Johnson Controls CSV060B-240B Air Conditioner User Manual
Contents
1. 8 Bop Fat Beg z LIMI ES 9 eeoo 99 BLUE P6 5 4 49 2 gt Tz ZITO COFS 1 Bird BS ax age an P11 151050 080 40 6 P9 10 24V FOR OUTPUTS LPS1 1 LPS2 HPS2 SK GEN 9 9 9 99 09990 9 9 9 7 CAP THIS END 1 L1 L2 nd 2 2 13 ere gt 1 2 l 1 1 5 Ser o gt 014 eee en TB1 LINE VOLTAGE TERMINAL BLOCK MB MICROPROCESSOR BOARD EFM EVAPORATOR FAN MOTOR 2 COMPRESSOR TWO CONTACTOR COMP 1 COMPRESSOR ONE C1 COMPRESSOR ONE CONTACTOR COMP 2 COMPRESSOR TWO FAN MOTOR CONTACTOR E HPC1 HIGH PRESSURE SWITCH COMP 1 cos CONDENSATE OVERFLOW SWITCH IRF TRANSFORMER LOW PRESSURE SWITCH COMP 1 680 GROUND 2 HIGH PRESSURE SWITCH COMP 2 JOHNSON CONTROLS LOW PRES2. 12 Nameplate Electrical 16 Fan Performance 17 Motor and Drive 19 Blower RPM 20 Water Pressure Drop Data 21 Start Up and Operation 22 Refrigerant Ch rges 22 Pressure 22 Microprocessor 23 23 Safety 23 24 Microprocessor Flash 24 5 26 ae 26 Evaporator 26 Refrigerant 26 26 Drive 26 7 27 R 410A Service Procedures Quick Reference Guide 28 JOHNSON 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 to
3. vi 5 9 6 LIMIT 19 929 Lis L3 1 lt 13 2 EFM LINE VOLTAGE TERMINAL BLOCK MB MICROPROCESSOR BOARD CFM CONDENSER FAN MOTOR C1 COMPRESSOR ONE CONTACTOR EFM EVAPORATOR FAN MOTOR C3 COND FAN MOTOR CONTACTOR COMP 1 COMPRESSOR ONE C4 EVAP FAN MOTOR CONTACTOR TRF TRANSFORMER OLS COND FAN MOTOR OVERLOAD GRD GROUND OL4 EVAP FAN MOTOR OVERLOAD HPC1 HIGH PRESSURE SWITCH COMP 1 LPC 1 LOW PRESSURE SWITCH COMP 1 COS CONDENSATE OVERFLOW SWITCH 12 JOHNSON CONTROLS 5 096 120 VERTICAI CSV180B VERTICAL W C UNIT 460 WIRING SCHEMATIC UNIT 208 230 460 575V 3PH 6 575V 3PH 60HZ FORM 145 15 IOM7 412 OHZ
4. 9 THIS END TB1 11 12 l 3 l 3 72 4 2 15 c2 2 oj et R l o Xe g 4 Xe 4 014 MB MICROPROCESSOR BOARD 1 LINE VOLTAGE TERMINAL BLOCK EFM EVAPORATOR FAN MOTOR C2 COMPRESSOR TWO CONTACTOR COMP 1 COMPRESSOR ONE 1 COMPRESSOR ONE CONTACTOR COMP 2 COMPRESSOR TWO FAN MOTOR 1 2 COMPRESSOR ONE FUSES OL4 EVAP FAN MOTOR OVERLOAD F2 COMPRESSOR TWO FUSES HIGH PRESSURE SWITCH COMP 1 FAN MOTOR FUSES LPC1 LOW PRESSURE SWITCH COMP 1 GRD GROUND 2 HIGH PRESSURE SWITCH COMP 2 COFS CONDENSATE OVERFLOW SWITCH 2 LOW PRESSURE SWITCH COMP 2 JOHNSON CONTROLS 15 ELECTRICAL DATA ELECTRICAL DATA STANDARD EVAPORATOR MOTOR MODEL VOLTAGE QTY ELECTRICAL DATA OVERSIZED EVAPORATOR MOTOR MODEL VOLTAGE QTY 16 CSV060B2 CSV060B4 CSV060B5 CSV096B2 CSV096B4 CSV096B5 CSV120B2 CSV120B4 CSV120B5 CSV180B2 CSV180B4 CSV180B5 CSV240B2 CSV240B4 CSV240B5 CSV060B2 CSV060B4 CSV060B5 CSV096B2 CSV096B4 CSV096B5 CSV120B2 CSV120B4 CSV120B5 CSV180B2 CSV180B4 CSV180B5 CSV240B2 CSV240B4 CSV240B5 20
5. 1 CHEE EERE E PRESSURE DROP 20 2 14 6 CSV120 CSV096 CSV060 JOHNSON CONTROLS 21 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 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 The Air Conditioning section of this equipment is charged with R 410A a hi pressure refrigerant Only qualified technicians using appropriately pressure rated test instruments should perform troubleshooting or service on this equipment WARNING Pressure Switch Settings All Models High Low Cut Out PSIG 600 50 Cut In PSIG 450 75 Refrigerant Charge LBS
