Envision NDS026 Series, NDS064 Series, NDS072 Series, NDS038 Series, NDS049 Series Installation Manual

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Page 1

Geothermal/Water Source Outdoor Split Heat Pump 2 to 6 Tons Dual Capacity

Installation Information

Water Piping Connections

Electrical Data

Startup Procedures

Troubleshooting

Preventive Maintenance

NDS Installation Manual

IM1004SN 03/11

Page 2

Page 3

Table of Contents

Model Nomenclature........................................................... 4

General Installation Information ................................................5-8

Water Quality ................................................................. 8

Water Piping.................................................................. 9

Electrical Data ................................................................10

Thermostat Wiring ............................................................10

Dimensional Data..............................................................11

Physical Data .................................................................11

Model Nomenclature - Air Handler ...............................................12

Coil Data - Air Handler .........................................................12

Physical Data - Air Handler .....................................................13

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Model Nomenclature - Coil .....................................................13

Refrigerant Coil Compatibility...................................................13

Wiring Schematics..........................................................14-17

Microprocessor Control .....................................................18-21

Operation Logic Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DIP Switch Settings........................................................... 22

Refrigeration ............................................................. 23-24

Line Set Sizes ................................................................ 24

Pressure/Temperature Conversion Chart for R-410A............................... 25

Operating Parameters......................................................... 26

Pressure Drop................................................................ 27

Compressor and Thermistor Resistance ......................................... 27

Refrigerant Circuit Guideline ................................................... 28

Heat of Extraction/Rejection Data .............................................. 28

Reference Calculations........................................................ 29

Legend ..................................................................... 29

Operating Limits .............................................................29

Startup and Troubleshooting................................................ 30-32

Preventative Maintenance ..................................................... 33

Replacement Procedures ......................................................33

Service Parts List ............................................................. 34

Page 4

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Model Nomenclature

1 2 3

D S

Model Type

N = Envision

Compressor Type

D = Dual Capacity

Cabinet Configuration

S = Outdoor Split

Unit Capacity 026

038 049 064 072

NOTE: *026-049 uses the FC1-GL and 060-072 uses the FC2-GL, the flow center is factory installed. If these flow centers do not meet the flow requirements, select A = None for digit 10.

4-6

0497A819010A11C

Coax Options

C = Copper N = Cupronickel

Flow Center

A = None B = Flow Center*

IntelliStart Options

0 = No IntelliStart 3 = IntelliStart

Voltage

1 = 208-230/60/1

Vintage

A = Current

Page 5

General Installation Information

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Safety Considerations

WARNING: Before performing service or maintenance operations on a system, turn off main power switches to both units. Turn off accessory heater power switch if applicable. Electrical shock could cause personal injury. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment.

Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply, such as the following safety measures:

• Follow all safety codes.

• Wear safety glasses and work gloves.

• Use a quenching cloth for brazing operations.

• Have a fire extinguisher available for all brazing operations.

Moving and Storage

Move units in the normal “up” orientation. Units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Do not attempt to move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage.

Condensate Drain

Follow the blower coil manufacturer’s instructions.

Duct System

All blower coil units/air coils must be installed as specified by the manufacturer’s installation instructions; however, the following recommendations should considered to minimize noise and service problems.

An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grill be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil.

In applications using galvanized metal ductwork, a flexible duct connector is recommended on both the supply and return air plenums to minimize vibration from the blower. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of 1-inch thick glass fiber or be constructed of ductboard. Insulation is usually not installed in the supply branch ducts. Ducts in unconditioned areas should be wrapped with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected. If the air handler is connected to existing ductwork, a previous check should have been made to assure that the duct system has the capacity to handle the air required for the unit application. If ducting is too small, as in replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repairs made accordingly. The duct systems and diffusers should be sized to handle the design airflow quietly. If air noise or excessive airflow is a problem, the blower speed can be changed to a lower speed to reduce airflow. This will reduce the performance of the unit slightly in heating; however, it will increase the temperature rise across the air coil. Airflow must still meet minimum requirements.

Split Unit Location

Locate the split compressor section away from areas that may disturb the customer and in a way that allows easy removal of the access panels and the top of the cabinet. Provide sufficient room to make water, electrical and refrigerant line connections and allow space for service personnel to perform maintenance. The NDS split is approved for outdoor installation when properly installed.

Air Coil Location

Refer to the air handler manufacturer’s instructions for the blower coil unit for details on installing the air handling portion of the system.

Equipment Selection

The following guidelines should be used when mating an Envision Split to an air handler/coil.

• Select R-410A components only.

• Match the air handler to the air handler coil data table.

• Indoor matching adjustable TXV is factory installed on every NAH air handler/coil. Fixed orifice or cap tube systems should not be used.

• Minimum of two (2) blower speeds

Utilizing Existing Coil or Air Handler

It is recommended that a new R-410A air handler be installed with an Envision Split considering the long term

Page 6

NDS OUTDOOR SPLIT INSTALLATION MANUAL

General Installation Information cont.

benefits of reliability, warranty, etc. versus the short term installation cost savings. However, the existing air handler may be retained provided the following:

• Coil currently is R-410A rated

• Coil uses a TXV. No capillary or fixed orifice systems should be used

• A life expectancy of more than 7 years remaining for the air handler and components

• Flush air coil and line set

When utilizing the existing air coil or line set, only flushing compounds that vaporize should be used; which means they are packaged in a pressurized disposable cylinder. It is preferable to use a flushing agent that removes oil, water, and acid, plus, is biodegradeable and non-toxic. The flushing agent should be safe to use with both HCFC and HFC refrigerants. Once a flushing agent has been selected, follow the instructions provided with the product.

The first step should be purging the lines or air coil with nitrogen. Purging with nitrogen first will remove some of the particulate and residual oil which will allow the flushing agent to work better. Never blow the flushing agent through a compressor, filter drier, or txv as it will cause the components to fail.

When flushing is complete and the final system is assembled, an acid check should be preformed on the system. Acid test kits are available from most HVACR distributors.

An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grille be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil.

Ensure that the line set size is appropriate to the capacity of the unit (refer to Line Set Sizes table). Line sets should be routed as directly as possible, avoiding unnecessary bends or turns. All wall penetrations should be sealed properly. Line set should not come into direct contact with water pipes, floor joists, wall studs, duct work, floors, walls and brick. Line set should not be suspended from joists or studs with a rigid wire or strap which comes into direct contact with the tubing. Wide hanger strips which conform to the shape of the tubing are recommended. Isolate hanger straps from line set insulation by using metal sleeves bent to conform to the shape of insulation. Line set insulation should be pliable, and should completely surround the refrigerant line.

NOTE: Improper installation of equipment may result in undesirable noise levels in the living areas.

Typical Split System Application Remote Blower Coil

Connection to Air Coil

Typical Split System Application - Remote Blower Coil and Typical Split System Heat Pump Coil Add-on Fossil Fuel Furnace illustrations show typical Envision Split installations. The Line Set Sizes table shows typical line set diameters and maximum length. Line sets over 60 feet are not recommended. If the line set is kinked or deformed and cannot be reformed, the bad section of pipe should be replaced. A restricted line set will affect unit performance. As in all R-410A equipment, a reversible liquid line filter drier is required to ensure all moisture is removed from the system. This drier should be replaced whenever “breaking into” the system for service. All line sets should be insulated with a minimum of 1/2” closed cell insulation. All exterior insulation should be painted with UV resistant paint or covering to ensure long insulation life.

Air Handler Installation

Air handlers used with dual capacity units must be capable of operating with a minimum of 2 blower speeds. Refer to the manufacturer’s instructions for the blower coil unit for details on installing the air handling portion of the system. All blower coil units/air coils must be installed as specified by the manufacturer’s installations instructions. However, the following recommendations should be considered to minimize noise and service problems.

Insulated

Suction Line

Lineset

To Air Handler

Condensate Drain (must be trapped)

Disconnect

Low

Voltage Wire

Remote Air Handler

(Maximum Recommended Distance is

60' Between Units)

Supply

Duct

Air

Handler

Return

Duct

Page 7

General Installation Information cont.

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Dual Fuel Systems

Envision units can be connected to fossil fuel furnaces that include an A-coil or slab coil. Dual fuel installations utilize the Envision heat pump for heating until the point that auxiliary heat is called for on the thermostat. At that point, the furnace will be enabled and the heat pump will be disabled. The Envision heat pump provides air conditioning through the furnace’s refrigerant coils.

Refer to the furnace manufacturer’s installation manual for the furnace installation, wiring and coil insertion. A WaterFurnace Dual Fuel thermostat or a field-installed DPST relay is required. See the Typical Split System Heat Pump Coil Add-on Fossil Fuel Furnace illustration for typical Dual Fuel application.

Typical Split System Heat Pump Coil Add-on Fossil Fuel Furnace

Disconnect

Insulated

Suction Line

In add-on Envision Split applications, the coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger. A high temperature limit should be installed upstream of the coil to de-energize the compressor whenever the furnace is operating. Without this switch, the Envision Split will trip out on high pressure. A dual fuel thermostat can remove the Y1 and Y2 calls when a W call is energized to allow gas furnace backup on an Envision Split application. Refer to the Thermostat Wiring section for details.

Supply Duct

"A" or

Slab Coil

Lineset To Air Handler

Wire From Furnace

Thermostat

Wire To

Thermostat

Return

Duct

Condensate

Drain

(must be trapped)

Up-Flow

Fossil Fuel

Furnace

Page 8

NDS OUTDOOR SPLIT INSTALLATION MANUAL

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mpp 5. naht sseLmpp 5. naht sseLmpp 5. naht sseLetafluS ainommA

Water Quality

In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period

with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Failure to adhere to the guidelines in the water quality table

could result in loss of warranty. of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils can likewise become scaled and possibly plugged. In areas

pH Acidity/Alkalinity 9 - 7 9 - 7 9 -7

Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm

Hydrogen Sulfide

Corrosion mpp 5. naht sseLmpp 5. naht sseLmpp 5. naht sseLedirolhC ainommA

LSI Index

Iron Fouling

(Biological Growth) Iron Oxide

Erosion Suspended Solids

Note:

Grains = PPM divided by 17 mg/l is equivalent to PPM

Bacterial Iron Potential

Less than .5 ppm (rotten egg smell

appears at 0.5 PPM)

0.5 to -.05

Less than 1 ppm. Above this level

deposition will occur.

