WaterFurnace Envision2 Compact Installation Manual

COMPACT

Water Source/Geothermal Heat Pump - 50 Hz

• R-410A Refrigerant

• Commercial 005 to 017 kW

Installation Information

Water Piping Connections

Hot Water Connections

Electrical

Startup Procedures

Troubleshooting

Preventive Maintenance

Compact Installation Manual

Envision

IM1025AN 01/15

Table of Contents

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

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installing Horizontal Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hanger Bracket Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Water Piping and Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Cleaning and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hot Water Generator Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Freeze Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wiring Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Unit Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Operating Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Reference Calculations and Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Heat of Extraction/Rejection Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Startup and Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Heating/Cooling Cycle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Preventive Maintenance and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Revision Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

1-3 4 5-7 8 9 10

11 12 13 15

NBK V 015 T L 7 0 4 C A N14A16N17118A19120021SS

22-23*24

Model Nomenclature

Model Type

NBK – Envision Compact 50Hz

Cabinet Configuration

V – Vertical H - Horizontal

Unit Capacity (kW)

Single Speed 005, 017 Dual-Capacity 006, 009, 012, 015

Discharge Configuration

T – Top (Vertical) E – End (Horizontal) S – Side (Horizontal)

Return Air Configuration

L – Left R – Right

Voltage

6 – 220-240/50/1 (005-017) 7 – 320-420/50/3 (006-017)

Refrigeration Option

0 – None 2 – HWG Only w/o Pump G – Hot Gas Bypass R – Hot Gas Reheat B – Hot Gas Bypass w/Hot Gas Reheat

Blower Options 1 – Variable Speed ECM Blower 4 – 5-Speed ECM Blower

Water Coil Option

C – Copper D – Insulated Copper N – CuproNickel P – Insulated CuproNickel

Sound Kit Option

A – None B – Sound Kit

Note: 1 - Phase Guard Only Available on 380-420/50/3

Vintage

* - Factory Use Only

Non-Standard Options

SS – Standard

Drain Pan Option

0 – Composite, No Secondary Connection 1 – Composite, Secondary Connection 2 – Stainless Steel, No Secondary Connection 3 – Stainless Steel, Secondary Connection

Air Coil Option

3 – Standard 4 – AlumiSeal

Filter Option

A – MERV 4 B – MERV 13

Cabinet Option

0 – Unpainted Cabinet, Filter Rail 1 – Painted Cabinet, Filter Rail 2 – Unpainted Cabinet, 4-Sided Filter Rack 3 – Painted Cabinet, 4-Sided Filter Rack

Electrical Option

N – None A – IntelliStart E – IntelliStart and Disconnect P – Phase Guard, No Disconnect B – Phase Guard, Disconnect D – No Phase Guard, Disconnect

Control Option

A – Aurora E – Aurora F – Aurora

Water Control Option

N – None R – Water Flow Regulator V – 2-Way Valve B – 2-Way Valve w/ Water Flow Regulator

Rev.: 22 May 2014D

Only

Base Control (ABC)

DDC

DDC w/Lon

All Envision2 NBK 50Hz product is safety tested to CE standards and performance tested in accordance with standard EN 14511-2.

General Installation Information

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

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 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.

Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a fire 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 filter and access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined 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 difficult 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 configurations. Top flow vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor (see figure below).

Vertical Unit Mounting

50.8 mm

PEX Foam

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Vertical Dimensional Data

AIR COIL SIDE

4 3

FRONT

1.4 in (3.5 cm)

Top View - Right Return Top View - Left Return

Air coil

FRONT

1.4 in (3.5 cm)

Standard filter rails for

open return applications

Deluxe filter rack for

ductable return applications

Air coil

2' (61 cm)

Alternate Service Access

4 3

2' (61 cm)

Service Access Left Return

(Right Return opposite side)

Air coil

ACCESS

PANEL

Isometric View - Left Return

Field installed duct flange

ACCESS

PANEL

1.6 in (4.1 cm) Condensate 3/4 in

PVC glue socket

1.6 in (4.1 cm)

6 8

1 in (25.4 mm)

1/2" (12.7 mm)

Power supply

knockout

Low voltage

knockout

Front View - Right Return

ACCESS

PANEL

Condensate

3/4 in PVC

glue socket

1.6 in (4.1 cm)

8 7

5 2

Front View - Left Return

1.6 in (4.1 cm)

ACCESS

PANEL

8 7

Right View - Right Return

Left View - Left Return

Vertical Dimensional Data cont.

