Congratulations!

You have selected a Data Aire precision control system, one of the finest available in
the market today. 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.
 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 Horizontal Airflow Units..............................................................................................7
1.3.2 Vertical Airflow Units...................................................................................................7
1.4 Paperwork.......................................................................................................................7
1.5 Storage............................................................................................................................8
1.6 Model Identification..........................................................................................................8

2.0 PIPING .........................................................................................................................9

2.1 Split Air Cooled Unit Piping..............................................................................................9
2.1.1 Discharge Lines.........................................................................................................9
2.1.2 Liquid Lines..............................................................................................................10
2.1.3 Suction Lines............................................................................................................10
2.1.4 Connection Sizes, Air Cooled Units.........................................................................11
2.1.5 Field Piping, Remote Condenser/ Condensing Unit Above Evaporator...................12
2.1.6 Field Piping, Remote Condenser/ Condensing Unit Below Evaporator...................12
2.2 Water/Glycol Cooled Unit Piping...................................................................................13
2.3 Auxiliary Chilled Water Coil Piping................................................................................14
2.4 Condensate Drain System.............................................................................................14
2.5 Condensate Trap...........................................................................................................14
2.6 Humidifier Piping...........................................................................................................15
2.7 Dry Steam Humidifier.....................................................................................................15
2.8 Leak Testing...................................................................................................................16
2.9 Evacuation.....................................................................................................................16

3.0 ELECTRICAL CONNECTIONS ...........................................................................16

3.1 Electrical Service...........................................................................................................17
3.2 Nameplate Ratings........................................................................................................17
3.3 Grounding......................................................................................................................17
3.4 Voltage Tolerance..........................................................................................................17
3.5 Auxiliary Control Wiring.................................................................................................17
3.6 Remote Shutdown.........................................................................................................18
3.7 Remote Alarm Contacts.................................................................................................18
3.8 Remote Sensors............................................................................................................18
3.9 Condensate Pumps.......................................................................................................18

4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER ..............19

4.1 Rigging..........................................................................................................................19
4.2 Leg Assembly................................................................................................................19
4.3 Locating the Remote Heat Exchanger...........................................................................19
4.4 Electrical Service...........................................................................................................20
3
 . Table of Contents, continued
4.0 INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER - (continued)
4.5 Air Cooled Condensers - Model DARC.............................................................................. 20
4.5.1 Fan Speed Control........................................................................................................ 20
4.5.2 Ambient Thermostats.................................................................................................... 20
4.6 Fluid Coolers - Model DAFC............................................................................................... 21
4.6.1 Fluid-Sensing Thermostats........................................................................................... 21
4.6.2 Energy Saver Cooling................................................................................................... 21

5.0 CHARGING .................................................................................................................... 22

5.1 Voltage Phase Check........................................................................................................... 22
5.1.1 Evaporator..................................................................................................................... 22
5.1.2 Secondary Heat Exchanger.......................................................................................... 22
5.2 Air Cooled Systems....................................................................................................... 22
5.2.1 Split Indoor Air Cooled Systems Charging.................................................................... 22
5.2.2 Fan Speed Control System Charging........................................................................... 23
5.2.3 Flooded System Charging............................................................................................. 23
5.3 Water/Glycol Cooled Systems....................................................................................... 24
5.3.1 Water/Glycol Cooled Systems Charging....................................................................... 24
5.4 Refrigerant Handling..................................................................................................... 25
5.5 Important Refrigeration Components............................................................................ 25
5.5.1 Expansion Valve............................................................................................................ 25
5.5.2 High Pressure Cutout Switch....................................................................................... 26
5.5.3 Low Pressure Cutout Switch......................................................................................... 26

6.0 GLYCOL SYSTEMS .................................................................................................... 26

6.1 Glycol Concentration.......................................................................................................... 26
6.2 Internal (Fluid) Volume....................................................................................................... 26
6.3 Fluid Cooler Internal Volume.............................................................................................. 26
6.4 Copper Piping Internal Volume........................................................................................... 27
6.5 Freezing Point of Aqueous Solutions.................................................................................. 27

7.0 CONTROLS ................................................................................................................... 27

7.1 Mini dap4 Controller........................................................................................................... 27
7.2 Optional Expanded dap4 Controller................................................................................... 27
7.3 Secondary Heat Exchangers.............................................................................................. 27
7.4 Wiring Diagrams................................................................................................................. 28

4
 Table of Contents, continued
8.0 REGULAR MAINTENANCE ITEMS
8.4 Humidifier Canisters.......................................................................................................... 29
8.5 Fuses................................................................................................................................. 30
8.6 Heating Elements.............................................................................................................. 30
8.7 Refrigerant Filter Drier....................................................................................................... 30

9.0 WARRANTY ................................................................................................................. 31

10.0 CONTACT DATA AIRE .............................................................................................. 32

Line Sizing Chart ........................................................................................................................ 33

Monthly Maintenance Inspection Checklist ................................................................................ 34

Quarterly Maintenance Inspection Checklist .............................................................................. 35

Superheat and Suction Pressure Troubleshooting Guide .......................................................... 36

Temperature Pressure Chart for R-407C and R-410A................................................................ 37

5
 1.0 INSTALLATION

There is no intent on the part of Data Aire, Inc. to define local codes or statutes which
may supersede common trade practices. The manufacturer assumes no responsibility
for their interpretation. Consult local building codes and 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 on walls and ceilings. Walls and 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 external spaces. Failure to provide a vapor barrier can
compromise the ability to control space conditions.

Introduction of outside air into the space should be minimized. Outside air in excess of 5% of the
total circulated air volume can have a significant effect on the overall space conditions and result
in poor space control. 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 manila shipping tag located on the unit panel 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 at least a 50% safety factor to the weight of the unit
to determine the necessary strength of the supporting structural members or follow local code.

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. Consult local building codes and National Electric Code for special
installation requirements.
6
 Note: There are many available unit configurations for the LCS. 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 flush-

ing (when humidifier is installed) are normal functions of this equipment. Drain connec-
tions must be made to ensure proper water removal. Unit will require drain connections
for condensate removal and water connections possibly for humidifier (when installed)
makeup 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 Horizontal Airflow Units
All LCS units have horizontal airflow configuration with a 29.5” tall evaporator section. Duct collars
are factory provided for the supply and return air.

Four threaded support rods must be securely attached to the building structure. Two field provided
support channels connect to the pairs of threaded support rod. (See detail on drawing 536-900-001
shown on page 27.) 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.

1.3.2 Indoor Condensers and Condensing Units

Although most split air cooled systems have outdoor condensers or condensing units, indoor
condensers and condensing units are occasionally used. These 29.5” tall 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.

