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NXW REVERSIBLE CHILLER INSTALLATION MANUAL

Service Parts List

Part Description

096

108

120

208-

230/60/3

460/60/3

575/60/3

208-

230/60/3

460/60/3

575/60/3

208-

230/60/3

460/60/3

575/60/3

efriger

tion C

omponents

Compressor

34P613-03

34P613-04

34P613-05

34P616-03

34P616-04

34P616-05

34P569-03

34P569-04

34P569-05

Compressor Sound Jacket

92P519-02

92P504A03

Thermal Expansion Valve

33P608-18

33P608-10

33P608-16

TXV’s per circuit

Filter Dryer

36P500B02

Reversing Valve with Coil

33P526-04

Brazed Plate Heat Exchanger

62P562-01

Heat Exchanger Support Bracket

47C775-03

Saf

eties /

Sensors

High Pressure Switch

35P506B02

Low Pressure Switch

35P506B01

Water Temperature Sensor

12P529-01

Freeze Detection Sensor

12P529-01

Electrical

Compressor Contactor

13P537B03

Transformer

15P501B01

15P505B01

15P506B01

15P501B01

15P505B01

15P506B01

15P501B01

15P505B01

15P506B01

Power In Terminal Block

12P524A01

Connection Block - Small

12P503-06

Connection Block - Low Voltage

12P520-01

Grounding Lug

12P004A

Phase Guard Monitor

19P541A05

19P541A04

19P541A05

19P541A04

19P541A05

19P541A04

ontr

FX10 Main Board - no communications

17X51606-09

FX10 Main Board & N2 Open Com Card

17X51606-10

FX10 Main Board & Lonworks Com Card

17X51606-12

FX10 Main Board & BACnet Com Card

17X51606-11

FX10 Expansion Board

17P516-07

Display

19P563-01

FX10 Display Interface Board

17P516-11

Enclosur

Side Access Panel

40C792-10

Front Upper Access Panel

40C792-08

Lower Front Access Panel

40C792-09

Top Panel

40C792-05

Rear Left Panel

40C792-07

Rear Right Panel

40C792-06

04/10/09

Содержание NXW 096

Страница 1: ...llation Information Water Piping Connections Electrical Data Microprocessor Control Startup Procedures Preventive Maintenance NXW Reversible Chiller Installation Manual Commercial Reversible Chiller 60 Hz NXW 8 to 50 Tons ...

Страница 2: ......

Страница 3: ...s 16 18 Field Wiring and Control Setup 19 20 Control Features 21 22 Sequence of Operation 23 Inputs and Outputs Configuration 24 Networking Protocol 24 Unit Display and Interface 25 27 Reference Calculations 28 Legend 28 Unit Startup 28 Operating Parameters 29 Compressor Resistance 29 Pressure Drop 30 Heat of Extraction Rejection Data 31 Troubleshooting 32 Heating and Cooling Cycle Analysis 33 Sta...

Страница 4: ...0 3 Phase protection P Phase Guard Chassis E Enclosed F Open Frame 208 230 60 3 is not available on NXW540 Vintage A Current B 360 540 Non Standard Options SS Non Standard Future Use N Future Use Future Use N Future Use Controls 8 FX10 without communication with User Interface 9 FX10 w Open N2 Com Card w User Interface 0 FX10 w Lonworks Com Card with User Interface 3 FX10 w BacNet Com Card w User ...

Страница 5: ...ecessary to properly inspect unit Units in question should also be internally inspected If any damage is observed the carrier should make the proper notation on delivery receipt acknowledging the damage Units are to be stored in a location that provides adequate protection from dirt debris and moisture WARNING To avoid equipment damage do not leave the system filled in a building without heat duri...

Страница 6: ...applicable remove the compressor shipping brackets located at the base of each compressor To do so lift up the bottom of the compressor sound jacket and remove the two bolts that hold the bracket see Figure 3a Discard the brackets On NXW540 the hold down shipping bolts should then be removed and discarded Figure 3b Figure 3a Removing Shipping Brackets Remove wooden shipping skids CAUTION A minimum...

