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Johnson Controls DSH024C Series, Installation Manual

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Johnson Controls DSH024C Series Installation Manual Download Page 8

Nomenclature

Note:

1.  Evaporator and condenser motor VFD option available only on 8 ton units and up.
2.  Evaporator motor VFD standard on 8 ton units and up.
3.  Condenser VFD not available in 575V.
4.  Evaporator motor without VFD available only on 2, 3, 4 and 5 ton.

Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller

8

Johnson Controls

Summary of Contents for DSH024C Series

Page 1: ...umber 145 32 IOM5 321 Supersedes 145 32 IOM5 1220 Installation Guide Issue date 2021 03 22 Johnson Controls Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller ...

Page 2: ...2 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 3: ...ata 19 Typical service clearances 23 Unit corner weights 25 Ductwork 26 Louver sizing guidelines 26 Electrical wiring 27 Packaged unit 27 Split system 27 Low voltage wiring 27 Typical wiring schematics 28 Fan performance 32 Motor and pulley data 35 Blower speed adjustment 36 Adjusting the blower speed 36 Low ambient damper 36 Airside economizer ASE 38 Sequences of operation 38 Air temperature sens...

Page 4: ... service 49 Evaporator and condenser coils 49 Refrigerant circuits 49 Blowers 49 Drive belts 49 Filters 49 Appendix A Wiring diagrams 51 Appendix B SEC parameters for DSH024C DSH120C units 58 R 410A Quick reference guide 63 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 4 Johnson Controls ...

Page 5: ...als possess independent training that will enable them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood the on product labels this document and any referenced materials This individual shall also be familiar with and comply with all applicable industry and governmental standards an...

Page 6: ... and operating service personnel to verify the applicability of these documents to the equipment If there is any question regarding the applicability of these documents rigging lifting and operating service personnel should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the equipment Revision not...

Page 7: ... for D Series DSV DSH Air Cooled Self Contained Units C Generation 145 13 NO2 Smart Equipment Controls SEC Parameters for DSH Units Style C 145 32 IOM5 LS01 General Piping Recommendations and Refrigerant Line Length for Split System Air Conditioners and Heat Pumps 247077 UAD H 0209 Technical support If Technical Support is required please contact the Product Technical Support team at 877 329 7430 ...

Page 8: ...units and up 2 Evaporator motor VFD standard on 8 ton units and up 3 Condenser VFD not available in 575V 4 Evaporator motor without VFD available only on 2 3 4 and 5 ton Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 8 Johnson Controls ...

Page 9: ... installed on the corner post in the condenser section of the unit The VFD on the condenser allows operation to 0 0 F ambient which is needed to maintain a proper refrigerant head pressure CAUTION Only qualified personnel should perform installation and service of this equipment Pre installation inspection of equipment All units are factory tested to ensure safe operation and quality assembly The ...

Page 10: ...ing area Occupants may object to common vibration and sound levels associated with the unit WARNING Failure to allow adequate space between units condenser intake and discharge may result in poor unit performance and possible unit failure Install thermostats air supplies and returns so that each unit operates only on an individual unit control To assure fast drainage of the condensate run off the ...

Page 11: ...actory split with a nitrogen holding charge only No refrigerant shut off coupling valves are included DANGER Factory nitrogen holding charge is 200 psig This pressure must be released from the evaporator and condenser section BEFORE cutting any refrigerant lines for installation N is for installations where the unit is installed as a split system Separate condenser and evaporator sections facilita...

Page 12: ...ent point of the rods to the building structure is sufficient to support the unit weight To ensure efficient condensate drainage the unit can be pitched towards the evaporator end of the unit A minimum of 4 inch clearance is required under the unit to allow for trapping of the evaporator condensate drain See Typical Service Clearances on page 20 for more unit clearance information Separation of th...

Page 13: ...ing refrigerant couplings Figure 3 Packaged unit with couplings Once the couplings are unscrewed the female coupling can be pulled away and allowed to rest in the opening No loss of refrigerant occurs due to the spring seal mechanism in the couplings Separating the units The evaporator and condenser sections can be separated by performing the following procedures These procedures are for the 2 8 t...