Typical installations have the condenser or condensing section physically near the evaporator,
especially since most have some shared electrical line power. The mounting of these sections is
independent 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 must be completed during installation. Also
included in the paperwork is a warranty/information packet that provides important wiring diagrams,
specific component literature, warranty registration card and other valuable paperwork, including a
copy of this Installation/Operation and Maintenance manual.

A manila (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.

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 in warranty related services and in some cases void the warranty.

7
 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, in non-freezing temperatures, protected from damage by other
equipment in storage or transportation equipment, never stacked, and avoid frequent relocation.

CAUTION: Complete system drain-down cannot be assured for this product. Freezing
system fluid can rupture piping.

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. 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.

When equipment is installed after storage caution should be taken to inspect and replace, if required,
rubber hoses and belts. All moving parts, such as blowers and motors, should be hand tested to ensure
that they are free and clear prior to start-up. Finally, verify that all lubrication is fresh and full.

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
in some cases void the warranty.

1.6 Model Identification

LCS UNITS
DAL A 06 3 2 -E -CO D

DATA AIRE LCS D – Dual compressor

UNIT S – Single compressor

A----------Air cooled
W----- Water cooled P – Package system
G----- Glycol cooled
C -----Chilled water CO – Split system with
outdoor condenser (DARC)
Nominal tons
06, 08, 10 and 13 AO – Split system with
outdoor condensing unit
3 – Three phase (DRCU)

2 – 208 or 230 volt C – Auxiliary chilled water coil
4 – 460 volt E – Energy Saver
5 – 575 volt

LCS units are not available in air cooled packaged configuration.

CONDENSER – Condenser coil only, no compressor

CONDENSING UNIT – Condenser coil and compressor

The order write-up should have the condenser or condensing unit model number.
Refer to applicable condenser or condensing model number identification.

Example: DATA AIRE LCS unit, air cooled, 6 ton, 3Ø – 230 volt, split system
with outdoor condenser and dual compressors –
Evaporator model: DALA 0632 CO D Condenser model: DARC 0632

8
 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 design engineer.
Data Aire does not assume this responsibility. The chart covers distances up to 200 equivalent feet.

For installations greater than this distance, consult ASHRAE or similar references.
Standard piping practice must be used to ensure proper oil return and efficient operation.
The interconnecting lines to the remote air cooled condenser or condensing unit must
be installed by a qualified refrigeration mechanic.

2.1.1 Discharge Lines

Discharge lines, also called hot gas lines, should be trapped at the top (inverted) and bottom, as well
as every 15 to 20 feet (4.6 to 6.1 m) of vertical rise. Discharge line check valves are required on all
installations, especially those where there are long pipe runs or cold climate.

For air-cooled units built after 3/14/2017, the discharge check valves are already installed inside the
evaporator section and do not need to be installed external to the unit. For units built before this
date, the check valves must be field supplied and installed externally to the evaporator section. If
there is doubt as to whether or not the check valve is already installed in the unit, look for it on the
hot gas line close to the exit point of the unit (see example picture below). The externally installed
check valve should be placed from six (6) to ten (10) feet (1.8 to 3.1 m) from the compressor.

Note: Picture is only intended to show an example of a common check valve installation. It may
9 not represent your specific unit, check valve size, location or orientation.
 The check valve will prevent flow from the condenser to the compressor during the “off” cycle.

The discharge, suction and liquid lines need to be refrigerant grade copper and in accordance with local
code. All refrigeration piping should be installed with high temperature brazed joints. When brazing,
a supply of nitrogen gas needs to be fed through the refrigerant lines. Be sure to open the other
end of the refrigerant line to allow the nitrogen to bleed off and not pressurize the piping. Prevailing
good refrigeration practices should be employed for piping support, leak testing, dehydration and
charging of the refrigerant circuits. During the installation the lines should be capped off and filled
with dry nitrogen at the end of each day’s work or until the system is completed and sealed.
Data Aire recommends a silver/phosphorus/copper alloy with 5 to 15% silver be used to braze the
refrigerant line sets to the indoor and outdoor units. Nitrogen needs to be flowing through the lines to
eliminate carbon deposit buildup on the inside of the joints. Carbon could contaminate the refrigerant
and restrict the metering device.
Piping must be supported within 18” of the inlet and outlet connections. The inlet connection is
located on the top header of all units. The discharge outlet is located at the bottom of the header.
Discharge line pressure drop should not exceed 6 PSI for R-407C and 9 PSI for R-410A. 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. Discharge lines do not require insulation but
due to the high temperatures of the refrigerant inside the line, the pipes may be insulated to protect
against burns to individuals near or around the lines.

2.1.2 Liquid Lines

Liquid line size is determined by pressure drop and velocity. The liquid line pressure drop for R-407C
should not exceed 5 PSI or 9 PSI for R-410A. 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 15 feet
below the evaporator is not recommended. Insulation of liquid lines is not required but can be useful
in preventing excessive sub-cooling or flashing on long exposed pipe runs.

2.1.3 Suction Lines

Some applications call for the compressor(s) to be mounted as part of the condenser, more commonly
referred to as a condensing unit. Such cases require field piping of liquid and suction lines. Suction
lines are trapped similarly to discharge lines. Common practice for suction line selection and
installation should be followed. Suction lines should always be insulated.

10
 2.1.4 Connection Sizes
Air Cooled Units
Model Circuiting Hot Gas Liquid Suction
DALA 06 Single circuit 5/8” 5/8” 1 1/8”
DALA 08 Single circuit 3/4” 5/8” 1 3/8”
DALA 10 Single circuit 3/4” 5/8” 1 3/8”
DALA 13 Single circuit 7/8” 7/8” 1 3/8”
DALA 06 Dual circuit 1/2” 1/2” 7/8”
DALA 08 Dual circuit 5/8” 1/2” 7/8”
DALA 10 Dual circuit 5/8” 1/2” 1 1/8”
DALA 13 Dual circuit 5/8” 5/8” 1 1/8”

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
sizes will vary significantly.

