Data Aire gForce Ultra Instruction manual

2
CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION ENVIRONMENTAL
CONTROL SYSTEM. PROPER INSTALLATION, OPERATION AND MAINTENANCE OF THIS
EQUIPMENT WILL ENSURE YEARS OF OPTIMAL PERFORMANCE.
There are separate Installation, Operation and Maintenance and User Manuals for other
components of your Data Aire precision environmental cooling system including dap4 micro-
processor controller and condenser/condensing unit and fluid cooler.
NOTE: This manual is intended to assist trained service personnel by
providing necessary guidelines for this equipment. Service to Data Aire
units should be done by qualified individuals with an adequate background
in areas such as HVAC, electrical, plumbing and electronics, as applicable.
WARNING: Service performed by unauthorized or unqualified technicians
may void manufacturers’ warranties and could result in property damage
and/or personal injury
Safety Alert Symbols and Words for Hazard Alerting Safety
DANGER: Indicates a hazardous situation which, if not avoided, will
result in serious injury or death
WARNING: Indicates a hazardous situation which, if not avoided, could
result in serious injury or de ath.
CAUTION: Indicates a hazardous si tuation which, if not avoided, could
result in minor or moderate injur y .
NOTICE: Indicates information considered important but may have
potential hazard for personal injury or property damage.
Data Aire, Inc. reserves the right to make design changes for the purpose
of product improvement or to withdraw any design without notice.

TABLE OF CONTENTS
3
INTRODUCTION............................................................................................................................9
Product Information.............................................................................................................................9
Model Identification ...........................................................................................................................10
Inspection..........................................................................................................................................10
Paperwork.........................................................................................................................................11
Storage..............................................................................................................................................11
Suggested Reference Storage Room Conditions .......................................................................11
General Storage Considerations ................................................................................................12
Registered Trademarks –Copy Rights –References Section...........................................................12
INSTALLATION...........................................................................................................................13
Recommended Tools for Installation .................................................................................................14
Pre-Installation ..................................................................................................................................14
Installation must be planned so that: .................................................................................................14
Room Considerations........................................................................................................................15
Equipment Handling and Rigging ......................................................................................................15
Door and Rear Panel Removal...................................................................................................16
Rear Panel.................................................................................................................................17
Moving Unit into Final Location...................................................................................................17
Rigging..............................................................................................................................................18
Locating the Unit ...............................................................................................................................19
Downflow Units..................................................................................................................................19
Upflow Units......................................................................................................................................20
Piping................................................................................................................................................21
Air-cooled Unit Piping........................................................................................................................22
Discharge Lines.................................................................................................................................22
Liquid Lines.......................................................................................................................................24
Recommended Line Sizing, Air-cooled Units.....................................................................................24
Connection Sizes, Air-cooled Units....................................................................................................25
Field Piping, Remote Condenser Above Evaporator..........................................................................26
Field Piping, Remote Condenser Below Evaporator..........................................................................27
Refrigerant Piping Protection.............................................................................................................28
Water/Glycol Cooled Unit Piping........................................................................................................29
Factory Charge for Water/Glycol Cooled System...............................................................................30
Connection Sizes, Water/Glycol Cooled Units...................................................................................30
Field Piping, Water/Glycol System.....................................................................................................31
Connection Sizes, Fluid Coolers (Dry Coolers)..................................................................................32
Auxiliary Chilled Water/Energy Saver Coil Piping..............................................................................32
Condensate Drain System.................................................................................................................32
Condensate Trap........................................................................................................................33
Auxiliary Chilled Water/Energy Saver Coil Piping ..............................................................................35
Humidifier Piping...............................................................................................................................35
Steam Generator Humidifier.......................................................................................................35
Leak Testing......................................................................................................................................35
Electrical Installation..........................................................................................................................36
Commissioning Information...............................................................................................................36

