Johnson Controls DSH096B Installation Operation & Maintenance

Brand: Johnson Controls

Model: DSH096B

Type: Installation Operation & Maintenance

AIRSIDE ECONOMIZER KIT

MODELS DSH/DSV

AIR COOLED AIR CONDITIONING UNITS

R-410A

STYLE B

Issue Date:

April 2015

INDOOR PACKAGED EQUIPMENT

INSTALLATION, OPERATION, MAINTENANCE

NEW RELEASE Form 145.10-IOM3 (415)

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, protects

themselves, and proceed safely in completing their

tasks. Failure to comply with any of these

requirements could result in serious damage to the

equipment and the property in which it is situated, as

well as sever personal injury or death to themselves

and people at the site.

This document is intended for use by owner-authorized

operating/service personnel. It is expected that this

individual possesses independent training that will en-

able them to perform their assigned tasks properly and

safely. It is essential that, prior to performing any task

on this equipment, this individual shall have read and

understood this document and any referenced materials.

This individual shall also be familiar with and comply with

all applicable governmental standards and regulations

pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to areas of potential hazard.

DANGER indicates an imminently haz-

ardous situation which, if not avoided,

will result in death or serious injury.

WARNING indicates a potentially haz-

ardous situation which, if not avoided,

could result in death or serious injury.

CAUTION identifies a hazard which

could lead to damage to the machine,

damage to other equipment and/or

environmental pollution. Usually and

instruction will be given, together with a

brief explanation.

NOTE is used to highlight additional in-

formation which may be helpful to you.

All wiring must be in accordance with published specifications and must be performed ONLY by

qualified service personnel. Johnson Controls will not be responsible for damages/problems

resulting from improper connections to the controls or application of improper control signals.

Failure to follow this will void the manufacturer’s warranty and cause serious damage to 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

1 …… Installation

2 ……Mixing Box Dimensions &

Component Layout

3 …….Interconnection Harness

4 ……Damper & Actuator Set-up

5 …. Wiring Schematics

6 …. Sequence of Operation

7 …. Parameter Table

PRIOR TO INSTALLING OR SERVICING THE UNIT, LOCK ALL ELECTRICAL POWER SUPPLY

SWITCHES IN THE OFF POSTION. FAILURE TO DISCONNECT POWER SUPPLY MAY RESULT IN

ELECTRICAL SHOCK OR EVEN DEATH.

1. INSTALLATION

Horizontal/Vertical Economizers

1. Attach mixing box to unit evaporator return,

using the metal securing strip provided.

Fasteners may also be used around the

perimeter of the mixing box, at the location of

the filter frame, for additional security. This is

intended to connect the units, and not to support

the full weight of the economizer mixing box –

ADDITIONAL FIELD SUPPORT IS REQUIRED.

This may be from the ceiling, or from beneath

the unit.

2. Determine which inlet will be outside air, and

which will be return air. If the normal

open/closed position of the dampers needs to be

reversed, remove the actuator, reset the damper

positions so that the outside air damper is

closed and the return air damper is fully open.

Adjust the linkage rod to these normal positions,

and secure. Reattach the actuator so that it is

rotating in the appropriate direction.

3. The module is connected to the unit wiring via a

2-part molex wiring harness. Minimal field

rewiring of the unit is required in order to

accommodate the Air-Side Economizer option.

Refer to Section 6 for detailed instructions.

Connect the wiring harness to the

microprocessor board as indicated in Section 4

– Wiring Harness Installation.

4. With the power to the module, the actuator

springs will wind and lock. The enthalpy

changeover setting may be altered, and the

outside air damper minimum position adjusted.

See the attached Honeywell JADE – W7220

Economizer Controller Manual for details.

NOTE: Jade will be in the "set up" mode for the

first 60 minutes after powered. If a sensor for

Outdoor Air (OA) is disconnected during the set

up mode, the Jade will not alarm that failure. The

Mixed Air (MA) sensor is a system "critical"

sensor, if the MA sensor is removed during the

set up mode, the Jade will alarm. After 60

minutes the Jade controller will change to

operation mode and all components removed or

failed will alarm in the operation mode.

