IOM - CPV060 Waterside Economizer Kit

Model CPV060
Waterside Economizer Kit
Supersedes: 145.15-IOM2 (708)
Form 145.15-IOM2 (908)
WATERSIDE ECONOMIZER KIT
FOR MODEL CPV 060
WATER-COOLED
AIR CONDITIONERS
INSTALLATION INSTRUCTIONS
PRIOR TO INSTALLING OR SERVICING THE UNIT, LOCK ALL ELECTRICAL POWER SUPPLY
SWITCHES IN THE OFF POSTION. FAILURE TO DISCONNECT POWER SUPPLY MAY RESULT IN
ELECTRICAL SHOCK OR EVEN DEATH.
FORM 145.15-IOM2 (908)
IMPORTANT!
Read BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, oils,
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 responsibility 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
which it is situated, as well as severe 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 this document and any referenced materials.
This individual shall also be familiar with and comply with
all applicable governmental standards and regulations
pertaining to the task in question.
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.
CAUTION identifies a hazard which could
lead to damage to the machine, damage
to other equipment and/or environmental
pollution. Usually an instruction will
be given, together with a brief explanation.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
NOTE is used to highlight additional information which may be helpful to you.
All wiring must be in accordance with published specifications and must be performed only
by qualified service personnel. Johnson Controls will not be responsible for damages/problems
resulting from improper connections to the controls or application of improper control signals.
Failure to follow this will void the manufacturer’s warranty and cause serious damage to property or injury to persons.
2
JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
Changeability of this document
In complying with Johnson Controls policy for continuous product improvement, the information contained
in this document is subject to change without notice.
While Johnson Controls makes no commitment to update 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.
Work on this equipment should only be done by properly trained personnel who are qualified to
work on this type of equipment. Failure to comply with this requirement could expose the worker,
the equipment and the building and its inhabitants to the risk of injury or property damage.
The instructions are written assuming the individual who will perform this work is a fully trained
HVAC & R journeyman or equivalent, certified in refrigerant handling and recovery techniques, and
knowledgeable with regard to electrical lock out/tag out procedures. The individual performing
this work should be aware of and comply with all national, state and local safety and environmental regulations while carrying out this work. Before attempting to work on any equipment,
the individual should be thoroughly familiar with the equipment by reading and understanding
the associated service literature applicable to the equipment. If you do not have this literature,
you may obtain it by contacting a Johnson Controls Service Office.
Should there be any question concerning any aspect of the tasks outlined in this instruction,
please consult a Johnson Controls Service Office prior to attempting the work. Please be aware
that this information may be time sensitive and that Johnson Controls reserves the right to revise
this information at any time. Be certain you are working with the latest information.
Johnson Controls
3
FORM 145.15-IOM2 (908)
TABLE OF CONTENTS
Economizer Coil Installation
Economizer Piping & Valve Installation
Temperature Control Panel Installation
WSE Harnesss Connections
Sequence of Operation
Unit Schematic Diagram
4
6
7
12
13
17
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JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
This kit includes all necessary terminations and hardware, for installing the waterside economizer assembly
to late model water-cooled air conditioners (built after
Sept 1, 2005). The kit may also be installed to early
model units (built prior to Sept 1, 2005), with additional
field modification (field addition of some mounting and
wire routing holes is required).
COIL INSTALLATION
1) Position the drain pan using the notched flange of
the drain pan according to illustration. Make sure
the drain pan is level, do not force it. Push the
drain pan firmly against the unit; using self-drilling
screws, attach drain pan through the pre-punched
holes in the notched flange and support angles.
2) Pilot hole locations for attaching the economizer
coil are pre-punched in the vertical corner posts
of the unit; three holes on each side of the return
air opening. (Note: early model units require field
marking of hole locations – temporarily place the
coil in the drain pan, center the coil over the return
air opening, and mark the six fastening hole locations on the vertical coil flanges). Drill out the pilot
holes to 3/8” diameter.
3) Carefully lift the WSE coil and place it inside of the
drain pan, coil connections facing left side of the
unit (see illustration). Push the WSE Coil against
the Brackets; align holes on the WSE Coil flange
with mating holes on the vertical corner posts.
