Johnson Controls CSV060B-240B User Manual

Model CSV

Vertical R-410A

Supersedes: 145.15-IOM7 (312)

WATER COOLED AIR CONDITIONING UNITS

Air Conditioning Units

MODEL CSV060B-240B

VERTICAL R-410A

Form 145.15-IOM7 (4 12)

INSTALLATION INSTRUCTIONS

B Style

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDLINES

This equipment is a relativ ely complicated apparatus.
During installation, oper ation, maintenance or service,
individuals may be expose d to certain components or
conditions includi ng, but not l imi ted to: ref ri gerant s
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 respon­sibilty 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

SAFETY SYMBOLS

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

DANGER indicates an imminently haz­ardous situation which, if not avoided,
will result in death or serious injury.

WARNING indicates a potentially haz­ardous situation which, if not avoided,
could result in death or serious injury.

All wiring must be in ac cordance with published spec ifications and must be performe d ONLY
by qualified service personnel. Johnson Controls will not be responsible for damages/problems
resulting from improper connections to the contr ols or appli ca tion of impr oper contr ol si gnals .
Failure to follow this will void the manufacturers warranty and cause serious da mage to prop­erty or injury to persons.

, oils,

FORM 145.15-IOM7 (412)

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 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 t his docum ent a nd a ny referenc e d materials.
This individual shall also be familiar with and comply with
all applicable governmental standards and regulations
pertaining to the task in question.

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 in­formation which may be helpful to you.

2 JOHNSON CONTROLS

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Contr ols policy for continu­ous product im provem ent, the inform ation containe d in
this document is subject to change without notice.
While Johnson Controls makes no commitment to up­date or provide current info rm ation autom aticall y to the
manual owner, that information, if applicable, can be
obtained by contacting the nearest Johnson Controls
service office.

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)

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 d ocum ents, then, prior to work ing
on the equipment, they should verify with the owner
whether the equipment has been modified and if
current literature is available.

JOHNSON CONTROLS 3

FORM 145.15-IOM7 (412)

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 sin gle com pressor. All 8 ~ 20
ton models are dual compressor units with two
independent refrigerant circuits. All units come
standard with a micr oprocessor c ontrol 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 assem bly. Units are pac kaged and sealed
on shipping skids and sh ipped in first class condi tion.
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 pressur e ports to conf irm pres sure
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 ca rrier 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 PERFORM­ING A TEST LIFT. LIFTING AN UNBAL­ANCED UNIT CAN CAUSE PERSONAL
INJURY OR EVEN DEATH.

INSTALLATION SITE

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.

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 locat ion to install the unit. Comm on
vibration and sound lev els as s oc iated w it h com mercial
equipment may be objectionable to people or
equipment.

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 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)

CSV060B 590 635
CSV096B 795 835
CSV120B 955 995
CSV180B 1310 1365
CSV240B 1465 1525

Shipping

Weight (Lbs)

4 JOHNSON CONTROLS

FORM 145.15-IOM7 (412)

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 secur e d o n a s olid, level pa d or stur dy
stand. The use of an isolating rubber sheet is
recommended to reduce vibration and noise
transmission. Ensure that the entire base is
continuously supporte d - 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 a nd 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.

- Car efully position the evaporator section atop the
condensing section. Align all sides, the e vap orator
motor wire routing hole, and the refrigerant line
routing holes.

- Ins tall the securi ng brack ets at all four cor ners, 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.

- Char ge circuit( s) to th e value ind icated o n the un it

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 term inates 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 sup ply and return lines if noise
and vibration transmiss ion could be a problem.

Water piping should inc lude shutoff / balancing val ves
so that the unit can be serviced without shutting d own
and draining the entire water supply circuit. Since
units are piped in parallel piping circuits, the shutoff
valves may be used to eq ualize the pressure drop to
each branch for even condens er 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.

JOHNSON CONTROLS 5

CSV060 DIM ENS IONAL DATA

FORM 145.15-IOM7 (412)

6 JOHNSON CONTROLS

CSV096-120 DIMENSIONAL DATA

FORM 145.15-IOM7 (412)

JOHNSON CONTROLS 7

CSV180 DIME NSIONAL D ATA

FORM 145.15-IOM7 (412)

8 JOHNSON CONTROLS

CSV240 DIMEN SIONAL DATA

FORM 145.15-IOM7 (412)

JOHNSON CONTROLS 9