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Envision R-410A Residential Installation Manual

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RESIDENTIAL
Geothermal/Water Source Heat Pumps
• R-410A Refrigerant
• 2, 2.5, 3, 3.5, 4, 5, 6 Ton Single Speed
• 2, 3, 4, 5, 6 Ton Dual Capacity
Installation Information
Water Piping Connections
Desuperheater Connections
Electrical
Startup Procedures
Troubleshooting
Preventive Maintenance
IM1585 12/08

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Summary of Contents for Envision R-410A

  • Page 1 RESIDENTIAL Geothermal/Water Source Heat Pumps • R-410A Refrigerant • 2, 2.5, 3, 3.5, 4, 5, 6 Ton Single Speed • 2, 3, 4, 5, 6 Ton Dual Capacity Installation Information Water Piping Connections Desuperheater Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance IM1585 12/08...

  • Page 2: Model Nomenclature

    ENVISION RESIDENTIAL INSTALLATION MANUAL Model Nomenclature Model Type Return Air Configuration Envision Left Right Compressor Type Discharge Air Configuration Dual Capacity Bottom Single Speed Side Cabinet Configuration Vertical Horizontal Coax Options Copper Unit Capacity Cupronickel Vintage Fan Option Current Voltage...

  • Page 3: Table Of Contents

    ENVISION RESIDENTIAL INSTALLATION MANUAL Table of Contents General Installation Information Closed Loop Ground Source Systems Open Loop Ground Water Systems Desuperheater Connection & Startup 11-12 Electrical Connections 13-14 Electronic Thermostat Installation Auxiliary Heat Ratings Unit Electrical Data Fan Performance Table...

  • Page 4: General Installation Information

    ENVISION RESIDENTIAL INSTALLATION MANUAL General Installation Information Safety Considerations Before performing service or maintenance operations on a system, turn off main WARNING: power switches to the indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury.

  • Page 5: Installing Horizontal Units

    ENVISION RESIDENTIAL INSTALLATION MANUAL Installing Horizontal Units Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket prior to setting the unit in place. Horizontal units are available with side or end discharge. Horizontal units are normally sus- pended from a ceiling by six 3/8-inch diameter threaded rods. The rods are usually attached to the unit by hanger bracket...

  • Page 6: Duct System

    ENVISION RESIDENTIAL INSTALLATION MANUAL Duct System An air outlet collar is provided on vertical top air discharge units and all horizontal units to facilitate a duct connection (vertical bottomflow units have no collar). A flexible connector is recommended for discharge and return air duct connec- tions on metal duct systems. Uninsulated duct should be insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected.

  • Page 7: Water Quality

    ENVISION RESIDENTIAL INSTALLATION MANUAL Water Quality In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be pres- ent, 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...

  • Page 8: Freeze Protection

    ENVISION RESIDENTIAL INSTALLATION MANUAL Freeze Protection Set the freeze sensing switch SW2-2 on the printed circuit board for applications using a closed loop antifreeze solution to “LOOP”. On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to “WELL”, the factory default setting. (Refer to the Dip Switch Field Selection table on page 24.) Condensate Drain On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a 3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical upflow units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary.

  • Page 9: Closed Loop Ground Source Systems

    ENVISION RESIDENTIAL INSTALLATION MANUAL Closed Loop Ground Source Systems Note: For closed loop systems with antifreeze protection, set SW2-2 to the “loop” position (see table on page 28). Once piping is completed between the unit, pumps and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a 1.5 HP pump minimum) is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the sys- tem adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 PSI (summer) or 50-75 PSI (winter). This is normally adequate for good system operation. Loop static pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when initially charging the system.

