ComfortStar EHK05A Service Manual
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ComfortStar EHK05A Service Manual

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DC Inverter R410A
Air Conditioners & Heat Pump
Service Manual 2014
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Summary of Contents for ComfortStar EHK05A

  • Page 1 DC Inverter R410A Air Conditioners & Heat Pump Service Manual 2014 - 0 -...

  • Page 2: Table Of Contents

    CONTENTS 1. Precaution ............................- 2 - 1.1 Safety Precaution......................- 2 - 1.2 Warning & Caution ......................- 2 - 2. Function ............................- 4 - 2.1 Model Names Of Indoor/Outdoor Units ........ Error! Bookmark not defined. 2.2 Specifications ............... Error! Bookmark not defined. 3.

  • Page 3: Precaution

    1. Precaution 1.1 Safety Precaution This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury. This is an attention alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.
  • Page 4 Failure to follow the safety warnings exactly could result in serious injury, death or property damage. A fire or electrical hazard may result causing property damage, personal injury or loss of life. If using existing refrigerant lines make certain that all joints are brazed, not soldered. ...

  • Page 5: Function

    2. Function (Refer the specification) 3. Dimension 3.1 Indoor Units DIMENSIONAL DATA Dimensions inch MODEL SIZE LIQUID LINE / UNIT HEIGHT "H" IN. UNIT WIDTH "W" IN. UNIT LENGTH "D" IN. VAPOR LINE 46-1/2" 19-5/8" 21-5/8" 3/8"/3/4" 54-1/2" 22” 24" 3/8"/3/4"...

  • Page 6: Outdoor Units

    3.2 Outdoor Units DIMENSIONAL DATA Refrigerant connection Mode size Dimensions Service Valve Size “H” in. “W” in. “L” in. Liquid in. Suction in. 24/36 24/36 24-15/16 29-1/8 29-1/8 48/60 48/60 33-3/16 29-1/8 29-1/8 - 5 -...

  • Page 7: Refrigerant Cycle Diagram

    4. Refrigerant Cycle Diagram For cooling only models: Outdoor Unit Indoor Unit condenser temp. expansion condenser sensor high pressure valve switch stop volve evaporator pressure discharge senser temp.sensor stop volve C O M P REFRIGERATION FLOW For heat pump models: Outdoor Unit Indoor Unit high pressure...

  • Page 8: Wiring Diagram

    5. Wiring Diagram 5.1 Indoor Units Indoor unit wiring diagram for PSC motor A/C systems and H/P systems. - 7 -...
  • Page 9 Indoor unit wiring diagram for ECM motor A/C systems and H/P systems(24K/36K/48K). - 8 -...
  • Page 10 Indoor unit wiring diagram for ECM motor A/C systems and H/P systems (60K). - 9 -...
  • Page 11 Indoor unit wiring diagram for electric heat. BROWN BLUE ELEMENTS BLUE RELAY1 NOTE1 YELLOW WHITE BLACK BLACK L1Ў L2Ў CB CIRCUIT BREAKER LS LIMIT SWITCH 5kW HEAT KIT POWER FL FUSE LINK YELLOW RELAY1 BLACK YELLOW BROWN WHITE BLUE ELEMENTS BLUE RELAY2 ELEMENTS...
  • Page 12 BLACK YELLOW RELAY2 ELEMENTS BLUE BLACK/WHITE BLACK NOTE1 YELLOW RELAY1 BLACK YELLOW BROWN WHITE BLUE ELEMENTS BLUE RELAY2 ELEMENTS BLUE WHITE BLACK BLACK BLACK Cb2:30A Cb1:60a L1Ў L2Ў L2Ў L1Ў CB CIRCUIT BREAKER LS LIMIT SWITCH 15kW HEAT KIT(10kW+5kW) FL FUSE LINK POWER POWER BLACK...

