Johnson Controls D Series User manual

Form Number: 145.29-IOM4 (1220)
Supersedes: 145.29-IOM4 (1119)
Installation Guide
Issue Date: 2020-12-02
Johnson Controls
D-Series Vertical (DSV060C-300C)
Air-Cooled Self-Contained Units, C
Generation with Smart Equipment
Controller
Installation, Operation, and Maintenance Manual

2 D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment
Controller
Johnson Controls

Contents
ContentsGeneral safety guidelines.............................................................................................................................. 5
Important!............................................................................................................................................ 5
Read before proceeding!.......................................................................................................................... 5
Safety symbols............................................................................................................................................ 5
Changeability of this document............................................................................................................... 7
Associated literature.................................................................................................................................. 7
Technical support....................................................................................................................................... 7
Replacement parts..................................................................................................................................... 7
Nomenclature............................................................................................................................................. 8
Installation...................................................................................................................................................... 9
Pre-installation inspection of equipment......................................................................................... 9
Rigging................................................................................................................................................ 11
Installation site.................................................................................................................................. 11
Location..................................................................................................................................................... 11
Unit mounting.................................................................................................................................... 12
Evaporator/condenser assembly.................................................................................................... 12
Assembling split units (8–25 ton models)............................................................................................. 12
Connecting the VFD control wires......................................................................................................... 14
Changing fan speeds............................................................................................................................... 15
Separating the units (DSV060C model)................................................................................................. 15
Condensate trap................................................................................................................................ 15
Ductwork............................................................................................................................................ 16
Air temperature sensors......................................................................................................................... 16
Louver sizing guidelines.......................................................................................................................... 17
Variable frequency drive (VFD)........................................................................................................ 18
Indoor fan VFD......................................................................................................................................... 18
Outdoor fan VFD...................................................................................................................................... 19
Hot gas bypass (HGBP)..................................................................................................................... 19
Adjusting HGBP setpoint......................................................................................................................... 19
Airside economizer (ASE).................................................................................................................. 19
Sequences of operation.......................................................................................................................... 20
Dimensions......................................................................................................................................... 20
Discharge plenum............................................................................................................................. 22
Low ambient damper installation................................................................................................... 24
Evaporator blower discharge conversion....................................................................................... 26
Converting the fan discharge................................................................................................................. 26
Electrical wiring.................................................................................................................................. 26
High voltage wiring................................................................................................................................. 26
Low voltage wiring................................................................................................................................... 27
Electrical data..................................................................................................................................... 30
Fan performance............................................................................................................................... 32
Motor and pulley data...................................................................................................................... 35
Johnson Controls
D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment
Controller
3

Blower speed adjustment................................................................................................................ 36
Adjusting the blower speed.................................................................................................................... 36
Start-up and operation................................................................................................................................ 38
Checking superheat and subcooling.............................................................................................. 39
Subcooling................................................................................................................................................ 39
Superheat.................................................................................................................................................. 40
Leak checking........................................................................................................................................... 40
Start-up (cooling).............................................................................................................................. 41
Prestart checklist...................................................................................................................................... 41
Operating instructions............................................................................................................................ 41
Post start checklist................................................................................................................................... 41
Microprocessor controller................................................................................................................ 41
Temperature sensors.............................................................................................................................. 41
USB port.................................................................................................................................................... 41
LCD display............................................................................................................................................... 42
Safety monitoring.................................................................................................................................... 42
Low ambient............................................................................................................................................. 42
Anti-short cycle delay (ASCD) protection.............................................................................................. 42
Fan delays................................................................................................................................................. 42
Nuisance trip protection and three strikes........................................................................................... 42
Lead-lag..................................................................................................................................................... 42
Condensate overflow switch.................................................................................................................. 42
Operation.................................................................................................................................................. 43
Maintenance and service............................................................................................................................ 45
Evaporator and condenser coils...................................................................................................... 45
Refrigerant circuits............................................................................................................................ 45
Blowers............................................................................................................................................... 45
Drive belts.......................................................................................................................................... 45
Filters................................................................................................................................................... 45
Appendices.................................................................................................................................................... 47
Appendix A: Unit dimensional drawings........................................................................................ 47
Appendix B: Typical service clearances.......................................................................................... 65
Appendix C: High voltage unit wiring schematics......................................................................... 66
Appendix D: Low voltage unit wiring schematics......................................................................... 76
Appendix E: SEC parameters for DSV units, C generation........................................................... 82
R-410A Quick reference guide.................................................................................................................... 87
Notes............................................................................................................................................................. 88
D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller4
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General safety guidelines
Important!