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Overall Cabinet Water Connections

Vertical

Models

005 006 009

012

015-017

Vertical

Models

005 006 009

012

015-017

Condensate is 3/4 in. PVC female glue socket and is switchable from side to front. *Discharge flange is field installed and extends 25.4 mm from top of cabinet.

**Vertical units shipped with standard 50.8 mm (field adjustable to 25.4 mm) open application filter rack extending

55.88 mm from unit and is not suitable for duct connection. For ductable return connection applications, order the deluxe 50.8 mm (field adjustable to 25.4 mm) duct collar/filter rack which extends 82.55 mm from the unit and is suitable for duct connections.

12345 JKL

A B C D E F G H Loop Knockout

Width Depth Height* In Out HWG In HWG Out

cm 57.2 66.5 102.1 6.6 19.3 3.6 11.2 27.4 19.1 mm 22.2 mm 25.7 15.5 20.6 cm 57.2 66.5 112.3 6.6 19.3 3.6 11.2 27.4 19.1 mm 22.2 mm 25.7 15.5 20.6 cm 64.8 79.2 112.3 6.6 19.3 3.6 11.2 27.4 25.4 mm 22.2 mm 25.7 15.5 20.6 cm 64.8 79.2 122.4 6.6 19.3 3.6 11.2 27.4 25.4 mm 22.2 mm 25.7 15.5 20.6 cm 64.8 79.2 132.6 6.6 19.3 3.6 11.2 27.4 25.4 mm 22.2 mm 25.7 15.5 20.6

Discharge Connection

duct flange installed (±2.54 mm)

MNPQR S T U VW

Filter Rack

Width

cm 5.6 35.6 35.6 15.5 11.4 19.6 5.1 56.1 55.9 4.8 cm 5.6 35.6 35.6 15.5 11.4 19.6 5.1 56.1 66.3 4.6 cm 5.6 45.7 45.7 16.8 11.7 16.0 4.1 71.4 66.3 5.1 cm 5.6 45.7 45.7 16.8 11.7 16.0 4.1 71.4 76.2 5.1 cm 5.6 45.7 45.7 16.8 12.7 16.3 4.1 71.4 86.4 5.1

Supply

Width

Supply

Depth

Cond-

ensate

Water

FPT

HWG

Provi-

sions

**Return Connection

using deluxe filter rack (±2.54 mm)

Return

Depth

Electrical Knockouts

678

12.7 mm cond

Low Volt-

age

12.7 mm

Low Volt-

Return Height

cond

age

25.4 mm

Power

Supply

6/25/12

Vertical Disconnect

When using disconnect, do not use dimension L from the standard vertical dimensional data. Use dimension LL from the vertical disconnect dimensional data.

Vertical Models LL

005 006 009

012 015 017

Dimensions in cm 6/25/12

36.3

38.9

36.3

External

Power

Supply

1.8 in.

