gForceUltraIOM 09-2020

CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION ENVIRONMENTAL
CONTROL SYSTEM. PROPER INSTALLATION, OPERATION AND MAINTENANCE OF THIS

EQUIPMENT WILL ENSURE YEARS OF OPTIMAL PERFORMANCE.
There are separate User Manuals for other components of your Data Aire precision
environmental cooling system including dap4™, condenser/condensing unit and fluid cooler.
NOTE: 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.
WARNING: Service performed by unauthorized or unqualified technicians may

void manufacturers’ warranties and could result in property damage and/or per-
sonal injury.
NOTE: Special care should be given to those areas where

these symbols appear.
Data Aire, Inc. reserves the right to make design changes for the purpose of product
improvement or to withdraw any design without notice.
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Table of Contents
1. INTRODUCTION........................................................................................................7
1.1 Product Information..............................................................................................7
1.2 Model Identification..............................................................................................8
1.3 Inspection.............................................................................................................8
1.4 Paperwork............................................................................................................9
2. INSTALLATION.......................................................................................................10
2.1 Installation Checklist..........................................................................................10
2.2 Room Considerations.........................................................................................10
2.3 Equipment Handling...........................................................................................10
2.4 Rigging............................................................................................................... 11
2.5 Locating the Unit................................................................................................ 11
2.5.1 Downflow Units............................................................................................12
2.5.2 Upflow Units.................................................................................................12
2.6 Storage...............................................................................................................13
2.7 Piping.................................................................................................................13
2.7.1 Air Cooled Unit Piping.................................................................................14
2.7.2 Discharge Lines...........................................................................................14
2.7.3 Liquid Lines.................................................................................................15
2.7.4 Recommended Line Sizing, Air Cooled Units..............................................16
2.7.5 Connection Sizes, Air Cooled Units.............................................................17
2.7.6 Field Piping, Remote Condenser Above Evaporator...................................17
2.7.7 Field Piping, Remote Condenser Below Evaporator...................................18
2.7.8 Water/Glycol Cooled Unit Piping.................................................................18
2.7.9 Field Piping, Water/Glycol Cooled Units…………………………………… .19

2.7.10 Connection Sizes, Water/Glycol Cooled Units…………………………… …20
2.7.11 Conection Sizes, Fluid Coolers…………………………………………………20
2.7.12 Factory Charge for Water/Glycol Cooled Systems………………………….21
2.7.13 Auxiliary Chilled Water/Energy Save Coil Piping…………………………….21
2.8 Condensate Drain Piping...................................................................................21
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2.9 Humidifier Piping................................................................................................22
2.9.1 Steam Generator Humidifier........................................................................22
2.10 Leak Testing.......................................................................................................23
2.11 Evacuation.........................................................................................................23
3. ELECTRICAL CONNECTIONS...............................................................................25
3.1 Electrical Service................................................................................................25
3.2 Nameplate Ratings.............................................................................................25
3.3 Grounding..........................................................................................................25
3.4 Voltage Tolerance...............................................................................................25
3.5 Auxiliary Control Wiring......................................................................................26
3.6 Remote Shutdown..............................................................................................27
3.7 Remote Alarm Contacts.....................................................................................27
3.8 Condensate Pumps............................................................................................28
3.9 Condensate Probe.............................................................................................28
3.10 Water Sensing Cable (Optional).........................................................................28
3.11 Remote Temperature and Humidity Sensors (Optional).....................................28
3.12 Manual Override Switches.................................................................................29
3.13 Wiring Diagrams.................................................................................................29
3.14 EEV Connection.................................................................................................30
4. INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER...........................31
5. CHARGING..............................................................................................................31
5.1 General Charging Guidelines.............................................................................31
5.2 Triple Evacuation................................................................................................32
5.3 Voltage Phase Check.........................................................................................33
5.4 Air Cooled System Charging..............................................................................33
5.4.1 Constant Speed Compressor......................................................................33
5.4.2 Variable Capacity Compressor....................................................................34
5.5 Flooded System Charging..................................................................................38
5.5.1 Constant Speed Compressor......................................................................38
5.5.2 Variable Capacity Compressor....................................................................44

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5.6 Water/Glycol System..........................................................................................48
5.7 Check a Running Compressor...........................................................................49
5.8 Refrigerant Handling..........................................................................................49
5.9 Commissioning...................................................................................................49
5.10 Important Refrigeration Components.................................................................50
5.10.1 Variable Capacity Compressor with VFD.....................................................50
5.10.2 Electronic Expansion Valve.........................................................................50
5.10.3 High Pressure Cutout Switch.......................................................................50
5.10.4 Low Pressure Cutout Switch.......................................................................50
5.10.5 Liquid Line Solenoid Valve...........................................................................51
6. GLYCOL SYSTEMS................................................................................................52
6.1 Glycol Concentration..........................................................................................52
6.2 Internal (Fluid) Volume – Downflow Units..........................................................52
6.3 Internal (Fluid) Volume – Upflow Units...............................................................52
6.4 Internal (Fluid) Volume – Fluid Coolers..............................................................53
6.4.1 Fluid Cooler Information..............................................................................53
7. VARIABLE SPEED COMPRESSOR.......................................................................54
7.1 Features.............................................................................................................54
7.2 Oil Management.................................................................................................54
7.3 Crankcase Heaters............................................................................................54
7.4 Oil Level.............................................................................................................54
7.5 VFD Drive...........................................................................................................54
7.5.1 Local Control for Charging...........................................................................56
7.5.2 View Drive Alarms........................................................................................57
8. CONTROLS.............................................................................................................58
9. REGULAR MAINTENANCE ITEMS.....................................................................59
9.1 Air Filters............................................................................................................59
9.2 Fuses..................................................................................................................60
9.3 Electric Reheat...................................................................................................60
9.4 Humidifier...........................................................................................................60
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9.4.1 Humidifier Canisters.................................................................................60
9.5 Refrigerant Filter Drier........................................................................................60
9.6 Current Sensing Relay.......................................................................................60
9.7 Plug Fans...........................................................................................................61
9.7.1 Electronically Commutated Motors...........................................................61
9.7.2 Testing......................................................................................................61
10. MAINTENANCE/INSPECTION CHECKLIST.......................................................61
11. CONTACT DATA AIRE.........................................................................................62
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1. INTRODUCTION
1.1 Product Information

The Data Aire gForce Ultra environmental control, direct expansion, single and dual circuit Computer
Room Air Conditioner (CRAC) equipment provides a high sensible cooling, is self-contained, factory
assembled, piped, wired, and factory tested prior to shipment. These units include an enclosure/cabinet
assembly, fan section, filter section, cooling coil, controls, and interconnecting piping internal to unit.
The Data Aire CRAC unit provides cooling, reheat, humidification, dehumidification and air filtration.
The unit is provided with a Data Aire dap4™ microprocessor controller for precision control. The unit
must be operated in a conditioned space within the operating envelope ASHRAE recommends for data
centers. Maximum dew point is 59°F (15°C). Operating outside this envelope can alter the operat-
ing performance and decrease equipment reliability. Return air to the unit must be no cooler than the
ASHRAE recommendation of 68°F (20°C) DB and 40% RH or minimum WB of 54°F (12.2°C) for proper
unit operation. Operating below this can alter the operating performance and decrease equipment reli-
ability. Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.”
The unique feature of the gForce Ultra is the application of variable capacity compressors. The quest
for greater energy efficiency is continuous; efficiency benchmarks are always moving up. That’s why
Data Aire is moving toward variable capacity compressor technology for quieter, more energy-saving
performance. Conventional compressors are designed to run at constant speed to handle a given
capacity requirement. But in data center applications, the capacity requirement varies. In these situ-
ations, a constant speed compressor uses various capacity-regulation techniques and can be less ef-
ficient than a compressor utilizing variable capacity technology. A variable capacity compressor (VCC),
on the other hand, saves energy and operates more quietly by varying speed to match the workload.
Tests with VCC compressors have shown an immediate energy savings and sound level reductions.
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1.2 Model Identification
1.3 Inspection
This Data Aire CRAC unit has been factory run-tested and has gone through a comprehensive inspec-
tion prior to its packaging and shipment to ensure that it arrives in excellent condition. However, ship-
ping damage can occur and a visual inspection of the outer crating immediately upon delivery should be
performed. Upon arrival of the unit and before unpacking it, verify that the labeled equipment matches
the bill of lading.
Note: any external damage or transportation damage on the freight carrier’s

forms. Inspect the unit itself for internal damage. A claim should be filed with
the shipping company if the equipment is damaged or incomplete.
Loose items such as remote control panels, disconnect switch handles, and spare air filters are packed
inside the unit. Refer to the yellow shipping tag located on the unit door for details.
NOTE: Freight damage claims are the responsibility of the purchaser. Action
to recover losses should be filed immediately. Please notify factory personnel
of any claims.
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1.4 Paperwork
Each Data Aire CRAC unit ships with a start-up sheet that should be completed during installation. Also
included in the paperwork is a warranty/information packet that provides important wiring diagrams,
specific component literature, warranty registration cards and other valuable paperwork, including a
copy of this User Manual.
A yellow tag is attached to the outside decorative door to indicate articles that may have been packaged
and shipped loose within the unit cabinet. Typically this would be jackstands, condensate pumps and
other loose components that are not factory mounted.
WARNING: It is the responsibility of the installing contractor to return the start-

up sheet and warranty registration card to Data Aire for proper activation of the
unit warranty. Failure to do so may cause delays and some cases void the war-
ranty.
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2. INSTALLATION
NOTE: There is no intent on the part of Data Aire, Inc. to define local codes
or statutes which may supersede common trade practices. The manu-
facturer assumes no responsibility for their interpretation. Consult local
building codes and National Electrical Code (NEC) for special installation
requirements.
2.1 Installation Checklist

As a precaution, review the following checklist to ensure proper operation:
Check for any damage
Check all wiring connections
Filters are properly positioned in air intake
WARNING: Before removing from the packaging inspect the unit for any
damage. Report any damage to the carrier and file a damage claim.
2.2 Room Considerations

