Johnson Controls R-Series Single Zone System Installation guide

Installation

and

Maintenance

Manual

"R" SERIES

INVERTER-DRIVEN

AIR CONDITIONING UNITS

PLEASE READ AND

UNDERSTAND THIS MANUAL

BEFORE USING THIS

INVERTER-DRIVEN AIR

CONDITIONING UNIT

. KEEP

THIS MANUAL FOR FUTURE

REFERENCE.

OUTDOOR UNITS

DHR18CSB21S

DHR24CSB21S

DHR30CSB21S

DHR36CSB21S

DHR42CSB21S

DHR48CSB21S

INDOOR UNITS

DUCT

DHR18NDB21S

DHR24NDB21S

DHR30NDB21S

DHR36NDB21S

DHR42NDB21S

DHR48NDB21S

Type

Model

Type

,03257$17

INDOOR UNITS

CASSETTE

DHR18NKB21S

DHR24NKB21S

DHR30NKB21S

DHR36NKB21S

DHR42NKB21S

DHR48NKB21S

Type

Model

INDOOR UNITS

CEILING

DHR18NCB21S

DHR24NCB21S

DHR30NCB21S

DHR36NCB21S

DHR42NCB21S

DHR48NCB21S

Type

Model

2

P5415467

Important Notice

● Johnson Controls, Inc. pursues a policy of continuing improvement in design and performance in its

products. As such, Johnson Controls, Inc. reserves the right to make changes at any time without

prior notice.

● Johnson Controls, Inc. cannot anticipate every possible circumstance that might involve a potential hazard.

● This inverter air conditioning unit is designed for standard air conditioning applications only. Do not use

this unit for anything other than the purposes for which it was intended for.

● The installer and system specialist shall safeguard against leakage in accordance with local pipetter

and electrical codes. The following standards may be applicable, if local regulations are not available.

International Organization for Standardization: (ISO 5149 or European Standard, EN 378). No part of

this manual may be reproduced in any way without the expressed written consent of Johnson Controls,

Inc.

● This inverter-driven (cooling or heat pump) air conditioning unit will be operated and serviced in the

United States of America and comes with all required Safety, Danger, and Caution, warnings.

● If you have questions, please contact your distributor or dealer.

● This manual provides common descriptions, basic and advanced information to maintain and service

this inverter-driven (cooling or heat pump) air conditioning unit which you operate, as well for other

models.

● This inverter-driven (cooling or heat pump) air conditioning unit has been designed for a specic

temperature range. For optimum performance and long life, operate this unit within range limits.

● This manual should be considered as a permanent part of the air conditioning equipment and should

remain with the air conditioning equipment.

Product Inspection upon Arrival

1. Upon receiving this product, inspect it for any damages incurred in transit. Claims for damage, either

apparent or concealed, should be led immediately with the shipping company.

2. Check the model number, electrical characteristics (power supply, voltage, and frequency rating), and

any accessories to determine if they agree with the purchase order.

3. The standard utilization for this unit is explained in these instructions. Use of this equipment for

purposes other than what it designed for is not recommended.

4. Please contact your local agent or contractor as any issues involving installation, performance, or

maintenance arise. Liability does not cover defects originating from unauthorized modications

performed by a customer without the written consent of Johnson Controls, Inc. Performing any

mechanical alterations on this product without the consent of the manufacturer will render your

warranty null and void.

Table of Contents

2. INDOOR UNIT INSTALLATION ................................................................................................................1

2.1 Installation of Duct Type ................................................................................................................. 1

2.2 Installation of Floor Ceiling Type ................................................................................................10

2.3 Installation of Cassette Type ........................................................................................................16

3. OUTDOOR UNIT INSTALLATION............................................................................................................26

3.1 Before Installation .......................................................................................................................... 26

3.2 Installation Site ................................................................................................................................26

3.3 Caution for Installation ................................................................................................................. 27

3.4 Dimension Data ................................................................................................................................27

4. REFRIGERATION PIPING WORK ........................................................................................................... 28

4.1 Refrigeration Piping Work Procedures and Caution in Connecting ...................................28

4.2 Specification of Connection Pipe .................................................................................................33

5. ELECTRIC WIRING WORK ........................................................................................................................33

5.1 Wiring Precautions ...........................................................................................................................33

5.2 Electrical Wiring................................................................................................................................ 34

1. INTRODUCTION AND SAFETY SUMMARY ......................................................................................... i

6. MAINTENANCE TROUBLESHOOTING.................................................................................................. 41

6.1 Main Control Malfunction ............................................................................................................... 41

6.2 Description of Drive Malfunction ..................................................................................................43

