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ComfortStar 18 Installation Manual

1.5-5 tons up to 15.2 seer2
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INSTALLER'S GUIDE
CONDENSING UNITS
Split System Air Conditioner
1.5-5 Tons
UP TO 15.2 SEER2
R410a
Thank you very much for purchasing our product.
Before using your unit, please read this manual carefully and keep it for future reference.
The figure shown in this manual is for reference only and may be slightly different from the actual product.

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Summary of Contents for ComfortStar 18

  • Page 1 INSTALLER’S GUIDE CONDENSING UNITS Split System Air Conditioner 1.5-5 Tons UP TO 15.2 SEER2 R410a Thank you very much for purchasing our product. Before using your unit, please read this manual carefully and keep it for future reference. The figure shown in this manual is for reference only and may be slightly different from the actual product.

  • Page 2: Table Of Contents

    RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION WARNING These instructions are intended as an aid to qualified licensed service personnel for proper installation, adjustment and operation of this unit. Read these instructions thoroughly before attempting installation, or operation. Failure to follow these instructions may result in improper installation, adjustment, service, or maintenance possibly resulting in fire, electrical shock, property damage, personal injury, or death.
  • Page 3 8 REFRIGERANT LINE LEAK CHECK Check for Leaks 9 EVACUATION Evacuate the Refrigerant Lines and Indoor Coil 10 SERVICE VALVES 10.1 Open the Service Valves 11 ELECTRICAL - LOW VOLTAGE 11.1 Low Voltage Maximum Wire Length 11.2 Low Voltage Hook-up Diagrams 12 ELECTRICAL - HIGH VOLTAGE 12.1 High Voltage Power Supply...

  • Page 4: Key To Symbols And Safety Instructions

    1 KEY TO SYMBOLS AND These units use R-410A refrigerant which operates SAFETY INSTRUCTIONS at 50% to 70% higher pressures than R-22. Use only R-410A approved service equipments. Refrig- erant cylinders are painted a “Rose” color to 1.1 Key to Symbols indicate the type of refrigerant and may contain a “dip”...

  • Page 5: Unit Location Considerations

    2 UNIT LOCATION Cold climate considerations (heat pump only) CONSIDERATIONS NOTE 2.1 Unit Dimensions Precautions must be taken for units being installed in areas where snow accumulation and prolonged below-freezing temperatures occur. Unit Dimensions Model H(inches) W(inches) L(inches) 24-15/16 23-5/8 23-5/8 Units should be elevated 3-12 inches above the pad or rooftop, depending on local weather.

  • Page 6: Unit Preparation

    The pad must be at least 1-2" larger than the unit on all sides. The pad must be separate from any structure. Min. 12" The pad must be level. Snow barrier The pad must be high enough above grade to allow for drainage.

  • Page 7: Refrigerant Line Considerations

    0.95 0.97 0.94 1.00 0.95 1.00 0.98 Suction line Liquid line 0.94 Models 1.00 0.97 connection connection 0.96 1.00 0.98 18/24/30/36 0.94 0.90 1.00 0.97 0.97 0.96 1.00 0.99 42/48/60/61 0.95 0.93 1.00 0.98 Table 5-1 0.97 0.96 1.00 0.98 0.95...

  • Page 8: Reuse Existing Refrigerant Lines

    Required Optional Insulated Liquid Line Figure 5-4 Insulated Suction Line Tape Sheet Metal Hanger 6 REFRIGERANT LINE ROUTING Figure 5-3 6.1 Precautions NOTE 5.5 Reuse Existing Refrigerant Lines Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines.
  • Page 9 8 Feet Maximum Jo ist/Raft er Isolator Side View 8 Feet Maximum Line Set Secure Suction line from joists using isolators every 8 feet. Secure Liquid Line directly to Suction line using tape, wire, or other appropriate method every 8 feet. Jo ist/Raft er Isolation In Spaces...

  • Page 10: Refrigerant Line Brazing

    7 REFRIGERANT LINE BRAZING 4. Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge (Fig. 7-4). 7.1 Braze The Refrigerant Lines Braze the refrigerant lines to the service valves. 1. Remove caps or plugs. Use a deburing tool to debur Check liquid line filter drier’s directional flow arrow to the pipe ends.

  • Page 11: Refrigerant Line Leak Check

    8 REFRIGERANT LINE LEAK 9 EVACUATION CHECK 9.1 Evacuate the Refrigerant Lines 8.1 Check For Leaks and Indoor Coil 1. Pressurize the refrigerant lines and evaporator coil NOTE to 150 PSIG using dry nitrogen. Do not open the service valves until the 150 PSIG refrigerant lines and indoor coil leak check and evacuation are complete.

  • Page 12: Service Valves

    11.1 Low Voltage Maximum Wire Length Table 11-1 Defines the maximum total length of low voltage wiring from the outdoor unit to the indoor unit and to the thermostat. 24 Volts - Wire Size Max. Wire Length 18 AWG 150 Ft. 16 AWG 225 Ft.
  • Page 13 FOR ONE STAGE FOR TWO STAGE HEAT THERMOSTAT HEAT THERMOSTAT INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT Control Wiring for 18K-60K AC Systems Figure 11-2 Notes: “-----”The electric auxiliary heat connection (optional). W :Electric auxiliary heat signal. W1 :The first Electric auxiliary heat signal. W2 :The second Electric auxiliary heat signal.

