gForce IR Installation, Operation and Maintenance Manual · However, shipping damage can occur and...

Data Aire, Inc.230 W. BlueRidge Avenue

Orange, CA 92865

www.dataaire.com

gForce IRInstallation, Operation

and Maintenance Manual

Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice.

Table of Contents

1.0 Introduction 1.1 Product Information ......................................................................................................... 4 1.2 Inspection ........................................................................................................................ 4 1.3 Paperwork........................................................................................................................ 5 1.4 Storage............................................................................................................................ 5 1.5 Equipment Handling ........................................................................................................ 5 1.51 Preparing the In-Row Cooling Unit .......................................................................... 5 2.0 Installation 2.1 Piping ............................................................................................................................... 6 2.2 Condensate Drain Piping ................................................................................................. 6 2.3 Steam Generator Humidifi er ........................................................................................... 6 2.4 Leak Testing ..................................................................................................................... 6 2.5 Water Connections .......................................................................................................... 7

3.0 Electrical Connections 3.1 Electrical Service ............................................................................................................. 8 3.2 Nameplate Ratings .......................................................................................................... 8 3.3 Grounding ........................................................................................................................ 8 3.4 Voltage Tolerance ............................................................................................................ 8 3.5 Remote Shutdown ........................................................................................................... 9 3.6 Remote Alarm Contacts ................................................................................................... 9 3.7 Condensate Pumps ......................................................................................................... 9 3.8 Condensate Probe ........................................................................................................... 9 3.9 Water Sensing Cable ....................................................................................................... 9 3.10 Rack Temperature Sensors ........................................................................................ 9 3.11 Sensor Location ....................................................................................................... 10 3.12 Installation Checklist................................................................................................. 10 3.13 Manual Override Switches ....................................................................................... 10 3.14 Adjusting Air Delivery ................................................................................................11

4.0 Controls 4.1 Powering the Unit ON/OFF ........................................................................................... 12 4.1.1 Accessing Menus/Passwords .............................................................................. 13 4.1.2 Changing the Service Level Password ................................................................ 14 4.1.3 Entering Menu Settings ....................................................................................... 15 4.1.4 Menu A - ON/OFF ................................................................................................ 15

Table of Contents - Continued

4.1.5 Menu B - Setpoints .............................................................................................. 16 4.1.6 Menu C - Clock/Scheduler ................................................................................... 18 4.1.7 Menu D - Input/Output ......................................................................................... 18 4.1.8 Menu E - Historical Data ...................................................................................... 18 4.1.9 Menu F - Information ........................................................................................... 19 4.1.10 Menu G - Network Confi guration ....................................................................... 20 4.1.11 Menu H - Calibrate Sensors ............................................................................... 21 4.1.12 Menu I - Manual Control .................................................................................... 23 4.1.13 Menu J - Factory Settings .................................................................................. 25 4.1.13 Menu K - Alarms and Limits ............................................................................... 25 4.1.14 Menu L - Confi gure I/O ...................................................................................... 33 4.2 Zone Master ................................................................................................................. 33

5.0 Control Logic 5.1 Introduction .................................................................................................................... 34 5.2 CW Valve Control .......................................................................................................... 34 5.3 Fan Control Logic .......................................................................................................... 34

6.0 Electronically Commutated Motors 6.1 Protective Features........................................................................................................ 36 6.2 Maintenance.................................................................................................................. 37

7.0 Filters ................................................................................................................................. 37

8.0 Electric Reheat ................................................................................................................... 37

9.0 Maintenance/Inspection Checklist....................................................................................... 38

6 Page gForce IR IOM

1.0 INTRODUCTION to the gForce IR from Data Aire, Inc.

1.1 Product Information

The gForce IR is a precision cooling unit. It is designed to be installed within high-density server racks that are placed in a hot aisle/cold aisle design. The air enters the unit from the rear (hot aisle) and is discharged into the cold aisle.

The unit provides cooling, reheat*, humidifi cation*, dehumidifi cation and air fi ltration.

The unit is provided with Data Aire’s dap4 microprocessor controller for precision control.

WARNING: There is no intent on the part of Data Aire, Inc. to defi ne local codes and statutes which may supercede common trade practices. The manufacturer assumes no responsibil-ity for their interpretation. Consult local building codes and the National Electrical Code for special installation requirements.

1.2 Inspection

This equipment has gone through a comprehensive inspection prior to its packaging and shipment to ensure that it arrives in excellent condition. However, shipping damage can occur and a visual inspection of the outer crating immediately upon delivery should be performed.

Note any external damage or other transportation damage on the freight carrier’s forms. Inspect the unit itself for internal damage. A claim should be fi led with the shipping company if the equipment is damaged or incomplete.

*Electric reheat and steam generator humidifi er are optional but only 24” or GICW-060xx model.

O C O

gForce IR IOM

WARNING: Freight damage claims are the responsibility of the purchaser. Action to recov-er losses should be fi led immediately. Please notify Data Aire of any claims.

1.3 Paperwork

Each Data Aire unit ships with start-up sheets that must completed. The start-up sheets are en-closed in a packet with the unit. The packet includes the warranty certifi cate, wiring diagrams, spe-cifi c component literature, warranty registration card and a copy of the unit’s Installation/Operation and Maintenance manual.

A manila tag is attached to the outside panel to indicate articles that have been packaged and shipped loose within the unit cabinet.

1.4 Storage

Your Data Aire equipment comes ready for immediate installation. In some instances it may be necessary to store the equipment for a period of time. If you must store the equipment it should be done in a dry area, out of the weather, protected from damage by other equipment in storage or transportation equipment and avoid frequent relocation.

1.5 Equipment Handling

Use a pallet jack or fork lift to move the Data Aire cooling unit. Make sure the forks are spread to their widest allowable width for proper balance. Do not lift the unit any higher than 4 inches off the ground. If necessary to lift higher than the suggested 4 inches, 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.

WARNING: Use care when moving. Improper handling could result in injury.