6. 361 814 0 43 888 0 50 958 0 57 1024 0 64 1087 0 72 1154 0 83 1211 0 91 1245 0 99 2000 763 0552 37_0 61 907 069 973 077 1035 0 86 1095 055 220 069 904 0 78 969 087 1030 0 97 1089 1 06 1145 1 15 1199 125 1252 1 35 1303 145 2400 961 08 1021 1 08 1079 1 18 1135 128 1188 138 1240 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 CSV096B SUPPLY AIR BLOWER PERFORMANCE AVAILABLE EXTERNAL STATIC PRESSURE Inches Optional Hi Static Drive 2 HP 927 158 585 1778 1037 199 aS ii Es 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 CSV120B SUPPLY AIR BLOWER PERFORMANCE AVAILABLE EXTERNAL STATIC PRESSURE Inches Field Static Standard Drive 2 HP Optional Hi Static Drive 3 HP 599 0 62 675 0 79 745 0 98 815 1 18 875 1 38 927 1 58 984 1 78 1037 1 99 1082 2 22 1128 2 42 1004 2 19 1062 2 44 1098 270 1146 297 985 230 1035 2 60 1085 290 be BREEN EE 1 Blower performance includes evaporator coil and 2 filters 2 At higher evaporator airflows and wet bulb condition
7. 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 WARNING Remove corner connecting brackets which secure the blower module to the lower evaporator unit Carefully lift the blower module and rotate 180 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 t
8. 8 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 208 230 3 60 460 3 60 575 3 60 NIN N NIM N NIN N 2 2 2 2 2 2 2 2 2 2 2 2 COMPRESSOR RLA 30 1 16 7 12 2 6 6 6 MJO 9 9 COMPRESSOR RLA 30 1 16 7 12 2 AAJA 99 9 9 9 9 LRA 225 0 114 0 80 0 LRA 225 0 114 0 80 0 EVAPORATOR FAN HP FLA 1 00 3 1 1 00 1 5 1 00 1 2 1 50 4 5 1 50 2 2 1 50 1 8 2 00 5 8 2 00 2 9 2 00 2 3 3 00 8 5 3 00 4 2 3 00 3 4 5 00 14 0 5 00 6 6 5 00 5 3 EVAPORATOR FAN HP FLA FORM 145 15 IOM7 412 MIN CCT AMPACITY 23 10 11 25 8 33 33 98 15 93 11 70 41 80 20 45 15 13 60 70 29 40 21 18 81 73 44 18 32 75 MIN CCT AMPACITY 24 50 11 95 8 93 35 28 16 63 12 20 44 50 21 75 16 23 66 20 31 80 22 98 88 13 47 28 35 25 MAX FUSE CCT BKR AMP MAX FUSE CCT BKR AMP JOHNSON CONTROLS FORM 145 15 IOM7 412 FAN PERFORMANCE CSV060B SUPPLY AIR BLOWER PERFORMANCE ED AVAILABLE EXTERNAL STATIC PRESSURE Inches W C 1 am b 22 1 04 Field Static Standard Drive 1 Optional Hi Static Drive 1 5 1600 645 0 29 733 0
9. Decrease airflow downward as necessary 18 JOHNSON CONTROLS FORM 145 15 IOM7 412 MOTOR AND PULLEY DATA EVAPORATOR STANDARD BLOWER MOTOR AND DRIVE DATA Adjustable Fixed Motor Belts 907 Pulley BONE Pulley Browning Browning Rating Size Part No Part No CSV060B 745 1117 1 145 88 5 1 9 2 9 1VP34X7 8 4 7 AK49H A29 CSV096B 614 921 1 5 145 88 5 1 9 2 9 1VP34X7 8 5 7 AK59H AX35 CSV120B 711 984 2 145 88 5 2 4 3 4 1VP40X7 8 6 4 AK66H AX37 CSV180B 724 925 3 184 90 2 3 4 4 4 1VP50X1 1 8 8 7 AK89H AX39 CSV240B 848 1064 5 184 90 2 4 7 5 9 1VP60X1 1 8 9 7 BK100H BX60 EVAPORATOR OVERSIZED BLOWER MOTOR AND DRIVE DATA Browning Browning Rating Size Part No Part No CSV060B 897 1346 1 5 145 88 5 1 9 2 9 1VP34X7 8 3 9 AK41H A28 CSV096B 798 1105 2 145 88 5 2 4 3 4 1VP40X7 8 5 7 AK59H AX36 CSV120B 875 1118 3 184 90 2 3 4 4 4 1VP50X1 1 8 7 2 AK74H AX36 CSV180B 894 1122 5 184 90 2 4 7 5 9 1VP60X1 1 8 9 2 BK95H BX40 CSV240B 1046 1287 7 5 213 90 2 5 2 6 4 1VP65X1 3 8 10 2 BK90H BX57 JOHNSON CONTROLS 19 FORM 145 15 IOM7 412 BLOWER SPEED ADJUSTMENT 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 With this information the RPM for the blowers can be determined from the blower performance tables Adjustment of blowe
