Model DSH
Ceiling Mounted Ducted R-410A
Air Conditioning Units
Form 145.32-IOM1 (908)
New Release
CEILING MOUNTED DUCTED R-410A
AIR CONDITIONING UNITS
INSTALLATION INSTRUCTIONS
FORM 145.32-IOM1 (908)
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained
in this document is subject to change without notice.
While Johnson Controls makes no commitment to up-
date or provide current information automatically to the
manual owner, that information, if applicable, can be
obtained by contacting the nearest Johnson Controls
service office.
It is the responsibility of operating/service personnel as
to the applicability of these documents to the equipment
in question. If there is any question in the mind of oper-
ating/service personnel as to the applicability of these
documents, then, prior to working on the equipment, they
should verify with the owner whether the equipment has
been modified and if current literature is available.
TABLE OF CONTENTS
SAFETY SYMBOLS.......................................................................................................................2
CHANGEABILITY OF THIS DOCUMENT.....................................................................................3
TABLE OF CONTENTS.................................................................................................................3
GENERAL INFORMATION ...........................................................................................................4
PRE-INSTALLATION INSPECTION OF EQUIPMENT .................................................................6
RIGGING.................................................................................................................................................6
INSTALLATION .............................................................................................................................6
UNIT MOUNTING ...................................................................................................................................7
SEPARATION OF UNITS .......................................................................................................................8
INTERCONNECTING REFRIGERANT TUBING - SPLIT INSTALLATION ...........................................8
DUCTWORK ...............................................................................................................................11
LOUVER SIZING GUIDELINES ...........................................................................................................11
ELECTRICAL WIRING ................................................................................................................12
PACKAGED UNIT .......................................................................................................................12
SPLIT SYSTEM ...........................................................................................................................12
MOTOR AND PULLEY DATA...............................................................................................................14
BLOWER SPEED ADJUSTMENT .......................................................................................................14
START-UP AND OPERATION ....................................................................................................15
REFRIGERANT CHARGES..................................................................................................................15
PRESSURE SWITCH SETTINGS.........................................................................................................15
MAINTENANCE / SERVICE .......................................................................................................17
FILTERS................................................................................................................................................17
EVAPORATOR AND CONDENSER COILS.........................................................................................17
BLOWERS ............................................................................................................................................17
DRIVE BELTS.......................................................................................................................................17
REFRIGERANT CIRCUIT(S) ................................................................................................................17
COMFORT ALERT™ DIAGNOSTICS ........................................................................................18
LED DESCRIPTION..............................................................................................................................18
INTERPRETING THE DIAGNOSTIC LEDS .........................................................................................18
INSTALLATION VERIFICATION .................................................................................................21
3
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
GENERAL INFORMATION
Our units are designed to meet the ever-changing
(unique) installation requirements of today’s market. The
horizontal configuration is unitized for single package
or split installation. Low profile design allows the unit to
be installed on the floor or suspended from the ceiling.
All unit components are securely mounted inside the
heavy gauge “Galvalume” sheet metal cabinet. All units
are lined with a 1/2 in. thick – 21lb density acoustical
insulation to ensure the quietest operation. All models
are shipped with medium-efficiency 2-in. thick throw-
away filters. Multi-position filter rack is external to the
cabinet.
Service access doors are equipped with handles and
are located on all sides of the unit to allow easy servic-
ing of all components. Service access doors are factory
shipped with knock-outs allowing gauge lines to be
installed and pressure readings to be taken while the
machine is operating. In addition there is a removable
panel on the access door so visual observation of the
sight glass is possible without removing the access door.
All units are equipped with centrifugal blowers combined
with variable pitch adjustable pulleys. Forward curved
double width and inlet centrifugal blowers are used for
condenser & evaporator air movement. All models em-
ploy a draw-through air flow system. All blower wheels
are galvanized steel, with solid steel shafts and are
equipped with permanently lubricated ball bearings. V-
belt driven blowers are used in all models; RPM can be
adjusted through the variable pitch motor sheave.
Unit can be turned on its side for short periods of time,
which allows passage through standard door sizes.
Removal of the cross supports on the top and sides will
convert packaged unit into a split system, allowing the
condensing section to be installed remotely from the
evaporator section.
ONLYQUALIFIEDPERSONNELSHOULD
PERFORM INSTALLATION AND SER-
VICE OF THIS EQUIPMENT.
Horizontal units 2, 3, 4 & 5 ton models have a single
refrigerant circuit configuration.All models are equipped
with an adjustable thermal expansion valve (with exter-
nal equalizer), one valve per circuit. Each refrigerant
circuit is also equipped with a liquid line filter drier, sight
glass/moisture indicator and easy access service gauge
ports.All 2-5 ton models are shipped as factory-charged
unitized packages. The 2-5 ton units include refrigerant
line shut-off valves to allow the units to be field split.
High efficiency scroll compressors are used in all mod-
els, mounted on durable rubber isolator pads reducing
vibration and noise while operating. Large evaporator
and condenser coil face areas reduce noise levels, air
pressure drops and minimize potential for condensate
blow off. All models are equipped with copper tube and
rippled aluminum plate fin coils.
Installation time is minimized with all models. When plan-
ning an installation consider power supply, thermostat,
condensate drain line, duct run, servicing allowances,
and load points. A remote thermostat control device is
field supplied and installed to control the units operation.
