NorAire NC-FE series Manual

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Indoor Unit (IDU)
Installation & Operating Instructions
Model: NC-FE-***
Application
Air source heat pump with hydronic (or warm water) and chilled
water output
Equipped with Electro-Boiler boost and Backup
Dual heat (gas boiler) – mode selection, external backup boiler
and/or gas furnace only possible with Buffer Tank Controller (see
Field Setup section)
LMC (Load Management Control), PC setup selects –HP and Boiler
or Boiler only
Effective – Version 2.** and above.
System Configuration
This IDU is designed and configured to work with a standard
outdoor air source heat pump unit (ODU). The specific ODU
combined with this IDU is controlled by Electro Industries and their
associated HVAC distributor. Electro Industries maintains a list of
approved ODU make and model series. The distribution of this list
is limited to the distributors or contractors involved in this program.
This update includes capability for buffer controller combination.
Notice – If this IDU is installed with an ODU not shown on the approved list; functional integrity,
performance, support, warranty, and product liability does not apply.
Minimum Qualified Installer
Since this is a split heat pump configuration, HVAC trade or experienced technicians are required.
-ODU – Responsibility and knowledge for this part of the configuration with refrigerant
line set installation and adjustments related to superheat, sub-cool, and refrigerant charge.
-Hydronic – field provided accessories and configuration relating to circulator pump
sizing, flow rates, buffer tank, zoning, chiller water coil, forced air flow, etc.
Drawings: HX103, NH205, NR203, UAW105, XX017, XX036
DO NOT DESTROY THIS MANUAL. PLEASE READ CAREFULLY AND KEEP IN A SAFE
PLACE FOR FUTURE REFERENCE BY A SERVICE TECHNICIAN.
4003560

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Table of Contents
Introduction 1
Safety Considerations 2
Product Configurator (NC208) 3
Mechanical Specifications 4
Electrical Data 5
Installation Overview, Required System Components 5
Installation Requirements 6
Mechanical Installation
Hydronic – Heating 7
Chilled Water – Cooling 7
Water Fill/Purge Procedure 9
Mechanical Installation – Outdoor Unit (ODU) 14
Electrical Hookup
Power Source 15
Outdoor Unit (ODU) 15
Control 15
Additional Hookup or Special Equipment Concerns 17
Field Setup or Programming 19
Operation Indicators 21
User Instructions 22
Control Sequence 23
Start Up, Power On 27
Preventative Maintenance 29
Troubleshooting 30
Accessories 34
Replacement Parts 34
Drawings HX103
NH205
NR203
UAW105
XX017
XX036

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Introduction
When used and controlled properly, NorAire heat pumps can save hundreds of dollars in heating and cooling
costs per year. NorAire air to water heat pump is designed to provide maximum efficiency, comfort, and
reliability. Solid and simple electric controls allow for low maintenance and built in safety protection.
This installation and operating manual covers the indoor unit (IDU) only. As an installed heat pump system this
will also include an outdoor unit (ODU) manufactured by others, but used or installed from an approved Electro
Industries’ list. This ODU will have its own installation and operating instruction manual supplied by the ODU
manufacturer. Also, there may be additional hydronic output items such as buffer tank, Electro Buffer Tank
Controller, hydronic loop circulator pumps, zone valves, zone controller, room thermostat, radiant floor
thermostat, chiller water coil, air handler, gas furnace, etc. which will have their own manufacturer installation
and operating instructions.
Attached HX103 drawing set provides various suggestions for plumbing and piping. Each page shows a sample
heating or cooling possibility, depending upon the complexity of the heating system. On each page the upper
left statements attempt to categorize the specific design example. Also, attention needs to be given to the notes
pertaining to each page. These can be useful for the designer, installer, and perhaps the user to verify the best
and most efficient installation.
It is important the hydronic system be designed and installed according to the building layout, the total heat loss
requirement, and proper hydronic installation practices. This NorAire is the energy source for the radiant heat
or forced air cooling system, but critical field designed and installed items such as water flow, system
component selection, plumbing, and water coil size and airflow will affect performance. The installed NorAire
may not necessarily supply the comfort and heat/cool expected.
The operating efficiency of a heat pump product increases as the compressor current decreases. But compressor
current increases with outlet supply water temperature increase. Thus, the closer the supply water temperature
can be maintained to the true seasonal heating or cooling requirement, the more efficient (less operating cost)
the heat pump system will be. Optional or add-on devices (such as Buffer Tank Controller) with outdoor reset
supply water temperature control generally reduce annual operating cost.
Installation Tasks
This system requires more than a basic electrical hookup and refrigerant line sets. Attention needs to be given to
all installation and troubleshooting sections of this manual starting with page 8 through Start Up, Power On.
Especially the Field Setup or Programming and Additional Special Equipment Concerns could be unique for
each installation.
Control
This IDU is operated from an external and field provided heat or heat/cool aquastat (water temperature sensing
thermostat). From this external on/off electrical connection, the IDU internal controller provides all connections
and control for the external outdoor heat pump unit (ODU), IDU internal pump, IDU internal electric boiler, and
internal safety/limit devices.
The user must become familiar with the external aquastat, IDU front panel monitor lights, and various external
option controllers or other thermostats. Installer or service person will set up various dials and switches on the
back of the IDU control module and may adjust or change various factory defaults via a software PC program
and special Electro Industries provided communication cable (part number ET-SOFT-NA-USB).
This IDU controller has four temperature sensors (three internal plus outdoor, OT, field installed) and a mode
dial switch on the controller board back. The mode switch sets up three operating sequence and temperature
monitoring associated with three outlined system configurations. See Field Setup to verify this is properly set
for your specific configuration.
The front panel STATUS, SERVICE, and ALARM indicator lights can provide significant information to the
service technician. Suggest the user write down all status and light pulse count information before calling the
authorized service technician. This could greatly shorten his troubleshooting function.