Water/Glycol Cooled Units

Model Condenser Water In Condenser Water Out

DALW/G 06 1 5/8” 1 5/8”
DALW/G 08 1 5/8” 1 5/8”
DALW/G 10 1 5/8” 1 5/8”
DALW/G 13 1 5/8” 1 5/8”

Chilled Water Units with 3-Way Valves

Model Chilled Water In Valve CV

DALC 06 1 1/8” 14.0
DALC 08 1 5/8” 20.0
DALC 10 1 5/8” 20.0
DALC 13 1 5/8” 20.0

2-Way Chilled Water Units

Model Chilled Water In Valve CV
DALC 06 1 1/8” 14.0
DALC 08 1 5/8” 20.0
DALC 10 1 5/8” 20.0
DALC 13 1 5/8” 20.0

Fluid Coolers

Fluid Cooler Water IN and OUT Fluid Cooler Water IN and OUT
Model Connections, OD Model Connections, OD
DAFC 06 1 5/8” DAFC 17 2 1/8”
DAFC 07 1 5/8” DAFC 24 2 1/8”
DAFC 09 1 5/8” DAFC 28 2 1/8”
DAFC 11 2 1/8” DAFC 30 2 5/8”
11
 2.1.5 Field Piping, Remote Condenser/ Condensing Unit Above Evaporator

1. THIS IS THE RECOMMENDED PIPING. ALL PIPING TO BE PER LOCAL

AND/OR STATE CODE.
2. CONDENSER TO BE NO MORE THAN 60 FEET ABOVE EVAPORATOR.
3. FOR UNITS BUILT AFTER APRIL 2017, THE CHECK VALVES ARE INCLUDED
INTERNALLY IN THE EVAPORATOR SECTION.
4. SLOPE HORIZONTAL LINES DOWNWARD IN THE DIRECTION OF THE
REFRIGERANT FLOW, ½” FOR EVERY 10 FEET OF LINE LENGTH.
5. INVERTED TRAP TO EXTEND 8" ABOVE THE BOTTOM OF THE CONDENSER
COIL.

CONDENSER OR LIQUID LINE

CONDENSING UNIT CHECK VALVE

INVERTED TRAPS 5

LIQUID LINE
HOT GAS LINE
OR SUCTION LINE

2
Maximum
Vertical Rise

TRAPS EVERY 15-20 VERTICAL

FEET ON THE GAS LINE

TRAP AT BOTTOM
OF THE GAS LINE
4

Field Piping

2.1.6 Field Piping, Remote Condenser/ Condensing Unit Below Evaporator

1. THIS IS THE RECOMMENDED PIPING. ALL PIPING TO BE PER LOCAL

AND/OR STATE CODE.
2. CONDENSER TO BE NO MORE THAN 15 FEET BELOW
EVAPORATOR.
3. SLOPE HORIZONTAL LINES DOWNWARD IN THE DIRECTION OF THE
REFRIGERANT FLOW, ½” FOR EVERY 10 FEET OF LINE LENGTH.
4. INVERTED TRAP NEEDED ON SUCTION LINE WHEN COMPRESSOR IS
OUTDOORS ONLY.

3 4

HOT GAS LINE

OR SUCTION LINE

LIQUID LINE

CONDENSER OR
CONDENSING UNIT
3

LIQUID LINE
CHECK VALVE

Field Piping

12
 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. (Refer to 2.1.4 for connection sizing.) 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.

Shutoff valves, field provided, should be installed within a few feet of the inlet and outlet connections
of the evaporator to allow the unit to be isolated for service. There should be a means of draining the
unit for service. Drain/fill valves should be located at the lowest point on the connected piping.

All water/glycol units are shipped with plate/fin heat exchangers as standard equipment. A strainer
is shipped loose and is to be field installed in the supply line with shut-off valves, field provided,
before and after the strainer. The strainers and water/glycol piping must be cleaned on a periodic
basis. If the unit is shipped with an optional shell and tube condenser, stainers are not required nor
shipped with the unit.

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.

Glycol system piping may include a centrifugal pump (or pumps for redundancy). Pumps must be
primed before operating per the pump manufacturer’s guidelines.

13
 2.3 Auxiliary Chilled Water Coil Piping

Units with an Auxiliary Chilled Water cooling coil require a separate source of chilled water. These
chilled water connection sizes will be equal to the condenser water connection sizes on the chart in
Section 2.1.4. Units with an Energy Saver cooling coil typically have shared piping with the condenser
supply and therefore do not require a separate water source.

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 unit. Use a tube cutter for
smaller pipes and a reciprocating say with a metal cutting blade for larger pipes sizes or if there is a
clearance problem. All connections need to be cleaned before connections are brazed together.

2.4 Condensate Drain System

To properly drain the condensate from the ceiling evaporator condensate pan, the evaporator section
is equipped with a 3/4” FPT connection on the bottom of the unit for condensate removal. The following
are recommendation for condensate drain systems:

1. Do not reduce the size of the condensate drain piping.

2. The condensate drain piping must be run to an unrestricted waste line and must
be protected from freezing.
3. In high humidity conditions it is recommended to insulate the condensate drain
line to prevent condensation forming on the exterior of the piping.
4. It is recommended that a union (field supplied) be installed at the ¾” FPT
connection to permit easy disassembly of the condensate drain piping from
the unit for cleaning.
5. Drain lines should be pitched downward not less than 1/4” for each ten (10) feet
of horizontal run.
6. Where local codes permit, PVC pipe may be used.
7. Ceiling units with an optional vertical discharge have a 5” plenum below the
evaporator drain pan. The plenum has knockouts that allow routing of the field
supplied and installed condensate drain piping system. The drain line can be
routed out either side of these units.

2.5 Condensate Trap

Probably the most misunderstood portion of a condensate drain system is trap installation. The
primary purpose of a condensate trap is to prevent air from being drawn back into the unit during
operation. Traps must be installed in a manner that will stop the air from passing through, but still
allow the condensate to drain from the condensate pan.

Therefore, a trap (field supplied and installed) must be fabricated into the ceiling unit drain system
external of the evaporator section. In order to eliminate air trapping, an air vent must be used to allow
air to exit. Venting the drain after the first trap is recommended.

Figure 1 shows the recommended dimensions for fabricating a proper trap:

14
 Figure 1 Recommended Condensate Trap Dimensions

Notes:

1. This trap is capable of handling static pressures equal to 4” H2O which is the
maximum static available for ceiling units. If the unit fans are standard, there is no need
to consider different dimensions but if higher total static pressure is expected, more
vertical drop is required.

2. 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.

3. Condensate pumps that ship loose or are 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 short cycling. Pumps must be
located below the condensate drain pan level.

2.6 Humidifier Piping

The optional humidifier offered on LCSs 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 for 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.

2.7 Dry Steam Humidifier

Units with optional dry steam type humidifiers require a strainer on the inlet steam line. An outlet
connection with field provided steam trap is also required. Steam pressure is typically 10-15 psi.

15
 2.8 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 rotolock
service valves. Check both field and factory connections.

In addition to the refrigeration system, check all condenser water lines, humidifier makeup lines,
condensate lines, condensate pumps, chilled water lines, centifugal 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.

2.9 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.
If it does, re-start the vacuum pump and evacuate until the system reaches 250 microns. If the system
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.

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.
16
 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. Units with outdoor secondary heat exchangers will require a separate power
source and field-provided, interconnecting control wires as well. 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. 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 (MCA), also known as wire sizing amps, will dictate the minimum required wire gauge.
Maximum Overcurrent Protection (MOP) Device amps will dictate the maximum circuit breaker or
fuse size.

