4-5 TON SERIES - FOR EXPORT ONLY

USER’S MANUAL / INSTALLATION INSTRUCTIONS

SPLIT SYSTEM AIR CONDITIONER - SINgLE & 3 PhASE, R-22

10 SEER

IMPORTANT

Please read this information thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit.

Keep this literature where you have easy access to it in the future. If a problem occurs, check the instructions and follow recommendations given. If these suggestions don’t eliminate your problem, call your servicing contractor.

The installation 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.

DO NOT DESTROY. PLEASE READ CAREFULLY AND

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

2

USER INFORMATION

IMPORTANT SAFETY INFORMATION .......................3

OPERATINg INSTRUCTIONS .....................................3

Cooling Operation .....................................................3

Heating Operation .....................................................3

Operating the Air Conditioner for Automatic

Cooling and Heating ..................................................3

Operating the Indoor Blower Continuously ................3

Turning the Air Conditioner Off ..................................3

AIR CONDITIONER MAINTENANCE ..........................3

TROUbLEShOOTINg .................................................3

WARRANTY INFORMATION

A warranty certificate with full details is included with the air conditioner. Carefully review these responsibilities with your dealer or service company. The manufacturer will not be responsible for any costs found necessary to correct problems due to improper setup, improper installation, adjustments, improper operating procedure on the part of the user, etc. Some specific examples of service calls which are not included in the limited warranty are:

• Correcting wiring problems in the electrical circuit supplying the air conditioner.

• Resetting circuit breakers or other switches.

• Adjusting or calibrating of thermostat.

INSTALLER INFORMATION

IMPORTANT SAFETY INFORMATION .......................4

AIR CONDITIONER INSTALLATION ..........................5

General Information ...................................................5

Before You Install this Unit .........................................5

Locating the Air conditioner .......................................5

Packaging Removal ...................................................5

Ground Level .............................................................5

Rooftop ......................................................................5

Connecting Refrigerant Tubing Between the

Indoor & Outdoor Unit ...............................................6

ELECTRICAL WIRINg .................................................6

Pre-Electrical Check List ...........................................6

Line Voltage ...............................................................6

Grounding..................................................................7

Thermostat Connections ...........................................7

Unbalanced 3-Phase Supply Voltage ........................7

Optional Electric Heater Kits .....................................8

STARTUP & ADjUSTMENTS .....................................8

Pre-Start Check List ..................................................8

Start-up Procedures ..................................................8

Air Circulation - Indoor Blower ..................................8

Anti-Short Cycle Timer Protection .............................8

System Cooling .........................................................8

System Heating .........................................................9

Refrigerant Charging .................................................9

Charging Units in AC Mode when

Outdoor Temperature is Above 55° F ........................9

AIR CONDITIONER MAINTENANCE ..........................9

FIgURES & TAbLES .................................................10

Figure 4. - Unit Dimensions .....................................10

Table 2. - Unit Dimensional Data .............................10

Wiring Diagrams ......................................................11

Figure 4. - Single Phase Units (4 Ton) ...................11

Figure 5. - Single Phase Units (5 Ton) ...................12

Figure 6. - 3 Phase Units (4 Ton) ............................13

Figure 7. - 3 Phase Units (5 Ton) ............................14

Refrigerant Charging Tables ....................................15

Table 3. - Charging Table for 4 Ton Units .................15

Table 4. - Charging Table for 5 Ton Units .................15

INSTALLATION / PERFORMANCE ChECK LIST ....16

REPLACEMENT PARTS ............................................16

USER INFORMATION

IMPORTANT SAFETY INFORMATION

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.

The continuous indoor blower operation can be obtained with the thermostat system mode set in any position, including OFF.

Turning the Air conditioner Off

Change the thermostat’s system mode to OFF and the fan mode to AUTO (See Figure 1). NOTE: The system will not operate, regardless of the temperature selector setting.

OPERATINg INSTRUCTIONS

NOTE: Thermostat styles vary. Some models may not include the AUTO mode and others will have the AUTO in place of the HEAT and COOL. Others may include all three. Please refer to the thermostat manufacturer’s User

Manual for detailed programming instructions.

Cooling Operation

1. Set the thermostat’s system mode to COOL or AUTO and change the fan mode to AUTO. See Figure 1.

2. Set the temperature selector to the desired temperature level. The outdoor fan, compressor, and blower motor will all cycle on and off to maintain the indoor temperature at the desired cooling level.