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208 Voltage Application
The boiler electric elements are rated at 240 volts. If operated at 208, there will be an approximate 25% reduced
capacity. Also, the internal transformer may or may not adequately operate the control system from 208 volt
source. Voltage measurement between R and C must be greater than 23VAC when the system is in complete
operational mode. The control transformer primary winding tap wire (240 – orange or 208 – red) will need to be
changed for 208.
Warranty Statement
See the last page of this manual for detailed limited warranty coverage explanation. As stated in paragraph 2
above, this relates to the IDU only, other field provided and installed equipment will have their own coverage.
However, this IDU warrants proper operation and safety associated with the ODU’s represented by Electro
Industries’ official approved list.
Please read and understand conditions associated with proper installation, unauthorized changes, POWER ON
procedures, etc.
Moving and Storage
Units should be stored in original packaging in a clean dry area. Store and move units in normal upright
position. Do not stack units.
Initial Inspection
Be certain to inspect all cartons and crates as units are received before signing the freight bill. Verify that all
items received have no physical damage. Report any damages or shortages on the freight bill. The purchaser is
responsible for filing the necessary claims with the carrier. Concealed or hidden damages not discovered until
removing packaging must be reported to the carrier within 15 days of receipt.
Unit Location and Mounting
Locate the unit in an indoor area where the ambient temperature will remain above 45° F (__° C) [8°C]. See
next page for minimum clearance; however, allow enough room to remove panels for service and maintenance.
We suggest setting the unit on spacer so moisture at the bottom of the cabinet does not cause rusting. Water
loop should not be hard plumbed directly with rigid pipe as this could transfer any vibration to living space.
Safety Considerations
WARNING
BEFORE PERFORMING SERVICE OR MAINTENANCE OPERATIONS ON A SYSTEM, TURN OFF
MAIN POWER SWITCHES TO THE INDOOR UNIT. IF APPLICABLE, TURN OFF THE ACCESSORY
HEATER POWER SWITCH. ELECTRICAL SHOCK COULD CAUSE PERSONAL INJURY.
Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and
electrical components. Only trained and qualified service personnel should install, repair or service heating and
air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils
and cleaning and replacing filters. All other operations should be performed by trained service personnel.
When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels
attached to the unit and other safety precautions that may apply, such as the following safety measures:
Follow all safety codes.
Wear safety glasses and work gloves.
Use a quenching cloth for brazing operations.
Have a fire extinguisher available for all brazing operations.

09/21/2011 NC208
NorAire®Configurator
NC-FE-060-1-CPXX1-20-US
NorAire Air to Water IDU (1)
Unit Type (2)
C = Heat and Cool
H = Heat Only*
Unit Style (3)
F = Hydronic, Large Floor Mount
Refrigerant (4)
E = R-410A
Nominal BTU (5, 6, 7)
036 (Hydronic) 3-ton
048 (Hydronic) 4-ton
060 (Hydronic) 5-ton
Country (16, 17)
US = United States
CA = Canada
Auxiliary kW Option (14, 15)
10 = 10 kW
15 = 15 kW
20 = 20 kW
XX = N/A*
Vintage (13)
1 = Electro
Miscellaneous Kit (12)
X = N/A
Domestic Water Option (11)
X = No domestic water
Configuration Option (10)
P = Factory Installed Pump
X = N/A
Heat Exchanger Option (9)
C = Copper
Voltage Option (8)
1 = 208/230V, 1 Ph
2 = 208/230V, 3 Ph*
*Non-stocked
N C - F E - 0 6 0 - 1 - C P X X 1 - 2 0 - U S
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Model Number Digits

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Mechanical Specifications
IDU
(excluding internal EL boiler,
see below) Units -036 -048 -060
Water connection NPT, female 1” 1” 1”
Min water flow GPM 10 13 15
L/min 38 49 57
Internal pressure drop Ft of head 5.5 6.2 8.0
Hydronic pump (at stated flow) Ft of head 19 22 25
Line set sizing Follow outdoor unit manufacturer’s specifications
R-410A charged (if packaged
with factory ODU) Feet 25 25 25
Max line set Feet 100 100 100
Max vertical separation Feet 35 35 35
IDU width Inches 20 20 20
IDU height Inches 48 48 48
IDU depth Inches 23 23 23
Shipping weight Pounds 191 197 205
Note: Due to continuous product improvement, specifications are subject to change and update without notice.