1.5.1 Preparing the In-Row Cooling UnitWARNING: Proper care should be taken when uncrating the unit. The packaging has wrapping bands with sharp edges that are under tension, crating has staples and splinters. Proper protective equipment should be worn by qualifi ed personnel. • Remove the metal strapping bands• Remove the wooden crating• Remove the protective plastic covering

WARNING: Before removing from the skid inspect the unit for any damage. Report any damage to the carrier and fi le a damage claim.

The unit is shipped with four zinc plated carbon steel ball casters to help move the unit once on the fi nished fl oor. Be sure the fl oor is clear of any debris or grit. The wheels are removable.

Leveling legs are shipped with the unit. The unit needs to be lowered and leveled with the leveling legs before piping and electrical wiring is installed.


2.0 Installation

2.1 Piping

Supply and return chilled water connections are sweat copper. All fi eld piping must be installed according to local codes. The piping must be properly assembled, supported and insulated. The piping should be properly insulated.

In raised fl oor applications the piping must be installed so that it does not create any resistance to airfl ow. The piping should be positioned in a horizontal plane not stacked one above the other.

Note: Isolation valves are recommended on both the supply and return chilled water lines.

WARNING: With any fl uid connection there is risk of leakage. Water leakage could result in property damage to mission critical equipment. A water drain connection is required. Units with optional steam generator humidifi ers will require an external potable water supply. Water leakage can result from improper installation and/or practices.

2.2 Condensate Drain Piping

Every unit has a ¾” copper stub provided for condensate removal. A union is recommended at the fi eld connection which will permit easy disconnection from the unit for cleaning.

A trap needs be built into the drain line to allow for proper drainage. Drain lines should be pitched downward not less than ¼” for every ten feet of horizontal run. Do not reduce the size of the drain line. Do not expose the drain line to freezing temperatures.

Some installations have no convenient means of allowing a gravity drain. In these applications, a condensate pump can be used. Optional condensate pumps are factory mounted and wired. Factory installed condensate pumps do not require a separate power source.

2.3 Steam Generator Humidifi er (optional - GICW-060xx 24” version only)

Steam generator humidifi ers with disposable cylinders are optional. The humidifi er make-up water should be brought to the humidifi er through the fi led connection opening using ¼” copper tubing. A compression fi tting is provided at the humidifi er.

A shut-off valve should be provided outside the cooler to allow disconnection for service. An in-line water pressure regulator should be (fi eld) installed. Water pressure should be set between 20 and 50 PSIG.

The humidifi er has a drain line at the bottom which is factory piped to the main condensate drain line. No additional fi eld piping is required.

2.4 Leak Testing

No installation is complete until the entire system has been checked for leaks. This includes water lines, compression and Shrader fi ttings. Check all humidifi er water make-up lines, condensate lines, condensate pumps and chilled water lines.

gForce IR IOM

Tightening of fi ttings and valves is the responsibility of the installing contractor.

2.5 Water Connections

Units may be ordered with top or bottom connections. Use copper tubing with support devices (supporting saddles, etc.). Insulate both the supply and return chilled water lines. Install shut-off valves (fi eld supplied) on the chilled water lines to ensure ease of maintenance and service.

An in-line strainer (fi eld supplied) is also recommended.


3.0 Electrical Connections

WARNING: The Data Aire cooling unit must be connected by a licensed and qualifi ed electri-cian. Risk of electrical shock could result in injury or death. Disconnect all remote electrical power supplies prior to working on the unit.

WARNING: The gForce IR has a plunger switch (kill switch), only on the GICW-060xx 24” model, that inhibits the low voltage power and component power (motors, humidifi er, reheat) when the front door is opened. It is located on the upper right hand side.

The GICW-030xx 12” have “hot swapable” fan power connections. To remove the fans simply take the four holding screws out and pull the fan out, using handles provided. The unit will remain pow-ered and operate. Remaining motors will operate and run unless power to the unit is powered off using the dap4 controller.

The GICW-060xx 24” electrical section for both models have two locking devices that require a fl at blade screwdriver to open.

Disconnect switches are optional. The disconnect switch when turned OFF will de-ener-gize the high voltage.

WARNING: Before proceeding with the electrical connections, make certain that the volts, hertz and phase correspond to that specifi ed on the unit electrical nameplate. Use copper conductors only.

3.1 Electrical Service

Check to be sure the service provided by the utility is suffi cient to handle the additional load imposed by this equipment.

3.2 Nameplate Ratings

Refer to the unit electrical nameplate for equipment electrical requirements. Minimum circuit am-pacity (MCA) also known as wire sizing amps, will dictate the minimum required wire gauge. Maxi-mum overcurrent protection (MOP) device amps will dictate the maximum circuit breaker or fuse size.

3.3 Grounding

The unit cabinet must have an uninterrupted true earth ground. An electrical ground wire of ad-equate 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 nameplate. Phase to phase imbalance must not exceed 3%. The local utility company should be contacted for improper line voltage. Deviation from voltage ratings can cause premature failures and possibly void unit warranties.

gForce IR IOM

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 respon-sibility of the installing contractor.

3.5 Remote Shutdown

Every Data Aire unit has remote shutdown contacts. These are intended for a fi eld supplied dry contact or switch to be wired across two terminals. When the contact or switch opens, the control circuit power is interrupted and the unit shuts down, including the control panel. The control circuit is 24 VAC and the fi eld provided contact or switch should have a minimum rating of 10 amps. A minimum of 18 gauge wire needs to be used.

The remote shutdown contacts are always terminals #1 and #2A on the terminal block designated TB1. The unit will ship with a factory installed metal jumper that connects terminal #1 to terminal #2A. Remove this clip prior to installing the fi eld wires.

3.6 Remote Alarm Contacts

The microprocessor control panel provides a remote alarm output contact that can be fi eld ac-cessed on terminals #11 and #13 of terminal block TB1. This is a Normally Open, Close on Alarm, dry contact, intended to be used in a control circuit not exceeding 5 amps at 24 VAC.

