NDS Installation Manual Geothermal/Water Source Outdoor Split Heat Pump 2 to 6 Tons Dual Capacity Installation Information Water Piping Connections Electrical Data Startup Procedures Troubleshooting Preventive Maintenance IM1004SN 06/10 NDS INSTALLATION MANUAL Table of Contents Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Model Nomenclature - Air Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Coil Data - Air Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Physical Data - Air Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Model Nomenclature - Envision Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigerant Coil Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Heat Recovery Unit for Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19 Microprocessor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23 Operation Logic Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26 Line Set Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pressure/Temperature Conversion Chart for R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pressure Drop and Recommended Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Unit Startup and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 NDS INSTALLATION MANUAL Model Nomenclature 1 N 2 D 3 S 4-6 049 7 A 8 1 9 0 10 A 11 C Model Type N = Envision Coax Options C = Copper N = Cupronickel Compressor Type D = Dual Capacity Flow Center A = None B = Flow Center* Cabinet Configuration S = Outdoor Split IntelliStart Options 0 = No IntelliStart 3 = IntelliStart Unit Capacity 026 038 049 064 072 Voltage 1 = 208-230/60/1 Vintage A = Current NOTE: *026-049 uses the FC1-GL and 060-072 uses the FC2-GL, the flow center is factory installed. If these flow centers do not meet the flow requirements, select A = None for digit 10. Physical Characteristics Model 026 038 52 [1.47] 56 [1.59] 0.7 [2.6] 1.3 [4.9] Weight - Operating lb. [kg] 189  236  Weight - Packaged, lb. [kg] 209  256  Compressor (1 each) Factory Charge R-410A, oz. [kg] 049 064 072 90 [2.55] 92 [2.61] 104 [2.95] 1.6 [6.1] 1.6 [6.1] 2.3 [8.7] 250  271  290  270  291  310  Dual Capacity Scroll Coax and Water Piping Coax and Piping Water Volume - gal. [l] NOTE: All units have TXV expansion devices, and 1/2 in. [12.2 mm] and 3/4 in. [19.1 mm] electrical knockouts. 4 4/9/08 NDS INSTALLATION MANUAL Physical Dimensions Cabinet Dimensions and Refrigerant Piping Connections Top View B Front View Connection Point for Field Installed Heat Recovery Unit Rear View WATER OUT WATER IN D E J F Suction Line Connection K H I G L Lineset connections are braze type internally mounted Liquid Line Connection Side View Side View A C M Model A B C D E F G H I J K L M 36.0 23.9 25.7 9.3 7.1 9.0 5.6 8.2 10.7 18.9 8.7 14.8 7.0 [91.4] [60.7] [65.2] [23.7] [18.0] [22.8] [14.2] [20.9] [27.2] [48.0] [22.1] [37.6] [17.8] 026 thru 072 Notes: Refer to Physical Dimensions and Piping Connections drawings Inches [cm] 5 NDS INSTALLATION MANUAL General Installation Information Safety Considerations Condensate Drain Follow the blower coil manufacturer’s instructions. WARNING: Before performing service or maintenance operations on a system, turn off main power switches to both units. Turn off accessory heater power switch if applicable. Electrical shock could cause personal injury. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Duct System All blower coil units/air coils must be installed as specified by the manufacturer’s installation instructions; however, the following recommendations should considered to minimize noise and service problems. An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grill be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply, such as the following safety measures: • Follow all safety codes. • Wear safety glasses and work gloves. • Use a quenching cloth for brazing operations. • Have a fire extinguisher available for all brazing operations. In applications using galvanized metal ductwork, a flexible duct connector is recommended on both the supply and return air plenums to minimize vibration from the blower. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of 1-inch thick glass fiber or be constructed of ductboard. Insulation is usually not installed in the supply branch ducts. Ducts in unconditioned areas should be wrapped with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected. If the air handler is connected to existing ductwork, a previous check should have been made to assure that the duct system has the capacity to handle the air required for the unit application. If ducting is too small, as in replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repairs made accordingly. The duct systems and diffusers should be sized to handle the design airflow quietly. If air noise or excessive airflow is a problem, the blower speed can be changed to a lower speed to reduce airflow. This will reduce the performance of the unit slightly in heating; however, it will increase the temperature rise across the air coil. Airflow must still meet minimum requirements. Moving and Storage Move units in the normal “up” orientation. Units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Do not attempt to move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage. Equipment Selection Split Unit Location The following guidelines should be used when mating an Envision Split to an air handler/coil. • Select R-410A components only. • Match the air handler to the air handler coil data table. • Indoor matching adjustable TXV is factory installed on every NAH air handler/coil. Fixed orifice or cap tube systems should not be used. • Minimum of two (2) blower speeds Locate the split compressor section away from areas that may disturb the customer and in a way that allows easy removal of the access panels and the top of the cabinet. Provide sufficient room to make water, electrical and refrigerant line connections and allow space for service personnel to perform maintenance. The NDS split is approved for outdoor installation when properly installed. Air Coil Location Utilizing Existing Coil or Air Handler Refer to the air handler manufacturer’s instructions for the blower coil unit for details on installing the air handling portion of the system. It is recommended that a new R-410A air handler be installed with an Envision Split considering the long term 6 NDS INSTALLATION MANUAL General Installation Information cont. benefits of reliability, warranty, etc. versus the short term installation cost savings. However, the existing air handler may be retained provided the following: • Coil currently is R-410A rated • Coil uses a TXV. No capillary or fixed orifice systems should be used • A life expectancy of more than 7 years remaining for the air handler and components • Flush air coil and line set An air filter must always be installed upstream of the air coil on the return air side of the air handler of furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grille be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil. Ensure that the line set size is appropriate to the capacity of the unit (refer to Line Set Sizes table). Line sets should be routed as directly as possible, avoiding unnecessary bends or turns. All wall penetrations should be sealed properly. Line set should not come into direct contact with water pipes, floor joists, wall studs, duct work, floors, walls and brick. Line set should not be suspended from joists or studs with a rigid wire or strap which comes into direct contact with the tubing. Wide hanger strips which conform to the shape of the tubing are recommended. Isolate hanger straps from line set insulation by using metal sleeves bent to conform to the shape of insulation. Line set insulation should be pliable, and should completely surround the refrigerant line. When utilizing the existing air coil or line set, only flushing compounds that vaporize should be used; which means they are packaged in a pressurized disposable cylinder. It is preferable to use a flushing agent that removes oil, water, and acid, plus, is biodegradeable and non-toxic. The flushing agent should be safe to use with both HCFC and HFC refrigerants. Once a flushing agent has been selected, follow the instructions provided with the product. The first step should be purging the lines or air coil with nitrogen. Purging with nitrogen first will remove some of the particulate and residual oil which will allow the flushing agent to work better. Never blow the flushing agent through a compressor, filter drier, or txv as it will cause the components to fail. Note: Improper installation of equipment may result in undesirable noise levels in the living areas. When