3.3 Grounding
The unit cabinet must have an uninterrupted true earth ground. 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; - 5% to +10% for 208-230 voltage; +10%
for 460 volts. Phase to phase imbalance must not exceed 3%. The local utility company should
be contacted for correction of improper line voltage. Deviation from ratings can cause premature
failures and possibly void unit warranty.

3.5 Auxiliary Control Wiring

The interconnection of auxiliary control wiring for remote heat exchangers (condensers and fluid
coolers) requires the connection of two (2) - 18-gauge wires for installations up to 150 feet (45 m) or
16-gauge wires for installations from 151 feet (46 m) up to 200 feet (61 m) from the electrical control
box of the indoor evaporator to the electrical control box of the remote heat exchanger. Condensing
units (i.e., where the compressor(s) are mounted in the remote heat exchanger) will typically require
(4) or more wiring connection points and may require heavier gauge wire. In this case, the installing
contractor must follow the applicable electrical codes to determine the required wire gauge.

Because of the wide variety of indoor evaporators and remote heat exchangers offer by Data Aire,
the installing contractor must refer to the schematic which is provided inside the electrical control
box of each unit, for the required auxiliary control wiring interconnection terminal points.

Check the wiring connections in the unit control panel to ensure they are tight. Screw
terminals may become loose in transit. Tightening of wiring connections is the
responsibility of the installing contractor.

Examples:

17
 Figure 1 - Typical Remote Heat Exchanger Interconnection Points

Figure 2 - Typical Indoor Evaporator Interconnection Points

3.6 Remote Shutdown

Every Data Aire evaporator has remote shutdown contacts points available. This is intended for a
field supplied dry contact or switch to be wired across two terminals. When the contact or switch
opens, the control circuit power is interrupted and the unit shuts down, including the control panel.
The control circuit is 24 VAC and the field provided contact or switch should have a minimum rating
of 10 amps. A minimum wire size of 18 gauge wire is recommended. Check wiring diagram for
location of the terminals.

3.7 Remote Alarm Contacts

The Mini dap4 microprocessor control panel has, a remote alarm output contact that can be field
accessed on terminals #14, #15 and #16 of terminal block TB1. This is a Normally Open, Close on
Alarm, dry contact, intended to be used in a control circuit not exceeding 2 amps at 250 VAC. This
output contact will reverse position on a failure and remain reversed until the alarm is no longer present.

3.8 Remote Sensors

The Mini dap4 panel comes with remote mounted sensors for field installation. The sensors are
attached to 35 feet of cable and come mounted in a remote sensor enclosure. The temperature and
humidity sensors require a total of four 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.
18
 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. Outdoor heat exchangers
should be moved to their (typically rooftop) mounting location using a crane or fork lift. Each fan
section has 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

The legs of remote heat exchanger are shipped with the unit and need to be lowered during the
rigging process. The legs must be unbolted from their collapsed position and extended prior to placing
the unit on its pad. Each leg extends down 18 inches and reattached using the same bolts. The
bolts are placed through the lower set of holes on the bracket. Multiple fan units have leg supports
between each fan section.

Model number DARC-03 and DARC-05 do not have legs and are ready for installation.

Note: Failure to extend the legs will result in poor air distribution over the cooling coil
resulting in significant capacity reduction.

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 an area that will ensure free air flow into and out of
the heat exchanger plus adequate service access clearance. Short circuiting of the air flow 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 that is bordered by tall obstructions (i.e., higher than 10
feet) on no more than two sides. See figure on next page 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.
19
 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.

Air cooled condensers should be placed at a level that is above the level of the indoor evaporator.
Mounting a condenser or condensing unit more than ten feet below the evaporator is not recommended.
Excessive liquid line pressure drop can cause poor evaporator performance.

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

4.5.1 Fan Speed Control

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.

4.5.2 Ambient Thermostats

Additional motors (subsequent to the fan speed control operated motor) on multi-fan condensers
are cycled by ambient-sensing thermostats. These thermostats have a capillary tube with a remote
sensing bulb. They will function best if the sensing bulbs are mounted below the coil, away from
exposure to direct sunlight, with the bulb in a vertical position. An instruction set comes as part of a
mounting kit that includes a sheet metal bracket, mounting clamp(s) and TEK screws. This includes
directions for field mounting and adjusting the thermostat bulbs. Desired head pressure should be
maintained at approximately 250 psi.

20
 Typical settings for the ambient thermostats are as follows:
Number of fans Header fan Fan 2 Fan 3 Fan 4 Fan 5
2 FSC 65°
3 FSC 75° 65°
4 FSC 75° 85° 65°
5 FSC 65° 85° 75° 50°

4.6 Fluid Coolers - Model DAFC

4.6.1 Fluid-Sensing Thermostats

Fluid cooler fan motors are cycled on and off by individual water-sensing thermostats strapped to
the leaving water header. The first 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 105° F range. This is generally the desired range for glycol cooled
systems.

A surge tank is standard with all fluid coolers. This is sufficient for most applications. However,
an expansion tank should be installed at the highest point in the system and the point of least
pressure.

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 50° F), 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 45° F. 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 is too cold can cause excessive dehumidification and coil sweating. Fluid temperature that is
too high can also cause the indoor space temperature to rise. This could cause the evaporator’s
microprocessor control to lock out the energy saver mode for one hour while it reverts back to
compressor (mechanical) cooling. Adjust the setpoints of the thermostats to allow the maximum
free cooling time. Over cooling or under cooling 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.

21
 5.0 CHARGING

5.1 Voltage Phase Check

5.1.1 Evaporator
Prior to charging, the correct voltage phasing should be checked on the indoor evaporator. Check
blower direction on the evaporator by momentarily energizing the fan motor. Reverse any two of the
three line voltage wires at the line voltage field connection point to change the blower rotation.

Although the scroll compressor is phase dependent, units shipped from the factory are run tested,
ensuring the compressor rotation is consistent with the evaporator fan motor. However, a field change-
out of the compressor may require checking proper phase. An out-of-phase compressor will draw
relatively low amps and both suction and discharge pressures will remain nearly equal.

5.1.2 Secondary Heat Exchanger

The secondary heat exchanger may be ordered as three phase but the individual fan motors are single
phase and will only run in one direction. Check operation by placing a momentary jumper across
low voltage field terminals #39 and #40. (Disconnect pumps on glycol systems unless already filled
with water/glycol solution.) This will energize the control circuit. Fans may not run because: 1) the
thermostat setpoint is above the current ambient, or 2) the #1 fan on air cooled condensers with fan
speed control react to head pressure. The fan will not run until the head pressure is well over 200
psi.

5.2 Air Cooled Systems

5.2.1 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 DALA 0834-COS is a nominal 8 ton single circuit unit. Charge with about 24
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. Review the model number carefully because
LCS units are available with either single or dual compressors.

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.

Start the evaporator fan and compressor. 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 sub-cooling or low charge. It is likely that more refrigerant
will be required to complete the charging procedure.