This programmable output contact will close on a failure and remain closed until the alarm is no longer present. Three additional alarm output contacts are available. The terminal designations for these alarm output contact pairs are #40 and #42, #43 and #45, and #48 and #50.

3.7 Condensate Pumps

Condensate pumps are optional. Factory mounted pumps are pre-wired. While no outside power source is required, fi eld piping is still a requirement. Factory installed condensate pumps are wired to display a “High Condensate Water Level” alarm.

3.8 Condensate Probe

A condensate probe for sensing underfl oor water is included with this unit. The probe is in a plastic bag with approximately 15 feet of coiled wire. The probe is typically placed below the unit in a loca-tion where water is likely to accumulate. Secure the attached wires where necessary.

WARNING: Failure to remove from the plastic bag and uncoil the length of wire attached to the condensate probe can result in a nuisance water detected alarm. Remove/disconnect the probe if it is not to be used.

3.9 Water Sensing Cable

Water detection cable is also available (as an option). The cable can sense moisture anywhere along its length. It is typically placed below the unit in a rectangular pattern that matches the perim-eter of the unit.


3.10 Rack Temperature Sensors

The unit is shipped with one (1) rack temperature sensor. Two additional optional rack temperature sensors are available. The sensor is shipped with 20 feet of wire and can be mounted on the adjoin-ing server racks (see illustration).

In addition there are supply (discharge) and return air sensor pre-mounted and wired in the unit.

3.11 Sensor Location

For optimum performance the sensor or sensors may be installed in a variety of locations. Sensor location should be determined after the unit is operational. Recommended rack locations include:

Sensor at the top of the server rack, In the highest density area of the rack, In the path of the entering airfl ow of the server rack.

(See section 5.2 CW Control Logic for operation) 3.12 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

3.13 Manual Override Switches

For testing and during start-up each gForce IR unit is provided with manual override slide switches. There are seven slide switches. One for each of the following functions:

Water Valve

Fan Speed

Humidifi er

Heat 1

Cool 2

Cool 1

Blower

gForce IR IOM

All automatic control is disabled but the safety switches remain functional. Simply slide the manual switches to energize the blower, compressor, humidifi cation, reheat and other functions (as appli-cable).

The fan speed of the EC (Electronically Commutated) motor can be adjusted from 0 – 10 volts by adjusting potentiometer at the left of the Fan Speed switch. The fan will turn 10% for each volt ad-justment. One volt equals 10%. At ten 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.

3.14 Adjusting Air Delivery

The gForce IR unit has cartridges that direct the discharge airfl ow direction.

The cartridges can be adjusted. Adjustments allow for either right, left or straight air discharge.

Right side only discharge air:

Adjust the vanes in the cartridges so that they point to the right. Make certain that the vanes are closed or pinched together in the front.

Left side only discharge air:

Adjust the vanes in the cartridges so that they point to the left. Make certain that the vanes are closed or pinched together in the front.

Front only air discharge:

Adjust the vanes in the cartridges so that they point straight ahead. Make certain that the vanes are closed or pinched together in the front.


4.0 Controls

Every gForce IR unit is shipped with a dap4 microprocessor controller. The unit is shipped with fac-tory default settings. The settings can be changed to meet the controlled space criteria. The dap4 consists of two main components: the control module and the display panel. The control module is located in the unit’s electrical panel. The display panel is mounted on the front door. The two are connected by special telephone type cable* harness. All data displayed on the display screen origi-nates from the control module. The display panel has a backlit LCD (liquid crystal display). There are six keys on the face of the display panel to retrieve or enter settings

* Note: If used, regular telephone cable will not operate. Factory supplied cable is required.

The Main Menu allows you to see the current unit status (temperature, relative humidity and operat-ing mode – cooling, humidifi cation, etc.).

4.1 Powering the Unit ON/OFF

WARNING: Before powering the unit ON, check that power is available and proper connec-tions have been completed

Note: The unit is shipped with the control power in the OFF (Off by Key) position

Display Alarm

Enter Menu

Return to previous screen or hold to turn On or OFF

Up

Enter/Select

Down

Button Functions

Allows viewing of active alarmsSilences audible alarmsResets active alarms

Allows scrolling to next screenAllows values changes (increase)

Allows entry to Main Menu Allows entry to MenusAdvances cursor

Return to previous screenHold fi ve seconds to turn ON or OFF

Returns to previous screenAllows value changes (decrease)

gForce IR IOM

Turn the disconnect switch to the ON position. The controller display keys and screen will illuminate and the processor will conduct a self-test (the screen will remain illuminated with no messages until the testing is complete). The self-test takes approximately 45 seconds. Once completed, the Main Menu screen will be displayed.

The Main Menu screen will display the unit type, date and time, and unit status. In addition, the screen will scroll and display the temperature, relative humidity and operating mode.

The Unit Status will indicate the unit: “OFFbyKEY”

The unit may be turned ON at any time by holding old the ESC key for approximately 5 seconds. The display will continue to scroll and display messages. At the same time the unit status is changed to “Unit On”. Once powered there will be a 5 – 600 second start delay indicated by “Time Before Start: XXs”.

Note: The start time delay is programmable from 5 – 600 seconds (by accessing Menu J – Factory Settings). The factory default setting at shipment is 5 seconds.

For initial programming of setpoints, alarms, delays, etc. it is not necessary to have the unit ON. With the unit in the “OFF by Key” mode, all settings are available to view and change (other than Menu J – Factory Settings and Menu L Confi gure Inputs/Outputs) if the proper password is entered.

Once the desired settings are complete, change the Unit to ON by pushing and holding the ESC Key for approximately 5 seconds.

4.1.1 Accessing Menus/Passwords

To access any Menu, a numerical password is required.

To enter the menu and Sub-Menu screens, press the MENU key on the display panel. A password will be requested. The password is a four digit entry (including 0). Units are shipped from the fac-tory with the password requirement bypassed to accommodate start-up and set-up.The display screen will have following message:

The Service Level Password setting from the factory is: 0000

Security Access

Insert Service/Factorylevel password: 0000


The curser will be fl ashing by the Security Access message at the top of the screen. Press the Enter key to move the cursor. The cursor will fl ash at the fi rst input (represented by a 0). Press the UP or Down keys to increase or decrease the value. Once the value is entered, press the ENTER key to move to the next input. Increase or decrease the value by pressing the UP or DOWN keys. Once the value is entered, press the ENTER key to move to the next input.

