AIR-COOLED SELF-CONTAINED UNITS

D-SERIESMODEL DSV060B–300B

VERTICAL R-410A STYLE B

AIR-COOLED SELF-CONTAINED UNITS

INSTALLATION INSTRUCTIONS Supersedes:145.29-IOM2 (814) Form 145.29-IOM2 (217)

Issue Date: February 20, 2017

FORM 145.29-IOM2 (217)

2 JOHNSON CONTROLS

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

responsibility 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 en-

able 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 haz-ardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially haz-ardous situation which, if not avoided, could 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.

NOTE is used to highlight additional in-formation 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 manufacturer warranty and cause serious damage to property or injury to persons.

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 3

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

Safety Symbols………………………………………………………… 2

Changeability of This Document…………………….……………….. 3

Nomenclature……………………………………….………………….. 4

Typical Installation Diagram…………………………..………………. 5

General Information……………………………………………………. 6

Pre-Installation Inspection of Equipment……………………………. 6

Installation -

Unit Mounting / Unit Weights…………..……………………………..7

Evaporator / Condenser Assembly…………….…………………… 7

Condensate Trap…..…………………………………………………. 8

Ductwork………………………………………………………………. 9

Optional Accessories -

Variable Frequency Drive (VFD)………..……………………………9

Hot Gas Bypass (HGBP)……….…………….………………………10

Air Side Economizer…………….…………….………………………10

Discharge Plenum…………….……………..……..…………………11

Low Ambient Damper…………….…………..………………………12

Blower Discharge Conversion……..……………………………….....13

Electrical Wiring / Electrical Data……………………………………..13

Fan Performance Data…………………………………………………15 Motor and Pulley Data / Blower Speed Adjustment……………..20

Start-Up and Operation………………………………………………...22 Refrigerant Charges………………………………………………...22 Pressure Switch Settings…………………………………………..22

Microprocessor Controller……………………………………....……..23 Operation……………………………….…………………………….23 Microprocessor Flash Codes……………………………………….24

Maintenance/Service……………………………………………………26

Appendix A: Unit Dimensional Drawings……………………………..27

Appendix B: Typical Service Clearances……………………………..37

Appendix C: Typical Wiring Schematics……………………………..38

R-410A Service Procedures - Quick Reference Guide……………..47

FORM 145.29-IOM2 (217)

4 JOHNSON CONTROLS

NOMENCLATURE

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 5

DSV - TYPICAL INSTALLATION DIAGRAM

FORM 145.29-IOM2 (217)

6 JOHNSON CONTROLS

GENERAL INFORMATION All models 8 ~ 25 tons are shipped as separate condensing unit and evaporator section modules. The 5 ton models are shipped as factory-charged unitized packages. All models are designed for freestanding mounting on the floor, or on a field fabricated structural steel stand. All models can be ordered in either top or front fan discharge. The 5 ton model utilizes a single compressor. All 8 through 25 ton models are dual compressor units with two independent refrigerant circuits. The 8 ~ 25 ton models require field connection and charging of the refrigerant circuits. The 8 ~ 25 ton models are shipped with a nitrogen holding charge only. Refer to ‘Start-Up and Operation’ section for charge information. All units come standard with a microprocessor control board with safety controls and troubleshooting LED (refer to ‘Microprocessor’ section). Units will operate reliably at outdoor ambient down to

50F. In applications requiring operation below this temperature, a low ambient damper accessory is available. The damper installs on the condenser air

discharge, and allows operation to 0 F ambient. ONLY QUALIFIED PERSONNEL SHOULD PERFORM INSTALLATION AND SERVICE OF THIS EQUIPMENT.

PRE-INSTALLATION INSPECTION OF EQUIPMENT 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. Internal inspection of all units should be performed prior to installation. Remove all access doors and check for visual defects that can occur during transport. Any problems found internally should be reported to carrier and manufacturer immediately. Refrigerant circuit should be checked to ensure no leaks have occurred during shipment. Install gauge set to 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. See Appendix section for unit dimensional drawings.

Record any unit damage on the Bill of Lading and report to carrier and factory immediately. Shipping and handling damages are not warranty items.

RIGGING

PRIOR TO MOUNTING UNIT, CHECK INDIVIDUAL UNIT WEIGHTS (PAGE 10) AND VERIFY LIFTING CAPACITY OF LIFTING EQUIPMENT EXCEEDS WEIGHT OF UNITS BY SAFE MARGINS. FAILURE TO DO SO MAY RESULT IN UNIT DAMAGE, PERSONAL INJURY OR EVEN DEATH.

To ensure safe installation of the unit ensure the base of the unit is continuously supported.

DETERMINE THE ACTUAL CENTER OF GRAVITY OF THE UNIT BY PERFORM-ING A TEST LIFT. LIFTING AN UNBAL-ANCED UNIT CAN CAUSE PERSONAL INJURY OR EVEN DEATH.

INSTALLATION SITE LOCK ALL ELECTRICAL POWER SUP-PLY SWITCHES IN THE OFF POSITION BEFORE INSTALLING THE UNIT. FAIL-URE TO DISCONNECT POWER SUPPLY MAY RESULT IN ELECTRICAL SHOCK OR EVEN DEATH.

Location - To ensure unit operates at maximum efficiencies, choose a dry indoor area where the

temperature is controlled between 50F and 115F. Consideration 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, condenser intake and discharge may result in poor unit performance and possible unit failure.

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

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 7

can be slightly pitched in the same direction as drain pan outlet.

DSV Operating Weight (Lbs)

Unit Operating Weight (Condenser Only)

Shipping Weight (Condenser Only)

DSV060B 920 (620) 980 (675)

DSV096B 1240 (810) 1290 (865)

DSV120B 1325 (860) 1385 (915)

DSV144B 1560 (980) 1645 (1035)

DSV180B 1655 (1030) 1740 (1090)

DSV240B 1875 (1210) 1960 (1270)

DSV300B 2480 (1400) 2600 (1450)

UNIT MOUNTING The 5 ton model is shipped as a fully assembled integral package. The 8 ~ 25 ton models are shipped in two pieces - a separate condensing unit and evaporator module - which are intended for assembly into a freestanding vertical package on site. The unit is not designed for remote condenser / evaporator installation and must be installed as a packaged system. Installation or modification of the unit that is not described in this manual is not factory recommended nor is it factory supported. User is responsible for any damage that as a result may occur. Flanges for all duct connections, corner securing brackets, and refrigerant tubing couplings are shipped in the condensing section of the unit for field installation. Duct flanges for evaporator return are incorporated into the filter rack. Floor mounted units should be secured on a solid, level pad or sturdy stand. The base of the unit should be approximately 6 inches higher than the lower edge of the wall opening. This height will allow the condenser air ducts to be pitched away from the unit, offering protection from rain water entering the base pan (refer to typical installation diagram on Page 4). The use of an isolating rubber sheet is recommended to reduce vibration and noise transmission. Ensure that the entire base is continuously supported. Unit may be pitched slightly to ensure efficient drainage of condensate.

Ensure that entire base is continuously supported. DO NOT support unit at corner points only!

EVAPORATOR / CONDENSER ASSEMBLY ASSEMBLY OF SPLIT UNITS (8 - 25 TON MODELS)

- Place the condensing section in the required location.

- Carefully position the evaporator section atop the condensing section. Align all sides, the evaporator motor wire routing hole, and the refrigerant line routing holes.

- Install the securing brackets at all four corners, on the evaporator/condenser separation joint.

Securing Corner Bracket

- Units are provided with couplings to mate refrigerant piping between condenser and evaporator section. Unit with Hot Gas Bypass option will be provided with additional copper couplings for the HGBP piping. Remove shipping bracket securing spun copper ends in the condenser, this can be discarded and is not required.

- Cut off spun copper ends on each refrigerant pipe in evaporator and condenser. Cut pipe to appropriate length to fit on couplings. Ensure circuit 1 from condenser connects to circuit 1 piping in evaporator, follow same procedure for circuit 2. Do not cross circuits.