Each refrigerant circuit is equipped with auto-reset high
pressure and low pressure switches. Each circuit is con-
stantly monitored by ComfortAlert module. By monitoring
and analyzing data from the Copeland Scroll compressor
and the thermostat demand, the module can accurately
detect the cause of electrical and system related failures
and protect the compressor. A flashing LED indicator
communicates the ALERT code and guides the service
technician more quickly and accurately to the root cause
of a problem. Control circuit is 24-volt operation with
oversized transformer. Optional anti-short circuit timers
can be field/factory installed.
Units will operate reliably at an outdoor ambient down
to 60 deg F.
4
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
TYPICAL INSTALLATION DRAWING
5
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
PRE-INSTALLATION INSPECTION OF EQUIPMENT
INSTALLATION
Lock all electrical power supply switch-
es in the off position before installing
the unit. Failure to disconnect power
supply may result in electrical shock or
even death.
All units are factory tested to ensure safe operation
and quality assembly. Units are packaged and sealed
on shipping skids and shipped in first class condition.
Torn and broken packaging, scratched or dented panels
should be reported to carrier immediately. An internal
inspection of each unit should be performed prior to
installation. Remove all access doors and check for
visual defects that can occur during transport.Any prob-
lems found internally should be reported to carrier and
manufacturer immediately. Refrigerant circuit should be
checked to ensure no leaks have occurred during ship-
ment. Install gauge set on high and low pressure ports
to confirm pressure has been maintained and no leaks
have occurred during shipment. Repair any damage
prior to installation to ensure safe operation.
Location - To ensure unit operates at maximum efficien-
cies, choose a dry indoor area where the temperature
is controlled between 50 deg F and 115 deg F. Con-
sideration of surrounding areas should be taken when
choosing a location to install the unit. Common vibration
and sound levels associated with commercial equipment
may be objectionable to people or equipment.
Failure to allow adequate space between
units may result in poor unit perfor-
mance and possible unit failure.
Record any unit damage on the Bill of
Lading and report to carrier and factory
immediately. Shipping and handling
damages are not warranty items.
Refer to typical installation diagram (Page #5).
RIGGING
Install thermostats, air supplies and returns so that each
unit will operate only on individual unit control. To assure
fast drainage of condensate run-off, unit can be slightly
pitched in the same direction as drain pan outlet.
Prior to mounting unit, check individual
unit weights (pages 7-8) and verify lifting
capacity of lifting equipment exceeds
weight of units by safe margins. Failure
to do so may result in unit damage, per-
sonal injury or even death.
To ensure safe installation of the unit when ceiling mount
application is specified, estimate the approximate center
of gravity of the unit. The configuration of internal com-
ponents for each unit is different and weight is unevenly
distributed.
Determine the actual center of gravity of
the unit by performing a test lift. Lifting
an unbalanced unit can cause personal
injury or even death.
6
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
UNIT MOUNTING
Aminimum of 4-in. clearance is required under the unit to
allow for trapping of the evaporator condensate drain.
The 2 through 5 ton unit consist of an evaporator and
condenser module. These two modules are rigidly at-
tached by a joining strip across the top of the two cabinet,
and two long side cross-member angles which bridge the
mounting channels on the bottom of the unit. These units
may be field split to allow for passage through doors,
elevators, hallways, etc. Alternatively, the units may be
installed as a split system after separation.
Floor mounted units should be secured on a solid, level
pad. The use of isolating vibro-pads at several points
under the bottom mounting channels is recommended.
Ensure that provision is made for clearance to install a
trap on the condensate drain outlet.
Units may be either hung, or floor mounted. If unit is to
be hung, use all mounting points indicated - regardless
if unit is installed as a package or split system (See unit
dimension drawings). Use of 1/2in. dia hanger rods is
recommended. Ensure the attachment point of the rods
to the building structure is sufficient to support the unit
weight. In order to ensure efficient condensate drain-
age, the unit may be pitched towards the evaporator
end of the unit.
7
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
SEPARATION OF UNITS
INTERCONNECTING REFRIGERANT TUBING
- SPLIT INSTALLATION
The 2 through 5 ton units are provided with refrigerant
shut-off valves to allow the evaporator and condenser
sections to be field split - without the necessity of re-
claiming the entire unit refrigerant charge.
After the evaporator and condenser sections have been
mounted, the interconnecting refrigerant tubing can be
fabricated. Line sizing recommendations shown in the
accompanying table are suitable for most applications.
Consult sales office for applications outside the speci-
fied guidelines.
The evaporator and condenser sections may be sepa-
rated by performing the following procedure:
Route refrigerant tubing for minimum linear length, and
minimum number of bends and fittings. Use long radius
elbows for all 90-degree bends, except oil traps. Traps
should be constructed from short radius street elbows,
in order to keep the trap as small as possible.All brazing
should be done using a 2 to 8 psig dry nitrogen purge
flowing through the pipe being brazed.
1.Close all refrigerant shut-off valves, on both suction
and liquid lines. There are four valves in a single
compressor model, and a total of eight valves in the
dual compressor models. Valves are not a back-
seating design. Caps are wrench tight. Remove
caps and turn stem clockwise to seat in the closed
position.