  • Page 10: Open Loop Ground Water Systems

    ENVISION RESIDENTIAL INSTALLATION MANUAL Open Loop Ground Water Systems Typical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Insure proper water flow through the unit by checking pressure drop across the heat...
  • Page 11 (loop or well). Allowing the desuperheater pump to operate during these conditions actually removes heat from the DHW circulating through the unit. To overcome this, Envision unit microprocessors have been programmed to disengage the desuperheater pump during such conditions. (During low capacity cooling operation, the pump will operate only if the DHW temperature entering the unit is less than the liquid line temperature plus 35º F. During high capacity cooling...

  • Page 12: Desuperheater Connection & Startup

    ENVISION RESIDENTIAL INSTALLATION MANUAL Plumbing Installation 1. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the desuperheater circulator will occur. 2. Remove drain valve and fitting. 3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into the water heater drain port. 4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple. 5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit. 6. Install the drain valve on the tee opposite the adaptor. 7. Run interconnecting tubing from the tee to DHW water out. 8. Cut the cold water “IN” line going to the water heater. 9. Insert the reducing solder tee in line with cold water “IN” line as shown. 10. Run interconnecting copper tubing between the unit DHW water “IN” and the tee (1/2-inch nominal). The recommended maximum distance is 50 feet. 11. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines. 12. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation. Note: All plumbing and piping connections must comply with local plumbing codes Desuperheater Startup 1. Close the drain valve to the water heater.

  • Page 13: Electrical Connections

    ENVISION RESIDENTIAL INSTALLATION MANUAL Electrical Connections General Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

  • Page 14: Electronic Thermostat Installation

    ENVISION RESIDENTIAL INSTALLATION MANUAL Electrical Connections (cont.) Pump Wiring Figure 14: Pump Wiring 208-230/60/1 See Figure 14 for electrical connections from control box to pumps. Electronic Thermostat Position the thermostat subbase against the wall so that it is level and the Figure 15: Thermostat Wiring thermostat wires protrude through the middle of the subbase.

  • Page 15: Unit Electrical Data

    ENVISION RESIDENTIAL INSTALLATION MANUAL Unit Electrical Data Single speed with ECM motor Total Compressor Rated Voltage Model Pump Loop Motor Unit Circ Fuse/ Voltage MIN/MAX HACR 14.0 48.0 18.8 21.0 20.0 12.8 58.3 22.6 25.8 22.0 14.1 73.0 23.9 27.4 036* 22.0...

  • Page 16: Fan Performance Table

    ENVISION RESIDENTIAL INSTALLATION MANUAL Fan Performance Data - PSC Standard PSC Motor Motor Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Model Size 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.00...
  • Page 17 ENVISION RESIDENTIAL INSTALLATION MANUAL Fan Performance Data - ECM ECM2 Single Speed AIR FLOW DIP SWITCH SETTINGS MODEL 1000 1100 1200 0.50 1000 1100 1200 0.50 1000 1100 1200 1300 1400 1500 0.50 1000 1100 1300 1500 1600 1800 0.75...

  • Page 18: Vertical Dimensional Data

    ENVISION RESIDENTIAL INSTALLATION MANUAL Vertical Dimensional Data Top Air Discharge ENVISION DIMENSIONAL DATA V1-V4 LEFT RETURN RIGHT RETURN 1.9in [4.8cm] 1.9in [4.8cm] K J I D E H F FRONT 2ft [61cm] Primary Service Access RIGHT SIDE LEFT SIDE Water Connections...

  • Page 19: Horizontal Dimensional Data

    ENVISION RESIDENTIAL INSTALLATION MANUAL Horizontal Dimensional Data TOP VIEW 2.1in [5.4cm] MOUNT (2) HANGER BRACKETS AS SHOWN TO ALLOW ACCESS TO FILTER 2ft [61cm] Primary Service Access FRONT VIEW SIDE DISHCARGE VIEW END VIEW 1.9in [4.8cm] D E F K J I AS SHOWN LR UNIT (RR UNIT ON OPPOSITE SIDE—SAME DIMENSIONS)

  • Page 20: Vertical Bottomflow Dimensional Data

    ENVISION RESIDENTIAL INSTALLATION MANUAL Vertical Dimensional Data Bottomflow LEFT RETURN RIGHT RETURN 1.70 (4.3 cm) LEFT SIDE RIGHT SIDE 1.90 (4.7 cm) FRONT 2ft [61cm] Primary Service Access LEFT BOTTOM DISCHARGE RIGHT BOTTOM DISCHARGE FLOOR FOOT PRINT FLOOR FOOT PRINT...

