Johnson Controls DSH024B-120B User manual

MODEL DSH024B-120B
HORIZONTAL R-410A
AIR CONDITIONING UNIT
STYLE B
Issue Date:
December 28, 2013
MODEL DSH
AIR CONDITIONING UNIT
INSTALLATION, OPERATION, MAINTENANCE Supersedes: 145.32-IOM3 (312) Form 145.32-IOM3 (1213)

FORM 145.32-IOM3 (1213)
2JOHNSON CONTROLS
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDLINES
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants , oils,
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 respon-
sibilty of 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 sever personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will en-
able 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 this document and any referenced materials.
This individual shall also be familiar with and comply with
all applicable 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 areas of potential hazard.
DANGER indicates an imminently haz-
ardous situation which, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially haz-
ardous situation which, if not avoided,
could result in death or serious injury.
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually and
instruction will be given, together with a
brief explanation.
NOTE is used to highlight additional in-
formation which may be helpful to you.
All wiring must be in accordance with published specifications and must be performed ONLY
by qualified service personnel. Johnson Controls will not be responsible for damages/problems
resulting from improper connections to the controls or application of improper control signals.
Failure to follow this will void the manufacturer’s warranty and cause serious damage to prop-
erty or injury to persons.

FORM 145.32-IOM3 (1213)
JOHNSON CONTROLS 3
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained in
this document is subject to change without notice.
While Johnson Controls makes no commitment to up-
date or provide current information automatically to the
manual owner, that information, if applicable, can be
obtained by contacting the nearest Johnson Controls
service office.
It is the responsibility of operating/service personnel as
to the applicability of these documents to the
equipment in question. If there is any question in the
mind of operating/service personnel as to the
applicability of these documents, then, prior to working
on the equipment, they should verify with the owner
whether the equipment has been modified and if
current literature is available.
TABLE OF CONTENTS
Safety Symbols………………………………………………………… 2
Changeability of This Document…………………………………….. 3
Typical Installation Diagrams……..……………………………..…… 4
General Information..………………………………………………….. 7
Installation –
Pre-Installation Inspection of Equipment………………………….7
Rigging…………………………………………………………….... 7
Installation Site……………………………………………………… 7
Cabinet Configurations/Unit Mounting…………………………….8
Separation of Units (Evaporator / Condenser)………………….. 8
Physical Data…..………………………………………………………. 11
Service Clearances and Corner Weights…………………………….15
Interconnecting Refrigerant Tubing…….....………………………….18
Outdoor Air Ductwork………………………………………………….18
Louver Sizing Guidelines…………………………………………..18
Electrical Wiring………………………………..………………………19
Typical Wiring Schematics………………………………...………20
Nameplate Electrical Data………………………………………...23
Fan Performance Data………………………………………………..24
Motor and Drive Data………………………………………………27
Blower RPM Adjustment…………………………………………..28
Low Ambient Operation / Damper Kit Installation………………….29
Start-Up and Operation……………………………………………….30
Refrigerant Charges………………………………………………. 30
Pressure Switch Settings………………………………………….30
Microprocessor Controller……………………………………....……31
Operation……………………………….………………………….. 31
Safety Switches……….……………………………………………31
Safety Controls…………………...........…………………………..31
Microprocessor Flash Codes…………………………………….. 33
Maintenance/Service………………………………………………… 34
Filters………………..……………………………………………… 34
Evaporator and Condenser Coils………………………............. 34
Refrigerant Circuits………………………………………………...34
Blowers………………………………………………………………34
Drive Belts…………………………………………………………..34
R-410A Service Procedures - Quick Reference Guide……………35