Page 14: ...nit top joining strip Take care to remove only those screws that attach the joining strip to the evaporator and condenser cabinets 8 Remove the two side cross member angles 9 Carefully pull the evaporator section away from the condenser section Take care not to damage the short lengths of refrigerant tubing extending into the condenser section The separated evaporator and condenser modules can now...

Page 15: ...Figure 4 Single compressor unit typical installation configuration 15 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 16: ...Figure 5 Dual compressor unit typical installation configuration Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 16 Johnson Controls ...

Page 17: ...ecessary to ensure a proper leakproof seal between the couplings Interconnecting refrigerant tubing After the evaporator and condenser sections are mounted the interconnecting refrigerant tubing can be fabricated For cooling systems where the indoor and outdoor sections are installed at the same elevation the refrigerant line sizes usually can be matched with factory supplied fittings See Table 3 ...

Page 18: ...e interconnecting lines to hold a 350 micron vacuum for 15 30 minutes If gauge pressure rises above 500 microns in one minute then evacuation is incomplete or the system has a leak Table 3 Recommended refrigerant line sizes Less than 75 linear feet Model number Liquid line Suction line DSH024C 3 8 3 4 DSH036C 3 8 3 4 DSH048C 1 2 7 8 DSH060C 1 2 7 8 DSH096C 2 X 1 2 2 X 7 8 DSH120C 2 X 1 2 2 X 7 8 N...

Page 19: ...a 2 3 ton horizontal A C unit Note 1 Dimension tolerance is 1 16 in 2 Evaporator and condenser duct connections cannot be altered unless noted 19 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 20: ...n horizontal A C unit Note 1 Dimension tolerance is 1 16 in 2 Evaporator and condenser duct connections cannot be altered unless noted Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 20 Johnson Controls ...

Page 21: ...ontal A C unit Note 1 Dimension tolerance is 1 16 in 2 Evaporator and condenser duct connections cannot be altered unless noted 21 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 22: ...ontal A C unit Note 1 Dimension tolerance is 1 16 in 2 Evaporator and condenser duct connections cannot be altered unless noted Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 22 Johnson Controls ...

Page 23: ...ypical service clearances Figure 10 2 5 ton horizontal A C unit service clearances 23 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 24: ...ure 11 8 10 ton horizontal A C unit service clearances Note 8 ton packaged unit shown Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 24 Johnson Controls ...

Page 25: ...38 75 76 70 72 66 66 112 675 715 3 ton 140 76 76 70 72 67 67 112 680 720 4 ton 151 122 122 93 100 116 116 130 950 1010 5 ton 160 127 127 94 101 122 138 138 990 1060 8 ton 292 163 163 108 140 168 168 270 1470 1560 Figure 13 Split unit installation 25 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 26: ...o accommodate the external static pressure loss associated with properly sized storm proof louvers A storm proof louver typically has a free area approximately 40 45 of the actual louver size To determine the free area required for any given unit adhere to the following guidelines The size condenser air intakes are for 350 600 feet minute nominal velocity The maximum recommendation is 700 feet min...

Page 27: ...ible joints are used on the ductwork install a ground wire to the ductwork as well The unit requires the installer to provide a 24V thermostat with appropriate heating and cooling stages The condenser section electrical cover is installed with wiring diagrams on the inner access door which must be opened to read the diagrams WARNING Disconnect and lock out power when servicing unit Unit may start ...

Page 28: ...ics Figure 14 Typical control diagram for single stage cooling DSH024C DSH036C DSH048C and DSH060C Note 1 Unit is capable of supporting up to two stages of discrete heating 2 Unit is designed to only support single stage cooling 3 Jumper is required for any combination of R RC or RH 4 OCC is an output from the thermostat to indicate the occupied condition 5 X is an input to thermostat to display t...

Page 29: ...it is designed to support three stages of discrete cooling 4 Jumper is required for any combination of R RC or RH 5 OCC is an output from the thermostat to indicate the occupied condition 6 X is an input to thermostat to display the error status 7 Jumper is required if no option is installed between SD 24 and SD R 29 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Eq...

