DA Data Cool Series General instructions

Data Cool
Installation, Operation and Maintenance Manual
2 and 3 ton
Air, Water and Glycol Cooled DX and Chilled Water

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CONGRATULATIONSONTHESELECTIONOFADATAAIREPRECISIONENVIRONMENTAL
CONTROLSYSTEM. PROPERINSTALLATION,OPERATIONAND MAINTENANCE OFTHIS
EQUIPMENTWILLENSUREYEARS OF OPTIMALPERFORMANCE.
This manual is intended to assist trained service personnel by providing
necessary guidelines for this particular equipment. Installation and service to
Data Aire units should be done by qualified individuals with an adequate
background in areas such as HVAC, electrical, plumbing and electronics, as
applicable.
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.

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Table of Contents
MODEL IDENTIFICATION ........................................................................5
1.0 INSTALLATION.......................................................................................... 6
1.1 RoomConsiderations ................................................................................................ 6
1.2 Inspection .................................................................................................................. 6
1.3 Locating theUnit ........................................................................................................ 6
1.3.1 IndoorCondensingUnit.............................................................................................. 7
1.4 LevelingLegs ............................................................................................................ 7
1.5 Paperwork ................................................................................................................. 7
1.6 Storage......................................................................................................................7
2.0 PIPING........................................................................................................ 8
2.1 SplitAir Cooled Unit Piping ........................................................................................8
2.1.1 Liquid Lines ...............................................................................................................8
2.1.2 SuctionLines .............................................................................................................8
2.1.3 ConnectionSizes,AirCooled Units............................................................................ 9
2.1.4 FieldPiping, RemoteCondensing Unit....................................................................... 9
2.2 Water/GlycolCooledUnit Piping .............................................................................. 10
2.2.1 Liquid Lines .............................................................................................................10
2.2.2 SuctionLines ........................................................................................................... 10
2.2.3 ConnectionSizes,Water/GlycolCooled Units .......................................................... 11
2.2.4 ConnectionSizes, FluidCoolers .............................................................................. 11
2.3 Chilled Water Piping ................................................................................................ 11
2.4 Condensate Drain Piping......................................................................................... 11
2.5 Humidifier Piping .....................................................................................................12
2.6 LeakTesting ............................................................................................................ 12
2.7 Evacuation............................................................................................................... 12
3.0 ELECTRICAL CONNECTIONS............................................................... 13
3.1 Electrical Service .....................................................................................................13
3.2 Nameplate Ratings ..................................................................................................13
3.3 Grounding ................................................................................................................13
3.4 VoltageTolerance ....................................................................................................13
3.5 AuxiliaryControlWiring ............................................................................................ 13
4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER .......... 14
4.1 Rigging .................................................................................................................... 14
4.2 Locating theRemoteHeat Exchanger ......................................................................14
4.3 Electrical Service .....................................................................................................14
4.4 Air Cooled Condensers - Model DRCU.................................................................... 15
4.4.1 FanSpeedControl...................................................................................................15