FORM 145.32-IOM3 (1213)
4JOHNSON CONTROLS
DSH024B-DSH060B – SINGLE COMPRESSOR UNIT – TYPICAL INSTALLATION DIAGRAM

FORM 145.32-IOM3 (1213)
JOHNSON CONTROLS 5
DSH096B/120B – DUAL COMPRESSOR UNIT – TYPICAL INSTALLATION DIAGRAM

FORM 145.32-IOM3 (1213)
6JOHNSON CONTROLS
NOMENCLATURE TABLE
Product Category
DS =
Miscellaneous Options
A = None
D = Condensate Overflow Switch
Product Indentifier
H = Horizontal, Ceiling Mounted
Heating Options
0 = None
Nominal Capacity
024 = 2 TON Refrigerant Circuit Options
036 = 3 TON
Design Series
A = None
048 = 4 TON B= Current B = Hot Gas Bypass
060 = 5 TON
096 = 8 TON
120 = 10 TON
VOLTAGE Condenser Drive Options
1 = 208/230-60-1 1 = Std Motor & Drive
2 = 208/230-60-3 2 = High Static Drive
4 = 460-60-3
3 = High Static Motor & Drive
5 = 575-60-3
Control Options Outdoor Air-side Options
M = Std Microprocessor Controls A = Std Air-Side coil
C = Corrosion Protective Coating
ID Motor
1 = Std
2 = High Static
Indoor Air-side Options
A = Std Air-Side coil
C = Corrosion Protective Coating
Cabinet Configuration D = StainlessSteel Drain Pan
P = Single Pacakage (Std) F = Coated Coil w/ S-S Drain Pan
S = Factory Split (Charged R-410A)
N = Factory Split (Nitrogen Charge Only)
0
A
DS
H
060
B
2
M
1
P
Integral Air-Cooled
Packaged A/C, R-410A
A
A
1
A

FORM 145.32-IOM3 (1213)
JOHNSON CONTROLS 7
GENERAL INFORMATION
Models 2 to 8 tons can be ordered as packaged,
factory-charged unitized packages or as factory split.
The 10 ton model comes factory-split. See ‘Cabinet
Configuration Options’ for more information.
Units can be turned on their side for short periods of
time, which allows passage through standard door
sizes. All unit components are securely mounted
inside the heavy gauge galvanized steel cabinet. All
units are lined with 1/2" thick - 2 lb density acoustical
insulation to ensure the quietest operation. All models
are provided with medium-efficiency 2" thick
throwaway filters rated MERV 7.
All units 2 to 5 tons utilize a single scroll compressor.
The 8 and 10 ton model is a dual scroll compressor
unit with two independent refrigerant circuits. All units
come standard with a microprocessor control board
(refer to ‘Microprocessor’ section).
Units will operate reliably at outdoor ambient down to
50°F. In applications requiring operation below this
temperature, a low ambient damper accessory is
available. The damper installs on the condenser air
intake, and allows operation to 0°F ambient.
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. Units are packaged and sealed
on shipping skids and shipped in first class condition.
Torn and broken packaging, scratched or dented
panels should be reported to carrier immediately.
Internal inspection of all units should be performed
prior to installation. Remove all access doors and
check for visual defects that can occur during
transport. Any problems found internally should be
reported to carrier and manufacturer immediately.
Refrigerant circuit should be checked to ensure no
leaks have occurred during shipment. Install gauge set
to high and low pressure ports to confirm pressure has
been maintained and no leaks have occurred during
shipment. Repair any damage prior to installation to
ensure safe operation.
RECORD ANY UNIT DAMAGE ON THE
BILL OF LADING AND REPORT TO
CARRIER AND FACTORY IMMEDIATELY.
SHIPPING AND HANDLING DAMAGES
ARE NOT WARRANTY ITEMS.
RIGGING
PRIOR TO MOUNTING UNIT, CHECK
INDIVIDUAL UNIT WEIGHTS (PAGE 10)
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 when ceiling
mount application is specified, estimate the
approximate center of gravity of the unit. The
configuration of internal components for each unit is
different and weight is unevenly distributed.
DETERMINE THE ACTUAL CENTER OF
GRAVITY OF THE UNIT BY PERFORM-
ING A TEST LIFT. LIFTING AN UNBAL-
ANCED UNIT CAN CAUSE PERSONAL
INJURY OR EVEN DEATH.
INSTALLATION SITE
LOCK ALL ELECTRICAL POWER SUP-
PLY SWITCHES IN THE OFF POSITION
BEFORE INSTALLING THE UNIT. FAIL-
URE TO DISCONNECT POWER SUPPLY
MAY RESULT IN ELECTRICAL SHOCK
OR EVEN DEATH.
Location - To ensure unit operates at maximum
efficiencies, choose a dry indoor area where the
temperature is controlled between 50°F and 115°F.
Consideration of surrounding areas should be taken
when choosing a location to install the unit. Common
vibration and sound levels associated with commercial
equipment may be objectionable to people or
equipment.
FAILURE TO ALLOW ADEQUATE SPACE
BETWEEN UNITS MAY RESULT IN POOR
UNIT PERFORMANCE AND POSSIBLE
UNIT FAILURE.
Install thermostats, air supplies and returns so that
each unit will operate only on individual unit control. To
assure fast drainage of condensate run-off, unit can be
slightly pitched in the same direction as drain pan
outlet.