Read before proceeding!
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and
operating/service personnel to identify and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply with any of these requirements could
result in serious damage to the equipment and the property in which it is situated, as well as severe
personal injury or death to themselves and others at the site.
This document is intended for use by owner-authorized rigging, installation, and operating/service
personnel. It is expected that these individuals 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 and regulations pertaining to the task in
question.
Safety symbols
The following symbols are used in this document to alert the reader to specific situations:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
5D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with the manufacturer's published specifications and must be performed only by a qualified electrician.
The manufacturer will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
WARNING: This product can expose you to chemicals
including formaldehyde, which is known to the state of
California to cause cancer. For more information, go to
www.P65Warnings.ca.gov.
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Changeability of this document
In complying with the manufacturer's’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. There is no commitment to update
or provide current information automatically to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest service office.
It is the responsibility of rigging, lifting, 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 notes
Affected section Description Date implemented
Nomenclature Updated notes for DSV Nomenclature November 2020
Evaporator/
condenser assembly Nitrogen Warning added July 2020
Associated literature
Manual description Form number
Mobile Access Portal Gateway Product Bulletin LIT-12011884
Airside Economizer Kit for Models DSH/DSV Air-Cooled Air Conditioning Units,
C Generation, Installation and Operation Instructions 145.10-NO2
Low Ambient Damper Kit for Air-Cooled Self-Contained Units DSH/DSV
Models, B/C Styles Installation and Operation Instructions 145.10-IOM4
DSV/DSH and CSV Air and Water-Cooled Self-Contained Units Start-Up and
Performance Checklist 145.13-CL1
Variable Frequency Drive for D-Series (DSV/DSH) Air-Cooled Self-Contained
Units, C Generation Installation and Operation Instructions 145.13-NO2
Technical support
If Technical Support is required, please contact the Product Technical Support team at 877-329-7430
or AppliedDXT[email protected].
Replacement parts
For replacement parts, please contact your local Source1 Dealer.
Source1 Parts Phone Number: 800-536-6112
Source1 Parts Website: http://www.source1parts.com
7D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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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.
D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller8
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Installation
All models 8–25 tons ship in separate parts: a condensing unit and an evaporator section. The 5-
ton models ship as factory charged unitized packages. All models are designed for freestanding
mounting on the floor or on a field fabricated structural steel stand. All models can be ordered as
either a vertical or horizontal supply fan discharge orientation. This can be combined with standard
rear return air (RA) or optional front RA configuration (see dimensional drawings in Appendix A:
Unit dimensional drawings for more details).
The 5 ton model utilizes a single stage compressor. The 8–25 ton models are dual compressor units
with two independent refrigerant circuits. The 8–12 ton units are assembled from the following
components:
• A single speed scroll compressor
• A two stage scroll compressor
This configuration gives 8–12 ton units three effective cooling stages. The 15, 20, and 25 ton units
feature two 2 stage compressors. This configuration gives these units four stage cooling units.
The 8–25 ton models require the field connection of piping and charging of the refrigerant circuits.
The models ship with only a nitrogen holding charge. See the Start-up and operation section for
charge information.
All units come standard with a Smart Equipment (SE Controller) microprocessor control board with
safety controls and troubleshooting LED (see Microprocessor controller for more details).
Units operate reliably at outdoor ambient down to 50.0°F. In applications requiring operation below
this temperature, either a low ambient damper field kit accessory or low ambient control featuring
a variable frequency drive (VFD) on condenser fan is available (condenser fan VFD is available as a
factory installed option only on 8 and 10 ton units).
The damper is installed on the condenser air discharge and is allowed operation to 0.0°F ambient.
The VFD on the condenser is factory 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 units are packaged
and sealed on shipping skids and ship in first class condition. Report to the carrier any torn or
broken packaging, or scratched or dented panels.
Prior to installation, internally inspect all units. Remove all the access doors and check for visual
defects that can occur during transport. Any problems found internally should be immediately
reported to the carrier and the manufacturer. Check the refrigerant circuit to ensure no leaks have
occurred during shipment.
Install the gauge set to high and low pressure ports to confirm the pressure has been maintained
and no leaks have occurred during shipment. To ensure safe operation, repair any damage.