Precision air conditioning equipment is designed to control spaces within close tolerances of tempera-
ture 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 vapor-seal paint. Fail-
ure to provide a vapor barrier can compromise 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.
Install the units as close as possible to the largest heat load.
2.3 Equipment Handling
WARNING: Only properly trained personnel wearing appropriate safety head-

gear, gloves, shoes and glasses should attempt to move the unit, lift it, remove
packaging or prepare the unit for installation.
Move the unit in its upright position to the installation site using a forklift or pallet jack. It is recom-
mended that the unit be protected from damage to the decorative doors during any storage or moving.
Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to prevent exterior
and/or underside damage. Make sure the forks are spread to their widest allowable width for proper
balance. Do not lift the unit any higher than 4 inches (100mm) off the ground. If necessary to lift high-
er than the suggested 4 inches (100mm), exercise great care to ensure proper handling of the unit.
Personnel not involved with the lifting of the unit should keep a safe distance from the unit.
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The unit may be too tall to fit through a doorway while on the skid. Measure the unit and doorway
heights and refer to the installation plans to verify clearances prior to moving the unit.
WARNING: Use care when moving. Improper handling could result in injury.
Proper care should be taken when uncrating the unit. The packaging has wrap-
ping bands with sharp edges that are under tension, crating has staples and
splinters. Proper protective equipment should be worn by qualified personnel.
2.4 Rigging
Move the unit in its upright position to the installation site. It is recommended that the unit be protected
from damage to the decorative doors during any storage or moving. Removal of the decorative doors
is easily accomplished and may be done without moving the equipment.
The shipping skid should be left in place if the unit is being moved with a forklift. If the unit is being
lifted, use spreader bars to prevent damage to the doors and panels.
The unit has 3/4” (19mm) holes in the shipping skid to which casters with 3/4” (19mm) stems can be
attached. This allows easy movement down halls, into elevators and through doorways. If clearance
is a problem the casters may be inserted directly into the bottom of the 1” (25mm) tubular steel corner
posts at the bottom of the unit.
WARNING: Improper lifting or moving of the equipment may result in damage

to the decorative doors, panels or frame members.
2.5 Locating the Unit

Verify that the floor is level, solid and sufficient to support the unit. When installing the unit, sufficient
space must be allowed for airflow clearance, wiring, plumbing and service access. It is recommended
that each side and front have a clearance of at least 36” (914mm) to allow the doors to swing open
and for servicing the unit.
The doors on some sides may not require as much service clearance. Refer to the particular unit
component breakdown drawings for assistance. Rear clearance is not required, but 1” to 2” (25 to
50mm) of clearance is suggested.
For the best air distribution, the unit should be centered against the longest wall, distributing the cold
air as close to heat load as possible, unless the unit is ducted. The unit should not be placed near any
corner of the room or at the end of a long, narrow room. Install the units as close as possible to the
largest heat load. Multiple units should be evenly spaced, as far apart as possible. It is recommended
to install an under-floor water detection system.
NOTE: Condensation formation and frequent humidifier flushing are normal

functions of this equipment. Proper drain connections must be made to ensure
proper removal. Unit will require water connections for condensate removal
and possibly for humidifier makeup water, chilled water and/or hot water. In-
stallation of units above equipment that could sustain water damage should be
avoided.
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2.5.1 Downflow Units
Downflow units will typically sit on an elevated flooring system known as a raised floor. The unit dis-
charges air downward which pressurizes the raised floor and channels upward through perforated
floor tiles. Location and quantity of perforated tiles will dictate proper air distribution. If the raised floor
is strong enough to support the unit and local codes permit, the unit can be placed directly on top with
cutouts made for the discharge openings.
Verify that the raised floor has been properly sized for the unit’s airflow and the room is free of airflow
restrictions. Perforated floor tiles in the raised floor should ensure minimal pressure loss. The raised
floor must provide a minimum of 12” (305 mm) clearance. Ensure that there is adequate clearance
above the unit for service, such as replacing filters. Optional plenums are available for downflow unit
ducting.
There may be additional support required in the form of adjustable jackstands. These are adjustable,
threaded leveling rods which support the unit in each of the corners and in the center on longer length
units. Tighten the locknuts provided with each jackstand. The base plate can rest on the floor or on
vibration pads.
Floorstands are also a way of supporting the unit. These are ordered to the height of the raised floor
with leveling rods to allow adjustment. The floorstand has lips in each corner to align with the unit
which is placed on top. It is recommended that the unit frame be bolted or screwed to the floorstand
from below. Local building codes may dictate this procedure. After installation, the raised floor is typi-
cally built around the unit.
The raised floor serves as the distribution plenum for air on downflow units. Cables, piping, wiring
raceways, inadequate floor height and any other restrictions can inhibit proper airflow. Care should
be taken to avoid restrictions.
2.5.2 Upflow Units
Upflow units will typically be supported by vibration isolation pads and/or floorstands which may also
include leveling screws. An air discharge plenum may be factory provided which ships loose and must
be attached at the top of the unit frame. For in-room applications with supply and return grilles, several
feet of clearance must be maintained at the intake and discharge of the unit.
Alternately, an air distribution plenum must be field fabricated with supply grilles to distribute the air. If
a common plenum is utilized to connect the supply air for distribution from multiple units, it is recom-
mended that isolation backdraft dampers be installed on the discharge end of the unit or somewhere
prior to the common plenum to prevent cold discharge air from entering units that may be on standby.
Alternatively, we offer an AireSeal option which keeps the EC fans running at a selectable speed
between 20-50% when the unit is in standby to prevent air from entering the units from the common
plenum. Units are shipped with Electronically Commutated (EC) motors often referred to as “plug
fans”. Fan speed is factory set based on order. Fan speed can be changed in 1% increments through
the unit’s microprocessor controller, Data Alarm Processor 4™ (dap4™) by several different methods.
See the dap4™ User Manual for details and recommended settings.
WARNING: Do not operate upflow units without installing a plenum, ductwork

or guard over the fan opening(s) on the top surface of the cabinet. Ductwork
must be connected to the fan(s), or a plenum must be installed on the top of
the cabinet for protection from rotating blower wheel(s) on upflow units. Risk
of high-speed moving parts can cause injury or death. Disconnect all local
and remote electric power supplies before working in the unit.
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NOTE: Seal openings around piping and electrical connection to prevent air
leakage. Failure to do so could reduce the unit’s cooling performance.
2.6 Storage
Your Data Aire equipment comes ready for immediate installation. In some instances it may be neces-
sary to store the equipment for a period of time. If you must store the equipment it should be done in
a dry area, out of the weather, protected from damage by other equipment in storage or transportation
equipment, never stacked, and avoid frequent relocation.
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 (i.e., 1 to 3 PSIG, (7 to 21 kPa)) 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 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 components. All moving parts, such as fans and motors, should be hand tested to ensure that
they are free and clear prior to start-up. Finally, verify that all lubrication fresh and full.
2.7 Piping
Proper piping practices should be employed to ensure adequate oil return, even under minimum load
conditions with special consideration given to the size and proper slope of the tubing coming from the
evaporator. Tubing returns from the evaporator should be designed so as not to trap oil and to prevent
oil and refrigerant migration back to the compressor during off-cycles.
Piping should be designed with adequate three-dimensional flexibility. It should not be in contact with
the surrounding structure, unless a proper tubing mount has been installed. This protection proves
necessary to avoid excess vibration, which can ultimately result in connection or tube failure due to
fatigue or wear from abrasion. Aside from tubing and connection damage, excess vibration may be
transmitted to the surrounding structure and generate an unacceptable noise level within the structure
as well.
When piping, use copper tubing with appropriate supporting devices (supporting saddles, etc.). All field
piping must be installed according to local codes. Avoid piping runs through noise-sensitive areas,
such as office walls and conference rooms. Refer to Section 11.0 - Piping for piping guidelines and to
the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping.
All piping below the raised floor must be located so that it does not restrict airflow. Plan the piping
layout under the raised floor to prevent the airflow from being blocked. When installing piping on the
subfloor, it is recommended that the pipes be mounted in a horizontal plane rather than stacked one
above the other. Whenever possible, the pipes should be run parallel to the airflow.
Ensure that the tubing surfaces to be brazed are clean and that all burrs have been removed from the
ends of the tubes. Ensure that all loose material has been cleaned from inside the tubing before braz-
ing. Keep piping clean and dry, especially on units with R-410A refrigerant.
The units may be ordered with top or bottom connections.
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2.7.1 Air Cooled Unit Piping
Air-cooled unit piping is crimped and brazed closed from the factory and contains a nitrogen holding
charge. Each installation requires field-supplied refrigerant piping to a condenser.
Refer to section RECOMMENDED LINE SIZING charts in section 2.7.4 for a guideline on 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 (61 m). For installations beyond this distance, consult ASHRAE or similar references.
NOTE: 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.
2.7.2 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 check valves are required on all instal-
lations, especially those where there are long pipe runs or cold climates. 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 not
represent your specific unit, check valve size, location or orientation.
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The check valve will prevent flow from the condenser to the compressor during the “off”cycle.
The evaporator section ships with a nitrogen holding charge. Do not vent the evaporator until all re-
frigerant piping is in place, ready for connection to the evaporator and condenser. 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 refrig-
eration practices should be employed for piping support, leak testing, dehydration and charging 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 build-up on the inside of the joints. Carbon could contaminate the refrigerant
and restrict the metering device.
Piping must be supported within 18” (457 mm) of the inlet and outlet connections external to the unit.
Internal to the unit, 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 9 PSI (62 kPa) for R-410A. Recommended gas ve-
locity for proper oil return is 1,000 FPM (5.1 m/sec). Slope horizontal lines downward in the direction
of the refrigerant flow. The recommended slope is 1/2” (12 mm) for every ten (10) feet (3 m) 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.
2.7.3 Liquid Lines

Liquid line size is determined by pressure drop and velocity. The liquid line pressure drop should not
exceed 9 PSI (62 kPa) for R-410A. The recommended liquid velocity should be between 200 and 300
FPM (1 to 1.5 m/sec). To avoid excessive liquid line pressure drop, the air cooled condenser should
be located above or at the same level as the evaporator. Condenser installations more than 15 feet
below the evaporator are 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.
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2.7.4 Recommended Line Sizing, Air Cooled Units
NOTE: 1. If equivalent piping length falls between two columns above,

choose the longer equivalent length.
2. Dual circuit units should use the same line size on both circuits.
3. If hot gas line refrigerant flow is upward, use “VERTICALUP”. If it is

downward, use “HOR.VERTICAL DOWN”.
4. If hot gas line refrigerant flow is upward use, “VERTICAL UP”, if it is down-
ward or horizontal, use “HORIZ. & VERTICAL DOWN”.
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2.7.5 Connection Sizes, Air Cooled Units
Model Number Liquid Line Hot Gas Line

GUA* 022 5/8” (16 mm) O.D. 5/8” (16 mm) O.D.
GUA* 036 7/8” (22 mm) O.D. 7/8” (22 mm) O.D.
GUA* 045 7/8” (22 mm) O.D. 7/8” (22 mm) O.D.
GUA* 070 7/8” (22 mm) O.D. 7/8” (22 mm) O.D.
GUA* 091 7/8” (22 mm) O.D. 7/8” (22 mm) O.D.
GUA* 125 1-1/8” (29 mm) O.D. 7/8” (22 mm) O.D.
NOTE: Field connections at the indoor evaporator and remote condenser

will not necessarily be the same as the field pipe size required.
2.7.6 Field Piping, Remote Condenser Above Evaporator
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2.7.7 Field Piping, Remote Condenser Below Evaporator
2.7.8 Water/Glycol Cooled Unit Piping