Page 30: ...3 Unit is designed to support four stages of cooling 4 Jumper is required for any combination of R RC or RH 5 OCC is an output from the thermostat to indicate the occupied condition 6 X is an input to thermostat to display the error status 7 Jumper is required if no option is installed between SD 24 and SD R Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment C...

Page 31: ... 4 2 3 00 4 2 25 50 30 DSH120C5 575 3 60 2 5 3 38 9 3 00 3 4 3 00 3 4 18 73 20 Table 7 Electrical data oversized evaporator motor Compressor 1 Compressor 2 Evaporator fan Condenser fan Model number Voltage Qty RLA LRA Qty RLA LRA HP FLA HP FLA MCA Max fuse CCT BKR amp DSH048C2 208 230 3 60 1 13 8 83 1 1 00 3 1 1 50 4 4 24 75 35 DSH048C4 460 3 60 1 6 2 41 0 1 00 1 5 1 50 2 2 11 45 15 DSH048C5 575 3...

Page 32: ... 0 0 2 0 4 0 6 0 8 Outdoor CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard factory drive Hi static drive 1600 461 0 16 573 0 23 675 0 31 767 0 39 849 0 48 Table 11 DSH036C Supply air blower performance Available external static pressure iwg1 0 0 0 1 0 2 0 3 0 4 0 6 0 8 1 0 Supply CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Low static drive 3 Factory drive 0 75 HP Hi st...

Page 33: ...ive Table 14 DSH048C Condenser fan performance Available external static pressure iwg 0 0 0 2 0 4 0 6 0 8 1 0 1 2 Outdoor CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard factory drive Hi static drive 2400 503 0 40 577 0 50 645 0 60 708 0 71 767 0 82 822 0 93 875 1 05 Table 15 DSH060C Supply air blower performance Available external static pressure iwg1 0 0 0 1 0 2 0 3 0 4 0 6 ...

Page 34: ...er may occur Decrease airflow downward as necessary 3 Field supplied low static drive Table 18 DSH096C Condenser fan performance Available external static pressure iwg 0 0 0 2 0 4 0 6 0 8 1 0 1 2 Outdoor CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard factory drive 3 HP Optional hi static drive 3 HP 6100 516 1 53 572 1 79 623 2 06 672 2 33 718 2 60 762 2 88 805 3 16 Table 19 D...

Page 35: ... Pitch diameter inches DSH024C 614 906 0 5 56 62 2 0 3 0 5 9 DSH036C 739 1091 0 75 56 68 2 0 3 0 4 9 DSH048C 697 1028 1 0 145 88 5 2 0 3 0 5 2 DSH060C 784 1158 1 5 145 88 5 2 0 3 0 4 7 DSH096C 734 1016 2 0 145 88 5 2 4 3 4 6 2 DSH120C 640 854 3 0 184 88 5 2 8 3 8 8 2 Table 23 Condenser standard blower motor and drive data Motor Adjustable motor pulley Fixed blower pulley Model Drive range RPM HP F...

Page 36: ...g the blower speed Determine the RPM for the blowers from the tables in Fan performance To adjust the blower speed take the following steps 1 Loosen the belt tension by moving the motor towards the blower shaft via the adjustable mounting 2 Loosen the setscrew in the adjustable motor pulley flange 3 Remove the external key on pulleys that are 4 inches diameter or larger 4 Open or close the pulley ...

Page 37: ... and the control module Note On dual compressor units the actuator MUST be connected to the 1 circuit liquid line fitting Connection to the second stage refrigerant circuit will result in system malfunction For detailed installation instructions refer to the supplementary Low Ambient Damper Kit Installation and Operation Instructions Form 145 10 IOM4 Kit Model A B C LADK 036C 1 DSH024C 036C 25 875...

Page 38: ...f the damper is set proportionally between the Economizer Minimum Position and the Economizer Minimum Position Low Speed Fan setpoints in relation to the VFD output percentage Note On a constant volume single speed supply fan system both setpoints should be set to the same value Free cooling Four types of free cooling options are available dry bulb changeover single enthalpy dual enthalpy changeov...