Less than 10 ppm and filtered for max of

600 micron size

Units with cupronickel heat exchangers are recommended

for open loop applications due to the increased resistance

to build-up and corrosion, along with reduced wear caused

by acid cleaning.

0.5 to -.05

Less than 1 ppm. Above this level

deposition will occur.

Less than 10 ppm and filtered for max of

600 micron size

Less than 1 ppm. Above this level

Less than 10 ppm and filtered for max of

0.5 to -.05

deposition will occur.

600 micron size

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mpp 0051-0001mpp 0051-0001mpp 0001 naht sseL)SDT( sdiloS devlossiD latoT

mpp 2. < mpp 2. < mpp2. <

ces/tf 6<ces/tf 6 <ces/tf 6 < )retaW hserF( yticoleV dlohserhT

Page 9

Water Piping

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Residential NDS split units are supplied standard with GeoLink swivel connections with P.T. ports.

CAUTION: Water piping exposed to outside temperatures may be subject to freezing.

Water Piping

The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger.

Closed Loop - Earth coupled Systems (Outdoor Installations)

Locate unit on an air pad with access hole as shown below. When mounting on an existing concrete pad, holes must be bored through to accommodate 1 1/4-inch P.E. pipe with 1/2-inch insulation.

Connecting To Earth Loop

The earth loop trench should be continued directly under the unit as shown in the Typical Split System Outdoor Installation Using Closed Loop. Make the connections to optional fittings from the loop circulator pump(s) and ensure proper backfill to support the loop pipe during trench settling. All 1 1/4-inch piping should be insulated with a minimum of 1/2-inch closed cell insulation from below the ground surface to the loop circulator.

Flow Center Installation

Flow centers FC1-GL or FC2-GL, as needed, may be internally mounted on the NDS splits, Two stub tubes with barbs are pre connected to the coax. Two tubes with brass fittings, to adapt to the flow center, 2 hoses to connect between the two sets of tubes, and four hose clamps are included with each NDS unit. The brass adapter fittings have plastic swivel connectors that also accept 1 in. O.D. copper pipe (sweat).

NOTE: For ease of installation, attach provided hoses to coax first and then trim to fit to elbows on flow center.

Typical Split System Outdoor Installation Using Closed Loop

IMPORTANT: A freeze detection thermostat is installed in the unit to automatically start loop circulator pump if loop temperature drops below 20°F. Loop freeze detection should also be maintained to the lowest temperature the insulated loop may encounter in the case of power failure.

Open Loop (Indoor Installations)

NDS Splits can be installed on an open loop system, but only indoors. All NDS Splits are supplied with GeoLink swivel connectors. The swivel connectors will also accept a 1 in. O.D. copper pipe (sweat) which can be connected in an open loop system.

Loop Supply and Return Piping

Page 10

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Typical EZ Wiring Diagram

Electrical Data

General

Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. See unit electrical data for fuse or cicuit breaker sizing information.

Model

026

038

049

064

072

Rated

Voltage

208-230/60/1 197/253 16.0 10.2 52.0 18.0 5.4 15.6 17.0 25

208-230/60/1 197/253 26.0 16.6 82.0 29.0 5.4 22.0 23.4 40

208-230/60/1 197/253 33.0 21.1 96.0 34.0 5.4 26.5 2 7. 9 50

208-230/60/1 197/253 40.0 25.6 118.0 41.0 5.4 31.0 32.4 60

208-230/60/1 197/253 42.5 2 7.2 150.0 53.0 5.4 32.6 34.0 60

Rated voltage of 208-230/60/1. HACR circuit breaker in USA only. Min/Max voltage of 197/253. All fuses Class RK-5 * With optional IntelliStart

Thermostat Wiring

Air Handler

Common Common

24 VAC

Fan

Thermostat

Voltage

Min/Max

1st Stage Compressor

2nd Stage Compressor

Reversing Valve

Fault Signal

24 VAC

Compressor Ext

MCC RLA LRA LRA*

Thermostat Wiring for Dual Fuel Applications

Envision Split

Fossil Fuel

Furnace

Auxiliary Heat Relay

Loop

FLA

Thermostat

Common Common

24 VAC

Fan

Unit FLA

1st Stage Compressor

2nd Stage Compressor

Reversing Valve

Fault Signal

24 VAC

Total

Auxiliary

Heat Relay

Min

Circ

Amp

Max Fuse/ HACR

Envision Split

Shut

Down

1/17/11

Air Handler transformer must be at least 75 VA.

Note: Field installed DPST dual fuel relay

(Required for dual fuel installation) or use TP32U03 or TP32U04

Auxiliary Heat Relay

= chassis

Page 11

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Dimensional Data

Cabinet Dimensions and Refrigerant Piping Connections

Top View

Rear View

WATER OUT

WATER IN

Suction Line

Connection

Liquid Line

Connection

Front View

Lineset connections are braze type internally mounted

Side View

Model A B C D E F G H I J K L M

026 thru 072

Refer to Physical Dimensions and Piping Connections drawings

36.0 23.9 26.7 9.3 7.1 9.0 5.6 8.2 10.7 18.9 8.7 14.8 7.0

[cm] [91.4] [60.7] [67.8] [23.7] [18.0] [22.8] [14.2] [20.9] [27.2] [48.0] [22.1] [37.6] [17.8]

Physical Data

Model 026 038 049 064 072

Compressor (1 each) Dual Capacity Scroll Factory Charge R-410A, oz [kg] 52 [1.47] 56 [1.59] 90 [2.55] 92 [2.61] 104 [2.95]

Coax and Water Piping

Water Connections Size - Swivel- in [mm] GeoLink Swivel Connectors Brass Service Valve - Liquid Line - in [mm] 3/8 [9.525] 1/2 [12.7] Brass Service Valve - Suction Line - in [mm] 5/8 [15.875] 3/4 [19.05] 7/8 [22.2 25] Coax and Piping Water Volume - gal [l] 0.7 [2.6] 1.3 [4.9] 1.6 [6.1] 1 .6 [6.1] 1.6 [6.1] Weight - Operating, lb [kg] 189 [86] 236 [107] 250 [ 113] 271 [123] 290 [132] Weight - Packaged, lb [kg] 209 [95] 256 [116] 270 [122] 291 [132] 3 10 [141]

All units have TXV expansion devices, and 1/2 in. [12.2 mm] and 3/4 in. [19.1 mm] electrical knockouts. Brass service valves are sweat type valves.

10/29/08

Page 12

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Model Nomenclature - Air Handler

1-3 4-6 7 8-9 10 11 12

NAH 036 A 00 0 1 R

Model Type Air Coil

NAH = Envision Series Air Handler R = Refrigerant

Unit Capacity

Refrigerant Models Nom. CFM Motor

022 MBTUH 800 1 = ECM 208-230/60/1 026 MBTUH 925 030 MBTUH 980 036 MBTUH 1225 042 MBTUH 1425 048 MBTUH 1625 060 MBTUH 1760

Hydronic Models

026 MBTUH 925 036 MBTUH 1225 Electric Heat 048 MBTUH 1625 00 = No electric heat 060 MBTUH 1760 05 = 5 kW (available on 022-036 only)

Vintage 15 = 15 kW (available on 042-060 only) A = Current 20 = 20 kW (available on 060 only)

H = Hydronic

Disconnect

0 = No breaker installed (only on 5kW & 10kW heaters) 1 = Breaker installed (only on 15kW & 20kW heaters)

10 = 10 kW (available on 030-060 only)

NOTE: Kit NAHBC must be ordered to field convert the NAH042-060 to bottomflow air discharge.

Coil Data - Air Handler

Envision Split Model Matching Air Handler Coil Surface Area (ft2) FPI Rows Tube Diameter

022 - 038

042 - 072

NAH036 5.83 12 2 3/8 in.

NAH060 5.83 12 3 3/8 in.

Compatibilty Table - Air Handler

Air Handler

NAH022A***1R

NAH026A***1R

NAH030A***1R

NAH036A***1R

NAH042A***1R

NAH048A***1R

NAH060A***1R

Indoor Split Model

(Single)

NSZ022 - 800 5

- NDZ026 NDS026 925 5

NSZ030 - - 980 5, 10

NSZ036 - - 1225 5, 10

- NDZ038 NDS038 1225 5, 10

NSZ042 - - 1425 10, 15

NSZ048 - - 1625 10, 15

- NDZ049 NDS049 1625 10, 15

NSZ060 - - 1760 10, 15, 20

- NDZ064 NDS064 1760 10, 15, 20

NSZ070 - - 1760 10, 15, 20

- NDZ072 NDS072 1760 10, 15, 20

Indoor Split Model

(Dual Capacity)

Outdoor Split Model

(Dual Capacity)

Airﬂow(CFM) Electric Heat (kW)

6/9/08

Page 13

Physical Data - Air Handler

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Air Handler Model Number (Refrigerant)

Air Coil Total Face Area, ft2 [m2] Tube outside diameter - in. [mm]

Evaporator

Coil

Refrigerant R-410a Nominal cooling capacity - tons [kW] 1.8 [6.44] 2.1 [7.59] 2.5 [8.79] 3 [10.55] 3.5 [12.30] 4 [14.06] 5 [17.58] Condensate drain connection - (FPT) in. [mm] Blower Wheel Size (Dia x W), in. [mm] Blower motor type/speeds Blower motor output - hp [W] Filter Standard - 1" [51mm] MERV3 disposable, in. [mm] Electrical characteristics (60hz) Shipping weight - lbs. [kg] Operating weight - lbs. [kg]

Number of rows Fins per inch Suction line connection - in. [mm] sweat Liquid line connection - in. [mm] sweat

NAH022 NAH026 NAH030 NAH036 NAH042 NAH048 NAH060

5.83 [0.54] 3/8 [9.52]

2 3

5/8 [15.87] 7/8 [22.22]

3/8 [9.52]

3/4 [19.05]

11 x 10 [279 x 254]

ECM variable speed

1/2 [373] 1 [746]

20 x 24 [508 x 635]

208/230 - 1ph

215 [97.52] 220 [99.79]

195 [88.45] 200 [90.71]

Model Nomenclature - Coil

1-2 3

Model Type

NR = Envision Refrigerant Coil NH = Envision Hydronic Coil

Configuration Refrigerant Models

A = "A" Coil 026 MBTUH

Coil

5-7

026

Cabinet

C = Encased U = Uncased

Capacity

036 MBTUH 048 MBTUH 060 MBTUH

Hydronic Models

060 MBTUH

1/11/08

NOTE: All Refrigerant Coils include TXV.