Water/Glycol-cooled units are factory-charged and tested. Field-supplied and field-installed piping is
required from the unit to building water or tower water sources or the fluid cooler (i.e., dry cooler) and
pump package. Pipe size will depend on length of run and the maximum water flow required.
The required field installed fluid cooler pipe sizes may or may not be the same as the connection sizes
on the fluid cooler (refer to the Fluid Cooler User Manual for connection sizing). This will depend on the
length of pipe and the calculated pressure drop of peripheral components.
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. Drain/fill valves (field provided) should be
located at the lowest point on the connected piping.
Water/glycol cooled units are shipped with plate/fin heat exchangers as standard equipment. A strainer
(Data Aire provided) 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 optional shell and tube condensers, strainers are not
required and not shipped with the unit.
All water pipes have a cap installed on the end of the pipe prior to shipment from the factory for pres-
sure testing the system. These caps need to be removed before installing the piping to the units. Use
a tube cutter for smaller pipes and a reciprocating saw with a metal cutting blade for larger pipe sizes
or if there is a clearance problem. All connections need to be cleaned before connections are brazed
together.
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NOTE: One of the most common problems in a water/glycol system is the pres-
ence of air in the condenser water loop. Air vents must be installed in various
locations the piping system to purge the air.
The water/glycol system may include a centrifugal pump (or pumps, for redundancy) available from
Data Aire as an option, along with field provided union(s), shutoff valves, check valve(s) and a flow
switch (Data Aire option). Pumps must be primed before operating per the pump manufacturer’s guide-
lines.
2.7.9 Field Piping, Water/Glycol System
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2.7.10 Connection Sizes, Water/Glycol Cooled Units
Evaporator Model Water In Connection Water Out Connection

GUWX-022XX
1-1/8” (29mm) O.D. 1-1/8” (29mm) O.D.
GUGX-022XX
GUWX-036XX
1-5/8” (41mm) O.D. 1-5/8” (41mm) O.D.
GUGX-036XX
GUWX-045XX
1-5/8” (41mm) O.D. 1-5/8” (41mm) O.D.
GUGX-045XX
GUWX-070XX
1-5/8” (41mm) O.D. 1-5/8” (41mm) O.D.
GUGX-070XX
GUWX-091XX
2-1/8” (54mm) O.D. 2-1/8” (54mm) O.D.
GUGX-091XX
GUWX-125XX
2-1/8” (54mm) O.D. 2-1/8” (54mm) O.D.
GUGX-125XX

* D=Downflow U=Upflow
2.7.11 Connection Sizes, Fluid Coolers (Dry Coolers)
Evaporator Water In Water Out

Fluid Cooler Model
Model Connection Connection
GUWX-022XX GHFC-053 2-1/8” 2-1/8”
GUGX-022XX GHFC-074 2-1/8” 2-1/8”
GHFC-130 2-5/8” 2-5/8”
GUWX-036XX GHFC-060 2-1/8” 2-1/8”
GUGX-036XX GHFC-074 2-1/8” 2-1/8”
GHFC-141 2-5/8” 2-5/8”
GUWX-045XX GHFC-074 2-1/8” 2-1/8”
GUGX-045XX GHFC-106 2-5/8” 2-5/8”
GHFC-176 2-5/8” 2-5/8”
GUWX-070XX GHFC-084 2-1/8” 2-1/8”
GUGX-070XX GHFC-106 2-5/8” 2-5/8”
GHFC-176 2-5/8” 2-5/8”
GUWX-091XX GHFC-141 2-5/8” 2-5/8”
GUGX-091XX GHFC-176 2-5/8” 2-5/8”
GHFC-310 2-5/8” 2-5/8”
GUWX-125XX GHFC-176 2-5/8” 2-5/8”
GUGX-125XX GHFC-215 2-5/8” 2-5/8”
GHFC-352 2-5/8” 2-5/8”
20
2.7.12 Factory Charge for Water/Glycol Cooled System
Variable Speed
Evaporator Model R-410A Fixed Speed Circuit
Circuit
GUWX-022XX
10 10 N/A
GUGX-022XX
GUWX-036XX
16 16 N/A
GUGX-036XX
GUWX-045XX
18 18 N/A
GUGX-045XX
GUWX-070XX
30 16.5 13.5
GUGX-070XX
GUWX-091XX
36 19.8 16.2
GUGX-091XX
GUWX-125XX
42 23.1 18.9
GUGX-125XX
2.7.13 Auxiliary Chilled Water/Energy Saver Coil Piping

Units with 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 shown in the Fluid Cooler
User Manual. Units with an Energy Saver cooling coil have shared piping with the condenser supply
and return therefore do not require a separate water source.
All chilled water pipes have a cap installed on the end of the pipe for factory pressure testing of the sys-
tem. These caps need to be removed before installing the water piping to the unit. Use a tube cutter for
smaller pipes and reciprocating saw with a metal cutting blade for larger pipes or if there is a clearance
problem. All connections need to be cleaned before connections are brazed together.
2.8 Condensate Drain Piping

Every indoor unit has a 3/4” (19 mm) copper stub provided for condensate removal. A union (field pro-
vided) is recommended at the field connection which will permit easy disconnection from the unit for
cleaning.
A trap should be built into the drain line to prevent air from backing up into the unit. Drain lines should
be pitched downward not less than 1/4” (6.35 mm) for each ten (10) feet (3.1 m) of horizontal run. Do
not reduce the size of the drain line.
Some applications have no convenient means of allowing a gravity drain. When required, an optional
condensate pump can be used. Condensate pumps are either factory mounted or shipped loose. Fac-
tory mounted condensate pumps do not require a separate power source.
Condensate pumps shipped loose (or field provided) typically require a dedicated 110 volt power
source. Field pipe connections must be made to the pump discharge connection. A check valve must
be installed to prevent short cycling. See condensate pump electrical requirements in Section 3.9.
Do not expose drain line to freezing temperatures. Drain line may contain boiling water therefore use
copper or other suitable material. Drain line must comply with local building codes. It is recommended
to install under-floor leak detection equipment whenever possible.
21
NOTE: Condensation formation and frequent humidifier flushing are normal
functions of this equipment. Proper drain connections must be made to ensure
proper removal. Unit will require water connections for condensate removal and
possibly for humidifier makeup water, condenser water, chilled water and/or hot
water. Installation of units above equipment that could sustain water damage
should be avoided.
WARNING: The condensate drain MUST be connected to an external drain line

(provided by others) before unit start up.
NOTE: Clogged or leaking drain lines can cause damage to the equipment and
building.
Drain lines must be inspected regularly and maintenance must be performed to

ensure that drain lines are clear and condensation runs freely through the drain
system. The lines must be clear and free of obstructions and in good condition
with no visible sign of damage or leaks.
This unit also requires an external water supply to the humidifier.
Improper installation, application and service may result in water leakage from
the unit. Water leakage can result in severe property damage and loss of critical
data center equipment.
Do not locate unit directly above any equipment that could sustain water dam-
age. It is recommended to install leak detection equipment for unit and supply
lines.
2.9 Humidifier Piping

2.9.1 Steam Generator Humidifier
The standard humidifier in the systems is a steam generator humidifier type with disposable cylinder.
The humidifier makeup water should be brought to the humidifier through the field connection opening
using 1/4” (6.4 mm) copper tubing. A compression fitting is provided at the humidifier.
A shutoff valve (field provided) should be installed outside the air conditioner to allow disconnection
for service. An in-line water pressure regulator (field provided) and strainer (field provided) should be
installed. Water pressure should be set between 20 and 80 PSI (128 and 552 kPa).
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.
NOTE: Do not supply steam generating humidifier with softened water. Also,
do not use hot water source.
22
2.10 Leak Testing
WARNING: No installation is complete until the entire system has been thor-
oughly checked for leaks. This includes checking the refrigerant tubing, flare
fittings, pressure controls, Schrader fittings and compressor rotolock service
valves. Check both the field and factory connections.
In addition to the refrigeration system, check all condenser water lines, humidifier water makeup
lines, condensate lines, condensate pumps, chilled water lines, centrifugal pumps and fluid cooler
(where applicable).
When handling or 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 the systems circuit(s) to 150 PSIG (1034 kPa) using dry nitrogen with a trace of refrigerant.
Check the entire system for leaks with a suitable leak finder (per local code) including but not limited
to all braze joints, caps, 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.
WARNING: Tightening of fittings and valves is the responsibility of the
installing contractor.
WARNING: With any fluid connection there is risk of leakage. Water leak-
age could result in property damage to mission critical equipment. A water
drain connection is required. Units with optional steam generator humidifiers
will require an external potable water supply. Water leakage can result from
improper installation and/or practices.
2.11 Evacuation
Moisture prevents the proper operation of both the compressor and the refrigeration system. Air and
moisture reduces service life and increases condensation pressure, which causes abnormally high dis-
charge temperatures that are capable of degrading the lubricating properties of the oil. The risk of acid
formation is also increased by air and moisture, and it this condition can also lead to copper plating. All
of these phenomena may cause both mechanical and electrical compressor failure. The typical method
for avoiding such problems is to evacuate the system.
It is of the utmost importance that proper system evacuation and leak detection procedures be em-
ployed. Good evacuation processes include frequent vacuum pump oil changes and large diameter,
short hose connections to both high and low sides of the system preferably using copper tubing or
braided hose. If the compressor has service valves, they should remain closed. A deep vacuum gauge
capable of registering pressure in microns should be attached to the system for pressure readings. A
shut-off valve between the gauge connection and vacuum pump should be provided to allow the sys-
tem pressure to be checked after evacuation. Do not turn off vacuum pump when connected to an
evacuated system before closing shut-off valve.
23
Evacuate the refrigerant lines, condenser coil and evaporator coil to 500 microns or lower (a micron
gauge and 2-stage vacuum pump are required). Valve off and turn off the vacuum pump and wait at
least 15 minutes to make sure the micron gauge reading does not go back above 750 microns. If it
does, restart the vacuum pump and evacuate until the system reaches 500 microns. If the system still
does not hold the pressure below 750 microns the system needs to be rechecked for leaks.
After the system has been satisfactorily evacuated the lines can be charged with refrigerant. Connect
the pressure gauge manifold set to the high and low ports near the compressor. Connect the charg-
ing 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
to flow until the system pressure equalizes. 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 pressures and
temperatures.
WARNING: Do not apply power to the compressor when in a vacuum.
24
3. ELECTRICAL CONNECTIONS
WARNING: The Data Aire cooling unit must be connected by a licensed and
qualified electrician. Risk of electrical shock could result in injury or death.
Disconnect all remote electrical power supplies prior to working on the unit.
Follow all local codes.
NOTE: Disconnect switches are optional. The disconnect switch when

turned OFF will de-energize the high voltage.
WARNING: Before proceeding with the electrical connections, make certain

that the volts, hertz and phase correspond to that specified on the unit electri-
cal nameplate. Use copper conductors only.
3.1 Electrical Service