- Follow common A/C service practices by brazing copper couplings to refrigerant pipe using a flow of nitrogen gas (max. 1 psi) through the refrigerant piping to minimize contamination to internal piping. Otherwise damage to unit refrigeration components may occur. Use the service gauge ports for this procedure to introduce nitrogen flow. Once complete pressure test with nitrogen (500 psig).

- Evacuate each circuit to at least 350 microns. If gauge pressure rises above 500 microns in one minute, evacuation is incomplete or the system has a leak.

- Charge circuit(s) to the value indicated on the unit nameplate or see section ‘Start-Up and Operation’.

Corner Bracket

FORM 145.29-IOM2 (217)

8 JOHNSON CONTROLS

- Install bushing/clamp into evaporator wiring routing hole, and pull wires through into electrical control panel from evaporator. Connect motor leads to load terminals on contactor/overload relay.

Typical Piping Connections View (8/10 TON Model without HGBP Shown)

Do not cross circuits when brazing refrigerant piping between sections.

SEPARATION OF UNITS - (DSV060B MODEL) If separation of units is required to pass through doorways, elevators. Unit is not designed and not certified to be installed as a remote condenser and evaporator.

- Reclaim the entire refrigerant charge from each compressor circuit.

- Disconnect the evaporator motor high voltage wires. Pull all wiring into the evaporator compartment. Remove bushing/clamp from routing hole for evaporator motor wiring.

- Cut and remove sections of all liquid and suction refrigerant lines. Make two cuts in each line, approximately 6 inches above and below the evaporator floor/condenser roof.

Use a TUBING CUTTER ONLY - do not use a hacksaw to cut refrigerant tubing otherwise serious damage can occur to refrigeration system!

- Remove corner securing brackets from the outside corners of the cabinet, at the joint line between the evaporator and condenser sections.

- Remove the evaporator section.

- Refer to ‘Assembly of Split Units’ for assembly instructions.

CONDENSATE TRAP Unit requires a field installed external condensate trap otherwise without a trap condensate can be thrown into the air stream, cause water overflow resulting in unit and property damage. This system must be trapped according to a negative pressure (draw-through) system. Use dimensions given below. Adhere to local Codes for piping external trap and condensate. Example: Trapping a system up to 2” External static pressure A= (1” for each 1” of maximum negative static pressure) + 1” B= Half of A C= A + B + Pipe Diameter

Dimensions for trapping a negative pressure system

Example: Trapping a system up to 2” External static pressure A= (2”) + 1” B= A/2 C= A + B + 3/4” = 5-1/4”

Evaporator connections, couplings included with unit

Condenser piping for coupling to evaporator

Condenser Securing Bracket

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 9

DUCTWORK When installing ductwork, adhere to local Codes. 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 accumulation of explosive dust. Refer to blower performance charts, and engineer duct runs and accessory pressure drop so as not to exceed maximum external static values. Ensure continuous running condenser intake ambient air temperature do not exceed 115oF. The condenser exhaust should discharge into an open area to prevent short cycling of hot exhaust condenser air with the condenser intake. 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. Our indoor air cooled air-conditioners are designed to accommodate 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 350-600 feet/minute nominal velocity (Maximum recommended 700 feet/minute)

- Size condenser air discharge for 1,200-1,500 feet /minute nominal velocity (Maximum recommended 1,700 feet/minute)

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. Exceeding the static pressure capability of the condenser fan will result in insufficient condenser air volume. This will cause a loss in system capacity, and may cause compressor shut-down during high ambient periods. (Installation of an oversize condenser motor/drive, where applicable, may be considered in such cases.)

(As a general rule, these velocities will require an intake louver sized approximately 1.25 to 1.5 times the dimensions of the duct connection on the unit, and a discharge louver sized approximately 1.5 to 2 times the duct connection 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.

The Manufacturer will not accept any liability resulting from incorrect instal-lation of this equipment. Follow instal-lation instructions carefully.

VARIABLE FREQUENCY DRIVE (VFD) Optional VFD controller for the evaporator fan is available on the 10 to 25 ton models. Mounted in the evaporator module section, the VFD allows the operator to set the duct static. The VFD will control the frequency (speed) of the evaporator fan motor in order to meet the desired supply duct static set point. For reliable unit operation unit must have a factory installed Hot Gas Bypass circuit on refrigeration circuit # 1. In 20 ton and 25 ton units, the standard configuration is that the VFD is used for the evaporator fan motor for the purpose of 2 discrete speed automatic adjustment. In this case, if the two compressors are energized, the evaporator fan motor runs at high speed. However, if only the circuit #1 compressor is energized, the evaporator fan motor will switch to the low speed.

The unit does not carry a failsafe circuit to bypass the VFD and run the evaporator fan in the event of a VFD malfunction.

VFD is factory mounted and wired. The installer must field provide and install two sensor tubing lines complete with static pressure probes (except for the configuration of the 2 discrete speed application). Installer is required to field wire fan power wiring between the evaporator and condenser as a result of the unit being shipped factory split. The power wiring

FORM 145.29-IOM2 (217)

10 JOHNSON CONTROLS

can be found inside the VFD enclosure, no extra power wiring is required – sufficient length is provided. The VFD option does not include an evaporator fan bypass circuit in case of micro drive failure. The microdrive will need to be replaced to re-activate unit. In case of VFD failure the evaporator fan will stop running. However, unit compressors will continue to run until a low pressure safety trip is activated. Refer to separate ‘VFD Installation and Operation Manual’ for detailed installation and operation instructions.

Do not run evaporator fan motor below 30Hz otherwise coil freeze-up and nuisance lock-outs may occur.

Building excessive ductwork pressure can cause damage to unit or personnel

VFD Input/Output (208~230V, 460V)

Note: Jumper is required between contacts 10 & 11

HOT GAS BYPASS (HGBP) Optional HGBP on the lead compressor circuit (circuit #1) meters flow of compressor discharge hot gas to the system low side in order to balance the system capacity to the space load requirement. HGBP is factory installed using an adjustable hot gas regulator. The bypassed hot gas from the compressor is discharged to the evaporator inlet (i.e.: between the TX valve and distributor) via a Tee connection.

Adjusting HGBP set point The desired coil suction pressure or coil temperature when the HGBP valve opens is selectable by adjusting the screw on the HGBP valve. To set the load run the unit and cool down the evaporator coil by either shutting the fans or by blocking the airflow until the suction pressure drops at least 5psi below the desired evaporator coil setpoint. The next step is to allow the pressure to be raised by the bypassed gas, the screw spring adjustment can be set until the HGBP valve closes at the desired set point. The pressure of the evaporator coil is set to maintain an evaporator coil temperature above the point where frost and coil freeze up could form. AIR SIDE ECONOMIZER Optional air side economizer mixing box is designed to attach the return air side of the evaporator. Mixing comes with low-leakage opposed blade dampers. Economizer is used to provide ventilation and free cooling for the JCI DSV series of vertical air handlers. Economizer setup is done through the LCD keypad display locating on the economizer control module mounted on the mixing box. Access to the mixing box is required. The factory supplied economizer includes: economizer module, mixing box, actuator, enthalpy sensor, temperature sensor, dampers, and wiring harness. Refer to Appendix C for economizer electrical wiring schematics.

SEQUENCE OF OPERATION High enthalpy sequence Enthalpy sensor should be located in the outdoor air duct. When the outside air enthalpy exceeds the enthalpy set-point, the economizer module Y1-In and Y1-Out terminals are closed and economizer will be forced into the minimum damper position setting. The DSV unit’s microprocessor board will control mechanical cooling requirements. Low enthalpy sequence When the outside air enthalpy is below the enthalpy set-point, economizer module Y1-In and Y1-Out terminals are opened and free cooling is activated. The JCI unit’s microprocessor board turns off compressor operation. Damper Modulation The temperature sensor should be located in the supply discharge air duct. Locating the sensor in the discharge air provides effective 'low-limit' sensing and control. The outside-air damper remains at minimum position if the discharge air temperature is below 500 F or 100 C. If the discharge air temperature is between

Jumper set to 4-20mA

4-20mA Output from Transducer (–COM)

Transducer Power (+EXC) 24VDC

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 11

500 to 560 F (100 to 13.30 C) the outside air damper will modulate between minimum position and fully open. Above 560 F (13.30 C) the outside air damper will remain in the fully open position.

