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ComfortStar LUC7 Series Installation And Operation Manual

High efficiency air handlers 1.5-5 tons capacity
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INSTALLATION AND OPERATION MANUAL
High Efficiency Air Handlers
1.5-5 Tons Capacity | R454B
LUC7 SERIES
Original instructions.
Please read this manual carefully and keep it for future reference.
All the pictures in this manual are for illustrations purpose only.

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  • Page 1 INSTALLATION AND OPERATION MANUAL High Efficiency Air Handlers 1.5-5 Tons Capacity | R454B LUC7 SERIES Original instructions. Please read this manual carefully and keep it for future reference. All the pictures in this manual are for illustrations purpose only.
  • Page 2 RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMA- TION 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, which could possibly lead to fire, electrical shock, property damage, personal injury, or even death.

  • Page 3: Table Of Contents

    CONTENTS 1 SAFETY Safety Signs Safety Precautions 2 ABOUT THE PRODUCT Unit Dimensions Parts Introduction Attached Fittings Refrigerant Sensor 3 INSTALLATION Installation Instructions Vertical Upflow Vertical Downflow Horizontal Installation in an Unconditioned Space Refrigerant Charge and Room Area Limitations 4 REFRIGERANT LINE 5 AIRFLOW PERFORMANCE 6 DUCTWORK ABOUT THE AIR FILTER...

  • Page 4: Safety

    This document is customer property and is to remain with this unit. These instructions do not cover all the different variations, nor do they provide for every possible contingency to be met in connection with installation. All phases of this installation must comply with national state and local codes. If additional information is required, please contact your local distributor.

  • Page 5: Safety Precautions

    WARNING 1.2 Safety Precautions DANGER PROPOSITION 65: This appliance contains fiberglass insulation. Respirable particles of fiberglass are known to The State of California to Disconnect all power to unit before installing or cause cancer. servicing. More than one disconnect switch may be required to de-energize the equipment.
  • Page 6 WARNING WARNING WARNING Only use this unit in a well-ventilated area and When repairing the refrigerating system, comply ensure unit's airflow inlet and outlet would not be with the following precautions prior to conducting impeded by obstructions. Do not use this unit in work on the system: the following locations: –...
  • Page 7 Leak detection fluids are also suitable for use Refrigerating pipe or components are installed in with most refrigerants but the use of detergents a position where they are unlikely to be exposed containing chlorine shall be avoided as the to any substances which may corrode refrigerant chlorine may react with the refrigerant and containing components, unless the components corrode the copper pipe-work.
  • Page 8 Prior to recharging the system, it shall be When transferring refrigerant into cylinders, pressure-tested with the appropriate purging ensure that only appropriate refrigerant recovery gas. The system shall be leak-tested on comple- cylinders are employed. Ensure that the correct tion of charging but prior to commissioning. A number of cylinders for holding the total system follow up leak test shall be carried out prior to charge is available.
  • Page 9 training on the meaning of appropriate safety If electrical appliances are disposed of in landfills signs and the actions that need to be taken in or dumps, hazardous substances can leak into connection with these signs. the groundwater and get into the food chain, harming your health and well-being.

  • Page 10: About The Product

    2 ABOUT THE PRODUCT 2.1 Unit Dimensions Note: 25" clearance is required in the front of the unit for filter and coil maintenance. Electrical connections Supply air may exit top or right side Flanges are provided for field installation High voltage connection 7/8", 1-3/8", 1-3/4"...

  • Page 11: Parts Introduction

    2.2 Parts Introduction Fig.2-2 Number Parts Control Board Motor Blower AL-Evaporator R454B Refrigerant Sensor Table 2-2 2.3 Attached Fittings Name Name Appearance Quantity Appearance Quantity Indoor unit operation Sealing ring and installation manual Accessory package Alarm output wires Seal plug Pipe Joint Hook Table 2-3...