Fan

Mode

System

Mode

Temperature

Selector

Figure 1. Digital Thermostat

AIR CONDITIONER MAINTENANCE

Proper maintenance is most important to achieve the best performance from the appliance and should be performed frequently at the beginning of each air conditioning season.

NOTE: If the temperature level is re-adjusted, or the system mode is reset, the fan and compressor in the outdoor unit may not start immediately. A protective timer circuit holds the compressor and the outdoor fan off for approximately 5 minutes following a previous operation or the interruption of the main electrical power.

heating Operation

1. Set the thermostat’s system mode to HEAT or AUTO and change the fan mode to AUTO. See Figure 1.

2. Set the temperature selector to the desired temperature level. The optional heating equipment (furnace or electric heat) will cycle on & off to maintain the indoor temperature at the desired heating level.

Operating the AC for Automatic Cooling & heating

1. Set the thermostat system mode to AUTO and the thermostat fan mode to AUTO. See Figure 1.

2. Set the thermostat temperature selector to the desired temperature level. The thermostat will maintain the desired temperature level by switching between either the outdoor cooling unit or the indoor heating unit

(furnace or electric heat) automatically.

WARNINg:

This air conditioner contains liquid and g a s e o u s r e f r i g e r a n t u n d e r p r e s s u r e .

Installation and servicing should only be attempted by qualified, trained personnel thoroughly familiar with the equipment and safe responsible refrigerant handling procedures. Failure to comply with this warning could result in equipment damage, personal injury, or death.

• Keep the outdoor unit clean. Hose off periodically and keep unit fins clear of leaves and grass clippings.

• Keep the outdoor unit clear of obstructions. DO NOT obstruct airflow with tall plants or shrubs. DO NOT store gasoline or other flammable materials on or near the outdoor unit.

• Never operate the appliance without a filter installed in the return air duct. Inspect filters frequently and replace when necessary with filter of same dimensional size.

Operating the Indoor blower Continuously

The continuous indoor blower operation is typically used to circulate the indoor air to equalize a temperature unbalance due to a sun load, cooking, or fireplace operation.

Set the thermostat fan mode to ON (Figure 1). The indoor blower starts immediately, and will run continually until the fan mode is reset to AUTO.

TROUbLEShOOTINg

• Check the thermostat setting. Make sure the system mode and temperature settings are correct.

• Check the electrical panel for tripped circuit breakers.

• Check the filters for dust accumulation.

• Check the outdoor unit and make sure it is clean and not covered with grass or leaves.

3

4

INSTALLER INFORMATION

IMPORTANT SAFETY INFORMATION

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.

WARNINg:

Shut off all electrical power to the unit before performing any maintenance or service on the system. Failure to comply may result in personal injury or death.

CAUTION:

This unit uses R-22 refrigerant. DO NOT use any other refrigerant in this unit. Use of another refrigerant will damage the unit.

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 per sonal injury or death.

WARNINg:

Unless noted otherwise in these instructions, only factory authorized parts or accessory k i t s m a y b e u s e d w i t h t h i s p r o d u c t .

Improper installation, service, adjustment, o r m a i n t e n a n c e m ay c a u s e ex p l o s i o n , fire, electrical shock or other hazardous conditions which may result in personal injury or property damage.

WARNINg:

Split system air conditioners leave the factory with a nitrogen holding charge.

Follow all charging instructions for maximum unit performance and efficiency. Some local codes require licensed installation/ service personnel to service this type of equipment. Refrigerant charging must be done by qualified personnel familiar with s a f e a n d e nv i ro n m e n t a l ly r e s p o n s i b l e refrigerant handling procedures. Under no circumstances should the owner attempt to install and/or service this equipment.

Failure to comply with this warning could result in property damage, personal injury, or death.

• 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 for special installation requirements.

• All electrical wiring must be completed in accordance with local, state and national codes and regulations that take precedence.

• 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 of equipment.

• Fully annealed, refrigerant grade copper tubing should be used when installing the system. Refrigerant suction line tubing should be fully insulated.

• This unit is designed for outdoor installations only and should be located in a position as shown on page 5.

• 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.

• Refrigerant and electrical line should be routed through suitably waterproofed openings to prevent water from leaking into the structure.

AIR CONDITIONER INSTALLATION

general Information

This 4-5 ton air conditioner is designed only for outdoor rooftop or ground level installations. The unit has been tested and certified by AHRI for capacity and efficiency 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.