flushing is complete and the final system is assembled, an acid check should be preformed on the system. Acid test kits are available from most HVACR distributors. Typical Split System Application Remote Blower Coil Connection to Air Coil Supply Duct Typical Split System Application - Remote Blower Coil and Typical Split System Heat Pump Coil Add-on Fossil Fuel Furnace illustrations show typical Envision Split installations. The Line Set Sizes table shows typical line set diameters and maximum length. Line sets over 60 feet are not recommended. If the line set is kinked or deformed and cannot be reformed, the bad section of pipe should be replaced. A restricted line set will affect unit performance. As in all R-410A equipment, a reversible liquid line filter drier is required to ensure all moisture is removed from the system. This drier should be replaced whenever “breaking into” the system for service. All line sets should be insulated with a minimum of 1/2” closed cell insulation. All exterior insulation should be painted with UV resistant paint or covering to ensure long insulation life. Disconnect Low Voltage Wire Air Handler Insulated Suction Line Lineset To Air Handler Return Duct Condensate Drain (must be trapped) Air Handler Installation Remote Air Handler (Maximum Recommended Distance is 60' Between Units) Air handlers used with dual capacity units must be capable of operating with a minimum of 2 blower speeds. Refer to the manufacturer’s instructions for the blower coil unit for details on installing the air handling portion of the system. All blower coil units/air coils must be installed as specified by the manufacturer’s installations instructions. However, the following recommendations should be considered to minimize noise and service problems. 7 NDS INSTALLATION MANUAL General Installation Information cont. Dual Fuel Systems In add-on Envision Split applications, the coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger. A high temperature limit should be installed upstream of the coil to de-energize the compressor whenever the furnace is operating. Without this switch, the Envision Split will trip out on high pressure. A dual fuel thermostat can remove the Y1 and Y2 calls when a W call is energized to allow gas furnace backup on an Envision Split application. Refer to the Thermostat Wiring section for details. Envision units can be connected to fossil fuel furnaces that include an A-coil or slab coil. Dual fuel installations utilize the Envision heat pump for heating until the point that auxiliary heat is called for on the thermostat. At that point, the furnace will be enabled and the heat pump will be disabled. The Envision heat pump provides air conditioning through the furnace’s refrigerant coils. Refer to the furnace manufacturer’s installation manual for the furnace installation, wiring and coil insertion. A WaterFurnace Dual Fuel thermostat or a field-installed DPST relay is required. See the Typical Split System Heat Pump Coil Add-on Fossil Fuel Furnace illustration for typical Dual Fuel application. Typical Split System Heat Pump Coil Add-on Fossil Fuel Furnace Disconnect Supply Duct "A" or Slab Coil Insulated Suction Line Wire To Thermostat Condensate Drain (must be trapped) Lineset To Air Handler Return Duct Thermostat Wire From Furnace 8 Up-Flow Fossil Fuel Furnace NDS INSTALLATION MANUAL Electrical Data General Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. See unit electrical data for fuse or cicuit breaker sizing information. Rated Voltage Model Voltage Min/Max Compressor MCC RLA LRA LRA* HWA Pump FLA Ext Loop FLA Total Unit FLA Min Circ Amp Max Fuse/ HACR 026 208-230/60/1 197/253 16.0 10.2 52.0 18.0 0.4 5.4 16.0 18.6 25 038 208-230/60/1 197/253 26.0 16.6 82.0 29.0 0.4 5.4 22.4 26.6 40 049 208-230/60/1 197/253 33.0 21.1 96.0 34.0 0.4 5.4 26.9 32.2 50 064 208-230/60/1 197/253 40.0 25.6 118.0 41.0 0.4 5.4 31.4 37.8 60 072 208-230/60/1 197/253 42.5 27.2 150.0 53.0 0.4 5.4 33.0 39.8 60 05/06/09 Rated voltage of 208-230/60/1. HACR circuit breaker in USA only. Min/Max voltage of 197/253. All fuses Class RK-5 * With optional IntelliStart Thermostat Wiring Thermostat Wiring for Dual Fuel Applications Thermostat Wiring Typical EZ Wiring Diagram Y1 1st Stage Compressor Envision Split Thermostat Envision Split Thermostat Y1 Y1 Y2 Y2 2nd Stage Compressor 1st Stage Compressor Y1 2nd Stage Compressor Y2 Y2 O O Reversing Valve O L Air Handler Fossil Fuel Furnace P1 Fault Signal L Reversing Valve O P1 Fault Signal LO Lo C Common C C Common Common C Common C C R 24 VAC R R 24 VAC R W 24 VAC R 24 VAC R W W Auxiliary Heat Relay G G Fan G Fan Shut P2 G W Down Auxiliary Heat Relay Auxiliary Heat Relay Air Handler transformer must be at least 75 VA. Note: Field installed DPST dual fuel relay (Required for dual fuel installation) or use TP32U03 or TP32U04 9 = chassis NDS INSTALLATION MANUAL Water Quality In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils Material can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. Copper 90/10 Cupro-Nickel pH Acidity/Alkalinity 7- 9 7-9 7-9 Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm Hydrogen Sulfide Less than .5 ppm (rotten egg smell appears at 0.5 PPM) 10 - 50 ppm Less than 1 ppm Less than 200 ppm Sulfates Less than 125 ppm Less than 125 ppm Chlorine Less than .5 ppm Less than .5 ppm Less than .5 ppm Chlorides Less than 20 ppm Less than125 ppm Less than 300 ppm Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10- 50 ppm Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm Ammonia Chloride Less than .5 ppm Less than .5 ppm Less than .5 ppm Ammonia Nitrate Less than .5 ppm Less than .5 ppm Less than .5 ppm Ammonia Hydroxide Less than .5 ppm Less than .5 ppm Less than .5 ppm Ammonia Sulfate Less than .5 ppm Less than .5 ppm Less than .5 ppm Total Dissolved Solids (TDS) Less than 1000 ppm 1000-1500 ppm 1000-1500 ppm LSI Index +0.5 to -.05 +0.5 to -.05 +0.5 to -.05 < .2 ppm < .2 ppm < .2 ppm Less than 1 ppm. Above this level deposition will occur. Less than 1 ppm. Above this level deposition will occur. Corrosion Iron, Fe2+ (Ferrous) Bacterial Iron Potential Iron Fouling (Biological Growth) Iron Oxide Suspended Solids Erosion Threshold Velocity (Fresh Water) Grains = PPM divided by 17 316 Stainless Steel • Less than 1 ppm. Above this level deposition will occur. Less than 10 ppm and filtered for max of Less than 10 ppm and filtered for max of Less than 10 ppm and filtered for max of 600 micron size 600 micron size 600 micron size < 6 ft/sec < 6 ft/sec mg/l is equivalent to PPM < 6 ft/sec 2/8/08 10 NDS INSTALLATION MANUAL Water Piping Flow Center Installation Residential NDS split units are supplied standard with GeoLink swivel connections with P.T. ports. Flow centers FC1-GL or FC2-GL, as needed, may be internally mounted on the NDS splits, Two stub tubes with barbs are pre connected to the coax. Two tubes with brass fittings, to adapt to the flow center, 2 hoses to connect between the two sets of tubes, and four hose clamps are included with each NDS unit. The brass adapter fittings have plastic swivel connectors and are also internally threaded to accept 3/4 in. NPT fittings. CAUTION: Water piping exposed to outside temperatures may be subject to freezing. Water Piping The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. NOTE: For ease of installation, attach provided hoses to coax first and then trim to fit to elbows on flow center. Typical Split System Outdoor Installation Using Closed Loop Closed Loop - Earth coupled Systems (Outdoor Installations) Locate unit on an air pad with access hole as shown below. When mounting on an existing concrete pad, holes must be bored through to accommodate 1 1/4-inch P.E. pipe with 1/2-inch insulation. Connecting To Earth Loop The earth loop trench should be continued directly under the unit as shown in the Typical Split System Outdoor Installation Using Closed Loop. Make the connections to optional fittings from the loop circulator pump(s) and ensure proper backfill to support the loop pipe during trench settling. All 1 1/4-inch piping should be insulated with a minimum of 1/2-inch closed cell insulation from below the ground surface to the loop circulator. IMPORTANT: A freeze detection thermostat is installed in the unit to automatically start loop circulator pump if loop temperature drops below 20°F. Loop freeze detection should also be maintained to the lowest temperature the insulated loop may encounter in the case of power failure. Loop Supply and Return Piping Open Loop (Indoor Installations) NDS Splits can be installed on an open loop system, but only indoors. All NDS Splits are supplied with GeoLink swivel connectors. The swivel connectors that are supplied with the NDS Split also accept 3/4 in. NPT pipe which can be connected in an open loop system. 