Nordyne R4GD 024K045, R4GD 030K072, R4GD 024K072, R4GD 030K045, R4GD 036K072 Installation Instructions Manual
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High Efficiency
Installation Instructions
Single Package Gas Heating/Electric Cooling
WARNING:
!
Improper installation, adjustment, alteration, service, or maintenance can
cause injury or property
damage. Refer to this manual. For assistance or additional information consult a
qualified installer, service
agency, or the gas supplier.
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this
appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all
instructions carefully before starting the installation.
FOR YOUR SAFETY
Do not store or use gasoline
or other flammable vapors
and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any
• Do not touch any electrical
• Immediately call your gas
• If you cannot reach your gas
• Extinguish any open flame.
FOR YOUR SAFETY
appliance.
switch; do not use any phone
in your building.
supplier from a neighbor's
phone. Follow the gas
supplier's instructions.
supplier, call the fire
department.
2
TABLE OF CONTENTS
GENERAL SPECIFICATIONS ..................................... 4
SAFETY CONSIDERATIONS...................................... 4
• Literature, Labels, and Tags..................................4
• Pressures Within The System .............................. 4
INSTALLATION REQUIREMENTS .............................. 4
• Equipment Application .......................................... 4
• Equipment Check ................................................. 4
• Requirements and Codes...................................... 4
• Unit Location......................................................... 4
• Venting Requirements........................................... 4
• Unit Dimensions ................................................ 5-6
• Clearances to Combustible Materials.................... 7
• Thermostat ........................................................... 7
• Air Filter Requirements ......................................... 7
• Condensate Drain ................................................. 9
UNIT INSTALLATION .................................................. 9
• Ground Level ........................................................ 9
• Rigging and Hoisting ............................................. 9
• Rooftop ................................................................. 9
AIR SUPPLY FOR COMBUSTION
AND VENTILATION .............................................. 10
CIRCULATING AIR SUPPLY ..................................... 10
• Airflow Data ........................................................ 11
• Unconditioned Spaces ........................................ 12
• Acoustical Ductwork ........................................... 12
• Horizontal to Down Flow Conversion ................... 12
GAS SUPPLY AND PIPING ...................................... 12
• Leak Check ........................................................ 13
GAS AND HIGH ALTITUDE CONVERSIONS ............ 13
• High Altitude Application ..................................... 13
• Natural Gas High Altitude Conversion ................. 13
• LP/Propane Gas Conversion............................... 13
ELECTRICAL WIRING............................................... 14
• General ............................................................... 14
• Line Voltage........................................................ 14
• Electrical Data Table .......................................... 15
• Blower Speed ..................................................... 15
• Room Thermostat ............................................... 16
SYSTEM CHECK ..................................................... 16
• Pre-Start Check List .......................................... 16
WIRING DIAGRAMS ................................................ 18
START-UP PROCEDURE......................................... 16
• Air Circulation .................................................... 16
• Short Cycle Protection ....................................... 19
• System Cooling ................................................. 19
• System Heating ................................................. 19
• Verifying and Adjusting Firing Rate .................... 19
• Verifying and Adjusting Temperature Rise ......... 19
• Lighting/Operating Instructions .......................... 20
• Verifying Burner Operation ................................. 21
• Verifying Operation of Over-Temperature
Limit Control ................................................... 21
COMPONENT FUNCTIONS ..................................... 21
• Flame Sensor .................................................... 21
• Flame Roll-Out Control....................................... 21
• Gas Valve.......................................................... 21
• Pressure Switch ................................................ 21
• Over-Temperature Limit Control ......................... 21
UNIT MAINTENANCE............................................... 21
• Refrigerant Charging .......................................... 22
• Routine Maintenance ......................................... 22
• Air Filter............................................................. 22
• Vent Cover Assembly ........................................ 22
• Condensate Drain and Outdoor Coil ................... 22
• Electrical ........................................................... 23
• Motor Lubrication ............................................... 23
• Blower Compartment ......................................... 23
• Heat Exchanger and Burner Maintenance .......... 23
• Cleaning of Heat Exchanger............................... 23
• Cleaning of Burners ........................................... 24
OPERATING SEQUENCE ........................................ 24
• Cooling Mode..................................................... 24
• Blower Mode ...................................................... 24
• Heating Mode .................................................... 24
• Unit Fails to Operate.......................................... 2 5
INSTALLATION CHECKLIST................................... 26
3
GENERAL SPECIFICATIONS
!
