MINI CEILING SERIES Installation, Operation and Maintenance Manual 1, 1.5, 2 and 2.
CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION ENVIRONMENTAL CONTROL SYSTEM. PROPER INSTALLATION, OPERATION AND MAINTENANCE OF THIS EQUIPMENT WILL ENSURE YEARS OF OPTIMAL PERFORMANCE. 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.
Table of Contents 1.0 INSTALLATION ......................................................................................................... 6 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.4 1.5 Room Considerations ................................................................................................ 6 Inspection ................................................................................................................... 6 Locating the Unit ........................................................
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 ...............
Table of Contents, continued 9.0 WARRANTY ....................................................................................................................... 29 10.0 CONTACT DATA AIRE ....................................................................................................... 30 LINE SIZING CHART .................................................................................................................... 31 Monthly Maintenance Inspection Checklist ..................................
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.
Note there are many available unit configurations for Mini Ceiling systems. Be sure to identify the unit type and style before installing. For instance there may be split condenser/ condensing sections requiring separate or shared power. Note to Installing Contractor: Condensation formation and frequent humidifier flushing are normal functions of this equipment. Proper drain connections must be made to ensure proper removal.
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 95o F. 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.
If equipment is stored for longer than 30 days special precautions must be taken to avoid coil damage. All coils should be charged and sealed with a low pressure (1-3 psig) inert gas, such as nitrogen. This prevents contaminates from entering the coils; then when the seal is broken at installation, the rush of escaping gas verifies the coil is still leak free.
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. Data Aire does not assume this responsibility. The chart covers distances up to 200 equivalent feet. For installations beyond this distance, consult ASHRAE or similar references.
2.1.5 Field Piping, Remote Condenser 2.1.
2.2 Water/Glycol Cooled Unit Piping The required field installed condenser water pipe sizes may or may not be the same as the 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.
2.2.1 Connection Sizes, Water/Glycol Cooled Units Evaporator Model DAMA 0112 DAMA 1.512 DAMA 0212 DAMA 2.512 Water IN and OUT Connections, OD 3/4” 3/4” 3/4” 3/4” 2.2.2 Connection Sizes, Fluid Coolers Fluid Cooler Model DAFC 06 DAFC 07 DAFC 09 DAFC 11 DAFC 15 DAFC 17 2.3 Water IN and OUT Connections, OD 1-5/8” 1-5/8” 1-5/8” 2-1/8” 2-1/8” 2-5/8” Auxiliary Chilled Water/Energy Saver Coil Piping Units with an Auxiliary Chilled Water cooling coil require a separate source of chilled water.
2.5 Humidifier Piping The optional humidifier offered on Mini Ceiling systems is a steam generator type with a disposable cylinder. The humidifier makeup water should be brought to the humidifier through the field connection opening using 1/4” copper tubing. A compression fitting is provided at the humidifier. A shutoff valve should be provided outside the unit to allow disconnection of service. An in-line water pressure regulator and strainer should be installed.
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 Check to be sure the service provided by the utility is sufficient to handle the additional load imposed by this equipment. Indoor package units have a single power source.
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.
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.
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.
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. Adjust the setpoints of the thermostats to allow the maximum free cooling time. Overcooling or undercooling the fluid should be avoided.
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 o inches away from the compressor should be 8-15 F.
5.1.4. Flooded System Charging Flooded systems are units having refrigerant circuits with an optional liquid receiver and head pressure control valve. When the ambient temperature falls during cold weather, the head pressure control valve will regulate the flow of refrigerant to ensure nearly constant receiver pressure. The condenser is partially flooded with liquid in cold weather. In warm weather the extra refrigerant is stored in the receiver.
5.2 Water/Glycol Cooled Systems 5.2.1. Water/Glycol Cooled Systems Charging All water/glycol cooled units are factory charged. The water regulating valve should be adjusted to maintain 230 to 260 psi head pressure. 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 8-15 degrees. Field charging water/glycol systems should be done by referring to the unit electrical nameplate for the factory charge.
Except for extremely small releases of refrigerant such as what occurs when disconnecting service hoses (diminimous release), a technician who knowingly releases or vents refrigerant to the atmosphere is in violation of this regulation. Refrigerant purchasers must be certified technicians and have a valid EPA certification card. 5.4 Important Refrigeration Components 5.4.1. Expansion Valve Each refrigerant circuit has an adjustable thermo-expansion valve (TXV).
6.0 GLYCOL SYSTEMS 6.1 Glycol Concentration The system must be filled with water and the appropriate amount of ethylene or propylene glycol to protect against winter freeze-up. To achieve the approximate glycol concentration, it is necessary to know the total system volume. This consists of the sum of the fluid cooler volume, the evaporator unit volume, and the volume of the interconnecting piping. The following tables can be used for arriving at an approximate system volume.
