Johnson Controls CSV060B-240B User manual

Model CSV
Vertical R-410A
Supersedes: 145.15-IOM7 (312) Air Conditioning Units Form 145.15-IOM7 (412)
MODEL CSV060B-240B
VERTICAL R-410A
WATER COOLED AIR CONDITIONING UNITS
INSTALLATION INSTRUCTIONS
B Style

FORM 145.15-IOM7 (412)
2JOHNSON 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 respon-
sibilty 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 manufacturers warranty and cause serious damage to prop-
erty or injury to persons.

FORM 145.15-IOM7 (412)
JOHNSON CONTROLS 3
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained in
this document is subject to change without notice.
While Johnson Controls makes no commitment to up-
date or provide current information automatically to the
manual owner, that information, if applicable, can be
obtained by contacting the nearest Johnson Controls
service office.
It is the responsibility of operating/service personnel as
to the applicability of these documents to the
equipment in question. If there is any question in the
mind of 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
General Information…………………………………………………….4
Installation –
Pre-Installation Inspection of Equipment………………….………4
Rigging……………………………………………………………..... 4
Installation Site……………………………………………………… 4
Unit Mounting……………………………………………………….. 5
Separation of Unit (Evaporator / Condenser)…………………… 5
Water Piping………………………………………………………… 5
Dimensional Data…..…………………………………………………. 6
Ductwork…………..…………………………………………………. 10
Blower Discharge Conversion………………………………………..10
Electrical Wiring……………………...………………………………..11
Typical Electrical Schematic……………………………………...12
Nameplate Electrical Data………………………………………...16
Fan Performance Data………………………………………………..17
Motor and Drive Data………………………………………………19
Blower RPM Adjustment…………………………………………..20
Water Pressure Drop Data………………….……………………..…21
Start-Up and Operation……………………………………………….22
Refrigerant Charges………………………………………………. 22
Pressure Switch Settings………………………………………….22
Microprocessor Controller……………………………………....……23
Operation……………………………….………………………….. 23
Safety Switches……….……………………………………………23
Safety Controls…………………...........…………………………..24
Microprocessor Flash Codes…………………………………….. 24
Maintenance/Service………………………………………………… 26
Filters………………..……………………………………………… 26
Evaporator Coil…………………………………………….............26
Refrigerant Circuits………………………………………………...26
Blower.………………………………………………………………26
Drive Belts…………………………………………………………..26
Warranty……………….……………………………………………….27
R-410A Service Procedures - Quick Reference Guide…………...28

FORM 145.15-IOM7 (412)
4JOHNSON CONTROLS
GENERAL INFORMATION
All 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 are shipped with
vertical evaporator fan discharge as standard. The
evaporator fan discharge configuration is field
convertible on all units.
The 5 ton unit utilizes a single compressor. All 8 ~ 20
ton models are dual compressor units with two
independent refrigerant circuits. All units come
standard with a microprocessor control board (refer to
‘Microprocessor’ section).
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.
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 when ceiling
mount application is specified, estimate the
approximate center of gravity of the unit. The
configuration of internal components for each unit is
different and weight is unevenly distributed.
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 50°F and 115°F.
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 may result in poor unit perfor-
mance 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
can be slightly pitched in the same direction as drain
pan outlet.
CSV Operating Weight
Unit Operating
Weight (Lbs)
Shipping
Weight (Lbs)
CSV060B 590 635
CSV096B 795 835
CSV120B 955 995
CSV180B 1310 1365
CSV240B 1465 1525

