Envision Peripherals R-410A User Manual

RESIDENTIAL

Geothermal/Water Source Heat Pumps

• R-410A Refrigerant

• 2, 2.5, 3, 3.5, 4, 5, 6 Ton Single Speed

• 2, 3, 4, 5, 6 Ton Dual Capacity

Installation Information Water Piping Connections Desuperheater Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance

Envision Residential Installation Manual

IM1585 10/07

ENVISION RESIDENTIAL INSTALLATION MANUAL

Model Nomenclature

Model Type

N= Envision

Compressor Type

D= Dual Capacity S= Single Speed

Cabinet Configuration

V= Vertical H= Horizontal

Unit Capacity

Vintage

A= Current

Voltage

1= 208-230/60/1

N D V 049 A 1 1 1 C T L

Return Air Configuration

L= Left R= Right

Discharge Air Configuration

B= Bottom T= Top S= Side E= End

Coax Options

C= Copper N= Cupronickel

Fan Option

0= PSC 1= ECM 2= Oversized ECM Blower Option

(036,038,042,048,049)

3= Oversized PSC Blower Option

(022,030,036,042,048)

Hot Water Option

0= None 1= Hot Water Generation with

factory installed pump

Notes: PSC Motor - Single Speed Only

ENVISION RESIDENTIAL INSTALLATION MANUAL

T able of Contents

General Installation Information 4-8 Closed Loop Ground Source Systems 9 Open Loop Ground Water Systems 10 Desuperheater Connection & Startup 11-12 Electrical Connections 13-14 Electronic Thermostat Installation 14 Auxiliary Heat Ratings 14 Electrical Data 15 Fan Performance Table 16-17 Setting Fan Speed 16-17 Vertical Dimensional Data 18 Horizontal Dimensional Data 19 Vertical Bottomﬂ ow Dimensional Data 20 Physical Data 21-22 Wiring Schematics 23-27 Microprocessor Control 28-32 Unit Startup 33 Operation Logic 34 Unit Operating Parameters 35-36 Pressure Drop & Recommended Flow Rates 37 Troubleshooting 38 Preventive Maintenance 39 Replacement Procedures 39

ENVISION RESIDENTIAL INSTALLATION MANUAL

General Installation Information

Safety Considerations

WARNING: Before performing service or maintenance operations on a system, turn off main

power switches to the indoor unit. If applicable, turn off the accessory heater power switch. 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 qualiﬁ ed service personnel should install, repair or service heating and air conditioning equip- ment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing ﬁ lters. 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.

Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a ﬁ re extinguisher available.

Moving and Storage

Move units in the normal “up” orientation. Horizontal units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Vertical units may be stored one upon another to a maximum height of two units. 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.

Unit Location

Locate the unit in an indoor area that allows for easy removal of the ﬁ lter and access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufﬁ cient room to make water, electrical and duct connection(s). If the unit is located in a conﬁ ned space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Any access panel screws that would be difﬁ cult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. Care should be taken when units are located in

unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components.

Installing Vertical Units

Prior to setting the unit in place, remove and discard the compressor hold down

shipping bolt located at the front of the compressor mounting bracket. Vertical units are available in left or right air return conﬁ gurations. Top air dis- charge vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the ﬂ oor. It is not necessary to anchor the unit to the ﬂ oor (see right). Bottomﬂ ow units should be mounted level and sealed well to ﬂ oor to prevent air leakage. Bottomﬂ ow units require the supply air opening to be cut at least 1/2˝ larger than the unit’s air outlet. Protect the edges of combustible ﬂ ooring with sheet metal over-wrap or other non-combustible material.

Figure 1: Vertical Unit Mounting

2” Extruded Polystyrene

ENVISION RESIDENTIAL INSTALLATION MANUAL

Installing Horizontal Units

Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket prior to setting the unit in place. Horizontal units are available with side or end discharge. Horizontal units are normally suspended from a ceiling by six 3/8-inch diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit. Lay out the threaded rods per the dimensions below. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. To allow ﬁ lter access, one bracket on the ﬁ lter side should be installed 180° from the position shown in the ﬁ gure below. The unit should be pitched approximately 1/4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit to attach hanger brackets. The use of longer bolts could damage internal parts. Some residential applications require the installation of horizontal units on an attic ﬂ oor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad. The secondary drain pan prevents possible condensate overﬂ ow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material.

CAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling.