Check to be sure the electrical service provided by the utility is sufficient to handle the additional load
imposed by this equipment. Most units with secondary heat exchangers will require a separate power
source and field provided interconnecting wires (see Section 0).
Remote condensers will typically 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 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 ampac-
ity (MCA), also known as wire sizing amps, will dictate the minimum required wire gauge. Maximum
Overcurrent Protection (MOP) device amps will dictate the maximum 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 10% of the voltage indicated on the unit electrical name-
plate. The maximum allowable voltage phase to phase imbalance must not exceed 3%. Voltage
imbalance causes high amperage over one or several phases, which in turn leads to overheating and
possible damage. The local utility company should be contacted for correction of improper line volt-
age. Deviation from voltage ratings can cause premature failures and possibly void unit warranties.
25
WARNING: 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.
3.5 Auxiliary Control Wiring
The interconnection of auxiliary control wiring for remote heat exchangers (condensers and fluid cool-
ers) 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 contrac-
tor 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.
Examples:
Figure 1 - Typical Remote Heat Exchanger Interconnection Points
Figure 2 - Typical Indoor Evaporator Interconnection Points
26
3.6 Remote Shutdown
Every gForce Ultra unit has remote shutdown contacts. These are intended for a field supplied dry con-
tact or switch to be wired across two terminals. When the contactor 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. Use field-supplied
Class 1 wiring.
The remote shutdown contacts are always terminals # 1 and # 2 on the terminal block designated TB1.
The unit will ship with factory wired metal jumper clip that connects terminal # 1 to terminal # 2. Re-
move the clip prior to installing the field wires.
3.7 Remote Alarm Contacts

The dap4™ microprocessor control panel provides four (4) remote alarm output contacts that can be
field accessed. The contacts include a Normally Open (NO) or Normally Closed (NC) on Alarm, dry
contact, intended to be used in a control circuit not exceeding 5 amps at 24 VAC. Use field-supplied
Class 1 wiring.
These programmable output contacts will close on a failure and remain closed until the alarm is no
longer present. The terminal designations for these alarm output contact pairs are:
Remote Alarm Contacts Terminals

TB1 Function
# 11 Remote Alarm 1 (Common)
# 12 Remote Alarm 1 (Normally Closed)
# 13 Remote Alarm 1 (Normally Open)
27
3.8 Condensate Pumps
A condensate pump is optional. Factory mounted pumps are pre-wired. While no outside power
source is required, field piping is still a requirement.
WARNING: The condensate drain MUST be connected to an external drain

line (provided by others) before unit start up. Without field piping condensate
water will damage internal components.
Condensate pumps which ship loose, normally require a separate source of power. Always check
the pump power requirements before connecting power. Condensate pumps are available in various
voltages.
Factory installed condensate pumps are wired to display a “HIGH CONDENSATE WATER LEVEL”
alarm. The wiring for this must be done in the field on pumps that ship loose.
3.9 Condensate Probe

One (1) condensate probe for sensing water under the floor is standard and is included with this unit.
This comes in a plastic bag with about 15 feet (4.6 m) of coiled-up wire. The condensate probe is a
rectangular box that is typically placed below the unit in a location where the water is likely to accu-
mulate. Additional probes are available as an option.
Place the probe flat on the floor on top of a thin layer of non-conductive silicone. Secure the attached
wires where necessary. A longer length of standard hookup wire may be used if required.
WARNING: Failure to remove the condensate probe from the plastic bag and
uncoil the length of wire attached to the probe will leave the unit unprotected
for sensing water under the unit and can result in a nuisance water detected
alarm. Remove/disconnect the probe if it is not to be used.
3.10 Water Sensing Cable (Optional)

Some units may be equipped with an optional water detection cable in addition to or in lieu of the con-
densate probe. The cable can sense moisture anywhere along its length. It is typically placed below
the unit in a rectangular pattern that matches the perimeter of the unit. The cable is connected to the
terminal board and ready for installation. Cable lengths will vary depending on the original order and
specifications. Care should be taken when installing the cable. Be sure the cable is not touching
metal and/or any debris under the raised floor.
3.11 Remote Temperature and Humidity Sensors (Optional)

Remote temperature and humidity sensors are optional. Although existing unit mounted sensors
can be removed for remote mounting, the remote sensor option provides a more convenient means
of field installation. This is because the sensors are already connected to a predetermined length
of cable and come mounted in a remote sensor enclosure. The temperature and humidity sensors
require a total of five wires and should be twisted, shielded cable type.
28
3.12 Manual Override Switches
For testing and during start-up each gForce Ultra unit is provided with manual override slide switches.
There are seven (7) slide switches. One for each of the following functions:
Water Valve
Fan Speed
Humidifier
Heat 1
Cool 2
Cool 1
Blower
All automatic control is disabled but the safety switches remain functional. Simply slide the manual
switches to energize the fan, compressor(s), humidification, reheat and other functions (as appli-
cable).
The fan speed of the Electronically Commutated (EC) plug fan motor can be adjusted from 0 to 10
volts DC by adjusting the potentiometer at the left of the Fan Speed switch. The fan speed will in-
crease 10% of the fan base speed for each one (1) volt adjustment (e.g., one (1) volt equals 10%
speed). At ten (10) volts the motor is at full speed.
WARNING: Do not leave the unit in manual override. Slide the switches to
the OFF position when completing testing and/or start-up. An alarm will be
activated if units are left in the ON position.
3.13 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 ex-
changer. The internal wiring of the secondary 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 secured in the evaporator section.
29
3.14 Electrical Connection to EEV
The Electronic Expansion Valve (EEV) uses an electrical cable assembly with a DIN type
connector to interface with EEV valve stator. The connector is indexed by one large blade
connection so that the connector can only be properly mate one way. When it is necessary to
making this electrical connection, this connector can only properly mate in one position as
shown in the picture below (See Figure 1):
DIN Connector
Stator
Figure 1 - EEV with Electrical Mating Connector
DO NOT try to mate this connector in any other direction or attempt to use
excessive force to make the electrical connection.
EEV Connection November 8, 2016
30
4. INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER
Air cooled condenser and fluid coolers have individual User Manuals which should be referred to for
more complete details.
5. CHARGING
WARNING: Before starting a compressor, the crankcase heater should be

energized for a minimum of 12 hours to reduce the possibility of liquid slug-
ging on start-up. Failure to energize the crankcase heater could result in
compressor damage. If the system is charged from a vacuum, the preheat-
ing of the compressor is not necessary.
WARNING: Do not apply power to the compressor when in a vacuum.
WARNING: The constant speed compressor (2nd stage) must be charged

before charging the variable speed compressor (1st stage) in a dual circuit
system.
WARNING: The compressor power must be OFF and prevented from start-
ing inadvertently/automatically
NOTE: Prior to refrigerant charging, a system vacuum and moisture re-

moval procedure must have been carried out. Refer to Section __ for Triple
Evacuation prior to charging the system.
NOTE: Improper charging procedure could cause compressor damage in

several ways: excessive LP/HP pressure differences, liquid slugging or vac-
uum operation. The below system refrigerant charge procedure is strongly
recommended to reduce these risks.
5.1 General Charging Guidelines

• Check the unit nameplate for refrigerant type to be used
• The unit must be wired correctly and prepped for operation
• Always use a scale to weigh in the calculated refrigerant charge listed in tables in individual
compressor charging sections before starting the unit, record system charge when com-
pleted
• The initial refrigerant must be charged at the liquid side of the refrigeration circuit with the
compressor OFF
31
• Care must be taken to prevent charging the system with too much refrigerant
• See directions for system charging in sections 5.3 Air Cooled System Charging or 5.4 Flood-
ed System Charging
• The return air temperature to the unit being charged must be stable and must be maintained
greater than 65°F (18°C)
• If this is not possible due to lack of heat load, then load banks must be used to offset the
cooling load during startup
5.2 Triple Evacuation

Data Aire highly recommends a triple evacuation to be carried out on all Data Aire units, to insure the
highest quality vacuum. Moisture prevents the proper operation of both the compressor and the re-
frigeration system. Non-condensables and moisture reduces service life and increases condensation
pressure, which causes abnormally high discharge temperatures that are capable of degrading the
lubricating properties of the oil. The risk of acid formation is also increased by non-condensables and
moisture, and this condition can also lead to copper plating. All of these phenomena may cause both
mechanical and electrical compressor failure. The typical method for avoiding such problems is to
evacuate the system.
It is of the utmost importance that proper system evacuation and leak detection procedures be em-
ployed. Good evacuation processes include frequent vacuum pump oil changes and large diameter,
short hose connections to both high and low sides of the system preferably using copper tubing or
braided hose. All valves in the system, both liquid line solenoid valve and rotolock service valves (if the
compressor is equipped with them), need to remain open during the vacuum process and the system
must be purged of nitrogen. We recommend using a solenoid magnet tool to hold the liquid line sole-
noid valve open. A deep vacuum gauge capable of registering pressure in microns should be attached
to the system for pressure readings. A shut-off valve between the gauge connection and vacuum
pump should be provided to allow the system pressure to be checked after evacuation. Do not turn off
vacuum pump when connected to an evacuated system before closing shut-off valve.
Triple evacuate the refrigerant lines, condenser coil and evaporator coil to 500 microns or lower (a mi-
cron gauge and 2-stage vacuum pump are required).
Perform these procedures without contaminating the system with non-condensables
Step 1: Evacuate system down to 4000 microns from both service valves. Then close the manifold
gauges, shut off the vacuum pump and introduce dry nitrogen up to 5psi to the system without contami-
nating it. Then release the nitrogen and restart the vacuum pump.
Step 2: Evacuate system down to 1500 microns from both service valves. Then close the manifold
gauges, shut off the vacuum pump and introduce dry nitrogen up to 5psi to the system without contami-
nating it. Then release the nitrogen and restart the vacuum pump.
Step 3: Evacuate system down to 500 microns or below from both service valves.
Turn off the vacuum pump and conduct a rise test waiting at least 30 minutes to make sure the micron
gauge reading does not go back above 500 microns. If it does, restart the vacuum pump and evacuate
until the system reaches 500 microns. If the system still does not hold the pressure below 750 microns
the system needs to be rechecked for leaks.
32
5.3 Voltage Phase Check
5.3.1 Evaporator
Prior to fully charging a unit, the correct voltage phasing should be checked on the indoor evapora-
tor. EC plug fans are not dependent on the input power phasing and will always operate in the proper
direction.
Before checking the fixed speed scroll compressor voltage phasing make sure that its circuit has been
charged with between 70% and 80% of its refrigerant capacity by following the steps in section 5.4.1
or 5.6.1 for initial charging. Since the scroll compressors are phase dependent, the easiest way to
check proper phasing is to check the rotation of the constant speed scroll compressor (if available)
on the evaporator section of dual circuit units by momentarily energizing the COOL 2 (constant speed
compressor) switch on the Manual Override Module located next to the microprocessor control mod-
ule. Slide the Cool 2 switch to the ON position, observe the compressor operation for a few seconds,
and then slide the switch back to the OFF position. An out of phase constant speed scroll compressor
will draw relatively low amps and both suction and discharge pressures will remain nearly equal. If
necessary, reverse any two of the three input line voltage wires at the line voltage field connection
point to change the compressor rotation.
The gForce Ultra unit has a variable capacity compressor and an out of phase compressor will not
turn ON and the VFD will show an error message. On the Manual Override Module located next to
the microprocessor control module, slide the Cool 1 switch to the ON position, observe the VFD for an
error message then slide the switch back to the OFF position. If an error message is observed, reverse
any two of the three input line voltage wires at the line voltage field connection point to change the
compressor rotation.
Although constant speed scroll compressors are phase dependent, units shipped from the factory are
run tested, ensuring the compressor rotation is consistent with evaporator fan motor. However, a field
change-out of a compressor may require checking proper phase.
5.3.2 GHRC Air-Cooled Heat Exchanger
The GHRC air cooled heat exchanger are only offered in three phase voltages and the individual EC
fan motors will only operate in one direction so no additional phase verification is required.
The standard GHRC air-cooled condenser provided with Data Aire gForce Ultra equipment has a
modulating fan speed control feature built into the condenser control system and the fan motors.
The modulation speed of the fans is directly proportional to the compressor head pressure.
5.4 Air Cooled System Charging

