MODELS DSH/KSH/DSV/KSV R-410A LOW-AMBIENT KIT Supersedes Form145.10-IOM1 (810) Form 145.10-IOM1 (910) LOW-AMBIENT KIT MODELS DSH/KSH/DSV/KSV R-410A AIR CONDITIONING UNITS INSTALLATION INSTRUCTIONS
IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDLINES This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and responsibilty of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated, as well as sever personal injury or death to themselves and people at the site. This document is intended for use by owner-authorized operating/service personnel. It is expected that this individual possesses independent training that will enable 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 hazardous situation which, if not avoided, will 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. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. NOTE is used to highlight additional information which may be helpful to you. All wiring must be in accordance with published specifications and must be performed ONLY by qualified service personnel. Johnson Controls will not be responsible for damages/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this will void the manufacturers warranty and cause serious damage to property or injury to persons.
CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement, the information contained in this document is subject to change without notice. While Johnson Controls makes no commitment to up-date or provide current information automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest Johnson Controls service office. It is the responsibility of operating/service personnel as to the applicability of these documents to the equipment in question. If there is any question in the mind of operating/service personnel as to the applicability of these documents, then, prior to working on the equipment, they should verify with the owner whether the equipment has been modified and if current literature is available. TABLE OF CONTENTS 4 General Information 4....Damper Installation 6 Pressure Control Panel Installation 6 Pressure Transducer Installation 8 Damper Actuator Installation & Wiring 10 Actuator Rotation Verification 11 Interconnection Drawings 13 Sequence of Operation 14 Schematics Before installing this accessory kit, turn off electrical power to the equipment. Failure to do so could result in electrical shock, resulting in component damage, injury or death. GENERAL INFORMATION If unit operation is required at outdoor ambient below 45 deg F, the optional Low Ambient Damper kit should be installed to maintain acceptable condensing pressure. In horizontal units, the damper is installed directly over the intake duct connection. The damper in vertical units is installed over the exhaust duct connection (as illustrated below). The damper position is determined by refrigerant pressure. A direct-coupled electric damper actuator motor drives the damper open or closed, depending on the output signal from a proportional pressure control module. A pressure transducer senses the high-side refrigerant pressure, through a service access port, located on the liquid refrigerant line leaving the condenser. The pressure controller, complete with terminal connection blocks for wiring, is attached to a field-installed mounting bracket. Appropriate mounting hardware for the pressure control module and the damper actuator motor are provided with the kit. A routing hole is provided in the condenser corner panel, near the actuator mounting location, to allow installation of the plenum-rated cable between the motor and the control module. A solid-state timer(s) is provided with the damper kit. The timer will bypass the low pressure switch during compressor start-up. The time delay allows the condensing pressure to rise sufficiently for refrigerant flow through the evaporator to be established, thereby eliminating nuisance low-pressure lock-outs. 3
On Dual compressor units, the transducer MUST be connected to the #1 circuit liquid line fitting. Connection to the second stage refrigerant circuit will result in system malfunction. When installing the transducer, observe all regulations governing the handling and containment of hazardous or regulated materials (refrigerants or lubricants). DAMPER INSTALLATION HORIZONTAL UNITS (DSH / KSH SERIES) 1) Remove the factory installed duct attachment flanges from the condenser intake opening. Retain the two short (vertical) flanges these will be used in installation of the damper. 2) The kit contains two long flanges, which reduce the intake opening height to match the damper dimensions. Attach these replacement flanges using the original holes and screws. 3) Re-attach one of the original vertical flanges as close to the edge of the corner post as possible (approx 1/8 from edge of corner). 4) Position the damper casing between the two horizontal flanges surface, and butt the drive end of the damper against the vertical flange at the corner of the unit. Ensure that the damper is orientated as shown drive shaft at the top of unit. 5) Secure the damper using the self-drilling screws provided (drive screws the holes in the flanges, into the metal damper casing). 6) Attach the remaining vertical flange, opposite the drive end of the casing. 7) Ensure that the damper assembly rotates freely, with little or no resistance, by rotating the drive shaft by hand. 4