Once the brazing operation of refrigeration lines is com-
pleted, the field-brazed connections must be checked for
leaks. Pressurize the system through the shut-off valve
ports with dry nitrogen to a minimum of 400 psig. Use
soap bubbles or alternate methods of leak-checking all
field brazed joints. After completion of the leak check,
evacuate the interconnecting lines to hold a 350-micron
vacuum. If gauge pressure rises above 500 microns in
one minute, then evacuation is incomplete or the system
has a leak.
2.Use the valve access ports to reclaim the refrigerant
trapped in the lines between the pairs of shut-off
valves.
3.Cut the refrigerant line sections between the pairs of
shut-off valves. It is recommended to make this out
where accessibility is greatest - in the condensing
section of the unit. This will allow best access for
reconnection, or attachment of an extended line
set in the case of a split system.
Additional refrigerant (R-410A) must be added to the
system due to the extended refrigerant lines. Calculate
the amount of additional refrigerant required as fol-
lows:
4.Remove the interconnecting wiring between the
evaporator and condenser electrical panel. Dis-
connect the wire terminations in the condenser
electrical panel, and pull the excess wire into the
evaporator panel.
1.5/16 in OD liquid line - add 0.40 oz per linear foot
2.3/8 in OD liquid line - add 0.60 oz per linear foot
3.1/2 in OD liquid line - add 1.20 oz per linear foot
4.5/8 in OD liquid line - add 1.80 oz per linear foot
5.Remove the threaded wire bushing connecting the
two electrical panels.
6.Remove the unit top-joining strip; take care to re-
move only those screws which attaches the joining
strip to the evaporator and condenser cabinets.
7.Remove the two side cross-member angles.
8.Carefully pull the evaporator section away from the
condenser section. Take care not to damage the
short lengths of refrigerant tubing extending into
the condenser section.
The separated evaporator and condenser modules may
now be individually moved to the proposed installation
site for re-assembly, or separately located for split ap-
plications.
8
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
DIMENSIONAL DATA
9
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
DIMENSIONAL DATA (Cont.)
10
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
DUCTWORK
The use of louvers with higher velocities than above may
be employed, at the discretion of the engineer/installer,
provided that the total air pressure drop does not exceed
the capability of the condenser fan and motor. The use
of low restriction louvers with shallow blade angles can
allow higher face velocities without excessive static
pressure loss.
When installing ductwork, adhere to local Codes and
sensible practice. Minimize duct runs and avoid abrupt
changes in direction where possible.Allow ample access
space for servicing of the coils and changing of filters.
Perform regular maintenance on ducts to increase unit
life, maintain efficient operation, and reduce accumu-
lation of explosive dust. Refer to blower performance
charts, and engineer duct runs and accessory pres-
sure drop so as not to exceed maximum external static
values.
Exceeding the static pressure capability of the con-
denser fan will result in insufficient condenser air volume.
This will cause a loss in system capacity, and may cause
compressor shutdown during high ambient periods. (In-
stallation of an oversize condenser motor/drive, where
applicable, may be considered in such cases.)
LOUVER SIZING GUIDELINES
One of the key issues in obtaining optimum performance
from indoor air-conditioners is the proper selection of the
condenser intake and discharge louvers. Unlike outdoor
air cooled units, which intake and discharge their cooling
virtually unrestricted, indoor units must overcome the
resistance of grilles or louvers at the outside wall - plus
the restriction of any interconnecting ductwork.
(As a general rule, these velocities will require an intake
louver sized approximately 1.25 to 1.5 times the dimen-
sions of the duct connection on the unit, and a discharge
louver sized approximately 1.5 to 2 times the duct con-
nection dimensions.)
Use only louver sections that provide different deflection
angles for air discharge and air intake, to ensure the
unit does not short circuit. Protect the unit from weather
conditions (rain, snow) entering through the condenser
air intake. All outdoor air ducts should pitch away from
the unit, toward the outside wall. Connect all ducts to unit
with canvas section duct connectors or choose another
suitable noise and vibration absorbing device.
Our indoor air cooled air-conditioners are designed to ac-
commodate the external static pressure loss associated
with properly sized louvers of the “storm proof” type. This
type of louver typically has a free area approximately
40-45% of the actual louver size. To determine the free
area required for any given unit, adhere to the following
guidelines:
- Size condenser air intakes for 500-750 feet/minute
nominal velocity
The Manufacturer will not accept any
liability resulting from incorrect instal-
lation of this equipment. Follow instal-
lation instructions carefully.
(Maximum recommended 800 feet/minute)
- Size condenser air discharge for 1,200-1,500 feet/
minute nominal velocity
(Maximum recommended 1,700 feet/minute)
11
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
ELECTRICAL WIRING
PACKAGED UNIT
If unit is to be installed as a complete integral unit, the
thermostat (low voltage) wiring is to be brought through
connection “A”, while power wiring will be brought
through connection “C”). Make sure you check the unit
data plate for full specifications as previously mentioned
(i.e. minimum circuit ampacity and fuse size).
Follow local electrical codes when making electrical
connections.Unitsarecompletelyfactorywiredfornormal
supply voltages (ie.208-230, 460, 575/3phase/60Hz)
Confirm unit specifications by checking unit data plate.
The factory wiring terminates in two boxes, one in each
section of the unit. The electrical control boxes are
located behind outer access panels. Each electrical
compartment has its own control cover.