Adjust the refrigerant charge until the sight glass clears or 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 240 - 295
psi for R-407C and 340 - 415 psi for R-410A. Suction temperature should be 58 psi or greater for
R-407C and 104 - 121 psi for R-410A. The superheat at the compressor suction line at least 6 inches
away from the compressor should be 8 - 15°.

22
 Note: Charging to a full liquid line sight glass should never be the sole means of
determining the correct refrigerant charge. Other parameters such as superheat,
suction pressure, head pressure, sub-cooling and ambient temperature are also
important parameters. A system charged to a clear sight glass is often overcharged.

5.2.2. Fan Speed Control System Charging

The standard outdoor air cooled condenser for Data Aire equipment is a Fan Speed Control system.
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 DALA 0834-COD is a nominal 8 ton unit but has two nominal four ton circuits.
Charge each circuit with about 12 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. From a
vacuum feed liquid refrigerant into the high side of the system until the pressure equalizes. At this
point there will be about 70 - 80% of the total charge in the system.

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.

If the system is charged from a vacuum, the preheating of the compressor is not necessary. Start
the system and allow the system to stabilize to room temperature. Bubbles in the sight glass are
not unusual at this point and can be caused by flashing from liquid line pressure drop, low sub-
cooling or low charge. It is likely that more refrigerant will be required to complete the charging
procedure. Adjust the refrigerant charge until the sub-cooling is between 8 - 10° F and the superheat
is between 8 - 15° F. There may be flashing and/or bubbles in the sight glass when the system is
properly charged.

The unit should be allowed to stabilize for several minutes before meaningful measurements can
be taken. After the system is allowed to stabilize, verification of a few key measurements should be
noted. The discharge should be between 110 - 125° F condensing temperature and the sub-cooling
should be between 8 - 10° F depending on ambient conditions. Suction temperature should be 58
PSI or greater. Measure the superheat at the compressor suction line a least 6 inches away from
the compressor. The superheat should be between 8 - 15° F for units that are water/glycol cooled
and air-cooled units with air-cooled condensers. Units with remote condensing unit should have a
superheat between 20 - 25° F at the compressor. The sub-cooling will be the same 8 - 10° F.

Note: Charging to a full liquid line sight glass should never be the sole means of
determining the correct refrigerant charge. Other parameters such as superheat,
suction pressure, head pressure, sub-cooling and ambient temperature are also
important parameters. A system charged to a clear sight glass is often overcharged.

5.2.3. 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.

Flooded systems require more refrigerant than fan speed control systems. Connect the pressure
gauge manifold set to the high and low ports near the compressor. Connect the charging line to

23
 the refrigerant tank and set it for liquid feed. Open the refrigerant tank valve and purge the line a
the manifold. Open the high side valve on the manifold only and allow the refrigerant to flow until
the system pressure equalizes. At this point the system will have 78 - 85% of the total refrigerant
charge. Start the (evaporator) blower. Start the compressor and check the operating pressures
and temperatures.

A quick and easy way to run the blower and compressor is using the manual switches on the unit
microprocessor. Switch the blower and compressor manual switches to the “ON” position. All
automatic control is disabled but safety switches will remain functional.

Before starting a compressor, the crankcase heaters should be energized for a minimum
of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize
crankcase heaters could result in compressor damage.

Start the evaporator fan and verify the fan rotation. Start the compressor. 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 pressure drop, low sub-cooling or low charge. It is
likely that more refrigerant will be required to complete the charging procedure.

If the receiver (head) pressure is below 230 PSI, block part of the condenser coil surface until the
pressure rises to 230 PSI or higher. During extremely cold weather all the condenser fans may have
to be de-energized to maintain 230 PSI.

Observe the sight glass on the receiver. Add refrigerant through the suction line until the level of
liquid in the receiver is approximately 1/3 from the bottom (the leveling ball in the receiver will start
to float) of the sight glass. At this point the receiver is 80% full. Observing the receiver sight glass
becomes difficult when they are remote mounted near the condenser. The unit should be allowed
to stabilize for several minutes before meaningful measurements can be taken.

After the system is allowed to stabilize, the superheat at the compressor suction line (reading from at
least 6 inched from the compressor) should be 8 - 15°F. Unit with remote condensing units (DRCU)
the superheat should be 20 - 25°F at the compressor. The sub-cooling will be the same 8 - 10°F
as a standard. Remove any block that may have been used on the condenser coil. If the ambient
temperature while charging is below 60°F, some of the refrigerant will be backed up in the condenser
coil causing the liquid level in the receiver to drop, this is normal.

Note: Charging to a full liquid line sight glass should never be the sole means of
determining the correct refrigerant charge. Other parameters such as superheat, suction
pressure, head pressure, sub-cooling and ambient temperature are also important
parameters. A system charged to a clear sight glass is often overcharged.

5.3 Water/Glycol Cooled Systems

5.3.1. Water/Glycol Cooled Systems Charging

All water/glycol cooled units are factory charged with refrigerant. The water regulating valve should
be adjusted to maintain condensing temperature of 105 - 119° F. Saturated suction temperature

24
 should be 33° F or higher. The superheat at the compressor suction line at least 6 inches away from
the compressor should be 8-15° F.

Field charging water/glycol systems 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.

Adjust the refrigerant charge until the sight glass clears or has only sparse bubbles. The unit should
be allowed to stabilize for several minutes before meaningful measurements can be taken and the
conditioned room should be at or near the temperature setpoint.

All water/glycol cooled units have a water regulating valve. A head pressure sensing transducer is
connected to a shrader fitting on the discharge line and water is regulated into the condenser coil.
Condenser coils may be plate fin or coaxial type.

Before starting a compressor, the crankcase heaters should be energized for a minimum
of 12 hours to reduce the possibility of liquid slugging on start-up. Failure to energize
crankcase heaters could result in compressor damage.

Note: Charging to a full liquid line sight glass should never be the sole means of
determining the correct refrigerant charge. Other parameters such as superheat,
suction pressure, head pressure, sub-cooling and ambient temperature are also
important parameters. A system charged to a clear sight glass is often overcharged.

5.4 Refrigerant Handling

The use of recovery/recycling units is required by U.S. Environmental Protection Agency (EPA)
regulations. Technicians who service and dispose of air conditioning and refrigeration equipment
must recover the refrigerant instead of venting to atmosphere.

Except for extremely small releases of refrigerant such as what occurs when disconnecting service
hoses (diminutive release), a technician who knowingly releases or vents refrigerant to the atmosphere
is in violation of these regulations. Freon purchasers must be certified technicians and have a valid
EPA certification card.

Warning! Pressure relief lines(s) must be vented to the atmosphere per the latest edition
of ASHRAE Standard 15 and/or any local building, fire or mechanical codes.

This applies to all units with either sell and tube condensers or high pressure relief valve
options.