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ELECTRICAL...............................................................................................................................37
General Electrical Field Wiring Guidelines.........................................................................................38
Electrical Service...............................................................................................................................39
Nameplate Ratings............................................................................................................................39
Grounding .........................................................................................................................................39
Voltage Tolerance.............................................................................................................................39
Three Phase Voltage Tolerance.................................................................................................39
Single-Phase Voltage Tolerance................................................................................................40
Heat Exchanger Auxiliary Control Wiring...........................................................................................40
Remote Shutdown.............................................................................................................................41
Remote Alarm Contacts ....................................................................................................................41
dap4 Controller..................................................................................................................................42
Disconnect Switch (Optional).............................................................................................................42
How to Open the Electrical Enclosure ...............................................................................................42
Condensate Pumps (Optional) ..........................................................................................................42
Condensate Probe ............................................................................................................................43
Water Sensing Cable (Optional)........................................................................................................43
Remote Temperature and Humidity Sensors (Optional).....................................................................43
Manual Override Switch Board..........................................................................................................44
Plug Fan Current Sensing Switch......................................................................................................44
Wiring Diagrams................................................................................................................................45
Electronic Expansion Valve...............................................................................................................45
Electrical Connection to EEV......................................................................................................45
INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ................................................46
CHARGING..................................................................................................................................47
Charging/Installation Work Procedures .............................................................................................47
Triple Evacuation and Dehydration Procedure...................................................................................47
Tools Needed.............................................................................................................................48
First Stage Evacuation ...............................................................................................................48
Second Stage Evacuation..........................................................................................................49
Third Stage Evacuation..............................................................................................................49
Final Evacuation Stage...............................................................................................................50
General Pre-Charging Guidelines......................................................................................................50
Voltage Phase Check........................................................................................................................51
Evaporator Phase Check............................................................................................................51
Fixed Speed Scroll Compressor Phase Check...........................................................................52
Variable Speed Compressor Phase Check.................................................................................52
Heat Exchanger Phase Check....................................................................................................53
Line Set Charge Calculations............................................................................................................53
Component Functional Test...............................................................................................................53
Charging Procedures.........................................................................................................................54
Refrigerant Handling ..................................................................................................................54
Air-cooled System Charging.......................................................................................................54
Pre-Charge Fixed Speed Compressor........................................................................................55
Charging the Fixed Speed Compressor......................................................................................56
Additional Oil..............................................................................................................................57
Pre-Charge Variable Speed Compressor ...................................................................................58

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Charging the Variable Speed Compressor .................................................................................59
Flooded System Charging (Systems with Low Ambient Receiver Package)...............................61
Low Ambient Receiver Package.................................................................................................62
Additional Oil..............................................................................................................................67
Commissioning a Running Compressor.............................................................................................67
GLYCOL SYSTEMS.....................................................................................................................68
Glycol Concentration.........................................................................................................................68
Internal (Fluid) Volume......................................................................................................................68
Brazed-Plate Fin Condensers............................................................................................................69
Water Treatment ...............................................................................................................................69
Scale Treatment.........................................................................................................................69
Undissolved Solids (turbid water)...............................................................................................69
Dissolved Products.....................................................................................................................69
Cleaning.....................................................................................................................................70
Corrosion Protection...................................................................................................................70
Fluid Cooler.......................................................................................................................................70
Type L Copper Tubing Internal Volume.............................................................................................71
Freezing Point of Aqueous Solutions.................................................................................................71
Mixing Glycol and Water....................................................................................................................71
Important Refrigeration Components.......................................................................................73
Variable Speed Compressor (VSC) Features ....................................................................................73
Oil Management................................................................................................................................73
Crankcase Heaters............................................................................................................................73
Oil Level............................................................................................................................................74
Variable Frequency Drive (VFD)........................................................................................................74
Local Control for Charging.................................................................................................................75
To View the Drive Alarms...........................................................................................................75
VFD Parameter Settings....................................................................................................................76
VFD parameter settings - Danfoss CDS-803 Drive (22 kW Ultra units).....................................77
VFD parameter settings - Danfoss CDS-303 Drive (36 to 125 kW Ultra units)..........................78
Programing the VFD for Modbus Communications............................................................................78
Program Danfoss CDS-803 VFD for Modbus Communication....................................................78
Program Danfoss CDS-303 VFD for Modbus Communication....................................................79
Programming CDS303 VFDs with MCB105 Relay Card....................................................................80
Setting pCOe and c.pCOe Expansion Modules.................................................................................83
pCOe Expansion Module P/N 160-700-008................................................................................83
c.pCOe Expansion Module P/N 160-700-016.............................................................................84
Remote Heat Exchangers .................................................................................................................85
High Pressure Cutout Switch.............................................................................................................85
Low Pressure Cutout Switch..............................................................................................................85
Liquid Line Solenoid Valve.................................................................................................................85
Energy Saver Cooling (Optional).......................................................................................................85
CONTROLS .................................................................................................................................87
dap4 Microprocessor Controller.........................................................................................................87
dap4 Factory Settings........................................................................................................................87
dap4 Universal Security Access:................................................................................................87
gForce Ultra Settings:.................................................................................................................88

