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
FORM 145.15-IOM7 (412)
DUCTWORK
When installing duct work, adhere to local Codes and
sensible practice. Minimize duct runs and avoid a br upt
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 conn ecting the air d ucts to the unit.
The supply air duct collar c an be connected d irectl y to
the blower outlet flanges. Return air m ay be ducted to
the unit, or drawn direc tly from the conditi oned 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 installation of this equipment. Follow installation 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 rotate d
for top rear discharge applications (see below). In
180°
addition, the blower outlet panel may be interchang ed
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 f an
or dual fan.
- Remove blower drive be lt on all models with base
mounted motors. Rem ove the com plete fan m otor
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 m ust
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 bl owers to panel! The blo wers
are to remain attached to the mounting panel at all
times.
- Carefully remove the blower panel as sembly from
the evaporator cabinet. Do not allow blower
housings to contact the ev aporator 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 t he evapor ator coil. Ins tall the
attachment screws and tighten securely.
- Install the blank access panel into th e 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 m otor 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 conn ecting brack ets which sec ure
the blower module to the lower evaporator unit.
- Carefully lift the blower module, and rotate 180
0
.
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.
10 JOHNSON CONTROLS
FORM 145.15-IOM7 (412)
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 electric al com ponents ar e
accessible through an independent electrical panel
located on the right hand end of 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 INJURY OR DEATH DUE TO ELECT RICAL
SHOCK.
Provide individual power disconnects for each unit.
Install a secure ground to the bonding lug located in
the electrical contro l panel. If c anvas flexib le joints ar e
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.
Unit requires installer to provide a 24volt thermostat
with appropriate heating and cooling stages as
needed. For low voltage wir ing, 18 gau ge wire m a y 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 therm ostatic
controls. A low voltage terminal block is provided for
hook-up of conventional or programmable
thermostats.
JOHNSON CONTROLS 11
TYPICAL WIRING SCHEMATIC
FORM 145.15-IOM7 (412)
12 JOHNSON CONTROLS
FORM 145.15-IOM7 (412)
JOHNSON CONTROLS 13
FORM 145.15-IOM7 (412)
14 JOHNSON CONTROLS
FORM 145.15-IOM7 (412)
JOHNSON CONTROLS 15
ELECTRICAL DATA - STANDARD EVAPORATOR MOTOR
COMPRESSOR
EVAPORATOR
FAN
QTY RLA
LRA
HP
FLA
ELECTRICAL DATA - OVERSIZED EVAPORATOR MOTOR
COMPRESSOR
EVAPORATOR
FAN
QTY RLA
LRA
HP
FLA
ELECTRICAL DATA
FORM 145.15-IOM7 (412)
MODEL #
VOLTAGE
MIN. CCT.
AMPACITY
MAX FUSE /
CCT. BKR.
AMP
CSV060B2 208-230/3/60 1 @ 16.0 110.0 1.00 3.1 23.10 35
CSV060B4 460/3/60 1 @ 7.8 52.0 1.00 1.5 11.25 15
CSV060B5 575/3/60 1 @ 5.7 38.9 1.00 1.2 8.33 15
CSV096B2 208-230/3/60 2 @ 13.1 83.1 1.50 4.5 33.98 45
CSV096B4 460/3/60 2 @ 6.1 41.0 1.50 2.2 15.93 20
CSV096B5 575/3/60 2 @ 4.4 33.0 1.50 1.8 11.70 15
CSV120B2 208-230/3/60 2 @ 16.0 110.0 2.00 5.8 41.80 50
CSV120B4 460/3/60 2 @ 7.8 52.0 2.00 2.9 20.45 25
CSV120B5 575/3/60 2 @ 5.7 38.9 2.00 2.3 15.13 20
CSV180B2 208-230/3/60 2 @ 23.2 164.0 3.00 8.5 60.70 80
CSV180B4 460/3/60 2 @ 11.2 75.0 3.00 4.2 29.40 40
CSV180B5 575/3/60 2 @ 7.9 54.0 3.00 3.4 21.18 25
CSV240B2 208-230/3/60 2 @ 30.1 225.0 5.00 14.0 81.73 110
CSV240B4 460/3/60 2 @ 16.7 114.0 5.00 6.6 44.18 60
CSV240B5 575/3/60 2 @ 12.2 80.0 5.00 5.3 32.75 40
MODEL #
VOLTAGE
MIN. CCT.
