WaterFurnace Envision2 NXW Chiller User Manual

Download

NXW 10 to 50 Tons

Commercial Reversible Chiller - 60 Hz

Installation Information

Water Piping Connections

Electrical Data

Microprocessor Control

Startup Procedures

Preventive Maintenance

NXW Reversible Chiller Installation Manual

IM2502WN 06/14

Table of Contents

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

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Physical Dimensions

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Field Connected Water Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Typical Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

System Cleaning and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18

Field Wiring and Control Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

Control Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Inputs and Outputs Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Networking Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Unit Display and Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-26

Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Compressor / Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Heating and Cooling Cycle Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Factory Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-37

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Replacement Fuse Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-41

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

NXW 120 R 3 A E 8 N N

1-3 4-6 7 8 11 12 13

Vintage

Non-Standard Options

Future Option

Controls

Rev.:

14-15*16

9 10

Model Nomenclature

Model

NXW – Envision Reversible Chiller

Unit Capacity (MBTUH)

120, 180, 240, 360, 600

Operation

R - Reversible

Voltage

3 – 208-230/60/3 4 – 460/60/3 5 – 575/60/3 8 – 380/60/3

Phase Protection

A – Non-Fused Disconnect, Phase Guard B – Non-Fused Disconnect, IntelliStart® C – Fused Disconnect, Phase Guard D – Fused Disconnect, IntelliStart

Chassis

E – Enclosed P – Enclosed with Pressure Gauges

Notes:

See electrical availability table for detailed offering by voltage

Series

* - Factory Use Only

SS - Standard

N – Future Use

8 – FX10 without Communication, with User Interface 9 – FX10 with Open N2 Communication Card with User Interface 0 – FX10 with Lonworks Communication Card with User Interface 3 – FX10 with BacNet Communication Card with User Interface

14 February 2014D

Voltage Availability

Voltage

208-230/60/3

460/60/3

575/60/3

380/60/3

Legend: NA = Not Available

120 180 240 360 600

•• ••

•• •• •• • •

•••••

••

NA NA

Model

• = Voltage available in this size

•• = Voltage and IntelliStart available in this size

••

03/05/14

General Installation Information

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Safety Considerations

Installing and servicing air conditioning and heating 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. 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 quenching cloth for brazing operations. Have fire extinguisher available for all brazing operations.

NOTE: Before installing, check voltage of unit(s) to ensure proper voltage.

WARNING: Before performing service or maintenance operations on the system, turn off main power switches to the unit. Electrical shock could cause serious personal injury.

Application

Units are not intended for heating domestic (potable water) by direct coupling. If used for this type of application, a secondary heat exchanger must be used.

Unit Location

Provide sufficient room to make water and electrical connections. If the unit is located in a confined space, provisions must be made for unit servicing. Locate the unit in an indoor area that allows easy removal of the access panels and has enough space for service personnel to perform maintenance or repair. These units are not approved for outdoor installation and, therefore, must be installed inside the structure being conditioned. Do not locate units in areas subject to freezing conditions.

WARNING: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g. attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life.

WARNING: To avoid equipment damage and possible voiding of warranty, be sure that properly sized strainers are installed upstream of both brazed plate heat exchangers to protect them against particles in the fluid.

Moving and Storage

Move units in the normal “Up” orientation as indicated by the labels on the unit packaging. When the equipment is received, all items should be carefully checked against the bill of lading to ensure that all crates and cartons have been received in good condition. Examine units for shipping damage, removing unit packaging if necessary to properly inspect unit. Units in question should also be internally inspected. If any damage is observed, the carrier should make the proper notation on delivery receipt acknowledging the damage. Units are to be stored in a location that provides adequate protection from dirt, debris and moisture.

WARNING: To avoid equipment damage, do not leave the system filled in a building without heat during cold weather, unless adequate freeze protection levels of antifreeze are used. Heat exchangers do not fully drain and will freeze unless protected, causing permanent damage.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

General Installation Information cont.

Mounting Units

Remove the unit from the wooden shipping skids (see physical dimensions). Units will be shipped with heavy duty rubber grommets to reduce sound that can be transmitted through the floor via the frame (see isolator drawing). For additional sound attenuation, use heavy duty spring isolation that can reduce sound levels by 3 dBA (see springs drawing).

Rubber Isolators RD2 RD3

Part

Number

99S502-01 RD2 Green 380 0.50 4

• Compatible with NXW120-180

Type

Color Code

Max Load,

lbs

Deflection, in Qty

Part

Number

99S502-02 RD3 Green 750 0.50 4

• Compatible with NXW240-600

Type

Color Code

Max Load,

lbs

Deflection, in Qty

Spring Isolators

Number

IS-325-01 NXW120-180 Brown 325 lbs 1.23" 264 lbs/in 1/2 x 3.5 4 IS-750-01 NXW240-600 Orange 750 lbs 1.06" 707 lbs/in 1/2 x 3.5 4

Compatible

With

Spring

Color

Rated

Capacity

Rated

Deflection

Isolator

Constant

Adjustment

Bolt

Qty

Unpacking the Unit

Remove the stretch warp and protective cardboard from the unit. Where applicable, remove the compressor shipping brackets located at the base of each compressor. To do so, lift up the bottom of the compressor sound jacket and remove the two bolts that hold the bracket .

Physical Dimensions

SERVICE PORTS

SOURCE

WATER OUT

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

EMERGENCY STOP SWITCH

DISCONNECT SWITCH

CONTROL BOX COVER

MAIN POWE R CONNECTION

SOURCE

WATER IN

LOAD

WATER IN

LOAD

WATER OUT

2.40

TO PORT

(SERVICE)

TOP

FX-10

CONTROLLER

DISPLAY

ACCESS DOOR

SIDE ACCESS PANEL DOORS

VIBRATION PADS

NOTES:

1. DO NOT SCALE DRAWING.

FRONT

"B"

SOURCE

WATER OUT

SOURCE

WATER IN

REARSIDE

"G"

7.50

4.50

7.00

ELECTRICAL

HIGH VOLTAGE

ELECTRICAL

LOW VOLTAGE

4.50

4.00

"A"

LOAD

WATER IN

LOAD

WATER OUT

"C"

"H"

"F"

"E"

"D"

Model A B C D E F G H J

120-180

240-360

600

57.3

[1455]

64.2

[1631]

71.1

[1806]

24.1

[612]

24.1

[612]

24.0

[610]

42.5

[1080]

50.5

[1283]

58.5

[1486]

5.0

[127]

6.9

[175]

6.5

[165]

17.0

[432]

17.0

[432]

17.0

[432]

8.8

[224]

13.9

[353]

19.5

[495]

17.0

[432]

17.0

[432]

17.0

[432]

11.9

[302]

12.1

[307]

15.0

[381]

4.6

[117]

3.6

[91]

3.2

[81]

All dimensions in inches, [mm] 5/12/14

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Physical Dimensions, cont.

DETAIL A

25.00

24.00

52.00

24.00

SHADED AREAS REPRESENT REQUIRED CLEARANCE FOR SERVICE & MAINTENANCE OF EQUIPMENT.

Model K L M N P R S T*

120-180

240-360

600

57.0

[1448]

65.0

[1651]

70.0

[1778]

42.0

[1067]

42.0

[1067]

42.0

[1067]

63.1

[1603]

69.9

[1775]

76.8

[1951]

15.9

[404]

19.9

[505]

22.0

[559]

19.5

[495]

19.5

[495]

19.5

[495]

9.7

[246]

9.7

[246]

12.7

[323]

1.3

[33]

1.8

[46]

1.8

[46]

All dimensions in inches, [mm] *T - Units shipped with groove pipe connection

2.0

[50.8]

2.0

[50.8]

2.5

[63.5]

5/12/14

Physical Data

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Model Compressor

120

180

240

360

600

Weights shown in Pounds, [kg] 1/30/2014

* Refrigerant per circuit in Pounds, [kg] Add 32 lbs [15 kg] for fluid weight when full. (120) Add 48 lbs [22 kg] for fluid weight when full. (180) Add 64 lbs [29 kg] for fluid weight when full. (240) Add 110 lbs [50 kg] for fluid weight when full. (360) Add 144 lbs [65 kg] for fluid weight when full. (600)

Scroll (2)

Refrigerant

Charge*

5.3 720 710

[2.4] [327] [323]

7.8 838 844

[3.5] [381] [384]

10.5 1130 1152

[4.8] [514] [524]

17.9 1320 1388

[8.1] [600] [631]

27.3 1748 1850

[12.4] [795] [841]

Total Weight

Shipping Installed

NOTE: See page 12 for minimum fluid volume guidelines.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Field Connected Water Piping

General

System piping should be kept as simple as possible to minimize the pressure drop, but hand valves should be field installed to facilitate unit servicing. The piping installation should provide service personnel with the ability to measure and/or monitor water temperatures and pressures.

Source and load fluid connections are provided with 2-inch [50.8mm] Victaulic grooved nipples (see Figure 4). Each nipple will also have a PT port installed for test and balance purposes. It will be the installing contractor’s responsibility to adequately support incoming piping to avoid damage to the unit’s piping or heat exchangers. The water lines should be routed so as not to interfere with access to the unit.

For any installation where the transmission of vibration through the piping connections could cause unacceptable noise levels in occupied spaces it is important to provide adequate vibration damping. One method is to use the optional Adapter Hose Kit (kit number TKC16S-4). This Kit consists of four pieces of a braided stainless steel flexible hose with a 2” Victaulic connection on one end and a 2” MPT connection with pipe union on the other. Overall length of each piece is 18”.

NOTE: Units are factory run-tested using propylene glycol. Prior to connecting piping to unit, thoroughly flush heat exchangers.

NOTE: The placement and connection of the water circulating pump(s) must be taken into consideration prior to designing the final water piping systems.

Closed Loop Tower/Boiler Systems

The water loop is usually maintained between 60°F [15.5°C] and 90°F [32.2°C] for proper heating and cooling operation. This is accomplished with a cooling tower and a boiler.

To reject excess heat from the condenser water loop, the use of a closed-circuit evaporative cooler or an open type cooling tower with a secondary heat exchanger between the tower and the condenser water loop is recommended. If an open type cooling tower is used without a secondary heat exchanger, continuous chemical treatment and filtering of the water must be performed to ensure the water is free from damaging materials.

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

Open Loop Well Water Systems

Installation of an open loop system is not recommended without using a secondary heat exchanger unless water quality guidelines are met.

Before final connection to the unit, the supply and return hose kits must be connected to each other, bypassing the unit, and the system flushed to remove dirt, piping chips and other foreign material. Normally, a combination balancing and close-off (ball) valve is installed at the return, and a rated gate or ball valve is installed at the supply. The return valve can be adjusted to obtain the proper water flow. The valves allow the unit to be removed for servicing.

The proper water flow must be delivered to each unit whenever the unit heats or cools. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. A 3 GPM flow rate per ton [0.054 LPS per kW]

of cooling capacity (2.25 GPM per ton [0.0404 LPS per kW] minimum) is required.

CAUTION: Remove the plastic protective caps in the ends of each of the four water pipes on the heat exchangers prior to piping connection. Failure to remove the caps will result in serious damage and could void the warranty.

Earth Coupled Systems

All supply and return water piping should be insulated to prevent excess condensation from forming on the water lines. Ensure pumping system is capable of providing adequate flow rate at the system pressure drop, 3.0 GPM per ton [0.054 LPS per kW] (source side) is recommended. Antifreeze in the loop is strongly recommended.

Envision2 NXW Typical Piping

Standard Piping

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Field Supplied and InstalledFactory Installed

Pump

Water

Temperature

Sensors

Brazed Plate

Heat Exchanger

1/4” NPT

Pressure/Temperature

Port

Isolation Valves

Strainer

Isolation Valve

Note: System piping should have drain ports to enable flushing and cleaning of heat exchangers. On systems utilizing pumps with VFDs, an automatic flow control valve must be installed.

Pressure Regulated Piping

Field Supplied and InstalledFactory Installed

Isolation Valves

Pump

Pressure Actuated

Water Valve

From Load

To Load

Compressor

Discharge

Pressure

Strainer

Isolation Valve

Water

Temperature

Sensors

Brazed Plate

Heat Exchanger

1/4” NPT

Pressure/Temperature

Port

Note: System piping should have drain ports to enable flushing and cleaning of heat exchangers. On systems utilizing pumps with VFDs, an automatic flow control valve must be installed.

From Load

To Load

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Envision2 NXW Application Data

1.0. Minimum Fluid Volume

A. Water-to-water heat pumps require a minimum amount

of source and load side ﬂ uid volume to ensure accurate and stable temperatures during system operation. For normal air conditioning type applications, it is recommended to use at least 7 gallons/ton.

Applications that require more precise temperature control or low loading will occur the minimum ﬂ uid volume shall be no less than 10 gallons/ton. Installation of a buffer tank that will properly mix the ﬂ uid is recommended.