  • Page 12: Refrigerant Sensor

    2.4 Refrigerant Sensor 3 INSTALLATION R454B refrigerant leakage sensor is configured for the 3.1 Installation Instructions indoor unit. To meet different installation scenarios, the refrigerant sensor has two installation positions. The The unit can be positioned for bottom return air in the factory set of the refrigerant sensor is applied to the upflow position, left and right return in the horizontal vertical upflow and horizontal right.
  • Page 13 When the unit is installed in a hot and humid place, If the humidity inside the installation space might exceed 86 ℉ and RH 80 %, it is recommended to insulate the cabinet exterior. Use glass wool or polyethylene foam as insulation so that the thickness is more than 2 inches and fits inside the installation space opening.
  • Page 14 NOTICE If installed vertically downflow in a hot and humid place that might exceed 86 ℉ and RH 80 %,such as in the basement, the extra drain pan,sponge and sealant shall be installed as shown in Fig .3-7. Sealant must meet the fire rating requirements of 5VA.

  • Page 15: Vertical Upflow

    3.2 Vertical Upflow Vertical Upflow configuration is the factory set on all models. See Fig.3-8. 2-3/4 If return air is to be ducted, install duct flush with floor. Use fireproof resilient gasket 1/8 to 1/4 in. thick between the ducts, unit and floor. Set unit on floor over opening. 1-9/16 IMPORTANT NOTE Torque applied to drain connections should not exceed...
  • Page 16 Steps for Changing Cabinet Orientation to Vertical Downflow or Horizontal Left Orientation 1. Remove the screws and front panel and disconnect the refrigerant sensor from the control board 2. Pull out the coil with refrigerant sensor (Figure 3-10, Step 2). 3.
  • Page 17 When installing the evaporator, ensure the retaining channel is fully engaged with the coil rail. Ensure the retaining channel is fully engaged with the coil rail. Detail A Rails AIRFLOW Rails Fig.3-11 Vertical Downflow & Horizontal Left Applications Conversion in Horizontal Direction: NOTICE Horizontal right-hand supply can be changed to horizon- tal left-hand supply by removing the indoor coil and...

  • Page 18: Installation In An Unconditioned Space

    3.5 Installation in an Unconditioned For determination of room area (A) when used to calculate the refrigerant charge limit, the following shall Space apply. The room area (A) shall be defined as the room area enclosed by the projection to the base of the walls, NOTICE partitions and doors of the space in which the appliance is installed.
  • Page 19 3.6.2. The allowed maximum refrigerant The minimum opening for natural ventilation (Anv ) in connected rooms is related to the room area (A), the charge and required minimum room actual refrigerant charge of refrigerant in the system (m area and the allowable MAXIMUM REFRIGERANT CHARGE in the system (m ), Anv can be determined according to...
  • Page 20 The minimum circulation airflow Installation scheme flow chart Check if the minimum room area meets the requirements lb-oz lb-oz 10-2 10-9 Determine the room size and the 11-0 refrigerant system configuration 11-7 3-15 11-14 12 -5 Calculate the total refrigerant 4-13 12-12 charge...

  • Page 21: Refrigerant Line

    4 REFRIGERANT LINE Field-made refrigerant joints indoors shall be tightness tested. The test method shall have a sensitivity of 5 grams per year of refrigerant or better under a pressure The suction pipe and liquid pipe of the indoor unit need of at least 0.25 times the maximum allowable pressure.

  • Page 22: Airflow Performance

    5. AIRFLOW PERFORMANCE (AMERISTAR AIR HANDLERS ARE SUITABLE FOR MOBILE HOME APPLICATIONS) Airflow performance data is based on cooling performance with a coil and no filter in place. Select performance table for appropriate unit size. External static applied to unit allows operation within the minimum and maximum limits shown in table below for both cooling and electric heat operation.
  • Page 23 Outdoor CFM Wet Coil without filter and Electric Heat Motor Model Unit External Static Pressure (in w.c) Speed Number Size (Tons) Current / A 2.84 2.78 2.71 2.65 2.58 2.50 2.38 2.31 2.14 Power / W 1793 1750 1691 1635 1568 1497 1390...

  • Page 24: Ductwork

    6 DUCTWORK WARNING If appliances connected via an air duct system to Field ductwork must comply with the National Fire one or more rooms are installed in a room with an Protection Association NFPA 90A, NFPA 90B and any area less than shown in section 3.6 Table 3-3, applicable local ordinance.

  • Page 25: About The Air Filter

    7 ABOUT THE AIR FILTER IMPORTANT: Do not double filter the return air duct system. Do not filter the supply air duct system. This will change the performance of the unit and reduce airflow. 7.1 Air Filter (Not Factory-Installed) WARNING External filter or other means of filtration is required.