11 NDS INSTALLATION MANUAL Model Nomenclature - Air Handler 1-3 4-6 7 8-9 10 11 12 NAH 036 A 00 0 1 R Model Type NAH = Envision Series Air Handler Air Coil R = Refrigerant H = Hydronic Unit Capacity Refrigerant Models Nom. CFM 022 MBTUH 800 026 MBTUH 925 030 MBTUH 980 036 MBTUH 1225 042 MBTUH 1425 048 MBTUH 1625 060 MBTUH 1760 Hydronic Models 026 MBTUH 925 036 MBTUH 1225 048 MBTUH 1625 060 MBTUH 1760 Motor 1 = ECM 208-230/60/1 Disconnect 0 = No breaker installed (only on 5kW & 10kW heaters) 1 = Breaker installed (only on 15kW & 20kW heaters) Electric Heat 00 = No electric heat 05 = 5 kW (available on 022-036 only) 10 = 10 kW (available on 030-060 only) 15 = 15 kW (available on 042-060 only) 20 = 20 kW (available on 060 only) Vintage A = Current NOTE: Kit NAHBC must be ordered to field convert the NAH042-060 to bottomflow air discharge. Coil Data - Air Handler Envision Split Model Matching Air Handler Coil Surface Area (ft2) FPI Rows Tube Diameter 022 - 038 NAH036 5.83 042 - 072 NAH060 5.83 12 2 3/8 in. 12 3 3/8 in. Compatibilty Table - Air Handler Air Handler Indoor Split Model (Single) Indoor Split Model (Dual Capacity) NAH022A***1R NSZ022 - Outdoor Split Model (Dual Capacity) Airflow(CFM) Electric Heat (kW) 800 5 NAH026A***1R - NDZ026 NDS026 925 5 NAH030A***1R NSZ030 - - 980 5, 10 NAH036A***1R NSZ036 - - 1225 5, 10 NAH036A***1R - NDZ038 NDS038 1225 5, 10 NAH042A***1R NSZ042 - - 1425 10, 15 NAH048A***1R NSZ048 - - 1625 10, 15 NAH048A***1R - NDZ049 NDS049 1625 10, 15 NAH060A***1R NSZ060 - - 1760 10, 15, 20 NAH060A***1R - NDZ064 NDS064 1760 10, 15, 20 NAH060A***1R NSZ070 - - 1760 10, 15, 20 NAH060A***1R - NDZ072 NDS072 1760 10, 15, 20 6/9/08 12 NDS INSTALLATION MANUAL Physical Data - Air Handler Air Handler Model Number (Refrigerant) NAH022 NAH026 NAH030 NAH036 NAH042 NAH048 NAH060 Air Coil Total Face Area, ft2 [m2] 5.83 [0.54] Tube outside diameter - in. [mm] Evaporator Coil 3/8 [9.52] Number of rows 2 3 Fins per inch 12 Suction line connection - in. [mm] sweat 5/8 [15.87] 7/8 [22.22] 3/8 [9.52] Liquid line connection - in. [mm] sweat Refrigerant R-410a Nominal cooling capacity - tons [kW] 1.8 [6.44] 2.1 [7.59] 2.5 [8.79] 3 [10.55] 3.5 [12.30] 4 [14.06] 5 [17.58] 3/4 [19.05] Condensate drain connection - (FPT) in. [mm] Blower Wheel Size (Dia x W), in. [mm] 11 x 10 [279 x 254] Blower motor type/speeds ECM variable speed 1/2  Blower motor output - hp [W] 1  20 x 24 [508 x 635] Filter Standard - 1" [51mm] MERV3 disposable, in. [mm] 208/230 - 1ph Electrical characteristics (60hz) 215 [97.52] 195 [88.45] Shipping weight - lbs. [kg] Operating weight - lbs. [kg] 220 [99.79] 200 [90.71] 1/11/08 Air Handler Model Number (Hydronic) Hydronic Coil NAH026 NAH036 NAH048 NAH060 Air Coil Total Face Area, ft2 [m2] 6.94 [0.64] Tube outside diameter - in. [mm] 3/8 [9.52] Number of rows 3 Fins per inch 13 7/8 [22.22] 7/8 [22.22] Water In connection - in. [mm] sweat Water Out connection - in. [mm] sweat Nominal cooling capacity - tons [kW] 2.1 [7.59] 3 [10.55] 4 [14.06] Blower Wheel Size (Dia x W), in. [mm] 11 x 10 [279 x 254] Blower motor type/speeds ECM variable speed Blower motor output - hp [W] 5 [17.58] 3/4 [19.05] Condensate drain connection - (FPT) in. [mm] 1/2  1  20 x 24 [508 x 635] Filter Standard - 1" [51mm] MERV3 disposable, in. [mm] 208/230 - 1ph Electrical characteristics (60hz) 220 [99.79] 200 [90.71] Shipping weight - lbs. [kg] Operating weight - lbs. [kg] 3/11/08 NOTE: Water connection dimensions are O.D. 13 NDS INSTALLATION MANUAL Model Nomenclature - Envision Coil 1-2 NR 3 A 4 C 5-7 026 8 C Cabinet C = Encased U = Uncased Model Type NR = Envision Refrigerant Coil NH = Envision Hydronic Coil Capacity Refrigerant Models 026 MBTUH 036 MBTUH 048 MBTUH 060 MBTUH Hydronic Models 060 MBTUH Configuration A = "A" Coil Coil NOTE: All Refrigerant Coils include TXV. Refrigerant Coil Compatibility Encased/Uncased Coil NRAC026* NRAC026* NRAC026* NRAC036* NRAC036* NRAC048* NRAC048* NRAC048* NRAC060* NRAC060* NRAC060* NRAC060* Indoor Split Model (Single) NSZ022 NSZ030 NSZ036 NSZ042 NSZ048 NSZ060 NSZ070 - Indoor Split Model (Dual Capacity) NDZ026 NDZ038 NDZ049 NDZ064 NDZ072 14 Outdoor Split Model (Dual Capacity) NDS026 NDS038 NDS049 NDS064 NDS072 Recommended Airflow (CFM) 800 925 980 1225 1225 1425 1625 1625 1760 1760 1760 1760 7/14/08 NDS INSTALLATION MANUAL Heat Recovery Unit for Domestic Hot Water Service valves have been provided inside the unit for connecting the discharge gas line to a water heating heat recovery unit (see Service Valves for Heat Recovery Unit Connections illustration). To make the connections, close the service valves inside the unit by turning clockwise. Using a recovery canister connect to either of the schrader ports on the DSH service valves and recover the small amount of refrigerant trapped inside of the U-tube. Prior to brazing ensure that all refrigerant has been removed from U-tube. Once the refrigerant is removed, it is recommended that the tube be cut at the “U” to remove any excess oil that may be trapped. (This will also allow for easier removal of the tubing with a torch, since each section can be removed independently). Service valves must be protected to prevent overheating. Unbraze the 1/2-inch O.D. U-tube and run tubing from the left hand service valve to the inlet of the heat recovery unit and from the outlet of the heat recovery unit to the right hand of the service valve. Typically the one way discharge line length should be limited to 25-30 feet and line size must be increased depending on unit size and length of run. Follow the instructions supplied with the heat recovery unit for mounting location, water piping, and start up. A typical installation is shown below. IMPORTANT: Reopen discharge line service valves before starting up unit, but only after leak checking, purging, and evacuating new discharge line. Maximum One-Way Line Length Service Valves for Heat Recovery Unit Connections To Compressor Heat Recovery Unit “In” From Heat Recovery Unit “Out” to Reversing Valve SIZE 1/2” OD 5/8” OD 3/4” OD 026 - 038 Up to 9 ft. Up to 25 ft. Up to 30 ft. 049 Up to 5 ft. Up to 13 ft. Up to 30 ft. 064 N/A Up to 9 ft. Up to 25 ft. 072 N/A Up to 6 ft. Up to 20 ft. Typical Hot Water Piping Layout Cold Line set To Hot Water Generator Hot Venting Waste Valve or Vent Coupling P/T Relief Valve Insulated Line set With UV Paint To Air handler Add-on Hot Water Generator with Internal Pump 15 Drain Valve Pipe Tee NDS INSTALLATION MANUAL Wiring Schematics Dual Capacity Split Wiring Schematic - 208-230/60/1 S C R Loop Pump(s) 1/2 HP 208-230/60/1 Blue Gray(9) Red Pump Pump G G L2 CS + - CC Tan (16) Run Capacitor Heat Recovery Unit DC SOL Comfort Alert Unit Power 208-230/60/1 Yellow (8) 1 - Connection of remo for slave operation. 2 - 24V Accessory rela 3 - Field installed DPD installation) 4 - DHW pump only in 5 - Comfort Alert fault 6 - This Switch allows when OFF and finis second stage reduc compressors and s E-Series or Premie Black L2 L1 L1 FP Red (11) Green /Yellow Crankcase Heater NO COM CR1 NC CR3 COM NC F1-10A 240V Wire n COM CR4 Groun Relay N.O., Fuse R Black (5) P6 8 CCHI Violet (2) CC 13 Black (1) CC-GND P1 1 R 7 C 2 Y1 3 Y2 4 W 5 O 6 G 7 LO 8 4 5 14 12 Microprocessor Logic Control (DC Voltage) 6 15 10 9 2 Crank 1 C 11 22 C C SL1 In 33 4 SL1 Out 5 Not 6 Used 7 SL1 In Acc NC 2 Acc NO 3 1 2 3 SW2 1 2 3 4 5 6 7 8 9 10 11 12 SW3 On 1 Test / Norm 2 Loop / Well 3 Fan / Comp 4 Not Used 5 Not Used 6 Inputs / Norm 7 Outputs / Norm 8 Pulse L / Constant L 11 On 1 Dual/ Single Capacity 2 Normal/ Finish on 2nd NOTE 6 3 No RPM / RPM 4 Must be On 5 Envision / E Series or Premier P4 R R G Y R SW4 Tan L Comfort Alert LED Normal Display Mode Field Selection Dips - #1 On, #6 On, #7 On Not Used Drain FD thermistor(loop<15 °F,well <30°F) Lockout Water Flow High Pressure High Press Low Press /CA Low Pressure / Comfort Alert Not Used Air Flow Microprocessor malfunction* Status Not Used DHW Limit Not Used DHW off *Green LED not flashing 16 Current Fault Status #1 Off, #6 On, #7 On Not Used FD thermistor (loop <15°F, well <30°F) High Pressure Low Pressure / Comfort Alert Not Used Not Used Not Used Not Used Switch 4 9 Orange 2 Orange 10 Not Used 3 8 Not Used RV Switc P Not Used 1 Not Used 12 Yellow 5 Yellow 13 Blue 6 Blue 7 Black 14 Black T LP HP Diagnostic Modes R R R Capac NOTE 5 Inputs Outputs #6 Off, #7 On Y1 Y2 O Not Used Not Used SL1 SL2 Not Used #6 On, #7 Off Lo Capacity Compressor Hi Capacity Compressor RV FAN Not Used Loop Pump1 Loop Pump2 Not Used Outputs2 #6 Off, #7 Off Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used FD 1 1 Relay P5 3 Acc Com 16 2 NOTE 2 P3 Status LED PCB SL1 Out Optional Remote Unit Without Loop Pump Light G 11 ECM2 Air Flow Settings SW1 On NOT USED NOTE 1 Therm T 3 P2 Shut Down Comf Comp Comp Not U Loop Loop Not U Fuses Freez High P Low P Rever Not U DIP P DIP P CA CS CC CR1 CR2CR3 CR4 F1 and F2 FD HP LP RV SW1 SW2 SW3 - C White (4) CC Field w L1 Fused L1 Black (7) Yellow (6) Violet (3) 240V L1 NO NOT USED R Comfort C Alert Y2Y COM CR2 240V L2 Fused L2 NO Facto Facto Field l Field l Option DC Vo Intern Quick Black F1-10A 240V NO Brown (15) Orange (14 ) Black Fused L2 Lege Red (12) Polari NDS INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split Wiring Schematic - 208-230/60/1 cont. F1 F1 N.C. N.O. N.O. N.O . N.O. Com CR2- Loop Pump CR1- DHW Pump Com CR3- CR49 CC-GND CC CCLO CCHI Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal Wire nut Field wire lug L1 Ground 10 11 12 13 14 15 Microprocessor Legend SW1 Off On C C R R P4 1 2 3 1 2 3 P1 4 5 240V - L2 240V - L2 Fused L2 Fused L2 Fused L2 Fused L2 Fused L1 240V - L1 1 - Connection of remote unit that does not have a loop pump for slave operation. 