dsh-dsv asecon-05.2010 final - upgnet asecon-06.2010 _final_.pdf · ase-in-001-2010 . this...

INSTALLATION INSTRUCTIONS

HORIZONTAL & VERTICAL AIRSIDE ECONOMIZERS FOR DSH024A-DSH060A, DSH120A / DSV036A-DSV060A, DSV096-DSV240A

AIR CONDITIONERS

TABLE OF CONTENTS

3 …… Installation 4 ……Mixing Box Dimensions &

Component Layout 5 ……Interconnection Harness 10 …. Damper & Actuator Set-up 11 …. Sequence of Operation

ASE-IN-001-2010

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

materials under pressure, rotati

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 respon

sibilty of operating/service personnel to identify and

recognize these i

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










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The following symbols are used in this document to alert the reader to areas of potential hazard.










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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.










recognize these i
















recognize these i







All wiring must be in accordance with published specifications and must be performed ONLY byqualified service personnel. Johnson Controls will not be responsible for damages/problems resulting from Failure to follow this will void the manufacturer’s warranty and cause serious damage to propor injury to persons.










recognize these inherent hazards, protect themselves,

















nherent hazards, protect themselves,



























































READ BEFORE PROCEEDING!


























































































READ BEFORE PROCEEDING!GENERAL SAFETY GUIDLINES

















All wiring must be in accordance with published specifications and must be performed ONLY byqualified 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’s warranty and cause serious damage to propor injury to persons.






materials under pressure, rotating components, and












All wiring must be in accordance with published specifications and must be performed ONLY byqualified service personnel. Johnson Controls will not be responsible for damages/problems

improper connections to the controls or application of improper control signals.Failure to follow this will void the manufacturer’s warranty and cause serious damage to propor injury to persons.






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IMPORTANT!READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDLINES





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improper connections to the controls or application of improper control signals.Failure to follow this will void the manufacturer’s warranty and cause serious damage to prop







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SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to areas of potential hazard.











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conditions including, but not limited to: refrigerants, oils,

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DANGER indicates an imminently hazardous situation which, if not avoided,









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ardous situation which, if not avoided,

ardous situation which, if not avoided,



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which it is situated, as well as sever personal injury o

death to themselves and people at the site.

This document is intended for use by owner

operating/service personnel. It is expected that this

individual possesses independent training that will en

able them to perform their assigned tasks pro

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 go

pertaining to the task in question.
















all applicable go

















all applicable go

















all applicable go

















all applicable go

















all applicable go

















all applicable go

















all applicable go

















all applicable go


SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard.

CAUTION could lead to damage to the machine, damage to othenvironmentinstruction will be given, together with a brief explanation.

NOTE is used to highlight additional information which















all applicable go



















all applicable go



















all applicable governmental standards and regulations



















vernmental standards and regulations







IMPORTANT! READ BEFORE PROCEEDING!

























































































CAUTION identifies a hazard which could lead to damage to the machine, damage to othenvironmental pollution. Usually and instruction will be given, together with a brief explanation.


















identifies a hazard which could lead to damage to the machine, damage to oth

al 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.

















identifies a hazard which could lead to damage to the machine, damage to other equipment and/or


NOTE is used to highlight additional inmay be helpful to you.
















identifies a hazard which could lead to damage to the machine,

er equipment and/or al pollution. Usually and

instruction will be given, together with a




































































































































This document is intended for use by owner-authorized

















authorized



able them to perform their assigned tasks properly and














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NOTE is used to highlight additional in-may be helpful to you.


improper connections to the controls or application of improper control signals.Failure to follow this will void the manufacturer’s warranty and cause serious damage to prop-

which it is situated, as well as sever personal injury or

authorized


individual possesses independent training that will en-

perly and










improper connections to the controls or application of improper control signals.-erty

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authorized


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perly and










improper connections to the controls or application of improper control signals.erty

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

improper connections to the controls or application of improper control signals. erty

qualified service personnel. Johnson Controls will not be responsible for damages/problems

erty

1. INSTALLATION

Horizontal/ 1.

2.

3.

4.

1. INSTALLATION

Horizontal/ 1.

2.

3.

4.

1. INSTALLATION

Horizontal/

1. INSTALLATION

Horizontal/

Attach mixing box to unit evaporator return, using the metal securing strip provided. Fasteners may also be used around the perimeter of the mixing box, at the location of the filter frame, for additional security. This is intended to connect the uniFIELD SUPPORT IS REQUIRED

Determine which inlet will be outside air, and which will be return air. If the normal dampers needs to be reversed, remove the actuator, reset the damper positions so that the outside air damper is closed and the return air damper is fully open. Adjust the linkage rod to these normal positions, and secure. Reat

The module is connected to the unit wiring via a 2required in order to accommodate the AirConnect the thermostat wiring as indicated in the

With the power to the module, the actuator springs will wind and lock. The enthalpy changeover setting may be afor details.