  • Page 13: Outdoor Units

    5.2 Outdoor Units Outdoor unit wiring diagram for 28/36K models: 202075590748 YELLOW YELLOW YELLOW PFC-L Advance into the defrosting SW5-1 J1: ONLY FOR HP MODEL Normal defrosting Cn29 ONLY FOR HP MODEL BLACK W Y B C Time Delay of the end defrosting:120S Cn30 SW5-2 BROWN...
  • Page 14 Outdoor unit wiring diagram for 48/60K models: 202075890714 RED LED FLSAH Communication fault ONLY FOR HP MODEL The IPM module protection Cn10 Cn22 Cn27 ONLY FOR HP MODEL Low dc voltage protection W Y B C MOTOR Advance into the defrosting SW5-1 The IPM control fault Normal defrosting...

  • Page 15: Installation Details

    6. Installation Details 6.1 Outdoor Unit Installation 6.1.1 Location Before starting the installation, select and check the suitability of the location for both the indoor and outdoor unit. Observe all limitations and clearance requirements. The outdoor unit must have sufficient clearance for air entrance to the condenser coil, for air discharge and for service access. NOTE For multiple unit installations, units must be spaced a minimum of 18 inches apart.
  • Page 16 6.1.3 Roof Installation When installing units on a roof, the structure must be capable of supporting the total weight of the unit, including a padded frame unit, rails, etc., which should be used to minimize the transmission of sound or vibration into the conditioned space. 6.1.4 Unit Placement 1.
  • Page 17 weight evenly and prevent noise and vibration (See Fig.1). NOTE:Do not block drain openings shown in Fig.1. 3. If unit must be elevated because of anticipated snow fall, secure unit and elevating stand such that unit and/or stand will not tip over or fall off. NOTE: To tie down unit, see 6.1.6.
  • Page 18 fasteners. Step 2: Center and level unit onto pad. Step 3: Using field supplied L-shaped bracket to locate holes on concrete and drill pilot holes which is at least 1/4” deeper than fastener being used. Important Self drilling screws to base pan should not exceed 3/8” long to avoid damaging coil. Step 4: Using conventional practices to install brackets, tighten concrete fasteners and self-tapping screws (See Fig.2).
  • Page 19 6.1.7 Precautions During Line Installation 1. Install the lines with as few bends as possible. Care must be taken not to damage the couplings or kink the tubing. Use clean hard drawn copper tubing where no appreciable amount of bending around obstruction is necessary, if soft copper must be used, care must be taken to avoid sharp bends which may cause a restriction.
  • Page 20 WEATHERPROOF DISCONNECT POWER SWITCH SUPPLY INDOOR BLOWER COIL Seal opening(s) with permagum or equivalent NOTE:All outdoor wiring must be weather proof Fig.5 Typical Installation 6.1.8 Precautions During Brazing Of Lines All outdoor unit and evaporator coil connections are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent.
  • Page 21 6.1.9 Precautions During Brazing Service Valve Precautions should be taken to prevent heat damage to service valve by wrapping a wet rag around it as shown in Fig.6. Also, protect all painted surfaces, insulation, during brazing. After brazing cool joint with wet rag. The valve can be opened by removing the plunger cap and fully inserting a hex wrench into the stem and backing out counter-clockwise until valve stem just touches the chamfered retaining wall.
  • Page 22 connection has cooled, remove the nitrogen source from the liquid fitting service port. 7. Replace the Schrader core in the liquid and suction valves. 8. Leak test all refrigerant piping connections including the service port flare caps to be sure they are leak tight.
  • Page 23 Refer to Line Size Information in Tables 2 and 3 for correct size and multipliers to be used to determine capacity for various suction line diameters and lengths of run. The losses due to the lines being exposed to outdoor conditions are not included. The factory refrigerant charge in the outdoor unit is sufficient for 15 feet of standard size interconnecting liquid line.
  • Page 24 Table 2: Suction Line Length / Size VS Capacity Multiplier(R410A) Model size 2 Ton 3 Ton 4 Ton 5 Ton Suction Line Connection Size 3/4" O.D. 3/4" O.D. 7/8" O.D. 7/8" O.D. Suction Line Run － Feet 5/8 Opt. 5/8 Opt. 3/4 Opt.
  • Page 25 wiring label. Power wiring, control (Iow voltage) wiring, disconnect switches and over current protection must be supplied by the installer. Wire size should be sized per requirements. CAUTION All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance with Local, National Fire, Safety &...
  • Page 26 1/2” nut NOTE: 5/16” nuts Damage will occur to condenser unit if you remove fan nuts prior to cover removal. Fig.8 COVER AND FAN When motor requires changing follow the steps below: Step 1: Go into electrical panel, disconnect motor power lines. Important note Disconnect main power to unit.
  • Page 27 raise pressures (suction, liquid and discharge) . 6.1.13.1 Charging by liquid pressure In order to properly charge the system, the following conditions must be met: 1) Outdoor temperature above 60°F. 2) Indoor temperature between 70°F to 100°F. 3) Installation must be complete with brazed joints and drier visually inspected. 4) The unit electrical installation must be checked and unit powered for one (I) hour if crank case heater is used or five (5) minutes if no crankcase heater is used.

