Johnson Controls DSH060C Installation, Operation & Maintenance Instructions Manual

MODEL DSH024C–060C AND 096B–120B

HORIZONTAL R-410A

STYLE B/C

Issue Date:

August 30, 2018

AIR-COOLED SELF-CONTAINED UNITS

INSTALLATION, OPERATION, MAINTENANCE

Supersedes: 145.32-IOM4 (1216) Form 145.32-IOM4 (818)

FORM 145.32-IOM4 (818)

2

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. The manufacturer 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.

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.

FORM 145.32-IOM4 (818)

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

3

FORM 145.32-IOM4 (818)

4

FORM 145.32-IOM4 (818)

5

DSH024C-DSH060C – SINGLE COMPRESSOR UNIT – TYPICAL INSTALLATION DIAGRAM

FORM 145.32-IOM4 (818)

6

DSH096B/120B – DUAL COMPRESSOR UNIT – TYPICAL INSTALLATION DIAGRAM

FORM 145.32-IOM4 (818)

7

NOMENCLATURE TABLE

FORM 145.32-IOM4 (818)

8

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-IOM4 (818)

9

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)

DSH024C

675 (390)

715 (430)

DSH036C

680 (400)

720 (440)

DSH048C

955 (568)

1015 (608)

DSH060C

995 (593)

1065 (633)

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-IOM4 (818)

10

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*P / DSH096B*M*S

DSH096B-SPLIT-KIT

DSH096B*M*P / DSH096B*M*S

DSH096B-SPLIT-HGBP

w/ Hot Gas Bypass

DSH120B*M*S

DSH120B-SPLIT-KIT

DSH120B*M*S 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-IOM4 (818)

11

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 60

o

. This final

tightening is necessary to ensure a proper leak

proof seal between the couplings.

FORM 145.32-IOM4 (818)

12

DSH024C & DSH036C DIMENSIONAL DATA

EVAPORATOR OPENINGS

CONDENSER OPENINGS

EVAPORATOR

SECTION

CONDENSER

SECTION

RETURN

AIR

CONDENSER

INTAKE

CONDENSER

DISCHARGE

SUPPLY

AIR

16.00

13.25

25.63

23.13

23.75

26.00

38.00 C.C.29.00 C.C.

58.50 C.C.

61.00

OPTIONAL RETURN AIR

(FIELD CONVERTIBLE)

OPTIONAL CONDENSER INTAKE

(FIELD CONVERTIBLE)

3/4" NPT DRAIN

CONNECTION

2-3 TON HORIZONTAL A/C UNIT

DIMENSIONAL DATA

EVAPORATOR SECTION

ELECTRICAL BOX ACCESS

EVAPORATOR

FAN ACCESS

CONDENSER

FAN ACCESS

LOW VOLTAGE CONNECTION

23.75

7.18

7.00

56.00

71.88 C.C.

78.19

2.70

2.75

FRONT

BACK

FRONT

ELECTRICAL POWER CONNECTION

CONDENSER SECTION

ELECTRICAL BOX ACCESS

COMPRESSOR

ACCESS

EVAPORATOR

ACCESS

2.38

1.00

NOTE: DIMENSION TOLERANCE IS 1/16"

27.50

4.75

17.50

7.75

14.00

6.57

FORM 145.32-IOM4 (818)

13

DSH048C & DSH060C DIMENSIONAL DATA

NOTE: DIMENSION TOLERANCE IS 1/16"

4-5 TON HORIZONTAL A/C UNIT

DIMENSIONAL DATA

SUPPLY

AIR

RETURN

AIR

OPTIONAL RETURN AIR

(FIELD CONVERTIBLE)

OPTIONAL CONDENSER INTAKE

(FIELD CONVERTIBLE)

CONDENSER

INTAKE

CONDENSER

DISCHARGE

CONDENSER

SECTION

EVAPORATOR

SECTION

35.62 C.C.

40.00 C.C.

80.50 C.C.

66.50 C.C.

69.10

86.19

ELECTRICAL POWER CONNECTION

CONDENSER SECTION

ELECTRICAL BOX ACCESS

EVAPORATOR SECTION

ELECTRICAL BOX ACCESS

LOW VOLTAGE CONNECTION

CONDENSER OPENINGS

EVAPORATOR OPENINGS

FRONT

17.50

18.50

15.00

16.00

10.12

9.73

8.13

8.75

CONDENSER

FAN ACCESS

EVAPORATOR

FAN ACCESS

28.00

26.75

29.38

23.13

COMPRESSOR

ACCESS

EVAPORATOR

ACCESS

4.75

BACK

4.25

3.00

1.00

2.38

64.00

3/4" NPT DRAIN

CONNECTION

27.50

30.50

FORM 145.32-IOM4 (818)

14

DSH096B DIMENSIONAL DATA

FRONT VIEW

BACK VIEW

CONDENSER

DISCHARGE

CONDENSER

INTAKE

RETURN

AIR

SUPPLY

AIR

8 TON HORIZONTAL A/C UNIT

DIMENSIONAL DATA

NOTE: DIMENSION TOLERANCE IS 1/16"