[4.6 cm]

Disconnect Located on this

Side for a Right Return Disconnect Location

Alternative Power Location

Vertical Shown in

Left Return Configuration

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Horizontal Dimensional Data

Right Return

Condensate "X" PVC size

End Discharge

Deluxe filter rack option shown

2.3 in. [5.8 cm]

FILTER RACK

AIR COIL SIDE

2.1 in. [5.3 cm]

Right Return

End Discharge

BLOWER

OUTLET

Standard filter rails

1 in. [2.5 cm] knockout

0.5 in. [1.3 cm] knockout

Front

CMP

Service Access

Side Discharge

2' (61 cm)

1.7 in. [5.3 cm]

AP = Alternate Service Panel BP = Blower Service Panel CP = Control Access Panel CMP = Compressor Service Panel

CP AP

RR Front View

1.7

CP AP

LR Front View

Legend

1.7

1.7 in. [5.3 cm]

Service Access

0.5 in. [1.3 cm] knockout

1 in. [2.5 cm]

knockout

Standard filter rails

Front

CMP

2' (61 cm)

Side Discharge

Deluxe filter rack option shown

BLOWER

OUTLET

2.1 in. [5.3 cm]

Left Return

End Discharge

Left Return

Condensate

"X" PVC size

End Discharge

2.3 in.

AIR COIL SIDE

[5.8 cm]

FILTER RACK

Front

Air Coil

BLOWER

OUTLET

Right Return Side Discharge

Right Return Side View

1.5 in. [3.8 cm]

CMP

Left Return Side Discharge

Left Return Side View

1.5 in. [3.8 cm]

0.5 in. [1.3 cm]

CMP

FILTER RACK CONNECTION FILTER RACK CONNECTION

Front

1 in. [2.5 cm]

knockout

0.5 in. [1.3 cm] knockout

Deluxe filter

rack option

(shown)

knockout

Front

BLOWER

OUTLET

Air Coil

Front

Horizontal Dimensional Data cont.

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Overall Cabinet

Width

Supply

Depth

Horizontal

Models

005

cm 57.2 106.7 48.8 4.6 17.3 2.0 19.05 mm 23.1 18.0

006

cm 57.2 114.3 48.8 4.6 17.3 2.0 19.05 mm 23.4 18.0

009

cm 64.8 121.9 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

012

cm 64.8 134.6 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

015

cm 64.8 154.9 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

017

cm 64.8 172.7 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

Horizontal

Models

005

cm 17.0 26.7 23.9 12.4 69.6 42.2 5.1 3.6 108.6 63.8 54.4 1.9

006

cm 17.0 26.7 23.9 12.4 77.2 42.2 5.1 3.8 116.3 63.8 54.4 1.9

009

cm 12.4 34.5 33.5 11.7 89.9 47.2 5.8 3.6 124.0 71.4 62.0 1.9

012

cm 12.4 34.5 33.5 11.7 102.6 47.2 5.8 3.6 136.7 71.4 62.0 1.9

015

cm 12.4 34.5 33.5 11.7 115.3 47.2 5.8 3.6 157.0 71.4 62.0 1.9

017

cm 12.4 34.5 33.5 11.7 115.3 47.2 5.8 3.6 174.8 71.4 62.0 1.9

Horizontal units shipped with standard 50.8 mm (field adjustable to 25.4mm) open application filter rack extending 55.88 mm from unit and is not suitable for duct connection. For ductable return connection applications, order the deluxe 50.8 mm (field adjustable to 25.4 mm) duct collar/filter rack which extends 82.55 mm from the unit and is suitable for duct connections.

A B C D E H 12.7 mm cond 25.4 mm

Width Depth Height* In Out Condensate Low Voltage Power Supply

Discharge Connection

duct flange installed (±2.54mm)

LMNPQRS TUVWX

Supply

123

using deluxe filter rack option (±2.54 mm)

Return

Depth

Water Connections Electrical Knockouts

Return Connection

Return Height

Loop

Water FPT

Unit Hanger Dimensions PVC Size

6/25/12

Horizontal Disconnect

When using disconnect, do not use dimension K from the standard horizontal dimensional data. Use dimension KK from the horizontal disconnect dimensional data.

Horizontal Models KK

005 006 009

012 015 017

Dimensions in cm 6/25/12

23.4

28.4

25.9

28.4

25.9

Disconnect Located

on this Side for a

Left Return

2.1 in.