  • Page 28: Indoor Unit Installation

    6.1.13.3 Final leak testing After the unit has been properly evacuated and charged, a halogen leak detector should be used to detect leaks in the system. All piping within the condensing unit, evaporator, and interconnec ting tubing should be checked for leaks. If a leak is detected, the refrigerant should be recovered before repairing the leak.
  • Page 29 Conversion to Vertical Downflow: A vertical upflow unit may be converted to the vertical downflow on it. Remove the door and indoor coil and reinstall 180° from original position. See Fig. 9~10. Important: To comply with certification agencies and the National Electric Code for horizontal right application, the circuit breaker(s) on field-installed electric heater kits must be re-installed per procedure below so that the breaker switch “on”...
  • Page 30 6.2.1.3 Horizontal Horizontal right is the default factory configuration for the units. Horizontal left isn’t the default factory configuration for the units. Conversion to horizontal: A vertical upflow unit may be converted to horizontal right by removing indoor coil assembly and reinstalling coil as shown for right hand air supply. And reinstall coil in unit as shown for right hand air supply.
  • Page 31 ENSURE THE RETAINING CHANNEL IS FULLY ENGAGED WITH THE COIL RAIL. DETAIL A RAILS AIRFLOW RAILS Fig.11 VERTICAL DOWNFLOW & HORIZONTAL LEFT APPLICATIONS (lower front service panel removed “view”.) CAUTION Horizontal units must be configured for right hand air supply or left hand air supply. Horizontal drain pan must be located under indoor coil.
  • Page 32 WARNING Disconnect all power to unit before installing or servicing. More than one disconnect switch may be required to de-energize the equipment. Hazardous voltage can cause severe personal injury or death. 6.2.2.1 Power wiring It is important that proper electrical power is available for connection to the unit model being installed.
  • Page 33 MAX.Fuse or Breaker Heat Kit MIN. Circuit Ampacity Air Handler (kW)Electric (AC/HP) (HACR) Ampacity Model Model Heat Medium High • • • 27.2 24.6 EHK05A • • 40.8 36.9 EHK08A • • 54.4 49.2 EHK10A • • • EHK05A 27.2 24.6 •...
  • Page 34 Electric Heater Kits Kit# Description Ref. Air Handler use EHK05A 5kW Heat Strip 24,36,48,60 EHK08A 24,36,48,60 7.5kW Heat Strip EHK10A 24,36,48,60 10kW Heat Strip EHK15B 15kW Heat Strip, Double Breaker's panel 36,48,60 EHK20B 20kW Heat Strip, Double Breaker's panel 36,48,60 6.2.3 Ductwork...
  • Page 35 the blower outlet. Important: If an elbow is included in the plenum close to the unit, it must not be smaller than the dimensions of the supply duct flange on the unit. • Important: The front flange on the return duct if connected to the blower casing must not be screwed into the area where the power wiring is located.
  • Page 36 CONDENSATE DRAIN TRAP DO NOT OPERATE UNIT WITHOUT CONDENSATE DRAIN TRAP. UNIT DO NOT OVERTIGHTEN DRAIN FITTING UNIT MUST BE SLIGHTLY INCLINED TOWARD DRAIN CONNECTION TO APPROVED DRAIN Fig. 12 CONDENSATE DRAIN TRAP Important: 1. When making drain fitting connections to the drain pan, use a thin layer of Teflon paste, silicone or Teflon tape and install, hand tighten.
  • Page 37 that the top of the trap is below connection to the drain pan to allow complete drainage of pan (See Fig. 12). • Auxiliary drain line should be run to a place where it will be noticeable if it becomes operational. Homeowner should be warned that a problem exists if water should begin running from the auxiliary drain line.
  • Page 38 WARNING Do not operate the system without filters. A portion of the dust entrained in the air may temporarily lodge In the duct runs and at the supply registers. Any circulated dust particles could be heated and charred by contact with the air handler elements. This residue could soil ceilings, walls, drapes, carpets and other articles in the house.
  • Page 39 • Air Filter Removal 1.Remove bolts manually, remove air filter recover, see in Fig. 13; 2. Hold the edge of the air filter and extract out . 3. Clean the air filter (Vacuum cleaner or pure water may be used to clean the air filter. If the dust accumulation is too heavy, use soft brush and mild detergent to clean it and dry out in cool place) .
  • Page 40 THERMOSTAT Control Wiring for A/C systems Suggestion: Thermostat choose KJR-23B or Non-programmed eletrical thermostat series of Honeywell, such as TH 5220D. Wiring please refer to the Owner’s Manual of the thermostat. THERMOS TAT INDOOR UNI T OUTDOOR UNI T Control Wiring for H/P systems. Suggestion: Thermostat choose KJR-25B or Non-programmed eletrical thermostat series of Honeywell, such as TH 5220D.
  • Page 41 Note: If indoor unit has auxiliary heating already installed and a different auxiliary heating unit is required the indoor unit (A) and indoor line diameters will be different. Wiring gauge for H/P systems NOTE: If indoor unit has auxiliary heating already installed and a different auxiliary heating unit is required the indoor unit (A) and indoor line diameters will be different.