Refer to separate ‘Air Side Economizer Installation and Operation Manual’ for more detailed installation and operation instructions.

DISCHARGE PLENUM Optional discharge plenum is available for field mounting to the top of evaporator for the 5-20 ton models. Discharge plenum is only compatible with top (vertical) discharge evaporator blower configuration. Discharge plenum for 5 – 10 Ton model comes with single front grille and single side grilles. The 12 – 20 Ton models come with double front grilles and single side grilles. Discharge plenum is constructed of heavy gauge sheet metal with supply grilles mounted on three side (front, left and right sides). Discharge plenum is secured to the unit using 4X corner brackets included with plenum.

Plenum Dimensions (Inches)

MODEL W D H Side Grille Front Grille

DSV060B 52 29 24 16x12 (2x) 32x12

DSV096B 71.5 32 24 20x18 (2x) 48x18

DSV120B 71.5 32 24 20x18 (2x) 48x18

Plenum Dimensions (Inches)

MODEL W D H Side Grille Front Grille

DSV144B 82.5 34 28 24x20 (2x) 28x20 (2x)

DSV180B 82.5 34 28 24x20 (2x) 28x20 (2x)

DSV240B 90.5 34 28 24x20 (2x) 32x20 (2x)

A B C D E

DSV060B VASE-060B-1 49.00 27.75 24.00 40.00 14.00

DSV096B/120B VASE-120B-1 66.50 36.25 26.50 58.00 19.50

DSV144B/180B VASE-180B-1 78.00 35.75 28.50 70.00 19.50

DSV240B VASE-240B-1 86.00 41.25 34.00 78.00 25.00

DSV300B VASE-300B-1 104.00 45.00 34.00 90.00 25.00

MODEL PART NO.MIXING BOX DAMPER

1

1

2

2

A A

B B

ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER

HEREOF ARE RESERVED AND NO PERMISSION ISGRANTED TO REPRODUCE THIS PRINT IN WHOLE OR

IN PART OR DISCLOSE ANY OF THE INFORMATIONUPON IT TO OTHERS WITHOUT WRITTEN RELEASE BY

JOHNSON CONTROL

JOHNSON CONTROLS INC.

AS NOTED

MATERIAL:

DWG BY:

NOTES: UNLESS OTHERWISE SPECIFIED:

ALL DIM'S ARE OUTSIDE DIM'S

INSIDE BEND RAD. TO BE 1/16"

XXX.X ±0.06"

XXX.XX ±0.03"

XXX.XXX ±0.015"

ANGLES ±1DEG

DWG NO:

CHKD:

SCALE:

10 TON DSV-B ECONOMIZER

VASE120B-UAS-IOM

csiebee 4/14/2011

MIXING BOX UNIT ASSEMBLY

THIRD ANGLE

4/14/2011

SH. NO. 1 OF 2

REVISION HISTORY

DATE ECO # REV DESCRIPTION ENG.

JULY 29, 2014 A Initial Release ES

B

C

D

NOTE: * ALL BENDS FOLD UP 90° UNLESS OTHERWISE SPECIFIED

ALL DIMENSIONS ARE INCHES UNLESS OTHERWISE NOTED

FINISHED PRODUCTS

SPOT WELD WELD INSULATE PAINTING

NONONONODSV ECONOMIZER DAMPER ASSEMBLY DRAWING

6.75

3.625

E

D

BECONOMIZER CONTROL

BOX COVER

TOP VIEW

FRONT VIEW

ACTUATOR

CRANK ARM &

CONTROL ROD

4

FORM 145.29-IOM2 (217)

12 JOHNSON CONTROLS

LOW AMBIENT DAMPER INSTALLATION If unit operation is required at outdoor ambient below

50 F, the optional Low Ambient Damper kit should be installed to maintain acceptable condensing pressure. The damper is installed directly onto the intake duct connection as illustrated. 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.

On dual compressor units, the pressure transducer MUST be connected to the #1 circuit liquid line fitting. Connection to the second stage refrigerant circuit will result in system malfunction.

For detailed installation instructions, refer to the supplementary ‘Low Ambient Damper Kit’ installation instructions.

MODEL PART NO. A B C

DSV060B VADK-060B-1 47.375" 5.0" 11.875"

DSV096B/120B VADK-120B-1 66.375" 5.0" 14.125"

DSV144B/180B VADK-180B-1 77.5" 5.0" 14.125"

DSV240B VADK-240B-1 85.5" 5.0" 12.875"

DSV300B VADK-300B-1 103.5" 5.0" 12.875"

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 13

EVAPORATOR BLOWER DISCHARGE CONVERSION All models can be factory ordered with either front or top fan discharge. Procedure for converting the fan discharge is similar on all models. Original drive belts will need to be replaced, see ‘Drive Belt’ section for alternate belt information.

- Remove the panel attachment screws on the alternate location access panel. Remove the panel and set aside.

- Remove blower drive belt on all models with

base mounted motors.

- Remove the panel attachments screws on the blower mounting panel. Do not remove fasteners securing blowers to panel! The blowers are to remain attached to the mounting panel at all times.

- Carefully remove the blower panel assembly

from the evaporator cabinet. Do not allow blower housings to contact the evaporator coil during the removal. On some models, the housing(s) will have to be "rotated" to exit through the panel opening.

- Interchange the blower panel assembly with the

position of the alternate access panel. Exercise care in locating the panel. Do not allow blower housings to contact the evaporator coil. Install the attachment screws and tighten securely.

- Install the blank access panel into the remaining

evaporator opening. Fasten securely.

- Install new drive belts.

- Adjust drive belts to appropriate tension. Test run blower and observe operation for unusual sounds or vibration.

ELECTRICAL WIRING Follow local electrical codes when making electrical connections. Units are completely factory wired for normal supply voltages (ie.208-230, 460, 575V/3Ph/60Hz) Confirm unit specifications by checking unit data plate. All electrical components are accessible through an independent electrical panel located on the "front" face of the condensing section. The electrical control boxes are located behind outer access panels. The condenser section electrical cover is installed with wiring diagrams on the inside, which must be opened to be read.

Ensure evaporator motor rotation is correct upon unit start-up. Switch any two wires at contactor if blower rotation is not correct.

DISCONNECT AND LOCK OUT POWER WHEN SERVICING UNIT. UNIT MAY START AUTOMATICALLY IF POWER IS NOT DISCONNECTED. FAILURE TO DO SO MAY RESULT IN PERSONAL IN-JURY OR DEATH DUE TO ELECTRICAL SHOCK.

If canvas flexible joints are used on ductwork, install a ground wire to the ductwork as well.

IMPORTANT: All wiring must comply with applicable local and national codes (NEC). Type and location of disconnect switches must comply with all applicable codes.

For low voltage thermostat wiring, 18 gauge wire may be used for up to 50 feet lengths. Low voltage runs up to 125 feet require 16 gauge wire.

FORM 145.29-IOM2 (217)

14 JOHNSON CONTROLS

ELECTRICAL DATA - STANDARD EVAPORATOR MOTOR

MODEL # VOLTAGE COMPRESSOR

EVAP. FAN COND. FAN MCA

MAX FUSE / CCT.