TABLE OF CONTENTS
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Electronic Expansion Valve Drive (EDV)............................................................................................96
Setup Using Display Panel Guide...............................................................................................96
Configuration Menu....................................................................................................................97
Regulation Menu ........................................................................................................................98
Manually Open and Close the EEV ..........................................................................................100
Multiple EEV Configuration.......................................................................................................101
REGULAR MAINTENANCE ITEMS ..........................................................................................102
Service vs. Maintenance .................................................................................................................102
General Maintenance Requirements........................................................................................102
Daily Maintenance....................................................................................................................103
Maintenance/Inspection Checklist ............................................................................................103
Air Filters.........................................................................................................................................103
Downflow Unit Filter Replacement Procedure ..........................................................................104
Upflow Unit Filter Replacement Procedure...............................................................................105
Electric Reheat Elements ................................................................................................................105
Humidifier........................................................................................................................................105
Humidifier Canisters.................................................................................................................105
Cylinder Spent Fault.................................................................................................................106
Replacement Cylinder..............................................................................................................106
Removing the Cylinder.............................................................................................................106
Coil Drain Pan.................................................................................................................................107
Condensate Pump...........................................................................................................................107
Cabinet............................................................................................................................................107
Exterior Cabinet Maintenance Cleaning ...................................................................................107
Coils................................................................................................................................................108
Coil Cleaning............................................................................................................................108
Piping..............................................................................................................................................108
Water/Glycol Cooled System...........................................................................................................108
Refrigerant Filter Drier.....................................................................................................................109
Electrical Control Enclosure.............................................................................................................109
Fuses..............................................................................................................................................110
Fuse Replacement...................................................................................................................110
Plenum Plug Fans...........................................................................................................................110
EC Motor Testing .....................................................................................................................111
Current Sensing Switch Adjustment ................................................................................................112
MAINTENANCE/INSPECTION CHECKLIST ......................................................................113
Frequently Asked Questions (FAQ) .................................................................................116
Electrical FAQ Section.....................................................................................................................116
Mechanical FAQ Section.................................................................................................................117
CONTACT DATA AIRE........................................................................................................120

