Johnson Controls VFD Series Leitfaden

R-410A

VARIABLE FREQUENCY DRIVE

FOR

D-SERIES (DSV/DSH) AIR-COOLED SELF-CONTAINED UNITS, GEN C

Issue Date:

January 22, 2020

INDOOR PACKAGED EQUIPMENT

INSTALLATION & OPERATION NEW RELEASE Form 145.13-NO2 (120)

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

This equipment is a relatively complicated apparatus.

During rigging, installation, operation, maintenance,

or service, individuals may be exposed to certain com-

ponents or conditions including, but not limited to:

heavy objects, refrigerants, 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 rigging, instal-

lation, and 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

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

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

death to themselves and people at the site.

This document is intended for use by owner-authorized

rigging, installation, and operating/service personnel. It

is expected that these individuals possess 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 the on-product labels,

this document and any referenced materials. This in-

dividual shall also be familiar with and comply with

all applicable industry and 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 specific situations:

Indicates a possible hazardous situation

which will result in death or serious injury

if proper care is not taken.

Indicates a potentially hazardous situa-

tion which will result in possible injuries

or damage to equipment if proper care is

not taken.

Identies a hazard which could lead to

damage to the machine, damage to other

equipment and/or environmental pollu-

tion if proper care is not taken or instruc-

tions and are not followed.

Highlights additional information useful

to the technician in completing the work

being performed properly.

External wiring, unless specied as an optional connection in the manufacturer’s product line, is not

to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls

and any external wiring must not be installed inside the micro panel. All wiring must be in accor-

dance with the manufacturer's published specications and must be performed only by a qualied

electrician. The manufacturer will NOT be responsible for damage/problems resulting from improper

connections to the controls or application of improper control signals. Failure to follow this warn-

ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

CHANGEABILITY OF THIS DOCUMENT

In complying with policy for continuous product im-

provement, the information contained in this document

is subject to change without notice. There is no com-

mitment to update or provide current information au-

tomatically to the manual or product owner. Updated

manuals, if applicable, can be obtained by contacting

the nearest Service office or accessing the Offerings

Catalog through www.hvacnavigator.com.

It is the responsibility of rigging, lifting, and operating/

service personnel to verify the applicability of these

documents to the equipment. If there is any question

regarding the applicability of these documents, rig-

ging, lifting, and operating/service personnel should

verify whether the equipment has been modified and

if current literature is available from the owner of

the equipment prior to performing any work on the

equipment.

CHANGE BARS

Revisions made to this document are indicated with a

line along the left or right hand column in the area the

revision was made. These revisions are to technical in-

formation and any other changes in spelling, grammar

or formatting are not included.

ASSOCIATED LITERATURE

TECHNICAL SUPPORT

If Technical Support is required, contact the Product

Technical Support team at 877-329-7430 or Applied-

DXT[email protected].

REPLACEMENT PARTS

For replacement parts, contact your local Source1

Dealer.

Source1 Parts Phone Number: 800-536-6112

Source 1 Parts Website: http://www.source1parts.com

MANUAL DESCRIPTION FORM NUMBER

DSV060C-300C Air-Cooled Self-Contained Installation, Operation, Maintenance 145.29-IOM3

DSH024C-120C Air-Cooled Self-Contained Installation, Operation, Maintenance 145.32-IOM5

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

VFD NOMENCLATURE

Motor Model Number

233HE = 1 HP Motor

234HE = 1.5 HP Motor

235HE = 2.0 HP Motor

236HE = 3.0 HP Motor

237HE = 5.0 HP Motor

238HE = 7.5 HP Motor

239HE = 10.0 HP Motor

1, 2, 3 4, 5, 6 7, 8, 9, 10, 11 12 13

VFD LAC 234HE 2 A

Product Category

VFD = VFD Program

Parameter Set

VFD Option

LAC = Low Ambient Condenser

SEC = Smart Equipment Controller

Voltage

2 = 208-230/3/60

4 = 460/3/60

5 = 575/3/60

Design Series

A = Current

LAC option is not available on 575V.

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

TABLE OF CONTENTS

SECTION 1 - INSTALLATION ..................................................................................................................................7

Background ......................................................................................................................................................7

Factory Shipped ...............................................................................................................................................7

DSV Models .....................................................................................................................................................7

DSH Models .....................................................................................................................................................8

VAV Units..........................................................................................................................................................8

Multi-speed Fan Control ...................................................................................................................................9

VFD Keypad .....................................................................................................................................................9

Installation ......................................................................................................................................................10

Install Grille Cover ..........................................................................................................................................10

SECTION 2 - OPERATION ..................................................................................................................................... 11

Input/Output.................................................................................................................................................... 11

Parameter Tables ........................................................................................................................................... 11

Display............................................................................................................................................................ 11

VFD Option Schematics .................................................................................................................................16

LIST OF FIGURES

FIGURE 1 - Label On Unit/VFD For VAV With Pressure Transducer........................................................................ 8

FIGURE 2 - Label On Unit/VFD For Multi-Speed Fan Control .................................................................................. 9