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Electrical Data – IDU Control/Pump
(Part of Service Connected at CB1)
Units -036 -048 -060
Power voltage Volts/60Hz 208/240, 1 phase 208/240, 1 phase 208/240, 1 phase
Pump/transform current Amps 0.9 1.08 1.9
IDU basic power Watts 207 249 437
Electrical Data – Internal Electro-Boiler
(Backup Operating Mode Only)
Units 10 kW 15 kW 20 kW
Power voltage Volts/60Hz 208/240, 1 phase 208/240, 1 phase 208/240, 1 phase
Element current Amps 37/42 55/63 73/84
kW Kilowatts 7.7/10 11.5/15 15.2/20
Heating capacity Btu/h x 1000 26.3/34.1 39.1/51.2 51.8/68.2
Circuit breakers (disconnect) Amps 30 30 and 60* 60 and 60*
*Square D single feed bus adapter available, Electro part number 5701.
Installation Overview, Required System Components
Reference application drawing set HX103.
This NorAire heat pump generates hydronic warm water energy for heating and/or chilled water energy for cooling.
The application and plumbing usage for this hydronic energy can and will take an almost infinite number of system
design possibilities. This drawing set is intended to provide suggestions and system ideas for the overall building
application.
The NorAire heat pump may not provide satisfactory end results unless it is properly piped/plumbed and has proper
controls. Thus getting the total system design and system usage decisions made prior to starting installation can be a
significant step towards long-term satisfactory performance. Correct water flow and piping decisions certainly are
crucial, but along with this the system design needs to incorporate proper temperature sensing control and water pipe
distribution interface. Both are key to efficient and satisfactory performance.
The NorAire unit includes a circulator pump which when plumbed correctly can supply the primary circulation for
both heating and cooling. However, depending upon pressure drop in the external piping, additional series circulator
pump may be required. The IDU nameplate specifies a nominal GPM, it is the installer’s responsibility to make sure
flow is adequate. The PC CD software provides a GPM calculator.
The NorAire unit has a basic W and Y turn on. It depends upon external temperature sensing devices or zone
controllers to determine start and stop. The NorAire internal temperature sensing only relates to limits and internal
self diagnostics. All operating controls must be external. Depending upon the complexity of the heat/cool system
installation, Electro Industries’ Buffer Tank Controller has an integrated interface with the NorAire control board and
in most cases can greatly simplify the system control design. As a suggested concept, the HX103 drawing set also
provides some outline functional information about the accessory controller (HP-BTC).
As represented these systems can be as simple as a single radiant floor loop (sized to the full BTU output of the
specific NorAire unit) to added water coil cooling (sized to the NorAire capacity), to several buffer tank
arrangements, to both heat and cool forced air water coil, etc. Again, the NorAire heat pump will only perform to its
designed capability and efficiency if properly incorporated within a system design built around a compressor/heat
pump product.

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Installation Requirements
1. All installation work must be performed by trained, qualified contractors or technicians. Electro Industries
sponsors installation and service schools to assist the installer. Visit our Website at www.electromn.com
for upcoming service schools.
WARNING
ALL ELECTRICAL WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE
AND LOCAL ELECTRIC CODES, ORDINANCES, AND REGULATIONS.
WARNING
OBSERVE ELECTRIC POLARITY AND WIRING COLORS. FAILURE TO OBSERVE COULD
CAUSE ELECTRIC SHOCK AND/OR DAMAGE TO THE EQUIPMENT.
CAUTION
This unit can only be used for its intended design as described in this manual. Any internal
wiring changes, modifications to the circuit board, modifications or bypass of any controls, or
installation practices not according to the details of this manual will void the product warranty,
the safety certification label, and manufacturer product liability. Electro Industries cannot be
held responsible for field modifications, incorrect installations, and conditions which may
bypass or compromise the built-in safety features and controls.
2. If this is a Dual Heat system, this product relates only to the addition to the furnace ducting system external
to the gas or oil force air furnace. The owner/installer assumes all responsibility and/or liability associated
with any needed installation of the gas/oil furnace, fuel system, flue, chimney, etc. Any instructions or
comments made within this manual (or factory phone assistance) relating to the gas/oil furnace are provided
as comments of assistance and “helps” only.
CAUTION
This unit shall not be operated (either heating section or blower) until the interior of the
structure is completed and cleaned. This also means all duct work must be complete with
filter, etc. Manufacturer’s warranty is void if this unit is operated during structure
construction.
CAUTION
Hazards or unsafe practices could result in property damage, product damage, severe personal
injury and/or death.
3. All removed or discharged refrigerant must be recovered. Local and federal statutes are to be observed.
Should a compressor need replacing, the compressor oil is to remain with the compressor. Refrigerant lines
on the compressor must be sealed.
4. Remember, safety is the installer’s responsibility and the installer must know this product well enough to
instruct the end user on its safe use.
At Electro Industries the safety of the installer and the end user is of highest priority. Remember, safety is
the installer’s responsibility and the installer must know this product well enough to instruct the end user on
its safe use. Professional installers should be trained and experienced in the areas of handling electrical
components, sheet metal products, and material handling processes. Use them.