Johnson Controls
4) Slide provided bolts through the mounting holes on
the corner posts, and the WSE Coil flange. Insert
bolts,threaded end first, working from interior face
of corner posts (remove evaporator section service
panels foraccess).
5) Tighten the WSE Coil to the unit using provided
nuts and lock-washers.
6) Attach unit filter rack to entering air face of waterside economizer coil, using self-drilling screws.
Applies ONLY to DELUXE WSE KIT
7) After the unit piping has been completed, attach
Return Bends Cover and Header Cover using
provided selfdrilling screws.
Exercise care when working around the
sharp metal edges of door panels or
flanges. These
edges can be sharp, and can cause
injury.
5
FORM 145.15-IOM2 (908)
Attach Drain Pan
w/ Screws at 3 locations
along horizontal Flange
Economizer Coil
Drain Pan
Support Angles
Attach Drain Pan Support Angles
to Vertical Corner Posts on Unit
(3 Screws per Support Braacket)
6
JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
WATERSIDE ECONOMIZER PIPING AND VALVE INSTALLATION:
1) Refer to the accompanying illustrations for recommended piping and valve mounting layout. The
piping layout may be varied from that illustrated,
to suit on-site conditions or requirements, provided that the correct water flow arrangement is
maintained. The 3-way diverting valve ports are
marked ‘AB’, ‘A’, and ‘B’. Proper orientation of the
valve ports is critical for correct operation of the
economizer cycle. (NOTE: If additional clearance
between the valve actuator motor and the economizer piping, is required to facilitate mounting of
the valve with the ports in the correct orientation;
the actuator motor mounting plate may be rotated
to a different position). (See supplementary instruction sheet #WSEK-INS-01, packed with the
diverting valve.)
2) Wrought copper adapters are provided with the
kit to adapt the 3 X 1”NPT valve connections. The
balance of required fittings, and the straight tube
lengths, must be field provided provided unless
DELUXE Kit has been purchased (see piping
layout illustrations).
3) The copper adapters for the 3-way valve should be
first soldered to the short lengths of tubing (elbows)
connecting them to the adjacent fittings, before being threaded into the valve body (Do not install the
valve actuator until piping assembly is complete).
A low-temperature solder alloy should be used to
prevent annealing or out-of round distortion which
can occur with high temperature brazing. Use a
good quality pipe sealant on the threaded fittings,
and fully tighten the adapters into the brass valve
body (Torque should not exceed 75 ft-lb).
4) Assemble the tubing and fittings into the correct
arrangement as shown. Tack all tubes in place
before soldering to ensure proper fit-up.
5) It is recommended that the connection of the
economizer coil bypass pipe, to the CVWC condenser water inlet, be performed by cutting off the
factory installed threaded adapter, and extending
the inlet pipe to the outside of the cabinet by use of
a straight coupling. If desired, rather then using the
factory installed threaded adapter, the condenser
water outlet may also be extended to the outside
of the cabinet, in the same manner. (See accompanying photo and illustrations)
Johnson Controls
6) Pressure test the completed piping assembly with
nitrogen. Test pressure should at least equal the
working water supply pressure to the unit
Maximum pressure rating for the 3-way
diverting valve is 360 psig.
7) Locate the remote electronic temperature sensor (it
will be attached to the Temperature Control Panel
assembly). The sensor must be securely attached
to the surface of the incoming water supply line,
upstream of the 3-way valve (use wire ties, tape,
or gear clamps). The sensor leads will need to
be extended; the two sensor leads must be connected to the terminal strip on the Temperature
Control Panel. A wire routing hole is provided in
the condenser corner post of the unit (early model
units require field punching – use a wire protection
bushing).
8) Insulate all exposed water piping to prevent sweating; ensure that the water temperature sensor
location is well insulated. Insulation should cover
horizontal stub-outs on economizer coil; insulation
of the vertical coil headers is not required.
9) Install actuator motor to the 3-way diverting valve.
