NorAire NC-FE series Installation & Operating Instructions Manual Download Page 5

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09/21/2011

NC208

NorAire

Configurator

NC-FE-060-1-CPXX1-20-US

NorAire Air to Water IDU (1)

Unit Type (2)

C = Heat and Cool

H = Heat Only*

Unit Style (3)

F = Hydronic, Large Floor Mount

Refrigerant (4)

E = R-410A

Nominal BTU (5, 6, 7)

036 (Hydronic) 3-ton

048 (Hydronic) 4-ton

060 (Hydronic) 5-ton

Country (16, 17)

US = United States

CA = Canada

Auxiliary kW Option (14, 15)

10 = 10 kW

15 = 15 kW

20 = 20 kW

XX = N/A*

Vintage (13)

1 = Electro

Miscellaneous Kit (12)

X = N/A

Domestic Water Option (11)

X = No domestic water

Configuration Option (10)

P = Factory Installed Pump

X = N/A

Heat Exchanger Option (9)

C = Copper

Voltage Option (8)

1 = 208/230V, 1 Ph

2 = 208/230V, 3 Ph*

*Non-stocked

N C - F E - 0 6 0 - 1 - C P X X 1 - 2 0 - U S

1 2 3 4 5 6 7 8 9 10 11 12

14 15 16 17

Model Number Digits

Summary of Contents for NC-FE series

Page 1: ...ries The distribution of this list is limited to the distributors or contractors involved in this program This update includes capability for buffer controller combination Notice If this IDU is installed with an ODU not shown on the approved list functional integrity performance support warranty and product liability does not apply Minimum Qualified Installer Since this is a split heat pump config...

Page 2: ...ating 7 Chilled Water Cooling 7 Water Fill Purge Procedure 9 Mechanical Installation Outdoor Unit ODU 14 Electrical Hookup Power Source 15 Outdoor Unit ODU 15 Control 15 Additional Hookup or Special Equipment Concerns 17 Field Setup or Programming 19 Operation Indicators 21 User Instructions 22 Control Sequence 23 Start Up Power On 27 Preventative Maintenance 29 Troubleshooting 30 Accessories 34 R...

Page 3: ...ompressor current decreases But compressor current increases with outlet supply water temperature increase Thus the closer the supply water temperature can be maintained to the true seasonal heating or cooling requirement the more efficient less operating cost the heat pump system will be Optional or add on devices such as Buffer Tank Controller with outdoor reset supply water temperature control ...

Page 4: ...Concealed or hidden damages not discovered until removing packaging must be reported to the carrier within 15 days of receipt Unit Location and Mounting Locate the unit in an indoor area where the ambient temperature will remain above 45 F __ C 8 C See next page for minimum clearance however allow enough room to remove panels for service and maintenance We suggest setting the unit on spacer so moi...

Page 5: ... Hydronic 5 ton Country 16 17 US United States CA Canada Auxiliary kW Option 14 15 10 10 kW 15 15 kW 20 20 kW XX N A Vintage 13 1 Electro Miscellaneous Kit 12 X N A Domestic Water Option 11 X No domestic water Configuration Option 10 P Factory Installed Pump X N A Heat Exchanger Option 9 C Copper Voltage Option 8 1 208 230V 1 Ph 2 208 230V 3 Ph Non stocked N C F E 0 6 0 1 C P X X 1 2 0 U S 1 2 3 4...

Page 6: ...t stated flow Ft of head 19 22 25 Line set sizing Follow outdoor unit manufacturer s specifications R 410A charged if packaged with factory ODU Feet 25 25 25 Max line set Feet 100 100 100 Max vertical separation Feet 35 35 35 IDU width Inches 20 20 20 IDU height Inches 48 48 48 IDU depth Inches 23 23 23 Shipping weight Pounds 191 197 205 Note Due to continuous product improvement specifications ar...

Page 7: ... with this the system design needs to incorporate proper temperature sensing control and water pipe distribution interface Both are key to efficient and satisfactory performance The NorAire unit includes a circulator pump which when plumbed correctly can supply the primary circulation for both heating and cooling However depending upon pressure drop in the external piping additional series circula...

Page 8: ...sibility and or liability associated with any needed installation of the gas oil furnace fuel system flue chimney etc Any instructions or comments made within this manual or factory phone assistance relating to the gas oil furnace are provided as comments of assistance and helps only CAUTION This unit shall not be operated either heating section or blower until the interior of the structure is com...

Page 9: ... pumps A few of these benefits include chilled water does not go through the boiler the internal pump can be a direct output to the forced air water coil often the forced air water coil is a zone from the buffer tank this inefficient and harder to control with the radiant floor zone either the hottest or the coldest water will always get to the forced air water coil without the buffer tank etc The...