5.5 Important Refrigeration Components

5.5.1. Expansion Valve

Each refrigerant circuit has an adjustable thermo-expansion valve (TXV). These are factory adjusted
to their nominal rating. Any field adjustment should be to fine tune a system that has stabilized and
already has acceptable operating parameters.
25
 5.5.2. High Pressure Cutout Switch
Each refrigerant circuit is protected by a high head pressure cutout switch with a manual reset button.
The cutout pressure rating for refrigerant R-407C is 400 psi. Physical location is near the compressor
which may be either in the evaporator or the condensing section.

5.5.3. Low Pressure Cutout Switch

Each circuit also contains a low suction pressure cutout switch with automatic reset. The cutout
pressure rating for this switch is 30 psi. Physical location is near the compressor which can be either
in the evaporator or the condensing section.

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. After installation,
the glycol percentage should be checked. The glycol percentage should also be checked at regular
intervals to ensure freeze protection.

6.2 Internal (Fluid) Volume

Evaporator Without With
Internal Volume Energy Saver Coil Energy Saver Coil*
Model Volume, Gallons Volume, Gallons
DALG 06, single circuit 3.0 11.5
DALG 08, single circuit 3.0 11.5
DALG 10, single circuit 4.0 10.5
DALG 13, single circuit 4.0 10.5
DALG 06, dual circuit 4.0 12.5
DALG 08, dual circuit 4.0 12.5
DALG 10, dual circuit 5.0 11.5
DALG 13, dual circuit 5.0 11.5

6.3 Fluid Cooler Internal Volume

Fluid Cooler Internal Fluid Cooler Internal
Model Volume, Gallons Model Volume, Gallons
DAFC 06 2.5 DAFC 17 6.6
DAFC 07 3.4 DAFC 21 7.4
DAFC 09 4.2 DAFC 24 9.8
DAFC 11 3.3 DAFC 28 12.3
DAFC 15 4.9 DAFC 30 9.8

* 6 and 8 ton units use a 4 row energy save coil

10 and 13 ton units use a 3 row energy saver coil.

26
 6.4 Copper Piping Internal Volume

Pipe Diameter, Volume per 100 Feet

inches of Pipe, Gallons
5/8 1.2
3/4 1.8
7/8 2.5
1-1/8 2.5
1-5/8 4.3
2-1/8 9.2

6.5 Freezing Point of Aqueous Solutions

Ethylene Glycol, Freezing Point Propylene Glycol, Freezing Point
% by Volume Degrees F % by Volume Degree F
0 32 0 32
10 24 10 27
20 15 20 18
30 4 30 8
40 -13 40 -6
50 -33 50 -2

7.0 CONTROLS

7.1 Mini dap®4 Microprocessor Controller

The Mini dap4 microprocessor controller is the standard controller on the LCS equipment. There is
a separate manual that goes into extensive detail regarding functions, features, programming and
troubleshooting.

The Mini dap4 microprocessor controller has an entire manual dedicated to its use and
operation. This manual must be referenced to complete a thorough unit installation.
Start-up is not complete until the Mini dap4 controller settings are established.

7.2 Optional Expanded dap4 Microprocessor Controller

The Expanded dap4 microprocessor controller is available as an upgrade from the Mini dap4 and
offers additional features.

The dap4 microprocessor controller panel has an entire manual dedicated to its use and
operation. This manual must be referenced to complete a thorough unit installation.
Start-up is not complete until the dap4 control panel settings are established.

7.3 Secondary Heat Exchangers

Most of the controls on remote condensers, condensing unit and fluid coolers consist of basic
electromechanical type components. Secondary heat exchangers have separate installation and
operation manuals which give complete details on adjusting thermostat settings, etc. Refer also to
details in Section 3.5 within this manual.
27
 7.4 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.

The wiring diagram in the evaporator will indicate field interface terminals to the secondary heat
exchanger. The internal wiring of the heat exchanger is found on a separate diagram which can be
found on the inside cover of the heat exchanger electrical box. Both diagram types are also placed
inside the shipping/warranty packet that is placed inside the evaporator.

Evaporator wiring diagrams will have a drawing number which starts out with the three letter
designation, “DAL”. An example of a typical diagram is DAL-S-908. Wiring diagrams for condensers
or condensing units start out with the three letter designation, “DRC”. An example of a typical diagram
is DRC-S-001. Wiring diagrams for fluid coolers start out with the three letter designation, “DFC”.
An example of a typical diagram is DFC-S-001

Drawing #536-900-001 Large Ceiling Unit Mounting for 6-13 ton

28
 8.0 REGULAR MAINTENANCE ITEMS

8.1 Air Filters

Air filters should be checked on a regular basis and changed when they become dirty. This will
ensure efficient operation of the unit. Spare air filters should be kept in stock as these tend to be a
frequently replaced maintenance item. Air filters may require changing as often as monthly. Note
also that construction dust on new installations will quickly clog new filters.

The Mini dap4 control panel can monitor air filters status with an optional dirty air filter sensor.
Although the unit may have a dirty filter alarm, this should not be relied on as the only determinant
for replacing air filters. A mis-adjusted air filter differential pressure switch may not give a proper
indication of a clogged air filter.

To check the air filter differential pressure switch for proper adjustment, temporarily cover about 75%
of the return air opening using heavy cardboard or similar material. The alarm should energize when
75% of the air is blocked, simulating dirty filters. If the alarm energizes prematurely or does not
energize at all, the pressure switch should be adjusted. Panels must remain closed when determining
if an adjustment is necessary.

Air filters that require changing can restrict airflow and create problems such as coil
icing or poor air distribution.

8.2 Belts
Belt tension should be checked regularly (monthly) to ensure proper tension. If tightening is required,
loosen the four motor mounting bolts. Turn the adjustment screw on the end of the motor mounting
channel until the proper belt tension is attained. Retighten the four mounting bolts. Damage can
occur to belts that are overtightened. The amount of play in a typical driveset should be 1/2 inch.
When tightening the belts make sure the pulley alignment is true. If the belts are over tightened or
if the pulleys are misaligned the bearing and belt life can be significantly shortened.

8.3 Bearings
LCS units with either one (1) and two (2) HP motors have permanent lubricated bearings. Motors of
three (3) HP and above have a pillow block bearing that must be greased quarterly, or as needed.

Some motors have zirk type grease fittings on the bearings. If so the motor should be greased at
least annually. Use NLGI grade 2 lithium or lithium complex grease. Care should be taken to avoid
over-greasing. Only one or two pumps from a manual gun are required.

8.4 Humidifier Canisters

The optional steam generator type humidifier does not require maintenance other than to replace the
canister as required. This frequency will depend on usage and water type. A set of manufacturer’s
instructions for the humidifier is sent as part of the paperwork placed inside the unit when it ships.

