WIRING DIAGRAM - R2 UTEC REPLACEMENT KIT R2 Series Packaged Gas Heat/Electric Air Conditioner 208/230 Volt

Three Phase

60 Hz NOTES 1. C Duper le courant avant cl• Imre hin•uen.

1. Disconnect all power before senneing. 2. Employes untquernent des conducteurs•n curvre

2 For supply connections use copper conductors only. 3 Ile conslent tuts autt Installations de plus d. 150 V a la Mite.

1 Nol suitable on systems that exceed 150 V to ground. to warna v4c

4 If any of Iho original wir• as supplied with th• furnac• must De replaced. d Mu', i ._> •••1. 4.0 y C-• .

6 I I I I be replaced with *tins, material having a lornperature rafing of al least 105 . E. Clialli en... , , ,

5. For supply wde anipacities and ovetcurtont protection, sae unit rating plate.

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7039060 (2/98)

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WIRING DIAGRAM - R2 UTEC REPLACEMENT KIT

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R2 Series Packaged Gas Heat/Electric Air Conditioner 208/230 Volt NOTES: 1. Coupe. Is courant avant do fairs Ititrstlers 1. Disconnect all pow. baton s•rvicing. 2. Ernployez unlquem•rit des conductiours an [Wirt•

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7038730 (2/98)

R2 Series Packaged Gas Heat/Electric Air Conditioner 208/230 Volt 60 Hz Single Phase

O LIU OEN 01:1

WIRING DIAGRAM - R2 UTEC REPLACEMENT KIT

3. Not SUitable on systems that exceed 150 V to ground. 4 If any of the original w re •s supplied with the furnace must be replaced. It roust

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7039050 (2/98)

707684A (Replaces 7076840)

St. Louis, MO NORDYNE Specifications and illustrations subject to change without notice and without incurring obligations.

Printed in U.S.A. (4/98)

R2 Series Control Board Replacement Kit

Installation Instructions

Please read these instructions completely before attempting the installation of the conversion kit. Keep these instructions in a safe place for future reference.

A WARNING This kit most be installed by a qualified installing agency and

in accordance with local codes and ordinances. Failure to

properly install the conversion kit as described herein may

damage the equipment and/or the home, can create a fire

or asphyxiation hazard, violates U.S. listing requirements,

and will void the warranty.

A WARNING

The R2 control board conversion must be done only with

an approved NORDYNE conversion kit. Failure to do so

will void the warranty.

FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS

• Do not try to light any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

General

This conversion kit can be used to replace the existing R2

control board with a UTEC control board. These instructions assume that you are familiar with and have the Installation Instructions delivered with the R4 unit.

Before Starting the Conversion

First check your kit to ensure that all of the necessary items are enclosed. The components of the conversion kits are listed below:

1. Five 17" stripped-end wires (Colors: white, red, green, yellow, and black)

2. A six-position wire hamess 3. A nine-position wire harness 4. A UTEC control board 5. A 12" black wire terminated with insulated 1/4" female

quick-connect 6. An ignitor bracket 7. An 8-32 X % thread-forming screw 8. Four wire nuts 9. A 208/230 ignitor with loose two-position male housing

10. Three electrical wiring diagram labels 11. Installation instructions for control board conversion 12. Two burner top pans (one large and one small) 13. Six wire ties

14. An insulated 1/4" female quick-connect terminal

Converting the Burner Assembly

A. To Turn Off Gas to the Appliance:

1. Set the thermostat to "OFF" or to its lowest setting.

2. Turn off all electrical power to the appliance.

3. Turn the latch and open the furnace door.

4. Push in the gas control lever and move to "OFF." DO NOT FORCE LEVER.

B. Remove the Burner Assembly:

1. Follow instructions "To Turn Off the Gas to the Appliance".

2. Shut off gas supply at meter.

3. Disconnect the gas piping to gas valve.

4. Remove the yellow wire which connects the gas valve to

the 24V common terminal on the transformer and discard. Furthermore, disconnect the brown wire from the gas valve.

5. Before removing the wires, label each wire according to

the terminal from which it will be removed. Disconnect wires from the components of the burner assembly (flame sensor, flame roll-out limit switch, and ignitor).

6. Remove the burner assembly fasteners and remove burner assembly from the unit, as shown in Figure 1. Keep the screws that were removed.

C. Replace Burner Top Pan.

1. Remove the flame sensor, flame roll-out limit switch, and ignitor from the burner top pan which is located above the burners. Keep the flame sensor, roll-out limit switch and the screws that were removed.

2. Remove the bumer top pan and discard. Keep the screws

that were removed.

3. Using the original screws, install the burner top pan from the kit that is the same length as the one removed from the unit. Discard the unused burner top pan from the kit as well as the original burner top pan.

Figure 1. Removing Burner Assembly

11

A CAUTION: Do not use matches, lighters, candles or other sources of open flame to check for gas leaks.

A WARNING Do NOT overtighten ignitor onto the bracket. This could result in damage to the ignitor.

4. NOTE: Use caution when handling ignitor. Using thread forming screw provided, secure the ignitor to the ignitor bracket. Ensure that the ignitor leads are routed through the hole in the top of the bracket before securing the ignitor, as shown in Figure 2.

5. Insert the ignitor leads into the two-position male housing.

6. Secure the ignitor bracket assembly, flame sensor, and the flame roll-out limit switch onto the burner top pan with the original screws. Use caution when re-installing the ignitor bracket assembly.

7. Re-install the burner assembly into the unit with the original screws.

8. Reconnect the gas piping to the gas valve. Ensure that all gas connections are light and sealed.

9. Check for any gas leaks.

D. Install UTEC Control Board.

1. Before removing the wires from the existing control board, label each wire according to the terminal from which it will be removed. Remove all wires from the existing control board. Discard the wires which were removed from the terminals marked "R", "G", and "Al' of the old control board.

2. Remove the existing control board from the control panel and discard.

3. Align the two bottom holes of the control board template (see Section I) with the two existing bottom holes of the control panel where the original control board was secured, as shown in Figure 3. Secure the template.

4. Drill the two 3/16" holes marked at the top of the template.

5. Snap the UTEC board into place with terminal strip (R C Y G W) at the top.

A WARNING In certain installations, BOTH "L1" AND "NEUTRAL" terminals may be HIGH VOLTAGE. Damage to accessories, which are rated for a lower voltages, may occur. Use caution when connecting any accessories to this unit. DO NOT USE the "EAC" terminal for an electric air cleaner or the"HUM" terminal fora humidifier UNLESS these appliances are rated for 240V.

E. Reconnect theWiring.

1. Check to ensure that the electrical power to the unit is disconnected.

2. Snap the six-position wire harness into the UTEC control board.

3. Connect the ignitor two-position male housing to the two-position female housing from the six-position wire harness.

4. Cut the terminals off the inducer motor wire leads (originally removed from "IND DFT" and "L2") and strip the inducer wires.

5. Using two of the provided wire nuts, connect the inducer motor wire leads to the two pre-stripped wires from the six-position wire harness.

6. Snap the nine-position wire harness into UTEC control board.

7. Connect the yellow and brown wires from the nine-position wire harness to the terminals on the gas valve. (Section B - Part 4).

8. Remove the two orange wires from the pressure switch.

9. Connect the two orange wires from the nine-position wire harness to the pressure switch.

10. Plug the red wire with the one-position female housing from the nine-position wire harness into the flame sensor one-position male housing. Note: If the flame sensor is equipped with a 1/4" male quick connect, then the termination of the red wire from the nine-position wire harness will need to be changed. To change the termination, simply cut the housing off the red wire from the nine-position pin harness as close to the housing as possible. Then strip the end of the red wire and attach the provided 1/4" female quick connect. Plug the red wire onto the flame sensor.

11. Connect the blue wire terminated with a 1/4" female quick connect from the nine-position wire harness to one terminal of the roll-out limit on the burner assembly.

12. Reconnect the blue wire from the over-temperature limit switch that was originally attached to the roll-out limit. This blue wire should be terminated with an uninsulated 1/4" female quick-connect terminal.

13. Cut the remaining blue wire routed from the over-temperature limit switch off at the connector of the original wire harness which was attached to the old control board. Discard the original wire harness. Strip the remaining blue wire from the over-temperature limit switch. Then using another wire nut, attach it to the blue pre-stripped wire on the nine-position wire harness.

14. Secure the green wire from the nine-position harness under the green screw located near the transformer. Ensure that the original ground wire is still connected under the green screw when finished.

15. Attach the red wire from the 24 volt side of the transformer (originally connected to "24VAC" on the old arcuit board) to the terminal marked "24V" on the UTEC control board.

16. Remove the black wire (originally connected to "COM" terminal on the old circuit board) from the transformer. This wire is part of a three wire harness. Discard the black wire harness and reconnect the green wire to the "COM" terminal of the transformer.

17. Connect one end of the provided 12" black wire to the terminal on the transformer from which the black wire in the previous step was removed (See STEP 16). Connect the other end to the "COM" terminal on the UTEC control board.

2 7

6

1111:11121:11:10 1111111MIGICI

A WARNING In certain installations, the "NEUTRAL" terminals on the UTEC control board may be HIGH VOLTAGE.

ilk 1E11 -.1.

Two-Position Male Housing

II

Ignitor Leads are Attached to Male Housing After Being Inserted Through Ignitor Bracket

8-32 x311 Thread Forming

Screw 208/230 Ignitor

Ignitor Bracket

Figure 2. Ignitor Figure 3. Control Panel Template

3

Control net

Holes to be Drilled Using

Template /

Bottom Holes

/

Template

J. Wiring Diagrams.

18. Attach the black wire (originally connected to "L2" on the old control board) from "COM" on the 208/240 side of the transformer to one of the terminals marked °NEUTRAL" on the UTEC control board.

19. Attach the red wire (originally connected to "L1" on the old control board) from the "208" or "240" terminal of the transformer to the terminal marked "XFMR" on the UTEC control board.

20. Connect the common black wire from the blower motor (originally removed from the "L2" terminal of the old control board )to one of the termi nals marked "NEUTRAL" on the UTEC control board.

21. Attach the blower speed terminals that were removed from the "HEAT" and "COOL" terminals of the old control board to the "HEAT" and °COOL" terminals of the UTEC control board.

22. Attach the remaining unused blower speed wires to the terminals marked "Ml", "M2", or °M3" on the UTEC control board.

23. Examine the R2 being converted and determine the electrical phase and the number of drcuit breakers in the unit. Note that circuit breakers were an optional feature, so there may be no breakers present in the unit. Once the R2 electrical configuration has been determined, follow step below (a, b, c, or d) that matches the electrical configuration of the unit being converted.

a. If the unit being converted is single phase AND has either one or no circuit breaker, then attach the red wire (originally removed from the "L1" terminal of the old control board) from the contactor to the terminal marked "L1" on the UTEC control board. Furthermore, attach the black wire (originally

removed from the "L2" terminal of the old control board) from the contactor to the terminal marked 'NEUTRAL" on the UTEC control board.

b. If the unit being converted is single phase AND has two circuit breakers, then attach the red wire (originally removed from the °L1" terminal of the old control board) from the second circuit breaker to the terminal marked "L1" on the UTEC control board. Furthermore, attach the black wire (originally removed from the "L2" terminal of the old control board) from the second circuit breaker to the terminal marked "NEUTRAL" on the UTEC control board.

c. If the unit being converted is three phase AND has no circuit breaker, then attach the red wire (originally removed from the "L1" terminal of the old control board) from the contactor to the terminal marked "L1;on the UTEC control board. Furthermore, attach the black wire (originally removed from the "L2" terminal of the old control board) from the contactor to the terminal marked "NEUTRAL" on the UTEC control board.

d. If the unit being converted is three phase AND has a circuit breaker, then attach the red wire (originally removed from the "L1" terminal of the old control board) from the circuit breaker to the terminal marked "L1" on the UTEC control board. Furthermore, attach the black wire (originally removed from the "L2" terminal of the old control board) from the circuit breaker to the terminal marked "NEUTRAL" on the UTEC control board.

24. Connect the pre-stripped red, green, white, black, and yellow wires to the screw terminals on the UTEC control board marked "R", "G", °W", "C", and respectively. Route the ends of these wires through the divider panel and re-connect them to the wires from the thermostat. Note that must be connected to the thermostat to provide proper blower operation.

25. Use the wire ties provided to secure any loose wires. Ensure that wires are not touching any moving parts.

Drill two 3/16" holes in these spots

Using this paper as a template, carefully drill 3/16" diameter holes in the top two holes.

"I- Line these two holes up with the bottom holes in the control panel ►

$

L Control Board Template

4

F. Affix Electrical Label.

1. Depending upon the R2 that is being converted (see Part E - Step 23), overlay the appropriate wiring diagram over the diagram originally sent with the unit. Three labels are shipped with this kit. The first label is for a single phase R2 unit with one optional circuit breaker. The second one is for a single phase R2 unit with two

circuit breakers. The third label is for a three phase R2 unit with one circuit breaker.

G. Check Unit Operation.

1. Follow "Start Up and System Check" section in the R2

installation instructions to check the system operation.

H. Operating Sequence of the UTEC Control Board.

Cooling Mode:

1. On a call for cooling the thermostat closes, applying 24 VAC to the green and yellow leads in the low voltage area.

2. The green lead applies 24VAC to the "G" terminal of the integrated control energizing the main circulating blower circuit at the cooling speed.

3. The yellow lead applies 24VAC to the anti-short cycle timer if installed and then to the contactor.

4. When the thermostat is satisfied the contactor and integrated control are de-energized.

5. The circulating blower motor is de-energized after a 90-

second delay.

Blower Mode:

1. On a call for fan operation, the thermostat applies 24 VAC to the green lead connected to the "G" terminal of the integrated control.

2. The circulating blower is energized immediately at the heating speed.

3. If a call for heat occurs, the circulating blower de-energizes prior to normal heating cycle.

Heating Mode:

1. On a call for heat the thermostat doses, applying 24 VAC to the "W" terminal on the integrated control.

2. The integrated control monitors the safety circuit at all times. fteitherthe rollout control orthe over- temperature limit control opens, both the main blower and combustion blower will continue to run until the circuit closes. After the safety circuit doses the main blower and blower will run for a specified post purge time.

3. The integrated control checks the pressure switch at the beginning of the healing cycle. If it is dosed the inducer will run 30 seconds, the control will go into lock out, and the diagnostic light will flash three times. If it is open, it will start the inducer motor.

4. The inducer motor starts and doses the pressure switch. If the pressure switch does not dose in 10 seconds the integrated control will go into lock out and the diagnostic light will flash two times.

5. The inducer will pre-purge for 30 seconds and the ignitor will start the warm up cycle.

6. The integrated control will open the gas valve after 30 seconds.

7. The flame must be proven through the flame sensor in six seconds to hold the gas valve open. The integrated control will monitor the gas flame with the flame sensor for the entire time the gas valve is open. If for any reason the gas flame drops out the gas valve will immediately

close.

8. 30 seconds from the gas valve opening the main blower starts and continues to run.

9. When the thermostat is satisfied, the "W" terminal on the integrated control is de-energized.

10. The gas valve circuit is de-energized and the gas valve closes.

11. The inducer motor will continue to run for the post purge

period of 25 seconds.

12. The main blower will continue to run for the blower off delay of 120 seconds.

13. After the "blower off" timer has been satisfied, the integrated control de-energizes the main circulating blower circuit

14. If the unit fails to prove ignition after five attempts, it will go into soft lockout. The unit will re-attempt the start-up procedure every hour until the thermostat is satisfied

1. The thermostat is operating properly.

2. Electrical power to the unit is turned on.

3. The filters are not dirty.

4. The service doors are in place.

5. The 3 amp fuse is operational.

6. The anti-short cycle timer's 5-minute cycle has finished for single phase units.

If the unit does not operate in the heating mode, be certain to check the following:

1. The thermostat is operating properly.

2. Electrical power to the unit is tumed on.

3. The filters are not dirty.

4. The gas is tumed on.

5. The manual shut-off valve is open.

6. The service doors are in place.

7. The flame roll-out control is closed

8. Refer to the diagnostic code table on the wiring diagram or see Table 1.

9. The 5 amp fuse is operational.

FAULT CONDITION

STATUS LIGHT (RED)

PowerOn Limit CircuitOpen Pressure Switch Stuck Open Pressure Switch Stuck Closed Ignition Failure (Check Ground) 230 VAC & Neutral Reversed or No Ground False Flame or Gas Relay Shorted

Power Off

On 1 Flash 2 Flash 3 Flash 4 Flash 5 Flash Continuous Flash Off

FAULT CONDITION

STATUS LIGHT (YELLOW)

Low Flame Sensor Signal Flame Present

Continuous Flash On

Table 1. Diagnostic Codes.

Unit Fails to Operate

If the unit does not operate in the cooling mode, be certain to check the following:

4 5