TABLE OF CONTENTS
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TABLE OF FIGURES
Figure 1 Typical Upper Spring-Loaded Hinge.....................................................................................16
Figure 2 Upper Hole for Spring-Loaded Hinge....................................................................................17
Figure 3 Lower Fixed Pin Hinge..........................................................................................................17
Figure 4 Example of Lifting Method ....................................................................................................18
Figure 5 Typical Return & Discharge Air Distribution..........................................................................20
Figure 6 Typical Check Valve .............................................................................................................23
Figure 7 Typical Remote Condenser Above Evaporator Installation...................................................26
Figure 8 Typical Remote Condenser Below Evaporator .....................................................................27
Figure 9 Typical Water/Glycol System................................................................................................31
Figure 10 Recommended Condensate Trap Dimensions ...................................................................34
Figure 11 Typical Remote Heat Exchanger Interconnection Points....................................................40
Figure 12 Typical Indoor Evaporator Interconnection Points...............................................................41
Figure 13 Manual Override Switch Board ...........................................................................................44
Figure 14 EEV with Electrical Mating Connector.................................................................................45
Figure 15 Typical VFD to VS Compressor Wiring...............................................................................52
Figure 16 Typical Low Ambient Receiver Package.............................................................................64
Figure 17 CDS-803 Drive P/N 101-260-230 or 460-VFD (22 kW Ultra units)......................................77
Figure 18 CDS-303 Drive P/N Various (36 to 125 kW Ultra units)......................................................78
Figure 19 Danfoss Model CDS-803 Modbus Point List for dap4.........................................................79
Figure 20 Danfoss Model CDS-303 Modbus Point List for dap4.........................................................80
Figure 21 Danfoss VFD MCB105 Relay Card.....................................................................................80
Figure 22 Typical EVD Display View...................................................................................................96
Figure 23 Example Remote EPO Switch Connection.......................................................................117

TABLE OF CONTENTS
8
LIST OF TABLES
Table 1 Line Size Metric Conversion ..................................................................................................24
Table 2 Hot Gas Lines (Single Circuit Systems).................................................................................24
Table 3 Liquid Lines (Single Circuit Systems).....................................................................................24
Table 4 Hot Gas Lines (Dual Circuit Systems)....................................................................................24
Table 5 Liquid Lines (Dual Circuit Systems) .......................................................................................25
Table 6 Air-cooled Units Connection Sizes.........................................................................................25
Table 7 Water/Glycol Cooled Units Connection Sizes........................................................................30
Table 8 Three Phase Voltage Tolerance ............................................................................................40
Table 9 Remote Alarm Contacts Terminals.........................................................................................41
Table 10 Liquid Line Multiplier ............................................................................................................53
Table 11 Fixed Speed Compressor Pre-Charge R-410A....................................................................55
Table 12 Refrigerant Charge Values...................................................................................................57
Table 13 Variable Speed Compressor Pre-Charge.............................................................................58
Table 14 Refrigerant Charge Valves...................................................................................................60
Table 15 Refrigerant Receiver Charging Chart...................................................................................65
Table 16 Discharge Head Pressure....................................................................................................65
Table 17 Packaged Units without Receivers.......................................................................................66
Table 18 Packaged Units with Receivers............................................................................................66
Table 19 Ultra Downflow Unit Internal (Fluid) Volume.......................................................................68
Table 20 Ultra Upflow Unit Internal (Fluid) Volume............................................................................68
Table 21 Type L Copper Tubing Internal Volume ...............................................................................71
Table 22 Freezing Point of Aqueous Solutions...................................................................................71
Table 23 High Pressure Cutout Switch Setting...................................................................................85
Table 24 Low Pressure Cutout Switch Setting....................................................................................85

gForce Ultra IOM
9
INTRODUCTION
Product Information
The Data Aire gForce Ultra environmental control, direct expansion, single and dual circuit Computer
Room Air Conditioner (CRAC) equipment provides a high sensible cooling, is self-contained, factory
assembled, piped, wired, and factory tested prior to shipment. These units include an enclosure/cabinet
assembly, fan section, filter section, cooling coil, controls, and interconnecting piping internal to unit.
The Data Aire CRAC unit provides cooling, reheat, humidification, dehumidification and air filtration.
The unit is provided with a Data Aire dap microprocessor controller for precision control. The unit must
be operated in a conditioned space within the operating envelope ASHRAE recommends for data
centers. Maximum dew point is 59°F (15°C). 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 of 68°F (20°C) DB and 40% RH or minimum WB of 54°F (12.2°C) 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.
The unique feature of the gForce Ultra is the application of Variable Speed Compressors (VSC). The
quest for greater energy efficiency is continuous; efficiency benchmarks are always moving up. That’s
why Data Aire is moving toward variable capacity compressor technology for quieter, more energy-
saving performance. Conventional compressors are designed to run at fixed speed to handle a given
capacity requirement. But in data center applications, the capacity requirement varies. In these
situations, a fixed speed compressor uses various capacity-regulation techniques and can be less
efficient than a compressor utilizing variable capacity technology. A variable capacity compressor, on
the other hand, saves energy and operates more quietly by varying speed to match the workload. Tests
with VSC compressors have shown an immediate energy savings and sound level reductions.
NOTICE: gForce Ultra units are only available with R-410A refrigerant.