Page 10: ...ctices hydronic design and plumbing must be used for proper flow and long term performance and reliability The key mechanical components include Expansion Tank as a closed loop hydronic heating system a minimal expansion tank is required This can be an air diaphragm tank or a basic empty tank where air is compressed at the tank top Inlet Temperature Gauge recommended to observe the operation of th...

Page 11: ... time and result in undesired troubleshooting conditions A basic small hydronic circulator will not self prime or pull water There must either be a column of water 3 to 4 feet high above the inlet of the pump or a source pressure system which is initially forcing water through the pump As little as a 1 to 3 air bubble within the inlet pipe can cavitate the pump and can stop circulation 3 If there ...

Page 12: ...sel heating water OUT through air separator supply manifold top drain b This first pass will involve all of the above piping thus the times mentioned in paragraph 5 above will not apply 7 You should begin seeing air bubbles coming out of the drain hose Reference paragraph 5 above run the refill city water until you are absolutely sure all air is purged 8 Move to the next floor loop by simultaneous...

Page 13: ...ig Using the still connected city water set correct pressure 18 Disconnect city water hose and drain hose and remove the pump jumper Purge or Recheck Defrost Boiler Bypass 1 Setup or source drain should be the same as above and in heating mode 2 This should actually be run before step 15 above 3 On the back of the NorAire control board upper right at the heat pump connection remove the D wire Be p...

Page 14: ...se bib close to valve D 3 Connect a city water or well water source as shown 4 All valves A and B or any possible flow associated with radiant manifold circuit must be closed 5 Close valve D and open valve C 6 Valve C can be a throttling valve to limit pressure 7 Begin adding source water drain should show bubbles or discharge water a Flow is through hydronic IN internal pump chilled water OUT wat...

Page 15: ...trolled by the added Buffer Tank Controller HP BTC 3 Connect a city water or well water source as shown This source connection can be anyplace forcing either into the bottom of the buffer tank or directly into IDU IN there may be a drain valve at the bottom of the buffer tank 4 All valves A and B Radiant Heat Procedure must be close but in this case open valve B which is associated with the manifo...

Page 16: ...ilter dryer internally installed in this case do not use a loose filter dryer Add in the liquid line preferably at this IDU Line set use ODU manufacturer s requirements for line set However since the IDU coax heat exchanger has a smaller charge volume than the typical forced air A coil matched with this ODU this IDU includes a refrigerant liquid receiver There probably is no need to calculate extr...

Page 17: ...ference drawing NH205 Aquastat stat this heat pump system is basically turned on off with a standard HVAC type R to W or R to Y Piping suggestion drawing HX103 has various aquastat or thermostat suggestions Sheet 2 could be a single 4 wire air stat Sheets 4 and 5 begin to become more complex option HP BTC is suggested For sheets 6 through 9 optional Buffer Tank Controller HP BTC is required Buffer...

Page 18: ...s the data information from each sensor and must be connected to the appropriate OT or ST screw The sensor has polarity is sensitive to incorrect voltage and must be protected from static voltage Do not cross connect or inadvertently short out sensor wires with power on Permanent sensor damage may result Utility interrupt this is marked blue and blue white leave jumper intact unless PC download se...

Page 19: ...es to forced air water coil heating configuration must be HX103 page 9 or 10 with HP BTC and N 3WVK 1 This option 3 way valve kit has installation wiring details Also see Start Up section Mode C Backup Configuration Mode B should be used strictly for the internal Electro Boiler All external backup should use mode C with the backup isolated contact K2 Mode C using gas furnace not gas boiler connect...

Page 20: ...ating the E tab input Pump Tab An external contact from R to pump tab forces internal pump relay on This will override any internal software sequence Special Arrangement Gas Furnace Backup with Buffer Tank Controller Option With a field installed added wire it is possible to use the gas furnace and Buffer Tank Controller mode C as an additional backup or standby option See Buffer Tank Controller i...

Page 21: ...point is boiler only Factory default is position 4 10 F 12 C SW1 OT Reference 13 SEER OT Reference 16 SEER 0 Disable Disable Warning Some ODU s have a built in ODT thermostat function within their control board If it is adjustable set to disable or less than 10 F 26 C Others are fixed Example Electro ODU is fixed at 5 F 15 C thus do not set on position 3 or smaller Factory default is position 4 10...

Page 22: ...05 16 2014 20 NI216 ...

