Data Aire gForce DX series User manual

CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION
ENVIRONMENTAL CONTROL SYSTEM. PROPER INSTALLATION, OPERATION
AND MAINTENANCE OF THIS EQUIPMENT WILL ENSURE YEARS OF OPTIMAL
PERFORMANCE.
There are separate User Manuals for other components of your Data Aire precision
environmental cooling system including dap4™, condenser/condensing unit and uid
cooler.
NOTE: 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 qualied individuals with an adequate background in areas
such as HVAC, electrical, plumbing and electronics, as applicable.
WARNING: Service performed by unauthorized or unquali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 purpose of
product improvement or to withdraw any design without notice.

Table of Contents
1INTRODUCTION.......................................................................................................5
1.1 Product Information.............................................................................................5
1.1 Model Identication .............................................................................................5
1.2 Inspection............................................................................................................5
1.3 Paperwork ...........................................................................................................6
2INSTALLATION .........................................................................................................7
2.1 Installation Checklist............................................................................................7
2.2 Room Considerations..........................................................................................7
2.3 Equipment Handling............................................................................................7
2.4 Rigging ................................................................................................................8
2.5 Locating the Unit .................................................................................................8
2.5.1 Downow Units.............................................................................................8
2.5.2 Upow Units..................................................................................................9
2.6 Storage................................................................................................................9
2.7 Piping ................................................................................................................10
2.7.1 Air Cooled Unit Piping.................................................................................10
2.7.2 Discharge Lines..........................................................................................10
2.7.3 Liquid Lines................................................................................................. 11
2.7.4 Suction Lines .............................................................................................. 11
2.7.5 Recommended Line Sizing.........................................................................12
2.7.6 Connection Sizes, Air Cooled Units............................................................13
2.7.7 Field Piping, Remote Condenser................................................................13
2.7.8 Field Piping, Remote Condensing Unit.......................................................14
2.7.9 Refrigerant Piping Protection......................................................................14
2.7.10 Water/Glycol Cooled Unit Piping ................................................................15
2.7.11 Field Piping, Water/Glycol System .............................................................16
2.7.12 Connection Sizes, Water/Glycol Cooled Units ........................................17
2.7.13 Connection Sizes, Fluid Coolers .............................................................17
2.7.14 Auxiliary Chilled Water/Energy Saver Coil Piping ...................................17
2.8 Condensate Drain Piping ..................................................................................17
2.9 Humidier Piping ...............................................................................................18
2.9.1 Steam Generator Humidier.......................................................................18
2.9.2 Dry Steam Humidier..................................................................................18
2.10 Leak Testing ......................................................................................................18
3ELECTRICAL CONNECTIONS...............................................................................19
3.1 Electrical Service...............................................................................................19
3.2 Nameplate Ratings............................................................................................20
3.3 Grounding..........................................................................................................20
3.4 Voltage Tolerance..............................................................................................20
3.5 Auxiliary Control Wiring for Remote Heat Exchangers......................................20
3.6 Remote Shutdown.............................................................................................21
3.7 Remote Alarm Contacts ....................................................................................21
3.8 Condensate Pumps (Optional)..........................................................................21
3.9 Condensate Probe ............................................................................................22
3.10 Water Sensing Cable (Optional)........................................................................22
3.11 Remote Temperature and Humidity Sensors (Optional)....................................22
3.12 Manual Override Switches ................................................................................23
3.13 Wiring Diagrams................................................................................................23
3.14 EEV Connection................................................................................................24

4INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ...........................25
5CHARGING.............................................................................................................25
5.1 Voltage Phase Check........................................................................................25
5.1.1 Evaporator Power Phasing.........................................................................25
5.1.2 Remote Heat Exchanger Fan Motor Phasing.............................................25
5.2 Evacuation.........................................................................................................26
5.3 Air Cooled Systems...........................................................................................26
5.3.1 Fan Speed Control System Charging.........................................................26
5.3.2 Flooded System Charging ..........................................................................28
5.4 Water/Glycol System.........................................................................................29
5.4.1 Water/Glycol Cooled System Charging ......................................................29
5.5 Refrigerant Handling .........................................................................................30
5.6 Important Refrigeration Components ................................................................30
5.6.1 Expansion Valves .......................................................................................30
5.6.2 High Pressure Cutout Switch......................................................................30
5.6.3 Low Pressure Cutout Switch.......................................................................31
5.6.4 Liquid Line Solenoid Valve (Optional).........................................................31
6GLYCOL SYSTEMS ................................................................................................32
6.1 Glycol Concentration.........................................................................................32
6.2 Internal (Fluid) Volume – Up and Downow Evaporators..................................32
6.2.1 Brazed-Plate Condensers...........................................................................33
6.3 Internal (Fluid) Volume – Fluid Coolers.............................................................34
6.3.1 Fluid Cooler Information .............................................................................34
7CONTROLS1...........................................................................................................34
7.1 dap4™ Microprocessor Control Panel ..............................................................35
7.2 Remote Heat Exchangers .................................................................................35
7.3 Electronic Expansion Valve Drive (EDV)...........................................................35
7.3.1 Setup Using Display Panel Guide...............................................................35
7.3.2 Conguration Menu ....................................................................................36
7.3.3 Regulation Menu.........................................................................................38
7.3.4 How to Manually Open and Close an (EEV)...............................................39
7.3.5 Multiple EEV Conguration.........................................................................40
8REGULAR MAINTENANCE ITEMS........................................................................41
8.1 Air Filters ...........................................................................................................41
8.2 Fuses.................................................................................................................41
8.3 Electric Reheat..................................................................................................41
8.4 Humidier ..........................................................................................................41
8.4.1 Humidier Canisters ...................................................................................42
8.5 Refrigerant Filter Drier.......................................................................................42
8.6 Plenum (Plug) Fans...........................................................................................42
8.6.1 Electronically Commutated Motors.............................................................42
8.6.2 TESTING ....................................................................................................43
9CONTACT DATA AIRE..........................................................................................44
10 MAINTENANCE/INSPECTION CHECKLIST .......................................................45
1

5
1 INTRODUCTION
1.1 Product Information
The Data Aire gForce GF environmental control, direct expansion, dual circuit Computer Room Air
Conditioner (CRAC) equipment provides a high sensible cooling, is self-contained, factory assembled,
piped, wired, and factory tested prior to shipment. These units include an enclosure/cabinet assembly,
fan section, lter section, cooling coils, controls, and interconnecting piping internal to unit.
The Data Aire CRAC unit provides cooling, reheat, humidication, dehumidication and air ltration.
The unit is provided with a Data Aire dap4™ microprocessor controller for precision control. The unit
must be operated in a conditioned space within the operating envelope ASHRAE recommends for data
centers. Operating outside this envelope can alter the operating performance and decrease equipment
reliability. Return air to the unit must be no cooler than the ASHRAE recommendation for proper unit
operation. Operating below this can alter the operating performance and decrease equipment reliability.
Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.”
1.1 Model Identication
GF XX- XXX XX-XXX
│││││││
Model Series │││││││
gForce GF Dual Circuit
────
┘││││││Auxiliary Coils
│││ │ │ └ES - Energy Saver
Type of Cooling ││ │ │ │ACW - Auxilary Chilled Water
A - Air Cooled │ │ │ │ │
W - Water Cooled
────
────
┘││││Voltage
G - Glycol Cooled │││└
────
────
2 - 208/230 VAC
│││4 - 460 VAC
Configuration │││3 - 380/400V - 50Hz
Downflow
────
────
────
┘││
Upflow ││Phase
│└
────
────
3 - Three phase
Model/Capacity in kW │
021 kW │
028 kW │
035 kW
────
────
────
────
────
┘
046 kW
056 kW
070 kW
091 kW
106 kW
gForce GF Model Number
1.2 Inspection
This Data Aire CRAC unit has been factory run-tested and has gone through a comprehensive inspection
prior to its packaging and shipment to ensure that it arrives in excellent condition. However, shipping
damage can occur and a visual inspection of the outer crating immediately upon delivery should be
performed. Upon arrival of the unit and before unpacking it, verify that the labeled equipment matches
the bill of lading.

