Kelvinator JS4BD030KB Installation Guide
Contents
1. Table 3 Charging Table for S4BD 018 Series 1 5 Ton Units Orifice Matches OUTDOOR TEMPERATURE F Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 256 136 127 257 139 280 139 281 143 304 143 259 146 305 146 328 146 260 150 283 150 329 150 352 150 284 153 307 153 353 153 376 153 308 157 156 377 157 400 157 160 401 160 424 163 402 164 425 426 Table 4 Charging Table for S4BD 024 Series 2 Ton Units Orifice Matches 12 LEGEND HGS Shaded boxes indicate flooded conditions L Rated design values The suction pressure will be lower than design value if outdoor air flow entering dry bulb or entering wet bulb temperatures are lower than design NOTES 1 All pressures are listed psig and all temperatures in F 2 Discharge temperatures GREATER than charted values indicate an UNDERCHARGED system 3 Discharge temperatures LESS than charted values indicate an OVERCHARGED system OUTDOOR TEMPERATURE F Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 126 278 132 128 280 135 303 137 281 138 305 140 328 141 283 141 330 144 354 145 284 12. 200 Ampacity 6 4 4 4 3 3 2 2 2 1 Wire Size based on N E C for 60 type copper conductors Table 1 Copper Wire Size Grounding A WARNING The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur Do not use gas piping as an electrical ground This unit must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the CSA C22 1 Electrical Code Use the grounding lug provided in the control box for grounding the unit Comfort Alert Diagnostics Module Select Models Only The Comfort Alert Diagnostics Module Figure 2 is a breakthrough innovation thattroubleshoots heat pump and air conditioning system failures and accurately detects the cause of electrical and system related failures without any sensors The module installs easily in the electrical box of the outdoor unit near the compressor contactor By monitoring and analyzing data from the Copeland scroll compressor and the thermostat demand the module can accurately detect the cause of electrical 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 NOTE This module does
3. ANSI NFPA 70 e For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code CSA C22 1 and or local codes Pre Electrical Checklist Verify that the voltage frequency and phase of the supply source match the specifications on the unit rating plate V Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment Refer to the unit wiring label for proper voltage wiring V Verify factory wiring is in accordance with the unit wiring diagram Figure 10 page 16 Inspect for loose connections Line Voltage e A wiring diagram is located on the inside cover of the electrical box of the outdoor unit The installer should become familiar with the wiring diagram before making any electrical connections to the outdoor unit e An electrical disconnect must be located within sight of and readily accessible to the unit This switch shall be capable of electrically de energizing the outdoor unit e Line voltage to the unit should be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the unit Incoming field wiring and minimum size of electrical conductors and circuit protection must be in compliance with information listed onthe outdoor unit data label Any other wiring methods must be acceptable to authority having jurisdiction e The outdoor unit requires both power and control circ
4. a al Qa j eb J 5 al 7 Al N 4254 o d q as J Al 5 a 2 3 J S a oO 95 100 105 110 115 120 125 130 N o Liquid Temperature F Figure 4 Charging Chart for S4BD 024 Series 2 Ton Units TXV Matches NOTE Do not add or remove refrigerant if pressure reading is between the curves O fo Oo Remove refrigerant when above the curve oa N o a fo Oo A ol O EN Q O Liquid Pressure psig ao a Oo ao N o oe Oo Oo Add refrigerant when below the curve yr rget FEAN S FAA FA EAF Sra tf fe Pr ft 90 95 100 105 110 115 120 125 Liquid Temperature F Figure 5 Charging Chart for S4BD 030 Series 2 5 Ton Units TXV Matches Remove refrigerant when above the curve D 7 Q pan 5 n N fae oO ge 5 2 Z Add refrigerant when below the curve i Ta TIFI TITT TT TT Piel eS Eee epee ee 100 105 110 115 120 125 130 135 Liquid Temperature F Figure 6 Charging Chart for S4BD 036 Series 3 Ton Units TXV Matches NOTE Do not add or remove refrigerant if pressure reading is between the curves Liquid Pressure psig HUNI LUN Liquid Temperature F Figure 7 Charging Chart for S4BD 042
5. be field installed as shown using manufacturer s approved kit If not present connect Yellow and Black wires per Note 6 S OUTDOOR FAN MOTOR BLUE ORANGE Sak COMPRESSOR DUAL OPTIONAL CONTACTS CAPACITOR YELLOW RED OR RED BLACK YELLOW BLACK l l l l i GROUNDING LL1_L2 anpj SCREW CRANKCASE HEATER SEE NOTE6 OPTIONAL 24 VOLT FIELD CONNECTIONS LEGEND CC Contactor Coil ONORE D 71 0388B CCH Crankcase Heater HPS High Pressure Switch HIGH VOLTAGE Replaces 710388A 0109 Figure 10 Wiring Diagram for S4BD Single Phase Models 1 5 2 2 5 3 3 5 4 amp 5 Ton Units COMFORT ALERT TROUBLESHOOTING e Module has power Supply voltage is present at module terminals Compressor protector is open Check for high head pressure Check compressor supply voltage Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Broken wire or connector is not making contact Low pressure switch open if present in system Compressor contactor has failed open Thermostat demand signal Y is present but compressor is not running TRIP Red LED Low refrigerant charge Evaporator blower is not running Check blower relay coil and contacts Check blower motor capacitor Check blower motor for failure or blockage Check evaporator blower wiring and connectors Check indoor blower control board Check thermostat wiring for open circuit Evaporator coil is frozen Check for low suction
