In a Dutch oven, cook sausage and onion over medium heat 5-7 minutes or until sausage is no longer pink, breaking up sausage into crumbles; drain. Add beans, tomatoes, water, chilies, seasoning mix and sugar; bring to a boil. Reduce heat; simmer, covered, 20 minutes to allow flavors to blend, stirring frequently.
Top each serving with two halved round tortilla chips and one triangular tortilla chip inserted vertically into the chili between the round halves to resemble a witch's hat. Freeze option: Freeze cooled chili in freezer containers. To use, partially thaw in refrigerator overnight. Heat through in a saucepan, stirring occasionally and adding a little water if necessary.