AMPACITY
MAX FUSE /
CCT. BKR.
AMP
CSV060B2 208-230/3/60 1 @ 16.0 110.0 1.50 4.5 24.50 40
CSV060B4 460/3/60 1 @ 7.8 52.0 1.50 2.2 11.95 15
CSV060B5 575/3/60 1 @ 5.7 38.9 1.50 1.8 8.93 15
CSV096B2 208-230/3/60 2 @ 13.1 83.0 2.00 5.8 35.28 45
CSV096B4 460/3/60 2 @ 6.1 41.0 2.00 2.9 16.63 20
CSV096B5 575/3/60 2 @ 4.4 33.0 2.00 2.3 12.20 15
CSV120B2 208-230/3/60 2 @ 16.0 110.0 3.00 8.5 44.50 60
CSV120B4 460/3/60 2 @ 7.8 52.0 3.00 4.2 21.75 25
CSV120B5 575/3/60 2 @ 5.7 38.9 3.00 3.4 16.23 20
CSV180B2 208-230/3/60 2 @ 23.2 164.0 5.00 14.0 66.20 80
CSV180B4 460/3/60 2 @ 11.2 75.0 5.00 6.6 31.80 40
CSV180B5 575/3/60 2 @ 7.9 54.0 5.00 5.2 22.98 30
CSV240B2 208-230/3/60 2 @ 30.1 225.0 7.50 20.4 88.13 110
CSV240B4 460/3/60 2 @ 16.7 114.0 7.50 9.7 47.28 60
CSV240B5 575/3/60 2 @ 12.2 80.0 7.50 7.8 35.25 45
16 JOHNSON CONTROLS
FAN PERFORMANCE
SUPPLY AIR BLOWER PERFORMANCE
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
1600 645 0.29 733 0.36 814 0.43 888 0.50 958 0.57 1024 0.64 1087 0.72 1154 0.83 1211 0.91 1245 0.99
1800 708 0.40 788 0.48 863 0.55 933 0.63 999 0.71 1061 0.79 1121 0.87 1178 0.95 1233 1.04 1295 1.17
2000 763 0.52 837 0.61 907 0.69 973 0.77 1035 0.86 1095 0.95 1152 1.04 1207 1.13 1260 1.22 1311 1.31
2200 836 0.69 904 0.78 969 0.87 1030 0.97 1089 1.06 1145 1.15 1199 1.25 1252 1.35 1303 1.45 ~ ~
2400 898 0.88 961 0.98 1021 1.08 1079 1.18 1135 1.28 1188 1.38 1240 1.48 ~ ~ ~ ~ ~ ~
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.
SUPPLY
CFM
AVAILABLE EXTERNAL S TATIC PRESS URE - Inches W.C. ¹
0.2
0.4
0.6
0.8
1.0
1.2
Optional Hi-Static Drive + 1.5 HP
Standard Drive + 1 HP
Field Supplied Low Static
Drive
1.4
1.6
1.8
2.0
SUPPLY AIR BLOWER PERFORMANCE
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
2400 510 0.31 600 0.45 672 0.60 741 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 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
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.
Standard Drive + 1.5 HP
Field Supplied Low Static
Drive
AVAILABLE EXTERNAL S TATIC PRESS URE - Inches W.C. ¹
Optional Hi-Static Drive + 2 HP
1.4
1.6
1.8
2.0
SUPPLY
CFM
0.2
0.4
0.6
0.8
1.0
1.2
SUPPLY AIR BLOWER PERFORMANCE
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
3200 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
3600 661 0.86 730 1.03 795 1.23 853 1.43 915 1.64 973 1.85 1020 2.10 1070 2.37 1114 2.67 1160 2.89
4000 712 1.10 773 1.28 830 1.50 888 1.72 946 1.95 1004 2.19 1062 2.44 1098 2.70 1146 2.97 ~ ~
4400 768 1.42 824 1.62 877 1.82 930 2.04 985 2.30 1035 2.60 1085 2.90 ~ ~ ~ ~ ~ ~
4800 822 1.78 875 1.98 925 2.20 975 2.43 1026 2.68 1078 2.96 ~ ~ ~ ~ ~ ~ ~ ~
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.
