Johnson Controls D Series User manual

Form number: 145.13-NO2 (920)
Supersedes: 145.13-NO2 (520)
Installation Guide
www.johnsoncontrols.com
Issue date: 2020-09-23
Johnson Controls
VFD for D-Series (DSV/DSH) Air-cooled
Self-Contained Units, and C-Series (CSV)
Water-Cooled Self-Contained Units, C-
Gen

2 VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained
Units, C-Gen
Johnson Controls

Contents
ContentsImportant!....................................................................................................................................................... 5
Read before proceeding!.................................................................................................................... 5
General safety guidelines......................................................................................................................... 5
Safety symbols............................................................................................................................................ 5
Changeability of this document............................................................................................................... 6
Associated literature.................................................................................................................................. 6
Technical support....................................................................................................................................... 7
Replacement parts..................................................................................................................................... 7
VFD Nomenclature.............................................................................................................................. 7
Installation...................................................................................................................................................... 8
Background.......................................................................................................................................... 8
SZVAV option in D-Series / MZVAV option in C-Series........................................................................... 8
Factory shipped................................................................................................................................... 9
DSV models.......................................................................................................................................... 9
DSH models.......................................................................................................................................... 9
CSV models........................................................................................................................................... 9
VAV units............................................................................................................................................. 10
Differential pressure transducer............................................................................................................ 10
IntelliSpeed™ fan control (8-25T).................................................................................................... 11
VFD keypad......................................................................................................................................... 12
Installation.......................................................................................................................................... 15
Install grille cover.............................................................................................................................. 16
Operation...................................................................................................................................................... 17
Input/output...................................................................................................................................... 17
Parameter tables............................................................................................................................... 17
Display................................................................................................................................................. 17
VFD option schematics..................................................................................................................... 22
Johnson Controls
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained
Units, C-Gen
3

4 VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained
Units, C-Gen
Johnson Controls

Important!
Read before proceeding!
General safety guidelines
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 people 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.
5VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

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.
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 sales 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 Date implemented
Page 6 Associated literature section updated September 2020
Page 18 Table 1 updated with additional parameter September 2020
Page 19 Table 2 updated with additional parameter September 2020
Whole document Minor updates and clarifications September 2020
Associated literature
Manual description Form number
D-Series Vertical (DSV060C-300C) Air-Cooled Self-Contained Units, C
Generation with Smart Equipment Controller Installation, Operation, and
Maintenance Manual
145.29-IOM4
D-Series Horizontal (DSH024C-120C) Air-Cooled Self-Contained Units, C
Generation with Smart Equipment Controller Installation, Operation, and
Maintenance Manual
145.32-IOM5
C-Series Vertical (CSV) Water-Cooled Self-Contained Units, C-Generation,
R-410A, Model CSV060C–300C 145.15-IOM8
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
6
Johnson Controls

Technical support
If Technical Support is required, contact the Product Technical Support team at 877-329-7430 or
AppliedDXT[email protected].
Replacement parts
For replacement parts, contact your local Source1 Dealer.
Source1 Parts Phone Number: 800-536-6112
Source 1 Parts Website: http://www.source1parts.com
VFD Nomenclature
Note: LAC option is not available on 575V.
7VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

Installation
CAUTION
Do not enter Setup mode when powering on the VFD.
Do not change parameters 4009 and 4011 for the VAV option on DSH, DSV, or CSV C-gen units. These 2
parameters are used for B-gen units only (Simplicity 1A not SEC.)
For these units, use the Smart Equipment (SE) controller to set the VAV setpoint.
WARNING
Prior to installing or servicing the unit, ensure proper lockout/tagout (LOTO) procedures are followed
per OSHA safety regulations (29 CFR 1910.147 and 29 CFR 1910.333). Failure to disconnect power supply
may result in electrical shock or even death.
Always wait for at least 5 minutes after disconnecting the power before servicing the unit.
Background
All D-Series and C-Series units that are 8 tons or larger have a Variable Frequency Drive (VFD)
installed.
There are 2 controlled fan method VFD options for D-series. SZVAV differential pressure transducer
and IntelliSpeed™ (2, 3 or 4 speed) fan control.
There are 3 controlled fan method VFD options for C-series. SZVAV, MZVAV differential pressure
transducer and IntelliSpeed™ (2 speed) fan control.
Note:
Refer to the nomenclature breakdown in the appropriate DSV, DSH, or CSV Installation,
Operation, and Maintenance (IOM) manual and also the nameplate of the unit to determine
the Controlled Fan Method. The tenth digit of the nomenclature (ID Motor) identifies which
method the unit has.
Use the nomenclature to select the low ambient condenser option.
SZVAV option in D-Series / MZVAV option in C-Series
For C/D-Series units with the SZVAV or MZVAV option, the supplied VFD allows the operator to
set the external static (0.0–5.0 "WC), as measured from a supply duct location determined by
field installer and/or as per field specifications. The VFD controls the frequency (speed) of the
evaporator fan motor in order to meet the desired external static (ESP) setpoint. The VFD controls
amp draw of the motor and does not allow the motor draw more than FLA amps.
Note: Do not run the evaporator fan motor below 30Hz, as coil freeze-up and nuisance
lockouts may occur. The unit is factory set to minimum 30 Hz output with the exception of the
Low Ambient Condenser VFD, which is set to 15 Hz.
Note: The unit does not carry a failsafe circuit to bypass the VFD and run the evaporator fan in
the event of a VFD malfunction.
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
8
Johnson Controls

