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Nortek R104HD Series, Installation Instructions Manual

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Nortek R104HD Series Installation Instructions Manual Download Page 27

27

MODEL

NUMBER

R104HD

UNIT

WEIGHT

SHIPPING

WEIGHT

CENTER OF GRAVITY

UNIT DIMENSIONS (INCHES)

A

B

HEIGHT WITH

BASE RAILS

HEIGHT WITHOUT

BASE RAILS

LENGTH

WIDTH

SINGLE PHASE 

MODELS

X24K060C

380

410

26.5

26.5

35

31.3

55.8

47.5

X30K060C

384

414

26.5

26.5

35

31.3

55.8

47.5

X36K080C

391

417

26.5

26.5

35

31.3

55.8

47.5

X42K080C

407

436

27.0

26.5

39

35.3

55.8

47.5

X48K096C

455

482

27.5

26.5

43

39.3

55.8

47.5

X60K096C

485

510

28.0

26.5

47

43.3

55.8

47.5

Table 7. Center of Gravity & Shipping Weights

47.50

ELECTRIC SUPPLY

ENTRY 

(1.25” DIA.)

LOW VOLTAGE

ENTRY 

(0.875” DIA.)

GAS

SUPPLY

ENTRY

14.82

25.65

28

2.03

2.03

BLOWER

ACCESS

 5.40 

CONDENSATE

DRAIN AND

VENT ASSEMBLY

(HORIZONTAL APPLICATION)

SIDE VIEW

 28 

 25.65 

 14.82 

 2.03 

 5.40 

 6.53 

 7.03 

 25.15 

 2.03 

 47.50 

GAS SUPPLY ENTRY

(1.625” DIA)

LOW VOLTAGE

ENTRY (0.875” DIA.)

ELECTRIC 

SUPPLY

ENTRY (1.25” DIA.)

VENT 

ASSEMBLY

(DOWNFLOW APPLICATION)

BLOWER 
ACCESS

SIDE VIEW

Figure 8. Continued

Summary of Contents for R104HD Series

Page 1: ...s supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Nepasentreposerniutiliserdel essencenid autres vapeursouliquidesinflammablesdanslevoisinage de cet appareil ni de tout autre appareil QUE FAIRE SI UNE ODEUR DE GAZ EST DÉTECTÉE Ne mettre en marche aucun appareil Ne toucher aucun interrupteur électrique ne pas u...

Page 2: ...gle Stage Operation 23 De Humidification Control 23 Fan Mode 23 COMPONENT FUNCTIONS 23 EQUIPMENT MAINTENANCE 24 Heat Exchanger Burner Maintenance 24 Cleaning of Burners 25 REPLACEMENT PARTS 25 TROUBLESHOOTING 25 Cooling Mode 25 Heating Mode 25 FIGURES TABLES 26 Figure 8 Unit Dimensions 26 Table 7 Center of Gravity Shipping Weights 27 Airflow Information 28 Table 8 Cooling Airflow Settings 28 Table...

Page 3: ...tion maintenance or repair may expose you to fiberglass insulation Breathing this material may cause respiratory irritations Fiberglass insulation may also cause eye irritation skin sensitization or other allergic responses in susceptible individuals Always wear goggles disposable gloves long sleeved shirt and appropriate breathing protection when working near this insulation If contact with skin ...

Page 4: ...10 page 29 Table 11 page 30 Table 12 page 31 Table 13 page 32 and the rating plate for the proper circulating air flow and temperature rise It is important that the duct system be designed to provide the correct flow rates and external pressure rise An improperly designed duct system can result in nuisance shutdowns and comfort or noise issues Use only with the type of gas approved for this unit R...

Page 5: ... Please consult your dealer for maintenance information and availability of maintenance contracts Please read all instructions before installing the unit Locating the Equipment Select a solid level position preferably on a concrete slab slightly above the grade level and parallel to the home DO NOT PLACE UNIT UNDER THE HOME Overhead obstructions poorly ventilated areas and areas subject to accumul...