Refrigerant Coil Compatibility

Encased/Uncased Coil

NRAC026* NSZ022 - 800 NRAC026* - NDZ026 NDS026 925 NRAC026* NSZ030 - - 980 NRAC036* NSZ036 - - 1225 NRAC036* - NDZ038 NDS038 1225 NRAC048* NSZ042 - - 1425 NRAC048* NSZ048 - - 1625 NRAC048* - NDZ049 NDS049 1625 NRAC060* NSZ060 - - 1760 NRAC060* - NDZ064 NDS064 1760 NRAC060* NSZ070 - - 1760 NRAC060* - NDZ072 NDS072 1760

Indoor Split Model

(Single)

Indoor Split Model

(Dual Capacity)

Outdoor Split Model

(Dual Capacity)

Recommended Airﬂow

(CFM)

7/14/08

Page 14

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Thermistor

Light Emitting Diode - Green

Relay Coil

Capacitor w/ Bleed Resistor

Switch-High Pressure

Switch-Low Pressure

Polarized Connector

Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal

Wire nut

Field wire lug

Ground

Fuse

CC - CR1 - CR2- CR3 - CR4 - F1 and F2 - FD - HP - LP - RV - SW1 - SW2 - SW3 -

Compressor Contactor

Loop Pump Relay1

Fuses Freeze Detection sensor High Pressure Switch Low Pressure Switch Reversing Valve Coil Not Used DIP Package 8 Position DIP Package 5 Position

Relay Contacts - N.O., N.C.

132

Loop Pump Relay2 Not Used

CS -

Compressor Solenoid

Not Used

Legend

1 - Connection of remote unit that does not have a loop pump for slave operation. 2 - 24V Accessory relay (see SW2 -3 for description of operation) 3 - Field installed DPDT dual fuel relay. (Required for dual fuel installation) 4 - DHW pump only in models with hot water generation option. 5 - Comfort Alert fault output to Premier Control Board 6 - This Switch allows the unit to down stage with the t-stat when OFF and finish on second stage when ON. Finish second stage reduces stage changing in recip dual capacity compressors and should be ON for unzoned Dual Cap E-Series or Premier 2 speed units.

Notes

Crankcase Heater

CA -

Comfort Alert

LED Flash Code Desc ription

Green S olid Module Has Power

Red Solid Y1 Present But Compressor Not Running

Code 1 Long Run Time Code 2 Sy stem Pressure Trip Code 3 Short Cyc ling Code 4 Locked Rotor Code 5 Open Circuit Code 6 Open Start Circuit Code 7 Open Run Circuit Code 8 W elded Contactor Code 9 Low Voltage

Yellow

Comfort Alert Status

Wiring Schematics

Dual Capacity Split - 208-230/60/1

Loop Pump(s)

Comfort

Alert

R C

1/2 HP 208-230/60/1

Pump

Recovery

Violet (3)

Heat

Unit

Pump

NOTE 1

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

Yellow (6)

Black (5)

White (4)

Violet (2)

Black (1)

CR1

CCHI

CC-GND P1

P2 Shut Down

SL1 In

SL1 Out

Not

Used

NOTE 2

Acc Com

Acc NC

Acc NO

1 2 3

Gray(9)

Yellow(8)

COM

CR2

1 2

2 3

3C 4

ECM2 Air Flow Settings

SW1

Blue

Unit Power

208-230/60/1

Red (11)

Crankcase Heater

Black Black

Fused L2

COM

Fused L2

NO NC

COM

CR3

NO NC

CR4

Black (7)

Comfort Alert

Run

Capacitor

Red (12)

Green/Yellow

F1-10A 240V

COM

Fused L1

Microprocessor

Logic Control (DC Voltage)

SW2

1 2 3 4 5 6 7 8 9

NOT USED

11 12

Test / Norm

Loop / Well

Fan / Comp

Not Used

Inputs / Norm

Outputs / Norm

8 Pulse L / Constant L

SW3

Dual/ Single Capacity

1 2

3 4 5

Normal/Finish on 2 No RPM / RPM Must be On Envision / E Series or Premier

NOTE 6

Tan (16)

240V L2

Orange (14)

Red Black

L2 L1

Brown (15)

240V L1

3 8

DC SOL

Comfort A lert

F1-10A 240V

Tan

Orange

Not Used

Yellow

Blue

Black

NOTE 5

NOT USED

Status LED PCB

SW4

LED Normal Display Mode

Field Selection Dips - #1 On, #6 On, #7 On Not Used

Drain

FD thermistor (loop<15°F,well<30°F) Lockout

Water Flow

High Pressure

High Press

Low Pressure / Comfort Alert

Low Press/CA

Not Used

Air Flow

Microprocessor malfunction*

Status

Not Used

DHW Limit

Not Used

DHW off

*Green LED not flashing

Current Fault Status

#1 Off, #6 On, #7 On Not Used FD thermistor (loop<15°F, well<30°F) High Pressure Low Pressure / Comfort Alert Not Used Not Used Not Used Not Used

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1 Y2

O Not Used Not Used

SL1 SL2

Outputs

#6 On, #7 Off Lo Capacity Compressor Hi Capacity Compressor

RV FAN

Not Used Loop Pump 1 Loop Pump 2

Outpu ts2

#6 Off, #7 Off

Not Used Not Used Not Used Not Used Not Used Not Used Not Used

Not UsedNot UsedNot Used

Page 15

Wiring Schematics cont.

Dual Capacity Split - 208-230/60/1 cont.

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Notes

Legend

Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal

Wire nut

Field wire lug

Ground

Relay Contacts N.O., N.C.

Fuse

CA CS CC CR1 CR2CR3 CR4 F1 and F2 FD HP LP RV SW1 SW2 SW3 -

Comfort Alert Compressor Solenoid Compressor Contactor Not Used Loop Pump Relay1 Loop Pump Relay2 Not Used Fuses Freeze Detection sensor High Pressure Switch Low Pressure Switch Reversing Valve Coil Not Used DIP Package 8 Position DIP Package 5 Position

Crankcase Heater

Thermistor

Light Emitting Diode - Green

Relay Coil

Capacitor w/ Bleed Resistor

Switch-High Pressure

Switch-Low Pressure

132

Polarized Connector

240V - L1

CR1- DHW

Pump

CC-GND

CCLO CCHI

1 2 3 4 5 6 7 8

1 2 3

R C Y1 Y2 GOW L

Logic Board - Physical Layout

240V - L1

N.O.

Fused L1

N.O.

CR2- Loop Pump

Fused L2

CR3-

N.C. N.O.

Microprocessor

SW1

SW2

OnOff

C C R R

LED Flash Code Desc ription

Green S olid Module Has Power

Red Solid Y1 Present But Compressor Not Running

Yellow

OnOff

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8

3 4 5P26 71

Shut

C C

Down

Comfort Alert

Physical Layout

POWER

Data Port

DC Sol

ALERT

TRIP

Comfort Alert Status

Fused L2

Com

SL1INSL1

SW3

Fused L2

240V - L2

N.O.

Com

CR4-

Out

8 9

10 11 12 13 14

1 2 3

ACCNOACCNCACC

1 2

4 5 6

COM

OnOff

1 2 3 4 5

SL2INSL2

Out

97P788-01 4/19/10

Page 16

NDS OUTDOOR SPLIT INSTALLATION MANUAL

1 2 3

Thermistor

Light Emitting Diode-Green

Relay Coil

Capacitor w/ Bleed Resistor

Switch - High Pressure

Switch - Low Pressure

Polarized Connector

Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal

Wire nut

Field wire lug

Ground

Fuse

CC - CR1 - CR2- CR3 - CR4 - F1 and F2 - FP -

HP - LP - RV - SW1 - SW2 - SW3 -

Compressor Contactor

Loop Pump Relay 1

Fuses Freeze Detection sensor High Pressure Switch Low Pressure Switch Reversing Valve Coil Not Used DIP Package 8 Position DIP Package 5 Position

Relay Contacts - N.O., N.C.

132

Loop Pump Relay 2 Not Used

CS -

Compressor Solenoid

Not Used

Legend

Crankcase Heater

CA - Comfort Alert

Notes

Run Winding

Active

Start

Common

IntelliStart

PB2

Red

Blue

Pink

Black

LED Flash Code Desc ription

Green Solid Module Has Power

Red Solid Y1 Present But Compressor Not Running

Code 1 Long Run Time Code 2 Sys tem Pressure Trip Code 3 Short Cyc ling Code 4 Locked Rotor Code 5 Open Circuit Code 6 Open Start Circuit Code 7 Open Run Circuit Code 8 Welded Contactor Code 9 Low Voltage

Yellow

Comfort Alert Status

Wiring Schematics cont.