Page 39: ...emperature sensor a 5 16 inch hole must be field drilled in the duct work and the sensor inserted through the hole Small wings keep the sensor secured in the hole The RAT sensor can be installed in a pre punched hole on the filter frame There are two holes punched on both sides of the filter frame halfway through the height of the filter frame The extension wiring can be easily routed out of the u...

Page 40: ...re transducer must be connected to the unit controller see the unit schematic for more details The power and optional low voltage wiring for transducer wiring can be found inside the VFD enclosure No extra power wiring is required sufficient length is provided The VFD option does not include an evaporator fan bypass circuit in case of microdrive failure Microdrive must be replaced to re activate t...

Page 41: ...ect acting pressure modulating bypass control valve is installed on the system 1 discharge line To maintain a desired minimum evaporator pressure use this valve to divert high temperature high pressure refrigerant around the TXV HGBP is standard on all units with variable air volume VAV and optional on units with constant volume CV Adjusting HGBP setpoint When the HGBP valve opens select the coil ...

Page 42: ...hree phase supply Reconnect the power If one component is operating in the wrong direction then all other three phase components on the unit may be operating in the same phase Note Observe unit operation and check for unusual noise or vibration WARNING The air conditioning section of this equipment is charged with R 410A a high pressure refrigerant Only qualified technicians using appropriately pr...

Page 43: ...alue from Table 25 from the discharge pressure to determine the equivalent saturation temperature For example when the discharge pressure is 388 psig and the liquid line temperature is 95 0 F Liquid Pressure Discharge Pressure 388 psig minus 33 psig 355 psig Saturation Temperature for 355 psig 108 0 F Liquid Line Subcooling Saturation Temperature 108 0 F minus Liquid Line Temperature 95 0 13 0 F S...

Page 44: ...ion pressure is 130 psig and the suction line temperature is 57 0 F Saturation Temperature for 130 psig 45 0 F Evaporator Superheat Suction Line Temperature 57 0 F minus Saturation Temperature 45 0 F 12 0 F When adjusting the expansion valve do not turn the adjusting screw more than one turn at a time This allows sufficient time approximately 15 minutes between adjustments for the system and the t...

Page 45: ...n be configured to use with a standard thermostat a zone sensor or to communicate with the field controller FC bus using BACnet MS TP Modbus or N2 protocols Temperature sensors Each unit comes with standard supply air temperature SAT and return air temperature RAT sensors The outside air temperature OAT is provided with the airside economizer option All sensors are field wired and installed USB po...

Page 46: ...ow pressure switch anti freeze protection low voltage or heating high limit must trip three times within two hours before the unit control board locks out the associated compressor The LCD screen displays an alarm message Lead lag An integrated lead lag option is available However never enable it on DSH units This option can be selected on the unit control board The default factory setup is always...

Page 47: ...riable Occupied no heat or cool command 50 0 100 Occupied one stage of cool command 50 50 100 Occupied two stage of cool command 60 50 100 Occupied three stage of cool command 75 100 50 100 Occupied four stage of cool command 100 50 100 Occupied one stage of heat command 0 100 Occupied two stage of heat command 0 100 Occupied three stage of heat command 0 100 Economizer minimum position 0 100 Econ...

Page 48: ...l Command setpoint The cooling supply fan operation is as follows With a demand for cooling the VFD operates at the frequency relating to the setpoint Occupied Stage of Cool Command as defined under the Indoor Fan setting menu on the SE controller Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 48 Johnson Controls ...

Page 49: ...Bearings are a permanently sealed ball type and do not require lubrication Check the bearings for signs of wear movement between the inner and outer races Ensure that the bearing locking collars are secure to the shaft and that the collar locking screw is properly set Check that the blower wheel is tight on the shaft and that the hub set screws are properly torqued Drive belts Examine the belts pe...

Page 50: ... DSH060C 2 25 x 16 x 2 DSH096C 4 20 x 16 x 2 DSH120C 4 20 x 16 x 2 Figure 20 Belt tension adjustment Pounds force Cross section Minimum Maximum 4L 1 1 2 2 1 2 A 3 1 2 6 1 2 B 5 1 2 8 BX 8 11 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 50 Johnson Controls ...