  • Page 21: Physical Data

    ENVISION RESIDENTIAL INSTALLATION MANUAL Physical Data (Single Speed) SINGLE SPEED Model Compressor (1 each) Copeland Scroll Factory Charge R410a, oz [kg] Vertical 62 [1.76] 62 [1.76] 82 [2.32] 82 [2.32] 98 [2.78] 110 [3.12] 146 [4.14] Factory Charge R410a, oz [kg] Horizontal 60 [1.70]...

  • Page 22: Physical Data

    1 - 20 x 20 1 - 20 x 20 1 - 20 x 25 1 - 20 x 25 ENVISION RESIDENTIAL INSTALLATION MANUAL Filter Standard - 2" [51mm] Pleated 1 - 18 x 32 1 - 18 x 32...

  • Page 23: Wiring Schematics

    ENVISION RESIDENTIAL INSTALLATION MANUAL Wiring Schematics Envision - Single Speed Wiring Schematic - 208-230/60/1 - PSC 240V 240V Fused Fused Fused Fused Fused 240V 240V 240V F1-10A Status...
  • Page 24 ENVISION RESIDENTIAL INSTALLATION MANUAL Wiring Schematics Envision - Single Speed Wiring Schematic - 208-230/60/1 Envision - Single Speed Wiring Schematic - 208-230/60/1 - ECM Blue Black Ext Pump Comfort Alert 1/2 hp Total Unit Power 208-230/60/1 208-230/60/1 Pump Pump Capacitor...
  • Page 25 97P774-01 6/29/06 ENVISION RESIDENTIAL INSTALLATION MANUAL With optional ' EA' Series Auxiliary Electric Heat Power Auxiliary ElectricHeat 208-230/60/1 Typical schematic shown NOTE 5 Pink Pink Violet Gray Gray Pink Gray Gray Gray Gray ECM2 Fan Motor Pink Pink Pink Black...
  • Page 26 ENVISION RESIDENTIAL INSTALLATION MANUAL Wiring Schematics Envision - Dual Capacity Wiring Schematic - 208-230/60/1 Envision - Dual Capacity Wiring Schematic - 208-230/60/1- ECM Blue Black Ext Pump DC SOL Comfort Alert 1/2 hp Total Unit Power 208-230/60/1 208-230/60/1 Pump Pump...
  • Page 27 97P774-02 6/29/06 ENVISION RESIDENTIAL INSTALLATION MANUAL With optional ' EA' Series Auxiliary Electric Heat Power Auxiliary ElectricHeat 208-230/60/1 Typical schematic shown NOTE 5 Pink Pink Violet Gray Gray Pink Gray Gray Gray Gray ECM2 Fan Motor Pink Pink Pink Black...

  • Page 28: Microprocessor Control

    LED at the thermostat. The “fault retry” feature is every 5 minutes. designed to prevent nuisance service calls. 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 on page 24.)

