ComfortStar BAR5 Series Service Manual
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ComfortStar BAR5 Series Service Manual

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BAR5 SERIES
Read this manual carefully before operating your
new air conditioning unit. Make sue to save this
manual for future reference.

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June 6, 2025

What is a t5 temperature sensor

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Summary of Contents for ComfortStar BAR5 Series

  • Page 1 BAR5 SERIES Read this manual carefully before operating your new air conditioning unit. Make sue to save this manual for future reference.

  • Page 3: Table Of Contents

    Service Manual Service Manual PART 1 Product instructions PART 2 System Instruction ……………………………………………………………………………..….….… 3 Refrigerant Circuit ……………………………………………………………………………………...….… 3 Functional Parts Layout ……………………………………………………………………………...….… 5 Refrigerant Flow Chart for Each Operation Mode ……………………………………...….… 9 PART 3 Function and Control …………………………………………………………………………..….….… 10 Function General …………………………………………………………………………………………….… 11 3.1.1 Unit Shutdown Control ……………………………………………………………………….…….….…...
  • Page 4 2. Refrigerant Circuit PART 2 System Instruction ……………………………………………………………………………… 3 2.1 Refrigerant Circuit ……………………………………………………………………………………… 3 2.2 Functional Parts Layout ……………………………………………………………………………… 5 2.3 Refrigerant Flow Chart for Each Operation Mode …………………………………… … 9...

  • Page 5: Part 2 System Instruction

    2. System Instruction 2.1 Refrigerant Circuit No. in Symbol Part Name Major function diagram Rotary Rotary Compressor Inverter compressor is operated in multi-steps according to PT. Comp. Used to high pressure protection when up to 580 PSIG and High pressure switch recovery when below to 435PSIG.
  • Page 6 2. System Instruction 2.1 Refrigerant Circuit AC system with Scroll compressor HP system with Scroll compressor...
  • Page 7 2. Refrigerant Circuit 2.2 Functional Part 13.4 AC 53/71/90/105, 14.3AC 53/71/90 13.4 AC 160...
  • Page 8 2. Refrigerant Circuit 2.2 Functional Part 13.4 AC 120/140 14.3 AC 160...
  • Page 9 2. Refrigerant Circuit 2.2 Functional Part 14.3 HP 53/71/90 14.3 HP 105/120/140/160...
  • Page 10 2. Refrigerant Circuit 2.2 Functional Part...
  • Page 11 2. Refrigerant Circuit 2.3 Refrigerant Flow Chart Cooling Operation/Cooling Oil Return Operation/Defrost Operation High pressure gas High pressure liquid Low pressure Heating Operation/Heating Oil Return Operation High pressure gas High pressure liquid Low pressure...

  • Page 12: Part 3 Function And Control

    3. Function and Control PART 3 Function and Control …………………………………………………………………………… 10 3.1 Function General …………………………………………………………………………………………… 11 3.1.1 Unit Shutdown Control ……………………………………………………………………….…….… 12 3.1.2 Unit Standby Control ………………………………………………………………………….…….… 12 3.1.3 Unit Normal Operation …………………………………………………………………………….…… 13 3.1.4 Unit Special Control ………………………………………………………………………………..…… 15 3.1.5 Unit Protection Control or Restart……………………….…………………………….……………...

  • Page 13: Function General

    3. Function and Control 3.1 Function General Protection Normal 3.1.5 Unit protection control or restart 3.1.1 Unit shutdown control： ⑴ T3 Protection in cooling ⑴ Protection shutdown ⑵ T5(Discharge Temp.) Protection ⑵ System stops ⑶ Low Pressure Switch Protection 3.1.2 Unit standby control： ⑴...

  • Page 14: Unit Shutdown Control

    3. Function and Control 3.1.1 Unit shutdown control ⑴ Unit protection shutdown To protect the outdoor unit, our system will shut down when there is something abnormal. Also the LED 1(Red) or LED 2(Green) would show the fault code when fault present. ⑵...