Page 6: ...pas suivies pour chacun des appareils raccordés au système de ventilation au moment de sa mise en marche cela peut entraîner une intoxication au monoxyde de carbone ou la mort Les étapes suivantes doivent être suivies pour chacun des appareils raccordés au système de ventilation au moment de sa mise en marche alors que tous les autres appareils raccordés au système de ventilation ne sont pas en ma...

Page 7: ...e icing salts or chemicals Water softening chemicals Vent Termination This unit has been developed for use with a combination heat exchanger condensate drain and venting system designed to operate only with this type of system CondensateDrainandVentKitsareavailableforpurchase as accessory items HorizontalgroundmountapplicationscanuseP N 922323 toattachthe13 25 x2 PVCpipewithinthecontrolareaof this...

Page 8: ...nternal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts The vent termination must be located at least 3 feet above any forced air inlet located within 10 feet The vent termination must be located at least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building The unit should be installed in a w...

Page 9: ...clearanceforunobstructedairflowthroughthe outdoor coil must also be maintained in order to achieve rated performance For information about locating the equipment see page 5 Ground Level Ground level installations must be located according to localbuildingcodesorordinancesandtheserequirements Clearances must be in accordance with those shown in Figure 1 page 5 A suitable mounting pad must be provid...

Page 10: ...e 47 for additional lifting and setting of unit requirements Horizontal to Downflow Conversion The unit is shipped ready for horizontal duct connections Ifdownflowductsarerequired theunitmustbeconverted following the steps below for both the supply and return ducts 1 Remove both horizontal duct caps 2 Locatetheductcapinsidetheductopeningsandremove the screw holding it in place 3 Lift the cap out o...

Page 11: ... 1 to 2 Filter Conversion section below Horizontal installations require the air filter system be installed in the return air ductwork Installing Filters in the Internal Filter Rack If Equipped 1 Remove access panel screws from return air panel Hint Loosen the unit s top panel screws near the top edge of the access panel The access panel was designed to be captured underneath the top panel 2 Slide...

Page 12: ... ampacity and maximum overcurrent protection limits A wiring diagram is located on the inside cover of the control access panel of the outdoor unit The installer should become familiar with the wiring diagram before making any electrical connections to the outdoor unit See Figure 13 page 37 All 208 240 volt units are shipped from the factory wired for 240 volt transformer operation For 208V operat...

Page 13: ...to anticipate the space heating rate and time the burner to shutoff accordingly Always refer to the thermostatmanufacturer sinstructionsforcorrectsettings Addthecurrentdrawofthesystemheatingcomponents OR Measure the current flow on the thermostat R W circuit afterthecirculatingblowermotorhasstarted Settheheat anticipator according to the thermostat manufacturer s instructions for heat anticipator ...

Page 14: ...ify the selected rise is within the specification shown on the furnace rating label or in the tables Dehumidification Options The fixed speed motor control board has a DEHUM connection that allows the system to increase the amount of humidity that is removed from the circulating air This is accomplished by reducing the CFM and allowing the coolingcoiltobecomecolder Thisfunctionisonlyavailable when...

Page 15: ...y or gas supplier for additional requirements regarding placement of the manual main gas shut off See Figure 6 page 16 Themanifoldpressuremustbesettotheappropriate value for your installation To measure and adjust the manifold pressure see page 19 Gas piping must never run in or through air ducts chimneys gas vents or elevator shafts Compounds used to seal joints on gas piping must be resistant to...

Page 16: ...hangingtheorifices SeeTable 3 for the correct manifold pressure settings NOTE Ifinstallingthisunitabove2 000feet theinputrate must be reduced 4 per 1 000 feet of altitude Example 12 at 3 000 feet 16 at 4 000 feet etc Deration is necessary to compensate for low atmospheric pressure at high altitudes LP Propane Gas Conversion WARNING This unit was equipped at the factory for use with natural gas onl...