The unit does not carry a failsafe circuit bypass for the evaporator fan in the event of a VFD
malfunction. During a VFD failure, the evaporator fan becomes nonoperational. If there is a
demand for cooling, the unit compressors continue to run until the low pressure safety switch trips.
Factory shipped
Units that are 8 tons or larger ship with a VFD controller factory installed and wired in the
evaporator (air handler) corner post. See the dimensional drawings in the IOM for the location.
DSV models
The DSV units ship factory split (condenser and evaporator) and require assembly in the field. The
motor is pre-wired to the VFD in the factory.
To assemble the DSV model in the field:
1. Plug the low voltage wiring, shipped wired to the VFD, to the SE Controller.
2. Connect the low voltage wires from VFD unit (24VDC) to the evaporator fan VFD relay
(EVFDR). The EVFDR relay acts as a switch to turn on the VFD.
3. Connect two 1/4 inch Q.C. to common and normally open positions (red wire to “C,” orange
wire to “NO”).
The VFD switch runs on 24VDC.
CAUTION
Do not cross 24VAC and 24VDC wiring on EVFDR relay.
DSH models
The VFD controller on DSH units is factory wired. The evaporator fan power conductors are factory
wired to the distribution block. The control wiring for field split applications needs to be field
provided and routed from condenser to evaporator.
CSV models
The CSV units ship factory assembled except for the CSV240 which can optionally be split and the
CSV300C which ships split (condenser and evaporator) and requires assembly in the field. The
motor is pre-wired to the VFD in the factory.
To assemble the CSV300C model in the field:
1. Plug the low voltage wiring, shipped wired to the VFD, to the SE Controller.
2. Connect the low voltage wires from VFD unit (24VDC) to the evaporator fan VFD relay (EVF-
DR). The EVFDR relay acts as a switch to turn on the VFD.
3. Connect two 1/4 inch Q.C. to common and normally open positions (red wire to “C,” orange
wire to “NO”).
The VFD switch runs on 24VDC.
9VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

CAUTION
Do not cross 24VAC and 24VDC wiring on EVFDR relay.
VAV units
Differential pressure transducer
Figure 1: Label on unit/VFD for VAV with pressure transducer
For VAV option units, the differential pressure transducer (0-5" W.C) is factory wired and mounted
inside the VFD control box. The transducer senses gage pressure (static) and converts this pressure
difference to an analog signal. The unit is wired for 0–5VDC output for DSV, DSH, or CSV C-gen
units.
The transducer is supplied with two 1/4-inch OD pressure fittings and accepts field provided 1/4-
inch push-on tubing for lengths of up to 300 feet. The positive (HIGH) and negative (LOW) pressure
ports are indicated on the transducer. Connect unit RETURN AIR tubing to negative (LOW) fitting
and SUPPLY AIR tubing to positive (HIGH) fitting.
Note:
Do not enter Setup mode when powering on the VFD.
Do not change parameters 4009 and 4011 for the VAV option on DSH, DSV, or CSV C-gen units.
These 2 parameters are used for B-gen units only (Simplicity 1A, not SEC.)
For these units, use the Smart Equipment (SE) controller to set the VAV setpoint.
CAUTION
Do not adjust the VFD setpoint to greater than the maximum design pressures of the duct system or
the unit.
Note:
• Only use 24VAC from SE controller to the differential pressure transducer (Term. Exc.)
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
10
Johnson Controls