6
Note: any external damage or transportation damage on the freight carrier’s forms.
Inspect the unit itself for internal damage. A claim should be led with the shipping
company if the equipment is damaged or incomplete.
Loose items such as remote control panels, disconnect switch handles, and spare air lters are packed
inside the unit. Refer to the yellow shipping tag located on the unit door for details.
NOTE: Freight damage claims are the responsibility of the purchaser. Action to recover
losses should be led immediately. Please notify factory personnel of any claims.
1.3 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,
specic component literature, warranty registration cards and other valuable paperwork, including a
copy of this User Manual.
A yellow tag is attached to the outside decorative door to indicate articles that may have been packaged
and shipped loose within the unit cabinet. Typically this would be jackstands, condensate pumps and
other loose components that are not factory mounted.
WARNING: It is the responsibility of the installing contractor to return the 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 some cases void the warranty.

7
2 INSTALLATION
NOTE: There is no intent on the part of Data Aire, Inc. to dene local codes or
statutes which may supersede common trade practices. The manufacturer assumes
no responsibility for their interpretation. Consult local building codes and National
Electrical Code (NEC) for special installation requirements.
2.1 Installation Checklist
As a precaution, review the following checklist to ensure proper operation:
• Check for any damage
• Check all wiring connections
• Filters are properly positioned in air intake
WARNING: Before removing from the packaging inspect the unit for any damage. Report
any damage to the carrier and le a damage claim.
2.2 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 lm of polyethylene is
often used on walls and ceilings. Walls and oors must also be painted with vapor-seal paint. Failure
to provide a vapor barrier can compromise 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 signicant e󰀨ect on the overall space conditions and result in poor
space control.
2.3 Equipment Handling
WARNING: Only properly trained personnel wearing appropriate safety headgear,
gloves, shoes and glasses should attempt to move the unit, lift it, remove packaging or
prepare the unit for installation.
Move the unit in its upright position to the installation site using a forklift or pallet jack. It is recommended
that the unit be protected from damage to the decorative doors during any storage or moving.
Keep tines of the forklift level and at a height suitable to t below the skid and/or unit to prevent exterior
and/or underside damage. Make sure the forks are spread to their widest allowable width for proper
balance. Do not lift the unit any higher than 4 inches o󰀨 the ground. If necessary to lift higher than the
suggested 4 inches (100mm), exercise great care to ensure proper handling of the unit.
Personnel not involved with the lifting of the unit should keep a safe distance from the unit.
The unit may be too tall to t through a doorway while on the skid. Measure the unit and doorway
heights and refer to the installation plans to verify clearances prior to moving the unit.
WARNING: Use care when moving. Improper handling could result in injury. Proper
care should be taken when uncrating the unit. The packaging has wrapping bands with
sharp edges that are under tension, crating has staples and splinters. Proper protective
equipment should be worn by qualied personnel.