Field Supplied Low Static
Drive
SUPPLY
CFM
0.2
0.4
0.6
0.8
1.0
1.2
AVAILABLE EXTERNAL S TATIC PRESS URE - Inches W.C. ¹
Optional Hi-Static Drive + 3 HP
Standard Drive + 2 HP
1.4
1.6
1.8
2.0
CSV060B
FORM 145.15-IOM7 (412)
CSV096B
CSV120B
JOHNSON CONTROLS 17
CSV180B
SUPPLY AIR BLOWER PERFORMANCE
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
4800 634 1.20 697 1.42 757 1.62 813 1.84 867 2.06 918 2.30 968 2.52 1015 2.76 1065 3.02 1109 3.32
5400 701 1.66 758 1.90 812 2.14 864 2.38 914 2.62 962 2.88 1009 3.12 1053 3.38 1097 3.66 1139 3.92
6000 765 2.22 817 2.48 867 2.74 916 3.00 962 3.28 1007 3.54 1051 3.82 1093 4.10 1134 4.38 1174 4.68
6600 832 2.90 880 3.20 927 3.48 972 3.76 1015 4.06 1057 4.34 1099 4.64 1139 4.96 ~ ~ ~ ~
7200 900 3.72 945 4.02 988 4.34 1030 4.64 1070 4.96 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
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.
AVAILABLE EXTERNAL S TATIC PRESS URE - Inches W.C. ¹
Standard Factory Drive + 3 HP
Optional Hi-Static Drive + 5 HP
SUPPLY
CFM
0.2
0.4
0.6
0.8
1.0
1.2
2.0
1.8
1.4
1.6
Field Supplied Low Static
Drive
SUPPLY AIR BLOWER PERFORMANCE
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
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 6.90 1197 7.26 ~ ~ ~ ~
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. Decrease airflow downward as necessary.
AVAILABLE EXTERNAL S TATIC PRESS URE - Inches W.C. ¹
Optional Hi-Static Drive +7.5HP
Standard Factory Drive + 5 HP
Field Supplied Low Static Drive
SUPPLY
CFM
0.2
0.4
0.6
0.8
1.0
1.2
2.0
1.8
1.4
1.6
FORM 145.15-IOM7 (412)
CSV240B
18 JOHNSON CONTROLS
FORM 145.15-IOM7 (412)
EVAPORATOR-
Dia.
Dia.
CSV060B
745-1117
1
145
88.5
1.9-2.9
1VP34X7/8
4.7
AK49H
A29
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
EVAPORATOR-OVERSIZED BLOWER MOTOR AND DRIVE DATA
Dia.
Dia.
CSV060B
897-1346
1.5
145
88.5
1.9-2.9
1VP34X7/8
3.9
AK41H
A28
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
MOTOR AND PULLEY DATA
STANDARD BLOWER MOTOR AND DRIVE DATA
Adjustable Fixed
Model
Drive
Range
(RPM)
Frame Eff.
HP
Motor
Motor Pulley Blower Pulley
Pitch
Browning
Pitch
Browning
Belts
Rating/Size
Size (%) (in) Part No. (in) Part No.
CSV096B 614-921 1.5 145 88.5 1.9-2.9 1VP34X7/8 5.7 AK59H AX35
CSV240B 848-1064 5 184 90.2 4.7-5.9 1VP60X1 1/8 9.7 BK100H BX60
Adjustable Fixed
Model
Drive
Range
(RPM)
Frame Eff.
HP
Motor
Motor Pulley Blower Pulley
Pitch
Browning
Pitch
Browning
Belts
Rating/Size
Size (%) (in) Part No. (in) Part No.
CSV096B 798-1105 2 145 88.5 2.4-3.4 1VP40X7/8 5.7 AK59H AX36
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)
LD13547
BELT TENSION ADJUSTMENT
BLOWER SPEED ADJUSTMENT
The RPM of the supp l y air and c o nde ns er air blowers will d epe nd on the r equ ired CF M, and the s tat ic res ist a nces
of both the supply/discharg e and the return/intake duct systems . 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 towards the blower shaft via the adjustable mounting.
2) Loosen the setscr e w in the adj ustable motor pulley flange. Remove external ke y on pul leys 4 in. diameter and
larger.
3) Blower speed wil l incr ease w hen moveable flange is a dj ust ed to war ds th e fixed flange (clos ed). Bl o wer s p ee d
will decrease when the moveable flange is adjusted away from the fixed flange (opened). Pulleys are
adjustable only in half-turn increments. Do not op en pulley mor e than five ful l turns for "4L" and "A" belts, o r
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 FORCE VERSUS DRIVE BELT CROSS-SECTION
20 JOHNSON CONTROLS
0
5
10
15
20
25
30
35
40
45
20253035404550556065707580
PRE SS URE DROP (F T H20)
UNIT FLO W RATE (GPM )
CSV240
CSV180
0
5
10
15
20
25
30
35
40
6810121416182022242628303234
PRE SS URE DROP (F T H20)
UNIT FLO W RATE (GPM )
CSV120
CSV096
CSV060
FORM 145.15-IOM7 (412)
WATER PRESSURE DROP DATA
JOHNSON CONTROLS 21
FORM 145.15-IOM7 (412)
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 suc h 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 mic roprocessor 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 a lso results in an elevated sou nd
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 qua lified
technicians, using appropriately
pressure-rated test instruments,
should perform troubleshooting or
service on this equipment.
Pressure Switch Settings - All Models
High Low
Cut Out (PSIG) 600 50
Cut In (PSIG) 450 75
Refrigerant Charge (LBS)
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 compress ors internal protec t or will trip.
If opposite rotation is need ed, disconnect and rev erse
any two leads of the three phase supply. Reconnect
power.
Observe unit operation and check for
unusual noise or vibration.
UNIT
CSV060B 5.25 (5 lbs 4 oz) CSV096B 5.18 (5 lbs 3 oz) 5.30 (5 lbs 5 oz)
CSV120B 6.12 (6 lbs 2 oz) 6.25 (6 lbs 4 oz)
CSV180B 8.69 (8 lbs 11oz) 9.12 (9 lbs 2 oz)
CSV240B 12.45 (12 lbs 7 oz) 12.45 (12 lbs 7 oz)
Circuit 1 Circuit 2
22 JOHNSON CONTROLS
FORM 145.15-IOM7 (412)
MICROPROCESSOR CONTROLLER
The microprocessor control system is specifically
designed for single and dual stage systems. The
control system interfaces with a conventional type
thermostat.
• Unit shall be complete with self-contained low-
voltage control circuit
• Unit shall incorporate a lockout circuit which
provides reset capability at the space thermostat
or base unit, should a ny of the following s tandard
safety devices trip and shut off compressor.
- Loss-of-charge/Low-pressure switch
- High-pressure switch
- Condensate Overflow protection switch
• Unit shall operate with conventional thermostat
designs and have a low volta ge terminal strip for
easy hook-up.
• Unit control board shall ha v e on-board diagnostics
and fault code display.
• Standard controls shall include anti-short cycle
and low voltage protection
• Control board shall monitor eac h compressor and
refrigerant safety switch independently.
• Control board shall have random start feature
• Control board shall retain last 5 fault codes in non
volatile memory which will not be l ost in the event
of a power loss.
OPERATION
For cooling the room t-stat energizes the low-voltage
circuit between “R” & “Y1”.
The call is passed to t he 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 “ON”, the
supply air blower will op erate continuously. With the
room t-stat fan switch set to “AUTO”, the blower is
energized whenever a cooling oper ation is request ed.
The blower is energized after any specified delay
associated with the operation.
When energized, the indoor blower has a minimum
run time of 30 seco nds. Ad dition al l y, th e i ndo or b lo wer
has a delay of 10 seconds between operations.
When the room t-stat calls for cooling, the lo w-voltage
control circuit from “R” to “Y1”and “G” is completed.
The compressor and fan motor are energized. After
completing the specified f an on delay for cooling, the
microprocessor control will energize the blower motor.
Once the room t-stat has been satisfied, it will deenergize “Y1”. If the compressor has satisfied its
minimum run time, the compressor and fan deenergize. Otherwise, the unit operates the cooling
system until the minim um run time for the compr essor
has been completed. After the compressor deenergizes, the blower is st opped following the elapse
of the fan-off delay for cooling.
To be available, a compress or 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 s ystem is m onitored to e nsure it d oes
not operate outside of its intended operating
parameters. Safet y switch e s are hand led as des cr ibe d
below. All system er rors override minimum run times
for compressors.
