Johnson Controls CSV Series Installation, Operation And Maintenance Manual Download

Page: 1 / 70

Supersedes 145.15-IOM7 (1019)

Form Number: 145.15-IOM7 (220)

Issue date: 2020-02-18

2020-02-18

C-Series Vertical (CSV) Water-Cooled Self-

Contained Units, B Generation, R-410A

Installation, Operation, and Maintenance

Manual

Summary of Contents for CSV Series

Page 1: ...rsedes 145 15 IOM7 1019 Form Number 145 15 IOM7 220 Issue date 2020 02 18 2020 02 18 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 2: ...2 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 3: ...ping 13 Waterside economizer 13 Water regulating valve kit 15 Water quality 16 Dimensional data 17 Typical service clearances 37 Ductwork 41 Evaporator blower discharge conversion 41 Variable frequency drive VFD 42 VAV supply pressure control 42 Two discrete speeds 43 Electrical wiring 44 Unit wiring schematics 45 Typical VFD electrical schematic 50 Electrical data 56 Fan performance 57 Motor and ...

Page 4: ...erflow switch 66 Safety controls 66 Compressor protection 66 Microprocessor control unit flash codes 67 Maintenance service 68 Evaporator coil 68 Refrigerant circuit s 68 Blower 68 Drive belt 68 Filters 69 Drain pan condensate 69 R 410A quick reference guide 70 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 4 ...

Page 5: ...als 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 individual shall also be familiar with and comply with all applicable industry and governmental standards an...

Page 6: ... contained in this document is subject to change without notice There is no commitment to update or provide current information automatically to the manual or product owner Updated manuals if applicable can be obtained by contacting the nearest service office It is the responsibility of rigging lifting and operating service personnel to verify the applicability of these documents to the equipment ...

Page 7: ...VWSEK 120 for CSV096B 120B Installation Instructions 145 15 IOM2 1 Left Hand Waterside Economizer Model CVWSEK 180 for CSV180B Installation Instructions 145 15 IOM3 Right Hand Waterside Economizer Model CVWSEK 180 for CSV180B Installation Instructions 145 15 IOM3 1 Left Hand Waterside Economizer Model CVWSEK 240 for CSV240B Installation Instructions 145 15 IOM4 Right Hand Waterside Economizer Mode...

Page 8: ...Nomenclature Water cooled self contained unit C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 8 ...

Page 9: ...ted 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 pre...

Page 10: ...n site WARNING Lock all electrical power supply switches in the OFF position before installing the unit Failure to disconnect power supply may result in electrical shock or even death WARNING Do not install this unit outdoors WARNING The system should be installed by qualified personnel If not it may cause water leakage electric shock or fire DANGER Do not install units in a flammable environment ...

Page 11: ... 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 CAUTION Failure to allow adequate space between units may result in poor unit performance and possible unit failure Install thermostats air supplies and returns so that each unit will operate only on indiv...

Page 12: ...een the blower and evaporator sections Remove the blower section Evaporator condenser separation CSV240B model The 20 ton model requires the evaporator to be separated from the condenser 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 evap...

Page 13: ...alled water piping terminates at the face of the unit and features a wrenchless connection Multi condenser units feature manifolded single water in and out connections CAUTION Water connection fittings are threaded copper Use caution when tightening steel pipe into copper fittings It is recommended that flexible connectors be provided on the water supply and return lines if noise and vibration tra...

Page 14: ...e Form 145 15 IOM2 left hand or Form 145 15 IOM2 1 right hand For CSV180B see Form 145 15 IOM3 left hand or Form 145 15 IOM3 1 right hand For CSV240B see Form 145 15 IOM4 left hand or Form 145 15 IOM4 1 right hand For CSV300B see Form 145 15 IOM5 left hand or Form 145 15 IOM5 1 right hand Figure 1 Waterside economizer C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Inst...

Page 15: ...able standards as well as the Nationally Recognized Test Lab NRTL or other testing facility that conducted the testing where applicable If changes are made to the product an engineering review will be needed to assess the impact to the product certification In some instances the changes may be such that the NRTL or testing facility will need to review and potentially reapprove of the product by me...

Page 16: ...espan of the units otherwise damage to the units may occur Table 2 Water quality recommendation table Potential problem Controlled chemical condition Copper coaxial heat exchangers range Cupro nickel coaxial heat exchangers range Cleaning Proper surface cleaning required Proper surface cleaning required Filtration Best practice filtration Best practice filtration Suspended solids Less than 10 ppm ...

Page 17: ...l data Figure 2 CSV060B front return top discharge LH water connection dimensional data 17 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 18: ...ure 3 CSV060B front return front discharge LH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 18 ...

