WaterFurnace Envision Hydronic User Manual

Geothermal Hydronic Heat Pump Commercial 1.5 to 6 Tons

Installation Information

Water Piping Connections

Electrical Data

Startup Procedures

Preventive Maintenance

NSW Installation Manual

IM1056WN 03/13

NSW INSTALLATION MANUAL

Table of Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Field Connected Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Potable Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Hydronic Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Accessories and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23 External Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-25 Converting to a Dedicated Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Standard Board - Control Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-29 Standard Control - Panel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 Optional Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-36 Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Legend and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 AHRI/ISO 13256-2 Performance Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Thermistor and Compressor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Antifreeze Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Troubleshooting Guideline for Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Heating and Cooling Cycle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46-47 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-50 Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

NSW INSTALLATION MANUAL

Model Nomenclature

1-3

4-6

7

8

9

10

11

12

13-14

15

NSW

050

R

0

0

2

C

C

SS

A

Model

Vintage

NSW = Envision Series

A = NSW040 - NSW075

Hydronic Heat Pump

B = NSW025

C = NSW018

Capacity

Future Option

018 MBTUH

025 MBTUH

SS = Standard Option

040 MBTUH

050 MBTUH

Load Coax 3

060 MBTUH

C = Copper

075 MBTUH

N = Cupronickel

Reversible Option

Source Coax

H = Heating Only

C = Copper

R = Reversible

N = Cupronickel

Voltage

Controls Option

0 = 208-230/60/1 (Commercial)

2 = Standard Board

2 = 265/60/1 (025 & 050 only)

4 = FX10 without interface

3 = 208-230/60/3 (040 - 075 only)

5 = FX10 with N2 card without interface

4 = 460/60/3 (025 - 075 only)

6 = FX10 with LonWorks card without interface

5 = 575/60/3 (040 - 075 only)

7 = FX10 with BACnet card without interface

8 = FX10 with MUI

Hot Water Option

9 = FX10 with N2 card and MUI

0 = No Hot Water Generation, No IntelliStart

0 = FX10 with Lonworks card and MUI

2 = Hot Water Generation (requires accessory

3 = FX10 with BACnet card and MUI

pump kit), No IntelliStart 2

3 = No Hot Water Generation, IntelliStart 1

Rev.: 26 March 2013D

5 = Hot Water Generation (requires accessory

pump kit), IntelliStart 1, 2

NOTES: 1 IntelliStart is only available on 208-230/60/1 voltage

2 Available on 040, 050, 060, and 075 only. HWG requires field installed external pump kit.

3NSW018 and NSW025 heating only models are available only with copper double wall vented load coax for potable water.

All Envision Series product is safety listed under UL1995 thru ETL and performance listed with AHRI in accordance with standard 13256-1. The Envision Series is also ENERGY STAR® rated.

4

NSW INSTALLATION MANUAL

General Installation Information

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.

Process Water Applications

For process water applications, it is recommended that a secondary load heat exchanger be installed to prevent corrosion to the unit’s primary coaxial coil. In situations where scaling could be heavy or where biological growth

such as iron bacteria will be present, a closed loop system is recommended. Over a period of time, ground water unit heat exchanger coils may lose heat exchange capability due to a buildup of mineral deposits. These can be cleaned only by

a qualified service mechanic as special pumping equipment and solutions are required. Never use flexible hoses with a smaller inside diameter than that of water connections.

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.

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.

Mounting Units

Units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor. Allow access to the front, back, and side access panels for servicing.

DWP`ObW]\ >OR ;]c\bW\U

5

NSW INSTALLATION MANUAL

Water Quality

General

NSW water-to-water heat pumps may be successfully applied in a wide range of residential and light commercial 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. Failure to adhere to the guidelines in the water quality table could result in loss of warranty.

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 qualified water treatment specialist should be engaged to determine what treatment, if any, is required. The product warranty specifically excludes liability for corrosion, erosion or deterioration of equipment.

The heat exchangers and water lines in the units are copper or cupronickel tube. There may be other materials in the

Water Quality Guidelines

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 confirm it does not have a detrimental effect on the materials in the system.

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.