WARNING: The constant speed compressor (2nd stage) must be charged
before charging the variable speed compressor (1st stage) in a dual circuit
system.
NOTE: Prior to refrigerant charging, a system vacuum and moisture removal

procedure must have been carried out. Refer to Section 5.2 for Triple Evacu-
ation prior to charging the system.
5.4.1 Constant Speed Compressor

See the tables for the appropriate charging
33
After Charging and verifying Subcooling and oil level, close the valve on the refrigerant manifold gauge
set, switch “Cool 2” and “Blower” slide switches to the OFF position on manual bypass board, and close
the service valve on the refrigerant tank and disconnect the refrigerant manifold gauge set.
5.4.2 Variable Capacity Compressor

procedure must have been carried out. Refer to Section 5.2 for evacuation
procedures prior to charging the system.
1. After the system has been properly evacuated. Calculate the proper charge by following the
steps of the tables below.
Add the amount of refrigerant needed for the evaporator & condenser + the line-set then
multiply by .80.
Step 1: Select the model and refrigerant charge for evaporator and condenser.
Weight of Refrigerant in Evap + Condenser

Model Starting Charge (lbs.)
GUAX-022XX 15
GUAX-036XX 25
GUAX-045XX 32.5
GUAX-070XX 25
GUAX-091XX 32.5
GUAX-125XX 37.5
Step 2: Since the majority of refrigerant weight is in liquid form in the liquid line, refrigerant in
the hot gas line and suction line is ignored in the charging calculation.
Calculate the total of the liquid line run, then multiply the equivalent feet of line based on line
size by the correct multiplier to get the refrigerant weight needed for the Line-set.
Weight of Refrigerant in Liquid Line (lbs. /ft.)

Liquid Line OD (inches) Multiplier
1/2” .067
5/8” .107
3/4” .160
7/8” .223
1 1/8” .380
Note: Charge Weight calculated at 77F (25C).
34
1. After the system has been properly evacuated. Calculate the proper charge by
following the steps of the tables below.
Add the amount of refrigerant needed for the evaporator & condenser + the line-set
then multiply by .80.

GUAX-022XX NA
GUAX-036XX NA
GUAX-045XX NA
GUAX-070XX 25
GUAX-091XX 32.5
GUAX-125XX 37.5
Step 2: Since the majority of refrigerant weight is in liquid form in the liquid line, refrigerant
in the hot gas line and suction line is ignored in the charging calculation.
Calculate the total of the liquid line run, then multiply the equivalent feet of line based on
line size by the correct multiplier to get the refrigerant weight needed for the Line-set.
1. Weight of Refrigerant in Liquid Line (lbs. /ft.)

1/2” .067
5/8” .107
3/4” .160
7/8” .223
1-1/8” .380
Example: If the liquid line of an R-410A system is 150ft of 1-1/8” pipe, then multiply 150 *
0.38 = 57lbs
Step 3: Add refrigerant weights from step 1 and 2 together and multiply by .80 to get the
starting charge.
Example: model GUAX-125XX (37.5 + 57 lbs.) *.80 = 75.6 lbs.
2. Next connect the refrigerant tank to the refrigerant manifold gauge set and make sure the
manifold gauge set is properly purged
3. Then from a vacuum, slowly open the high side liquid line valve on the refrigerant manifold
gauge to feed liquid refrigerant through the high side.
4. Add the amount of refrigerant weight per tables, slowly open the high side liquid line valve
on the refrigerant manifold gauge to feed liquid refrigerant through the high side.
35
At this point there will be approximately 70-80% of the total charge in the system. It is likely
that more refrigerant will be required to complete the charging procedure. Close the valve on
the refrigerant manifold gauge set.

compressor damage. If the system is charged from a vacuum, the preheating
of the compressor is not necessary.
NOTE: A quick and easy way to run the fans and compressor is by using
the manual slide switches provided by the Manual Override Module (Exclu-
sively for floor mounted units. Ceiling mounted units are not equipped
with Manual Override Module!) All automatic control is disabled but safety
switches will remain functional.
Before turning the system on to finish charging the circuit make sure you check for voltage phasing.
For more information on this refer to section 5.3.
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. A system charged to a clear sight glass is
often overcharged.
Manually start the system by first sliding the “Blower” switch to ON position on the manual override
board. Allow time for all fans to start and come up to a constant airflow before starting the constant
speed compressor. Then manually start the constant speed compressor by sliding the “Cool 2” switch
to the ON position on the manual override board to turn on the constant speed compressor. Allow the
system to stabilize to room temperature. Bubbles in the sight glass are not unusual at this point. It
is likely that more refrigerant will be required to complete the charging procedure.
Finish charging by slowly opening the valve on the refrigerant manifold set to meter liquid refrigerant
into the low side of the system.
Adjust the refrigerant charge to the sub-cooling value shown in the table below and the sight glass
has sparse bubbles. The unit should be allowed to stabilize for 15 to 20 minutes to verify key mea-
surements in the table below.
Function R-410A Conditions

Discharge Pressure 340 to 415 PSIG (2344 to 2861 kPa)
Suction Pressure 104 to 121 PSIG (717 to 834 kPa)

6 to 12°F (3.33 to 6.67°C) Differential
Superheat
Sub-Cooling Depending on ambient conditions, at com-
pressor’s maximum speed
36
When the compressor starts, monitor closely the suction pressure, head pressure, compressor VFD
display and the EEV. Watch for any alarms that you might see. During startup, you might see some
alarms such as:
- “C1 Low Pressure”: If suction pressure is below 50 psi, make sure to add more
refrigerant per recommended charge calculation shown above
- “Compressor VFD Alarm”: This alarm shows up when the compressor is called upon
for cooling requirement, but either the VFD has stopped the compressor, or the
compressor is experiencing a Low or High pressure alarm.
Finish charging by slowly opening the valve on the refrigerant manifold set to meter liquid refrig-
erant into the low side of the system, with the compressor operating at a speed of 6000 RPM (or
200Hz), make sure to obtain the required sub-cooling and verify superheat shown in the table
below. The unit should be allowed to stabilize for 15 to 20 minutes to verify key measurements.

Discharge Pressure 340 to 415 PSIG (2344 to 2861 kPa)
Suction Pressure 104 to 165 PSIG (717 to 1138 kPa)
Superheat 10 to 12°F (5.56 to 6.67°C) Differential
Sub-Cooling Depending on ambient conditions, at compressor’s
maximum speed
Measure the superheat at the compressor suction line at least 6 inches (152 mm) away from the
compressor. Compare suction pressure and temperature reading between the dap4 and the manifold.
If the difference between the manifold reading and dap4 reading is more than 5%, check for the EEV
wiring and any possible alarms on dap4, or EEV driver. Measure sub-cooling at the liquid line.
When charging is complete, add the correct amount of oil, if the line run exceeds longer than 20m
or 66ft. This procedure must be conducted with the system running at high load (compressor at full
speed). (Ref to page. 43)
ALWAYS use original Danfoss POE oil 160SZ from new cans.
Oil addition is calculated based on refrigerant charge, shown in the table below
Additional Oil Required (oz)

Note: Additional oil is only needed if pipe run is longer than 20m or 66ft.
Total Refrigerant Weight Danfoss Variable Speed Danfoss Fixed Speed
(lbs.) Compressor Compressor
20 12 6
30 18 9
40 25 12
50 31 15
37
60 37 18
70 43 21
80 49 25
90 55 28
100 61 31
110 67 34
120 74 37
130 80 40
140 86 43
150 92 46
160 98 49
170 104 52
180 110 55
190 117 58
200 123 61
210 129 64
220 135 67
230 141 71
240 147 74
250 153 77
When charging is complete, close the valve on the refrigerant manifold set and close the service
valve on the refrigerant tank. Then go back into menu “H. Calibrate Sensors” and set either the
“Return Air Temp Sensor” or “Discharge Air Temp Sensor” menu offset values back to 0. If a cali-
bration offset value has been determined in the field that is different from 0 bring the offset num-
ber back to this value.
5.5 Flooded System Charging
WARNING: The constant speed compressor must be charged before charg-

ing the variable speed compressor in a dual circuit system.
Flooded systems are supplied with 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 minimum receiver pressure. The condenser is partially flooded with liquid
refrigerant in cold weather. In warm weather the extra refrigerant is stored in the receiver. Therefore,
flooded systems require more refrigerant than fan speed control systems.
5.5.1 Constant Speed Compressor
1. After the system has been properly evacuated. Calculate the proper charge by following
the steps of the tables below.
38
Measure the superheat at the compressor suction line at least 6 inches (152 mm) away from the com-
pressor. Compare suction pressure and temperature reading between the dap4 and the manifolds. If
the difference between the manifold reading and dap4 reading is more than 5%, check for the EEV wir-
ing and any possible alarms on dap4, or EEV driver. Measure sub-cooling at the liquid line.
When charging is complete, add the correct amount of oil, if the line run exceeds longer than 20m or
66ft. This procedure must be conducted with the system running at high load (compressor at full speed).
Oil addition is calculated based on refrigerant charge, shown in the table below:

20 12 6
30 18 9
40 25 12
50 31 15
60 37 18
70 43 21
80 49 25
90 55 28
100 61 31
110 67 34
120 74 37
130 80 40
140 86 43
150 92 46
160 98 49
170 104 52
180 110 55
190 117 58
200 123 61
210 129 64
220 135 67
230 141 71
240 147 74
250 153 77
39
Example: If the liquid line of an R-410A system is 150ft of 1-1/8” pipe, then multiply
150 * 0.38 = 57lbs

Step 3: Add refrigerant weights from step 1 and 2 together and multiply by .80 to get the
starting charge.
Example: model GUAX-125XX (37.5 + 57 lbs.) *.80 = 75.6 lbs.
2. Next connect the refrigerant tank to the refrigerant manifold gauge set and make sure
the manifold gauge set is properly purged.
3. Then from a vacuum, slowly open the high side liquid line valve on the refrigerant
manifold gauge to feed liquid refrigerant through the high side.
4. Add the amount of refrigerant weight per tables, slowly open the high side liquid line valve
on the refrigerant manifold gauge to feed liquid refrigerant through the high side.
At this point there will be approximately 70-80% of the total charge in the system. It is likely that more
refrigerant will be required to complete the charging procedure. Close the valve on the refrigerant mani-
fold gauge set.