[5.3 cm]

Disconnect Location

Power Supply

Horizontal Shown in

Right Return Configuration

ENVISION2 COMPACT - 50 HZ 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.

NOTE: Left (Right) Return Side Discharge cannot be converted to Left (Right) Return End Discharge or vice versa, without additional custom sheet metal parts. Horizontal units are normally suspended from a ceiling by four (006-015 models) or five (017 model) 9.5 mm 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 Hanger Bracket Dimensions table. 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 filter access, install hanger brackets as illustrated in the Hanger Bracket Locations section. The unit should be pitched approximately 6.35 mm 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 applications require the installation of horizontal units on an attic floor. 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 overflow 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 9.5 mm diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling.

Hanger Bracket Locations

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Compressor

Section

NOTE: Model size 017 will be shipped with six (6) hanger brackets. Only five(5) hanger brackets will be used on the unit. See the above

illustration for the fifth hanger bracket location. All other models will use four (4) hanger brackets.

Hanger Bracket Dimensions

Model

005

006

009

012

015

017

Dimensions are listed in cm. 6/25/12

Hanger Kit

Part Number

99S500A04 108.7 63.8 54.4 n/a

99S500A04 116.3 63.8 54.4 n/a

99S500A03 124.0 71.4 62.0 n/a

99S500A04 136.7 71.4 62.0 n/a

99S500A04 157.0 71.4 62.0 n/a

99S500A03 174.8 71.4 62.0 74.4

ABCD

Right

Air Handler

Section

Unit Hanger Dimensions

3/8” Threaded Rod (not supplied)

Bolt and Lockwasher

Compressor

Section

Vibration Isolator

Washer

Hex Nuts (not supplied)

Weight Distribution

Model

005

006

009

Weights are listed in kg. 6/25/12

Vertical Weight

012

015

017

Horizontal

Weight

95 100 29 18 32 16

127 134 34 31 34 13

163 170 52 43 34 27

168 172 54 45 36 29

186 191 54 50 43 36

202 206 61 54 45 39

Left

Air Handler

Section

Horizontal Weight Distribution

Front Back

DEFG

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Duct System

An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection. A flexible connector is recommended for discharge and return air duct connections 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.

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.

The duct system should be sized to handle the design airflow quietly and efficiently. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard for the first 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 airflow is a problem, the blower speed can be changed.

All source water connections on commercial units are fittings that accept a male pipe thread (MPT). Insert the connectors by hand, then tighten the fitting with a wrench to provide a leakproof joint. When connecting to an open loop (groundwater) system, thread any copper MPT fitting into the connector and tighten in the same manner as described above.

Condensate Drain

On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a 19.1 mm PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary.

Vent (if needed)

PVC tube stub

10.4 mm per meter

PVC tube stub

PVC coupling

38.1 mm

On horizontal units, a PVC stub or stainless steel tube 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 fieldinstalled condensate piping.

Unit Pitch for DrainHorizontal Drain Connection (Composite Drain Pan)

12.7 mm Pitch

Drain

Water Quality

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

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

Material Copper 90/10 Cupronickel 316 Stainless Steel

pH Acidity/Alkalinity

Scaling

Corrosion

Iron Fouling

(Biological Growth)

Erosion

NOTES: Grains = ppm divided by 17

mg/L is equivalent to ppm

Calcium and

Magnesium Carbonate

Hydrogen Sulfide

Chlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Nitrate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Hydroxide Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Sulfate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Total Dissolved Solids (TDS) Less than 1000 ppm 1000 - 1500 ppm 1000 - 1500 ppm

LSI Index +0.5 to -0.5 +0.5 to -0.5 +0.5 to -0.5

Iron, FE

Bacterial Iron Potential

Iron Oxide

Suspended Solids

Threshold Velocity

(Fresh Water)

Less than 0.5 ppm (rotten egg

smell appears at 0.5 ppm) Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm Chlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

+ (Ferrous)

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

7 - 9 7 - 9 7 - 9

(Total Hardness)

less than 350 ppm

< 0.2 ppm < 0.2 ppm < 0.2 ppm

< 1.8 m/sec < 1.8 m/sec < 1.8 m/sec

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.

