Model CSV
Vertical R-410A
Air Conditioning Units
Supersedes: 145.15-IOM7 (312)
Form 145.15-IOM7 (412)
MODEL CSV060B-240B
VERTICAL R-410A
WATER COOLED AIR CONDITIONING UNITS
INSTALLATION INSTRUCTIONS
B Style
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FORM 145.15-IOM7 (412)
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained in
this document is subject to change without notice.
While Johnson Controls makes no commitment to up-
date or provide current information automatically to the
manual owner, that information, if applicable, can be
obtained by contacting the nearest Johnson Controls
service office.
It is the responsibility of operating/service personnel as
to the applicability of these documents to the
equipment in question. If there is any question in the
mind of operating/service personnel as to the
applicability of these documents, then, prior to working
on the equipment, they should verify with the owner
whether the equipment has been modified and if
current literature is available.
TABLE OF CONTENTS
Safety Symbols………………………………………………………… 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
JOHNSON CONTROLS
3
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FORM 145.15-IOM7 (412)
GENERAL INFORMATION
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.
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.
DETERMINE THE ACTUAL CENTER OF
GRAVITY OF THE UNIT BY PERFORM-
ING A TEST LIFT. LIFTING AN UNBAL-
ANCED UNIT CAN CAUSE PERSONAL
INJURY OR EVEN DEATH.
The 5 ton unit utilizes a single compressor. All 8 ~ 20
ton models are dual compressor units with two
independent refrigerant circuits. All units come
standard with a microprocessor control board (refer to
‘Microprocessor’ section).
ONLY QUALIFIED PERSONNEL SHOULD
PERFORM INSTALLATION AND SERVICE
OF THIS EQUIPMENT.
INSTALLATION SITE
LOCK ALL ELECTRICAL POWER SUP-
PLY SWITCHES IN THE OFF POSITION
BEFORE INSTALLING THE UNIT. FAIL-
URE TO DISCONNECT POWER SUPPLY
MAY RESULT IN ELECTRICAL SHOCK
OR EVEN DEATH.
PRE-INSTALLATION INSPECTION OF EQUIPMENT
Location - To ensure unit operates at maximum
efficiencies, choose a dry indoor area where the
temperature is controlled between 50°F and 115°F.
Consideration of surrounding areas should be taken
when choosing a location to install the unit. Common
vibration and sound levels associated with commercial
equipment may be objectionable to people or
equipment.
All units are factory tested to ensure safe operation
and quality assembly. Units are packaged and sealed
on shipping skids and shipped in first class condition.
Torn and broken packaging, scratched or dented
panels should be reported to carrier immediately.
Internal inspection of all units should be performed
prior to installation. Remove all access doors and
check for visual defects that can occur during
transport. Any problems found internally should be
reported to carrier and manufacturer immediately.
Refrigerant circuit should be checked to ensure no
leaks have occurred during shipment. Install gauge
set to high and low pressure ports to confirm pressure
has been maintained and no leaks have occurred
during shipment. Repair any damage prior to
installation to ensure safe operation.
Failure to allow adequate space between
units may result in poor unit perfor-
mance 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.
Record any unit damage on the Bill of
Lading and report to carrier and factory
immediately. Shipping and handling
damages are not warranty items.
CSV Operating Weight
Operating
Weight (Lbs) Weight (Lbs)
Shipping
Unit
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.
CSV060B
CSV096B
CSV120B
CSV180B
CSV240B
590
795
635
835
955
995
1310
1465
1365
1525
4
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
UNIT MOUNTING
- Use appropriate tubing couplings and splice
previously cut refrigerant lines. Pressure test
refrigerant circuits with dry nitrogen (500 psig).
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.
- 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.
Duct flanges for evaporator return are incorporated
into the filter rack.
- Charge circuit(s) to the value indicated on the unit
nameplate.
Units should be secured on a solid, level pad or sturdy
stand. The use of an isolating rubber sheet is
recommended to reduce vibration and noise
transmission. Ensure that the entire base is
continuously supported - do not support unit at corner
points only! Unit may be pitched slightly to ensure
efficient drainage of condensate.
- 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.
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.
WATER PIPING
All factory installed water piping terminates inside the
unit. Multi-condenser units feature manifolded single
water in and out connections.
- Cut and remove sections of all liquid and suction
refrigerant lines. Make two cuts in each line,
approximately 6 inches above and below the
evaporator floor/condenser roof.