Figure 2: Horizontal Unit Mounting

Threaded Rods

Electrical

Disconnect

To Line

Power

To Thermostat

Line Voltage

Building Water Loop

Flexible Duct Collar

Insulate supply plenum and use at least one 90 elbow to reduce noise

Figure 3: Hanger Location and Assembly

Air Coil

Hanging

Brackets

(Included)

Hose

Kits

Ball Valves

3/8

Threaded Rod

(not supplied)

Bolt and Lockwasher

Model A B C D E F

022 - 030 24.8 036 - 038 72.4 24.1 43.1 042 - 049 77.4 24.1 48.1 060 - 072 82.4 24.1 53.1

Vibration Isolator

27.8

Washer

Hex Nuts (not supplied)

63.4 21.1 38.1

25.3

29.3

1.1

ENVISION RESIDENTIAL INSTALLATION MANUAL

Duct System

An air outlet collar is provided on vertical top air discharge units and all horizontal units to facilitate a duct connection (vertical bottomﬂ ow units have no collar). A ﬂ exible connector is recommended for discharge and return air duct connec- tions on metal duct systems. Uninsulated duct should be insulated 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 unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate the air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary. The duct system should be sized to handle the design airﬂ ow quietly and efﬁ ciently. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of ﬁ berglass or constructed of ductboard for the ﬁ rst few feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit and the ductwork. If air noise or excessive airﬂ ow is a problem, the blower speed can be changed.

CAUTION: Be sure to remove the shipping material from the blower discharge before connecting ductwork.

Water Piping

The proper water ﬂ ow must be provided to each unit whenever the

Figure 4: Swivel Connections (Residential Units)

unit operates. To assure proper ﬂ ow, use pressure/temperature ports to determine the ﬂ ow rate. These ports should be located at the supply and return water connections on the unit. The proper ﬂ ow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. All source water connections on commercial units are ﬁ ttin g s that accept a male pipe thread (MPT). Insert the connectors by hand, then tighten the ﬁ tting with a wrench to provide a leakproof joint. When con- necting to an open loop (groundwater) system, thread any copper MPT

Stainless Steel Snap Ring

Gasket Material

Locking Ring

Gasket Support Sleeve

ﬁ tting into the connector and tighten in the same manner as described above. All source water connections on residential units are swivel piping ﬁ ttings (see Figure 4) that accept a 1-inch male pipe thread (MPT) . The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the ﬂ ush end of any 1-inch threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in CK4L connector kit) against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the ﬁ tting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT ﬁ tting (SCH80 PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability. Never use ﬂ exible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection. Check carefully for water leaks.

ENVISION RESIDENTIAL INSTALLATION MANUAL

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 of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualiﬁ ed service mechanic, as special solutions and pumping equipment are required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional ﬂ ushing.

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.

ENVISION RESIDENTIAL INSTALLATION MANUAL

Freeze Protection

Set the freeze sensing switch SW2-2 on the printed circuit board for applications using a closed loop antifreeze solution

to “LOOP”. On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to “WELL”, the factory default setting. (Refer to the Dip Switch Field Selection table on page 24.)

Condensate Drain

On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a

3/4-inch PVC female adapter and a ﬂ exible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the ﬁ eld-installed PVC condensate piping. On vertical upﬂ ow units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary. On horizontal units, a PVC stub is provided for condensate drain piping connection. An external trap is required (see below). If a vent is necessary, an open stand pipe may be applied to a tee in the ﬁ eld-installed condensate piping.

Figure 5: Horizontal Drain Connection

3/4” PVC tube stub

Figure 6: Unit Pitch for Drain

3/4" PVC Coupling

1.5"

Vent (if needed)

3/4" PVC 1/8" per foot

1.5"

1/2'' Pitch

Drain

ENVISION RESIDENTIAL INSTALLATION MANUAL

Closed Loop Ground Source Systems

Note: For closed loop systems with antifreeze protection, set SW2-2 to the “loop” position (see table on page 28).

Once piping is completed between the unit, pumps and the ground loop (see ﬁ gure below), ﬁ nal purging and charging of the loop is required. A ﬂ ush cart (or a 1.5 HP pump minimum) is needed to achieve adequate ﬂ ow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 PSI (summer) or 50-75 PSI (winter). This is normally adequate for good system operation. Loop static pressure will ﬂ uctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This ﬂ uctuation is normal and should be considered when initially charging the system.