BKR. AMP QTY RLA LRA HP FLA HP FLA DSV060B2 208-230/3/60 1 @ 16.0 110.0 1.00 3.1 1.50 4.5 27.60 40

DSV060B4 460/3/60 1 @ 7.8 52.0 1.00 1.5 1.50 2.2 13.45 20

DSV060B5 575/3/60 1 @ 5.7 38.9 1.00 1.2 1.50 1.8 10.13 15

DSV096B2 208-230/3/60 2 @ 15.3 83.0 1.00 3.1 2.00 5.8 43.33 50

DSV096B4 460/3/60 2 @ 6.2 41.0 1.00 1.5 2.00 2.9 18.35 20

DSV096B5 575/3/60 2 @ 4.8 33.0 1.00 1.2 2.00 2.3 14.30 15

DSV120B2 208-230/3/60 2 @ 16.0 110.0 1.50 4.5 3.00 8.5 49.00 60

DSV120B4 460/3/60 2 @ 7.8 52.0 1.50 2.2 3.00 4.2 23.95 30

DSV120B5 575/3/60 2 @ 5.7 38.9 1.50 1.8 3.00 3.4 18.03 20

DSV144B2 208-230/3/60 2 @ 19.0 123.0 2.00 5.8 3.00 8.5 57.05 70

DSV144B4 460/3/60 2 @ 9.7 62.0 2.00 2.9 3.00 4.2 28.93 35

DSV144B5 575/3/60 2 @ 7.4 50.0 2.00 2.3 3.00 3.4 22.35 25

DSV180B2 208-230/3/60 2 @ 23.2 164.0 3.00 8.5 5.00 14.0 74.70 90

DSV180B4 460/3/60 2 @ 11.2 75.0 3.00 4.2 5.00 6.6 36.00 45

DSV180B5 575/3/60 2 @ 7.9 54.0 3.00 3.4 5.00 5.3 26.48 30

DSV240B2 208-230/3/60 2 @ 30.1 225.0 5.00 14.0 7.50 19.4 101.13 125

DSV240B4 460/3/60 2 @ 16.7 114.0 5.00 6.6 7.50 9.7 53.88 70

DSV240B5 575/3/60 2 @ 12.2 80.0 5.00 5.3 7.50 7.8 40.55 50

DSV300B2 208-230/3/60 2 @ 34.0 240.0 7.50 20.4 10.00 25.0 121.90 150

DSV300B4 460/3/60 2 @ 16.0 140.0 7.50 9.7 10.00 12.5 58.20 70

DSV300B5 575/3/60 2 @ 12.9 107.6 7.50 7.8 10.00 10.0 46.83 50

ELECTRICAL DATA - OVERSIZED EVAPORATOR MOTOR

MODEL # VOLTAGE COMPRESSOR EVAP.

FAN COND. FAN MCA MAX FUSE

/ CCT. BKR. AMP QTY RLA LRA HP FLA HP FLA

DSV060B2 208-230/3/60 1 @ 16.0 110.0 1.50 4.5 1.50 4.5 29.00 45

DSV060B4 460/3/60 1 @ 7.8 52.0 1.50 2.2 1.50 2.2 14.15 20

DSV060B5 575/3/60 1 @ 5.7 38.9 1.50 1.8 1.50 1.8 10.73 15

DSV096B2 208-230/3/60 2 @ 15.3 83.0 1.50 4.5 2.00 5.8 44.73 60

DSV096B4 460/3/60 2 @ 6.2 41.0 1.50 2.2 2.00 2.9 19.05 25

DSV096B5 575/3/60 2 @ 4.8 33.0 1.50 1.8 2.00 2.3 14.90 15

DSV120B2 208-230/3/60 2 @ 16.0 110.0 2.00 5.8 3.00 8.5 50.30 60

DSV120B4 460/3/60 2 @ 7.8 52.0 2.00 2.9 3.00 4.2 24.65 30

DSV120B5 575/3/60 2 @ 5.7 38.9 2.00 2.3 3.00 3.4 18.53 20

DSV144B2 208-230/3/60 2 @ 19.0 123.0 3.00 8.5 3.00 8.5 59.75 70

DSV144B4 460/3/60 2 @ 9.7 62.0 3.00 4.2 3.00 4.2 30.23 35

DSV144B5 575/3/60 2 @ 7.4 50.0 3.00 3.4 3.00 3.4 23.45 30

DSV180B2 208-230/3/60 2 @ 23.2 164.0 5.00 14.0 5.00 14.0 80.20 100

DSV180B4 460/3/60 2 @ 11.2 75.0 5.00 6.6 5.00 6.6 38.40 45

DSV180B5 575/3/60 2 @ 7.9 54.0 5.00 5.3 5.00 5.3 28.38 35

DSV240B2 208-230/3/60 2 @ 30.1 225.0 7.50 20.4 7.50 20.4 108.53 125

DSV240B4 460/3/60 2 @ 16.7 114.0 7.50 9.7 7.50 9.7 56.98 70

DSV240B5 575/3/60 2 @ 12.2 80.0 7.50 7.8 7.50 7.8 43.05 50

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 15

FAN PERFORMANCE DSV060B

DSV096B

SUPPLY AIR BLOWER PERFORMANCE

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

1600 408 0.13 555 0.29 652 0.38 739 0.45 819 0.54 893 0.63 963 0.71 1029 0.81

1800 459 0.20 600 0.39 689 0.48 770 0.58 846 0.66 917 0.76 984 0.86 1047 0.96

2000 510 0.25 647 0.51 729 0.61 806 0.71 877 0.81 944 0.92 1008 1.00 1069 1.14

2200 561 0.35 695 0.65 772 0.76 843 0.88 911 0.99 975 1.10 1036 1.23 1094 1.34

2400 612 0.45 745 0.83 816 0.95 883 1.07 947 1.19 1008 1.31 1066 1.44 ~ ~1. Blower performance includes evaporator coil and 2" f ilters

2. At higher evaporator airf lows and wet bulb condit ions, condensate carry-over may occur. Decrease airf low downward as necessary.

CONDENSER FAN PERFORMANCE

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

3100 513 0.50 615 0.65 706 0.80 790 0.98 867 1.15 938 1.33 1006 1.50

Hi-Static DriveStandard Factory Drive 1.5 HP

SUPPLY

CFM0.2 0.4 0.6 0.8 1.0 1.2 1.40.0

AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹

Optional Hi-Static Drive +1.5 HP

OUTDOOR

CFM

AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C.

0.0 0.2 0.4 0.6 0.8 1.0 1.2

Standard Factory Drive + 1 HPField Supplied Low Static

Drive


RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

2600 496 0.28 605 0.40 701 0.50 788 0.62 868 0.74 947 0.89 1016 1.04 1045 1.19 1075 1.35 1105 1.50

2900 514 0.36 618 0.48 710 0.60 794 0.72 872 0.86 944 0.98 1017 1.12 1075 1.28 1128 1.42 ~ ~

3200 538 0.44 636 0.58 725 0.70 806 0.84 881 0.98 952 1.12 1018 1.26 1081 1.42 ~ ~ ~ ~

3500 571 0.56 664 0.70 748 0.84 826 0.98 898 1.14 967 1.28 1031 1.44 ~ ~ ~ ~ ~ ~

3800 613 0.70 700 0.86 779 1.00 853 1.16 923 1.32 989 1.48 ~ ~ ~ ~ ~ ~ ~ ~1. Blower performance includes evaporator coil and 2" f ilters




4400 478 0.60 560 0.78 634 0.96 702 1.14 765 1.34 824 1.54 880 1.74

Standard Factory Drive + 2 HP Optional Hi-Static Drive + 2 HP

OUTDOOR

CFM


0.0 0.2 0.4 0.6 0.8 1.0 1.2

Optional Hi-Static Drive + 1.5 HPStandard Factory Drive + 1 HPLow Static

Drive

SUPPLY

CFM0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0


FORM 145.29-IOM2 (217)

16 JOHNSON CONTROLS

DSV120B

DSV144B



3200 573 0.48 668 0.62 754 0.76 833 0.88 906 1.02 975 1.18 1040 1.32 1102 1.48 1160 1.66 1225 1.86

3600 621 0.66 708 0.80 788 0.96 863 1.10 933 1.26 999 1.42 1061 1.58 1121 1.74 1178 1.90 ~ ~

4000 667 0.86 748 1.02 823 1.18 893 1.34 960 1.52 1023 1.68 1083 1.86 1141 2.04 ~ ~ ~ ~

4400 723 1.12 797 1.28 868 1.46 934 1.64 997 1.84 1057 2.02 ~ ~ ~ ~ ~ ~ ~ ~

4800 775 1.40 845 1.60 911 1.80 973 2.00 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~1. Blower performance includes evaporator coil and 2" f ilters




5500 614 1.22 680 1.44 741 1.66 799 1.90 854 2.14 906 2.38 956 2.62

Standard Factory Drive + 1.5 HPLow Static

DriveOptional Hi-Static Drive + 2 HP

Opt. Hi-Static Drive +3HPStandard Factory Drive + 3 HP

OUTDOOR

CFM


0.0 0.2 0.4 0.6 0.8 1.0 1.2

SUPPLY

CFM

AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0



4000 436 0.48 521 0.64 597 0.80 667 0.98 730 1.16 790 1.34 845 1.54 896 1.75 946 2.01 992 2.29