Page 17: ...ld run continuously Check the air delivery at the supply registers and adjust register openings for balanced air distribution Examine ductwork for leaks or obstruction if insufficient air is detected Set the thermostat fan mode to AUTO The blower should stop running NOTE When FAN ON is selected the blower will operate at 50 of selected airflow when no call for heating or cooling is present Lightin...

Page 18: ...ctory recommended setting see in Table 8 page 28 Table 9 page 28 Table 10 page 29 Table 11 page 30 Table 12 page 31 Table 13 page 32 If the measured temperature rise falls outside the specified range it may be necessary to change the blower speed Lowering the blower speed increases the temperature rise and a higher speed decreases the temperature rise The unit is equipped with an ECM type motors S...

Page 19: ...crewdriverorAllenwrench whereappropriate slowly turn the adjustment screw till the appropriate manifold pressure listed in Table 3 or Table 4 or the LOW and or HIGH firing rate for your specific gas HHV is achieved NOTE Turning the screw clockwise increases the pressure turning the screw counter clockwise decreases the pressure To prevent the screw from backing all the way out from the valve turn ...

Page 20: ...C 10 0 4 5 3 5 96 000 91 200 62 400 59 300 45 40 70 170 0 80 57 000 11 x 10 1 Table 3 Manifold Pressure Setting in WC Orifice Sizes for Natural Gas MANIFOLD PRESSURE IN W C FOR NATURAL GAS INSTALLATIONS ALTITUDE ABOVE SEA LEVEL HEATING VALUE BTU CU FT ORIFICE SIZE 800 TO 899 FT 900 TO 999 FT 1 000 TO 1 100 FT Zero to 1 999 Ft 3 5 3 5 3 5 45 2 000 to 2 999 Ft 3 2 3 2 3 2 45 3 000 to 3 999 Ft 2 9 2 ...

Page 21: ...l and or service this equipment Failure to comply with this warning couldresultinpropertydamage personalinjury or death CAUTION This unit uses R 410A refrigerant DO NOT use any other refrigerant in this unit Use of another refrigerant will damage the unit 1 Set the thermostat s system mode to COOL and the fan mode to AUTO Gradually lower the thermostat temperature setpoint below room temperature a...

Page 22: ...on failure occurs the warm up interval is increased by 3 seconds on the next try If successful it remains there Minimum and maximum warm up time limits are set at 9 and 54 seconds 7 Flame Proving Ignition Low Heat Operation The furnace control must prove flame via the flame sensor 5 seconds after the high main gas valve is energized If flame is sensed burners are on and the igniter cools off The Y...

Page 23: ...nd fan 4 When the thermostat is satisfied the contactor and integratedcontrolde energize Compressorandoutdoor fan will stop running 5 The circulating blower motor de energizes after a 60 second delay De Humidification Control If installing a humidistat install it in the return air duct as directed in the installation instructions included in the accessory kit Run the humidistat wiring through the ...

Page 24: ...ason or more frequently if required Inspecttheevaporatorcondensatedrainandoutdoorcoil at the beginning of each cooling season Remove any debris Clean the outdoor coil and louvers as necessary using a mild detergent and water Rinse thoroughly with water Inspect the electrical connections for tightness at the beginning of each heating and cooling season The blower compartment should be cleaned month...

Page 25: ...Fan Motor Inducer Blower Motor COMPONENTS Blower Assembly Fan Grille Burner Manifold Filter Driers Burners Orifices Gaskets Cabinet Panels Heat Exchanger Expansion Valves Table 5 Furnace Control Board Fault Conditions DIAGNOSTIC DESCRIPTION GREEN LED RED LED Control Fault No Power Off Off L1 Neutral Polarity Fault Flash Flash 1 Hour Lockout Alternating Flash Normal Operation On On Pressure Switch ...

