NORTEK P7RE SERIES Air Conditioner Instruction Manual

NORTEK P7RE SERIES Air Conditioner

Safety Instructions

Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that, if not avoided, could result in personal injury or death. CAUTION indicates a potentially dangerous situation that, if not avoided, may result in minor or moderate injury or property damage.

1. Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
2. Improper servicing could result in dangerous operation, serious injury, death, or property damage.
3. Before servicing, disconnect all electrical power to the indoor blower.
4. When servicing controls, label all wires before disconnecting. Reconnect wires correctly.
5. Verify proper operation after servicing.
6. Before beginning the installation, verify that the unit model is correct for the job.
7. This equipment contains liquid and gaseous refrigerant under high pressure.
8. Installation of equipment may require brazing.
9. Follow all precautions in the literature, on tags, and labels provided with the equipment.
10. Use caution when handling this appliance or removing components.

Requirements & Codes

Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards. To achieve optimum performance and minimize equipment failure, it is recommended that periodic maintenance be performed on this unit. The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools.

• All electrical wiring must comply with local,  state, and national codes and regulations, and with the National Electric Code (ANSI/NFPA 70) or, in Canada, Canadian Electric Code Part 1, CSA C.22.1.
• The installer must comply with all local codes and regulations that govern the installation of this type of equipment.
• Local codes and regulations take precedence over any recommendations contained in these instructions.
• Consult local building codes and the National Electrical Code (ANSI CI) for special installation requirements.
• Plug the appropriate wire into the appropriate motor speed tap for the required airflow.

Before You Install this Unit

• Check the electrical supply and verify that the power supply is adequate for unit operation.
• If there is any question concerning the power supply, contact the local power company.
• If necessary, comb fins to remove flattened or bent ones. Damage claim (apparent or concealed) should be filed immediately with the carrier.
• Please consult your dealer for maintenance information and the availability of maintenance contracts. Please read all instructions before installing the unit.

Locating the Air Conditioner

• Survey the job site to determine the best location for mounting the outdoor unit.
• Select a solid, level position, preferably on a concrete slab, slightly above the grade level, and parallel to the home.
• If possible, select a site for the unit that is as close as possible to the proposed return grille location.
• The unit should be located with consideration of minimizing the length of the supply and return ducts.
• If practical, place the air conditioner and its ducts in an area where they will be shaded from the afternoon sun, when the heat load is greatest.
• The length of the supply and return ducts should be kept to a minimum with no sharp radius bends.
• Overhead obstructions, poorly ventilated areas, and areas subject to the accumulation of debris should be avoided.
• The hot condenser air must be discharged up and away from the home, and if possible, in a direction with the prevailing wind. Do not place the unit in a confined space.
• Sufficient clearance for unobstructed airflow through the outdoor coil must be maintained in order to achieve rated performance.
• Consideration should also be given to the availability of electric power, service access, noise, and shade.

Minimum Clearance Requirements

Sufficient clearance for unobstructed airflow through the outdoor coil must be maintained in order to provide room for proper servicing and achieve rated performance. See Figure 1 for minimum clearances to obstructions.

Service Access Clearance

• Blower and electrical control access panels…………..24.”
• Compressor compartment access panel……………….2.4.”
• Clearance from top of unit ………………………………….72.”
• Clearance arthe ound condenser coil area to the Wall or shrubs (excludes duct panel side)……………..1.2.”

Clearances to Combustibles

• Combustible base – wood or Class A, B, or C
• roof covering material…………………………………………0”
• Supply & return air ducts …………………………………….0”
• Duct connection side ………………………………………….0”

Air Duct System

Air ducts must be instaby with the standards of the National Fire Protection Association “Standard 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 codes. NFPA publications are available by writing to: National Fire Protection Association, Batterymarch Park, QuiMAy, MA,02269, or visit www.NFPA.org on the web.

• Design ductwork according to methods described by the Air Conditioning Contractors of America (ACCA).
• The supply duct system, including the number and type of registers, will have much more effect on the performance of the system than any other factor.
• The duct must be sufficiently large to conduct an adequate amount of air to each register.
• Ductwork should be attached directly to the unit flanges for horizontal applications.
• For highly resistive duct systems, it may be necessary to use a return air duct and or supply to achieve maximum performance and prevent coil icing and refrigerant flood back.
• Use insulation with an outer vapor barrier. Refer to local codes for insulation material requirements.

Installation

Unpacking the Unit

It is recommended that the unit be unpacked at the installation site to minimize damage due to handling.

