Data Aire MINI CEILING SERIES User manual

MINI CEILING SERIES
Installation, Operation and Maintenance Manual
1, 1.5, 2 and 2.5 ton
Air, Water and Glycol Cooled DX and Chilled Water

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CONGRATULATIONS ON THE SELECTION OF ADATAAIRE PRECISION
ENVIRONMENTAL CONTROL SYSTEM. PROPER INSTALLATION, OPERATION
AND MAINTENANCE OF THIS EQUIPMENT WILL ENSURE YEARS OF OPTIMAL
PERFORMANCE.
This manual is intended to assist trained service personnel by providing
necessary guidelines for this particular equipment. Service to Data
Aire units should be done by qualified individuals with an adequate
background in areas such as HVAC, electrical, plumbing and electronics,
as applicable.
Service performed by unauthorized or unqualified technicians may void
manufacturers’ warranties and could result in property damage and/or
personal injury.
Special care should be given to those areas where these symbols appear.
Data Aire, Inc. reserves the right to make design changes for the purposes of product
improvement, or to withdraw any design without notice.

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Table of Contents
1.0 INSTALLATION .........................................................................................................6
1.1 Room Considerations ................................................................................................6
1.2 Inspection...................................................................................................................6
1.3 Locating the Unit ........................................................................................................6
1.3.1 Vertical Airflow Units...................................................................................................7
1.3.2 Air Cooled Package Units ..........................................................................................7
1.3.3 Horizontal Airflow Units ..............................................................................................8
1.3.4 Indoor Condensers & Condensing Units....................................................................8
1.4 Paperwork..................................................................................................................8
1.5 Storage.......................................................................................................................8
2.0 PIPING .......................................................................................................................10
2.1 Split Air Cooled Unit Piping ......................................................................................10
2.1.1 Discharge Lines........................................................................................................10
2.1.2 Liquid Lines..............................................................................................................10
2.1.3 Suction Lines............................................................................................................10
2.1.4 Connection Sizes, Air Cooled Units..........................................................................10
2.1.5 Field Piping, Remote Condenser ............................................................................. 11
2.1.6 Field Piping, Remote Condensing Unit .................................................................... 11
2.2 Water/Glycol Cooled Unit Piping..............................................................................12
2.2.1 Connection Sizes, Water/Glycol Cooled Units.........................................................13
2.2.2 Connection Sizes, Fluid Coolers..............................................................................13
2.3 Auxiliary Chilled Water Coil Piping...........................................................................13
2.4 Condensate Drain Piping .........................................................................................13
2.5 Humidifier Piping......................................................................................................14
2.6 Leak Testing.............................................................................................................14
2.7 Evacuation................................................................................................................14
3.0 ELECTRICAL CONNECTIONS ...........................................................................15
3.1 Electrical Service......................................................................................................15
3.2 Nameplate Ratings...................................................................................................15
3.3 Grounding.................................................................................................................15
3.4 Voltage Tolerance.....................................................................................................15
3.5 Auxiliary Control Wiring............................................................................................15
3.6 Remote.....................................................................................................................16
3.7 Remote Alarm Contacts ...........................................................................................16
3.7.1 Mini DAP™ II............................................................................................................16
3.7.2 Mini DAP III ..............................................................................................................16
3.8 Remote Sensors.......................................................................................................16
3.8.1 Mini DAP II ...............................................................................................................16
3.8.2 Mini DAP III ..............................................................................................................16
3.9 Condensate Pumps..................................................................................................16
4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ..............17
4.1 Rigging.....................................................................................................................17
4.2 Leg Assembly...........................................................................................................17
4.3 Locating the Remote Heat Exchanger .....................................................................17