Once all four values have been entered, press the Enter key. If the password is incorrect, the follow-ing message will appear: Password Wrong! The cursor will return to the fi rst input value. Follow the same procedure to re-enter the password.

Once the correct password is entered and accepted, the Menus will display on the screen. Only those Menus allowed through the Service Password will be available. Use the UP or DOWN keys to scroll through the available. Use the UP or DOWN keys to scroll through the available Menus.

Note: Factory Level menus are for confi guring the unit. The dap4 controller is used for a variety of equipment types. The controller is based on the unit type, unit components and options. Under normal circumstances these menus should not be changed. If they need to be changed, please contact Data Aire engineering or service personnel.

4.1.2 Changing the Service Level Password

The Service Level password can be changed by doing the following:

Enter the Main menu by pressing the Menu key. You will be prompted to insert the Service Level password. Enter the current password.

• Press the Menu key. The screen will display the following message:

• Press the Enter key. The cursor will highlight the fi rst input. Change the input by pressing the UP or DOWN key. Once the selected number is displayed, press the Enter key to move to the next input. Repeat the same steps for each input.

After the last input has been entered, press the Menu key to return to Main Menu. The new pass-word is stored.

Security Access

Change service levelPassword (PWI): 0000

gForce IR IOM

4.1.3 Entering Menu Settings

Note: The dap4 control panel is used on a variety of Data Aire equipment types including the gForce IR. Some Menus and Menu screens will appear that are not applicable to the gForce IR. In this document those Menu screens will be noted with the following message: Disregard this Menu – it is not applicable to in row cooling units.

4.1.4 Menu A – ON/OFF

Menu A allows the unit power to be switched from ON to OFF and from OFF to ON (the Service level password is required).

• Enter Menu A by pressing the MENU key. Use the UP or DOWN keys to scroll through the menus. Press the UP or DOWN key until “A. On/Off” is highlighted.

• Press the Enter key.

The following will appear on the display screen:

Hold ESC for 5 seconds to turn unit ON or OFF

The cursor will be fl ashing at the upper left hand corner of the screen. Press the ENTER key. The cursor will move to the “Change to: “SWITCH OFF”. Press either the UP of DOWN button to change the status. Press the ENTER key to save the setting.

• If selecting SWITCH OFF the STATUS will change to: OFFbyKey. The unit will be OFF• If selecting SWITCH ON the STATUS will change to: UnitON. The unit will be ON• When switching from the SWITCH OFF selection to the SWITCH ON (and pressing the

ENTER key), the following message will appear: Time Before Start: XXs

Note: The start time is a programmable time delay. It can be programmed from 5 to 600 seconds (see Menu J – Factory Settings)

Once the selection is made, to leave MENU A, press the MENU key. The Main Menu screen will continue to display other menus. To view any of these menus scroll to the desired menu. Press the ENTER key. If you choose to return to the main screen, press the ESC key.

On/Off Unit

Start-up Delay: 5sStart-up Mode: OffStatus: Unit On


4.1.5 Menu B - Setpoints

MENU B allows viewing and changing of Setpoints (Service Level password is required for entry)

• Press the UP or DOWN key until “B. Setpoint” appears and is highlighted. Press the EN-TER key.

• Use the UP or DOWN key to scroll through the screens. Menu B has two screens.

The following screen will appear:

This is for the cooling temperature setpoint settings (to control the chilled water valve):

Note: The Temp setpoint range is from 45.0°F to 105.0°F (factory setting is 72.0°F)

The Temp deadband range is from 2.0°F to 5.0°F (factory setting is 2.0°F)

The Stage-to-Stage value is not applicable for CW in row cooling units

To change the values press the Enter key to move the cursor to the desired input (Temp Setpoint). The cursor will fl ash next to the current entered value.

Press the UP or DOWN key to change the value. Once the value has been changed to the desired value, press the ENTER key. The cursor will move to the next input (Temp Deadband).

Change the value (if required) using the same procedure or press the ENTER key to return the cur-sor to the top of the screen (it will fl ash next to the title – Rack Temp Setpoints).

To see the next screen, press the DOWN key.

The following will appear on the fi rst Menu B screen (values are for reference only):

This is for the rack temperature setpoints. This will control the fan motor modulation.

Setpoints

Temp Setpoint: 72.0oFTemp Deadband: 2.0oFStage-To-Stage: 0.3oF

Rack Temp Setpoints

Temp Setpoint: 72.0oFTemp Deadband: 2.0oF

gForce IR IOM

Note: The Temp setpoint range is from 45.0°F to 105.0°F (factory setting is 72.0°F)

The Temp Deadband range is from 2.0°F to 5.0°F (factory setting is 2.0°F)

To change the values press the Enter key to move the cursor to the desired input (Temp Setpoint). The cursor will fl ash next to the current entered value.

Press the UP or DOWN key to change the value. Once the value has been changed to the desired value, press the ENTER key. The cursor will move to the next input (Temp Deadband).

Change the value (if required) using the same procedure or press the ENTER key to return the cur-sor to the top of the screen (it will fl ash next to the title – Rack Temp Setpoints).



Humidity Setpoints

Hum Setpoint: 50.0%Hum Deadband: 3.0%

Note: The hum setpoint range is from 25% to 70% (factory setting is 50%)

The hum deadband setpoint range is from 1% to 15% (factory setting is 2%)

Follow the same steps as detailed for Temperature Setpoints to make any desired changes



Disregard this Menu – it is not applicable to in-row cooling units.

Press the MENU key to return to the MAIN MENU

Energy Saver

Set Point: 72.0oFDeadband: 3.0oFChange Over: 2.0oF


4.1.6 Menu C – Clock/Scheduler

Disregard this Menu – it is not applicable to in-row cooling units.

