MODELS DSH/KSH/DSV/KSV
R-410A LOW-AMBIENT KI T
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 relativ ely complicated apparatus.
During installation, oper ation, maintenance or service,
individuals may be expose d to certain components or
conditions includi ng, but not l imi ted to: ref ri gerant s
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
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.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
All wiring must be in accordance with published specifi cations and must be per formed ONLY by
qualified service personnel. Johnson Controls will not be responsible for damages/problems
resulting from improper connections to the contr ols or appli ca tion of impr oper contr ol si gnals .
Failure to follow this will void the manufacturers’ warranty and cause serious damage to property
or injury to persons.
, oils,
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 t his document a nd any refer enced materi a ls.
This individual shall also be familiar with and comply with
all applicable governmental standards and regulations
pertaining to the task in question.
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually and
instruction will be given, together with a
brief explanation.
NOTE is used to highlight additional information which may be helpful to you.
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 automatic ally to the manual owner, that
information, if applicable, can be obtained by
contacting the nearest Johnson Controls service
office.
It is the responsibi lity of operating/serv ice personnel
as to the applicability of these documents to the
equipment in question. If there is any ques tion 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 e qui pment has been modif ied
and if current literature is available.
TABLE OF CONTENTS
4 ……General Information
4 ..…..Damper Installation
6 ……Pressure Control Panel Installation
6 ……Pressure Transducer Installation
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.
8 ……Damper Actuator Installation & Wiring
10 ……Actuator Rotation Verific ation
11 ……Interconnection Drawings
13 ……Sequence of Operation
14 ……Schematics
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.
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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.
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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.
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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 c ompressor 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 condens er 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
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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 quic kly
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 Cont rol 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.
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DAMP E R ACTUAT OR INSTALLATION & WIRING
1) Press and hold the gear rele ase 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 ac t uator s l ot 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 co ver 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 c onnection 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.)
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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.
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ACTUATOR ROTATION – VERIFYING JUMPER W1 SETPOINT
MODEL #
JUMPER W1
SETTING
DSH024-DSH060
KSH024-KSH060
DSH096-DSH120
KSH096-KSH120
DSV036-DSV240
KSV036-KSV240
RA (CCW)
DA (CW)
RA (CCW)
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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.
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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.
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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.
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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
Engineered Systems P.O. Box 1592 York
Products York, PA PA
Group 17405 17405
2010 by Unitary Products Group. All rights reserved. Supersedes 145.10-IOM1 (810)
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