G-Force Ultra User manual

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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.

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Table of Contents
1. INTRODUCTION............................................................................................................................................................... 7
1.1. Product Information................................................................................................................................................7
1.2. Model Identification................................................................................................................................................8
1.3. Inspection................................................................................................................................................................8
1.4. Paperwork...............................................................................................................................................................9
1.5. Storage ....................................................................................................................................................................9
1.5.1. Suggested Reference Storage Room Conditions.............................................................................................9
1.5.2. General Storage Considerations ...................................................................................................................10
1.6. Registered Trademarks –Copy Rights –References Section................................................................................10
2. INSTALLATION...............................................................................................................................................................11
2.1. Recommended Tools for Installation....................................................................................................................12
2.2. Pre-Installation......................................................................................................................................................12
2.3. Installation must be planned so that: ...................................................................................................................12
2.4. Room Considerations............................................................................................................................................13
2.5. Equipment Handling and Rigging..........................................................................................................................13
2.5.1. Door and Rear Panel Removal ......................................................................................................................13
2.5.2. Rear Panel .....................................................................................................................................................15
2.5.3. Moving Unit into Final Location....................................................................................................................15
2.6. Rigging...................................................................................................................................................................16
2.7. Locating the Unit...................................................................................................................................................16
2.8. Downflow Units.....................................................................................................................................................17
2.9. Upflow Units .........................................................................................................................................................18
2.10. Piping.....................................................................................................................................................................19
2.11. Air Cooled Unit Piping ...........................................................................................................................................20
2.12. Discharge Lines......................................................................................................................................................20
2.13. Liquid Lines............................................................................................................................................................22
2.14. Recommended Line Sizing, Air Cooled Units ........................................................................................................22
2.15. Connection Sizes, Air Cooled Units .......................................................................................................................23
2.16. Field Piping, Remote Condenser Above Evaporator.............................................................................................24
2.17. Field Piping, Remote Condenser Below Evaporator .............................................................................................25
2.18. Refrigerant Piping Protection................................................................................................................................26
2.19. Water/Glycol Cooled Unit Piping ..........................................................................................................................27
2.20. Field Piping, Water/Glycol System........................................................................................................................28
2.21. Connection Sizes, Water/Glycol Cooled Units ......................................................................................................29
2.22. Connection Sizes, Fluid Coolers (Dry Coolers) ......................................................................................................29
2.23. Factory Charge for Water/Glycol Cooled System..................................................................................................30
2.24. Auxiliary Chilled Water/Energy Saver Coil Piping..................................................................................................30
2.25. Condensate Drain Piping.......................................................................................................................................30
2.26. Humidifier Piping ..................................................................................................................................................31
2.26.1. Steam Generator Humidifier.........................................................................................................................31
2.27. Leak Testing...........................................................................................................................................................32