Dual Capacity Split with IntelliStart - 208-230/60/1

Loop Pump(s)

Comfort

Alert

R C

Violet (3)

1/2 HP 208-230/60/1

Pump

Heat

Recovery

Unit

Yellow (6)

NOTE

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

Pump

Black (5)

White (4)

Violet (2)

Black (1)

CR1

CCHI

CC-GND P1

P2 Shut Down

SL1 In

SL1 Out

Not

Used

NOTE 2

Acc Com

Acc NC

Acc NO

1 2 3

Gray(9)

Yellow(8)

SW1

CR2

ECM 2 Air Flow Settings

COM

SW2

1 2 3 4 5 6 7 8 9

NOT USED

11 12

COM

1 2

2 3

3C 4

Fused L2

NO NC

CR3

Red (11)

Fused L2

COM

Microprocessor

Logic Control (DC Voltage)

Test / Norm

Loop / Well

Fan / Comp

Not Used

Inputs / Norm

Outputs / Norm

8 Pulse L / Constant L

Unit Power

208-230/60/1

Crankcase Heater

Black B lack

NO NC

CR4

Black (7)

SW3

Dual/ Single Capacity

Normal/Finish on 2

No RPM / RPM

Must be On

Envision / E Series or Premier

Blue

Comfort Alert

Run

Capacitor

Red (12)

Green/Yellow

F1-10A 240V

COM

NOTE 6

240V L2

Fused L1

Tan (16)

Orange (14)

L2 L1

Brown (15)

240V L1

3 8

Black

DC SOL

Red

F1-10A 240V

NOT USED

NOTE 5

Tan

Orange

Not Used

Yellow

Blue

Black

Comfort A lert

Status LED PCB

SW4

LED Normal Display Mode

Field Selection Dips -#1 On, #6 On, #7 On

Drain

Not Used

Water Flow

FD thermistor (loop<15°F,well<30°F) Lockout

High Press

High Pressure

Low Press/CA

Low Pressure / Comfort Alert

Air Flow

Not Used

Status

Microprocessor malfunction*

DHW Limit

Not Used

DHW off

Not Used

*Green LED not flashing

Current Fault Status

#1 Off, #6 On, #7 On Not Used FD thermistor (loop<15°F, well<30°F) High Pressure Low Pressure / Comfort Alert Not Used Not Used Not Used Not Used

Diagnostic Modes

Inpu ts

#6 Off, #7 On

Y1 Y2

O Not Used Not Used

SL1 SL2

Outpu ts

#6 On, #7 Off

Lo Capacity Compressor

Hi Capacity Compressor

FAN

Not Used Loop Pump 1 Loop Pump 2

Outpu ts2

#6 Off, #7 Off

Not Used Not Used

Not Used Not Used Not Used Not Used Not Used

Not UsedNot UsedNot Used

Page 17

Wiring Schematics cont.

Dual Capacity Split with IntelliStart - 208-230/60/1 cont.

NDS OUTDOOR SPLIT INSTALLATION MANUAL

PB2

Pink

Blue

Black

Red

Run Winding

Active

Start

Common

Legend

Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal

Wire nut

Field wire lug

Ground

Relay Contacts N.O., N.C.

Fuse

CA - Comfort Alert CS CC CR1 CR2CR3 CR4 F1 and F2 FP -

HP LP RV SW1 SW2 SW3 -

Compressor Solenoid Compressor Contactor Not Used Loop Pump Relay 1

Loop Pump Relay 2 Not Used Fuses Freeze Detection sensor High Pressure Switch Low Pressure Switch Reversing Valve Coil Not Used DIP Package 8 Position DIP Package 5 Position

Crankcase Heater

Thermistor

Light Emitting Diode-Green

Relay Coil

Capacitor w/ Bleed Resistor

Switch - High Pressure

Switch - Low Pressure

132

Polarized Connector

IntelliStart

240V - L1

CR1- DHW

Pump

CC-GND

CCLO CCHI

1 2 3 4 5 6 7 8

1 2 3

R C Y1 Y2 GOW L

Logic Board - Physical Layout

240V - L1

N.O.

Fused L1

N.O.

CR2- Loop Pump

Fused L2

CR3-

N.C. N.O.

Microprocessor

SW1

SW2

OnOff

C C R R

LED Flash Code Desc ription

Green Solid Module Has Power

Red Solid Y1 Present But Compressor Not Running

Yellow

OnOff

1 2 3 4 5 6 7 8 9 10 11 12

Code 1 Long Run Time Code 2 Sys tem Pressure Trip Code 3 Short Cyc ling Code 4 Locked Rotor Code 5 Open Circuit Code 6 Open Start Circuit Code 7 Open Run Circuit Code 8 Welded Contactor Code 9 Low Voltage

1 2 3 4 5 6 7 8

3 4 5P26 71

Shut

SL1INSL1

C C

Down

Comfort Alert

Physical Layout

POWER

Data Port

DC Sol

ALERT

TRIP

Comfort Alert Status

240V - L2

Fused L2

240V - L2

N.O.

Com

CR4-

Out

8 9

10 11 12 13 14

1 2 3

ACCNOACCNCACC

1 2

4 5 6

COM

SW3

OnOff

1 2 3 4 5

SL2INSL2

Out

Notes

97P788-02 4/19/10

Page 18

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Microprocessor Control

Startup

The unit will not operate until all the inputs and safety controls are checked for normal conditions. At first powerup, a four-minute delay is employed before the compressor is energized.

Component Sequencing Delays

Components are sequenced and delayed for optimum space conditioning performance.

Accessory Relay

An accessory relay on the control board allows for field connection of solenoid valves, electronic air cleaners, etc. The accessory relay has a normally open output and a normally closed output.

Short Cycle Protection

The control employs a minimum “off” time of four minutes to provide for short cycle protection of the compressor.

Shutdown Mode

A 24VAC common signal to the “shutdown” input on the control board puts the unit into shutdown mode. Compressor and blower operation are suspended.

Heating Operation

Heat, 1st Stage (Y1)

The blower motor is started on low speed immediately (PSC ON), the loop pump is energized 5 seconds after the “Y1” input is received, and the compressor is energized on low capacity 10 seconds after the “Y1” input. The blower is switched to medium speed 15 seconds after “Y1” input (ECM only).

Heat, 2nd Stage (Y1,Y2) Dual Capacity Units

The Comfort Alert will delay the second stage compressor until 5 seconds after it receives a “Y2” from the board.

Heat, 3rd Stage (Y1,Y2,W) Dual Capacity Units

The 1st stage of resistance heat is energized 10 seconds after “W” input, and with continuous 3rd stage demand, the additional stages of resistance heat engage 90 seconds after the first stage.

Safety Controls

The Envision control receives separate signals for a high pressure switch for safety, a low pressure switch to prevent loss of charge damage, and a low suction temperature thermistor for freeze detection. Upon a continuous 30-second measurement of the fault (immediate for high pressure), compressor operation is suspended, the appropriate lockout LED begins flashing. (Refer to the “Fault Retry” section below.)

Testing

The Envision control allows service personnel to shorten most timing delays for faster diagnostics. (Refer to the Field Selection DIP switch table.)

Fault Retry

All faults are retried twice before finally locking the unit out. An output signal is made available for a fault LED at the thermostat. The “fault retry” feature is designed to prevent nuisance service calls.

Diagnostics

The Envision control board allows all inputs and outputs to be displayed on the LEDs for fast and simple control board diagnosis. (Refer to the Field Selection DIP Switch SW2-1 table.)

Emergency Heat (W only)

The blower is started on high speed, and the first stage of resistance heat is energized 10 seconds after the “W” input. Continuing demand will engage the additional stages of resistance heat 90 seconds after the first stage.

Cooling Operation

In all cooling operations, the reversing valve directly tracks the “O” input. Thus, anytime the “O” input is present, the reversing valve will be energized.

Cool, 1st Stage (Y1,O)

The blower motor is started immediately, the loop pump(s) is energized 5 seconds after the “Y1” input is received. The compressor will be energized (on low capacity for Dual Capacity units) 10 seconds after the “Y1” input. The ECM blower will shift from low to medium speed 15 seconds after the “Y1” input (85% of medium speed if in dehumidification mode).

Cool, 2nd Stage (Y1, Y2, O) Single Speed Units

The blower changes to high speed (85% of high speed if in dehumidification mode) 15 seconds after the “Y2” input (ECM only).

Page 19

Microprocessor Control cont.

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Cool, 2nd Stage (Y1, Y2, O) Dual Capacity Units

The second stage compressor will be activated 5 seconds after receiving a “Y2” input as long as the minimum first stage compressor run time of 1 minute has expired. The ECM blower changes to high speed 15 seconds after the “Y2” input (85% of high speed if in dehumidification mode). The Comfort Alert will delay the second stage compressor until 5 seconds after it receives a “Y2” from the board.

Blower (G only)

The blower starts on low speed (PSC ON). Regardless of blower input “G” from thermostat, the blower will remain on low speed for 30 seconds at the end of each heating, cooling or emergency heat cycle.

Lockout Conditions

During lockout mode, the appropriate unit and thermostat lockout LEDs will illuminate. The compressor, loop pump, and accessory outputs are de-energized. The blower will continue to run on low speed. If the thermostat calls for heating, emergency heat operation will occur.

Comfort Alert lockouts cannot be reset at the thermostat. All other lockout modes can be reset at the thermostat after turning the unit off, then on, which restores normal operation but keeps the unit lockout LED illuminated. Interruption of power to the unit will reset a lockout without a waiting period and clear all lockout LEDs.

High Pressure

This lockout mode occurs when the normally closed safety switch is opened momentarily (set at 600 PSI).

Low Pressure

This lockout mode occurs when the normally closed low pressure switch is opened for 30 continuous seconds (set at 40 PSI). A low pressure fault may also be indicated when a Comfort Alert lockout has occurred.

Freeze Detection (Water Flow)

This lockout mode occurs when the freeze detection thermistor temperature is at or below the selected point (well 30°F or loop 15°F) for 30 continuous seconds.

Page 20

NDS OUTDOOR SPLIT INSTALLATION MANUAL

* Reset ALERT flash code by removing 24 VAC power from module.

Microprocessor Control cont.

Compressor Monitoring/Comfort Alert

The Comfort Alert displays abnormal compressor conditions through a unique flash code and communicates the conditions to the heat pump microprocessor control. The heat pump microprocessor will determine which fault to act on and ignore. Fault codes 2 (system pressure), 4 (locked rotor), 6 (open start circuit), and 7 (open run circuit) will result in a lockout. All other fault codes are

passive. All compressor alerts are displayed on the module by flashing the yellow Alert LED a specific number of times consecutively followed by a pause, and then repeated. The number of consecutive flashes or “Flash Code” correlates to a specific abnormal condition. The red “TRIP” LED means there is a thermostat demand signal “Y” present but the compressor is not running. The green “POWER” LED means the module has power.