8
2.4 Rigging
Move the unit in its upright position to the installation site. It is recommended that the unit be protected
from damage to the decorative doors during any storage or moving. Removal of the decorative doors
is easily accomplished and may be done without moving the equipment.
The shipping skid should be left in place if the unit is being moved with a forklift. If the unit is being lifted,
use spreader bars to prevent damage to the doors and panels.
The unit has 3/4” (19mm) holes in the shipping skid to which casters with 3/4” (19mm) stems can be
attached. This allows easy movement down halls, into elevators and through doorways. If clearance
is a problem the casters may be inserted directly into the bottom of the 1” (25mm) tubular steel corner
posts at the bottom of the unit.
WARNING: Improper lifting or moving of the equipment may result in damage to the
decorative doors, panels or frame members.
2.5 Locating the Unit
Verify that the oor is level, solid and su󰀩cient to support the unit. When installing the unit, su󰀩cient
space must be allowed for airow clearance, wiring, plumbing and service access. It is recommended
that each side and front have a clearance of at least 36” (914mm) to allow the doors to swing open and
for servicing the unit.
The doors on some sides may not require as much service clearance. Refer to the particular unit
component breakdown drawings for assistance. Rear clearance is not required, but 1” to 2” (25 to
50mm) of clearance is suggested.
For the best air distribution, the unit should be centered against the longest wall, distributing the cold
air as close to heat load as possible, unless the unit is ducted. The unit should not be placed near any
corner of the room or at the end of a long, narrow room. Install the units as close as possible to the
largest heat load. Multiple units should be evenly spaced, as far apart as possible. It is recommended
to install an under-oor water detection system.
Note: Condensation formation and frequent humidier ushing 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 humidier
makeup water, water/glycol and hot water. Installation of units above equipment that
could sustain water damage should be avoided.
2.5.1 Downow Units
Downow units will typically sit on an elevated ooring system known as a raised oor. The unit
discharges air downward which pressurizes the raised oor and channels upward through perforated
oor tiles. Location and quantity of perforated tiles will dictate proper air distribution. If the raised oor
is strong enough to support the unit and local codes permit, the unit can be placed directly on top with
cutouts made for the discharge openings.
Verify that the raised oor has been properly sized for the unit’s airow and the room is free of airow
restrictions. Perforated oor tiles in the raised oor should ensure minimal pressure loss. The raised
oor must provide 12” (305 mm) of clearance. Ensure that there is adequate clearance above the unit
for service, such as replacing lters.
There may be additional support required in the form of adjustable jackstands. These are adjustable,
threaded leveling rods which support the unit in each of the corners and in the center on longer length

9
units. Tighten the locknuts provided with each jackstand. The base plate can rest on the oor or on
vibration pads.
Floorstands are also a way of supporting the unit. These are ordered to the height of the oor with
leveling rods to allow adjustment. The oorstand has lips in each corner to align with the unit which
is placed on top. It is recommended that the unit frame be bolted or screwed to the oorstand from
below. Local building codes may dictate this procedure. After installation, the raised oor is typically
built around the unit.
The raised oor serves as the distribution plenum for air on downow units. Cables, piping, wiring
raceways, inadequate oor height and any other restrictions can inhibit proper airow. Care should
be taken to avoid restrictions.
2.5.2 Upow Units
Upow units will typically be supported by vibration isolation pads and/or oorstands which may also
include leveling screws. An air discharge plenum may be factory provided which ships loose and must
be attached at the top of the unit frame. For in-room applications with supply and return grilles, several
feet of clearance must be maintained at the intake and discharge of the unit.
Alternately, an air distribution plenum must be eld fabricated with supply grilles to distribute the
air. If a common plenum is utilized to connect the supply air for distribution from multiple units, it
is recommended that isolation backdraft dampers be installed on the discharge end of the unit or
somewhere prior to the common plenum to prevent cold discharge air from entering units that may be
on standby. Alternatively, we o󰀨er an AireSeal option which keeps the EC fans running at a selectable
speed between 20-50% when the unit is in standby to prevent air from entering the units from the
common plenum. Units are shipped with EC (Electronically Commutated) motors often referred to as
“plug fans”. Fan speed is factory set based on order. Fan speed can be changed in 1% increments
through the unit’s microprocessor controller, Data Alarm Processor 4™ (dap4™) by several di󰀨erent
methods. See the dap4™ User Manual for details and recommended settings.
WARNING: Do not operate upow units without installing a plenum, ductwork or guard
over the fan opening(s) on the top surface of the cabinet. Ductwork must be connected
to the fan(s), or a plenum must be installed on the top of the cabinet for protection from
rotating blower wheel(s) on upow units. Risk of high-speed moving parts can cause
injury or death. Disconnect all local and remote electric power supplies before working
in the unit.
2.6 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 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 (i.e., 1 to 3 PSIG, (7 to 21 kPa)) inert gas,
such as nitrogen. This prevents contaminates from entering the coils: then when the seal is broken at
installation, the rush of escaping gas veries the coil is 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 components. All moving parts, such as fans and motors, should be hand tested to ensure that
they are free and clear prior to start-up.