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Table of Contents, continued
5.0 CHARGING..................................................................................................................... 15
5.1 Voltage Phase Check............................................................................................................ 15
5.1.1 Evaporator..................................................................................................................... 15
5.1.2 SecondaryHeatExchanger............................................................................................ 15
5.2 Air Cooled Systems....................................................................................................... 15
5.2.1 SplitIndoorAir Cooled Systems Charging...................................................................... 15
5.2.2 FanSpeed ControlSystem Charging ............................................................................. 16
5.3 Water/Glycol CooledSystems ........................................................................................ 17
5.3.1 Water/GlycolCooled SystemsCharging......................................................................... 17
5.4 RefrigerantHandling ...................................................................................................... 18
5.5 ImportantRefrigerationComponents.............................................................................. 18
5.5.1 ExpansionValve ............................................................................................................18
5.5.2 HighPressure Cutout Switch ......................................................................................... 18
5.5.3 LowPressureCutout Switch .......................................................................................... 18
6.0 CONTROLS ................................................................................................................... 18
6.1 StandardThermostat...................................................................................................... 18
6.2 OptionalProgrammableThermostat............................................................................... 19
6.3 OptionalMiniDAP II Microprocessor Control Panel........................................................ 19
6.4 Optional DAP IIMicroprocessor ControlPanel ............................................................... 19
6.5 Wiring Diagrams............................................................................................................ 19
7.0 REGULAR MAINTENANCE ITEMS..............................................................20
7.1 Air Filters ....................................................................................................................... 20
7.2 Bearings ........................................................................................................................ 20
7.3 HumidifierCanisters ...................................................................................................... 20
7.4 Fuses ............................................................................................................................ 20
7.5 HeatingElements........................................................................................................... 20
7.6 RefrigerantFilterDrier ................................................................................................... 21
8.0 WARRANTY...............................................................................................22
9.0 CONTACT DATA AIRE................................................................................................ 23
Line Sizing Chart......................................................................................................................... 24
Monthly Maintenance Inspection Checklist .............................................................................. 25
Quarterly Maintenance Inspection Checklist ............................................................................ 26
INDEX .................................................................................................................................. 28 - 29

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Model Identification

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1.0 INSTALLATION
Thereis no intenton thepartof DataAire,Inc. todefinelocal codesor statuteswhichmay
supercedecommontradepractices. Themanufacturer assumes noresponsibilityfortheir
interpretation. Consult local building codes and the National Electrical Code for special
installationrequirements.
1.1 Room Considerations
Precisionairconditioningequipmentisdesignedtocontrolspaceswithinclosetolerancesoftemperature
andhumidity. However,theroommustbebuiltwithapropervaporbarrier. Afilmofpolyethyleneisoften
usedon wallsand ceilings. Walls and floors mustalso bepaintedwith a vapor-seal paint. All doorsto
thedataroomshouldbeequippedwithweathersealstopreventtheinfiltrationofnon-neutralconditioned
airfromentering the dataroom. Failureto provide avaporbarrier cancompromisetheability tocontrol
spaceconditions.
Introductionof outsideair intothe spaceshould beminimized. Outside airin excessof 5%of thetotal
circulated air volume can have a significant effect on the overall space conditions and result in poor
spacecontrol. All outsideair thatisintroducedintothespaceshouldbeconditionedtothehumidityand
temperatureparametersofthecomputerroomairconditioning(CRAC)unitsetpointstomaintainproper
roomconditionsandtopreventtheCRACunitsfromrunningexcessivelytomaintaintheroomconditions.
1.2 Inspection
ThisDataAireunithas been factory run-testedandhasgonethroughacomprehensiveinspectionprior
toitspackagingandshipmenttoensurethatitarrivesinexcellentcondition. However,shippingdamage
canoccur and avisual inspectionofthe outercrating immediately upondelivery shouldbe performed.
Noteanyexternaldamageorothertransportationdamageonthefreightcarrier’sforms. Inspecttheunit
itselfforinternaldamage. Aclaimshouldbefiledwiththeshippingcompanyiftheequipmentisdamaged
orincomplete.
Looseitemssuch asthermostat or otheroptional controlpanelsare shippedwith the unit. Referto the
manilashipping taglocated on the unit panelfor details
Freight damage claims are the responsibility of the purchaser. Actionto recoverlosses
shouldbefiled immediately withthefreight company. Refer toyellowshipping taglocatedon
theunit doorfor details
Freightdamageclaimsare theresponsibilityofthe purchaser. Actiontorecoverlosses shouldbefiled
immediately. Pleasenotifyfactory personnel ofany claims.
1.3 Locating the Unit
When installing the unit, sufficient space must be allowed for airflow clearance, wiring, plumbing and
service access. It is recommended that each side and front have a clearance of at least 12" to allow
servicingoftheunit.
Some sides may not require as much service clearance. Refer to the unit component drawings for
assistance. Rearclearance isnot required.