Page 51: ...Appendix A Wiring diagrams 51 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 52: ...Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 52 Johnson Controls ...

Page 53: ...53 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 54: ...Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 54 Johnson Controls ...

Page 55: ...55 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 56: ...Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller 56 Johnson Controls ...

Page 57: ...57 Model DSH024C 120C Horizontal R 410A Air Conditioning Units C Generation Smart Equipment Controller Johnson Controls ...

Page 58: ...Amb En2 No Lead Lag En3 No Clg OAT Cutout En Yes Clg OAT Cutout 45 Clg Adap Tune En No SAT Cool Limit En Yes Sat Cool Limit SP 45 Cooling Freeze SP 26 Htg En4 No Heating Htg Stgs 0 Fan Ctl Type Single Speed Fan On Dly Cool 0 Details Fan Setup Fan Off Dly Cool 45 Note 1 Factory shipped units equipped with Occ jumper on UCB 2 Do not enable low ambient 3 Do not enable LeadLag 4 Field supplied option ...

Page 59: ...24vacOutputEnabled C3 En Yes C3 24vacOutputEnabled C4 En No C4 24vacOutputEnabled Clg En Yes Cooling Enabled Disabled LeadLag En No EqualCompRuntime 3 ClgOATCutout En Yes LowAmbComp LO ClgOATCutout 45 0 F LoAmbCompLO StPt ClgAdapTunEn No Cooling Auto Tune Enable SATCoolLimit En Yes Enable SAT Limit SATCoolLimit Sp 45 0 F SAT Limit SetPt LowAmb En No Low Ambient Enabled 4 Cooling Freeze Sp 26 0 F E...

Page 60: ...0 CV IntelliSpeed 4 Stg Cool ClgStgs 3 of Cooling Stages C1 En Yes C1 24vacOutputEnabled C2 En Yes C2 24vacOutputEnabled C3 En Yes C3 24vacOutputEnabled C4 En No C4 24vacOutputEnabled Clg En Yes Cooling Enabled Disabled LeadLag En No EqualCompRuntime 2 ClgOATCutout En Yes LowAmbComp LO ClgOATCutout 45 0 F LoAmbCompLO StPt ClgAdapTunEn No Cooling Auto Tune Enable SATCoolLimit En Yes Enable SAT Limi...

Page 61: ...24vacOutputEnabled C3 En Yes C3 24vacOutputEnabled C4 En Yes C4 24vacOutputEnabled Clg En Yes Cooling Enabled Disabled LeadLag En No EqualCompRuntime 3 ClgOATCutout En Yes LowAmbComp LO ClgOATCutout 45 0 F LoAmbCompLO StPt ClgAdapTunEn No Cooling Auto Tune Enable SATCoolLimit En Yes Enable SAT Limit SATCoolLimit Sp 45 0 F SAT Limit SetPt LowAmb En No Low Ambient Enabled 4 Cooling Freeze Sp 26 0 F ...

Page 62: ... CV IntelliSpeed 4 Stg Cool ClgStgs 4 of Cooling Stages C1 En Yes C1 24vacOutputEnabled C2 En Yes C2 24vacOutputEnabled C3 En Yes C3 24vacOutputEnabled C4 En Yes C4 24vacOutputEnabled Clg En Yes Cooling Enabled Disabled LeadLag En No EqualCompRuntime 2 ClgOATCutout En Yes LowAmbComp LO ClgOATCutout 45 0 F LoAmbCompLO StPt ClgAdapTunEn No Cooling Auto Tune Enable SATCoolLimit En Yes Enable SAT Limi...

Page 63: ...ve a service pressure rating of 800 psig Leak detectors must be designed to detect HFC refrigerants Systems must be charged with refrigerant Use a commercial type metering device in the manifold hose R 410A can only be used with polyester POE type oils POE type oils rapidly absorb moisture from the atmosphere Vacuum pumps do not remove moisture from POE type oils Do not use liquid line driers with...

Page 64: ... 2021 Johnson Controls All rights reserved Subject to change without notice 100 JCI Way York Pennsylvania USA 17406 8469 Johnson Controls ...

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