Страница 7: ...ical Dimensions Without Enclosure Dimensional Data for unit without enclosure Model A B C D E F G H J K 096 240 51 0 22 5 38 0 35 1 6 1 17 0 7 9 17 0 11 2 1 5 1295 572 965 891 155 432 202 432 285 38 360 63 2 22 5 50 0 42 0 6 4 17 0 13 9 17 0 11 3 1 5 1605 572 1270 1067 162 432 354 432 286 39 540 70 0 22 5 52 0 47 8 6 5 17 0 19 5 17 0 14 3 0 8 1778 572 1321 1215 166 432 495 432 362 20 All dimension...

Страница 8: ...S 360 SHOWN Physical Dimensions With Enclosure Dimensional Data for unit with enclosure Model A B C D E F G H 096 240 53 0 22 4 38 0 6 1 17 0 7 9 17 0 11 2 1347 568 965 154 432 202 432 285 360 64 2 23 9 50 0 6 4 17 0 13 9 17 0 11 8 1620 608 1270 162 432 354 432 301 540 71 0 23 9 52 4 6 5 17 0 19 5 17 0 14 9 1803 607 1330 166 432 495 432 378 All dimensions in inches mm All water connections are 2 V...

Страница 9: ...3 151 69 191 87 154 70 195 88 without enclosure Scroll 2 7 0 3 2 689 313 611 277 129 59 171 78 124 56 175 79 210 with enclosure Scroll 2 7 5 3 4 825 374 747 339 165 75 205 93 168 76 209 95 without enclosure Scroll 2 7 5 3 4 755 343 677 307 170 77 210 95 173 78 214 97 240 with enclosure Scroll 2 7 5 3 4 825 374 747 339 165 75 205 93 168 76 209 95 without enclosure Scroll 2 7 5 3 4 755 343 677 307 1...

Страница 10: ...g 2 Victaulic Grooved Nipples Figure 5 Chiller Back View NXW360 shown Water Connection Ports Out In In Out Brazed Plate Heat Exchanger Optional Connection Kit CKV160FL Includes four of each TKC16S 4 1 of 4 CAUTION Remove the plastic protective caps in the ends of each of the four water pipes on the heat exchangers prior to piping connection Failure to remove the caps will result in serious damage ...

Страница 11: ...ing of the water must be performed to ensure the water is free from damaging materials CAUTION Water piping exposed to outside temperature may be subject to freezing Open Loop Well Water Systems Installation of an open loop system is not recommended without using a secondary heat exchanger unless water quality guidelines are met Earth Coupled Systems All supply and return water piping should be in...

Страница 12: ...ss 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 Iron Fe2 Ferrous Bacterial Iron Potential 2 ppm 2 ppm 2 ppm Iron Oxide Less than 1 ppm Above this level deposition will occur Less than ...

Страница 13: ...sed precautions should be taken to protect the system from dirty water conditions Dirty water will result in system wide degradation of performance and solids may clog valves strainers flow regulators etc Additionally the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure In boiler tower application set the loop control panel set points to ...

Страница 14: ... 414 506 19 0 12 2 87 0 24 4 27 5 35 575 60 3 517 633 15 0 9 6 62 0 19 2 21 6 30 380 60 3 342 418 19 0 12 2 73 0 24 4 27 5 35 180 208 230 60 3 187 253 45 0 26 6 235 0 53 2 59 9 80 460 60 3 414 506 19 0 12 2 110 0 24 4 27 5 35 575 60 3 517 633 16 5 10 9 95 0 21 8 24 5 35 380 60 3 342 418 26 0 16 7 123 0 33 4 37 6 50 210 208 230 60 3 187 253 47 0 31 0 235 0 62 0 69 8 100 460 60 3 414 506 25 0 16 0 1...

Страница 15: ...or 230 Volt Switch If applicable Power Supply Field line voltage connection Phase Guard Compressor Contactor Lower Compressor Contactor Upper Compressor Current Sensors Field Low Voltage Connections FX10 Control Board FX10 Expansion Board User Interface Mounted here only on units without enclosure package ...