Before tightening the self-centering shaft adapter,
manually rotate the diverting valve stem to the fully
clockwise position. The actuator motor position
should be in the fully clockwise position; if not,
depress the gray ‘de-clutch’ button and rotate the
shaft adapter assembly against the fully CCW position stop. Slide the anti-rotation bracket forward to
engage the clip on the connection end of the actuator motor. Do not seat the anti-rotation bracket
at the end of the slot; allow sufficient end-play for
the motor to ‘float’ on the valve platform.
10) Remove the end cover from the valve, and connect three wire leads to the terminal strip. Lead
length must be sufficient to reach the terminal
strip of the ‘Temperature Control Panel’, previously
installed in the compressor compartment of the
unit. See Panel wiring diagram for proper terminal
connections.
11) DELUXE Kit ONLY: Assemble 3 Way Valve Box
according to illustration on page 7, then attach it
to the unit as illustrated.
7
FORM 145.15-IOM2 (908)
Remove threaded
adapter - extend pipes
using straight coupling
Factory-installed
Condenser clamp rail
Condenser water connections
extended to outside of cabinet
Condenser clamp rail replaced
w/ Temperature Control Panel
Mounting plate
LD13427
LD13428
8
JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
Standard motor mounting position shown.
See Instruction Sheet WSEK-INS-01 to
change motor mounting orientation.
LD13429
Johnson Controls
9
FORM 145.15-IOM2 (908)
Piping Parts Supplied in DELUXE KIT
Part #
CLR-118
CST-9138LR
RDC-11878
CPA-1181M
CPA-1181F
CPT-138
CTH-118
CTH-118
CTH-118
CTH-118
CTH-118
CTH-118
CTH-118
CTH-118
CTH-118
Qty
6
1
1
3
1
1
2-3/4"
4-1/2"
4-7/8"
5-1/4"
6-1/8"
7-1/2"
10-7/8"
21-1/4"
38"
Description
ELBOW - 1-1/8" LG RADIUS 90DEG CxC
ELBOW -STREET LG RAD. 1-3/8" 90DEG CxF
COUPLING - REDUCER 1-1/8"-7/8"
1-1/8 ODS X 1" MPT ADAPTER
1-1/8 ODS X 1" FPT ADAPTER
COPPER TEE - 1-3/8" CxCxC
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
COPPER TUBING - 1-1/8" HARD
LD13430
7
10
JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
ASSEMBLY D
ASSEMBLY C
ASSEMBLY A
ASSEMBLY B
LD13431
8
Johnson Controls
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FORM 145.15-IOM2 (908)
CONTROL PANEL INSTALLATION - WATERSIDE ECONOMIZER
Each Waterside Economizer is shipped with a pre-wired
Water Temperature Control / Compressor Staging Panel.
The panel is complete with a pre-terminated wiring harness, for connection to the low voltage control circuit of
the water-cooled unit. This kit includes all necessary
terminations and hardware, for installing the waterside
economizer assembly to late model water-cooled air
conditioners (built after Sept 1, 2005). The kit may also
be installed to early model units (built prior to Sept 1,
2005), with additional field modification (field addition of
some wire routing holes is required).
Installing Temperature Control Panel – Vertical Units:
1) The Temperature Control Panel fixture is intended
for mounting on the wide condenser clamp rail,
supplied with the economizer kit. (see photo’s).
Fasten the panel feet to the rail, using the provided
self-drilling screws.
2) Route the pre-terminated 4-wire harness towards
the back of the main electrical panel. The harness
wiring should be kept away from hot gas piping,
and the top of the compressor shell. Pass the wiring into the low voltage section of the main electrical panel, through the thermostat wire entrance
hole.) (See photo)
3) Remove the indicated existing wire(s) from the
low voltage section of the Unit Electrical Box. The
wire(s) to be removed are marked in Bold/Dashed
lines on the accompanying illustration (Step 1). The
wire(s) to be removed will be yellow in color.
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4) Feed the necessary harness wire(s) through the
routing holes in the voltage barrier (Review wire
termination tables for wire colors which must connect to TB2 - harness leads that connect with the
R1 relay need to pass through the voltage barrier).
Connect the harness leads to the units’ low voltage
terminal block (TB2), and R1 relay as indicated in
the accompanying illustration (Step 2). The harness wires are color coded for identification.