Green "POWER" LED - module has power Red "TRIP" LED - Thermostat "Y" demand signal is present, but the compressor is not running.

Comfort Alert Flash Codes

Yellow "ALERT" LED LED Description Cause

Flash Code 1 Long Run Time Not applicable Flash Code 2 System Pressure Trip Not applicable Flash Code 3 Short Cycling Compressor run time of less than 3 minutes on 4 consecutive cycles Flash Code 4 Locked Rotor Four consecutive compressor protector trips indicating compressor won't start Flash Code 5 Open Circuit "Y" thermostat demand signal with no compressor current Flash Code 6 Open Start Circuit "Y" thermostat demand signal with no current in the start circuit Flash Code 7 Open Run Circuit "Y" thermostat demand signal with no current in the run circuit Flash Code 8 Welded Contactor Current detected with no "Y" thermostat demand signal present Flash Code 9 Low Voltage Less than 17 VAC detected in control circuit

* Flash code number corresponds to a number of LED flashes, followed by a pause and then repeated.

* TRIP and ALERT LEDs flashing at the same time indicates control circuit voltage is too low for operation.

* Reset ALERT flash code by removing 24 VAC power from module.

* Last ALERT flash code is displayed for 1 minute after module is powered on.

Resetting Comfort Alert Codes

Alert codes can be reset manually by cycling power off and on to the Comfort Alert module. Alert codes will reset automatically if conditions return to normal.

Flash Code Number LED Description Automatic Reset of Alert Codes

Flash Code 1 Long Run Time Not applicable Flash Code 2 System Pressure Trip Not applicable Flash Code 3 Short Cycling Four "alert free" on and off cycles to reset automatically Flash Code 4 Locked Rotor Four "alert free" on and off cycles to reset automatically Flash Code 5 Open Circuit One "alert free" on and off cycles to reset automatically Flash Code 6 Open Start Circuit One "alert free" on and off cycles to reset automatically Flash Code 7 Open Run Circuit One "alert free" on and off cycles to reset automatically Flash Code 8 Welded Contactor One "alert free" on and off cycles to reset automatically Flash Code 9 Low Voltage Resets when voltage rises above 19 VAC

Page 21

Microprocessor Control cont.

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Thermostat Displays

Fault Flash

When using a TA32W02 or TP32W03 thermostat and SW2-8 is in the pulsing “L” position, FaultFlash will enable a user to view the thermostat and count the fault indicator flashes to determine the lockout condition the unit is experiencing.

user to view the thermostat and determine the fault. The thermostat can be configured to show either lockout text or lockout codes.

The LED board on the front of the unit will display all lockouts. The Low Pressure LED will flash for a low pressure condition or a Comfort Alert fault. If the low pressure lockout was caused by Comfort Alert codes 4, 6 or 7, then the Comfort Alert will be flashing. If no Comfort Alert code

ComforTalk

is visible, then it is a low pressure lockout. When using a TP32U03, 04 or 05 thermostat and SW2-8 is in the pulsing “L” position, ComforTalk will enable the

The following tables show the codes that will be displayed on the different ComforTalk and FaultFlash thermostats.

FaultFlash Thermostats ComforTalk Thermostats

TA32W02 and TP32W03 Thermostats TP32U03, TP32U04 and TP32U05 Thermostats

Thermostat Display

Lockout Code

Lockout Description Lockout Description

2 Flashes High Pressure Fault "High Pressure" or "E2" High Pressure Fault 3 Flashes Low Pressure Fault "Low Pressure" or "E3" Low Pressure Fault 4 Flashes Not Applicable "E4" Not Applicable 5 Flashes Water Flow Fault "Water Flow" or "E5" Water Flow Fault 6 Flashes Not Applicable "E6" Not Applicable 7 Flashes Condensate Fault "Condensate" or "E7" Condensate Fault 8 Flashes Voltage out of Range "Voltage Range" or "E8" Voltage out of Range 9 Flashes RPM Fault "RPM" or "E9" RPM Fault

10 Flashes

Lockout code 10 - see Comfort Alert module to determine the specific flash code for compressor abnormalities.

Comfort Alert Compressor Module Fault

Thermostat Display

Lockout Code

"Comfort Alert" or "E10"

These thermostats can be configured to display the lockout condition "text" or error number. * A slow flash of 1 second on and off means the heat pump microprocessor SW2-1 is configured for "Test Mode" or thermostat is miswired.

Lockout code 10 - see Comfort Alert module to determine the specific flash code for compressor abnormalities.

Comfort Alert Compressor Module Fault

Page 22

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Operation Logic Data

OPER ATION LOGIC

Compressor-Lo

Compressor-Hi

Rev Valve

Loop Pu mps

Secondary 1 - Out

Secondary 2- Out

Emerg LED

T-Stat Signal

STG1 STG2 STG3 EMERG STG1 STG2

On Off Off Off On Off -

Off On On Off Off On -

Off Off Off Off On On -

On On On Off On On On

On On On Off On On -

Off On On Off Off On -

Off Off Off On Off Off -

Y1 Y 1, Y2 Y1, Y2, W W Y1, O Y1 , Y2, O -

HE ATIN G COOLING

DUAL CAPACIT Y UNITS

DIP Switch Settings

DIP SWITCH

NUMBER

SW1 N /A NOT USE D N/A N/A

Service/Test Mode - Allows control of “NORM” or “TEST” operational

modes. Test mode accelerates most timing functions 16 times to allow

faster troubleshooting. Test mode also allows viewing the “CURRENT” status of the fault inputs on the LED display.

Freeze Detection Setting

This DIP allows ﬁeld selection of freeze detection fault sensing for well water (30°F) or anti-freeze protected earth loops (15°F).

Accessory Relay

Allows ﬁeld selection of the accessory relay to operate with the compressor

SW2

SW3

or blower.

4 NOT USED N/A N /A

5 NOT USED N /A N /A

Input Diagnostics - Allows viewing the inputs from the thermostat to the

control board such as Y1, Y2, O, G, W, SL1-In on the LED display.

Output Diagnostics - Allows viewing the outputs from the control board

such as the compressor, reversing valve, blower, and loop pump on the LED display.

Thermostat Selection

Conﬁgures the control for a pulsed lockout signal (ComforTalk and

FaultFlash thermostats) or continuous 5 VAC lockout signal.

1 Single or Dual Capacity Operation Dual Cap 1 Speed

Zoned/Finish on Second Stage

This switch allows the unit to down stage with the thermostat when off and

ﬁnish with second stage when on. Finish on second stage reduces stage changing in reciprocating dual capacity compressors.

3 ECM Blower Monitoring - Set for No PRM on split systems No RPM RPM

4 NOT USED N/A N/A

On dual capacity units this switch allows stage change: on the ﬂy when off,

and 1 minute delay when on. A delay is required on all reciprocating dual capacity units.

DESCRIPTION OFF POSITION ON POSITION

Te s t Norm

Loop

(Sensing 15° F)

Blower Comp

Diagnostic Inputs

viewed at LEDs

Diagnostic

Outputs viewed at

LEDs

Pulsed “L”

signal

Normal -

All other systems

Envision E-Series or Premier

Normal Display viewed at LEDs

Display viewed

SL1 - IN ON

Well

(Sensing 30° F)

Normal

at LEDs

Continuous “L”

signal

Finish on 2nd

Unzoned Dual

Capacity

E-Series or

Premier 2 speed

Page 23

Refrigeration

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Leak Testing

The refrigeration line set must be pressurized and checked for leaks before purging and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60 to 90 PSIG. Never use oxygen or acetylene to pressure test. Use an electronic leak detector or a good quality bubble solution to detect leaks on all connections made in the field. Check the service valve ports and stem for leaks and all connections made in the field. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize the system above 150 psi. Purge pressure from line set. The system is now ready for evacuating and charging.

System Evacuation

Ensure that the line set and air coil are evacuated before opening service valves to the split unit. The line set must be evacuated to at least 200 microns to remove the moisture and air that may still be in the line set and coil. Evacuate the system through both service ports to prevent false readings on the gauge because of pressure drop through service ports.

Charge Amount When Using NAH Air Handler

The Envision Split is shipped with a facotry pre-charge. This volume of refrigerant is not sufficient to run the system and additional refrigerant must be added. If using an NAH Air Handler please refer to the table in this section for charge amounts to be added. The “Factory Charge” column is the charge amount the compressor section/split is shipped with from the factory. The “Charge Amount with NAH Air Handler” column is the total amount of charge for the NAH Air Handler + Compressor section/split. This column does not factor in additional refrigerant needed for the line set. The installer of the system must add charge appropriately for the specific length of the line set. A 3/8 in. liquid line is calculated at 0.50 oz. of charge per linear foot, and a 1/2 in. liquid line is calculated at 1.0 oz. of charge per linear foot using R-410A refrigerant. The suction line will not hold “liquid” and should be ignored for the charge calculation.

Example: NDS036/NAH036 with 20 ft. of 3/8 in. liquid line. Remember that when using the NAH Air Handler, the column “Charge Amount with NAH Air Handler” will be used. Now calculate for the additional 20 ft. ineset. Additional refrigerant to be added = (20 ft. x 0.5 oz.) = 10 oz. Solution: 10 oz. should be added to the recommended charge of 86 oz. found in the “Charge Amount with NAH Air Handler” column for a total charge of 96 oz.

After initial charge, the system should be operated and

the system subcooling and superheat verified to the Unit

Operating Parameters table.

If an air handler manufactured by others is used then

refrigerant should be added to the Envision Split factory

pre-charge. Refrigerant should be added for liquid line

length. This should result in a slightly under-charged

system exhibiting low subcooling and high superheat.

As charge is added, the subcooling should rise and the

superheat should fall.

Charging the System

Charge Method – After purging and evacuating the line set,

fully open the service valves counterclockwise. Add R-410A

(liquid) into the liquid line service port until the pressure

in the system reaches approximately 200 PSIG. Never add

liquid refrigerant into the suction side of a compressor.