High-Pressure Limit Switch
If a high-pressure limit switch opens, the
microprocessor c ontrol de-energizes the compressor,
initiates the ASCD, and stops the fan. If a call for
cooling or heating is still present at the conclus ion of
the ASCD, the micropr ocessor control will re-energize
the compressor and unit fan.
Should a high-press ure s witch ope n three tim es within
two hours of operation, the micropr ocessor c ontrol will
permanently lock-out the compressor. The system
must be manually reset by de-energizing the 24 volt
power to unit, or turning t he room t-stat to the “OFF”
position then back to cooling position. The
microprocessor control will flash a fault code
indicating a high-pressure lock-out.
Low-Pressure Limit Switch
The low-pressure lim it 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. If the low-pressure
switch fails to close after the 30 second monitoring
phase, the micr oproces sor c ontrol 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
JOHNSON CONTROLS 23
FORM 145.15-IOM7 (412)
described above), the microprocessor control board
will continue to monitor the low-pressure limit switch
for any openings. If the low-pres sure s witch o pens 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 cooli ng is still present at the conc lusion
of the ASCD, the microprocessor control will reenergize 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 c ompressor and f lash a
fault code indicating a low-pressure lock-out.
Condensate Overflow Switch
A Condensate Overflow fault occurs when the
Condensate Overflow s witch opens for mor e than two
line cycles. The compr essor is shutdown r egardless
of Minimum Run Tim e, ASCD is initiated, and 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. A High-Pressure Switch on each compressor
circuit to protect against excessive discharge
pressures.
2. A Low-Pressure Switch on each compressor
circuit to protect against loss of refrigerant charge.
3. A Condensate Overf low Switch to protect agains t
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 f eatures to minimize compr essor
wear and damage. An anti-s hort cycle delay (ASCD)
is utilized to prev ent short cycling of the com pressor.
Additionally, a minim um run time is impos ed any time
a compressor is ener gized. 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.
24 JOHNSON CONTROLS
Current alarms or active re s tr ictions are flashed on the
microprocessor control LED.
1. LAST ERROR – W hen this button is press ed and
released, it flashes th e last five (5) f lash codes on
the board’s LED. The mos t recent alarm is shown
first and the oldest alarm is shown last.
2. TEST RESET – When this button is pressed and
released, any anti-short c ycle delays (ASCD) are
bypassed for one c ycle. W hen pressed twice, any
active lockouts are reset
COMM SETUP – If the board is to be networked
3.
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, (s tarts a t 2). It then f lashes that
address one time. Pressing the button twice
causes the control to flash the address
.
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
FORM 145.15-IOM7 (412)
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.
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 pressure rated test instruments, should
perform troubleshooting or service on
this equipment.
With the unit operating, check and record the
compressor discharge and suction pressures. The
compressor running c urrent should also be recorde d.
A maintenance log of these readings can indicate if
the unit is operating withi n its normal limit s. Abnormal
readings should be investigated, and the Cause
corrected.
BLOWER -
Inspect the evaporator blower at each regular ser vice
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 ti ght on the s haf t, and that the hub
set screws are properly torqued.
DRIVE BELT -
Examine belt periodically for wear. Glazed areas on
the drive surfaces indicate overheating due to belt
slippage. Ideal tensi on is the lowest tension at which
the belt will not slip u nder peak loa d conditions. O vertensioning 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 inc h per inch of belt s pan, with
the appropriate force applied at the midpoint of the
span (see section ‘Blower Speed Adjustment’).
Tension “New” belts at the maximum value indicated.
Used belts should be maintained at the minimum
value.
FILTERS -
Inspect filters m onthly and replace as necessary. Us e
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 air flow perf orm ance. Filter s izes are
as follows:
Filters Qty/Size
CSV060B 2/20x16x2
CSV096B 6/14x20x2
CSV120B 6/14x20x2
CSV180B
CSV240B 6/20x25x2
2/16x20x2
4/16x25x2
26 JOHNSON CONTROLS
FORM 145.15-IOM7 (412)
R-410A QUICK RE FE RE N CE GUI DE
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. 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 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
FORM 145.15-IOM7 (412)
Subject to change without notice. Printed in U.S.A.
©
Copyright
Engineered Systems P.O. Box 1592 York
Products York, PA PA
Group 17405 17405
2012 by Unitary Products Group. All rights reserved. Form 145.15-IOM7 (412)
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