4.1.7 Menu D – Input/Output

This is a view only menu. The values are factory set and only if instructed by Data Aire engineering or service personnel should these be changed.

4.1.8 Menu E – Historical Data

Menu allows viewing of alarms, component runtime hours and re-setting of runtimes. Alarms will be displayed by the alarm name and the time/date of occurrence. In addition, it will display the tem-perature and humidity at the time of the alarm.

The following will appear on the fi rst Menu E screen (values are for reference only):

Press the UP or DOWN key to view additional alarms.

Press the ENTER key to return to the title line.

Press the DOWN key to Run Hours and Reset

The following will appear on the fi rst Menu E screen (values are for reference only):

This screen (and the following two screens) gives you the option to reset the runtimes. Press the ENTER key to move the cursor over the No column. Press the Up or Down key to change the set-ting for No to Yes. When changing from No to Yes, the runtime will be erased to 0000.

Press the ENTER key to move the cursor. Follow the same procedure until all desired changes are made. Return the cursor to the title line (at the top of the screen) by pressing the ENTER key.

3:53:00 9/25/812-> Scroll Up/Down

Air Pr Sns Fail

Humidity: 41%Return Air: 75.8oF

Run Hours 1 Reset

Blower: 0000 No

Comp1: 0000 NoComp 2: 0000 NoComp 3: 0000 NoComp 4: 0000 No

gForce IR IOM

Note: This screen and the subsequent two screens will have information not applicable to in- row cooling units.

With the cursor fl ashing on the title, press the Down key to view the next screen

The following will appear on the second Menu E screen (values are for reference only):


With the cursor fl ashing on the title, press the Down key to view the next screen

The following will appear on the third Menu E screen (values are for reference only):


You also have the option to reset all runtimes (Screens 1 thru 3) by moving the cursor to “Reset All Runtimes”.To exit Menu E, with the cursor on the title line, press the MENU key.

Advance to Menu F (Information) by pressing the Down key.

4.1.9 Menu F – Information

This is a view only menu. Menu entry requires a service password to enter.

There are three screens – two with information detailing the processor version and data. The third screen details unit information including model number, serial number and Data Aire job number.

Run Hours 2 Reset

Htr 1: 0000 NoHtr 2: 0000 NoHtr 3: 0000 No

Humidify: 0000 NoDehum: 0000 No

Run Hours 3 Reset

Engy Svr: 0000 NoCW Cool: 0000 NoCond Aux: 0000 No

Reset All Runtimes: No


To view the screens, press the Down key. The cursor will not move as this is a view only screen. When calling for technical assistance please have the serial number from the Unit Identifi cation screen.

Press the Menu key to exit Menu F

4.1.10 Menu G – Network Confi g

This menu allows programming of available protocols. Menu entry requires a service password. This is a factory set menu dependent on whether optional communication cards were ordered.

The following will appear on the screen (values are for reference only):

Note: If N/A has been selected (no communication card ordered), this will be the only screen viewed. If a protocol has been selected, additional screens will appear as detailed.

The following protocols are available:

MODBUS MODBUS EXT (future use) BACnet TCP/IP BACnet MSTPLON

The following screen will appear when MODBUS protocol is selected:

The following screen will appear when LON protocol selected:

BMS Configuration

BMS PORT 1Protocol: N/ABMS PORT 2Protocol: N/A

Heartbeat: Ok: No

BMS Configuration

BMS PORT 1Address 1BMS PORT 19200

pp p

BMS Configuration

BMS PORT 1Protocol: LONBMS PORT 2Protocol: N/A

Heartbeat: OK No

BMS port 2 is for factory use only!

gForce IR IOM

The following screen will appear when BACnet TCP/IP protocol is selected:

The following screen will appear when BACnet MSTP protocol is selected:

Press the MENU key to exit Menu I

Press the ENTER key to advance to Menu H – Calibrate Sensors

4.1.11 Menu H – Calibrate Sensors

Menu H allows calibration of the installed unit sensors (if required). The service level password is required for entry.

Press the ENTER key

The following screen will be displayed (values are for reference only):

Press the ENTER key to advance the cursor. The cursor will fl ash by the Offset value. Press the Up or Down key to change the Offset value.

BMS Configuration

BMS PORT 1Protocol: BACnet TCP/IPBMS PORT 2Protocol: N/A

Heartbeat: Ok: No

BMS Configuration

BMS PORT 1Protocol: BACnet MSTPBMS PORT 2Protocol: N/A

Heartbeat: Ok: No

Analog InputHumidity Sensor

Input B01

Offset 0.0

Value 43.7


An independent calibrated meter should be used to verify humidity before changing Offset.

Press the ENTER key. The cursor will advance to the title page. The Offset will be displayed and the Value will automatically change adding or subtracting the Offset.

The following screen will be displayed (values are for reference only):The cursor will fl ash by the Offset value. Press the Up or Down key to change the Offset value.



With cursor on the title, Press the Down key to advance to the next screen.


The cursor will fl ash by the Offset value. Press the Up or Down key to change the Offset value.



Press the MENU key to exit Menu H – Calibrate Sensors

Press the ENTER to advance to Menu I – Manual Control

Analog InputDiff Air Pressure

Input B07

Offset 0.000

Air Press: 0.000” wtr

Analog InputRack #1 Temp

Input B05

Offset 0.0

Value 74.4oF

gForce IR IOM

4.1.12 Menu I – Manual Control

Menu I allows manually running different unit components (the Service Level password is required). This menu should be used during service of the unit.

Press the ENTER key.


Note: The “Return to Auto” is programmable from 10 to 300 seconds. Once the set time has elapsed the functions will return to normal programmed operation (the default is 60 seconds).

Each component can be manually tested. Press the ENTER key to move the cursor to the selected component. To change from Auto (automatic) to Man (manual) press the Down key. To change from Off to On press the Down key.

Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the Down key.