4400 456 0.58 536 0.76 609 0.94 676 1.12 738 1.32 796 1.52 851 1.72 902 1.82 950 2.17 996 2.52

4800 475 0.70 555 0.88 621 1.08 686 1.28 746 1.48 803 1.70 857 1.92 908 2.14 956 2.36 1000 2.70

5200 494 0.84 567 1.04 634 1.24 697 1.46 755 1.68 811 1.90 863 2.12 913 2.36 961 2.60 1007 2.84

5600 517 1.00 587 1.22 651 1.44 711 1.66 768 1.90 822 2.14 873 2.38 922 2.62 969 2.86 ~ ~1. Blower performance includes evaporator coil and 2" f ilters




6000 535 1.02 609 1.28 679 1.56 744 1.84 805 2.14 862 2.44 921 2.82

SUPPLY

CFM


OUTDOOR

CFM


0.0 0.2 0.4 0.6 0.8 1.0 1.2


Field Supplied Low Stat ic Drive Standard Factory Drive + 2 HP Optional Hi-Static Drive + 3 HP

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 17

DSV180B



4800 529 0.84 601 1.02 667 1.22 729 1.42 786 1.64 841 1.84 893 2.06 942 2.28 987 2.54 1037 2.78

5400 580 1.14 646 1.36 707 1.58 764 1.80 819 2.02 870 2.26 920 2.50 967 2.74 1012 2.98 1056 3.24

6000 610 1.42 671 1.66 729 1.90 783 2.14 835 2.40 885 2.64 933 2.90 979 3.16 1023 3.44 1066 3.70

6600 702 2.04 757 2.30 809 2.56 858 2.84 906 3.10 952 3.38 996 3.66 1039 3.96 1080 4.24 1121 4.54

7200 760 2.62 810 2.90 858 3.18 905 3.48 950 3.78 993 4.08 1035 4.38 1076 4.68 1116 5.00 ~ ~1. Blower performance includes evaporator coil and 2" f ilters




7200 642 1.78 706 2.08 766 2.40 823 2.74 877 3.08 929 3.42 979 3.78


Standard Factory Drive + 3 HP Optional Hi-Static Drive + 5 HPField Supplied Low Stat ic Drive

OUTDOOR

CFM


0.0 0.2 0.4 0.6 0.8 1.0 1.2

SUPPLY

CFM


FORM 145.29-IOM2 (217)

18 JOHNSON CONTROLS

DSV240B

SUPPLY AIR BLOWER PERFORMANCE - HIGH SPEED


6400 592 1.38 659 1.63 721 1.96 779 2.26 835 2.58 888 2.88 942 3.02 1001 3.38 1058 3.76 1101 4.18

7200 645 1.88 706 2.18 770 2.50 818 2.84 870 3.18 920 3.52 965 3.88 1014 4.24 1065 4.61 1113 4.98

8000 698 2.46 769 2.80 808 3.14 858 3.50 907 3.88 954 4.26 1000 4.64 1044 5.02 1087 5.42 1128 5.82

8800 756 3.20 808 3.56 858 3.96 905 4.34 951 4.72 995 5.14 1038 5.54 1080 5.96 1121 6.38 1160 6.82

9600 811 4.04 859 4.44 905 4.84 950 5.26 993 5.68 1035 6.12 1076 6.56 1116 7.00 1154 7.45 ~ ~1. Blower performance includes evaporator coil and 2" filters

2. At higher evaporator airflows and wet bulb conditions, condensate carry- over may occur. Decrease airflow downward as necessary.

Legend:

RPM L - RPM Low Speed ESP L - External Static Pressure Low Speed

RPM H - RPM High Speed ESP H - External Static Pressure High Speed

CFM L - CFM Low Speed BHP L - Break Horse Power Low Speed

CFM H - CFM High Speed BHP H - External Static Pressure High Speed

All data for High Speed Supply Blower Perfomance are given in above High Speed Table

All data for Low Speed Perfomance are to be calculated using formulas below

Formulas to calculate Low Speed Performance:

RPM L = (RPM H x 0.60) ESP L = (RPM L/RPM H)² x ESP H

CFM L = (RPM L/RPM H) x CFM H BHP L = (RPM L/RPM H)³ x BHP H



10800 775 3.87 827 4.29 877 4.71 925 5.16 971 5.61 1016 6.06 1052 7.00

SUPPLY

CFM


0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

Standard Factory Drive + 7.5HP

Field Supplied Low Static Drive Standard Factory Drive + 5HP Optional Hi-Static Drive +7.5HP

OUTDOOR

CFM


0.0 0.2 0.4 0.6 0.8 1.0 1.2

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 19

DSV300B

SUPPLY AIR BLOWER PERFORMANCE - HIGH SPEED


8200 581 1.80 647 2.16 707 2.49 765 2.85 819 3.24 870 3.60 920 3.99 967 4.38 1012 4.80 1056 5.19

8800 639 2.31 699 2.70 755 3.06 809 3.45 860 3.84 910 4.26 957 4.65 1002 5.07 1045 5.49 1087 5.94

9200 676 2.70 733 3.09 787 3.48 839 3.87 888 4.29 935 4.71 981 5.13 1025 5.58 1068 6.00 1109 6.45

9600 716 3.15 771 3.54 822 3.96 872 4.38 920 4.80 965 5.25 1010 5.70 1052 6.15 1093 6.60 1113 7.05

10000 755 3.63 807 4.05 856 4.47 904 4.92 950 5.37 994 5.82 1037 6.27 1079 6.75 1119 7.20 ~ ~

1. Blower performance includes evaporator coil and 2" filters

2. At higher evaporator airflows and wet bulb conditions, condensate carry- over may occur. Decrease airflow downward as necessary.

Legend:

RPM L - RPM Low Speed ESP L - External Static Pressure Low Speed

RPM H - RPM High Speed ESP H - External Static Pressure High Speed

CFM L - CFM Low Speed BHP L - Break Horse Power Low Speed

CFM H - CFM High Speed BHP H - External Static Pressure High Speed

All data for High Speed Supply Blower Perfomance are given in above High Speed Table

All data for Low Speed Perfomance are to be calculated using formulas below

Formulas to calculate Low Speed Performance:

RPM L = (RPM H x 0.60) ESP L = (RPM L/RPM H)² x ESP H

CFM L = (RPM L/RPM H) x CFM H BHP L = (RPM L/RPM H)³ x BHP H



12800 735 4.41 790 4.98 843 5.55 894 6.15 944 6.78 992 7.41 1031 8.01


Standard Factory Drive + 7.5HP Optional Hi-Static Drive +7.5HPField Supplied Low Static Drive

OUTDOOR

CFM


0.0 0.2 0.4 0.6 0.8 1.0 1.2

SUPPLY

CFM


0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

FORM 145.29-IOM2 (217)

20 JOHNSON CONTROLS

MOTOR AND PULLEY DATA

Frame Pitch Dia. Browning Pitch Dia. Browning

Size (in) Part No. (in) Part No.