Page 26: ...ZONTAL SUPPLY DUCT OPENING HORIZONTAL RETURN DUCT OPENING 4 0 1 75 9 75 24 75 CONDENSING COIL C 30 89 13 5 16 0 13 5 16 0 4 0 4 0 13 5 16 0 13 5 55 8 12 45 9 75 24 75 1 75 8 75 12 45 17 50 C 16 0 HORIZONTAL SUPPLY DUCT OPENING HORIZONTAL RETURN DUCT OPENING FILTER ACCESS 3 PHASE ONLY CONDENSING COIL BACK VIEW Downflow Application Shown BACK VIEW Horizontal Application Shown TOP VIEW Horizontal App...

Page 27: ...5 8 47 5 X48K096C 455 482 27 5 26 5 43 39 3 55 8 47 5 X60K096C 485 510 28 0 26 5 47 43 3 55 8 47 5 Table 7 Center of Gravity Shipping Weights 47 50 ELECTRIC SUPPLY ENTRY 1 25 DIA LOW VOLTAGE ENTRY 0 875 DIA GAS SUPPLY ENTRY 14 82 25 65 28 2 03 2 03 BLOWER ACCESS 5 40 CONDENSATE DRAIN AND VENT ASSEMBLY HORIZONTAL APPLICATION SIDE VIEW 28 25 65 14 82 2 03 5 40 6 53 7 03 25 15 2 03 47 50 GAS SUPPLY E...

Page 28: ...M RISE CFM RISE 1 2 3 4 CFM RISE CFM RISE 0 0 0 0 600 57 800 66 0 0 0 0 885 55 1180 64 1 0 0 0 656 52 875 60 1 0 0 0 938 52 1250 61 0 1 0 0 694 49 925 57 0 1 0 0 990 49 1320 58 1 1 0 0 750 46 1000 53 1 1 0 0 1035 47 1380 55 0 0 1 0 806 43 1075 49 0 0 1 0 1080 45 1440 53 1 0 1 0 844 41 1125 47 1 0 1 0 1125 43 1500 51 0 1 1 0 881 39 1175 45 0 1 1 0 1170 42 1560 49 1 1 1 0 919 37 1225 43 1 1 1 0 1208...

Page 29: ...0 0 70 0 80 0 90 1 00 1 2 3 4 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE 0 0 0 0 783 67 740 71 696 76 645 82 594 89 554 95 514 103 472 112 429 123 1 0 0 0 851 62 808 65 765 69 719 73 672 79 631 84 590 90 549 96 509 104 0 1 0 0 919 57 877 60 834 63 792 67 750 70 708 75 665 79 627 84 588 90 1 1 0 0 994 53 953 55 913 58 871 61 830 64 785 67 741 71 702 75 664 79 0...

Page 30: ...0 0 80 0 90 1 00 1 2 3 4 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE 0 0 0 0 1218 58 1175 60 1132 62 1097 64 1062 66 1024 69 986 71 950 74 914 77 1 0 0 0 1270 55 1230 57 1191 59 1153 61 1116 63 1079 65 1043 67 1005 70 966 73 0 1 0 0 1321 53 1285 55 1249 56 1209 58 1169 60 1135 62 1100 64 1059 66 1018 69 1 1 0 0 1373 51 1335 53 1298 54 1260 56 1222 58 1185 59 11...

Page 31: ...ETTINGS 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 1 2 3 4 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE 0 0 0 0 1308 55 1252 57 1196 60 1139 63 1082 66 1025 70 967 74 915 78 863 83 1 0 0 0 1363 52 1309 54 1255 57 1199 59 1143 62 1088 66 1033 69 979 73 926 77 0 1 0 0 1417 50 1366 52 1314 54 1259 57 1203 59 1151 62 1098 65 1043 68 988 72 1 1 0 0 1470 49 1418 50 ...

Page 32: ... 0 60 0 70 0 80 0 90 1 00 1 2 3 4 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE 0 0 0 0 1308 67 1252 70 1196 74 1139 77 1082 81 1025 86 967 91 915 96 863 102 1 0 0 0 1363 65 1309 67 1255 70 1199 73 1143 77 1088 81 1033 85 979 90 926 95 0 1 0 0 1417 62 1366 64 1314 67 1259 70 1203 73 1151 76 1098 80 1043 84 988 89 1 1 0 0 1470 60 1418 62 1366 64 1315 67 1265 70 12...