FORM 145.15-IOM7 (412)
JOHNSON CONTROLS 5
UNIT MOUNTING
The 5 ~ 20 ton models are shipped as a fully
assembled integral package. If required units may be
field split to allow for passage through doors,
elevators, hallways, etc.
Duct flanges for evaporator return are incorporated
into the filter rack.
Units should be secured on a solid, level pad or sturdy
stand. The use of an isolating rubber sheet is
recommended to reduce vibration and noise
transmission. Ensure that the entire base is
continuously supported - do not support unit at corner
points only! Unit may be pitched slightly to ensure
efficient drainage of condensate.
EVAPORATOR / CONDENSER SEPARATION - (All
models)
-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.
ASSEMBLY OF SPLIT UNITS - (All models)
-Place the condenser 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. Note
that one bracket, intended for use at the corner
with the +drain fitting, has a short "leg".
-Use appropriate tubing couplings and splice
previously cut refrigerant lines. Pressure test
refrigerant circuits with dry 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.
-Install bushing/clamp into evaporator wiring
routing hole, and pull wires through into electrical
control panel. Connect motor leads to load
terminals on contactor/overload relay.
Ensure evaporator motor rotation is
correct upon unit start-up. Switch any
two wires at contactor if blower
rotation is not correct.
WATER PIPING
All factory installed water piping terminates inside the
unit. Multi-condenser units feature manifolded single
water in and out connections.
Water connection fittings are threaded
copper. Use caution when tightening
steel pipe into copper fittings. Always
use a backing wrench on the hex
fittings inside the unit.
It is recommended that flexible connectors be
provided on the water supply and return lines if noise
and vibration transmission could be a problem.
Water piping should include shutoff / balancing valves
so that the unit can be serviced without shutting down
and draining the entire water supply circuit. Since
units are piped in parallel piping circuits, the shutoff
valves may be used to equalize the pressure drop to
each branch for even condenser water distribution. A
bibcock or a plugged tee fitting should be installed
between the shut-off valves and the unit in both the
inlet and outlet pipes. These connections are to
provide for acid cleaning of the condenser, if this
should become necessary.

FORM 145.15-IOM7 (412)
6JOHNSON CONTROLS
CSV060 DIMENSIONAL DATA

FORM 145.15-IOM7 (412)
JOHNSON CONTROLS 7
CSV096-120 DIMENSIONAL DATA

FORM 145.15-IOM7 (412)
8JOHNSON CONTROLS
CSV180 DIMENSIONAL DATA

FORM 145.15-IOM7 (412)
JOHNSON CONTROLS 9
CSV240 DIMENSIONAL DATA

FORM 145.15-IOM7 (412)
10 JOHNSON CONTROLS
DUCTWORK
When installing ductwork, adhere to local Codes and
sensible practice. Minimize duct runs and avoid abrupt
changes in direction where possible. Allow ample
access space for servicing of the coils and changing
of filters. Perform regular maintenance on ducts to
increase unit life, maintain efficient operation, and
reduce 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.
Canvas or other types of flexible collars are
recommended for connecting the air ducts to the unit.
The supply air duct collar can be connected directly to
the blower outlet flanges. Return air may be ducted to
the unit, or drawn directly from the conditioned space
(with optional return air grille). If a ducted return is
desired, duct connection flanges may be secured
directly to the air intake opening – filters are
accessible from the right hand side.
The Manufacturer will not accept any
liability resulting from incorrect instal-
lation of this equipment. Follow instal-
lation instructions carefully.
EVAPORATOR BLOWER DISCHARGE
CONVERSION
All models can be field converted to the alternate
evaporator discharge orientation, as indicated on the
unit dimensional drawings. All models are shipped
with vertical fan discharge as standard.
The removable upper fan module that can be rotated
180°for top rear discharge applications (see below). In
addition, the blower outlet panel may be interchanged
with the front panel of the fan module. Interchanging
these two panels allows horizontal fan discharge to
either front or rear of the unit.
Procedure for converting the fan discharge from
vertical to horizontal is similar on all models, single fan
or dual fan.
- Remove blower drive belt on all models with base
mounted motors. Remove the complete fan motor
and drive on models with blower mounted motor
assemblies.
- Remove the panel attachment screws on the
alternate location access panel (front blower
module panel). The front roof support angle must
be removed to allow access to the front panel.
Remove the panel and set aside.
- Remove the panel attachments screws on the
blower outlet 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.
- Relocate the evaporator fan drive motor to the
alternate location.
- Install and adjust drive belts to appropriate
tension. Test run blower and observe operation
for unusual sounds or vibration.
In order to utilize the ‘rear vertical’ or ‘rear horizontal’
discharge, the upper fan module must be rotated.
- Disconnect power wiring at motor terminal box.
DISCONNECT AND LOCK OUT
POWER WHEN SERVICING UNIT.
FAILURE TO DO SO MAY RESULT IN
PERSONAL INJURY OR DEATH DUE
TO ELECTRICAL SHOCK.
- Remove corner connecting brackets which secure
the blower module to the lower evaporator unit.
- Carefully lift the blower module, and rotate 1800.
Reposition the blower module on top of the
evaporator/compressor unit. Reinstall the corner
connecting brackets.
Connect new power wire leads, from the evaporator
motor contactor in the electrical box to the motor
terminal box. Ensure wires are routed clear of any
moving components. Secure the wiring so that it does
not contact the evaporator coil.