  • Page 14: Electrical - High Voltage

    2. After installation or maintenance, the tightening belt shall be tightened, can not be loosened or discarded; the control box access panel must be installed and the screws must be tightened. 12 ELECTRICAL - HIGH VOLTAGE 12.2 High Voltage Disconnect Switch 12.1 High Voltage Power Supply Install a separate disconnect switch at the outdoor unit.

  • Page 15: Start Up

    14 SYSTEM CHARGE 13 START UP ADJUSTMENT 13.1 System Start Up 14.1 Charging: Weigh-In Method 1. Ensure Sections 7, 8, 9, 10, 11, and 12 have been completed. Weigh-In method can be used for the initial installation, or anytime a system charge is being replaced. Weigh-In 2.

  • Page 16: Suction Line Pressure Charging And Refrigerant Adjustment In Cooling (Above 55°F Outdoor Temp.)

    14.2 Suction Line Pressure 2. Ensure Sections 7, 8, 9, 10,11,12 and 13 have been completed. Charging And Refrigerant Adjustment In Cooling (Above 55°F Outdoor Temp.) 3. Stabilize the system by operating for a minimum of 20 minutes. 1. Check the outdoor ambient temperatures. NOTE Suction line pressure (in cooling mode) is the only recommended method of charging above 55ºF...
  • Page 17 Design superheat with TXV throttle Indoor Unit Inlet DB/WB (°F) Outdoor DB (°F) 95/79 90/75 85/71 80/67 75/63 70/58 Design superheat with piston throttle Indoor Unit Inlet DB/WB (°F) Outdoor DB (°F) 95/79 90/75 85/71 80/67 75/63 70/58 Determine the final superheat value using total Line Length and Lift measured in 5.3 and the charts below 18K AC with TXV Add 2°...
  • Page 18 24K AC with Orifice Add 6° of Superheat Add 8° of Superheat Add 4° of Superheat Add 2° of Superheat Add 6° of Superheat Total Refrigerant Line Length-feet 30K AC with Orifice Add 4° of Superheat Add 6° of Superheat Add 4°...
  • Page 19 42K AC with TXV Add 4° of Superheat Add 2° of Superheat Add 4° of Superheat Add 6° of Superheat Add 2° of Superheat Use Design Superheat Value Add 4° of Superheat Total Refrigerant Line Length-feet 48K AC with Orifice Add 4°...
  • Page 20 5. Use the final superheat value, refrigerant temperature and pressure from STEP 4, to determine the proper suction gauge pressure using Table 14-1. Example: Assume a 12º F final superheat value and suction temp of 58º F. 1. Locate 12º F final Superheat in Table 14-1. 2.

  • Page 21: System Operation And Troubleshooting

    2.96 74.58 21.8 72.24 21.2 7.22 2.84 7.05 2.78 69.98 20.61 20.04 6.88 2.72 67.8 65.69 19.49 6.72 2.67 63.65 18.96 6.56 2.61 61.68 18.44 2.56 59.78 17.94 6.25 2.45 57.95 17.45 56.17 16.98 5.96 54.46 16.52 5.82 2.35 52.8 16.08...

  • Page 22: Electrical Data Table

    15.4 Electrical Data Table Model Minimum circuit ampacity (A) 11.6 14.7 15.8 24.9 25.3 35.1 38.9 Maximum circuit Protector (A) 15.5 Troubleshooting Table SYSTEM FAULTS REFRIGERANT CIRCUIT Head Pressure Too High Head Pressure Too Low Suction Pressure Too High Suction Pressure Too Low Liquid Refrig.

  • Page 23: Fault Code Table

    15.6 Fault Code Table 15.6.1 For 18K-60K AC System Fault code of main control module Fault code of motor driver module LED1 ERROR CODE LED2 ERROR CODE CONTENT CONTENT STEADY ON STEADY ON NORMAL OPERATION NORMAL OPERATION POWER SUPPLY FAILURE POWER SUPPLY FAILURE 1FLASH/CYCLE 2s ON...

  • Page 24: Warranty

    16 WARRANTY Assist owner with processing Warranty cards and/or online registration. 16.1 Maintenance Dirt should not be allowed to accumulate on the indoor or outdoor coils or other parts in the air circuit. Clean as often as necessary to keep the unit clean. Use a brush, vacuum cleaner attachment or other suitable means. The outdoor fan motor is permanently lubricated and does not require periodic oiling.

  • Page 25: Changing Motor

    16.3 Changing Motor When motor requires changing, follow the steps below: STEP 1 - Go into electrical panel, disconnect motor power lines. Note: Disconnect main power to unit. Severe burns and electrical shock will occur if you do not disconnect main power. STEP 2 - Remove cover (be careful of motor wires).

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