	Material		Copper	90/10 Cupronickel	316 Stainless Steel
	pH	Acidity/Alkalinity	7 - 9	7 - 9	7 - 9
	Scaling	Calcium and	(Total Hardness)	(Total Hardness)	(Total Hardness)
		Magnesium Carbonate	less than 350 ppm	less than 350 ppm	less than 350 ppm
		Hydrogen Sulfide	Less than 0.5 ppm (rotten egg	10 - 50 ppm	Less than 1 ppm
			smell appears at 0.5 ppm)
		Sulfates	Less than 125 ppm	Less than 125 ppm	Less than 200 ppm
		Chlorine	Less than 0.5 ppm	Less than 0.5 ppm	Less than 0.5 ppm
		Chlorides	Less than 20 ppm	Less than 125 ppm	Less than 300 ppm
		Carbon Dioxide	Less than 50 ppm	10 - 50 ppm	10 - 50 ppm
	Corrosion	Ammonia	Less than 2 ppm	Less than 2 ppm	Less than 20 ppm
		Ammonia Chloride	Less than 0.5 ppm	Less than 0.5 ppm	Less than 0.5 ppm
		Ammonia Nitrate	Less than 0.5 ppm	Less than 0.5 ppm	Less than 0.5 ppm
		Ammonia Hydroxide	Less than 0.5 ppm	Less than 0.5 ppm	Less than 0.5 ppm
		Ammonia Sulfate	Less than 0.5 ppm	Less than 0.5 ppm	Less than 0.5 ppm
		Total Dissolved Solids (TDS)	Less than 1000 ppm	1000 - 1500 ppm	1000 - 1500 ppm
		LSI Index	+0.5 to -0.5	+0.5 to -0.5	+0.5 to -0.5
		Iron, FE2+ (Ferrous)	< 0.2 ppm	< 0.2 ppm	< 0.2 ppm
	Iron Fouling	Bacterial Iron Potential
	(Biological Growth)	Iron Oxide	Less than 1 ppm, above this	Less than 1 ppm, above this	Less than 1 ppm, above this
			level deposition will occur	level deposition will occur	level deposition will occur
		Suspended Solids	Less than 10 ppm and filtered	Less than 10 ppm and filtered	Less than 10 ppm and filtered
			for max. of 600 micron size	for max. of 600 micron size	for max. of 600 micron size
	Erosion
		Threshold Velocity	< 6 ft/sec	< 6 ft/sec	< 6 ft/sec
		(Fresh Water)
	NOTES: Grains = ppm divided by 17				2/22/12
	mg/L is equivalent to ppm

6

NSW INSTALLATION MANUAL

Field Connected Water Piping

General

Each unit is equipped with captive FPT water connections to eliminate ‘egg-shaping’ from use of a backup wrench. For making the water connections to the unit, a Teflon tape thread sealant is recommended to minimize internal fouling

of the piping. Do not over tighten connections. All supply and return water piping should be insulated to prevent excess condensation from forming on the water lines.

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

The piping installation should provide service personnel with the ability to measure water temperatures and pressures. The water lines should be routed so as not to interfere with access to the unit. The use of a short length of high pressure hose with a swivel type fitting may simplify the connections and prevent vibration. Optional stainless steel hose kits are available as an accessory item.

Before final connection to the unit, the supply and return hose kits must be connected, 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. To assure proper flow, the use of pressure/temperature ports is recommended to determine the flow rate. These ports should be located adjacent to the supply and return connections on the unit. The proper flow rate cannot be accurately set without

measuring the water pressure drop through the refrigerant-

Typical Open Loop Installation

to-water heat exchanger (See Pressure Drop Table for water flow and pressure drop information). Normally about 3 GPM flow rate per ton of cooling capacity (2.25 GPM per ton minimum) is needed. Both source as well as load fluid piping must be at least as large as the unit connections on the heat pump (larger on long runs).

Never use flexible hoses of a smaller inside diameter than that of the water connection on the unit and limit hose length to 10 ft. per connection. Check carefully for water leaks.

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

Open Loop Well Water Systems

Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit. Use a closed bladder type expansion tank to minimize mineral deposits. Ensure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in the pressure drop table.

Normally, about 2 GPM flow rate per ton of cooling capacity is needed in open loop systems, (1.5 GPM per ton minimum if entering source temperature is above 50°F [10°C].