Page 23: ...been restricted ALARM These conditions are more serious there are two tries and on the consecutive third the ODU compressor is shut down Hard Hold Depending upon the mode selection the system will automatically go to backup for continued heating There is no backup for cooling To prevent continuous use of the electric boiler troubleshooting or service should be initiated as soon as possible See Tro...

Page 24: ... winter freeze up but service and repair must be taken care of as soon as possible The front panel switch could be moved to the boiler position thus preventing this continual cycling and hunting without any result Setup Options The Field Setup or Programming section in this manual may also have user information and attention requirements The Additional Hookup or Special Equipment Concerns section ...

Page 25: ...output action at the Heat Pump terminal block INT the result of utility interrupt remote device However depends upon setup utility interrupt selection illustrated in Figure 5 SW OVER the above or below OT temperature as selected by the SW OVER dial switch Probably do not use positions 7 or 0 the front panel switch is more convenient If the OT temperature changes to affect a specific line item the ...

Page 26: ...s declared HP Y1 or ODU is off pump is on power on LED is slow pulsing and the W input now controls the internal electric boiler and backup K2 contact The backup boiler will continue until the stat W call is completed At this point the next stat W or Y call cancels the Hard Hold condition and the NorAire controller sequence again evaluates these inputs If it processes through to the next Hard Hold...

Page 27: ...ognize the second When the first goes low ACD is activated and completes its cycle At ACD end the stat W and Y are checked to determine which heat or cool mode should now become active The cool mode K4 is a latching function and remains as Y call cycles It is only released with the next W call again after ACD Cool mode disables any backup function Electro Boiler and K2 contact Defrost boost a spec...

Page 28: ...ckup INT blues Start End Off Y1 Y2 1 W MID 9 9 2 W MID 9 9 9 3 W MID 9 9 9 4 W MID 9 9 9 Stg 1 5 W MID 9 9 6 W 9 Open 7 W MID 9 9 Controls at 3 F 2 C below limit Controls at boiler target setup PC Open if PC setup HP or All Figure 4 Mode C external boiler plumbed at buffer tank STAT OT SW OVER MU1 MU2 Heat Pump K2 close backup INT blues Start End Off Y1 Y2 1 W MID 9 9 2 W MID 9 9 9 3 W MID 9 9 9 4...

Page 29: ...ownloaded which alters the temperature value used by the internal software sequences This is much easier than putting sensors in a bucket of ice etc to cool the sensor or its reported value In this case the offset in essence causes the sensor to report a different value As an example changing the OT temp allows a simulation of any of the sequences outlined in the control sequence section WARNING O...

Page 30: ...or conditions associated with the various zones coming out of the buffer tank are not critical for this start up b If a forced air water coil is piped directly to the chilled water out the system must be run in cooling long enough to stabilize the water temperature and air temperature outlet to make sure the water coil is large enough for the specific NorAire model capacity and there is adequate a...

Page 31: ...tem loop pressure the system must be maintained between 10 and 25 psig at all times Below 10 psi there is potential for the internal pump to cavitate and become blocked At 30 psig the safety relief could open Refrigerant liquid line filter dryer should only be replaced if there is a pump out or opening within the refrigeration system Suggest mandatory replacement whenever refrigerant system is ope...

Page 32: ...agraph must return default values Properly evaluate boiler staging OT disables Alt A history could be a valuable piece of information At the beginning of each ACD green power light blinking the reason for triggering ACD is written out on a pull down screen This will show the history of the last five ACD s the first is written over for a rotating list of five Hint testing the control board by itsel...

Page 33: ...the condition without consideration for W Y or Utility Interrupt inputs Also fast pulsing with the same power on pulsing means the mode switch is in D position which is not used SERVICE reference the factory default setup limits Low water flow is calculated 5 minutes after each new W IN It does not repeat but there is an initial cycle off and on with the service light indicating this condition ALA...

Page 34: ...his terminal block connection Selection Boiler or All refers to the internal Electro Boiler The backup relay contact K2 is not controlled by the utility interrupt It is assumed this is for a gas boiler If a mode C and backup contact it is an external Electro Boiler and utility interrupt is required the utility device must have its own contact at the Electro Boiler blue wire Low voltage fusing the ...

Page 35: ...Low Low Troubleshooting Guide for NorAire Cooling Head pressure Subcool Suction pressure Superheat Compressor Amp Draw Water temp differential Undercharged system Low Low Low High Low Low Overcharged system High High High Low High High Low water flow Low High Low Low Low High Low AH airflow Low High Low Low Low High Low return water temperature Low High Low Low Low Low High return water temperatur...