6. e Sufficient clearance for unobstructed airflow through the outdoor coil must be maintained in order to achieve rated performance See Figure 1 for minimum clearances to obstructions e Overhead obstructions Figure 1 poorly ventilated areas and areas subject to accumulation of debris should be avoided e Consideration should be given to availability of electric power service access noise and shade Packaging Removal NOTE To prevent damage to the tubing connections carefully remove the carton and user s manual from the equipment Discard the shipping carton Ground Level Ground level installations must be located according to local building codes or ordinances and these requirements e Clearances must be in accordance with those shown in Figure 1 e A suitable mounting pad Figure 1 must be provided and separate from the building foundation The pad must be level and strong enough to support the weight of the unit The slab height must be a minimum of 2 5 cm above grade and with adequate drainage Roof Mount e The method of mounting should be designed so that it does not overload roof structures or transmit noise to the interior of the structure The roof must be structurally capable of handling the weight of the unit e Full perimeter support is required under the unit Support must be made of weather resistant materials and installed prior to unit installation e The support must be built to raise the unit 6 a
7. ensure thatthe field installed refrigerant containing components of the system have been installed in accordance with these instructions and sound installation practices to insure reliable system operation and longevity e The maximum recommended interconnecting refrigerant line lengths is 75 ft and the vertical elevation difference between the indoor and outdoor sections should not exceed 20 ft e A filter dryer is provided with the unit and must be installed in the liquid line ofthe system If the installation replaces a system with a filter dryer already present in the liquid line the filter dryer must be replaced with the one supplied with the unit The filter dryer must be installed in strict accordance with the manufacturer s installation instructions e Optional equipment such as liquid line solenoid valves low ambient etc should be installed in strict accordance with the manufacturer s installation instructions ELECTRICAL WIRING A 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 Wiring errors can cause improper and dangerous operation e All electrical connections must be in compliance with all applicable local codes and ordinances and with the current revision of the National Electric Code
8. for Y amp C wiring ALERT Flash Code 8 displayed incorrectly Welded Contactor Table 11 Module Wiring Troubleshooting 18 19 INSTALLATION PERFORMANCE CHECK LIST INSTALLATION ADDRESS CITY STATE UNIT MODEL UNIT SERIAL Unit Installed Minimum clearances per Figure 1 page 3 NO INSTALLER NAME CITY STATE DESIGNERS ASSEMBLED ASO 1 CERTIFIED www ahridirectory org Unitary Small AC LIsTED AHRI Standard 210 240 ELECTRICAL SYSTEM Electrical connections tight YES Zz O zZ O Line voltage polarity correct YES Rated Voltage L1 L2 Volts L1 L3 Volts L2 L3 Volts Avg Volts Max deviation of voltage from avg volts Volt imbalance Blower Motor HP Sheave Setting Has the thermostat been calibrated Is the thermostat level REPLACEMENT PARTS Replacementparts are available through all Nordyne distributors Please have the complete model and serial number of the unit when ordering replacement parts Is the heat anticipator setting correct If Applicable Certification applies only when the complete system is listed with AHRI Cabinet Panels Expansion Valves We Encourage Professionalism o i Clan So YOUR ENVIRONMENT OUR EXPERTISE v MEMBER COMPANY wud ENCE Through Technician Certification by NATE Electrical Capacitors Temperature Limit Switches Compressors Thermostats C
9. installing the system Refrigerant suction line tubing should be fully insulated e Installation of equipment may require brazing operations Installer must comply with safety codes and wear appropriate safety equipment safety glasses work gloves fire extinguisher etc when performing brazing operations e Follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment e Refrigerantand electrical line should be routed through suitably waterproofed openings to prevent water from leaking into the structure AIR CONDITIONER INSTALLATION General Information The S4BD series air conditioner is designed only for outdoor rooftop or ground level installations This unit has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort providing it is properly installed and maintained Abuse improper use and or improper maintenance can shorten the life of the appliance and create unsafe hazards To achieve optimum performance and minimize equipment failure it is recommended that periodic maintenance be performed on this unit The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools Before You Install this Unit The cooling load of t