Some water control valves draw their power directly from the unit’s 24V transformer and can overload and possibly burn out the transformer. Check total VA draw of the water valve(s) and ensure it is under 40 VA.

Discharge water from a heat pump can be disposed of in various ways depending on local building codes (i.e. recharge well, storm sewer, drain field, adjacent stream or pond,

etc.). Most local codes restrict the use of sanitary sewer for disposal. Consult your local building and zoning departments to ensure compliance in your area.

		Rubber Bladder
		Expansion Tank
		Flow Regulator Valve
Line Voltage	Shut-off Valve
Disconnect	(to isolate solenoid	Solenoid
	valve while acid	Valve	Water Out
	flushing)
			Water In

		Boiler Drains for	Shut-off
		HX Flushing	Valve
		P/T Plugs
	Load Liquid	Vibration Absorbing	NOTE: Valves and boiler drains must be installed
		Mesh or Air Pad	so the heat exchanger can be acid flushed.
	Connections

7

NSW INSTALLATION MANUAL

Field Connected Water Piping cont.

Earth Coupled Systems with Flow Center

Once piping is completed between the unit, flow center and the earth loop, final purging and charging of the loop is needed. A flush cart (at least a 1.5 HP or 1.12 kW 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. Maintain the pH in the 7.6-8.2 range for final charging.

Flush the system adequately to remove as much air as possible. Then, pressurize the loop to a static pressure of 50-75 psi [345-517 kPa]. This is normally adequate for good system operation. Ensure that the flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger and by comparing it to the figures shown in the Pressure Drop tables. Usually, 3 GPM/ ton [0.054 L/s/kW] L/s/kW or minimum 2.25 GPM/ton [0.04 L/s/kW] of cooling capacity is needed in closed loop earth-coupled applications

Typical Closed Loop Earth Coupled Installation

Earth Coupled Loop

Piping with Insulation

Line Voltage

Disconnect

Unit Connector Kits

with Insulation

P/T Plugs

Load Liquid

Vibration Absorbing

Connections

Mesh or Air Pad

Potable Water Systems

The NSW018 and NSW025 models can be equipped to provide domestic hot water generation. An optional factory-installed hot water generator coil may be provided with the NSW040, NSW050, NSW060, and NSW075 to assist with this process.

Suggested Domestic Water Heater Hookup

30 psi	Pressure
RELIEF VALVE	Gauge	Air
		Vent

LOAD PUMP

		HYDRONIC
	Air	LOAD	Vent Valve/
	Separator
Back Flow Preventer /			P/T Port**
	Expansion
Pressure Relief Valve	Tank
Dielectric		HOT	COLD
Unions		(Piped in
		series to
		an electric
		water heater)

GEO	PUMP
STORAGE	DOMESTIC
TANK
Dip Tube	TO
FROM
HWG	HWG

1-1/2 in.

Dielectric FPT Unions

	Source OUT
P/T Ports	P/T Ports
Ball Valve	Source IN
Ball Valve

NOTES:

* A 30 psi pressure relief valve (Part No: SRV30) should be used in hydronic applications.

** Vent valve or P/T port at highest point in return line prior to ball valve.

WaterFurnace

NSW Series

8

NSW INSTALLATION MANUAL

Potable Water Systems cont.

NOTES:

1)Unions and valves must be installed so that acid flushing of the heat exchanger is possible.

2)Route thermistor wires to NSW. Remove yellow thermistor wires on TB 3 and 4 from control box and connect thermistor wires from geothermal storage tank. Set the pump sampling (PS) in the set up of the control board to continuously (C) sampling (reference Note 5 in the Wiring Schematic).

Alternate Hot Water Installation with

Direct Coupling to a Double Wall Unit

6=B 1=:2

2WSZSQb`WQ

C\W]\a

Hot Water Generator Connections

The heat reclaiming hot water generator coil is vented doublewall copper construction and is suitable for potable water. To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended. For higher demand applications, use an 80-gallon water heater as shown below or two 50-gallon water heaters connected in a series. A geo storage tank should not be used in this application unless it is plumbed in a series with an electric water heater. The geo storage tank

is equipped with a single 4500 Watt element and will not be able to provide adequate water heating if used as a standalone water heater. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are met for installing a hot water generator. The Envision NSW is not supplied with an internal circulator. A DPK5 kit will need to be purchased to

connect to the hot water generator. The DPK5 kit is supplied with installation instructions, circulator, tank adaptor and temperature limit switch. Be sure to burp (vent) the pump. Open the screw

2 turns only in the end of the pump motor (if Grundfos® pumps are used) to allow trapped air to be discharged and to ensure the motor housing has been flooded.