1.1. Water-to-Water Heat Pump Sizing

A. Heat pumps should be adequately sized for optimal

system efﬁ ciency and run time. Oversizing by more than 15% can diminish performance resulting in higher power consumption, short cycling of compressors, and unstable conditioning temperatures.

B. In applications where the minimum load is signiﬁ cantly

less than the design condition, it is better to install 2 smaller heat pumps for load matching rather than a single large heat pump.

1.2. Heat Pump Piping

A. Multiple heat pumps can be installed in series or

parallel conﬁ gurations. The preferred system design is to pipe the equipment in parallel due to its simplicity and ﬂ exibility. In parallel systems, the heat pump equipment can vary in size as long as ﬂ ow rate and system volume are accounted for.

B. Piping equipment in series is not desired; however,

it can be done if proper guidelines are followed. Always observe proper temperature and ﬂ ow rate requirements for each unit. Sometimes this method is desired to achieve larger temperature differences.

1.3. Strainers

A. All brazed-plate heat exchangers shall have a

strainer within 8 ft of the water/brine inlet. It is highly recommended to use a minimum of 60 mesh in order to provide maximum ﬁ ltration. In any case, the strainers should never have a mesh size less than 20.

B. Failure to install proper stainers and perform regular

service can result in serious damage to the unit, and cause degraded performance, reduced operating life and failed compressors. Improper installation of the unit (which includes not having proper strainers to protect the heat exchangers) can also result in voiding the warranty.

C. Strainers should be selected on the basis of acceptable

pressure drop, and not on pipe diameter. The strainers selected should have a pressure drop at the nominal ﬂ ow rate of the units; low enough to be within the pumping capacity of the pump being used.

1.4. Flow Sensing Devices

A. A ﬂ ow switch or equivalent must be installed on the

evaporator for each unit to be installed. If the unit is to operate as both modes (heating/cooling), a ﬂ ow switch is needed on both heat exchangers.

B. A differential pressure switch can be used in place of a

ﬂ ow switch. The differential switch must be capable of pressure range as indicated in the pressure drop tables.

1.5. Water Quality

A. General: Reversible chiller systems may be successfully

applied in a wide range of commercial and industrial applications. It is the responsibility of the system designer and installing contractor to ensure that acceptable water quality is present and that all applicable codes have been met in these installations.

B. Water Treatment: Do not use untreated or improperly

treated water. Equipment damage may occur. The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae or slime. The services of a qualiﬁ ed water treatment specialist should be engaged to determine what treatment, if any, is required. The product warranty speciﬁ cally excludes liability for corrosion, erosion or deterioration of equipment.

The heat exchangers in the units are 316 stainless steel

plates with copper brazing. The water piping in the heat exchanger is steel. There may be other materials in the building’s piping system that the designer may need to take into consideration when deciding the parameters of the water quality.

If an antifreeze or water treatment solution is to be

used, the designer should conﬁ rm it does not have a detrimental effect on the materials in the system.

C. Contaminated Water: In applications where the

water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat exchanger is recommended to separate the unit from the contaminated water.

The following table outlines the water quality

guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is required. Failure to supply a secondary heat exchanger where needed will result in a warranty exclusion for primary heat exchanger corrosion or failure.

WARNING: Must have intermediate heat exchanger when used in pool applications.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Envision2 NXW Application Data cont.

1.6. Insulation

A. Heat pumps are built with factory installed insulation

on any surface that may be subject to temperatures below the room dew point.

Surface Condensation Chart

Room Ambient Condition

Normal (Max 85°F, 70% RH) 1/2" 3/4" 1"

Mild (Max 80°F, 50% RH) 1/8" 1/4" 1/2"

Severe (Max 90°F, 80% RH) 3/4" 1" 2"

Surface Temperature

50°F 35°F 0°F

Water Quality Guidelines

Material 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 Less than 1 ppm

Sulfates Less than 200 ppm

Chlorine Less than 0.5 ppm

Chlorides Less than 300 ppm

Carbon Dioxide 10 - 50 ppm

Ammonia Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm

Ammonia Nitrate Less than 0.5 ppm

Ammonia Hydroxide Less than 0.5 ppm

Ammonia Sulfate Less than 0.5 ppm

Total Dissolved Solids (TDS) 1000 - 1500 ppm

LSI Index +0.5 to -0.5

Iron, FE

Bacterial Iron Potential

+ (Ferrous)

Iron Oxide

Suspended Solids

Threshold Velocity

(Fresh Water)

(Total Hardness)

less than 350 ppm

< 0.2 ppm

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

< 6 ft/sec

7 - 9

1.7. Brine Applications

A. Applications where the leaving ﬂ uid temperature goes

below 40°F a suitable brine solution must be used. Failure to do so can cause immediate damage to the system. The brine must be approved for use with heat exchangers. Automotive antifreeze solutions are not suitable for use in brazed plate heat exchangers.

The freeze detection must be adjusted appropriately for brine applications. The brine solution concentration should be at least 15°F below the lowest leaving ﬂ uid temperature.

2/22/12

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

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.

Flushing with Water Shutoff Valve Equipped Systems

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts Initially Connected Together

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 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 40-50 PSI (summer) or 50-75 PSI (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.

Electrical Data

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Model

120

180

240

360

600

HACR circuit breaker in USA only

- MCC, RLA, & LRA rating per compressor. Breaker & FLA sized for both compressors.

- Equipment supplied with Class J fuses per minimum fuse size.

Rated

Voltage

208-230/60/3 187/253 36.0 23.1 160.0 46.2 52.0 60.0 70

460/60/3 414/506 19.0 12.2 87.0 24.4 27.5 30.0 35

575/60/3 517/633 13.5 8.7 62.0 17.4 19.6 20.0 25

380/60/3 342/418 19.0 12.2 95.0 24.4 27.5 30.0 35

208-230/60/3 187/253 45.0 28.8 235.0 57.6 64.8 70.0 90

460/60/3 414/506 19.0 12.2 110.0 24.4 27.5 30.0 35

575/60/3 517/633 16.5 10.9 95.0 21.8 24.5 25.0 35

208-230/60/3 187/253 52.2 35.2 250.0 70.4 79.2 80.0 110

460/60/3 414/506 27.0 19.2 140.0 38.4 43.2 45.0 60

575/60/3 517/633 19.1 14.5 100.0 29.0 32.6 35.0 45

208-230/60/3 187/253 75.0 48.1 351.0 96.2 108.2 110.0 150

460/60/3 414/506 38.6 24.7 197.0 49.4 55.6 60.0 80

575/60/3 517/633 35.0 22.4 135.0 44.8 50.4 60.0 70

380/60/3 342/418 51.0 32.7 239.0 65.4 73.6 80.0 100

460/60/3 414/506 62.0 39.7 260.0 79.4 89.3 100.0 125

575/60/3 517/633 45.0 28.8 210.0 57.6 64.8 70.0 90

380/60/3 342/418 72.0 46.2 310.0 92.4 104.0 110.0 150

Voltage

Min/Max

Compressor

MCC RLA LRA

Total

Unit FLA

Min Circ

Amp

Min Fuse/ HACR

Max

Fuse/

HACR

3/5/14

Compressor Protection Module

An electronic protection module is provided with

compressors utilized in model size 600. This module will protect against phase reversal and phase loss at start-up. Protection is active for 5 seconds after the first second of compressor operation. In the event that either phase sequencing or phase loss has occurred the following blink sequence will display on the module.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Electrical Data cont.

Figure 6: Control Box

Power Supply

(Field line voltage

connection)

Fused / Non-Fused Disconnect

Class J Fuses

Transformer

Class CC Fusing

for Transformer

FX10 Control Board

FX10 Expansion Board

Compressor

Contactor (Lower)

Compressor

Contactor (Upper)

Compressor Current Sensors

Field Low Voltage Connections

Wiring Schematics

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Chiller with IntelliStart

11/14/13

97P862-01

Yellow (17)

Black/White (18)

Yellow (19)

Black/White (20)

Red

Grn/Yel

Blue

Red

Compressor

Unit Power Supply

L1 L2 L3

Disconnect(fused disconnectoptional)

LP – Low Pressure

Legend

CC – Compressor Contactor

Black

F10

Black (97)

Protection

Compressor

T2S2S1

Earth Ground

Grn/Yel

Blue

(Circuit 2)

Compressor

(CPM1)

Protection

Module#1

Compressor

T2S2S1

Black

Earth Ground

(Circuit 1)

Disconnecthandle

PB – Power Block

RV – Reversing Valve

SFS – Source Flow Switch

PGM – Phase Guard Monitor

LST – Leaving Source Temp

L-WCT – Load Water Coil Temp

ressor Protection Module

EST – Entering Source Temp

HP – High Pressure

CPM – Comp

CS – Current Switch

ELT – Entering Load Temp

ES – Emergency Shutdown

PB1

Yellow

Black/White

24V

Transformer

Red for 208V

Blue for 230-240V

F11

Blue (98)

NOTE 10

(CPM2)

Module#2

Blue

Black

Red

NOTE 10

Blue

Black

Blue

White

Red

Current Switch

Red(C)

(throughthe door)

L2L1 L3

Black(G)

Closed Jumper

Open Jumper

S-WCT – Source Water Coil Temp

F - Fuse

TB – Terminal Board

Field low voltage wiring

Field line voltage wiring

Factory low voltage wiring

Optional block

Factory line voltage wiring

S - Splice

LFS – Load Flow Switch

LLT – Leaving Load Temp

Black (95)

231

Green/Yellow (16)

Red for 380V

Blue for 460V

Blue for 575V

L2(IN) L2(OUT) L1(IN) L1(OUT) L3

Black(Q)

White

White(R)

T1T2T3

Black

CC2

Black

Current Switch

CS2

L2(IN) L2(OUT) L1(IN) L1(OUT) L3

Black(N)

White(P)

T1T2T3

White(B)

White(H)

L1L2L3

CC1

Black

CS1

F5 F6

L1 L2 L3

Black(A)

Red(J)

L1 L2 L3

F7 F8 F9

Black

Ground

¼” Quick Connector

Relay coil

Field Supplied Option

Thermistor

(22)

Black/White

(62)

Black/White

(21)

Yellow

Soft

Start

L1L2L3

Soft

Start

Red (F)

White (E)

Black(D)

L2L1 L3

24VAC COM

DO-9

24VACSSDO-8

Black (R)

Black (C)

Black (RS)

Black (SS)

14613

Black (30)

Black (29)

Black/White (26)

(26)

Black/White

Yellow (24)

Black (F20)

Green/Yellow (23)

White/Red (81)

White/Red (80)

White/Blue (33)

L-WCT

S-WCT

Circuit 1

Black (30)

Black (F19)

D09

GROUND 24VAC Com 24VAC

AI3

5VDC

White/Red (80)

1019202122

White/Blue (34)

Yellow/Red (35)

S-WCT

Circuit 1

Black (29)

Black (F18)

AI5

White/Red (81)

White/Blue (33)

Yellow/Red (36)

Yellow/Blue (37)

TTT

L-WCT

Circuit 2

D08

NOTE 6

White/Blue (34)

Yellow/Blue (38)

Circuit 2

(24)

Yellow

Orange (61A)

Orange (61B)

Yellow (21)

Blue (98)

Black (97)

Black/White (22)

Red (M)

White (L)

Black(K)

Orange (61A)

Orange (61B)

Orange (60)

21789

Orange (60A)

Orange (61A)

Orange/Wht (60B)

Orange/Wht (61B)

RV2

RV1

NOTE 7

DO-7

Black (X2)

Yellow (25)

Yellow

Black (F17)

AI4

Yellow/Red (35)

Yellow/Red (36)

353132

Tan/Black (85)

Tan/Black (84)

LLT

Comp B

Alarm

LC2

Black (LC2)

Black (28)

Brown (53)

Black (28)

Brown (53)

161514

Black (F16)

D07

A34

A24 A14

AI6

Tan/Black (84)

Yellow/Blue (37)

Yellow/Blue (38)

Blue (76A)

Tan/White (83)

Tan/White (82)

LP-1

ELT

Comp A

Alarm

LC1

Black (LC1)

Black (F15)

AI2

3332313029282726252423

Tan/Black (85)

Blue (49A)

NOTE 3

Acc

Black (X1)

Brown (52)

Yellow

Black (F14)

A33

A35

A25

5VDC

353637

Tan/White (82)

Black (49)

Blue/Wht (49B)

Blue/Wht (76B)

LP-2

Blue (51)

AI1

Black (73A)

HP-1

COMP 1

Black (Y1)

Blue (45)

Black/White (62)

Black (F13)

A31

A32 A22

A21A12

LED

Tan/White (83)

1718292826

Black (74A)

Black/Org (73B)

HP-2

COMP 2

Black (Y2)