• Set S1 jumper on VFD, AI1, to Volts
• The VFD is enabled by the Evaporator Fan VFD Relay (EVFDR)
IntelliSpeed™ fan control (8-25T)
Figure 2: Label on unit/VFD for IntelliSpeed™ fan control
Note:
Figure 2 is an example of a label.
The Intellispeed™ fan control is available on all 8 ton and larger DSH, DSV, and CSV units.
Table 1: Fan speed % vs. compressor stage
Stage 1 Stage 2 Stage 3 Stage 4
DSH024C-
DSH060C 100% N/A N/A N/A
DSH096C 50% 60% 100% N/A
DSH120C 50% 60% 75% 100%
DSV060C 100% N/A N/A N/A
DSV096C-144C 50% 60% 100% N/A
DSV180C-300C 50% 60% 75% 100%
CSV060C 100% N/A N/A N/A
CSV096C-300C 60% 100% N/A N/A
11VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

VFD keypad
The VFD requires a keypad to program the VFD. The keypad is not required to operate the unit
when the VFD is programmed. The keypad is required during initial startup of the unit. Each
unit comes with a factory installed and programmed remote keypad and short Ethernet clip on
connector. An Ethernet communication cable is supplied by the factory. You can use a single keypad
to program multiple units. Consult with your sales office to order additional keypads. A copy of the
factory default settings is saved to the keypad memory available for restore if needed.
To clone a VFD on another unit, refer to the upload/download procedure in the ACS320 drives User
Manual (pg.72-74). ABB Code 3AUA0000062599.
Figure 3: VFD keypad
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
12
Johnson Controls

Figure 4: VFD keypad and Ethernet connector (CSV/DSH shown)
13VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

Figure 5: Internally routed ethernet cable
Note: (On DSV only, keypad is mounted in condenser post)
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
14
Johnson Controls

Installation
For units utilizing the VAV option, install a field supplied 1/4-inch push-on tube to the return air side
of the unit. Pass the tube through the opening on the side of the corner post adjacent to the VFD
controls, and connect to the negative (LOW) side fitting.
Install a field supplied Pitot tube in the supply duct as required, run 1/4-inch push-on tube to
the corner post opening, and connect to the positive (HIGH) side fitting. Where possible, it is
recommended to have the pitot tube located a minimun of 6ft away from the supply discharge and
located centrally in the supply duct.
Figure 6: Connecting negative and positive side fittings
Check that the tubes are secure inside the duct and firmly connected to transducer fitting. If they
are not, the unit will not operate as intended.
15VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

Install grille cover
When the unit is wired and the push-on tubing is connected to the transducer, attach the grille
cover using the screws provided, with angled blades point upward at the top.
Figure 7: VFD grille cover
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
16
Johnson Controls

Operation
Input/output
Figure 8: Input/output diagram
Jumper required between 10, 11
Note: S1 is set to mA on "B" Generations.
Parameter tables
In the parameter menu, set the following parameters listed in the following parameters tables to
operate the VFD controller correctly. For troubleshooting, check that the parameters match.
Display
In AUTO MODE, the following parameters display on control display:
1. 30–60Hz is the output frequency to the motor. The minimum factory set frequency allowed is
30 Hz.
2. 0.0–Nominal Motor Amps. The maximum amps draw is factory set, and is set to nominal amp
draw of motor used.
3. 0.0–5.0 "WC is the actual reading from the pressure transducer.
4. The setpoint value is displayed in the upper-right corner. Values range from 0% to 100%. That
is the actual setpoint for the controller. The setpoint can be 0%, which is 0.0 "WC or 100%,
which is 5.0"WC.
17VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

Table 2: DSH/DSV/CSV only factory parameters for multi-speed evaporator application -
208/230V and 460 VAC (ABB ACS320)
Name Value Unit
99 Start-up data
01 Language English
02 Applic macro HVAC default
05 Motor nom volt Drive dependent V
06 Motor nom curr Drive dependent A
07 Motor nom freq 60 Hz
08 Motor nom speed Drive dependent rpm
09 Motor nom power Drive dependent hp
10 Start/stop/dir
01 Ext1 commands DI1
02 Ext2 commands DI1
11 Reference select
01 Keypad ref sel Ref1 (Hz/rpm)
02 Ext1/ext2 sel Ext2
03 Ref1 select KEYPAD
04 Ref1 min 0 Hz
05 Ref1 max 60 Hz
06 Ref2 select AI1
07 Ref2 min 0
08 Ref2 max 100
13 Analogue inputs
01 Minimum AI1 20 %
02 Maximum AI1 100 %
14 Relay outputs
01 Relay output 1 FLT/alarm
16 System controls
01 Run enable DI1
08 Start enable 1 Not sel
09 Start enable 2 Not sel
20 Limits
03 Max current Drive dependent A
07 Minimum freq 30 Hz
08 Maximum freq 60 Hz
34 Panel display
01 Signal1 param Output freq
02 Signal1 min 0 Hz
03 Signal1 max 60 Hz
04 Output1 DSP form +0.0
05 Output1 unit Hz
06 Output1 min 0
07 Output1 max 60
08 Signal2 param Current
09 Signal2 min A 0
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
18
Johnson Controls