10. EIGHT OF UNITS BY SAFE MARGINS FAILURE TO DO SO MAY RESULT IN UNIT DAMAGE PERSONAL INJURY OR EVEN DEATH WARNING FORM 145 15 IOM7 412 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 WARNING 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 WARNING 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 A CAUTION 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 Failure to allow adequate space between units may result in poor unit perfor mance
11. FORM 145 15 IOM7 412 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 JOHNSON CONTROLS 25 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 WARNING A CAUTION Exercise care when working around the sharp metal edges of door panels or door frames etc These edges can cause injury EVAPORATOR COIL Inspect the evaporator coil at filter change intervals 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 The Air Conditioning section of this equipment is charged with R 410A a high pressure refrigerant Only qualified technicians using appropriately press rated test
12. Model CSV Vertical R 410A Supersedes 145 15 IOM7 312 Air Conditioning Units Form 145 15 IOM7 412 MODEL 5 060 240 VERTICAL R 410A WATER COOLED AIR CONDITIONING UNITS INSTALLATION INSTRUCTIONS B Style FORM 145 15 IOM7 412 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 unde
13. OLS 7 FORM 145 15 IOM7 412 CSV180 DIMENSIONAL DATA 2 63 24 MINIMUM 24 MINIMUM SERVICE SERVICE CLEARANCE CLEARANCE 36 MINIMUM SERVICE CLEARANCE 8 JOHNSON CONTROLS FORM 145 15 IOM7 412 CSV240 DIMENSIONAL DATA 19 25 2 38 24 MINIMUM 24 MINIMUM SERVICE SERVICE CLEARANCE Tiks 36 MINIMUM SERVICE CLEARANCE SUPPLY aie He as jill JOHNSON CONTROLS 9 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 fr
14. SURE SWITCH COMP 2 13 CSV WIRI 180B VERTICAL NG SCHEMATIC FORM 145 15 IOM7 412 UNIT 208 230V 3PH 60HZ 007 Fog Ss m I lt gt 1 2 1 5 BUF pel P3 528 H2 2 lt 15 Zit COFS 1 45 R 42 P11 SD 9 680 qo 2 P9 pay ON 24 FOR outeurs FAN LPS1 HPS1 LPS2 52 FAN 1995 99997907 z THIS END 181 L1 L2 Los 5 me 2 2 9 F5 AUO Xo o EFM OL4 81 LINE VOLTAGE TERMINAL BLOC MB MICROPROCESSOR BOARD EFM EVAPORATOR FAN MOTOR C2 COMPRESSOR TWO CONTACTOR COMP 1 COMPRESSOR ONE 1 COMPRESSOR ONE CONTACTOR COMP 2 COMPRESSOR TWO C4 FAN MOTOR CONTACTOR EVAP FAN MOTOR F
15. UNIT Circuit 1 Circuit 2 CSV060B 5 25 5 Ibs 4 02 CSV096B 5 18 5 Ibs 3 02 5 30 5 Ibs 5 02 CSV120B 6 12 6 lbs 2 02 6 25 6 Ibs 4 02 CSV180B 8 69 8 16 1102 9 12 9 lbs 2 02 CSV240B 12 45 12 55 7 02 12 45 12 lbs 7 02 22 FORM 145 15 IOM7 412 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 NOTE JOHNSON CONTROLS MICROPROCESSOR CONTROLLER The microprocessor control system 1 specifically designed for single and dual stage systems The control system interfaces with a conventional type thermostat e Unit shall be complete with self contained low voltage control circuit e 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 e Unit shall operate with conventional thermostat designs and have a low voltage terminal strip for easy hook up e Unit control board shall have on board diagnos