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:

• Clearances must be in accordance with those shown in Figure 2.

• A suitable mounting pad (Figure 2) must be provided and be separate from the building foundation. The pad must be level and strong enough to support the unit’s weight. The slab height must be a minimum of 2”

(5 cm) above grade and with adequate drainage.

before You Install this Unit

√

The cooling load of the area to be conditioned must be calculated and a system of the proper capacity selected.

It is recommended that the area to be conditioned be completely insulated and vapor sealed.

√

Check the electrical supply and verify the power supply is adequate for unit operation. The system must be 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.

√

Always install a unit disconnect switch within sight of the unit or in accordance with local codes.

√

The indoor section (air handler, furnace, etc) should be installed before routing the refrigerant tubing. Refer to the indoor unit's installation instructions for installation details.

√

All units 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. Claims for damage should be filed immediately with the carrier.

√

Please consult your dealer for maintenance information and availability of maintenance contracts. Please read all instructions before installing the unit.

Rooftop

Rooftop installations must be located according to local building codes or ordinances and these requirements:

•

Units may be installed on Class A, B, or C roof covering material.

• Secure optional mounting pad or frame to roof using acceptable mechanical methods per local codes.

• 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.

• Full perimeter support is required under the unit. The support must be built to raise the unit 6" above the roof, must be made of weather resistant materials, and installed prior to unit installation.

6” from Building or Structure

24" for

Service Access

DO NOT

OBSTRUCT

TOP OF UNIT

12" or 18”

See Note

12" or 18”

See Note

Locating the Air Conditioner

• Survey the job site to determine the best location for mounting the outdoor unit.

• Overhead obstructions (Figure 2), poorly ventilated areas, and areas subject to accumulation of debris should be avoided.

• Sufficient clearance for unobstructed airflow through the outdoor coil must be maintained in order to achieve rated performance. See Figure 2 for minimum clearances to obstructions.

• Consideration should be given to availability of electric power, service access, noise, and shade.

• See Figure 3 & Table 2 (page 10) for unit dimensions

.

NOTE:

Units require full perimeter clearances.

Installer must maintain 18” between two units or 12” between single unit and structure.

48”

2” Mounting Pad

Figure 2. Clearance Requirements

5

6

Connecting Refrigerant Tubing between the Indoor

& Outdoor Unit

ELECTRICAL WIRINg

CAUTION:

This system uses R-22 refrigerant with mineral oil. When servicing, cover or seal openings to minimize the exposure of the refrigerant system to air to prevent accumulation of moisture and other contaminants.

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.

After outdoor and indoor unit placement has been determined, route refrigerant tubing between the equipment in accordance with sound installation practices.

• When connecting refrigerant linesets together, it is recommended that dry nitrogen be flowing through the joints during brazing. This will prevent internal oxidation and scaling from occurring.

• Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing.

• Refrigerant tubing should be supported in a manner that the tubing will not vibrate or abrade during system operation.

• Tubing should be kept clean of foreign debris during installation.

• Every effort should be made by the installer to ensure that the 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.

• Recommended maximum length of the interconnecting refrigerant line is 75 feet (4 Ton) and 90 feet (5 Ton).

And the maximum vertical elevation difference between the indoor and outdoor sections should not exceed 20 feet.

• 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.

• Optional equipment such as liquid line solenoid valves, start assist kit, low suction pressure cutout switch kit, high pressure cutout switch kit, etc., should be installed in strict accordance with the manufacturer’s installation instructions.

Label all wires prior to disconnection when servicing the unit. Wiring errors can cause improper and dangerous operation.

• All electrical connections must be in compliance with all applicable state, national, or local codes and ordinances that take precedence.

Pre-Electrical Check List

√

Verify that the voltage, frequency, and phase of the supply source match the specifications on the unit rating plate.

√

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 high and low voltage wiring.

√

Verify factory wiring is in accordance with the unit wiring diagram (Figures 4, 5, 6 & 7, pages 11-14). Inspect for loose connections.

√

Phase balance on 3 phase units must always be checked. See Unbalanced 3-Phase Supply Voltage section (page 7).

Line Voltage

• 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.

•

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.

• 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 on the outdoor unit data label. Any other wiring methods must be acceptable to authority having jurisdiction.

• The outdoor unit requires both power and control circuit electrical connections. Refer to the wiring diagram / schematic for identification and location of outdoor unit field wiring interfaces. See Figures 4, 5, 6, & 7 (pages

11-14). Make all electrical connections in accordance with all applicable codes and ordinances.