29
 8.5 Fuses
Always replace fuses with those of the equivalent rating with regard to: 1) amperage, 2) voltage,
and 3) speed. For instance compressors and motors are inductive loads which require time delay
fuses. Electric reheat and humidifiers are resistive loads requiring fast acting fuses.

8.6 Heating Elements

Heating elements do not normally require maintenance. However sometimes they may accumulate
a film of dust or dirt when unused for extended periods of time. When energized, the burning debris
can create smoke or unpleasant odor. To help avoid this, periodic cleaning is recommended.

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.

30
 9.0 Warranty Policy

Seller warrants its equipment to Buyer to be free from defects in material and workmanship for a
period of eighteen (18) months from date of shipment, as long as equipment is utilized under normal
conditions and service and is properly installed; however, the warranty shall not be applicable to any
of the following items: refrigerant, belts, filters, humidifier, heaters not regularly cleaned, light bulbs,
and any other items either consumed or worn out by normal wear and tear, or by conditions beyond
Seller’s control, including (without limitation as to generally) polluted or contaminated air or water.

The Seller’s obligation under this warranty is limited solely to the repair or replacement, at Seller’s
options, of any part or parts thereof which shall, within eighteen (18) months from date of shipment
of the equipment to the original purchaser be returned to the factory, transportation charges prepaid,
which upon examination shall disclose to the Seller’s satisfaction to have been defective under
normal use and service. This agreement to repair or replace defective parts is expressly in lieu of all
other warranties, expressed or implied and all other obligations or liabilities on the part of Seller and
Seller neither assumes nor authorizes any other person to assume for it any liability or obligation in
connection with the sales or service of its equipment, except said repair or replacement of defective
parts set forth above.

This warranty does not include any labor charges for work done outside of the factory for replacement
of parts, adjustments, repairs, or any other work. Seller’s liability does not include any resulting
damage to persons, property, equipment, goods or merchandise arising out of any defect in or failure
of any equipment of its manufacture and Buyer hereby waives any claim against Seller arising out
of such claim. This warranty shall not cover the repair or replacement of any equipment which has
been repaired or altered outside of the factory in any way or which has been subject to negligence,
misuse, or abuse, or to pressures in excess of stated limits.

This warranty applies only to the original purchaser of the equipment and does not extend, expressly or
by implication, to the third parties or others without the specific written approval and acknowledgment
of Seller. Buyer’s exclusive remedy and Seller’s maximum liability for any and all loss, injury, damage,
costs, or expense arising from any defect covered by this warranty shall be limited to the repair or
replacement, but not the installation of any defective material, F.O.B., Seller’s plant; provided however,
that Seller shall not be required to replace any part or component (a) which can be repaired, or (b)
unless Buyer has given Seller immediate written notice that replacement or repair. In addition, Seller
shall not be liable for any cost or expense of replacement or repair contracted for by Buyer with
any third person, unless, and then only to the extent that Seller authorizes in writing, such costs or
expense.

Seller shall not be liable for any direct, indirect incidental, consequential, or other form of loss, injury,
damage, cost, or expense, whether caused by delay, failure, or performance, breach of warranty,
or by any cause whatsoever.

Seller’s obligation under this warranty shall be void if Buyer fails: (a) without legal justification to pay
Seller, when due, the full purchase price for the equipment sold hereunder; or (b) to have the equipment
sold hereunder installed, maintained, and serviced by competent personnel and in accordance with
Seller’s instructions.

31
 10.0 Contact Data Aire

Address:
Data Aire, Inc.
230 W. BlueRidge Avenue
Orange, CA 92865

Phone:
714-921-6000
800-347-AIRE (2473) Toll Free

Fax:
714-921-6010 Main
714-921-6011 Engineering

E-mail:
service@dataaire.com Technical Support
engineering@dataaire.com Engineering
sales@dataaire.com Sales

Web site:
www.dataaire.com

Job Information:

Data Aire Job Number: _________________________________________

Evaporator Serial Number:______________________________________

Evaporator Model Number: ______________________________________

Condenser/Condensing Unit/
Fluid Cooler Serial Number: __________________________________

Condenser/Condensing Unit
Fluid Cooler Model Number: __________________________________

32
 RECOMMENDED LINE SIZING FOR AIR COOLED SPLIT SYSTEMS
UP TO 200 EQUIVALENT FEET

HOT GAS LINES

SINGLE CIRCUIT SYSTEMS DUAL CIRCUIT SYSTEMS
Unit Tons per EQUIVALENT FEET Unit Tons per EQUIVALENT FEET
Tonnage Circuit 50 100 150 200 Tonnage Circuit 50 100 150 200

6 6 7/8 1-1/8 1-1/8 1-1/8 6 3 7/8 7/8 7/8 7/8
8 8 1-1/8 1-1/8 1-3/8 1-3/8 8 4 7/8 7/8 7/8 1-1/8
10 10 1-1/8 1-1/8 1-3/8 1-3/8 10 5 7/8 1-1/8 1-1/8 1-1/8
13 13 1-1/8 1-3/8 1-3/8 1-3/8 13 6.5 7/8 1-1/8 1-1/8 1-1/8

LIQUID LINES
SINGLE CIRCUIT SYSTEMS DUAL CIRCUIT SYSTEMS
Unit Tons per EQUIVALENT FEET Unit Tons per EQUIVALENT FEET
Tonnage Circuit 50 100 150 200 Tonnage Circuit 50 100 150 200

6 6 1/2 5/8 5/8 5/8 6 3 1/2 1/2 1/2 1/2

8 8 5/8 7/8 7/8 7/8 8 4 1/2 5/8 5/8 5/8
10 10 5/8 7/8 7/8 7/8 10 5 1/2 5/8 5/8 5/8
13 13 7/8 7/8 7/8 7/8 13 6.5 1/2 5/8 5/8 5/8

SUCTION LINES
SINGLE CIRCUIT SYSTEMS
EQUIVALENT FEET
Unit Tons per 50 100 150 200
Tonnage Circuit HOR VER HOR VER HOR VER HOR VER

6 6 1-1/8 1-1/8 1-3/8 1-1/8 1-3/8 1-1/8 1-5/8 1-3/8

8 8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-3/8
10 10 1-3/8 1-3/8 1-5/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8
13 13 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-5/8

SUCTION LINES
DUAL CIRCUIT SYSTEMS
EQUIVALENT FEET
Unit Tons per 50 100 150 200
Tonnage Circuit HOR VER HOR VER HOR VER HOR VER

6 3 7/8 7/8 1-1/8 7/8 1-1/8 7/8 1-1/8 7/8

8 4 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-1/8
10 5 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-1/8 1-3/8 1-1/8
13 6.5 1-1/8 1-1/8 1-3/8 1-1/8 1-3/8 1-1/8 1-5/8 1-3/8

