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1. 5 a o d UY YN i o gt O N y Le 3 O O Heat Pump 1 5 tons to 5 tons WRAY MUI Ni IIMB te md LLL Comfortstar Service manual for 13seer Heatpump Condensing Contents Description of Products amp Fearures Physical And Electrical Specifications Safety Caution Application Installation Instructions Defrost Cycle Maintenance Instructions Service And Troubleshooting Wiring Diagrams 0 Explosive Diagram And Spare Parts List Comfortstar Service manual for 13seer Heatpump Condensing 1 Description Of Products amp Fearures 1 1 Summary The main components of Condensing UnitS Sroll compressor with high efficiency better reliability super quiet operation High efficiency heat exchanger with inner groove copper pipe inserting aluminum fin The expansion valve can maintain heating capacity Painted and zinc gilt metal parts with corrosion protection Compressor overload protection 1 2 Condensing Unit Outline Top discharge air flow with low noise Smaller body with high efficiency With ULcertification Effortless Installation Annular outdoor unit Fast heat dispersion and Powful cooling heating Beautiful outline with powerful antiseptics ability Reliable and steady operation 1 3 Working Principle lt gt MIH series heat pump condensing unit Comfortstar Service manual for 13seer Heatpump Condensing Filter2. 07210037 03410107 021400055 07138233 07138232 07138203 07138202 01318206 Tube exit plate 01388210 Temperature Sensor 3900012125 Electric box cover 01418231 Capacitor CBB61 CBB611A 6uF 500V 33010037 AC Contactor CJX9B 25S D C1 44010250 42011242 30221401 02143401 33000001 01388222 01152210 07220011 06642036 01318213 43000405 Comfortstar Service manual for 13seer Heatpump Condensing 10 3 42K 10 3 1 Explosive view 10 3 2 Spare parts list D No discription PartNo 7 eastiquid Separator 072827 1 DE Compressor 00220 1 3 as Plate Sub sy 0120822007 S Sway Valve 43000405 1 Con RC 43008214 1 Aer H T A EE econ ST A H SSS DOM HT T 0214000688 1 EE H T A 96 EE 0713822 4 T rea Expansion Valve 0208 1 U H H 0713820 1 Ai ona 1 DD 0 Tubesmpae 0138820 A DB TemperatureSensor 3600012125 4 ZE T 014182 DB Capacitor CBB61TA TUFBOOVAS 33010041 1 DM Ac Contactor Gce assvorct 4401023 O 4 Terminal Board 4201122 4 T ain Board 3022140 E 27 Capacitor lamp 02141375 E 21 PS a Af Af k k A lk lk A l l lk Al o Comfortstar Service manual for 13seer Heatpump Condensing 10 4 48K 10 4 1 Explosive view 10 4 2 Spare parts list No discription PartNo Q PNM 70818204 2 pp CoverPlate 258210 Pp To FanmotorswisoD 16702103 1 4 po Ripple Pipe 05278205 1 pT FixedBl
3. discription PartNo Q oo NE xr o zoezo 2 pp CoverPate 01258248 14 3 pp Fan Motor SW120C 15702101 314 Pp pp Ripple Pipe 0501240 1 pT Fed Blok 01722121 1 6 AialFlowFan 10358203 1 o pp GCasmiquidSeparator_ 07228217 1 Pp Compressor 00202207 1 pe Base Plate Sub Assy 01202104 14 k po tO awayVave 430004088 6 14 o way Valve Accessary 43008214 1 a Fite TI os 1 oa Bidirection Strainer 03410107 1 As Tube Clip 021400085 1 sa CutoffVae 58 0713824 1 Cutoffvawesis 07138232 1 17 Thermal Expansion Valve BAE1 1 2HCA ODF 07332206 3 8X1 2 a pp OnewayVave 07138202 1 a Cabinet otss208s 1 a pp Tube exitplate 01388210 1 pp Temperature Sensor 39000121285 1 oz pp Electicboxcover 01418231 1 2 Capacitor CBB61 CBB611A 6uF 500V__ 33010087 1 o AC Contactor CJX9B 25S D C1 44010250 1 k TerminalBoad 42011248 14 S ajalala alalalaljalalala alalalals e lk A Af A Comfortstar Service manual for 13seer Heatpump Condensing 32 70318204 01258248 15018254 05012140 01722121 10358203 07228217 Compressor Compressor 00202202 012021091 43000404 43008214 07215201 03410107 021400055 07138234 07138232 Thermal Expansion Valve BAE2HCA ODF 07332207 3 8X1 2 07138202 01318208 01388210 3900012125 01418231 33010064 42011242 30221401 0214340
4. l Expansion check Expansion check Valve Valve Service Valve of Liquid Pipe Outdoor Heat Filter Exchanger Service Valve of Gas Pipe Heat Exchanger Centrifugal Fan Compressor Cooling _ Heating Fig 1 Working Principle Diagram of Heat Pump Condensing Unit The working principle diagram of the heat pump Air Conditioner is shown above in fig 1 When the system operates in cool mode the low temperature and low pressure refrigerant gas from the heat exchanger of the indoor unit is sucked by compressor and compressed the high temperature and high pressure gas is discharged into heat exchanger of outdoor unit heating exchanges with air of outside and turns into the refrigerant liquid the liquid is throttled by throttling element and changed into the low temperature and low pressure liquid then flows into the heat exchanger of indoor unit heating exchange with the air of the indoor then turns into the low temperature and low pressure refrigerant gas The above circle goes round and round When the system operates in heat mode the refrigerant flows in the reversible cycle as the cool mode The refrigerant gas discharges the heat volume in the indoor heat exchanger through the expansion valve and sucks the heating volume from outdoor heat exchanger and forms the heat pump cycle this cycle goes round and round and the demanded high temperature environment is maintained WAINIAN TY WAINIAN TY WAINIAIN TY WAINIAN TY NAINIA