Start the unit and measure superheat and subcooling. Keep

adding refrigerant until the unit meets the superheat and

subcooling values in the Operating Parameters tables.

Checking Superheat and Subcooling

Determining Superheat

1. Measure the temperature of the suction line at the point where the expansion valve bulb is clamped.

2. Determine the suction pressure in the suction line by attaching refrigeration gauges to the schrader connection on the suction side of the compressor.

3. Convert the pressure obtained in Step 2 to the saturation temperature by using the Pressure Temperature Conversion Chart for R-410A.

4. Subtract the temperature obtained in Step 3 from Step 1. The difference is the amount of superheat for the unit. Refer to the Operating Parameters tables for superheat ranges at specific entering water conditions.

Superheat Adjustment

TXVs are factory set to a specific superheat; however, the superheat should be adjusted for the application. To adjust the TXV to other superheat settings:

1. Remove the seal cap from the bottom of the valve.

2. Turn the adjustment screw clockwise to increase superheat and counterclockwise to decrease superheat. One complete 360° turn changes the superheat approximately 3-4°F, regardless of refrigerant type. You may need to allow as much as 30 minutes after the adjustment is made for the system to stabilize.

3. Once the proper superheat setting has been achieved, replace and tighten the seal cap.

WARNING: There are 8 total (360°) turns on the superheat adjustment stem from wide open to fully closed. When

Page 24

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Refrigeration cont.

adjusting the superheat stem clockwise (superheat increase) and the stop is reached, any further clockwise turning adjustment will damage the valve.

Determining Subcooling

1. Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated.

2. Measure the liquid line pressure by attaching refrigerant gauges to the schrader connection on the liquid line service valve.

3. Convert the pressure obtained in Step 2 to the saturation temperature by using the Pressure Temperature Conversion Chart for R-410A.

4. Subtract the temperature in Step 1 from the temperature in Step 3. The difference will be the subcooling value for that unit. Refer to the Operating Parameters tables for subcooling ranges at specific enter water conditions.

Line Set Sizes

20 feet 40 feet 60 feet

Unit Size

026 NAH026 5/8” OD 3/8” OD 3/4” OD 3/8” OD 3/4” OD 1/2” OD 52 74 038 NAH036 3/4” OD 3/8” OD 3/4” OD 3/8” OD 3/4” OD 1/2” OD 56 86 049 NAH048 3/4” OD 3/8” OD 7/8” OD 3/8” OD 7/8” OD 1/2” OD 90 115 064 NAH060 7/8” OD 1/2” OD 7/8” OD 1/2” OD 1-1/8” OD 1/2” OD 92 112 072 NAH060 7/8” OD 1/2” OD 7/8” OD 1/2” OD 1-1/8” OD 1/2” OD 104 132

NOTES: * The “Charge Amount with NAH Air Handler” column is based on the charge amount for an NAH Air Handler + Compressor Section Split. Additional charge will have to be added accordingly for line set length. After charge is added, adjustments can be made to get appropriate subcooling and superheat. Additional charge for R-410A is 0.50 oz. per ft. for 3/8 in. and 1.0 oz. per ft. for 1/2 in. tube.

Air

Handler

Suction Liquid Suction Liquid Suction Liquid

Factory

Charge (oz.)

*Charge Amount

with NAH

Air Handler

(oz.)

4/16/10

Page 25

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Pressure/Temperature Coversion Chart for R-410A

PRESSURE

(PSIG)

60 8.5 180 63.5 300 96.3 420 120.6 540 140.0

62 9.9 182 64.2 302 96.8 422 120.9 542 140.3 64 11.2 184 64.8 304 97. 2 424 121.3 544 140.6 66 12.5 186 65.5 306 97. 7 426 121.6 546 140.9

68 13.8 188 66.1 308 98.1 428 122.0 548 141.2 70 15.1 190 66.8 310 98.6 430 122.3 550 141.4

72 16.3 192 6 7. 4 312 99.0 432 122.7 552 141.7

74 17.5 194 68.0 314 99.5 434 123.0 554 142.0

76 18.7 196 68.7 316 99.9 436 123.4 556 142.3

78 19.8 198 69.3 318 100.4 438 123.7 558 142.6 80 21.0 200 69.9 320 100.8 440 124.1 560 142.9

82 22.1 202 70.5 322 101.2 442 124.4 562 143.2 84 23.2 204 71.1 324 101.7 444 124.8 564 143.5 86 24.3 206 71.7 326 102.1 446 125.1 566 143.7

88 25.4 208 72.3 328 102.5 448 125.4 568 144.0 90 26.5 210 72.9 330 103.0 450 125.8 570 144.3

92 2 7.5 212 73.5 332 103.4 452 126.1 572 144.6 94 28.6 214 74. 1 334 103.8 454 126.5 574 144.9 96 29.6 216 74 .7 336 104.2 456 126.8 576 145.1 98 30.6 218 75.3 338 104.7 458 127.1 578 145.4

100 31.6 220 75.8 340 105.1 460 127.5 580 145.7 102 32.6 222 76.4 342 105.5 462 127.8 582 146.0 104 33.5 224 77. 0 344 105.9 464 128.1 584 146.2 106 34.5 226 77.5 346 106.3 466 128.5 586 146.5 108 35.4 228 78 .1 348 106.7 468 128.8 588 146.8

110 36.4 230 78.7 350 107.2 470 129.1 590 1 47.1 112 37. 3 232 79.2 352 107.6 472 129.4 592 147.3 114 38.2 234 79.8 354 108.0 474 129.8 594 147.6 116 39 .1 236 80.3 356 108.4 476 130.1 596 147.9 118 40.0 238 80.9 358 108.8 478 130.4 598 148.2

120 40.9 240 81.4 360 109.2 480 130.7 600 148.4

122 41.7 242 81.9 362 109.6 482 131.1 602 148.7

124 42.6 244 82.5 364 110.0 484 131.4 604 149.0 126 43.4 246 83.0 366 110.4 486 131.7 606 149.2 128 44.3 248 83.5 368 110.8 488 132.0 130 45.1 250 84.1 370 111.2 490 132.3

132 45.9 252 84.6 372 111.6 492 132.7

134 46.7 254 85.1 136 4 7.5 256 85.6 376 112.3 496 133.3

138 48.3 258 86.1 378 112.7 498 133.6

140 49.1 260 86.6 380 113.1 500 133.9 142 49.9 262 8 7.1 382 113.5 502 134.2 144 50.7 264 87.7 384 113.9 504 134.5 146 51.5 266 88.2 386 114.3 506 134.9 148 52.2 268 88.7 388 114.7 508 135.2 150 53.0 270 89.2 390 115.0 510 135.5

152 53.7 272 89.6 392 115.4 512 135.8

154 54.5 274 90.1 394 115.8 514 136.1 156 55.2 276 90.6 396 116.2 516 136.4

158 55.9 278 91.1 398 116.5 518 136.7

160 56.6 280 91.6 400 116.9 520 13 7.0

162 5 7. 4 282 9 2.1 402 117.3 522 137.3

164 58.1 284 92.6 404 117.6 524 137.6 166 58.8 286 93.0 406 118.0 526 137.9 168 59.5 288 93.5 408 118.4 528 138.2 170 60.2 290 94.0 410 118.7 530 138.5

172 60.8 292 94.5 412 119.1 532 138.8 174 61.5 294 94.9 414 119.5 534 139.1 176 62.2 296 95.4 416 119.8 536 139.4 178 62.9 298 95.8 418 120.2 538 139.7

TEMP

°F

PRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

374 112.0 494 133.0

TEMP

°F

PRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

608 149.5

TEMP

°F

Page 26

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Operating Parameters

First Stage Operation

Entering

Water Temp

°F

Entering

Water Temp

°F

Water Flow

GPM/Ton

1.5 130-150 193-230 130-150 200-245 8-16 7-14 15-21 18-24

3.0 128-153 190-230 125-140 205-240 8-16 3-10 9-14 18-25

1.5 130-150 238-282 135-150 240-280 6-16 4-16 12-18 18-25

3.0 130-155 238-262 125-145 245-270 6-18 5-11 5-10 18-24

1.5 133-148 308-340 130-155 300-365 7-16 6-18 10-16 19-25

3.0 138-153 303-333 130-165 305-350 7-18 7-14 5-10 17-22

Water Flow

GPM/Ton

1.5 78-100 275-325 85-105 325-385 6-11 4-16 5-9 20-29

3.0 78-110 285-325 90-120 335-375 6-11 4-16 3-7 20-32

1.5 105-120 305-350 100-130 340-400 5-12 4-16 5-12 24-32

3.0 110-125 305-355 110-125 345-395 9-15 2-14 4-9 20-34

1.5 140-155 305-355 130-165 370-430 5-12 2-14 8-12 24-39

3.0 145-160 330-360 140-160 375-425 7-17 7-15 4-10 24-39

NDS026 thru NDS064 NDS072 NDS026 thru NDS072 Suction

Pressure

PSIG

NDS026 thru NDS064 NDS072 NDS026 thru NDS072 Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Cooling -- No Desuperheater

Suction

Pressure

PSIG

Heating -- No Desuperheater

Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Superheat Subcooling

Water Temp

Rise °F

Water Temp

Drop °F

Air Temp

Drop °F DB

Air Temp

Rise °F DB

Second Stage Operation

Cooling -- No Desuperheater

Entering

Water Temp

°F

Entering

Water Temp

°F

Cooling performance based on entering air temperatures of 80°F DB, 67°F WB. Heating performance based on entering air temperature of 70°F DB.