Page 36: ...ilter Dryer 5701 Single Feed Adapter for Two CB Square D EE 5051 Zone Pump Relay 24V Coil with Enclosure 6211 Flow Meter Vertical 1 2 16 GPM ET SOFT NA USB PC Program CD and NorAire Cable Chilled Water Coils R CWC 50U 21 Chill Water Coil Uncased 5 Ton 21 W x 22 D x 21 5 H R CWC 40U 21 Chill Water Coil Uncased 4 Ton 21 W x 22 D x 21 5 H R CWC 30U 18 Chill Water Coil Uncased 3 Ton 18 W x 21 D x 19 5...

Page 37: ...MMENDS PRESSURE SYSTEM SEE INSTALLATION MANUAL WARNING THESE ARE SUGGESTED AND CONCEPT DRAWINGS INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT ADDITIONAL COMPONENTS AND DETAILING REQUIRED BY LOCAL CODES SLAB STAT IDU ODU W 2 1 3 NORAIRE AIR TO WATER HEAT PUMP Heating only radiant floor One large zone Must size to match heat pump BTU h HX103 Rev 08 6 16 2014 Sheet 1 of 12 ...

Page 38: ...4 FOR COOLING ALL CHILLED WATER PIPING MUST BE INSULATED 5 SEE P 1 FOR RELIEF VALVE NORAIRE AIR TO WATER HEAT PUMP Add cooling forced air water coil see sheet 1 Must size to match heat pump BTU h Water coil not configured for heating water coil heating see sheets 9 10 HX103 Rev 08 6 16 2014 Sheet 2 of 12 SLAB STAT IDU ODU 4 2 1 AIR STAT W Y G 3 5 ...

Page 39: ...OR RELIEF VALVE TANK IDU HEATER ELECTRIC WATER 3 1 AQUASTAT W 2 ZONE STATS CONTROLLER ODU ZONE 4 NORAIRE AIR TO WATER HEAT PUMP Heating only Using standard electric water heater as the tank Suggest 35 000 BTUh maximum load capacity For larger systems must use sheet 6 type buffer tank HX103 Rev 08 6 16 2014 Sheet 3 of 12 ...

Page 40: ...cooling forced air water coil see sheet 3 Must size to match heat pump BTU h Water coil not configured for heating see sheets 9 10 Heating uses standard electric water heater as the tank Suggest 35 000 BTUh maximum load capacity For larger systems must use sheet 6 type buffer tank HX103 Rev 08 6 16 2014 Sheet 4 of 12 TANK IDU HEATER ELECTRIC WATER 5 1 AQUASTAT W 2 ZONE STATS CONTROLLER ODU ZONE 3 ...

Page 41: ...Y AQUASTAT COOL 4 ZONE CONTROLLER NOTE 4 SEE SHEET 12 ELECTRO HP BTC CAN REPLACE AQUASTAT 6 NORAIRE AIR TO WATER HEAT PUMP Heating Using standard electric water heater as the tank Suggest 35 000 BTUh maximum load capacity For larger systems must use sheet 6 type buffer tank Cooling 2nd tank pressure water coil air handler or furnace Must use stainless steel tank and insulate all piping Undersized ...

Page 42: ...UFFER TANK SYSTEM Heating larger tank flow and piping upgrade from sheets 3 4 Cannot use water coil for heating see sheet 9 10 Suggest using optional HP BTC see sheet 12 HP BTC can service 8 zones Cooling water coil must be larger or match heat pump BTU h See sheets 5 10 for undersized or multiple water coils HX103 Rev 08 6 16 2014 Sheet 6 of 12 LINE SET CONNECTIONS FROM OUTDOOR UNIT 3 1 TANK HP B...

Page 43: ...tuators 24V system Suggest HP BTC 24 See and read page 6 same application notes HX103 Rev 08 6 16 2014 Sheet 7 of 12 4 1 TANK HP BTC 24 IDU ODU 2 4 3 P0 IS CONTROLLED BY ZONE BOARD W OUT PUMP RELAY P0 NOTES 1 SEE PAGE 1 FOR RELIEF VALVE 2 FOR COOLING ALL CHILLED WATER PIPING MUST BE INSULATED 3 WHEN USING BTC MODE B THIS CAN BE A GAS FURNACE ...

Page 44: ...ing HP BTC controls tank auto switch over radiant heating to chilled water HP BTC locks out radiant zones during cooling HX103 Rev 08 6 16 2014 Sheet 8 of 12 LINE SET CONNECTIONS FROM OUTDOOR UNIT 4 4 4 COMPARE TO PAGE 6 FOR RETURN PIPING COIL SIZE IS IMPORTANT 1 TANK HP BTC IDU ODU 2 3 NOTES 1 SEE PAGE 1 FOR RELIEF VALVE 2 FOR COOLING ALL CHILLED WATER PIPING MUST BE INSULATED 3 WHEN USING BTC MO...