FIGURE 3 - VFD Keypad ..........................................................................................................................................9

FIGURE 4 - VFD Keypad And Ethernet Connector ...................................................................................................9

FIGURE 5 - Connecting Negative And Positive Side Fittings.................................................................................. 10

FIGURE 6 - VFD Grille Cover..................................................................................................................................10

FIGURE 7 - Input/Output Diagram .......................................................................................................................... 11

FIGURE 8 - Evaporator VFD Low Voltage Wiring Schematic With Optional VAV Sensor (208/230/460V)............. 16

FIGURE 9 - Evaporator VFD Low Voltage Wiring Schematic (575v) ......................................................................17

FIGURE 10 - Evaporator High Voltage Power Schematic For All Units (208/230/460/575V) .................................17

FIGURE 11 - Condenser VFD Low Voltage Wiring Schematic (208/230/460V)......................................................18

FIGURE 12 - Condenser VFD High Voltage Wiring Schematic With Optional Manual Bypass (208/230/460V) .... 18

TABLE 1 - DSH/DSV Only Factory Parameters For Multi Speed Evaporator Application (ABB ACS320) ............12

TABLE 2 - DSH/DSV Only Factory Parameters For Low Ambient Condenser Application (ABB ACS320)........... 13

TABLE 3 - DSH/DSV Only Factory Parameters and Signals For 575V Evaporator Settings (ABB ACS250)........ 14

TABLE 4 - DSV Only Drive Dependent Parameters Group 99 .............................................................................. 15

LIST OF TABLES

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

THIS PAGE INTENTIONALLY LEFT BLANK.

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

Do not run the evaporator fan motor be-

low 30Hz, as coil freeze-up and nuisance

lockouts may occur. The unit is factory set

to minimum 30 Hz output with the excep-

tion of the Low Ambient Condenser VFD,

which is set to 15 Hz.

The unit does not carry a failsafe circuit

to bypass the VFD and run the evaporator

fan in the event of a VFD malfunction.

The unit does not carry a failsafe circuit bypass for the

evaporator fan in the event of a VFD malfunction. Dur-

ing a VFD failure, the evaporator fan becomes non-

operational. If there is a demand for cooling, the unit

compressors continue to run until the low pressure

safety switch trips.

FACTORY SHIPPED

Units that are 8 tons or larger ship with a VFD control-

ler factory installed and wired in the evaporator (air

handler) corner post. See the dimensional drawings in

the IOM for the location.

DSV MODELS

The DSV units ship factory split (condenser and evap-

orator) and require assembly in the field. The motor is

pre-wired to the VFD in the factory.

To assemble the DSV model in the field:

1. Plug the low voltage wiring, shipped wired to the

VFD, to the SE Controller.

2. Connect the low voltage wires from VFD unit

(24VDC) to the evaporator fan VFD relay (EVF-

DR). The EVFDR relay acts as a switch to turn on

the VFD.

3. Connect two 1/4 inch Q.C. to common and nor-

mally open positions (red wire to “C,” orange

wire to “NO”).

The VFD switch runs on 24VDC.

Do not cross 24VAC and 24VDC wiring

on EVFDR relay.

SECTION 1 - INSTALLATION

Do not enter Setup mode when powering

on the VFD.

Do not change parameters 4009 and 4011

for the VAV option on DSH/DSV C-gen

units.

For these units, use the Smart Equipment

(SE) controller to set the VAV setpoint.

Prior to installing or servicing the unit,

ensure proper lockout/tagout (LOTO)

procedures are followed per OSHA

safety regulations (29 CFR 1910.147 and

29 CFR 1910.333). Failure to disconnect

power supply may result in electrical

shock or even death.

Always wait for at least 5 minutes after

disconnecting the power before servicing

the unit.

BACKGROUND

All D-Series and C-Series units that are 8 tons or larg-

er have a Variable Frequency Drive (VFD) installed.

There are 2 Controlled Fan Method VFD options: VAV

differential pressure transducer and discrete speed (3 or

4 speed) fan control.

Refer to the nomenclature breakdown in

the appropriate DSV/DSH Installation,

Operation, and Maintenance (IOM)

manual and also the nameplate of the unit

to determine the Controlled Fan Method.

The tenth digit of the nomenclature (ID

Motor) identies which method the unit

has.

Use the nomenclature to select the low

ambient condenser option.

For units with the VAV option, the supplied VFD al-

lows the operator to set the external static (0.0–2.5

"WC), as measured from a supply duct location deter-

mined by field installer and/or as per field specifica-

tions. The VFD controls the frequency (speed) of the

evaporator fan motor in order to meet the desired exter-

nal static (ESP) setpoint. The VFD controls amps draw

of the motor and does not allow the motor draw more

than nominal amps.

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

SECTION 1 - INSTALLATION

DSH MODELS

The VFD controller on DSH units is factory wired. The

evaporator fan power conductors are factory wired to

the distribution block. The control wiring for field split

applications needs to be field provided and routed from

condenser to evaporator.