2 - 24V Accessory relay (see SW2 -3 for description of operation) 3 - Field installed DPDT dual fuel relay. (Required for dual fuel installation) 4 - DHW pump only in models with hot water generation option. 5 - Comfort Alert fault output to Premier Control Board 6 - This Switch allows the unit to down stage with the t-stat when OFF and finish on second stage when ON. Finish second stage reduces stage changing in recip dual capacity compressors and should be ON for unzoned Dual Cap E-Series or Premier 2 speed units. 240V - L1 Logic Board - Physical Layout Notes 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 R C Y1 Y2 W O G L SW2 Off On SW3 Off On 1 2 3 4 5 6 7 8 P2 1 2 3 Shut Down C C 1 2 3 4 5 4 5 SL1 IN SL 1 SL 2 Out IN 6 7 1 SL 2 Out ACC NO 1 2 3 4 5 6 7 16 8 8 1 9 2 10 3 11 4 12 5 13 6 14 7 P3 2 P6 P5 3 ACC ACC NC COM Relay Contacts N.O., N.C. Fuse Comfort Alert Compressor Solenoid Compressor Contactor Not Used Loop Pump Relay1 Loop Pump Relay2 Not Used Fuses Freeze Detection sensor High Pressure Switch Low Pressure Switch Reversing Valve Coil Not Used DIP Package 8 Position DIP Package 5 Position CA CS CC CR1 CR2CR3 CR4 F1 and F2 FD HP LP RV SW1 SW2 SW3 - Comfort Alert Physical Layout POWER Y2 Y Data Port L R Crankcase Heater C Thermistor T DC Sol Light Emitting Diode - Green G ALERT TRIP Relay Coil Capacitor w/ Bleed Resistor E5 Comfort Alert Switch-High Pressure RV Switch-Low Pressure 1 FD 3 T 2 P Polarized Connector LED Flash Code Green Solid Red Solid Code 1 Code 2 Code 3 Code 4 Yellow Code 5 Code 6 Code 7 Code 8 Code 9 Comfort Alert Status Description Module Has Power Y1 Present But Compressor Not Running Long Run Time System Pressure Trip Short Cycling Locked Rotor Open Circuit Open Start Circuit Open Run Circuit Welded Contactor Low Voltage LP HP Outputs2 #6 Off, #7 Off Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used 97P788-01 17 4/19/10 NDS INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with IntelliStart Wiring Schematic - 208-230/60/1 S C Blue PB2 2 R Black Loop Pump(s) 1/2 HP 208-230/60/1 Pump Pump Heat Recovery Unit Tan (16) G L2 Pink Blue CC Run Capacitor L2 Black T1 T2 Red CS + - Red Unit Power 208-230/60/1 Yellow (8) G 1 DC SOL Comfort Alert Gray(9) Leg L1 L1 Fa Fa Fi Fi Op DC In Qu FP Red (11) Red (12) Green /Yellow Crankcase Heater Brown (15) Orange (14 ) Black W Black Fi L1 NO NO COM CR1 COM CR3 NC COM Violet (3) NO NC Re N. F1-10A 240V Fu COM CR4 R Black (5) C White (4) CC CA CS CC CR1 CR2CR3 CR4 F1 and F2 FP HP LP RV SW1 SW2 SW3 - Fused L1 Black (7) Yellow (6) Gr 240V L1 P6 8 CCHI Violet (2) CC 13 Black (1) CC-GND P1 1 R 7 C 2 Y1 3 Y2 4 W 5 O 6 G 7 LO 8 Co Co Co No Lo Lo No Fu Fr Hi Lo Re No DI DI 4 5 14 12 Microprocessor Logic Control (DC Voltage) 6 15 10 9 2 NOT USED R Cr T Th G Lig Re Ca 1 3 33 4 SL1 Out SL1 Out 5 Optional Remote Unit Without Loop Pump Not 6 Used 7 ECM 2 Air Flow Settings SW1 On NOTE 2 P3 Acc Com 1 Acc NC 2 Acc NO 3 1 2 3 P5 SW2 1 2 3 4 5 6 7 8 9 10 11 12 SW3 On 1 Test / Norm 2 Loop / Well 3 Fan / Comp 4 Not Used 5 Not Used 6 Inputs / Norm 7 Outputs / Norm 8 Pulse L / Constant L R R G Y R SW4 NOTE 5 11 On 1 Dual/ Single Capacity 2 Normal/Finish on2nd NOTE 6 3 No RPM / RPM 4 Must be On 5 Envision / E Series or Premier P4 Tan L LED Drain Water Flow High Press Low Press/CA Air Flow Status DHW Limit DHW off Normal Display Mode Field Selection Dips - #1 On, #6 On, #7 On Not Used FD thermistor (loop<15 °F,well <30°F) Lockout High Pressure Low Pressure / Comfort Alert Not Used Microprocessor malfunction* Not Used Not Used *Green LED not flashing 18 Current Fault Status #1 Off, #6 On, #7 On Not Used FD thermistor (loop <15°F, well <30°F) High Pressure Low Pressure / Comfort Alert Not Used Not Used Not Used Not Used P Comfort Alert Po 4 9 Orange 2 Orange 10 Not Used 3 8 Not Used 1 Not Used 12 Yellow 5 Yellow 13 Blue RV Not Used 6 Blue 7 Black 14 Black T Inputs Outputs #6 Off, #7 On Y1 Y2 O Not Used Not Used SL1 SL2 Not Used #6 On, #7 Off Lo Capacity Compressor Hi Capacity Compressor RV FAN Not Used Loop Pump1 Loop Pump2 Not Used FD LP HP Diagnostic Modes R R R Sw 1 SL1 In C SL1 In 16 3 C C Sw 11 2 NOTE 1 11 22 NOT USED P2 Shut Down Status LED PCB Comfort C Alert Y2Y NO CR2 240V L2 Fused L2 F1-10A 240V Fused L2 Outputs2 #6 Off, #7 Off Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used 1 - Connection for slave op 2 - 24V Access 3 - Field install installation) 4 - DHW pump 5 - Comfort Ale 6 - This Switch when OFF second sta compresso Series or P NDS INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with IntelliStart Wiring Schematic - 208-230/60/1 cont. Run Winding Pink Active Blue Start Black N.C. N.O. N.O. N.O. Com CR2- Loop Pump CR1- DHW Pump 9 SW1 Off On C C R R Field wire lug Ground Relay Contacts N.O., N.C. P4 Comfort Alert Compressor Solenoid Compressor Contactor Not Used Loop Pump Relay 1 Loop Pump Relay 2 Not Used Fuses Freeze Detection sensor High Pressure Switch Low Pressure Switch Reversing Valve Coil Not Used DIP Package 8 Position DIP Package 5 Position CR4- 1 2 3 1 2 3 P1 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 R C Y1 Y2 W O G L SW2 Off On SW3 Off On 1 2 3 4 5 6 7 8 P2 1 2 3 Shut Down C C 1 2 3 4 5 6 7 16 8 8 1 9 2 10 3 11 4 12 5 13 6 14 7 P3 10 11 12 13 14 15 Microprocessor Wire nut Fuse Com CR3- CC-GND CC CCLO CCHI Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal 240V - L2 F1 N.O . Legend CA CS CC CR1 CR2CR3 CR4 F1 and F2 FP HP LP RV SW1 SW2 SW3 - 240V - L2 Fused L2 F1 IntelliStart Common L1 Fused L2 Fused L2 Fused L2 Red 240V - L1 240V - L1 1 Fused L1 Logic Board - Physical Layout PB2 2 1 2 3 4 5 4 5 SL1 IN SL 1 SL 2 Out IN 6 7 1 SL 2 Out ACC NO 2 P6 P5 3 ACC ACC NC COM Comfort Alert Physical Layout POWER Y2 Y Data Port Crankcase Heater L R T Thermistor G Light Emitting Diode-Green C DC Sol Relay Coil ALERT TRIP Capacitor w/ Bleed Resistor Switch- High Pressure Switch- Low Pressure 1 P Comfort Alert 3 L 2 NOTE 5 Polarized Connector RV T LED Flash Code Green Solid Red Solid Code 1 Code 2 Code 3 Code 4 Yellow Code 5 Code 6 Code 7 Code 8 Code 9 Comfort Alert Status Description Module Has Power Y1 Present But Compressor Not Running Long Run Time System Pressure Trip Short Cycling Locked Rotor Open Circuit Open Start Circuit Open Run Circuit Welded Contactor Low Voltage FD LP HP Outputs2 #6 Off, #7 Off Not Used Not Used Not Used Not Used Not Used Not Used Not Used Notes 1 - Connection of remote unit that does not have a loop pump for slave operation. 2 - 24V Accessory relay (see SW2 -3 for description of operation) 3 - Field installed DPDT dual fuel relay. (Required for dual fuel installation) 4 - DHW pump only in models with hot water generation option. 