Page 19: ...gure 4 CSV060B front return top discharge RH water connection dimensional data 19 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 20: ...ure 5 CSV060B front return front discharge RH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 20 ...

Page 21: ...re 6 CSV096 120B front return top discharge LH water connection dimensional data 21 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 22: ...e 7 CSV096 120B front return front discharge LH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 22 ...

Page 23: ...re 8 CSV096 120B front return top discharge RH water connection dimensional data 23 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 24: ...e 9 CSV096 120B front return front discharge RH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 24 ...

Page 25: ...gure 10 CSV180B front return top discharge LH water connection dimensional data 25 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 26: ...ure 11 CSV180B front return front discharge LH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 26 ...

Page 27: ...gure 12 CSV180B front return top discharge RH water connection dimensional data 27 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 28: ...ure 13 CSV180B front return front discharge RH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 28 ...

Page 29: ...ure 14 CSV240B front return rear discharge LH water connection dimensional data 29 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 30: ...gure 15 CSV240B front return top discharge LH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 30 ...

Page 31: ...ure 16 CSV240B front return rear discharge RH water connection dimensional data 31 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 32: ...gure 17 CSV240B front return top discharge RH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 32 ...

Page 33: ...ure 18 CSV300B front return rear discharge LH water connection dimensional data 33 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 34: ...gure 19 CSV300B front return top discharge LH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 34 ...

Page 35: ...ure 20 CSV300B front return rear discharge RH water connection dimensional data 35 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 36: ...gure 21 CSV300B front return top discharge RH water connection dimensional data C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 36 ...

Page 37: ...Typical service clearances Figure 22 CSV060B service clearances 37 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 38: ...Figure 23 CSV096 120B service clearances C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 38 ...

Page 39: ...Figure 24 CSV180B service clearances 39 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 40: ...Figure 25 CSV240B service clearances Figure 26 CSV300B service clearances C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 40 ...

Page 41: ...elow 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 The procedure for converting the fan discharge from vertical to horizontal is similar on all models 1 Remove blower drive belt on all models with base mounted motors Remove the complete fan motor and drive on mode...

Page 42: ... the wiring so that it does not contact the evaporator coil Figure 27 Evaporator blower discharge conversion Variable frequency drive VFD Optional Variable Frequency Drive VFD controller for the evaporator fan mounted in the corner post of the evaporator module is available on the 10 25 ton models The VFD shall be approved for plenum duty applications There are two VFD applications that are availa...

Page 43: ...ween evaporator and condenser if the unit being shipped factory split The power wiring can be found inside the VFD enclosure no extra power wiring is required sufficient length is provided The VFD option does not include a bypass circuit in case of microdrive failure Microdrive will need to be replaced to reactivate unit In case of VFD failure the evaporator fan will stop running however unit comp...

Page 44: ...OCK Provide individual power disconnects for each unit Install a secure ground to the bonding lug located in the electrical control panel If canvas flexible joints are used on ductwork install a ground wire to the ductwork as well WARNING All wiring must comply with applicable local and national codes NEC Type and location of disconnect switches must comply with all applicable codes Unit requires ...

Page 45: ...Unit wiring schematics Figure 29 CSV060B units with 208 230 460 575V 3Ph 60Hz 45 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 46: ...V096B 120B units with 208 230 460 575V 3Ph 60Hz and CSV180B units with 460 575V 3Ph 60Hz C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 46 ...

Page 47: ...Figure 31 CSV180B units with 208 230V 3Ph 60Hz 47 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 48: ...Figure 32 CSV240B units with 208 230 460 575V 3pH 60Hz C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 48 ...

Page 49: ...Figure 33 CSV300B units with 208 230V 3pH 60Hz 49 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 50: ...trical schematic Figure 34 CSV096B 180B CSV300B units with 208 230 460 575V 3Ph 60Hz and VFD C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 50 ...

Page 51: ... 35 CSV120 180B 300B units with 208 230V 460V 3Ph 60Hz and VFD for 2 discrete speed 51 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 52: ...gure 36 CSV120 180B 300B units with 575V 3Ph 60Hz and VFD for 2 discrete speed C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 52 ...

Page 53: ...Figure 37 Typical wiring diagrams for VFD options 53 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 54: ...Figure 38 Single compressor unit water condensate overflow switch optional C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 54 ...