16. USES OL4 EVAP FAN MOTOR OVERLOAD GRD GROUND HPC1 HIGH PRESSURE SWITCH COMP 1 COS CONDENSATE OVERFLOW SWITCH LPC1 LOW PRESSURE SWITCH COMP 1 TRF TRANSFORMER 2 HIGH PRESSURE SWITCH COMP 2 GRD GROUND LPC2 LOW PRESSURE SWITCH COMP 2 14 JOHNSON CONTROLS FORM 145 15 IOM7 412 CSV240B VERTICAL RING SCHEMATIC 2 UNIT 208 250 460 575V 3PH 60HZ ag 6 4 m SS ESS l 69 9 1 4 BLUE Re 3 5 2 qx 45 5 9 13 z lo COFS 1 l 6 8 4 11 9 2 GRD 5 P10 P9 24 FOR OUTPUTS ci c2 FAN FAN LPS1 HPS1 LPS2 52 FAN 9 990090999
17. and possible unit failure CSV Operating Weight Unit Operating Shipping Weight Lbs Weight Lbs CSV060B 590 635 CSV096B 795 835 CSV120B 955 995 CSV180B 1310 1365 CSV240B 1465 1525 JOHNSON CONTROLS UNIT MOUNTING 5 20 ton models are shipped as 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 not use a hacksaw to cut refrigerant tubing otherwise serious damage can occur to refrigeration system Remove corner securing brackets fr
18. erminal box Ensure wires are routed clear of any moving components Secure the wiring so that it does not contact the evaporator coil JOHNSON CONTROLS 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 the right hand end the evaporator compressor section The electrical control boxes are located behind outer access panels The compressor section electrical cover is provided with wiring diagrams on the inside which must be opened to be read 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 JURY OR DEATH DUE TO ELECTRICAL WARNING SHOCK STANDARD OPTIONAL SUPPLY 4a FAN MOTOR ACCESS 2 A FRONT AIR RETURN FILTER ACCESS N FILTER NO DRAIN PAN ELECTRICAL PANEL UNIT CONFIGURATI 1 STANDARD JOHNSON CONTROLS FORM 145 15 IOM7 412 Provide individual power disconnects for each unit Install a secure ground to the bonding lug located in the electrical control panel I
19. essor control will flash 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 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 23 described above the microprocessor control board will continue to monitor the low pressure limit switch 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 a
20. f canvas flexible joints are used on ductwork install a ground wire to the ductwork as well All wiring must comply with applicable local and national codes NEC Type and location of disconnect switches must comply with all applicable codes WARNING Unit requires installer to provide a 24volt thermostat with appropriate heating and cooling stages as needed For low voltage wiring 18 gauge wire may be used for up to 50 feet lengths Low voltage runs up to 125 feet require 16 gauge wire All models are designed for single zone cooling applications utilizing space or return air thermostatic controls A low voltage terminal block is provided for hook up of conventional programmable thermostats STANDARD OPTIONAL AR SUPPLY AIR N FAN MOTOR ACCESS 2 H AIR RETURN FILTER ACCESS Nor Nera N 2 nd DRAIN ELECTRICAL PANEL UNIT CONFIGURATION 2 11 FORM 145 15 IOM7 412 TYPICAL WIRING SCHEMATIC CSVO60B VERTICAL W C UNI 208 230 480 57 SPH 60HZ WIRING SCHEMATIC COS HPC LPC ola plo polo EGONOMIZER MB BLACK 0000 90099 P4 H1 X1 R H2 5 2 X 5 oe