See Appendix A: Unit dimensional drawings for unit dimensional drawings.
9D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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Note: Record any unit damage on the Bill of Lading and report to carrier and factory
immediately. Shipping and handling damages are not warranty items.
Figure 1: Typical installation configuration
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Rigging
WARNING
Prior to mounting unit, check individual unit weights (Table 1 ) and verify lifting capacity of lifting
equipment exceeds weight of units by safe margins. Failure to do so may result in unit damage,
personal injury, or even death.
To ensure safe installation of the unit, ensure the base of the unit is continuously supported.
WARNING
Determine the actual center of gravity of the unit by performing a test lift. Lifting an unbalanced unit
can cause personal injury, or even death.
Installation site
CAUTION
Lock all electrical power supply switches in the OFF position before installing the unit. Failure to
disconnect the power supply may result in electrical shock or even death.
Location
To ensure the unit operates at maximum efficiencies, choose a dry indoor area where the
temperature is controlled between 50.0°F and 115.0°F. When choosing a location to install the
unit, consider the surrounding 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 unit can be slightly pitched in the
same direction as the drain pan outlet.
Unit Operating weight
(condenser only)
Shipping weight
(condenser only)
DSV060C 920 (620) 980 (675)
DSV096C 1240 (810) 1290 (865)
DSV120C 1325 (860) 1385 (915)
11D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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Unit Operating weight
(condenser only)
Shipping weight
(condenser only)
DSV144C 1560 (980) 1645 (1035)
DSV180C 1720 (1040) 1800 (1130)
DSV240C 1875 (1210) 1960 (1270)
DSV300C 2480 (1400) 2600 (1450)
Note: All weights are in lbs.
Unit mounting
The 5 ton model ships as a fully assembled integral package. The 8–25 ton models ship with two
parts that assemble into a freestanding vertical package on site. The unit is not designed for
remote condenser or evaporator installation. It is installed as a packaged system. The factory does
not recommend or support any installation or modification of the unit that is not described in this
manual. The user is responsible for any damage arising from unrecommended or unsupported
installation or modification.
Flanges for all condenser duct connections (intake and discharge), corner securing brackets
(securing corners between two sections), and refrigerant tubing couplings ship in the condensing
section of the unit for field installation. Duct flanges for evaporator return are incorporated into the
filter rack.
Secure floor-mounted units on a solid, level pad or a sturdy stand. Ensure that the unit's base is
approximately 6 inches higher than the lower edge of the wall opening. This height allows the
condenser air ducts to be pitched away from the unit, offering protection from rain water entering
the base pan (see Figure 1). The use of an isolating rubber sheet is recommended to reduce
vibration and noise transmission. Ensure that the entire base is continuously supported. The unit
can be pitched slightly to ensure efficient drainage of the condensate.
CAUTION
Ensure that the entire base is continuously supported. DO NOT support the unit at its corner points
only!
Evaporator/condenser assembly
Assembling split units (8–25 ton models)
1. Place the condensing section in the required location.
2. Carefully position the evaporator section on top of the condensing section. Align all the sides,
the evaporator motor wire routing hole, and the refrigerant line routing holes.
3. On the evaporator/condenser separation joint, install the securing brackets at all four
corners.
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Figure 2: Securing the corner bracket
Units are provided with couplings to mate refrigerant piping between the condenser and
evaporator sections. A unit with the hot gas bypass (HGBP) option is provided with additional
copper couplings for HGBP piping. Remove piping shipping brackets in both the condenser
and the evaporator section. The brackets secure spun copper ends in the condenser and
evaporator sections. They are only required to protect the piping during shipping. They can
be discarded in the fully assembled unit.
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.
4. In the evaporator and condenser, cut off the spun copper ends on each refrigerant pipe. Cut
the pipe to an appropriate length to fit the couplings.
5. Ensure that circuit 1 from the condenser connects to the circuit 1 piping in the evaporator.
Ensure that circuit 2 from the condenser connects to the circuit 2 piping. Do not cross the
circuits.
6. Following common A/C service practices, braze the copper couplings to the refrigerant pipe
using a flow of nitrogen gas (max. 1 psi) through the refrigerant piping. This flow minimizes
contamination to internal piping. Otherwise, there can be damage to the unit refrigeration
components.
Use the service gauge ports for this procedure to introduce nitrogen flow. Once the
procedure is complete, test the pressure with nitrogen (500 psig).