Manual Output Mgnt. 1Return to Auto: 60s

Blower Auto OffCompressor 1 Auto OffCompressor 2 Auto OffCompressor 4 Auto Off

Manual Output Mgmt. 2

Humidifier Auto OffStatus Rely Auto OffCond Aux Rly Auto OffReheat 1 Auto OffReheat 2 Auto OffReheat 3 Auto Off





The following screen will be displayed (values are for reference only):Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the Down key.

The following screen will be displayed (values are for reference only):Move the cursor to the title block by pressing the ENTER key stepping through all the inputs. To return to the main Menu press the ESC key or to view the following screen press the Down key.

Manual Output Mgmt. 3

Energy Saver Auto OffAlarm 1 Auto OffAlarm 2 Auto OffAlarm 3 Auto OffAlarm 4 Auto OffDrain Auto Off

Analog Output 1Chilled Water ValveMode: Auto

Manual Value: 0.00 vdc

Output: 0.00vdc

Analog Output 3 Fan Speed Mode: Auto


Output: 0.00vdc

gForce IR IOM




Press the ENTER key to return to the main Menu.

Press the Down key to advance to Menu J – Factory Settings

4.1.13 Menu J – Factory Settings

Menu J is for setting the control to the type equipment and options ordered. This requires the Fac-tory Level password and entry should be limited to Data Aire factory and service personnel.

See the dap4 Operation Manual (dap4-IOM-0811) for details – available on the Data Aire web-site (www.dataaire.com).

Press the ENTER key to return to the main Menu.

Press the Down key to advance to Menu K – Alarms and Limits

4.1.14 Menu K – Alarms and Limits

Menu K is for the setting control alarms, limits, alarm enunciation mode, and to confi gure optional and custom alarms. Requires Service level password.

Press the Down key to advance to Menu K – Alarms and Limits

Analog Output 4 Optional #1 Mode: Auto


Output: 0.00vdc

Analog Output 5 Chilled Water Valve Mode: Auto


Output: 0.00 vdc



Press the ENTER key to move through the alarm/message inputs.

Press the Up or Down keys to change the alarm/message.

The following selections are available:

Audio Mode: None (factory setting) Full On Long Beep Short Beep

Pwr-Up: Auto, No Alarm (factory setting) Auto, With Alarm Man, Clr Alarm

Maint Due Msg: None (factory setting) 1 – 1000 hours

Once the selections have been made, with the cursor on the title line, Press the Down key to ad-vance to the next screen




Alarm Setting Audio Mode: NonePwr-Up: Auto, No-Alarm

Maint Due Msg: None

Alarm SettingsComp Short Cycle: YesFloor Water AlarmAction Alarm OnlyReset Alarm Log: NoAlarm Screen Contact:No Contact Message

gForce IR IOM


Comp Short Cycle: Yes or No (Yes - factory setting)

Floor Water Alarm: Alarm Only (factory setting) Shutdown Unit Lockout Comps

Reset Alarm Log: Yes or No (No – factory setting)

Alarm Screen Contact: No Contact Message (factory setting) Service Company Maint Engineer Data Proc Mngr Custom Message (factory installed)






No Water Flow Action: Alarm Only (factory setting) Turn Compressors Off

Wtr Flow Alm Dly: 5 to 190 seconds (5 - factory setting)

Air Flow Alm Dly: 5 to 180 seconds (5 – factory setting)


Flow Alarm

No Water Flow Action: Alarm Only

Wtr Flow Alm Dly: 5sAir Flow Alm Dly: 5s






Firestat: 100 – 150°F (factory setting is 100°F)

Hi Temp Alarm: Yes or No (factory setting is Yes)

Set Point: 70 - 90°F (factory setting is 80°F)

Lo Temp Alarm: Yes or No (factory setting is Yes)

Set Point: 55 - 75°F (factory setting is 60°F)

Note: If No is selected for the Hi or Low Temp, the setpoint will not be displayed.





Return Air Alarms

Firestat Setpoint: 100oF

Hi Temp Alarm: Yes Set Point: 80oFLo Temp Alarm: Yes Set Point: 60oF

Humidity Alarms Hi Humidity Alarm: Yes Set Point 60%

Lo Humidity Alarm: Yes Set Point 40%

gForce IR IOM


Hi Humidity Alarm: Yes or No (factory setting is Yes)

Set Point: 35 – 90% RH (factory setting is 60%)

Lo Humidity Alarm: Yes or No (factory setting is Yes)

Set Point: 10 – 65% RH (factory setting is 40%)

Note: If No is selected for the Hi or Low Humidity, the setpoint will not be displayed.Once the selections have been made, with the cursor on the title line, Press the Down key to ad-vance to the next screen

The following screen will be displayed (values are for reference only):Press the ENTER key to move through the alarm/message inputs.



Alarm Number 1 Alarm Number 2 SEE TAG INSIDE DOOR SEE TAG INSIDE DOOR REHEAT INHIBITED REHEAT INHIBITED HUMIDIFIER INHIBITED HUMIDIFIER INHIBITED REHEAT & HUM INHIBIT REHEAT & HUM INHIBIT UNIT IN STBY UNIT IN STBY UPS ON-CHK MAIN PWR UPS ON-CHK MAIN PWR STANDBY PUMP ON STANDBY PUMP ON CHECK HUMIDIFIER CYL CHECK HUMIDIFIER CYL FAN MOTOR OVERLOAD FAN MOTOR OVERLOAD Custom Message Custom Message POWER A OPERATING POWER A OPERATING POWER B OPERATING POWER B OPERATING POWER A AVAILABLE POWER A AVAILABLE POWER B AVAILABLE POWER B AVAILABLE