10
2.7 Piping
When piping, use copper tubing with appropriate supporting devices (supporting saddles, etc.). All eld
piping must be installed according to local codes. Avoid piping runs through noise-sensitive areas,
such as o󰀩ce walls and conference rooms. Refer to Section 9.0 - Piping for piping guidelines and to
the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping.
All piping below the elevated oor must be located so that it does not restrict airow. Plan the piping
layout under the raised oor to prevent the airow from being blocked. When installing piping on the
suboor, it is recommended that the pipes be mounted in a horizontal plane rather than stacked one
above the other. Whenever possible, the pipes should be run parallel to the airow.
Ensure that the tubing surfaces to be brazed are clean and that all burrs have been removed from
the ends of the tubes. Ensure that all loose material has been cleaned from inside the tubing before
brazing. Keep piping clean and dry, especially on units with R-410A refrigerant.
The units may be ordered with top or bottom connections.
2.7.1 Air Cooled Unit Piping
Refer to the attached RECOMMENDED LINE SIZING charts in section 2.7.5 for a guideline for sizing
refrigerant lines. The ultimate responsibility for line size selection is that of the installing contractor or
design engineer. Data Aire does not assume this responsibility. The chart covers distances up to 200
equivalent feet (61 m). For installations beyond this distance, consult ASHRAE or similar references.
Note: Standard piping practice must be used to ensure proper oil return and e󰀩cient
operation. The interconnecting lines to the remote air cooled condenser or condensing
unit must be installed by a qualied refrigeration mechanic.
2.7.2 Discharge Lines
Discharge lines, also called hot gas lines, should be trapped at the top (inverted) and bottom as well
as every 15 to 20 feet (4.6 to 6.1 m) of vertical rise. Discharge check valves are required on all
installations, especially those where there are long pipe runs or cold climates. For air-cooled units built
after 3/14/2017, the discharge check valves are already installed inside the evaporator section and do
not need to be installed external to the unit. For units built before this date, the check valves must be
eld supplied and installed externally to the evaporator section. If there is doubt as to whether or not
the check valve is already installed in the unit, look for it on the hot gas line close to the exit point of the
unit (see example picture below). The externally installed check valve should be placed from six (6) to
ten (10) feet (1.8 to 3.1 m) from the compressor.
The check valve will prevent ow from the condenser to the compressor during the “o󰀨” cycle.
Indoor unit ships with a nitrogen holding charge. Do not vent the evaporator until all refrigerant piping is
in place, ready for connection to the unit and condenser. 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 o󰀨 and not pressurize the piping. Prevailing good refrigeration practices should be employed
for piping support, leak testing, dehydration and charging the refrigerant circuits. During the installation
the lines should be capped o󰀨 and 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 owing through the lines to
eliminate carbon deposit build-up on the inside of the joints. Carbon could contaminate the refrigerant

11
and restrict the metering device.
Piping must be supported within 18” (457 mm) 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 (41 kPa) for R-407C and 9 PSI (62 kPa) for
R-410A. Recommended gas velocity for proper oil return is 1,000 FPM (5.1 m/sec). Slope horizontal
lines downward in the direction of the refrigerant ow (1/2” (12 mm) for every ten feet (3 m) 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.
2.7.3 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 (35 kPa) or 9 PSI (62 kPa) for R-410A. The recommended liquid velocity
should be between 200 and 300 FPM (1 to 1.5 m/sec). To avoid excessive liquid line pressure drop,
the air cooled condenser should be located above or at the same level as the evaporator. Condenser
installations more than 15 feet below the evaporator are not recommended. Insulation of liquid lines is
not required but can be useful in preventing excessive sub-cooling or ashing on long exposed pipe
runs.
2.7.4 Suction Lines
Some applications call for the compressor to be mounted as part of the condenser (more commonly
referred to as a condensing unit). Condensing units require 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.
Note: Picture is only intended to show an example of a common check valve installation. It may not
represent your specic unit, check valve size, location or orientation.