10. 45 308 146 355 148 379 149 309 149 333 150 380 152 404 154 334 153 154 406 157 429 158 157 431 161 454 161 456 Table 5 Charging Table for S4BD 030 Series 2 5 Ton Units Orifice Matches OUTDOOR TEMPERATURE F Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 147 337 150 292 149 339 293 153 317 152 318 155 390 157 416 159 Table 6 Charging Table for S4BD 036 Series 3 Ton Units Orifice Matches 13 LEGEND HS Shaded boxes indicate flooded conditions C Rated design values The suction pressure will be lower than design value if outdoor air flow entering NOTES 1 All pressures are listed psig and all temperatures in F 2 Discharge temperatures GREATER than charted values indicate an UNDERCHARGED system 3 Discharge temperatures LESS than charted values indicate an OVERCHARGED system dry bulb or entering wet bulb temperatures are lower than design OUTDOOR TEMPERATURE F 257 Temp Press 135 Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 130 132 259 138 282 138 261 141 283 262 144 264 146 286 285 145 142 306 142 307 1
11. 47 288 150 310 145 330 146 149 331 151 312 154 333 152 149 354 150 355 357 153 378 153 156 379 159 162 381 160 156 402 157 404 405 165 160 163 426 428 Table 7 Charging Table for S4BD 042 Series 3 5 Ton Units Orifice Matches OUTDOOR TEMPERATURE F 261 Temp Press 136 Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 125 127 262 140 285 140 263 143 286 265 146 287 266 149 289 143 309 144 147 149 310 290 152 312 311 151 147 333 148 334 153 314 156 151 357 151 154 358 359 158 155 381 155 382 159 405 159 162 406 407 163 166 429 430 431 14 Table 8 Charging Table for S4BD 048 Series 4 Ton Units Orifice Matches LEGEND HGS Shaded boxes indicate flooded conditions LC Rated design values The suction pressure will be lower than design value if outdoor air flow entering dry bulb or entering wet bulb temperatures are lower than design NOTES 1 All pressures are listed psig and all temperatures in F 2 Discharge temperatures GREATER than charted values indicate an UNDERCHARGED system 3 Discharge temperatures LESS than charted values indicate a
12. ARNING To prevent 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 Proper maintenance is important to achieve optimum performance from the air conditioner The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools If you do not possess these skills contact your dealer for maintenance Consult your local dealer aboutthe availability of maintenance contracts Routine maintenance should include the following Inspect and clean or replace air filters at the beginning of each heating andcooling season or more frequently if required e Inspect the condensate drain and outdoor coil at the beginning of each cooling season Remove any debris Clean the outdoor coil and louvers as necessary using a mild detergent and water Rinse thoroughly with water e Inspect the electrical connections for tightness at the beginning of each heating and cooling season Service as necessary A CAUTION The unit should never be operated without a filter inthe return air system Replace disposable filters with the same type and size e Do not attempt to add additional oil to motors un equipped with oil tubes The compressor is hermetically sealed at the factory and does not require lubrication START UP amp ADJUSTMENTS aia Check List lt lt 42424
13. ENANCE ELECTRICAL DIAGRAMS amp TABLES STARTUP amp ADJUSTMENTS Figure 10 W D Single Phase 1 5 5 Ton Pre Start Checklist Table 10 Comfort Alert LED Diagnostics Start up Procedures Table 11 Module Wiring Troubleshooting Am oiroulanon Magor EIWer INSTALL PERFORMANCE CHECKLIST System Cooling System Heating REPLACEMENT PARTS IMPORTANT ATTENTION INSTALLERS 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 furnace 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 Please read all instructions carefully before starting the installation Return these instructions to the customer s package for future reference DO NOT DESTROY PLEASE READ CAREFULLY amp KEEP IN A SAFE PLACE FOR FUTURE REFERENCE IMPORTANT
14. Ni Verify the indoor unit is level and allows proper condensate drainage Verify the outdoor coil and top of the unit are free from obstructions and debris and all equipment access control panels are in place Verify air filters are cleaned and properly installed Verify duct work is sealed to prevent air leakage Verify line voltage power leads are securely connected and the unit is properly grounded Verify low voltage wires are securely connected to the correct leads on the low voltage terminal strip Verify power supply branch circuit overcurrent protection is sized properly Verify the thermostat is wired correctly Start Up Procedures The thermostat s function mode should be set to OFF and the fan mode should be set to AUTO Close all electrical disconnects to energize the system Air Circulation Indoor Blower 1 2 3 Set the thermostat system mode on OFF and the fan mode to ON Verify the blower runs continuously Check the air delivery at the supply registers and adjust register openings for balanced air distribution If insufficient air is detected examine ductwork for leaks or obstructions Set the thermostat fan mode to AUTO and verify the blower stops running System Cooling 1 2 3 4 Set the thermostat s system mode to COOL and the fan mode to AUTO Gradually lower the thermostat temperature setpoint below room temperature and verify the outdoor unit and indoor blower energize Ve