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.
Use a TUBING CUTTER ONLY - do
not use a hacksaw to cut refrigerant
tubing otherwise serious damage
can occur to refrigeration system!
It is recommended that flexible connectors be
provided on the water supply and return lines if noise
and vibration transmission could be a problem.
- Remove corner securing brackets from the
outside corners of the cabinet, at the joint line
between the evaporator and condenser sections.
Water piping should include shutoff / balancing valves
so that the unit can be serviced without shutting down
and draining the entire water supply circuit. Since
units are piped in parallel piping circuits, the shutoff
valves may be used to equalize the pressure drop to
each branch for even condenser water distribution. A
bibcock or a plugged tee fitting should be installed
between the shut-off valves and the unit in both the
inlet and outlet pipes. These connections are to
provide for acid cleaning of the condenser, if this
should become necessary.
- Remove the evaporator section.
ASSEMBLY OF SPLIT UNITS - (All models)
- Place the condenser section in the required
location.
- Carefully position the evaporator section atop the
condensing section. Align all sides, the evaporator
motor wire routing hole, and the refrigerant line
routing holes.
- Install the securing brackets at all four corners, on
the evaporator/condenser separation joint. Note
that one bracket, intended for use at the corner
with the +drain fitting, has a short "leg".
JOHNSON CONTROLS
5
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FORM 145.15-IOM7 (412)
CSV060 DIMENSIONAL DATA
6
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
CSV096-120 DIMENSIONAL DATA
JOHNSON CONTROLS
7
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FORM 145.15-IOM7 (412)
CSV180 DIMENSIONAL DATA
8
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
CSV240 DIMENSIONAL DATA
JOHNSON CONTROLS
9
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FORM 145.15-IOM7 (412)
DUCTWORK
When installing ductwork, adhere to local Codes and
sensible practice. Minimize duct runs and avoid abrupt
changes in direction where possible. Allow ample
access space for servicing of the coils and changing
of filters. Perform regular maintenance on ducts to
increase unit life, maintain efficient operation, and
reduce accumulation of explosive dust. Refer to
blower performance charts, and engineer duct runs
and accessory pressure drop so as not to exceed
maximum external static values.
-
-
Remove the panel attachments screws on the
blower outlet mounting panel. Do not remove
fasteners securing blowers to panel! The blowers
are to remain attached to the mounting panel at all
times.
Carefully remove the blower panel assembly from
the evaporator cabinet. Do not allow blower
housings to contact the evaporator coil during the
removal. On some models, the housing(s) will
have to be "rotated" to exit through the panel
opening.
Canvas or other types of flexible collars are
recommended for connecting the air ducts to the unit.
The supply air duct collar can be connected directly to
the blower outlet flanges. Return air may be ducted to
the unit, or drawn directly from the conditioned space
(with optional return air grille). If a ducted return is
desired, duct connection flanges may be secured
directly to the air intake opening – filters are
accessible from the right hand side.
-
Interchange the blower panel assembly with the
position of the alternate access panel. Exercise
care in locating the panel. Do not allow blower
housings to contact the evaporator coil. Install the
attachment screws and tighten securely.
-
-
-
Install the blank access panel into the remaining
evaporator opening. Fasten securely.
The Manufacturer will not accept any
liability resulting from incorrect instal-
lation of this equipment. Follow instal-
lation instructions carefully.
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.
EVAPORATOR BLOWER DISCHARGE
CONVERSION
In order to utilize the ‘rear vertical’ or ‘rear horizontal’
discharge, the upper fan module must be rotated.
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.
-
Disconnect power wiring at motor terminal box.
DISCONNECT AND LOCK OUT
POWER WHEN SERVICING UNIT.
FAILURE TO DO SO MAY RESULT IN
PERSONAL INJURY OR DEATH DUE
TO ELECTRICAL SHOCK.
The removable upper fan module that can be rotated
180°for top rear discharge applications (see below). In
addition, the blower outlet panel may be interchanged
with the front panel of the fan module. Interchanging
these two panels allows horizontal fan discharge to
either front or rear of the unit.
-
-
Remove corner connecting brackets which secure
the blower module to the lower evaporator unit.
Procedure for converting the fan discharge from
vertical to horizontal is similar on all models, single fan
or dual fan.
0
.
Carefully lift the blower module, and rotate 180
Reposition the blower module on top of the
evaporator/compressor unit. Reinstall the corner
connecting brackets.