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2.28. Electrical Installation.............................................................................................................................................32
2.29. Commissioning Information..................................................................................................................................33
3. ELECTRICAL CONNECTIONS...........................................................................................................................................34
3.1. General Electrical Field Wiring Guidelines............................................................................................................35
3.2. Electrical Service ...................................................................................................................................................36
3.3. Nameplate Ratings................................................................................................................................................36
3.4. Grounding .............................................................................................................................................................36
3.5. Voltage Tolerance .................................................................................................................................................36
3.5.1. Three Phase Voltage Tolerance ....................................................................................................................36
3.5.2. Single-Phase Voltage Tolerance (Not available for gForce Ultra units).......................................................37
3.6. Auxiliary Control Wiring........................................................................................................................................37
3.7. Remote Shutdown ................................................................................................................................................38
3.8. Remote Alarm Contacts ........................................................................................................................................38
3.9. dap4 Controller .....................................................................................................................................................38
3.10. Disconnect switch (Optional)................................................................................................................................39
3.11. How to Open the Electrical Enclosure Panel.........................................................................................................39
3.12. Condensate Pumps (Optional) ..............................................................................................................................39
3.13. Condensate Probe.................................................................................................................................................40
3.14. Water Sensing Cable (Optional) ............................................................................................................................40
3.15. Remote Temperature and Humidity Sensors (Optional).......................................................................................40
3.16. Manual Override Switch Board.............................................................................................................................40
3.17. Plug Fan Current Sensing Switch...........................................................................................................................41
3.18. Wiring Diagrams....................................................................................................................................................41
3.19. Electronic Expansion Valve ...................................................................................................................................42
3.19.1. Electrical Connection to EEV .........................................................................................................................42
4. INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER............................................................................................43
5. CHARGING.....................................................................................................................................................................44
5.1. Triple Evacuation and Dehydration Procedure.....................................................................................................44
5.1.1. Tools Needed ................................................................................................................................................44
5.1.2. First Stage Evacuation...................................................................................................................................45
5.1.3. Second Stage Evacuation ..............................................................................................................................45
5.1.4. Third Stage Evacuation..................................................................................................................................46
5.1.5. Final Evacuation Stage ..................................................................................................................................46
5.2. General Pre-Charging Guidelines..........................................................................................................................47
5.3. Voltage Phase Check .............................................................................................................................................48
5.3.1. Evaporator Phase Check ...............................................................................................................................48
5.3.2. Fixed Speed Scroll Compressor Phase Check................................................................................................48
5.3.3. Variable Speed Compressor Phase Check.....................................................................................................48
5.3.4. Heat Exchanger Phase Check ........................................................................................................................49
5.4. Line Set Charge Calculations .................................................................................................................................49
5.5. Component Functional Test..................................................................................................................................50

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5.6. CHARGING PROCEDURES ......................................................................................................................................50
5.6.1. Air Cooled System Charging..........................................................................................................................50
5.7. Refrigerant Handling.............................................................................................................................................50
5.7.2. Flooded System Charging (Systems with Low Ambient Receiver Package)..................................................56
5.7.3. Water/Glycol-Cooled System Charging.........................................................................................................58
5.8. Commissioning a Running Compressor ................................................................................................................59
6. GLYCOL SYSTEMS...........................................................................................................................................................61
6.1. Glycol Concentration.............................................................................................................................................61
6.2. Internal (Fluid) Volume –Downflow Units ...........................................................................................................61
6.3. Internal (Fluid) Volume –Upflow Units ................................................................................................................61
6.4. Internal (Fluid) Volume –Fluid Coolers.................................................................................................................62
6.4.1. Fluid Cooler Information...............................................................................................................................62
7. Important Refrigeration Components ..........................................................................................................................63
7.1. Variable Capacity Compressor Features ...............................................................................................................63
7.2. Oil Management ...................................................................................................................................................63
7.3. Crankcase Heaters.................................................................................................................................................63
7.4. Oil Level.................................................................................................................................................................64
7.5. Variable Frequency Drive......................................................................................................................................64
7.5.1. Local Control for Charging.............................................................................................................................65
7.5.2. To View the Drive Alarms..............................................................................................................................65
7.6. High Pressure Cutout Switch.................................................................................................................................66
7.7. Low Pressure Cutout Switch .................................................................................................................................66
7.8. Liquid Line Solenoid Valve.....................................................................................................................................66
7.9. Low Ambient Receiver Package ............................................................................................................................67
7.9.1. Refrigerant Receiver .....................................................................................................................................67
7.9.2. Applications...................................................................................................................................................68
7.9.3. Selection Guidelines......................................................................................................................................68
7.9.4. Receiver Location..........................................................................................................................................68
7.9.5. Safety Relief Devices .....................................................................................................................................68
7.10. Energy Saver Cooling (Optional) ...........................................................................................................................68
8. CONTROLS.....................................................................................................................................................................69
9. Maintenance .................................................................................................................................................................70
9.1. Service vs. Maintenance .......................................................................................................................................70
9.2. General Maintenance Requirements....................................................................................................................70
9.3. Daily Maintenance ................................................................................................................................................70
9.4. Maintenance/Inspection Checklist .......................................................................................................................70
9.5. Air Filters ...............................................................................................................................................................71
9.5.1. Downflow Unit Filter Replacement Procedure .............................................................................................72
9.5.2. Upflow Unit Filter Replacement Procedure..................................................................................................72
9.6. Humidifier .............................................................................................................................................................73
9.6.1. Humidifier Canisters......................................................................................................................................73