After pressurization, be sure to open the plug 1 turn in the end of the loop pump motor(s) (if applicable) to allow trapped air to be discharged and to ensure that the motor housing has been ﬂ ooded. Ensure that the loop pumps provide adequate ﬂ ow through the unit(s) by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in the speciﬁ cation catalog. 2.5 to 3 GPM of ﬂ ow per ton of cooling capacity is recommended in earth loop applications.

Figure 7: Closed Loop Ground Source Application

Auxiliary Heat

Disconnects

(If Applicable)

Unit Supply

Thermostat

Supply

Low

Voltage to

Vibration Absorbing Pad

Polyethylene w/

P/T Plugs

Multiple Units on One Flow Center

When two units are connected to one loop pumping system, pump control is automatically achieved by connecting the SL terminals on connector P2 in both units with 2-wire thermostat wire. These terminals are polarity dependant (see Figure 8). The loop pump(s) may be powered from either unit, whichever is more convenient. If either unit calls, the loop pump(s) will automatically start. The use of two units on one ﬂ ow center is generally limited to a total of 20 GPM capacity.

GeoLink

Armaflex Insulation

Flexible Duct Collar

Auxiliary Heater Knockout

Unit Power

Desuperheater Connections

Drain

P/T

Envision to Envision

Microprocessor Units

Dual Capacity Envision Unit #1

Shut

Down

With pump wired to Unit 1

With pump wired to Unit 2

Shut

Down

Envision Unit #2 Dual Capacity

Link

Flow

Insulated piping or hose kit

SL1InSL1

Out

SL1InSL1

Out

LOOP

Note: Additional information can be found in Flow Center installation manual (IM1961) and Flush Cart manual (WFS302).

Figure 8: Primary/Secondary Hook-up

Envision to Envision

Microprocessor Units

Single Speed Envision Unit #1

Shut

Down

Shut

Down

Envision Unit #2 Single Speed

SL1InSL1

Out

SL1InSL1

Out

With pump wired to Unit 1

With pump wired to Unit 2

Envision to

Electromechanical Units

Envision Unit #1

Shut

Down

To Electromechanical Unit

SL1InSL1

Out

ENVISION RESIDENTIAL INSTALLATION MANUAL

)

Open Loop Ground Water Systems

Typical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Insure proper water ﬂ ow through the unit by checking pressure drop across the heat exchanger and comparing it to the ﬁ gures in unit capacity data tables in the speciﬁ cation catalog. 1.5-2 GPM of ﬂ ow per ton of cooling capacity is recommended in open loop applications. Due to only minor differences in ﬂ ow rate from low to high, only one solenoid valve should be used. The valve should be sized for full ﬂ ow .

Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local codes, i.e. recharge well, storm sewer, drain ﬁ eld, adjacent stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning departments to assure compliance in your area.

Note: For open loop/groundwater systems or systems that do not contain an antifreeze solution, set SW2-Switch #2 to the “WELL ” position. (Refer to the table on page 28.) Slow opening/closing solenoid valves ( type VM) are recommended to eliminate water hammer.

Figure 9a: Open Loop Solenoid Valve Connection Option

Typical quick operating external 24V water solenoid valve (type PPV100 or BPV100) wiring.

Acc Com Acc NC Acc NO

1 2

Solenoid

Valve

Note:

SW2-3 should be in the Comp “ON” position.

Figure 10: Open System - Groundwater Application

Unit Supply

Aux. HeatSupply

Figure 9b: Open Loop Solenoid Valve Connection Option

Typical slow operating external 24V water solenoid valve (type VM) wiring.

CC-GND

CCHI

Logic Board

Comfort

Alert

Flexible Duct Collar

Violet(2

VM valve

Blk(1

Violet(3

Y1 Y2

Wht(4)

Rubber Bladder Expansion Tank

Auxiliary

Disconnects

(IfApplicable)

Compressor Line Voltage

Low Voltage

to Thermostat

and Valve

P/T Plugs

Vibration

Absorbing Pad

Heater Knockout

Desuperheater

Connections

Drain

Strainer

Solenoid

Valve

valve whileacid flushing)

Boiler Drains

For HXFlushing

(to isolatesolenoid

Flow Control

(on outletof

Solenoid Valve)

Water Out

Shut OffValves

Valve

Water In

ENVISION RESIDENTIAL INSTALLATION MANUAL

Desuperheater Connections

To m a x i m i ze t h e b e n e ﬁ ts of the desuperheater a minimum 50- gallon water heater is recommended. For higher demand applications, use an 80 -gallon water heater or two 50 -gallon water heaters connec ted in a series as shown below. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are met for installing a desuperheater.