gForce Ultra IOM
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Model Identification
Inspection
This 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, ship- ping 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.
Loose items such as remote-control panels, disconnect switch handles, and spare air filters are packed
inside the unit. Refer to the yellow shipping tag located on the unit door for details.
NOTE: Any external damage or transportation damage on the freight
carrier’s forms. Inspect the unit itself for internal damage. A claim should
be filed with the shipping company if the equipment is damaged or
incomplete.
NOTE: Freight damage claims are the responsibility of the purchaser.
Action to recover losses should be filed immediately. Please notify factory
personnel of any claims.
GU X X - XXX X X
│ │ │ │ │ │
GU - gForce Ultra, │ │ │ │ │ │
Single and Dual Circuit
────
┘ │ │ │ │ │
│ │ │ │ │
A- Air Cooled │ │ │ │ └
────
W - Water Cooled
────
────
┘ │ │ │
G - Glycol Cooled │ │ │
│ │ │
D - Downflow
────
────
────
┘ │ └
────
────
U- Upflow │
│
Nominal Kilowatts │
036 kW │
045 kW │
056 kW
────
────
────
────
┘
070 kW
091 kW
125 kW
gForce Ultra Model Number
2 - 208/230 VAC
4 - 460 VAC
Voltage
Phase
3 - Three phase

gForce Ultra IOM
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Paperwork
Each 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, specific
component literature, warranty registration cards and other valuable paperwork, including a copy of this
Installation, Operation, and Maintenance manual.
A yellow tag isattached to the outside decorative door to indicatearticles thatmay 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
Storage
Short-term storage is considered 60 days or less from shipment date. Long-term storage is considered
any period beyond 60 days from date of shipment. It is mandatory that a detailed record be maintained
during this long-term period, such as, but not limited to: proper sealing of the cabinet, rotation of the
blowers and bearings, and protection of all motors from moisture. Check the fan rotation monthly, the
fan and motor should be rotated several times to replenish the bearing surfaces with fresh grease as
needed and to prevent flat spots of the fan shaft. The fan impeller should be left at approximately 180°
from that of the previous month to prevent the belts from taking a set position.
It will be the responsibility of the customer to submit a monthly log sheet showing the condition of the
unit and noting any discrepancies. A copy of the log sheet should be sent to Data Aire. Failure to
perform the long-term storage requirements may void the warranty.
Suggested Reference Storage Room Conditions
•Dry bulb temperature range: 65°F to 85°F (18.3C) to 85°F (29.4C).
•Effects of high temperatures may dry out components or may damage electrical
components.
•Effects of low temperatures may cause freezing damage to coil, compressor, system
components, electrical components, etc. Freezing temperatures must be avoided.
•Humidity range: 25 to 50% RH.
•High humidity may cause damage to insulation and electrical components. Storage in moist
air, above 50%, should be avoided. High humidity may cause rust on metal components
such as sheave, pulley, blower housing, cabinet parts, supports, etc.
•Low Humidity may cause brittle conditions to components within the unit. At low humidity,
problems of brittleness or electrical static might arise for the equipment.
•Level with floor.
•Units with compressor maximum tilt angle is 30° (compressor not running) but recommend
the unit be set level for 24 hours prior to final installation.
•Store at non-condensing temperature and humidity conditions.