-
Remove blower drive belt on all models with base
mounted motors. Remove the complete fan motor
and drive on models with blower mounted motor
assemblies.
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.
-
Remove the panel attachment screws on the
alternate location access panel (front blower
module panel). The front roof support angle must
be removed to allow access to the front panel.
Remove the panel and set aside.
10
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
ELECTRICAL WIRING
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.
Follow local electrical codes when making electrical
connections. Units are completely factory wired for
normal
supply
voltages
(ie.208-230,
460,
575V/3Ph/60Hz) Confirm unit specifications by
checking unit data plate. All electrical components are
accessible through an independent electrical panel
located 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.
All wiring must comply with applicable
local and national codes (NEC). Type
and location of disconnect switches
must comply with all applicable codes.
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 IN-
JURY OR DEATH DUE TO ELECTRICAL
SHOCK.
Unit requires installer to provide a 24volt thermostat
with appropriate heating and cooling stages as
needed. For low voltage wiring, 18 gauge wire may be
used for up to 50 feet lengths. Low voltage runs up to
125 feet require 16 gauge wire.
All models are designed for single zone cooling
applications, utilizing space or return air thermostatic
controls. A low voltage terminal block is provided for
hook-up
of
conventional
or
programmable
thermostats.
JOHNSON CONTROLS
11
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FORM 145.15-IOM7 (412)
TYPICAL WIRING SCHEMATIC
12
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
JOHNSON CONTROLS
13
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FORM 145.15-IOM7 (412)
14
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
JOHNSON CONTROLS
15
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FORM 145.15-IOM7 (412)
ELECTRICAL DATA
ELECTRICAL DATA - STANDARD EVAPORATOR MOTOR
EVAPORATOR
FAN
MAX FUSE /
CCT. BKR.
AMP
MIN. CCT.
AMPACITY
COMPRESSOR
VOLTAGE
MODEL #
QTY
RLA
LRA
HP
FLA
CSV060B2
CSV060B4
CSV060B5
CSV096B2
CSV096B4
CSV096B5
CSV120B2
CSV120B4
CSV120B5
CSV180B2
CSV180B4
CSV180B5
CSV240B2
CSV240B4
CSV240B5
208-230/3/60
460/3/60
1
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
16.0 110.0 1.00
3.1
23.10
11.25
8.33
35
15
15
45
20
15
50
25
20
80
40
25
110
60
40
1
1
2
2
2
2
2
2
2
2
2
2
2
2
7.8
5.7
52.0
38.9
1.00
1.00
1.50
1.50
1.50
1.5
1.2
4.5
2.2
1.8
5.8
2.9
2.3
8.5
4.2
3.4
14.0
6.6
5.3
575/3/60
208-230/3/60
460/3/60
13.1 83.1
33.98
15.93
11.70
41.80
20.45
15.13
60.70
29.40
21.18
81.73
44.18
32.75
6.1
4.4
41.0
33.0
575/3/60
208-230/3/60
460/3/60
16.0 110.0 2.00
7.8
5.7
52.0
38.9
2.00
2.00
575/3/60
208-230/3/60
460/3/60
23.2 164.0 3.00
11.2 75.0
7.9 54.0
3.00
3.00
575/3/60
208-230/3/60
460/3/60
30.1 225.0 5.00
16.7 114.0 5.00
575/3/60
12.2 80.0
5.00
ELECTRICAL DATA - OVERSIZED EVAPORATOR MOTOR
EVAPORATOR
FAN
MAX FUSE /
CCT. BKR.
AMP
MIN. CCT.