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NotetoInstallingContractor: Condensationformationand frequenthumidifierflushing(when
humidifier is installed) are normal functions of this equipment. Drain connections must be
made to ensure proper water removal. Unit will require drain connections for condensate
removalandwaterconnectionspossiblyforhumidifier(wheninstalled)makeupwater,chilled
waterand/or hot water. Installation ofunitsaboveequipment that couldsustain water dam-
age should be avoided.
1.3.1 Indoor Condensing Units
These24” tallsection is to be mounted using four threadedrods. Air cooledcondensing unitshave
factoryprovided ductcollars onthe supplyand intakeair openingsas appropriate. Split water cooled
condensingsections do notrequire airflowconnections.
Typical installationshave thecondensingsection physically neartheevaporator,especially since
mosthaveshared electricalline power.
1.4 Leveling Legs
EachDataCool comesequipped with fourleveling legs. Whenmounting the uniton thefloor, to
ensurethe best possibleoperation theleveling legsshould be adjustedso thatthe unitis level.
1.5 Paperwork
EachDataAireunitshipswithastart-upsheetthatmustbecompletedduringinstallation,and startupof
the unit(s). Also included in the paperwork is a warranty/information packet that provides important
wiringdiagrams,specificcomponentliterature,warranty registrationcardandothervaluablepaperwork,
includingacopyofthis Installation/Operation andMaintenancemanual.
A manila tag is attached to the outside panel to indicate articles that may have been packaged and
shippedloosewithintheunitcabinet. Thiscouldbe the thermostatorotheroptionalcontroldevicesthat
arenotfactorymounted.
Itis theresponsibility ofthe installing contractor to return the start-upsheet andwarranty registration
card to Data Aire for proper activation of the unit warranty. Failure to do so may cause delays in
warrantyrelatedservices andin some casesvoid the warranty.
1.6 Storage
YourDataAireequipmentcomesreadyforimmediateinstallation. Insomeinstancesitmaybenecessary
to store the equipment for a period of time. If you must store the equipment it should be done in a dry
area,outoftheweather,protectedfromfreezingtemperatures,protectedfromdamagebyotherequipment
instorageor transportationequipment, never stacked,and avoidfrequentrelocation.
Ifequipment is storedfor longer than30 daysspecial precautions mustbe taken toavoid coildamage.
Allcoilsshouldbechargedandsealedwithalowpressure(lessthan25psig)inertgas,suchasnitrogen.
Thispreventscontaminatesfromenteringthecoils;thenwhentheseal is broken atinstallation,therush
ofescapinggasverifiesthecoil isstillleakfree. Ifcoilsare not chargedandsealedcondensationmixes
withair pollutantsforming aweak acidand cancause pin hole leaks to develop inthe coiltubes.
Whenequipment is installedafter storage cautionshould be takento inspect andreplace, if required,
rubberhoses. Allmovingparts,suchasblowersand motors, shouldbehandtested to ensurethatthey
arefreeand clearprior to start-up. Finally, verifythat alllubricationis freshandfull.
Itis the responsibilityof theinstalling contractor toreturn thestart-up sheet andwarranty registration
cardto DataAire for proper activation ofthe unitwarranty. Failureto do so may cause delays andin
somecasesvoid thewarranty.