  • Page 15: Unit Normal Operation

    3. Function and Control 3.1.3 Unit normal operation Anytime the compressor is operating, the digital tube will show the frequency of compressor. ⑴ List of functions in normal [Cooling] Symbol Part Name Major function The Reversing Valve Outdoor fan motor 10 speeds ECM motor.
  • Page 16 3. Function and Control 3.1.3 Unit Normal operation ⑷ PEV control The PEV's function is to help equalize the refrigerant pressures on the high and low sides prior to compressor operation . You will hear a "hissing" sound every time after the compressor stops, this is the PEV equalizing the pressure.
  • Page 17 3. Function and Control 3.1.4 Unit special control ⑴ [dF] Defrost control ● The Demand Defrost Control (DDC) monitors the ODU coil temperature using thermistor (T3). A second thermistor (T4) monitors outdoor ambient temperature. Based on these parameters, as well as accumulative running time and Standby time, the DDC calculates proper initiation of defrost.

  • Page 18: Unit Protection Control Or Restart

    3. Function and Control 3.1.7 Unit protection control or restart： ⑴ T3 Protection in cooling Normal operation T3 sensor ≥143.6 ℉ T3 sensor <125.6 ℉ Outputting the LED 1 code System standby ”2S ON/2S OFF” .. ⑵ T5(Discharge Temp.) Protection Normal operation T5 sensor <167 ℉...

  • Page 19: Fault Of Main Board

    3. Function and Control 3.1.6 Fault of Main board： Protection control Operation LED Protection code Supposed cause description T3 sensor not reading T3 sensor is not properly placed/High pressure LED2 1 Flash/cycle correctly in cooling switch fault T4 sensor not reading T4 sensor is not properly placed/High pressure LED2 2 Flash/cycle...
  • Page 20 3. Function and Control 3.1.7 Unit protection control or restart： ⑴ T3 sensor not reading correctly in cooling Normal operation T3 is shorted or open Automatic restart T3 is seated fault Outputting the LED 2 code standby and restart ”1 Flash/cycle ” . ⑵...
  • Page 21 3. Function and Control 3.1.7 Unit protection control or restart ： ⑷ OFM Failure Normal operation Motor speed<100rpm when operating for 40 seconds Motor speed<100rpm when starting for 30 seconds DC fan motor fault Outputting the LED 2 code standby and restart ”5 Flash/cycle ”...

  • Page 22: Fault Of Motor Driver Module

    3. Function and Control 3.1.8 Fault of Motor driver module ： Protection control Operation LED Protection code Supposed cause description 0.2S ON/0.2S Inter integrated circuit LED1 Main board is broken communication error LED1 1 Flash/cycle Motor current error Motor shaft is stuck or Motor is broken Inverter module LED1 2 Flash/cycle...
  • Page 23 4. Field settings PART 4 Field settings ………………………………………………………………………………………… 21 4.1 Test Operation …………………………………………………………………………………………… 22 4.1.1 Checks before Test Operation ……………………………………………………………………… 22 4.1.2 Turn Power on …………………………………………………………………………………………… 23 4.1.3 Charging Refrigerant ………………………………………………………………………………… 24 4.1.4 Manual Defrost …………………………………………………………………………………………… 27 4.2 Field Setting ………………………………………………………………………………………………… 28 4.2.1 Setting by DIP Switches ………………………………………………………………………………...

  • Page 24: Test Operation

    4. Field settings 4.1 Test operation 4.1.1 Checks before test operation Checkpoints Cautions or warnings Dangerous for turning over during storm Are all units securely installed? Possible damage to pipe connections Is the earth wire installed according to the applicable Dangerous if electric leakage occurs local standard? Are the condenser unit installed according to location...

  • Page 25: Turn Power On

    4. Field settings 4.1 Test operation 4.1.2 Turn power on Note: Make field setting if needed. Settings of outdoor unit (For the setting procedure, refer to information in “4.2.2 Setting by DIP switches”) Set system thermostat OFF Note: Supply power to the indoor and In a normal condition, the LED1 flesh slowly outdoor units (2S ON/2S OFF) and LED2 steady on.

  • Page 26: Charging Refrigerant

    4. Field settings 4.1 Test operation 4.1.3 Charging Refrigerant (1) Charging method selection Weigh-in charging method Use weigh-in charging method the initial installation, or anytime a system charge is being replaced. Weigh-in charging method can also be used when power is not available to the equipment site or operating conditions (Indoor/Outdoor temperatures) are out of range to verify with the subcooling charging method.
  • Page 27 4. Field settings 4.1 Test operation (4) Method for charging mode For more information, plese go to read installation manual...
  • Page 28 4. Field settings 4.1 Test operation (4) Method for charging mode Notes: 1. If superheating is low, remove refrigerant. If superheating is high, add refrigerant. 2. If superheat >30℉, please check if there are abnormal condition for insulation, high humidity, high room temperature. Also check if discharge superheat>60 ℉...