7.0 CONTROLS 7.1 Standard Thermostat The standard controls on all Mini Ceiling system equipment is a single stage cooling thermostat. Units requiring optional reheat and/or humidifier require the optional Mini DAP II control panel described below. 7.2 Optional Programmable Thermostat This optional thermostat is the same as the standard thermostat except it has some simple programmable functions. This control cannot be used with optional reheat or humidifier options. 7.
7.6 Wiring Diagrams Every Data Aire evaporator, condenser, condensing unit or fluid cooler comes with a wiring diagram. These diagrams are ‘ladder’-type schematics intended for service personnel. The intent is to allow the technician to understand the wiring details associated with the electrical components and how they interface with the controls as well as peripheral equipment, including secondary heat exchangers.
8.0 REGULAR MAINTENANCE ITEMS 8.1 Air Filters Filters should be checked on a regular basis and changed when they become dirty. This will ensure efficient operation of the unit. Spare filters should be kept in stock as these tend to be a frequently replaced maintenance item. Filters may require changing as often as monthly. Note also that construction dust on new installations will quickly clog new filters.
8.7 Refrigerant Filter Drier Factory installed refrigerant filter driers do not normally require maintenance. When replacing compressors or other repairs that open the refrigeration system to atmosphere, it is advisable to replace the filter drier. The equivalent type and size should be used.
9.
10.0 Contact Data Aire Address: DATA AIRE INC. 230 W. BLUERIDGE AVE. ORANGE, CA 92865 Phone: 714-921-6000 800-347-AIRE (2473) Toll Free Fax: 714-921-6003 714-921-6010 714-921-6011 714-921-6022 Main Engineering Part Sales E-mail: tech_support@dataaire.com engineering@dataaire.com sales@dataaire.com Technical Support Engineering Sales Web site: www.dataaire.
RECOMMENDED LINE SIZING FOR AIR COOLED SPLIT SYSTEMS UP TO 200 EQUIVALENT FEET HOT GAS LINES SINGLE CIRCUIT SYSTEMS Tons per EQUIVALENT FEET Unit Tonnage 1 1.5 2 2.5 3 4 5 6 8 10 13 Circuit 50 1 5/8 1.5 5/8 2 5/8 2.5 5/8 3 7/8 4 7/8 5 7/8 6 7/8 8 1-1/8 10 1-1/8 13 1-1/8 100 5/8 5/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 150 5/8 7/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 DUAL CIRCUIT SYSTEMS EQUIVALENT FEET Unit Tons per Tonnage Circuit 6 3 8 4 10 5 13 6.
Data Aire, Inc. Monthly Maintenance Inspection Checklist Model No.__________________ Prepared by: _______________ Serial No.
Data Aire, Inc. Quarterly Maintenance Inspection Checklist Model No.
Superheat and Suction Pressure Trouble Shooting Guide Low Suction Pressure and High Superheat 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Moisture, dirt, wax Undersized valve* High superheat adjustment Gas charge condensation Dead thermostatic element charge Wrong thermostatic charge Evaporator pressure drop - no external equalizer External equalizer location Restricted or capped external equalizer Low refrigerant charge Liquid line vapor a. Vertical lift b. High friction loss c. Long or small line d.
Temperature Pressure Chart for R-22 and R-407C Temperature 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 R-22 R-407C Pressure, PSI Pressure, PSI 50.0 43.6 51.2 52.4 46.0 53.7 54.9 48.4 56.2 57.5 50.9 58.8 60.2 53.5 61.5 62.9 56.2 64.3 65.7 58.9 67.1 68.6 51.7 70.0 71.5 64.6 73.0 74.5 67.6 76.1 77.6 70.7 79.2 80.8 73.8 82.
- A Air Cooled Systems ................ 7, 8, 10, 20 Air Filters .............................................. 27 Air Vents ............................................... 12 Ambient Thermostats ........................... 18 Auxiliary Wiring ........................................ 15 - B Bearings .................................................. 27 Belts......................................................... 27 - C Charging Air Cooled Fan Speed Systems ......... 20 Air Cooled Flooded Systems..........
Rigging .................................................... 17 - S Sight Glass .................................. 19, 20, 21 Start Up Sheet ........................................... 8 Strainer .................................................... 12 Subcooling ................................... 20, 21, 22 Suction Lines ........ 10, 11,19, 20, 21, 22, 31 Superheat ........................ 19, 20, 21, 22, 34 - T Thermo-expansion Valve (TXV) .............. 23 Thermostats Ambient ............................
Notes: _______________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _________________________________________
230 W. BlueRidge Avenue Orange, CA 92865 800-347-2473 www.dataaire.com e-mail: sales@dataaire.com A Member of the CS Group of Companies © 2009 Data Aire, Inc. Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice.