Страница 16: ... 51 Blue 51 Black 75A Black Org 75B Black Org 73B Black Org 74B CC B CC A Black 73A Black 74A Violet 67 Violet 66 Black White 63 Black White 62 Black White 62 2 3 1 PB2 Black 54 Red 55 Gray 56 Pink 58 Brown 57 Gray 59 14 6 7 16 9 8 17 14 5 18 13 4 1 3 12 10 11 2 T EST Brn Wht 86 Brn Wht 87 T LST Brn Blk 41 Brn Blk 42 Black Black CS A Circuit A Black Black CS B Circuit B Blue 45 Blue 45 Blue 46 Blu...

Страница 17: ...rown 52 Blue 51 Blue 51 Black 75A Black Org 75B Black Org 73B Black Org 74B CC B CC A Black 73A Black 74A Violet 67 Violet 66 Black White 63 Black White 62 Black White 62 2 3 1 PB2 Black 54 Red 55 Gray 56 Pink 58 Brown 57 Gray 59 14 6 7 16 9 8 17 14 5 18 13 4 1 3 12 10 11 2 T EST Brn Wht 86 Brn Wht 87 T LST Brn Blk 41 Brn Blk 42 Black Black CS A Circuit A Black Black CS B Circuit B Blue 45 Blue 45...

Страница 18: ... 52 Blue 51 Blue 51 Black 75A Black Org 75B Black Org 73B Black Org 74B CC B CC A Black 73A Black 74A Violet 67 Violet 66 Black White 63 Black White 62 Black White 62 2 3 1 PB2 Black 54 Red 55 Gray 56 Pink 58 Brown 57 Gray 59 14 6 7 16 9 8 17 14 5 18 13 4 1 3 12 10 11 2 T EST Brn Wht 86 Brn Wht 87 T LST Brn Blk 41 Brn Blk 42 Black Black CS A Circuit A Black Black CS B Circuit B Blue 45 Blue 45 Blu...

Страница 19: ...flow proving switch installed Load Flow Switch LFS Unit is factory shipped with no connections on Flow Switch pins J9 56 leaving If flow proving switch is required hook up as shown in Fig 10 and Note 4 The unit will not operate with out a flow proving switch installed ATTENTION Flow Switches must be installed before unit will operate Figure 10 Wiring Schematic SFS LFS ES Johnson FX 10 5VDC AI3 35 ...

Страница 20: ...tivation or OFF for deactivation Lead Lag Time Runtime in Hours Compressor Lead Lag Time is factory set 100 hours but can be set from 1 to 100 hours To change Lead Lag Time On FX10 control using the left and right arrow keys scroll to PASSWORD menu password 5667 Once you have entered the password scroll to MAINT menu Using up and down keys scroll to LEAD LAG TIME hit ENTER and LEAD LAG TIME begins...

Страница 21: ... cooling demand the unit will go into lockout mode turning off the compressor Control Features and enabling the alarm output until the controller is reset The fault count will automatically reset when the heating or cooling command becomes satisfied If a fault occurs on a dual compressor unit the other compressor will continue to operate based on the heating or cooling demand The lockout condition...

Страница 22: ...tinuous 5 seconds for a fault to occur After 3 faults in 60 minutes the control will put the unit into an alarm state Flow Proving Switch DI 1 and DI 10 The load and source flow proving switches are a field installed option These switches shall be normally open flow switches that will close when the water flow through the heat exchangers reach an acceptable level The flow proving switches must be ...

Страница 23: ... the reversing valves will be positioned for heating operation The thermostat or aquastat will command the reversing valves On for heating If the compressor short cycle time delay has been satisfied the lead compressor will turn on after the accessory output has been enabled the low pressure switches has been verified and the fixed compressor start delay timer has been satisfied When heating is no...