Prior to installing or servicing the

unit, lock all electrical power supply

switches in the OFF position. Failure

to disconnect power supply may

result in electrical shock or even

death.

Additional field support of the mixing

box is required. Failure to provide

adequate support for the unit may

result in injury or even death.

Exercise care when working around

the sharp metal edges of door panels

or flanges. These edges are sharp

and can cause injury.

2. VERTICAL MIXING BOX DIMENSIONS

Vertical Unit

Model Number

Economizer

Model Number

MIXING BOX DIM'N

DAMPER

DIM'N

CONTROL

MODULE

DSV060B

VASE-060B-1

49.00

27.75

24.00

40.00

14.00

8.00

15.00

DSV096B/120B

VASE-120B-1

66.50

36.25

26.50

58.00

19.50

8.00

15.00

DSV144B/180B

VASE-180B-1

78.00

35.75

28.50

70.00

19.50

8.00

15.00

DSV240B

VASE-240B-1

86.00

41.25

34.00

78.00

25.00

8.00

15.00

DSV300B

VASE-300B-1

104.00

45.00

34.00

90.00

25.00

8.00

15.00

3. HORIZONTAL MIXING BOX DIMENSIONS

Horizontal Unit

Model Number

Economizer

Model Number

MIXING BOX DIM'N

DAMPER

DIM'N

CONTROL

MODULE

DSH024B/036B

HASE-036B-SF

26.06

23.32

23.44

17.00

14.00

8.00

15.00

DSH048B/060B

HASE-060B-SF

29.68

23.44

30.44

24.00

14.00

8.00

15.00

DSH096B/120B

HASE-100B-SF

33.63

25.25

33.63

28.00

19.50

8.00

15.00

Horizontal Unit

Model Number

Economizer

Model Number

MIXING BOX DIM'N

DAMPER

DIM'N

CONTROL

MODULE

DSH024B/036B

HASE-036B-BF

26.06

23.32

23.44

17.00

14.00

8.00

15.00

DSH048B/060B

HASE-060B-BF

29.68

23.44

30.44

24.00

14.00

8.00

15.00

DSH096B/120B

HASE-100B-BF

33.63

25.25

33.63

28.00

19.50

8.00

15.00

STANDARD SIDE & FRONT

DAMPER ARRANGEMENT

OPTIONAL BOTTOM & FRONT

DAMPER ARRANGEMENT

4. WIRING HARNESS INSTALLATION -

AIRSIDE ECONOMIZER TO UNIT

CONNECTION

Each Air-Side Economizer is shipped complete with

a two-part wiring harness. The terminated end of the

wiring harness that is shipped in a package with the

economizer must be field wired into microprocessor

board. The second part of the harness assembly is

pre-wired into the Economizer module panel. The

two parts of the harness are connected together by

integrated polarized molex plugs.

For split unit applications (horizontal units only)

the harness will need to be extended in the field

using 18 gauge wire.

Locate the Mixed Air sensor (C7250A1001) inside

supply discharge duct. Wire other end into the MAT

terminals of the W7220 module.

Locate the Outdoor Air Temp/Humidity Sensor

(C7400S1000) in the outdoor air duct. This will be

wired into the S-BUS terminals of W7220 module.

All Models

6 Pin Molex Plug

Pin #

Color

Connection ID

Yellow/Red

Y-OUT

Yellow/Red

ECON

Gray/Red

G-OUT

Pink

OCCUPIED

White

COMMON

Installing Harness (Vertical Units):

1) Working from the side access door, feed the

loose pre-terminated ends of the harness in

through the back of the low voltage section of

the electrical box, through the bushed hole.

2) Connect the harness terminations to the

microprocessor board economizer harness

terminations (Y-Out, G-Out, ECON, and

OCCUPIED), as shown in the electrical

schematic.

3) Connect the WHITE COMMON wire from the

harness onto the Common tab on the

microprocessor board, using the provided tab

adapter, as shown in the electrical schematic.