7. Evacuate each circuit to at least 350 microns. If the gauge pressure rises above 500 microns in
one minute, the evacuation is incomplete or the system has a leak.
8. Charge the circuit(s) to the value on the unit nameplate (or as detailed in the Start-up and
operation section).
13D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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9. Install the supplied bushing/clamp into the evaporator wiring routing hole, and pull the
wires through into the electrical control panel from the evaporator. Extra plastic bushings are
located inside the electrical box. Connect the indoor fan motor leads to the load terminals on
VFD fuse terminals.
Figure 3: Typical piping connections view (8–10 ton model without HGBP shown)
CAUTION
Do not cross circuits when brazing refrigerant piping between sections.
Connecting the VFD control wires
1. Connect the VFD 3-pin Molex harness (115/ OR, 116/R, or 117/WH) to the SE control (SEC)
terminal P5.
2. Connect 151/R to the common terminal on the EVFR relay in the condenser box.
3. Connect 152/OR to the NO terminal on EVFR relay in the condenser box.
4. For variable air volume (VAV) units, connect the pressure transducer wiring harness (138/WH,
139/BLK) to P4.
D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller14
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5. Connect 140/R pressure transducer EXEC to the SEC (24V FOR OUTPUT) terminal.
Changing fan speeds
Change the fan speeds on an SEC by changing the parameters in the controller itself. Refer to
Appendix E: SEC parameters for DSV units, C generation.
Separating the units (DSV060C model)
The DSV060C model's parts can be separated to move it though doorways and elevators. However,
the unit is not designed or certified for installation as a remote condenser and evaporator.
1. Reclaim the whole refrigerant charge from each compressor circuit.
2. Disconnect the evaporator motor high voltage wires. Pull all the wiring into the evaporator
compartment. Remove the bushing/clamp from the routing hole for the evaporator motor
wiring.
3. Cut and remove sections of all the liquid and suction refrigerant lines. Make two cuts in each
line, approximately 6 inches above and below the evaporator floor/condenser roof.
CAUTION
Use a TUBING CUTTER ONLY - do not use a hacksaw to cut refrigerant tubing otherwise serious
damage can occur to refrigeration system!
4. Remove the corner securing the brackets from the outside corners of the cabinet, at the joint
line between the evaporator and condenser sections.
5. Remove the evaporator section.
6. For assembly instructions, see Assembling split units (8–25 ton models).
Condensate trap
Condensate trap fitting is provided on all units and is 3/4-inch functional performance testing (FPT).
The unit requires a field installed external condensate trap. Without a trap, condensate can be
thrown into the airstream. This can cause water overflow, unit damage, and property damage.
This system must be trapped according to a negative system pressure (draw-through). Use the
dimensions in Figure 4. Adhere to local codes for piping the external trap and condensate.
Example: trapping a system up to 2 inches external static pressure
Note:
• A = (1 inch for each inch of maximum negative static pressure) + 1 inch
• B = Half of A
• C =A + B + pipe diameter
15D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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Figure 4: Dimensions for trapping a negative pressure system
Note: A = (2 inches) + 1 inch B = A/2 C = A + B + 3/4 inches = 5-1/4 inches
Ductwork
When installing ductwork, adhere to local codes. Where possible, minimize duct runs and avoid
abrupt changes in direction. Allow ample access space to service the coils and change the filters.
Perform regular maintenance on the ducts to increase the unit life, maintain efficient operation,
and reduce the accumulation of dust and debris.
To not exceed the maximum external static values, refer to blower performance charts in Fan
performance, engineer duct runs, and accessory pressure drop. Ensure continuous running of
the condenser intake ambient air temperature does not exceed 115.0°F. The condenser exhaust
discharges into an open area to prevent the short cycling of hot exhaust condenser air with the
condenser intake.
Air temperature sensors
Figure 5: RAT SAT sensor
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Figure 6: Extension wiring
Each unit is equipped with standard SA temperature (SAT) and RAT sensors. Sensors ship inside the
electrical box, the wire tied to the wiring. In addition to sensors, 8-foot long wiring extensions also
ship inside the electrical box (see Figure 5).
In order to insert a temperature 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 unit through 7/8-inch prepunched holes that are
located on both sides of the unit.
The location of the sensor has to be chosen according to local codes and installation practices.