12
2.7.5 Recommended Line Sizing
Note1: If equivalent piping length falls between two columns above, choose the longer
equivalent length.
Note 2: Dual Circuit units should use the same line size on both circuits.
Note 3: If hot gas line or suction line refrigerant ow is upward use, “VERTICAL UP”,
if it is downward or horizontal, use “HORIZ. & VERTICAL DOWN”.

13
2.7.6 Connection Sizes, Air Cooled Units
Model Number Liquid Line
(2 per unit) Hot Gas Line
(2 per unit)
Suction Line
(2 per unit)
GFA* 021 1/2” (12 mm) O.D. 1/2” (12 mm) O.D. 7/8” (22 mm) O.D.
GFA* 028 1/2” (12 mm) O.D. 5/8” (16 mm) O.D. 7/8” (22 mm) O.D.
GFA* 035 1/2” (12 mm) O.D. 5/8” (16 mm) O.D. 1-1/8” (29 mm) O.D.
GFA* 046 5/8” (16 mm) O.D. 5/8” (16 mm) O.D. 1-1/8” (29 mm) O.D.
GFA* 056 5/8” (16 mm) O.D. 3/4” (19 mm) O.D. 1-3/8” (35 mm) O.D.
GFA* 070 5/8” (16 mm) O.D. 3/4” (19 mm) O.D. 1-3/8” (35 mm) O.D.
GFA* 091 7/8” (22 mm) O.D. 7/8” (22 mm) O.D. 1-3/8” (35 mm) O.D.
GFA* 106 7/8” (22 mm) O.D. 7/8” (22 mm) O.D. 1-3/8” (35 mm) O.D.
* D=Downow U=Upow
NOTE: Units will have a liquid line and either a hot gas (condenser) or suction line (condensing unit).
Note: Field connections at the indoor evaporator and remote condenser or condensing
unit will not necessarily be the same as the eld pipe size required. In some cases
these will vary signicantly.
2.7.7 Field Piping, Remote Condenser/Condensing Unit Above Evaporator

14
2.7.8 Field Piping, Remote Condenser/Condensing Unit Below Evaporator
2.7.9 Refrigerant Piping Protection
The refrigerant in the system(s) is under high-pressure and this pressure can rapidly increase if the
refrigerant is unintentionally conned (or trapped) between isolation devices such as service valves,
liquid line solenoid valves, expansion valves, etc. If the ambient temperature surrounding the piping
system increases, this may cause the contained refrigerant pressure to increase to an unacceptable
level.
WARNING: This increased pressure can cause piping ruptures, discharge of refrigerant,
pollution, equipment damage, injury or death.
Use extreme caution when:
1. Installing the piping lines and make certain that these isolation devices are open
to prevent unintended containment (trapping) of refrigerant.
2. When charging a refrigerant system, do not exceed the Design Pressure
indicated on the unit nameplate.
3. Ensure that pressure has a path to expand when cutting or making connections,
disconnections and piping repairs.

15
The installing contractor must review the piping system and guard against these possible areas where
the refrigerant could be conned. If the areas cannot be vented and allow the refrigerant to expanded
freely or eliminate pressure increases, the installing contractor must eld supply pressure relief devices.
Additionally, the installing contractor must consult local building and piping codes regarding installing
pressure-safety devices in the required areas of the piping system(s) that could be unintentionally
isolated during eld installation, maintenance or repairs of the refrigerant systems.
Note: Receivers are often installed on condensers and condensing units. The receiver includes a safety
pressure-device to protect the receiver, but the receiver also includes service valves which, if closed,
will isolate this pressure-safety device and only protect the receiver. If these valves are closed, the rest
of the piping system would not be protected from unintended refrigerant pressure increases. Again,
the installing contractor must review the piping system and guard against trapping the refrigerant by
installing eld supplied pressure-safety devices.
2.7.10 Water/Glycol Cooled Unit Piping
The required eld installed uid cooler pipe sizes may or may not be the same as the connection sizes
on the uid cooler (refer to the Fluid Cooler User Manual for connection sizing). This will depend on the
length of pipe and the calculated pressure drop of peripheral components.
Water/glycol 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 ow required.
Shuto󰀨 valves (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. Drain/ll valves should be located at the
lowest point on the connected piping.
All water/glycol cooled units are shipped with plate/n heat exchangers as standard equipment. A
strainer is shipped loose and is to be eld installed in the supply line with shut-o󰀨 valves (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 shell and tube condensers, strainers are not required and not shipped with
the unit.
All water pipes have a cap installed on the end of the pipe prior to shipment from the factory for pressure
testing the system. These caps need to be removed before installing the piping to the units. Use a tube
cutter for smaller pipes and a reciprocating saw with a metal cutting blade for larger pipe sizes or if there
is a clearance problem. All connections need to be cleaned before connections are brazed together.