(Total Hardness)

less than 350 ppm

10 - 50 ppm Less than 1 ppm

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

(Total Hardness)

less than 350 ppm

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

2/22/12

System Cleaning and Flushing

Cleaning and Flushing

Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris.

If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location (This will prevent the introduction of dirt into the unit, see Flushing with Water Shutoff Valve Equipped Systems illustration). The system should be filled at the water make-up connection with all air vents open. After filling, vents should be closed.

The contractor should start the main circulator with the pressure reducing valve makeup open. Vents should be checked in sequence to bleed off any trapped air and to verify circulation through all components of the system.

As water circulates through the system, the contractor should check and repair any leaks found in the piping system. Drain(s) at the lowest point(s) in the system should

Flushing with Water Shutoff Valve Equipped Systems

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts Initially Connected Together

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

System Cleaning and Flushing cont.

be opened for initial flush and blowdown, making sure water fill valves are set at the same rate. Check the pressure gauge at the pump suction and manually adjust the makeup water valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if required, until drain water is clean and clear.

The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the system. Short-circuited supply and return runouts should now be connected to the unit supply and return connections.

Refill the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (pH 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Environol™ brand antifreeze is recommended.

Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure.

In boiler/tower application, set the loop control panel set points to desired temperatures. Supply power to all motors and start the circulating pumps. After full flow has

been established through all components including the heat rejector (regardless of season), air vented and loop temperatures stabilized, each of the units will be ready for check, test and start up and for air and water balancing.

Ground Source Loop System Checkout

Once piping is completed between the unit pumping system and ground loop, final purging and charging of the loop is needed. A high pressure pump is needed to achieve adequate flow 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 276-345 kPa (summer) or 345-517 kPa (winter). This is normally adequate for good system operation. Loop static pressure may decrease soon after initial installation, due to pipe expansion and loop temperature change. Running the unit for at least 30 minutes after the system has been completely purged of air will allow for the “break-in” period. It may be necessary to adjust static loop pressure (by adding water) after the unit has run for the first time. Loop static pressure will also fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the system initially.

Ensure the pump provides adequate flow through the unit by checking pressure drop across the heat exchanger. Usually 0.14-0.19 L/s of flow per ton of cooling capacity is recommended in earth loop applications.

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 flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in unit capacity data tables in the specification catalog. 0.09-0.13 L/s of flow per ton of cooling capacity is recommended in open loop applications. Due to only minor differences in flow rate from low to high, only one solenoid valve should be used. The valve should be sized for full flow.

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 field, 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.

Open System - Groundwater Application

Unit Supply

Aux. Heat Supply

Flexible Duct Collar

Hot Water Generator

Connections

Drain

Disconnects

(IfApplicable)

Compressor Line Voltage

Low Voltage

to Thermostat

and Valve

Vibration

Absorbing Pad

P/T Plugs

Strainer

Rubber Bladder Expansion Tank

Solenoid

Valve

valve while acid flushing)

Boiler Drains

For HX Flushing

Flow Control

(on outlet of

Solenoid Valve)

Water Out

Shut Off Valves

(to isolate solenoid

Valve

Water In

Hot Water Generator Connections

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

The heat reclaiming hot water generator coil is of vented double-wall copper construction and is suitable for potable water.

To maximize the benefits of the hot water generator a minimum 189 L water heater is recommended. For higher demand applications, use an 303 L water heater or two 189 L water heaters connected in a series as shown below. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are met for installing a hot water generator. A water softener is recommended with hard water (greater than 0.65 g or 170 total hardness).

Water Tank Preparation

To install a unit with a hot water generator, follow these installation guidelines.