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Mechanical Installation – Hydronic/Warm Water Output
Use standard water heating loop parts/components and piping/plumbing best practices as if this NorAire IDU is
a “boiler”. Using a buffer tank, the input plumbing can be viewed as the “primary loop”. If a single radiant heat
loop is sized for the Btu output of the boiler, no primary loop is required, simply plumb direct to the loop
manifolds.
Drawing HX103 provides suggested piping for ten possible hydronic heat/cool arrangements. Potentially there
can be various combinations of these ten suggestions, but with an experienced hydronic installer, the
information on the HX103 drawing set should provide adequate details to design and install an appropriate
hydronic heat/cool supply arrangement. The upper left introductory statements and the notes on each page are
very important. Do not overlook the intended application associated with its suggested plumbing/piping. This
is specifically true with the chilled water direct supply output going to the water coil and whether or not the
forced air water coil can be used for both heat and cool.
Note: As these heat/cool configurations lead to control complexity, Electro Industries’ Buffer Tank
Controller is recommended and in the case of forced air water coil heat and cool the BTC is required
(order HP-BTC). The BTC has a special operating mode (mode D) designed just for proper interface
with this IDU and this IDU controller must have J3 jumper pulled.
This IDU has an internal circulator hydronic pump with one water return female NPT port and two water
supply NPT female ports – warm and chilled water are separate.
This NorAire heat pump has separate heating water and chilled water piped outputs. This is an important
feature typically not provided with other air to water (or even water to water) heat pumps. A few of these
benefits include – chilled water does not go through the boiler, the internal pump can be a direct output to the
forced air water coil (often the forced air water coil is a zone from the buffer tank, this inefficient and harder to
control with the radiant floor zone), either the hottest or the coldest water will always get to the forced air water
coil without the buffer tank, etc.
The return/supply piping and external hydronic load components must be sized to maintain the minimum water
flow stated in the Specification Chart. For design planning purposes the IDU external pumping allowed
pressure drop is the Specification Chart pump feet of head minus the internal pressure drop feet of head.
Since this is primarily a heat pump compressor energy generating product, provisions must be made in the
external hydronic arrangement to make sure a small heating zone does not short cycle the compressor. In other
words, if the smallest zone cannot use or absorb the Btu capacity of the ODU, a buffer tank type arrangement is
required. This same requirement relates to cooling or chilled water direct output. If the forced air water coil
cannot absorb or use the cooling Btu/h of the ODU, piping and system design will require a buffer tank (single
tank will result in heat/cool switchover) or dedicated cooling buffer tank.
Note: The IDU control system is limited, when the system involves buffer tank (single or dual) various
thermostats, air handler, etc. the option Electro Buffer Tank Controller (HP-BTC) is strongly
recommended.
Disclaimer – the intent of the HX103 drawing set is suggested application and system concepts. The end use
designer and installing contractor have the responsibility for all equipment, any additional components not
shown, and detailing required system performance and local codes.
Flow switch – there is a built-in safety flow switch at the internal pump return. Typically this will indicate flow
above 2.0 GPM. The contacts of the flow switch feed into the controller board at the OPT tab.

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Hydronic floor zones – recommend slab stats for temperature sensing control of radiant floor heating. If the
system is hydronic storage, a slab stat is definitely required. In order to provide a single W-in control to this
IDU controller, a zone controller (EB-ZEA8) or Electro’s Buffer Tank Controller (HP-BTC) is strongly
recommended.
Water fill and purge comment – plan the field method of water fill and method for purging air. See next
section for suggested details.
Water condition – if properly filtered and softened water is used, water additive should not be necessary.
However, depending upon the buffer tank selection and the type of piping, a water additive is recommended.
Open system/non-oxygen barrier tubing/Polybutylene – if there is opportunity for oxygen and corrosive
build-up to accumulate within the hydronic water loop, either a zone side isolation water to water heat
exchanger or this IDU must be updated with stainless steel Electro-Boiler vessel and brass or stainless steel
circulator pump. Also, the vertical lift must be less than approximately 15 feet.
WARNING
DEFROST BYPASS TUBE (½” NEXT TO BOILER VESSEL) WILL NOT SELF PRIME AND CAN AIR
LOCK THE PUMP DURING ODU DEFROST.
Closed system/oxygen barrier PEX – this is recommended to prevent deterioration of internal piping and
components. Standard best practices hydronic design and plumbing must be used for proper flow and long-term
performance and reliability. The key mechanical components include:
Expansion Tank – as a closed loop hydronic heating system, a minimal expansion tank is required.
This can be an air diaphragm tank or a basic “empty” tank where air is compressed at the tank top.
Inlet Temperature Gauge – recommended to observe the operation of the system.
Air Vent – install with the pressure relief valve.
Inline Air separator – this can be installed ahead of the pump with the expansion tank moved to this
point.
Pressure Safety Valve – this is required and is furnished as a loose component. Failure to install the
provided, 30 PSI, pressure relief valve as shown void warranty and the CSA product listing. Add the
necessary pipe extension to the relief valve to prevent water damage on this unit or surrounding area.
Gate Valve/Drain Valve – these are for servicing and easy fill purposes.
Circulating Pump – the internal IDU capability is shown in the Mechanical Specification chart.
Depending upon load system piping and hydronic load components, an additional pump may be
required to provide the minimum flow stated with the Mechanical Specification chart. Basically parallel
wire this external series pump to the pump within the IDU cabinet.
Approved tubing/piping – when plumbing this NorAire system and radiant floor loop system, all plumbing
parts and/or tubing must be sealed to prevent re-circulating new oxygen.
Use only tubing or Polyethylene tubing with oxygen diffusion barrier.

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Water Fill/Purge Procedure
Piping design and installation must include adequate shutoff valving and external connection valve/ports to
force pressure water around the system without any pockets or air voids within all plumbing loops. Careful
placement of these source and dump ports is very important with an in-between shutoff valve to make sure
exiting air does not get back into the system or remain trapped.
IDU heating and chilled supply out – both need to be purged independent and care must be taken so when
purging air does not re-enter the previous. Also, there is potential for trapped air within the internal defrost
bypass loop which can cavitate the internal pump.
Suggested purge and fill – to properly work through heating and chilled water supply outputs, with the defrost
bypass concern; it is mandatory that the installer perform proper purge and fill process. These next pages
provide a step by step procedure, following this is not necessary but it is provided as a guide. However, the
“purge or recheck defrost boiler bypass” section within this procedure is extremely important. This is over and
above what is normally required for a typical boiler/hydronic system. IDU power-on and the aquastat type
device (R to W or R to Y) should be active (installing technician could use an R to W or R to Y jumper). Note:
After IDU power-on, must allow ACD timeout (power on LED is solid).
Basics
1. The pressure relief valve (R) is set at 30 psi. Verify there is an extension pipe bringing the output to a
bucket or floor drain. Typically city water and well water is higher than 30 psi. Thus you will either
need a regulator or a hand valve to manually make sure the hydronic circulating pressure is less than 30
psi so you do not “blow” the pressure relief. By throttling the introduced city water with a hand valve
you can control the pressure within the hydronics loop down.
2. Do not run a hydronic circulator dry or without water flowing. The motor can overheat in a very short
time and result in undesired troubleshooting conditions. A basic small hydronic circulator will not self
prime or pull water. There must either be a column of water (3 to 4 feet high) above the inlet of the
pump or a source pressure system which is initially forcing water through the pump. As little as a 1” to
3” air bubble within the inlet pipe can cavitate the pump and can stop circulation.
3. If there is a buffer tank, this should be totally filled before starting at the zone/loops. Remove the top
plug or cap and fill completely.
4. Typically there will be more than one radiant loop and probably more than one zone (zone typically
means several loops with a manifold collection). You must always start with one zone, then one loop,
and when all loops are individually purged, you move on to the next zone and repeat. When you feel
the previous zone is air purged, hand valve it closed, preferably on both sides of the manifold (A and B).
5. Determining when all the air is removed takes experience. Do not quit after it appears a set of bubbles
are gone and there is now a clear stream of water. Typically you need to drain long enough to where
there is a new circulation of water through the loop and system after seeing the last bubble. If a typical
header piping and one 250-foot ½” loop holds 3.5 gallons and the city water is flowing at 2 GPM, you
should continue to see a steady stream of water for 3 minutes.
6. For purge and fill purposes, a forced air water coil circuit is treated basically the same as a zone, the
circuit must have its own input connection and drain connection with a valving method to force the city
water all the way around the circuit.
7. Almost any pressure water source could be used for purging, but at the end you should consider refilling
with a softened or mineral free water or rust inhibitor additives.
8. If your system needs antifreeze, first purge with a continuous water source and this procedure. If there
is a buffer tank, drain out (all valves around the tank closed) the water equal to the antifreeze you need
to add. Make sure the tank is totally filled (no air) before re-circulating system test and pressure
verification, reference the following steps 10 through 17.

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Radiant (Only) Heat Circuit Procedure
1. Condition the heat aquastat to on for 5 to 10 seconds (jumper R to W). The front panel STATUS light
should be full on indicating the control board is set up for heating mode.
2. Connect a city water or well water source as shown.
3. If your system does not have a loop manifold with easily connected hose ports on each end (as shown),
you will need to make a valving arrangement with two ports (hose bib) as shown on the next
Cooling/Chilled Water Direct drawing.
4. Notice the two valves marked Aand B. Again if your loop manifold does not have shutoff valves going
to the leader pipe you should be installing these on your system.
5. Only open one loop (small valve above each tube), the others should be closed.
6. Begin with both Aand Bvalves open. Begin introducing city water with hand valve S, being aware of
Basics paragraph 1 above.
a. Flow is through the return manifold/NorAire IN/through boiler vessel/heating water
OUT/through air separator/supply manifold top/drain.
b. This first pass will involve all of the above piping, thus the times mentioned in paragraph 5
above will not apply.
7. You should begin seeing air bubbles coming out of the drain hose. Reference paragraph 5 above, run
the refill city water until you are absolutely sure all air is purged.
8. Move to the next floor loop by simultaneously opening the next and closing off the previous. Continue
steps 5-7. Repeat until all radiant loops are air purge and water filled.
9. Simultaneously close valves Aand B. Keep this zone circuit in this condition until all others are air
purged and filled.
10. At the end keep city water and drain connected. At the IDU cabinet, left side, remove the side panel.
This will allow easier viewing of the pressure/temperature gauge (also will need to be inside later for
defrost bypass purging). Observe gauge, set at 15 psig. Turn off the city water source and close drain.
But continue to keep the hoses connected.
WARNING – AVERTISSEMENT
RISK OF ELECTRIC SHOCK – CAN CAUSE INJURY OR DEATH
RISQUE DE CHOCS ÉLECTRIQUES – PEUT CAUSER DES BLESSURES ET MÊME
ENTRAÎNER LA MORT

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11. Control board, left center, locate a tab marked “pump”. Clip jumper R voltage to the “pump” tab. This
will force the internal circulator pump on and you should be experiencing flow throughout the system.
12. Depending upon the air separator and air relief system, loosen the top air cap.
13. Open all manifold valves – A and B.
14. Depending upon the number of zones and the zone control system, the zone controller may need to be
bypassed to activate zone valves or to turn on zone pumps to adequately verify flow within the total
system.
15. If the pressure gauge goes down or fluctuates there is probably still air in the system. Again, depending
upon the quality of the air separator it may purge out itself or you may need to start over.
16. Open all radiant zones and the manifold individual loop valves. Depending upon the manifold features,
you may have small flow indicators which can verify equal or adequate flow in each loop.
17. After you feel comfortable there is good circulation and all the air has been purged, recheck pressure
gauge. A one or two story building/house system with cold water should be set at about 10 to 12 psig.
Using the still connected city water set correct pressure.
18. Disconnect city water hose and drain hose and remove the “pump” jumper.
Purge or Recheck Defrost Boiler Bypass
1. Setup or source/drain should be the same as above and in heating mode.
2. This should actually be run before step 15 above.
3. On the back of the NorAire control board, upper right, at the heat pump connection remove the “D” wire.
Be prepared to clip jumper R to D.
4. This test needs to verify that the water going through the pump begins to heat up from the boiler during
a simulated defrost. If it does not heat up at the pump (but the top of the boiler vessel gets hot), you
must assume the ½” pipe between the vessel top and the tee at the pump input is air logged and has
caused the pump to stop circulating.
5. Jumper heat pump R to D terminal block point, wait approximately 2 minutes and you should begin
feeling warm water entering the pump. As time goes on the ½” pipe should be getting hotter and hotter
because water is simply circulating through the boiler/pump/heat exchanger/ back through the boiler.
WARNING
DO NOT LEAVE THIS TEST UNATTENDED.
6. With confidence that the warm water is indeed circulating through the heat exchanger, remove the R to
D jumper and replace the wire from the ODU into the D screw terminal block point (reference step 3
above).
7. Continue step 15 above.

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Radiant Heat & Cooling/Chilled Water I Circuit Procedure
Comment – the following relates to the chilled water out piping and water coil circuit. It is assumed a
procedure similar to the previous will be used to take care of the heating water out and the radiant floor
circuits.
1. Condition the air stat (Y) or cool aquastat for a 10-second cooling call, remove jumper or condition stat
back to off. The front panel STATUS light should indicate cooling mode with a slight off blip.
a. This conditions the internal NorAire pump to “chilled water OUT”.
2. Suggest a hose and valving arrangement as shown, shutoff valves C and D with two connection hose
bibs. Valve D should be as close as possible to the tee and also the drain hose bib close to valve D.
3. Connect a city water or well water source as shown.
4. All valves A and B or any possible flow associated with radiant manifold circuit must be closed.
5. Close valve D and open valve C.
6. Valve C can be a “throttling valve” to limit pressure.
7. Begin adding source water, drain should show bubbles or discharge water.
a. Flow is through hydronic IN/internal pump/chilled water OUT/water coil/drain.
b. Comment – depending upon buffer tank/water coil arrangement (HX103 sheets 3, 4, 5, 6, 11)
where the buffer tank is heating only and feeds directly into the NorAire IN. Also, the next
section shows a buffer tank arranged for heat/cool switchover (HX103 sheets 7, 8, 9).
8. Reread paragraph 5 (basics) above.
9. Close both source and drain hose bibs and open valves D and C.
10. Probably recheck above steps 10 through 17 under Radiant Heat Procedure. The existing setup for
source and drain can be used to correctly set the system pressure.

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Cooling/Chilled Water II Circuit Procedure
Comment – the previous page circuit had the chilled water return feeding directly to the hydronic IN pipe.
In this circuit the chilled water return feeds at the buffer tank top for buffer tank switchover application.
1. Condition the air stat or cool aquastat for a 10-second cooling call, remove jumper or condition stat back
to off. The front panel STATUS light should indicate cooling mode with a slight off blip.
a. This conditions the internal NorAire pump to “chilled water OUT”.
2. In this plumbing arrangement the water coil uses the buffer tank as it returns to the NorAire hydronic IN.
The buffer tank is used for both heat and cool thus switchover is required and needs to be controlled by
the added Buffer Tank Controller (HP-BTC).
3. Connect a city water or well water source as shown. This source connection can be anyplace forcing
either into the bottom of the buffer tank or directly into IDU IN (there may be a drain valve at the
bottom of the buffer tank).
4. All valves A and B (Radiant Heat Procedure) must be close but in this case open valve B which is
associated with the manifold having the source connection.
5. Close valve F and open valve E. Suggest valve F and drain hose bib as close as possible to the tee.
6. Begin adding source water.
a. Flow is through the source attached manifold/buffer tank/hydronic IN/internal pump/chilled
water OUT/water coil/drain.
7. Reread paragraph 5 (basics) above.
8. Close both source and drain hose bibs and open valves F and E.
9. Probably recheck above steps 10 through 17 under Radiant Heat Procedure. The existing setup for
source and drain can be used to correctly set the system pressure.

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Mechanical Installation – Outdoor Unit (ODU)
Consult and use details within the ODU manufacturer’s supplied installation manual. The refrigerant to water
heat exchanger within this IDU is essentially the same as the refrigerant to air coil within the ODU
manufacturer’s specified A-coil (dual fuel) or matched air handler.
Since this is a heat pump (winter use) it needs to be installed off the ground, on a stand or blocks with at least 8”
to 12” ice build-up space under the unit.
This IDU includes an adjustable TXV expansion, common with air coils. This IDU only has a nitrogen charge.
The ODU has extra charge volume for line set and this IDU internal heat exchanger (coax).
See ODU installation manual for special line set slope conditions or oil trap if the elevation between the ODU
and the IDU at a certain height.
This ODU requires a field added filter/dryer; however, there are some ODU’s which have the filter/dryer
internally installed, in this case do not use a loose filter/dryer. Add in the liquid line preferably at this IDU.
Line set – use ODU manufacturer’s requirements for line set. However, since the IDU coax heat exchanger has
a smaller charge volume than the typical forced air A-coil matched with this ODU, this IDU includes a
refrigerant liquid receiver. There probably is no need to calculate extra charge for extra line set length because
the IDU receiver will have as much as 16 oz. additional charge available.
Note: There is a concern for possible ODU overcharge, the IDU receiver may not take up the full ODU
extra charger. Thus, it is very important during the power-up checks and adjustments to make sure the
sub-cool/superheat is within tolerance shown within the ODU provided Operating Conditions chart or
ODU nameplate chart.
Evacuate and leak check – as required with all air conditioning or heat pump line set installations, the prudent
and proper vacuum pump down and leak check are required. The ODU manufacturer’s supplied installation
manual details must be followed as well as refrigeration best practices.

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Electrical Hookup
IDU – Power Source – Reference NH205
From the internal circuit breakers, route and install the proper current carrying conductors to the building fuse or
circuit breaker panel. See Electric Data specification chart or product nameplate for ratings.
This IDU contains built-in circuit breakers and meets the requirement for local disconnect.
CB1 is highest priority stage.
WARNING
USE ONLY COPPER WIRE FOR CONNECTION TO THE CIRCUIT BREAKER TERMINALS AND
INSIDE THIS PRODUCT’S CABINET.
If using single feed method, a single feed bus adapter is available, order part number 5701.
Comment – the IDU internal circulator pump is pre-wired from CB1.
Grounding – copper conductor is required, size per NEC/CSA code relating to the current of each feed.
WARNING
TO AVOID THE RISK OF ELECTRIC SHOCK OR DEATH, WIRING TO THE UNIT MUST BE
PROPERLY GROUNDED. FAILURE TO PROPERLY GROUND THE UNIT CAN RESULT IN A
HAZARD LEADING TO PERSONAL INJURY OR DEATH.
Outdoor Unit (ODU) – Power Source
See the appropriate nameplate and/or instruction manual supplied with the ODU.
Control Hookup
Reference drawing NH205
Aquastat (stat) – this heat pump system is basically turned on/off with a standard HVAC type R to W or R to Y.
Piping suggestion drawing HX103 has various aquastat or thermostat suggestions. Sheet 2 could be a
single 4-wire air stat. Sheets 4 and 5 begin to become more complex, option HP-BTC is suggested. For
sheets 6 through 9 optional Buffer Tank Controller (HP-BTC) is required.
Buffer tank controller – see comments above and BTC hookup (NH205, page 2).
Outdoor Unit (ODU) – Control
Five or six low voltage or thermostat type wires are required between this IDU and the ODU control wires. The
IDU control board connection is the upper right 5-place terminal block (heat pump). Drawing NH205 page 1
provides general contact points and suggested wire colors.
Comment: In each particular shipment there may be a non-Electro ODU (see cover comment). In this
case there will be a separate ODU hookup drawing associated with the specific ODU.
ODU with 2nd stage compressor – the HP-Y2 output is a K6 contact inside of the wiring compartment, behind
the hinged controller door. Reference wiring schematic decal, UAW105, just above the color code chart is a K6
shown as an open contact. Typically this requires an R (or 24V) field connection on one tab and the 2nd tab is
wired directly to the ODU HP-Y2.

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Outdoor temperature sensor (OT) – extend sensor to an outdoor location properly
sampling the outdoor temperature. Select a location away from direct sunlight and
where the sensor will not pick up false temperature from the heat pump outdoor unit,
refrigerant line sets, dryer vent, reflection off of steel siding, etc. Do not install the
sensor in any type of enclosure, as this will falsely trap and pick up radiant sun
temperature. Mount the sensor horizontally on the structure using the screws provided.
Other sensor related comments – if additional cable length is required, you must use the following rules for
extending the cable.
Use unshielded (low capacitance, preferred twisted) 3 or 4-wire low voltage cable.
50 feet (15 meters) is maximum (total).
Do not, under any circumstances, use leftover wires within the normal thermostat cable.
Route the sensor cable making sure you do not crimp, cut, staple, or damage the cable in any way.
Keep sensor cables at least 12” (30.5cm) away from any line voltage wiring, romex, etc.
For easy sensor cable disconnect and reconnect, the WarmFlo board has a plug-in 4-place terminal block.
Before disconnecting, you will notice two red wires are under the red screw and two white wires is under the
COM screw. The black wire represents the data information from each sensor and must be connected to the
appropriate OT or ST screw.
The sensor has polarity, is sensitive to incorrect voltage, and must be protected from static voltage. Do not cross
connect or inadvertently short out sensor wires with power on. Permanent sensor damage may result.
Utility interrupt – this is marked “blue and blue/white”, leave jumper intact unless PC download setup is for
HP, boiler, or all. In this case remove blue jumper wire and connect the two screw terminals to a utility device
with closed = off-peak.
Note: The PC setup “utility interrupt” determines the action from this remote time clock or utility
device. If this setup is set as “none” any connection associated with these two terminal screw points
have no effect (see Field Setup section).
More than one controller within the overall system: Depending upon the configuration it is possible
to have other control boards requiring interrupt. Example, if the Electro Buffer Tank Controller is
connected (next section), the blue wire jumper remains on this NorAire board. Also, if the buffer tank
has a backup Electro-Boiler (for whatever reason there isn’t one within the NorAire cabinet) operating
as mode C, the external Electro-Boiler must have its own utility interrupt connection if it is to be
controlled. The mode C application assumes an external gas boiler.
Backup – only relates to operating mode C. The two tabs (T8 and T9) provide an isolated contact to the backup
or auxiliary boiler.

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Additional Hookup or Special Equipment Concerns
Buffer Tank Controller
Recommended, see various drawing HX103 notes and pages and previous control hookup page.
J3 pin jumper – this must be pulled when the optional Buffer Tank Controller is connected. The internal
micro software must know the buffer tank is now directing all control functions to this NorAire
controller. Also the Buffer Tank Controller mode must be set to D.
RV Logic Selection, Control Board Top
The controller must match reversing valve logic of the specific outdoor unit (ODU) connected to this IDU. See
next section – Field Setup.
Utility Interrupt Device, Blue and Blue/Wht Terminal Block
See previous page for connection, but the PC setup download must select the control mode or control load. The
factory default is “ALL” thus a utility load interrupt will drop both compressor and boiler. PC download allows
the option of selecting boiler only.
UTIL INT Tab
External switch to common forces a utility interrupt. This is the same as opening the blue and blue/white
jumper.
Option – COM/NC/NO Tabs
The boiler shutoff valve relay has an auxiliary Form C contact. COM to NO is heating or COM to NC is chilled
water.
Configuration, Forced Air Stat-W (Heating)
Only applies to forced air water coil heating, configuration must be HX103 page 9 or 10 with HP-BTC and N-
3WVK-1. This option 3-way valve kit has installation wiring details. Also see Start Up section.
Mode C, Backup Configuration
Mode B should be used strictly for the internal Electro-Boiler. All external backup should use mode C with the
backup isolated contact (K2). Mode C using gas furnace (not gas boiler connected to the buffer tank) gets very
tricky, the system must be configured with optional Buffer Tank Controller with its mode B (gas furnace)
sequence. K2 is activated in mode C but controlling a gas furnace directly from K2 is not recommended. See
hookup drawing NH205 page 2 and HP-BTC installation manual for gas furnace usage during NorAire declared
B/U mode.
Reference mode C, the requirements for external boiler, backup mode:
1. This external boiler shall not be piped in series with the NorAire in/out (internal pump).
2. NorAire W-in controls the boiler via K1/K2 isolated contact – bottom left, Backup COM and NO.
3. No other connection to IDU board, including C or 24V.
4. Contains its own safety limits, etc.
5. Contains its own pump or pump relay for its own buffer tank parallel or “side arm” pumping
arrangement.
6. NorAire backup mode is activated from SW OVER setting, Figure 4 sequence, front panel backup
switch, and Hard Hold alarm.
7. If electric boiler, suggest EB-MA-** series and set the target at 120° F (49° C).
a. Requires independent load control device.

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Variable Speed Pump
Variable pump can be used on the load side of the buffer tank, but not in the NorAire supply OUT circuits.
Low Flow, Need Larger Pump
If the IDU internal pump does not have adequate capacity or lift, add a series 2nd pump at the IDU “IN” pipe and
wire in parallel to the internal pump (240VAC). However, one of the OUT’s may have higher flow resistance
(head). In this case adding a small series pump in the OUT may be the best solution.
E-Tab (Compressor No Response)
If the connected ODU has an “L” or a fault wire available, extend this wire to the E tab. This must be a
continuous 24V, not pulsing or “flashes”. When this is raised to 24VAC, this controller assumes the compressor
is off and provides an alarm front panel LED plus initiates backup or emergency heat. The HP-Y will continue
until either stat W or stat Y is satisfied. Cycling of either stat W or Y will reset and the IDU controller will go
through a sequence of again evaluating the E tab input.
Pump Tab
An external contact from R to “pump” tab forces internal pump relay on. This will override any internal
software sequence.
Special Arrangement, Gas Furnace Backup with Buffer Tank Controller Option
With a field installed added wire it is possible to use the gas furnace and Buffer Tank Controller mode C as an
additional backup or standby option. See Buffer Tank Controller installation manual HI114 which will detail a
field installed wire added between this control board B/U wire or tab and the BTC board MON-A tab.
PC Remote Default or Setup Downloads
The controller left pin connector (J5) receives the Electro Industries’ special cable for PC communication to this
controller (order ET-SOFT-NA-USB). See the instruction sheet or software CD Help file accompanying this
cable.
Comment – No Factory Installed Electric Boiler
If the radiant system return (RT) is < 70° F (21° C) there may be an ODU defrost delay and problem. Adequate
refrigerant energy may not be developed from cold return water to properly defrost and permanent freeze-up of
the ODU may occur.
ODU with 2nd Stage Compressor
Where this applies, see page 15 bottom and the K6 wiring.