  • Page 29: Manual Defrost

    4. Field settings 4.1 Test operation 4.1.4 Manual defrost Step 1 Starting the system in heating mode for more than 10 minutes. Step 2 Set the SW3-1 switch to “ON” . Note: Step 3 Defrost will exit automatically. The system defrost Step 4 If needed, repeat step 2 again after a few minutes.

  • Page 30: Setting By Dip Switches

    4. Field settings 4.2 Field setting 4.2.1 Setting by DIP switches---13.4AC 42/48/60K...
  • Page 31 4. Field settings 4.2 Field setting 4.2.1 Setting by DIP switches---4/5TON...

  • Page 32: Dip Switch Position Indication

    4. Field settings 4.2 Field setting 4.2.2 DIP switch position indication ---2/3TON LED 1 LED 2...

  • Page 33: Thermostat

    4. Field settings 4.3 Thermostat Note: B signal need thermostat programming settings. 4.3.1 Control wiring...
  • Page 34 5. Intelligent Troubleshooting PART 5 Intelligent Troubleshooting ………………………………………………………………… 33 Diagnosis System Introduction …………………………………………………………………… 33 Symptom-based Troubleshooting ………………………………………………………………… 34 5.3 Troubleshooting by Main board Fault code……………………………………………………… 37 5.4 Troubleshooting by Motor driver module code………………………………………………… 43...

  • Page 35: Part 5 Intelligent Troubleshooting

    5. Intelligent Troubleshooting 5.1 diagnosis system introduction There are two types of auxiliary diagnosis code in system: Main board code and Motor driver module code 5.1.1 Fault of Main board Protection control Operation LED Protection code Supposed cause description T3 sensor not reading T3 sensor is not properly placed/High pressure LED2 1 Flash/cycle...