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2.0 PIPING
2.1 Split Air Cooled Unit Piping
Refer to the attached Line Sizing chart on page 24 for a guideline for sizing refrigerant lines. The
ultimateresponsibilityfor linesize selection isthat oftheinstallingcontractor or projectengineer. Data
Aire does not assume this responsibility. The chart covers distances up to 200 equivalent feet. For
installationsbeyond thisdistance,consult ASHRAE or similarreferences.
Standard pipingpracticemust beused toensure proper oilreturn andefficientoperation.
Theinterconnectinglines tothe remote aircooled condensingunitmust beinstalledby a
qualifiedrefrigeration mechanic.
The discharge, suction and liquid lines need to be refrigerant grade copper and in accordance with
localcode. Allrefrigerationpipingshouldbeinstalledwithhightemperaturebrazedjoints. Whenbrazing,
asupply of nitrogengas needstobe fedthrough the refrigerantlines. Be sureto open theother endof
therefrigerant line allowingthe nitrogentobleed offand not causeexcess pressurebuildup.
DataAire recommendsa silver/phosphorus/copper alloy with between5% and15% silverbe usedto
brazerefrigerantlinesettotheindoorandoutdoorunits. Nitrogenneedstobeflowingthroughthelines
toeliminate carbondeposit buildup onthe insideof thejoints whichcould contaminate therefrigerant
andrestrict the meteringdevice.
2.1.1 Liquid Lines
Liquid line size is determined by pressure drop and velocity. The liquid line pressure drop should not
exceed5 PSI. Therecommended velocityshould bebetween 200and 300FPM. Toavoid excessive
liquidlinepressuredrop,theaircooled condensing unitshouldbelocatedaboveorat the samelevelas
theevaporator. Condensingunitinstallationmorethantenfeetbelowtheevaporatorshouldbeavoided.
2.1.2 Suction Lines
Thisunithas the compressorinthe condensingunitandrequires fieldpipingof liquid andsuctionlines.
Suctionlines are trappedsimilarly to dischargelines. Common practice forsuction line selectionand
installationshouldbefollowed.

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2.1.3
Connection Sizes, Air Cooled Units
Model Liquid Suction
DACU 02 1/2" 3/4" Note: Unitwill havea LiquidLine and
DACU 03 1/2" 3/4" SuctionLine
DACU 04 1/2" 3/4"
DACU 05 1/2" 3/4"
Fieldconnectionsattheindoorevaporatorandremotecondensingunitwillnotnecessarilybe
thesame asthe fieldpipe sizerequired. In somecases thesesizes willvary significantly.
2.1.4 Field Piping, Remote Condensing Unit

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2.2 Water/Glycol Cooled Unit Piping
Therequired field installedcondenser water pipesizes mayor may notbe the sameas theconnection
sizesattheevaporatororfluidcooler. Thiswilldependonthelengthofpipeandthecalculatedpressure
dropof peripheral components.
Remotewatercooledcondensingunitsmayalso be connected tobuildingwaterortowerwatersources.
Pipesizewill dependon length ofrun andthemaximum waterflow required.
Shutoffvalvesshouldbeinstalledwithin afewfeetoftheinletandoutletconnectionsoftheevaporatorto
allowtheunittobeisolatedforservice. Afill valve with ahosebibconnectionshouldalsobeusedonthe
supplylineor returnlineat theunitto allowtheunit tobedrained.
Water/glycol cooled units with plate-fin type condensers ship with a strainer. Strainer should be field
installedon the inlet water pipe. Strainers mustbe cleanedperiodically.
2.2.1 Liquid Lines
Liquid line size is determined by pressure drop and velocity. The liquid line pressure drop should not
exceed5 PSI. Therecommended velocityshould bebetween 200and 300FPM. Toavoid excessive
liquidlinepressuredrop,theaircooled condensing unitshouldbelocatedaboveorat the samelevelas
theevaporator. Condensingunitinstallationmorethantenfeetbelowtheevaporatorshouldbeavoided.
2.2.2 Suction Lines
This unit has the compressor in the condensing unit. These cases require field piping of liquid and
suctionlines. Suction linesare trappedsimilarly to discharge lines. Common practice for suctionline
selectionandinstallation should befollowed.
One of the most common problems in a water/glycol system is the presence of air in the
condenserwaterloop. Airventsmustbeinstalledinvariouslocationsinthepipingsystemto
purgetheair, including thehighest point inthe waterloop..
Data Cool