1. Remove the bands from around the unit.
2. Unfold the top and bottom cap flanges.
3. Carefully remove the top cap and tube.

Installing Return & Supply Air Collars (Optional)

Supply and return collars are not supplied with the unit but are offered as an accessory item. Check with your distributor for pricing and availability. They can be easily positioned over the unit openings and secured with sheet metal screws.

• The diameter of the return duct collar is 14”.
• The diameter of the supply duct collar is 12”.

Supply Duct

1. Assemble the collar by overlapping the two ends.
2. Position the end with small screw holes underneath the slotted end.
3. Fasten the collar ends with two self-drilling sheet metal screws.
4. Position the collar over the opening and align the 4 holes in the collar with the 4 holes (or dimples, depending on the model) in the rear panel.
5. Using self-drilling screws (10-16x.5), secure the collar to the rear panel.

Return Duct

1. Assemble the collar by overlapping the two ends.
   Fasten the collar ends with self-drilling sheet metal screws.
2. Position the collar over the opening.
3. Align the four holes in the collar with the four dimples or holes in the panel.
4. Secure the collar to the rear panel using self-tapping screws (10-16x.5)

Locating & Installing the Return Air Assembly

To simplify installation, locate and install the return air assembly first. If desired, the return opening can be located inside a closet with louvered doors that has an open area equal to or greater than a 12” x 20” grille. The return air grille can be placed in the wall of a closet, and the air ducted into the filter box through a boxed-in area at the closet floor level (Figure 4). Verify the filter is readily accessible.

The return air box with grille and filter should not be located in heavy traffic areas, like hallways or the center of rooms. A good spot is in a corner or under a table, if a minitwo-inch clearance is available.

1. Start the installation from under the home by cutting a small hole in the subfloor. Determine how the floor joist location will affect cutting the opening needed for the return air box.
2. After measuring the return air box (approximately 12-1/4” x 20-1/4”), cut the hole through the floor so that the box will fit between the floor joists.
3. Care should be taken when cutting through carpeting to avoid snags.
4. In most installations, it will be necessary to cut a similar hole in the fiberboard directly under the hole in the floor. However,
5. if the floor is more than ten inches deep, it will only be necessary to cut a hole for the collar on the return air box or for the insulated duct.
6. Set the box into the opening and fasten n with screws or nails.
7. Install the filter and return air grille in the air box.

Connecting the Ducts

• Flexible ducts may be cut to the required length and spliced with sheet metal sleeves and clamps. Keep all ducts as short and straight as possible. Avoid sharp bends. Please follow all instructions packed with the duct.
• Flexible ducts can be secured to the corresponding fittings with the clamps provided with the ducts. To prevent a loss in cooling capacity, make sure all connections are tight.

Locating & Installing the Supply Damper(s)

When locating the supply damper(s), carefully check floor joists and frame members that could interfere with the installation of the damper or flexible duct. Ideally, the damper should be located at the bottom of the main duct, forward of the center of the home, at least three feet from the nearest register. See Figure 5. The round supply opening in the slanted side of the damper should face the side of the home where the air conditioner is located.

1. Locate the center of the heat duct by cutting a small hole in the fiberboard below the duct at the desired location.
2. Cut a hole approximately 3/4” larger than the damper opening in the fiberboard.
3. Cut a 9-1/8” x 13-1/8” hole in the duct and bend over all tabs flat on the inside of the heat duct.
4. Insert the damper into the duct and bend over all tabs flat on the inside of the heat duct.
5. Seal the opening between the fiberboard and the damper or flexible duct.

Condensate Drainage

A 3/4” condensate fitting extends out of the side of the unit (Figure 6). The drain trap, shipped in the electrical compartment, must be installed to prevent water from collecting inside the unit.

1. Thread the elbow provided with the unit into the drain connection until hand-tight.
2. Connect the condensate tubing to the fitting, forming a trap near the drain connection.
3. Route the condensate tube from the trap to a suitable drain.

Electrical Connections

Failure to follow safety warnings exactly could result in serious injury, death, or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage.

• Before servicing, disconnect all electrical power to the indoor blower.
• When servicing controls, label all wires before disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
• All electrical connections must be in compliance with all applicable local codes and ordinances, and with the current revision of the National Electric Code (ANSI/NFPA 70).
• For Canadian installations, the electrical connections and grounding shall comply with the current Canadian Electrical Code (CSA C22.1 and/or local codes).