7. FLOW CHART OF TROUBLESHOOTING ............................................................................................. 45

7.1 Troubleshooting Flow Chart of Main Control Malfunction ....................................................45

7.2 Troubleshooting Flow Chart of Drive Malfunction...................................................................52

7.3 Interface ..............................................................................................................................................57

7.4 IPM, PFC Testing Method ...............................................................................................................63

8. WIRING DIAGRAM ....................................................................................................................................64

8.1 Outdoor unit ...................................................................................................................................... 64

8.2 Indoor unit ......................................................................................................................................... 67

CUSTOMER SERVICE, TECHNICAL SUPPORT........................................................................................ 71

31

P5415467

1. Introduction

This manual should be considered as a permanent part of the air conditioning equipment and should

remain with the air conditioning equipment.

This manual concentrates on inverter-driven cooling or heat pump air conditioning units. Read this manual

carefully before installation.

2. Important Safety Instructions

Safety Messages

Indicates a hazardous situation that, if not avoided, could result in death or

serious injury.

Indicates a hazardous situation that, if not avoided, could result in minor or

moderate injury.

Indicates information considered important, but not hazard-related (for

example, messages relating to property damage).

General Precautions

To reduce the risk of serious injury or death, read these instructions

thoroughly and follow all warnings or cautions included in all manuals that

accompanied the product and are attached to the unit. Refer back to these

safety instructions as needed.

● This system should be installed by personnel certied by Johnson Controls, Inc. Personnel must be

qualied according to local, state and national building and safety codes and regulations. Incorrect

installation could cause leaks, electric shock, re or explosion. In areas where Seismic ‘’Performance

requirements are specied, the appropriate measures should be taken during installation to guard against

possible damage or injury that might occur in an earthquake if the unit is not installed correctly, injuries may

occur due to a falling unit.

● Use appropriate Personal Protective Equipment (PPE), such as gloves and protective goggles and,

where appropriate, have a gas mask nearby. Also use electrical protection equipment and tools suited

for electrical operation purposes. Keep a quenching cloth and a re extinguisher nearby during brazing.

Use care in handling, rigging, and setting of bulky equipment.

● When transporting, be careful when picking up, moving and mounting these units. Although the unit may

be packed using plastic straps, do not use them for transporting the unit from one location to another. Do

not stand on or put any material on the unit. Get a partner to help, and bend with your knees when lifting

to reduce strain on your back. Sharp edges or thin aluminum ns on the air conditioner can cut ngers,

so wear protective gloves.

● Do not touch or adjust any safety devices inside the indoor or outdoor units. All safety features,

disengagement, and interlocks must be in place and functioning correctly before the equipment is put

into operation. If these devices are improperly adjusted or tampered with in any way, a serious accident

can occur. Never bypass or jump-out any safety device or switch.

● Johnson Controls, Inc. will not assume any liability for injuries or damage caused by not following steps

outlined or described in this manual. Unauthorized modications to Johnson Controls products are

prohibited as they…

◦ May create hazards which could result in death, serious injury or equipment damage.

◦ Will void product warranties.

◦ May invalidate product regulatory certications.

◦ May violate OSHA standards.

i

4

P5415467

Take the following precautions to reduce the risk of property damage.

● Be careful that moisture, dust, or variant refrigerant compounds not enter the refrigerant cycle during

installation work. Foreign matter could damage internal components or cause blockages.

● If air lters are required on this unit, do not operate the unit without the air lter set in place. If the air

lter is not installed, dust may accumulate and breakdown may result.

● Do not install this unit in any place where silicon gases can coalesce. If the silicon gas molecules

attach themselves to the surface of the heat exchanger, the nned surfaces will repel water. As a

result, any amount of condensate can overow from the condensate pan and could run inside of the

electrical box, possibly causing electrical failures.

● When installing the unit in a hospital or other facility where electromagnetic waves are generated

from nearby medical and/or electronic devices, be prepared for noise and electronic interference

Electromagnetic Interference (EMI). Do not install where the waves can directly radiate into the

electrical box, controller cable, or controller. Inverters, appliances, high-frequency medical equipment,

and radio communications equipment may cause the unit to malfunction. The operation of the unit

may also adversely affect these same devices. Install the unit at least 10 ft. (approximately 3m) away

from such devices.

● When a wireless zone controller is used, locate at a distance of at least 3.3 ft. (approximately 1 meter)

between the indoor unit and electric lighting. If not, the receiver part of the unit may have difculty

receiving operation commands.

● Do not install the unit in any location where animals and plants can come into direct contact with the

outlet air stream. Exposure could adversely affect the animals and plants.