Note: Under certain conditions, Envision dual capacity units operate with very low refrigerant discharge temperatures, producing little or no water heating capability. This scenario occurs when the unit is operating with cold entering source water (loop or well). Allowing the desuperheater pump to operate during these conditions actually removes heat from the DHW circulating through the unit. To overcome this, En vision unit microprocessors have been programmed to disengage the desuperheater pump during such conditions. (Dur ing low capac ity c ooling oper ation, the pump will operate only if the DHW temperature entering the unit is less than the liquid line temperature plus 35º F. During high capacity cooling operation, the pump will operate only if the DHW temperature is less than the l i quid line t emperature plus 60º F.) Using a preheat tank, as shown in Figure 12, will maximize desuperheater capabilities.

Water Tank Preparation

To install a unit with desuperheater, follow these installation guidelines.

Turn off the power to the water heater.

1. Attach a water hose to the water tank drain connection and run the other end of the hose to an open drain or

2. outdoors. Close the cold water inlet valve to the water heater tank.

3. Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve or hot water

4. faucet. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. Close when

5. draining water is clear. Disconnect the garden hose and remove the drain valve from the water heater.

6. Refer to Plumbing Installation and Desuperheater Startup on page 12.

Residential units with desuperheaters contain an internal circulator and ﬁ ttings.

CAUTION: Elements will burn out if energized dry.

Figure 11: Typical Desuperheater Installation

3/4 x 3/4 x 1/2 tee

Venting Waste

Valve or Vent

Coupling

DHW

Water In

DHW

Water Out

Cold

Water In

P/T Relief

Drain Valve

Valve

Water Out

Hot

Figure 12: Desuperheater Installation In Preheat Tank

Venting Waste Valve or Vent Coupling

Note: This conﬁ guration maximizes desuperheater capability.

3/4" x 3/4" x 1/2" tee

DHW

Water In

DHW

Water Out

Cold

Water In

P/T Relief

Valve

Drain ValveDrain Valve

Hot

Water Out

P/T Relief

Valve

ENVISION RESIDENTIAL INSTALLATION MANUAL

Plumbing Installation

1. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the desuperheater circulator will occur.

2. Remove drain valve and ﬁ tti n g .

3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into the water heater drain port.

4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple.

5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit.

6. Install the drain valve on the tee opposite the adaptor.

7. Run interconnecting tubing from the tee to DHW water out.

8. Cut the cold water “IN” line going to the water heater.

9. Insert the reducing solder tee in line with cold water “IN” line as shown.

10. Run interconnecting copper tubing between the unit DHW water “IN” and the tee (1/2-inch nominal). The recommended maximum distance is 50 feet.

11. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.

12. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation. Note: All plumbing and piping connections must comply with local plumbing codes

Desuperheater Startup

1. Close the drain valve to the water heater.

2. Open the cold water supply to the tank.

3. Open a hot water faucet in the building to bleed air from the system. Close when full.

4. Open the pressure relief valve to bleed any remaining air from the tank, then close.

5. If so equipped, unscrew the indicator plug 1 turn on the motor end of the pump until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines.

6. Carefully inspect all plumbing for water leaks and correct as required.

7. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank.

• On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 100°F. The upper element should be adjusted to 120°F to 130°F. Depending upon the speciﬁ c needs of the customer, you may want to adjust the upper element differently.

• On tanks with a single element, lower the thermostat setting to 120°F.

8. After the thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater.

9. Make sure that any valves in the desuperheater water circulating circuit are open.

10. Turn on the unit to ﬁ rst stage heating.

11. The DHW pump should be running. When the pump is ﬁ rst started, open the inspection port 1 turn (if equipped) until water dribbles out, then replace. Allow the pump to run for at least ﬁ ve minutes to ensure that water has ﬁ lled the circulator properly. Be sure the switch for the DHW pump (SW4) is “ON”. The DHW “OFF” LED on the unit should not be illuminated.

12. The temperature difference between the water entering and leaving the desuperheater should be 5°F to 15°F. The water ﬂ ow should be approximately 0.4 GPM per ton of nominal cooling.

13. Allow the unit to heat water for 15 to 20 minutes to be sure operation is normal.

CAUTION: Never operate the DHW circulating pump while dry. If the unit is placed in operation before the desuperheater piping is connected, be sure that the pump switch is set to the OFF position.

+ 28 hidden pages