5. Refrigerant Line Sizing Refrigerant Line Length Ft Unit Size Ton Line Outside Diameter In 4 0 1 1 8 1 2 1 1 8 1 2 1 1 8 1 2 5 0 1 1 8 1 2 1 1 8 1 2 1 1 8 1 2 R 22 Cooling Capacity Loss For Various Line Lengths amp Tube Diameters Acceptable Cooling Capacity loss at Total Equivalent Line Length ft Refer to Liquid pia Long Line Application Guideline to calculate equivalentlength ap Vapor Line line in Size in Standard Application Long line Application Requires Accessories 50 80 81 175 200 225 250 8 7 7 9 En 8 9 1 7 8 10 11 The factory charge is sufficient for 25 feet of standard liquid line For longer or shorter liquid line lengths adjust the charge as follows 3 8 Liquid line 0 6 oz Per foot 1 2 Liquid line 0 8 oz Per foot Vertical Separation between Indoor and Outdoor Units Maximum allowable vertical separations between indoor and outdoor units are 100 when the indoor unit is below the outdoor unit and 60 when the indoor unit is above the outdoor unit To ensure good oil return to the compressor when the indoor unit is below the outdoor unit suction line oil trap should be used as illustrated in Fig 5 Tubing Connections CAUTION Use extreme caution in removing the caps from the suction and liquid line fittings as there is pressure present A fitting is on the liquid line to remove pressure CAUTION Condens
6. air conditioner POWER SUPPLY Adequate power supply adequate cross section of wire Please consult it with distributor and professional The Air Conditioner must be reliably earthed The earth wire must be connected to the special grounding devices It is forbidden to connect it to water pipe gas pipe wires of the lightning rod and telephone The cable must be wired by qualified personnel in accordance with national wiring regulation Electricity leakage protection switch and air switch should be fixed in the wire circuit APPLICATION Before specifying any air conditioning equipment a survey of the structure and a heat gain calculation must be made A heat gain calculation involves identifying all surfaces and openings that gain heat from the surrounding air and quantifying that heat gain It also calculates the extra heat load caused by sunlight and by humidity removal These factors must be considered before selecting an air conditioning system to provide year round comfort The Air Conditioning Contractors of America ACCA J Manual method of load calculation is one recognized procedure for determining the cooling load The cooling load calculation determines the unit size There are two capacities that enable the equipment to provide comfort The first is sensible capacity How much sensible heat can the unit remove Sensible heat is the heat energy measured on the dry bulb thermometer The second form of heat is called latent or hidd
7. ambient kit low ambient kit compressor iced Moisture in the system Recover Re ERIN I I evacuate amp recharge evaporator coil add filter drier Recheck load calculation High vapor pressure Defective compressor Defective compressor EXE Fluctuating head and Air or non condensibles in system Recover E an evacuate Lease evacuate amp recharge vapor pressures Pulsing noise at Air or non condensibles in system Recover refrigerant evacuate amp recharge metering device or liquid line Comfortstar 9 Wiring Diagram 9 1 Exterior Wiring Diagram Power 380V 3PH 50Hz outdoor unit ES 9 2 Interior Wiring Diagram W2 BLUE Service manual for 13seer Heatpump Condensing Power 208 230V 3PH 60Hz outdoor unit ADS Fig6 UNE VOLTAGE Power 20B 230V 1PH 60Hz Power 230V 1PH 50Hz FZ D H Li In L2 IDH GROUND FACTORY STANDARD FELD INSTALLE OPTIONAL DW VOLTAGE lug Plate 1 D FACTORY STANDARD FELD INSTALLE OPTIONAL COMPRESSO W15 BLUE D USE COPPER CONDUCTORS ONLY WARNING CABINET MUST BE PERMANENTLY GROUNDED AND ALL MIRING TD CONFORN TO LEC NEC CELL LC AND LOCAL CODES AS APPLICABLE REPLACENENT WIRE NIST BE THE SAVE GAGE AND INSULATION TYPE AS ORGINAL WIRE Comfortstar Service manual for 13seer Heatpump Condensing 10 Explosive view And Spare Parts List 10 1 18K 8 24K 10 1 1 Exposive view 10 1 2 Spare parts list No