SPLIT SYSTEM
If the unit is a split system application (condenser sec-
tion remote from evaporator section), the following wir-
ing instructions are applicable. The thermostat wiring
is brought through connection “A” on the evaporator
section, and is then interconnected via connection “B”
on the condenser section. The power wiring is brought
through “C” on the condenser section. The power feed
to the evaporator is run through “D” on the evaporator
section.
Provide individual power disconnects for each unit, or
each section in the case of split applications. Install a
secure ground to both evaporator and condenser. If
canvas joiners are used on ductwork, install a ground
wire to the ductwork as well. Unit requires installer to
provide a 24volt thermostat with appropriate heating
and cooling stages as needed. The condenser section
electrical cover is installed with wiring diagrams on the
inner access door, which must be opened to read the
diagrams.
IMPORTANT: All wiring must comply
with applicable local and national codes
(NEC). Type and location of disconnect
switches must comply with all applicable
codes.
Disconnect and lock out power when
servicing unit. Unit may start automati-
cally if power is not disconnected. Fail-
ure to do so may result in personal injury
or death due to electrical shock.
For low voltage wiring, 18 gauge wire may be used for
up to 50 feet lengths. Low voltage runs up to 125 feet
require 16-gauge wire.
12
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
STANDARD MOTORS
MODEL
VOLTAGE
COMPRESSOR
RLA
EVAPORATOR FAN
CONDENSER FAN
MIN. CCT.
"MOP"
Max Overcurrent
Prot.
#
QTY
1
1
LRA
HP
FLA
HP
FLA
AMPACITY
23.98
14.35
DSH
24H12 208-230/1/60
DSH
24H32 208-230/3/60
@
@
13.5
8.6
58.3
55.0
0.25
0.25
2.6
1.4
0.50
0.50
4.5
2.2
35
20
DSH
36H12 208-230/1/60
DSH
36H32 208-230/3/60
1
1
1
1
@
@
@
@
14.1
9.0
5.6
3.8
77.0
71.0
38.0
36.5
0.33
0.33
0.33
0.50
3.3
1.6
0.8
0.9
0.75
0.75
0.75
0.75
5.5
2.6
1.3
1.0
26.43
15.45
9.10
40
20
15
15
DSH
36H34
36H35
DSH
460/3/60
575/3/60
6.63
D
S
H
48H12 208-230/1/60
1
1
1
1
@
@
@
@
19.9
13.1
6.1
109.0
83.1
41.0
34.0
0.75
0.75
0.75
0.75
5.5
2.6
1.3
1.0
1.00
1.00
1.00
1.00
6.3
3.3
1.5
1.1
36.68
22.28
10.43
8.35
50
35
15
15
48H32 208-230/3/60
DSH
48H34
DSH
D
S
H
460/3/60
575/3/60
48H35
5.0
60H32 208-230/3/60
DSH
1
1
1
@
@
@
16.0
7.8
5.7
110.0
52.0
38.9
1.00
1.00
1.00
3.3
1.5
1.1
1.50
1.50
1.50
4.6
2.1
1.7
27.90
13.35
9.93
40
20
15
DSH
60H34
460/3/60
575/3/60
DSH
60H35
Notes:
Data shown for packaged unit installation, with single point power supply.
For split installation with separate evaporator motor power supply, calculate MCA and MFS as follows -
Min. Circuit Ampacity ( MCA ) = 1.25 X Largest motor amps (FLA or RLA) + sum of the remaining motor amps
Max Fuse / Cct. Bkr Size ( MFS ) = 2.25 X Largest motor amps + sum of the remaining motor amps
Select next smallest NEC listed fuse size from calculated value
FAN PERFORMANCE DATA
SUPPLY AIR BLOWER PERFORMANCE
EXTERNAL STATIC PRESSURE - Inches W.C.
0.8 1.0 1.2
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
MODEL
SUPPLY
CFM
0.2
0.4
0.6
1.4
1.6
1.8
700
800
900
593 0.06 755 0.10 915 0.13 1048 0.17 1175 0.23
629 0.08 777 0.12 914 0.16 1169 0.20 1178 0.25
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2 TON
668 0.11 804 0.15 930 0.19 1170 0.24
-
-
1000
1200
1400
598 0.11 722 0.16 835 0.19 930 0.25 1141 0.32
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3 TON
4 TON
727 0.20 831 0.25 929 0.31 972 0.33
747 0.26 844 0.32
-
-
-
-
-
-
-
-
1450
1600
1800
595 0.22 661 0.27 745 0.31 836 0.38 909 0.45 982 0.52 1046 0.61
601 0.26 691 0.33 773 0.39 847 0.44 921 0.51 987 0.61 1056 0.67
-
-
-
-
-
-
-
-
-
-
-
-
652 0.35 735 0.42 812 0.5 883 0.57 948 0.64 1018 0.72
-
-
1800
2000
2200
583 0.30 674 0.37 755 0.44 830 0.52 900 0.59 966 0.69 1037 0.75
688 0.45 767 0.53 839 0.61 907 0.69 971 0.77 1029 0.85 1086 0.92
-
-
-
-
-
-
-
-
-
-
-
-
5 TON
677 0.5 754 0.59 826 0.68 894 0.77 957 0.86 1018 0.95
-
-
NOTE:
1. At higher evaporator airflows and wet bulb conditions, condensate carry-over may occur. Adjust airflow downward as necessary.