5) Secure the harness to the insulated condenser
water piping, or compressor suction piping, in the
condensing section of the unit, using wire ties.
Ensure that the harness is routed clear of hot
surfaces, sharp edges, or screw points.
6) Apply power to the unit, and observe for proper
operation of the temperature control, and correct
valve actuator rotation (valve position is fully CW
for full mechanical cooling operation, fully CCW
for economizer mode).
JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
Temperature Control / Compressor Staging Panel
Main Electrical Panel
WSE Control Harness
Low Voltage Connection Section – Main Electrical Panel
Waterside Economizer Harness
Connection Points
Single-Compressor Units
WSE Control Harness
Wire #
Color
Connection ID
1
WHITE
TB2-C
2
RED
TB2-R
3
YELLOW
TB2-Y1
4
BLUE
R1-5, -1
LD13432
Johnson Controls
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FORM 145.15-IOM2 (908)
WATERSIDE ECONOMIZER HARNESS – Temperature Control Panel to CVWC Unit Interconnection
- STEP 1 TYPICAL SINGLE COMPRESSOR UNIT
- STEP 2 -
Thermostat Cable
Entrance Hole
LD13433
Free Harness Leads
(Connect as indicated)
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JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
TYPICAL SINGLE COMPRESSOR UNIT
LD13434
Johnson Controls
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FORM 145.15-IOM2 (908)
LD13435
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JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
SEQUENCE OF OPERATION - Single & Dual Compressor Models
The economizer/unit control package is designed for
use with a conventional 24-Volt cooling thermostat. A
Honeywell T7079B Electronic Temperature control – with
remote sensor – is used to measure the temperature
of the cooling water supplied to the unit. The T7079B
will energize/de-energize its relay output stages as
dictated by the deviation of the measured water supply
temperature to the control set point. LED’s for ‘Stage1’
and ‘Stage2’ indicate the T7079B relay status. When
water temperatures are suitable for economizing, the
control circuit will engage a Honeywell N2024 actuator
motor; driving a 3-way diverting valve. The actuator
motor power supply is 24vac, connected to the motor
for 2-postion control logic.
The control set point for the economizing cycle is useradjustable. The recommended operating set point is
55°F. At the recommended economizer activation set
point of 55°F, the economizer coil capacity is equivalent
to the cooling output of the first mechanical compressor
stage. Entering Water Temperatures higher than this
value (i.e. 60°F) will provide only marginal cooling benefit
from the economizing coil – near continuous operation
of the compressor circuits may be required to maintain
desired space temperature.
‘Stage1’ Cooling: If the entering water temperature to
the unit is above the “Economizer Activation Thermostat”
(EAS) set point, the water valve relay (RV) remains
de-energized and full water flow is directed through the
refrigerant condensers. The first stage compressor will
be energized and remain in operation until Y1 is satisfied, or the EWT drops to a lower temperature. When
the EWT is below the set point of the EAS1 contacts
(i.e. 50°F) the ‘Economizer staging relay’ (R4) is energized, and the water valve relay (RV) drives the 3-way
valve to divert full flow through the economizer coil. The
switching of the economizer staging relay does not disable the first stage compressor; mechanical cooling is
maintained to ensure adequate cooling output to meet
space temperature conditions (Total unit capacity is
significantly increased, thereby reducing compressor
operating time).
‘Stage2’ Economizer Cooling: The first stage compressor will be locked out by the opening of the EAS2 (J5)
contacts when the EWT falls below the inter-stage differential temperature (EAS set point minus 10°F; factory
preset). When the EWT is at a temperature that results
in opening of the EAS2 contacts (typically 45°F), the
economizer cooling capacity will be capable of handling
the required unit load.
Second Stage Mechanical Cooling (two compressor
units only): On 2-compressor units, the 2nd compressor
stage (Y2) remains active and available at all times. This
allows back-up mechanical cooling capacity in the event
of a high peak-cooling load from the building core.