!
Single Package Gas Heating/Electric Cooling units are
designed for outdoor rooftop or ground level slab installations.
The units are shipped ready for horizontal duct connections
and are easily converted for down flow connections.
All models are shipped from the factory with the following:
1. Multispeed fixed torque variable speed blower.
2. Horizontal or down flow duct connections.
3. 24V fuse protection.
The unit dimensions are shown in Figure 1.
SAFETY CONSIDERATIONS
It is the responsibility of the installer to ensure that the
installation is made in accordance with all applicable local
and national codes.
WARNING:
Improper installation, service, adjustment, or
maintenance may cause explosion, fire, electrical
shock or other hazardous conditions which may
result in personal injury or property damage.
Unless otherwise noted in these instructions,
only factory authorized kits or accessories may
be used with this product.
Equipment Check — All units have been securely packaged
at the point of shipment. After unpacking the unit, carefully
inspect it for apparent and concealed damage. Claims for
damage should be filed with the carrier by the consignee.
Requirements and Codes — The installer must comply
with all local codes and regulations which govern this type
equipment. Local codes and regulations take precedence
over any recommendations contained in these instructions.
In the absence of local codes, the installation must
conform with the National Fuel Gas Code (ANSI 2223.1,
NFPA-54), or Canadian installations must conform with
CAN/CGA-B149 installation codes. All electrical wiring
must be made in accordance with codes and regulations
and with the National Electric Code (ANSI/NFPA 70) or in
Canada the Canadian Electric Code Part 1 CSA C.22.1. Air
Ducts must be installed in accordance with the standards
of the National Fire Protection Association “Standards for
Installation of Air Conditioning and Ventilation Systems”
(NFPA 90A), “Standard for Installation of Residence Type
Warm Air Heating and Air Conditioning Systems” (NFPA
90B), these instructions, and all applicable local codes.
The National Fuel Gas Code is available by writing:
American National Standards Institute, Inc.
1430 Broadway
New York, NY 10018
NFPA publications are available by writing:
National Fire Protection Association
Batterymarch Park
Quincy, ME 02269
Literature, Labels, and Tags — When working with this
equipment, follow all precautions in the literature, on tags,
and on labels provided with the unit and/or approved field
installed kits. The type of hazard and severity are described
on each label or tag.
Pressures Within The System — This equipment contains
liquid and gaseous refrigerant under high pressure.
Installation or servicing should only be performed by
qualified trained personnel thoroughly familiar with this type
equipment.
INSTALLATION REQUIREMENTS
Equipment Application — Before beginning the installation,
verify that the unit model is correct for the job. The unit
model number is printed on the data label. This furnace is
NOT to be used for temporary heating of buildings or
structures under construction.
4
Unit Location — The gas/electric unit is designed only for
outdoor installations. Choosing the location of the unit
should be based on minimizing the length of the supply and
return ducts. Consideration should also be given to
availability of fuel, electric power, service access, noise,
and shade.
Venting Requirements — This unit has been equipped
with an integral venting system and designed to operate
only with this venting system. No additional venting shall
be used. This unit must be vented to the outdoors.
WARNING:
Do not vent furnace through a conventional
venting system.
3
.0
.0
DIMENSIONS
1.0
24.6
1.8
16.6
2.9
Electric
Supply Entry
Low V oltage Entry
Gas Supply
Entry
47.5
4
Side View
1.75
Horizontal
Supply Duct
Opening
C
16.0
16.0
8.75
13.5
12.45
9.75 24.75
12.45
Horizontal
Return Duct
Opening
16.0
13.5
55.8
4.0
Condensing
Coil
4
Back View
5
4
5
DIMENSIONS-Continued
Center of Gravity
Height (in inches)
C
R4GD
Shipping
To Electrical
Opening
5.7
B
13.3
Downflow
Supply Duct
Opening
12.0
13.5
24.9
A
16.0
23.5
CG
13.5
16.0
Downflow
Return Duct
Opening
Inside
Perimeter
of Base Rail
2.63"
12.0
47.