  • Page 42: Maintenance And Replacement Of Outdoor Unit Electronic Control Box

    6.3 Maintenance And Replacement Of Outdoor Unit Electronic Control Box When outdoor unit electronic control box requires changing follow the steps below: Step 1: Disconnect the cover and upside board. Step 2: Replace a new electronic control box - 41 -...
  • Page 43 Step 3: Install the cover and upside board - 42 -...

  • Page 44: Operation Characteristics

    7. Operation Characteristics Temperature Cooling operation Heating operation Mode Room temperature ≥17℃(62℉) ＜30℃(86℉) 10℃～48℃ -15℃～30℃ Outdoor temperature (50℉～118℉) (5℉～86℉) CAUTION: 1. If air conditioner is used outside of the above conditions, certain safety protection features may come into operation and cause the unit to function abnormally. 2.

  • Page 45: Electronic Function

    8. Electronic Function 8.1 Abbreviation T3: Condenser coil temperature T4: Ambient temperature T5: Discharge temperature of compressor Tf： Heat sink temperature of IPM 8.2 Main Control Logic 8.2.1 Temperature protection of compressor discharge When the compressor discharge temp. is getting higher, the running frequency will be limited as below rules: ---Compressor discharge temp.
  • Page 46 8.2.3 Condenser temperature T3 protection When condenser temperature is getting higher, the running frequency will be limited as below rules: --- When condenser temp. T3≥62℃, the system will display P5 protection; F3 error will display when system appear 5 times P5 protection in 180 minutes, it cannot resume automatically, and it can resume only by restarting the machine.
  • Page 47 ---72≤Tf<76℃, keep running at the current frequency. ----Tf<69℃, no limit for frequency. 8.2.6 COMPRESSOR CRANKCASE HEATER (CCH) (Heat pump only,optional) Refrigerant migration during the off cycle can result in a noisy start up. Add a crankcase heater to minimize refrigeration migration, and to help eliminate any start up noise or bearing “wash out”. All heaters must be located on the lower half of the compressor shell.
  • Page 48 When JUMP switch is set to “1”, the mode will start up in either of the two following conditions: --- Compressor operating, when T4 is >-2℃ and T3 is < 0℃ last for 40 minutes. --- Compressor operating, when T4 is <-2℃ and T3 is < 0℃ last for 50 minutes. When JUMP switch is set to “0”: --- Compressor operating, when T3 is <...