● Do not install the unit with any downward slope to the side of the drain boss. If you do, you may have

water owing back which may cause leaks.

● Be sure the condensate hose discharges water properly. If connected incorrectly, it may cause leaks.

● Do not install the unit in any place where oil can seep onto the units, such as table or seating areas in

restaurants, and so forth. For these locations or social venues, use specialized units with oil-resistant

features built into them. In addition, use a specialized ceiling fan designed for restaurant use. These

specialized oil-resistant units can be ordered for such applications. However, in places where large

quantities of oil can splash onto the unit, such as a factory, even the specialized units cannot be used.

These products should not be installed in such locations.

Installation Precautions

To reduce the risk of serious injury or death, the following installation

precautions must be followed.

● When installing the unit into…

▫ A wall: Make sure the wall is strong enough to hold the unit’s weight. It may be necessary to

construct a strong wood or metal frame to provide added support.

▫ A room: Properly insulate any refrigerant tubing run inside a room to prevent “sweating” that can

cause dripping and water damage to wall and oors.

▫ Damp or uneven areas: Use a raised concrete pad or concrete blocks to provide a solid, level

foundation for the unit to prevent water damage and abnormal vibration.

▫ An area with high winds: Securely anchor the outdoor unit down with bolts and a metal frame.

Provide a suitable air bafe.

▫ A snowy area (only for heat pump model): Install the outdoor unit on a raised platform that is

higher than drifting snow. Provide snow vents.

● Do not install the unit in the following places. Doing so can result in an explosion, re, deformation,

corrosion, or product failure.

▫ Explosive or ammable atmosphere

▫ Where re, oil, steam, or powder can directly enter the unit, such as in close proximity or directly

above a kitchen stove.

▫ Where oil (including machinery oil) may be present.

▫ Where corrosive gases such as chlorine, bromine, or sulde can accumulate, such as near a hot

tub or hot spring.

▫ Where dense, salt-laden airow is heavy, such as in coastal regions.

▫ Where the air quality is of high acidity.

▫ Where harmful gases can be generated from decomposition.

ii

5

P5415467

● Do not position the condensate pipe for the indoor unit near any sanitary sewers where corrosive

gases may be present. If you do, toxic gases can seep into breathable air spaces and can cause

respiratory injuries. If the condensate pipe is installed incorrectly, water leakage and damage to the

ceiling, oor, furniture, or other possessions may result. If condensate piping becomes clogged,

moisture can back up and can drip from the indoor unit. Do not install the indoor unit where such

dripping can cause moisture damage or uneven locations: Use a raised concrete pad or concrete

blocks to provide a solid, level foundation for the unit to prevent water damage and abnormal

vibration.

● Before performing any brazing work, be sure that there are no ammable materials or open

ames nearby.

● Perform a run test to ensure normal operation. Safety guards, shields, barriers, covers, and protective

devices must be in place while the compressor/unit is operating. During the test run, keep ngers and

clothing away from any moving parts.

● Clean up the site when nished, remembering to check that no metal scraps or bits of wiring have

been left inside the unit being installed.

● During transportation, do not allow the backrest of the forklift to make contact with the unit,

otherwise, it may cause damage to the heat exchanger and also may cause injury when

stopped or started suddenly.

● Remove gas inside the closing pipe when the brazing work is performed. If the brazing ller metal is

melted with remaining gas inside, the pipes will be blown off and it may cause injury.

● Be sure to use nitrogen gas for an airtight test. If other gases such as oxygen gas, acetylene gas or

uorocarbon gas are accidentally used, it may cause explosion or gas intoxication.

After installation work for the system has been completed, explain the “Safety Precautions,” the proper use

and maintenance of the unit to the customer according to the information in all manuals that came with the

system. All manuals and warranty information must be given to the user or left near the Indoor Unit.

Refrigerant Precautions

To reduce the risk of serious injury or death, the following refrigerant

precautions must be followed.

● As originally manufactured, this unit contains refrigerant installed by Johnson Controls. Johnson

Controls uses only refrigerants that have been approved for use in the unit’s intended home country

or market. Johnson Controls distributors similarly are only authorized to provide refrigerants that

have been approved for use in the countries or markets they serve. The refrigerant used in this unit

is identied on the unit’s faceplate and/or in the associated manuals. Any additions of refrigerant into

this unit must comply with the country’s requirements with regard to refrigerant use and should be

obtained from Johnson Controls distributors. Use of any non-approved refrigerant substitutes will void

the warranty and will increase the potential risk of injury or death.