• 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.

• Provide power supply for the 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.

• Use only copper wire for the line voltage power supply to this unit. 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.

• 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.

• Optional equipment requiring connection to the power or control circuits must be wired in strict accordance with the applicable local codes, and the instructions provided with the equipment.

Unbalanced 3-Phase Supply Voltage

Voltage unbalance occurs when the voltages of all phases of a 3-phase power supply are no longer equal. This unbalance reduces motor efficiency and performance.

Some underlying causes of voltage unbalance may include:

Lack of symmetry in transmission lines, large single-phase loads, and unbalanced or overloaded transformers. A motor should never be operated when a phase imbalance in supply is greater than 2%.

Perform the following steps to determine the percentage of voltage imbalance:

grounding

1. Measure the line voltages of your 3 phase power supply where it enters the building and at a location that will only be dedicated to the unit installation (at the units circuit protection or disconnect).

Example

:

AB = 226V

BC = 230V

AC = 227V

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!

2. Determine the average voltage in the power supply.

In this example, the measured line voltages were

226, 230, and 227. The average would be 228 volts

(226 + 230 + 227 = 683 / 3 = 228).

3. Determine the maximum deviation:

This unit must be electrically grounded in accordance with all applicable state, national, or local codes that take precedence. Use the grounding lug provided in the control box for grounding the unit.

Thermostat Connections

• Thermostat connections should be made in accordance with the instructions supplied with the thermostat and the indoor equipment.

• Single stage or two-stage thermostats can be used with this equipment depending on optional accessories

(i.e. economizer) installed with the unit. Select a thermostat that operates in conjunction with the installed accessories.

• The outdoor unit is designed to operate from a 24 VAC

Class II control circuit. The control circuit wiring must comply with applicable local codes having jurisdiction.

• The low voltage wires must be properly connected to the unit's low voltage terminal block. Recommended wire gauges and wire lengths for typical thermostat connections are listed in Table 1 (page 8).

• The thermostat should be mounted about 5 feet (1.52m) 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 appliances. Refer to the thermostat manufacturer’s instruction sheet for detailed mounting and installation information.

Example:

From the values given in step 1, the BC voltage

(230V) is the greatest difference in value from the average:

230 - 228 = 2

228 - 226 = 2

228 - 227 = 1

4. Determine percent of voltage imbalance by using the results from steps 2 & 3 in the following equation.

% Voltage Imbalance

= 100 x

100 x

Highest Value

Example:

2

228

= 0.88% max voltage deviation from average voltage average voltage

The amount of phase imbalance (0.88%) is satisfactory since the amount is lower than the maximum allowable

2%. Please contact your local electric utility company if your voltage imbalance is more than 2%.

7

8

Thermostat

Wire gauge

24

22

20

18

Recommended T-Stat Wire

Length (Unit to T-Stat)

2-Wire

(Heating)

55

90

140

225

5-Wire

(Heating/Cooling)

25

45

70

110

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. Set the thermostat system mode on OFF and the fan mode to ON.

2. 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.

3. Set the thermostat fan mode to AUTO and verify the blower stops running.

Table 1. Thermostat Wire gauge

Optional Electric heater Kits

Optional field-installed electric heater kits may be available in multiple heating capabilities up to a maximum of 36kw. Split System Air Conditioners are designed to allow optional auxiliary electric heat to be field installed as required by the building’s particular heating load. The options available for each unit are shown in the heater kit installation instructions or the air handler's Technical

Service Literature.

Install the heater kits as directed by the instructions supplied with the heater kit. Follow all cautions and warnings as directed.

STARTUP & ADjUSTMENTS

Pre-Start Check List

√

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 that the refrigerant tubing is properly connected and leak checked.

√

Verify that the unit is properly charged with the refrigerant listed on the rating label.

√

Verify that the line voltage power leads are securely connected and the unit is properly grounded.

√

Verify that the low voltage wires are securely connected to the correct leads on the low voltage terminal strip.

√

Verify that the power supply branch circuit overcurrent protection is sized properly.

√

Verify that the thermostat is wired correctly.

Start-up Procedures

WARNINg:

If this unit is equipped with a crankcase heater, allow 24 hours prior to continuing the start-up procedures to allow for heating of the refrigerant compressor crankcase.