21. instruments should ure WARNING perform troubleshooting or service on this equipment 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 BLOWER Inspect the evaporator blower at each regular service interval Clean blower wheel 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 26 FORM 145 15 IOM7 412 DRIVE BELT Examine belt 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 see section Blower Speed Adjustment Tension belts at the
22. 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 CSVO60B 2 20x16x2 CSVO96B 6 14 20 2 CSV120B 6 14x20x2 osvisos 219209 CSV240B 6 20 25 2 JOHNSON CONTROLS FORM 145 15 7 412 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 U
23. mposed 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 JOHNSON CONTROLS Current alarms 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 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
24. n 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 A CAUTION 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 handling damages are not warranty items NOTE RIGGING PRIOR TO MOUNTING UNIT CHECK INDIVIDUAL UNIT WEIGHTS PAGE 10 AND VERIFY LIFTING CAPACITY OF LIFTING EQUIPMENT EXCEEDS W
25. nce 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 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 microproc
26. nd 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 High Pressure Switch on each compressor circuit to protect against excessive discharge pressures 2 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 24 FORM 145 15 IOM7 412 is utilized to prevent short cycling of the compressor Additionally a minimum run time is i
27. nser units feature manifolded single water in and out connections steel pipe into copper fittings Always use backing wrench on the 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 connection fittings are threaded copper Use caution when tightening 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 CSV060 DIMENSIONAL DATA 2 63 13 50 24 MINIMUM 24 MINIMUM SERVICE SERVICE CLEARANCE CLEARANCE 36 MINIMUM SERVICE CLEARANCE SUPPLY AIR CONDENSATE DRAIN 6 JOHNSON CONTROLS FORM 145 15 IOM7 412 CSV096 120 DIMENSIONAL DATA F 2 63 24 MINIMUM 24 MINIMUM SERVICE SERVICE CLEARANCE CLEARANCE 36 MINIMUM SERVICE CLEARANCE SUPPLY CONDENSATE DRAIN COMPRESSOR CONDENSER ACCESS JOHNSON CONTR
28. om the outside corners of the cabinet at the joint line between the evaporator and condenser sections Remove the evaporator section Use a TUBING CUTTER ONLY do 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 JOHNSON CONTROLS FORM 145 15 IOM7 412 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 conde
29. om the right hand side The Manufacturer will not accept any liability resulting from incorrect instal lation of this equipment Follow instal lation instructions carefully NOTE 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 10 FORM 145 15 IOM7 412 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
30. r 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 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 DEFLECTION 1 64 perinch of span length Cross Section POUNDS FORCE Min 1 1 2 2 1 2 3 1 2 6 1 2 5 1 2 8 8 11 1013547 BELT TENSION ADJUSTMENT DEFLECTION FORCE VERSUS DRIVE BELT CROSS SECTION 20 JOHNSON CONTROLS FORM 145 15 7 412 WATER PRESSURE DROP DATA IT LETT titt 20 75 80 UNIT FLOW RATE CSV240 CSV180 TL TATT UT PRESSURE DROP 20 5 111111