DSV060B 568-852 1 145 1.9-2.9 1VP34X7/8 6.2 AK64H A28 A36

DSV096B 593-890 1 145 1.9-2.9 1VP34X7/8 5.9 AK61H A42 A51

DSV120B 614-921 1.5 145 1.9-2.9 1VP34X7/8 5.7 AK59H AX42 AX51

DSV144B 555-768 2 145 2.4-3.4 1VP40X7/8 8.2 AK84H AX46 AX55

DSV180B 640-854 3 184 2.8-3.8 1VP44X1 1/8 8.2 AK84H AX45 AX52

DSV240B 769-965 5 184 4.7-5.9 1VP60X1 1/8 10.4 BK110H B56 B65

DSV300B 716-882 7.5 213 5.2-6.4 1VP65X1 3/8 12.7 BK130H BX65 BX75



DSV060B 803-1112 1.5 145 2.4-3.4 1VP40X7/8 5.7 AK59H A28 A36

DSV096B 745-1117 1.5 145 1.9-2.9 1VP34X7/8 4.7 AK49H AX40 AX49

DSV120B 843-1167 2 145 2.4-3.4 1VP40X7/8 5.2 AK56H AX42 AX51

DSV144B 724-925 3 184 3.4-4.4 1VP50X1 1/8 8.7 AK89H AX46 AX55

DSV180B 837-1027 5 184 4.4-5.4 1VP56X1 1/8 9.2 BK95H BX48 BX55

DSV240B 949-1145 7.5 213 5.4-6.6 1VP71X1 3/8 10.4 BK110H BX57 BX66

DSV300B 850-1047 7.5 213 5.2-6.4 1VP65X1 3/8 10.4 BK110H BX61 BX72



DSV060B 568-852 1.5 145 1.9-2.9 1VP34X7/8 6.9 AK71H AX70

DSV096B 486-729 2 145 1.9-2.9 1VP34X7/8 7.2 AK74H AX68

DSV120B 640-854 3 184 2.8-3.8 1VP44X1 1/8 8.2 AK84H AX70

DSV144B 571-761 3 184 2.8-3.8 1VP44X1 1/8 9.2 AK94H AX79

DSV180B 686-866 5 184 3.4-4.4 1VP50X1 1/8 9.7 BK100H BX80

DSV240B 769-965 7.5 213 4.8-5.2 1VP60X1 3/8 10.4 BK110H BX89

DSV300B 741-894 10 215 5.8-7.0 1VP71X1 3/8 13.7 BK140H BX103



DSV060B 568-852 1.5 145 1.9-2.9 1VP34X7/8 5.2 AK54H A68

DSV096B 486-729 2 145 1.9-2.9 1VP34X7/8 5.4 AK56H AX65

DSV120B 640-854 3 184 2.8-3.8 1VP44X1 1/8 6.9 AK71H AX68

DSV144B 571-761 3 184 2.8-3.8 1VP44X1 1/8 7.7 AK79H AX76

DSV180B 686-866 5 184 3.4-4.4 1VP50X1 1/8 8.3 BK85H BX77

DSV240B 769-965 7.5 213 4.8-5.2 1VP60X1 3/8 9.7 BK100H BX87

DSV300B 854-1020 10 215 6.2-7.4 1VP75X1 3/8 12.7 BK130H BX103

Belts

Belts

EVAPORATOR-STANDARD BLOWER MOTOR AND DRIVE DATA

Drive

Range

(RPM)

Motor

HP

Adjustable

EVAPORATOR-OVERSIZED BLOWER MOTOR AND DRIVE DATA

Model

Drive

Range

(RPM)

MotorAdjustable Fixed

Motor Pulley

Model

Blower Pulley

HP

Motor Pulley

Fixed

Blower Pulley

Horizontal

Discharge

Vertical

Discharge

Horizontal

Discharge

Model

Drive

Range

(RPM)


BeltsMotor Pulley Blower Pulley

HP Standard

CONDENSER-STANDARD BLOWER MOTOR AND DRIVE DATA

Vertical

Discharge

CONDENSER-OVERSIZED DRIVE DATA

Model

Drive

Range

(RPM)


BeltsMotor Pulley Blower Pulley

HP Standard

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 21

BLOWER SPEED ADJUSTMENT

The blower speed can be adjusted to increase or decrease the unit CFM for non-VFD units. The RPM of the supply air and condenser air blowers will depend on the required CFM, and the static resistances of both the supply/discharge and the return/intake duct systems. An air balance should be done after installation to verify air flow and static. Adjustments to drive may be required. Only operate unit in the regions defined by the fan tables. Units can be ordered with oversized motors and/or drive kits for high static requirements.

Units with oversized motors or oversized drive kits are designed to operate in the shaded region of the fan table otherwise motor amp draw will exceed overload setting resulting in overload trips and possible damage to unit. Refer to fan tables for recommended operating range of standard and oversized motors and drive kits.

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. 2) Loosen the setscrew in the adjustable motor pulley flange. Remove external key on pulleys 4 in. diameter and

larger. 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.

4) Once the pulley has been opened/closed the appropriate number of turns, replace the external key and tighten the adjustment setscrew. Proper torque is 110-130 in.-lbs.

5) Install drive belt and adjust motor mount to tension belt (see page 20: MAINTENANCE/SERVICE for further information).

FORM 145.29-IOM2 (217)

22 JOHNSON CONTROLS

START-UP AND OPERATION Start unit and check rotation of fans and compressors. 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.

Prior to start-up it is important to ensure proper compressor and fan rotation direction is achieved when the system is installed and operated.

Monitor the microprocessor board for any fault codes. This will ensure proper unit operation. Verification of proper compressor direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse compressor rotation also results in an elevated sound level as well as substantially reduced current draw.

Pressure Switch Settings - All Models

High Low

Cut Out (PSIG) 625 25

Cut In (PSIG) 500 38

Refrigerant Charge (LBS)

UNIT Circuit 1 Circuit 2

DSV060B 13.25 (13 lbs 4 oz) -

DSV096B 11.35 (11 lbs 6 oz) 11.60 (11 lbs 10 oz)

DSV120B 13.90 (13 lbs 14 oz) 14.20 (14 lbs 3 oz)

DSV144B 16.60 (16 lbs 10 oz) 15.60 (15 lbs 10 oz)

DSV180B 19.00 (19 lbs 0 oz) 17.80 (17 lbs 13 oz)

DSV240B 25.00 (25 lbs 0 oz) 24.10 (24 lbs 2 oz)

DSV300B 32.00 (32 lbs 0 oz) 32.80 (32 lbs 13 oz)

There is no negative impact on durability caused by operating three phase Scroll compressors in the reversed direction for a short period of time (under one hour). However, after several minutes of operation the compressors internal protector will trip. If opposite rotation is needed, disconnect and reverse any two leads of the three phase supply. Reconnect power.

Observe unit operation and check for unusual noise or vibration.

The Air Conditioning section of this equipment is charged with R-410A; a high pressure refrigerant. Only qualified technicians, using appropriately press-ure rated test instruments, should perform troubleshooting or service on this equipment.

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 23

MICROPROCESSOR CONTROLLER The microprocessor control system is specifically designed for single and dual stage air cooled systems. The control system interfaces with a conventional type thermostat. Unit shall be complete with self-contained low-

voltage control circuit

Unit shall incorporate a lockout circuit which provides reset capability at the space thermostat or base unit, should any of the following standard safety devices trip and shut off compressor.

- Loss-of-charge/Low-pressure switch

- High-pressure switch

- Condensate Overflow protection switch

Unit shall operate with conventional thermostat designs and have a low voltage terminal strip for easy hook-up.

Unit control board shall have on-board diagnostics and fault code display.

Standard controls shall include anti-short cycle and low voltage protection

Control board shall monitor each compressor and refrigerant safety switch independently.

Control board shall have random start feature

Control board shall retain last 5 fault codes in non volatile memory which will not be lost in the event of a power loss.

OPERATION For cooling the room t-stat energizes the low-voltage circuit between “R” & “Y1”. The call is passed to the unit microprocessor control, which then determines whether the requested operation is available and, if so, which components to energize. CONTINUOUS BLOWER By setting the room t-stat fan switch set to “ON”, the supply air blower will operate continuously. With the room t-stat fan switch set to “AUTO”, the blower is energized whenever a cooling operation is requested. The blower is energized after any specified delay associated with the operation. When energized, the indoor blower has a minimum run time of 30 seconds. Additionally, the indoor blower has a delay of 10 seconds between operations.

When the room t-stat calls for cooling, the low-voltage control circuit from “R” to “Y1”and “G” is completed. The compressor and fan motor are energized. After completing the specified fan on delay for cooling, the microprocessor control will energize the blower motor. Once the room t-stat has been satisfied, it will de-energize “Y1”. If the compressor has satisfied its minimum run time, the compressor and fan de-energize. Otherwise, the unit operates the cooling system until the minimum run time for the compressor has been completed. After the compressor de-energizes, the blower is stopped following the elapse of the fan-off delay for cooling. To be available, a compressor must not be locked-out due to a high-pressure switch; low- pressure switch; condensate overflow switch; and the anti-short cycle delay (ASCD) must have elapsed.