AMPACITY
COMPRESSOR
VOLTAGE
MODEL #
QTY
1
RLA
LRA
HP
FLA
4.5
2.2
1.8
CSV060B2
CSV060B4
CSV060B5
208-230/3/60
460/3/60
@
@
@
16.0 110.0 1.50
24.50
11.95
8.93
40
15
15
1
7.8
5.7
52.0
38.9
1.50
1.50
575/3/60
1
CSV096B2
CSV096B4
CSV096B5
CSV120B2
CSV120B4
CSV120B5
CSV180B2
CSV180B4
CSV180B5
CSV240B2
CSV240B4
CSV240B5
208-230/3/60
460/3/60
2
2
2
2
2
2
2
2
2
2
2
2
@
@
@
@
@
@
@
@
@
@
@
@
13.1 83.0
2.00
2.00
2.00
5.8
2.9
2.3
8.5
4.2
3.4
14.0
6.6
5.2
20.4
9.7
7.8
35.28
16.63
12.20
44.50
21.75
16.23
66.20
31.80
22.98
88.13
47.28
35.25
45
20
15
60
25
20
80
40
30
110
60
45
6.1
4.4
41.0
33.0
575/3/60
208-230/3/60
460/3/60
16.0 110.0 3.00
7.8
5.7
52.0
38.9
3.00
3.00
575/3/60
208-230/3/60
460/3/60
23.2 164.0 5.00
11.2 75.0
7.9 54.0
5.00
5.00
575/3/60
208-230/3/60
460/3/60
30.1 225.0 7.50
16.7 114.0 7.50
575/3/60
12.2 80.0
7.50
16
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
FAN PERFORMANCE
CSV060B
SUPPLY AIR BLOWER PERFORMANCE
AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹
0.8 1.0 1.2 1.4
SUPPLY
CFM
0.2
0.4
0.6
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Low Static
Standard Drive + 1 HP
Optional Hi-Static Drive + 1.5 HP
Drive
1600
1800
2000
2200
2400
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
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
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
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
~
~
~
~
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.
CSV096B
SUPPLY AIR BLOWER PERFORMANCE
AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹
0.8 1.0 1.2 1.4
SUPPLY
CFM
0.2
0.4
0.6
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Low Static
Standard Drive + 1.5 HP
Optional Hi-Static Drive + 2 HP
Drive
2400
2800
3200
3600
4000
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
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
~
~
~
~
~
~
~
~
599 0.62 675 0.79 745 0.98 815 1.18 875 1.38 927 1.58 985 1.78 1037 1.99
~
~
~
~
~
~
661 0.86 730 1.03 795 1.23 853 1.43 915 1.64 973 1.85
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.
CSV120B
SUPPLY AIR BLOWER PERFORMANCE
AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹
0.8 1.0 1.2 1.4
SUPPLY
CFM
0.2
0.4
0.6
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Low Static
Standard Drive + 2 HP
Optional Hi-Static Drive + 3 HP
Drive
3200
3600
4000
4400
4800
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
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
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
~
~
~
~
~
~
768 1.42 824 1.62 877 1.82 930 2.04 985 2.30 1035 2.60 1085 2.90
~
~
~
~
~
~
~
~
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.
JOHNSON CONTROLS
17
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FORM 145.15-IOM7 (412)
CSV180B
SUPPLY AIR BLOWER PERFORMANCE
AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹
0.8 1.0 1.2 1.4
SUPPLY
CFM
0.2
0.4
0.6
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Low Static
Standard Factory Drive + 3 HP
Optional Hi-Static Drive + 5 HP
Drive
4800
5400
6000
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
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
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
7200
832 2.90 880 3.20 927 3.48 972 3.76 1015 4.06 1057 4.34 1099 4.64 1139 4.96
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.
CSV240B
SUPPLY AIR BLOWER PERFORMANCE
AVAILABLE EXTERNAL STATIC PRESSURE - Inches W.C. ¹
0.8 1.0 1.2 1.4
SUPPLY
CFM
0.2
0.4
0.6
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Low Static Drive
Standard Factory Drive + 5 HP
Optional Hi-Static Drive +7.5HP
6400
7200
8000
8800
9600
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
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
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
949 4.94 970 5.12 1010 5.46 1049 5.82 1087 6.18 1125 6.52 1161 6.90 1197 7.26
~
~
~
~
~
~
~
~
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.
18
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
MOTOR AND PULLEY DATA
EVAPORATOR-STANDARD BLOWER MOTOR AND DRIVE DATA
Adjustable
Motor
Fixed
Belts
Motor Pulley
Blower Pulley
Drive
Range
(RPM)
Model
Pitch
Pitch
Dia.
Frame
Size
Eff.
(%)
Browning
Part No.
Browning
Dia.
HP
Rating/Size
(in)
(in)
Part No.