5 - Comfort Alert fault output to Premier Control Board 6 - This Switch allows the unit to down stage with the t-stat when OFF and finish on second stage when ON. Finish second stage reduces stage changing in recip dual capacity compressors and should be ON for unzoned Dual Cap E Series or Premier 2 speed units. Not Used 97P788-02 19 4/19/10 NDS INSTALLATION MANUAL Microprocessor Control Startup Heating Operation The unit will not operate until all the inputs and safety controls are checked for normal conditions. At first powerup, a four-minute delay is employed before the compressor is energized. Heat, 1st Stage (Y1) The blower motor is started on low speed immediately (PSC ON), the loop pump is energized 5 seconds after the “Y1” input is received, and the compressor is energized on low capacity 10 seconds after the “Y1” input. The blower is switched to medium speed 15 seconds after “Y1” input (ECM only). Component Sequencing Delays Components are sequenced and delayed for optimum space conditioning performance. Heat, 2nd Stage (Y1,Y2) Dual Capacity Units Accessory Relay The second stage compressor will be activated 5 seconds after receiving a “Y2” input as long as the minimum first stage compressor run time of 1 minute has expired. The ECM blower changes from medium to high speed 15 seconds after the “Y2” input. An accessory relay on the control board allows for field connection of solenoid valves, electronic air cleaners, etc. The accessory relay has a normally open output and a normally closed output. The Comfort Alert will delay the second stage compressor until 5 seconds after it receives a “Y2” from the board. Short Cycle Protection The control employs a minimum “off” time of four minutes to provide for short cycle protection of the compressor. Heat, 3rd Stage (Y1,Y2,W) Dual Capacity Units The 1st stage of resistance heat is energized 10 seconds after “W” input, and with continuous 3rd stage demand, the additional stages of resistance heat engage 90 seconds after the first stage. Shutdown Mode A 24VAC common signal to the “shutdown” input on the control board puts the unit into shutdown mode. Compressor and blower operation are suspended. Emergency Heat (W only) Safety Controls The blower is started on high speed, and the first stage of resistance heat is energized 10 seconds after the “W” input. Continuing demand will engage the additional stages of resistance heat 90 seconds after the first stage. The Envision control receives separate signals for a high pressure switch for safety, a low pressure switch to prevent loss of charge damage, and a low suction temperature thermistor for freeze detection. Upon a continuous 30-second measurement of the fault (immediate for high pressure), compressor operation is suspended, the appropriate lockout LED begins flashing. (Refer to the “Fault Retry” section below.) Cooling Operation In all cooling operations, the reversing valve directly tracks the “O” input. Thus, anytime the “O” input is present, the reversing valve will be energized. Testing Cool, 1st Stage (Y1,O) The Envision control allows service personnel to shorten most timing delays for faster diagnostics. (Refer to the Field Selection DIP switch table.) The blower motor is started immediately, the loop pump(s) is energized 5 seconds after the “Y1” input is received. The compressor will be energized (on low capacity for Dual Capacity units) 10 seconds after the “Y1” input. The ECM blower will shift from low to medium speed 15 seconds after the “Y1” input (85% of medium speed if in dehumidification mode). Fault Retry All faults are retried twice before finally locking the unit out. An output signal is made available for a fault LED at the thermostat. The “fault retry” feature is designed to prevent nuisance service calls. Cool, 2nd Stage (Y1, Y2, O) Single Speed Units The blower changes to high speed (85% of high speed if in dehumidification mode) 15 seconds after the “Y2” input (ECM only). Diagnostics The Envision control board allows all inputs and outputs to be displayed on the LEDs for fast and simple control board diagnosis. (Refer to the Field Selection DIP Switch SW2-1 table.) 20 NDS INSTALLATION MANUAL Microprocessor Control cont. Cool, 2nd Stage (Y1, Y2, O) Dual Capacity Units High Pressure The second stage compressor will be activated 5 seconds after receiving a “Y2” input as long as the minimum first stage compressor run time of 1 minute has expired. The ECM blower changes to high speed 15 seconds after the “Y2” input (85% of high speed if in dehumidification mode). The Comfort Alert will delay the second stage compressor until 5 seconds after it receives a “Y2” from the board. This lockout mode occurs when the normally closed safety switch is opened momentarily (set at 600 PSI). Low Pressure This lockout mode occurs when the normally closed low pressure switch is opened for 30 continuous seconds (set at 40 PSI). A low pressure fault may also be indicated when a Comfort Alert lockout has occurred. Blower (G only) The blower starts on low speed (PSC ON). Regardless of blower input “G” from thermostat, the blower will remain on low speed for 30 seconds at the end of each heating, cooling or emergency heat cycle. Freeze Detection (Water Flow) This lockout mode occurs when the freeze detection thermistor temperature is at or below the selected point (well 30°F or loop 15°F) for 30 continuous seconds. Lockout Conditions During lockout mode, the appropriate unit and thermostat lockout LEDs will illuminate. The compressor, loop pump, and accessory outputs are de-energized. The blower will continue to run on low speed. If the thermostat calls for heating, emergency heat operation will occur. Comfort Alert lockouts cannot be reset at the thermostat. All other lockout modes can be reset at the thermostat after turning the unit off, then on, which restores normal operation but keeps the unit lockout LED illuminated. Interruption of power to the unit will reset a lockout without a waiting period and clear all lockout LEDs. 21 NDS INSTALLATION MANUAL Microprocessor Control cont. Compressor Monitoring/Comfort Alert passive. All compressor alerts are displayed on the module by flashing the yellow Alert LED a specific number of times consecutively followed by a pause, and then repeated. The number of consecutive flashes or “Flash Code” correlates to a specific abnormal condition. The red “TRIP” LED means there is a thermostat demand signal “Y” present but the compressor is not running. The green “POWER” LED means the module has power. The Comfort Alert displays abnormal compressor conditions through a unique flash code and communicates the conditions to the heat pump microprocessor control. The heat pump microprocessor will determine which fault to act on and ignore. Fault codes 2 (system pressure), 4 (locked rotor), 6 (open start circuit), and 7 (open run circuit) will result in a lockout. All other fault codes are Green "POWER" LED - module has power Red "TRIP" LED - Thermostat "Y" demand signal is present, but the compressor is not running. Comfort Alert Flash Codes Yellow "ALERT" LED Flash Code 1 Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 6 Flash Code 7 Flash Code 8 Flash Code 9 LED Description Long Run Time System Pressure Trip Short Cycling Locked Rotor Open Circuit Open Start Circuit Open Run Circuit Welded Contactor Low Voltage Cause Eighteen consecutive hours of compressor run time Not applicable Compressor run time of less than 3 minutes on 4 consecutive cycles Four consecutive compressor protector trips indicating compressor won't start "Y" thermostat demand signal with no compressor current "Y" thermostat demand signal with no current in the start circuit "Y" thermostat demand signal with no current in the run circuit Current detected with no "Y" thermostat demand signal present Less than 17 VAC detected in control circuit * Flash code number corresponds to a number of LED flashes, followed by a pause and then repeated. * TRIP and ALERT LEDs flashing at the same time indicates control circuit voltage is too low for operation. * Reset ALERT flash code by removing 24 VAC power from module. * Last ALERT flash code is displayed for 1 minute after module is powered on. Resetting Comfort Alert Codes Alert codes can be reset manually by cycling power off and on to the Comfort Alert module. Alert codes will reset automatically if conditions return to normal. Flash Code Number Flash Code 1 Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 6 Flash Code 7 Flash Code 8 Flash Code 9 LED Description Long Run Time System Pressure Trip Short Cycling Locked Rotor Open Circuit Open Start Circuit Open Run Circuit Welded Contactor Low Voltage Automatic Reset of Alert Codes Thirty "alert free" on and off cycles to reset automatically Not applicable Four "alert free" on and off cycles to reset automatically Four "alert free" on and off cycles to reset automatically One "alert free" on and off cycles to reset automatically One "alert free" on and off cycles to reset automatically One "alert free" on and off cycles to reset automatically One "alert free" on and off cycles to reset automatically Resets when voltage rises above 19 VAC * Reset ALERT flash code by removing 24 VAC power from module. 