If the Economizer Activation Setpoint is
desired to be higher than 55°F, the interstage differential of the T7079 controller
should be adjusted. If the inter-stage
switching differential is not increased,
lock-out of the compressor will occur at
an EWT higher than that which will allow
the economizer coil alone to handle the
space cooling load (factory setting: EAS
set point minus 10°F). To adjust the interstage differential, remove the cover from
the T7079B, and locate the internal potentiometers for setting the stage differentials. Turn the ‘INTER’ potentiometer
clockwise to increase the differential.
The desired switching setpoint for the
second relay stage is 45°F. Adjustment
of the individual stage differentials is
not recommended (excessive valve /
compressor cycling may result).
T7079 FACTORY SETTINGS
ST1
ST2
DIFF1
DIFF2
INTER
HEAT
HEAT
o
5 F
o
5 F
o
10 F
LD13436
Johnson Controls
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FORM 145.15-IOM2 (908)
SCHEMATIC WIRING DIAGRAM
LD13437
18
JOHNSON CONTROLS
FORM 145.15-IOM2 (908)
LIMITED WARRANTY
Johnson Controls warrants this product to be free from defects in workmanship or material for a period of one year from date of original
installation or 18 months from date of shipment, whichever comes first.
Johnson Controls obligation under this Warranty is LIMITED to repairing or replacing at our sole option, at our factory, any part thereof
which shall be returned to our factory, transportation charges prepaid and which on examination proves to have been thus defective
under normal domestic use not exceeding the fuel rating. The defective part should be returned through a qualified servicing dealer.
Upon warranty determination, the replacement part will be shipped freight collect and assumes the unexpired portion of this Limited
Warranty.
When a defective part can be repaired or replaced, Johnson Controls shall not be obligated to repair the entire unit or any part thereof
other than the defective part.
This warranty applies only to the original homeowner, and is subject to the terms and conditions hereof.
COMPRESSOR – FIVE YEAR LIMITED WARRANTY
In addition to the One Year Limited Warranty, Johnson Controls warrants the compressor to be free from defects in workmanship or
material for a period of five (5) years from the date of original installation. If a compressor fails during this five year period, a new compressor will be supplied. The customer will be responsible for freight costs from our factory for delivery of the replacement compressor and also for the return of the defective compressor which may be required under the terms of the Warranty. Labor and any other
expense involved in replacing the compressor is not covered by this Warranty.
LABOR AND COST NOT COVERED
This Warranty provides only replacement parts or credits, and does not provide for or cover any labor, shipping, handling or other costs
for service travel, servicing, removing, or installing any parts.
This Warranty shall be void if:
EXCLUSIONS
1. The unit is not installed by a licensed or otherwise qualified or contractor and in compliance with the Installation Manual, applicable
installation and good trade practices.
2. The defect or damage is caused by accident, abuse, negligence of any person or company, misuse, riot, flood, fire or Acts of
God.
3. The unit is not operated and regularly serviced and maintained as called for in the Users’ Manual.
4. Damages are caused by operating the unit in a commercial or corrosive atmosphere containing any damaging or dangerous
chemicals.
5. The unit is modified or services in a manner not in accordance with the Installation Manual and Users’ Manual.
6. Components, replacement parts, or other accessories not compatible with the unit or not approved by Johnson Controls have
been used with or attached to the unit.
7. The defect or damage is not caused by Skymark, or it arises from circumstances beyond the control of Johnson Controls.
8. The unit is installed outside the United States or Canada, or has been removed from the place where it was originally installed.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, OBLIGATIONS OR LIABILITIES, EXPRESSED OR IMPLIED BY
EMPLOYEES OR REPRESENTATIVES OF JOHNSON CONTROLS. ALL STATUTORY, EXPRESSED OR IMPLIED WARRANTIES,
INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY
NEGATED AND EXCLUDED. ANY CLAIMS FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES, OR ANY OTHER DAMAGES
OR EXPENSES BEYOND THE TERMS OF THIS LIMITED WARRANTY ARE HEREBY EXPRESSLY NEGATED AND EXCLUDED.
Johnson Controls
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Subject to change without notice. Printed in U.S.A.
Copyright© 2008 by Unitary Products Group. All rights reserved.
Engineered Systems
Products
Group
Form 145.15-IOM2 (908)
Supersedes 145.15-IOM2 (708)
P.O. Box 1592
York, PA
17405
York
PA
17405