SAFETY SWITCHES

Each refrigerant system is monitored to ensure it does not operate outside of its intended operating parameters. Safety switches are handled as described below. All system errors override minimum run times for compressors. High-Pressure Limit Switch If a high-pressure limit switch opens, the microprocessor control de-energizes the compressor, initiates the ASCD, and stops the fan. If a call for cooling or heating is still present at the conclusion of the ASCD, the microprocessor control will re-energize the compressor and unit fan. Should a high-pressure switch open three times within two hours of operation, the microprocessor control will permanently lock-out the compressor. The system must be manually reset by de-energizing the 24 volt power to unit, or turning the room t-stat to the “OFF” position then back to cooling position. The microprocessor control will flash a fault code indicating a high-pressure lock-out. Low-Pressure Limit Switch The low-pressure limit switch is not monitored during the initial 30 seconds of compressor operation. After the initial 30 seconds have passed, the microprocessor control will monitor the low-pressure switch for another 30 seconds. If the low-pressure switch fails to close after the 30 second monitoring phase, the microprocessor control will de-energize the compressor, initiate the ASCD, and stop the fan. Once the low-pressure switch has been proven (closed during the 30-second monitoring period as described above), the microprocessor control board will continue to monitor the low-pressure limit switch

FORM 145.29-IOM2 (217)

24 JOHNSON CONTROLS

for any openings. If the low-pressure switch opens for greater than 5 seconds, the microprocessor control board will de-energize the compressor, initiate the ASCD, and stop the fan. If the call for cooling is still present at the conclusion of the ASCD, the microprocessor control will re-energize the compressor. Should a low-pressure switch fault three (3) times within one (1) hour of operation, the microprocessor control board will lock-out the compressor and flash a fault code indicating a low-pressure lock-out. Condensate Overflow Switch A Condensate Overflow fault occurs when the Condensate Overflow switch opens for more than two line cycles. The compressor is shutdown regardless of Minimum Run Time, ASCD is initiated, and alarm is tripped. The fan continues operating in its current state. Compressor will re-energize once the Condensate Overflow switch closes, and ASCD has been satisfied and a call for cooling is still present. The microprocessor control board logs the first incident per compressor request. If the compressor request is removed, the fault occurrence counter is reset to zero. Should the Condensate Overflow switch open three within two hours of run time, the microprocessor control board will lock-out the compressor, turn off the fan and flash a fault code indicating a Condensate Overflow lock-out.

SAFETY CONTROLS

The microprocessor control monitors the following inputs:

1. A High-Pressure Switch on each compressor circuit to protect against excessive discharge pressures.

2. A Low-Pressure Switch on each compressor circuit to protect against loss of refrigerant charge.

3. A Condensate Overflow Switch to protect against condensate overflow.

Compressor Protection In addition to the external pressure switches, the compressor also has inherent (internal) protection. If there is an abnormal temperature rise in a compressor, the internal protection will immediately shut down the compressor. The microprocessor control incorporates features to minimize compressor wear and damage. An anti-short cycle delay (ASCD) is utilized to prevent short cycling of the compressor. Additionally, a minimum run time is imposed any time

a compressor is energized. The ASCD is initiated on unit start-up and on any compressor reset or lockout.

Microprocessor Control Unit Flash Codes Various flash codes are utilized by the microprocessor control to aid in troubleshooting. Flash codes are distinguished by the short on and off cycle used (approximately 200ms on and 200ms off). To show normal operation, the control boards flash a 1 second on, 1 second off “heart beat” during normal operation. This is to verify that the microprocessor is functioning correctly. Do not confuse this with an error flash code. To avoid confusion the 1-flash, fault code is not used.

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 25

Current alarms or active restrictions are flashed on the microprocessor control LED.

1. LAST ERROR – When this button is pressed and released, it flashes the last five (5) flash codes on the board’s LED. The most recent alarm is shown first and the oldest alarm is shown last.

2. TEST RESET – When this button is pressed and released, any anti-short cycle delays (ASCD) are bypassed for one cycle. When pressed twice, any

active lockouts are reset.

3. COMM SETUP – If the board is to be networked with other units, this button is used to set the network address. Press the button once and it scans the bus, then assigns itself the first available address, (starts at 2). It then flashes that address one time. Pressing the button twice

causes the control to flash the address.

FLASH CODES Description

On Steady This is Control Failure

2 Flashes Control waiting ASCD (Anti-Short Cycle Delay) *

3 Flashes High Pressure Compressor 1 Lockout

4 Flashes High Pressure Compressor 2 Lockout

5 Flashes Low Pressure Compressor 1 Lockout

6 Flashes Low Pressure Compressor 2 Lockout

7 Flashes Condensate Overflow Switch Lockout

11 Flashes Compressor(s) locked out due to Economizer running (Free Cooling) *

13 Flashes Compressor Held Off due to Low Voltage

14 Flashes EEPROM Storage Failure

OFF No Power or Control Failure

Note: Flash rates marked with * are NOT alarms.

FORM 145.29-IOM2 (217)

26 JOHNSON CONTROLS

MAINTENANCE / SERVICE

DISCONNECT AND LOCK OUT POWER WHEN SERVICING UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL IN-JURY OR DEATH DUE TO ELECTRICAL SHOCK. Exercise care when working around the sharp metal edges of door panels or door frames, etc. These edges can cause injury.

EVAPORATOR AND CONDENSER COILS 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 causes low suction pressure and lost capacity. If the coils appear dirty, they should be cleaned using a mild detergent or a commercial coil cleaning agent. REFRIGERANT CIRCUIT(S)- With the unit operating, check and record the compressor discharge and suction pressures. The compressor running current should also be recorded. A maintenance log of these readings can indicate if the unit is operating within its normal limits. Abnormal readings should be investigated, and the Cause corrected. BLOWERS - 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). Ensure 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 hub set screws are properly torqued.

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 (see section ‘Blower Speed Adjustment’). The tension on the belt should be adjusted for a deflection of 1/64 of an inch per inch of belt span, with the appropriate force applied at the midpoint of the span. Tension “New” belts at the maximum value indicated. Used belts should be maintained at the minimum value. 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

DSV060B 4/25x14x2

DSV096B 4/24x18x2 2/20x18x2

DSV120B 4/24x18x2 2/20x18x2

DSV144B 8/20x18x2

DSV180B 8/20x18x2

DSV240B 4/24x20x2 4/20x20x2

DSV300B 6/25x18x2 6/20x18x2

LD13547 BELT TENSION ADJUSTMENT

DEFLECTION FORCE VERSUS DRIVE BELT CROSS-SECTION

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 27

APPENDIX A: DIMENSIONAL DRAWINGS DSV060B DIMENSIONAL DATA – TOP DISCHARGE

DETAIL D

SCALE 0.1 : 1

D

FRONT VIEW

3/4" NPT

DRAIN

CONNECTION

BACK VIEW

29.00 52.00

76

.50

48

.63

47.50

12

.00

33

.18

14.50

ELECTR. POWER

CABLE ENTRANCE

1.75

1.00

RETURN

AIR

CONDENSER

INTAKE

CONDENSER

DISCHARGE

SUPPLY

AIR

BACK RETURN,

VERTICAL DISCHARGE

ELECTRICAL BOX

ACCESS PANEL

CONDENSER ACCESS PANEL

EVAPORATOR ACCESS PANEL

FILTER ACCESS

(BOTH SIDES)

LOW VOLTAGE

CONNECTION

5 TON VERTICAL A/C UNIT

DIMENSIONAL DATA

NOTE: DIMENSION TOLERANCE IS 1/16"

14

.50

47.13

25

.88

3.12

EVAPORATOR

FAN DRIVE

ACCESS PANEL

CONDENSER

FAN DRIVE

ACCESS PANEL

8.0

0

1.0

0

1.5

02.25

2.44

18.75

FORM 145.29-IOM2 (217)