Pre-Electrical Checklist

• Verify that the voltage, frequency, and phase of the supply source match the specifications on the unit rating plate.
• Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment. Refer to the unit wiring label NORTEK P7RE SERIES Air Conditioner for proper high and low voltage wiring.
• Verify factory wiring by the unit wiring diagram, as shown in Figure 10 (page 12) and Figure 11 (page 13). Inspect for loose connections.

Wiring Diagram

Line Voltage

• A wiring diagram is located on the inside NORTEK P7RE SERIES Air Conditioner cover of the electrical box of the unit. The installer should become familiar with the wiring diagram before making any electrical connections to the unit.
• Provide power supply for the unbyith the unit wiring diagram and the unit rating plate. Connect the line-voltage leads to the terminals on the contactor inside the control compartment. Extend the power wiring hole (Figure 7). Connect L1 & L2 directly to the contactor.
• The unit requires both power and control circuit electrical connections. Make all electrical connections by all applicable codes and ordinances.
• Use only copper wire for the line voltage power supply to this unit. 208/230 Volt units are shipped from the factory wired for 230 volt operation. For 208V operation, remove the lead from the transformer terminal marked 240V and connect it to the terminal marked 208V.

Grounding

The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. Do not use gas piping as an electrical ground! Ground the air conditioning unit using the green grounding screw provided in the control panel.

Overcurrent Protection

Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes. Generally, the best fuse or breaker for any heat pump is the smallest size that will permit the equipment to run under normal usage and provide maximum equipment protection. Properly sized fuses and breakers also prevent nuisance trips during unit startup.

Thermostat / Low Voltage Connections

• The unit is designed to operate from a 24 VAC Class II control circuit. The control circuit wiring must comply with the current provisions of the NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction.
• Low-voltage wires must be properly connected. Route 24V control wires through the sealing grommet near the power entrance.
• Select a thermostat that operates in conjunction with the installed accessories.
• Refer to the thermostat manufacturer’s instruction sheet for detailed mounting information.

Cooling Only Thermostat

Connect the red & yellow wires from the unit to the R & Y terminals on the thermostat subbase. Connect the green wire to the yellow wire at the unit. See Figure 8.

Heat / Cool Thermostat

Connect the red, yellow-green, and brown/orange-voltage wires to the R or RCY,  G, W, or W2 (if applicable) terminals on the thermostat base. The black wire 24-volt common is required on some thermostats. See Figure 8 (page 7).

Blower Speed

For optimum system performance and comfort, it may be necessary to change the factory speed setting. Table 3 (page 11) for factory settings.

• Label all wires before disconnection when servicing controls.
• Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
• Disconnect all electrical power to the unit and remove the service panel.
• Locate the orange and red wires terminated to the blower motor.
• The orange wire controls the he operation, and the red wire controls the heating operation.
• Check all factory wiring as shown in the wiring diagram and inspect the connections to make sure none of them loosened during shipping or installation.

Start Up & Adjustment

Pre pre-start checklist

should be observed before starting the unit.

• Verify the unit is level and allows proper condensate drainage.
• Verify the ductworkssealed to prevent air leakage.
• Check the condenser fan to make sure it turns freely.
• After unit startup, the compressor must run for a minimum of 12 hours.

Start-Up Procedure

Failure to comply may result in damage and could cause premature failure of the system. The control circuit thermostat may consist of an anti-short cycle timer that will not let the compressor start before 5 minutes have elapsed.

1. Set the system mode to OFF and the temperature mode to its highest setting.
2. Turn the power on at the disconnect switch.
3. Set the system mode to ON or COOL.
4. The ductwork has no air leaks.
5. Set the temperature mode above room temperature. The unit should stop.
6. Instruct the homeowner on unit and thermostat operation and filter servicing.

Air Circulation

Leave the thermostat system mode on OFF, and set the fan mode to ON. The blower should run continuously. Check the air delivery at the supply registers and adjust register openings for balanced air distribution. Examine ducts for leaks or obstruction if insufficient air is detected. Set the thermostat fan mode to AUTO. The blower should stop running.

System Cooling

Set the thermostat’s system mode to COOL and the fan mode to AUTO. Lower the thermostat temperature selector below the existing room temperature. Allow the cooling system to operate for several minutes and check for the discharge of cool air at the supply registers.

System Heating

Raise the thermostat’s temperature selector above the existing room temperature and check the following:

1. The compressor and outdoor fan should not run.
2. The blower will run according to the thermostat’s fan mode setting.

Maintainance

Proper maintenance is important to achieve the optimum performance of the NORTEK P7RE SERIES Air Conditioner. The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools. If you do not possess these skills, contact your dealer for maintenance. Consult your local dealer about the availability of maintenance contracts. Routine maintenance should include the following:

• Inspect and clean or replace air filters at the beginning of each heating and cooling season, or more frequently if required.
• Inspect the condensate drain and outdoor coil 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 NORTEK P7RE SERIES Air Conditioner for tightness at the beginning of each heating and cooling season. Service as necessary.
• Do not add additional oil to motors unequipped with oil tubes.