8. back to the blower If they are too small they also cause noise The installers should balance the air distribution system to ensure proper air flow to all rooms in the home This ensures a comfortable living space 5 Installation Instructions 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 5 1 Outdoor Unit Inspection This product has been inspected at the factory and released to the transportation agency without known damage Inspect exterior of carton for evidence of rough handling in shipment Unpack carefully If damage is found report immediately to the transportation agency 5 2 Equipment Protection From Environment The metal parts of the unit may be subject to rust or corrosion in adverse environmental conditions This oxidation could shorten the unit life Salt spray or mist in seacoast areas sulphur or chlorine from lawn watering systems and various chemical contaminants from industries such as paper mills and petroleum refineries are especially corrosive Comfortstar Service manual for 13seer Heatpump Condensing If the unit is to be install
9. defective 4 way valve check the valve coil or replace it Insufficient Cooling Dirty filters Clean amp replace Indoor air blockage Check supply registers and return grills for blockage Improperly sized unit Recalculate load Air non condensable or moisture in system Recover refrigerant evacuate amp recharge add filter drier Incorrect voltage At compressor terminals voltage must be PO within 10 of rating plate volts when unit is running A AAA Water on floor or in Blocked condensate drain and P trap Remove blockage AA Condenser fan and AC Contact not connect to the power Re connect the power supply wire and tightly The outdoor power supply main circuit Dial the power supply switch to ON Comfortstar Service manual for 13seer Heatpump Condensing switch locate OFF position or fuse failure position or change the fuse and make sure the of main circuit main touch point of AC Contactor have current go through The control coil of AC Contactor no 24 V Check if the relay P2 of 3 minute timer board have AC power current output if not check if P1 P3 have 24 V AC input if have 24V AC please check if it keep for 3 minutes if so and P2 no output change the 3 minute timer board if keep time lt 3 minutes P2 no output if P1 P3 no24V AC first check the thermostat C Y terminal have 24 VAC if no 24 VAC then check the thermostat or reset the setting temp if have 24 V AC check if th
10. system is only 30 CFM Two or three unsealed joints can cause this leak Sealing the return and supply ducts pays dividends in increased system capacity and lower operating costs Effective duct insulation is essential to prevent loss of capacity and sweating ducts in the cooling mode Duct systems installed in the conditioned space can be left uninsulated but a dense 1 2 fiberglass duct liner reduces blower and air noises and prevents sweating ducts when humidity levels are high Supply and return duct systems in attics and crawl spaces require a minimum 1 of dense duct liner or 2 fiberglass wrap with a sealed vapor barrier A leaky vapor barrier results in duct sweating causing wet insulation Wet insulation does not insulated Heat transfer through poorly insulated systems can result in over 50 loss in operating capacity Sweating ducts also promote rusting ducts resulting in premature duct failure Other duct materials have been successfully used Carefully follow the duct manufacturers installation instructions The duct system is only as good as the planners and installers construct Air supply diffusers must be selected and located carefully They must be sized and positioned to deliver treated air along the perimeter of the space If they are too small for their intended air flow the become noisy If they are not located properly they cause drafts on the occupants in the rooms Return air grilles must be properly sized to carry air