Louver sizing guidelines
An important issue in obtaining optimum performance from indoor air conditioners is proper
selection of the condenser intake and discharge louvers. In practice, outdoor air-cooled units intake
and discharge their cooling without restriction. However, indoor units must first overcome the
resistance of grilles or louvers at the outside wall and then the restriction of any interconnecting
ductwork.
The DSH's indoor air-cooled air conditioners are designed to 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/minute.
• The size condenser air discharge is for 1,200–1,500 feet/minute nominal velocity. The
maximum recommendation is 1,700 feet/minute.
Louvers with higher velocities than stated above can be employed. This is at the discretion of the
engineer or installer provided that the total air pressure drop does not exceed the capability of the
condenser fan and motor.
Low restriction louvers with shallow blade angles can allow higher face velocities without excessive
static pressure loss. Exceeding the static pressure capability of the condenser fan results in
insufficient condenser air volume. This causes a loss in system capacity and can cause compressor
shutdown during high ambient periods. Where applicable in such cases, the installation of an
oversize condenser motor/drive may be considered.
17D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
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Note: As a general rule, these velocities require an intake louver sized approximately 1.25
to 1.5 times the dimensions of the duct connection on the unit, and a discharge louver sized
approximately 1.5 to 2 times the duct connection dimensions
To ensure the unit does not short circuit, only use louver sections that provide different deflection
angles for air discharge and air intake. Protect the unit from weather such as rain or snow entering
through the condenser air intake.
Pitch all outdoor air ducts away from the unit and toward the outside wall. Connect all ducts to the
unit with canvas section duct connectors or choose another suitable noise and vibration absorbing
device.
Note: The manufacturer will not accept any liability resulting from incorrect installation of this
equipment. Follow installation instructions carefully.
Variable frequency drive (VFD)
Indoor fan VFD
A standard VFD controller for the evaporator (indoor) fan applies on 8–25 ton models. Mounted in
the evaporator module section, the VFD allows the operator to set the duct static pressure or to
control discrete indoor fan speed steps. To meet the desired supply duct static setpoint or a specific
discrete speed step, the VFD controls the evaporator fan motor's frequency (or speed). For reliable
operation, the unit must have a factory installed HGBP circuit on refrigeration circuit # 1 for units
with a duct pressure control option. Unless requested by the customer as a selectable feature, the
unit setup for discrete speed steps does not require HGBP for reliable operation.
In 8 and 12 ton units, the standard discrete speed step configuration is that the VFD has been setup
for three automatically adjusted discrete speeds. 15, 20, and 25 ton units feature 4 discrete speed
steps. In both cases, the discrete fan speeds are matched and adjusted automatically based on the
active cooling stage.
Note: The unit does not carry a failsafe circuit to bypass the factory installed VFD and run the
evaporator or condenser fan in the event of a VFD malfunction.
The VFD is factory mounted and wired. The installer must provide and field install two sensor
tubing lines complete with static pressure probes (except to the configuration for discrete speed
application). The installer must field wire the fan power wiring between the evaporator VFD and
the unit electrical box (located in the condenser section) because the unit ships factory-split. For
units with a static pressure control option, low voltage wiring from the pressure 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 the unit. In case of a VFD failure, the evaporator fan stops running. However, unit
compressors continue to run until a low pressure safety trip activates.
For detailed installation and operation instructions, refer to Variable Frequency Drive Installation and
Operation Instructions (Form 145.13-NO2).
Note: Do not run evaporator fan motor below 30Hz otherwise coil freeze-up and nuisance
lock-outs may occur.
CAUTION
Building excessive ductwork pressure can cause damage to unit or personnel.
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Outdoor fan VFD
If the unit must operate at an outdoor ambient temperature below 50.0°F, install the optional VFD
condenser fan option to maintain an acceptable condensing pressure. The optional VFD controller
for the condenser fan is available on 8–25 ton models (208-230/3/60 and 460/3/60 power supply
only).
The purpose of this option is to control high head pressure during low ambient conditions. The
VFD for the condenser fan is available as either a factory built option or field installed kit. The field
installed kit comes complete with a manual bypass electrical circuit. In the unlikely case of VFD
failure, it can be used to revert condenser fan control back to standard starter mode.
Mounted in the condenser corner post (or the special enclosure for a field kit VFD), the VFD allows
the operator to set the high head pressure level (the factory default is 320 psig). To meet the
desired refrigerant pressure setpoint, the VFD controls the condenser fan motor's frequency
(speed). The pressure transducer must be only connected to circuit #1.