Charging

Charging the Unit

This air conditioner contains liquid and gaseous refrigerant under pressure. Under no circumstances should the homeowner attempt to install and/or service this equipment. Failure to comply with this warning could result in equipment damage, personal injury, or death.

For a fixed orifice system

• If your measured superheat at the suction valve is LESS THAN the recommended superheat value in the table refrigerant.
• If your measured superheat at the NORTEK P7RE SERIES Air Conditioner suction valve is GREATER THAN the recommended superheat value in the tab, le then ADD refrigerant.

For TXV systems

• If your measured subcooling at the NORTEK P7RE SERIES Air Conditioner liquid valve is LESS THAN the recommended subcooling value in the table, then ADD refrigerant.
• If your measured subcooling at the liquid valve is GREATER THAN the recommended subcooling value in the tab, le then REMOVE refrigerant.

If the outdoor temperature is below 65 degrees F: After leak checking the system and evacuating the system, perform the following steps:

1. Weigh in the charge amounts recommended and printed on the unit rating plate.
2. Return to the system when the outdoor temperature is 65 degrees F or higher and follow the instructions in If the outdoor temperature is 65 degrees F or higher” section above.

Switches

If the NORTEK P7RE SERIES Air Conditioner liquid pressure rises above 650 psig, the switch will open and de-energize the unit. The switch will close again when the liquid pressure decreases to 460 psig.

Figures & Tables

Unit Dimensions

• Top View
• Side View
• Rear View (1.5, 2, 2.5, & 3 Ton)
• Rear View (3.5, 4, & 5 Ton)

MODEL NUMBER	LENGTH -L-	WIDTH W	HEIGHT   -H-	-A-	-B-	RETURNDIAMETER (IN)	SUPPLY DIAMETER (IN)
018K	49	35	22.2	35.02	2.48	12	12
024K	49	35	22.2	35.02	2.48	12	12
030K	49	35	22.2	35.02	2.48	12	12
036K	49	35	22.2	35.02	2.48	12	12
042K	49	35	30.2	35.02	2.48	14	12
048KA	49	35	30.2	35.02	2.48	14	12
X60KA	49	35	34.2	35.02	2.48	14	12