1. INSTALLATION

Horizontal/





1. INSTALLATION

Horizontal/





1. INSTALLATION

Horizontal/




With the power to the module, the actuator springs will wind and lock. The enthalpy changeover setting may be altered, and the outside air damper minimum position adjusted. See the attached Honeywell information for details.

1. INSTALLATION

Horizontal/




With the power to the module, the actuator springs will wind and lock. The enthalpy changeover setting may ltered, and the outside air damper minimum position adjusted. See the attached Honeywell information

for details.

1. INSTALLATION

Horizontal/





for details.

1. INSTALLATION

Horizontal/Vertical Economizer





for details.

Prior to installing or servicing the unit, lock all electrical power supply switches in the OFF position. Failure to disconnect powe Additional field support of the mixing box is required. Failure to provide adequate support for the unit may result in injury or even death. Exercise care when working around the sharp metaledges are sharp and can cause injury.

1. INSTALLATION

Vertical Economizer





for details.

Prior to installing or servicing the unit, lock all electrical power supply switches in the OFF position. Failure to disconnect powe Additional field support of the mixing box is required. Failure to provide adequate support for the unit may result in injury or even death. Exercise care when working around the sharp metaledges are sharp and can cause injury.

1. INSTALLATION

Vertical Economizer





Prior to installing or servicing the unit, lock all electrical power supply switches in the OFF position. Failure to disconnect powe

Additional field support of the mixing box is required. Failure to provide adequate support for the unit may result in injury or even death.

Exercise care when working around the sharp metaledges are sharp and can cause injury.

1. INSTALLATION

Vertical Economizer








1. INSTALLATION

Vertical Economizer








1. INSTALLATION

Vertical Economizer








1. INSTALLATION

Vertical Economizer


Determine which inlet will be outside air, and which will be return air. If the normal dampers needs to be reversed, remove the actuator, reset the damper positions so that the outside air damper is closed and the return air damper is fully open. Adjust the linkage rod to these normal positions, and secure. Reattach the actuator so that it is rotating in the appropriate direction.






1. INSTALLATION

Vertical Economizer


Determine which inlet will be outside air, and which will be return air. If the normal dampers needs to be reversed, remove the actuator, reset the damper positions so that the outside air damper is closed and the return air damper is fully open. Adjust the linkage rod to these normal positions,

tach the actuator so that it is rotating in the appropriate direction.






1. INSTALLATION

Vertical Economizer









1. INSTALLATION

Vertical Economizer









1. INSTALLATION

Vertical Economizer









Vertical Economizer









Vertical Economizer









Vertical Economizer

Attach mixing box to unit evaporator return, using the metal securing strip provided. Fasteners may also be used around the perimeter of the mixing box, at the location of the filter frame, for additional security. This is intended to connect the units, and not to support the full weight of the economizer mixing box FIELD SUPPORT IS REQUIRED








Vertical Economizer

Attach mixing box to unit evaporator return, using the metal securing strip provided. Fasteners may also be used around the perimeter of the mixing box, at the location of the filter frame, for additional security. This is

ts, and not to support the full weight of the economizer mixing box FIELD SUPPORT IS REQUIRED








Vertical Economizer










Vertical Economizer










Vertical Economizers


ts, and not to support the full weight of the economizer mixing box FIELD SUPPORT IS REQUIRED. This may be from the ceiling, or from beneath the unit.








s


ts, and not to support the full weight of the economizer mixing box . This may be from the ceiling, or from beneath the unit.
















































The module is connected to the unit wiring via a 2required in order to accommodate the Air-Side Economizer option. Refer to Connect the thermostat wiring as indicated in the









The module is connected to the unit wiring via a 2Side Economizer option. Refer to

Connect the thermostat wiring as indicated in the










































Prior to installing or servicing the unit, lock all electrical power supply switches in the OFF position. Failure to disconnect power supply may result in electrical shock or even death.








Installation Instruction for Vertical Air Conditioners.


Prior to installing or servicing the unit, lock all electrical power supply switches in the OFF r supply may result in electrical shock or even death.