15. SAFETY INFORMATION INSTALLER Please read all instructions before servicing this equipment Pay attention to all safety warnings and any other special notes highlighted in the manual Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage A WARNING Shut off all electrical power to the unit before performing any maintenance or service on the system Failure to comply may resultin personal injury or death A WARNING Unless noted otherwise in these instructions only factory authorized parts or accessory kits may be used with this product Improper installation service adjustment or maintenance may cause explosion fire electrical shock or other hazardous conditions which may result in personal injury or property damage A WARNING S4BD Split System Air Conditioners are shipped charged with R410A refrigerant and ready for installation If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Under no circumstances should the owner attempt to install and or service this equipment Failure to comply with thi
16. SPLIT SYSTEM AIR CONDITIONER 13 SEER SINGLE PHASE MODELS INSTALLATION INSTRUCTIONS S4BD SERIES 018 024 030 036 042 048 amp 060 1 5 2 2 5 3 3 5 4 amp 5 Ton IMPORTANT SAFETY INFORMATION Refrigerant Charging AIR CONDITIONER INSTALLATION Charging the Unit in AC Mode with General Information Outdoor Temperatures Above 55 F Before You Install this Unit Application Notes for Using Charging Charts Locating the Air conditioner S4BD CHARGING CHARTS Packaging Removal Figure 3 Charging Chart for 1 5 Ton Units Ground Level Figure 4 Charging Chart for 2 Ton Units Roof Mount Figure 5 Charging Chart for 2 5 Ton Units Connecting Refrigerant Tubing between the Figure 6 Charging Chart for 3 Ton Units Indoor amp Outdoor Unit Figure 7 Charging Chart for 3 5 Ton Units ELECTRICAL WIRING Figure 8 Charging Chart for 4 Ton Units Pre Electrical Checklist Figure 9 Charging Chart for 5 Ton Units Line Voltage S4BD CHARGING TABLES Comfort Alert Diagnostics Module Table 3 Charging Table for 1 5 Ton Units 24VAC Power Wiring Table 4 Charging Table for 2 Ton Units Thermostat Demand Wiring Table 5 Charging Table for 2 5 Ton Units Interpreting the Diagnostic LED s Table 6 Charging Table for 3 Ton Units LED Description Table 7 Charging Table for 3 5 Ton Units Grounding Table 8 Chargi ging Table for 4 Ton Units Thermostat Low Voltage Connections Table 9 Charging Table for 5 Ton Units AIR CONDITIONER MAINT
17. Series 3 5 Ton Units TXV Matches __ Remove refrigerant when above the curve C ee I a D o 2 5 D 7 fod ou ge 5 T l Liquid Temperature F Figure 8 Charging Chart for S4BD 048 Series 4 Ton Units TXV Matches NOTE Do not add or remove refrigerant if pressure reading is between the curves remove refrigerant when above te curve a se ee a Liquid Pressure psig Liquid Temperature F Figure 9 Charging Chart for S4BD 060 Series 5 Ton Units TXV Matches S4BD REFRIGERANT CHARGING TABLES COOLING ONLY LEGEND HS Shaded boxes indicate flooded conditions Rated design values The suction pressure will be lower than design value if outdoor air flow entering dry bulb or entering wet bulb temperatures are lower than design NOTES 1 All pressures are listed psig and all temperatures in F 2 Discharge temperatures GREATER than charted values indicate an UNDERCHARGED system 3 Discharge temperatures LESS than charted values indicate an OVERCHARGED system OUTDOOR TEMPERATURE F Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 257 137 134 258 140 280 140 281 144 304 144 260 147 305 147 327 147 261 150 283 150 328_ 150 351 150 284 153 307 153 352 153 374 154 308 156 156 375 157 398 157 159 399 160 421 162 400 163 422 423
18. arged e If the pressure measured in Step 1 is less than the required liquid refrigerant pressure determined in Step 3 there is too little charge in the system Add refrigerant and repeat Steps 1 through 3 until the system is correctly charged Application Notes for Using Charging Charts This equipment s cooling system contains refrigerant under high pressure Always use safe and environmentally sound methods when handling refrigerant handling or servicing the unit Review the factory literature and safety warnings prior to servicing When repairing system leaks always use a nitrogen inert gas to protect the refrigerant system and pressure check the repair before re charging Always replace the filter dryers when performing any repair to the refrigeration system with one capable of acid removal After completing the repairs evacuate the system to 350 500 microns and weigh in the refrigerant to the amount specified on the unit rating label Charging charts are valid for a variety of indoor return air conditions and are most influenced by the outdoor ambient temperature outdoor fan operation and the unit operating voltage Before using these charts make sure the unit is in a stable operating mode As shown in the charging charts Figures 3 9 pages 8 11 the ideal system sub cooling can vary over the range of operation Reference the charts to determine the ideal amount of sub cooling for a given liquid pressure Units cha