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Note: 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 the
piping system to purge the air.
Water/glycol system piping may include a centrifugal pump (or pumps for redundancy). Pumps must
be primed before operating per the pump manufacturer’s guidelines.
2.7.11 Field Piping, Water/Glycol System

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2.7.12 Connection Sizes, Water/Glycol Cooled Units
Model Number Water In Water Out
GFW or G* 021 1-5/8” (41 mm) O.D. 1-5/8” (41 mm) O.D.
GFW or G* 028 1-5/8” (41 mm) O.D. 1-5/8” (41 mm) O.D.
GFW or G* 035 1-5/8” (41 mm) O.D. 1-5/8” (41 mm) O.D.
GFW or G* 046 1-5/8” (41 mm) O.D. 1-5/8” (41 mm) O.D.
GFW or G* 056 2-1/8” (54 mm) O.D. 2-1/8” (54 mm) O.D.
GFW or G* 070 2-1/8” (54 mm) O.D. 2-1/8” (54 mm) O.D.
GFW or G* 091 2-1/8” (54 mm) O.D. 2-1/8” (54 mm) O.D.
GFW or G* 106 2-1/8” (54 mm) O.D. 2-1/8” (54 mm) O.D.
* D=Downow U=Upow
2.7.13 Connection Sizes, Fluid Coolers
The information regarding uid cooler (or often referred to as a “dry cooler”) connection sizes can
be found in the individual Fluid Cooler User Manuals which should be referred to for more complete
details.
Models GHFC-200 and larger are double-wide units. Although the header connection for each section
is 2-5/8” (67 mm), each unit comes with a factory provided header manifold kit with 3-1/8” (79 mm)
eld connections.
2.7.14 Auxiliary Chilled Water/Energy Saver Coil Piping
Units with 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 shown in the Fluid Cooler
User Manual. Units with an Energy Saver cooling coil 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 factory pressure testing of the
system. These caps need to be removed before installing the water piping to the unit. Use a tube
cutter for smaller pipes and reciprocating saw with a metal cutting blade for larger pipes or if there is a
clearance problem. All connections need to be cleaned before connections are brazed together.
2.8 Condensate Drain Piping
Every indoor unit has a 3/4” (19 mm) copper stub provided for condensate removal. A union is
recommended at the 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” (6.35 mm) for each ten (10) feet (3.1 m) of horizontal run. Do
not reduce the size of the drain line.
Some applications have no convenient means of allowing a gravity drain. When required, a condensate
pump can be used. Condensate pumps are either factory mounted or shipped loose. Factory mounted
condensate pumps do not require a separate power source.
Condensate pumps shipped loose (or 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 condensate pump electrical requirements in Section 3.9.