● If installed in a small room, take measures to prevent the refrigerant from exceeding the maximum

allowable concentration in the event that refrigerant gases should escape. Refrigerant gases can

cause asphyxiation (0.42 kg/m3 based on ISO 5149 for R410A). Consult with your distributor for

countermeasures (ventilation system and so on). If refrigerant gas has leaked during the installation

work, ventilate the room immediately.

● The design pressure for this product is 601 psi (4.15MPa). The pressure of R410A refrigerant is 1.4

times higher than that of the refrigerant R22. Therefore, the refrigerant piping for R410A shall be

thicker than that for R22. Make sure to use the specified refrigerant piping. If not, the refrigerant

piping may rupture due to an excessive refrigerant pressure. Besides, pay attention to the piping

thickness when using copper refrigerant piping. The thickness of copper refrigerant piping differs

depending on its material.

● The refrigerant R410A is adopted. The refrigerant oil tends to be affected by foreign matters such

as moisture, oxide lm, (or fat). Perform the installation work with care to prevent moisture, dust, or

different refrigerant from entering the refrigerant cycle. Foreign matter can be introduced into the

cycle from such parts as expansion valve and the operation may be unavailable.

● To avoid the possibility of different refrigerant or refrigerant oil being introduced into the cycle, the

sizes of the charging connections have been changed from R407C type and R22 type. It is necessary

to prepare the appropriate tools before performing the installation work.

● Use refrigerant pipes and joints which are approved for use with R410A.

● A compressor/unit comprises a pressurized system. Never loosen threaded joints while the system is

iii

6

P5415467

under pressure and never open pressurized system parts.

● Before installation is complete, make sure that the refrigerant leak test has been performed. If

refrigerant gases escape into the air, turn OFF the main switch, extinguish any open ames and

contact your service contractor. Refrigerant (Fluorocarbon) for this unit is odorless. If the refrigerant

should leak and come into contact with open ames, toxic gas could be generated. Also, because the

uorocarbons are heavier than air, they settle to the oor, which could cause asphyxiation.

● When installing the unit, and connecting refrigerant piping, keep all piping runs as short as

possible, and make sure to securely connect the refrigerant piping before the compressor starts

operating. If the refrigerant piping is not connected and the compressor activates with the stop

valve opened, the refrigerant cycle will become subjected to extremely high pressure, which can

cause an explosion or re.

● Tighten the are nut with a torque wrench in the specied manner. Do not apply excessive force to the

are nut when tightening. If you do, the are nut can crack and refrigerant leakage may occur.

● When maintaining, relocating, and disposing of the unit, dismantle the refrigerant piping after the

compressor stops.

● When pipes are removed out from under the piping cover, after the insulation work is completed,

cover the gap between the piping cover and pipes by a packing (eld-supplied). If the gap is not

covered, the unit may be damaged if snow, rain water or small animals enter the unit.

● Do not apply an excessive force to the spindle valve at the end of opening. Otherwise, the spindle

valve ies out due to refrigerant pressure. At the run test, fully open the gas and liquid valves,

otherwise, these devices will be damaged. (It is closed before shipment.)

● If the arrangement for outdoor units is incorrect, it may cause owback of the refrigerant and result in

failure of the outdoor unit.

● The refrigerant system may be damaged if the slope of the piping connection kit exceeds +15

o

.

Electrical Precautions

Take the following precautions to reduce the risk of electric shock, re or

explosion resulting in serious injury or death.

● Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram

and these instructions when wiring. Improper connections and inadequate grounding can cause

serious injury or death.

● Perform all electrical work in strict accordance with this installation and maintenance manual and all

the relevant regulatory standards.

● Before servicing, open and tag all disconnect switches. Never assume electrical power is

disconnected. Check with meter and equipment.

● Only use electrical protection equipment and tools suited for this installation.

● Use specied cables between units.

● The new air conditioner may not function normally in the following instances:

▫ If electrical power for the new air conditioner is supplied from the same transformer as the device*

referred to below.

▫ If the power source cables for this device* and the new air conditioner unit are located in close

proximity to each other.

Device*: (Example): A lift, container crane, rectier for electric railway, inverter power

device, arc furnace, electric furnace, large-sized induction motor and large-sized switch.

Regarding the cases mentioned above, surge voltage may be inducted into the power supply

cables for the packaged air conditioner due to a rapid change in power consumption of the

device and an activation of a switch.