19. bove the roof 6 from Building or Structure 24 for Service Access DONOT X OBSTRUCT TOP OF UNIT 12 or 18 See Note NOTE Units require full perimeter clearances Installer must maintain 18 between two units or 12 between single unit and structure oe Dz 2 Mounting Pad SEs Figure 1 Clearance Requirements Connecting Refrigerant Tubing Between the Indoor amp Outdoor Unit A CAUTION When servicing cover or seal openings to minimize the exposure of the refrigerant system to air to prevent accumulation of moisture and other contaminants After outdoor and indoor unit placement has been determined route refrigerant tubing between the equipmentin accordance with sound installation practices e When connecting refrigerant linesets together it is recommended that dry nitrogen be flowing through the joints during brazing to prevent internal oxidation and scaling e Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing If precise forming of refrigerant lines is required a copper tubing bender is recommended Avoid sharp bends and contact of the refrigerant lines with metal surfaces e Refrigerant tubing should be supported in a manner that the tubing will not vibrate or abrade during system operation e Tubing should be kept clean of foreign debris during installation e Every effort should be made by the installer to
20. ctor coil falls below 0 5VAC when off e Verify 24VAC is present across Y amp C when thermostat demand signal is preset If not R amp C are reversed wired Trip LED is on but system and compressor check OK TRIP LED amp ALERT LED TRIP LED amp ALERT LED flashing together together Verity R amp terminals are supplied with 19 28VAC R amp C terminals are supplied with 19 28VAC ALERT Flash CODE 3 displayed incorrectly Verify Y terminal is connected to 24VAC at contactor coil Compressor short cycling Verify voltage at contactor coil falls below 0 5VAC when off e Verify the compressor run and start wires are routed through the module s current ALERT Flash Code 5 6 or 7 displayed incorrectly sensing holes Open Circuit Open Start Circuit or Open Run Circuit e Verify the Y terminal is connected to 24VAC at contactor coil e Verify voltage at contactor coil falls below 0 5VAC when off ALERT Flash Code 6 Open Start Circuit displayed for Code 7 e Verify the compressor run and start wires are routed through the correct module sensing Open Run Circuit or vice versa holes e Determine if module s Y terminal is connected e Verify Y terminal is connected to 24VAC at contactor coil e Verify 24VAC is present across Y amp C when thermostat demand signal is present If not R amp C are reversed wired e Verify voltage at contactor coil falls below 0 5VAC when off e Review Thermostat Demand Wiring page 10
21. damaged Check compressor motor winding resistance ALERT Open circuit in compressor run wiring or connections Flash Code 7 Open run circuit Check wiring and connectors between supply and the compressor R terminal Current only in start circuit Compressor run winding is damaged Yellow LED aaah Check compressor motor winding resistance ALERT Flash Code 8 Welded Contactor Compressor contactor has failed closed Yellow LED Compressor always runs Thermostat demand signal not connected to module ALERT Low Voltage Control circuit transformer is overloaded Flash Code 9 Control cai lt 17VAC Low line voltage contact utility if voltage at disconnect is low Yellow LED Check wiring connections Flash code number corresponds to a number of LED flashes followed by a pause and then repeated Trip and alert LED s flashing at same time means control circuit voltage is too low for operation Table 10 LED Diagnostics Continued Miswired Module Indication Recommended Troubleshooting Action z e Determine if both R amp C module terminals are connected Green LED is not on module does not power up e Verify voltage is present at module s R amp C terminals Green LED intermittent module powers up only when compressor e Determine if R amp Y terminals are wired in reverse runs e Verify modules R amp C terminals have a constant source e Verify Y terminal is connected to 24VAC at contactor coil e Verify voltage at conta
22. ermostat demand signal is connected verify that 24 VAC across Y amp C when demand is present Interpreting the Diagnostic LED s When an abnormal system condition occurs the Comfort Alert module displays the appropriate ALERT and or TRIP LED will flash a number of times consecutively pause and then repeat the process To identify a Flash Code number count the number of consecutive flashes Each time the module powers up the last ALERT Flash Code that occurred prior to shut down is displayed for one minute The module will continue to display the LED until the condition returns to normal or if 24 VAC power is removed from the module See Table 10 page 17 for flash code identification or Table 11 page 18 for module wiring troubleshooting LED Description e POWER LED Green indicates voltage is present at the power connection of the module e ALERT LED Yellow communicates an abnormal system condition through a unique flash code NOTE The ALERT LED will flash consecutively pause and then repeat the process The number of consecutive flashes referred to as the Flash Code correlates to a particular abnormal condition Detailed descriptions of these ALERT Flash Codes are listed in Tables 10 amp 11 e TRIPLED Red indicates ademand signal is received from the thermostat but current to the compressor is not detected by the module The TRIP LED typically indicates if the compressor protector is open or the compresso