2. Values include pressure drop from wet coil and clean filters.
3. Shaded areas indicate oversize motors
4. Adjustment limits of standard factory-installed drives are indicated by bold borders. (See pulley data on Pg. 17)
14)
CONDENSER AIR BLOWER PERFORMANCE
EXTERNAL STATIC PRESSURE - Inches W.C.
MODEL OUTDOOR
CFM
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
2 TON
3 TON
4 TON
5 TON
1600
1950
2500
2900
750 0.29 852 0.35 948 0.42 996 0.46
864 0.47 949 0.55 1032 0.63 1112 0.72
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
645 0.53 749 0.63 812 0.74 872 0.86 945 0.98
723 0.79 800 0.84 871 1.07 935 1.20 996 1.55 1057 1.42
13
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
MOTOR AND PULLEY DATA
EVAPORATOR
- STANDARD BLOWER MOTOR AND DRIVE DATA
Adjustable
Motor Pulley
Fixed
Blower Pulley
Motor
Belts
Drive Range
Model
(RPM)
Pitch Dia.(in)
Browning #
Pitch Dia.(in) Browning#
Rating / Size
HP
Frame Eff.(%)
Qty
2 TON
3 TON
4 TON
5 TON
845-1170
675-1010
675-1010
745-1120
1/4
1/3
3/4
1
56
56
56
66.0
75.0
75.0
75.0
2.6-3.6
2.0-3.0
2.0-3.0
2.0-3.0
1VP40 X 5/8
1VP34 X 5/8
1VP34 X 5/8
1VP34 X 7/8
5.4
5.2
5.2
4.7
AK56H
AK54H
AK54H
AK49H
4L370
4L370
4L400
4L390
1
1
1
1
143
CONDENSER
- STANDARD BLOWER MOTOR AND DRIVE DATA
Adjustable
Motor Pulley
Fixed
Blower Pulley
Motor
Belts
Drive Range
Model
(RPM)
Pitch Dia.(in)
Browning #
Pitch Dia.(in) Browning#
Rating / Size
HP
Frame Eff.(%)
Qty
2 TON
3 TON
4 TON
5 TON
770-1070
745-1071
615-920
1/2
3/4
1
56
56
143
145
75.0
82.5
82.5
84.0
2.6-3.6
2.0-3.0
2.0-3.0
2.6-3.6
1VP40 X 5/8
1VP34 X 5/8
1VP34 X 7/8
1VP40 X 7/8
5.9
4.7
5.7
5.9
AK61H
AK49H
AK59H
AK61H
4L500
4L390
4L490
4L500
1
1
1
1
770-1070
1.5
BLOWER SPEED ADJUSTMENT
3.Blower speed will increase when moveable flange is
adjusted towards the fixed flange (closed). Blower
speed will decrease when the moveable flange
is adjusted away from the fixed flange (opened).
Pulleys are adjustable only in half-turn increments.
Do not open pulley more than five full turns for “4L”
and “A” belts, or six full turns for “B” belts.
The RPM of the supply air and condenser air blow-
ers will depend on the required CFM, and the static
resistance of both the supply/discharge and the return/
intake duct systems. With this information, the RPM
for the blowers can be determined from the blower
performance tables. Adjustment of blower speed is
accomplished as follows:
1.Loosen belt tension by moving motor towards the
blower shaft via the adjustable mounting base.
4.Once the pulley has been opened/closed the ap-
propriate number of turns, replace the external key
and tighten the adjustment set screw. Proper torque
is 110 - 130 in-lbs.
2.Loosen the setscrew in the adjustable motor pul-
ley flange. Remove external key on pulleys 4-in.
dia and larger.
5.Install drive belt and adjust motor mount to tension
belt.
14
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
START-UP AND OPERATION
Prior to starting unit for the first time,
If opposite rotation is needed, disconnect and reverse
any two leads of the three phase supply. Reconnect
power and observe for correct rotation.
turn the thermostat system switch to
oFF - or raise the cooling setpoint to
the highest temperature, to prevent the
unit from starting. Close the electrical
disconnect switch. This will energize the
compressor crankcase heater(s). WAIT
A MINIMUM OF FOUR HOURS BEFORE
STARTING THE SYSTEM. This period will
allow the crankcase heater to vaporize
any liquid refrigerant in the compressor
crankcase.
Observe unit operation and check for unusual noise or
vibration.
REFRIGERANT CHARGES
Ref. Charge
No. of Circuits
Per Circuit (lb)
2 TON
1
3 TON
1
4 TON
1
5 TON
1
7.625
8.125
11.188
10.938
Start unit and check rotation of fans and compressors.
The Air Conditioning section of this
equipment is charged with R-410A; a hi-
pressure refrigerant. Only qualified techni-
cians, using appropriately pressure-rated
test instruments, should perform trouble-
shooting or service on this equipment.
Scroll compressors will only compress in one rotational
direction. Three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 50-50 chance of connecting power in such a
way as to cause rotation in the reverse direction, it is
important to ensure proper rotation direction is achieved
when the system is installed and operated.
