Johnson Controls DSH024C Series User manual

Form number: 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

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

Contents
ContentsGeneral safety guidelines.............................................................................................................................. 5
Important!............................................................................................................................................ 5
Read before proceeding!.......................................................................................................................... 5
Safety symbols............................................................................................................................................ 5
Changeability of this document............................................................................................................... 6
Associated literature.................................................................................................................................. 7
Technical support....................................................................................................................................... 7
Replacement parts..................................................................................................................................... 7
Nomenclature............................................................................................................................................. 8
Installation...................................................................................................................................................... 9
Pre-installation inspection of equipment......................................................................................... 9
Rigging...................................................................................................................................................... 10
Installation site.................................................................................................................................. 10
Location..................................................................................................................................................... 10
Cabinet configuration options......................................................................................................... 10
Unit mounting.................................................................................................................................... 11
Separation of the units..................................................................................................................... 12
Separating the units................................................................................................................................ 13
Interconnecting refrigerant tubing................................................................................................. 17
Dimensional data............................................................................................................................... 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 sensors................................................................................................................... 39
Variable frequency drive (VFD)........................................................................................................ 39
Indoor fan VFD......................................................................................................................................... 40
Outdoor fan VFD (208-230V and 460V only)......................................................................................... 40
Hot gas bypass (HGBP)..................................................................................................................... 41
Adjusting HGBP setpoint......................................................................................................................... 41
Johnson Controls
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller 3