22 NDS INSTALLATION MANUAL Microprocessor Control cont. Thermostat Displays thermostat can be configured to show either lockout text or lockout codes. Fault Flash When using a TA32W01 or TP32W02 thermostat and SW28 is in the pulsing “L” position, FaultFlash will enable a user to view the thermostat and count the fault indicator flashes to determine the lockout condition the unit is experiencing. The LED board on the front of the unit will display all lockouts. The Low Pressure LED will flash for a low pressure condition or a Comfort Alert fault. If the low pressure lockout was caused by Comfort Alert codes 4, 6 or 7, then the Comfort Alert will be flashing. If no Comfort Alert code is visible, then it is a low pressure lockout. ComforTalk When using a TP32U03, 04 or 05 thermostat and SW2-8 is in the pulsing “L” position, ComforTalk will enable the user to view the thermostat and determine the fault. The The following tables show the codes that will be displayed on the different ComforTalk and FaultFlash thermostats. FaultFlash Thermostats ComforTalk Thermostats TA32W01 and TP32W02 Thermostats Thermostat Display Lockout Code 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes 9 Flashes 10 Flashes TP32U03, TP32U04 and TP32U05 Thermostats Thermostat Display Lockout Code Lockout Description High Pressure Fault Low Pressure Fault Not Applicable Water Flow Fault Not Applicable Condensate Fault Voltage out of Range RPM Fault Comfort Alert Compressor Module Fault Lockout code 10 - see Comfort Alert module to determine the specific flash code for compressor abnormalities. "High Pressure" or "E2" "Low Pressure" or "E3" "E4" "Water Flow" or "E5" "E6" "Condensate" or "E7" "Voltage Range" or "E8" "RPM" or "E9" "Comfort Alert" or "E10" Lockout Description High Pressure Fault Low Pressure Fault Not Applicable Water Flow Fault Not Applicable Condensate Fault Voltage out of Range RPM Fault Comfort Alert Compressor Module Fault These thermostats can be configured to display the lockout condition "text" or error number. * A slow flash of 1 second on and off means the heat pump microprocessor SW2-1 is configured for "Test Mode" or thermostat is miswired. Lockout code 10 - see Comfort Alert module to determine the specific flash code for compressor abnormalities. 23 NDS INSTALLATION MANUAL Operation Logic Data OPERATION LOGIC HEATING STG1 STG2 On Off COOLING STG3 EMERG STG1 STG2 Off On Off SL1 - IN ON DUAL CAPACITY UNITS Compressor-Lo Off - Compressor-Hi Off On On Off Off On - Rev Valve Off Off Off Off On On - Loop Pumps On On On Off On On On Secondary 1- Out On On On Off On On - Secondary 2- Out Off On On Off Off On - Emerg LED Off Off Off On Off Off - T-Stat Signal Y1 Y1, Y2 Y1, Y2, W W Y1, O Y1, Y2, O - DIP Switch Settings DIP SWITCH NUMBER SW1 SW2 DESCRIPTION N/A OFF POSITION NOT USED ON POSITION N/A N/A 1 Service/Test Mode - Allows control of “NORM” or “TEST” operational modes. Test mode accelerates most timing functions 16 times to allow faster troubleshooting. Test mode also allows viewing the “CURRENT” status of the fault inputs on the LED display. Test Norm 2 Freeze Detection Setting This DIP allows field selection of freeze detection fault sensing for well water (30°F) or anti-freeze protected earth loops (15°F). Loop (Sensing 15° F) Well (Sensing 30° F) 3 Accessory Relay Allows field selection of the accessory relay to operate with the compressor or blower. Blower Comp 4 NOT USED N/A N/A 5 NOT USED N/A N/A 6 Input Diagnostics - Allows viewing the inputs from the thermostat to the control board such as Y1, Y2, O, G, W, SL1-In on the LED display. Diagnostic Inputs viewed at LEDs 7 Output Diagnostics - Allows viewing the outputs from the control board such as the compressor, reversing valve, blower, and loop pump on the LED display. Diagnostic Outputs viewed at LEDs 8 Thermostat Selection Configures the control for a pulsed lockout signal (ComforTalk and FaultFlash thermostats) or continuous 5 VAC lockout signal. Pulsed “L” signal Continuous “L” signal 1 Single or Dual Capacity Operation Dual Cap 1 Speed Normal All other systems Finish on 2nd Unzoned Dual Capacity E-Series or Premier 2 speed Zoned/Finish on Second Stage 2 This switch allows the unit to down stage with the thermostat when off and finish with second stage when on. Finish on second stage reduces stage changing in reciprocating dual capacity compressors. 3 ECM Blower Monitoring - Set for No PRM on split systems SW3 Normal Display viewed at LEDs Normal Display viewed at LEDs No RPM RPM 4 NOT USED N/A N/A 5 On dual capacity units this switch allows stage change: on the fly when off, and 1 minute delay when on. A delay is required on all reciprocating dual capacity units. Envision E-Series or Premier 24 NDS INSTALLATION MANUAL Refrigeration Leak Testing After initial charge, the system should be operated and the system subcooling and superheat verified to the Unit Operating Parameters table. The refrigeration line set must be pressurized and checked for leaks before purging and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60 to 90 PSIG. Never use oxygen or acetylene to pressure test. Use an electronic leak detector or a good quality bubble solution to detect leaks on all connections made in the field. Check the service valve ports and stem for leaks and all connections made in the field. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize the system above 150 psi. Purge pressure from line set. The system is now ready for evacuating and charging. If an air handler manufactured by others is used then refrigerant should be added to the Envision Split factory pre-charge. Refrigerant should be added for liquid line length. This should result in a slightly under-charged system exhibiting low subcooling and high superheat. As charge is added, the subcooling should rise and the superheat should fall. Charging the System Charge Method – After purging and evacuating the line set, fully open the service valves counterclockwise. Add R-410A (liquid) into the liquid line service port until the pressure in the system reaches approximately 200 PSIG. Never add liquid refrigerant into the suction side of a compressor. Start the unit and measure superheat and subcooling. Keep adding refrigerant until the unit meets the superheat and subcooling values in the Operating Parameters tables. System Evacuation Ensure that the line set and air coil are evacuated before opening service valves to the split unit. The line set must be evacuated to at least 200 microns to remove the moisture and air that may still be in the line set and coil. Evacuate the system through both service ports to prevent false readings on the gauge because of pressure drop through service ports. Checking Superheat and Subcooling Determining Superheat Charge Amount When Using NAH Air Handler 1. Measure the temperature of the suction line at the point where the expansion valve bulb is clamped. 2. Determine the suction pressure in the suction line by attaching refrigeration gauges to the schrader connection on the suction side of the compressor. 3. Convert the pressure obtained in Step 2 to the saturation temperature by using the Pressure Temperature Conversion Chart for R-410A. 4. Subtract the temperature obtained in Step 3 from Step 1. The difference is the amount of superheat for the unit. Refer to the Operating Parameters tables for superheat ranges at specific entering water conditions. The Envision Split is shipped with a facotry pre-charge. This volume of refrigerant is not sufficient to run the system and additional refrigerant must be added. If using an NAH Air Handler please refer to the table in this section for charge amounts to be added. The “Factory Charge” column is the charge amount the compressor section/split is shipped with from the factory. The “Charge Amount with NAH Air Handler” column is the total amount of charge for the NAH Air Handler + Compressor section/split. This column does not factor in additional refrigerant needed for the line set. The installer of the system must add charge appropriately for the specific length of the line set. A 3/8 in. liquid line is calculated at 0.50 oz. of charge per linear foot, and a 1/2 in. liquid line is calculated at 1.0 oz. of charge per linear foot using R-410A refrigerant. The suction line will not hold “liquid” and should be ignored for the charge calculation. Superheat Adjustment TXVs are factory set to a specific superheat; however, the superheat should be adjusted for the application. To adjust the TXV to other superheat settings: 1. Remove the seal cap from the bottom of the valve. 2. Turn the adjustment screw clockwise to increase superheat and counterclockwise to decrease superheat. One complete 360° turn changes the superheat approximately 3-4°F, regardless of refrigerant type. You may need to allow as much as 30 minutes after the adjustment is made for the system to stabilize. 