gForce Ultra IOM
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General Storage Considerations
•All equipment shall be stored for safety of occupants. Per OSHA codes and codes
applicable to your installation.
•Maintain clearance from working space and traffic areas.
•Our indoor products are not designed or intended to be stored outdoors or exposed to
outdoor conditions.
•Components sealed in plastic shrink-wrap are not exempt from this requirement. Moisture
will collect inside the plastic, resulting in corrosion of the cabinet, the electronic components
and or other water sensitive components.
•Provide proper fire protection per local and national codes.
•Protect from all water or fluid sources. Equipment should be protected from possible water
damage, such as from leaks, fire-sprinkler discharge, and flooding.
•The storage space should be filtered to remove dust, cleansed of gaseous contaminants, if
present, and controlled to the desired relative humidity and temperature.
•Isolate this equipment from pressure testing of water, steam, gas and air piping.
•Isolate this equipment from temporary building power.
•The unit must also be protected from damage to the exterior of the cabinet or coil
connections by construction vehicles and personnel.
•Isolate from vibration sources.
•Isolate from direct sun light.
•Isolate from storage of hazardous materials and substances.
•Refrigerant coils have been evacuated and pre-charged with slight nitrogen holding charge.
DO NOT damage or disturb these coils and connections.
•Water coils must have all inlet and outlet connections capped or closed tight to prevent
foreign materials and liquids from gaining entrance during the storage period.
When equipment is installed after storage, caution should be taken to inspect and replace, if required,
any components that may have deteriorated during storage. All moving parts, such as fans and motors,
should be hand tested to ensure that they are free and clear prior to start-up.
Registered Trademarks –Copy Rights –References Section
NOTE: Data Aire Inc. Trademarks Disclaimer: All names, logos, brand,
materials and other Registered Trademarks, Trademarks, or Copy Rights
seen featured or referred to within documents or our website are explicitly
the sole property of their respective and rightful trademark holders or
owners.
This disclaimer shall not be construed or manipulated from hereafter.
Said trademarks or copy rights are only used to directly or indirectly
familiarize, reference, identify and describe the services.

gForce Ultra IOM
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INSTALLATION
NOTE: There is no intent on the part of Data Aire, Inc. to define 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.
During installation, operation, maintenance or service, individuals may be exposed to certain
components or conditions including, but not limited to: refrigerants, oils, and materials under pressure,
rotating components, and both high and low voltage. Each of these items has the potential, if misused
or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of
operating/service personnel to identify and recognize these inherent hazards, protect themselves, and
proceed safely in completing their tasks. Failure to comply with any of these requirements could result
in serious damage to the equipment and the property in which it is situated, as well as severe personal
injury or death to themselves and people at the site.
This document is intended for use by owner-authorized operating/service personnel. It is expected that
this individual possesses independent training that will enable them to perform their assigned tasks
properly and safely. It is essential that, prior to performing any task on this equipment, this individual
shall have read and understood this document and any referenced materials. This individual shall also
be familiar with and comply with all applicable governmental standards and regulations pertaining to
the task in question.
This manual contains important safety instructions that should be followed during the installation and
maintenance of Data Aire equipment. Read this manual thoroughly before attempting to install or
operate this unit.
Only qualified personnel should move, install or service this equipment. Adhere to allwarnings, cautions
and installation, operating and safety instructions on the unit and in this manual. Follow all operating
and user instructions.
WARNING: Risk of handling heavy and lengthy parts, risk of top-heavy
unit falling over, risk of sharp edges, splinters and exposed fasteners; can
cause personal injury and equipment damage. Cabinet doors and panels
can weigh more than 35lb. (15.9kg) therefore follow relevant OSHA lifting
recommendations and consider using a two-person lift for safe and
comfortable removal and installation of cabinet doors and panels.
Only properly trained and qualified personnel wearing appropriate safety
headgear, gloves and shoes should attempt to remove or install cabinet
doors and panels.