Страница 24: ...ion Select 30ºF DI 4 Future PWM1 Load Htg Freeze Detection Select 30ºF DI 5 Future PWM2 Stage 1 Low Pressure DI 6 Thermostat Y1 DI 7 Thermostat Y2 DI 8 Thermostat B DI 9 Source Flow Proving Switch D10 Stage 1 High Pressure DI11 Stage 2 High Pressure DI12 XP10 Expansion Card Input Name Input Output Name Output Entering Source Water Temperature AI 1 Unused DO 1 Leaving Source Water Temperature 1 AI ...

Страница 25: ...t in Test mode Figure 10 Unit Display Interface Escape Key Return Key Directional Keys LEDs MUI Menu Navigation for NXW Reversible Chiller Welcome Info Temp Stat Outputs Settings Alarm ALM_History Password Maint WFI Dual Stage Reversible Chiller PRODCWWE 06 MM DD YY Info Outputs Comp1 Status ON Comp2 Status OFF Lead Comp1 Acc1 Status OFF Stg1 Status Normal Stg2 Status Normal BO7 OFF BO8 OFF BO9 OF...

Страница 26: ... are reset by cycling power by pressing the ESC and Return keys simultaneously for a minimum of 15 seconds or by commanding the nviAlarmReset over the BAS network Test mode is enabled by holding the Esc and Down Arrow simultaneously for a minimum of 15 seconds and releasing Test mode times out after 30 minutes and may also be ended by pressing ESC and Up Arrow simultaneously and releasing Test Mod...

Страница 27: ... setpoint LD FP 1 Sensor Bad The sensor for Load freeze detection on compressor circuit 1 is unreliable or is not reading Source Flow Source Flow switch is not closed The source flow switch must be closed prior to either compressor starting and must remain closed for the entire run time of the compressor s Unit Display and Interface cont High Pressure 1 Compressor Circuit 1 High Pressure Switch If...

Страница 28: ...d ready or wires are jumpered Freeze detection setpoints have been set in the microprocessor WARNING Verify ALL water controls are open and allow water flow PRIOR to engaging the compressor Failure to do so can result in freezing the heat exchanger or water lines causing permanent damage to the unit Unit Startup Startup Steps Set thermostat control above cooling setpoint Set thermostat control in ...

Страница 29: ...7 11 50 110 135 385 400 12 14 7 11 70 135 165 400 415 14 18 3 7 120 50 110 135 485 500 12 14 7 11 70 135 165 500 515 14 18 3 7 1 15 10 Cooling Mode Entering Load Temp F Entering Source Temp F Suction Pressure psig Discharge Pressure psig Superheat F Subcooling F 50 30 80 90 140 175 15 20 3 6 50 90 100 200 235 11 15 6 9 70 100 110 250 285 11 15 9 12 90 100 120 330 365 8 12 12 14 110 110 130 430 465...

Страница 30: ...4 9 3 9 140 18 0 7 0 4 0 3 0 1 0 1 27 1 5 1 3 1 2 1 0 0 9 36 3 1 2 8 2 5 2 2 1 9 48 5 2 4 8 4 2 3 8 3 3 180 23 1 1 0 9 0 8 0 6 0 5 34 2 7 2 5 2 2 1 9 1 7 45 4 7 4 3 3 8 3 4 3 0 60 7 4 6 8 6 0 5 4 4 7 210 26 0 7 0 5 0 3 0 2 0 1 39 1 4 1 1 0 9 0 7 0 5 52 2 5 2 2 1 9 1 6 1 3 72 5 2 4 7 4 2 3 7 3 2 240 30 0 9 0 6 0 4 0 2 0 1 45 2 2 1 9 1 6 1 3 1 0 60 4 3 3 8 3 4 3 0 2 5 80 6 5 5 8 5 3 4 7 4 1 360 45 1...

Страница 31: ...182 1 na 173 8 216 4 259 1 na 110 not available 166 4 208 6 na na 180 45 45 30 136 0 116 3 96 6 na 226 0 279 5 333 1 386 6 50 172 8 152 0 131 3 110 5 216 7 270 8 324 9 379 0 70 209 6 187 8 166 0 144 1 207 5 262 1 316 8 na 90 246 5 223 6 200 7 na 198 3 253 4 308 6 na 110 not available 189 0 244 7 na na 210 52 52 30 151 1 131 2 111 4 na 286 7 345 6 404 5 463 5 50 207 1 183 9 160 7 137 5 274 0 333 8 ...