Top View
Model
Number
Unit
Weight
Weight A B
with base rails without base rails
024K045† 425 435 26.5 26.5 39.0 35.3
024K072† 435 445 26.0 26.5 39.0 35.3
030K045† 430 440 26.5 26.5 39.0 35.3
030K072† 440 450 26.0 26.5 39.0 35.3
036K072† 470 480 26.5 26.5 39.0 35.3
036K096† 485 495 26.0 26.5 39.0 35.3
042K072† 500 510 27.0 26.5 39.0 35.3
042K096† 515 525 27.0 26.5 39.0 35.3
048K096† 540 550 27.5 26.5 43.0 39.3
048K120† 555 565 27.5 26.5 43.0 39.3
060K096† 560 570 27.5 26.5 43.0 39.3
060K120† 575 585 27.5 26.5 43.0 39.3
† Denotes either "C" or "X"
6
A vent cover assembly has been supplied with the unit. It
!
!
can be found secured to the gas controls within the control
area of this unit. Figure 2 shows the proper installation of
the vent cover assembly over the vent outlet on the exterior
of the corner panel. The fasteners used to secure the vent
cover assembly have been included in the homeowner's
package.
WARNING:
The vent cover assembly must be installed to
assure proper operation of the unit.
Corner Panel
of Unit
Exhaust Duct
Opening
Vent Cover
Assembly
Fastener
Figure 2. Vent Assembly
The following list is a summary of the requirements for the
location of the termination of the venting system:
1. The location of the vent termination must be consistent
with the National Fuel Gas Code (ANSI Z223.1) or CAN/
CGA-B149 Installation Codes.
2. The vent termination must be located at least four (4)
feet horizontally from any electric meters, gas meters,
regulators, and relief equipment.
3. The vent termination must be located at least three (3) feet
above any forced air inlet located within ten (10) feet.
4. The vent termination must be located at least four (4) feet
below, four (4) feet horizontally from, or one (1) foot above any
door, window, or gravity air inlet into any building.
5. The vent termination must be located at least one (1)
foot above grade.
6. The unit should be installed in such a manner as to
prevent snow accumulation from obstructing the vent
termination.
7. The unit installation shall avoid areas where condensate
drainage may cause problems by dropping on planters
or patios, etc. Furthermore, ensure that the exhaust
gases will not impinge on windows or building surfaces,
which may be compromised or damaged by
condensation. Do not install the unit such that exhaust
from the vent termination is directed into window wells,
stairwells, under decks, or in alcoves or similarly
recessed areas. The vent termination must not be
located above any public walkways.
Clearances to Combustible Materials — See Table 2 for
required clearances to combustible materials. Refer to the
unit data label for the model number. The gas/electric unit
is suitable for installation on combustible flooring or class
A, B, or C roofing materials. A clearance of at least 36
inches from the blower access panel and from the louvered
control access panel is recommended to allow for servicing
and maintenance. Where accessibility to combustibles
clearances are greater than minimum clearances,
accessibility clearances must take preference. Sufficient
clearance for unobstructed airflow through the louvered
control access panel and through the outdoor coil must be
maintained in order to achieve rated performance. See
Figure 3 for minimum clearances to obstructions.
Thermostat — A single stage cooling/single stage heating
24VAC thermostat should be used with these units. A twostage cooling/single-stage heating thermostat is
recommended for economizer operation.
Air Filter Requirements — A suitable air filter system
must be installed in the unit or in the return air system
upstream of the evaporator coil. Refer to Table 1 for
recommended filter sizes. Air filter pressure drop must not
exceed 0.08 inches WC. This unit is not supplied with air
WARNING:
Never operate unit without a filter. A failure to
follow this warning could result in a fire, personal
injury, or death.
IMPORTANT NOTICE TO INSTALLER: After installing
or replacing the filtration system for this unit, add the
following marking on the filter service panel or reasonably
adjacent thereto: “Replace filter(s) installed in your
system only with the same dimensional size filters
that are being replaced.”
Nominal Approximate Approximate Recommended
Cooling Air Flow Range Filter Area (Sq. In.)* Filter Size (In. x In.)