gForce Ultra IOM
14
Recommended Tools for Installation
•Wrenches –Common sizes
•Flat tip and Phillip screwdrivers –Common sizes
•Wiring tools
•Brazing tools
•Multimeter
•Pressure gauges –Sized for design pressure
•Electric hand tools
•Equipment handing
•Safety items
•Level
Pre-Installation
The unit you have received is very special. It is specifically designed for indoor Computer Room cooling
applications. This unit is designed and intended to be installed indoors unless otherwise noted on the
equipment serial name plate. Compare the data on the nameplate of the air-conditioning unit and other
modules with the packing list and the order documents.
During the design of the data center, consider should be given for ease of entry for the equipment, floor
loading factors, ceiling loading factors and accessibility to piping and wiring.
Before installing unit, determine whether any building alterations are required to move the unit into the
space intended, run piping, wiring and ductwork. Carefully follow all unit dimensional drawings and refer
to the submittal package and engineering dimensional drawings of individual units for proper
clearances.
If possible, transport the Data Aire unit with a forklift or pallet jacks. If using a forklift or pallet jack, make
sure that the forks (if adjustable) are spread to the widest allowable distance that will fit under the skid.
Ensure the fork length is suitable for the unit length. Keep tines of the forklift level and at a height
suitable to fit below the skid and/or unit to prevent exterior and/or underside damage. When moving
the packaged Data Aire unit with a forklift, lift the unit no higher than 6" (152 mm) off the ground. The
unit is to be pulled by the forklift. Personnel who are not directly involved in moving the unit must be
kept 20' (5 m) or farther from the lift point of the unit.
Measure the unit and doorway heights and refer to the installation plans to verify clearances prior to
moving the unit.
Installation must be planned so that:
•Damage to building sections, including room wall insulation, is minimal.
•Components are located correctly for function and adequate air flow configuration.
•Pipe runs and electrical runs are as short as feasibly possible.
•Confirm configuration and options for the unit to be installed are to design specifications.
•The unit may be too tall to fit through a doorway while on the skid. Measure the unit and
doorway heights and follow the installation plans to verify clearances prior to moving the unit.
•Allow enough space around the unit for removing the access panels and various parts of the
unit. A minimum clearance equal to the width of the unit is suggested on one side of the unit

gForce Ultra IOM
15
for removing the coil or fan assembly. Add dimension of pipe chase, ducts, control and
electrical panels, etc. to minimum clearances. Allow additional clearance as required by local
and national codes.
•It is also necessary to consider access requirements for safe operation and maintenance of
the unit, and power and control panels. Local health and safety regulations, or practical
considerations for service replacement of large components (such as coil),may require larger
clearances.
•Clearance dimensions provided elsewhere are necessary to maintain proper service access.
If clearances given are not maintained, service the unit will be more difficult or impossible
maintain.
WARNING: Risk of improper moving, can cause equipment damage, injury
or death.
WARNING: Before removing from the packaging inspect the unit for any
damage. Report any damage to the carrier and file a damage claim.
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 film of
polyethylene is often used on walls and ceilings. Walls and floors 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 significant effect on the overall space conditions and result in poor
space control.
•Install the units as close as possible to the largest heat load.
•For floor units, verify that the floor is level, solid and enough to support the unit. The
equipment must be level to operate properlyand prevent damage to the internal components.
Shimming and/or grouting may be necessary. This is to ensure the unit base is on a perfectly
flat plane.
•It is recommended that support is structurally engineered to prevent flexing, sagging or
twisting. Do not obstruct door operation, filter access, piping, electrical control panel or
control connections.
•Avoid the transfer of vibrations to the mounting materials which may cause audible noise.
Equipment Handling and Rigging
WARNING: Only properly trained personnel wearing appropriate safety
head- gear, gloves, shoes and glasses should attempt to move the unit,
lift it, remove packaging or prepare the unit for installation.