3. Once the proper superheat setting has been achieved, replace and tighten the seal cap. Example:NDS036/NAH036 with 20 ft. of 3/8 in. liquid line. Remember that when using the NAH Air Handler, the column “Charge Amount with NAH Air Handler” will be used. Now calculate for the additional 20 ft. ineset. Additional refrigerant to be added= (20 ft. x 0.5 oz.) = 10 oz. Solution: 10 oz. should be added to the recommended charge of 86 oz. found in the “Charge Amount with NAH Air Handler” column for a total charge of 96 oz. Warning: There are 8 total (360°) turns on the superheat adjustment stem from wide open to fully closed. When 25 NDS INSTALLATION MANUAL Refrigeration cont. adjusting the superheat stem clockwise (superheat increase) and the stop is reached, any further clockwise turning adjustment will damage the valve. Determining Subcooling 1. Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated. 2. Measure the liquid line pressure by attaching refrigerant gauges to the schrader connection on the liquid line service valve. 3. Convert the pressure obtained in Step 2 to the saturation temperature by using the Pressure Temperature Conversion Chart for R-410A. 4. Subtract the temperature in Step 1 from the temperature in Step 3. The difference will be the subcooling value for that unit. Refer to the Operating Parameters tables for subcooling ranges at specific enter water conditions. Line Set Sizes 20 feet 40 feet 60 feet Unit Size Air Handler Suction Liquid Suction Liquid Suction Liquid Factory Charge (oz.) 026 038 049 064 072 NAH026 NAH036 NAH048 NAH060 NAH060 5/8” OD 3/4” OD 3/4” OD 7/8” OD 7/8” OD 3/8” OD 3/8” OD 3/8” OD 1/2” OD 1/2” OD 3/4” OD 3/4” OD 7/8” OD 7/8” OD 7/8” OD 3/8” OD 3/8” OD 3/8” OD 1/2” OD 1/2” OD 3/4” OD 3/4” OD 7/8” OD 1-1/8” OD 1-1/8” OD 1/2” OD 1/2” OD 1/2” OD 1/2” OD 1/2” OD 52 56 90 92 104 NOTES: * The “Charge Amount with NAH Air Handler” column is based on the charge amount for an NAH Air Handler + Compressor Section Split. Additional charge will have to be added accordingly for line set length. After charge is added, adjustments can be made to get appropriate subcooling and superheat. Additional charge for R-410A is 0.50 oz. per ft. for 3/8 in. and 1.0 oz. per ft. for 1/2 in. tube. 26 *Charge Amount with NAH Air Handler (oz.) 74 86 115 112 132 4/16/10 NDS INSTALLATION MANUAL Pressure/Temperature Coversion Chart for R-410A PRESSURE (PSIG) 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 TEMP °F 8.5 9.9 11.2 12.5 13.8 15.1 16.3 17.5 18.7 19.8 21.0 22.1 23.2 24.3 25.4 26.5 27.5 28.6 29.6 30.6 31.6 32.6 33.5 34.5 35.4 36.4 37.3 38.2 39.1 40.0 40.9 41.7 42.6 43.4 44.3 45.1 45.9 46.7 47.5 48.3 49.1 49.9 50.7 51.5 52.2 53.0 53.7 54.5 55.2 55.9 56.6 57.4 58.1 58.8 59.5 60.2 60.8 61.5 62.2 62.9 PRESSURE (PSIG) 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 TEMP °F 63.5 64.2 64.8 65.5 66.1 66.8 67.4 68.0 68.7 69.3 69.9 70.5 71.1 71.7 72.3 72.9 73.5 74.1 74.7 75.3 75.8 76.4 77.0 77.5 78.1 78.7 79.2 79.8 80.3 80.9 81.4 81.9 82.5 83.0 83.5 84.1 84.6 85.1 85.6 86.1 86.6 87.1 87.7 88.2 88.7 89.2 89.6 90.1 90.6 91.1 91.6 92.1 92.6 93.0 93.5 94.0 94.5 94.9 95.4 95.8 PRESSURE (PSIG) 300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332 334 336 338 340 342 344 346 348 350 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 394 396 398 400 402 404 406 408 410 412 414 416 418 27 TEMP °F 96.3 96.8 97.2 97.7 98.1 98.6 99.0 99.5 99.9 100.4 100.8 101.2 101.7 102.1 102.5 103.0 103.4 103.8 104.2 104.7 105.1 105.5 105.9 106.3 106.7 107.2 107.6 108.0 108.4 108.8 109.2 109.6 110.0 110.4 110.8 111.2 111.6 112.0 112.3 112.7 113.1 113.5 113.9 114.3 114.7 115.0 115.4 115.8 116.2 116.5 116.9 117.3 117.6 118.0 118.4 118.7 119.1 119.5 119.8 120.2 PRESSURE (PSIG) 420 422 424 426 428 430 432 434 436 438 440 442 444 446 448 450 452 454 456 458 460 462 464 466 468 470 472 474 476 478 480 482 484 486 488 490 492 494 496 498 500 502 504 506 508 510 512 514 516 518 520 522 524 526 528 530 532 534 536 538 TEMP °F 120.6 120.9 121.3 121.6 122.0 122.3 122.7 123.0 123.4 123.7 124.1 124.4 124.8 125.1 125.4 125.8 126.1 126.5 126.8 127.1 127.5 127.8 128.1 128.5 128.8 129.1 129.4 129.8 130.1 130.4 130.7 131.1 131.4 131.7 132.0 132.3 132.7 133.0 133.3 133.6 133.9 134.2 134.5 134.9 135.2 135.5 135.8 136.1 136.4 136.7 137.0 137.3 137.6 137.9 138.2 138.5 138.8 139.1 139.4 139.7 PRESSURE (PSIG) 540 542 544 546 548 550 552 554 556 558 560 562 564 566 568 570 572 574 576 578 580 582 584 586 588 590 592 594 596 598 600 602 604 606 608 TEMP °F 140.0 140.3 140.6 140.9 141.2 141.4 141.7 142.0 142.3 142.6 142.9 143.2 143.5 143.7 144.0 144.3 144.6 144.9 145.1 145.4 145.7 146.0 146.2 146.5 146.8 147.1 147.3 147.6 147.9 148.2 148.4 148.7 149.0 149.2 149.5 NDS INSTALLATION MANUAL Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Desuperheater Entering Water Temp °F 50 70 90 Water Flow GPM/Ton 1.5 3.0 1.5 3.0 1.5 3.0 Suction Pressure PSIG 125-140 120-135 135-145 126-143 138-150 136-148 Discharge Pressure PSIG 205-225 190-210 260-290 230-250 315-345 300-330 Suction Pressure PSIG 76-89 80-93 105-120 110-125 135-155 140-160 Discharge Pressure PSIG 260-325 265-330 295-355 300-360 330-385 335-390 Suction Pressure PSIG 120-135 115-130 121-136 118-133 126-143 123-140 Discharge Pressure PSIG 215-235 200-220 270-305 255-285 325-360 310-340 Suction Pressure PSIG 72-81 76-85 100-115 105-120 133-147 138-152 Discharge Pressure PSIG 280-330 285-335 305-370 310-375 340-400 345-405 Superheat Subcooling 9-15 9-15 9-18 9-18 8-14 8-14 3-10 3-10 5-11 5-11 7-14 7-14 Water Temp Air Temp Rise °F Drop °F DB 17-21 8-12 16-20 9-13 14-20 8-12 17-23 17-23 17-23 17-23 17-23 17-23 Heating -- No Desuperheater Entering Water Temp °F 30 50 70 Water Flow GPM/Ton 1.5 3.0 1.5 3.0 1.5 3.0 Superheat Subcooling 7-12 7-12 7-14 7-14 9-14 9-14 4-16 4-16 4-16 4-16 7-15 7-15 Water Temp Air Temp Drop °F Rise °F DB 5-9 3-7 7-11 5-9 8-12 6-10 12-16 14-18 18-22 20-24 24-28 22-30 Second Stage Operation Cooling -- No Desuperheater Entering Water Temp °F 50 70 90 Water Flow GPM/Ton 1.5 3.0 1.5 3.0 1.5 3.0 Superheat Subcooling 10-16 10-16 9-15 9-15 8-14 8-14 3-11 3-11 5-12 5-12 7-15 7-15 Water Temp Air Temp Rise °F Drop °F DB 17-21 8-12 16-20 9-13 14-20 8-12 17-23 17-23 17-23 17-23 17-23 17-23 Heating -- No Desuperheater Entering Water Temp °F 30 50 70 Water Flow GPM/Ton 1.5 3.0 1.5 3.0 1.5 3.0 Superheat Subcooling 6-12 6-12 6-12 6-12 7-14 7-14 10-20 10-20 6-18 6-18 4-15 4-15 Note: Cooling performance based on entering air temperatures of 80º F DB, 67º F WB. Heating performance based on entering air temperature of 70º F DB. 28 Water Temp Air Temp Drop °F Rise °F DB 5-9 3-7 7-11 5-9 8-12 6-10 12-16 14-18 18-22 20-24 24-28 22-30 NDS INSTALLATION MANUAL Pressure Drop and Recommended Flow Rates Dual Capacity 110°F 0.7 1.3 2.2 3.6 1.1 2.3 3.9 5.8 0.8 1.6 2.6 4.8 0.6 1.7 3.3 5.4 0.8 1.7 3.0 5.1 1.8 2.9 4.3 7.2 2.2 3.3 4.4 7.3 5/30/06 Model 026 full load 026 part load 038 full load 038 part load 049 full load 049 part load 064 full load 064 part load 072 full load 072 part load GPM 4 6 8 10 3 5 7 9 5 7 9 11 4 6 8 10 6 9 12 15 5 8 11 14 8 12 16 20 6 10 14 18 12 15 18 21 10 13 16 19 30°F 1.4 2.8 4.7 7.0 0.8 2.0 3.6 5.8 1.2 2.2 3.4 4.9 0.9 1.7 2.8 4.2 1.2 2.4 3.9 5.7 0.9 2.0 3.4 5.0 1.8 3.8 6.5 9.7 1.0 2.6 5.0 8.1 3.2 4.5 6.0 7.8 2.3 3.6 5.0 6.5 Pressure Drop (psi) 50°F 70°F 90°F 1.3 1.2 1.1 2.6 2.4 2.3 4.4 4.1 3.8 6.6 6.2 5.8 0.7 0.7 0.7 1.8 1.7 1.6 3.4 3.2 3.0 5.5 5.1 4.8 1.2 1.1 1.0 2.1 1.9 1.8 3.2 3.0 2.8 4.6 4.3 4 0.8 0.8 0.7 1.6 1.5 1.4 2.6 2.5 2.3 3.9 3.7 3.4 1.2 1.1 1.0 2.2 2.1 2.0 3.6 3.4 3.2 5.3 5 4.7 0.9 0.8 0.8 1.8 1.7 1.6 3.1 2.9 2.8 4.7 4.4 4.1 1.7 1.6 1.4 3.5 3.3 3.0 6.0 5.6 5.2 9.1 8.5 8.0 0.9 0.9 0.8 2.5 2.3 2.1 4.7 4.4 4.1 7.6 7.1 6.6 3.0 2.8 2.6 4.2 4.0 3.7 5.7 5.3 4.9 7.3 6.8 6.4 2.1 2.0 1.9 3.3 3.0 2.8 4.6 4.3 4.0 6.2 5.8 5.4 110°F 1.0 2.1 3.5 5.3 0.6 1.5 2.8 4.4 1.0 1.7 2.6 3.7 0.7 1.3 2.1 3.2 1.0 1.8 2.9 4.3 0.7 1.5 2.5 3.8 1.3 2.8 4.8 7.4 0.8 2.0 3.8 6.1 2.4 3.4 4.6 5.9 1.7 2.6 3.7 5.0 5/30/06 29 NDS INSTALLATION MANUAL Unit Startup Before Powering Unit, Check The Following: Startup Steps 8. Decrease the cooling set point several degrees and verify high-speed blower operation. 9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate. 10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature. 11. First stage heating will energize after a time delay. 12. Check the temperature of both the supply and discharge water (see Operating Parameters tables). 13. Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the blower speed and entering water temperature. 14. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on. All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element. 15. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate. 16. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required. 17. Set system to desired normal operating mode and set temperature to maintain desired comfort level. 18. Instruct the owner/operator in the proper operation of the thermostat and system maintenance. Notes: Complete the Equipment Start-Up/Commissioning Check Sheet during this procedure. Refer to thermostat operating instructions and complete the startup procedure. Notes: Be certain to fill out and forward all warranty registration papers. • • • • • • • • • • • • • • • 1. 2. 3. 4. 5. 6. 7. High voltage is correct and matches nameplate. Fuses, breakers and wire size correct. Low voltage wiring complete. Piping completed and water system cleaned and flushed. Air is purged from closed loop system. Isolation valves are open, water control valves or loop pumps wired. Transformer switched to 208V if applicable. DIP switches are set correctly. DHW pump switch is “OFF” unless piping is completed and air has been purged. Blower rotates freely. Blower speed correct. Air filter/cleaner is clean and in position. Service/access panels are in place. Return air temperature is between 50-80ºF heating and 60-95ºF cooling. Check air coil cleanliness to ensure optimum performance. Clean as needed according to maintenance guidelines. To obtain maximum performance the air coil should be cleaned before startup. A 10-percent solution of dishwasher detergent and water is recommended for both sides of coil, a thorough water rinse should follow. Initiate a control signal to energize the blower motor. Check blower operation. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature. First stage cooling will energize after a time delay. Be sure that the compressor and water control valve or loop pump(s) are activated. Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T plugs and comparing to unit capacity data in specification catalog. Check the temperature of both the supply and discharge water (see Operating Parameters tables). Check for an air temperature drop of 15°F to 25°F across the air coil, depending on the blower speed and entering water temperature. Final Evaluation After the initial check of superheat/subcooling values in the heating mode, shut off the unit and allow it to sit 3 to 5 minutes until pressures equalize. Restart the unit in the cooling mode and check the values against those in the Operating Parameters tables. If the unit performs satisfactorily, charging is complete. If the unit does not perform to specifications, the charge may need to be readjusted until the values are close. Adding refrigerant will increase subcooling. Recovering some of the refrigerant will decrease subcooling and increase superheat. If the superheat/subcooling values are still not close to the specifications in the Operating Parameters tables, analyze refrigerant circuit operation. 30 NDS INSTALLATION MANUAL Unit Startup and Troubleshooting Heating Cycle Analysis Measure suction temperature here at TXV bulb in cooling modes. Measure suction temperature here at TXV bulb in heating modes. Volts ____ Suct PSI____ Amps ____ Suct sat temp____ Suct temp____ Super heat____ Lineset length Air Coil Suction Comp Bi-flow filter/drier ClgTXV HtgTXV COAX Discharge Hot Water Generator Discharge PSI____ COOLING TXV - ACTIVE RIGHT TO LEFT Measure liquid line temperature and pressure here in both heating and cooling modes Disch. sat temp____ EWT ____ Liquid temp____ LWT ____ Sub cooling____ HEATING TXV - ACTIVE LEFT TO RIGHT Note: DO NOT hook up pressure gauges unless there appears to be a performance problem. Cooling Cycle Analysis Measure suction temperature here at TXV bulb in cooling modes. Measure suction temperature here at TXV bulb in heating modes. Volts ____ Suct PSI ____ Amps ____ Suct sat temp ____ Suct temp ____ Super heat ____ Lineset length Air Coil Suction Comp ClgTXV Bi-flow filter/drier HtgTXV COAX Discharge Hot Water Generator Discharge PSI ____ COOLING TXV - ACTIVE RIGHT TO LEFT Measure liquid line temperature and pressure here in both heating and cooling modes EWT ____ LWT ____ Disch. sat temp ____ Liquid temp ____ Sub cooling ____ HEATING TXV-ACTIVE LEFT TO RIGHT 31 NDS INSTALLATION MANUAL Troubleshooting Standard Microprocessor Controls 4. If control responds improperly: • Ensure that component being controlled is functioning (compressor, blower, reversing valve, etc.). • Ensure that wiring from control to the component is functioning (refer to the LED Definition table below and use the diagnostic outputs mode). • If steps above check properly, replace unit control. To check the unit control board for proper operation: 1. Disconnect thermostat wires at the control board. 2. Jumper the desired test input (Y1, Y2, W, O or G) to the R terminal to simulate a thermostat signal. 3. If control functions properly: • Check for thermostat and field control wiring (use the diagnostic inputs mode). LED Definitions and Diagnostics Standard Microprocessor LED NORMAL DISPLAY MODE DIAGNOSTIC MODES CURRENT FAULT STATUS INPUTS OUTPUTS 1 OUTPUTS 2 Field Selection DIPS SW2- 1 On SW2- 1 Off SW2- 1 NA SW2- 1 NA SW2- 1 NA SW2- 6 On SW2- 6 On SW2- 6 Off SW2- 6 On SW2- 6 Off SW2- 7 On SW2- 7 On SW2- 7 On SW2- 7 Off SW2- 7 Off Drain Drain Pan Overflow Lockout Drain Pan Overflow Y1 Compressor (On or Low) Blower Low Water Flow FD Thermistor (Loop <15°F, Well<30°F) Lockout FD Thermistor (Loop <15°F, Well<30°F) Y2 Compressor (On or High) Blower Medium High Pressure >600 PSI Lockout High Pressure >600 O Reversing Valve Blower High Low Pressure <40/ Comfort Alert Low Pressure <40/ Comfort Alert G Blower Aux Heat 1 Status Microprocessor Malfunction Not Used SL1 Loop Pump 1 Aux Heat 3 DHW Limit HWL Thermistor >130°F HWL Thermistor >130°F Not Used Loop Pump 2 Aux Heat 4 DHW Off DHW Pump Switch Off DHW Pump Switch Off – – – High Pressure Low Pressure, Comfort Alert Refrigerant Systems Notes: Refrigerant tests must be made with hot water generator turned “OFF”. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit. To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in temperature on the air side as well as the water side to the Operating Parameters tables. If the unit’s performance is not within the ranges listed, and the airflow and water flow are known to be correct, gauges should then be installed and superheat and subcooling numbers calculated. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary. 32 NDS INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Condensate Drain 1. In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow. Keep all air out of the water. 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. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure. Blower Motors Blower motors on most air handlers are equipped with sealed ball bearings and require no periodic oiling. Notes: On open loop systems, if the installation is in an area with a known high mineral content (125 PPM or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. Generally, the more water flowing through the unit the less chance for scaling. Air Coil The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Care must be taken not to damage the aluminum fins while cleaning. CAUTION: Fin edges are sharp. Other Maintenance Filters Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a filter. Replacement Procedures Obtaining Parts In-Warranty Material Return When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required. Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance. 33 NDS INSTALLATION MANUAL Service Parts List Refrigeration Components Compressor Part Description 038 049 064 072 Compressor 34P585-01 34P573-01 34P574-01 34P575-01 34P586-01 Run Capacitor 16P002D19 16P002D20 Sound Jacket 11P781-01 Solenoid Harness 11P782-01 Accumulator 36P509-02 Coax 62I504B01 62I542B01 TXV 33P609-01 33P609-03 Reversing Valve 33P506-04 33P503-05 Hot Water Generator 62I543B01 33P609-05 33P609-06 33P526-04 36P500B01 36P500B02 62P516-05 62P516-03 Hot Water Generator Pump 24P501-02 Comfort Alert 19P571-02 13P004A03 Transformer Electrical 16P002D39 36P509-01 Contactor 15P501B01 3 Pole Power Block 12P503-06 2 Pole Screw Term. Block 12P500A01 Status Light Board 17P503-02 Harness, Status Light Board 11P783-01 Premier Board Sensors & Safeties 16P002D21 92P504A16 Power Harness Filter Dryer Hot Water Generator Dual Capacity Split Units 026 17P513-07 Freeze Detection Thermistor 12P505B03 HWL Thermistor 12P505B02 High Pressure Switch 35P506B02 Low Pressure Switch 35P506B01 Part numbers subject to change 6/8/10 34 Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com IM1004SN 06/10 Product: Type: Size: Document: Envision NDS Geothermal/Water Source Outdoor Split Heat Pump 2-6 Tons Dual Capacity Installation Manual ©2010 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.