  • Page 36: Symptom-Based Troubleshooting

    5. Intelligent Troubleshooting 5.2 Symptom-based Troubleshooting 5.2.1 LED1/LED2 OFF Issue LED1/LED2 OFF Model Fault name Classify Power/electric issue  Frequently power off and power on （within 3 minutes） Possible cause  Abnormal power input Abnormal wire connections Notes: Troubleshooting Note: Check for the following 4 points: ①...
  • Page 37 5. Intelligent Troubleshooting 5.2 Symptom-based Troubleshooting 5.2.2 System does not start operation Issue System does not start operation Model Fault name Classify Thermostat fault  The thermostat doesn’t start Possible cause  Wrong wire connections between thermostat and unit  Damaged thermostat ...
  • Page 38 5. Intelligent Troubleshooting 5.2 Symptom-based Troubleshooting 5.2.3 Capacity is low Issue Capacity is low Model Name Classify System fault Poor heat dissipation in indoor unit Possible cause  Poor heat dissipation in outdoor unit  Under charged  First start Estimate the output capacity in Troubleshooting forced mode:...
  • Page 39 5. Intelligent Troubleshooting 5.3 Troubleshooting by Main board Fault code 5.3.1 LED2-1 Flash/cycle LED2-1 Flash/cycle Faulty code Model Name T3 sensor not reading correctly in cooling System fault Classify  Wrong location of T3 sensor Possible cause  Faulty T3 sensor ...
  • Page 40 5. Intelligent Troubleshooting 5.3 Troubleshooting by Main board Fault code 5.3.2 LED2-2 Flash/cycle LED2-2 Flash/cycle Faulty code Model Name T4 sensor not reading correctly/Discharge Temperature switch (T5)open System fault Classify  Wrong location of T4 sensor Possible cause  Faulty T4 sensor ...
  • Page 41 5. Intelligent Troubleshooting 5.3 Troubleshooting by Main board Fault code 5.3.3 LED2-2 Flash/cycle LED2-2 Flash/cycle Faulty code Model Name Compressor discharge temperature (T5) protection System fault Classify  TXV/EEV/filter drier blocked Possible cause  Under charged  Service valves not open/filter drier restriction ...
  • Page 42 5. Intelligent Troubleshooting 5.3 Troubleshooting by Main board Fault code 5.3.4 LED2-3 Flash/cycle LED2-3 Flash/cycle Faulty code Mode Name Low pressure protection System fault Classify  Indoor unit motor stopped abnormally / poor heat exchange Possible cause  TXV/EEV/filter drier/indoor coil blocked ...
  • Page 43 5. Intelligent Troubleshooting 5.3 5.3 Troubleshooting by Main board Fault code 5.3.5 LED2-5 Flash/cycle LED2-5 Flash/cycle Faulty code Model Name DC fan motor fault Electric issue Classify  Start electromagnetic interference Possible cause  Motor failed  Electric issue Troubleshooting 【6.
  • Page 44 5. Intelligent Troubleshooting 5.3 Troubleshooting by Main board Fault code 5.3.5 LED2-6 Flash/cycle LED2-6 Flash/cycle Faulty code Model No machine type Name Electric issue Classify  Speed message isn’t wrote in main board Possible cause Control board broken Troubleshooting LED2-6 Flash/cycle Need to replace control board...
  • Page 45 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.1 LED1- 0.2S ON 0.2S OFF LED1- 0.2S ON 0.2S OFF Faulty code Model Name Inter integrated circuit communication error fault Electric issue Classify  Motor driver module poor contact Possible cause Control board broken Troubleshooting...
  • Page 46 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.2 LED1--1 Flash/cycle LED1--1 Flash/cycle Faulty code Model Motor current error fault Name Electric issue Classify  Motor shaft stuck Possible cause  Motor broken Control board broken Troubleshooting Motor current error fault If Motor shaft Correct it is stuck...
  • Page 47 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.3 LED1--2 Flash/cycle LED1—2 Flash/cycle Faulty code Model Inverter module temperature error Name Electric issue Classify  Motor is broken Possible cause Control board broken Troubleshooting Inverter module temperature error If Motor is Replace the motor broken...
  • Page 48 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.4 LED1--3 Flash/cycle LED1—3 Flash/cycle Faulty code Model Dc bus voltage error Name Electric issue Classify  Power supply wrong Possible cause Control board broken Troubleshooting Dc bus voltage error If Power Correct it Voltage : 187V-253V...
  • Page 49 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.5 LED1--4 Flash/cycle LED1—4 Flash/cycle Faulty code Model Motor parameter error Name Electric issue Classify Control board broken Possible cause Troubleshooting Motor parameter error Need to replace control board...
  • Page 50 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.6 LED1--5 Flash/cycle LED1—5 Flash/cycle Faulty code Model Motor startup failure Name Electric issue Classify Motor broken Possible cause Motor shaft stuck Control board broken Troubleshooting Motor startup failure If Motor shaft Correct it is stuck If Motor is...
  • Page 51 5. Intelligent Troubleshooting 5.4 Troubleshooting by Motor driver module code 5.4.7 LED1--6 Flash/cycle LED1—6 Flash/cycle Faulty code Model Phase sequence error Name Electric issue Classify Motor wring broken Possible cause Control board broken Troubleshooting Phase sequence error If motor wring is Correct it broken Need to replace control board...
  • Page 52 6 Check PART 6 Check …………………………………………………………………………………………………… 50 6.1 Check for Causes of Rise in High Pressure …………………………………………………… 51 6.2 Check for Causes of Dropping Low Pressure in Cooling ……………………………… 52 6.3 Check for Causes of Dropping Low Pressure in Heating ………………………………...

  • Page 53: Part 6 Check

    6 Check 6.1 Check for Causes of Rise in High Pressure CHECK 1 Note: 310-380PSIG head pressure is normal for heating in normal conditions operation. The pressure may be as high as 440PSIG at 40℉ outdoor temperature or higher. Start-up or return oil stages during heating. ←Check to be sure the Service valve closed service valve is open.

  • Page 54: Check For Causes Of Dropping Low Pressure In Cooling

    6 Check 6.2 Check for Causes of Dropping Low Pressure in cooling CHECK 2 Note: 110-140PSIG head pressure is normal in cooling conditions. The value may be lower/higher at maximum/minimum/limited frequency of compressor operation . Start-up or return oil stages. ←Check to be sure the Service valve closed service valve is open.