EVAPORATOR

SECTION

CONDENSER

SECTION

112.00

48.00 C.C. 52.00 C.C.

82.50

106.13

112.00

4.75

17.00

25.00

21.25

10.88

85.21

80.00

1.25

1.00

CONDENSER SECTION

ELECTRICAL BOX ACCESS

EVAPORATOR SECTION

ELECTRICAL BOX ACCESS

EVAPORATOR

BLOWER DRIVE

ACCESS PANEL

FILTER ACCESS

(BOTH SIDE)

CONDENSER

BLOWER DRIVE

ACCESS PANEL

COMPRESSOR

ACCESS PANEL

CONDENSER OPENING

48.00

29.38

33.38

4.94

2.63

38.13

30.13

1.56

1.00

2.19

23.88

20.94

2.25

8.56

39.88

3/4" NPT DRAIN

CONNECTION

EVAPORATOR OPENING

EVAPORATOR

SECTION

CONDENSER

SECTION

2.94

TOP VIEW

TX VALVE & FILTER DRIER

ACCESS PANEL

FORM 145.32-IOM4 (818)

15

DSH120B DIMENSIONAL DATA

FRONT VIEW

BACK VIEW

RIGHT VIEW

LEFT VIEW

CONDENSER

DISCHARGE

CONDENSER

INTAKE

RETURN

AIR

SUPPLY

AIR

10 TON HORIZONTAL A/C UNIT

DIMENSIONAL DATA

EVAPORATOR

SECTION

CONDENSER

SECTION

60.88

55.00 C.C. 65.00 C.C.

86.50

60.88

4.70

70.88

11.31

84.00

1

1.25

CONDENSER SECTION

ELECTRICAL BOX ACCESS

EVAPORATOR SECTION

ELECTRICAL BOX ACCESS

EVAPORATOR

BLOWER DRIVE

ACCESS PANEL

FILTER ACCESS

(BOTH SIDES)

CONDENSER

BLOWER DRIVE

ACCESS PANEL

COMPRESSOR

ACCESS PANEL

CONDENSER DISCHARGE

61.00

29.35

33.25

4.94

2.5

38.10

30.10

1.58

1.25

2.20

11.26

41.79

3/4" NPT DRAIN

CONNECTION

EVAPORATOR DISCHARGE

2.94

TOP VIEW

TX VALVE & FILTER DRIER

ACCESS PANEL

1.08

20.52

21.27

70.88

18.44

POWER

CONNECTION

EVAPORATOR INTAKE

CONDENSER INTAKE

48.20

SERVICE

HOSE ACCESS

SIGHT GLASS

VIEW ACCESS

89.10

FORM 145.32-IOM4 (818)

16

TYPICAL SERVICE CLEARANCES

2-5 TON HORIZONTAL A/C UNIT

SERVICE CLEARANCES

SUPPLY

AIR

RETURN

AIR

CONDENSER

INTAKE

CONDENSER

DISCHARGE

CONDENSER

SECTION

EVAPORATOR

SECTION

FRONT

CONDENSER

FAN ACCESS

EVAPORATOR

FAN ACCESS

36 IN. MINIMUM CLEARANCE

4 IN. MINIMUM CLEARANCE

(FOR DRAIN TRAP)

FORM 145.32-IOM4 (818)

17

8 & 10 TON HORIZONTAL A/C UNIT

SERVICE CLEARANCES (8 TON PACKAGED UNIT SHOWN)

CONDENSER

INTAKE

RETURN

AIR

SUPPLY

AIR

8 TON HORIZONTAL A/C UNIT

SERVICE CLEARANCES

EVAPORATOR

SECTION

CONDENSER

SECTION

EVAPORATOR

SECTION

CONDENSER

SECTION

TOP VIEW

4 IN. MINIMUM CLEARANCE

(FOR DRAIN TRAP)

36 IN. MINIMUM

CLEARANCE

36 IN. MINIMUM

CLEARANCE

36 IN. MINIMUM

CLEARANCE

BACK VIEW

FORM 145.32-IOM4 (818)

18

UNIT CORNER WEIGHTS

FORM 145.32-IOM4 (818)

19

INTERCONNECTING REFRIGERANT TUBING

After the evaporator and condenser sections have

been mounted, the interconnecting refrigerant tubing

can be fabricated. For cooling systems where the

indoor and outdoor sections are installed at the same

elevation, refrigerant line sizes can be usually matched

with the factory supplied fittings, shown in the

accompanying table below. There are exceptions for

total line lengths exceeding 75 feet where pressure

drop limitations are exceeded. For further information

refer to JCI Application Data Sheet 247077-UAD-H-

0209: “General Piping Recommendations and

Refrigerant Line Length for Split-System Air

Conditioners and Heat Pumps”.

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, care should be taken to avoid sharp

bends which may cause a restriction. Route

refrigerant tubing for minimum linear length, and

minimum number of bends and fittings. Use of long

radius elbows for all 90-degree bends is

recommended.