23. he area to be conditioned must be calculated and a system ofthe proper capacity selected It is recommended that the area to be conditioned be completely insulated and vapor sealed V Check the electrical supply and verify the power supply is adequate for unit operation The system mustbe wired and provided with circuit protection in accordance with local building codes If there is any question concerning the power supply contact the local power company V The indoor section air handler furnace etc shouldbe installed before routing the refrigerant tubing Refer to the indoor unit s installation instructions for installation details V Allunits are securely packed at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site Verify coil fins are straight If necessary comb fins to remove flattened or bent fins Claims for damage apparent or concealed shouldbe filed immediately with the carrier Please consultyour dealer for maintenance information and availability of maintenance contracts Please read all instructions before installing the unit Locating the Air Conditioner e Survey the job site to determine the best location for mounting the outdoor unit e The outdoor unit should be installed no closer than 18 inches from the outside walls of the facility and in an area free from overhead obstructions to ensure unrestricted airflow through the outdoor unit
24. in property damage personal injury or death After refrigerant line connections are completed it is required that you leak check and evacuate the indoor section and all line connections using proper methods before finalizing the full system refrigerant charge Refrigerant charging charts are applicable only to matched assemblies of NORDYNE equipment and listed airflows for the indoor coil Refer to Figures 3 9 pages 8 11 and Tables 3 9 pages 12 15 for correct system charging S4BD outdoor units with non AHRI listed indoor coils are notrecommended Deviations from rated airflows or non listed combinations may require modification to the expansion device and refrigerant charging procedures for proper and efficient system operation The refrigerant charge can be checked and adjusted through the service ports provided external to the outdoor unit Use only gage line sets which have a Schrader depression device present to actuate the valve A high pressure switch is factory installed and located in the liquid line internal to the outdoor unit The switch is designed to protect the system when very high pressures occur during abnormal conditions Under normal conditions the switch is closed If the liquid pressure rises above 575 psig then the switch will open and de energize the outdoor unit The switch will close again once the liquid pressure decreases to 460 psig Please note that the switch interrupts the thermostat
25. inputs to the unit Thus when the switch opens and then closes there may be a 5 minute short cycling delay before the outdoor unit will energize A low pressure switch Select Models is factory installed and located in the suction line internal to the outdoor unit The switch is designed to protect the compressor from a loss of charge Under normal conditions the switch is closed If the suction pressure falls below 5 psig then the switch will open and de energize the outdoor unit The switch will close again once the suction pressure increases above 20 psig Please note that the switch interrupts the thermostat inputs to the unit When the switch opens and then closes there will be a 5 minute short cycling delay before the outdoor unit will energize Charging the Unit in AC mode at outdoor temperatures above 55 F for optimized sub cooling of 10 F 12 F 1 With the system operating at steady state measure the liquid refrigerant pressure in psig at the outdoor unit service valve 2 Measure the liquid refrigerant temperature in Fahrenheit at the service valve 3 Determine the required liquid refrigerant pressure from the appropriate charging chart Figures 3 9 e If the pressure measured in Step 1 is greater than the required liquid refrigerant pressure determined in Step 3 then there is too much charge in the system Remove refrigerant and repeat Steps 1 through 3 until the system is correctly ch
26. n OVERCHARGED system OUTDOOR TEMPERATURE F Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press 121 149 123 1 aE 289 153 290 157 313 157 161 338 161 164 167 339 340 170 165 362 165 363 365 168 169 169 172 388 173 411 173 412 414 176 177 180 437 159 reese Pa 314 162 163 316 294 166 317 319 Table 9 Charging Table for S4BD 060 Series 5 Ton Units Orifice Matches 15 16 ELECTRICAL DIAGRAMS amp TABLES WIRING DIAGRAM Split System Air Conditioner Outdoor Section Single Phase NOTES 1 Disconnect all power before servicing 1 Couper le courant avant de faire letretien 2 For supply connections use copper conductors only 2 Employez uniquement des conducteurs en cuivre 3 Not suitable on systems that exceed 150 volts to ground 3 Ne convient pas aux installations de plus de 150 volt a la terre 4 For replacement wires use conductors suitable for 105 deg C 5 For ampacities and overcurrent protection see unit rating plate 6 Connect to 24 vac 40ca class 2 circuit See furnace airhandler installation instructions for control circuit and optional relay transformer kits 7 Anti Short Cycle Timer ASCT may or may not be installed in the unit If desired ASCT is factory installed on select models only or may
