Unitary products group DSH Manual de usuario

MODELS DSH/KSH/DSV/KSV

R-410A LOW-AMBIENT KIT

Supersedes Form145.10-IOM1 (810) Form 145.10-IOM1 (910)

LOW-AMBIENT KIT

MODELS DSH/KSH/DSV/KSV

R-410A AIR CONDITIONING UNITS

INSTALLATION INSTRUCTIONS

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 manufacturers’ warranty and cause serious damage to property

or injury to persons.

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls policy for

continuous 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

4 ……General Information

4 ..…..Damper Installation

6 ……Pressure Control Panel Installation

6 ……Pressure Transducer Installation

8 ……Damper Actuator Installation & Wiring

10 ……Actuator Rotation Verification

11 ……Interconnection Drawings

13 ……Sequence of Operation

14 ……Schematics

Before installing this accessory kit, turn off electrical power to the equipment. Failure to do so

could result in electrical shock, resulting in component damage, injury or death.

GENERAL INFORMATION

If unit operation is required at outdoor ambient below

45 deg F, the optional Low Ambient Damper kit should

be installed to maintain acceptable condensing

pressure.

In horizontal units, the damper is installed directly over

the intake duct connection. The damper in vertical

units is installed over the exhaust duct connection (as

illustrated below). The damper position is determined

by refrigerant pressure. A direct-coupled electric

damper actuator motor drives the damper open or

closed, depending on the output signal from a

proportional pressure control module. A pressure

transducer senses the high-side refrigerant pressure,

through a service access port, located on the liquid

refrigerant line leaving the condenser. The pressure

controller, complete with terminal connection blocks for

wiring, is attached to a field-installed mounting bracket.

Appropriate mounting hardware for the pressure control

module and the damper actuator motor are provided

with the kit. A routing hole is provided in the condenser

corner panel, near the actuator mounting location, to

allow installation of the plenum-rated cable between the

motor and the control module.

A solid-state timer(s) is provided with the damper kit.

The timer will bypass the low pressure switch during

compressor start-up. The time delay allows the

condensing pressure to rise sufficiently for refrigerant

flow through the evaporator to be established, thereby

eliminating nuisance low-pressure lock-outs.

On Dual compressor units, the transducer MUST be connected to the #1 circuit liquid line fitting.

Connection to the second stage refrigerant circuit will result in system malfunction.

When installing the transducer, observe all regulations governing the handling and containment of

hazardous or regulated materials (refrigerants or lubricants).

DAMPER INSTALLATION

HORIZONTAL UNITS (DSH / KSH SERIES)

1) Remove the factory installed duct attachment flanges from the condenser intake opening. Retain the two short

(vertical) flanges – these will be used in installation of the damper.

2) The kit contains two long flanges, which reduce the intake opening height to match the damper dimensions.

Attach these replacement flanges using the original holes and screws.

3) Re-attach one of the original vertical flanges as close to the edge of the corner post as possible (approx 1/8”

from edge of corner).

4) Position the damper casing between the two horizontal flanges surface, and butt the drive end of the damper

against the vertical flange at the corner of the unit. Ensure that the damper is orientated as shown – drive shaft

at the top of unit.

5) Secure the damper using the self-drilling screws provided (drive screws the holes in the flanges, into the metal

damper casing).

6) Attach the remaining vertical flange, opposite the drive end of the casing.

7) Ensure that the damper assembly rotates freely, with little or no resistance, by rotating the drive shaft by hand.

VERTICAL UNITS (DSV / KSV SERIES)

1) The kit includes two vertical and two horizontal factory supplied duct flanges.

2) Locate pilot holes at condenser exhaust and line up duct flanges accordingly.

3) Secure flanges using self-drilling sheet metal screws. The horizontal flanges should be flush with the

condenser exhaust opening.

4) Position the damper inside the flanges and secure with screws.

PRESSURE CONTROL PANEL INSTALLATION & WIRING

1) The Pressure Control Panel is intended for mounting, to the interior base pan in horizontal units and on the base

rails in vertical units, in the compressor/condenser section, immediately behind the compressor side access panel

(see photo). Fasten the panel bracket to the vertical flange of the interior base pan (recommended) or to the

horizontal surface of the pan, using the provided self-drilling screws.

2) The kit contains a pre-terminated two-wire harness (red and white) to connect the Connect Control Panel to the 24

VAC power supply terminal, located in the main electrical panel of the condensing unit. The harness must be fed

through the electrical routing hole, for horizontal units at the intake end of the condenser coil, and for vertical units

at the low voltage end of the electrical panel (see photos).

3) Route the harness across the blower section of the unit, for horizontal units - into the back of the electrical panel via

the low voltage entrance hole. Secure the harness, using the self-adhesive mounts provided, to ensure that the

wiring is kept well clear of the belt driven blower and motor assembly.