Note: Some alarm messages require optional devices

Alarm InputsCustom alarm MessageAlarm #1 (D1-13)SEE TAG INSIDE DOOR

Alarm #2 (D1-14)SEE TAG INSIDE DOOR









Alarm Number 3 Alarm Number 4 SEE TAG INSIDE DOOR SEE TAG INSIDE DOOR REHEAT INHIBITED REHEAT INHIBITED HUMIDIFIER INHIBITED HUMIDIFIER INHIBITED REHEAT & HUM INHIBIT REHEAT & HUM INHIBIT UNIT IN STBY UNIT IN STBY UPS ON-CHK MAIN PWR UPS ON-CHK MAIN PWR STANDBY PUMP ON STANDBY PUMP ON CHECK HUMIDIFIER CYL CHECK HUMIDIFIER CYL FAN MOTOR OVERLOAD FAN MOTOR OVERLOAD Custom Message Custom Message POWER A OPERATING POWER A OPERATING POWER B OPERATING POWER B OPERATING POWER A AVAILABLE POWER A AVAILABLE POWER B AVAILABLE POWER B AVAILABLE


Alarm InputsCustom Alarm MessageAlarm #1 (D1-15)SEE TAG INSIDE DOOR

Alarm #2 (D1-16)SEE TAG INSIDE DOOR

gForce IR IOM


Alarm Output Function 1

Alarm 1 Alarm 2 Alarm 3 Alarm 4CW Sensor Yes or No Yes or No Yes or No Yes or NoDA Sensor Yes or No Yes or No Yes or No Yes or NoFan Ovld Yes or No Yes or No Yes or No Yes or NoSmoke Yes or No Yes or No Yes or No Yes or NoCond Wtr Yes or No Yes or No Yes or No Yes or NoFirestat Yes or No Yes or No Yes or No Yes or No




Alarm 1 Alarm 2 Alarm 3 Alarm 4C1 Hi Pr Yes or No Yes or No Yes or No Yes or NoC1 Low Pr Yes or No Yes or No Yes or No Yes or NoC2 Hi Pr Yes or No Yes or No Yes or No Yes or NoC2 Low Pr Yes or No Yes or No Yes or No Yes or NoShort Cycl Yes or No Yes or No Yes or No Yes or NoMaint Tmr Yes or No Yes or No Yes or No Yes or No




Alarm 1 Alarm 2 Alarm 3 Alarm 4Hi Humid Yes or No Yes or No Yes or No Yes or NoLow Humid Yes or No Yes or No Yes or No Yes or NoHumidifi er Yes or No Yes or No Yes or No Yes or NoDA Low T Yes or No Yes or No Yes or No Yes or NoRA Low T Yes or No Yes or No Yes or No Yes or NoRA Hi Temp Yes or No Yes or No Yes or No Yes or No





Alarm 1 Alarm 2 Alarm 3 Alarm 4Override Yes or No Yes or No Yes or No Yes or NoAir Flow Yes or No Yes or No Yes or No Yes or NoWtr Flow Yes or No Yes or No Yes or No Yes or NoPower Up Yes or No Yes or No Yes or No Yes or NoFloor Wtr Yes or No Yes or No Yes or No Yes or NoHum Inhbt Yes or No Yes or No Yes or No Yes or No




Alarm 1 Alarm 2 Alarm 3 Alarm 4Heat Inhbt Yes or No Yes or No Yes or No Yes or NoFilter Yes or No Yes or No Yes or No Yes or NoManl Ovrd Yes or No Yes or No Yes or No Yes or NoHum Sensor Yes or No Yes or No Yes or No Yes or NoRA Sensor Yes or No Yes or No Yes or No Yes or No“See Tag” Yes or No Yes or No Yes or No Yes or No




Alarm 1 Alarm 2 Alarm 3 Alarm 4Unit Stdby Yes or No Yes or No Yes or No Yes or NoUPS is On Yes or No Yes or No Yes or No Yes or NoStby Pump Yes or No Yes or No Yes or No Yes or NoHum Cyl Yes or No Yes or No Yes or No Yes or NoCstm Msg 1 Yes or No Yes or No Yes or No Yes or NoCstm Msg 2 Yes or No Yes or No Yes or No Yes or No


gForce IR IOM



Alarm 1 Alarm 2 Alarm 3 Alarm 4Cstm Msg 3 Yes or No Yes or No Yes or No Yes or NoCstm Msg 4 Yes or No Yes or No Yes or No Yes or NoC1 Lockout Yes or No Yes or No Yes or No Yes or NoC2 Lockout Yes or No Yes or No Yes or No Yes or No

Once the selections have been made, with the cursor on the title line, Press the MENU key to return to the Main menu

4.1.15 Menu L – Confi gure I/O

Menu L is for setting the control to the type equipment and options ordered. This requires the Fac-tory Level password and entry should be limited to Data Aire factory and service personnel.

See the dap4 Operation Manual (dap4-IOM-0811) for details – available on the Data Aire website (dataaire.com).

4.2 Zone Master

gForce IR units with optional Zone Master control will be shipped with a supplemental manual detail-ing programming and individual screens on the dap4 controller.


5.0 Control Logic

5.1 Introduction

The following describes the implementation of the chilled water gForce IR logic with dap4 control-ler:

5.2 CW Valve Control

The chilled water valve for the gForce IR is the default to be controlled by supply air temperature. In this mode the chilled water valve is modulating based on the control loop feedback PI (Propor-tional Integral loop).

In the dap4 control menu Menu J – Factory Settings/Discharge Air PID screen), Band and Integra-tion Time are seen. Band is the inverse of Proportional; the higher the band the slower the valve responds to a change in temperature. Integration Time is the same as the integral term. The higher the Integration Time, the closer the supply temperature will reach setpoint. However, if it is too high it could cause the system to be unstable.

The CW valve can also be controlled by return temperature.

5.3 Fan Control Logic

Unit is factory programmed with “Mod to Rack” mode into the chilled water fan mode selection (Menu J – Factory Settings). “Mod to Rack” is the default control logic.

In this mode the fans will be controlled based on the maximum rack temperature. A single sensor is standard. Two additional sensors are available as an option. If additional sensors are installed, the control logic will be based on the highest value.

The fan will operate on rack air SP (Setpoint) and DB(Deadband) as follows:

• When the Maximum Rack Temperature is increasing:

If the Maximum Rack Temperature is greater than the Rack Temperature SP plus the (DB), the fans will start to ramp up from minimum allowable speed.