  • Page 49: Main Control Board Ports Instructions

    8.3 Main Control Board Ports Instructions For 24/36K models: Main control board ports instruction Content Compressor wiring terminal Reactor wiring terminal (connect a reactor between 2 and 3) Reactor wiring terminal (connect a reactor between 2 and 3) Defrosting function dial code SW5 Pressure sensor port Air discharge temp.
  • Page 50 4-way valve port (HP only) Temp. controller connection port Function dial code SW4 Point check button Forced operation button Reserved Nixie tube display Fan control port Crankcase heating zone control terminal Short wire Power supply connection terminal Power supply connection terminal Indicator lamp - 49 -...
  • Page 51 For 48/60K models: 17 18 - 50 -...
  • Page 52 Main control board ports instruction Content EXV driving port (HP only) High pressure switch port Radiator temp. sensor port Condenser temp. sensor port Outdoor temp. sensor port (HP only) Air discharge temp. sensor port Pressure sensor port Connection wire port between main boards DC motor driving source(15V-P2) The voltage between 10 and 11 is 380Vdc (Compressor is running normally) The voltage between 10 and 11 is 380Vdc (Compressor is running normally)

  • Page 53: Outdoor Unit Status Display

    8.4 Outdoor Unit Status Display Sequence System operation parameters Remarks Capacity of outdoor unit Type + Ton Running mode 0-Stand by、2-Cooling、3-Heating The setting frequency of outdoor unit Open degree of Electric expansion valve Actual value /8 T3 Pipe temperature T4 ambient temperature Reserved Te Low pressure temp.

  • Page 54: Troubleshooting

    9. Troubleshooting 9.1 Outdoor Unit Error Display Error Content Note code Environmental temperature sensor fault time voltage protection resume Voltage protection automatically, and two times voltage protection can resume only by restarting the machine DC fan motor error 10 minutes appear two times E6 protection It can resume only by restarting the machine The exhaust gas sensor is not seated fault Communication fault in main control chip...