The variable speed compressor requires a little more care while charging. All unit safeties must be
active while charging the compressor. In order to ensure this, manual bypass switches on the Manual
Override Board MUST NOT be used. Instead the unit must be started in the normal operating mode
based on a call for cooling required by the dap4 controller once an initial charge has been added to
the circuit. Before starting the system, make sure pressure gauges are hooked up and pressure read-
ings are aligned with EEV reading. For dual circuit units, remove the fixed speed compressor’s fuses
to prevent it from starting.
If the unit is in OFFbyKEY position, hold the “Esc” button for 5 seconds to start the system via the dap4
controller. Next, controlled temperature needs to be higher than temperature setpoint for the compres-
sor to start. To do this, press the “Menu” button where you will be prompted to enter in the service pass-
word before continuing. The default service password is “0000” By utilizing the arrow keys, scroll up
or down to menu “H. Calibrate Sensors” and press ENTER. If the system is being controlled from the
return air temperature sensors simply scroll down to the “Return Air Temp Sensor” menu and press EN-
TER to move the cursor to the offset value. Use the up and down arrow keys to change the offset value
to +20 °F. Then press ENTER to set the offset. This should allow the temperature to be much higher
than the temperature setpoint and the variable speed compressor will start and run at a full speed of
6000 RPM (or 200Hz). If controlling with discharge air temperature sensor follow the same steps but
use the “Discharge Air Temp Sensor” menu.
40
Add the amount of refrigerant needed for the evaporator & condenser + the line-set then
multiply by .80.

GUAX-022XX NA
GUAX-036XX NA
GUAX-045XX NA
GUAX-070XX 25
GUAX-091XX 32.5
GUAX-125XX 37.5
Step 2: Since the majority of refrigerant weight is in liquid form in the liquid line,
refrigerant in the hot gas line and suction line is ignored in the charging calculation.

1/2” .067
5/8” .107
3/4” .160
7/8” .223
1 1/8” .380
Note: Charge Weight calculated at 77F (25C).
Example: If the liquid line of an R-410A system is 150ft of 1-1/8” pipe, then multiply
150 * 0.38 = 57lbs
Step 3: Select model and refrigerant charge of receiver based on condenser size
and circuit type
Weight of Refrigerant per Standard Liquid Receiver (lbs.)

Receiver Type Condenser Circuit type Lbs. of Refrigerant
GHRC 011-039 Single 29
GHRC 025-074 Dual 29
GHRC 264-352 Dual 143
41
Step 4: Add refrigerant weights from step 1 through 3 together and multiply by .80 to
get the starting charge.
Example: model GUAX-125XX (37.5 + 57 lbs. + 55) *.80 = 119.6 lbs.
3. Then from a vacuum, slowly open the high side liquid line valve on the refrigerant manifold
gauge to feed liquid refrigerant through the high side.
4. Add the amount of refrigerant weight per tables, slowly open the high side liquid line valve on
the refrigerant manifold gauge to feed liquid refrigerant through the high side.
At this point there will be approximately 70-80% of the total charge in the system. It is likely that more
refrigerant will be required to complete the charging procedure. Close the valve on the refrigerant
manifold gauge set.

NOTE: A quick and easy way to run the fans and compressor is by using
the manual slide switches provided by the Manual Override Module (Exclu-
sively for floor mounted units. Ceiling mounted units are not equipped
with Manual Override Module!) All automatic control is disabled but safety
switches will remain functional.
Before turning the system on to finish charging the circuit make sure you check for voltage phasing.
For more information on this refer to section 5.3.
Manually start the system by first sliding the “Blower” switch to ON position on the manual override
board. Allow time for all fans to start and come up to a constant airflow before starting the constant
speed compressor. Then manually start the constant speed compressor by sliding the “Cool 2” switch
to the ON position on the manual override board to turn on the constant speed compressor. Allow the
system to stabilize to room temperature. Bubbles in the sight glass are not unusual at this point.
Finishing charging by slowly opening the valve on the refrigerant manifold set to meter liquid refriger-
ant into the low side of the system.
If the receiver head pressure is below the required pressure (350 PSIG (2413 kPa) for R-410A), block
part of the condenser coil surface until the pressure rises. During extremely cold weather all the con-
denser fans may have to be de-energized to maintain head pressure.
42
Observe the sight glass on the receiver. Meter 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. The unit should be allowed to stabilize for 15 to 20 minutes to verify key
measurements in the table below.

Discharge Pressure 322 PSIG (2220 kPa)
104 PSIG (717 kPa)
Suction Pressure
or greater
Superheat 10 to 12°F (5.56to 6.67°C) Differential
the difference between the manifold reading and dap4 reading is more than 5%, check for the EEV
wiring and any possible alarms on dap4, or EEV driver. Measure sub-cooling at the liquid line.
When charging is complete, add the correct amount of oil, if the line run exceeds longer than 20m
or 66ft. This procedure must be conducted with the system running at high load (compressor at full
speed).

20 12 6
30 18 9
40 25 12
50 31 15
60 37 18
70 43 21
80 49 25
90 55 28
100 61 31
110 67 34
120 74 37
130 80 40
140 86 43
150 92 46
160 98 49
170 104 52
180 110 55
43
190 117 58
200 123 61
210 129 64
220 135 67
230 141 71
240 147 74
250 153 77
often overcharged.
When charging is complete, close the valve on the refrigerant manifold set, switch “Cool 2” and
“Blower” slide switches back to OFF position on manual bypass board, and close the service valve on
the refrigerant tank and remove the manifold set.
5.5.2 Variable Capacity Compressor

procedure must have been carried out. Refer to Section 5.2 for evacuation
procedures prior to charging the system.
WARNING: The compressor power must be OFF and safeties ON and pre-
vented from starting inadvertently/automatically

1. After the system has been properly evacuated. Calculate the proper charge by following
the steps of the tables below.
Add the amount of refrigerant needed for the evaporator & condenser + the line-set
then multiply by .80.

GUAX-022XX 15
GUAX-036XX 25
GUAX-045XX 32.5
GUAX-070XX 25
GUAX-091XX 32.5
GUAX-125XX 37.5
44
At this point there will be approximately 70-80% of the total charge in the system. It is likely that
more refrigerant will be required to complete the charging procedure. Close the valve on the refriger-
ant manifold gauge set.

The variable speed compressor requires a little more care while charging. All unit safeties must be
active while charging the compressor. In order to ensure this, manual bypass switches on the Manual
Override Board MUST NOT be used. Instead the unit must be started in the normal operating mode
based on a call for cooling required by the dap4 controller once an initial charge has been added to
the circuit. Before starting the system, make sure pressure gauges are hooked up and pressure read-
ings are aligned with EEV reading. For dual circuit units, remove the fixed speed compressor’s fuses
to prevent it from starting.
If the unit is in OFFbyKEY position, hold the “Esc” button for 5 seconds to start the system via the
dap4 controller. Next, the controlled temperature needs to be higher than temperature setpoint for
the compressor to start. To do this, press the “Menu” button where you will prompted to enter in the
service password before continuing. The default service password is “0000” By utilizing the arrow
keys, scroll up or down to menu “H. Calibrate Sensors” and press ENTER. If the system is being con-
trolled from the return air temperature sensors simply scroll down to the “Return Air Temp Sensor”
menu and press ENTER to move the cursor to the offset value. Use the up and down arrow keys to
change the offset value to +20 °F. Then press ENTER to set the offset. This should allow the tem-
perature to be much higher than the temperature setpoint and the variable speed compressor will
start and run at a full speed of 6000 RPM (or 200Hz). If controlling with discharge air temperature
sensor follow the same steps but use the “Discharge Air Temp Sensor” menu.
When compressor starts, monitor closely the suction pressure, head pressure, compressor VFD dis-
play and the EEV. Watch for any alarms that you might see. During startup, you might see some
alarms such as:
- “C1 Low Pressure”: If suction pressure is below 50 psi, make sure to add more refrigerant per
recommended charge calculation shown above
- “Compressor VFD Alarm”: This alarm shows up when the compressor is called upon for cooling
requirement, but either the VFD has stopped the compressor, or the compressor is experiencing a Low
or High pressure alarm.
Finish charging by slowly opening the valve on the refrigerant manifold set to meter liquid refrigerant
into the low side of the system, with the compressor operating at a speed of 6000 RPM (or 200Hz),
making sure to obtain the required sub-cooling and verify superheat shown in the table below. The
unit should be allowed to stabilize for 15 to 20 minutes to verify key measurements.
Discharge Pressure 322 PSIG (2220 kPa)

104 PSIG (717 kPa)
Suction Pressure
or greater
Superheat 10 to 12°F (5.56 to 6.67°C) Differential
45
the difference between the manifold reading and dap4 reading is more than 5%, check for the EEV wir-
ing and any possible alarms on dap4, or EEV driver. Measure sub-cooling at the liquid line.
When charging is complete, add the correct amount of oil, if the line run exceeds longer than 20m or
66ft. This procedure must be conducted with the system running at high load (compressor at full speed).

20 12 6
30 18 9
40 25 12
50 31 15
60 37 18
70 43 21
80 49 25
90 55 28
100 61 31
110 67 34
120 74 37
130 80 40
140 86 43
150 92 46
160 98 49
170 104 52
180 110 55
190 117 58
200 123 61
210 129 64
220 135 67
230 141 71
240 147 74
250 153 77
46
Step 2: Since the majority of refrigerant weight is in liquid form in the liquid line,
refrigerant in the hot gas line and suction line is ignored in the charging calculation.

1/2” .067
5/8” .107
3/4” .160
7/8” .223
1 1/8” .380
Note: Charge Weight at 77F (25C).
Example: If the liquid line of an R-410A system is 150ft, then the estimated refrigerant in the
line for 1-1/8” pipe is 150 * 0.38 = 57lbs
Step 3: Select model and refrigerant charge of receiver based on condenser size and circuit
type
Weight of Refrigerant per Standard Liquid Receiver (lbs.)