4) Inside the condenser section secure the harness

to the side of the blower housing using the

supplied cable clips. Ensure that the harness is

routed clear of moving parts and sharp edges,

and that there are no loose wires that can be

pulled into the blower inlet. Coil excess wire

length, and secure with cable clips (see photo).

5) The plug end of the harness should terminate

inside the rear corner post. The economizer half

of the harness will enter through the knockout

hole in this area. Ensure the harness is secured

on the outside of the unit using the cable clips

provided.

Installing Harness (Horizontal Units):

1) Working from the evaporator blower access

door, feed the loose pre-terminated ends of the

harness along the base of the unit towards the

right end and back out, using the low voltage

electrical conduit, to the condenser section and

into the condenser electrical panel. For split

unit applications the harness will need to be

extended in the field using 18 gauge wire.

Ensure the cable is protected from damage and

the wiring meets all local code requirements.

2) Inside the condenser electrical box, connect the

harness terminations to the microprocessor

board economizer harness terminations (Y-Out,

G-Out, ECON, and OCCUPIED), as shown in

the electrical schematic. Note the Occupied

terminal is not being used in the standard factory

setup and has been provided if required in the

field.

3) Connect the WHITE COMMON wire from the

harness onto the Common tab on the

microprocessor board, using the provided tab

adapter, as shown in the electrical schematic.

4) Inside the blower section of the evaporator unit

secure the harness along base towards the left

corner post using the supplied cable clips.

Ensure that the harness is routed clear of

moving parts and sharp edges, and that there

are no loose wires that can be pulled into the

blower inlet. Coil excess wire length, and secure

with cable clips (see photo).

5) The plug end of the harness should terminate

inside the bottom left corner post. The

economizer half of the harness will enter through

the knockout hole in this area. Use a punch out

tool or screwdriver. Feed the plug end harness

through and connect to the other half of the

economizer harness. Ensure the harness is

secured on the outside of the unit using the

cable clips provided.

5. ECONOMIZER – DAMPER & ACTUATOR SETUP (VERTICAL SETUP)

Installed Harness

VERTICAL ECONOMIZER

HORIZONTAL ECONOMIZER

SINGLE STAGE ECONOMIZER WIRING SCHEMATIC

DUAL STAGE ECONOMIZER WIRING SCHEMATIC

6. SEQUENCE OF OPERATION

NOTE: Refer to the ‘Honeywell JADE (W7220)

ECONOMIZER MODULE’ manual accompanied

with this kit for additional information regarding

additional sensors, enthalpy settings and alarms

Modulating Economizer with Typical Electro -

Mechanical Thermostat

The Honeywell W7220 module, ML series actuators,

JCI damper sections, and factory wiring harness

comprise an integrated economizer. These

economizers are used to provide ventilation and free

cooling for the JCI Series of vertical and horizontal

air handlers.

The Honeywell W7220 can accept inputs from

additional optional sensors (field provided), including

a return-air enthalpy sensor (for differential enthalpy

control) or a CO

sensor for Indoor Air quality

strategies.

The economizer module setup is done through the

LCD keypad display. For more information regarding

setup and other features, consult the Honeywell

JADE - W7220 Economizer Controller Manual

included with the Economizer kit.

Powering the Thermostat (24vac) -

Power to the electromechanical thermostat is

provided from R terminal of the JCI unit’s low voltage

terminal strip. Electromechanical thermostats do not

require a 24vac common connection.

Powering the W7220 (24vac) -

The W7220 is powered from the JCI unit’s

microprocessor board at the G-Out pin whenever the

fan of the evaporator section is operating. To ensure

that the W7220 is continuously powered, the fan

switch on the thermostat sub-base should be left on

at all times.

High Enthalpy Sequence:

Enthalpy sensor C7400S on all units should be

located in the outdoor air duct. When the outside air

enthalpy exceeds the enthalpy set-point, the

economizer W7220 module Y1-In and Y1-Out

terminals are closed and economizer will be forced

into the minimum damper position setting. The JCI

unit’s microprocessor board will control cooling

requirements.