  • Page 55: Diagnosis And Solution

    9.2 Diagnosis And Solution E4 (Temp. sensor error) Diagnosis Handling Re-insert the sensor Whether sensor T3、T4、TF、 tight according to T5 are inserted and connected wiring nameplate reliably (No T4 for cooling only) Unplug the sensor, check if Replace T3 or T4 sensor resistance for T3, T4 is in the range of TABLE1 Unplug the sensor, check if...
  • Page 56 H4/P6 ( Compressor instant over-current protection) Diagnosis Handling Open gas valve and Check if ball valves are open liquid valve Y es Re-start after wiring Check whether the compressor correctly according to the wiring is normal wiring nameplate Y es Whether compressor insulation Compressor exchange resistance is below 100k?
  • Page 57 P8 (DC fan typhoon protection(applicable for 48、60)) Diagnosis Handling Check whether motor wiring is Re-insert the sensor according to wiring reliably connected according to nameplate the nameplate Check if there’s 15VDC If wiring is correct, replace between P8 and P2 the mainboard Whether motor leads to fan Avoid external motor is...
  • Page 58 E5(Voltage protection) Handling Diagnosis Check power supply Whether the power supply to troubleshoot voltage is between 208V-10% problems and 230V+10% Check if the power supply is reliably Replace power supply connected, whether the power wire or connect power supply wire diameter meets supply wire well requirements in the manual Cut off the power, and wait until...
  • Page 59 F4/P0 (Module radiator temp. Tf protection) Diagnosis Handling Fix the radiator. If If the radiator is damaged or radiator is damaged, badly fixed replace it If there’s dust or fallen leaves Clean radiator duct influencing radiating Whether the fan and blade can Replace motor or blade normally operate Whether the duct, including...
  • Page 60 E7 (air discharge temp. sensor loose error) Diagnosis Handling Fix air discharge temp. Check whether the sensor sensor to the air doesn’t fix to discharge pipe discharge pipe, re-power on to start the unit Check if wiring of T3，T5 Wiring according to the sensors and pressure sensor nameplate and re-power are in accordance with wiring...
  • Page 61 H3/P3 (Frequency-conversion over-current protection) Diagnosis Handling Open gas valve and If ball valves are open liquid valve Wiring according to the If compressor wiring is normal nameplate and re-power on to start the unit Whether compressor insulation Compressor exchange resistance is below 100kΩ Restart after powering on to Start after pressure balance make sure that high and low...
  • Page 62 H5/P2 (Low pressure protection) Diagnosis Handling Whether gas valve and liquid Open gas valve and valve are open liquid valve Whether indoor side is normal, Exclude inside reasons valve is blocked or radiator is and restart sheltered, fan is stopped Unplug low pressure sensor Replace the mainboard LPC to see if resistance is 0 Ω...
  • Page 63 F5/Hb (Heating high pressure protection) Diagnosis Handling Whether gas valve and liquid Open gas valve and valve are open liquid valve Whether indoor side is normal, valve is blocked or radiator is Exclude indoor side error sheltered, fan is stopped Troubleshooting.
  • Page 64 F1 (High pressure protection switch error) Diagnosis Handling Whether gas valve and liquid Open gas valve and valve are open liquid valve Whether high pressure switch resistance is normal Replace sensors Stop the unit for an hour to see Replace the mainboard whether it reports the same error Keep operating...
  • Page 65 HH/PH (Compressor liquid return) Diagnosis Handling Whether T3，T5 are abnormal Replace sensors (refer to sensor error testing) Whether indoor unit is Troubleshoot indoor unit abnormal, valve is blocked or radiator is sheltered, fan is stopped If there’s TXV or EV adjusting Not applicable for valve for indoor unit(Not applicable element...
  • Page 66 C3 (T3 sensor loosely-inserted protection) Diagnosis Handling Fix the sensor to the Whether the sensor is fixed to heat exchanger to U pipe, and power on to the heat exchanger restart Wiring according to the Check if T3, T4 sensors and nameplate correctly and pressure switch are wired according to wiring nameplate...
  • Page 67 H6/P4 (Air discharge overtemperature protection) Diagnosis Handling Whether gas valve and liquid Open gas valve and valve are open liquid valve Check whether air discharge Replace air discharge temp. sensor T5 resistance is temp. sensor normal, refer to TABLE2 Whether position of air Troubleshooting discharge temp.
  • Page 68 F3/P5 (T3 tube high temp.protection) Diagnosis Handling Whether gas valve and liquid Open gas valve and valve are open liquid valve Replace sensors Whether T3，T5 are abnormal Check whether outdoor unit fan Replace the fan and is abnormal and whether the exclude the surrounding outdoor heat exchanger is debris of heat exchanger...
  • Page 69 Table 1: comparison table about temperature, resistance and voltage, it is suitable for T3/T4 sensor. TEMP F TEMP C RESISTANCE kΩ VOLTS DC -20.6 107.73 4.65 -17.8 93.54 79.52 4.54 -12.2 67.80 4.47 -9.4 57.95 4.39 -6.7 49.65 -3.9 42.65 4.21 -1.1 36.71...
  • Page 70 Table 2: comparison table about temperature, resistance and voltage, it is suitable for T5/Tf sensor. TEMP F TEMP C RESISTANCE kΩ VOLTS DC -20.6 600.13 4.93 -17.8 505.55 4.92 427.46 4.91 -12.2 362.74 4.89 -9.4 308.89 4.87 -6.7 265.40 4.85 -3.9 227.48 4.83...
  • Page 71 87.8 5.47 2.02 90.6 5.03 1.92 93.3 4.65 1.83 96.1 4.28 1.73 98.9 3.95 1.64 101.7 3.65 1.56 104.4 3.38 1.48 107.2 3.13 2.90 1.32 112.8 2.69 1.25 115.6 2.50 1.18 118.3 2.33 1.12 121.1 2.17 1.06 123.9 2.02 126.7 1.89 0.95 129.4...

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