PRESSURE SWITCH SETTINGS
Verification of proper direction is made by observing
that suction pressure drops and discharge pressure
rises when the compressor is energized. Reverse rota-
tion also results in an elevated sound level as well as
substantially reduced current draw.
ALL MODELS
High
600
Low
55
Cut Out (PSIG)
Cut In (PSIG)
450
75
There is no negative impacts on durability caused by
operating three phase Scroll compressors in the re-
versed direction for a short period of time (less than one
hour). However, after several minutes of operation the
compressors internal protector will trip.
RECCOMENEDED REFRIGERANT LINE SIZES
LESS THAN 60 LINEAR FEET
60 - 150 LINEAR FEET
UNIT SIZE
LIQUID LINE
SUCTION LINE
5/8
LIQUID LINE
SUCTION LINE
3/4
2 TON
3 TON
4 TON
5 TON
8 TON
10 TON
12 TON
15 TON
5/16
3/8
3/8
3/8
3/4
7/8
3/8
7/8
1/2
1-1/8
3/8
1-1/8
1/2
1-1/8
2 X 3/8
2 X 3/8
2 X 1/2
2 X 1/2
2 X 7/8
2 X 1-1/8
2 X 1-1/8
2 X 1-1/8
2 X 3/8
2 X 1/2
2 X 1/2
2 X 5/8
2 X 1-1/8
2 X 1-1/8
2 X 1-3/8
2 X 1-3/8
NOTES: - Maximum Suction Lift 60 FT
- Maximum Liquid Line Rise 40 FT (measured from condensing unit level).
- Liquid Line Solenoid Valve required on systems over 100 linear feet.
- Suction Accumulator(s) required on systems over 125 linear feet.
15
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
TYPICAL SCHEMATIC
16
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
MAINTENANCE / SERVICE
Disconnect And Lock Out Power When
DRIVE BELTS
Examine belts periodically for wear. Glazed areas on the
drive surfaces indicate overheating due to belt slippage.
Ideal tension is the lowest tension at which the belt will
not slip under peak load conditions. Over-tensioning
shortens belt and bearing life.
Servicing Unit. Failure To Do So May
Result In Personal Injury Or Death Due
To Electrical Shock.
The tension on the belt should be adjusted for a deflec-
tion of 1164 of an inch per inch of belt span, with the ap-
propriate force applied at the midpoint of the span. Ten-
sion “New” belts at the maximum value indicated. Used
belts should be maintained at the minimum value.
Exercise care when working around
the sharp metal edges of door panels
or door frames, etc. These edges can
cause injury.
FILTERS
Inspect filters monthly and replace as necessary. Use UL
Class 2 rated filters. Factory supplied filters are medium
efficiency, extended surface pleated type. Replacements
should be of the same type, to maintain optimum airflow
performance. Filter sizes are as follows:
FILTERS
QTY / SIZE
FILTERS
2 TON
2 / 20 x 14 x 2
4 TON
3 TON
2 / 20 x 14 x 2
5 TON
QTY / SIZE
2 / 25 x 16 x 2
2 / 25 x 16 x 2
POUNDS FORCE
EVAPORATOR AND CONDENSER COILS
Belt Cross Section
Min.
1-1/2
3-1/2
5-1/2
8
Max.
2-1/2
6-1/2
8
Inspect the evaporator coil at filter change intervals.
Inspect the condenser coil at least semi-annually. A
dirty condenser coil will result in elevated condensing
pressures and poor unit performance. Dirty or clogged
evaporator coils cause low suction pressure and lost
capacity. If the coils appear dirty, clean them using mild
detergent or a commercial coil cleaning agent.
4L
A
B
BX
11
BLOWERS
REFRIGERANT CIRCUIT(S)
Inspect both the evaporator and condenser blowers at
each regular service interval. Clean blower wheels as
needed. Bearings are permanently sealed ball type, and
do not require lubrication. Check bearings for any signs
of wear (movement between inner and outer races). En-
sure bearing locking collars are secure to the shaft, and
that collar locking screw is properly set. Check that the
blower wheel is tight on the shaft, and that the setscrews
in the blower hub are properly torqued.
With the unit operating, check and record the compres-
sor discharge and suction pressures. The compressor
running current should also be recorded.Amaintenance
log of these readings can indicate if the unit is operating
within its normal limits. Abnormal readings should be
investigated, and the cause corrected.
17
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
COMFORT ALERT™ DIAGNOSTICS
The ComfortAlert diagnostics module is a breakthrough
innovation for troubleshooting and protecting three
phase Copeland Scroll® compressors. The module
installs easily in the electrical box of the condensing
unit near the compressor contactor. By monitoring and
analyzing data from the Copeland Scroll compressor
and the thermostat demand, the module can accurately
detect the cause of electrical and system related failures
and protect the compressor. A flashing LED indicator
communicates the ALERT code and guides the service
technician more quickly and accurately to the root cause
of a problem.
This module provides compressor
protection and will shut down the com-
pressor when compressor damaging
conditions are detected.
INTERPRETING THE DIAGNOSTIC LEDS
When an abnormal system condition occurs, the Comfort
Alert module displays the appropriate ALERT and/or
TRIP LED. The yellowALERT LED will flash a number of
times consecutively, pause and then repeat the process.