4) Within the condenser electrical panel, the harness is to be connected to terminal block ‘TB4C’ for horizontal units

and terminal block ‘TB2’ for vertical units. The red harness lead is to be connected to the ‘R’ terminal; the white

harness lead is to be connected to the ‘C’ terminal (refer to Lo-Ambient Control inter-connection drawing).

5) Mount the timer(s) in low voltage section of the condenser electrical panel. Connect the timers into the low-voltage

control circuit as shown in the electrical schematic diagrams. The wire splice between the LPC and HPC switches is

accessible inside the electrical panel, in the low voltage section of the enclosure.

6) Within the compressor compartment, secure the harness to the existing compressor wiring, and route the

terminated ends to the 2-pole terminal block on the Pressure Control Panel. Attach the terminated harness ends to

the appropriate terminals (red-to-red, and white-to-white).

HORIZONTAL WIRING

VERTICAL WIRING

PRESSURE TRANSDUCER INSTALLATION

1) The compact ‘P499’ transducer mounts directly to the liquid refrigerant pressure port. This port is either

incorporated into the refrigerant shut-off valve (as illustrated in DSH Series units), or an access port fitting brazed to

the copper refrigerant line (KSH Series condensing units).

2) Hand thread the transducer onto the pressure port. (Wear a glove for protection, and seat the transducer as quickly

as possible to minimize release of liquid refrigerant.

3) Tighten the connection using the wrench flats provided to avoid damaging the transducer.

4) The connecting harness for the pressure transducer is pre-wired to the Pressure Control Panel. The sensor end of

the harness is equipped with a polarized plug connection. Insert the plug into the end of the transducer, ensuring

that the locking tab on the plug is engaged.

5) Perform a leak test on the refrigerant port connection before putting the system into operation.

DAMPER ACTUATOR INSTALLATION & WIRING

1) Press and hold the gear release lever, and rotate the

drive coupler to the fully clockwise position. Release

the gear lever.

2) Fully close the damper, by turning the drive shaft

clockwise.

3) Insert the tab on the anti-rotation bracket into the slot

at the bottom of the actuator, and slide the actuator

onto the damper drive shaft.

4) Position the anti-rotation bracket at the indicated

dimension below the drive shaft center (6-3/16 in.).

5) Use the holes in the anti-rotation bracket as a guide

and secure the bracket to the damper casing, using

the self-drilling screws provided. (Do not drive screws

near the center of the damper casing. Use the

outermost holes in the anti-rotation bracket.)

6) Adjust the anti-rotation bracket, as necessary, to

position the tab mid-way into the slot at the bottom of

the actuator.

The tab on the anti-rotation bracket

must fit midpoint in the actuator slot to

prevent actuator binding and

premature wear.

7) Hold the actuator in place, and evenly hand tighten

each clamp nut onto the U-bolt. Ensure that the

damper drive shaft remains in the fully closed position,

while tightening the clamp nuts. Secure the U-bolt to

the damper shaft.

8) Press and hold the gear release. Rotate the coupler

and drive shaft from fully closed to fully open to verify

that the damper and actuator rotate freely throughout

the range.

9) Loosen the actuator cover screw (No. 1 Phillips), and

remove the actuator cover. Push the plastic plug,

adjacent to the actuator terminal block, out of the

conduit opening.

10) Use the Phillips screwdriver to punch the center hole

through the plug, and reinsert the plug into the

opening.

11) A plenum-rated connection cable is provided, pre-

wired to the Pressure Control Panel, for supply of 24

VAC power and 0-10 VDC signal voltage. The cable

is routed to the actuator through a 7/8 knock-out in

the unit corner post.

12) Remove the knock-out, and insert the plastic bushing

provided in the kit. Pull a sufficient length of cable

through the bushing, to reach the connection terminal

block at the bottom of the actuator.

13) Push the cable through the hole in the plastic conduit

plug (enlarge if necessary), strip approximately 1-inch

of the outer cable sheath, and connect the red, white,

and black wires to the applicable terminals. (Green

cable wire is not used.)

14) Secure the cable with a large nylon wire-tie

(provided), to prevent the cable from being

accidentally pulled from the actuator housing

(see photo).

15) Verify M9108 is configured correctly for

either CW or CCW rotation. See following

page, ‘ACTUATOR ROTATION’ for jumper

location and configuration table.

Jumper W1 is factory set for CW

rotation.

16) Reattach the actuator cover, and tighten the

cover screw.

17) Using the cable routing hardware provided,

secure the cable to avoid accidental damage, or

contact with moving components.

ACTUATOR ROTATION – VERIFYING JUMPER W1 SETPOINT

MODEL # JUMPER W1

SETTING

DSH024-DSH060

KSH024-KSH060 RA (CCW)

DSH096-DSH120

KSH096-KSH120 DA (CW)

DSV036-DSV240

KSV036-KSV240 RA (CCW)

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