  • Page 29: Cooling Operation

    ENVISION RESIDENTIAL INSTALLATION MANUAL Microprocessor Control (cont.) Heat, 3rd Stage (Y1,Y2,W) Dual Capacity Units Lockout Conditions The hot water pump is de-energized which directs all heat During lockout mode, the appropriate unit and thermostat to satisfy the thermostat. The 1st stage of resistance heat is lockout LEDs will illuminate. The compressor, loop pump, hot energized 10 seconds after “W” input, and with continuous 3rd...
  • Page 30 ENVISION RESIDENTIAL INSTALLATION MANUAL Microprocessor Control (cont.) Compressor Monitoring/Comfort Alert 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 (sys- tem pressure), 4 (locked rotor), 6 (open start circuit), and 7 (open run circuit) will result in a lockout. All other fault codes are 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.
  • Page 31 ENVISION RESIDENTIAL INSTALLATION MANUAL Microprocessor Control (cont.) Thermostat Displays Fault Flash When using a TA32W01 or TP32W02 thermostat and SW2-8 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. 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 thermostat can be configured to show either lockout text or lockout codes. 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. The following tables show the codes that will be displayed on the different ComforTalk and FaultFlash thermostats.

  • Page 32: Microprocessor Control

    ENVISION RESIDENTIAL INSTALLATION MANUAL Microprocessor Control (cont.) DIP Switch Settings Prior to powering unit, ensure that all DIP switches on SW2 & SW3 are set properly according to the tables below. FACTORY SETUP DIP SWITCHES (SW3) SWITCH DESCRIPTION OFF POSITION ON POSITION NUMBER Dual Capacity/Single-Speed Dual Capacity Opera- SW 3- Single-Speed Operation Configures the control for single-speed compressor operation or dual capacity opera- tion tion. Zoned/Finish on Second Stage Finish on 2nd - Unzoned Dual...

  • Page 33: Unit Startup

    ENVISION RESIDENTIAL INSTALLATION MANUAL Unit Startup Before Powering Unit, Check The Following Note: Remove and discard the two compressor hold down shipping bolts located at the front and rear of the compressor mounting bracket. The bolts can then be discarded.

  • Page 34: Operation Logic

    ENVISION RESIDENTIAL INSTALLATION MANUAL Operation Logic Data HEATING COOLING OPERATION LOGIC FAN ON SL1 - IN ON STG1 STG2 STG3 EMERG STG1 STG2 SINGLE SPEED UNITS Compressor High High High High ECM2 Normal High High High 85% Med 85% High ECM2 Dehumidify...

  • Page 35: Unit Operating Parameters

    ENVISION RESIDENTIAL INSTALLATION MANUAL Unit Operating Parameters Single Speed Models Cooling -- No Desuperheater Entering Water Water Flow Suction Discharge 022-070 022-070 Water Temp Air Temp Drop Temp °F GPM/Ton Pressure Pressure Superheat Subcooling Rise °F °F DB PSIG PSIG...
  • Page 36 ENVISION RESIDENTIAL INSTALLATION MANUAL Unit Operating Parameters Dual Capacity Models FIRST STAGE OPERATION Cooling -- No Desuperheater Entering Water Water Flow Suction Discharge Water Temp Air Temp Drop Temp °F GPM/Ton Pressure PSIG Pressure PSIG Superheat Subcooling Rise °F °F DB...

  • Page 37: Pressure Drop & Recommended Flow Rates

    ENVISION RESIDENTIAL INSTALLATION MANUAL Pressure Drop Single Speed Models Dual Capacity Models Pressure Drop (psi) Pressure Drop (psi) Model Model 30°F 50°F 70°F 90°F 110°F 30°F 50°F 70°F 90°F 110°F 026 full load 10.0 026 part load 10.0 038 full load 12.0...

  • Page 38: Troubleshooting

    ENVISION RESIDENTIAL INSTALLATION MANUAL Troubleshooting Standard Microprocessor Controls 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). 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. LED Definitions and Diagnostics...

  • Page 39: Preventive Maintenance

    ENVISION RESIDENTIAL INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance 1. 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. Note: 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.
  • Page 40 Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com Envision Residential Product: Type: Geothermal/Water Source Heat Pumps Size: 2-6 Ton Single Speed 2-6 Ton Dual Capacity Document: Installation Manual I M 1 5 8 5 1 2 /0 8 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794.

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