11. when the unit doesn t operate properly Where the system varies from its normal sequence is a major clue to any problems COOLING CYCLE Comfortstar Service manual for 13seer Heatpump Condensing Mechanical the operation sequence as follows 1 The compressor pumps out high pressure superheated refrigerant vapor 2 The vapor leaves the compressor and passes through the reversing valve 3 It flows through the outdoor vapor line to the finned outdoor coil Air from the outdoor fan removes heat from the refrigerant vapor When enough heat is removed the vapor condenses into a high pressure liquid The liquid temperature is slightly warmer than ambient air temperature 4 This warm high pressure liquid leaves the outdoor coil and flows through the small copper 5 Atthe end of the liquid line the refrigerant passes through the a flowcheck device reducing a pressure and temperature 6 As the cool liquid under reduced pressure enters the indoor coil surface it expands and absorbs heat from the indoor air passing over the finned surface Heat from the indoor air causes the low pressure liquid to evaporate and cools the indoor air The refrigerant is now a cool vapor 7 The cool refrigerant vapor travels through the larger insulated vapor line to the accumulator 8 The accumulator separator separates any liquid refrigerant and holds it Only vapor refrigerant and refrigerant oil leave the accumulator The oil is drawn out through a sp
12. with the location of the over current protection the proper size for this application and the proper procedure for disconnecting power service to the unit The condensing unit control wiring requires a 24 Volt minimum 25 VA service from the indoor transformer as shown on the wiring diagram 5 9 SYSTEM STARTUP 1 Turn thermostat to OFF turn on power supply at connect switch 2 Turn temperature setting as high as it will go 3 Turn fan switch to ON Indoor blower should run Be sure it is running in the right direction 4 Turn fan switch to AUTO Turn system switch to COOL and turn temperature setting below room temperature Unit should run in cooling mode 5 Check to see if compressor and outdoor fan are running correctly 6 Check the refrigerant charge see Instructions under Charging the System 7 Replace service port caps Service port cores are for system access only and will leak if not tightly capped 8 Check unit for tubing and sheet metal rattles 9 Instruct the owner on operation and maintenance Leave this Installation and Operating Manual and the Use and Care Manual with owner 5 10 OPERATION SEQUENCE OF OPERATION In order to service and troubleshoot an air conditioning system a service technician must understand the units sequence of operation this is the order of events the system undergoes to cycle itself on and off Knowing how the units operate properly aids in determining where to start troubleshooting
13. 1 33000012 013882141 01152218 Current Divider 07224041 01308228 44010250 Comfortstar Service manual for 13seer Heatpump Condensing 10 2 30K amp 36K 10 2 1 Explosive view 10 2 2 Spare parts list No discription PartNo Q Nut M5X7 70318204 segs nnn nn AE A HA AE AAA As Ripple Pipe 0527825 1 Pp Fred Blok 1087821 1 6 _Axialflowtan 1035821 14 gt pp Gas liquid Separator 07228217 1 k y Compressor 00100106 1 os Base Plate Sub Assy 0120822001 1 Oo poo way Vale 43000405 1 way Valve Accessary 43008214 1 pte 07210087 Dono o Bidirection Strainer 03410107 1 Pp Tube lip 0214000585 1 As Cutoff Vahe 4 07138288 1 Cutoff ae se 07138282 1 Thermal Expansion Valve TDEX3 ODF 07332204 17 f 10X16 a One wayVave 07138202 1 A Cabret 0131826 1 a Tube exitplate 01388210 1 21 Temperature Sensor 3900012125 1 oz Electric box cover 0141821 14 o Capacitor CBB61 CBB611A 6uF 500V__ 33010037 1 o AC Contactor CJX9B 258 D C1 44010250 1 2 o Terminal Board 42011242 1 2 Main Board 30221407 1 2 k Af Aj Af Af AA ff Al al Al A e Af af Af Af A fa Af a Comfortstar Service manual for 13seer Heatpump Condensing 70318204 01258210 15702102 05278205 10878211 10358211 07228217 compressor Compressor 00202203 0120822001 43008214
14. 327 Table 2 Note 1 The piston placed in the indoor unit is used when cooling 2 Expansion Valve placed in the outdoor unit is used for indoor unit when heating The air distribution system has the greatest effect The duct system is totally in the control of the contractor The industry can only recommend the correct procedure The correct air quantity is critical on air conditioning system Proper operation efficiency compressor life and humidity control depend on the correct balance between indoor load and outdoor unit capacity High indoor air flow increases the possibility of high humidity problems in cooling Low indoor air flow reduces total capacity and causes coil icing Serious harm can be done to the compressor in either condition Air conditioning requires a specified air flow Each ton of air conditioning requires 400 cubic feet of air per minute 400CFM TON Comfortstar Service manual for 13seer Heatpump Condensing Duct design and construction should be carefully done System performance can be lowered dramatically through bad planning or workmanship In cooling a hot attic can cause a temperature gain of 3 in the return duct and 4 in the supply duct This can reduce the cooling capacity of an air conditioning system by as much as 30 This means a loss of almost one ton of cooling capacity from a three ton system Air leakage of only 3 in a return duct can cause a 5 loss in system capacity 3 leakage on a three ton