Low Enthalpy Sequence:

When the outside air enthalpy is below the enthalpy

set-point, W7220 economizer Y1-In and Y1-Out

terminals are opened and free cooling is activated.

The JCI unit’s microprocessor board turns off

compressor operation.

Damper Modulation:

On all JCI units' the C7250A temperature sensor

should be located in the supply discharge air duct.

Locating the sensor in the discharge air provides

effective 'low-limit' sensing and control. The outside-

air damper remains at minimum position if the

discharge air temperature is below 50

F or 10

C. If

the discharge air temperature is between 50

to 56

F (10

to 13.3

C) the outside air damper will

modulate between minimum position and fully open.

Above 56

F (13.3

C) the outside air damper will

remain in the fully open position.

Occupied:

The OCCUPIED harness terminal is not connected

to the economizer OCC terminal in the economizer

box. It has been provided if site conditions require

field connection of an Occupied function. Consult the

Honeywell JADE - W7220 Economizer Controller

Manual for more information.

7. PARAMETER TABLES

Menu Parameter

Parameter

Default Value

Parameter Range Notes

STATUS ECON AVAIL NO YES/NO YES = economi zing a vai l a ble; the s ystem can use Outdoor Ai r for

free cooling when required.

ECONOMIZING NO YES/NO YES = Outdoor Ai r bei ng us ed for 1st s tage cool i ng.

OCCUPIED NO YES/NO YES = OCC si gna l recei ved from space thermos ta t or uni ta ry

controller.

YES = 24 Vac on termi nal OCC

No = 0 Va c on termina l OCC.

COOL Y1-IN OFF ON/OFF Y1-I signa l from s pace thermos ta t or uni ta ry control l er for

cooling s ta ge 1.

ON = 24 Va c on term Y1-I

OFF = 0 Va c on term Y1-I

COOL Y1-OUT OFF ON/OFF Cool Stage 1 Relay Output to mechani ca l cool i ng (Y1-OUT

termina l ).

MA TEMP _ _._ ºF -40 to 150 ºF Di s pl a ys value of mea s ured mi xed air from MAT s ens or.

Di s pl a ys --.-°F if not connected, s hort, or out- of-ra nge.

DA TEMP _ _._ ºF -40 to 150 ºF Di s pl a ys when Dis charge Ai r Syl k Bus s ensor is connected a nd di s pl a ys

mea s ured di s charge a i r te mperature. Di s pl a ys --.-°F

OA TEMP _ _._ ºF -40 to 140 ºF Displays mea s ured val ue of outdoor air temperature.

Di s pl a ys --°F

OA HUM _ _ % 0 to 100% Di s pl a ys mea s ured val ue of outdoor humi dity from QA Sylkbus s ens or.

Di s pl a ys --%

DAMPER OUT 2.0V 2.0 to 10.0 V Di s pl a ys output voltage or pos i ti on to the da mper a ctuator.

ACT POS n/a 0 to 100% Di s pl a ys a ctua l pos iti on of a ctua tor

ACT COUNT n/a 1 to 65,535 Di s pl a ys number of times a ctuator ha s cycled. 1 Cycle equals

the s um of 180° of movement in a ny di rection.

ACTUATOR OK/Al a rm (on Di s pl a ys Error i f vol ta ge or torque is below a ctuator ra nge

Alarm menu)

SETPOINTS MAT SET 53ºF 38 to 70 ºF; The economi zer will modul a te the OA dampe r to ma i nta i n the

increment by 1 mi xed air tempera ture a t the s etpoint.

LOW T LOCK 32ºF -45 to 80 ºF; Setpoi nt determi nes outdoor te mperature when the mecha ni cal

increment by 1 cool i ng cannot be turned on. Commonl y referred to a s the

Compres s or l ockout. At or bel ow the setpoint the Y1-O a nd

Y2-O wi l l not be energize d on the control l er.