:==> 473:2

4:=E 13<B3@

Þ

2WSZSQb`WQ 4>B C\W]\a

	> B >]`ba	> B >]`ba
0OZZ DOZdS	0OZZ DOZdS

EObS`4c`\OQS	EObS`4c`\OQS
53=B/<9	<AE & ]` <AE # 6SObW\U =\Zg
	eWbV 2]cPZS EOZZ :]OR 1]Of

NOTES:

1)Unions and valves must be installed so that acid flushing of the heat exchanger is possible.

2)Make sure there is not a check valve in the diptube of the tank.

3)Route thermistor wires to NSW. Remove yellow thermistor wires on TB 3 and 4 from control box and connect thermistor wires from geothermal storage tank. Set the pump sampling (PS) in the set up of the control board to continuously (C) sampling (reference Note 5 in the Wiring Schematic).

9

NSW INSTALLATION MANUAL

Hydronic Section

General guidelines are shown below for component selection and design/installation criteria for the piping system. Local codes supersede any recommendations in this manual.

Shut Off/Flow Regulation Valves

Use full port ball valves or gate valves for component isolation. If valves are going to be used frequently, ball valves are recommended. Globe valves are designed for flow regulation. Always install globe valves in the correct direction (fluid should enter through the lower body chamber).

Check valves

Swing check valves must be installed in the horizontal position with the bonnet of the valve upright. Spring check valves can be mounted in any position. A flow check valve is required to prevent thermo-siphoning (or gravity flow) when the circulator pump is off or when there are two circulators on the same system.

Storage (Buffer) Tank

A buffer tank is required for all hydronic heating systems using Envision NSW heat pumps. The tank should be sized to provide 2 gallons of storage capacity for every one thousand Btuh’s of nominal heat pump capacity.

Pressure Relief Valve

Most codes require the use of a pressure relief valve if a closed loop heat source can be isolated by valves. Even if local code does not require this device, WaterFurnace recommends its installation. If the pressure relief valve in the buffer tank is not already rated at 30 psi (207 kPa) maximum pressure, one must be installed. The pressure

relief valve should be tested at start up for operation. Note that the waste pipe must be at least the same diameter

as the valve outlet (never reduce), and valves may not be added to this pipe. The bottom of the pipe must terminate at least 6” (15 cm) above the floor. If the piping is connected to a drain, there must be an air gap.

Backflow Prevention Check Valves

Most codes require backflow prevention check valves. Note that a single check valve is not equal to a backflow prevention check valve. Even if local code does not require this device, WaterFurnace recommends its installation. This is particularly important if the system will use antifreeze.

0 psi (0 kPa), potentially causing pumps(s) failure. A valve should be installed on each side of the pressure reducing valve for servicing. Both valves should have tags reading “Do not shut this valve under normal operation – service valve only.”

Expansion Tanks

Expansion tanks are required on hydronic systems to help absorb the pressure swings as the temperature in the system fluctuates.

Elbows/Tees

Long radius elbows or two 45° elbows will lower pressure drop. Standard tees have a greater restriction on the “T” portion than tees designed with angled outlet ports.

Antifreeze

Antifreeze is required if any of the piping system is located in areas subject to freezing.

Dielectric Unions

Dielectric unions are recommended whenever connecting two dissimilar metals to one and other to prevent electrogalvanic corrosion.

When using the various types of hydronic heat distribution systems, the temperature limits of the geothermal system must be a major consideration. In new construction, the distribution system can easily be designed with the temperature limits in mind. In retrofits, care must be

taken to address the operating temperature limits of the existing distribution system. The maximum storage tank temperature for the Envision NSW is 130°F (54.4°C). Typical in floor radiant systems require much lower temperatures, typically 100°-115°F, which is ideal for the Envision NSW.

Pressure Reducing Valves or Feed Water Valves

This valve lowers the pressure from the make-up water line to the system. Most are adjustable and directional. A “fast fill” valve is required for initial filling of the system. Some have screens, which must be cleaned after the initial filling. If there is a restriction in the screen, the system could go to

10

NSW INSTALLATION MANUAL

Hydronic Section cont.

Open the screw 2 turns only in the end of the pump motor (if Grundfos® pumps are used) to allow trapped air to be

discharged and to ensure the motor housing has been flooded.

Route thermistor wires to NSW. Remove yellow thermistor wires on TB 3 and 4 from control box and connect thermistor wires from geothermal storage tank. Set the pump sampling (PS) in the set up of the control board to continuously (C) sampling (reference Note 5 in the Wiring Schematic).

Adequate rate of flow (GPM) is very important to system performance and long term reliability. Follow the guidelines for recommended flow and pipe sizing in the NSW recommendations table.

WaterFurnace Geothermal Storage Tank Thermostat

and Thermistor

Synergy3D

Thermostat

NSW

Yellow Thermistor Wires Connected to TB (3 and 4) on

NSW Control Board

30 psi	Pressure
RELIEF VALVE	Gauge	Air
		Vent

LOAD PUMP

		HYDRONIC
	Air	LOAD	Vent Valve/
	Separator
Back Flow Preventer /			P/T Port**
	Expansion
Pressure Relief Valve	Tank
Dielectric		HOT	COLD
Unions		(Piped in
		series to
		an electric
		water heater)

GEO	PUMP
STORAGE	DOMESTIC
TANK
Dip Tube	TO
FROM
HWG	HWG

1-1/2 in.

Dielectric FPT Unions

	Source OUT
P/T Ports	P/T Ports
Ball Valve	Source IN
Ball Valve

NOTES:

* A 30 psi pressure relief valve (Part No: SRV30) should be used in hydronic applications.

** Vent valve or P/T port at highest point in return line prior to ball valve.

WaterFurnace

NSW Series

11

NSW INSTALLATION MANUAL

Accessories and Options

Water Connection Kits (Field Installed)

Water connection kits have been designed to facilitate loadside and loop-side water connections.

Earth Loop Pump Kit (Field Installed)

A specially designed one or two-pump module provides all liquid flow, fill and connection requirements for independent single unit systems (230/60/1 only). The one-pump module is capable of 20 feet of head at 16.0 GPM, while the twopump module is capable of 40 feet of head at 16.0 GPM.

Hot Water Generator (Factory Installed, NSW040, NSW050, NSW060, and NSW075 Only)

An optional heat reclaiming hot water generator coil constructed of vented double-wall copper construction suitable for potable water is available. The coil is factory mounted inside the unit. A DPK5 pump kit is required (field installed), which includes a DHW tank connection and a temperature limit pump shutoff.

Load-side Pump Kit (Field Installed)

Four (4) load pump kits are available to provide all liquid flow requirements for independent single unit systems (230/60/1 only). WaterFurnace part number 24P501A04 (Grundfos UP15-42B7) and EWPK2 (Grundfos UP26-64BF) are bronze body pumps. Bronze body pumps should be used when water conditions exist that are not compatible with cast iron or for applications such as domestic water heating. WaterFurnace part number EWPK1 and EWPK3 come with a cast iron body pump (Grundfos UP26-99F) that can be used for hydronic heating applications.

Calculate the system pressure drop then refer to the pump curves to select the proper pump. All four of the WaterFurnace pump kits can be used for hydronic heating

applications as long as they meet the flow requirements. If the flow requirements are outside the pump curve, an alternate pump will need to be obtained to maintain the necessary flow.

IntelliStart®

The optional IntelliStart single phase soft starter will reduce the normal start current (LRA) by 60-70%. This allows the heat pump to go off-grid. Using IntelliStart also provides a substantial reduction in light flicker, reduces start-up noise, and improves the compressor’s start behavior. IntelliStart is available in a field retrofit kit (WaterFurnace part number IS60RKL or IS60RKS) or as a factory installed option for all Envision and Synergy3D units.

Water Connection Kits (Field Installed)

Water connection kits are available to facilitate loop side and load side water connections.

•MA4FPT - Forged brass 1” MPT x 1” FPT square street elbow with P/T plug for NSW018-NSW040 water side connections

•MA5FPT - Forged brass 1.25” MPT x 1.25” FPT square street elbow with P/T plug for NSW050-NSW075 water side connections

•HKC8S - 1 inch x 24 inch stainless steel braided hose kit

•HKC10S - 1 1⁄4 inch x 24 inch stainless steel braided hose kit

Single Pump Curve: UP15-42B7, UP26-64BF, and UP26-99F

	35
	30										UP26-99F
											UP26-64BF
Head	25										UP15-42B7
	20
of
Feet	15
	10
	5
	0

0	5	10	15	20	25	30	35
				GPM

Two Pump Curve: UP26-64BF and UP26-99F

	70
	60												UP26-99F (2 pumps)
													UP26-64BF (2pumps)
Head	50
	40
of
Feet	30
	20
	10
	0
	0		5	10		15		20		25			30		35
								GPM

NOTE: Never use piping smaller than 1 inch. Limit length of pipe to 50 feet or less.

Type L Copper Pressure Loss

Ft of Hd per 100 ft

			Type L Copper Tube
GPM	3/4	1		1-1/4	1-1/2	2
2	1.5
3	3.2
4	5.5	1.4
5	8.5	2.1
6		2.9		1.1
7		3.9		1.4
8		5.0		1.8
9		6.1		2.3	0.9
10		7.5		2.8	1.1
12				3.9	1.6
14				5.2	2.1
16				6.6	2.7
18				8.2	3.4
20				10.0	4.1	1.1
22					5.0	1.3
25					6.3	1.6
30						2.2
35						2.9
40						3.8
45						4.7
50						5.7

NOTE: Standard piping practice limits pressure drop to 4 feet of hd per 100 feet in 2 inch and larger pipe.

12

NSW INSTALLATION MANUAL

Accessories and Options cont.

Geo Storage Tank Dimensions

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MODEL

GALLON

ELEMENT

NUMBER

R

DIMENSIONS IN INCHES

APPROX.

WATTAGE

OF

SHIPPING

NUMBER

CAPACITY

VALUE

HEIGHT

DIAMETER

(240 VOLT)

ELEMENTS

WEIGHT (lbs.)

GEO-STORAGE-80

80

4500

1

16

63-1/4

24

204

GEO-STORAGE-120

119

4500

1

16

63-1/4

28

311

13

NSW INSTALLATION MANUAL

Electrical Data

Model		Rated	Voltage		Compressor				Load	Source	Total Unit	Min Ckt	Maximum
		Voltage	Min/Max	RLA		LRA		LRA*	Pump	Pump	FLA	Amp	Fuse/HACR
018		208-230/60/1	197/254	9.0		48.0		17.0	1.8	5.4	16.2	18.5	30
		208-230/60/1	197/254	13.5		61.0		21.4	1.8	5.4	20.7	24.1	35
025
		265/60/1	239/292	10.9		58.0		-	-	-	10.9	13.6	20
		460/60/3	414/506	4.5		27.0		-	-	-	4.5	5.6	10
		208-230/60/1	197/254	20.0		115.0		40.3	1.8	5.4	27.2	32.2	50
040		208-230/60/3	197/254	12.8		95.0		-	-	-	12.8	16.0	25
		460/60/3	414/506	6.4		45.0		-	-	-	6.4	8.0	10
		575/60/3	518/632	5.4		38.0		-	-	-	5.4	6.8	10
		208-230/60/1	197/254	26.4		134.0		46.9	1.8	5.4	33.6	40.2	60
		265/60/1	239/292	19.9		130.0		-	-	-	19.9	24.9	40
050
		208-230/60/3	197/254	16.0		110.0		-	-	-	16.0	20.0	35
		460/60/3	414/506	7.8		52.0		-	-	-	7.8	9.8	15
		575/60/3	518/632	5.7		38.9		-	-	-	5.7	7.1	10
		208-230/60/1	197/254	30.1		145.0		50.8	1.8	5.4	37.3	44.8	70
060		208-230/60/3	197/254	17.3		120.0		-	-	-	17.3	21.6	35
		460/60/3	414/506	9.6		70.0		-	-	-	9.6	12.0	20
		575/60/3	518/632	8.0		53.0		-	-	-	8.0	10.0	15
		208-230/60/1	197/254	26.9		145.0		50.8	1.8	5.4	34.1	40.8	60
075		208-230/60/3	197/254	22.4		190.0		-	-	-	22.4	28.0	50
		460/60/3	414/506	12.2		87.0		-	-	-	12.2	15.3	25
		575/60/3	518/632	9.6		62.0		-	-	-	9.6	12.0	20
NOTES: All fuses type “D” time delay (or HACR circuit breaker in USA).													03/26/13
	Source pump amps shown are for up to a 1/2 HP pump.
	Load pumps amps shown are for small circulators.
	*LRA with optional IntelliStart installed (208-230/60/1).

NSW Control Box
		Terminal Board
Optional IntelliStart
		Terminal Power Strip
Power Block		Power Block
IntelliStart Only
Compressor Contactor		Load Pump Fuse Block
		(Single Phase Only)
Run Capacitor
(Single Phase Only)		Source Pump Fuse Block
		(Single Phase Only)
Ground Lug
		Reversing Valve Relay
Transformer		(Reversible Units Only)
Load Pump Relay		Source Pump Relay

14

NSW INSTALLATION MANUAL

Electrical Data cont.

208 Volt Operation

All 208-230 volt units are factory wired for 230 volt operation. To convert the unit from a 230V unit to a 208V unit follow these steps:

1.Remove the blue transformer wire from terminal L2 on the compressor contactor and secure the wire taking care to insulate the end with electrical tape.

2.Locate the red transformer wire and connect it to the L2 terminal of the compressor contactor.

Electrical

Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. Refer to the Electrical Data table for wire and fuse or circuit breaker sizing information.

Flow Center Pump Connection (208-230/60/1)

Two fuse internal terminal block connections with 1/4-inch spade connectors are provided; one for the load pump and one for the source pump. The source pump directly connects to the fuse terminal block for the source pump. The load pump directly connects to the fuse terminal block for the load pump.

NSW Control Box Relocation

The NSW control box can be installed on the rear of the unit. To relocate the control box, follow the procedures below.

1.Remove all power sources to the unit.

2.Remove the unit’s top panel.

3.Cut all plastic wire ties to the following:

a)High pressure switch (black wires)

b)Low pressure switch (blue wires)

c)Freeze sensing (yellow wires)

d)Load temperature sensor (black wires)

e)Compressor wires

4.Remove the four screws from the control box.

5.Relocate the control box to opposite end of the unit.

6.Using the screws removed in step 4 above, reattach the control box.

7.Secure all wires so they do not come in contact with refrigerant lines.

8.Replace the top of the unit.

9.Replace both access panels.

10.Reapply power sources.

NOTE: If geothermal storage tank is used, connect yellow thermistor wires from the bottom access panel of the tank to spade connectors 3 and 4 on the terminal block.

15

NSW INSTALLATION MANUAL

Wiring Schematics

For all NSW 208/230 volt single-phase units, the circulator wiring is as shown in the illustrations below. The internal relay and fusing allow for external pumps no larger than .5 horsepower. The external loop pump connections mentioned in this manual include a dedicated flow center for each unit as well as an NSW unit connected to an Envision; “P” or an “E” series unit containing a microprocessor.

Load Circulator Wiring

		T1		T2
CAPACITOR	COMPRESSOR
		CONTACTOR
		L1		L2

LOW VOLTAGE		TERMINAL STRIP	VOLTAGE LOW THERMOSTAT CONNECTIONS

FUSE

BLOCKS

LOAD

CIRCULATOR

PUMP

TRANSFORMER

CONTROL BOX

Dedicated Flow Center Wiring

		T1		T2
CAPACITOR	COMPRESSOR
		CONTACTOR
		L1		L2

STRIP TERMINAL		VOLTAGE LOW	VOLTAGE LOW THERMOSTAT CONNECTIONS

FUSE

BLOCKS

FLOW CENTER

TRANSFORMER

CONTROL BOX

16