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

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9.7. Coil Drain Pan........................................................................................................................................................74
9.8. Condensate Pump.................................................................................................................................................74
9.9. Cabinet ..................................................................................................................................................................74
9.9.1. Exterior Cabinet Maintenance –Cleaning ....................................................................................................75
9.10. Coils.......................................................................................................................................................................75
9.10.1. Coil Cleaning..................................................................................................................................................75
9.11. Piping.....................................................................................................................................................................75
9.12. Water/Glycol Cooled System ................................................................................................................................75
9.13. Refrigerant Filter Drier..........................................................................................................................................76
9.14. Electrical Control Enclosure ..................................................................................................................................76
9.14.1. Fuses..............................................................................................................................................................77
9.15. Electric Reheat Elements ......................................................................................................................................77
9.16. Plug Fans with Electronically Commutated Motor ...............................................................................................77
9.17. Current Sensing Switch Adjustment (Plug Fans Only)...........................................................................................78
10. MAINTENANCE/INSPECTION CHECKLIST.......................................................................................................................79
11. Frequently Asked Questions –FAQ ..............................................................................................................................82
11.1. Electrical FAQ Section ...........................................................................................................................................82
11.2. Mechanical FAQ Section .......................................................................................................................................83
12. CONTACT DATAAIRE......................................................................................................................................................85
Table of Figures
Figure 1 Typical Upper Spring-Loaded Hinge.......................................................................................................................16
Figure 2 Upper Hole for Spring-Loaded Hinge .....................................................................................................................16
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 Remote Condenser Above Evaporator Installation....................................................................................26
Figure 7 Typical Remote Condenser Below Evaporator.......................................................................................................27
Figure 8 Typical Water/Glycol System..................................................................................................................................30
Figure 9 Typical Remote Heat Exchanger Interconnection Points.......................................................................................40
Figure 10 Typical Indoor Evaporator Interconnection Points................................................................................................40
Figure 11 Manual Override Board.........................................................................................................................................43
Figure 12 EEV with Electrical Mating Connector..................................................................................................................45
Figure 13 Typical VFD to VS Compressor Wiring.................................................................................................................52
Figure 14 Typical Low Ambient Receiver Package..............................................................................................................70
Figure 15 Example Remote EPO Switch Connection...........................................................................................................86

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1. INTRODUCTION
1.1. 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%
RHor minimum WB of 54°F(12.2°C)forproper 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 capacity compressors. 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 (VCC), on the other hand, saves energy and
operates more quietly by varying speed to match the workload. Tests with VCC compressors
have shown an immediate energy savings and sound level reductions.

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1.2. Model Identification
1.3. Inspection
This Data Aire CRAC unit has been factory run-tested and has gone through a comprehensive
inspection prior to its packaging and shipment to ensure that it arrives in excellent condition.
However, 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
│ │ │ │ │ │
gForce Ultra, │ │ │ │ │ │
Single and Dual Circuit
────
┘ │ │ │ │ │ Voltage
│ │ │ │ │ 2 - 208/230 VAC
A- Air Cooled │ │ │ │ └
────
4 - 460 VAC
W - Water Cooled
────
────
┘ │ │ │
G - Glycol Cooled │ │ │
│ │ │ Phase
D - Downflow
────
────
────
┘ │ └
────
────
3 - Three phase
U- Upflow │
│
Nominal Kilowatts │
036 kW │
045 kW │
056 kW
────
────
────
────
┘
070 kW
091 kW
125 kW
gForce Ultra Model Number

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1.4. Paperwork
EachDataAireCRACunitshipswithastart-upsheetthatshouldbecompletedduringinstallation.
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 is attached to the outside decorative door to indicate articles that may have been
packaged and shipped loose within the unit cabinet. Typically this would be jackstands,
condensate pumps and other loose components that are not factory mounted.
WARNING: It is the responsibility of the installing contractor to return the
start- up sheet and warranty registration card to Data Aire for proper
activation of the unit warranty. Failure to do so may cause delays and
some cases void the warranty
1.5. 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.
1.5.1. Suggested Reference Storage Room Conditions
•Dry bulb temperature range: 65°F to 85°F.
•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.

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•Store at non-condensing temperature and humidity conditions.
1.5.2. 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.
1.6. 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.