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Do not expose drain line to freezing temperatures. Drain line may contain boiling water therefore use
copper or other suitable material. Drain line must comply with local building codes. It is recommended
to install under-oor leak detection equipment whenever possible.
Note: Condensation formation and frequent humidier ushing 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 humidier
makeup water, condenser water, water/glycol and/or hot water. Installation of units above
equipment that could sustain water damage should be avoided.
WARNING: The condensate drain MUST be connected to an external drain line (provided
by others) before unit start up.
2.9 Humidier Piping
2.9.1 Steam Generator Humidier
The standard humidier in the systems is a steam generator humidier type with disposable cylinder.
The humidier makeup water should be brought to the humidier through the eld connection opening
using 1/4” (6.4 mm) copper tubing. A compression tting is provided at the humidier.
A shuto󰀨 valve should be provided outside the air conditioner to allow disconnection for service. An in-
line water pressure regulator and strainer should be installed. Water pressure should be set between
20 and 80 PSI (128 and 552 kPa).
The humidi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 eld piping is required.
Note: Do not supply steam generating humidier with softened water. Also, do not use
hot water source.
2.9.2 Dry Steam Humidier
2.0.1 The optional dry steam humidier requires a strainer on the inlet steam line. An outlet connection
with eld-provided steam trap is also required. Steam pressure is typical 10 to 15 PSI (69 to 103 kPa).
2.10 Leak Testing
WARNING: No installation is complete until the entire system has been thoroughly
checked for leaks. This includes checking the refrigerant tubing, are ttings, pressure
controls, Schrader ttings and compressor roto-lock service valves. Check both the
eld and factory connections,
In addition to refrigeration system, check all condenser water lines, humidier water makeup lines,
condensate lines, condensate pumps, chilled water lines, centrifugal pumps and uid cooler (where
applicable).

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When handling or 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 the system’s circuit to 150 PSIG (1034 kPa) by using dry nitrogen with a trace of refrigerant.
Check the entire system for leaks with a suitable leak nder (per local code) including but not limited
to all braze joints, caps, ttings, and are nuts on both eld and factory furnished components. After
completion of leak testing, release test pressure and pull a vacuum on the system.
Note: Tightening of ttings and valves is the responsibility of the installing contractor.
WARNING: With any uid connection there is risk of leakage. Water leakage could
result in property damage to mission critical equipment. A water drain connection is
required. Units with optional steam generator humidiers will require an external potable
water supply. Water leakage can result from improper installation and/or practices.
3 ELECTRICAL CONNECTIONS
WARNING: The Data Aire cooling unit must be connected by a licensed and qualied
electrician. Risk of electrical shock could result in injury or death. Disconnect all remote
electrical power supplies prior to working on the unit.
NOTE: Disconnect switches are optional. The disconnect switch when turned OFF
will de-energize the high voltage.
WARNING: Before proceeding with the electrical connections, make certain that the
volts, hertz and phase correspond to that specied on the unit electrical nameplate. Use
copper conductors only.
3.1 Electrical Service
Check to be sure the electrical service provided by the utility is su󰀩cient to handle the additional load
imposed by this equipment. Most units with remote heat exchangers will require a separate power
source and eld provided interconnecting wires (see Section 3.5).
Remote condensers will typically require one power source. Glycol systems with uid coolers and loose
pump(s) typically require one power source for the uid cooler and will require one additional source for
single pump or two additional sources for dual pumps. Systems where the pump(s) are mounted and
piped integral to the uid cooler will usually require a single power source.

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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 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 10% of the voltage indicated on the unit electrical nameplate.
Phase to phase imbalance must not exceed 3%. The local utility company should be contacted for
correction of improper line voltage. Deviation from voltage ratings can cause premature failures and
possibly void unit warranties.
WARNING: 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.
3.5 Auxiliary Control Wiring for Remote Heat Exchangers
The interconnection of auxiliary control wiring for remote heat exchangers (condensers and uid coolers)
requires the connection of two (2) - 18-gauge wires for installations up to 150 feet (45 m) or 16-gauge
wires for installations from 151 feet (46 m) up to 200 feet (61 m) from the electrical control box of the
indoor evaporator to the electrical control box of the remote heat exchanger. Condensing units (i.e.,
where the compressor(s) are mounted in the remote heat exchanger) will typically require (4) or more
wiring connection points and may require heavier gauge wire. In this case, the installing contractor must
follow the applicable electrical codes to determine the required wire gauge.
Because of the wide variety of indoor evaporators and remote heat exchangers o󰀨er by Data Aire, the
installing contractor must refer to the schematic which is provided inside the electrical control box of
each unit, for the required auxiliary control wiring interconnection terminal points.
Examples:
Figure 1 - Typical Remote Heat Exchanger Interconnection Points