To identify a Flash Code number, count the number of
consecutive flashes. Every time the module powers up,
the last ALERT Flash Code that occurred prior to shut
down is displayed for one minute. If the yellow ALERT
LED is on solid more than 2 amps are conducted through
the PROT terminal. The contactor coil may be shorted
or the PROT terminal miswired.
LED DESCRIPTION
POWER LED (Green): indicates voltage is present at
the power connection of the module.
ALERT LED (Yellow): communicates an abnormal sys-
tem condition through a unique flash code. The ALERT
LED will flash a number of times consecutively, pause
and then repeat the process. The number of consecu-
tive flashes, defined as the Flash Code, correlates to a
particular abnormal condition. Detailed descriptions of
specific ALERT Flash Codes are shown in two tables
attached to this manual.
Some ALERT codes indicate a compressor damaging
condition and the Comfort Alert module will shut down
and lock out the compressor. Refer to the tables below
TRIP LED (Red): indicates there is a demand signal
from the thermostat but no current to the compressor
is detected by the module. The TRIP LED typically indi-
cates the compressor protector is open or may indicate
missing supply power to the compressor. A flashing
TRIP LED indicates the anti-short cycle timer is active,
preventing compressor from starting.
to identify ALERT codes that result in a lock out.
18
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
Status LED
Green “POWER”
Status LED Description
Status LED Troubleshooting Information
Supply voltage is present at module terminals
Module has power
Red “TRIP” LED Thermostat demand signal Y 1. Compressor protector is open
On Solid
is present, but the
compressor is not running
2. Condensing unit power disconnect is open
3. Compressor circuit breaker or fuse(s) is open
4. Broken supply wires or connector is not making contact
5. Compressor power wires not routed
through Comfort Alert
6. Compressor contactor has failed open
Red “TRIP” LED
Flashing
The anti-short cycle timer (3 minutes), in module is preventing compressor restart.
Module locks out compressor when compressor damaging ALERT codes appear.
Lockout ALERT codes are noted in the Status LED Description.
During a compressor lock out, 24VAC power must be removed from module to manually reset
Yellow "ALERT" A short circuit or over current 1. Compressor contactor coil shorted.
LED On Solid
condition exists on PROT
terminal.
2. Electrical load too high for PROT circuit
(maximum 1 Amp)
3. 24 VAC wired directly to PROT terminal
Yellow “ALERT”
Flash Code 2
System Pressure Trip
Discharge pressure out of
limits or compressor over-
loaded (if no high pressure
switch in system)
1. High head pressure
2. Condenser coil poor air circulation (dirty,
blocked, damaged)
3. Condenser fan is not running
LOCKOUT
4. If low pressure switch is open:
Refer to Code 3 for troubleshooting
Yellow “ALERT”
Flash Code 3
Short Cycling
1. If low pressure switch is open:
a. Low refrigerant charge
Compressor is running only
briefly
LOCKOUT
b. Evaporator blower is not running
c. Evaporator coil is frozen
d. Faulty metering device
e. Condenser coil is dirty
(filter drier
f. Liquid line restriction
blocked if present)
2. If high pressure switch is open, go to
Flash Code 2 information
3. Intermittent thermostat demand signal
4. System or control board defective
19
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
Status LED
Status LED Description
Status LED Troubleshooting Information
1. Low line voltage to compressor
Yellow “ALERT”
Flash Code 4
Locked Rotor
LOCKOUT
2. Excessive liquid refrigerant in compressor
3. Compressor bearings are seized
Yellow “ALERT”
Flash Code 5
Open Circuit
1. Condensing unit power disconnect is open
2. Compressor circuit breaker or fuses are open
3. Compressor contactor has failed open
4. High pressure switch is open and requires manual reset
5. Broken supply wires or connector is not making contact
6. Unusually long compressor protector reset time due to
extreme ambient temperature
7. Compressor windings are damaged
Yellow “ALERT”
Flash Code 6
Missing Phase
LOCKOUT
1. Compressor fuse is open on one phase
2. Broken wire or connector on one phase
3. Compressor motor winding is damaged
4. Utility supply has dropped one phase
Yellow “ALERT”
Flash Code 7
Reverse Phase
LOCKOUT
1. Compressor running backward due to
supply phase reversal
Yellow “ALERT”
Flash Code 8
Welded Contactor
Compressor always runs
1. Compressor contactor has failed closed
2. Thermostat demand signal not connected to module
1. Control circuit transformer is overloaded
Yellow “ALERT”
Flash Code 9
Low Voltage
Control circuit < 18VAC
2. Low line voltage to compressor
Resetting Alert Codes
Flash code number corresponds to a number of LED
Alert codes can be reset manually and automatically.
The manual method to reset anAlert code is to cycle the
power to Comfort Alert off and on. For automatic reset,
Comfort Alert continues to monitor the compressor and
system after an Alert is detected. If conditions return to
normal, theAlert code is turned off automatically.ALERT
codes that result in a compressor lock out can only be
reset manually. ALERT codes that result in a lockout
can only be reset manually.
flashes, followed by a pause and then repeated.
TRIP and ALERT LED’s flashing at the same time
means control circuit voltage is too low for opera-
tion.
20
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
Miswiring the Comfort Alert module will cause false LED codes. Table 1 describes LED opera-
tion when the module is miswired and what troubleshooting action is required to correct the
problem.