Check eld regulations and standards before performing electrical work in order to protect the

power supply for the new air conditioner unit.

iv

7

P5415467

● Communication cabling shall be a minimum of 18-Gauge, 2-Conductor, Stranded Copper. Shielded

cable must be considered for applications and routing in areas of high EMI and other sources of

potentially excessive electrical noise to reduce the potential for communication errors. When shielded

cabling is applied, proper bonding and termination of the cable shield is required as per Johnson

Controls guidelines. Plenum and riser ratings for communication cables must be considered per

application and local code requirments.

● Use an exclusive power supply for the air conditioner at the unit’s rated voltage.

● Be sure to install circuit breakers (ground fault interrupter, isolating switch, molded case circuit

breaker and so on), with the specied capacity. Ensure that the wiring terminals are tightened securely

to recommended torque specications.

● Clamp electrical wires securely with a cable clamp after all wiring is connected to the terminal block.

In addition, run wires securely through the wiring access channel.

● When installing the power lines, do not apply tension to the cables. Secure the suspended cables at

regular intervals, but not too tightly.

● Make sure that the terminals do not come into contact with the surface of the electrical box. If the

terminals are too close to the surface, it may lead to failures at the terminal connection.

● Turn OFF and disconnect the unit from the power source when handling the service connector. Do not

open the service cover or access panel to the indoor or outdoor units without turning OFF the main

power supply.

● After ceasing operation, be sure to wait at least ve minutes before turning off the main power

switch. Otherwise, water leakage or electrical breakdown may result. Disconnect the power source

completely before attempting any maintenance for electrical parts. Check to ensure that no residual

voltage is present after disconnecting the power source.

● Do not clean with, or pour water into, the controller as it could cause electric shock and/or damage the

unit. Do not use strong detergent such as a solvent. Clean with a soft cloth.

● Check that the ground wire is securely connected. Do not connect ground wiring to gas piping, water

piping, lighting conductor, or telephone ground wiring.

● If a circuit breaker or fuse is frequently activated, shut down the system and contact your

service contractor.

● Perform all electrical work in accordance with this manual and in compliance with all regulations and

safety standards.

● Do not open a service access cover or panel of an indoor or outdoor unit without rst turning OFF the

power at the main power supply.

● Residual voltage can cause electric shock. At all times, check for residual voltage after disconnecting

from the power source before starting work on the unit.

● This equipment can be installed with a Ground Fault Circuit Breaker (GFCI), which is a recognized

measure for added protection to a properly grounded unit. Install appropriate sized breakers/fuses/

overcurrent protection switches, and wiring in accordance with local, state and NEC codes and

requirements. The equipment installer is responsible for understanding and abiding by applicable

codes and requirements.

v

1

2. INDOOR UNIT INSTALLATION

2.1 Installation of Duct Type

2.1.1 Before Installation

After receiving the machine, please check for any transport damage. If finding any surface or internal

damage, please immediately report to the transport company or equipment company in writing.

After receiving the machine, please check the unit and accessories in reference to the packing list.

Ensure that the model is correct and the machine is in good condition. Please also check if the specification

and quantity of accessory parts are correct.

Determine the correct handling route and methods to avoid damaging the unit or causing possible

hazard. For the sake of protection and safety, it is suggested to move the unit with the packaging box.

Even though it is not the best to do this under some special situations,

do not remove the packaging box,

thus to avoid loosening or falling during handling.

Confirm if the installing foundation is solid. When this unit is to be installed on the metal section of the

building, make sure that the electrical insulation must comply with applicable standards.

Ensure that the place of installation is far from the area where the inflammable or explosive

substances are stored, thus to avoid possible explosion or fire due to leakage.

2.1.2 Installation Site

Ensure the top mounting bracket is strong enough to withstand the weight of the unit.

Ensure condensate pipe has convenient flow of water.

Ensure there is no obstacle blocking the return air inlet and exhaust outlet, so as to ensure

sound air circulation.

The installation spaces required by the drawing must be ensured, so as to provide enough space

for service and maintenance.

The installation site must be far away from

heat source, leakage of inflammable gas or smoke.

The indoor unit is of ceiling mount (indoor unit is hidden inside the ceiling).

The indoor and outdoor units, the power cable and the connecting electrical lines must be at least

40 inches from any TV set or radio. This is to avoid image interference or noise of the TV set or radio.

(Eve

n if the distance is 40 inches, noise can also exist if there is a strong electric wave.)

2.1.3 Caution for Installation

Generally, the unit is installed indoors on a ceiling. For ceiling mounting, ensure that the

hangers on

ceiling have adequate strength to support the weight of the unit.

To meet the noise and vibration requirements, the unit should be installed by using a rubber pad

(thickness ≥20mm (13/16inch)) and rubber connector.