VERTICAL UNITS (DSV / KSV SERIES) 1) The kit includes two vertical and two horizontal factory supplied duct flanges. 2) Locate pilot holes at condenser exhaust and line up duct flanges accordingly. 3) Secure flanges using self-drilling sheet metal screws. The horizontal flanges should be flush with the condenser exhaust opening. 4) Position the damper inside the flanges and secure with screws. 5
PRESSURE CONTROL PANEL INSTALLATION & WIRING 1) The Pressure Control Panel is intended for mounting, to the interior base pan in horizontal units and on the base rails in vertical units, in the compressor/condenser section, immediately behind the compressor side access panel (see photo). Fasten the panel bracket to the vertical flange of the interior base pan (recommended) or to the horizontal surface of the pan, using the provided self-drilling screws. 2) The kit contains a pre-terminated two-wire harness (red and white) to connect the Connect Control Panel to the 24 VAC power supply terminal, located in the main electrical panel of the condensing unit. The harness must be fed through the electrical routing hole, for horizontal units at the intake end of the condenser coil, and for vertical units at the low voltage end of the electrical panel (see photos). 3) Route the harness across the blower section of the unit, for horizontal units - into the back of the electrical panel via the low voltage entrance hole. Secure the harness, using the self-adhesive mounts provided, to ensure that the wiring is kept well clear of the belt driven blower and motor assembly. 4) Within the condenser electrical panel, the harness is to be connected to terminal block TB4C for horizontal units and terminal block TB2 for vertical units. The red harness lead is to be connected to the R terminal; the white harness lead is to be connected to the C terminal (refer to Lo-Ambient Control inter-connection drawing). 5) Mount the timer(s) in low voltage section of the condenser electrical panel. Connect the timers into the low-voltage control circuit as shown in the electrical schematic diagrams. The wire splice between the LPC and HPC switches is accessible inside the electrical panel, in the low voltage section of the enclosure. 6) Within the compressor compartment, secure the harness to the existing compressor wiring, and route the terminated ends to the 2-pole terminal block on the Pressure Control Panel. Attach the terminated harness ends to the appropriate terminals (red-to-red, and white-to-white). HORIZONTAL WIRING 6
VERTICAL WIRING PRESSURE TRANSDUCER INSTALLATION 1) The compact P499 transducer mounts directly to the liquid refrigerant pressure port. This port is either incorporated into the refrigerant shut-off valve (as illustrated in DSH Series units), or an access port fitting brazed to the copper refrigerant line (KSH Series condensing units). 2) Hand thread the transducer onto the pressure port. (Wear a glove for protection, and seat the transducer as quickly as possible to minimize release of liquid refrigerant. 3) Tighten the connection using the wrench flats provided to avoid damaging the transducer. 4) The connecting harness for the pressure transducer is pre-wired to the Pressure Control Panel. The sensor end of the harness is equipped with a polarized plug connection. Insert the plug into the end of the transducer, ensuring that the locking tab on the plug is engaged. 5) Perform a leak test on the refrigerant port connection before putting the system into operation. 7
DAMPER ACTUATOR INSTALLATION & WIRING 1) Press and hold the gear release lever, and rotate the drive coupler to the fully clockwise position. Release the gear lever. 2) Fully close the damper, by turning the drive shaft clockwise. 3) Insert the tab on the anti-rotation bracket into the slot at the bottom of the actuator, and slide the actuator onto the damper drive shaft. 4) Position the anti-rotation bracket at the indicated dimension below the drive shaft center (6-3/16 in.). 5) Use the holes in the anti-rotation bracket as a guide and secure the bracket to the damper casing, using the self-drilling screws provided. (Do not drive screws near the center of the damper casing. Use the outermost holes in the anti-rotation bracket.) 6) Adjust the anti-rotation bracket, as necessary, to position the tab mid-way into the slot at the bottom of the actuator. The tab on the anti-rotation bracket must fit midpoint in the actuator slot to prevent actuator binding and premature wear. 7) Hold the actuator in place, and evenly hand tighten each clamp nut onto the U-bolt. Ensure that the damper drive shaft remains in the fully closed position, while tightening the clamp nuts. Secure the U-bolt to the damper shaft. 8) Press and hold the gear release. Rotate the coupler and drive shaft from fully closed to fully open to verify that the damper and actuator rotate freely throughout the range. 9) Loosen the actuator cover screw (No. 1 Phillips), and remove the actuator cover. Push the plastic plug, adjacent to the actuator terminal block, out of the conduit opening. 10) Use the Phillips screwdriver to punch the center hole through the plug, and reinsert the plug into the opening. 11) A plenum-rated connection cable is provided, prewired to the Pressure Control Panel, for supply of 24 VAC power and 0-10 VDC signal voltage. The cable is routed to the actuator through a 7/8 knock-out in the unit corner post. 12) Remove the knock-out, and insert the plastic bushing provided in the kit. Pull a sufficient length of cable through the bushing, to reach the connection terminal block at the bottom of the actuator. 13) Push the cable through the hole in the plastic conduit plug (enlarge if necessary), strip approximately 1-inch of the outer cable sheath, and connect the red, white, and black wires to the applicable terminals. (Green cable wire is not used.) 8
14) Secure the cable with a large nylon wire-tie (provided), to prevent the cable from being accidentally pulled from the actuator housing (see photo). 15) Verify M9108 is configured correctly for either CW or CCW rotation. See following page, ACTUATOR ROTATION for jumper location and configuration table. Jumper W1 is factory set for CW rotation. 16) Reattach the actuator cover, and tighten the cover screw. 17) Using the cable routing hardware provided, secure the cable to avoid accidental damage, or contact with moving components. 9
ACTUATOR ROTATION VERIFYING JUMPER W1 SETPOINT MODEL # DSH024-DSH060 KSH024-KSH060 DSH096-DSH120 KSH096-KSH120 DSV036-DSV240 KSV036-KSV240 JUMPER W1 SETTING RA (CCW) DA (CW) RA (CCW) 10
LO-AMBIENT CONTROL HORIZONTAL WIRING INTERCONNECTION DRAWING Single compressor application is shown. Two bypass timers required on dual compressor units. Connect second stage timer to Y2, HPC2/LPC2, and C. 11
LO-AMBIENT CONTROL VERTICAL WIRING INTERCONNECTION DRAWING Single compressor application is shown. Two bypass timers required on dual compressor units. Connect second stage timer to Y2, HPC2/LPC2, C. 12
SEQUENCE OF OPERATION FUNCTIONAL CHECK This condensing pressure control package is designed to maintain a minimum refrigerant liquid pressure of 260 psig, which is sufficient to ensure proper expansion valve operation under all normal conditions. The electronic proportional control module generates a 0 to 10 VDC output signal, based on sensed pressure. This output signal is employed to modulate the condenser air volume, from 0% to 100%, via an electrically motorized intake damper. The P352PN control module is factory configured for Reverse Acting mode. The analog signal output increases as the sensed pressure drops. (Note: Dashed areas in accompanying graph show throttling range possibilities from minimum to maximum.) The control set-point is factory set at 360 psig, with a 100 psi throttling range. If outdoor air temperature and system load result in a condensing pressure above 360 psig the output signal will be 0 volts. At a signal voltage of 0, the damper actuator motor will drive fully counter-clockwise, opening the damper 100%. At refrigerant pressures below 260 psig, the control output signal will be 10 VDC, driving the actuator fully clockwise. In practical operation, the condenser intake damper will be fully closed whenever sensed refrigerant pressure is below 260 psig. This would normally occur during an extended system OFF interval, especially during periods of moderate to low outdoor temperatures. Upon compressor start, the pressure in the system will increase until the 260 psig minimum throttling range is reached. The damper will only begin to modulate at pressures above 260 psig, ensuring that the actual operating condensing pressure will always be greater than this minimum value. 13
SCHEMATIC (HORIZONTALUNIT SHOWN) 14
SCHEMATIC (VERICAL UNIT SHOWN) 15
Subject to change without notice. Printed in U.S.A. Form 145.10-IOM1 (910) Copyright 2010 by Unitary Products Group. All rights reserved. Supersedes 145.10-IOM1 (810) Engineered Systems P.O. Box 1592 York Products York, PA PA Group 17405 17405