27. not provide safety protection The Comfort Alert Diagnostics Module is a monitoring device and cannot control or shut down other devices 24 VAC Power Wiring The Comfort Alert module requires a constant nominal 24 VAC power supply The module cannot be powered by the C terminal on a defrost board or other control board without experiencing nuisance alerts NOTE The wiring to the module s R amp C terminals must be routed directly from the indoor unit or thermostat Ifthe constant 24 VAC R wire is not presentin the outdoor unit use one of the spare wires in the thermostat cable to bring power to the module Connect the other end of the spare wire to R at the indoor unit or thermostat Thermostat Demand Wiring The Comfort Alert module requires a thermostat demand signal to operate properly The thermostat demand signal input labeled Y on the module should always be connected to the compressor contactor coil NOTE When the coil is energized the demand signal input is 24 VAC When the coil is not energized the demand signal input should be less than 0 5 VAC POWER LED Green As Wi N Diagnostics Key ge TAN y x N ALERT LED Yellow T Er Figure 2 Comfort Alert Diagnostics Module NOTES e Factory installed modules have different thermostat demand signal wiring Always follow manufacturer wiring instructions when replacing the module e Afterthe th
28. ontactors Time Delay Relays Pressure Switches Transformers Relays Motors Blower Motor c US Fan Motor Components Intertek Blower Assembly Fan Grille Filter Driers NORDYNE COMPLETE COMFORT GENUINE VALUE Specifications amp illustrations subject to change without notice or incurring obligations O Fallon MO Printed in U S A 10 12 Ee TILL 709292B Replaces 709292A
29. pressure Check for excessively low thermostat setting Check evaporator airflow coil blockages or return airfilter Check ductwork or registers for blockage Faulty metering device Check TXV bulb installation size location and contact Check if TXV fixed orifice is stuck closed or defective Condenser coil is dirty Liquid line restriction filter drier blocked if present in system Thermostat is malfunctioning Solenoid plug not connected Y2 not wired at Comfort Alert Check thermostat sub base or wiring for short circuit Check thermostat installation location level Comfort Alert failure ALERT Long Run Time Flash Code 1 Compressor is running Yellow LED extremely long run cycles High head pressure Check high pressure switch if present in system Check if system is overcharged with refrigerant Check for non condensable in system ALERT Discharge or suction e Condenser coil poor air circulation dirty blocked damaged System Pressure Trip Flash Code 2 e Condenser fan is not running Yellow LED Check fan capacitor Pressure ou tofilimits Check fan wiring and connectors Check fan motor for failure or blockage e Return air duct has substantial leakage Compressor overloaded e If low pressure switch present in system check Flash Code 1 information Thermostat demand signal is intermittent Short Cycling Compressor is Low line voltage contact utility if vol
30. r has no power The scroll compressor s R run C common and S start wires are routed through the holes in the Comfort Alert module marked R C amp S NOTE The common wire does not need to be routed through the module for it to operate Thermostat Connections e Thermostat connections should be made in accordance with the instructions supplied with the thermostat and the indoor equipment e The outdoor unit is designed to operate from a 24 VAC Class II control circuit The control circuit wiring must comply with the current provisions of the NEC ANSI NFPA 70 and with applicable local codes having jurisdiction e The low voltage wires must be properly connected to the units low voltage terminal block Recommended wire gauge and wire lengths for typical thermostat connections are listed in Table 2 e The thermostat should be mounted about 5 feet above the floor on an inside wall DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures and convective heat from warm air registers or electrical Thermostat Wire Gauge Recommended T Stat Wire Unit to T Stat Length in FT 2 Wire 5 Wire _e es ae Table 2 Thermostat Wire Gauge appliances Refer to the thermostat manufacturers instruction sheet for detailed mounting and installation information AIR CONDITIONER MAINTENANCE A W
31. rged to other values will not perform atthe rated unit efficiency EER or rated Coefficient of Performance COP in heating mode To inspect a systems operation using quality instruments match the measured liquid temperature to the units chart The measured liquid pressure reading should be within 3 of the charts value for most installations For systems that are operating with more than a 5 deviation inspect the unit for the proper voltage and phase balance and the refrigeration system for leaks Units that are operating at less then 95 of the nominal voltage or with a2 phase imbalance may see a more significant deviation than the amount stated above DO NOT use the charts in systems that have a fan cycling under low ambient control Refer to the low ambient kit instructions for more information If applicable S4BD REFRIGERANT CHARGING CHARTS D D 2 pe 5 D eb oO ge 5 Ss l Lo T__ Aad refrigerant when below the curve Ce a a ee ee ce ee 80 85 90 95 100 105 110 115 120 12 5 130 Liquid Temperature F Figure 3 Charging Chart for S4BD 018 Series 1 5 Ton Units TXV Matches a DD N O a O oa a Oo Remove refrigerant when above the curve oa N oa a Q Oo A A a N O ua A Q Oo wo NJ oa oo a oO ie M ol Add refrigerant when below the cu oO Q O M ar oa 5007