Failure to comply may result in damage and could cause premature failure of the system. This warning should be followed at initial start-up and any time the power has been removed for 12 hours or longer.

NOTE: On 3 phase air handler models only - If blower is spinning opposite of arrow direction, shut off the main power to the unit and switch any two field wires at the disconnect. DO NOT alter unit wiring.

Anti-Short Cycle Timer Protection

1. Set the thermostat system mode to COOL. Note the temperature setting of the thermostat and gradually raise the set-point temperature until the unit de-energizes.

2. Immediately lower the set-point temperature of the thermostat to its original setting and verify that the indoor blower is energized and outdoor unit remains de-energized.

3. After approximately 5 minutes, verify the compressor and fan energize and the temperature of the discharge air is cooler than the room temperature. NOTE: 3 phase air conditioners DO NOT have short cycle protection.

System Cooling

1. 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.

2. Verify 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.

3. Verify HI and LO refrigerant pressures.

NOTE: If refrigerant pressures are abnormal and the compressor is rotating backwards, shut off main power to the unit and switch any two field wires at the disconnect.

DO NOT alter unit wiring.

4. 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. Set the thermostat's system mode to HEAT and the temperature mode above room temperature.

2. 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

WARNINg:

4-5 Ton Split System Air Conditioners leave the factory with a nitrogen holding charge.

Follow these charging instructions for maximum unit performance and efficiency.

Some local codes require licensed installation/ service personnel to service this type of equipment. Refrigerant charging must be done by qualified personnel familiar with s a f e a n d e nv i ro n m e n t a l ly r e s p o n s i b l e refrigerant handling procedures. Under no circumstances should the owner attempt to install and/or service this equipment.

Failure to comply with this warning could result in property damage, personal injury, or death.

Charging Units in AC mode when Outdoor Temperature is above 55° F (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

Table 3 & Table 4 (page 15).

• 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 charged.

• 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.

AIR CONDITIONER MAINTENANCE

WARNINg:

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.

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.

• To achieve rated capacity and efficiency the compressor must be exposed to refrigerant for at least 24 hours prior to running and then the compressor must be run for a minimum of 12 hours.

• Tables 3 & 4 (page 15) are applicable only to matched assemblies of NORDYNE equipment and listed airflows for the indoor coil. Outdoor units with indoor coils not listed are not recommended and 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 linesets which have a

“Schrader” depression device present to actuate the valve.

• 4 Ton units should use 0.079 orifice in the liquid line and should be charged with 67 oz. of R-22 refrigerant as specified in the supplied addendum (7091540).

5 Ton units should use 0.093 orifice in the liquid line and should be charged with 82 oz. of R-22 refrigerant as specified in the supplied addendum (7091540).

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 about the availability of maintenance contracts.

Routine maintenance should include the following:

• Inspect and clean or replace air filters at the beginning of each heating and cooling season, or more frequently if required.

• 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.

• Inspect the electrical connections for tightness at the beginning of each heating and cooling season. Service as necessary.

CAUTION:

The unit should never be operated without a filter in the return air system. Replace disposable filters with the same type and size.

• 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.

9

10

FIgURES & TAbLES

DO NOT OBSTRUCT TOP OF UNIT

Allow adequate clearance for airflow

D

W

H

Figure 3. Unit Dimensions

S5BA-

H

W

D

048KA/CA

27

22-3/4

22-3/4

060KB/CD

27

30-3/4

30-3/4

Table 2. Unit Dimensional Data

WIRINg DIAgRAMS

ACK YELLOW BL

YELLOW or

K RED or RED BLAC

OR ACT CONT

BLACK

YELLOW

BLACK

BLACK

Figure 4. Wiring Diagram for Single Phase Units (4 Ton)

11

OR ACT CONT

RED OR RED BLACK

K

OR

BLAC YELLOW

YELLOW

K BLAC

YELLOW

12

Figure 5. Wiring Diagram for Single Phase Units (5 Ton)

K

K

BLAC

BLAC

TOR CONT AC

Figure 6. Wiring Diagram for 3 Phase Units (4 Ton)

13

TOR CONT AC

YELLOW

BLACK

14

Figure 7. Wiring Diagram for 3 Phase Units (5 Ton)

REFRIgERANT ChARgINg TAbLES FOR

COOLINg MODE OF OPERATION

LEgEND

Shaded boxes indicate flooded conditions and should not be relied on to determine system charge.

Rated design values. The suction pressure will be lower than design value if indoor 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.