Water Flow

GPM/Ton

1.5 120-140 200-245 105-150 210-270 7-17 6-14 15-21 19-26

3.0 115-140 195-290 110-130 215-260 7-15 4-11 9-14 20-24

1.5 121-136 265-310 105-150 280-350 9-15 6-18 12-18 19-25

3.0 123-139 265-310 110-140 285-320 10-16 8-16 5-10 18-24

1.5 122-140 310-360 115-140 325-385 8-14 6-18 10-16 18-24

3.0 123-139 310-350 120-135 330-355 8-14 7-15 5-10 17-23

Water Flow

GPM/Ton

1.5 72-89 295-350 70-100 320-370 7-18 10-20 5-9 18-24

3.0 73-87 305-330 75-90 315-365 7-18 10-20 3-7 18-27

1.5 100-120 320-365 95-130 375-430 6-14 6-18 5-12 23-34

3.0 105-120 355-365 100-125 370-420 6-14 6-18 4-9 20-37

1.5 142-158 360-380 130-165 400-470 6-12 4-15 8-12 28-38

3.0 138-152 365-390 135-160 405-465 7-14 4-15 4-10 24-42

NDS026 thru NDS064 NDS072 NDS026 thru NDS072 Suction

Pressure

PSIG

NDS026 thru NDS064 NDS072 NDS026 thru NDS072 Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Suction

Pressure

PSIG

Heating -- No Desuperheater

Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Superheat Subcooling

S u p e r h e a t Subcooling

Water Temp

Rise °F

Water Temp

Drop °F

Air Temp

Drop °F DB

Air Temp

Rise °F DB

Page 27

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Pressure Drop

Dual Capacity

Model GPM

026

full

load

026 part

load

038

full

load

038 part

load

049

full

load

049 part

load

064

full

load

064 part load

072

full

load

072 part load

10 7.0 6.6 6.2 5.8 5.3

10 4.2 3.9 3.7 3.4 3.2

12 3.9 3.6 3.4 3.2 2.9 15 5.7 5.3 5 4.7 4.3

14 5.0 4.7 4.4 4 .1 3.8

12 3.8 3.5 3.3 3.0 2.8 16 6.5 6.0 5.6 5.2 4.8

20 9.7 9.1 8.5 8.0 7. 4

10 2.6 2.5 2.3 2.1 2.0 14 5.0 4.7 4.4 4 .1 3.8 18 8.1 7.6 7. 1 6.6 6.1 12 3.2 3.0 2.8 2.6 2.4 15 4.5 4.2 4.0 3.7 3.4 18 6.0 5.7 5.3 4.9 4.6 21 7. 8 7.3 6.8 6.4 5.9 10 2.3 2 .1 2.0 1.9 1.7 13 3.6 3.3 3.0 2.8 2.6 16 5.0 4.6 4.3 4.0 3.7 19 6.5 6.2 5.8 5.4 5.0

30°F 50°F 70°F 90°F 110°F

4 1.4 1.3 1.2 1 .1 1.0 6 2.8 2.6 2.4 2.3 2.1 8 4.7 4.4 4 .1 3.8 3.5

3 0.8 0.7 0.7 0.7 0.6 5 2.0 1.8 1.7 1.6 1.5 7 3.6 3.4 3.2 3.0 2.8 9 5.8 5.5 5 .1 4.8 4.4 5 1.2 1.2 1.1 1.0 1.0 7 2.2 2.1 1.9 1.8 1.7 9 3.4 3.2 3.0 2.8 2.6 11 4.9 4.6 4.3 4 3.7 4 0.9 0.8 0.8 0.7 0.7 6 1.7 1.6 1.5 1.4 1.3 8 2.8 2.6 2.5 2.3 2.1

6 1.2 1.2 1.1 1.0 1.0 9 2.4 2.2 2.1 2.0 1.8

5 0.9 0.9 0.8 0.8 0.7 8 2.0 1.8 1.7 1.6 1.5 11 3.4 3 .1 2.9 2.8 2.5

8 1.8 1.7 1.6 1.4 1.3

6 1.0 0.9 0.9 0.8 0.8

Pressure Drop (psi)

5/30/06

Compressor Resistance

Compressor Resistance Chart (Ohms)

Model

026 038 049 064 072

1.23-1.30 1.41-1.50 .829-.954 1.19-1.38 .590-.679 1.41-1.62 .455-.524 .558-.643 .344-.395 .495-.570

208-230/60/1

Run Start

Thermistor Resistance

Thermistor Resistance Chart

Thermistor

Temperature (°F)

5 75757-70117

14 57392-53234 23 43865-40771 32 33809-31487

41 26269-24513 50 20570-19230 59 16226-15196 68 12889-12093 77 10310-9688 86 8300-7812 95 6723-6337

104 5480-5172

113 4490-4246

122 3700-3504

131 3067-2907

140 2554-2424 149 2149-2019

Microprocessor

Resistance (Ohms)

1/13/11

7/6/ 1 0

Page 28

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Refrigerant Circuit Guideline

Symptom

Under Charged System (Possible Leak) Low Low Low High Low Low Low Over Charged System High High High Normal High Normal/Low Normal Low Air Flow Heating High High High High/Normal Low High Low Low Air Flow Cooling Low Low Low Low/Normal High High Low Low Water Flow Heating Low/Normal Low/Normal Low Low High Low High Low Water Flow Cooling High High High High Low Low High High Air Flow Heating Low Low Low Low High Low Low High Air Flow Cooling Low High Normal High Low Low Normal High Water Flow Heating Normal Low Normal High Normal Normal Low High Water Flow Cooling Low Low Low Low High Normal Low Low Indoor Air Temperature Heating Low Low Low Normal High Normal Normal/High Low Indoor Air Temperature Cooling Low Low Low Normal/Low High Low Low High Indoor Air Temperature Heating High High High Normal/High Normal/Low Low Normal High Indoor Air Temperature Cooling High High High High Low Low High Restricted TXV (Check Service Advisory) High Low Normal/Low High High Low Low Insufficient Compressor (Possible Bad Valves) Low High Low High Normal/High Low Low TXV - Bulb Loss of Charge Low Low Low High High Low Low Scaled Coaxial Heat Exchanger Heating Low Low Low Normal/Low High Low Low Scaled Coaxial Heat Exchanger Cooling High High High Normal/Low Low Low Low Restricted Filter Drier Check temperature difference (delta T) across filter drier.

Head

Pressure

Suction

Pressure

Compressor

Amp Draw

Superheat Subcooling

Air Temp.

Differential

Water Temp.

Differential

7/6/ 1 0

Heat of Extraction/Rejection Data

Model GPM

Part

Load

026

Full

Load

Part

Load

038

Full

Load

Part

Load

049

Full

Load

Part

Load

064

Full

Load

Part

Load

072

Full

Load

Heat of Extraction (kBtuh) Heat of Rejection (kBtuh)

30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F

3.0 13.1 17.6 21.5 23.5 22.9 21.8

5.0 9.4 13.8 18.6 22.6 21.7 23.6 23.0 21.7 20.2

7.0 9.6 14.1 18.9 23.0 21.9 23.7 23.1 21.7 20.2

4.0 17.8 23.4 28.5 31.0 31.2 30.0

6.0 13.4 18.8 24.7 29.9 29.9 31.1 31.3 29.9 28.1

8.0 13.6 19.3 25.1 30.5 30.1 31.2 31.3 29.9 28.1

4.0 17.9 23.3 28.1 32.5 31.8 30.0

6.0 12.8 18.7 24.5 29.8 29.8 32.7 32.0 30.1 28.2

8.0 13.9 19.7 25.2 29.8 30.3 33.1 32.4 30.4 28.5

5.0 25.1 31..5 36.1 44.8 45.1 42.8

7.0 18.7 26.2 33.2 38.6 41.8 45.2 45.7 43.6 41.0

9.0 19.1 26.9 34.3 40.0 42.0 45.5 46.0 43.8 41.1

5.0 24.0 29.5 33.7 44.9 46.1 44.0

8.0 19.2 26.4 32.6 37.5 40.6 45.0 45.8 43.4 40.5

11.0 19.8 27. 5 34.3 39.9 40.0 44.9 46.1 44.3 41.5

6.0 33.3 40.6 46.1 60.2 60.2 56.4

9.0 26.0 34.7 42.8 49.1 56.0 60.2 60.8 57. 4 52.9

12.0 26.5 35.7 44.2 50.9 56.1 60.4 61 .1 57.6 53.2

6.0 31.0 39.2 46.1 56.3 55.4 52.1

10.0 21.6 31.4 40.9 49.7 52.4 56.2 55.5 52.4 49.4

14.0 22.6 32.6 41.7 49.8 52.2 56.2 55.6 52.6 49.7

8.0 40.8 52.7 64.7 73.7 75.7 70.3

12.0 31.9 43.8 55.1 65.8 66.8 74 .1 76.1 70.5 66.2

16.0 32.2 44.7 56.8 68.6 6 7. 2 74.5 76.5 70.9 66.3

10.0 36.4 46.5 54.7 63.4 63.0 58.9

13.0 25.2 36.7 48.5 59.1 57. 7 63.2 63.0 59.2 55.1

16.0 26.7 38.2 49.4 59.1 57.3 63.2 63.3 59.5 55.4

12.0 48.3 62.7 69.0 81.8 83.0 77.8

15.0 37. 2 51.6 65.4 70.9 73.6 82.1 83.3 78.0 71.9

18.0 3 7.6 52.7 67. 5 73.5 74 .1 82.6 83.8 78.4 72.2 1/14/11

Page 29

Reference Calculations

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Heating Calculations:

LWT = EWT -

LAT = EAT +

TH = HC + HW

GPM x 500

CFM x 1.08

Cooling Calculations:

LWT = EWT +

LAT (DB) = EAT (DB) -

LC = TC - SC

S/T =

GPM x 500

Legend

ABBREVIATIONS AND DEFINITIONS:

CFM = airﬂow, cubic feet/minute EWT = entering water temperature, Fahrenheit GPM = water ﬂow in gallons/minute WPD = water pressure drop, PSI and feet of water EAT = entering air temperature, Fahrenheit (dry bulb/wet bulb) HC = air heating capacity, MBTUH TC = total cooling capacity, MBTUH SC = sensible cooling capacity, MBTUH KW = total power unit input, kilowatts HR = total heat of rejection, MBTUH

CFM x 1.08

HE = total heat of extraction, MBTUH HW = hot water generator capacity, MBTUH EER = Energy Efﬁciency Ratio = BTU output/Watt input COP = Coefﬁcient of Performance = BTU output/BTU input LWT = leaving water temperature, °F LAT = leaving air temperature, °F TH = total heating capacity, MBTUH LC = latent cooling capacity, MBTUH S/T = sensible to total cooling ratio

Operating Limits

Operating Limits Cooling Heating

Air Limits

Minimum ambient air, DB -10°F [-23.3°C] -10°F [-23.3°C]

Rated ambient air, DB 80.0 [26.7°C] 70°F [21.1°C]

Maximum ambient air, DB 120 [48.8°C] 85°F [29°C]

Water Limits

Minimum entering water 30°F [-1°C] 20°F [-6.7°C]

Normal entering water 50-110°F [10-43°C] 30-70°F [-1 to 21°C]

Maximum entering water 120°F [49°C] 90°F [32°C]

Normal water flow

1.5 to 3.0 gpm per ton

[1.6 to 3.2 l/m per kW]

NOTES: Minimum/maximum limits are only for start-up conditions, and are meant for bringing the space up to occupancy temperature. Units are not designed to operate at the minimum/maximum conditions on a regular basis. The operating limits are dependent upon three primary factors: 1) water temperature, 2) return air temperature, and 3) ambient temperature. When any of the factors are at the minimum or maximum levels, the other two factors must be at the normal level for proper and reliable unit operation.