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Table of Contents, continued
4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER - Continued
4.4 Electrical Service........................................................................................................... 18
4.5 Air Cooled Condensers - Model DARC......................................................................... 18
4.6 Fluid Coolers - Model DAFC ......................................................................................... 18
4.6.1 Fluid-Sensing Thermostats ........................................................................................... 18
4.6.2 Energy Saver Cooling ...................................................................................................18
5.0 CHARGING ........................................................................................................................19
5.1 Air Cooled Systems.............................................................................................................19
5.1.1 Package Air Cooled Systems.........................................................................................19
5.1.2 Split Indoor Air Cooled Systems Charging.....................................................................19
5.1.3 Fan Speed Control System Charging.............................................................................20
5.1.4 Flooded System Charging..............................................................................................21
5.2 Water/Glycol Cooled Systems........................................................................................22
5.2.1 Water/Glycol Cooled Systems Charging........................................................................22
5.2.2 Factory Charge for Water/Glycol Cooled Systems.........................................................22
5.3 Refrigerant Handling ......................................................................................................22
5.4 Important Refrigeration Component...............................................................................23
5.4.1 Expansion Valve.............................................................................................................23
5.4.2 High Pressure Cutout Switch ........................................................................................23
5.4.3 Low Pressure Cutout Switch..........................................................................................23
6.0 GLYCOL SYSTEMS ...........................................................................................................24
6.1 Glycol Concentration......................................................................................................24
6.2 Internal (Fluid) Volume...................................................................................................24
6.3 Fluid Cooler Internal Volume..........................................................................................24
6.4 Copper Piping Internal Volume.......................................................................................24
6.5 Freezing Point of Aqueous Solutions .............................................................................24
7.0 CONTROLS ........................................................................................................................25
7.1 Standard Thermostat......................................................................................................25
7.2 Optional Programmable Thermostat..............................................................................25
7.3 Optional Mini DAP II Microprocessor Control Panel.......................................................25
7.4 Optional DAP II Microprocessor Control Panel..............................................................25
7.5 Secondary Heat Exchangers..........................................................................................25
7.6 Wiring Diagrams.............................................................................................................26
8.0 REGULAR MAINTENANCE ITEMS
8.1 Air Filters........................................................................................................................27
8.2 Belts ...............................................................................................................................27
8.3 Bearings.........................................................................................................................27
8.4 Humidifier Canisters.......................................................................................................27
8.5 Fuses..............................................................................................................................27
8.6 Heating Elements...........................................................................................................27
8.7 Refrigerant Filter Drier....................................................................................................28

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Table of Contents, continued
9.0 WARRANTY .......................................................................................................................29
10.0 CONTACT DATA AIRE .......................................................................................................30
LINE SIZING CHART ....................................................................................................................31
Monthly Maintenance Inspection Checklist ..............................................................................32
Quarterly Maintenance Inspection Checklist ............................................................................33
Superheat and Suction Pressure Troubleshooting Guide .......................................................34
Temperature Pressure Chart ......................................................................................................35
INDEX .......................................................................................................................................36,37

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1.0 INSTALLATION
There is no intent on the part of Data Aire, Inc. to define local codes or statutes which
may supercede common trade practices. The manufacturer assumes no responsibility
for their interpretation. Consult local building codes and the National Electrical Code
for special installation requirements.
1.1 Room Considerations
Precision air conditioning equipment is designed to control spaces within close tolerances of
temperature and humidity. However, the room must be built with a proper vapor barrier. A film of
polyethylene is often used onwalls and ceilings or wallsand floors must also be painted with a vapor-
seal paint. All doors to the controlled space should be equipped with weather seals to prevent the
infiltration of non-neutral conditioned air from entering the space. Failure to provide a vapor barrier
can compromise the ability to control space conditions.
Introduction of outside air into the controlled space should be minimized. Outside air in excess of
5% of the total circulated air volume can have a significant effect on the overall space conditions and
result in poor space control. All outside air that is introduced should be conditioned to the humidity
and temperature parameters of the computer room air conditioner (CRAC) unit set points to maintain
proper room conditions and to prevent the CRAC units from running excessively to maintain the
room’s conditions.
1.2 Inspection
This Data Aire unit has been factory run-tested and has gone through a comprehensive inspection
prior to its packaging and shipment to ensure that it arrives in excellent condition. However, shipping
damage can occur and a visual inspection of the outer crating immediately upon delivery should be
performed.
Note any external damage or other transportation damage on the freight carrier’s forms. Inspect the
unit itself for internal damage. A claim should be filed with the shipping company if the equipment
is damaged or incomplete.
Loose items such as remote control panels, disconnect switch handles, spare belts and spare filters
are packed inside the unit. Refer to the yellow shipping tag located on the unit door for details.
Freight damage claims are the responsibility of the purchaser. Action to recover losses
should be filed immediately. Please notify factory personnel of any claims.
1.3 Locating the Unit
The unit is intended for above the ceiling installation and is typically suspended from structural
members in the building above the ceiling. Add a 50% safety factor to the weight of the unit to
determine the strength of the supporting structural members.
Appropriate service access above the ceiling is required around all service and electrical access
panels. There must be unobstructed clearance below the unit allowing ladder access to enable
routine maintenance and service.

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Note there are many available unit configurations for Mini Ceiling systems. Be sure to
identifytheunittype andstyle beforeinstalling. Forinstancetheremay besplitcondenser/
condensing sections requiring separate or shared power.
Note to Installing Contractor: Condensation formation and frequent humidifier flush-
ing are normal functions of this equipment. Proper drain connections must be made
to ensure proper removal. Unit will require water connections for condensate removal
and possibly for humidifier make-up water, condenser water, chilled water and/or hot
water. Installation of units above equipment that could sustain water damage should
be avoided.
1.3.1 Vertical Airflow Units
The evaporator (cooling) section is typically mounted over a standard 2’ x 4’ T-bar ceiling grid,
supportedby four threadedrods. Theevaporator (cooling) sectionwillbereferred to astheevaporator
section from here on even though the coil on chilled water units is not a true evaporator coil.
Fourthreadedsupportrodsmustbesecurelyattachedtothebuildingstructure. Raisetheevaporator
section with an appropriate lifting device. Attach washers, nuts and jam nuts to each threaded rod.
Tighten the nuts so the weight is supported evenly by the four rods and the unit is level. Be sure
to allow for the depth of the Supply/Return air plenum when calculating the height of the unit above
the ceiling.
The5” tall vertical Supply/Return plenum assemblyisattachedtothe bottom of the evaporator section
after the evaporator section has been hung. Six screws fasten the plenum to the evaporator section.
The Supply/Return air grilles should be temporarily removed for access. The plenum mounts flush
to the ceiling grid.
1.3.2 Air Cooled Packaged Units
Air cooled package units require an additional condenser fan section to be mounted to the end of
the evaporator section at the condenser coil. Place a gasket around the perimeter of the condenser
coil opening. Connect the female motor plug from the condenser blower section to the male plug
inside the evaporator section. Attach the condenser blower section using four (4) self-drilling #10
self drilling sheet metal screws.

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Most applications will allow for the condenser discharge air to blow out into the ceiling space and no
ducting is required. The ceiling space must be large enough to dissipate the rejected heat. Plenum
space temperature should not exceed 95oF. If ducting is required the additional static imposed by
ductwork on the air intake and/or discharge should not exceed 0.3”. In some applications a factory
provided low ambient damper is used at the condenser air intake. The air intake is modified from its
normal grilled openings to a single 15” x 17” duct collar.
1.3.3 Horizontal Airflow Units
Ductwork is connected to factory provided duct collars on the supply and return air openings. Four
threaded support rods must be securely attached to the building structure. Raise the evaporator
section with an appropriate lifting device. Attach washers, nuts and jam nuts to each threaded rod.
Tighten the nuts so the weight is supported evenly by the four rods and the unit is level.
Note some options call for a combination of vertical and horizontal airflow configuration.
In that case, the 5” plenum assembly described above is necessary.
1.3.4 Indoor Condensers and Condensing Units
These sections are to be mounted in the same manner as the evaporator sections using four
threaded rods. Air cooled condensers or condensing units have factory provided duct collars on the
supply and intake air openings as appropriate. Water cooled condensing sections have no airflow
connections.
Typical installations have the condenser or condensing section physically near the evaporator,
especiallysincemosthave sharedelectrical linepower. Themountingof thesesectionsisindependent
of the evaporator mounting. The same service and maintenance clearance requirements apply to
these units as well.
1.4 Paperwork
Each Data Aire unit ships with a start-up sheet that should be completed during installation. Also
included in the paperwork is a warranty/information packet that provides important wiring diagrams,
specific component literature, warranty registrations cards and other valuable paperwork, including
a copy of this Installation/Operation and Maintenance manual.
A yellow tag is attached to the outside panel to indicate articles that may have been packaged and
shipped loose within the unit cabinet. Typically this would be a condensate pump and other loose
components that are not factory mounted.
Itistheresponsibility of the installing contractor to return the start-up sheet andwarranty
registration card to DataAire for proper activation of the unit warranty. Failure to do so
may cause delays and in some cases void the warranty.
1.5 Storage
Your Data Aire equipment comes ready for immediate installation. In some instances it may be
necessary to store the equipment for a period of time. If you must store the equipment it should be
done in a dry area, out of the weather, protected from freezing temperatures, protected from damage
by other equipment in storage or transportation equipment, never stacked, and avoid frequent
relocation.

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Ifequipment is stored for longer than 30daysspecialprecautionsmustbe taken to avoid coil damage.
Allcoilsshouldbechargedandsealedwithalowpressure(1-3psig)inertgas,suchas nitrogen. This
prevents contaminates from entering the coils; then when the seal is broken at installation, the rush
of escaping gas verifies the coil is still leak free. If coils are not charged and sealed condensation
mixes with air pollutants forming a weak acid and over time can cause pin hole leaks to develop in
the coil tubes.
Whenequipmentis installed after storage caution should betaken to inspect and replace,if required,
rubberhosesandbelts. All movingparts,suchasblowers andmotors,shouldbehand testedtoensure
that they are free and clear prior to start-up. Finally, verify that all lubrication is fresh and full.
Itis the responsibility of the installingcontractortoreturnthe start-up sheet and warranty
registration card to DataAire for proper activation of the unit warranty. Failure to do so
may cause delays and in some cases void the warranty.

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2.0 PIPING
2.1 Split Air Cooled Unit Piping
Refer to the attached Line Sizing chart on page 31 for a guideline for sizing refrigerant lines. The
ultimate responsibility for line size selection is that of the installing contractor or project engineer.
DataAire does not assume this responsibility. The chart covers distances up to 200 equivalent feet.
For installations beyond this distance, consult ASHRAE or similar references.
StandardPiping practice must be used to ensure proper oil return and efficient operation.
The interconnecting lines to the remote air cooled condenser must be installed by a
qualified refrigeration mechanic.
2.1.1 Discharge Lines
Dischargelines,alsocalled Hot Gas lines, should be trapped atthe top (inverted) and bottom, as well
as every 20 feet of vertical rise. Discharge line check valves are recommended on all installations,
especially those where there are long pipe runs or cold climate. Check valves should be installed
six feet from the compressor.
Discharge line pressure drop should not exceed 6 PSI. Recommended gas velocity for proper oil
return is 1,000 FPM. Slope horizontal lines downward in the direction of refrigerant flow 1/2” for
every ten feet of line length.
2.1.2 Liquid Lines
Liquid line size is determined by pressure drop and velocity. The liquid line pressure drop should be
not exceed 5 PSI. The recommended velocity should be between 200 and 300 FPM.
To avoid excessive liquid line pressure drop, the air cooled condenser should be located above or at
the same level as the evaporator. Condenser installation more than ten feet below the evaporator
should be avoided.
2.1.3 Suction Lines
Some applications call for the compressor to be mounted in the outdoor condenser, or condensing
unit. Such cases require field piping of liquid and suction lines. Suction lines are trapped similarly
to discharge lines except for the inverted trap at the top of the suction line and the line needs to be
insulatedwith a minimum 1/2”thickinsulationor per code. Common practiceforsuctionline selection,
see page 31, and installation should be followed.
2.1.4 Connection Sizes, Air Cooled Units
Model Hot Gas Liquid Suction
DAMA 0112 1/2” 1/2” 3/4” Note: Unit will have a Liquid Line and
DAMA 1.512 1/2” 1/2” 3/4” either a Hot Gas or Suction Line
DAMA 0212 1/2” 1/2” 3/4”
DAMA 2.512 1/2” 1/2” 3/4”
Field connections at the indoor evaporator and remote condenser or condensing unit will
not necessarily be the same as the field pipe size required. In some cases these will

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2.1.5 Field Piping, Remote Condenser
2.1.6 Field Piping, Remote Condensing Unit

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2.2 Water/Glycol Cooled Unit Piping
Therequired fieldinstalledcondenserwater pipe sizesmayormay not be thesameasthe connection
sizes at the evaporator or fluid cooler. This will depend on the length of pipe and the calculated
pressure drop of peripheral components.
Water cooled units may also be connected to building water or tower water sources. Pipe size will
depend on length of run and the maximum water flow required.
All chilled water pipes have a cap installed on the end of the pipe for pressure testing the system,
these caps need to be removed before installing the water piping to the CRAC unit. This can be
accomplished with a tubing cutter for smaller pipes and reciprocating saw with a metal cutting blade
for larger pipes or if there is a clearance problem.
Shutoff valves, field provided, should be installed within a few feet of the inlet and outlet connections
of the CRAC unit to allow the unit to be isolated for service. There should be a means of draining
the unit for service. Drain valves with hose bib connections should be located at the lowest point
on the piping connected to the units for this purpose. A fill valve with a hose bib connection should
also be used on the supply line or return line at the unit to allow the unit to be drained.
All water/glycol cooled units with plate-fin type condensers have a strainer shipped loose. This
strainer should be field installed in the supply line with shut off valves, field provided, before and
after the strainer, the strainer must be cleaned periodically.
One of the most common problems in a water/glycol system is the presence of air in the
condenser water loop. Air vents must be installed in various locations in the piping system
to purge the air.

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2.2.1 Connection Sizes, Water/Glycol Cooled Units
Evaporator Water IN and OUT
Model Connections, OD
DAMA 0112 3/4”
DAMA 1.512 3/4”
DAMA 0212 3/4”
DAMA 2.512 3/4”
2.2.2 Connection Sizes, Fluid Coolers
Fluid Cooler Water IN and OUT
Model Connections, OD
DAFC 06 1-5/8”
DAFC 07 1-5/8”
DAFC 09 1-5/8”
DAFC 11 2-1/8”
DAFC 15 2-1/8”
DAFC 17 2-5/8”
2.3 Auxiliary Chilled Water/Energy Saver Coil Piping
Units with an Auxiliary Chilled Water cooling coil require a separate source of chilled water. The
chilled water connection sizes will be equal to the condenser water connection sizes on the chart in
Section 2.2.2. Units with an Energy Saver cooling coil have shared piping with the condenser supply
and therefore do not require a separate water source.
2.4 Condensate Drain Piping
The evaporator section has a 3/4” FPT connection on the bottom for condensate removal. Vertical
units have the 5” plenum below the evaporator drain pan with knockouts that allow field supplied
and installed condensate lines to be routed out either side of the unit. A union is recommended at
the field connection which will permit easy disconnection from the unit for cleaning.
Atrap should be built into the drainline to prevent airfrom backing up into theunit. Drain lines should
be pitched downward not less than 1/4” for each ten feet of horizontal run. Do not reduce the size
of the drain line. Where local codes permit, PVC pipe may be used.
Some applications have no convenient means of allowing a gravity drain. In this case, a condensate
pump can be used. These come either factory mounted or shipped loose. Factory mounted
condensate pumps do not require a separate power source.
Condensate pumps shipped loose (or field 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 backflow. Also see condensate pump electrical requirements in Section
3.9.

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2.5 Humidifier Piping
The optional humidifier offered on Mini Ceiling systems is a steam generator type with a disposable
cylinder. Thehumidifiermakeup watershouldbe brought tothehumidifierthrough thefieldconnection
opening using 1/4” copper tubing. Acompression fitting is provided at the humidifier. Ashutoff valve
should be provided outside the unit to allow disconnection of service. An in-line water pressure
regulator and strainer should be installed. Water pressure should be set between 30 and 80 PSI.
The humidifier 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 field piping is required.
2.6 Leak Testing
No installation is complete until the entire system has been thoroughly checked for leaks. This
includes checking refrigerant tubing, flare fittings, pressure controls, shrader fittings and compressor
rotalock service valves.
In addition to the refrigeration system, check all condenser water lines, humidifier makeup lines,
condensate lines, condensate pumps, chilled water lines, centrifugal pumps and fluid coolers as
applicable.
When handling and recovering refrigerant, it is not permissible to release refrigerant into the
atmosphere. Many leak-test methods recommended in the past are no longer possible. Current
standard practices must be used.
Pressurize system circuit to 150 PSIG (1034kPa) by using dry nitrogen with a trace of refrigerant.
Check the entire system for leaks with suitable leak finder, (per local code) including but not limited
to all braze joints, caps and fittings, and flare nuts on both field and factory furnished components.
After completion of leak testing, release test pressure and pull a vacuum on the system.
Tightening of fittings and valves is the responsibility of the installing contractor.
2.7 Evacuation
Evacuate the refrigerant lines, condenser coil, and evaporator coil to 250 microns or lower (a micron
gauge and 2-stage vacuum pump are required). Valve off and turn off the vacuum pump and wait for
at least 15 minutes to make sure the micron gauge reading does not go back up above 700 microns.
Ifit does, re-start the vacuum pumpandevacuateuntilthe system reaches 250 microns. If thesystem
still does not hold the pressure below 700 microns the system needs to be rechecked for leaks.
After the system has been satisfactorily evacuated the unit(s) can be charged with refrigerant.
Connect the pressure gauge manifold set to the high and low ports near the compressor, connect
the charging line to the refrigerant tank and set it for liquid feed. Open the refrigerant tank valve
and purge the line at the manifold, then open the high side valve on the manifold only, and allow
the refrigerant flow until the system pressure equalize, at this point the system will have 75 to 80%
of the total refrigerant charge. Start the blower and then the compressor checking the operating
pressure and temperatures.
Do not apply power to the compressor when in a vacuum.

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3.0 ELECTRICAL CONNECTIONS
Before proceeding with the electrical connections, make certain that the volts,
hertz and phase correspond to that specified on the unit electrical nameplate. Use
copper conductors only.
3.1 Electrical Service
Checktobesure the service provided by the utility issufficient to handle the additionalload imposed
by this equipment. Indoor package units have a single power source. Indoor split units typically
have a single power source but can also be provided with separate sources. Field-provided,
interconnecting control wires are also required. Units with outdoor secondary heat exchangers
will require a separate power source and field-provided, interconnecting control wires as well. See
section 3.5 below.
Remote outdoor condensers and condensing units require one power source. Glycol systems
with fluid coolers and loose pump(s) typically require one power source for the fluid cooler and will
require one additional source for a single pump or two additional sources for dual pumps. Systems
where the pump(s) are mounted and piped integral to the fluid cooler will usually require a single
power source.
3.2 Nameplate Ratings
Refer to the unit electrical nameplate for equipment electrical requirements. Minimum Circuit
Ampacity, also known as Wire SizingAmps, will dictate the minimum required wire gage. Maximum
Overcurrent Protection Device amps will dictate the maximum circuit breaker or fuse size.
3.3 Grounding
Theunit cabinet must have anuninterruptedtrueearthground. An electrical ground wire of adequate
size must be connected to the ground lug provided inside the main electrical box.
3.4 Voltage Tolerance
The supply voltage to the unit must be within tolerance of -5%, +10% for 208-230 volt, +/- 10% for
277 volts. 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 warranty.
Check the wiring connections in the unit control panel to ensure they are tight. Screw
terminalsmay become loose in transit. tightening of wiring connections is the responsibility
of the installing contractor.
3.5 Auxiliary Control Wiring
For secondary heat exchangers (condensers and fluid coolers) connect two 18 gage wires from the
electricalboxoftheindoorevaporatorto the electrical box of the remote heat exchanger. Refertothe
wiringdiagrams located int heelectrical control panelof each unit. Onmost remoteheat exchangers
the terminals will also be #39 and #40. All control wiring on Data Aire equipment is 24 VAC.
Condensing units (compressors mounted in condenser) typically require more wires. Refer to wiring
diagrams in the units.

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Check the wiring connections in the unit control panel to ensure they are tight. Screw
terminals may become loose in transit. Tightening of all wiring connections is the
responsibility of the installing contractor.
3.6 Remote Shutdown
Every Data Aire evaporator has remote shutdown contact points available. These are intended for
a field supplied dry contact or switch to be wired across two terminals. When the contact or switch
opens,the control circuitpowerisinterrupted and theunitshutsdown, including thecontrolpanel. The
control circuit is 24 VAC and the field provided contact or switch and wiring should have a minimum
rating of 10 amps, a minimum of 18 gauge wire is recommended.
Theremoteshutdowncontactsarealwaysterminals#1and#2ontheterminalblockdesignatedTB1.
The unit is shipped with a factory jumper wire that connects terminal #1 to terminal #2. Remove this
wire prior to installing the field wires.
3.7 Remote Alarm Contacts
3.7.1 IftheoptionalMiniDAP®IImicroprocessorcontrolpanelisorderedwiththeoptionalsummary
alarm module, a remote alarm output contact can be field accessed on terminals #14 and #15 of
terminal block TB1. This is a normally Open, Close on Alarm, dry contact, intended to be used in a
controlcircuit not exceeding 5amps at24 VAC. This output contact willclose ona failureand remain
closed until the alarm is no longer present.
3.7.2 If the optional Mini DAP III microprocessor control panel is ordered with the optional summary
alarm module , a remote alarm output contact can be field accessed on terminals #11 (common)
and #12 (normally closed) or #13 (normally open) of terminal block TB1. This is a normally open or
normally closed, dry contact, will reverse position upon alarm and is intended to be used in a control
circuit not exceeding 5 aps at 24 VAC. This output contact will reverse position on a failure and
remain reversed until the alarm is no longer present.
3.8 Remote Sensors
3.8.1 The optional Mini DAP II panel normally comes with sensors mounted in the panel. Although
these existing sensors can be removed for remote mounting, the remote sensor option provides a
more convenient means of field installation. This is because the sensors are already connected to
a predetermined length of cable and come mounted in a remote sensor enclosure. The temperature
and humidity sensors require a total of six wires. This should be a twisted, shielded cable.
3.8.2 The optional Mini DAP III panel normally comes with sensors mounted in the panel. Although
these existing sensors can be removed for remote mounting, the remote sensor option provides a
more convenient means of field installation. This is because the sensors are already connected to
a predetermined length of cable and come mounted in a remote sensor enclosure. The temperature
and humidity sensors require a total of five wires. This should be a twisted, shielded cable.
3.9 Condensate Pumps
Condensate pumps which ship loose normally require a separate source of 110 volt power. Always
check the pump power requirements before connecting power. Condensate pumps are available
in other voltages.
Condensate pumps may also come unit mounted and wired in the unit as a factory option. While no
outside power source is required, field piping is still a requirement.

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4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER
Air cooled condensers and fluid coolers have individual Installation, Operation and Maintenance
manuals which should be referred to for more complete details.
4.1 Rigging
This section covers outdoor condensers/condensing units and fluid coolers. For indoor condensers
and condensing units refer to section 1.3.4. Outdoor heat exchangers should be moved to their
(typically rooftop) mounting location using a crane or fork lift. Each fan section have supports with
lifting holes at the top.
Do not lift with a choke sling around the unit. Spreader bars are recommended for lifting multiple fan
units. Under no circumstances should the coil headers or piping be used for lifting the unit. Ideally,
the unit should be kept in its shipping crate until it is ready to be set in place.
4.2 Leg Assembly
Most condensers and condensing units matched up with Mini Ceiling units are self-contained and
require no field modification to the mounting legs. Larger condensers/condensing units and fluid
coolers, size “06” and larger, have legs that must be unbolted from their collapsed shipping position
and extended prior to placing the unit on its pad.
Each leg extends down approximately 18” and reattaches using the same bolts, the bolts are placed
through the lower set of holes on the bracket.
Note: Failuretoextendthelegswillresultinpoorairdistributionoverthecoolingcoilresulting
in significant capacity reduction and potential high discharge pressure problems.
Concrete pads or a rail system are often used to provide support for the heat exchanger. Bolt holes
in the bottom of each leg can be used to anchor the unit.
4.3 Locating the Remote Heat Exchanger
The remote heat exchanger must be located in
anarea that willensurefreeair flowintoandout
of the heat exchanger plus adequate service
accessclearance. Shortcircuitingof theairflow
or the intake of warmer air from another unit
will seriously degrade the performance of the
air cooled heat exchanger.
Do not locate the heat exchanger in a location
thatisborderedbytallobstructions(i.e.,higher
than 10 feet) on no more than two sides. See
Figure at right for minimum clearance from
obstructions and between units. With proper
clearance on all sides, two units can be placed
side by side. Additional units should be placed
at least 48 inches apart.

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Noise factors should be also considered when locating an air cooled heat exchanger. Proximity to
windows, walls, and surrounding structures can cause objections by the occupants. An acoustical
expert should be consulted when noise is of a particular concern.
Air cooled heat exchangers should be placed at a level that is higher than the indoor evaporator.
Mounting the remote heat exchanger (condenser or condensing unit) more than 10 feet below the
evaporator is not recommended. Excessive liquid line pressure drop can cause poor evaporator
performance.
Piping must be supported within 18 inches of the inlet and outlet connections. The inlet connection
is located on the top header on all remote heat exchangers and the outlet connection is located on
the bottom header of all units.
4.4 Electrical Service
Refer to Sections 3.1 to 3.5 for information regarding line voltage and control voltage wiring
details.
4.5 Air Cooled Condensers - Model DARC
Standard outdoor air cooled condensers have a fan speed controller on the first fan. On single-
fan condensers this is the only means of control. A variable speed controller modulates the motor
speed based on system head pressure. The fan speed controller will normally not require field
adjustment.
Air cooled condensers should be placed at a level that is above the level of the indoor evaporator.
Mountingacondenserorcondensingunitmorethantenfeetbelowtheevaporatorisnotrecommended.
Excessive liquid line pressure drop can cause poor evaporator performance.
4.6 Fluid Coolers - Model DAFC
4.6.1 Fluid-Sensing Thermostats
Fluidcoolerfan motors are cycled on andoffby individual water-sensingthermostats strapped to the
leaving water header. The fan motor will only have a thermostat if the unit has an energy saver coil.
Without the optional energy saver coil, the first fan motor runs whenever there is a call for cooling
via an auxiliary signal sent by the indoor evaporator (see also Section 3.5).
The water-sensing thermostats have adjustable setpoints which are typically staggered to maintain
water temperature in the 85 to 105oF range. This is generally the desired range for glycol cooled
systems.
4.6.2 Energy Saver Cooling
In colder climates, the evaporator will often be equipped with an additional free cooling coil to take
advantage of the colder ambient temperatures. When incoming fluid falls below the setpoint of a
water-sensing thermostat in the evaporator (typically about 50oF), energy saver cooling becomes
available.
Systems with an energy saver coil should have at least one fluid-sensing thermostat on the fluid
cooler set lower to take advantage of colder ambient temperatures. The desired fluid temperature
for energy saver cooling is 45oF. Field adjustment of fluid-sensing thermostats is not unusual.
It is desirable to use the energy saver mode as much as possible. However, fluid temperature that

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is too cold can cause excessive dehumidification and coil sweating. Fluid temperature that is too
high can cause the indoor space temperature to rise. This can cause the optional microprocessor
controls to lock out the energy saver mode for one hour while it reverts back to compressorized
cooling. Adjustthesetpoints of the thermostats to allow the maximumfree cooling time. Overcooling
or undercooling the fluid should be avoided.
Every application will have a different ambient temperature and indoor heat load/
air distribution profile. Therefore it is not possible to dictate the exact water-sensing
thermostat setpoints. Field adjustments are typical to allow fine-tuning to specific
conditions
5.0 CHARGING
5.1 Air Cooled Systems
5.1.1. Package Air Cooled Systems
Package air cooled units come factory charged because, even though the condenser blower section
ships loose, all of the refrigerant carrying components are self-contained within the evaporator
section.
A properly charged system operating at typical parameters will have a head pressure of 225 to 275
psi. Suction temperature should be 58 psi or greater. The superheat at the compressor suction line
at least 6 inches away from the compressor should be 8-15oF.
An air cooled package unit may require field charging if a compressor is changed, if a leak develops
or if non-condensables are in the system. Field charging should be done by referring to the unit
electrical nameplate for the factory charge.
Although this figure represents the original factory charge, it is still necessary to measure and note
proper unit operation including superheat, head and suction pressure. Some adjustment to charge
may be required.
Before starting a compressor, the crankcase heater should be energized for a minimum
of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize
the crankcase heater could result in compressor damage.
5.1.2 Split Indoor Air Cooled Systems Charging
After the field refrigerant piping is properly completed, connect the refrigerant drum to the low side
and charge with vapor. Charge with approximately three lbs. per nominal ton. For example, a model
DAPA 0334-CO is a nominal three ton unit. Charge with about nine lbs. of refrigerant to begin. It is
likely that more refrigerant will be required to complete the charging procedure. Make sure all hoses
are properly purged. Before starting a compressor, the crankcase heater should be energized for a
minimum of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize the
crankcaseheater couldresultin compressordamage Starttheevaporator fanandcompressor.Check
the liquid line sight glass to get a feel for the approximate charge. Bubbles in the sight glass are not
unusual at this point and can be caused by flashing from liquid line pressure drop, low subcooling or
low charge. It is likely that more refrigerant will be required to complete the charging procedure.

20
Adjust the refrigerant charge until the sight glass has only sparse bubbles. The unit should be
allowed to stabilize for several minutes before meaningful measurements can be taken. A properly
charged system operating at typical parameters will have a head pressure of 225 to 275 psi. Suction
temperature should be 58 psi or greater. The super heat at the compressor suction line at least six
inches away from the compressor should be 8-15oF.
Note: Charging to a full liquid line sight glass should never be the sole means of
determiningthe correct refrigerant charge. Other parameters such as superheat, suction
pressure, head pressure, subcooling and ambient temperature are also important
parameters. A system charged to a clear sight glass is often over-charged.
5.1.3. Fan Speed Control System Charging
The standard outdoor air cooled condenser for DataAire equipment is a fan speed control system.
Connect the refrigerant drum to the low side of the system. Make sure all hoses are properly
purged. From a vacuum, feed liquid refrigerant into the high side of the system until the pressure
equalized, at this pint there will be about 79 to 80% of the total charge of the system. Charge with
approximately three pounds per nominal ton plus the line set. Charge circuit with about six pounds
of refrigerant to begin.
For example, a model DAMA0212 is a nominal 2 ton unit. Charge with about six lbs. of refrigerant
to begin. It is likely that more refrigerant will be required to complete the charging procedure. Make
sure all hoses are properly purged.
Before starting a compressor, if the system has a refrigerant holding charge, the crankcase
heatershouldbeenergizedforaminimumof12hourstoreducethepossibilityofliquidslugging
on start-up. Failure to energize the crankcase heater could result in compressor damage.
If the system is charged from a vacuum, the pre-heating of the compressor is not necessary, start
thesystem and allow the systemto stabilize to roomtemperature. Bubbles in thesight glass arenot
unusual at this point and can be caused by flashing from liquid line pressure drop, low sub-cool, or
low charge. It is likely that more refrigerant will be required to complete the charging procedure.
Adjust the refrigerant charge until the subcooling is between 8 and 10oF and the super heat is 8 to
15oF, there will be flashing and/or bubbles in the sight glass when the system is properly charged.
After the system is allowed to stabilize, verification of a few key measurements should be noted.
The discharge pressure should be about 225 to 275 psi and the subcooling should be 8-10oF,
depending on ambient conditions. Suction temperature should be 58 psi or greater. The superheat
at the compressor suction line at least six inches away from the compressor should be 8-15oF, for
unitsthat are water/glycol cooledand aircooled unitswith air cooledcondensers. Units withremote
condensing units the superheat should be 20 to 25oF at the compressor, the subcooling will be the
same 8 to 10o F.
Note: Charging to a full liquid line sight glass should never be the sole means of
determiningthecorrectrefrigerantcharge. Otherparameterssuchassuperheat,suction
pressure, head pressure, subcooling and ambient temperature are also important
parameters. A system charged to a clear sight glass is often over-charged.