Receiver Type Condenser Circuit type Lbs. of Refrigerant
GHRC 264-352 Dual 143
Step 4: Add refrigerant weights from step 1 through 3 together and multiply by .80 to get
the starting charge.
Example: model GUAX-125XX (37.5 + 57 lbs. + 55) *.80 = 119.6 lbs.
3. Then from a vacuum, slowly open the high side liquid line valve on the refrigerant
manifold gauge to feed liquid refrigerant through the high side.
4. Add the amount of refrigerant weight per tables, slowly open the high side liquid line valve on
the refrigerant manifold gauge to feed liquid refrigerant through the high side.
47
often overcharged.
When charging is complete, close the valve on the refrigerant manifold set and close the service valve
on the refrigerant tank. Then go back into menu “H. Calibrate Sensors” and set either the “Return Air
Temp Sensor” or “Discharge Air Temp Sensor” menu offset values back to 0. If a calibration offset value
has been determined in the field that is different from 0 bring the offset number back to this value.
5.6 Water/Glycol System
5.6.1 Water/Glycol Cooled System Charging
All water/glycol cooled units are factory charged with refrigerant. The water regulating valve should
be adjusted to maintain the required conditions. Field charging, if required, of water/glycol systems
should be done by referring to the unit’s electrical nameplate. The factory charge is indicated on the
nameplate. Although this figure represents the initial factory charge, it is still necessary to measure
and note proper unit operation including superheat, head and suction pressure. Some adjustment of
charge may be required.
Adjust the refrigerant charge until the sight glass clears or has sparse bubbles. The system should
be allowed to stabilize for 15 to 20 minutes before meaningful measurements can be taken. After the
system is allowed to stabilize, verification of a few key measurements should be noted.
Condensing Temperature 105 to 119⁰F (41 to 48⁰C)

Saturated Suction Temperature 33⁰F (0.6⁰C) or higher
Superheat 8 to 15⁰F (4.44 to 8.33⁰C) Differential
The superheat at the compressor suction line at least 6 inches (152 mm) away from the compressor.
All water/glycol cooled units have a water regulating valve. A head pressure transducer is connected
to a Schrader fitting on the discharge line and water is regulated into the condenser coil (plate fin con-
densers are standard).

48
5.7 Check a Running Compressor
• Check current draw and voltage.

• Check suction superheat to reduce risk of slugging.
• Observe the oil level at start and during operation to confirm that the oil level remains visible.
• Excess foaming in oil sight glass indicates refrigerant on the sump.
• Monitor the oil sight glass for 1 hour after system equilibrium to ensure proper oil return to
the compressor. This oil check has to be done over the speed range to guarantee:
- A good oil return at low speed with minimum gas velocity.
- A good oil management at high speed with maximum oil carry over.
• Check all tubes for abnormal vibration. Movements in excess of 1.5 mm require corrective
measures such as tube brackets.
• When needed, add refrigerant.
• Do not overcharge the system.
• Record type and amount of refrigerant charge as well as operating conditions as a reference
for future inspections.
5.8 Refrigerant Handling
The use of recovery/recycling units is required by U.S. Environmental Protection Agency (EPA) regula-
tions. Technicians who service and dispose of air conditioning and refrigeration equipment must re-
cover the refrigerant instead of venting it to the atmosphere.
Except for extremely small releases of refrigerant such as what occurs when disconnecting service
hoses, 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.
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 shell and tube con-
densers or high pressure relief valve options.
5.9 Commissioning
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operat-
ing characteristics such as:
• Proper metering device operation and desired superheat readings

• Suction and discharge pressures are within acceptable levels
• Correct oil level in compressor sump indicating proper oil return
• Low foaming in sight glass and compressor sump temperature 10⁰ F above saturation
temperature to show there is no refrigerant migration taking place
• Acceptable cycling rates of compressors, including duration or run times
Short cycling protection is provided in the VFD. It is factory preset “enabled” with default
parameters. The minimum run time is set to ensure long enough running time at start up in
order to create enough refrigerant flow velocity in the system to recover the oil to the
compressor sump.
• Current draw of compressor within acceptable values
• No abnormal vibration or noise
49
5.10 Important Refrigeration Components
5.10.1 Variable Capacity Compressor with VFD
The unique feature of the gForce Ultra is the application of variable capacity compressor. The quest for
greater energy efficiency is continuous; efficiency benchmarks are always moving up. That’s why Data
Aire is moving toward variable capacity compressor technology for quieter, more energy-saving perfor-
mance. Conventional compressors are designed to run at constant speed to handle a given capacity
requirement. But in data center applications, the capacity requirement varies. In these situations, a
constant speed compressor uses various capacity-regulation techniques and can be less efficient than
a compressor utilizing variable capacity technology. A variable capacity compressor (VCC), on the
other hand, saves energy and operates more quietly by varying speed to match the workload. Tests
with VCC compressors have shown an immediate energy savings and sound level reductions.
5.10.2 Electronic Expansion Valve
The Electronic Expansion Valve (EEV) is standard for this unit. This high efficiency feature provides an
EEV in place of the standard Thermal Expansion Valve (EEV). The EEV controls superheat through the
dap4™ controls by actively measuring suction pressure via a transducer attached to the suction line
and suction temperature via a thermal transducer strapped to the suction line. The EEV actively adjusts
the orifice size and resulting mass flow of refrigerant to maintain the superheat setpoint. The EEV
maintains more stable system balance and is more energy efficient. With variable capacity systems,
an electronic expansion valve is the solution to handle refrigerant mass flow variations.
5.10.3 High Pressure Cutout Switch
Each refrigerant circuit is protected by a high pressure cutout switch with manual reset button. The
switch is typically located in the evaporator near the compressor. The high pressure switch rating is:
R-410A Refrigerant Setting
Cut-out (Open) 575 PSI

Cut-in (Close) Manual Reset
5.10.4 Low Pressure Cutout Switch

Each refrigerant circuit has a low pressure cutout switch which features SPST open-low switch action
and automatic reset. The switch is typically located in the evaporator near the compressor. The low
pressure switch rating is:
R-410A Refrigerant Setting
Cut-out (Open) 50 PSI

Cut-in (Close) 90 PSI
50
5.10.5 Liquid Line Solenoid Valve
Liquid line solenoid valve(s) (LLVS) are a standard feature on this unit. The LLSV are direct acting, NC
(normally closed; i.e. closed when de-energized) solenoid operated valve(s). This has the advantage
that the valve is closed when the system is not running and when the solenoid valve is not energized.
For this reason, an electrical power failure does not lead to any problems with the refrigeration system.
The primary purpose of a solenoid valve in a refrigerant liquid line is to helps prevent refrigerant migra-
tion (i.e., flow into the evaporator) during the OFF cycle.
often overcharged.
51
6. GLYCOL SYSTEMS
6.1 Glycol Concentration

The system must be filled with water and the appropriate amount of glycol (either ethylene or pro-
pylene) inhibitors to protect against winter freeze-up and premature coil corrosion. 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 inter-connecting
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 – Downflow Units

Evaporator Model Standard Unit Volume In Energy Saver Unit Volume In
Gallons (Liters) Gallons (Liters)
GUWX-022XX
2.5 (9.46) 5.0 (18.92)
GUGX-022XX
GUWX-036XX
7.9 (30.0) 10.1 (38.2)
GUGX-036XX
GUWX-045XX
9.5 (35.9) 10.6 (40.1)
GUGX-045XX
GUWX-070XX
9.9 (37.4) 16.3 (61.7)
GUGX-070XX
GUWX-091XX
12.2 (46.1) 18.8 (71.2)
GUGX-091XX
GUWX-125XX
16.2 (61.3) 6.9 (86.7)
GUGX-125XX
6.3 Internal (Fluid) Volume – Upflow Units

Evaporator Standard Unit Volume In Gal- Energy Saver Unit Volume In
Model lons (Liters) Gallons (Liters)
GUWX-022XX 4.5 (17.03)
2.0 (7.57)
GUGX-022XX
GUWX-036XX 9.2 (34.8)
7.9 (30.0)
GUGX-036XX
GUWX-045XX 9.2 (34.8)
9.5 (35.9)
GUGX-045XX
52
GUWX-070XX
9.9 (37.4) 15.9 (60.2)
GUGX-070XX
GUWX-091XX
12.2 (46.1) 16.3 (61.7)
GUGX-091XX
GUWX-125XX
16.2 (61.3) 23.1 (87.4)
GUGX-125XX
NOTE: Risk of a leaking coil due to freezing and/or corrosion. Can cause
equipment and serious building damage.
NOTE: Risk of corrosion can cause equipment damage. Contact a water

consultant about water quality, corrosion and freeze protection requirements.
Water chemistry varies greatly by location, as do the required additives, called
inhibitors that reduce the corrosive effect of the fluids on the piping systems
and components. The chemistry of the water used must be considered, be-
cause water from some sources may contain corrosive elements that reduce
the effectiveness of the inhibited formulation. Preferably, surface waters that
are classified as soft and are low in chloride and sulfate ion content should
be employed. Proper inhibitor maintenance must be performed to prevent
corrosion of system components. Consult glycol manufacturer for testing
and maintenance of inhibitors.
Commercial ethylene glycol, when pure, is generally less corrosive to the

common metals of construction than water itself. It will, however, assume the
corrosively of the water from which it is prepared and may become increas-
ingly corrosive with use if not properly inhibited.
6.4 Internal (Fluid) Volume – Fluid Coolers
6.4.1 Fluid Cooler Information

The information regarding fluid cooler (or often referred to as a “dry cooler”) internal volume, the vol-
ume of the inter-connecting piping and the freezing point of aqueous solutions can be found in the
individual Fluid Cooler User Manuals which should be referred to for more complete details.
53
7. Variable Speed Compressor
7.1 Features
As the leader in variable capacity compressor technology in the data center industry responding to
environmental and energy challenges, Data Aire developed the gForce Ultra variable capacity com-
pressor CRAC unit. The compressor technology uses a brushless Interior Permanent Magnet (IPM)
design to provide higher efficiency. And it delivers efficiency across a wider range. A cooling solution
optimized for energy consumption and for power grid requirements. Thanks to a 4:1 modulation ratio,
the gForce Ultra can cycle from 25 to 100 RPS to provide greater savings.
Match exactly your cooling requirements to control temperature and humidity, critical for the best pro-
cess as well as product quality.
7.2 Oil Management