CSV060B
CSV096B
CSV120B
CSV180B
CSV240B
745-1117
614-921
711-984
724-925
848-1064
1
1.5
2
145
145
145
184
184
88.5
88.5
88.5
90.2
90.2
1.9-2.9
1.9-2.9
2.4-3.4
3.4-4.4
4.7-5.9
1VP34X7/8
1VP34X7/8
1VP40X7/8
1VP50X1 1/8
1VP60X1 1/8
4.7
5.7
6.4
8.7
9.7
AK49H
AK59H
AK66H
AK89H
BK100H
A29
AX35
AX37
AX39
BX60
3
5
EVAPORATOR-OVERSIZED BLOWER MOTOR AND DRIVE DATA
Adjustable
Motor
Fixed
Blower Pulley
Belts
Motor Pulley
Drive
Range
(RPM)
Model
Pitch
Pitch
Frame
Size
Eff.
(%)
Browning
Part No.
Browning
Part No.
Dia.
Dia.
HP
Rating/Size
(in)
(in)
CSV060B
CSV096B
CSV120B
CSV180B
CSV240B
897-1346
798-1105
875-1118
894-1122
1046-1287
1.5
2
145
145
184
184
213
88.5
88.5
90.2
90.2
90.2
1.9-2.9
2.4-3.4
3.4-4.4
4.7-5.9
5.2-6.4
1VP34X7/8
1VP40X7/8
3.9
5.7
AK41H
AK59H
AK74H
BK95H
BK90H
A28
AX36
AX36
BX40
BX57
3
1VP50X1 1/8
1VP60X1 1/8
1VP65X1 3/8
7.2
5
9.2
7.5
10.2
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
BLOWER SPEED ADJUSTMENT
The RPM of the supply air and condenser air blowers will depend on the required CFM, and the static resistances
of both the supply/discharge and the return/intake duct systems. With this information, the RPM for the blowers
can be determined from the blower performance tables. Adjustment of blower speed is accomplished as follows:
1) Loosen belt tension by moving motor towards the blower shaft via the adjustable mounting.
2) Loosen the setscrew in the adjustable motor pulley flange. Remove external key on pulleys 4 in. diameter and
larger.
3) Blower speed will increase when moveable flange is adjusted towards the fixed flange (closed). Blower speed
will decrease when the moveable flange is adjusted away from the fixed flange (opened). Pulleys are
adjustable only in half-turn increments. Do not open pulley more than five full turns for "4L" and "A" belts, or
six full turns for "B" belts.
4) Once the pulley has been opened/closed the appropriate number of turns, replace the external key and
tighten the adjustment setscrew. Proper torque is 110-130 in.-lbs.
5) Install drive belt and adjust motor mount to tension belt.
LD13547
BELT TENSION ADJUSTMENT
DEFLECTION FORCE VERSUS DRIVE BELT CROSS-SECTION
20
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
WATER PRESSURE DROP DATA
45
40
35
30
25
20
15
10
5
0
20
25
30
35
40
45
50
55
60
65
70
75
80
UNIT FLOW RATE (GPM)
CSV240
CSV180
40
35
30
25
20
15
10
5
0
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
UNIT FLOW RATE (GPM)
CSV120
CSV096
CSV060
JOHNSON CONTROLS
21
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FORM 145.15-IOM7 (412)
START-UP AND OPERATION
Start unit and check rotation of fans and compressors.
There is no negative impact on durability caused by
operating three phase Scroll compressors in the
reversed direction for a short period of time (under
one hour). However, after several minutes of
operation the compressors internal protector will trip.
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.
If opposite rotation is needed, disconnect and reverse
any two leads of the three phase supply. Reconnect
power.
Observe unit operation and check for
unusual noise or vibration.
Monitor the microprocessor board for any fault codes.
This will ensure proper unit operation. Verification of
proper compressor direction is made by observing
that suction pressure drops and discharge pressure
rises when the compressor is energized. Reverse
compressor rotation also results in an elevated sound
level as well as substantially reduced current draw.
The Air Conditioning section of this
equipment is charged with R-410A; a
hi-pressure refrigerant. Only qualified
technicians, using appropriately
pressure-rated test instruments,
should perform troubleshooting or
service on this equipment.
Pressure Switch Settings - All Models
High
600
450
Low
50
Cut Out (PSIG)
Cut In (PSIG)
75
Refrigerant Charge (LBS)
Circuit 1
Circuit 2
UNIT
CSV060B
CSV096B
CSV120B
CSV180B
CSV240B
5.25 (5 lbs 4 oz)
5.18 (5 lbs 3 oz)
6.12 (6 lbs 2 oz)
8.69 (8 lbs 11oz)
12.45 (12 lbs 7 oz)
-
5.30 (5 lbs 5 oz)
6.25 (6 lbs 4 oz)
9.12 (9 lbs 2 oz)
12.45 (12 lbs 7 oz)
22
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
MICROPROCESSOR CONTROLLER
When the room t-stat calls for cooling, the low-voltage
control circuit from “R” to “Y1”and “G” is completed.