Page 55: ...Figure 39 Dual compressor unit water condensate overflow switch optional 55 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 56: ...0 0 7 50 20 4 96 90 125 CSV 300B4 460 3 60 2 16 0 140 0 7 50 9 7 45 70 60 CSV 300B5 575 3 60 2 12 9 107 6 7 50 7 8 36 83 45 Table 4 Oversized evaporator motor electrical data Compressor Evaporator fan Model Voltage Qty RLA LRA Hp FLA Min CCT ampacity Max fuse CCT bkr amp CSV 060B2 208 230 3 60 1 16 0 110 0 1 50 4 5 24 50 40 CSV 060B4 460 3 60 1 7 8 52 0 1 50 2 2 11 95 15 CSV 060B5 575 3 60 1 5 7 3...

Page 57: ...741 0 78 810 0 96 878 1 14 936 1 33 982 1 54 1033 1 76 1074 2 00 2800 538 0 44 628 0 57 700 0 71 778 0 89 830 1 10 890 1 29 950 1 50 1010 1 72 1048 1 92 3200 599 0 62 675 0 79 745 0 98 815 1 18 875 1 38 927 1 58 985 1 78 1037 1 99 3600 661 0 86 730 1 03 795 1 23 853 1 43 915 1 64 973 1 85 4000 712 1 10 773 1 28 830 1 50 888 1 72 946 1 95 Note At higher evaporator airflows and wet bulb conditions c...

Page 58: ... 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 6 90 1197 7 26 9600 1028 6 34 1066 6 72 1103 7 10 1139 7 48 Note At higher evaporator airflows and wet bulb conditions condensate carry over may occur ...

Page 59: ...designed to operate in the shaded region of the fan table otherwise nuisance overloads trips can occur Motor overload trips can be remedied by increasing the external static pressure Refer to fan tables With this information the RPM for the blowers can be determined from the blower performance tables Adjustment of blower speed is accomplished as follows 1 Loosen belt tension by moving motor toward...

Page 60: ...ion adjustment Pounds force Cross section Min Max 4L 1 1 2 2 1 2 A 3 1 2 6 1 2 B 5 1 2 8 BX 8 11 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual 60 ...

Page 61: ...dard units manifolded condensers water pressure drop Figure 42 CSV060 120 standard units manifolded condensers water pressure drop 61 C Series Vertical CSV Water Cooled Self Contained Units B Generation R 410A Installation Operation and Maintenance Manual ...

Page 62: ...R 410A a hi pressure refrigerant Only qualified technicians using appropriately pressure rated test instruments should perform troubleshooting or service on this equipment 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...

Page 63: ... the equivalent saturation temperature For example when the discharge pressure is 388 psig and the liquid line temperature is 95 0 F Liquid Pressure Discharge Pressure 388 psig minus 33 psig 355 psig Saturation Temperature for 355 psig 108 0 FLiquid Line Subcooling Saturation Temperature 108 0 F minus Liquid Line Temperature 95 0 13 0 F Subcooling should be 12 0 15 0 F at design conditions Table 1...

Page 64: ...ient time approximately 15 minutes between adjustments for the system and the thermal expansion valve to respond and stabilize The superheat setting should be adjusted to 8 0 11 0 F at design conditions Leak checking Leak check compressors fittings and piping to ensure there are no leaks Verify the evaporator distributor tubes do not have bare copper touching each other or are against a sheet meta...

Page 65: ...l will energize the blower motor Once the room t stat has been satisfied it will de energize Y1 If the compressor has satisfied its minimum run time the compressor and fan de energize Otherwise the unit operates the cooling system until the minimum run time for the compressor has been completed After the compressor de energizes the blower is stopped following the elapse of the fan off delay for co...

Page 66: ...the fault occurrence counter is reset to zero Should the condensate overflow switch open 3 times within 1 hour 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 lockout The condensate overflow switch is a normal close switch For the condensate overflow switch shown in Figure 39 in the normal situation ...

Page 67: ...ed 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 Table 16 Controller flash fault codes Flash c...

Page 68: ...e 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 B...

Page 69: ...d surface pleated type Replacements should be of the same type in order to maintain optimum airflow performance Filter sizes are as follows Table 17 Filter sizes Filters Qty size CSV060B 2 20x18x2 CSV096B 6 14x20x2 CSV120B 6 14x20x2 CSV180B 2 16x20x2 4 16x25x2 CSV240B 6 20x25x2 CSV300B 6 25x18x2 6 20x18x2 Drain pan condensate Inspect the field installed condensate trap for any blockage Remove and ...

Page 70: ...ses must have a service pressure rating of 800 psig Leak detectors must be designed to detect HFC refrigerants Systems must be charged with refrigerant Use a commercial type metering device in the manifold hose R 410A can only be used with POE type oils POE type oils rapidly absorb moisture from the atmosphere Vacuum pumps will not remove moisture from POE type oils Do not use liquid line driers w...

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