Страница 32: ...the S1 S2 wires If the resistance measures 2750 ohms then the internal compressor resistance has tripped the compressor protection module The compressor protection module will reset after a 30 minute delay and the resistance measures 2250 ohms Cycling the power off for a minimum of 3 seconds will manually reset the compressor module The internal compressor resistance must measure 2250 ohms for the...

Страница 33: ...e PSI Entering Load Water F Entering Load Water Pressure PSI Leaving Load Water F Leaving Load Water Pressure PSI Load Coax Suction Discharge Compressor RV Source Coax FD ______PSI ______SAT F ______ F ______PSI ______SAT F ______ F ______ F Liquid Line Load Coax Unit Amp Draw Line Voltage Loop Open Closed Subcooling Superheat NOTE Do not attach refrigerant gauges unless a problem is suspected Ent...

Страница 34: ...____ AMPS n ______ AMPS n ______ AMPS Watts m x n x 0 85 o _____ WATTS o ______ WATTS o ______ WATTS 6 CAPACITY Cooling Capacity HR o x 3 413 p _____ btu hr Heating Capacity HE o x 3 413 p _____ btu hr 7 EFFICIENCY Cooling EER p o q _____ EER Heating COP p o x 3 413 q _____ COP 8 SUPERHEAT S H SUBCOOLING S C COOLING HEATING HYDRONIC Suction Pressure r ______ PSI r ______ PSI r ______ PSI Suction S...

Страница 35: ...re is for scaling Low GPM flow rates produce higher temperatures through the heat exchanger To avoid excessive pressure drop and the possibility of metal erosion do not exceed GPM flow rate as shown on the specification sheets for each unit Preventive Maintenance Replacement Procedures When contacting the company for service or replacement parts refer to the model number and serial number of the u...

Страница 36: ...03 13P537B03 Transformer 15P501B01 15P505B01 15P506B01 15P501B01 15P505B01 15P506B01 15P501B01 15P505B01 15P506B01 Power In Terminal Block 12P524A01 12P524A01 12P524A01 Connection Block Small 12P503 06 12P503 06 12P503 06 Connection Block Low Voltage 12P520 01 12P520 01 12P520 01 Grounding Lug 12P004A 12P004A 12P004A Phase Guard Monitor 19P541A05 19P541A04 19P541A05 19P541A04 19P541A05 19P541A04 C...

Страница 37: ...37B03 Transformer 15P501B01 15P505B01 15P506B01 15P501B01 15P505B01 15P506B01 15P501B01 15P505B01 15P506B01 Power In Terminal Block 12P524A01 12P524A01 12P524A01 Connection Block Small 12P503 06 12P503 06 12P503 06 Connection Block Low Voltage 12P520 01 12P520 01 12P520 01 Grounding Lug 12P004A 12P004A 12P004A Phase Guard Monitor 19P541A05 19P541A04 19P541A05 19P541A04 19P541A05 19P541A04 Control ...

Страница 38: ...Transformer 15P501B01 15P505B01 15P506B01 15P501B01 15P505B01 15P506B01 15P505B01 15P506B01 Power In Terminal Block 12P524A01 12P524A01 12P524A01 Connection Block Small 12P503 06 12P503 06 12P503 06 Connection Block Low Voltage 12P520 01 12P520 01 12P520 01 Grounding Lug 12P004A 12P004A 12P004A Phase Guard Monitor 19P541A05 19P541A04 19P541A05 19P541A04 19P541A05 19P541A04 Control FX10 Main Board ...

Страница 39: ......

Страница 40: ...nace 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 Product Envision NXW Type Reversible Chiller 60 Hz Size 8 50 Tons Document Installation Manual 7 1002WN 02 10 ...

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