Exercise care when working around the sharp metal

3





The module is connected to the unit wiring via a 2-part wiring harness. Minimal field rewiring of the unit is Side Economizer option. Refer to










part wiring harness. Minimal field rewiring of the unit is Side Economizer option. Refer to














Additional field support of the mixing box is required. Failure to provide adequate support for







































































Exercise care when working around the sharp metal edges of door panels or flanges. These










edges of door panels or flanges. These























































part wiring harness. Minimal field rewiring of the unit is Side Economizer option. Refer to Section










part wiring harness. Minimal field rewiring of the unit is Section






































Determine which inlet will be outside air, and which will be return air. If the normal open/closed position of the dampers needs to be reversed, remove the actuator, reset the damper positions so that the outside air damper is closed and the return air damper is fully open. Adjust the linkage rod to these normal positions,









open/closed position of the dampers needs to be reversed, remove the actuator, reset the damper positions so that the outside air damper is closed and the return air damper is fully open. Adjust the linkage rod to these normal positions,

part wiring harness. Minimal field rewiring of the unit is Section 6









part wiring harness. Minimal field rewiring of the unit is 6 for detailed instructions.









part wiring harness. Minimal field rewiring of the unit is for detailed instructions.
















ts, and not to support the full weight of the economizer mixing box



























ts, and not to support the full weight of the economizer mixing box –









ADDITIONAL









ADDITIONAL









ADDITIONAL









ADDITIONAL









ADDITIONAL








ADDITIONAL








ADDITIONAL








ADDITIONAL








ADDITIONAL




Prior to installing or servicing the unit, lock all electrical power supply switches in the OFF




ADDITIONAL








ADDITIONAL







4

2. VERTICAL MIXING BOX DIMENSIONS

Vertical Unit Model Number

Economizer Model Number

MIXING BOX DIM'N DAMPER

DIM'N

CONTROL MODULE

A B C D E F G

DSV036 VASE-036H 36.00 24.00 24.00 31.00 14.00 8.00 15.00

DSV048-060 VASE-060H 38.00 24.00 24.00 31.00 14.00 8.00 15.00

DSV096/120 VASE-120H 55.25 29.75 26.50 44.00 19.50 8.00 15.00

DSV144/180 VASE-180H 69.25 35.00 26.50 64.00 19.50

8.00 15.00

DSV240 VASE-240H 79.25 39.00 32.00 69.00 25.00

8.00 15.00

5

3. HORIZONTAL MIXING BOX DIMENSIONS

Horizontal Unit Model Number



DIM'N CONTROL MODULE

A B C D E F G

DSH024/036 HASE-036H-SF 26.06 18.56 23.44 17.00 14.00 8.00 15.00

DSH048/060 HASE-060H-SF 29.68 23.44 30.44 24.00 14.00 8.00 15.00

DSH096/120 HASE-120H-SF 33.63 25.25 33.63 28.00 19.50 8.00 15.00

Horizontal Unit Model Number



DIM'N CONTROL MODULE

A B C D E F G

DSH024/036 HASE-036H-BF 26.06 18.56 23.44 17.00 14.00 8.00 15.00

DSH048/060 HASE-060H-BF 29.68 23.44 30.44 24.00 14.00 8.00 15.00

DSH096/120 HASE-120H-BF 33.63 25.25 33.63 28.00 19.50 8.00 15.00

STANDARD SIDE & FRONT DAMPER ARRANGEMENT

OPTIONAL BOTTOM & FRONT DAMPER ARRANGEMENT

6

4. WIRING HARNESS INSTALLATION - AIRSIDE ECONOMIZER TO UNIT CONNECTION

Each Air-Side Economizer is shipped complete with a two-part wiring harness. The terminated end of the wiring harness (J1) must be field wired into the low voltage control terminals of the unit. The second part of the harness assembly (P1) is pre-wired into the Economizer module panel. The two parts of the harness (J1 and P2) are connected together by integrated polarized plugs.

Installing Harness (J1):

1) Remove the indicated existing wires from the low voltage section of the Unit Electrical Box. The wires to be removed are marked in Bold/Dashed lines on the accompanying illustration (Step 1). The wires to be removed will be yellow in color.

2) Working from the side access door, feed the loose pre-terminated ends of the harness in through the back of the low voltage section of the electrical box, through the bushed hole near the 10-pole terminal block.

3) Connect the harness (J1) terminations to the units’ low voltage terminal block (TB2) as indicated in the preceding table. The harness wires are color coded for identification.

a) In SINGLE-compressor units, disconnect black LPC1 wire from Y1 on TB2 and splice with the BLUE harness wire.

b) For DUAL-compressor units, disconnect red HPC1 wire from Y1 on TB2 and splice wire together with the BLUE harness wire. Disconnect red HPC2 wire from Y2 on TB2 and splice with the PURPLE harness wire.

4) Secure the harness to the side of the blower housing in the condensing section of the unit, using the supplied cable clips. Ensure that the harness is routed clear of moving parts, and that there are no loose wires that can be pulled into the blower inlet. Coil excess wire length, and secure with cable clips (see photo).

5) The plug end of the harness should terminate inside the rear corner post (the economizer half of the harness will enter through the 7/8” OD hole in this area – see economizer installation manual).