VAV UNITS

Differential Pressure Transducer

FOR TECHNICAL SUPPORT, CALL: 877-329-7430

STK-VFD

VFD FACTORY PROGRAMMED

PARAMETERS ARE SET IN THE SE CONTROLLER

AJAX, CANADA

VFD PART #:

VFD APPLICATION:

DATE PROGRAMMED:

VFD-SEC-XXXHE-X

05/10/16

DRIVE FACTORY PROGRAMMED

VAV w/ PRESSURE TRANSDUCER

LD20871

FIGURE 1 - LABEL ON UNIT/VFD FOR VAV WITH

PRESSURE TRANSDUCER

For VAV option units, the differential pressure trans-

ducer is factory wired and mounted inside the VFD

control box. The transducer senses gage pressure (stat-

ic) and converts this pressure difference to an analog

signal. The unit is wired for 0–5VDC output for DSV/

DSH C-gen units.

The transducer is supplied with two 1/4-inch OD pres-

sure fittings and accepts field provided 1/4-inch push-

on tubing for lengths of up to 300 feet. The positive

(HIGH) and negative (LOW) pressure ports are indi-

cated on the transducer. Connect unit RETURN AIR

tubing to negative (LOW) fitting and SUPPLY AIR

tubing to positive (HIGH) fitting.

• Only on 208/230-460 VAC units; not on 575 VAC

• 4009 and 4011 are parameters within the

ABB VFD drive and are factory set at

0.5 ”WC. These eld adjusted points are adjusted

at start-up. These setpoints are based on system

requirements.

Example: If the Supply Duct Static Pressure is

designed for 1.0 "WC, set both Parameters 4009

and 4011 to 1. Adjust Parameters 4009 and 4011

up or down accordingly until the required setpoint

is achieved. Once the setpoint is adjusted, docu-

ment Parameters 4009 and 4011 for future refer-

ence.

Do not adjust the VFD setpoint to greater

than the maximum design pressures of the

duct system or the unit.

• Only use 24VAC from SE controller to the differ-

ential pressure transducer (Term. Exc.)

• Set S1 jumper on VFD, AI1, to Volts

• The VFD is enabled by the Evaporator Fan VFD

Relay (RVFD)

SECTION 1 - INSTALLATION

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

MULTI-SPEED FAN CONTROL

FOR TECHNICAL SUPPORT, CALL: 877-329-7430

STK-VFD

VFD FACTORY PROGRAMMED

NO FIELD PROGRAMMING REQUIRED

AJAX, CANADA

VFD PART #:

VFD APPLICATION:

DATE PROGRAMMED:

VFD-SEC-XXXHE-X

05/10/16

DRIVE FACTORY PROGRAMMED

INDOOR FAN SPEED CONTROL

LD20872

FIGURE 2 - LABEL ON UNIT/VFD FOR MULTI-

SPEED FAN CONTROL

Figure 2 is an example of a label.

C-gen units are 3 or 4 speed depending

on staging.

The multi-speed Fan Control is available on all 8 ton

DSH and DSV units.

For the 15–25 ton DSV units and 10 ton DSH with four

refrigeration stages, the evaporator fan runs at 50%,

60%, 75%, and 100% speed.

For 8–12 ton DSV units and the 8 ton DSH unit with 3

refrigeration stages, the evaporator fan is set to run at

50%, 60%, and 100% speed.

The 2–5 ton DSH units and 5 ton DSV unit do not have

a VFD as a standard and operate at single fixed speed

(100%).

VFD KEYPAD

The VFD requires a keypad to program the VFD. The

keypad is not required to operate the unit when the

VFD is programmed. The keyboard is required dur-

ing initial startup of the unit. Each unit comes with a

factory installed and programmed remote keypad and

short Ethernet clip on connector. An Ethernet commu-

nication cable is supplied by the factory. You can use a

single keypad to program multiple units. Consult with

your sales office to order additional keypads. A copy

of the factory default settings is saved to the keypad

memory available for restore if needed.

LD20860

FIGURE 3 - VFD KEYPAD

LD20861 LD20862

FIGURE 4 - VFD KEYPAD AND ETHERNET

CONNECTOR

FORM 145.13-NO2

ISSUE DATE: 1/22/2020

SECTION 1 - INSTALLATION

INSTALLATION

For units utilizing the VAV option, install a field sup-

plied 1/4-inch push-on tube to the return air side of the

unit. Pass the tube through the opening on the side of

the corner post adjacent to the VFD controls, and con-

nect to the negative (LOW) side fitting.

Install a field supplied Pitot tube in the supply duct as

required, run 1/4-inch push-on tube to the corner post

opening, and connect to the positive (HIGH) side fit-

ting.

LD20863

FIGURE 5 - CONNECTING NEGATIVE AND

POSITIVE SIDE FITTINGS

Check that the tubes are secure inside the duct and

firmly connected to transducer fitting. If they are not,

the unit will not operate as intended.

INSTALL GRILLE COVER

When the unit is wired and the push-on tubing is con-

nected to the transducer, attach the grille cover using

the screws provided, with angled blades point upward

at the top.

LD20864

FIGURE 6 - VFD GRILLE COVER

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