  • Page 55: Check For Causes Of Dropping Low Pressure In Heating

    6 Check 6.3 Check for Causes of Dropping Low Pressure in heating CHECK 3 ←Check to be sure the Service valve closed service valve is open. ← Conduct visual checks Bent or crashed pipe for pipe conditions. High pipe ← Is there more than 2℉ resistance Impurities clogging before and after the filter or...

  • Page 56: Check For Causes Of Refrigeration Cycling Blocked

    6 Check 6.4 Check for Causes of Refrigeration cycling blocked CHECK 4 Note: Check at normal and force mode operation, some problems will be more obvious. ←Check to be sure the Service valve closed service valve is open. ← Conduct visual checks Bent or crashed pipe High pipe General...

  • Page 57: Check For Control Board

    6 Check 6.5 Check for control board CHECK 5...

  • Page 58: Check For Temperature Sensor (T3/T4)

    6 Check 6.6 Check for Temperature Sensor（T3/T4） CHECK 6 Check temp transducer（T3/T4）： Compare the temperature checked (T3-3#/T4-4#/T5-5#, refer to 4.1.5), it’s normal if the temperature difference was within 15℉ when standby.(need to avoid the waste heat affect T5/Tf when standby mode) T3/T4: 77 ℉...

  • Page 59: Check For High Pressure Switch (Hps)

    6 Check CHECK 7 6.7 Check for High Pressure Switch（HPS） High Pressure Switch ： Whether the switch can start normally when start the machine Start Work well normally When power off and pull up High pressure Reconnect/fix switch secure, no the wiring wiring damages? damages...

  • Page 60: Check For Low Pressure Switch (Lps)

    6 Check CHECK 8 6.8 Check for Low Pressure Switch（LPS） High Pressure Switch ： Whether the switch can start normally when start the machine Start Work well normally When power off and pull up High pressure Reconnect/fix switch secure, no the wiring wiring damages? damages...

  • Page 61: Check For Discharge Temperature Switch (T5)

    6 Check CHECK 9 6.8 Check for Discharge Temperature Switch（T5） Discharge Temperature Switch ： Whether the switch can start normally when start the machine Start Work well normally When power off and pull up High pressure Reconnect/fix switch secure, no the wiring wiring damages? damages...

  • Page 62: Check For Condenser Fan Motor

    6 Check 6.10 Check for Condenser fan motor CHECK 10 Condenser fan motor： Whether fan can start normally Normal? Work well When power off，after 3minutes and unplugged Resistance （Ω） 100W/200W Normal motor Motor replace winding? Between U and V <36 Between V and W <36 Between W and U...
  • Page 63 6 Check 6.11 Check for Compressor CHECK 11 Compressor： Whether compressor can start normally Normal? Work well When power off，after 3minutes and unplugged For Scroll compressor, supply wring is unitary, you can check it with colour (Red for L1, Black for L2, White for S) Normal Resistance （Ω）...

  • Page 64: Check For Indoor Air Flow

    6 Check 6.12 Check for indoor air flow CHECK 12 Indoor air flow： Indoor air flow is normal/Check the capacity by BTU=△T*CFM*1.5 in force mode。 Check if the airflow is very If It is Work normal small or no airflow normally Measure the power supply If there is...
  • Page 65 7. Appendix PART 7 Appendix 7.1 Wiring Diagrams ……………………………………………………………… 64 7.2 Control Board Replacement Procedure …………………………………… 66 7.3 Diagnosis System Introduction …………………………………………… 67 7.4 Troubleshooting Guide ……………………………………………………… 68 7.5 Temperature and Resistance Relationship Tables …………………… 69...
  • Page 66 7 Appendix Appendix 1 7.1 Wiring diagrams-42/48/60K...
  • Page 67 7 Appendix Appendix 1 7.1 Wiring diagrams-for 18/24/30/36K...
  • Page 68 7 Appendix Appendix 2 7.2 Control board replacement procedure 1. Power off and wait at least 3 minutes before opening the electric control box. 2. Remove the wirings carefully. 3. Remove the screws on the board (as shown by the red circle and the serial number ) 4.Install the new board on the unit.
  • Page 69 7 Appendix Appendix 3 7.3 Fault code introduction...
  • Page 70 7 Appendix Appendix 4 7.4 Troubleshooting guide...
  • Page 71 7 Appendix 7.5 Temperature and Resistance Relationship Tables Appendix 5...

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