Pin # Color Connection ID

1 WHITE TB2-C

3 BLUE LPC1

5 YELLOW TB2-Y1

6 RED TB2-G

7 BROWN TB2-A2

8 BLACK TB2-A1

Pin # Color Connection ID

1 WHITE TB2-C

2 PURPLE HPC2

3 BLUE HPC1

4 ORANGE TB2-Y2

5 YELLOW TB2-Y1

6 RED TB2-G

7 BROWN TB2-A2

8 BLACK TB2-A1

Single-Compressor Units - 6-Pin Molex Plug

Unit Harness

Dual-Compressor Units - 9-Pin Molex Plug

Unit Harness

7

5. ECONOMIZER – DAMPER & ACTUATOR SETUP

Installed Harness

8

VERTICAL ECONOMIZER

9

HORIZONTAL ECONOMIZER

11

6. SEQUENCE OF OPERATION

Modulating Economizer with Typical Electro - Mechanical Thermostat The Honeywell W7215 module, ML series actuators, JCI damper sections, and factory wiring harness comprise an integrated economizer. These economizers are used to provide ventilation and free cooling for the JCI Series of vertical, and horizontal, through-the-wall air handlers. The Honeywell W7215 can accept inputs from additional optional sensors, including a return-air enthalpy sensor (for differential enthalpy control) or a CO2 sensor (for Indoor Air quality strategies).

Powering the Thermostat (24vac) - Power to the electromechanical thermostat is provided from R terminal of the JCI unit’s low voltage terminal strip. Electromechanical thermostats do not require a 24vac common connection.

Powering the W7215 (24vac) - The W7215 is powered from the JCI unit whenever the fan of the evaporator section is operating. To ensure that the W7215 is continuously powered, the fan switch on the thermostat sub-base should be left on at all times.

High Enthalpy Sequence: When the outside air enthalpy exceeds the enthalpy setpoint, the NO contacts of relays 1K and 2K close.

First Stage Cooling: A cooling signal from the thermostat Y1, first stage cooling is routed through NO contact 1K to engage compressor #1 of the Skymark unit.

Second Stage Cooling: A call for cooling Y2 is routed through the NO contact 2K to engage the compressor #2.

Third Stage Cooling (Twenty-five ton units only): A third call for cooling is routed directly from the thermostat via the wiring harness to through the NC contact of R4 and the NC contact of R3 (4-5) to compressor #3.

During this sequence, the outside dampers are held at a preset minimum position. The minimum may be overridden from a remote potentiometer.

Low Enthalpy Sequence: First Stage Cooling: During the low enthalpy sequence, relays 1K and 2K are not energized. The first call for cooling Y1 powers relay IS through the NC contact 1K. When IS is powered IS1 closes enabling the discharge sensor C7046 to modulate the outside air and return air damper.

Second Stage Cooling: A second call for cooling Y2 is routed through the NC contact 2K of the W7215 to energize compressor #2.

Third Stage Cooling (Twenty-five ton units only): The holding coil of R4 is energized whenever a low enthalpy condition is sensed by the W7215. The third call for cooling Y3 is routed through the closed contacts of R4, then through the NC contact of R3 (2-1) to terminal 4 of the W7215 and from there to compressor #2. At this time, the outside damper will be fully open (or modulating in response to the discharge sensor), Y2 will engage the compressor #1 and Y3 will engage compressor #2.

Note: To prevent operation of mechanical cooling at low outdoor temperatures during the economizer cycle, an outdoor thermostat LL-1 can be connected to the terminals of TB-3. If the outdoor temperature is below the set point of LL-1, and the N.O. FREE COOLING contacts of the W7215 are closed, the R3 relay contacts will open, so that mechanical cooling will be disabled.

Damper Modulation: On all JCI units' the C7046 temperature sensor should be located in the 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 50

0 F or 10

0 C. If the discharge air temperature is between 50

0

to 560 F (10

0 to 13.3

0 C) the outside air damper will modulate between minimum position and fully open. Above

560 F (13.3

0 C) the outside air damper will remain in the fully open position.

Unoccupied Operation: Typically, the evaporator blower operates intermittently during unoccupied periods (cooling or heating). Since the economizer controller is powered directly from the fan (G) terminal on the thermostat, this would cause the economizer to open to the pre-set minimum position during unoccupied heating periods. If terminals A1 and A2 on the units' low voltage terminal block are connected, this effectively jumpers together SD and SD1 on the W7215. This engages the 'Shut-Down' mode of the controller; the economizer will remain fully closed during night operation of the blower.

The A1 and A2 terminals may be connected to an independent time clock, or to the sub-base terminals of a thermostat that features internal occupied/unoccupied switching (Honeywell T7300).

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