Nortek GR4GM-150 Series User manual

These instructions are intended primarily to assist qualified individuals experienced in the proper installation of this
appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all
instructions carefully before starting the installation.
GR4GM - 150/180 Series High Efficiency
Installation Instructions
Single Package Gas Heating/Electric Cooling Rooftop Units
Improper installation, adjustment, alteration,
service, or maintenance can cause injury or
property damage. Refer to this manual. For
assistance or additional information consult
a qualified installer, service agency, or the
gas supplier.
• Donottrytolightanyappliance.
• Donottouch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.
• Extinguishanyopename.
Do not store or use gasoline or other
ammablevaporsandliquidsinthevicinity
of this or any other appliance.
WARNING:
!WHATTODOIFYOUSMELLGAS:
DONOTDESTROY.PLEASEREADCAREFULLYANDKEEPINASAFEPLACEFORFUTUREREFERENCE.
Model GR4GM-150/180 Shown

2

3
GENERAL SPECIFICATIONS......................................4
SAFETY CONSIDERATIONS.......................................4
 •Literature,Labels,andTags ..................................4
 •PressuresWithinTheSystem ...............................4
INSTALLATION REQUIREMENTS...............................4
 •EquipmentApplication ..........................................4
 •EquipmentCheck..................................................4
 •RequirementsandCodes .....................................4
 •UnitLocation .........................................................4
 •VentingRequirements..........................................4
 •UnitDimensions .................................................5-6
 •ClearancestoCombustibleMaterials....................7
 •Thermostat ............................................................7
 •AirFilterRequirements .........................................7
 •CondensateDrain .................................................7
UNIT INSTALLATION ...................................................8
 •Rooftop..................................................................8
 •GroundLevel.........................................................8
 •RiggingandHoisting .............................................9
AIR SUPPLY FOR COMBUSTION
 ANDVENTILATION .................................................9
CIRCULATING AIR SUPPLY......................................10
 •UnconditionedSpaces ........................................10
 •AcousticalDuctwork............................................10
 •DownowtoHorizontalConversion.....................10
GAS SUPPLY AND PIPING .......................................11
 •LeakCheck .........................................................11
GASCONVERSIONANDHIGH
ALTITUDE DERATE...............................................11
 •Conversion ..........................................................11
 •HighAltitudeDe-Rate .........................................12
ELECTRICALWIRING ...............................................12
 •General ...............................................................12
 •LineVoltage.........................................................12
 •BlowerSpeed......................................................13
 •RoomThermostat................................................13
SYSTEMCHECK .......................................................13
 •Pre-StartCheckList ............................................13
 •ElectricalDataTable......................................14,20
START-UP PROCEDURE..........................................14
 •AirCirculation.....................................................14
 •SystemCooling ..................................................15
 •SystemHeating..................................................15
 •VerifyingandAdjustingTemperatureRise..........15
 •VerifyingBurnerOperation.................................15
 •VerifyingOperationofOver-Temperature
Limit Control ....................................................15
COMPONENT FUNCTIONS .....................................16
 •FlameSensor.....................................................16
 •FlameRoll-OutControl ......................................16
 •PressureSwitch .................................................16
 •Over-TemperatureLimitControl .........................16
UNIT MAINTENANCE...............................................16
 •RefrigerantCharging..........................................16
 •RoutineMaintenance .........................................17
 •AirFilters ............................................................17
 •VentCoverAssembly .........................................17
 •CondensateDrainandOutdoorCoil ..................17
 •Electrical.............................................................17
 •MotorLubrication ...............................................17
 •BlowerCompartment .........................................17
 •HeatExchangerandBurnerMaintenance .........17
 •CleaningofHeatExchanger ..............................17
 •CleaningofBurners ...........................................18
OPERATING SEQUENCE.........................................18
 •CoolingMode .....................................................18
 •BlowerMode ......................................................18
 •HeatingMode.....................................................18
 •UnitFailstoOperate ..........................................19
 •HeatingRise/RangeTable..................................19
SPECIFICATIONS/ELECTRICAL DATA ....................20
LIGHTINGINSTRUCTIONS......................................21
WIRINGDIAGRAMS ............................................22-23
BLOWERPERFORMANCE .................................24-25
UNITFEATURES,LAYOUT.......................................26
ACCESSORIES,REPLACEMENTPARTS ...............27
INSTALLATIONCHECKLIST........................backcover
TABLEOFCONTENTS

4
GENERALSPECIFICATIONS
GR4GM Series Single Package Gas Heating/Electric
Cooling units are designed for outdoor rooftop or ground
level slab installations. The units are shipped ready for
downowductconnectionsandareeasilyconvertedfor
horizontalowconnections.
All models are shipped from the factory with the
following:
 1. AdjustableBelt
 2. Downowductconnections
 3. 24Vcircuitbreakerprotection.
UnitdimensionsareshownonthePhysicalDatapages.
SAFETYCONSIDERATIONS
It is the responsibility of the installer to ensure that the
installationismadeinaccordancewithallapplicablelocal
and national codes.
Equipment Check — All units have been securely
packaged at the point of shipment.  After unpacking
theunit,carefullyinspectitforapparentandconcealed
damage.  Claims for damage should be led with the
carrier by the consignee.
Requirements and Codes — The installer must comply
withalllocalcodesandregulationswhichgovernthistype
equipment.Localcodesandregulationstakeprecedence
overanyrecommendationscontained inthese instructions.
Intheabsenceoflocalcodes,theinstallationmustconform
withtheNationalFuelGasCode(ANSI2223.1,NFPA-54),
orCanadianinstallationsmustconformwithCAN/CGA-
B149installationcodes.Allelectricalwiringmustbemade
inaccordancewithcodesandregulationsandwiththe
NationalElectricCode(ANSI/NFPA70)orinCanadathe
Canadian Electric Code Part 1 CSA C.22.1. Air Ducts
must be installed in accordance with the standards of
the National Fire Protection Association “Standards for
InstallationofAirConditioningandVentilationSystems”
(NFPA90A),“Installationofcombinationheating/cooling
unitsmustalsoconformwithcurrentC.S.A.StandardB52
“MechanicalRefrigerationCode.”
TheNationalFuelGasCodeisavailablebywriting:
 AmericanNationalStandardsInstitute,Inc.
 1430Broadway
 NewYork,NY10018
NFPApublicationsareavailablebywriting:
National Fire Protection Association
 BatterymarchPark
 Quincy,ME02269
Unit Location — The R4 series gas/electric unit is
designed only for outdoor installations. Choosing the
locationoftheunitshouldbebasedonminimizingthe
lengthof thesupply andreturn ducts.Considerationshould
alsobegiventoavailabilityoffuel,electricpower,service
access,noise,andshade.
Venting Requirements — This unit has been equipped
withanintegralventingsystemanddesignedtooperate
onlywiththisventingsystem.Noadditionalventingshall
be used. This unit must be vented to the outdoors.
WARNING:
Improper installation, service, adjustment,
or maintenance may cause explosion, re,
electricalshockor otherhazardousconditions
whichmayresultinpersonalinjuryorproperty
damage. Unless otherwise noted in these
instructions, only factory authorized kits or
accessoriesmaybeusedwiththisproduct.
!
Literature,Labels,andTags—Whenworkingwiththis
equipment,followallprecautionsintheliterature,ontags,
and on labels provided with the unit and/or approved
eldinstalledkits.Thetypeofhazardandseverityare
described on each label or tag.
Pressures Within The System — This equipment
contains liquid and gaseous refrigerant under high
pressure. Installationor servicingshouldonly beperformed
byqualiedtrainedpersonnelthoroughlyfamiliarwiththis
type equipment.
INSTALLATIONREQUIREMENTS
Equipment Application — Before beginning the
installation,verify that the unitmodelis correct forthe
job.Theunitmodelnumberisprintedonthedatalabel.
This furnace is NOT to be used for temporary heating of
buildings or structures under construction.
WARNING:
Donotventfurnacethroughaconventional
venting system.
!

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GR4GM-150/180SERIES–PHYSICALDATA
FRONT VIEW
COMPRESSOR
ACCESS
BLOWER MOTOR
ACCESS
ELECTRICAL PANEL
ACCESS
BURNER
ACCESS
CG
TOP VIEW
HEAT EXCHANGER
CONDENSER
COIL
CONDENSER
FANS (3)
4 (102) TYP
VENT HOOD
38.75"
93 (2362)
85 (2159)
INDUCER/BURNER
ASSY
4 (102) TYP
87 (2210)
41.25"
79 (2007)
CORNER "A"
CORNER "D"
CORNER "C"
CORNER "B"
REAR VIEW
STAGE 2
EVAPORATOR
FILTERS (8)
HOISTING
CONNECTION
POINTS
STAGE 1
EVAPORATOR HEAT EXCHANGER
TUBE ACCESS
88.50 (2248)
2 (51) TYP
43 (1092)
47 (1194)
AIRFLOW
COMPRESSOR
ACCESS
BLOWER
ACCESS
FILTER
ACCESS
Dimensionsshownininches(mm)