The compressor and fan motor are energized. After
completing the specified fan on delay for cooling, the
microprocessor control will energize the blower motor.
The microprocessor control system is specifically
designed for single and dual stage systems. The
control system interfaces with a conventional type
thermostat.
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 cooling.
•
•
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 any of the following standard
safety devices trip and shut off compressor.
-
-
-
Loss-of-charge/Low-pressure switch
High-pressure switch
To be available, a compressor must not be locked-out
due to a high-pressure switch; low- pressure switch;
condensate overflow switch; and the anti-short cycle
delay (ASCD) must have elapsed.
Condensate Overflow protection switch
•
Unit shall operate with conventional thermostat
designs and have a low voltage terminal strip for
easy hook-up.
SAFETY SWITCHES
•
•
•
Unit control board shall have on-board diagnostics
and fault code display.
Each refrigerant system is monitored to ensure it does
not operate outside of its intended operating
parameters. Safety switches are handled as described
below. All system errors override minimum run times
for compressors.
Standard controls shall include anti-short cycle
and low voltage protection
Control board shall monitor each compressor and
refrigerant safety switch independently.
High-Pressure Limit Switch
•
•
Control board shall have random start feature
Control board shall retain last 5 fault codes in non
volatile memory which will not be lost in the event
of a power loss.
If
a
high-pressure limit switch opens, the
microprocessor control de-energizes the compressor,
initiates the ASCD, and stops the fan. If a call for
cooling or heating is still present at the conclusion of
the ASCD, the microprocessor control will re-energize
the compressor and unit fan.
OPERATION
For cooling the room t-stat energizes the low-voltage
circuit between “R” & “Y1”.
Should a high-pressure switch open three times within
two hours of operation, the microprocessor control will
permanently lock-out the compressor. The system
must be manually reset by de-energizing the 24 volt
power to unit, or turning the room t-stat to the “OFF”
position then back to cooling position. The
The call is passed to the unit microprocessor control,
which then determines whether the requested
operation is available and, if so, which components to
energize.
microprocessor control will flash
indicating a high-pressure lock-out.
a
fault code
CONTINUOUS BLOWER
Low-Pressure Limit Switch
By setting the room t-stat fan switch set to “ON”, the
supply air blower will operate continuously. With the
room t-stat fan switch set to “AUTO”, the blower is
energized whenever a cooling operation is requested.
The blower is energized after any specified delay
associated with the operation.
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.
When energized, the indoor blower has a minimum
run time of 30 seconds. Additionally, the indoor blower
has a delay of 10 seconds between operations.
Once the low-pressure switch has been proven
(closed during the 30-second monitoring period as
JOHNSON CONTROLS
23
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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-pressure switch opens for
greater than 5 seconds, the microprocessor control
board will de-energize the compressor, initiate the
ASCD, and stop the fan.
is utilized to prevent short cycling of the compressor.
Additionally, a minimum run time is imposed any time
a compressor is energized. The ASCD is initiated on
unit start-up and on any compressor reset or lockout.
Microprocessor Control Unit Flash Codes
If the call for cooling is still present at the conclusion
of the ASCD, the microprocessor control will re-
energize the compressor.
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.
Should a low-pressure switch fault three (3) times
within one (1) hour of operation, the microprocessor
control board will lock-out the compressor and flash a
fault code indicating a low-pressure lock-out.
Condensate Overflow Switch
A Condensate Overflow fault occurs when the
Condensate Overflow switch opens for more than two
line cycles. The compressor is shutdown regardless
of Minimum Run Time, ASCD is initiated, 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 Overflow Switch to protect against
condensate overflow.
Compressor Protection
In addition to the external pressure switches, the
compressor also has inherent (internal) protection. If
there is an abnormal temperature rise in
a
compressor, the internal protection will immediately
shut down the compressor. The microprocessor
control incorporates features to minimize compressor
wear and damage. An anti-short cycle delay (ASCD)
24
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
Current alarms or active restrictions are flashed on the
microprocessor control LED.