gForce Ultra IOM
16
Door and Rear Panel Removal
Removal of the decorative doors is easily accomplished and may be done when moving equipment.
The door hinge is spring loaded and slides down using the catch, for easy removal of the doors. Door
hinges allow the door to be lift off.
WARNING: When releasing the spring-loaded upped door hinge, be
prepared for the weight of the door. Risk of handling doors can cause
personal injury and equipment damage. Follow relevant OSHA lifting
recommendations and consider using a two-person lift for safe and
comfortable removal and installation of doors. Only properly trained and
qualified personnel wearing appropriate safety headgear, gloves and
shoes should attempt to remove or install doors.
Unlock and open the door by using a flat blade screwdriver or other tool to turn the door latch 90
degrees to unlock the door. Most doors on larger floor mounted units will have a door latch at the top
and bottom of each door. Unplug the dap display connection cables, if needed.
Pull down on the spring-loaded catch to disengage the top of the door, then lift the door up and off the
fixed bottom hinge pin. When re-installing doors, remember to reconnect the dap4 display interface
connection cable, if needed.
Figure 1 Typical Upper Spring-Loaded Hinge

gForce Ultra IOM
17
Figure 2 Upper Hole for Spring-Loaded Hinge
Figure 3 Lower Fixed Pin Hinge
Rear Panel
Remove screws from rear panel to remove rear panel.
Moving Unit into Final Location
Move the unit in its uprightposition 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.
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 shipping skid as 3/4”
holes in the shipping skid to which casters with 3/4” (35 mm) stems can be attached. This allows easy
movement down halls, into elevators and through doorways. Improper lifting or moving of equipment
may result in damage to decorative doors, panels or frame members.
When rigging, make sure all wiring and tube connections are protected to prevent any damage.
Keep tines of the forklift level and at a height suitable to fit 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 (100 mm) off the ground. If necessary, to lift higher
than the suggested 4 inches (100 mm), 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.

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The unit may be too tall to fit 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 wrap- ping bands with sharp edges that are under tension,
crating has staples and splinters. Proper protective equipment should be
worn by qualified personnel.
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.
Figure 4 Example of Lifting Method
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.

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Locating the Unit
Verify that the floor is level, solid and appropriate construction to support the unit. When installing the
unit, enough 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 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 specific 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-floor water detection system.
NOTE: Condensation formation and frequent humidifier flushing 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 humidifier makeup water, chilled
water and/or hot water. Installation of units above equipment that could
sustain water damage should be avoided
Downflow Units
Downflow units will typically sit on an elevated flooring system known as a raised floor. The unit dis-
charges air downward which pressurizes the raised floor and channels upward through perforated floor
tiles. Location and quantity of perforated tiles will dictate proper air distribution. If the raised floor 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 floor has been properly sized for the unit’s airflow and the room is free of airflow
restrictions. Perforated floor tiles in the raised floor should ensure minimal pressure loss. The raised
floor must provide a minimum of 12” (305 mm) clearance. Ensure that there is adequate clearance
above the unit for service, such as replacing filters. Optional plenums are available for downflow unit
ducting.

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Figure 5 Typical Return & Discharge Air Distribution
There may be additional support required in the form of adjustable jack stands. These are adjustable,
threaded leveling rods which support the unit in each of the corners and in the center on longer length
units. Tighten the locknuts provided with each jack stand. The base plate can rest on the floor or on
vibration pads.
Floor stand are also a way of supporting the unit. These are ordered to the height of the raised floor
with leveling rods toallow adjustment. The floor stand has lips in each corner to align with the unitwhich
is placed on top. It is recommended that the unit frame be bolted or screwed to the floor stand from
below. Local building codes may dictate this procedure. After installation, the raised floor is typically
built around the unit.
The raised floor serves as the distribution plenum for air on downflow units. Cables, piping, wiring
raceways, inadequate floor height and any other restrictions can inhibit proper airflow. Care should be
taken to avoid restrictions.
Verify that the raised floor has been properly sized for the unit’s airflow and the room is free of airflow
restrictions. Perforated floor tiles in the raised floor should ensure minimal pressure loss. The raised
floor must provide a minimum of 12” (305 mm) clearance. Ensure that there is adequate clearance
above the unit for service, such as replacing filters. Optional return air plenums are available for
downflow unit ducting.
Upflow Units
Upflow units will typically be supported by vibration isolation pads and/or floor stand which may also
include leveling legs. 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 field 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