should be completed during installation. Also included in the paperwork is a warranty/information packet that provides important wiring diagrams, speciﬁ c component literature, warranty registrations cards and other valuable paperwork, including a copy of this Installation/Operation and Maintenance manual.

A 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 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, protected from freezing temperatures, protected from damage by other equipment in storage or transportation equipment, never stacked, and avoid frequent relocation.

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.

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 beyond 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 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 six feet from the compressor.

Discharge line pressure drop should not exceed 6 PSI. 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.

2.1.2 Liquid Lines

Liquid line size is determined by pressure drop and velocity . The liquid line pressure drop should be not exceed 5 PSI. 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 should be avoided.

2.1.3 Suction Lines

Some applications call for the compressor to be mounted in the outdoor condenser, or condensing unit. Such cases require ﬁ eld piping of liquid and suction lines. Suction lines are trapped similarly to discharge lines except for the inverted trap at the top of the suction line and the line needs to be insulated with a minimum 1/2” thick insulation or per code. Common practice for suction line selection, see page

2.1.4 Connection Sizes, Air Cooled Units

31, and installation should be followed.

Model Hot Gas Liquid Suction

DAMA 0112 1/2” 1/2” 3/4” Note: Unit will have a Liquid Line and DAMA 1.512 1/2” 1/2” 3/4” either a Hot Gas or Suction Line DAMA 0212 1/2” 1/2” 3/4” DAMA 2.512 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 will

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. 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.

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 CRAC unit. This can be accomplished with a tubing cutter for smaller pipes and reciprocating saw with a metal cutting blade for larger pipes or if there is a clearance problem.

Shutoff valves, ﬁ eld provided, should be installed within a few feet of the inlet and outlet connections of the CRAC unit to allow the unit to be isolated for service. There should be a means of draining the unit for service. Drain valves with hose bib connections should be located at the lowest point on the piping connected to the units for this purpose. A ﬁ ll valve with a hose bib connection should also be used on the supply line or return line at the unit to allow the unit to be drained.

All water/glycol cooled units with plate-ﬁ n type condensers have a strainer shipped loose. This strainer should be ﬁ eld installed in the supply line with shut off valves, ﬁ eld provided, before and after the strainer, the strainer must be cleaned periodically.

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.

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Data Aire DAMA 0112, DAMA 1.512, DAMA 0212, DAMA 2.512, DAFC 06 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

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