82

84

86

88

90

92

74

76

78

80

66

68

70

72

Suct.

Press.

Liq.

Press.

70

Dis.

Temp.

Liq.

Press.

75

Dis.

Temp.

Liq.

Press.

80

Dis.

Temp.

OUTDOOR TEMPERATURE (°F)

Liq.

Press.

85

Dis.

Temp.

Liq.

Press.

90

Dis.

Temp.

Liq.

Press.

95

Dis.

Temp.

100

Liq.

Press.

Dis.

Temp.

105

Liq.

Press.

Dis.

Temp.

177

179

181

184

187

153

158

163

168

171

193

196

198

200

204

157

162

167

172

175

210

214

217

221

161

212 166

171

175

178

227

229

231

234

237 182

241

165

170

174

178

186

243

245

247

251

254

257

169

174

178

182

186

190

260

262

264

267

271

274

173

177

182

186

190

194

276

278

280

284

287

291

177

181

185

189

194

198

293

295

297

301

304

181

185

188

193

198

307 202

Table 3. Charging Table for 4 Ton Units

74

76

78

80

82

84

66

68

70

72

58

60

62

64

Suct.

Press.

Liq.

Press.

70

Dis.

Temp.

Liq.

Press.

75

Dis.

Temp.

Liq.

Press.

80

Dis.

Temp.

OUTDOOR TEMPERATURE (°F)

Liq.

Press.

85

Dis.

Temp.

Liq.

Press.

90

Dis.

Temp.

Liq.

Press.

95

Dis.

Temp.

100

Liq.

Press.

Dis.

Temp.

105

Liq.

Press.

Dis.

Temp.

165 159

167 164

169

171

169

176

174 178

182

185

187

189

192

163

168

174

179

182

200 168

202 173

204

207

210

178

182

185

218

220

222

225

228

232

172

177

181

186

189

193

235

238

240

243

246

250

176

181

185

189

193

197

253

255

257

261

264

267

180

185

189

193

197

201

271

273

275

279

282

285

184

188

192

197

201

205

288

290

292

296

300

188

192

196

201

205

303 209

Table 4. Charging Table for 5 Ton Units

15

INSTALLATION ADDRESS:

INSTALLATION / PERFORMANCE ChECK LIST

CITY ________________________ STATE ________________

UNIT MODEL #

________________________________________

ELECTRICAL SYSTEM

Electrical connections tight?

Line voltage polarity correct?

YES

YES

NO

NO

Rated Voltage: ___________________________________ VOLTS

L1-L2 Volts: _____________________________________ VOLTS

UNIT SERIAL #

________________________________________

Unit Installed Minimum Clearances per Figure 2 (page 5)?

YES

NO

INSTALLER NAME:

L1-L3 Volts: _____________________________________ VOLTS

L2-L3 Volts: _____________________________________ VOLTS

CITY _______________________ STATE ________________

REFRIgERATION SYSTEM

Was unit given 24 hr warm up period for crankcase heaters (if applicable)?

YES

NO

Stage-1 Liquid Pressure (high side) ________________________

Avg. Volts: ______________________________________ VOLTS

Max. deviation of voltage from avg. volts: ___________________________________ VOLTS

% Volt imbalance: ________________________________ VOLTS

Blower Motor HP: ________ Sheave Setting ___________

# Turns

Has the thermostat been calibrated?

YES

NO

Is the thermostat level?

YES

NO

Is the heat anticipator setting correct?

(If Applicable)

YES

NO

Stage-1 Liquid Temperature ____________________________ °F

Stage-1 Suction Pressure (low side) ________________________

Final Unit Charge _______________________________________

Has the owner’s information been reviewed with the customer?

Has the Literature Package been left with the unit?

YES

YES

NO

NO

REPLACEMENT PARTS

Replacement parts are available through all Nordyne distributors.

Please have the complete model and serial number of the unit when ordering replacement parts.

Capacitors

Compressors

Contactors

Pressure Switches

Relays

ELECTRICAL

Temperature Limit Switches

Thermostats

Time Delay Relays

Transformers

MOTORS

Blower Motor

Fan Motor

COMPONENTS

Blower Assembly

Cabinet Panels

Expansion Valves

Fan Grille

Filter/Driers

Specifications & illustrations subject to change without notice or incurring obligations.

O’ Fallon, MO | Printed in U.S.A. (01/13)

709227C (Replaces 709227B)