Page 30

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Startup

Before Powering Unit, Check The Following:

• High voltage is correct and matches nameplate.

• Fuses, breakers and wire size correct.

• Low voltage wiring complete.

• Piping completed and water system cleaned and flushed.

• Air is purged from closed loop system.

• Isolation valves are open, water control valves or loop pumps wired.

• Transformer switched to 208V if applicable.

• DIP switches are set correctly.

• DHW pump switch is “OFF” unless piping is completed and air has been purged.

• Blower rotates freely.

• Blower speed correct.

• Air filter/cleaner is clean and in position.

• Service/access panels are in place.

• Return air temperature is between 50-80ºF heating and 60-95ºF cooling.

• Check air coil cleanliness to ensure optimum performance. Clean as needed according to maintenance guidelines. To obtain maximum performance the air coil should be cleaned before startup. A 10-percent solution of dishwasher detergent and water is recommended for both sides of coil, a thorough water rinse should follow.

Startup Steps

NOTES: Complete the Equipment Start-Up/Commissioning

Check Sheet during this procedure. Refer to thermostat operating instructions and complete the startup procedure.

8. Decrease the cooling set point several degrees and verify high-speed blower operation.

9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate.

10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.

11. First stage heating will energize after a time delay.

12. Check the temperature of both the supply and discharge water (see Operating Parameters tables).

13. Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the blower speed and entering water temperature.

14. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on. All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element.

15. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate.

16. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.

17. Set system to desired normal operating mode and set temperature to maintain desired comfort level.

18. Instruct the owner/operator in the proper operation of the thermostat and system maintenance.

NOTES: Be certain to fill out and forward all warranty registration papers.

1. Initiate a control signal to energize the blower motor. Check blower operation.

2. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.

3. First stage cooling will energize after a time delay.

4. Be sure that the compressor and water control valve or loop pump(s) are activated.

5. Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T plugs and comparing to unit capacity data in specification catalog.

6. Check the temperature of both the supply and discharge water (see Operating Parameters tables).

7. Check for an air temperature drop of 15°F to 25°F across the air coil, depending on the blower speed and entering water temperature.

Final Evaluation

After the initial check of superheat/subcooling values in the heating mode, shut off the unit and allow it to sit 3 to 5 minutes until pressures equalize. Restart the unit in the cooling mode and check the values against those in the Operating Parameters tables. If the unit performs satisfactorily, charging is complete. If the unit does not perform to specifications, the charge may need to be readjusted until the values are close. Adding refrigerant will increase subcooling. Recovering some of the refrigerant will decrease subcooling and increase superheat. If the superheat/subcooling values are still not close to the specifications in the Operating Parameters tables, analyze refrigerant circuit operation.

Page 31

Startup and Troubleshooting

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Heating Cycle Analysis

Measure suction temperature here at TXV bulb in cooling modes.

Air

Coil

ClgTXV

COOLING TXV - ACTIVE RIGHT TO LEFT

filter/drier

Measure liquid line temperature and pressure here in both heating and cooling modes

Lineset

length

Bi-flow

Measure suction temperature here at TXV bulb in heating modes.

Volts ____

Amps ____

HtgTXV

COAX

EWT ____

LWT ____

HEATING TXV - ACTIVE LEFT TO RIGHT

Suct PSI____

Suct sat temp____

Suct temp____

Super heat____

Suction

Comp

Discharge

Hot Water Generator

Discharge PSI____

Disch. sat temp____

Liquid temp____

Sub cooling____

Note: DO NOT hook up pressure gauges unless there appears to be a performance problem.

Cooling Cycle Analysis

Measure suction temperature here at TXV bulb in cooling modes.

Air

Coil

ClgTXV

COOLING TXV - ACTIVE RIGHT TO LEFT

filter/drier

Measure liquid line temperature and pressure here in both heating and cooling modes

Lineset

length

Bi-flow

Measure suction temperature here at TXV bulb in heating modes.

Volts ____

Amps ____

HtgTXV

COAX

EWT ____ LWT ____

HEATING TXV-ACTIVE LEFT TO RIGHT

Suct PSI ____

Suct sat temp ____

Suct temp ____

Super heat ____

Suction

Comp

Discharge

Hot Water Generator

Discharge PSI ____

Disch. sat temp ____

Liquid temp ____

Sub cooling ____

Page 32

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Troubleshooting

Standard Microprocessor Controls

To check the unit control board for proper operation:

1. Disconnect thermostat wires at the control board.

2. Jumper the desired test input (Y1, Y2, W, O or G) to the R terminal to simulate a thermostat signal.

3. If control functions properly:

• Check for thermostat and field control wiring (use the diagnostic inputs mode).

LED Definitions and Diagnostics

Standard Microprocessor

LED

Drain

Water Flow

NORMAL

DISPLAY MODE

Field Selection DIPS

SW2- 1 On SW2- 1 Off SW2- 1 NA SW2- 1 NA SW2-

SW2- 6 On SW2- 6 On SW2- 6 Off SW2- 6 On SW2-

SW2- 7 On SW2- 7 On SW2- 7 On SW2- 7 Off SW2-

Drain Pan Overﬂow

Lockout

FD Thermistor

(Loop <15°F,

Well<30°F) Lockout

CURRENT

FAULT STATUS

Drain Pan Overﬂow Y1

FD Thermistor

(Loop <15°F,

Well<30°F)

4. If control responds improperly:

• Ensure that component being controlled is functioning (compressor, blower, reversing valve, etc.).

• Ensure that wiring from control to the component is functioning (refer to the LED Definition table below and use the diagnostic outputs mode).

• If steps above check properly, replace unit control.

DIAGNOSTIC MODES

INPUTS OUTPUTS 1 OUTPUTS 2

Compressor (On or Low)

Compressor (On or High)

Blower

Low

Blower

Medium

1 NA

6 Off

7 Off

High

Pressure

High Pressure >600

PSI Lockout

High Pressure >600 O Reversing Valve

Low

Pressure,

Comfort

Low Pressure <40/

Comfort Alert

Low Pressure <40/

Comfort Alert

Alert

Status

DHW Limit

DHW Off

Microprocessor

Malfunction

HWL Thermistor

>130°F

DHW Pump

Switch Off

Not Used SL1 Loop Pump 1 Aux Heat 3

HWL Thermistor

>130°F

DHW Pump Switch

Off

Refrigerant Systems

To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in temperature on the air side as well as the water side to the Operating Parameters tables. If the unit’s performance is not within the ranges listed, and the airflow and water flow are known to be correct, gauges should then be installed and superheat and subcooling numbers calculated. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary.

Blower

High

G Blower Aux Heat 1

Not Used Loop Pump 2 Aux Heat 4

– – –

NOTES: Refrigerant tests must be made with hot water generator turned “OFF”. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.

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Preventive Maintenance

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Water Coil Maintenance

1. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line. Lines should always be airtight.

2. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure.

NOTES: On open loop systems, if the installation is in an area with a known high mineral content (125 PPM or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. Generally, the more water flowing through the unit the less chance for scaling.

Other Maintenance

Filters

Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a filter.

Condensate Drain

In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow.

Blower Motors

Blower motors on most air handlers are equipped with sealed ball bearings and require no periodic oiling.

Air Coil

The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Care must be taken not to damage the aluminum fins while cleaning.

CAUTION: Fin edges are sharp.

Replacement Procedures

Obtaining Parts

When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

In-Warranty Material Return

Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance.

Page 34

NDS OUTDOOR SPLIT INSTALLATION MANUAL

Service Parts List

Part Description

Compressor 34P585-01 34P573-01 34P574-01 34P575-01 34P586-01

Run Capacitor 16P002D19 16P002D20 16P002D21 16P002D39

Sound Jacket 92P504A16

Power Harness 11P781-01

Compressor

Solenoid Harness 11P782-01

Accumulator 36P509-02 36P509-01

Coax 62I504B01 62I542B01 62I543B01

TXV 33P609-01 33P609-03 33P609-05 33P609-06

Reversing Valve 33P506-04 33P503-05 33P526-04

Components

Refrigeration

Filter Dryer 36P500B01 36P500B02

Comfort Alert 19P571-02

Contactor 13P004A03

Transformer 15P501B01

3 Pole Power Block 12P503-06

2 Pole Screw Term. Block 12P500A01

Electrical

Status Light Board 17P503-02

Harness, Status Light Board 11P783-01

Premier Board 17P513-07

Freeze Detection Thermistor 12P505B03

High Pressure Switch 35P506B02

Safeties

Sensors &

Low Pressure Switch 35P506B01

Part numbers subject to change 11/12/10

026 038 049 064 072

Dual Capacity Split Units

Page 35

Page 36

Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com

IM1004SN 03/11

reserves the right to change design and speciﬁcations without notice.

Product: Envision NDS Type: Geothermal/Water Source Outdoor Split Heat Pump Size: 2-6 Tons Dual Capacity Document: Installation Manual

Envision NDS026 Series, NDS064 Series, NDS072 Series, NDS038 Series, NDS049 Series Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual