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Nortek iHybrid DF6SF Series Installation Instructions Manual

Dual fuel heating and cooling packaged system
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DF6SF SERIES
INSTALLATION INSTRUCTIONS
Dual Fuel Heating and Cooling Packaged System
Premium Model Shown
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings exactly
could result in serious injury or property
damage.
• Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
• Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
It is your responsibility to know this product better than your customer. This includes being able to install the product according
to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product.
Safety should always be the deciding factor when installing this product and using common sense plays an important role as
well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the unit
or failure to follow safety warnings could result in serious injury, death, or property damage. 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. After completing the installation, return these instructions to
the customer's package for future reference.
!
WARNING:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fire department.
ATTENTION INSTALLERS:
WHAT TO DO IF YOU SMELL GAS
15 SEER

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  • Page 1 DF6SF SERIES 15 SEER INSTALLATION INSTRUCTIONS Dual Fuel Heating and Cooling Packaged System Premium Model Shown WARNING: FIRE OR EXPLOSION HAZARD WHAT TO DO IF YOU SMELL GAS • Failure to follow safety warnings exactly • Do not try to light any appliance. could result in serious injury or property •...

  • Page 2: Table Of Contents

    USER INFORMATION Operating the Heat Pump for Automatic SAFETY IINFORMATION ..........4 Cooling and Heating ..........5 ABOUT THE HEAT PUMP ...........4 Oper. the Indoor Blower Continuously .......5 OPERATING IINSTRUCTIONS ........4 Shutting the Heat Pump Off ........5 Cooling Operation .............4 HEAT PUMP MAINTENANCE ........5 Heating Operation .............4 Regular Cleaning............5 Emergency Heat............4...
  • Page 3 INSTALLER INFORMATION SAFETY IINFORMATION ..........6 STARTUP & ADJUSTMENTS ........20 Pre - Start Checklist ..........20 REQUIREMENTS & CODES ........7 Start-up Procedure ..........20 GENERAL INFORMATION ..........8 Air Circulation ............21 Pre - Installation Check ..........8 Short Cycle Protection .........21 Locating the Heat Pump Unit ........8 System Cooling ............21 Field Connections for Electrical Power Secondary Heating ..........21...

  • Page 4: About The Heat Pump

    USER INFORMATION OPERATING INSTRUCTIONS IMPORTANT SAFETY INFORMATION A thermostat with fossil fuel back-up heat capability is Safety markings are used frequently throughout this required to operate the Dual Fuel iHybrid™ heat pump manual to designate a degree or level of seriousness and system.

  • Page 5: Operating The Heat Pump For Automatic Cooling And Heating

    USER INFORMATION HEAT PUMP MAINTENANCE At the beginning of the defrost cycle, both the outdoor condenser fan and compressor will turn off. After CAUTION: approximately 30 seconds, the compressor will turn on and begin to heat the outdoor coil causing the ice and Shut off all electrical power to the unit before snow to melt.

  • Page 6: Safety Iinformation

    INSTALLER INFORMATION IMPORTANT SAFETY INFORMATION WARNING: Please read all instructions before servicing this equipment. Do not place combustible material on or against Pay attention to all safety warnings and any other special the unit cabinet. Do not place combustible notes highlighted in the manual. Safety markings are materials, including gasoline and any other used frequently throughout this manual to designate a flammable vapors and liquids, in the vicinity of...

  • Page 7: Requirements & Codes

    REQUIREMENTS AND CODES • This equipment contains liquid and gaseous refrigerant under high pressure. Installation or servicing should only This unit must be installed in accordance with be performed by qualified trained personnel thoroughly instructions outlined in this manual, all applicable familiar with this type equipment.

  • Page 8: General Information

    GENERAL INFORMATION See Note 1 See Note 2 The Dual Fuel iHybrid™ heat pump has been designed and tested for capacity and efficiency in accordance with A.R.I. Standards. This unit will provide many years of safe and dependable comfort, providing it is properly installed and maintained.

  • Page 9: Venting Requirements

    Air openings in the door of the unit, warm air registers, and of the corner panel. The fasteners used to secure the vent return air grilles must never be restricted. If the unit does cover assembly have been included in the homeowner’s not receive an adequate supply of air for combustion, the package.
  • Page 10 AVERTISSEMENT: WARNING: RISQUE D’EMPOISONNEMENT AU CARBON MONOXIDE POISONING HAZARD MONOXYDE DE CARBONED Failure to follow the steps outlined below for each appliance connected to the venting Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système system being placed into operation could result d’évacuation mis en service pourrait entraîner in carbon monoxide poisoning or death.

  • Page 11: Circulating Air Supply

    Circulating Air Supply • If outside air is utilized as return air to the unit for ventilation or to improve indoor air quality, the system WARNING: must be designed so that the return air to the unit is not less than 50° F (10° C) during heating operation. Products of combustion must not be allowed to •...

  • Page 12: Acoustical Duct Work

    Acoustical Duct Work • If using bottom discharge with return air ducts a roof Certain installations may require the use of acoustical curb must be installed prior to unit installation. See lining inside the supply duct work. Rigging and Hoisting section for setting of the unit. •...

  • Page 13: Electrical Wiring

    ELECTRICAL WIRING WARNING: To avoid risk of electrical shock, personal injury, or death,disconnect all electrical power to the unit before performing any maintenance or service. The unit may have more than one electrical supply. Label all wires prior to disconnection when servicing the unit.

  • Page 14: Grounding

    Voltage Range Compressor Single Circuit Maximum Nominal Indoor Model Heating Electrical Motor Blower Number Input Supply DF6SF-X24K072C 72,000 208-230/60/1 11.4 52.0 0.91 20.8 30.0 DF6SF-X36K100C 100,000 208-230/60/1 19.0 82.0 34.7 50.0 DF6SF-X48K120C 120,000 208-230/60/1 24.0 96.0 43.3 60.0 DF6SF-X60K096C 96,000 208-230/60/1 26.0 118.0...

  • Page 15: Heating Configurations

    Heating Configurations Configuring the Variable Speed Blower The back-up furnace in this heat pump is factory configured The variable speed blower has been designed to give to operate on high fire only, but can be field converted to the installer maximum flexibility for optimizing system operate as a two-stage furnace.

  • Page 16: Delay Profile

    Ambient Sensor Mounting Delay Profile The delay profile controls the start-up and shut-down For optimum performance of the heat pump system, the characteristics of the packaged heat pump unit. By varying ambient sensor must be mounted on the outside of the the start-up and shut-down characteristics of the packaged unit.

  • Page 17: 24Vac Power Wiring

    Copeland scroll compressor and the thermostat demand, Minimum Time Terminate Jumper Compressor the module can accurately detect the cause of electrical Between Defrosts Temperature Position Delay Function (min) (° F) and system related failures without any sensors. A flashing LED indicator communicates the ALERT code and a diagnostic key is also imprinted on the side of the module to quickly direct the technician to the root cause of a problem.

  • Page 18: Dc Sol Connection

    The scroll compressor’s R (run), C (common), and S DC SOL Connection The two pin DC SOL connector provides a connection (start) wires are routed through the holes in the Comfort to the Copeland UltraTech second stage compressor Alert module marked R, C, & S. NOTE: The common solenoid.

  • Page 19: Gas Supply & Piping

    GAS SUPPLY & PIPING other gas connectors. A soap and water solution can be applied on each joint or union using a small paintbrush. • All gas piping must be installed in compliance with If any bubbling is observed, the connection is not sealed local codes and utility regulations.

  • Page 20: Lp/Propane Gas Conversion

    LP/Propane Gas Conversion START UP & ADJUSTMENTS Pre-Start Check List WARNING: √ Verify the unit is level and allows proper condensate drainage. This unit was equipped at the factory for use √ Verify all clearance requirements are met and there is with natural gas only.

  • Page 21: Short Cycle Protection

    Short Cycle Protection taking any temperature readings. The temperature rise is the difference between the supply and return 1. With the system operating in cooling mode, note the air temperatures. temperature setting of the thermostat and gradually raise the set-point temperature until the unit de-energizes. NOTE: For typical duct systems, the temperature rise will 2.

  • Page 22: Manifold Pressure Adjustment

    Manifold Pressure Adjustment properly adjusted burner assembly, the flame bends The manifold pressure must be set to the appropriate down and to the right at the end of the heat exchanger value for your installation. To adjust the manifold pressure: tube.

  • Page 23: Charging An R-410A Unit In Ac Mode

    Charging an R-410A Unit in AC Mode at Outdoor OPERATING SEQUENCE Temperatures Above 65° F. The operating sequences for the heating, cooling, and fan 1. With the system operating at steady-state, measure modes are described below. Refer to the field and furnace the liquid refrigerant pressure in psig at the service wiring diagrams.

  • Page 24: Stage Cooling Mode

    5. When the thermostat is satisfied, the G, O and Y After Initial Power up: The control has a programmed adaptive ignition feature which varies the warm-up terminals on the control board are de-energized period as follows: If ignition is successful the warm-up opening the compressor contactor, and de-energizing is reduced by 3-seconds on each subsequent call for the reversing valve.

  • Page 25: Cleaning Of Heat Exchanger

    any dirt and lint that may have accumulated in the 9. Using 2 wrenches, separate the ground-joint union in compartment or on the blower and motor. Buildup of dirt the gas supply piping at the unit. and lint on the blower and motor can create excessive 10.

  • Page 26: Troubleshooting

    COMPONENT FUNCTIONS 9. Carefully remove the burner assembly from the furnace. DO NOT DAMAGETHE IGNITERWHILE REMOVING Comfort Alert™ Diagnostics THE BURNER ASSEMBLY. The Comfort Alert diagnostics module troubleshoots 10. Inspect the burners for accumulated dust or debris. heat pump and air conditioning system failures and If necessary carefully clean them with a soft wire accurately detects the cause of electrical and system brush and a vacuum cleaner.

  • Page 27: Figures & Tables

    FIGURES & TABLES 3/4" NPT Female 24 9/10 Drain Connector DOWNFLOW SUPPLY DUCT OPENING 47 1/2 13 1/2 13 1/2 13 3/10 DOWNFLOW 23 1/2 RETURN DUCT OPENING Electric Top View Supply Entry Low Voltage Entry Gas Supply 29.75 Entry 23.75 15.75 47.5...

  • Page 28: Airflow Information

    AIRFLOW INFORMATION Model Number Heating Input Heating Output Heat Switch Heating Rise Cooling Output Blower Motor DF6SF- (Btuh) (Btuh) Setting Range (° F) (Btuh) Size (HP) 1,062 72,000 57,600 X24K072C 35-65 24,000 10 X 10 46,800 37,440 1,640 100,000 80,000 2,005 X36K100C 40-70...

  • Page 29: Gas Information

    GAS INFORMATION CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60) NOMINAL BLACK LENGTH OF PIPE RUN (FT) IRON PIPE DIAMETER (IN.) 1 1/4 1,050 1 1/2 1,600 1,100 NOTES The cubic feet per hour listed above must be greater than the cubic feet per hour of gas flow required by the equipment. To determine the required cubic feet per hour of gas flow, divide the input rate of the unit by the heating value (from gas supplier) of the gas.
  • Page 30 FOR YOUR SAFETY READ BEFORE OPERATING POUR VOTRE SÉCURITÉ. À LIRE AVANT L’EMPLOI ATTENTION! L’inobservation de ces instructions peut WARNING: If you do not follow these instructions entraîner un incendie ou une explosion pouvant causer exactly, a fire or explosion may result causing property des dammages à...

  • Page 31: Electrical Information

    ELECTRICAL INFORMATION Figure 13. Two Stage Cool, Two Stage Heat (Heat Pump) High Fire Only - Gas Heating (2 & 5 Ton Only)
  • Page 32 Figure 14. Two Stage Cool, Two Stage Heat (Heat Pump) High Fire Only - Gas Heating - With Optional Comfort Alert (2 & 5 Ton Only)
  • Page 33 Figure 15. Two Stage Cool, Two Stage Heat (Heat Pump) High Fire Only-Gas Heating (3 & 4 Ton)
  • Page 34 Figure 16. Two Stage Cool, Two Stage Heat (Heat Pump) High Fire Only-Gas Heating “With Optional Comfort Alert” (3 & 4 Ton)

  • Page 35: Cooling Charging Charts

    COOLING CHARGING CHARTS - 15 SEER HEAT PUMPS DF6SF-X24 Charging Chart - Cooling Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (° F) Figure 17. Charging Chart for 2 Ton Units DF6SF-X36 Charging Chart - Cooling Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (°...
  • Page 36 COOLING CHARGING CHARTS - 15 SEER HEAT PUMPS DF6SF-X48 Charging Chart - Cooling Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (° F) Figure 19. Charging Chart for 4 Ton Units DF6SF-X60 Charging Chart - Cooling Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (°...

  • Page 37: Comfort Alert Troubleshooting Charts

    TROUBLESHOOTING Status LED Status LED Description Status LED Troubleshooting Information POWER Module has power Supply voltage is present at module terminals (Green LED) • Compressor protector is open • Check for high head pressure • Check compressor supply voltage Thermostat demand signal Y •...
  • Page 38 Status LED Status LED Description Status LED Troubleshooting Information • Thermostat demand signal is intermittent ALERT Short Cycling / Compressor • Low line voltage (contact utility if voltage at disconnect is low) Flash Code 3 is running only briefly • Excessive liquid refrigerant in compressor (Yellow LED) •...
  • Page 39 Miswired Module Indication Recommended Troubleshooting Action • Determine if both R & C module terminals are connected. Green LED is not on, module does not power up • Verify voltage is present at module’s R & C terminals. • Determine if R & Y terminals are wired in reverse. Green LED intermittent, module powers up only when compressor runs •...

  • Page 40: French Translations

    FRENCH TRANSLATIONS AVERTISSEMENT: AVERTISSEMENT: RISQUE D’INCENDIE OU D’ EXPLOSION RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE • Le non-respect avertissements OU D’EXPLOSION sécurité pourrait entraîner des blessures Le non-respect des avertissements de sécurité graves, la mort ou des dommages matériels. pourrait entraîner un fonctionnement dangereux •...
  • Page 44 Is the vent hood installed? Is vent hood free from restrictions Filter(s) secured in place? Filter(s) clean? Specifications & illustrations subject to change without notice or incurring obligations (05/15). O’Fallon, MO, © Nortek Global HVAC LLC 2015. All Rights Reserved. 7090350 (Replaces 7089160)

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