Related Manuals for Johnson Controls CSV Series
Summary of Contents for Johnson Controls CSV Series
- Page 1 C-Series Vertical (CSV) Water-Cooled Self- Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual Form Number: 145.15-IOM7 (220) Issue date: 2020-02-18 Supersedes 145.15-IOM7 (1019) 2020-02-18...
- Page 2 C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
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Page 3: Table Of Contents
Contents Important!............................... 5 Read before proceeding!........................5 General safety guidelines......................... 5 Safety symbols............................5 Changeability of this document....................... 6 Revision notes............................6 Associated literature..........................7 Nomenclature..............................8 Installation..............................9 General information..........................9 Pre-installation inspection of equipment..................9 Rigging..............................9 Installation site..........................10 Location.............................. - Page 4 Superheat..............................64 Leak checking............................64 Microprocessor controller........................ 64 Operation............................65 Continuous blower..........................65 Safety switches..........................65 High-pressure limit switch....................... 65 Low-pressure limit switch......................... 66 Condensate overflow switch......................66 Safety controls........................... 66 Compressor protection........................66 Microprocessor control unit flash codes..................67 Maintenance/service...........................
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Page 5: Important
Important! Read before proceeding! General safety guidelines This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage. -
Page 6: Changeability Of This Document
WARNING External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with the manufacturer's published specifications and must be performed only by a qualified electrician. -
Page 7: Associated Literature
Associated literature Manual description Form number Variable Frequency Drive (VFD) for Self-Contained Units Installation and 145.13-NO1 Operation Instructions Water Regulating Valve Kit for CSV096B-300B Units Installation Instructions 145.15-N1 Left-Hand Waterside Economizer (Model CVWSEK-060) for CSV060B Installation 145.15-IOM1 Instructions Right-Hand Waterside Economizer (Model CVWSEK-060) for CSV060B 145.15-IOM1.1 Installation Instructions Left-Hand Waterside Economizer (Model CVWSEK-120) for CSV096B/120B... -
Page 8: Nomenclature
Nomenclature Water-cooled self-contained unit C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual... -
Page 9: Installation
Installation General information All models 5–20 tons are shipped as factory-charged unitized packages. The 25-ton model is shipped factory split with nitrogen holding charge only. Refer to Start-up and operation for charge information All models can be selected with either a horizontal (front) or vertical (top) fan discharge. The evaporator fan discharge configuration is field convertible on all units. -
Page 10: Installation Site
WARNING Follow all applicable regulations and safety practices during rigging and lifting. Prepare and follow written rigging and lifting plan. Lifting must be directed by trained professional rigger. Spreader bars must be used and be long enough to prevent rigging from contacting unit. Use all and only designated lift points according to unit's manual(s). -
Page 11: Location
WARNING Safety guards, shields, barrier, covers, and protective devices must not be removed while the compressor/unit is operating. WARNING All safety features, disengagement and interlocks must be in place and function correctly before the equipment is put into operation. Never bypass or wire around any safety device. WARNING Use gloves, protective goggles, and where appropriate, make sure to have a gas mask close at hand. -
Page 12: Unit Mounting
Unit mounting The 5–20 ton models are shipped as a fully assembled integral package. The 25-ton model ships factory split with nitrogen holding charge only. Factory provided couplings are included for field assembly of the 25-ton model. 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. -
Page 13: Water Piping
• 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. • For the 25-ton model, cut off spun copper ends on each refrigerant pipe in evaporator and condenser. - Page 14 the appropriate Waterside Economizer Installation, Operation, and Maintenance manuals for more information on installation and sequence of operation: • For CSV060B, see Form 145.15-IOM1 (left hand) or Form 145.15-IOM1.1 (right hand) • For CSV096B/120B, see Form 145.15-IOM2 (left hand) or Form 145.15-IOM2.1 (right hand) •...
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Page 15: Water Regulating Valve Kit
Water regulating valve kit Optional Water Regulating Valve Kit modulates the condenser water flow in order to control the condensing pressure in each refrigeration circuit. Valves open and close in response to rise and fall of the condensing pressure as sensed by the capillary tube, which is connected to the liquid line access fittings of the respective refrigerant circuits. -
Page 16: Water Quality
Water quality General guidelines for required water quality are provided as a part of this manual. Having a proper water treatment and maintenance program in place is essential for all closed and open loop hydronic systems. Local codes and requirements of various other components used in specific hydronic systems might mandate some changes to recommended values. -
Page 17: Dimensional Data
Dimensional data Figure 2: CSV060B 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... - Page 18 Figure 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...
- Page 19 Figure 4: CSV060B 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...
- Page 20 Figure 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...
- Page 21 Figure 6: CSV096/120B 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...
- Page 22 Figure 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...
- Page 23 Figure 8: CSV096/120B 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...
- Page 24 Figure 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...
- Page 25 Figure 10: CSV180B 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...
- Page 26 Figure 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...
- Page 27 Figure 12: CSV180B 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...
- Page 28 Figure 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...
- Page 29 Figure 14: CSV240B front return/rear discharge/LH water connection dimensional data C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
- Page 30 Figure 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...
- Page 31 Figure 16: CSV240B front return/rear discharge/RH water connection dimensional data C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
- Page 32 Figure 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...
- Page 33 Figure 18: CSV300B front return/rear discharge/LH water connection dimensional data C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
- Page 34 Figure 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...