  • Page 26: Drain Pipe Installation

    AIR FILTER REMOVAL 1. Remove bolts manually, remove air filter recover. See in Fig.7-1. 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 27 1/4" 1/4" Fig.8-2 Vertically upflow view Fig.8-3 Vertically downflow view 1/4" Fig.8-4 Horizontally right view 1/4" Fig.8-5 Horizontally left view...

  • Page 28: Electrical Wiring

    9 ELECTRICAL WIRING Power cords and conventional 24VAC non- communicating thermostat control wires must be In the U.S.A., wiring must conform with current local separated from each other with a distance of codes and the current National Electric Code (NEC). In more than 2 inches.
  • Page 29 2. Low voltage wires connections with outdoor unit. 2.1 Wires connections diagram. THERMOSTAT Terminal TO THERMOSTAT INDOOR UNIT OUTDOOR UNIT Fig.9-2 2.2 Connect the conventional 24VAC non-communicating thermostat control wires (C, B, Y and W) to the four field supplied wires.
  • Page 30 3. Low voltage wires connections with thermostat. 3.1 Connect the Control communication cables by wire nut. The unused wires should be insulated Connect the wires by wire nut THERMOSTAT Fig.9-4 3.2 Wiring diagram of the thermostat. Wiring for 3H and 1C thermostat Y E L LO W R E D B LA C K...
  • Page 31 Wiring for 2H and 1C thermostat Y E L LO W R E D B LA C K GR E E N P U R PL E H/DH G R AY THERMOSTAT BL U E W H ITE BR O W N INDOOR UNIT Note: W1 and W2 are jumped, so Electric Heat will only function in...

  • Page 32: Power Wiring

    9.2 Power Wiring NOTICE In the U.S.A., wiring must conform with current local Electrostatic discharge can affect electronic codes and the current National Electric Code (NEC). In components. Take care during unit installation Canada, wiring must conform with current local codes and service to protect the unit’s electronic and the current Canadian Electrical Code (CEC).

  • Page 33: Alarm Wiring

    9.3 Alarm Wiring 9.3.1 Wiring Diagram Alarm output CN34 wires Ext output wiring Control board Central monitor Fig.9-9 Note: The remote control of the internal circuit is for reference only, the user can change the wiring mode according to the actual situation.

  • Page 34: Electric Heater Kit

    9.4 Electric Heater Kit 9.4.1 Electric heater kit breaker information Ref.Air Handler Use Description Breaker CHE7A-05B 5 kW Heater Max. 240 V, 30 A, 2 P 18,24,30,36,42,48,60 CHE7A-08B 7.5 kW Heater Max. 240 V, 50 A, 2 P 18,24,30,36,42,48,60 CHE7A-10B 10 kW Heater Max.
  • Page 35 9.4.2 Electric Heater Kit Electrical Data (only Eletric Heat) Min. Circuit Max. Fuse or Breaker Fan Speed Heater Kit Electric Ampacity (HACR) Ampacity (AC/HP) Handler Model Heat (kW) Model Used 240 V 208 V 240 V 208 V Medium High •...
  • Page 36 9.4.3 Electric Heater Kit Electrical Data（Eletric Heat combines with Indoor motor ） Min. Circuit Max. Fuse or Breaker Fan Speed Heater Kit Electric Ampacity (HACR) Ampacity (AC/HP) Handler Model Heat (kW) Model Used 240 V 208 V 240 V 208 V Medium High •...

  • Page 37: Setting

    11 SERVICE 10 SETTING 11.1 Error Code and Troubleshooting Check whether the DIP switch is correct according to the wiring nameplate after the electrical wiring is complete. The unit LED will flash when the unit is abnormal. Securi- SW6-1,2 is used to set the blower motor speed. The ty consideration, the outdoor unit shutdown until the factory default settings of different models as shown in abnormal condition is corrected except.

  • Page 38: Disposal

    12 DISPOSAL A TXV may be required to achieve minimum efficiency ratings or for long refrigerant line set applications. Reference AHRI for system combination ratings. Comply with national regulations. Factory installed piston size for each model. Additional Components and accessories from the units are not part of piston sizes are provided in the ship with literature bag ordinary domestic waste.

This manual is also suitable for:

Che7a-05bChe7a-08bChe7a-10bChe7a-15bChe7a-20b

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