Page 45: ... BTU h 47 RATING B COIL BLOWER IS LARGER THAN ODU H MAX BTU h 47 RATING ALSO SEE SHEET 6 8 NORAIRE WITH OPTIONAL 3 WAY VALVE WATER COIL KIT Heat cool with forced air water coil heat radiant floor Add 3 way valve kit N 3WVK 1 and HP BTC required See sheet 12 HP BTC controls tank auto switch over heating to chilled water HP BTC locks out radiant zones during cooling HX103 Rev 08 6 16 2014 Sheet 9 of...

Page 46: ... FUEL Add gas boiler back up NorAire Mode C NI203 P 19 Using standard electric water heater or hydronic tank If water heater suggest 35 000 BTUh maximum load capacity For larger systems must use sheet 6 type buffer tank NorAire B U tab controls gas boiler R W After MU2 time out OT temperature below SW OVER setting HX103 Rev 08 6 16 2014 Sheet 10 of 12 5 6 7 1 4 AQUASTAT 3 W ODU IDU 2 TANK HEATER C...

Page 47: ...CTRIC SUPPLY F HOT 130 F NORAIRE AIR TO WATER HP BUFFER TANK AND WATER HEATER SYSTEM Heating larger tank flow and piping Cannot use forced air water coil for heating see sheet 9 10 Must use HP BTC also HP BTC can keep tank at 110 F For WH coil see sheet 12 HP BTC can service 8 zones Cooling water coil must match heat pump BTU h see sheet 9 See sheet 5 for undersized or multiple water coils HX103 R...

Page 48: ...OR 24V APPLICATIONS HP BTC 24 BT SENSOR FACTORY SET UP FOR 120V PUMPS IF ALL 240V PUMPS L2 CAN BE WIRED TO NEUTRAL BUT TRANSFORMER WIRE MUST BE CHANGED IF ZONE VALVES SHEET 7 FIELD CONVERT TO 24V OUTPUT 1 REMOVE ZONE BOARD BLACK AND WHITE WIRES FROM SOURCE T B 2 ADD 1 4 PUSH ON TO THESE WIRES AND CONNECT AT LOWER LEFT 24VAC AND C TABS 3 INSTALLER RESPONSIBILITY TO DETERMINE VA AND REPLACE IF USED ...

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Page 58: ...NR203 P1 Rev 04 07 21 2011 NORAIRE HEATING MODE WATER LOAD LOAD COIL COND TB3 3 TB3 2 IN AUX EL EB MS STh T7 T8 TB2 2 J6 TB2 3 TB3 3 6 TB2 2 W STc W RT BUFFER TANK BY PASS VALVE RELIEF VALVE 5453 ELECTRO INDUSTRIES INC MONTICELLO MN 55362 FIELD PROVIDED AND INSTALLED CHILLED WATER OUT P COLOR LEGEND BLUE WATER PIPING ORANGE LIQUID RED GAS VIOLET VAPOR PINK MIXED LIQUID GAS GREEN SENSORS FACTORY ON...

Page 59: ...DU ODU T 3 ORIFICE LO PRESS 500 PSIG LIMIT RECEIVER NR203 P2 Rev 04 07 21 2011 NORAIRE COOLING MODE WATER LOAD LOAD COIL COND TB3 3 TB3 2 IN T7 T8 TB2 2 J6 TB2 3 TB3 3 6 TB2 2 W STc W RT AIR HANDLER ELECTRO INDUSTRIES INC MONTICELLO MN 55362 P COLOR LEGEND BLUE WATER PIPING ORANGE LIQUID RED GAS VIOLET VAPOR PINK MIXED LIQUID GAS GREEN SENSORS FACTORY ONLY A COIL HEATING WATER OUT NOTES 1 LINE SET...

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Page 61: ...acement Labor Allowance Schedule for a period of ninety 90 days from the date of original purchase to the original owner at the original installation site The Repair Replacement Labor Allowance is designed to reduce the cost of repairs This Repair Replacement Labor Allowance may not cover the entire labor fee charged by your dealer contractor TWENTY YEAR 20 LIMITED WARRANTY ON BOILER ELEMENTS AND ...

Page 62: ...ubject to adjustment upon verification of defect 2 Any product or product part that has been damaged as a result of being improperly serviced or operated including but not limited to the following operated during construction phase with insufficient water or air flow allowed to freeze subjected to flood conditions subjected to improper voltages or power supplies operated with air flow or water con...

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