If the Maximum Rack Temperature is greater than or equal to Rack Temperature SP plus DB plus 1°F, the fans will run at maximum speed

• When the Maximum Rack Temperature is decreasing:

If the Maximum Rack Temperature is less than the Rack Temperature SP plus 1°F, the fans will start to ramp down from allowable speed.

If the Maximum Rack temperature is less than or equal to Rack Temperature SP, the fans will run at minimum speed.

gForce IR IOM

There are other selections available. These can be used to customize the unit to individual choic-es. Consult Data Aire engineering for further details.

Constant Fan: In this mode, the fan speed can be set at the required speed and remains fi xed at that speed. Field adjustment is available via the front display panel and can be manually adjusted.

Constant Static Pressure Control is an optional setting in which the fan proportionally increases or decreases the speed to maintain a constant static pressure set-point in the controlled space. This feature requires an optional differential pressure transmitter to measure and control the static pressure of the controlled space.

Proportional Fan Speed Control Based on the CW Valve Action is an optional setting in which the chilled water valve opens and closes, and the fan speed modulates proportionally based on the CW valve action.

Fan Speed Controlled by BMS is an optional setting in which the fan speed is completely con-trolled by the BMS. The dap4 controller will change (normally increase) the fan speed during humidifi cation and dehumidifi cation cycles but other than these cycles, the BMS controls the fan speed.

Fan Speed Controlled by Return Air Temperature: The dap4 controller is set for fan speed control based on return air (RA) temperature. As the RA temperature rises, the fan will start at the minimum speed and increase by 10% for every 0.1 degree F above RA Temp setpoint plus RA Temp deadband. This feature is only available on CW equipment and requires an optional return air temperature sensor.


6.0 Electronically Commutated Motors

Three electronically commutated (EC) motors with “plug fans” are standard on all GICW-060xx units. On the GICW-030xx there are six electronically commutated motors with hybrid axial fans.

Note: The plug fan modules are powered by high voltage input line power (i.e. 208/230/1PH/60HZ, 208-230V/3PH/60HZ or 460V/3PH/60HZ.)

Fan speed is factory set. The motor speed will vary with a change in the rack temperature.

6.1 Protective Features

EC motors have built in protective features that include the following:

Over-Temperature protection of the (motor) electronics, Over-Temperature protection of the motor, Locked rotor protection, Phase failure protection, Under voltage detection, Short circuit protection.

If any of the conditions exist, the motor stops electronically and an alarm (FAN FAILURE) will be indicated on the unit’s controller screen. The remaining motors will increase in speed trying to maintain the units CFM (airfl ow).

The motor will not start-up automatically. To reset, the power supply must be switched to OFF for a minimum of twenty (20) seconds.

If for any reason the rotor is blocked, the motor will electronically switch off. Before looking for blockage make certain to power down the unit. Once the blockage is cleared the motor will auto-matically restart when powered on.

If there is an alarm condition indicated as “NO AIRFLOW”, all active functions (cooling, heating and humidifi cation will stop until the alarm is cleared.

EC motors have an under voltage protection. If the power supply voltage falls below 150 VAC/3Ø (for 230 volt motors) 290 VAC/3Ø (for 460 motors) for a minimum of fi ve (5) seconds, the mo-tor will automatically switch off and an alarm condition (NO AIRFLOW) will be energized and displayed. If the power supply voltage returns to the correct values, the motor will automatically restart.

Note: The unit’s control panel (dap4) has a time delay before the NO AIRFLOW alarm is ener-gized. It is adjustable from 5 to 180 seconds (in 5 second increments). On site where a voltage problem is known to exist, the delay can be adjusted to eliminate “nuisance” alarms until the prob-lem is corrected (in Menu K – Alarms and Limits).

gForce IR IOM

6.2 Maintenance

Maintenance is not required on EC motor/plug fan modules. The motors are sealed, have mainte-nance free ball bearings and permanent lubrication. The only acceptable service is replacement.

7.0 Filters

There are three fi lters in the return end of the cooling unit (facing the hot aisle). There is a hinged access door for easy access. The fi lters are easily removed for maintenance. The fi lter size are 20”x25”x2” (MERV 8 rating).

8.0 Electric Reheat (optional - on GICW-060xx 24” only)

There are three reheat elements. The reheat elements are attached to the motor assembly. Each element is 2 kW in capacity, for a total capacity of 6 kW. The reheat is single stage (all three will operate at once). Each heater has an auto resetting and a “one-time” blow temperature limit switch. The auto resetting cuts out at 110°F (43.3°C) and comes back at 90°F (32.2°C). The “one time” blow switch cuts out at 165°F (73.9°C). If tripped, the “one time switch” needs to be replaced.

9.0 Maintenance/Inspection ChecklistUnit Model Number: ____________________

Unit Serial Number: ____________________

Air Filters Motor/Blower ____ Inspect and replace as required ______ Check that fan moves freely ____ Inspect return air grille of restrictions ______ Check motor mounting

Electrical Section Water Lines ____ Inspect fuses ____ ___Check piping for leaks ____ Inspect wire connections _______Check water connections for leaks ____ Inspect contactors

Condensate Pan Reheat ____ Check for debris _______Inspect elements (clean if required) ____ Inspect/check fl oat operation _______Check wiring ____ Check pump operation

Controls Humidifi er ____ Control type: dap4 _______Inspect drain valve/trap/drain line ____ Check unit control operation _______Check for leaks (make-up water) ____ Check operation of the following _______Check humidifi er cylinder & replace if required ____ High water alarm _______ Check operation ____ Pressure differential switch Record amp draw ____ Air fl ow switch L1 ______ L2 ______ L3 ______

230 W. BlueRidge AvenueOrange, CA 92865

800-347-2473

www.dataaire.com e-mail: [email protected]

A Member of the CS Group of Companies

© 2012 Data Aire, Inc.

Data Aire, Inc. reserves the right to make design changes for the purpose of product improvement or to withdraw any design without notice.

gForce IR IOM

gForce IR Installation, Operation and Maintenance Manual · However, shipping damage can occur and...

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