Insert a M10 expansion bolt into the hole. Drive a nail into the bolt. Refer to the profile dimensions

2

drawing of the indoor unit for the distance between the holes. Refer to Figure 3-1-1 for the installation of the

expansion bolt.

Ceiling-mount

Screw

Air-conditioning Unit

Hanger

Figure 3-1-1 Figure 3-1-2

Hook

Screw

Nut

Figure 3-1-3

Install the hanger onto the indoor unit as Figure 3-1-2 and Figure 3-1-3 shows.

Install the indoor unit at the ceiling as Figure 3-1-4 shows.

I

Air Intake

Air Supply

Screw

Hanger

Nut

≤48mm(1-7/8inch)

"I" Detail

Figure 3-1-4

Precautions for unfavorable installation:

The preparation of all pipes (connecting pipes and condensate pipes) and cables (connecting lines of

wire zone controller, indoor unit and outdoor unit) must be ready before the installation, so as to achieve

smooth installation.

Drill an opening on the ceiling depending on the ceiling type. Providing additional support may be required to

prevent vibration and ensure the evenness of the ceiling. Consult with the user or a construction company

for advice.

In case the strength of ceiling is not enough, use angle iro

n sections to set up a beam support.

Place the unit at the beam and secure it.

Level inspection of the indoor unit

After the indoor unit is installed, it is required to check the level of the whole unit. The unit must be

placed horizontally, but the condensate pipe shall be installed obliquely, so as to facilitate the drainage of

condensate.

3

Condensate

Pipes

Level Instrument

Air Intake

Air Supply

B

A

B

Enlarged View

Condensate Pipe

As the inside of the unit is in the negative

pressure status, it is required to set up a

backwater elbow. The requirement is:

A=B≥(0.145P/10000+20)/25.4(inch)

P is the absolute pressure inside the unit.

The unit of the pressure is psig.

Figure 3-1-5

2.1.4 Dimension Data

 For the units: 18k

 For the units: 24k~42k

4

 For the units: 48k

A

B

C

D

E

F

G

H

I

J

Figure 3-1-6

Table 3-1-1

Unit

: mm (inch)

Item

Model

A

B

C

D

E

F

G

H

I

J

DHR18NDB21S

945

(37-1/4)

618

(24-3/8)

738

(29)

892

(35-1/8)

1037

(40-7/8)

721

(28-3/8)

738

(29)

125

(4-7/8)

203

(8)

266

(10-1/2)

DHR24NDB21S

1101

(43-3/8)

517

(20-3/8)

820

(32-1/4)

1159

(45-5/8)

1279

(50-3/8)

558

(22)

1002

(39-1/2)

160

(6-1/4)

235

(9-1/4)

268

(10-1/2)

DHR30NDB21S

DHR36NDB21S

1011

(39-3/4)

748

(29-1/2)

820

(32-1/4)

1115

(43-7/8)

1226

(48-1/4)

775

(30-1/2)

979

(38-1/2)

160

(6-1/4)

231

(9-1/8)

290

(11-3/8)

DHR42NDB21S

DHR48NDB21S

1177

(46-3/8)

646

(25-3/8)

852

(33-1/2)

1150

(45-1/4)

1340

(52-3/4)

750

(29-1/2)

953

(37-1/2)

190

(7-1/2)

316

(12-1/2)

350

(13-3/4)

Table 3-1-2 Installation Accessor

ies List for Duct-type Indoor Unit

Name & Shape

QTY

Notes

Installation and Operating

Instructions

1

Insulation materials for gas pipe

1

Used for gas pipe connector on indoor unit.

Insulation materials for liquid

pipe

1

Used for liquid pipe connector on indoor unit.

Insulation materials for drainage

pipe

2

Used for wrapping the condensate pipe and

rubber plug.

Nut

1

To connect liquid pipe.

Nut

1

To connect gas pipe.

Nut M6 with gasket

8

Use for fixing the hanger hook.

Nut M10 with gasket

4

Use for fixing the hanger hook.

Nut M10

4

4 sets, used for ceiling mounting of the indoor

unit.

spring gasket

4

Hook

4

Used for ceiling mounting of the indoor unit.

Wired zone controller

1

Screw M4 2

To fix the base plate of wired zone c

ontroller

and installation hole of the wall together.

5

2.1.5 Installation Clearance Data

஘2500mm

(98-3/8inch)

Nut with

Washer

Nut Spring

Washer

G 250mm

(9-7/8inch)

G 250mm

(9-7/8inch)

Figure 3-1-7

Warning! The height of installation for the indoor unit should be 2.5m (8-1/5ft) above.

2.1.6 Condensate Piping Work

Installation of Condensate Pipeline:

Install the condensate hose in accordance with the instructions in this

installation manual and keep the a rea warm

enough to prevent condensation. Problems with the piping may lead to water leaks.

(1) (Install the condensate hose with downward gradient (1/50 to 1/100) and no risers or traps are

used for the hose (Figure 3-1-8).

(2) Be sure there i

s no crack or leak on the condensate hose to avoid the formation of air pockets

(Figure 3-1-8).

(3) When the hose is long, install supporters (Figure 3-1-9).

(4) Always use the condensate

hose which has been insulated properly.

Condensate hose

Arrange the condensate

hose lower than this

drain port

Trap

Air bleeding

Rise

√

Figure 3-1-8

6

Supporter

Condensate hose

1~1.5m(3-2/7~5feet)

Figure 3-1-9 Figure 3-1-10

Condensate Pipe

B

A

As the inside of the unit is in the

negative pressure status, it is required

to set up a backwater elbow. The

requirement is:

A=B≥(0.145P/10000+20)/25.4(inch)

P is the absolute pressure inside the

unit. The unit of the pressure is psig.

Enlarged View

Condensate Pipe

B

A

Figure 3-1-11

(5) Use a suitable condensate hose, and see Table 3-3-3 for its size.

(6)

There is a drain port on both the left and right sides. Select the drain port

to match the local

conditions (Figure 3-1-10).

(7) When the unit is shipped from the factory, the drain port is defaulted to be the one on the left side

(electric box side). T

he port on right side has been plugged.

(8) When using the drain port on the right side of the unit, reinstall the drain cap to the left side drain

port (Figure 3-1-12).

Drain port

Fastener

Drain cap

Figure 3-1-12

Always check that the drain cap is installed to the unused drain port and is fastened with the nylon fastener. If the drain

cap is not installed, or is not sufficiently fastened by the nylon fastener, water may drip during the cooling operation.

(9) Be sure to insulate where

the drain port and the condensate hose is connected (Figure

3-1-13).(10) The unused drain port also should be insulated properly (Figure 3-1-14).

7

Condensate hose insulation

Drain port

Insulated Condensate hose

Insulated condensate hose

Unit

0mm(0inch)

Condensate hose insulation

Drain port

Drain cap

0mm(0inch)

Unit

Drain cap

Figure 3-1-13 Figure 3-1-14

(11) There is adhesive on one side of the insulation so that after removing the protective paper over it

the insulation can be directly attached to the condensate

hose.

(12) Considerations for the unit with the condensate pump:

1)

For the unit with the condensate pump, only one drain port at the side close to the electric box

is prep

ared and only through it can the condensate hose can be connected.

2)

See table 3 for the size of the drain port of the unit with the condensate pump, which is different

from that of the unit without the condensate pump.

3)

For the unit with the condensate pump, two drain ports at the bottom are defaulted to be

factory

plugged with drain caps. After the installation of the condensate hose, these two drain

ports also need to be insulated properly with the same way as aforementioned.

4)

The condensate hose for the unit with

the condensate pump should be arranged as shown

in the figure below.

Ceiling

Hoisting stand

Clamp(attachment)

≤300mm(11-3/4inch)

Condensate hose(attachment)

Drain raising

hose

1000~1500mm(39-3/8~59inch)

≤100mm

(39-3/8inch)

Figure 3-1-15

ķ The vertical height of the condensate hose should be 75mm (3inch) or less so that it is

unnecessary for the drain port

to withstand additional force.

Condensate hose(attachment)

≤75mm(3inch)

≤1000mm

(39-3/8inch)

Figure 3-1-16

8 When multiple condensate hoses are used, their installation should be performed as

shown in the figure below.

8

0~1000mm(0~39-3/8inch) ≥100mm(3-7/8inch)

T-joint converging condensate pipes

Figure 3-1-17

2.1.7 Installation of air duct

Dimensions of the Supply Air Outlet/Return Air Inlet

B

A

21mm(7/8inch)

Figure 3-1-18 Su

pply Air Outlet

C

D

Figure 3-1-19 Return Air Inlet

Table 3-1-3

Unit: mm (inch)

Item

Model

Supply Air Outlet

Return Air Inlet

A

B

C

D

DHR18NDB21S

123(4-7/8)

736(29)

710(28)

166(6-1/2)

DHR24NDB21S

158(6-1/4)

818(32-1/4)

994(39-1/8)

195(7-5/8)

DHR30NDB21S

158(6-1/4)

818(32-1/4)

994(39-1/8)

195(7-5/8)

DHR36NDB21S

158(6-1/4)

818(32-1/4)

1000(39-3/8)

206(8-1/8)

DHR42NDB21S

158(6-1/4)

818(32-1/4)

1000(39-3/8)

206(8-1/8)

DHR48NDB21S

190(7-1/2)

850(33-1/2)

940(37)

286(11-1/4)

9

2.1.8 Installation of the Supply Air Duct

(1) Installation of the Rectangular Duct.

Figure 3-1-20

ķ.

The maximum length of the duct means the maximum length of the supply air duct plus the maximum length of the

return air duct.

ĸ. The duct is rectangular and connected with the air inlet/outlet of the indoor unit.

Among all supply air outlets, at

least one should be kept open.

Bottom Return Air Installation only for Units 18k

(2) The default installation location of the rectangular flange is at the back and the return air cover

plate is at the bottom, as shown in Figure 3-1-21

.

Rear Return Air

Rectangular Flange

Bottom Return Air

Return Air Cover Plate

Figure 3-1-21

(3) If a bottom return air is desired,

just change the place of the rectangular flange and the return air

cover plate.

(4) Connect one end of the return air duct to the return air outlet of the unit by rivets and the other to

the return air louver. For the sake of convenience to freely adjust the height, a cutting of

canvas duct will be helpful, which can be reinforced and folded by 8# iron wire.

(5)

More noise is likely to be produced in the bottom return air mode than the backward return air

mode, so it is suggested to install a silencer and a static pressure box to minimize the noise.

(6) The installation method can be chosen with considering the conditions of the building and

Table 3-1-4 Installation of the r

ectangular duct

No.

Name

No.

Name

1

Hanger

5

Filter

2

Air Intake

Pipe

6

Main Air

Supply Pipe

3

Canvas Air

Pipe

7

Air Supply

Outlet

4

Air Intake

10

maintenance etc., as shown in Figure 3-1-22.

Supply air

Return air

1

Supply air

Return air

Install the return air duct(a) Install the return air duct(b)

2

4

5

4

6

3

1

Figure 3-1-22

Table 3-1-5 Installation of the return air duct

No.

Name

No.

Name

1

Return Air Inlet (with filter)

4

Indoor unit

2

Canvas Duct

5

Supply Air Duct

3

Return Air Duct

6

Grille

2.2 Installation of Floor Ceiling Type

2.2.1 Before Installation

After receiving the unit, please check for any transport damage

. If finding any surface or internal

damage, please immediately report to the transport company or equipment company in writing.

After receiving the machine, please check the unit and accessories in reference to the packing list.

Ensure that the model is correct and the machine is in good condition. Please also check if the specification

and quantity of accessory parts are correct.

Determine the correct handling route and methods, thus to avoid damaging the unit or causing

possible hazard. For the sake of protection and safety, it is suggested to move the unit with the packaging

box. Even though it is not permitted to do like this under special occasions, do not remove the packaging

box, thus to avoid loosening or falling during handling.

Confirm if the installing foundation is solid. When this unit is to be installed on the metal section of the

building, make sure that the electrical insulation must comply with applicable standards.

Ensure that the place of installation is far from the area where the inflammable or explosive

substances are stored, thus to avoid possible explosion or fire due to leakage.

2.2.2 Installation Site

(1) Install the unit at a place strong enough to withstand the weight of the unit.

(2) The air inlet and outlet of the unit s

hould never be clogged so that the airflow can reach every

corner of the room.

(3) Leave service space around the unit as required in Figure 3-1-23.

11

 Floor type

 Ceiling type

Figure 3-1-23

(4) Install the unit where the condensate pipe can be easily installed.

(5) The space from the unit to the ceiling should be kept

as much as possible so as for more

convenient service.

2.2.3 Indoor Unit Installation

(1) Determine the location of the hanger through the paper template, and then remove the paper

template.

Figure 3-1-24

(2) Insert the anchor bolts into the drilled holes, and drive the pins completely into the anchor bolts

with a hammer.

12

(3) First, unfix two buckles on the grille as s

hown on the picture. Remove the screws under the

buckles by a screwdriver and then open the inlet grille.

Remove the screw

Figure 3-1-25

(4) Remove the screws shown in the picture. Push the side plate as per the arrow direction and

take it down.

Remove the screw

Figure 3-1-26

(5) Put the hanger bolt into the clasp of the indoor unit and tighten screws on the hanger to prevent

the indoor unit from moving.

(6) Reinstall and tighten the right and left side panels.

 Floor type

Left side panel

Wall

Paper template

Right side panel

Figure 3

-1-27

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Johnson Controls R-Series Single Zone System Installation guide

Johnson Controls R-Series Single Zone System Installation guide

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