1. LAST ERROR – When this button is pressed and
released, it flashes the last five (5) flash codes on
the board’s LED. The most recent alarm is shown
first and the oldest alarm is shown last.
2. TEST RESET – When this button is pressed and
released, any anti-short cycle delays (ASCD) are
bypassed for one cycle. When pressed twice, any
active lockouts are reset.
3. COMM SETUP – If the board is to be networked
with other units, this button is used to set the
network address. Press the button once and it
scans the bus, then assigns itself the first
available address, (starts at 2). It then flashes that
address one time. Pressing the button twice
causes the control to flash the address.
FLASH CODES
Description
On Steady
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
11 Flashes
13 Flashes
14 Flashes
OFF
This is Control Failure
Control waiting ASCD (Anti-Short Cycle Delay) *
High Pressure Compressor 1 Lockout
High Pressure Compressor 2 Lockout
Low Pressure Compressor 1 Lockout
Low Pressure Compressor 2 Lockout
Condensate Overflow Switch Lockout
Compressor(s) locked out due to Economizer running (Free Cooling) *
Compressor Held Off due to Low Voltage
EEPROM Storage Failure
No Power or Control Failure
Note: Flash rates marked with * are NOT alarms.
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
MAINTENANCE / SERVICE
DRIVE BELT -
DISCONNECT AND LOCK OUT
POWER WHEN SERVICING UNIT.
FAILURE TO DO SO MAY RESULT IN
PERSONAL IN-JURY OR DEATH
DUE TO ELECTRICAL SHOCK.
Examine belt periodically for wear. Glazed areas on
the drive surfaces indicate overheating due to belt
slippage. Ideal tension is the lowest tension at which
the belt will not slip under peak load conditions. Over-
tensioning shortens belt and bearing life (see section
‘Blower Speed Adjustment’).
Exercise care when working around
the sharp metal edges of door panels
or door frames, etc. These edges can
cause injury.
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.
EVAPORATOR COIL
FILTERS -
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.
Inspect filters monthly and replace as necessary. Use
UL Class 2 rated filters. Factory supplied filters are
medium efficiency, extended surface pleated type.
Replacements should be of the same type, to
maintain optimum airflow performance. Filter sizes are
as follows:
REFRIGERANT CIRCUIT(S)-
The Air Conditioning section of this
equipment is charged with R-410A; a high
pressure refrigerant. Only qualified
technicians, using appropriately press-
ure rated test instruments, should
perform troubleshooting or service on
this equipment.
Filters
Qty/Size
CSV060B
CSV096B
CSV120B
2/20x16x2
6/14x20x2
6/14x20x2
With the unit operating, check and record the
compressor discharge and suction pressures. The
compressor running current should also be recorded.
A maintenance log of these readings can indicate if
the unit is operating within its normal limits. Abnormal
readings should be investigated, and the Cause
corrected.
2/16x20x2
4/16x25x2
CSV180B
CSV240B
6/20x25x2
BLOWER -
Inspect the evaporator blower at each regular service
interval. Clean blower wheel as needed. Bearings are
permanently sealed ball type, and do not require
lubrication. Check bearings for any signs of wear
(movement between inner and outer races). Ensure
bearing locking collars are secure to the shaft, and
that collar locking screw is properly set. Check that
the blower wheel is tight on the shaft, and that the hub
set
screws
are
properly
torqued.
26
JOHNSON CONTROLS
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FORM 145.15-IOM7 (412)
R-410A QUICK REFERENCE GUIDE
Refer to Installation Instructions for specific installation requirements.
•
R-410A Refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing
equipment and replacement components are designed to operate with R-410A.
•
•
•
•
R-410A Refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.
Recovery equipment must be rated for R-410A.
Do not use R-410A service equipment on R-22 systems. All hoses, gages, recovery cylinders,
charging cylinders and recovery equipment must be dedicated for use on R-410A systems only.
•
•
•
•
Manifold sets must be at least 700 psig high side, and 180 psig low side, with 550 psig retard.
All hoses must have a service pressure rating of 800 psig.
Leak detectors, must be designed to detect HFC refrigerants.
Systems must be charged with refrigerant. 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
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FORM 145.15-IOM7 (412)
Subject to change without notice. Printed in U.S.A.
Copyright© 2012 by Unitary Products Group. All rights reserved.
Form 145.15-IOM7 (412)
Engineered Systems
Products
P.O. Box 1592
York, PA
York
PA
Group
17405
17405
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