31. rstood 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 DANGER WARNING indicates a potentially haz ardous situation which if not avoided could result in death or serious injury WARNING environmental pollution Usually and instruction will be given together with a brief explanation CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or CAUTION NOTE is used to highlight additional in formation which may be helpful to you NOTE 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 JOHNSON CONTROLS FORM 145 15 IOM7 412 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continu ous product improvement the information con
32. s condensate carry over may occur Decrease airflow downward as necessary JOHNSON CONTROLS 17 FORM 145 15 IOM7 412 CSV180B SUPPLY AIR BLOWER PERFORMANCE AVAILABLE EXTERNAL STATIC PRESSURE Inches Optional Hi Static Drive 5 HP 5 00 201 166 765 222 880 3 20 927 972 3 76 1015 4 06 1057 4 34 1099 4 64 1139 945 4 02 4 34 1030 4 64 1070 496 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 CSV240B SUPPLY AIR BLOWER PERFORMANCE AVAILABLE EXTERNAL STATIC PRESSURE Inches Field Supplied Low Static Drive Standard Factory Drive 5 HP Optional Hi Static Drive 7 5HP 6400 705 1 96 760 2 22 812 2 48 862 2 72 910 3 02 956 3 28 1001 3 56 1043 3 84 1085 4 12 1125 4 42 7200 788 2 76 837 3 06 884 3 34 930 3 64 952 3 78 995 4 08 1037 4 38 1078 4 70 1118 5 00 1156 5 32 8000 861 3 70 906 4 02 950 4 34 992 4 66 1033 4 98 1073 5 32 1111 5 66 1149 5 98 1186 6 32 1222 6 68 8800 949 4 94 970 5 12 1010 5 46 1049 5 82 1087 6 18 1125 6 52 1161 60 1197 726 9600 1028 6 34 1066 6 72 1103 7 10 1139 7 48 1 Blower performance includes evaporator coil and 2 filters 2 At higher evaporator airflows and wet bulb conditions condensate carry over may occur
33. se 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 JOHNSON CONTROLS 27 Subject to change without notice Printed U S A Copyright 2012 by Unitary Products Group All rights reserved Engineered Systems P O Box 1592 Products York PA Group 17405 FORM 145 15 IOM7 412 Form 145 15 IOM7 412 York PA 17405
34. tained 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 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 oioi eds 2 Changeability of This 3 General Information 4 Installation Pre Installation Inspection of 4 RIGGING 4 4 Unit 01019 EG 5 Separation of Unit Evaporator 5 Water PIPING 8 5 Dimensional Data 6 8 111941 61 10 Blower Discharge 10 El trical a 11 Typical Electrical
35. tics and fault code display e Standard controls shall include anti short cycle and low voltage protection e Control board shall monitor each compressor and refrigerant safety switch independently e Control board shall have random start feature e 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 amp 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 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 JOHNSON CONTROLS FORM 145 15 IOM7 412 When the room t stat calls for cooling the low voltage control circuit from to Y1 and 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 O
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