Model CPV120 Waterside Economizer Kit WATERSIDE ECONOMIZER KIT FOR MODEL CPV 120 WATER-COOLED AIR CONDITIONERS INSTALLATION INSTRUCTIONS

Transcription

1 Model CPV120 Waterside Economizer Kit Supersedes: IOM3 (708) Form IOM3 (908) WATERSIDE ECONOMIZER KIT FOR MODEL CPV 120 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.

2 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

3 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

4 TABLE OF CONTENTS Economizer Coil Installation 5 Economizer Piping & Valve Installation 7 Temperature Control Panel Installation 12 WSE Harnesss Connections 14 Sequence of Operation 16 Unit Schematic Diagram 17 4 JOHNSON CONTROLS

5 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. 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. Johnson Controls 5

6 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

7 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) 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. Johnson Controls 7

8 Remove threaded adapter - extend pipes using straight coupling Condenser water connections extended to outside of cabinet Factory-installed Condenser clamp rail Condenser clamp rail replaced w/ Temperature Control Panel LD13427 Mounting plate LD JOHNSON CONTROLS

9 Standard motor mounting position shown. See Instruction Sheet WSEK-INS-01 to change motor mounting orientation. LD13439 Johnson Controls 9

10 Piping Parts Supplied in DELUXE KIT Part # Qty Description CLR ELBOW - 1-3/8" LG RADIUS 90DEG CxC CST-9138LR 2 ELBOW -STREET LG RAD. 1-3/8" 90DEG CxF RSC COUPLING - ROLLED STOP 1-3/8" CPA-13814M 3 1-3/8 ODS X 1 1/4" MPT ADAPTER CPA-13814F 1 1-3/8 ODS X 1-1/4" FPT ADAPTER CPT COPPER TEE - 1-3/8" CxCxC CTH /8" COPPER TUBING - 1-3/8" HARD CTH /8" COPPER TUBING - 1-3/8" HARD CTH /8" COPPER TUBING - 1-3/8" HARD CTH /4" COPPER TUBING - 1-3/8" HARD CTH /4" COPPER TUBING - 1-3/8" HARD CTH /8" COPPER TUBING - 1-3/8" HARD CTH /2" COPPER TUBING - 1-3/8" HARD CTH " COPPER TUBING - 1-3/8" HARD LD JOHNSON CONTROLS

11 ASSEMBLY D ASSEMBLY C ASSEMBLY A ASSEMBLY B LD13441 Johnson Controls 11

12 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. 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). Temperature Control / Compressor Staging Panel 12 JOHNSON CONTROLS

13 Single & Dual 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 Main Electrical Panel WSE Control Harness Low Voltage Connection Section Main Electrical Panel Thermostat Cable Entrance Hole Free Harness Leads (Connect as indicated) LD13443 Johnson Controls 13

14 WATERSIDE ECONOMIZER HARNESS Temperature Control Panel to CVWC Unit Interconnection - STEP 1 - TYPICAL TWO COMPRESSORS UNIT - STEP 2 - TYPICAL TWO COMPRESSORS UNIT LD JOHNSON CONTROLS

15 LD13445 Johnson Controls 15

16 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 HEAT ST2 HEAT DIFF1 5 o F DIFF2 5 o F INTER 10 o F LD JOHNSON CONTROLS

17 LD13437 Johnson Controls 17

18 NOTES 18 JOHNSON CONTROLS

19 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 19

20 2008 by Johnson Controls, Inc P.O. Box 423, Milwaukee, WI Printed in USA IOM3 (908) Supercedes IOM3 (708)