Blue (46)

Black (F12)

A11 A13 A23

5VDC

Brn/Blk (42)

Black/Org (74B)

LST

Yellow

Brn/Blk (41)

REV VALVE

O/B

Black (O/B)

Orange (47)

Black (F11)

PWM2

PWM2 Com

Brn/Wht (87)

Brn/Wht (86)

EST

NOT USED

Black (G)

294

10611

Black (F10)

D05

D04

PWM1

AIC

A15

Brn/Blk (41)

Brn/Blk (42)

Black (AIC)

Black (F9)

24VAC Com

J10

Brn/Wht (87)

Black (75A)

Black (L)

Black (SC)

Black/Org (75B)

Black

Orange (60)

Black (F7)

Black (F8)

765

D03

Johnson FX-10

DI12

DI11

DI10

DI9

DI8

444546

Blue (46)

Gray (48)

White (88)

White (89)

Orange (47)

SFS

NOTE 5

Connect to R on TB

CS-B

Circuit B

CS-A

Circuit A

Brn/Wht (86)

Black (TO)

White (89)

Black (F6)

DI7

Blue (45)

D02

Black Black

Notes

1 - Disconnect for 15 degree source side freeze protection

2 - Disconnect for 15 degree load side freeze protection

Black/White (63)

CC2

CC1

(72B)

Black/Org

Black (72A)

M2M1

CPM1

CPM2

NOTE 9

Black

(71A)

(71B)

Black/Org

Black/Org (70B)

Black (70A)

Violet (67)

Violet (66)

Black (F2)

Black (F4)

Black (F3)

Black (F5)

D01

DI 3/4/5/6/ Com

DI6

DI5

DI4

DI3

DI2

Black

Red (55)

Gray (56)

Blue (76A)

Blue (76B)

Brown (57)

NOTE 8

NOTE 1

NOTE 2

Black (54)

PB2

White (B)

31 30 29

Black (A)

28 27 26 25 24 23 22 21 20

17 16 15 14 13 12 11 10

be removed to check the jumpers.

PB2-3 for the unit to operate.

5 – A field installed flow switch is required for the source side and must be connected

to R for the unit to operate.

3 – Acc output is cycled with the lead compressor.

4 - A field installed flow switch is required for the load side and must be connected to

NOTE 9

White (88)

Black (F1)

DI1

9VDC

Pink (58)

Gray (59)

Brown (99)

5Vdc Com

AI4 EXP

c 5Vd

5Vdc Com

AI3 EXP

c 5Vd

5Vdc Com

AI2 EXP

c 5Vd

5Vdc Com

AI1 EXP

c 5Vd

DO3

24 Vac DO4 DO5

24 Vac DO6

24 Vac Com

24 Vac

8 – In Emergency Shutdown, line voltage is still present in control box. Emergency

7 – Reversing Valve will be energized for heating mode.

6 - Jumpers must be set as shown for correct control operation. If a communication

card is present, it must

White (89)

Black/Org (70B)

Black (70A)

White (88)

NOTE 4

LFS

White (88)

White (89)

Black (70A)

Black/Org (70B)

Connection

Main Board

A43

A41

A42

A31

A32

A33 A21A22

A23 A13

A12

A11

Johnson FX10

Expansion Board

Page 1

inside of the compressor junction boxes. Only used on the 600 model.

9 – M1 and M2 are located on the compressor protection modules (CPM1 and CPM2)

Switch is wired on low voltage circuit only.

10 – Only used on the 600 model.

Orange (47)

Blue (46)

Blue (45)

Black (75A)

Black/Org (75B)

Orange (60)

BLACK WIRE HARNESS

Black/Org (75B)

Black (75A)

Blue (45)

Orange (60)

Blue (46)

Orange (47)

D08

D07

D02

3 2 1

D01

NOTE 7

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Wiring Schematics cont.

Chiller with Phase Guard

11/14/13

97P862-02

Y-OUT

PGM

Yellow (17)

Black/White (18)

Yellow (19)

Black/White (20)

Red

Grn/Yel

Blue

Red

Compressor

Unit Power Supply

L1 L2 L3

Disconnect(fused disconnectoptional)

LP – Low Pressure

Legend

CC – Compressor Contactor

Yellow (100)

Yellow

24V

Black

F10

Black (97)

Protection

Module#2

Compressor

T2S2S1

Earth Ground

Grn/Yel

Blue

(Circuit 2)

Compressor

(CPM1)

Protection

Module#1

Compressor

T2S2S1

Black

Earth Ground

(Circuit 1)

Disconnecthandle

PB – Power Block

RV – Reversing Valve

SFS – Source Flow Switch

S-WCT – Source Water Coil Temp

PGM – Phase Guard Monitor

LST – Leaving Source Temp

L-WCT – Load Water Coil Temp

ressor Protection Module

EST – Entering Source Temp

HP – High Pressure

LFS – Load Flow Switch

CPM – Comp

CS – Current Switch

ELT – Entering Load Temp

ES – Emergency Shutdown

Yellow (80)

PB1

Black/White

Transformer

Red for 208V

Red for 380V

Blue for 230-240V

F11

Blue (98)

NOTE 10

(CPM2)

Blue

Black

Red

NOTE 10

Blue

Red

Current Switch

Red(C)

(throughthe door)

White(B)

L2L1 L3

White(H)

Black(G)

Open Jumper

F - Fuse

TB – Terminal Board

Field low voltage wiring

Factory low voltage wiring

Factory line voltage wiring

LLT – Leaving Load Temp

S - Splice

Black (95)

231

Green/Yellow (16)

Blue for 460V

Blue for 575V

L3L2L1

Phase

Guard

Monitor

(PGM)

Black

White

Black

Current Switch

CS2

Black

T1T2T3

CC1

White

Black

CS1

F5 F6

L1 L2 L3

Black(A)

Red(J)

L1 L2 L3

F7 F8 F9

Ground

Closed Jumper

¼” Quick Connector

Relay coil

Field line voltage wiring

Field Supplied Option

Optional block

Thermistor

Black/White

(62)

Black/White

Yellow

Black/White (27)

White (8)

Black(7)

T1T2T3

L1L2L3

CC2

L1L2L3

Red (F)

White (E)

L2L1 L3

(22)

(21)

Black(D)

24VAC COM

DO-9

24VACSSDO-8

Black (R)

Black (C)

Black (RS)

Black (SS)

14613

Black (30)

Black (29)

Yellow (25)

Black/White (26)

(26)

Black/White

Yellow (24)

Black (F20)

Green/Yellow (23)

White/Red (81)

White/Red (80)

S-WCT

Circuit 1

Black (30)

Black (F19)

D09

GROUND 24VAC Com 24VAC

5VDC

White/Red (80)

1019202122

White/Blue (34)

White/Blue (33)

L-WCT

Circuit 1

Black (29)

Black (F18)

AI3

White/Red (81)

White/Blue (33)

Yellow/Red (35)

Yellow/Red (36)

Yellow/Blue (37)

TTT

L-WCT

S-WCT

Circuit 2

D08

NOTE 6

AI5

White/Blue (34)

Yellow/Blue (38)

Circuit 2

(24)

Yellow

Orange (61A)

Orange (61B)

Yellow (21)

Blue (98)

Black (97)

Black/White (22)

Red (9)

Red (M)

White (L)

Black(K)

Orange (61A)

Orange (61B)

Orange (60)

21789

Orange (60A)

Orange (61A)

Orange/Wht (60B)

Orange/Wht (61B)

RV2

RV1

NOTE 7

DO-7

Black (X2)

Yellow

Black (F17)

AI4

Yellow/Red (35)

Yellow/Red (36)

353132

Tan/Black (85)

Tan/Black (84)

LLT

Comp A

Comp B

Alarm

LC2

Black (LC2)

Black (28)

Brown (53)

Black (28)

Brown (53)

161514

Black (F16)

Black (F15)

D07

A34

A24 A14

AI2

AI6

Tan/Black (84)

Yellow/Blue (37)

Yellow/Blue (38)

Blue (49A)

Blue (76A)

Tan/White (83)

Tan/White (82)

LP-1

ELT

Alarm

LC1

Black (LC1)

Brown (52)

Yellow

A33

A35

A25

5VDC

3332313029282726252423

Tan/Black (85)

Black (49)

Blue/Wht (49B)

Blue/Wht (76B)

LP-2

NOTE 3

Acc

Black (X1)

Black (F14)

AI1

353637

Tan/White (82)

Black (73A)

Blue (51)

Black/White (62)

Blue (51)

Black (F13)

A31

A32 A22

A21A12

Tan/White (83)

Black (74A)

HP-1

COMP 1

Black (Y1)

LED

COMP 2

Black (Y2)

Blue (45)

Blue (46)

Black (F12)

5VDC

1718292826

Brn/Blk (42)

Black/Org (73B)

Black/Org (74B)

HP-2

LST

A11 A13 A23

Brn/Blk (41)

Black (O/B)

Yellow

REV VALVE

O/B

Orange (47)

Black (F11)

PWM2

Brn/Wht (87)

Brn/Wht (86)

EST

D05

PWM2 Com

NOT USED

Black (G)

294

10611

Black (F10)

D04

PWM1

NOT USED

AIC

A15

Brn/Blk (42)

Black (AIC)

Black (F9)

24VAC Com

J10

Brn/Wht (87)

Brn/Blk (41)

NOT USED

Black (L)

Black (SC)

Black (75A)

Black/Org (75B)

Black

Orange (60)

Black (F8)

Black (F7)

765

D03

Johnson FX-10

DI12

DI11

DI10

444546

Gray (48)

White (88)

White (89)

SFS

NOTE 5

Connect to R on TB

CS-B

Circuit B

CS-A

Circuit A

Brn/Wht (86)

NOT USED

DI9

Orange (47)

Black (TO)

DI8

Blue (46)

White (89)

Black (F6)

DI7

Blue (45)

D02

Black Black

Notes

1 - Disconnect for 15 degree source side freeze protection

2 - Disconnect for 15 degree load side freeze protection

Black/White (63)

CC2

CC1

(72B)

Black/Org

Black (72A)

M2M1

CPM1

CPM2

NOTE 9

Black

(71A)

(71B)

Black/Org

Black/Org (70B)

Black (70A)

Violet (67)

Violet (66)

Black (F3)

Black (F2)

Black (F4)

Black (F5)

D01

DI 3/4/5/6/ Com

DI6

DI5

DI4

DI3

DI2

Black

Red (55)

Gray (56)

Blue (76A)

Blue (76B)

Brown (57)

NOTE 8

NOTE 1

NOTE 2

Black (54)

PB2

White (B)

31 30 29

Black (A)

28 27 26 25 24 23 22 21 20

17 16 15 14 13 12 11 10

Page 1

be removed to check the jumpers.

inside of the compressor junction boxes. Only used on the 600 model.

PB2-3 for the unit to operate.

5 – A field installed flow switch is required for the source side and must be connected

3 – Acc output is cycled with the lead compressor.

4 - A field installed flow switch is required for the load side and must be connected to

NOTE 9

White (88)

Black (F1)

DI1

9VDC

Pink (58)

Gray (59)

NOTE 4

LFS

Brown (99)

5Vdc Com

AI4 EXP

c 5Vd

A43

5Vdc Com

AI3 EXP

A42

5Vd

5Vdc Com

A32

AI2 EXP

A33

5Vd

5Vdc Com

AI1 EXP

A21A22

c 5Vd

A12

A11

DO3

24 Vac DO4 DO5

24 Vac DO6

24 Vac Com

24 Vac

9 – M1 and M2 are located on the compressor protection modules (CPM1 and CPM2)

to R for the unit to operate.

8 – In Emergency Shutdown, line voltage is still present in control box. Emergency

Switch is wired on low voltage circuit only.

7 – Reversing Valve will be energized for heating mode.

6 - Jumpers must be set as shown for correct control operation. If a communication

card is present, it must

10 – Only used on the 600 model.

Orange (47)

Blue (46)

Blue (45)

Black (75A)

Black/Org (75B)

Orange (60)

White (89)

Black/Org (70B)

Black (70A)

White (88)

BLACK WIRE HARNESS

White (88)

White (89)

Black/Org (75B)

Black (70A)

Black/Org (70B)

Black (75A)

Blue (45)

Orange (60)

Blue (46)

Orange (47)

Connection

Main Board

Expansion Board

D08

D07

D02

3 2 1

D01

A41

A31

A23 A13

Johnson FX10

NOTE 7

Field Wiring and Control Setup

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

High Voltage Connections

Unit Power Supply

208-230/60/3,

460/60/3, or 575/60/3

L3L1L2

Black Black

Red Red

White White

Low Voltage Connections

TB Typical AquaStat

24VAC

24V COM

Rev Valve

Circuit 1 Alarm

Circuit 2 Alarm

NOTES:

1) Acc Output 1 is cycled with the lead compressor

2) Acc Output 2 is cycled with the lag compressor

Comp 1

Comp 2

Acc 2

Acc 1

Alarm

O/B

LC1

LC2

Wiring Schematic

SFS

NOTE 5

24VAC

24V COM

Comp 1

Comp 2

Rev Valve

Accessory Item 1

Orange ( 47)

White (66) White (67)

Gray (48)Connect to R on TB

Blue (46) Blue (45)

Line Voltage

Power supply wiring connects directly to lugs on the topo of the electrical disconnect. In 208-230V applications, heat pumps are factory wired for 208V supply. In the case of 230V supply, the blue and red wires from the primary of the transformer will need to be swapped.

Low Voltage Operation

Thermostat/Controller (Aquastat)

A two-stage 24VAC aquastat or liquid controller (field supplied) must be used to turn the reversible chiller on/off, and to switch modes for heating/cooling. Multiple chillers in the same bank must be controlled from one aquastat/controller (must be isolation relays for multiple unit applications).

Low Voltage Connections

Connect low voltage wiring as shown in Figure 9. Connections shown are for typical aquastat. Actual connections may vary with specific device used.

NOTE: If a separate transformer is used to supply a Y1, Y2, or B signal to the unit controls, isolation relays must be used.

CAUTION: Use only copper conductors for field installed wiring. Terminals in the unit are not designed for other types of conductors.

WARNING: All wiring must comply with local and state codes. Disconnect the power supply before beginning to wire to prevent electrical shock or equipment damage.

NOTE: Accessory 1 output is selectable as on with

compressor or off with compressor using the unit display. on with compressor is the factory default setting.

J10

24VAC Com

DI12

DI11

DI10

DI9

DI8

DI7

Source Flow Switch (SFS)

Unit is factory shipped with no connections on Flow Switch pins J10-45 (entering). If flow proving switch is required, hook up as shown in Fig. 10 and Note 5. The unit will not operate without flow proving inputs open.

PB2

49 50 51 52 53 54 55 56

DI 3/4/5/6/ Com DI6 DI5 DI4 DI3 DI2

9VDC

DI1

Black (54) Blue (76A)

NOTE 2 NOTE 1

NOTE 8

LFS

NOTE 4

Red (55) Gray (56)

Blue (76B)

Brown (57)

Pink (58) Gray (59)

Load Flow Switch (LFS)

Unit is factory shipped with no connections on Flow Switch pins J9-56 (leaving). If flow proving switch is required, hook up as shown in Fig. 10 and Note 4. The unit will not operate without flow proving inputs open.

ATTENTION: Flow Switch inputs must be made before unit will operate!

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Field Wiring and Control Setup cont.

Accessory Relay Setup

The accessory output set to “close” upon Y1 compressor call (compressor is delayed 90 sec. after Y1) but can be set to “open” with Y1.

To change ACC1:

• Using up and down keys, scroll to “Acc 1 Sel” hit “ENTER” and “ON Comp” begins flashing

• Using up and down keys, select “ON Comp” for activation with Y1 Call or “OFF Comp” for deactivation with Y1

Lead/Lag Selection

Compressor Lead/Lag Selection is factory set to “ON” but can be set to “OFF”.

To change Lead/Lag On/Off:

• Using up and down keys, scroll to “LEAD/LAG SELECT” hit “ENTER” and “ON” begins flashing

• Using up and down keys, select “ON” for activation or “ OFF” for deactivation

Control Features

Anti Short Cycle High Pressure Protection Low Pressure Protection Advanced Freeze Detection Setpoint Random Start Display for diagnostics Reset Lockout at disconnect Intelligent reset for field installed flow switches 1 Accessory output Compressor Lead/Lag Compressor Current Switches

°F or °C - Unit of Measure

Degrees Fahrenheit is factory set, however degrees Celsius can be selected using the following procedure:

To Change Unit of Measure:

• On FX10 control using up and down keys, scroll to “SETTINGS”

• Using up and down keys, scroll to “UNIT OF MEASURE” hit “ENTER” and “UNIT OF MEASURE” begins flashing

• Using up and down keys, select “F” for degrees Fahrenheit or “C” for degrees Celsius

Other Field Options

Other field selectable options are available as shown in the maintenance menu on page 24 of the FX10 control using a similar procedure as shown in the above examples. These would include aquastat enabling, and emergency shutdown.

Control and Safety Features

Emergency Shutdown

The emergency shutdown mode can be activated by a command from a facility management system or a closed contact on DI-2. The default state for the emergency shutdown data point is off. When the emergency shutdown mode is activated, all outputs will be turned off immediately and will remain off until the emergency shutdown mode is deactivated. The first time the compressor starts after the emergency shutdown mode has been deactivated, there will be a random start delay present.

Field Selectable Options

Freeze Detection Sensing Select (DI-4 and DI-5)

The freeze detection temperature sensing selection inputs allow the user to adjust the setpoints. The source sensors are wired to inputs AI-3 and AI-4 while the load sensors are wired to inputs AI-5 and AI-6. The setpoints for both, the load and source, are factory set for 33°F. In order to change the setpoint to 15°F on the source, remove the jumper wire from DI-4 (wire #56). The load setpoint can be changed by removing the jumper wire from DI-5 (wire #55).

Accessory Output (DO-4)

The accessory output will be energized 90 seconds prior to the lead compressor output being energized. When the lead compressor output is turned off the accessory output will be deactivated after 90 seconds. The output is selectable for on with compressor or off with compressor operation through the unit mounted user interface.

Lockout Mode

Lockout mode can be activated by any of the following fault signals: refrigerant system high pressure, refrigerant system low pressure, heating freeze detection, cooling freeze detection, and compressor current sensor. any valid fault signal remains continuously active for the length of its recognition delay, the controller will go into fault retry mode, which will turn off both compressors. After the compressor short cycle delay, the compressors will attempt to operate once again. If three consecutive faults occur in 60 minutes, the unit will go into lockout mode, turning off the compressor(s), enabling the alarm output until the controller is reset. If the control faults due to the low pressure input being open during the pre-compressor startup check, the control will go into lockout mode immediately, disabling the compressors from starting and enabling the alarm output.

The lockout condition can be reset by powering down the

controller, by a command from the BAS, or by the holding the ESC and Return keys on the user interface for 5 seconds.

When

Control Features

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Advanced Freeze Detection System

The source and load heat exchangers are protected by a multi-sourced temperature logic strategy. The temperature logic is based upon the refrigerant temperature sensed as the refrigerant is about to enter the heat exchanger; while entering and leaving water temperatures are being used as correlating factors. The detection scheme is shown as basic and advanced algorithms.

Basic Freeze Detection Operation: “Comp1 or Comp2 Freeze” Alarm

This alarm can be triggered by one of two detection schemes.

Hard Limit Freeze Detection

If the refrigerant temperature drops below the freeze detection setpoint by 1.8°F, the associated compressor is locked out immediately regardless of any other factors and requires a manual reset. NOTE: This Lockout

produces a “Comp 1 or Comp 2 Freeze” error on the MUI display.

Freeze Detection

The refrigerant temperature is compared to the freeze detection setpoint (15°F [antifreeze] or 33°F [water] field selectable), and if the temperature falls below the setpoint for 30 continuous seconds, the associated compressor will be halted. This function becomes enabled after the first two minutes of compressor operation. Three such events in 60 minutes will trigger a compressor lockout that requires a manual reset. NOTE:

This Lockout produces a “Comp 1 or Comp 2 Freeze” error on the MUI display.

In addition to the above:

Entering Water Temperature Influence

If the entering water temperature of the evaporative heat exchanger is within 10°F of the freeze setpoint, the previously mentioned two minute delay will be eliminated. This allows the freeze detection to operate immediately when the compressor starts based on entering water temperature.

Leaving Water Temperature Influence

If the leaving water temperature of the evaporative heat exchanger is within 10°F of the freeze setpoint, the previously mentioned 30 second delay will begin to be proportionately reduced, ending at a 1 second delay when the leaving water temperature is 1.5°F above the freeze setpoint.

Dual Circuited Heat Exchanger Protection

A low temperature condition on either refrigerant circuit will prevent the start of both compressors. If the low temperature condition exists for 5 minutes when both compressors are off, a lockout is triggered for both compressors. However, if –for instance-both compressors are operating and circuit 1 experiences a refrigerant temperature below the freeze detection setpoint such that compressor 1 is halted, compressor 2 will not be halted as a result.

Advanced Freeze Detection Operation:

“Pre Freeze” Alarm

Predictive freeze condition detection:

If the refrigerant temperature is within 7.2°F of the freeze detection setpoint, the predictive freeze detection algorithm is enabled, and if the logic determines that a freeze condition is likely to happen based on current conditions, the compressor of the involved refrigerant circuit is immediately stopped. Three (3) such events in 60 minutes will trigger a compressor lockout that requires a manual reset. In the absence of such a condition, the compressor is allowed to operate so that the refrigerant temperature may eventually be at the threshold of the freeze detection setpoint. NOTE: This

Lockout produces a “Pre Freeze” detection error on the MUI display.

Capacity Limiting

If the leaving water temperature drops to 1.8°F above the freeze detection setpoint, the lead compressor is halted. When the leaving water temperature rises to 3.6°F above the freeze detection setpoint, it will be allowed to resume operation. This limiting is allowed to repeat indefinitely. This causes “COMP1 Low Limit” to be displayed on the MUI.

If the leaving water temperature drops to the freeze detection setpoint, the lag compressor is halted. When the leaving water temperature rises to 1.8°F above the freeze detection setpoint, it will be allowed to resume operation. This limiting is allowed to repeat indefinitely. This causes

“COMP2 Low Limit” to be displayed on the MUI.

Compressor Current Switch (AI-3 EXP and AI-4 EXP)

The compressor current switch is designed to insure that the compressor is on when the compressor output is energized. This switch is normally open and closes when current is flowing to the compressor. If the compressor fails to start the switch will open. The switch must be open for a continuous 15 seconds for a fault to occur. After 3 faults in 60 minutes the control will put the unit into an alarm state.

Flow Proving Switch (DI-1 and DI-10)

The load and source flow-proving switches are optional and can be field installed. These switches shall be normally open flow switches that will close when the water flow through the heat exchangers reach an acceptable level. The flowproving switches must be closed 15 seconds prior to enabling either compressor output (DO-1 and DO-2). If the load flowproving switch opens at any time both compressor outputs (DO-1 and DO-2) must be disabled immediately.

High Pressure (DI-11 and DI-12)

The high-pressure switches shall be a normally closed (NC) switch that monitors the systems compressor discharge refrigerant pressures. There shall be an individual high pressure switch for each circuit. If the input senses the high-pressure switch is open during the period that the compressor output is enabled, it must shut down the compressor immediately and count the fault. The compressor

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Control Features cont.

minimum on time does not apply if the high-pressure switch trips. The compressor will not restart until the short cycle time delay has been satisfied. If the high-pressure fault occurs in one circuit the other compressor will continue to operate based on the heating or cooling demand.

Low Pressure (DI-3 and DI-6)

The low-pressure switches shall be a normally closed (NC) switch that monitors the systems compressor suction line refrigerant pressure. The input shall be checked 15 seconds before compressor start up to insure the pressure switch is closed and then ignored for the first 2 minutes after the compressor output (DO-1 or DO-2) is enabled. If the switch is open continuously for (30) seconds the compressor output for that circuit will be disabled. The compressor will not restart until the short cycle time delay has been satisfied. If a low-pressure fault occurs in one circuit the other compressor will continue to operate based on the heating or cooling demand.

Compressor 1 Alarm Output (DO-5)

The compressor 1 alarm output will be enabled when stage 1 is in the lockout mode and will be disabled when the lockout is reset.

Compressor 2 Alarm Output (DO-6)

The compressor 2 alarm output will be enabled when stage 2 is in the lockout mode and will be disabled when the lockout is reset.

Test Mode

The unit controls system can be put into test mode to eliminate startup delays to aid in trouble shooting. To put the unit into test mode hold the “ESC” and “Down Arrow” keys until LED 8 begins to flash. The control will remain in test mode until power is cycled or after 30 minutes.

Reversible Chiller Setpoint Control

This control software is by default set to operate in ‘Aquastat’ mode, which requires external setpoint logic to generate the Y1 or Y2 call. The mode may be changed to ‘Setpoint’ by use of the ‘Settings’ menu in the MUI in the ‘Mode’ item which is on the 5th line from the top.

CAUTION! Setpoint mode is not recommended on applications that have more than two water-to-water heat pumps installed. Unique temperature setting should be set for each unit on a common load.

To operate in setpoint mode, consider the following:

• The selected mode must be changed from Aquastat

to Setpoint

• The ‘Y1’ input must be activated. This may be done

by connecting ‘R’ to ‘Y1’ on the terminal board, or by commanding Y1 to ‘ON’ in the Maint menu of the MUI, or by commanding the ComprEnable network variable from the BAS.

• The Heat/Cool mode is by default in the cooling mode,

and may be set to heating by connecting R to O/B on the terminal board, or by commanding the ‘B’ item in the Maint menu of the MUI, or by commanding the reversing valve variable from the BAS network.

• The setpoint mode temperature sensor can be selected

to either Load LW Temp (Leaving Water) or Load EW Temp (Entering Water Temp). The default is set for Entering Water Temp control.

• The cooling setpoint and the heating setpoint are two

separate setpoints, and can be adjusted in the MUI Settings menu.

• When the controlling temperature sensor is set to

select the Load EW Temp, the setpoint control will operate in a PID (Proportional-Integrating-Derivative) mode. In this mode, the temperature rate of change and direction of change will be part of deciding whether or not to add or reduce capacity. Additionally the amount of difference between setpoint and temperature AND the length of time that the difference existed are used to determine if adding or reducing capacity is needed.

o The tuning parameters for this mode should only

be adjusted if you know why you are choosing the value that you plan to use. You should keep a permanent record of the beginning values and record any changes that you make. The parameters used in PID operation and their (default values) are:

• D NegThrshld (-0.03)

• Int Rate (200)

• Stage Delay (30)

• Gain (2)

• D PosThrshld (0.04)

• PIDY1 Ref (7.2)

• PID Y1 Diff (7)

• PID Y2RefShift (5)

• PID Y2 Diff (6)

Control Features cont.

• When the controlling temperature sensor is set to select the Load LW Temp, the setpoint control will operate strictly in a proportional mode with offsets and differentials used to determine the appropriate capacity to use. In this mode, the following parameters are used:

• Stage Delay (30)

• Gain (2)

• PIDY1 Ref (7.2)

• PID Y1 Diff (7)

• PID Y2RefShift (5)

• PID Y2 Diff (6)

• The default values were used in the test lab and seem to be a reasonably good beginning point for parameter settings.

Compressor Lead-Lag Operation

In the Maint menu of the MUI, Lead –Lag operation may be enabled or disabled. When disabled, a Y1 call will always be a request for compressor 1 and a Y2 call will be a request for compressor 2. When Lead-Lag is enabled, the operation is as follows:

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

• If only a single Y call is introduced (either Y1 or Y2), then one compressor will start and it will be the compressor that has been Off the longest. When that call is removed, the compressor will stop—if the compressor minimum run time has been satisfied.

• If the single Y call is re-introduced, then the ‘other’ compressor will start. In this manner, if single compressor operation is used, then each time a call is given, the compressors will alternate.

• If a Y call is existing and a compressor is running, then adding a second Y call will bring on the second compressor. When one of the Y calls is dropped and the other remains, then the compressor that was first started will be dropped. In this manner, if the chiller is alternating between one and two compressor operation, both compressors will be cycled.

• If no Y calls exist and a sudden and simultaneous application of both Y1 and Y2 occur, then fist the ‘longest off’ compressor will start. After 150 seconds, the second compressor will start.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Sequence of Operation

Power Fail Restart

When the controller is first powered up, the outputs will be disabled for a random start delay. The delay is provided to prevent simultaneous starting of multiple heat pumps. Once the timer expires, the controller will operate normally.

Random Start Delay

This delay will be used after every power failure, as well as

the first time the compressor is started after the control exits the unoccupied mode or the emergency shutdown mode.

The delay should not be less than 1 second and not longer

than 120 seconds. If the control is in test mode the random start delay will be shortened to 5 seconds.

Lead Compressor Start Delay Time

The Lead Compressor Fixed On Delay Time will ensure that

the lead compressor output is not enabled for 90 seconds after the control receives a call to start the compressor. This delay is adjustable from 30 – 300 seconds over a BAS or a MUI. If the control is in test mode the Lead Compressor Start Delay Timer will be shortened to 5 seconds.

Lag Compressor Start Delay Time

The Lag Compressor Fixed On Delay Time will ensure that

the lag compressor output is not enabled for 90 seconds after the control receives a call to start the compressor. This delay is adjustable from 30 – 300 seconds over a BAS or a MUI. If the control is in test mode the Lag Compressor Start Delay Timer will be shortened to 5 seconds.

Compressor Lead/Lag

Compressor lead/lag is a standard part of the FX10 control system. The unit is shipped from the factory with lead/ lag enabled. Lead/lag can be activated through the unit mounted user interface.

Heating Cycle

The control will run the unit in heating mode when there is a

command on the O/B terminal on the terminal board.

Cooling Cycle

The control will run the unit in cooling mode when there is no

command on the O/B terminal on the terminal board.

MUI Alarm History Reporting

If a fault occurs the fault will be recorded in history for display on the medium user interface in the History Menu. Each fault type will be displayed in the history menu with a number between 0 and 3. A reading of 3+ will mean that fault has occurred more than three times in the past. The history menu can be cleared with a power cycle only. Alarm date and time are not included in the history.

Compressor Minimum On Delay

The compressor minimum on delay will ensure that the

compressor output is enabled for a minimum of five (5) minutes each time the compressor output is enabled. This will apply in every instance except in the event the high pressure switch is tripped, freeze protection, or emergency shutdown then the compressor output will be disable immediately.

Compressor Minimum Off Delay Time

The compressor minimum off time delay will ensure that

the compressor output will not be enabled for a minimum of five (5) minutes after it is disabled. This allows for the system refrigerant pressures to equalize after the compressor is disabled.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Inputs and Outputs Conﬁ guration

DUAL STAGE WW Input Name Input Output Name Output

Entering Load Water Temperature AI 1 Compressor 1 DO1 Leaving Load Water Temperature 1 AI 2 Compressor 2 DO2 Source Heating Freeze Detection 1 AI 3 Reversing Valve DO3 Source Heating Freeze Detection 2 AI 4 Accessory DO4 Load Cooling Freeze Detection 1 AI 5 Compressor 1 Alarm DO5 Load Cooling Freeze Detection 2 AI 6 Compressor 2 Alarm DO6

Network Output DO7 Load Flow Proving Switch DI 1 Network Output DO8 Emergency Shutdown DI 2 Network Output D09 Stage 2 Low Pressure DI 3 Source Htg Freeze Detection Select - 30ºF DI 4 Future PWM1 Load Htg Freeze Detection Select - 30ºF DI 5 Future PWM2 Stage 1 Low Pressure DI 6 Thermostat Y1 DI 7 Thermostat Y2 DI 8 Thermostat B DI 9 Source Flow Proving Switch D10 Stage 1 High Pressure DI11 Stage 2 High Pressure DI12

XP10 Expansion Card Input Name Input Output Name Output

Entering Source Water Temperature AI 1 Unused DO 1 Leaving Source Water Temperature 1 AI 2 Unused DO 2 Current Switch 1 - Compressor 1 AI 3 Unused DO 3 Current Switch 2 - Compressor 2 AI 4 Unused DO 4

Unit Display and Interface

The Unit Display allows the user to view entering and leaving water temperatures, freeze detection readings, inputs and

outputs, and allows the user enable and disable certain control functions through the various menus. The interface also displays all faults on the LCD once the unit has locked out to aid in diagnostics.

There are 10 LED indicator lights that indicate the following:

Power - Shows that the FX processor

is operational

Alarm - Lights when there is a

lock-out or faulty freeze

detection sensor

1 - Flashing shows Compressor 1

is running

2 - Flashing shows Compressor 2

is running 3 - On shows Compressor 2 is lead 4 - On shows Reversing valve in cool 8 - On shows unit in ‘Test’ mode

Figure 5 - Unit Display/Interface

LEDs

Directional Keys

Escape Key

Return Key

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Unit Display and Interface Cont.

MUI Menu Navigation

Welcome

Info Temp Stat Outputs Settings Maint Alarm ALM_History

Info

Dual Stage Setpt Reversible Chiller PRODCWWE-10 MM/DD/YY

Settings

Settings Unit of Measure F CoolSetpt XX.X HeatSetpt XXX.X D NegThrshld X.X Int Rate XXXXS Mode Aquastat Stage Delay XXX S Sensor Select LWT Gain X.X D PosThrshld X.X PIDY1 Ref XXX PID Y1 Diff XX.X PID Y2RefShift XX.X PID Y2 Diff XX.X

Temp

Temperatures Enter Load 77.2 ºF Leave Load 51.0 ºF Enter Source 70.0°F Leave Source 66.0°F Source Frz 1 77.8°F Source Frz 2 30.0°F Load Frz 1 30.0°F Load Frz 2 30.0°F Src Frz Setpt 30.0°F LD Frz Setpt 30.0°F

Maintenance Y1 Input Off Y2 Input Off B Input Off Emerg SD Normal

Acc 1 Sel OnComp

Lead/Lag Select On

Low Frz Setpt XX.X°F

Hi Frz Setpt XX.X°F Acc I Dly XXXX S LagCompDly XXX S

Stat

Status Unit Status Auto Y1 Status OFF Y2 Status OFF O Status OFF Emerg Shutdown OFF Current Sens 1 OFF Current Sens 2 OFF Load Flow OFF Src Flow OFF Low Pres 1 ON Hi Pres 1 NML Low Pres 2 ON Hi Pres 2 NML Comp1 Low Limit NML Comp2 Low Limit NML

Alarm #Events PreFrz1 0 Lo Press 1 0

Src Freeze 1 0 Ld Freeze 1 0

Bad Ld Sensor 0

Lo Press 2 0 Src Freeze 2 0

PreFrz 2 0

Hi Press 1 0

Bad Src Sensor 0

Ld Freeze 2 0 Hi Press 2 0 StrtFail 1 0 StrtFail 2 0

FP1 Log Off FP2 Log Off Int 1 XX.X Temp Err XX.X RndmStrtDly Run Derivative XX.X Integ’r Ena PID Y1 Off PID Y2 Off D_Neg Off D_Pos Off O 2 Off O 4 Enum_0 Pos Err Off PID Out XXX.X

When in the stat page, press the

right arrow once to go this screen

Alarm HistoryMaintenance

Outputs

Outputs Comp 1 Status ON Comp 2 Status OFF RV Status Heat Acc 1 Status OFF Stg 1 Status Normal Stg 2 Status Normal EXPB01 OFF EXPB02 OFF EXPB07 OFF Cp1 0 CP2 0

Alarm

ALARM SUMMARY

^/High Pressure

NOTE: This FX10 application implements an alarm history which is reset only by cycling power. This history shows on the Alm-History page. Any alarm showing 2+ events has occurred more than 2 times.

Alarm lock-outs are reset by cycling power, by pressing the “ESC” and Return keys simultaneously for a minimum of 15 seconds, or by commanding the nviAlarmReset over the BAS network.

Test mode is enabled by holding the ‘Esc’ and Down Arrow simultaneously

for a minimum of 15 seconds and releasing. Test mode times out after 30 minutes, and may also be ended by pressing ‘ESC’ and Up Arrow simultaneously and releasing. Test Mode bypasses the On Delay (90 sec) and Random Start timers for quicker troubleshooting. It also allows cycling the reversing valve without compressor shutdown.

Unit Display and Interface cont.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Menu and Menu Contents

Alarm

• Displays unit alarms until the unit has been reset (Unit alarms can be reset by holding both the Escape (ESC)

key and Return (←) key for five seconds or by power

cycling the unit.)

Alarm History

If a fault occurs the fault will be recorded in history viewable on the unit mounted display. Each fault type will be displayed in the history menu with a number between 0 and 3. A reading of 3+ means that the fault has occurred more than 3 times in the past. The history menu can be cleared with a power cycle only. Alarm date and time are not included in the history.

Unit Alarms

Unit alarms are shown on the display once the unit has locked out.

Load Flow – Load Flow Switch is Not Closed

• The load flow switch must be closed prior to either compressor starting and must remain closed for the entire run time of the compressor(s).

Low Pressure 1 – Compressor Circuit 1 Low Pressure Switch

• The low pressure switch is checked before compressor start up and is monitored during compressor operation.

Src FP 1 Temp Low – Source Freeze Detection Sensor 1

• The source freeze detection sensor on compressor circuit 1 has reached its setpoint.

Src FP 1 Sensor Bad

• The sensor for source freeze detection on compressor circuit 1 is unreliable or is not reading.

LD FP 1 Temp Low – Load Freeze Detection Sensor 1

• The load freeze detection sensor on compressor circuit 1

has reached its setpoint.

Source Flow – Source Flow Switch is Not Closed

• The source flow switch must be closed prior to either compressor starting and must remain closed for the entire run-time of the compressor(s).

High Pressure 1 – Compressor Circuit 1 High Pressure Switch

• If high pressure switch 1 opens at any time during compressor 1 run time the compressor will be shut down immediately.

Low Pressure 2 - Compressor Circuit 2 Low Pressure Switch

• The low pressure switch is checked before compressor start up and is monitored during compressor operation.

Src FP 2 Temp Low - Source Freeze Detection Sensor 2

• The source freeze detection sensor on compressor circuit 2 has reached its setpoint.

Src FP 2 Sensor Bad

• The sensor for source freeze detection on compressor circuit 2 is unreliable or is not reading.

LD FP 2 Temp Low - Load Freeze Detection Sensor 2

• The load freeze detection sensor on compressor circuit 2 has reached its setpoint.

LD FP 2 Sensor Bad

• The sensor for load freeze detection on compressor circuit 2 is unreliable or is not reading.

High Pressure 2 - Compressor Circuit 2 High Pressure Switch

• If high pressure switch 2 opens at any time during compressor 2 run time the compressor will be shut down immediately.

Comp Start Failure – Compressor Start Failure

• If either compressor fails to start when the contactor pulls in the compressor current switch will cause that compressor to be locked out after 2 retries. The other compressor will continue to operate normally in this condition.

LD FP 1 Sensor Bad

• The sensor for load freeze detection on compressor circuit 1 is unreliable or is not reading.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Reference Calculations

Heating Calculations:

LWT = EWT -

NOTE: * When using water. Use 485 for 15% methanol/water or Environol solution.

GPM x 500*

Cooling Calculations:

LWT = EWT +

GPM x 500*

Legend

Abbreviations and Definitions

ELT = entering load fluid temperature to heat pump LLT = leaving load fluid temperature from heat pump LGPM = load flow in gallons per minute LWPD = load heat exchanger water pressure drop EST = entering source fluid temperature to heat pump LST = leaving source fluid temperature from heat pump SGPM = source flow in gallons per minute SWPD = source heat exchanger water pressure drop EER = cooling energy effciency (TC/KW)

PSI = pressure drop in pounds per square inch FT HD = pressure drop in feet of head KW = kilowatt HR = heat rejected in MBTUH TC = total cooling capacity in MBTUH

COP = coefficient of performance (HC/KW x 3.413) HC = heating capacity in MBTUH HE = heat of extraction in MBTUH

Unit Startup

Verify the following:

• High voltage is correct and matches nameplate

• Fuses, breakers and wire size are correct

• Low voltage wiring is complete

• Piping is complete and the water system has been cleaned and flushed

• Air is purged from closed loop system

• Isolation valves are open and water control valves or loop pumps are wired

• Service/access panels are in place

• Transformer has been switched to lower voltage tap if needed (208/230 volt units only)

• Unit controls are in “off” position

• Flow switches are installed and ready or wires are jumpered

• Freeze detection setpoints have been set in the microprocessor

WARNING: Verify ALL water controls are open and allow water flow PRIOR to engaging the compressor. Failure to do so can result in freezing the heat exchanger or water lines causing permanent damage to the unit.

Startup Steps

• Set aquastat control above cooling setpoint.

• Set aquastat control in cooling mode.

• Slowly reduce the control setting until both the compressor and water control valve/loop pumps are activated. Verify that the compressor is on and that the water flow rate is correct by measuring pressure drop through the heat exchanger and comparing to the Pressure Drop table (page 32). Check for correct rotation of scroll compressors. Switch any two power leads at the L1, L2, and L3 line voltage termination block if incorrect.

• Perform a cooling capacity test by multiplying GPM x ΔT x 485 (antifreeze/water). Use 500 for 100% water. Check capacity against catalog data at same conditions.

• Set control to “OFF” position.

• Leave unit “OFF” for approximately five (5) minutes to allow pressure to equalize.

• Adjust control below heating setpoint.

• Set control in “HEAT” position mode.

• Slowly increase the control setting until both compressor and water control valve/loop pumps are activated. The reversing valve should be heard changing over.

• Perform a heating capacity test by multiplying GPM x ΔT x 485 (antifreeze/water). Use 500 for 100% water. Check capacity against catalog data at same conditions.

• Check for vibrations, noise and water leaks.

• Set system to maintain desired setpoint.

• Instruct the owner/operator of correct control and system operation.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Operating Parameters

Heating Mode

Entering

Load Temp (oF)

100

120

NOTE: Operating data based on normal conditions with 4 gpm/ton for the load and source.

Entering

Source Temp (oF)

30 75-100 200-215 10-12 10-13 50 100-125 200-215 12-14 8-12 70 125-150 215-230 14-18 8-12

90 150-165 230-255 25-30 8-12 30 75-100 285-300 10-12 10-13 50 100-125 300-315 12-14 8-12 70 125-150 315-330 14-18 8-12

90 150-165 330-345 25-30 8-12 30 85-110 365-380 10-12 7-11 50 110-135 385-400 12-14 7-11

70 135-165 400-415 14-18 3-7 50 110-135 485-500 12-14 7-11

70 135-165 500-515 14-18 3-7

Suction

Pressure (psig)

Discharge

Pressure (psig)

Superheat

(oF)

Subcooling

(oF)

1/30/14

Cooling Mode

Entering

Load Temp (oF)

110

NOTE: Operating data based on normal conditions with 4 gpm/ton for the load and source.

Entering

Source Temp (oF)

30 80-90 140-175 15-20 3-6 50 90-100 200-235 11-15 6-9 70 100-110 250-285 11-15 9-12 90 100-120 330-365 8-12 12-14

110 110-130 430-465 8-12 14-19 30 80-90 150-185 15-20 3-6 50 90-100 210-245 11-15 6-9 70 100-110 260-295 11-15 9-12 90 110-120 340-375 8-12 12-14

110 110-140 440-485 8-12 14-19 30 80-90 150-185 15-20 3-6 50 90-100 210-245 11-15 6-9 70 100-110 260-295 11-15 9-12

90 110-120 340-375 8-12 12-14 30 90-100 160-195 40-45 3-6

50 110-130 220-255 30-40 6-9

Suction

Pressure (psig)

Discharge

Pressure (psig)

Superheat

(oF)

Subcooling

(oF)

1/30/14

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Pressure Drop

Model GPM

20 0.8 0.7 0.6 0.6 0.5

120

30 2.1 1.9 1.8 1.7 1.5

40 3.3 3.1 2.9 2.8 2.5

30 0.9 0.8 0.7 0.7 0.6

180

45 2.3 2.2 2.0 2.0 1.8

60 3.7 3.5 3.3 3.2 2.9

40 1.3 1.2 1.1 1.1 1.0

240

60 3.2 3.0 2.9 2.8 2.6

80 5.0 4.7 4.6 4.4 4.2

60 1.3 1.2 1.1 1.0 0.9

360

90 3.1 2.9 2.8 2.7 2.4

120 4.8 4.6 4.4 4.3 3.9

100 2.8 2.5 2.4 2.2 2.0

600

150 4.7 4.5 4.4 4.0 3.9

200 6.4 6.2 6.1 5.7 5.6

Pressure Drop (psi)

30°F 50°F 70°F 90°F 110°F

4/29/14

6.8

Water Pressure Drop vs. Flow at 30°F

6.6

6.4

6.2

6.0

5.8

5.6

5.4

5.2

5.0

4.8

4.6

4.4

4.2

4.0

3.8

3.6

3.4

3.2

3.0

2.8

2.6

Pressure Drop (psi)

2.4

2.2

2.0

1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Flow (gpm)

Model 120

Model 180

Model 240

Model 360

Model 600

Note: Pressure drop is the same for load and source heat exchangers at 30°F fluid temperature.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Compressor Resistance

Model 208-230 380 460 575

120 .539 / .528 /.528 .575 / .575 / .575 2.116 / 2.088 / 2.072 3.333 / 3.289 / 3.263

180 .32 / .32 / .33 N/A 1.29 / 1.28 / 1.33 1.99 / 1.96 / 2.05

240 .33 / .33 / .33 N/A 1.13 / 1.11 / 1.10 1.73 / 1.66 / 1.75

360 .20 / .20 / .20 0.57 / 0.57 / 0.57 .83 / .83 / .83 1.32 / 1.32 / 1.32

600 N/A .36 / .36 / .36 0.52 / .52 / .52 .82 / .82 / .82

Resistance values listed in ohms and measured at 25C between phases 1-2, 1-3, 2-3, respectively. Specialized measurement device should be used for accurate resistance readings due to low resistance values.

Thermistor Resistance

1/30/14

Thermistor

Temperature (°F)

5 746-770

14 775-803

23 808-836

32 841-869

41 875-903

50 910-938

59 946-974

68 981-1013

77 1019-1051

86 1058-1090

95 1097-1129

104 1137-1169

113 1179-1211

122 1221-1253

131 1261-1297

140 1305-1341

149 1350-1386

FX10

Resistance (Ohms)

1/30/14

Operating Limits

Source Side Water Limits

Min. Entering Water 30 -1.1 30 -1.1

Normal Entering Water 85 29.4 60 15.6

Max. Entering Water 110 43.3 90 32.2

Load Side Water Limits

Min. Entering Water 50 10.0 60 15.6

Normal Entering Water 60 15.6 100 37.8

Max. Entering Water 90 32.2 120 48.9

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 dependant upon three primary factors: 1) entering source temperature, 2) entering load temperature, and 3) flow rate (gpm). 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. Consult the Capacity Tables for each model to determine allowable normal operating conditions. Units are not designed for outdoor installation.

(°F) (°C) (°F) (°C)

Cooling Heating

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Troubleshooting

Should a major problem develop, refer to the following information for possible causes and corrective steps.

If compressor won’t run:

1. The fuse may be open or the circuit breaker is tripped. Check electrical circuits and motor windings for shorts or grounds. Investigate for possible overloading. Replace fuse or reset circuit breakers after fault is corrected.

2. Supply voltage may be too low. Check it with a volt meter.

3. Control system may be faulty. Check control for correct wiring of aquastat and check the 24 volt transformer for proper voltage.

4. Wires may be loose or broken. Replace or tighten.

5. The low pressure switch may have tripped due to one or more of the following:

a) Heating

1) Plugged heat exchanger on source side

2) Water flow source side -(Low)

3) Water too cold source side

4) Low refrigerant

b) Cooling

1) Plugged heat exchanger on load side

2) Water flow load side - (Low)

3) Water too cold load side

4) Low refrigerant

6. The high pressure switch may have tripped due to one or more of the following:

a) Heating

1) Plugged heat exchanger on load side

2) Low water flow load side

3) Water too warm load side

b) Cooling

1) Plugged heat exchanger on source side

2) Low water flow on source side

3) Water too warm source side

7. The compressor overload protection may be open. Disconnect power. Remove S1 & S2 wires from the compressor protection module. Measure the resistance between the S1 & S2 wires. If the resistance measures > 2750 ohms, then the internal compressor resistance has tripped the compressor protection module. The compressor protection module will reset after a 30 minute delay and the resistance measures < 2250 ohms. Cycling the power off for a minimum of 3 seconds will manually reset the compressor module. The internal compressor resistance must measure < 2250 ohms for the compressor module to reset.

8. The internal winding of the compressor motor may be grounded to the compressor shell. If so, replace the compressor.

9. The compressor winding may be open or shorted. Disconnect power. Check continuity with ohm meter. If the winding is open, replace the compressor.

If sufficient cooling or heating is not obtained:

1. Check control for improper location or setting.

2. Check for restriction in water flow.

3. Check refrigerant subcooling and superheat for proper refrigerant charge and expansion valve operation.

4. The reversing valve may be defective and creating a bypass of refrigerant. If the unit will not heat, check the reversing valve coil.

If the unit operation is noisy:

1. Check compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. Check for tubing contact with the compressor or other surfaces. Readjust it by bending slightly.

2. Check screws on all panels.

3. Check for chattering or humming in the contactor or relays due to low voltage or a defective holding coil. Replace the component.

4. Check for proper installation of vibration absorbing material under the unit.

5. Check for abnormally high discharge pressures.

6. Compressor rotation incorrect

Heating Cycle Analysis

Braze Plate

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

______PSI = ______SAT°F ______°F

Suction

Compressor

______°F Liquid Line

Unit Amp Draw ____________ Line Voltage _________ Loop:______ Open ______ Closed Subcooling _______ Superheat _______

NOTE: Do not attach refrigerant gauges unless a problem is suspected!

Cooling Cycle Analysis

Braze Plate

Discharge

Braze Plate

______PSI = ______SAT°F ______°F

Entering Source Water ________°F Entering Water Pressure Drop _____ PSI Leaving Source Water ________°F Leaving Water Pressure Drop _____ PSI

______PSI = ______SAT°F ______°F

Suction

Compressor

Unit Amp Draw ____________

Line Voltage _________ Loop:______ Open ______ Closed Subcooling _______ Superheat _______

NOTE: Do not attach refrigerant gauges unless a problem is suspected!

______°F Liquid Line

Discharge

Braze Plate

______PSI = ______SAT°F ______°F

Entering Source Water ________°F Entering Water Pressure Drop _____ PSI Leaving Source Water ________°F Leaving Water Pressure Drop _____ PSI

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

______

(

)

Envision NXW Troubleshooting Form

Company Name: _________________________________ Technician Name: ________________________________ Model No: ______________________________________ Owner’s Name: __________________________________ Installation Address: ______________________________

Company Phone No:______________________________ Date: __________________________________________ Serial No:_______________________________________ Open or Closed Loop: _____________________________ Installation Date: _________________________________

Check One

Start up/Check-out for new installation

1. FLOW RATE IN GPM (SOURCE SIDE HEAT EXCHANGER) Water In Pressure: a.______ PSI

Water Out Pressure: b.______ PSI Pressure Drop = a - b c.______ PSI Convert Pressure Drop to Flow Rate

(refer to Pressure Drop table) d.______ GPM

2. TEMPERATURE RISE OR DROP ACROSS SOURCE SIDE HEAT EXCHANGER

Water In Temperature: e.______ °F e.______ °F Water Out Temperature: f. ______ °F f. ______ °F Temperature Difference: g.______ °F g.______ °F

3. TEMPERATURE RISE OR DROP ACROSS LOAD SIDE HEAT EXCHANGER

Water In Temperature: h.______ °F h.______ °F Water Out Temperature: i. ______ °F i. ______ °F Temperature Difference: j. ______ °F j. ______ °F

T Troubleshooting Problem:___________________________________T

COOLING HEATING

4. HEAT OF REJECTION (HR) / HEAT OF EXTRACTION (HE) CALCULATION HR or HE = Flow Rate x Temperature Difference x Brine Factor*

d. (above) x g. (above) x 485 for Methanol or Environol, 500 for water* Heat of Extraction (Heating Mode) = btu/hr Heat of Rejection (Cooling Mode) = btu/hr Compare results to Capacity Data Tables

Note: Steps 5 through 8 need only be completed if a problem is suspected

5. WATTS Volts: m._____

Total Amps (Comp. + Fan): n. _____ AMPS n. ______ AMPS n. Watts = m. x n. x 0.85 o. _____ WATTS o. ______ WATTS o.

6. CAPACITY Cooling Capacity = HR. - (o. x 3.413) Heating Capacity= HE. + (o. x 3.413)

7. EFFICIENCY Cooling EER = p. / o. Heating COP = p. / (o. x 3.413)

8. SUPERHEAT COOLING HEATING HYDRONIC Suction Pressure: r. ______ PSI r. ______ PSI r. ______ PSI Suction Saturation Temperature: s. ______ °F s. ______ °F s. ______ °F Suction Line Temperature: t. ______ °F t. ______ °F t. ______ °F Superheat = t. - s. u. _____ °F u. ______ °F u. ______ °F

Head Pressure: v. ______ PSI v. ______ PSI v. ______ PSI High Pressure Saturation Temp.: w. _____ °F w. _____ °F w. _____ °F Liquid Line Temperature*: x. ______ °F x. ______ °F x. ______ °F Subcooling = w. - x. y. ______ °F y. ______ °F y. ______ °F

* Note: Liquid line is between the source heat exchanger and the expansion valve in the cooling mode; between the load heat exchanger and the expansion valve in the heating mode.

S.H.) / SUBCOOLING (S.C.

COOLING HEATING HYDRONIC

VOLTS m.______ VOLTS m.

. _____ btu/hr . _____ btu/hr

. _____ EER . _____ COP

COOLING

VOLTS AMPS WATTS

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

XW Startup

Job Site Recording Process

1. Complete the top of the NXW Start-Up Form for each unit.

*Be sure to note the mode (Heat/Cool) you will be testing the unit in as well as freeze protection details of

type and concentration (Test to Verify). If starting-up in both heating and cooling modes, a start-up form for

each mode will need to be completed.

*The unit must be tested in both heating and cooling modes.

2. Take the unit offline (disconnect the aqua stat or BAS system) to obtain full control of the compressors from the MUI (Controls contractor must disable all external controls).

a. Place load/source pumps in “Hand” position so they can be manually controlled. (Mechanical contractor must enable pumps).

b. Check the incoming power supply voltage and record it.

c. On 208V-230V and 380-420V units verify that the transformer is set correctly prior to testing.

3. Energize line power to the unit and record Thermistor Checks prior to energizing the compressors or water flow.

4. Start Pumps and verify flow through the heat exchangers by recording the pressure drop in the Evaporator/ Condenser Flow Analysis section.

5. Locate the maintenance menu in the MUI and enable Y1, compressor 1. If lead/lag is enabled, compressor 1 might not always be the first compressor to start.

6. Allow the unit to run for a minimum of 10 minutes so that the refrigeration circuit can balance itself out before recording any of the data. Ideally the unit should be operating at anticipated operating conditions. In other

words if the unit is spec’d to run with a entering water temperature of 90° on the load side, we would like to see the start-up data recorded with the unit operating at these conditions, however this may not be possible.

7. Once the unit reaches desired load conditions, record the amp draw on the compressor that is running.

8. Record the entering and leaving water temps on the load and source side and record the load and source freeze

temps for the circuit that is running.

9. Disable Y1 and enable the Y2 call and repeat steps 6, 7, and 8 for compressor 2.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

NXW Pre-Start-Up Checklist

CHILLER PRE-START-UP CHECKLIST

Project Name: Mechanical Contractor: Address: Contact Name: City/State/Zip: Telephone: WaterFurnace Order #: Purchase Order #:

Prior to starting the chiller(s), the mechanical contractor is responsible for reviewing all of the installation and operational information supplied by the manufacturer to ensure that the system is ready to be started. Failure to do so may result in additional delays and expenses charged back to the mechanical contractor. The contractor is to provide necessary equipment to

gain access to all units and have a service technician on site with the factory technician at all times.

A. Installation/Serviceability

1. Building completely enclosed with a consistent indoor space temperature of between 50Ý and 90Ý F

2. Minimum 2-feet of service clearance around chiller(s) to allow proper access from all sides

3. Chiller mounting and vibration isolation complete

4. Chiller(s) ordered with proper voltage r

B. Water Piping

1. Load side water piping installed between unit, pumps, and load supply/return

2. Source side water piping installed between unit, pumps, and source supply/return

3. Flow switch installed

4. All specialty components including water strainer(s) and isolation/control/balance valve(s) installed

ating for application

Date:

Complete (X)

C. Electrical Wiring

1. Wiring completed from chiller to main power supply

2. Wiring completed for disconnects and circuit overload protection

3. Wirin

D. Controls

1. Building automation control network installed and functional

E. Preparation

1. Arrangements made for service technician to be onsite with factory technician at all times

2. Arrangements made for controls contractor to be onsite and available during normal working hours

The undersigned, and the entity he or she represents, hereby accepts responsibility for the accuracy of the information provided herein, and thus agrees to compensate WaterFurnace International, Inc. in full for all expenses incurred by WaterFurnace International, Inc. and its representatives that are directly related to the accuracy of said information.

Signature (Hand Written) Date

Name and Title (Please Print)

g completed for load and source water pumps and proper rotation of each verified

Brand/Model

Comm. (BacNet, Open N2, LON)

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

NXW Start-Up Form

Start-up Date Unit Model # Size:

Unit Tag # Unit Serial #

Start-up Company Start-Up Mode

Employee Name Cooling / Heating

Job Name

Voltage across L1-L2

Water Side

Balance Complete

208/230V Transformer

Configuration

380/420V Transformer

Configuration

Antifreeze Installed

(Select)

Load Source

None Prop. Glycol Methanol Ethanol

Freeze Protection

Setpoint in The MUI.

LOAD SOURCE

33° / 15° 33° / 15°

LOAD

NO / YES

None Prop. Glycol Methanol Ethanol

SOURCE

NO / YES

Electrical Data

Thermistor Checks,

Prior to Starting

Compressors

Energized

Evaporator/

Condenser Flow

Analysis

Refrigerant

Thermistors,

Compressors

Running

Voltage across L2-L3

Voltage across L1-L3 YES / NO

Circuit 1 Circuit 2

Compressor Amps (Red Wire) 208 230

Compressor Amps (White Wire)

Compressor Amps (Black Wire) 380 420

Circuit 1 Circuit 2

Entering Load Water Temperature

with no Compressors running

Leaving Load Water Temperature

with no Compressors Running

Entering Source Water Temperature

with no Compressors running

Leaving Source Water Temperature

with no Compressors running

Source Freeze Temperature

Water Flowing thru unit only

(No compressors on)

Load Freeze Temperature

Water Flowing thru unit only

(No compressors on)

Entering Load Water Temperature Fluid Samples Taken

Leaving Load Water Temperature

Entering Source Water Temperature Antifreeze Concentration (%)

Leaving Source Water Temperature LOAD SOURCE

Entering Water Pressure on

Source Heat Exchanger

Leaving Water Pressure on

Source Heat Exchanger

Entering Water Pressure on

Load Heat Exchanger

Leaving Water Pressure on

Load Heat Exchanger

Circuit 1 Circuit 2

Source Freeze Temperature

Load Freeze Temperature

Source Flow Rate

(GPM)

Load Flow Rate

(GPM)

General Notes

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Preventive Maintenance

Unit Heat Exchanger Maintenance

1. Keep all air out of the water or antifreeze solution.

2. Keep the system under pressure at all times. Closed loop systems must have positive static pressure or air vents may draw air into the system.

NOTES: If the installation is in an area with a known high mineral content in the water, it is best to establish with the owner a periodic maintenance schedule for checking the water-to-refrigerant heat exchanger on a regular basis. Should periodic cleaning be necessary, use standard cleaning procedures. Generally, the more water flowing through the unit, the less chance there is for scaling. Low GPM flow rates produce higher temperatures through the heat exchanger. To avoid excessive pressure drop and the possibility of metal erosion, do not exceed GPM flow rate as shown on the specification sheets for each unit.

Replacement Fuse Chart

Model

Size

120

180

240

360

600

* Meets Class J requirements

Line Voltage/

Frequency/ Phase

208-230/60/3 60 Class J, Round 19P605-06 30 Cube* 19P602-04 1.3 Class CC 19P600-07

380/60/ 3

460/60/3 30 Class J, Round 19P605-03 20 Cube* 19P602-02 0.6 Class CC 19P600-01

575/60/3 20 Class J, Round 19P605-01 15 Cube* 19P602-01 0.5 Class CC 19P600-13

208-230/60/3 70 Class J, Blade 19P605-07 40 Cube* 19P602-06 1.3 Class CC 19P600-07

380/60/ 3

460/60/3 30 Class J, Round 19P605-03 20 Cube* 19P602-02 0.6 Class CC 19P600-01

575/60/3 25 Class J, Round 19P605-02 15 Cube* 19P602-01 0.5 Class CC 19P600-13

208-230/60/3 80 Class J, Blade 19P605-08 45 Cube* 19P602-07 1.3 Class CC

380/60/ 3

460/60/3 45 Class J, Round 19P605-05 25 Cube* 19P602-03 0.6 Class CC 19P600-01

575/60/3 35 Class J, Round 19P605-04 20 Cube* 19P602-02 0.5 Class CC 19P600-13

208-230/60/3 110 Class J, Blade 19P605-10 60 Cube* 19P602-09 1.3 Class CC 19P600-07

380/60/3 80 Class J, Blade 19P605-08 45 Cube* 19P602-07 0.8 Class CC 19P600-03

460/60/3 60 Class J, Round 19P605-06 35 Cube* 19P602-05 0.6 Class CC 19P600-01

575/60/3 60 Class J, Round 19P605-06 30 Cube* 19P602-04 0.5 Class CC 19P600-13

208-230/60/3

380/60/3 110 Class J, Blade 19P605-10 60 Cube* 19P602-09 0.8 Class CC 19P600-03

460/60/3 100 Class J, Blade 19P605-09 50 Cube* 19P602-08 0.6 Class CC 19P600-01

575/60/3 70 Class J, Blade 19P605-07 40 Cube* 19P602-06 0.5 Class CC 19P600-13

Disconnect Fuse (if applicable) Branch Circuit Fuse Transformer Primary Fuse

Size (A) Type Part # Size (A) Type Part # Size (A) Type Part #

30 Class J, Round 19P605-03 20 Cube* 19P602-02 0.8 Class CC 19P600-03

Replacement Procedures

When contacting the company for 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.

19P600-07

Service Parts List

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Part Description

Compressor

Compressor Sound Jacket

Thermal Expansion Valve

TXV’s per circuit

Filter Dryer

Filter Dryers per circuit

Reversing Valve with Coil

Vibration Absorber (suction)

Vibration Absorber (discharge)

Refrigeration Components

Brazed Plate Heat Exchanger

Brazed Plate Heat Exchanger Insulation Kit

High Pressure Switch

Low Pressure Switch

Emergency Stop Switch 13P709-01 13P709-01

Sensors

Water Temperature Sensor

Switches /

Refrigerant Temp (Freeze) Sensor

Compressor Contactor

Transformer

Connection Block - Low Voltage

Grounding Lug

Non-Fused Disconnect 13P708-01-02 13P708-01-02

Fused Disconnect 13P710-01-04 13P710-01-04

Disconnect Fuses 19P605-01-10 19P605-01-10

Branch Circuit Fuse Holder 19P603-01-03 19P603-01-03

Electrical

Branch Circuit Fuses 19P602-01-09 19P602-01-09

Transformer Fuse Holder 19P601-01 19P601-01

Transformer Fuse 19P600-01-13 19P600-01-13

Emergency Stop Switch 13P709-01 13P709-01

Phase Guard Monitor

FX10 Main Board - no communications

FX10 Main Board & N2 Open Com Card

FX10 Main Board & Lonworks Com Card

FX10 Main Board & BACnet Com Card

Control

FX10 Expansion Board

Display

FX10 Display Interface Board

Right Side Water Line Access Panel (1) 40P409-06 40P409-06

Control Box Assembly Non-Fused Option (1) 45P404-01 45P404-01

Enclosure

Misc.

Control Box Assembly Fused Option (1) 45P404-11 45P404-11

Water Line Access Panel Support Bracket (3) 46P808-03 46P808-03

Door Latches

Keyed Door Lock

Compressor Shipping Bracket (4) 47P707-03 47P707-03

Heat Exchanger Mounting Brkt (2) 47P698-12 47P698-12

Water Line Corner Post (Right) (1) 43P443-04 43P443-04

Water Line Corner Post (Left) (1) 43P443-03 43P443-03

Control Box Corner Post (Right) (1) 43P443-02 43P443-02

Control Box Corner Post (Left) (1) 43P443-01 43P443-01

Left Side Water Line Access Panel (1) 40P409-05 40P409-05

Front Bottom Access Panel (1) 40P406-03 40P406-03

Control Box Terminal Strip Bracket (1) 46P808-06 46P808-06

Copper Vibration Reducer Bracket (4) N/A N/A

Korean Pressure Gauge Bracket (1) 46P808-04 46P808-04

Frame Assembly (1) 47P410-03 47P410-03

Top Panel (1) 42P400-03 42P400-03

Center Panel (2) 43P443-05 43P443-05

Control Box Base (1) 46P808-02 46P808-02

Control Box Fx-10 Bracket (1) 46P808-05 46P808-05

Rv Assembly Bracket (2) N/A N/A

Left Side Access Panel (2) 40P408-05 40P408-05

Right Side Access Panel (2) 40P408-06 40P408-06

Top Panel Ko Bracket (1) 42P400-11 42P400-11

208-230/60/3 380/60/3 460/60/3 575/60/3 208-230/60/3 460/60/3 575/60/3

34P658-06 34P658-03 34P658-04 34P658-05

13P537B03 13P537B03 13P537B03 13P537B03 13P537B04 13P537B03 13P537B03

15P501B01 15P511-02 15P505B01 15P506B01 15P501B01 15P505B01 15P506B01

120 180

34P617-03 34P617-04 34P617-05

92P519-04 92P519-03

33P620-05 33P620-04

36P500B04 36P500B04

33P526-05 33P077-06

32P508-06 32P508-05

32P508-05 32P508-04

62P563-11 62P564-11

92P520-11 92P520-12

35P506B02 35P506B02

35P506B01 35P506B01

12P529-05 12P529-05

12P529-06 12P529-06

12P503-06 12P503-06

12P004A 12P004A

19P541A06 19P541A06

17X51606NXW-05 17X51606NXW-05

17X51606NXW-06 17X51606NXW-06

17X51606NXW-07 17X51606NXW-07

17X51606NXW-08 17X51606NXW-08

17P516-07 17P516-07

19P563-01 19P563-01

17P516-11 17P516-11

91P570-01 91P570-01

99P532-01 99P532-01

1/30/14

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Service Parts List, cont.

Part Description

Compressor

Compressor Sound Jacket

Thermal Expansion Valve

TXV’s per circuit

Filter Dryer

Filter Dryers per circuit

Reversing Valve with Coil

Vibration Absorber (suction)

Vibration Absorber (discharge)

Refrigeration Components

Brazed Plate Heat Exchanger

Brazed Plate Heat Exchanger Insulation Kit

High Pressure Switch

Low Pressure Switch

Emergency Stop Switch 13P709-01 13P709-01

Sensors

Water Temperature Sensor

Switches /

Refrigerant Temp (Freeze) Sensor

Compressor Contactor

Transformer

Connection Block - Low Voltage

Grounding Lug

Non-Fused Disconnect 13P708-01-02 13P708-01-02

Fused Disconnect 13P710-01-04 13P710-01-04

Disconnect Fuses 19P605-01-10 19P605-01-10

Branch Circuit Fuse Holder 19P603-01-03 19P603-01-03

Electrical

Branch Circuit Fuses 19P602-01-09 19P602-01-09

Transformer Fuse Holder 19P601-01 19P601-01

Transformer Fuse 19P600-01-13 19P600-01-13

Emergency Stop Switch 13P709-01 13P709-01

Phase Guard Monitor

FX10 Main Board - no communications

FX10 Main Board & N2 Open Com Card

FX10 Main Board & Lonworks Com Card

FX10 Main Board & BACnet Com Card

Control

FX10 Expansion Board

Display

FX10 Display Interface Board

Right Side Water Line Access Panel (1) 40P409-04 40P409-04

Control Box Assembly Non-Fused Option (1) 45P404-01 45P404-01

Enclosure

Misc.

Control Box Assembly Fused Option (1) 45P404-11 45P404-11

Copper Vibration Reducer Bracket (4) N/A N/A

Water Line Access Panel Support Bracket (3) 46P808-03 46P808-03

Door Latches

Keyed Door Lock

Compressor Shipping Bracket (4) 47P707-03 47P707-04

Heat Exchanger Mounting Brkt (2) 47P698-11 47P698-11

Water Line Corner Post (Right) (1) 43P442-04 43P442-04

Water Line Corner Post (Left) (1) 43P442-03 43P442-03

Control Box Corner Post (Right) (1) 43P442-02 43P442-02

Control Box Corner Post (Left) (1) 43P442-01 43P442-01

Left Side Water Line Access Panel (1) 40P409-03 40P409-03

Front Bottom Access Panel (1) 40P406-02 40P406-02

Control Box Terminal Strip Bracket (1) 46P808-06 46P808-06

Korean Pressure Gauge Bracket (1) 46P808-04 46P808-04

Frame Assembly (1) 47P410-02 47P410-02

Top Panel (1) 42P400-02 42P400-02

Center Panel (2) 43P442-05 43P442-05

Control Box Base (1) 46P808-02 46P808-02

Control Box Fx-10 Bracket (1) 46P808-05 46P808-05

Rv Assembly Bracket (2) N/A N/A

Left Side Access Panel (2) 40P408-03 40P408-03

Right Side Access Panel (2) 40P408-04 40P408-04

Top Panel Ko Bracket (1) 42P400-11 42P400-11

208-230/60/3 460/60/3 575/60/3 208-230/60/3 380/60/3 460/60/3 575/60/3

34P619-06 34P619-04 34P619-05 34P655-06 34P655-03 34P655-04 34P655-05

13P537B05 13P537B03 13P537B03 13P537B05 13P537B05 13P537B04 13P537B04

15P501B01 15P505B01 15P506B01 15P501B01 15P511-02 15P505B01 15P506B01

240 360

92P519-03 92P519-05

33P620-03 33P620-02

36P500B04 36P500B06

33P546-04 33P546-04

32P508-04 32P508-04

32P508-03 32P508-03

62P550-11 62P551-11

92P520-13 92P516-11

35P506B02 35P506B02

35P506B01 35P506B01

12P529-05 12P529-05

12P529-06 12P529-06

12P503-06 12P503-06

12P004A 12P004A

19P541A06 19P541A06

17X51606NXW-05 17X51606NXW-05

17X51606NXW-06 17X51606NXW-06

17X51606NXW-07 17X51606NXW-07

17X51606NXW-08 17X51606NXW-08

17P516-07 17P516-07

19P563-01 19P563-01

17P516-11 17P516-11

91P570-01 91P570-01

99P532-01 99P532-01

1/30/14

Service Parts List, cont.

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Part Description

Compressor

Compressor Sound Jacket

Thermal Expansion Valve

TXV’s per circuit

Filter Dryer

Filter Dryers per circuit

Reversing Valve with Coil

Vibration Absorber (suction)

Vibration Absorber (discharge)

Refrigeration Components

Brazed Plate Heat Exchanger

Brazed Plate Heat Exchanger Insulation Kit

High Pressure Switch

Low Pressure Switch

Emergency Stop Switch 13P709-01

Sensors

Water Temperature Sensor

Switches /

Refrigerant Temp (Freeze) Sensor

Compressor Contactor

Transformer

Connection Block - Low Voltage

Grounding Lug

Non-Fused Disconnect 13P708-01-02

Fused Disconnect 13P710-01-04

Disconnect Fuses 19P605-01-10

Branch Circuit Fuse Holder 19P603-01-03

Electrical

Branch Circuit Fuses 19P602-01-09

Transformer Fuse Holder 19P601-01

Transformer Fuse 19P600-01-13

Emergency Stop Switch 13P709-01

Phase Guard Monitor

FX10 Main Board - no communications

FX10 Main Board & N2 Open Com Card

FX10 Main Board & Lonworks Com Card

FX10 Main Board & BACnet Com Card

Control

FX10 Expansion Board

Display

FX10 Display Interface Board

Right Side Water Line Access Panel (1) 40P409-02

Control Box Assembly Non-Fused Option (1) 45P404-01

Enclosure

Misc.

Control Box Assembly Fused Option (1) 45P404-11

Water Line Access Panel Support Bracket (3) 46P808-03

Door Latches

Keyed Door Lock

Compressor Shipping Bracket (4) 47P707-05

Heat Exchanger Mounting Brkt (2) N/A

Water Line Corner Post (Right) (1) 43P441-04

Water Line Corner Post (Left) (1) 43P441-03

Control Box Corner Post (Right) (1) 43P441-02

Control Box Corner Post (Left) (1) 43P441-01

Left Side Water Line Access Panel (1) 40P409-01

Front Bottom Access Panel (1) 40P406-01

Control Box Terminal Strip Bracket (1) 46P808-06

Copper Vibration Reducer Bracket (4) 46P835-05

Korean Pressure Gauge Bracket (1) 46P808-04

Frame Assembly (1) 47P410-01

Top Panel (1) 42P400-01

Center Panel (2) 43P441-05

Control Box Base (1) 46P808-02

Control Box Fx-10 Bracket (1) 46P808-05

Rv Assembly Bracket (2) 47P712-01

Left Side Access Panel (2) 40P408-01

Right Side Access Panel (2) 40P408-02

Top Panel Ko Bracket (1) 42P400-11

380/60/ 3 460/6 0/3 575/60/ 3

34P654-03 34P654-04 34P654-05

13P537B05 13P537B05 13P537B05

15P511-02 15P505B01 15P506B01

600

92P519-06

33P620-01

36P500B06

33P607-02

32P508-03

32P508-01

62P595-11

92P516-12

35P506B02

35P506B01

12P529-05

12P529-06

12P503-06

12P004A

19P541A06

17X51606NXW-05

17X51606NXW-06

17X51606NXW-07

17X51606NXW-08

17P516-07

19P563-01

17P516-11

91P570-01

99P532-01

1/30/14

ENVISION2 NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Revision Guide

Pages: Description: Date: By:

All First Published 02 Jun 2014 DS

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

Product: Envision2 NXW Type: Reversible Chiller - 60 Hz Size: 10-50 Tons

IM2502WN 06/14

reserves the right to change design and speciﬁ cations without notice.

Document: Installation Manual

WaterFurnace Envision2 NXW Chiller User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Model Nomenclature

General Installation Information

Mounting Units

Physical Dimensions

Physical Data

Field Connected Water Piping

Envision2 NXW Typical Piping

Envision2 NXW Application Data

System Cleaning and Flushing

Electrical Data

Wiring Schematics

Field Wiring and Control Setup

Control Features

Sequence of Operation

MUI Menu Navigation

Reference Calculations

Legend

Unit Startup

Operating Parameters

Pressure Drop

Compressor Resistance

Thermistor Resistance

Operating Limits

Troubleshooting

Heating Cycle Analysis

Cooling Cycle Analysis

Envision NXW Troubleshooting Form

NXW Pre-Start-Up Checklist

NXW Start-Up Form

Preventive Maintenance

Replacement Fuse Chart

Service Parts List