tallation Manual W Ins NS Geothermal Hydronic Heat Pump

NSW Installation Manual
Geothermal Hydronic Heat Pump
1.5 to 6 Tons
Installation Information
Water Piping Connections
Electrical Data
Startup Procedures
Preventive Maintenance
IM1006WN 07/14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19
External Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Converting to a Dedicated Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Standard Board - Control Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Standard Control - Panel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Legend and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AHRI/ISO 13256-2 Performance Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Thermistor and Compressor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Antifreeze Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting Guideline for Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Heating and Cooling Cycle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-38
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
NSW INSTALLATION MANUAL
Model Nomenclature
1
2
3
4-6
7
8
9
10
11
12
13
14
15
16
N
S
W
050
*
1
0
R
C
S
S
0
S
N
IntelliStart®
N – None
A – IntelliStart
Model
N – Envision Hydronic
Heat Pump
Controls Option
S – Microprocessor
Compressor Type
S – Single Speed
Future Option
0 – Standard
Cabinet Configuration
W – Water-to-Water
Future Option
S – Standard
Unit Capacity
018, 025, 040, 050, 060, 075
Future Option
S – Standard
Vintage
* - Factory Use Only
Water Coil Option2
C – Copper
N - CuproNickel
L – Source CuproNickel & Load Copper
S – Source Copper & Load CuproNickel
Voltage
1 – 208-230/60/1
Hot Water Option1
0 – No Hot Water Generation
2 – Hot Water Generation
Reversible Option
H – Heating Only
R – Reversible
Rev.: 09 July 2014M
NOTES: 1 – Available on 040, 050, 060, and 075 only. Hot water generator requires field installed external pump kit.
2 – NSW018 and NSW025 heating only models are available only with copper double wall vented load coax for potable water,
and are not designed to be converted to dedicated cooling units.
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
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.
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.
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.
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.
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.
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.
Mounting Units
Prior to setting the unit in place, remove and discard the
compressor hold down shipping bolt located at the front of
the compressor mounting bracket.
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.
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.
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5
NSW INSTALLATION MANUAL
Water Quality
building’s piping system that the designer may need to take
into consideration when deciding the parameters of the
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.
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.
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 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.
The heat exchangers and water lines in the units are copper
or cupronickel tube. There may be other materials in the
Water Quality Guidelines
Material
pH
Scaling
Acidity/Alkalinity
Calcium and
Magnesium Carbonate
Hydrogen Sulfide
Corrosion
Iron Fouling
(Biological Growth)
Sulfates
Chlorine
Chlorides
Carbon Dioxide
Ammonia
Ammonia Chloride
Ammonia Nitrate
Ammonia Hydroxide
Ammonia Sulfate
Total Dissolved Solids (TDS)
LSI Index
Iron, FE2+ (Ferrous)
Bacterial Iron Potential
Iron Oxide
Suspended Solids
Erosion
Threshold Velocity
(Fresh Water)
NOTES: Grains = ppm divided by 17
mg/L is equivalent to ppm
Copper
7-9
(Total Hardness)
less than 350 ppm
Less than 0.5 ppm (rotten egg
smell appears at 0.5 ppm)
Less than 125 ppm
Less than 0.5 ppm
Less than 20 ppm
Less than 50 ppm
Less than 2 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 1000 ppm
+0.5 to -0.5
90/10 Cupronickel
7-9
(Total Hardness)
less than 350 ppm
316 Stainless Steel
7-9
(Total Hardness)
less than 350 ppm
10 - 50 ppm
Less than 1 ppm
Less than 125 ppm
Less than 0.5 ppm
Less than 125 ppm
10 - 50 ppm
Less than 2 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
1000 - 1500 ppm
+0.5 to -0.5
Less than 200 ppm
Less than 0.5 ppm
Less than 300 ppm
10 - 50 ppm
Less than 20 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
1000 - 1500 ppm
+0.5 to -0.5
< 0.2 ppm
< 0.2 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
Less than 1 ppm, above this
level deposition will occur
Less than 10 ppm and filtered
for max. of 600 micron size
Less than 1 ppm, above this
level deposition will occur
Less than 10 ppm and filtered
for max. of 600 micron size
< 6 ft/sec
< 6 ft/sec
< 6 ft/sec
2/22/12
6
NSW INSTALLATION MANUAL
Field Connected Water Piping
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).
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.
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.
NOTE: Units are factory run-tested using propylene
glycol. Prior to connecting piping to unit, thoroughly flush
heat exchangers.
CAUTION: Water piping exposed to outside
temperature may be subject to freezing.
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.
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].
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.
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.
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-
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.
Typical Open Loop Installation
Rubber Bladder
Expansion Tank
Flow Regulator Valve
Line Voltage
Disconnect
Shut-off Valve
(to isolate solenoid
valve while acid
flushing)
Solenoid
Valve
Water Out
Water In
Boiler Drains for
HX Flushing
Shut-off
Valve
P/T Plugs
Load Liquid
Connections
Vibration Absorbing
Mesh or Air Pad
NOTE: Valves and boiler drains must be installed
so the heat exchanger can be acid flushed.
7
NSW INSTALLATION MANUAL
Field Connected Water Piping cont.
Typical Closed Loop Earth Coupled Installation
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.
Earth Coupled Loop
Piping with Insulation
Line Voltage
Disconnect
Unit Connector Kits
with Insulation
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
P/T Plugs
Vibration Absorbing
Mesh or Air Pad
Load Liquid
Connections
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
RELIEF VALVE
Pressure
Gauge
Back Flow Preventer /
Pressure Relief Valve
Air
Vent
Expansion
Tank
LOAD PUMP
HYDRONIC
LOAD
Air
Separator
Dielectric
Unions
HOT
COLD
(Piped in
series to
an electric
water heater)
GEO
STORAGE
TANK
PUMP
DOMESTIC
Dip Tube
FROM
HWG
TO
HWG
Source OUT
Dielectric
Unions
Vent Valve/
P/T Port**
1-1/2 in.
FPT
P/T Ports
Ball Valve
P/T Ports
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).
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.
Alternate Hot Water Installation with
Direct Coupling to a Double Wall Unit
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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.
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.”
Shut Off/Flow Regulation Valves
Expansion Tanks
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).
Expansion tanks are required on hydronic systems to help
absorb the pressure swings as the temperature in the
system fluctuates.
Elbows/Tees
Check valves
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.
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.
Antifreeze
Antifreeze is required if any of the piping system is located
in areas subject to freezing.
Storage (Buffer) Tank
Dielectric Unions
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.
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 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.
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.
There are two methods for controlling the load pump:
1.) Pump Sampling – Uses the NSW internal thermistor
located on the entering load water line to sense water
temperature (see ‘Load Pump Control’ in Control Features
section).
2.) Continuous Pump Mode – Uses the Geothermal Storage
tank thermistor to sense water temperature (see ‘Load Pump
Control’ in Control Features section).
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.
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.
WaterFurnace Geothermal Storage Tank Thermostat
and Thermistor
If using a Geothermal Storage tank there will be two red
wires exiting out the top of the tank. These red wires extend
internally down to the thermistor/tank thermostat section of
the tank. Remove the bottom tank control cover to expose
the red wires as well as the yellow tank thermistor wires. If
using ‘Continuous Pump Mode’ as the sampling method then
connect the two red wires to the two yellow thermistor wires
using wire nuts. Next, at the heat pump, remove the yellow
thermistor wires from TB3 and TB4 from the control box
and tape off. Then route the red wires from the Geothermal
Storage tank to the heat pump control box, terminals TB3
and TB4. Remove the orange wire from the LPR (load pump
relay) and tape off. Attach a jumper wire from the LPR coil,
where the orange wire was removed, to CC (compressor
contactor) coil along with the violet wire that is already there
(see schematics). Set the pump sampling parameter (PS) in
the setup of the control board to continuously sampling (C).
If using ‘Pump Sampling’ as the method for controlling the
load pump then neither of the tank’s red or yellow wires will
be used.
Synergy3D
Thermostat
NSW
Thermistor Wires Connected to TB (3 and 4) on NSW
Control Board
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.
30 psi
RELIEF VALVE
Pressure
Gauge
Back Flow Preventer /
Pressure Relief Valve
Air
Vent
Expansion
Tank
LOAD PUMP
HYDRONIC
LOAD
Air
Separator
Dielectric
Unions
HOT
COLD
(Piped in
series to
an electric
water heater)
GEO
STORAGE
TANK
PUMP
DOMESTIC
Dip Tube
FROM
HWG
TO
HWG
Source OUT
Dielectric
Unions
Vent Valve/
P/T Port**
1-1/2 in.
FPT
P/T Ports
Ball Valve
P/T Ports
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
UPS15-42RU Three-Speed Pump Curve
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.
UPS15-42RU 3-Speed Pump
16
UPS15-42RU (Low)
14
UPS15-42RU (Med)
Feet of Head
12
Hot Water Generator (Factory Installed, NSW040,
NSW050, NSW060, and NSW075 Only)
UPS15-42RU (High)
10
8
6
4
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.
2
0
0
2
4
6
8
10
12
14
16
GPM
UP26-64BF and UP26-99F Single and Two Pump Curve
Load-side Pump Kit (Field Installed)
70
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 24S516-10 (Grundfos
UPS15-42RU) is a composite body pump. EWPK2 (Grundfos
UP26-64BF) is a bronze body pump. Bronze or composite
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 (1”
FPT flange) and EWPK3 (1 1⁄4” FPT flange) come with a cast
iron body pump (Grundfos UP26-99F) that can be used for
hydronic heating applications.
60
UP26-64BF & UP26-99F Single and Two Pump
UP26-99F (2 Pumps)
UP26-64BF (2 Pumps)
UP26-99F (1 Pump)
Feet of Head
50
UP26-64BF (1 Pump)
40
30
20
10
0
0
5
10
15
20
25
30
GPM
NOTE: Never use piping smaller than 1 inch. Limit length of
pipe to 50 feet or less.
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.
Type L Copper Pressure Loss
Ft of Hd per 100 ft
GPM
2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
25
30
35
40
45
50
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.
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
•
2-HVAC-1x24 - 1 inch x 24 inch stainless steel braided
hose kit
•
2-HVAC-1 1/4x24 - 1 1⁄4 inch x 24 inch stainless steel
braided hose kit
3/4
1.5
3.2
5.5
8.5
1
1.4
2.1
2.9
3.9
5.0
6.1
7.5
Type L Copper Tube
1-1/4
1-1/2
1.1
1.4
1.8
2.3
2.8
3.9
5.2
6.6
8.2
10.0
0.9
1.1
1.6
2.1
2.7
3.4
4.1
5.0
6.3
2
1.1
1.3
1.6
2.2
2.9
3.8
4.7
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
30°
30°
To Geo 59˝ Dip Tube
w/1˝ x 3˝ Nipple
From Geo
1˝ x 3˝ Nipple
PRIMARY ANODE
39˝ - 80 Gallon
42˝ - 119 Gallon
8˝
3/4˝ HOT OUTLET
3/4˝ COLD INLET
w/14˝ SECONDARY ANODE
52˝ DIP TUBE
Approx. 1˝
Red Wire attached
to Thermistor or Thermostat
for Top Exit
T&P
VALVE
HEIGHT
Optional “To Geo”
Connection Shipped with
1-1/2˝ Pipe Plug Installed
Element Location
Lower Sensor Thermistor (12P541-01)
to be used by Water to Water Units
35-3/4˝
Optional “From Geo” Connection
Shipped with 1-1/2˝ Pipe Plug Installed
5-1/4˝
DRAIN VALVE
MODEL
NUMBER
GALLON
CAPACITY
ELEMENT
WATTAGE
(240 VOLT)
DIAMETER
NUMBER
OF
ELEMENTS
Lower Thermostat to be used
with Synergy units
R
VALUE
DIMENSIONS IN INCHES
HEIGHT
DIAMETER
APPROX.
SHIPPING
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
Voltage
Min/Max
Compressor
RLA
LRA
LRA*
Load
Pump
Source
Pump
Total Unit
FLA
Min Ckt
Amp
Maximum
Fuse/HACR
018
208-230/60/1
187/253
9.0
48.0
17.0
1.8
5.4
16.2
18.5
25
025
208-230/60/1
187/253
13.5
61.0
21.4
1.8
5.4
20.7
24.1
35
040
208-230/60/1
187/253
20.0
115.0
40.3
1.8
5.4
27.2
32.2
50
050
208-230/60/1
187/253
26.4
134.0
46.9
1.8
5.4
33.6
40.2
60
060
208-230/60/1
187/253
30.1
145.0
50.8
1.8
5.4
37.3
44.8
70
075
208-230/60/1
187/253
26.9
145.0
50.8
1.8
5.4
34.1
40.8
60
5/12/2014
NOTES: All fuses type “D” time delay (or HACR circuit breaker in USA).
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
IntelliStart Only
Power Block
Load Pump Fuse Block
Compressor Contactor
Run Capacitor
(Single Phase Only)
Source Pump Fuse Block
Ground Lug
Reversing Valve Relay
Transformer
Load Pump Relay
Source Pump Relay
14
NSW INSTALLATION MANUAL
Electrical Data cont.
208 Volt Operation
NSW Control Box Relocation
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:
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
d) Load temperature sensor
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.
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.
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 as
discussed in the Hydronic section of this manual.
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 another unit containing
a microprocessor.
CAPACITOR
L1
L2
LOW VOLTAGE
T2
LOW VOLTAGE
THERMOSTAT
CONNECTIONS
T1
COMPRESSOR
CONTACTOR
TERMINAL STRIP
Load Circulator Wiring
LOAD
CIRCULATOR
PUMP
FUSE
BLOCKS
TRANSFORMER
CONTROL BOX
Dedicated Flow Center Wiring
L1
L2
LOW VOLTAGE
THERMOSTAT
CONNECTIONS
COMPRESSOR
CONTACTOR
LOW VOLTAGE
CAPACITOR
T2
TERMINAL STRIP
T1
FLOW CENTER
FUSE
BLOCKS
TRANSFORMER
CONTROL BOX
16
NSW INSTALLATION MANUAL
Wiring Schematics cont.
Multiple Units on a Single Flow Center Wiring
P1
R
C
Y1
Y2
W
WATER TO AIR
HEAT PUMP
CONTROL
BOX
O
G
LO
P2
SHUT
DOWN
C
C
SL1 IN
SL1OUT
Not
Used
L1
LOW VOLTAGE
THERMOSTAT
CONNECTIONS
COMPRESSOR
CONTACTOR
LOW VOLTAGE
CAPACITOR
T2
TERMINAL STRIP
T1
L2
FUSE
BLOCKS
13P003B RELAY
(FIELD SUPPLIED)
TRANSFORMER
WATER TO WATER CONTROL BOX
17
NSW INSTALLATION MANUAL
Wiring Schematics - Residential
NSW Heating Only - 208-230/60/1
Compressor
External
S
External
G
C
Blue
G
R
Red
Load
Pump
T1
NOTE 2
T2
T1
L1
Tan
T2
SFB
LFB
L2
L1
Black
Cap
Source
Pump
L2
Unit
Power Supply
208-230/60/1
T1
T2
CC
Blue/Wht
Brown/Blk
L2
L1
G
Brown/Wht
LPR
Brown
Blue
Blue
230V
Green/Yellow
Red
208V
Black
Com
NOTE 1
PS1
B
C
D
Transformer
Red
24V
Black
Black/
White
Yellow
24 V
9
10
11
C
LO
HI
CG
CC
HP
L P LP
R
L P LP
R
Orange
Gray
Gray
RT
RT
8
Violet
Violet
Orange
X1 E LT E LT
Orange
Yellow
Yellow
X2 X1
5
6
7
1
Not Used
X2
4
Black
Not Used
X3
3
T
Microprocessor Control
Not Used
X3
ELT
Not Used
12
SI
P3
Not Used
P2
Black
X2
2
X3
TB
1
T
X3
SI
HP
Black
White/Blue
White/Blue
Red
RT
C
HP
Black
TEST
PIN
1
HP
Violet
LP
HI
CC
Blk/Wht
HP
RT
CC
Orange
X1 E LT E LT R T
Note 3
LPR
X2 X1
Black/Wht
CG
Green/Yellow
LO
P1
Black/Gry
RV RVG
MODE
Interface Panel
Violet
R C Y1 O X1
04/02/09
Legend
Factory low voltage wiring
Factory line voltage wiring
Field low voltage wiring
Field line voltage wiring
Optional block
Quick connect terminal
L1
P
1
3
Fuse
Compressor contactor
Reversing Valve output
Entering Load Side Water Temperature
High pressure switch
Low pressure switch
Load Pump Relay
Refrigerant Liquid line Temperature
Slave Input relay
Reversing Valve Coil
Load Pump Fuse Block
Source Pump Fuse Block
2
Screw terminal - field connection
CC RV ELT HP LP LPR RT SI RC LFB SFB -
Switch - High pressure
Field wire lug
Ground
Switch - Low pressure
Relay Contacts N.O., N.C.
Relay coil
Polarized connector
Capacitor
T
18
Thermistor
Notes:
1. Taped and wire tied off
2. 3 AG 10 Amp fuse
3. For cycle load pump with a geo storage
tank. Remove the orange wire from the LPR
relay coil and install a jumper between the
LPR relay coil and the comp contactor coil
as shown in the schematic above.
NSW INSTALLATION MANUAL
Wiring Schematics - Residential cont.
NSW Reversible with IntelliStart - 208-230/60/1
External
Compressor
S
External
G
Blue
G
PB
2
C
R
1
Red
Red
Run Winding
IntelliStart
Load
Pump
T1
NOTE2
T2
T1
L1
L2
L1
Active
Blue
Black
Tan
T2
Start
Black
Black
SFB
LFB
Pink
Cap
Source
Pump
L2
CC
Brown/Blk
Blue/Wht
L2
Common
Unit
Power Supply
208-230/60/1
T1
T2
L1
G
Brown/Wht
LPR
Brown
Blue
Blue
230V
Green/Yellow
Red
208 V
Black
Com
NOTE 1
PS1
B
C
D
Transformer
Red
24V
Black
Black/
White
Yellow
24 V
9
10
RVR
11
C
HI
C
HI
CG
CC
HP
HP
CC
CG
LO
Orange
Gray
Gray
RT
RT
Violet
Violet
Orange
X1 E LT E LT
8
Yellow
Violet
X2 X1
NOTE 3
Orange
X2
5
6
7
X3
Orange
Yellow
4
1
Not Used
X3
Org/Grn
3
Black
RT
Yellow
Black
X1 E LT E LT R T
Yellow
T
P2
2
Org/Gry
ELT
RVR
SI
TB
1
Black
T
X2 X1
Blue
T
RT
X2
Black
RT
X3
Blue
NOTE 4
Microprocessor Control
HP
Black
White/Blue
White/Blue
Red
LP
HP
Black
P3
Not Used
L P LP
Violet
L P LP
Blk/Wht
HP
TEST
PIN
1
R
CC
Black/Org
Orange
R
Note 5
LPR
X3
Black/Wht
Green/Yellow
LO
P1
Black/Gry
Not Used
RV RVG
MODE
12
RVR
Interface Panel
Org/Brn
SIR
Org/Wht
Org/Blk
RC
04/02/09
R C Y1 O X1
Legend
Factory low voltage wiring
Factory line voltage wiring
Field low voltage wiring
Field line voltage wiring
Optional block
Quick connect terminal
Compressor Contactor
Reversing Valve Output
Entering Load Side Water Temperature
High Pressure Switch
Low Pressure Switch
Load Pump Relay Contacts
Refrigerant Liquid Line Temperature
Slave Input Relay
Reversing Valve Coil
Load Pump Fuse Block
Source Pump Fuse Block
Reversing Valve Relay
L1
P
1
3
Fuse
-
2
Screw terminal - field connection
CC
RV
ELT
HP
LP
LPR
RT
SIR
RC
LFB
SFB
RVR
Switch - High pressure
Field wire lug
Ground
Switch - Low pressure
Relay Contacts N.O., N.C.
Relay coil
Polarized connector
Capacitor
T
19
Thermistor
Notes:
1. Taped and wire tied off
2. 3AG 10 Amp fuse
3. Move jumper wire to 5 and 6 for reversible
secondary unit.
4. Black Thermistor - Source Coax Blue
Thermistor - Load Coax
5. For cycle load pump with a geo storage tank.
Remove the orange wire from the LPR relay coil
and install a jumper between the LPR relay coil
and the comp contactor coil as shown in the
schematic above.
NSW INSTALLATION MANUAL
External Control
Primary Mode
Secondary Mode
In dedicated heating or cooling units, the unit is controlled
by the internal controller. Compressor output is determined
by the entering load-side water temperature.
In dedicated heating or cooling units, secondary mode
allows the unit to be controlled by an external source.
Compressor output is determined by the Y1 input only.
The secondary output will be energized if two
conditions occur:
1. The initial temperature is greater than IC away from the
set point.
2. The change in temperature in a given period of time P is
less than d.
The secondary output will be energized after the following
condition occurs:
1. The change in temperature in a given period of time P is
less than d.
In reversible units, secondary mode allows the unit to
be controlled by an external source. Compressor output
is determined by the Y1 input and the reversing valve
is determined by the O input. In reversible units, the
jumper wire must be positioned across terminals 5 and 6.
Reversible units do not have a secondary input.
In a reversible unit, the unit is controlled by the internal
controller. Compressor output is determined by the
entering load-side water temperature. For reversible units,
the jumper wire must be positioned across terminals 6 and
7, (factory default set to this position). Reversible units do
not have a secondary output.
NOTES: SL in the configuration menu must be set to 1. P
and d must be setup for each secondary unit.
NOTES: SL in the configuration menu must be set to 0,
(factory default). All parameters should be checked for each
application on primary unit, (refer to the parameter table).
Wiring an Aquastat - Reversible Unit
• To create a secondary unit, set SL to 1 in the
configuration menu.
• Position the jumper wire in the control box across
terminals 5 and 6.
WARNING: Reversible units cannot be
staged.
Aquastat Wiring for Dedicated Heating or Cooling Unit
Aquastat Wiring for Reversible Unit
Secondary Unit
(SL=1)
Typical Aquastat
Typical Aquastat
C
Y1 = Compressor call
G
Y1
W1
W2
L
S
X1
X2
Y2
R = 24VAC
Secondary Unit
(SL=1)
O
C
O
G
Y1
3
W1
W2
4
L
S
5
X1
X2
Y2
R
1
R
2
Jumper
Wire
6
7
8
9
10
11
Y1 = Compressor call
O = Reversing valve call
R = 24VAC
12
Control Box
Note: Jumper wire must be
moved to terminals 5 & 6.
Control Box
20
NSW INSTALLATION MANUAL
External Control cont.
Wiring for Primary/Secondary Unit Staging
Staging with Primary/Secondary Mode
Staging is only possible with dedicated heating or cooling
units. Reversible units cannot be staged. Staging can be
accomplished with primary/secondary modes or by using
an aquastat.
C
O
C
O
C
O
G
Y1
G
Y1
G
Y1
W1
W2
W2
L
W1
W2
W1
S
L
S
L
S
X1
X2
X1
X2
X1
X2
Y2
R
Y2
R
Y2
R
WARNING: Do not stage more than 6 units.
The first stage must be setup as a primary unit. All other
units must be setup as secondary units. The set point is
stored in the primary unit. Once the set point in the primary
unit has been satisfied, all units will immediately shutdown.
First Stage
Second Stage
Third Stage
NOTES: X1 = Secondary output
Y1 = Compressor call
Wiring for Dedicated Heating or Cooling Units
with Aquastat
Staging with Aquastat
When staging units using an Aquastat, all units must be
setup as secondary units.
(
)
Typical Aquastat
WARNING: Do not stage more than 6 units.
C
O
C
O
G
Y1
G
Y1
W1
W2
W1
W2
L
S
L
S
X1
X2
X1
X2
Y2
R
Y2
R
First Stage
NOTES: X1 = Secondary output
Y1 = Compressor call
R = 24 VAC
21
Second Stage
NSW INSTALLATION MANUAL
Converting to a Dedicated Cooling Unit
13. Open the control box.
14. Find the connection marked “P4” as shown in the
Control Board with Jumper illustration.
15. Move the “P4” jumper from across 1 and 2 to across 2
and 3.
16. Close the control box and secure the screws.
17. Replace the top and access panel.
18. Make sure all screws have been re-installed.
19. Turn on the power.
20. Using the touch-pad, press the UP arrow.
21. The displays should blink “44” to show set point. Now,
the unit should operate as a cooling only unit.
Procedure to Convert a Heating Only Unit to a
Cooling Only Unit
All non-reversible NSW units are built at the factory as
dedicated heating units. Follow the procedures below to
make the unit a dedicated cooling unit.
1. Shut off all power to the unit.
2. Remove the top and access panel.
3. Remove the brass in-well thermistor from the load
water-in line.
4. Remove the brass plug from the source water-in line.
5. Place new Teflon® tape on the threads of the brass inwell thermistor.
6. Thread the brass in-well thermistor into the source
water-in line.
7. Make sure the thermistor wires do not touch the
discharge line.
8. Place new Teflon® tape on the threads of the brass plug.
9. Thread the brass plug into the load water-in line.
10. Refer to the labels on the unit for the location of ports
and lines.
11. Connect the “Source Water-In” line to the port marked
“Load Water-In.” Then, connect the “Source Water-Out”
line to the port marked “Load Water-Out.”
12. Connect the “Load Water-In” line to the port marked
“Source Water-In.” Then, connect the “Load Water-Out”
line to the port marked “Source Water-Out.”
Jumper Pin Location
The location of the jumper pin determines the controller’s
mode of operation. Move the jumper pins to the correct
location for dedicated heating, dedicated cooling or
reversible settings as indicated below.
Dedicated heating
Dedicated cooling
Reversible
-1&2*
-2&3
-3&4*
* Indicates factory setting.
NOTE: A reversible unit can not be configured to heating only.
P5 Key Pad
(Interface)
Control Board with Jumper
P4
P9
Not Used
P2
P1
22
NSW INSTALLATION MANUAL
Unit Startup
Before Powering Unit
Secondary Unit Startup
Check the following:
• High voltage wiring is correct and matches the nameplate.
• Fuses, breakers and wire size are correct.
• Piping is completed and water system has been cleaned
and flushed.
• Air is purged from the closed loop system.
• Isolation valves are open and loop water control valves or
loop pumps are wired.
• Service/access panels are in place.
1. Apply power to the unit.
2. After a three to five-minute delay, the water temperature
shall be sampled. If the controller receives a remote
aquastat signal, the compressor shall activate.
3. Verify that the compressor and load side, source side
pumps are running.
4. By using a pressure gauge and the PT ports, check
the pressure drop through both the load and source
coaxes, and compare this to the capacity tables in the
specification catalog to verify the proper flow rate
through the unit.
5. After determining the flow rates, use a thermometer and
the PT ports to determine the change in temperature on
both the load and source side coaxes.
6. Compute the formula GPM flow rate X Change in
temperature X 500 (485 on source side if antifreeze
is used in the loop) = Heat of Extraction on the source
side in heating, Heat of rejection on the source side in
cooling. To ensure proper operation, compare these
values to the capacity tables in the specification catalog.
7. Press the down arrow on the control to disrupt the
remote aquastat signal. Unit should shut off.
8. Instruct the owner or operator about the correct control
and system operation.
Primary Unit Startup
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Apply power to the unit. Upon power up, the unit will
display the current operation mode.
• H for dedicated heating.
• C for dedicated cooling.
• U for reversible units.
Press the mode button. The LED screen will display the
current entering water temperature. The load pump will
activate after a 5 minute delay.
Once the load pump has been active for 3 minutes, the
controller will sample the temperature of the water
system. In heating mode, when the temperature of the
water shown on the display is lower than the set point
the compressor will activate.
By using a pressure gauge and the P/T ports, check the
pressure drop through both the load and source coaxes.
Compare this to the capacity tables in the specification
catalog to verify the proper flow rate through the unit.
Verify that the compressor, load side and source side
pumps are operating.
After determining the flow rates, use a thermometer and
the PT ports to determine the change in temperature on
both the load and source side coaxes.
Compute the formula GPM flow rate X Change in
temperature X 500 (485 on source side if antifreeze/brine
is used in the loop) = Heat of Extraction on the source
side in heating, Heat of Rejection on the source side in
cooling. To ensure proper operation, compare these
values to the capacity tables in the specification catalog.
Press the down arrow on the keypad to reduce the
set point below the incoming load temperature.
Compressor should shut off and the load pump should
shut off 30 seconds after the compressor.
Wait 7 minutes. The load pump should start to sample
load temperature.
Compressor and source side circulator should not start.
Press the up arrow on the keypad to increase the
set point to 5 degrees above the water temperature
displayed on the LED screen.
Three minutes after the load pump activates, the
compressor and source pump should activate.
23
NSW INSTALLATION MANUAL
Standard Board - Control Features
Anti Short Cycle Time
Test Mode
The anti short cycle time consists of a three minute
minimum “off” time plus a randomly chosen 0-2 minute
additional “off” delay. The random delay is chosen by the
control after each compressor shut down. The 3-5 minute
startup delay is applied after all compressor shutdowns and
also to system startups due to ac power interruption.
Connection of a jumper wire from chassis ground to P3
will place the control in the test mode. This shortens most
timing delays for faster troubleshooting. In the Primary
Mode the control will respond immediately if a demand
is present. The anti-short cycle delay is replaced by a
10 second pump and compressor on delay. Minimum
compressor run time becomes 15 seconds. Test mode will
remain in effect for a maximum of 15 minutes at any one
time should the jumper remain in place.
Safety Controls
The control board receives separate signals for a high
pressure switch for safety, low pressure switch to prevent
loss of charge damage, and a low suction temperature for
freeze detection. Upon a 30-second measurement of the
fault (immediate for high pressure), compressor operation is
suspended and the fault will be shown on the display.
Fault Conditions
There are two classes of faults, retry faults and no retry
faults. Retry faults allow the system to try 2 additional times
to establish operation before displaying the fault condition
and entering lockout. No-Retry Faults prevent compressor
operation for the duration of the fault. If the fault activity
ceases while the system is inactive, the fault code is cleared
from the display and operation is permitted.
Setpoint Temperature Ranges
In Primary mode, the heating temperature setpoint range
is adjustable from 60°F (15.5°C) to 130°F (54.4°C) with
an adjustable deadband range of 1° - 15°F. The cooling
setpoint temperature is adjustable from 25° (-3.9°C) to 85°F
(29.4°C) with a fixed non-adjustable deadband of 5°F.
Retry Faults
High pressure, low pressure and freeze detection
faults are retried twice before locking the unit out and
displaying the fault condition.
Load Pump Control
High Pressure (HP)
Compressor operation will be disabled immediately
when the normally closed high-pressure switch is
opened momentarily (set at 600 psi). The LED display
shall read “HP” only when the control has completed
two retries, and is in lockout. The pump continues to
operate throughout the retry period.
There are two options for controlling the load pump, Pump
Sampling (PS) or Continuous Pump (C), and these are
selectable in the service Menu.
Pump Sampling (PS)
In Primary Mode, the control operates on a 10 minute
sample cycle in which the load pump is turned on and
run to obtain a meaningful sample of the temperature
the load is presenting. If the water temperature
measured after the pump has been on for PS minutes
(selected and adjusted from the Service Menu) is
outside the user selectable deadband amount, dB
(also selected and adjusted from the Service Menu),
the compressor is turned on and Heating or Cooling
is initiated. If the water temperature is within the
deadband of the set point when sampled, the pump
shuts off and is idle for (10 – PS) minutes when it starts
another PS minute sample period. For example, if
the PS setting is two minutes, the pump will run for 2
minutes before sampling the load temperature. If the
water temperature is within the selected dead band
temperature of the set point, the pump will shut off
for 10 – 2 = 8 minutes before beginning another pump
sampling cycle. Heating deadband is selectable in the
Service Menu while the Cooling deadband is nonadjustable and fixed at 5°F.
Low Pressure (LP)
Compressor operation will be disabled when the
normally closed low-pressure switch (set at 40 psi)
has opened for 30 continuous seconds (if the bypass
period has been satisfied). The Low Pressure switch is
bypassed (ignored) for two minutes after startup. The
LED display shall read “LP” only when the control has
completed two retries, and is in lockout. The pump
continues to operate throughout the retry period.
Freeze Detection (FP)
Compressor and loop pumps will be disabled if the
control senses that the refrigerant loop temperature
drops below the FP value (set in the service menu) for
30 continuous seconds (if the bypass period has been
satisfied). If the compressor and the loop pump outputs
are disabled because of this condition, the LED display
shall read “FP.” There is a two (2) minute by-pass timer
for the freeze detection at compressor start up.
Continuous Pump Mode (C)
If continuous pump mode (PS=C In Service Menu) is
selected, the control will respond immediately to a
recognized call or termination of call for heat or cool
subject to minimum run times and anti short cycle delays.
No-Retry Faults
High Temperature, Water Temperature Probe Open,
Water Temperature Probe Closed and Brown Out faults
prevent compressor operation for the duration of the
24
NSW INSTALLATION MANUAL
Standard Board - Control Features cont.
fault. If the fault activity ceases while the system is
inactive, the fault code is cleared from the display and
operation is permitted.
Freeze Detection Probe Closed (dC)
Compressor and pump operation will be disabled
when the control senses that the freeze detection
probe is closed or has no resistance. The LED display
shall read “dC.”
High Temperature
Compressor operation will be disabled when the control
senses an entering load side water temperature of 130°
F regardless of mode.
Brown-Out (B0)
All operation will be disabled when the control voltage
falls below 18VAC for 10-15 continuous seconds.
Water Temperature Probe Open (PO)
Compressor and pump operation will be disabled when
the control senses that the water probe is open or has
infinite resistance. The LED display shall read “PO.”
Resetting Lockouts
To reset any lockout condition, place the unit into the
standby mode for at least 5 seconds. After the lockout
has been reset, the fault display will be turned off. Cycling
control power will also clear the display. Non-Retry Faults
must be cleared for the display and lockout to clear.
Water Temperature Probe Closed (HC)
Compressor and pump operation will be disabled when
the control senses that the water probe is closed or has
no resistance. The LED display shall read “HC.”
Power Down (power outage)
Freeze Detection Probe Open (dO)
Compressor and pump operation will be disabled when
the control senses that the freeze detection probe is
open or has infinite resistance. The LED display shall
read “dO.”
The controller will store its Service Menu settings and
current Mode selection in non-volatile memory so that these
settings are retained through any power outage. Current
operating conditions are not stored and the controller must
evaluate its current conditions.
25
NSW INSTALLATION MANUAL
Standard Control - Panel Configuration
Control Panel
The control panel allows you to access the service menu
on the unit. The control panel has three 7-segment LED
screens that display the:
• Water temperature
• Configuration menu
There are six (6) LED indicators that indicate when the
SECONDARY OUTPUT is active or the unit is on one of the
following modes:
• Standby Mode
• Heating Mode
• Cooling Mode
• Primary (Master) Mode
The control panel has both UP and DOWN (arrow) buttons
and a MODE button. The UP and DOWN buttons allow you
to change the set point or scroll through the configuration
menu. The MODE button allow you to change mode as well
as enter and exit parameters while in configuration mode.
Control Panel Configuration
The configuration menu allows you to properly set and adjust
all of the unit’s operating parameters to fit your application.
Changing the Setpoint
1. Pressing the UP or DOWN arrow once will display
the setpoint.
2. The setpoint will flash.
3. When the setpoint is flashing, the UP and DOWN arrow
will change the setpoint by one degree.
4. In Primary mode, the heating temperature setpoint
range is adjustable from 60°F (15.5°C) to 130°F (54.4°C)
with an adjustable deadband range of 1° - 15°F. The
cooling setpoint temperature is adjustable from 25°
(-3.9°C) to 85°F (29.4°C) with a fixed non-adjustable
deadband of 5°F.
To enter configuration mode and configure parameters,
follow these procedures:
1. Hold down both the UP and DOWN buttons
simultaneously for five seconds, or until the LED screen
displays “LC”.
2. Press the UP or DOWN arrow until “50” is displayed.
3. Press the MODE button. The screen should display “Fd”
to indicate the controller is in configuration mode.
4. Once in configuration mode, press the UP or DOWN
arrow to scroll through the menu.
5. Press the MODE button to enter the parameter.
(Refer to the parameter table below for a list of
configurable parameters.)
6. Once in the parameter, press the UP or DOWN arrow to
change the parameter.
7. Press the MODE button to return to the main menu.
NOTE: The controller will exit the configuration mode after
30 seconds if no key is pressed.
26
NSW INSTALLATION MANUAL
Standard Control - Panel Configuration cont.
Remote Aquastat Secondary Mode (Y1)
In secondary mode the compressor output is determined by an external aquastat. The compressor shall engage 10 seconds
after the Y1 call has been received. The compressor shall de-activate 10 seconds after the Y1 has been removed. The
secondary output is controlled by a Derivative Controller. If the change in the water temperature is less than a selected
value (d) in a selected period of time (P), the secondary output shall activate.
Parameter Functions and Settings
Parameter
Function
Description
dB
Dead Band This parameter is used to determine when
(Heating)
the compressor should be activated. If the
temperature is below the setpoint minus the dB
value (in heating mode) then the compressor will
activate. The cooling deadband is fixed at 5°F
and non-adjustable.
CF
Celsius/
Fahrenheit
Selection
This parameter selects the units for which the
temperature will be displayed.
Freeze
Detection
There are three settings for this parameter; OL,
CL, and P. OL is the open loop setting which
corresponds to 32°F (0°C). CL is the closed loop
setting which is 15°F (-9°C). P is the process
setting which is 5°F (-15°C).
FP
SL
Primary/
Secondary
Setting
Primary mode utilizes an internal aquastat to
determine the activity of the compressor. In
secondary mode the compressor output is
determined by an external aquastat.
Initial
Condition
This parameter is used to determine the state of
the secondary output of the primary unit. If the
actual water temperature is greater than the IC
value away from the set point, the secondary
output will be activated.
IC
Derivative
d
P
PS
Fd
This parameter is used to determine the state
of the secondary output of the primary and
secondary unit. If the change in temperature is less
than the d value the secondary output will activate.
Factory
Setting
Range
Increments
1°F
1° to 15°
1
F
F or C
N/A
32°F
P,CL,OL
N/A
0
(Primary)
0 or 1
1 = Secondary
0 = Primary
10°F
0° to 20°
1°
1°F
0° to 5°
1°
Period
This determines how often the derivative will
be calculated.
5 min
1 to 5 min
1 min
Pump
Sampling
Time
Selection
This parameter determines how long the pump
is activated before the controller takes a sample
of the water temperature. The range of this
parameter is from 1 to 5 minutes and is factory
set to 3 minutes. The pump can also be set to run
continuously when PS is set to C.
3 min
1 to 5 min
or C
1 min
Freeze
Detection
Display
This displays the current temperature of the
freeze detection sensor.
N/A
0° to 130°
N/A
27
NSW INSTALLATION MANUAL
Reference Calculations
Heating Calculations:
LWT = EWT -
Cooling Calculations:
HE
GPM x C*
HE = C* x GPM x (EWT - LWT)
LWT = EWT +
HR
GPM x C*
HR = C* x GPM x (LWT - EWT)
NOTE: * C = 500 for pure water, 485 for brine.
Legend and Notes
Abbreviations and Definitions
ELT
= entering load fluid temperature to heat pump
SWPD = source coax water pressure drop
kW
= kilowatts
EST
= entering source fluid temperature to heat pump
LLT
= leaving load fluid temperature from heat pump
HE
= heat extracted in MBTUH
PSI
= pressure drop in pounds per square inch
LST
= leaving source fluid temperature from heat pump
LGPM = load flow in gallons per minute
HC
= total heating capacity in MBTUH
FT HD = pressure drop in feet of head
COP = coefficient of performance, heating [HC/kW x 3.413]
LWPD = load coax water pressure drop
EER = energy efficiency ratio, cooling
LWT
= leaving water temperature
TC
= total cooling capacity in MBTUH
EWT
= entering water temperature
HR
= heat rejected in MBTUH
Brine
= water with a freeze inhibiting solution
Notes to Performance Data Tables
The following notes apply to all performance data tables:
• Three flow rates are shown for each unit. The lowest flow rate shown is used for geothermal open loop/well water
systems with a minimum of 50°F EST. The middle flow rate shown is the minimum geothermal closed loop flow rate.
The highest flow rate shown is optimum for geothermal closed loop systems and the suggested flow rate for boiler/
tower applications.
• Entering water temperatures below 40°F assumes 15% antifreeze solution.
• Interpolation between ELT, EST, and GPM data is permissible.
• Operation in the gray areas is not recommended.
28
NSW INSTALLATION MANUAL
AHRI/ISO 13256-2 Performance Ratings
English (IP) Units
Water Loop Heat Pump
Cooling
Heating
86°F Source
68°F Source
53.6°F Load
104°F Load
Flow Rate
Model
018
025
040
050
060
075
Capacity
Modulation
Single
Single
Single
Single
Single
Single
Load
Gpm
Source
Gpm
Capacity
Btuh
EER
Btuh/W
Capacity
Btuh
COP
Capacity
Btuh
EER
Btuh/W
Capacity
Btuh
COP
5
7
10
15
18
19
5
7
10
15
18
19
16,400
23,700
35,900
49,800
55,400
66,000
14.0
13.6
15.5
13.9
13.6
12.3
22,200
32,800
47,900
65,000
78,000
93,100
4.5
4.6
4.8
4.4
4.7
4.2
18,800
26,700
40,900
55,600
62,500
74,100
22.9
21.2
23.4
21.6
20.6
18.0
18,500
27,100
39,100
54,200
63,200
77,100
3.7
3.8
3.9
3.7
3.8
3.5
Flow Rate
Model
018
025
040
050
060
075
Capacity
Modulation
Single
Single
Single
Single
Single
Single
Ground Water Heat Pump
Cooling
Heating
59°F Source
50°F Source
53.6°F Load
104°F Load
Cooling
77°F Source
53.6°F Load
Ground Loop Heat Pump
Heating
32°F Source
104°F Load
Load
Gpm
Source
Gpm
Capacity
Btuh
EER Btuh/W
Capacity
Btuh
COP
5
7
10
15
18
19
5
7
10
15
18
19
17,300
24,700
37,700
51,500
58,000
68,400
16.6
16.1
17.5
16.4
16.1
14.0
14,700
22,000
30,500
44,200
50,100
61,500
3.1
3.1
3.1
3.1
3.1
2.9
Energy
Star
Compliant
Yes
Yes
Yes
Yes
Yes
No
01/03/12
NOTE: All ratings based upon 208V operation.
29
Energy
Star
Compliant
Yes
Yes
Yes
Yes
Yes
No
NSW INSTALLATION MANUAL
Pressure Drop
Model
GPM
018R*
025R*
040H/R
050H/R
060H/R
075H/R
3.0
4.0
5.0
6.0
4.0
5.5
7.0
8.5
5.0
7.5
10.0
12.5
8.0
11.5
15.0
18.5
9.0
13.5
18.0
22.5
10.0
14.5
19.0
23.5
30°F
0.5
1.1
1.6
2.1
0.7
1.3
1.9
2.6
0.9
2.3
3.7
5.0
1.7
3.6
5.6
8.3
1.4
4.2
6.9
10.7
3.2
5.5
7.9
11.5
NSW Vented Only Load Side
Pressure Drop (psi)
60°F
80°F
100°F
0.4
0.4
0.3
0.9
0.9
0.8
1.4
1.4
1.3
1.9
1.9
1.8
0.6
0.4
0.3
1.1
0.9
0.7
1.7
1.5
1.3
2.4
2.2
2.0
0.6
0.6
0.5
2.1
2.0
1.9
3.5
3.3
3.2
4.7
4.4
4.2
1.4
1.4
1.3
3.4
3.2
3.0
5.4
5.0
4.6
8.1
7.6
7.2
1.1
1.0
1.0
3.9
3.5
3.1
6.7
6.0
5.2
10.5
10.0
9.4
3.0
2.8
2.7
5.3
5.1
4.9
7.6
7.3
7.1
11.3
11.0
10.8
120°F
0.3
0.8
1.3
1.8
0.3
0.6
1.2
1.9
0.5
1.8
3.0
4.0
1.3
2.8
4.2
6.8
0.9
2.7
4.5
8.7
2.5
4.7
6.8
10.5
8/9/10
NOTES: Temperatures are Entering Water Temperatures
*Domestic water heating units source side
pressure drop and reversible units load and
source pressure drop.
Model
018H
025H
GPM
3.0
4.0
5.0
6.0
4.0
5.5
7.0
8.5
60°F
0.5
1.4
2.2
3.0
1.3
3.0
4.6
6.7
Pressure Drop (psi)
80°F
100°F
0.4
0.4
1.3
1.2
2.1
2.1
2.9
2.9
1.3
1.2
2.9
2.8
4.4
4.3
6.5
6.4
NOTES: Temperatures are Entering Water Temperatures.
Double wall vented coax for heating potable water
120°F
0.3
1.2
2.0
2.8
1.2
2.7
4.1
6.2
7/13/09
Operating Limits
Cooling
Heating with High Source Temperatures
Heating
Operating Limits
°F
°C
°F
°C
30
-1.1
20
-6.7
Heating water with a water to water unit using high source
temperatures can lead to operating conditions that fall
outside of the system operating range. The condition occurs
when the loop (source) temperature exceeds 70°F [21.1°C]
with a full flow of 3 GPM per ton [0.054 LPS per kW].
Under this scenario, the evaporating temperature can fall
outside of the compressor operating window.
Source Side Water Limits
Minimum Entering Water
Normal Entering Water
85
29.4
60
15.6
Maximum Entering Water
110
43.3
90
32.2
Minimum Entering Water
50
10.0
60
15.6
Normal Entering Water
60
15.6
100
37.8
Maximum Entering Water
90
32.2
120
48.9
Load Side Water Limits
To allow the system to operate correctly, restricting the
source side flow when the evaporating temperature
exceeds 55°F [12.7°C] is recommended. One way of
accomplishing this is to use a flow-restricting valve on the
source loop circuit that is controlled by the evaporating
temperature. Locate the sensing device on the refrigerant
inlet of the evaporator.
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.
As an alternative to the evaporating temperature, the
suction line temperature can be monitored with the same
control capability. In this control, temperature should be a
maximum of 65°F [18.3°C].
30
NSW INSTALLATION MANUAL
Physical Data
Model
018
025
040
44.0 [1.25]
58.0 [1.64]
70 [1.98]
Compressor (1 each)
050
060
075
68 [1.93]
104 [2.95]
110 [3.12]
Scroll
Factory Charge R410a, oz [kg]
Coax & Piping Water Volume - gal [l]*
.52 [1.97]
.89 [3.38]
1.0 [3.94]
1.4 [5.25]
1.6 [6.13]
1.6 [6.13]
Weight - Operating, lb [kg]
191 [86.6]
225 [102.1]
290 [131.5]
325 [147.4]
345 [156.5]
345 [156.5]
Weight - Packaged, lb [kg]
213 [96.6]
247 [112.0]
305 [138.3]
340 [154.2]
360 [163.3]
360 [163.3]
8/6/10
NOTE: * Source or load side only.
Flow Rates
Source Flow Rates
Minimum Open Loop
Flow Rate
Minimum Closed Loop
Flow Rate
Normal Load Flow Rate
018
3.0
4.0
5.0
7.0
025
4.0
5.0
7.0
9.0
12.0
Model
Maximum Flow Rate
040
5.0
8.0
10.0
050
8.0
12.0
15.0
17.0
060
9.0
13.0
18.0
20.0
075
10.0
14.0
19.0
21.0
5/15/09
Load Flow Rates
Model
Minimum Load Flow Rate
Normal Load Flow Rate
018
3.0
5.0
Maximum Flow Rate
7.0
025
4.0
7.0
9.0
040
5.0
10.0
12.0
050
8.0
15.0
17.0
060
9.0
18.0
20.0
075
10.0
19.0
21.0
5/15/09
Thermistor and Compressor Resistance
Thermistor Table
Compressor Resistance Table (77°F)
Thermistor Temperature (°F)
Resistance (Ohms)
78.8
9,230 - 10,007
77.5
9,460 - 10,032
76.5
9,690 - 10,580
75.5
9,930 - 10,840
33.5
30,490 - 32,080
32.5
31,370 - 33,010
31.5
32,270 - 33,690
30.5
33,190 - 34,940
1.5
79,110 - 83,750
0.5
81,860 - 86,460
0.0
82,960 - 87,860
Terminals
018
ZP16K5E
025
ZP23K3E
040
HRH034U
050
ZP51K5E
060
HRH056U
075
HLJ072T
1.30 - 1.49 0.74 - 0.85 0.76 - 0.88 0.78 - 0.90
C to S
2.14 - 2.28
2.12 - 2.44
C to R
1.42 - 1.64
0.94 - 1.08 0.49 - 0.57 0.42 - 0.48 0.26 - 0.30 0.27 - 0.31
S to R
3.56 - 4.10 3.06 - 3.52 1.79 - 2.06
1.16 - 1.33
1.02 - 1.18
1.05 - 1.21
NOTE: Resistance listed are for single phase (208-230/60Hz) compressors.
31
7/15/13
NSW INSTALLATION MANUAL
Operating Parameters
Heating Mode
Entering
Load Temp (°F)
60
80
100
120
Entering
Source Temp (°F)
Suction
Pressure (psig)
Discharge
Pressure (psig)
Superheat
(°F)
Subcooling
(°F)
20
52-67
195-227
8-16
5-15
30
67-82
208-235
7-14
6-14
6-12
50
95-113
216-245
7-14
70
124-144
225-255
8-19
5-15
90
143-167
230-275
14-26
8-12
20
54-69
283-316
8-16
7-15
30
69-84
293-323
10-12
7-18
50
98-125
302-335
12-14
8-16
70
121-148
311-346
14-18
8-16
90
144-179
319-363
14-26
8-16
20
56-71
369-405
8-10
6-14
30
77-85
378-411
10-12
7-15
50
104-126
388-425
12-14
7-15
70
123-152
398-438
14-18
3-12
90
148-191
408-452
14-22
3-12
4-16
20
59-74
455-495
8-18
30
74-87
464-500
6-16
5-17
50
106-128
474-515
5-17
5-15
70
125-156
485-530
6-16
4-15
90
Operation not recommended
NOTES: Operating parameters at 3 gpm/ton source and load flow. Consult the Capacity Tables for each NSW model for normal allowable operating
conditions. Some of the conditions shown above are outside of the compressor operational limits for specific models.
Cooling Mode
Entering
Load Temp (°F)
50
70
90
110
Entering
Source Temp (°F)
Suction
Pressure (psig)
Discharge
Pressure (psig)
Superheat
(°F)
Subcooling
(°F)
30
86-99
135-160
12-22
2-15
50
92-107
191-214
10-19
4-15
70
98-115
248-268
5-15
6-16
90
101-119
335-367
6-15
8-16
110
105-122
425-465
8-16
10-19
30
89-106
131-163
15-20
3-6
50
103-125
194-223
11-15
6-9
70
118-143
257-273
11-15
9-12
90
125-151
344-381
8-12
12-14
30
92-113
128-166
15-20
3-6
50
115-143
197-233
11-15
6-9
70
129-158
266-294
11-15
9-12
90
150-168
354-395
8-12
12-14
30
96-121
125-170
55-65
2-20
50
127-161
200-243
41-52
4-18
70
158-200
275-315
21-38
8-19
90
Operation not recommended
NOTES: Operating parameters at 3 gpm/ton source and load flow. Consult the Capacity Tables for each NSW model
for normal allowable operating conditions. Some of the conditions shown above are outside of the compressor
operational limits for specific models.
32
6/16/09
NSW INSTALLATION MANUAL
Antifreeze Correction
Catalog performance can be corrected for antifreeze use. Please use the following table and note the example given.
Antifreeze Type
Antifreeze %
by wt
Ethylene Glycol
Propylene Glycol
Ethanol
Methanol
Cooling
Source
Load
Source
Pressure
Drop
80 [26.7]
30 [-1.1]
50 [10.0]
90 [32.2]
30 [-1.1]
0
1.000
1.000
1.000
1.000
1.000
10
0.990
0.973
0.976
0.991
1.075
20
0.978
0.943
0.947
0.979
1.163
30
0.964
0.917
0.921
0.965
1.225
40
0.953
0.890
0.897
0.955
1.324
50
0.942
0.865
0.872
0.943
1.419
10
0.981
0.958
0.959
0.981
1.130
20
0.967
0.913
0.921
0.969
1.270
EWT - °F [°C]
Water
Heating
Load
30
0.946
0.854
0.869
0.950
1.433
40
0.932
0.813
0.834
0.937
1.614
50
0.915
0.770
0.796
0.922
1.816
10
0.986
0.927
0.945
0.991
1.242
20
0.967
0.887
0.906
0.972
1.343
30
0.944
0.856
0.869
0.947
1.383
40
0.926
0.815
0.830
0.930
1.523
50
0.907
0.779
0.795
0.911
1.639
10
0.985
0.957
0.962
0.986
1.127
20
0.969
0.924
0.929
0.970
1.197
30
0.950
0.895
0.897
0.951
1.235
40
0.935
0.863
0.866
0.936
1.323
50
0.919
0.833
0.836
0.920
1.399
WARNING: Gray area represents antifreeze concentrations greater than 35% by weight and should
be avoided due to the extreme performance penalty they represent.
Antifreeze Correction Example
Antifreeze solution is propylene glycol 20% by weight for the source and methanol 10% for the load. Determine the
corrected heating at 30°F source and 80°F load as well as pressure drop at 30°F for an Envision Series NSW050. Also,
determine the corrected cooling at 90°F source and 50°F load.
The corrected heating capacity at 30°F/80°F would be:
46,700 MBTUH x 0.913 x 0.985 = 41,998 MBTUH
The corrected cooling capacity at 90°F/50°F would be:
44,200 x 0.969 x 0.962 = 41,202 MBTUH
The corrected pressure drop at 30°F and 15 GPM would be:
5.2 psi x 1.270 = 6.60 psi
33
NSW INSTALLATION MANUAL
Troubleshooting Guideline for Refrigerant Circuit
The chart below will assist in determining if measurements taken at the unit are within factory specifications and aid in
accurate diagnosis (SYMPTOM) and repair. The chart is general in nature and represents whether a symptom would result in
normal, high, or low readings from the typical operating range.
Symptom
Head
Pressure
Suction
Pressure
Compressor
AMP Draw
Superheat
Subcooling
Water (Loop)
Temperature
Differential
Under Charged System (Possible Leak)
Low
Low
Low
High*
Low
Low
Over Charged System
High
High
High
Normal
High
Normal
Low Air Flow Heating
High
High
High*
High/Normal
Low
Low
Low Air Flow Cooling
Low
Low
Low
Low/Normal
High
Low
Low Water Flow Heating
Low/Normal
Low/Normal
Low
Low
High
High
Low Water Flow Cooling
High
High
High
High*
Low
High
High Air Flow Heating
Low
Low
Low
Low
High
Low
High Air Flow Cooling
Low
High
Normal
High*
Low
Normal
High Water Flow Heating
Normal
Low
Normal
High*
Normal
Low
High Water Flow Cooling
Low
Low
Low
Low
High
Low
Low Indoor Air Temperature Heating
Low
Low
Low
Normal
High
Normal/High
Low Indoor Air Temperature Cooling
Low
Low
Low
Normal/Low
High
Low
High Indoor Air Temperature Heating
High
High
High
Normal/High*
Normal/Low
Normal
High Indoor Air Temperature Cooling
High
High
High
High*
Low
High
Restricted TXV
High
Low
Normal/Low
High*
High
Low
Insufficient Compressor (Possible Bad Values)
Low
High
Low
High*
Normal/High
Low
TXV - Bulb Loss of Charge
High
Low
Low
High*
High
Low
Scaled Coaxial Heat Exchange Heating
Low
Low
Low
Normal/Low
High
Low
Scaled Coaxial Heat Exchanger Cooling
High
High
High
Normal/Low
Low
Low
Restricted Filter Drier
Check temperature difference (delta T) across filter drier
* Superheat will be high with high evaporator temperatures.
34
NSW INSTALLATION MANUAL
Heating Cycle Analysis
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35
>A7
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NSW INSTALLATION MANUAL
Envision NSW Startup and 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
T Start up/Check-out for new installation
T Troubleshooting
Problem:___________________________________
1. FLOW RATE IN GPM (SOURCE SIDE HEAT EXCHANGER)
Water In Pressure:
Water Out Pressure:
Pressure Drop = a - b
Convert Pressure Drop to Flow Rate
(refer to Pressure Drop table)
a.______
b.______
c.______
PSI
PSI
PSI
d.______
GPM
2. TEMPERATURE RISE OR DROP ACROSS SOURCE SIDE HEAT EXCHANGER
Water In Temperature:
Water Out Temperature:
Temperature Difference:
COOLING
e.______ °F
f. ______ °F
g.______ °F
HEATING
e.______
°F
f. ______
°F
g.______
°F
3. TEMPERATURE RISE OR DROP ACROSS LOAD SIDE HEAT EXCHANGER
Water In Temperature:
Water Out Temperature:
Temperature Difference:
COOLING
h.______ °F
i. ______ °F
j. ______ °F
HEATING
h.______
°F
i. ______
°F
j. ______
°F
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:
Total Amps (Comp. + Fan):
Watts = m. x n. x 0.85
COOLING
VOLTS
m._____
n. _____
AMPS
o. _____
WATTS
HEATING
m.______ VOLTS
n. ______ AMPS
o. ______ WATTS
6. CAPACITY
Cooling Capacity = HR. - (o. x 3.413)
Heating Capacity= HE. + (o. x 3.413)
p. _____
p. _____
btu/hr
btu/hr
7. EFFICIENCY
Cooling EER = p. / o.
Heating COP = p. / (o. x 3.413)
q. _____
q. _____
EER
COP
8. SUPERHEAT (S.H.) / SUBCOOLING (S.C.)
COOLING
Suction Pressure:
Suction Saturation Temperature:
Suction Line Temperature:
Superheat = t. - s.
Head Pressure:
High Pressure Saturation Temp.:
Liquid Line Temperature*:
Subcooling = w. - x.
HYDRONIC
m. ______ VOLTS
n. ______ AMPS
o. ______ WATTS
COOLING
r. ______ PSI
s. ______ °F
t. ______ °F
u. _____
°F
HEATING
r. ______
PSI
s. ______ °F
t. ______
°F
u. ______ °F
HYDRONIC
r. ______
PSI
s. ______ °F
t. ______
°F
u. ______ °F
v. ______
w. _____
x. ______
y. ______
v. ______
w. _____
x. ______
y. ______
v. ______
w. _____
x. ______
y. ______
PSI
°F
°F
°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.
36
PSI
°F
°F
°F
PSI
°F
°F
°F
NSW INSTALLATION MANUAL
Troubleshooting
Should a major problem develop, refer to the following
information for possible causes and corrective steps:
9. The internal winding of the compressor motor may be
grounded to the compressor shell. If so, replace
the compressor.
10. The compressor winding may be open. Check
continuity with an ohm meter. If the winding is open,
replace the compressor.
Compressor Won’t Run
1.
2.
3.
4.
5.
6.
7.
8.
The fuse may be blown or the circuit breaker is open.
Check electrical circuits and motor windings for shorts or
grounds. Investigate for possible overloading. Replace
fuse or reset circuit breakers after the fault is corrected.
Supply voltage may be too low. Check voltage with a
volt meter.
Remote control system may be faulty. Check aquastat
for correct wiring, setting and calibration. Check 24-volt
transformer for burnout.
Wires may be loose or broken. Replace or tighten.
The low pressure switch may have tripped due to one or
more of the following:
a. Fouled or plugged coaxial heat exchangers
b. Low or no water flow (source side heating, load
side cooling)
c. Water too cold (source side heating)
d. Low refrigerant
The high pressure switch may have tripped due to one
or more of the following:
a. Fouled or plugged coaxial heat exchanger
b. Low or no water flow (source side cooling, load
side heating)
c. Water too warm (source side cooling)
Check the capacitor.
The compressor overload protection may be open. If
the compressor dome is extremely hot, the overload
will not reset until cooled down. If the overload does
not reset when cool, it may be defective. If so, replace
the compressor.
Insufficient Cooling or Heating
1.
2.
3.
4.
5.
Check aquastat for improper location (secondary
mode only).
Check for restriction in water flow.
Check subcooling for low refrigerant charge.
The reversing valve may be defective and creating a
bypass of refrigerant. If the unit will not cool, check the
reversing valve coil.
Check thermal expansion valve for possible restriction of
refrigerant flow.
Noisy Unit Operation
1.
2.
3.
4.
5.
6.
37
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.
Check screws on all panels.
Check for chattering or humming in the contactor or
relays due to low voltage or a defective holding coil.
Replace the component.
Check for proper installation of vibration absorbing
material under the unit. Unit must be fully supported,
not just on corners.
Check for abnormally high discharge pressures.
NSW INSTALLATION MANUAL
Troubleshooting cont.
Troubleshooting Controls
Check the jumpers on the control board:
Check the unit. If a lockout mode is displayed, refer to the
table below to determine the meaning of the failure. Follow
the procedure listed to correct the problem.
1.
Refer to the Control Board with Jumper illustration in
the Converting to a Dedicated Cooling Unit section to
see the location of the jumper on the board. If the unit is
a heating only unit, the jumper should be across 1 and 2.
2. If the unit is a cooling only unit, the jumper should be
across 2 and 3.
3. If the unit is a reversible unit, the jumper should be
across 3 and 4.
Check the mode:
1.
If the unit is running on the internal aquastat, verify the
unit is in “Primary” mode. The SL should be set to 0 in
the setup menu.
2. If the unit is running on an external aquastat, the SL
should be set to 1.
Check the thermistor calibration:
1.
Using a thermometer in the P/T port, check the
incoming water temperature.
2. Verify that the measured temperature is within 3
degrees of the temperature displayed on the unit.
3. If it is not, adjust the calibration in the setup menu.
Standard Control Diagnostic Table
DISPLAY
FAILURE
DIAGNOSTIC
DC
Freeze detection thermistor is closed (shorted)
Replace the freeze detection thermistor
(clip-on thermistor)
DO
Freeze detection thermistor is open
Verify that the freeze detection thermistor is
secured properly in the board connector. If the
connection is secure, replace the thermistor.
FP
Freeze detection
The water going through the unit has reached the
freeze point setting (P=5, CL=15, OL=30).
Verify that the freeze detection setting is correct
for the application.
HC
Water set point thermistor is closed (shorted)
Replace the water set point thermistor
(threaded thermistor).
HP
High Pressure
The unit has cut out on high pressure. Discharge
pressure is >600.
LP
Low Pressure
The unit has cut out on low pressure. Suction
pressure is <40
PO
Water set point thermistor is open
Verify that the water set point thermistor is
properly secured in the board connector. If the
connection is secure, replace the thermistor.
38
NSW INSTALLATION MANUAL
Preventive Maintenance
4. Connect a plastic hose from the circulating pump inlet
to the bottom of a plastic five (5) gallon pail (refer to
the Cleaning Connections illustration).
5. Connect a plastic hose from the inlet line of the waterto-refrigerant heat exchanger to the plastic pail. Secure
tightly to ensure that circulating solution does not spill
(refer to the Cleaning Connections illustration).
6. Partially fill the plastic pail with clear water (about twothirds full) and prime the circulating pump. Circulate
until lines are full.
7. Start the circulating pump and slowly add a commercial
scale remover** to the water as recommended by the
scale remover manufacturer’s directions.
8. Be sure the pump circulation is opposite to the normal
water flow through the water-to-refrigerant heat exchanger.
9. Maintain re-circulation until all scale and other material
has been dissolved and flushed from the heat exchanger.
10. Upon completion of the procedure. Safely dispose of
the solution.
11. Rinse the pump and plastic pail. Refill with clear water.
12. Start the pump circulation and flush the system until all
acid residue has been removed from the system. Refill
the plastic pail until only clear water is circulated.
13. Turn off the circulating pump and disconnect all hoses
and fittings.
14. Replace solenoid valves, pumps, hoses and other
devices in their original locations. On closed loop
systems, be sure to purge between the flow center and
unit to avoid getting air into the loop.
15. Put the heat pump back into operation. Check for
proper operating temperature.
1.
Keep all air out of the water lines. An open loop system
should be checked to ensure that the well head is not
allowing air to infiltrate the water line. Lines should
always be airtight.
2. Keep the system under pressure at all times. In open
loop systems, it is recommended that a water control
valve be placed in the discharge line to prevent loss of
pressure during off cycles. Closed loop systems must
have a positive static pressure.
NOTES: If the installation is performed in an area with
a known high mineral content in the water, it is best to
establish a periodic maintenance schedule to check the
water-to-refrigerant heat exchanger on a regular basis.
Should periodic cleaning be necessary, use standard
cleaning procedures which are compatible with either the
cupronickel or copper water lines. Generally, the more water
flowing through the unit, the less chance there is for scaling.
Low GPM flow rates produce higher temperatures through
the coil. To avoid excessive pressure drop and the possibility
of copper erosion, do not exceed GPM flow rate as shown
on the specification sheets for each unit.
Cleaning Procedure
1.
Close the inlet and outlet water valves to isolate the heat
pump from the well system, water heater or loop pumps.
2. Disconnect piping and remove solenoid valve, pumps, etc,
from the inlet and outlet connections on the heat pump.
3. Connect plastic hoses from the circulating pump* to the
outlet of the water-to-refrigerant heat exchanger to be
de-limed (refer to the Cleaning Connections illustration).
Cleaning Connections
Five-gallon Bucket
Pump
WARNING: This process involves a caustic
solution and may be harmful to people and
animals. Wear protective equipment (glasses,
rubber gloves, apron, etc.)
NOTES: *Virginia Chemical Co. makes a Pump model H460.
* W.W. Granger Co. sells a Pump #2P-017 made by Little Giant.
**Virginia Chemical Co. makes a liquid ice machine cleaner which should be used on water-to-refrigerant heat exchangers
serving a domestic hot water system. Calci-Solve by NYCO is available for use on other heat exchangers
39
NSW INSTALLATION MANUAL
Service Parts - Residential
018
025
040
050
060
075
Part Description
208-230/60/1 208-230/60/1 208-230/60/1 208-230/60/1 208-230/60/1 208-230/60/1
Electrical
Safeties /
Sensors
Refrigeration Components
Compressor
34P568-05
34P621-01
34P580-01
34P616-01
34P614-01
Compressor Capacitor
16P002D18
16P002D20
16P002D36
16P002D25
16P002D39
16P002D39
Compressor Sound Jacket
92P504A05
92P504A05
92P519-01
92P519-02
92P519-02
92P519-02
Thermal Expansion Valve
33P605-16
33P605-18
33P605-10
33P605-15
33P605-17
33P605-17
Filter Drier for ‘Reversible Models’
36P500B01
36P500B01
36P500B01
36P500B02
36P500B02
36P500B02
33P506-04
33P506-04
33P503-05
33P526-04
33P526-04
33P526-04
Filter Drier for ‘Heating Only’ Models
Reversing Valve with Coil
Hot Water Generator (Desuperheater)
36P510-01
n/a
n/a
62I516-03
62I516-03
62I516-03
62I516-03
Source Coaxial Heat Exchanger (copper)
62I566-01
62I573-01
62I574-01
62I543-04
62I557-01
62I557-01
Source Coaxial Heat Exchanger (cupronickel)
62I566-02
62I573-02
62I574-02
62I543-03
62I557-02
62I557-02
Load Coaxial Heat Exchanger (copper)
62I566-01
62I573-01
62I574-01
62I543-04
62I557-01
62I557-01
62I557-02
Load Coaxial Heat Exchanger (cupronickel)
62I566-02
62I573-02
62I574-02
62I543-03
62I557-02
DHW Load Coax Vented Double Wall (copper)
62P567-01
62P549-01
n/a
n/a
n/a
n/a
High Pressure Switch
35P506B02
35P506B02
35P506B02
35P506B02
35P506B02
35P506B02
Low Pressure Switch
35P506B01
35P506B01
35P506B01
35P506B01
35P506B01
35P506B01
12P541-01
12P541-01
12P541-01
12P541-01
12P541-01
12P541-01
Water Temperature Sensor
Freeze Detection Sensor
12P505-05
12P505-05
12P505-05
12P505-05
12P505-05
12P505-05
Compressor Contactor
13P004A03
13P004A03
13P004A03
13P004A03
13P004A03
13P004A03
Transformer
15P501-02
15P501-02
15P501-02
15P501-02
15P501-02
15P501-02
Load Pump Relay and/or Status Input
13P003-02
13P003-02
13P003-02
13P003-02
13P003-02
13P003-02
Connection Block - 3 Position
12P503-06
12P503-06
12P503-06
12P503-06
12P503-06
12P503-06
Connection Block - 12 Position
12P503-07
12P503-07
12P503-07
12P503-07
12P503-07
12P503-07
Connection Block - 12 Position Double Tab
12P528B01
12P528B01
12P528B01
12P528B01
12P528B01
12P528B01
Fuse Power Block
12P539-01
12P539-01
12P539-01
12P539-01
12P539-01
12P539-01
Fuse 1-1/4 3AB Normal Blow 10 Amp
19P502A01
19P502A01
19P502A01
19P502A01
19P502A01
19P502A01
Control Touch Screen
19S561-03
19S561-03
19S561-03
19S561-03
19S561-03
19S561-03
Control Board
17P572-01
17P572-01
17P572-01
17P572-01
17P572-01
17P572-01
IntelliStart Soft Starter
IS060S
IS060S
IS060L
IS060L
IS060L
IS060L
IntelliStart Power Block
12P546-01
12P546-01
12P546-01
12P546-01
12P546-01
12P546-01
Grounding Lug
Cabinet
34P657-01
Rear Access Panel
12P004A
12P004A
12P004A
12P004A
12P004A
12P004A
40F749-10
40F749-10
40F749-10
40F749-10
40F749-10
40F749-10
Front Plastic Access Panel
40P542-50
40P542-50
40P542-50
40P542-50
40P542-50
40P542-50
Top Panel
42P557-01B
42P557-01B
42C548-01
42C548-01
42C548-01
42C548-01
04/23/13
40
NSW INSTALLATION MANUAL
Notes
41
NSW INSTALLATION MANUAL
Revision Guide
Pages:
Description:
Date:
By:
4
Updated Nomenclature to New Format
09 Aug 2013
DS
14
Updated Electrical Data
09 Aug 2013
DS
31
Updated Compressor Resistances
09 Aug 2013
DS
4
Updated NSW018 Revision Level
09 May 2013
DS
12
Updated Load Side Pump Kits
09 May 2013
DS
14
Updated NSW018 Electrical Data
09 May 2013
DS
40
Updated Service Parts List
09 May 2013
DS
All
Moved All Commercial Features to Dedicated Commercial Literature
13 Nov 2012
DS
All
Minor Formatting Corrections
13 Nov 2012
DS
12
Added Water Connection Kits
13 Nov 2012
DS
Updated Cooling Setpoint Values
13 Nov 2012
DS
29
Updated AHRI Data Table
13 Nov 2012
DS
40
Updated Parts Lists - New Control Board, Control Touch Screen
13 Nov 2012
DS
42
Added Revision Guide
13 Nov 2012
DS
14
Updated NSW018 Electrical Data
16 May 2014
MA
24, 26
42
Manufactured by
WaterFurnace International, Inc.
9000 Conservation Way
Fort Wayne, IN 46809
www.waterfurnace.com
IM1006WN
07/14
Product:
Type:
Size:
Document:
Envision NSW
Geothermal Hydronic Heat Pump
1.5-6 Tons
Installation Manual
©2014 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and
reserves the right to change design and specifications without notice.