 Braze all copper to copper joints with Silfos-5 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.

Traps are not required if the piping is properly sized as

they will only increase the pressure drop across the

system, further reducing capacity.

Once the brazing operation of refrigeration lines is

completed, the field-brazed connections must be

checked for leaks. Pressurize the system to a minimum

of 200 psig. Use soap bubbles or alternate methods of

leak-checking all field brazed joints. After completion of

the leak check, evacuate the interconnecting lines to

hold a 350-micron vacuum. If gauge pressure rises

above 500 microns in one minute, then evacuation is

incomplete or the system has a leak.

RECOMMENDED REFRIGERANT LINE SIZES

Model #

LESS THAN 75 LINEAR FEET

LIQUID LINE

SUCTION LINE

DSH024C

3/8

3/4

DSH036C

3/8

3/4

DSH048C

1/2

7/8

DSH060C

1/2

7/8

DSH096B

2 X 1/2

2 X 7/8

DSH120B

2 X 1/2

2 X 7/8

DUCTWORK

When installing ductwork, adhere to local Codes and

sensible practice. Minimize duct runs and avoid abrupt

changes in direction where possible. Allow ample

access space for servicing of the coils and changing of

filters. Perform regular maintenance on ducts to

increase unit life, maintain efficient operation, and

reduce accumulation of explosive dust. Refer to blower

performance charts, and engineer duct runs and

accessory pressure drop so as not to exceed maximum

external static values.

Louver sizing guidelines

One of the key issues in obtaining optimum

performance from indoor air-conditioners is the proper

selection of the condenser intake and discharge

louvers. Unlike outdoor air cooled units, which intake

and discharge their cooling virtually unrestricted, indoor

units must overcome the resistance of grilles or louvers

at the outside wall - plus the restriction of any

interconnecting ductwork.

Our indoor air cooled air-conditioners are designed to

accommodate the external static pressure loss

associated with properly sized louvers of the "storm

proof” type. This type of 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:

- Size condenser air intakes for 500-750 feet/minute

nominal velocity (Maximum recommended 800

feet/minute)

- Size condenser air discharge for 1,200-1,500 feet

/minute nominal velocity (Maximum recommended

1,700 feet/minute)

FORM 145.32-IOM4 (818)

20

The use of louvers with higher velocities than above

may be employed, at the discretion of the

engineer/installer, provided that the total air pressure

drop does not exceed the capability of the condenser

fan and motor. The use of 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 will result in insufficient condenser air

volume. This will cause a loss in system capacity, and

may cause compressor shut-down during high ambient

periods. (Installation of an oversize condenser

motor/drive, where applicable, may be considered in

such cases.)

(As a general rule, these velocities will 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.)

Use only louver sections that provide different

deflection angles for air discharge and air intake, to

ensure the unit does not short circuit. Protect the unit

from weather conditions (rain, snow) entering through

the condenser air intake. All outdoor air ducts should

pitch away from the unit, toward the outside wall.

Connect all ducts to unit with canvas section duct

connectors or choose another suitable noise and

vibration absorbing device.

The Manufacturer will not accept any

liability resulting from incorrect instal-

lation of this equipment. Follow instal-

lation instructions carefully.

ELECTRICAL WIRING

Follow local electrical codes when making electrical

connections. Units are completely factory wired for

normal supply voltages (i.e. 208-230, 460,

575V/3Ph/60Hz) Confirm unit specifications by

checking unit data plate. The factory wiring terminates

in two boxes, one in each section of the unit. The

electrical control boxes are located behind outer

access panels. Each electrical compartment has its

own control cover.

Provide individual power disconnects for each unit, or

each section in the case of split applications. Install a

secure ground to both evaporator and condenser. If

canvas flexible joints are used on ductwork, install a

ground wire to the ductwork as well. Unit requires

installer to provide a 24volt thermostat with appropriate

heating and cooling stages as needed. The condenser

section electrical cover is installed with wiring diagrams

on the inner access door, which must be opened to

read the diagrams

DISCONNECT AND LOCK OUT POWER

WHEN SERVICING UNIT. UNIT MAY

START AUTOMATICALLY IF POWER IS

NOT DISCONNECTED. FAILURE TO DO

SO MAY RESULT IN PERSONAL IN-JURY

OR DEATH DUE TO ELECTRICAL

SHOCK.

PACKAGED UNIT

If unit is to be installed as a packaged unit, the

thermostat (low voltage) wiring and power wiring will be

brought through the evaporator section. Check the unit

nameplate for minimum circuit ampacity and fuse

sizing.

SPLIT SYSTEM

If the unit is a split system application (condenser

section remote from evaporator section), refer to the

wiring diagram below.

IMPORTANT: All wiring must comply with

applicable local and national codes

(NEC). Type and location of disconnect

switches must comply with all applicable

codes.

For low voltage thermostat wiring, 18 Ga. wires may be

used for up to 50 feet lengths. Low voltage runs up to

125 feet require 16 Ga. wires.

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Johnson Controls DSH060C Installation, Operation & Maintenance Instructions Manual

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