Table 2: DSH/DSV/CSV only factory parameters for multi-speed evaporator application -
208/230V and 460 VAC (ABB ACS320)
Name Value Unit
10 Signal2 max A 0
11 Output2 DSP form Direct
12 Output2 unit A
Table 3: DSH/DSV only factory parameters for low ambient condenser application - 208/230V
and 460 VAC (ABB ACS320)
Name Value Unit
99 Start-up data
01 Language English
02 Applic macro Condenser
05 Motor nom volt Drive dependent V
06 Motor nom curr Drive dependent A
07 Motor nom freq 60 Hz
08 Motor nom speed Drive dependent rpm
09 Motor nom power Drive dependent hp
10 Start/stop/dir
01 Ext1 commamds Not sel
02 Ext2 commands DI1
03 Direction Forward
11 Reference select
01 Keypad ref sel Ref1 (Hz/rpm)
02 Ext1/ext2 sel Ext2
03 Ref1 select Keypad
04 Ref1 min 0 Hz
05 Ref1 max 60 Hz
06 Ref2 select Pid1out
07 Ref2 min 0 %
08 Ref2 max 100 %
13 Analogue inputs
01 Minimum AI1 0 %
02 Maximum AI1 100 %
14 Relay outputs
01 Relay output 1 FLT/ALARM
16 System controls
01 Run enable DI1
08 Start enable 1 DI1
09 Start enable 2 Not sel
20 Limits
03 Max current Drive dependent A
07 Minimum freq 15 Hz
08 Maximum freq 60 Hz
34 Panel display
01 Signal1 param Output freq
02 Signal1 min 0 Hz
03 Signal1 max 60 Hz
05 Output1 unit Hz
08 Signal2 param Pid 1 setpnt
19VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
Johnson Controls

Table 3: DSH/DSV only factory parameters for low ambient condenser application - 208/230V
and 460 VAC (ABB ACS320)
Name Value Unit
09 Signal2 min A 0
11 Output2 DSP form Direct
40 Process pid set 1
04 Pid deriv filter 1
05 Error value inv Yes s
06 Units PSI
08 0% 0 PSI
09 100% value 750 PSI
10 Set point sel Internal
11 Internal setpnt 320 PSI
16 Act1 input AI1
Table 4: DSH/DSV/CSV only factory parameters and signals for 575V evaporator settings (ABB
ACS250)
Name Value Unit
99 Start-up data
02 Applic macro 1
05 Motor nom volt Drive dependent V
06 Motor nom curr Drive dependent A
07 Motor nom freq Drive dependent Hz
08 Motor nom speed Drive dependent rpm
11 Reference select
03 Primary command 0: Terminal control
13 Analogue inputs
00 Analog input 1 U 0 - 10
14 Relay outputs
01 User relay output 12: Drive tripped
20 Limits
17 Maximum motoring 100 %
Current limit
26 Motor control
03 V/F mode voltage boost Auto
SEC Parameters (DSH120C, DSV180C-DSV300C)
1ClgStg% - 50% (CV IntelliSpeed 1 stg cool)
2ClgStg% - 60% (CV IntelliSpeed 2 stg cool)
3ClgStg% - 75% (CV IntelliSpeed 3 stg cool)
4ClgStg% - 100% (CV IntelliSpeed 4 stg cool)
SEC Parameters (DSH096C, DSV096C-DSV144C)
1ClgStg% - 50% (CV IntelliSpeed 1 stg cool)
2ClgStg% - 60% (CV IntelliSpeed 2 stg cool)
3ClgStg% - 100% (CV IntelliSpeed 3 stg cool)
SEC Parameters (CSV096C-300C)
1ClgStg% - 60% (CV IntelliSpeed 1 stg cool)
2ClgStg% - 100% (CV IntelliSpeed 2 stg cool)
VFD for D-Series (DSV/DSH) Air-cooled Self-Contained Units, and C-Series (CSV) Water-Cooled Self-Contained Units,
C-Gen
20
Johnson Controls