Page 33: ...BIC FEET PER REVOLUTION OF GAS METER 1 5 10 10 360 1 800 3 600 12 300 1 500 3 000 14 257 1 286 2 571 16 225 1 125 2 250 18 200 1 000 2 000 20 180 900 1 800 22 164 818 1 636 24 150 750 1 500 26 138 692 1 385 28 129 643 1 286 30 120 600 1 200 32 113 563 1 125 34 106 529 1 059 36 100 500 1 000 38 95 474 947 40 90 450 900 42 86 429 857 44 82 409 818 46 78 391 783 48 75 375 750 50 72 360 720 52 69 346 ...

Page 34: ... compagnie du gaz en utili sant le téléphone d un voisin A défaut de la compagnie du gaz avertir le service des pompiers C Enfoncer ou faire tourner le robinet à gaz à la main seulement Ne jamais utiliser d outils S il n est pas possible de faire tourner ou d enfoncer le robinet à la main ne pas essayer de le réparer Faire appel à un spécialiste Forcer ou tenter de réparer le robinet pourrait être...

Page 35: ... 253 19 9 110 1 5 7 0 33 3 50 Low 52 000 X48K096C High 96 000 0 30 208 230 1 60 187 253 21 8 117 1 5 7 0 35 7 50 Low 62 400 X60K096C High 96 000 0 30 208 230 1 60 187 253 26 9 171 1 5 7 0 42 1 60 Low 62 400 NOTES LRA Locked Rotor Amps RLA Rated Load Amps Electrical Data COPPER WIRE SIZE AWG 1 VOLTAGE DROP SUPPLY WIRE LENGTH FEET SUPPLY CIRCUIT AMPACITY 200 150 100 50 6 8 10 14 15 4 6 8 12 20 4 6 8...

Page 36: ... AUTO STAGE BLOWER OFF DELAY THERMOSTAT CONNECTIONS NEUTRALS FLAME 3 AMP FUSE INPUTS ON Figure 12 Ignition Control Board 624817 Figure 10 Two Stage Heating Single Stage Cooling Configuration TERMINAL STRIP THERMOSTAT R G C W2 W1 RED YELLOW GREEN BLACK Optional WHITE C R W1 G Y2 Y1 Y1 Y2 W2 BROWN A1 O E NOT USED NOT USED Blower Auto or Continuous ON 24VAC Common 1ST Stage Heat 24VAC To Blower Contr...

Page 37: ... Yellow LED Continuous Flash Control Fault No Power Off Off Normal Operation On On Motor Fault On Flash Communications Fault Flash Flash Blower Control Diagnostic Description Green LED Red LED 10414180 NEW 2 22 Y2 E O Y1 G C A1 W1 W2 R COM 230 24V 208 IGNITOR FLAME SENSOR 2 STAGE GAS VALVE HIGH TEMP LIMIT FLAME ROLL OUT LIMIT INDUCER LIMIT HIGH PRESSURE SWITCH 11 4 1 8 7 10 5 2 9 3 12 6 LINE N XMF...

Page 38: ...emove refrigerant when above curve Add refrigerant when below curve Figure 14 Charging Chart for 2 Ton Units 260 280 300 320 340 360 380 400 420 440 460 480 500 80 85 90 95 100 105 110 115 120 Liquid Temperature F Liquid Pressure psig 2 5 TON CHARGING CHART Remove refrigerant when above curve Add refrigerant when below curve Figure 15 Charging Chart for 2 5 Ton Units ...

Page 39: ...rant when below curve Remove refrigerant when above curve 220 240 Figure 16 Charging Chart for 3 Ton Units 280 300 320 340 360 380 400 420 440 460 480 500 80 85 90 95 100 105 110 115 120 Liquid Temperature F Liquid Pressure psig 3 5 TON CHARGING CHART 520 Remove refrigerant when above curve Add refrigerant when below curve 125 130 Figure 17 Charging Chart for 3 5 Ton Units ...