DRYBLB SET 63ºF 48 to 80 ºF; Setpoint determi nes where the economizer wi l l a s s ume outdoor

increment by 1 a i r temperature i s good for free cool i ng; e.g.; a t 63 ºF s etpoint

uni t will economizer a t 62 ºF and be l ow a nd not economi ze a t

64 ºF and above. There i s a a 2 ºF deadba nd.

ENTH CURVE ES3 ES1, ES2, ES3, Entha l py boundary “curves ” for economizi ng us ing s ingle

ES4, or ES5 entha l py.

MIN POS 2.8 V 2 to 10 Vdc Displ a ys ONLY if a CO2 sens or is NOT connected. Wi th 2-s peed

fa n uni ts MIN POS L (l ow s peed fa n) a nd MIN POS H (hi gh

spe ed fan) s ettings a re requi red. Defa ult for MIN POS L i s 3.2V

and MIN POS H i s 2.8V.

SYSTEM INSTALL 01/01/11 Di s play order = MM/DD/YY

SETUP Setti ng order = DD, MM, then YY

UNITS DEG ºF ºF or ºC Sets economi zer controller i n degrees Fa hrenhei t or Cel s i us .

EQUIPMENT CONV CONV CONV = conventi ona l .

HP HP O/B = Ena bl es Heat Pump mode

OCC INPUT INPUT or When us ing a s etba ck thermos ta t with occupa ncy out (24 Vac),

ALWAYS the 24 Va c is i nput “INPUT” to the OCC termi nal. If no

occupa ncy output from the thermos tat then change program to

“ALWAYS” OR a dd a jumper from termi nal R to OCC terminal.

FACTORY DEFAULT NO YES/NO Res ets a l l s et points to factory defa ults when s et to YES. LCD

will briefly flas h YES and cha nge to NO but a l l parameters wi l l

cha nge to factory default val ues .

ADVANCED MA LO SET 45ºF 35 to 55 ºF; Temp to a cti vate Freeze Protecti on (clos e da mper or modul a te to

SETUP increment by 1º MIN POS i f temp fa l l s bel ow s et val ue)

SD DMPR POS CLO CLO Indi ca tes s hutdown s i gna l from spa ce thermos tat or unitary

OPN controller. When control l er recei ves 24 Va c i nput on the SD

termi na l in conventi ona l mode, the OA da mper will open i f

programmed for OPN and OA da mper wi l l clos e if programmed

for CLO. All other control s , e.g., Y1-O, etc. wi l l shut off.

MAT T CAL 0.0 F° +/-2.5F° Al lows for the opera tor to adjus t for a n out of calibration

temperature sens or

OA T CAL 0.0 F° +/-2.5F° All ows for the opera tor to adjus t for a n out of cal i bration

temperature sens or

OA H CAL 0% RH +/-10% RH Allows for the operator to a djus t for a n out of ca l i brati on

humidity s ens or

RA T CAL 0.0 F° +/-2.5F° Allows for the operator to a djus t for a n out of ca l i brati on

temperature sens or

RA H CAL 0% RH +/-10% RH Allows for the operator to a djus t for a n out of ca l i brati on

humidity s ens or

DA T CAL 0.0 F° +/-2.5F° Allows for the operator to a djus t for a n out of ca l i brati on

temperature sens or

CHECKOUT DAMPER VMIN-HS n/a n/a Pos i ti ons da mper to VMIN pos i ti on.

DAMPER VMAX n/a n/a Pos iti ons damper to VMAX pos i ti on

DAMPER OPEN n/a n/a Pos iti ons damper to the ful l open pos i ti on

DAMPER CLOSE n/a n/a Pos iti ons damper to the ful l y clos ed pos i ti on.

CONNECT Y1-O n/a n/a Clos es the Y1-O relay (Y1-O).

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA

Form 145.10-IOM3 (415)

NEW RELEASE

Johnson Controls DSH096B Installation Operation & Maintenance

Johnson Controls DSH096B Installation Operation & Maintenance

Johnson Controls DSH096B Installation Operation & Maintenance

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