TABLE 1 - COMFORT ALERT MODULE TROUBLESHOOTING
Installation Verification
To verify the installation of Comfort Alert is correct, a functional test can be performed. Force a call for cooling and
when the compressor starts to run, monitor the yellowALERT LED. The LED should remain off during test. Disconnect
power to the compressor while the call for cooling is still active. The red TRIP LED will flash indicating the anti-short
cycle timer is active. If the red LED does not function as described, refer to Table 1 to verify the wiring.
21
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
LIMITED WARRANTY
ONE YEAR LIMITED WARRANTY
Johnson Controls warrants this product to be free from defects in workmanship or material for a period of one year from date of original
installation or 18 months from date of shipment, whichever comes first.
Johnson Controls obligation under this Warranty is LIMITED to repairing or replacing at our sole option, at our factory, any part thereof
which shall be returned to our factory, transportation charges prepaid and which on examination proves to have been thus defective
under normal domestic use not exceeding the fuel rating. The defective part should be returned through a qualified servicing dealer.
Upon warranty determination, the replacement part will be shipped freight collect and assumes the unexpired portion of this Limited
Warranty.
When a defective part can be repaired or replaced, Johnson Controls shall not be obligated to repair the entire unit or any part thereof
other than the defective part.
This warranty applies only to the original homeowner, and is subject to the terms and conditions hereof.
COMPRESSOR – FIVE YEAR LIMITED WARRANTY
In addition to the One Year Limited Warranty, Johnson Controls warrants the compressor to be free from defects in workmanship or
material for a period of five (5) years from the date of original installation. If a compressor fails during this five year period, a new com-
pressor will be supplied. The customer will be responsible for freight costs from our factory for delivery of the replacement compres-
sor and also for the return of the defective compressor which may be required under the terms of the Warranty. Labor and any other
expense involved in replacing the compressor is not covered by this Warranty.
LABOR AND COST NOT COVERED
This Warranty provides only replacement parts or credits, and does not provide for or cover any labor, shipping, handling or other costs
for service travel, servicing, removing, or installing any parts.
EXCLUSIONS
This Warranty shall be void if:
1. The unit is not installed by a licensed or otherwise qualified or contractor and in compliance with the Installation Manual, applicable
installation and good trade practices.
2. The defect or damage is caused by accident, abuse, negligence of any person or company, misuse, riot, flood, fire or Acts of
God.
3. The unit is not operated and regularly serviced and maintained as called for in the Users’ Manual.
4. Damages are caused by operating the unit in a commercial or corrosive atmosphere containing any damaging or dangerous
chemicals.
5. The unit is modified or services in a manner not in accordance with the Installation Manual and Users’ Manual.
6. Components, replacement parts, or other accessories not compatible with the unit or not approved by Johnson Controls have
been used with or attached to the unit.
7. The defect or damage is not caused by Johnson Controls, or it arises from circumstances beyond the control of Johnson Controls.
8. The unit is installed outside the United States or Canada, or has been removed from the place where it was originally installed.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, OBLIGATIONS OR LIABILITIES, EXPRESSED OR IMPLIED BY
EMPLOYEES OR REPRESENTATIVES OF JOHNSON CONTROLS. ALL STATUTORY, EXPRESSED OR IMPLIED WARRANTIES,
INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY
NEGATED AND EXCLUDED. ANY CLAIMS FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES, OR ANY OTHER DAMAGES
OR EXPENSES BEYOND THE TERMS OF THIS LIMITED WARRANTY ARE HEREBY EXPRESSLY NEGATED AND EXCLUDED.
22
JOHNSON CONTROLS
FORM 145.32-IOM1 (908)
R-410A QUICK REFERENCE GUIDE
Refer to Installation Instructions for specific installation requirements.
• R-410A Refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing
equipment and replacement components are designed to operate with R-410A.
• R-410A Refrigerant cylinders are rose colored.
• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.
• Recovery equipment must be rated for R-410A.
• Do not use R-410Aservice equipment on R-22 systems. All hoses, gages, recovery cylinders, charging
cylinders and recovery equipment must be dedicated for use on R-410A systems only.
• Manifold sets must be at least 700 psig high side, and 180 psig low side, with 550 psig retard.
• All hoses must have a service pressure rating of 800 psig.
• Leak detectors, must be designed to detect HFC refrigerants.
• Systems must be charged with refrigerant. Use a commercial type metering device in the manifold
hose.
• R-410A can only be used with POE type oils.
• POE type oils rapidly absorb moisture from the atmosphere.
• Vacuum pumps will not remove moisture from POE type oils.
• Do not use liquid line driers with a rated working pressure rating less than 600 psig.
• Do not install suction line drivers in the liquid line.
• A liquid line drier is required on every unit.
• Do not use an R-22 TXV. If a TXV is to be used, it must be an R-410A TXV.
• Never open system to atmosphere when under vacuum.
• If system must be opened for service, evacuate system then break the vacuum with dry nitrogen and
replace filter driers.
23
JOHNSON CONTROLS
Subject to change without notice. Printed in U.S.A.
Copyright© 2008 by Unitary Products Group. All rights reserved.
Form 145.32-IOM1 (908)
New Release
Engineered Systems
Products
P.O. Box 1592
York, PA
York
PA
Group
17405
17405
|