1. Turn off the power to the water heater.

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

3. Close the cold water inlet valve to the water heater tank.

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

5. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. Close when draining water is clear.

6. Disconnect the garden hose and remove the drain valve from the water heater.

7. Refer to Plumbing Installation and Hot Water Generator Startup.

Typical Hot Water Generator Installation

19.1mm x 19.1mm x 12.7mm Tee

Ball Valve

Vent

HWG

Water Out

Field Installed

HWG Pump

HWG

Water In

Cold

Water In

Drain Valve

P/T Relief

Valve

Water Out

Hot

Hot Water Generator Installation In Preheat Tank

Cold

19.1mm x 19.1mm x 12.7mm Tee Ball Valve

Vent

Water Out

Field Installed

HWG

Water In

HWG

HWG Pump

Water In

P/T Relief

Valve

Drain Valve

NOTE: This configuration maximizes hot water generator capability.

Hot

Water Out

P/T Relief

Valve

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 hot water generator circulator will occur.

2. Remove drain valve and fitting.

3. Thread the 19.1 mm NPT x 89 mm brass nipple into the water heater drain port.

4. Attach the center port of the 19.1 mm FPT tee to the opposite end of the brass nipple.

5. Attach the 12.7 mm copper to 19.1 mm 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 HWG water out.

CAUTION: Elements will burn out if energized dry.

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 (12.7 mm nominal). The recommended maximum distance is 9.1 m.

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 9.5 mm wall closed cell insulation.

NOTE: All plumbing and piping connections must comply with local plumbing codes.

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

Hot Water Generator Connections cont.

Hot Water Generator Startup

1. Make sure the power is off to the heat pump. Connect the wire from the hot water generator pump to T1 on the contactor.

2. Close the drain valve to the water heater.

3. Open the cold water supply to the tank.

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

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

6. If so equipped, turn the venting (burping) screw in the center of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines.

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

8. 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 37.8°C. The upper element should be adjusted to 48.9°C to

54.4°C. Depending upon the specific needs of the customer, you may want to adjust the upper element differently.

• On tanks with a single element, lower the thermostat setting to 48.9°C.

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

10. Make sure that any valves in the hot water generator circuit are open.

11. Turn on the unit to heating.

12. The HWG pump should be running. When the pump is first started, turn the venting (burping) screw (if equipped) in the center of the pump two (2) turns open until water dribbles out, then replace. Allow the pump to run for at least five minutes to ensure that water has filled the circulator properly.

13. The temperature difference between the water entering and leaving the hot water generator should be 2.8°C to

8.3°C. The water flow should be approximately 0.007 L/S per KW of nominal cooling.

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

CAUTION: Never operate the HWG circulating pump while dry. If the unit is placed in operation

before the hot water generator piping is connected, be sure that the pump wires are disconnected from the contactor.

Freeze Detection

ENVISION2 COMPACT - 50 HZ INSTALLATION MANUAL

For Aurora Base Control, set SW2-1, FP1, on the printed circuit board for applications using a closed loop antifreeze solution to -9.4°C. On applications using an open loop/ ground water system (or closed loop no antifreeze), set this dip switch to -1.1°C, the factory default setting. (Refer to the Dip Switch Field Selection table).

Electrical Connections

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.

Power Connection

Connect the incoming line voltage wires to L1 and L2 of the contactor for single-phase unit. Consult the Electrical Data tables for correct fuse sizes.

Aurora Base Control Box

For FX10 board, the “red” wire must be removed from PB2-3 to change from -1.1°C, the factory default setting, to -9.4°C.

220 Volt Operation

All 220-240 units are factory wired for 240 volt operation. For 220 volt operation, the red and blue transformer wires must be switched on terminal strip PS.

CAUTION: When installing a unit with a variable speed ECM blower motor in 420/50/3 voltage, a neutral wire is required to allow proper unit operation.

FX10 Control Box

+ 37 hidden pages

WaterFurnace Envision2 Compact Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual