Johnson Controls R-Series Single Zone System Installation guide

Type
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
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.
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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
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
QTY
Notes
1
1
Used for gas pipe connector on indoor unit.
1
Used for liquid pipe connector on indoor unit.
2
Used for wrapping the condensate pipe and
rubber plug.
1
To connect liquid pipe.
1
To connect gas pipe.
8
Use for fixing the hanger hook.
4
Use for fixing the hanger hook.
4
4 sets, used for ceiling mounting of the indoor
unit.
4
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
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
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

Type
Installation guide

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