Insufficient oil level can be the result of oil depositing itself in pipes and heat exchangers. The oil
deposit can be returned to the crankcase by increasing velocity for short periods, at regular time inter-
vals or when the velocity is too low to ensure adequate oil return.
With oil return management functions that are built into the control system, these two oil return mech-
anisms can be programmed in the variable frequency drive (VFD).
With the oil return management function enabled, the VFD performs oil return by boosting the com-
pressor speed to an appropriate RPM for a selectable duration as programmed into the VFD param-
eters. This boost is performed at programmable fixed time intervals or if the compressor speed has
been less than 3000 RPM (50 rps) for too long which is again a programmable parameter, whichever
comes first. Therefore the maximum time between two consecutive oil return boosts is fully program-
mable.
7.3 Crankcase Heaters

A crankcase heater will minimize refrigerant migration caused by the large temperature gradient be-
tween the compressor and the remainder of the systems. When the compressor is idle, the oil tem-
perature in the sump of the compressor must be maintained at no lower than the 10⁰ F above the
saturation temperature of the refrigerant on the low pressure side. This ensures that liquid refrigerant
is not accumulating in the sump.
7.4 Oil Level

When the compressor is running under stable conditions the oil level must be visible in the sight glass.
The presence of foam filling the sight glass indicates large concentration of refrigerant in the oil and/or
presence of liquid returning to the compressor. The oil level can also be checked a few minutes after
the compressor is shut down, the level must be between ¼ and ¾ of the sight glass. When the com-
pressor is OFF, the level in the sight glass can be influenced by the presence of refrigerant in the oil.
Always use original Danfoss POE oil 160SZ from new cans. Top-up the oil while the compressor is
at idle. Use a Schrader connector or any other accessible connector on the compressor suction line
and a suitable pump.
7.5 VFD Drive

There are tremendous energy saving and application advantages available by applying a VFD drive
54
to compressor cooling. Variable speed control offers the ability to match the cooling capacity to the
actual need. Costs are reduced through direct energy savings of operating at a lower speed. The
drive can operate a variable capacity compressor over a wider range. Other advantages of the VFD
are limiting the number starts and reduced start system shock thus reducing peak energy demand
and system wear. Below is a figure showing the VFD control display and some general instructions
required to charge the unit and monitor any alarms.
The local control panel (LCP) for the VFD drive is the combined display and keypad on the front of the
unit. The LCP has several user functions:
• Start, stop, and control speed when in local control mode
• Display operational data, status, warnings and cautions
• Programming frequency converter functions
• Manually reset the frequency converter after a fault when auto-reset is inactive
55
7.5.1 Local Control for Charging
• Press the “Hand on” button. The display will show Hand Local Running.
• Use the  and  keys to move the cursor to the desired digit position, then use the and  keys
to increase or decrease the desired RPM setting. As you change the value, the compressor will
increase or decrease in speed.
• See example display below:
When done charging, press the “Auto on” key to return to normal operation controlled by the
dap4™ controller.
56
7.5.2 View Drive Alarms
• Press the Alarm log key
• Use the  and  keys to move the cursor through the various alarms.
• See example display below:
When done, press the Auto on key to return to normal operation controlled by the dap4™
controller.
NOTE: If more information is required, see the full operating manual for the
drive system.
57
8. CONTROLS
Refer to dap4 IOM for controls and control logic
58
9. MAINTENANCE/INSPECTION CHECKLIST
NOTE: Maintenance/inspection items are monthly unless otherwise specified.
MAINTENANCE/INSPECTION CHECKLIST
Evaporator Model No.: Evaporator Serial No.:
Technician: Date:
Temperature/Humidity set at _______ °F _______ % RH

Air Filters Air Distribution Section
___ Inspect and replace (if required) ___ Check restriction of grilles and discharge
louvers
___ Inspect grille area and ensure unre-
stricted
Electrical Section Controls
___ Inspect fuses ___ Check unit control operation
___ Inspect/tighten all wire connections Check operation of the following:
___ Inspect contactor operation ___ High water alarm
___ Check operation sequence ___ Pressure differential switch
___ Check calibration of change over ___ Fan current sensing switch
thermostat (Energy Saver system
only)
EC Plug Fan Section:
___ Check plug fan wheel movement to be free and clear of any debris
Record motor voltage Record motor amp draw
Fan#1 L1 _____ V L2 _____ V L3 _____ V L1 _____ A L2 _____ A L3 _____ A
Record fan wheel speed (RPM)
Fan#1 ______ Fan#2 ______ Fan#3 ______
59
Humidifier (Steam Generator) is equipped
___ Inspect drain valve/trap/drain line
___ Check for leaks (make-up water/hoses)
___ Check humidifier canister (replace if needed)
___ Check and clean fill strainer
___ Check operation
___ Record humidifier amp draw L1_____ L2 _____ L3 _____
Reheat Refrigeration Piping
___ Inspect element (and clean if required) ___ Check for lines (leaks/lines secure)
___ Check wiring ___ Check capillary lines
___ Record amps ______ A
Condensers (Water-Cooled)
___ Check for leaks
___ Entering/leaving water temperatures ENT ____°F LVG ____°F
Compressor (Monthly)
___ Check for oil leaks
___ Check compressor mounting
___ Inspect wire connection
Compressor (Quarterly) Compressor 1 Compressor 2
___ Record suction pressure ______ PSIG ______ PSIG
___ Record discharge pressure ______ PSIG ______ PSIG
___ Record superheat ______ °F ______ °F
___ Record sub-cooling ______ °F ______ °F
___ Check high pressure cut-out ______ PSIG ______ PSIG
___ Check low pressure cut-in ______ PSIG ______ PSIG
___ Check low pressure cut-out ______ PSIG
___ Record compressor amp draw ______ L1 ______ L1
______ L2 ______ L2
______ L3 ______ L3
60
Condensate Pan and Pump (if equipped) Air Cooled Condenser (if applicable)
___ Check for leaks ___ Inspect coil/clean if required
___ Check for debris ___ Inspect motor/motor mounts
___ Inspect/check float operation ___ Inspect fan blade(s)
___ Check pump operation ___ Check wiring
___ Inspect piping for leaks
Dry Cooler (if applicable) Glycol Pump (if applicable)
___ Inspect coil/clean if required ___ Glycol leaks (pump area)
___ Inspect motor/motor mounts ___ Pump operation
___ Inspect fan blade(s) ___ Auto air vent clean of mineral deposits
___ Check wiring
___ Inspect piping for leaks
Equipment Runtimes
Blower _______ hrs
Compressor #1 _______ hrs
Compressor #2 _______ hrs
Condenser _______ hrs
Reheat #1 (if equipped) _______ hrs
Humidifier (if equipped) _______ hrs
Dehumidification _______ hrs
Energy Saver (if equipped) _______ hrs
_______ Reset all to zero runtimes
61
10. CONTACT DATA AIRE
Address: Data Aire, Inc.
230 West Blueridge Avenue
Orange, CA 92865
Telephone: 714-921-6000
800-347-AIRE (2473) Toll Free
E-mail: Service@dataaire.com
Engineering@dataaire.com
Sales@dataaire.com
Fax: 714-921-6010 Main
714-921-6011 Engineering
714-921-6022 Parts Sales
Web Site: www.dataaire.com

Job/Unit Information:
Data Aire Job Number: ___________________________________
Evaporator Serial Number: ________________________________
Evaporator Model Number: ________________________________
Condenser/Fluid Cooler Serial Number: ______________________
Condenser/Fluid Cooler Model Number: ______________________
Date installed: _______ / _____ / 20_____
Installing Contractor: ____________________________________
62
63
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CONGRATULATIONS ON THE SELECTION OF A DATA AIRE PRECISION ENVIRONMENTAL

CONTROL SYSTEM. PROPER INSTALLATION, OPERATION AND MAINTENANCE OF THIS

NOTE: This manual is intended to assist trained service personnel by providing

WARNING: Service performed by unauthorized or unqualified technicians may

NOTE: Special care should be given to those areas where

improvement or to withdraw any design without notice.

1.1 Product Information..............................................................................................7

1.2 Model Identification..............................................................................................8

2.1 Installation Checklist..........................................................................................10

2.2 Room Considerations.........................................................................................10

2.3 Equipment Handling...........................................................................................10

2.5 Locating the Unit................................................................................................ 11

2.5.1 Downflow Units............................................................................................12

2.5.2 Upflow Units.................................................................................................12

2.7.1 Air Cooled Unit Piping.................................................................................14

2.7.2 Discharge Lines...........................................................................................14

2.7.3 Liquid Lines.................................................................................................15

2.7.4 Recommended Line Sizing, Air Cooled Units..............................................16

2.7.5 Connection Sizes, Air Cooled Units.............................................................17

2.7.6 Field Piping, Remote Condenser Above Evaporator...................................17

2.7.7 Field Piping, Remote Condenser Below Evaporator...................................18

2.7.8 Water/Glycol Cooled Unit Piping.................................................................18

2.7.9 Field Piping, Water/Glycol Cooled Units…………………………………… .19

2.8 Condensate Drain Piping...................................................................................21

2.9.1 Steam Generator Humidifier........................................................................22

2.10 Leak Testing.......................................................................................................23

3.1 Electrical Service................................................................................................25

3.2 Nameplate Ratings.............................................................................................25

3.4 Voltage Tolerance...............................................................................................25

3.5 Auxiliary Control Wiring......................................................................................26

3.6 Remote Shutdown..............................................................................................27

3.7 Remote Alarm Contacts.....................................................................................27

3.8 Condensate Pumps............................................................................................28

3.9 Condensate Probe.............................................................................................28

3.10 Water Sensing Cable (Optional).........................................................................28

3.11 Remote Temperature and Humidity Sensors (Optional).....................................28

3.12 Manual Override Switches.................................................................................29

3.13 Wiring Diagrams.................................................................................................29

3.14 EEV Connection.................................................................................................30

4. INSTALLATION OF REMOTE OUTDOOR HEAT EXCHANGER...........................31

5.1 General Charging Guidelines.............................................................................31

5.2 Triple Evacuation................................................................................................32

5.3 Voltage Phase Check.........................................................................................33

5.4 Air Cooled System Charging..............................................................................33

5.4.1 Constant Speed Compressor......................................................................33

5.4.2 Variable Capacity Compressor....................................................................34

5.5 Flooded System Charging..................................................................................38

5.5.1 Constant Speed Compressor......................................................................38

5.5.2 Variable Capacity Compressor....................................................................44

5.7 Check a Running Compressor...........................................................................49

5.8 Refrigerant Handling..........................................................................................49

5.10 Important Refrigeration Components.................................................................50

5.10.1 Variable Capacity Compressor with VFD.....................................................50

5.10.2 Electronic Expansion Valve.........................................................................50

5.10.3 High Pressure Cutout Switch.......................................................................50

5.10.4 Low Pressure Cutout Switch.......................................................................50

5.10.5 Liquid Line Solenoid Valve...........................................................................51

6.1 Glycol Concentration..........................................................................................52

6.2 Internal (Fluid) Volume – Downflow Units..........................................................52