FORM 145.32-IOM3 (1213)
8JOHNSON CONTROLS
CABINET CONFIGURATION OPTIONS
Horizontal unit consists of an evaporator and
condenser module. It is recommended to order the
units in the appropriate configuration minimize
installation costs and delays on site. Units 2 to 8 tons
can be ordered from the factory as either packaged or
split. The 10 ton unit only comes factory split. The
following cabinet configurations are possible (see
‘Nomenclature Table’ for other available options):
P– (2 to 8 ton models only) Unit comes assembled as
a packaged unit and factory-charged with R-410A.
Ideal for installations where unit will be installed as a
packaged system – no separation is required while
moving equipment into position or during installation.
S– Unit is factory-split and factory-charged with R-
410A. Unit comes with refrigerant shut-off/coupling
valves that hold charge in both condenser and
evaporator sections. Ideal for installations where unit
will be installed as a packaged system and separation
of evaporator and condenser is required during
installation to move equipment through tight spaces
(hallways, elevators, etc.). Both evaporator and
condenser sections contain R-410A refrigerant.
N– Unit is factory-split with a Nitrogen holding charge
only. No refrigerant shut-off/coupling valves are
included. For installations where unit will be installed
as a split system. Separate condenser and evaporator
sections facilitate moving equipment into position.
UNIT MOUNTING
Flanges for all duct connections, corner securing
brackets, and refrigerant tubing couplings (‘S’ cabinet
configurations only) are shipped in the condensing
section of the unit for field installation. Duct flanges for
evaporator return are incorporated into the filter rack.
Remove shipping securing straps and brackets from
refrigerant piping and couplings before assembling
and piping the units, see pictures below (8 & 10 ton
model shown).
Units may be either hung, or floor mounted. If unit is to
be hung, use all mounting points indicated –
regardless if unit is installed as a package or split
system (refer to typical installation diagram on Page 4-
5). Use of minimum ½ in. dia. hanger rods is strongly
recommended. Ensure the attachment point of the
rods to the building structure is sufficient to support the
unit weight. In order to ensure efficient condensate
drainage, the unit may be pitched towards the
evaporator end of the unit.
A minimum of 4-in. clearance is required under the unit
to allow for trapping of the evaporator condensate
drain. See ‘Typical Service Clearances’ section for
more unit clearance information.
DSH Operating Weight (Lbs)
Unit
Operating
Weight
(Condenser
Only)
Shipping Weight
(Condenser Only)
DSH024B 675 (390) 715 (430)
DSH036B 680 (400) 720 (440)
DSH048B
950 (565)
1010 (605)
DSH060B
990 (590)
1060 (630)
DSH096B 1470 (815) 1560 (855)
DSH120B 1800 (1020) 1870 (1060)
SEPARATION OF UNITS
All models can be ordered with refrigerant shut-off
valves/couplings to allow the evaporator and
condenser sections to be shipped factory-split for
assembly on site without the necessity of reclaiming
the entire unit refrigerant charge. The 2 to 5 ton
models are available with shut-off valves. The 8 and
10 ton models are available with self-sealing brass
refrigerant couplings. A Field Split Coupling Kit is
available for field split applications of the 8 and 10 ton
models ordered with couplings.
Self-Sealing Refrigerant Couplings
The male coupling is fastened to the condenser wall
via a mounting bracket. The 8 ton unit when ordered
as a single packaged unit can be field split. To
separate the couplings, you must use a back up
wrench on the female coupling to avoid stressing the
refrigerant piping (see picture below showing a
packaged unit with couplings).

FORM 145.32-IOM3 (1213)
JOHNSON CONTROLS 9
Once the couplings are unscrewed the female
coupling can be pulled away and allowed to rest in the
opening. No loss of refrigerant will occur due to the
spring-seal mechanism in the couplings.
The evaporator and condenser sections may be
separated by performing the following procedures.
These procedures are for the 2 to 8 ton capacities
only. On the 8 ton model unscrew all four couplings
(pictured above) with the aid of a back-up wrench to
separate the unit:
1) (2 – 5 ton models) Close all refrigerant
isolation valves, on both suction and liquid and
hot gas bypass (if applicable) line. Valves are
not a back-seating design. Caps are wrench
tight. Remove caps and turn stem clockwise to
seat in the closed position.
2) (2 to 5 ton models) Use the valve access ports
to reclaim the refrigerant trapped in the lines
between the pairs of shut-off valves.
Use a TUBING CUTTER ONLY - do not
use hacksaws to cut refrigerant tubing
otherwise serious damage can occur to
refrigeration system!
3) (2 – 5 ton models) Cut the refrigerant line
sections between the pairs of shut-off valves.
It is recommended to make this out where
accessibility is greatest - in the condensing
section of the unit. This will allow best access
for reconnection, or attachment of an
extended line set in the case of a split system.
4) Remove the interconnecting wiring between
the evaporator and condenser electrical panel.
Disconnect the wire terminations in the
condenser electrical panel, and pull the
excess wire into the evaporator panel.
5) Remove the threaded wire bushing connecting
the two electrical panels
6) Remove the unit top-joining strip; Take care to
remove only those screws which attach the
joining strip to the evaporator and condenser
cabinets.
7) Remove the two side cross-member angles.
8) 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
may now be individually moved to the desired location
for re-assembly, or separately located for split
applications. Splitting units with couplings will require
a mating coupling kit. See table below. For split
installations, the cross member angles will need to be
field cut for each section length and re-attached.
FIELD SPLIT COUPLING KITS
Model No.
Part No.
DSH096B*M*S / DSH096B*M*P
DSH096B-SPLIT-KIT
DSH096B*M*S / DSH096B*M*P
DSH096B-SPLIT-HGBP
w/ Hot Gas Bypass
DSH120B*M*P
DSH120B-SPLIT-KIT
DSH120B*M*P w/ Hot Gas Bypass
DSH120B-SPLIT-HGBP
The couplings must be protected for any
foreign material, dust or debris if they
are left uncapped for any extended
period of time.
When brazing couplings ensure the following is
adhered to:
1) When applying paste flux to copper tube,
avoid applying excessive amounts to avoid
flux running inside coupling where it can cause
corrosion and damage.
2) The coupling should be immersed in cold
water bath, ensuring the diaphragm (threaded)
is fully immersed
3) Double tipped torches are recommended to
reduce brazing time. After brazing quench the
couplings to reduce the temperature.
When assembling the couplings ensure the following:

FORM 145.32-IOM3 (1213)
10 JOHNSON CONTROLS
1) R-410A refrigerant oil is applied to entire
diaphragm surface, o-ring, and threaded male
coupling end.
2) Coupling halves must be held in proper
alignment with each other prior to starting the
threads of the female coupling nut onto the
male half. Thread by hand the first 3 rotations
of the union nut. If nut does not start by hand,
adjust position of the line set or if necessary
position of unit module.
3) Using a back-up wrench tighten the female
union nut until a definite increase in resistance
is felt. At this point most of threads will have
been covered by the nut. Ensure that the
female and male bodies during any portion of
the wrench installation do not rotate.
4) Make note of the location of the female nut to
the bulkhead. Using a marker or scribe to
mark a line lengthwise. Then finally tighten an
additional one wrench flat or 60o. This final
tightening is necessary to ensure a proper
leak proof seal between the couplings.