For detailed installation and operation instructions, refer to the Variable Frequency Drive manual
(Form 145.13-NO2).
Hot gas bypass (HGBP)
To allow for low cooling load operation, a direct-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 suction pressure or coil temperature by adjusting the
screw on the HGBP valve.
To set the load, run the unit and cool down the evaporator coil. To do this, either shut the fans or
block the airflow until the suction pressure drops at least 5 psi below the chosen evaporator coil
setpoint. Next, allow the bypassed gas to raise the pressure. The screw spring adjustment can be
set until the HGBP valve closes at the chosen setpoint.
The pressure of the evaporator coil is set to maintain an evaporator coil temperature above the
point that frost and coil freeze-up can form.
Airside economizer (ASE)
The optional airside economizer mixing box is designed to attach to the return air (RA) side of the
evaporator. Mixing comes with low-leakage opposed blade dampers. The economizer is used to
provide ventilation and free cooling for the DSH series of horizontal air handlers.
The economizer is set up through the LCD keypad display and joystick located on the unit SEC
board or through a recommended mobile access portal (MAP) gateway, available for purchase from
the factory - see Mobile Access Portal Gateway Product Bulletin (LIT-12011884). The control board is
mounted inside of the unit main electrical box.
Access to the mixing box is not required to setup ASE sequence of operation. Communication
between SEC board and ASE board automatically establishes through an SA bus connection. The
factory supplied economizer includes: economizer module, mixing box, actuator, enthalpy sensor,
temperature sensor, dampers, and wiring harness. See Appendix D: Low voltage unit wiring
schematics for economizer electrical wiring schematics or Airside Economizer Kit Installation and
Operation Instructions (Form 145.10-NO2) for more details on installation and application.
19D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller
Johnson Controls

Sequences of operation
Several functions can drive the economizer, including minimum position, free cooling, economizer
loading, and minimum outdoor air supply.
Economizer minimum position
The economizer minimum position is set during occupied mode when the outside air (OA) is not
suitable for free cooling. The position of 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
changeover, and auto.
Dry Bulb Changeover – For dry bulb economizer operation, the outside air is suitable for free
cooling if the outside air temperature (OAT) is 1.0°F below the Economizer OAT Enable setpoint and
1.0°F below the RA temperature (RAT). Free cooling is no longer available if the OAT rises above
either the Economizer OAT Enable setpoint or the RAT.
Single/Dual Enthalpy Changeover – For single enthalpy economizer operation, the outside air is
suitable for free cooling if the OA enthalpy is at least 1 Btu/lb below the economizer OA enthalpy
setpoint and the OAT is no greater than the RAT plus 9.0°F.
If the OAT rises above the RAT plus 10.0°F, free cooling is no longer available. The OAT must drop to
no greater than RAT plus 9.0°F to enter free cooling again.
Free cooling is no longer available if the OA enthalpy rises above the economizer OA enthalpy
setpoint. For dual enthalpy economizer operation, the OA enthalpy must be lower than the RA
enthalpy by 1 Btu/lb and the OAT is no greater than the RAT plus 9.0°F.
Auto – The control determines the type of free cooling changeover based on which sensors are
present and reliable. Conditions include:
• Return and outside air dry bulb = dry bulb changeover
• Return and outside air dry bulb and outside air humidity = single enthalpy
• Return and outside air dry bulb and return and outside air humidity = dual enthalpy
• If either the return or outside air dry bulb sensors are unreliable, free cooling is not available
For detailed installation and operation instructions, refer to Airside Economizer Kit (Form 145.10-
NO2).
Dimensions
Table 1: Dimensions
Mixing box dimension Damper dimension
Vertical unit Economizer A B C D E
DSV060C VASE-060C-1 49.00 27.75 24.00 40.00 14.00
DSV096C/120C VASE-120C-1 66.50 36.25 26.50 58.00 19.50
DSV144C VASE-144C-1 78.00 35.75 28.50 70.00 19.50
DSV180C VASE-180C-1 82.00 37.75 28.50 74.00 21.50
DSV240C VASE-240C-1 86.00 41.00 34.00 78.00 25.00
DSV300C VASE-300C-1 104.00 45.00 34.00 90.00 25.00
D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C Generation with Smart Equipment Controller20
Johnson Controls