Page 40: ...nt when above curve Add refrigerant when below curve Figure 18 Charging Chart for 4 Ton Units 260 280 300 320 340 360 380 400 420 440 460 480 500 90 95 100 105 110 115 120 125 130 Liquid Temperature F Liquid Pressure psig 5 TON CHARGING CHART 70 75 80 85 220 240 Remove refrigerant when above curve Add refrigerant when below curve 520 Figure 19 Charging Chart for 5 Ton Units ...

Page 41: ...41 1 Inch Filter Installations 2 Inch Filter Installations Figure 20 Filter Comversion Internal Filter Conversion ...

Page 42: ...e Depth for unit on standard 2 concrete pad NOTE For a trench style drain installation page 3 you will also need 4 x36 min corrugated flexible pipe w drain holes a 2 x4 PVC reducer 4 corrugated piping connection 2 x90 degree PVC elbow and 4 filtration sleeve or permeable barrier material Not Shown 40 80 Lb Rock or chat Limestone rock or lime pellets if required by local code for neutralizing the c...

Page 43: ... by code with the initial rock base 2 Measure the distance between the top of the rock base and bottom of drain fitting 3 Cut the field supplied 2 PVC pipe to the measured length 4 Cutthedrainhoseandinsulationtothemeasuredlength less 3 so the drain cannot become blocked 5 Connect vinyl drain tube to the barbed drain connection at bottom of 2 PVC Tee and secure with spring hose clamp 6 Install flex...

Page 44: ...ng hose clamp 8 Install flexible insulation over the entire length of drain tube and cut away any excess then secure at the top with wire tie provided 9 Cement the 2 PVC pipe into the elbow reducer assembly 10 Work the drain hose assembly into the pipe until the entire length is inside and the PVC pipe is vertical 11 Glue or use two 1 2 long screws field supplied to secure the 2 PVC Tee to the uni...

Page 45: ...ND CONDENSATE DISPOSAL USING A VERTICAL DRAIN PIT Figure 21 Condensate Disposal Using A Vertical Drainage Pit BACK FILL ROCK ROCK BASE GRADE LEVEL PAD GRADE LEVEL SLAB MOUNT FLUE GAS AND CONDENSATE DISPOSAL USING A HORIZONTAL DRAIN TRENCH Figure 22 Condensate Disposal Using A Horizontal Drainage Trench ...

Page 46: ...urb and 1 2 in from the long side of curb See Figure 23 If drilling a hole is not an option routing the condensate drainhoseovertotheductpassageopeningwithenough slope is acceptable as long as drain line is secured to curb and duct ensuring no kinks or traps can form betweenthecollectorboxdrainorinteriorofthebuilding Leave a minimum of 24 drain line extending out the top of roof curb front close o...

Page 47: ...ition of the condensate drain valve be changed from the horizontal H to downflow D position The condensate drain valve is located in the bottom left corner of the heat exchanger collector box to the left of the inducer motor See Figure 24 Carefully rotate the valve 90 degrees in a clockwise direction until the arrow is pointing vertically downward 1 Slide the rubber grommet large diameter first do...

Page 48: ... Degree Elbow 1 4 Mesh Screen 1 2 ID x 84 Drain Hose Flexible Insulation Optional Condensate Drain Valve D Position for Downflow Applications Only To building drain per State and Local Codes J Trap Height 3 Min DRAIN TRAP REQUIRED INTERIOR OF BUILDING Figure 24 Condensate Disposal ...

Page 49: ...49 ...

Page 50: ...50 ...

Page 51: ...51 ...

Page 52: ...ES NO SINGLE PHASE UNITS Rated Voltage VOLTS L1 L2 Volts VOLTS VENTING SYSTEM Is the heat exchanger condensate drain and vent pipe installed YES NO Is pipe free of restrictions YES NO Filter s secured in place YES NO Filter s clean YES NO ATTENTION INSTALLERS It is your responsibility to know this product better than your customer This includes being able to install the product according to strict...

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