28 JOHNSON CONTROLS

DSV060B DIMENSIONAL DATA – FRONT DISCHARGE

DETAIL F

SCALE 0.1 : 1

F

FRONT VIEW

3/4" NPT

DRAIN

CONNECTION

BACK VIEW

RETURN

AIR

CONDENSER

INTAKE

CONDENSER

DISCHARGE

SUPPLY

AIR

BACK RETURN,

FRONT DISCHARGE

ELECTRICAL BOX

ACCESS PANEL

CONDENSER ACCESS PANEL

FILTER ACCESS

(BOTH SIDES)

14.5

014.50

1.0

0

1.75

52.00

76.5

0

12.0

033.1

8

47.50

48

.63

5 TON VERTICAL A/C UNIT

DIMENSIONAL DATA

CONDENSER

FAN DRIVE

ACCESS PANEL

EVAPORATOR

FAN DRIVE

ACCESS PANEL

47.13

25

.88

1.5

0

1.0

0

2.1

33.12

ELECTR. POWER

CABLE ENTRANCE

LOW VOLTAGECONNECTION


2.44

2.25

18.75

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 29

DSV096B & DSV120B DIMENSIONAL DATA – FRONT DISCHARGE

DETAIL A

AELECTRICAL BOXACCESS PANEL

COMPRESSOR ACCESS PANEL

CONDENSERINTAKE

CONDENSER DISCHARGE

RETURNAIR

10 TON VERTICAL A/C UNITDIMENSIONAL DATA

REAR RETURN,FRONT DISCHARGE

FRONT VIEW

BACK VIEW

SUPPLYAIR


2.88

0.9

3

3/4" NPT DRAIN CONNECTION

71.50

41.88

13

.69

88.1

3

2.7

5

14.81

52

.06

32.00

36.06

EVAPORATORBLOWER DRIVEACCESS DOOR

FILTER ACCESS(BOTH SIDES)

POWER SUPPLYCABLE ENTRANCE


VFD LOCATION(OPTIONAL)

CONDENSERBLOWER DRIVEACCESS DOOR

64.63

34

.13

32

.50

14

.31

1.0

0

2.20

66.50

FILTER

FORM 145.29-IOM2 (217)

30 JOHNSON CONTROLS

DSV096B & DSV120B DIMENSIONAL DATA - TOP DISCHARGE

DETAIL A

A


REAR RETURN,TOP DISCHARGE

CONDENSER DISCHARGE

RETURNAIR

CONDENSERINTAKE


ELECTRICAL BOXACCESS PANEL

FRONT VIEW

BACK VIEWNOTE: DIMENSION TOLERANCE IS 1/16"

71.50

41.88

13

.69

14.81

88

.13

52.0

6

32.00

35.13

SUPPLYAIR




LOW VOLTAGECONNECTIONCONDENSER

BLOWER DRIVEACCESS DOOR


64.63

34

.131

.00

2.20

32.5

0

14.3

1

66.50

FILTER

2.88

0.9

3

3/4" NPT DRAIN CONNECTION

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 31

DSV144B & DSV180B DIMENSIONAL DATA - FRONT DISCHARGE

DETAIL A

A

FRONT VIEW

BACK VIEW


COMPRESSORACCESS PANEL

CONDENSERDISCHARGE

CONDENSERINTAKE

RETURN AIR

SUPPLYAIR

12/15 TON VERTICAL A/C UNITDIMENSIONAL DATA



82.50

47.6334.00

38.06

15.97

91.6

3

55.8

8

2.8

8EVAPORATOR BLOWER DRIVEACCESS DOOR




2.880.8

0

3/4" NPT DRAINCONNECTION

76.13

33

.63

1.97

1.0

0

14.3

1

36.6

9

77.63



FILTER

FORM 145.29-IOM2 (217)

32 JOHNSON CONTROLS

DSV144B & DSV180B DIMENSIONAL DATA - TOP DISCHARGE

DETAIL A



CONDENSERINTAKE

CONDENSER DISCHARGE

RETURNAIR

12/15 TON VERTICAL A/C UNITDIMENSIONAL DATA


FRONT VIEW

BACK VIEW

SUPPLYAIR


82.50

47.63

16

.13

9.2

5

16.00

91.6

3

55.8

8

34.00

37.13

EVAPORATOR BLOWER DRIVEACCESS DOOR






76.13

33

.63

36.6

9

14

.31

1.97

1.0

0

2.88

0.8

0


77.63

FILTER

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 33

DSV240B DIMENSIONAL DATA - FRONT DISCHARGE

DETAIL A

A

FRONT VIEW

BACK VIEW



CONDENSERDISCHARGE

CONDENSERINTAKE

RETURN AIR

SUPPLY AIR




57.44

90.50

14.50

60.6

9

102.0

6

2.8

8

16.1

3

37.06

EVAPORATORBLOWER DRIVEACCESS PANEL


CONDENSERBLOWER DRIVEACCESS PANEL



85.633.19

42.6

913.0

6

84.13 1.97

38.3

81.5

01.3

8

2.0

6

1.88

0.8

0



34.0

0

FILTER

FORM 145.29-IOM2 (217)

34 JOHNSON CONTROLS

DSV240B DIMENSIONAL DATA - TOP DISCHARGE

DETAIL A



CONDENSERINTAKE

CONDENSER DISCHARGE

RETURNAIR



FRONT VIEW

BACK VIEW

SUPPLYAIR


90.5014.56

60.6

9

102

.06

0.9

4

34.00

9.38

EVAPORATORBLOWER DRIVEACCESS PANEL

FILTER ACCESS(BOTH SIDE)

CONDENSER BLOWER DRIVEACCESS PANEL




1.880.8

0


16

.13

57.44

84.13 1.97

13.0

64

2.6

92

.06

85.633.20

38

.38

2.4

41

.38

FILTER

37.06

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 35

DSV300B DIMENSIONAL DATA - FRONT DISCHARGE

DETAIL A

A

FRONT VIEW

BACK VIEW



CONDENSERDISCHARGE

CONDENSERINTAKE

RETURN AIR

SUPPLY AIR




102.13 2.00

42

.38

1.2

51

.50

13

.06

48

.17

2.0

6103.633.19

FILTER

108.50

77.63 17.44

11

0.0

6

64

.69

16.1

3




CONDENSER BLOWER DRIVE

ACCESS DOOR


LOW VOLTAGE

CONNECTION

2.88

0.8

0


34.00

38.00

3.1

2

FORM 145.29-IOM2 (217)

36 JOHNSON CONTROLS

DSV300B DIMENSIONAL DATA - TOP DISCHARGE

DETAIL A



CONDENSERINTAKE

CONDENSER DISCHARGE

RETURNAIR



FRONT VIEW

BACK VIEW

SUPPLYAIR


103.633.19

2.0

64

8.1

913

.06

102.13 2.00

1.2

54

2.3

81.3

8

FILTER

108.50

77.63

16

.13

11

0.0

6

64

.69

0.9

4

34.00

37.06







2.88

0.8

0


17.44

9.8

8

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 37

APPENDIX B: TYPICAL SERVICE CLEARANCES

24 In. Side

42 In. Front

20 TON A/C VERTICAL UNITSERVICE CLEARANCE




FORM 145.29-IOM2 (217)

38 JOHNSON CONTROLS

APPENDIX C: TYPICAL UNIT WIRING SCHEMATICS

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 39

FORM 145.29-IOM2 (217)

40 JOHNSON CONTROLS

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 41

FORM 145.29-IOM2 (217)

42 JOHNSON CONTROLS

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 43

FORM 145.29-IOM2 (217)

44 JOHNSON CONTROLS

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 45

TYPICAL VFD UNIT WIRING SCHEMATIC

FORM 145.29-IOM2 (217)

46 JOHNSON CONTROLS

TYPICAL ECONOMIZER WIRING SCHEMATICS (SINGLE AND DUAL STAGE SHOWN)

DSV060B Economizer Schematic

DSV096B-DSV300B Economizer Schematic

FORM 145.29-IOM2 (217)

JOHNSON CONTROLS 47

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-410A service 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 driers 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.

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2017 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 145.29-IOM2 (217)Issue Date: February 20, 2017 Supersedes: 145.29-IOM2 (814)

Documents

AIR-COOLED SELF-CONTAINED UNITS