Physical Data

HEAT RISE DATA (BASED ON NOMINAL 10KW ELECTRIC HEAT KIT)
UNIT	BLOWER SETTING	EXTERNAL STATIC PRESSURE DROP – INCHES WATER COLUMN
		0.1		0.2		0.3		0.4		0.5		0.6		0.7		0.8
		CFM	HEAT RISE	CFM	HEAT RISE	CFM	HEAT RISE	CFM	HEAT RISE	CFM	HEAT RISE	CFM	HEAT RISE	CFM	HEAT RISE	CFM	HEAT RISE
018K	Tap T1	609	52	541	58	522	61	450	70	390	81	333	95	–	–	–	–
	Tap T2*	729	43	690	46	651	49	599	53	542	58	475	67	421	75	357	88
	Tap T3	859	37	813	39	768	41	724	44	673	47	609	52	555	57	497	64
	Tap T4**	1123	28	1100	29	1065	30	1023	31	978	32	929	34	877	36	820	39
	Tap T5	1359	23	1320	24	1302	24	1280	25	1243	25	1205	26	1162	27	1112	28
024K	Tap T1*	950	33	823	38	881	36	832	38	788	40	722	44	655	48	593	53
	Tap T2**	1123	28	1100	29	1065	30	1023	31	978	32	929	34	877	36	820	39
	Tap T3	1189	27	1158	27	1141	28	1084	29	1047	30	1009	31	959	33	906	35
	Tap T4	1291	24	1246	25	1236	26	1195	26	1161	27	1120	28	1075	29	1031	31
	Tap T5	1359	23	1320	24	1302	24	1280	25	1243	25	1205	26	1162	27	1112	28
030K	Tap T1	965	33	910	35	870	36	800	39	720	44	665	48	615	51	560	56
	Tap T2**	1100	29	1050	30	1010	31	955	33	890	35	830	38	750	42	700	45
	Tap T3*	1160	27	1120	28	1080	29	1030	31	980	32	930	34	880	36	800	39
	Tap T4	1440	22	1400	23	1360	23	1320	24	1280	25	1220	26	1180	27	1120	28
	Tap T5	1560	20	1530	21	1490	21	1440	22	1400	23	1360	23	1310	24	1270	25
036K	Tap T1**	1215	26	1175	27	1130	28	1075	29	1020	31	970	33	900	35	840	38
	Tap T2	1313	24	1277	25	1236	26	1190	27	1153	27	1104	29	1051	30	992	32
	Tap T3	1460	22	1415	22	1385	23	1335	24	1275	25	1225	26	1170	27	1120	28
	Tap T4*	1502	21	1466	22	1437	22	1388	23	1345	23	1305	24	1251	25	1204	26
	Tap T5	1565	20	1525	21	1490	21	1450	22	1410	22	1370	23	1315	24	1270	25
042K	Tap T1	1375	23	1345	23	1310	24	1275	25	1240	25	1205	26	1160	27	1120	28
	Tap T2**	1470	21	1435	22	1400	23	1370	23	1335	24	1300	24	1260	25	1215	26
	Tap T3*	1600	20	1570	20	1535	21	1505	21	1470	21	1440	22	1400	23	1355	23
	Tap T4	1715	18	1680	19	1650	19	1620	20	1585	20	1545	20	1505	21	1470	21
	Tap T5	1895	17	1865	17	1830	17	1795	18	1760	18	1730	18	1695	19	1655	19
048KA	Tap T1	1375	23	1345	23	1310	24	1275	25	1240	25	1205	26	1160	27	1120	28
	Tap T2**	1470	21	1435	22	1400	23	1370	23	1335	24	1300	24	1260	25	1215	26
	Tap T3	1600	20	1570	20	1535	21	1505	21	1470	21	1440	22	1400	23	1355	23
	Tap T4*	1642	19	1620	20	1580	20	1545	20	1511	21	1472	21	1433	22	1390	23
	Tap T5	1895	17	1865	17	1830	17	1795	18	1760	18	1730	18	1695	19	1655	19
X60KA	Tap T1**	1390	23	1350	23	1310	24	1270	25	1240	25	1205	26	1160	27	1120	28
	Tap T2	1540	21	1510	21	1480	21	1440	22	1410	22	1380	23	1340	24	1310	24
	Tap T3	1700	19	1670	19	1630	19	1600	20	1580	20	1540	21	1510	21	1480	21
	Tap T4*	1800	18	1762	18	1737	18	1705	19	1661	19	1630	19	1600	20	1565	20
	Tap T5	2080	15	2030	16	2020	16	1970	16	1940	16	1910	17	1870	17	1840	17

Installation Checklist

INSTALLATION ADDRESS: CITY _________________________________________ STATE _____________________________ UNIT MODEL # _______________________________________________________________________ UNIT SERIAL # _______________________________________________________________________ Unit Installed Minimum clearances per Figure 1 (page 4)? YES NO INSTALLER NAME: CITY _________________________________________ STATE _____________________________ Has the owner’s information been reviewed with the customer? YES NO Has the Literature Package been left with the unit? YES NO

REFRIGERATION SYSTEM Was the unit given 24 hr warm-up period for crankcase heaters (if equipped)? YES NO Stage-1 Liquid Pressure (high side) _______________________________________________________ Stage-1 Suction Pressure (low side) _______________________________________________________

ELECTRICAL SYSTEM Are electrical connections tight? YES NO Line voltage polarity correct? YES NO Has the thermostat been calibrated? YES NO Is the thermostat level? YES NO Is the heat anticipator setting correct? (If Applicable) YES NO Rated Voltage: _________________________________________________________________ VOLTS L1-L2 Volts: ___________________________________________________________________VOLTS

Replacement Parts

Replacement parts are available through your distributor. Please have the complete model and serial number of the unit when ordering replacement parts.

Electrical

• Capacitors
• Temperature Limit Switches
• Compressors
• Thermostats
• Contactors
• Time Delay Relays
• Pressure Switches
• Transformers
• Relays

Motor

• Blower Motor
• Fan Motor

Components

• Blower Assembly
• Fan Grille
• Cabinet Panels
• Filter/Driers
• Expansion Valves

Warranty Information

A warranty certificate with full details is included with the equipment. Carefully review these responsibilities with your dealer or service company. The manufacturer will not be responsible for any costs found necessary to correct problems due to improper setup.

• Resetting circuit breakers or other switches.
• Adjusting or calibrating the thermostat.

Customer Service

• Ph: +47 6717 4500
• Website https://support.nortekgroup.com/