32. rify blower wheel is spinning in direction indicated by arrow Feel the air being circulated by the indoor blower and verify that it is cooler than ambient temperature Listen for any unusual noises If unusual sounds occur determine the source of the noise and correct as necessary Verify HI and LO refrigerant pressures Allow the system to operate for several minutes and then set the temperature selector above room temperature Verify the fan and compressor cycle off with the thermostat NOTE The blower should also stop unless fan mode is set to the ON position System Heating optional 1 2 Set the thermostat s system mode to HEAT and the temperature mode above room temperature Verify the optional heating equipment furnace or electric heat and indoor blower energize Feel the air being circulated by the indoor blower and verify that it is warmer than ambient temperature Listen for any unusual noises If unusual sounds occur determine the source of the noise and correct as necessary Refrigerant Charging A WARNING S4BD Split System Air Conditioners are shipped charged with R410A refrigerant and ready for installation If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Under no circumstances should the owner attempt to install and or service this equipment Failure to comply with this warning could result
33. s warning could resultin property damage personal injury or death A CAUTION This unit uses refrigerant R 410A DO NOT use any other refrigerant in this unit Use of another refrigerant will damage the unit A WARNING The information listed below must be followed during the installation service and operation of this unit Unqualified individuals should not attempt to interpret these instructions or install this equipment Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death e The installer must comply with all local codes and regulations which govern the installation of this type of equipment Local codes and regulations take precedence over any recommendations contained in these instructions Consult local building codes and the National Electrical Code ANSI Cl for special installation requirements All electrical wiring must be completed in accordance with local state and national 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 e This equipment contains liquid and gaseous refrigerant under high pressure DO NOT USE ANY PORTION OF THE CHARGE FOR PURGING OR LEAK TESTING Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment e Fully annealed refrigerant grade copper tubing should be used when
34. tage at disconnect is low running only briefly Excessive liquid refrigerant in compressor Compressor bearings are seized ALERT Flash Code 3 Yellow LED Run capacitor has failed Low line voltage contact utitlity if voltage at disconnect is low Check wiring connections Excessive liquid refrigerant in compressor Compressor bearings are seized Measure compressor oil level ALERT Flash Code 4 Locked Rotor Yellow LED Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Compressor contactor has failed open Check compressor contactor wiring and connectors Check for compressor contactor failure burned pitted or open Check wiring and connectors between supply and compressor Check for low pilot voltage at compressor contactor coil High pressure switch is open and requires manual reset Open circuit in compressor supply wiring or connections Unusually long compressor protector reset time due to extreme ambient temperature Compressor windings are damaged Check compressor motor winding resistance ALERT Flash Code 5 Open Circuit Yellow LED Table 10 LED Diagnostics 17 COMFORT ALERT TROUBLESHOOTING CONTINUED e Run capacitor has failed ALERT Open circuit in compressor start wiring or connections Open Start Circuit ELEG Current only in run circuit Check wiring and connectors between supply and the compressor S terminal Compressor start winding is
35. uit electrical connections Refer to the wiring diagram schematic for identification and location of outdoor unit field wiring interfaces Figure 10 page 16 Make all electrical connections in accordance with all applicable codes and ordinances e Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes See the unit rating plate for minimum circuit ampacity and maximum overcurrent protection limits e Provide power supply forthe unit in accordance with the unit wiring diagram and the unit rating plate Connect the line voltage leads to the terminals on the contactor inside the control compartment e Use only copper wire for the line voltage power supply to this unitas listed in Table 1 Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit Use of rain tight conduit is recommended e 208 230 Volt units are shipped from the factory wired for 230 volt operation For 208V operation remove the lead from the transformer terminal marked 240V and connect it to the terminal marked 208V e Optional equipment requiring connection to the power or control circuits must be wired in strict accordance of the NEC ANSI NFPA 70 applicable local codes and the instructions provided with the equipment COPPER WIRE SIZE AWG 1 Voltage Drop Supply Wire Length Feet 150 Supply Circuit
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