Tonnage (Ton) (CFM) Disposable High Velocity Disposable High Velocity
2.0 600-1200 450 275 20 x 25 15 x 20
2.5 600-1200 550 325 20 x 30 16 x 20
3.0 800-1250 625 375 25 x 25 20 x 20
3.5 850-1500 725 450 24 x 30 20 x 25
4.0 1050-1650 825 500 18 x 24 (2 required) 20 x 25
5.0 1050-1650 1000 600 20 x 25 (2 required) 25 x 25
*Based on velocity of 300 ft/min for disposable filters and 500 ft/min for high velocity (cleanable) filters.
Table 1. Air Filter Requirements
7
A
C
Blower
Control
Duct
Coil
Minimum Clearances to Combustible Material**
E
B
D
Figure 3. Minimum Clearances.
Heating
Model
Number
024(-)045(†) 45 ,000 36 36 1* 36 36
024(-)072(†) 72 ,000 36 36 1* 36 36
030(-)045(†) 45 ,000 36 36 1* 36 36
030(-)072(†) 72 ,000 36 36 1* 36 36
036(-)072(†) 72 ,000 36 36 1* 36 36
036(-)096(†) 96 ,000 36 36 1* 36 36
042(-)072(†) 72 ,000 36 36 1* 36 36
042(-)096(†) 96 ,000 36 36 1* 36 36
048(-)096(†) 96 ,000 36 36 1* 36 36
048(-)120(†) 120,000 36 36 1* 36 36
060(-)96(†) 96,000 36 36 1* 36 36
060(-)120(†) 120,000 36 36 1* 36 36
* If accessories (filters, economizers, fresh air dampers . . .) are installed, see accessory installation instructions for proper clearances.
**Suitable for installation on combustible flooring or class A, B, or C roofing material.
† Can be C or X.
Input
(Btuh)
Panel (A) Panel (B) Panel (C) End (D) T o p (E)
Minimum Clearances (Inches)
Table 2. Minimum Clearances to Combustible Materials.
8
!
!
!
Condensate Drain
Figure 4. Condensate Drain.
filter(s) and has no factory equipped means for
accommodating internal air filter(s). For downflow
installations only, an internal filter accessory kit can be
ordered. For horizontal installations, the air filter system
must be installed in the return air ductwork. All return air
to this unit must pass through the filter(s) before entering
the evaporator coil.
Rigging and Hoisting — The unit should be lifted using
slings and spreader bars. The spreader bars are necessary
to prevent damaging the top of the unit’s cabinet. Make
sure
that the lifting equipment is adequate for the load.
Refer to Figure 1 for unit weights. Keep the unit in an
upright position at all times. The rigging must be located
outside the unit’s center of gravity. Refer to Figure 1 for
center of gravity location. For rooftop installations,
remove and discard the two supports attached beneath
the unit.
WARNING:
To avoid the risk of property damage or personal
injury, it is the rigger’s responsibility to ensure
that whatever means are used to hoist the unit
are safe and adequate.
CAUTION:
All panels must be securely in place when rigging
and hoisting.
Condensate Drain — Condensate is removed from the
unit through the 3/4" female pipe fitting located on the front
side of the unit. (See Figure 4.) Install a 2 inch deep
condensate trap in the drain line of the same size and prime
with water.
When connecting rigid drain line, hold the female fitting with
a wrench to prevent twisting. Do not over tighten! Refer
to local codes and restrictions for proper condensate
disposal requirements.
UNIT INSTALLATION
Ground Level — When installing the unit at ground level
(See Figure 5), provide a concrete mounting pad separate
from the building foundation. The pad must be level to insure
proper condensate disposal and strong enough to support the
unit’s weight (Refer to Figure 1). Make sure the slab is a
minimum of 2" above the grade and in an area that drains well.
Rooftop — For rooftop installations (See Figure 6) use the
appropriate accessory roof curb and follow all instructions
included with it. Make sure the supports beneath the unit
have been removed. Locate the unit according to local
building codes and ordinances. The curb must be level to
insure proper condensate drainage.
The roof must be capable of handling the weight of the unit.
See Figure 1 for unit weights. Reinforce the roof if
required.
WARNING:
Do not place combustible material on or against
the unit cabinet. Do not place combustible
materials, including gasoline and any other
flammable vapors and liquids, in the vicinity of
the unit.
Figure 5. Ground Level Installation.
2"
2”
Figure 6. Roof Curb Installation.
9
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