Start-up and operation................................................................................................................................ 42
Checking superheat and subcooling.............................................................................................. 43
Subcooling................................................................................................................................................ 43
Startup (cooling)...................................................................................................................................... 45
Microprocessor controller...................................................................................................................... 45
Maintenance and 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 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.
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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.
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
Revisions made to this document are indicated in the following table. These revisions are to
technical information, and any other changes in spelling, grammar, or formatting are not included.
Affected section Description Date implemented
Nomenclature Updated notes for DSH Nomenclature March 2020
Figure 14 Figure 14 caption and notes 1 and 2 updated to reflect
two-stage discrete heating and single stage cooling. March 2020
Figure 16 Figure 16 caption and note 3 updated to reflect four-
stage cooling March 2020
Appendix B:
SEC parameters
for DSH024C–
DSH120C units
Added Appendix B: SEC Parameters for DSH024C–
DSH120C Units March/April 2020
Figure 15 and
Figure 16
Updated Figure 15 and Figure 16 to remove optional
jumper cable, and added note 1 to require installation
of a thermostat that supports all stages of operation.
April 2020
Cabinet
configuration
options
Added a DANGER warning to the Cabinet Configuration
Options section. May 2020
Nomenclature Updated Nomenclature November 2020
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller6
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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 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
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
7Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation 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.
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller8
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Installation
Models 2–8 tons can be ordered as packaged, factory-charged unitized packages, or as factory-split.
The 10 ton model comes factory-split.
All units are lined with 1/2-inch thick and 2 pound density acoustical insulation to ensure quiet
operation. All models are provided with medium-efficiency 2-inch thick throwaway filters rated
MERV 7.
The 2–5 ton units use a single scroll compressor. The 8–10 ton units use a dual scroll compressor
with two independent refrigerant circuits. The 8 ton unit uses one single speed scroll compressor
and one two-stage scroll compressor, giving the unit three effective cooling stages. The 10 ton unit
features two 2 stage compressors, which allows for four stage cooling.
All units come standard with a Smart Equipment (SE) microprocessor control board with safety
controls and troubleshooting LEDs (see Microprocessor Controller on page 41 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.
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.
WARNING
Prior to mounting unit, check individual unit weights (Table 1 on page 11) 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.
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Rigging
To ensure safe installation of the unit when a ceiling mount application is specified, estimate the
unit's approximate center of gravity. The configuration of internal components for each unit is
different and the weight is unevenly distributed.
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.
Cabinet configuration options
Horizontal units have two parts: an evaporator and a condenser section. To minimize installation
costs and delays on site, it is recommended to order the units in the appropriate configuration.
Units 2–8 tons can be ordered from the factory as either packaged or split. The 10 ton unit only
comes factory-split.
Here are examples of cabinet configurations. See Nomenclature for other available options:
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller10
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P
Applies to only 2–8 ton models. The unit comes assembled as a packaged unit and
factory charged with R-410A refrigerant.
P is ideal for installations where the unit is installed as a packaged system. While moving
the equipment into position or during installation, no separation is required.
S
The unit is factory-split and factory-charged with R-410A refrigerant. The unit comes
with refrigerant shut-off/coupling valves that hold charge in both the condenser and
evaporator sections.
S is ideal for installations where the unit is installed as a packaged system. Separate
evaporator and condenser sections are required during installation to move the
equipment through tight spaces (for example, hallways or elevators).
Both evaporator and condenser sections contain R-410A refrigerant.
N
The unit is factory-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 facilitate moving the equipment into position.
Unit mounting
Flanges for all duct connections, corner securing brackets, and refrigerant tubing couplings (S
cabinet configurations only) ship in the condensing section of the unit for field installation. Duct
flanges for evaporator return are incorporated into the filter rack.
Before assembling and piping the units, remove the tiedown straps and brackets from the
refrigerant piping and couplings. See Figure 1 (8 and 10 ton models are shown).
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Figure 1: Securing straps and brackets
Table 1: Operating weight
Unit Operating weight
(condenser only)
Shipping weight
(condenser only)
DSH024C 675 (390) 715 (430)
DSH036C 680 (400) 720 (440)
DSH048C 955 (568) 1015 (608)
DSH060C 995 (593) 1065 (633)
DSH096 1470 (815) 1560 (855)
DSH120C 1800 (1020) 1870 (1060)
Note: All weights are in lbs.
Units may be either hung or floor mounted. If the unit is hung, use all the indicated mounting
points, whether the unit is installed as a package or split system (see Figure 4 on page 13 and
Figure 5 on page 14). Hanger rods with a minimum 1/2-inch diameter are strongly recommended.
Ensure the attachment 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 the units
All models can be ordered with refrigerant shut-off valves or couplings. These components allow
the evaporator and condenser sections to ship factory-split. The evaporator and condenser can
then be assembled onsite without requiring the entire unit refrigerant charge be reclaimed.
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller12
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The 2–5 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 8 and 10 ton models ordered with couplings. Refer to General Piping
Recommendations and Refrigerant Line Lengths (Form 247077-UAD-H-0209).
The male coupling is fastened to the condenser wall via a mounting bracket. The 8 ton unit ordered
as a single packaged unit can be field split. To separate the couplings without stressing the
refrigerant piping, use a backup wrench on the female coupling (see Figure 3).
Figure 2: Self-sealing 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 ton capacities only. On the 8 ton model, unscrew all four
couplings (Figure 3) with the aid of a backup wrench to separate the unit.
1. For 2–5 ton models, close all of the refrigerant isolation valves on the suction, liquid, and hot
gas bypass line (if applicable). Valves are not a backseating design. Caps are wrench tight.
13Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller
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2. Remove the caps and turn the valve stem clockwise to seat the valve in the closed position.
3. For 2–5 ton models, use the valve access ports to reclaim the refrigerant trapped in the lines
between the pairs of shut-off valves.
CAUTION
Use a TUBING CUTTER ONLY - do not use a hacksaw to cut refrigerant tubing. Otherwise serious
damage can occur to refrigeration system!
4. For 2–5 ton models, cut the refrigerant line sections between the pairs of shut-off valves.
It is recommended to make this cut where accessibility is greatest - in the condensing section
of the unit. This allows the best access for reconnection or attachment of an extended line set
in the case of a split system.
5. 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.
6. Remove the threaded wire bushing connecting the two electrical panels.
7. Remove the unit 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 be individually moved to the desired
location for re-assembly or separately located for split applications. Splitting units with couplings
requires a mating coupling kit. See Table 2. For split installations, the cross member angles must be
field cut for each section length and re-attached.
Table 2: Field split coupling kits
Model number Part number
DSH096C***P/DSH096C***S DSH096B-SPLIT-KIT
DSH096C***P/DSH096C***S with Hot Gas
Bypass (HGBP) DSH096B-SPLIT-HGBP
DSH120C***S DSH120B-SPLIT-KIT
DSH120C***S with HGBP DSH120B-SPLIT-HGBP
Note: The couplings must be protected from any foreign material, dust, or debris if they are
left uncapped for any extended period of time.
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller14
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Figure 4: Single compressor unit – typical installation configuration
15Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller
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Figure 5: Dual compressor unit – typical installation configuration
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller16
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When brazing couplings, ensure the following:
1. When applying paste flux to the copper tube, avoid applying excessive amounts. This
prevents flux running inside the coupling where it can cause corrosion and damage.
2. Immerse the coupling in a 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:
1. Use clean oil.
2. The refrigerant oil is applied to the entire diaphragm surface, O-ring, and threaded male
coupling end.
3. Before starting the threads of the female coupling nut onto the male half, coupling halves
must be held in proper alignment with each other. Thread by hand the first three rotations
of the union nut. If the nut does not start by hand, adjust the position of the line set or, if
necessary, the unit module's position.
4. Use a backup wrench to tighten the female union nut until a definite increase in resistance is
felt. At this point, most of threads have been covered by the nut. Ensure that the female and
male bodies do not rotate at any point in the wrench installation.
5. Make a note of the location of the female nut to the bulkhead. Use a marker or scribe to mark
a line lengthwise. Finally, tighten an additional one wrench flat or 60°. This final tightening is
necessary 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.
Note: There are exceptions for total line lengths exceeding 75 feet where pressure drop
limitations are exceeded. For further information, refer to General Piping Recommendations and
Refrigerant Line Length (Form 247077-UAD-H-0209).
The following guidelines apply to field fabricated piping:
• Use hard drawn refrigeration type copper tubing where no appreciable amount of bending
around pipes or obstructions is necessary. If soft copper must be used, take care to avoid
sharp bends that may cause a restriction. Route refrigerant tubing for minimum linear length
and minimum number of bends and fittings. The use of long radius elbows for all 90° bends
is recommended.
• Braze all copper to copper joints with brazing rod high in silver or equivalent brazing
material. DO NOT USE SOFT SOLDER.
• During brazing operations, flow an inert gas such as nitrogen through the system to prevent
internal scaling and contamination.
If the piping is properly sized, traps are not required. They only increase the pressure drop across
the system, further reducing capacity.
17Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller
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Once the brazing operation of refrigeration lines is completed, the field-brazed connections must
be checked for leaks:
1. Pressurize the system with clean nitrogen 200 and 400 psig.
2. Monitor the pressure for 15–30 minutes. Use soap bubbles or alternate methods of leak-
checking for all field brazed joints.
3. After completing the leak check, evacuate the 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
Note: Measurements are in inches
Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller18
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Dimensional data
Figure 6: DSH024C and DSH036C dimensional data: 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.
19Model DSH024C–120C Horizontal R-410A Air Conditioning Units C-Generation Smart Equipment Controller
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Figure 7: DSH048C and DSH060C dimensional data: 4–5 ton horizontal A/C unit
Note:
1. Dimension tolerance is 1/16 in.
2. Evaporator and condenser duct connections cannot be altered unless noted.
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