- Page 35 Figure 20: CSV300B front return/rear discharge/RH water connection dimensional data C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
- Page 36 Figure 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...
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Page 37: Typical Service Clearances
Typical service clearances Figure 22: CSV060B service clearances 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...
- Page 39 Figure 24: CSV180B service clearances 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...
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Page 41: Ductwork
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. -
Page 42: Variable Frequency Drive (Vfd)
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. WARNING DISCONNECT AND LOCK OUT POWER WHEN SERVICING UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK. -
Page 43: Two Discrete Speeds
single stage thermostat on CSV060 or a two-stage thermostat on CSV096–300. If equipped, the factory hot gas bypass option is installed on refrigerant circuit #1. Two discrete speeds Indoor fan shall have two discrete speeds. High and Low indoor fan discrete speeds are achieved by means of VFD. -
Page 44: Electrical Wiring
Electrical wiring Follow local electrical codes when making electrical connections. Units are completely factory wired for normal supply voltages (e.g., 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 on the right-hand (left-hand for RH units) end of the evaporator/compressor section. -
Page 45: Unit Wiring Schematics
Unit wiring schematics Figure 29: CSV060B 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... - Page 46 Figure 30: CSV096B-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...
- Page 47 Figure 31: CSV180B units with 208–230V/3Ph/60Hz 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...
- Page 49 Figure 33: CSV300B units with 208–230V/3pH/60Hz C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
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Page 50: Typical Vfd Electrical Schematic
Typical VFD electrical 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... - Page 51 Figure 35: CSV120-180B & 300B units with 208–230V, 460V/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...
- Page 52 Figure 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...
- Page 53 Figure 37: Typical wiring diagrams for VFD options 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...
- Page 55 Figure 39: Dual 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...
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Page 56: Electrical Data
Electrical data Table 3: Standard evaporator motor electrical data Compressor Evaporator fan Max fuse/ Min. CCT. Model # Voltage CCT. bkr. ampacity CSV 060B2 208–230/3/60 16.0 110.0 1.00 23.10 CSV 060B4 460/3/60 52.0 1.00 11.25 CSV 060B5 575/3/60 38.9 1.00 8.33 CSV 096B2 208–230/3/60... -
Page 57: Fan Performance
Fan performance Table 5: CSV060B supply air blower performance Available external static pressure - inches W.C.* Supply RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied Standard drive + 1HP Optional hi-static + 1.5HP low static drive 1600... - Page 58 * Blower performance includes evaporator coil and 2" filters. Table 8: CSV180B supply air blower performance Available external static pressure - inches W.C. Supply RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied Standard drive + 3HP Optional hi-static + 3.5HP...
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Page 59: Motor And Pulley Data
Motor and pulley data Table 11: Evaporator - standard blower motor and drive data Motor Adjustable motor pulley Fixed motor pulley Model Drive range (RPM) Frame size Pitch diameter (inches) Pitch diameter (inches) CSV060B 745-1117 1.9–2.9 CSV096B 614-921 1.9–2.9 CSV120B 711-984 2.4–3.4 CSV180B... - Page 60 Figure 40: Belt tension adjustment Pounds force Cross section 1-1/2 2-1/2 3-1/2 6-1/2 5-1/2 C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual...
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Page 61: Waterside Pressure Drop Data
Waterside pressure drop data Figure 41: CSV180–300 standard units - manifolded condensers water pressure drop Figure 42: CSV060–120 standard units - manifolded condensers water pressure drop C-Series Vertical (CSV) Water-Cooled Self-Contained Units, B Generation, R-410A Installation, Operation, and Maintenance Manual... -
Page 62: Start-Up And Operation
Start-up and operation 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. -
Page 63: Checking Superheat And Subcooling
Checking superheat and subcooling R-410A temperature charts list the associated saturation temperature in one column and the associated pressure in another column. See Table 15. Subcooling When the refrigerant charge is correct, there is no vapor in the liquid sight glass with the system operating under full load conditions. -
Page 64: Superheat
Table 15: R-410A pressure and temperature chart PSIG Temp ˚F PSIG Temp ˚F Superheat Only check superheat after establishing the steady state operation of the unit, pulling down the discharge air temperature to within the control range, and running the unit in a fully loaded condition. -
Page 65: Operation
• Unit shall operate with conventional thermostat designs and have a low voltage terminal strip for easy hook-up. • Unit control board shall have on-board diagnostics and fault code display. • Standard controls shall include anti-short cycle and low voltage protection. •... -
Page 66: Low-Pressure Limit Switch
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. If 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. -
Page 67: Microprocessor Control Unit Flash Codes
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. -
Page 68: Maintenance/Service
Maintenance/service WARNING DISCONNECT AND LOCK OUT POWER WHEN SERVICING UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK. CAUTION Exercise care when working around the sharp metal edges of door panels, door frames, etc. These edges can cause injury. -
Page 69: Filters
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 “New” belts at the maximum value indicated. Used belts should be maintained at the minimum value. -
Page 70: R-410A Quick Reference Guide
• If system must be opened for service, evacuate system then break the vacuum with dry nitrogen and replace filter driers. © 2020 Johnson Controls. All rights reserved. Subject to change without notice. 100 JCI Way, York, Pennsylvania USA 17406-8469.
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