HOR = HORIZONTAL VERT = VERTICAL

33
 Data Aire, Inc.

Monthly Maintenance Inspection Checklist

Model No.___________________ Serial No._____________________

Prepared by:________________ Date: ___ / ___/ 201__

Air Filters Steam Generating Humidifier (if applicable)

____ Check for restricted air flow ____ Check canister for deposits and water level
____ Check condition of steam hose and clamps
Blower Section
____ Blower wheel free of debris moves freely Electrical Panel
____ Check belt tension and condition ____ Check contactor operation
____ Bearings in good condition ____ Mini dap4 controller operations
____ Check pulleys and motor mounts
Equipment Runtimes
Air Distribution Section Blower __________ hrs
____ Check for restriction in grille(s) Condenser __________ hrs
Compressor(s) __________ hrs
Compressor(s) Reheat __________ hrs
____ Check for leaks Humidifier __________ hrs
Dehumidification __________ hrs
Refrigeration Cycle/Section Energy Saver __________ hrs
____ Check crank case temperature
____ Reset all to read zero runtimes
Air Cooled Condenser (if applicable)
____ Condenser coil clean Temperature/Humidity set at: ___° ___% RH
____ Motor mounts tight
____ Motor fan bearings in good condition Notes: _______________________________
____ Refrigeration lines properly supported _____________________________________
_____________________________________
Water/Glycol Fluid Cooler (if applicable) _____________________________________
____ Water regulating valve function _____________________________________
____ Check for water/glycol leaks (piping _____________________________________
area) _____________________________________
_____________________________________
Glycol Pump(s) (if applicable) _____________________________________
____ Glycol leaks (pump area) _____________________________________
____ Pump operation _____________________________________
____ Auto air vent clean of mineral deposits _____________________________________

Condensate Drain and Pump (if applicable)

____ Check for water leaks
____ Check for restricted air flow
____ Pump operation

34
 Data Aire, Inc.
Quarterly Maintenance Inspection Checklist

Model No.________________________ Serial No.____________________________

Prepared by:______________________ Date: ___ / ___/ 201__

Air Filters Steam Generating Humidifier (if applicable)

_____ Check for restricted air flow _____ Check canister for deposits and water level
_____ Check filter differential switch _____ Check condition of steam hose and clamps
_____ Wipe filter rack section clean _____ Check drain and fill valve for deposits

Blower Section Reheat (if applicable)

_____ Blower wheel free of debris and moves freely _____ Check reheat element(s) for dust
_____ Check belt tension and condition _____ Check high limit switch operation
_____ Bearings in good condition
_____ Check air flow safety switch operation Electrical Panel
_____ Check pulleys and motor mounts _____ Check fuses
_____ Check contactor operation
Air Distribution Section _____ Check all electrical connections
_____ Check for restriction in grille(s) _____ Check operation sequence
_____ Check calibration of change over thermostat
Compressor(s) (Energy Saver System Only)
_____ Check for leaks
Equipment Runtimes
Refrigeration Cycle/Section Blower _____________ hrs
_____ Check for moisture (site glass) Condenser _____________ hrs
_____ Check suction pressure Compressor(s) _____________ hrs
_____ Check discharge pressure Reheat _____________ hrs
_____ Check hot gas bypass valve operation Humidifier _____________ hrs
_____ Check thermostatic expansion valve operation Dehumidification _____________ hrs
_____ Check solenoid valve operation Energy Saver _____________ hrs

Air Cooled Condenser (if applicable) _____Reset all to read zero runtimes
_____ Condenser coil clean
_____ Motor mounts tight Temperature/Humidity set at: _____° _____% RH
_____ Motor fan bearings in good condition
_____ Refrigeration lines properly supported Notes: ______________________________________
_____ Heated receiver site ____________________________________________
____________________________________________
Water/Glycol Fluid Cooler (if applicable) ____________________________________________
_____ Water regulating valve function ____________________________________________
_____ Check solution _____%
_____ Check for water/glycol leaks (piping area)
_____ Water/Glycol flow switch operational

Glycol Pump(s) (if applicable)

_____ Glycol leaks (pump area)
_____ Pump operation
_____ Auto air vent clean of mineral deposits

Condensate Drain and Pump (if applicable)

_____ Check for water leaks and restricted flow
_____ Pump operation

35
 Superheat and Suction Pressure
Trouble Shooting Guide
Low Suction Pressure and High Superheat
1. Moisture, dirt, wax
2. Undersized valve*
3. High superheat adjustment
4. Gas charge condensation
5. Dead thermostatic element charge
6. Wrong thermostatic charge
7. Evaporator pressure drop - no external equalizer
8. External equalizer location
9. Restricted or capped external equalizer
10. Low refrigerant charge
11. Liquid line vapor
a. Vertical lift
b. High friction loss
c. Long or small line
d. Plugged drier or strainer
12. Low pressure drop across valve
a. Same as #11 above
b. Undersized distributor nozzle or circuits
c. Low condensing temperature

High Suction Pressure - Low Superheat

1. Oversized valve*
2. TXV seat leak
3. Low superheat adjustment
4. Bulb installation
a. Poor thermal contact
b. Warm location
5. Wrong thermostatic charge
6. Bad compressor - low capacity
7. Moisture, dirt, wax
8. Incorrectly located external equalizer

Low Suction Pressure - Low Superheat

1. Low load
a. Not enough air
b. Dirty air filters
c. Coil icing
2. Poor air distribution
3. Poor refrigerant distribution
4. Improper compressor-evaporator balance
5. Evaporator oil logged
6. Flow from one TXV affecting another’s bulb

* Data Aire has ensured that valves are sized properly as the unit ships from the factory.

36
 Temperature Pressure Chart
Temperature (°F) R-407C R-410A
26 43.6 89.7
27 44.7 91.6
28 45.9 93.5
29 47.1 95.5
30 48.4 97.5
31 49.6 99.5
32 50.9 101.6
33 52.1 103.6
34 53.4 105.7
35 54.8 107.9
36 53.2 110.0
37 57.5 112.2
38 58.9 114.4
39 60.3 116.7
40 61.7 118.9
41 63.1 121.2
42 64.6 123.6
43 66.1 125.9
44 67.6 128.3
45 69.1 130.7
46 70.6 133.2
47 72.2 135.6
48 73.8 138.2
49 75.1 140.7
50 77.1 143.3
55 106.0 156.6
60 116.2 170.7
65 127.0 185.7
70 138.5 201.5
75 150.6 218.2
80 163.5 235.9
85 177.0 254.6
90 191.3 274.3
95 206.4 295.0
100 222.3 316.9
105 239.0 339.9
110 256.5 364.1
115 274.9 389.6
120 294.2 416.4
125 314.5 444.5
130 335.7 474.0
135 357.8 505.0
140 380.9 537.6
145 405.1 571.7
150 430.3 607.6
37
LCS_IOM 07/2019