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16. The refrigerant piping is very important as it the base of the natural operation and high efficiency of the air conditioning system Comfortstar Service manual for 13seer Heatpump Condensing OUTDOOR UNIT 27 2714 ADDITIONAL SUCTION LINE ZA OIL TRAP FOR EACH 20 PITCH SUCTION LINE TOWARD OUTDOOR AA FOOT RISE OF PIPE UNIT 4 2 FRO EVERY 10 OF LINE ZARZA INDOOR UNIT ABOVE OR LIQUI LEVEL TO OUTDOOR UNIT SUCTION LINE OIL TRAP WHEN INDOOR L L UNIT IS 4 FEET OR OUTDOOR UNIT ZELAN EE MORE BELOW OUTDOOR UNIT INDOOR UNIT LIQUID LINE INDOOR UNIT BELOW OUTDOOR UNIT FigureA Figure B LIQUID LINE INDOOR UNIT OUTDOOR UNIT ATA LAE 1 AA TT ZA IZA AAA P SUCTION LINE a NAA CALE T rere Fig5 Only refrigeration grade copper piping dehydrated and sealed should be used Take extreme care to keep the refrigerant tubing clean and dry prior to and during installation If in doubt blow out the tubing with dry nitrogen to remove any chips or debris before connection Always keep tubing sealed until it is in place and the connections are to be made Refrigerant piping should be as short as possible with a minimum of elbows or bends to avoid capacity loss and increased operating costs Refrigerant lines must be adequately supported If metal strapping is used to secure the tubing do not allow the strapping to directly contact the tubing Use a closed cell insulation to separate the strapping from the tubing Do not kink or tw
17. ct to the vacuum pump again turn on the pump to vacuumizing 30 minutes until the vacuum reach 1 0kgf cn Comfortstar Service manual for 13seer Heatpump Condensing 8 5 Checking before Operation yes no other __ yes no other __ yes no other yes no other __ yes no other __ yes no other __ Eligible pipe for condensing water yes no other ___ Proper copper pipe and thermal insulation pipe yes no other ___ Clean the impurity after welding 7 no other ___ Correct fixing position of outdoor other 13 Proper shock absorption of outdoor 7 no other 14 Vacuumizing for both liquid pipe and gas pipe no other ___ 15 Enough time for Vacuumizing 16 Whether the pressure coming back after 1 hour yes no other ___ holding 8 yes no other___ 20 21 Make sure the switch for leaking current installed yes no other yes no other___ yes no other___ Y salao NJO N o _ 8 6 Troubleshooting WARNING Disconnect all electrical power to the unit before servicing Disconnect power to both the indoor and outdoor units NOTE There may be more than one electrical disconnect switch Failure to shut off power can cause electrical shock resulting in personal injury or death Symptom Possible Cause No cooling heating Power off or loose electrical Make sure main switch is ON Check and connection tighten all connections Incorrect thermostat setting Set thermostat correctly
18. e C Y and P1 P3 connection wire cut off or fasten loosely if cut off then change the parts Compressor stuck grounded or open motor Wait for 2 hours for overload to reset Replace PO within 10 of rating plate volts when unit is Condenser fan runs running compressor doesn t Condenserfan doesn t Do E within 10 of rating plate volts when unit is running Defective overload protector Replace check for correct voltage Refrigerant undercharge Add refrigerant Register sweat Low evaporator airflow Increase blower speed or reduce restriction Restriction in liquid line metering Replace defective components High head Low device or filter drier vapor pressures Flowrator piston size too small Change to correct size piston Incorrect capillary tubes Change coil assembly Blocked outdoor coil Clear away leaves and other debris High head High or Refrigerant overcharge Correct system charge normal vapor Condenser fan not running Repair or replace pressures Air non condensibles or moisture in system Recover refrigerant evacuate amp recharge add filter drier Flowcheck piston size too large Change to correct size piston Low head High Defective compressor valves Replace compressor vapor pressures Incorrect capillary tubes Replace coil assembly Low evaporator airflow Increase blower speed or reduce restriction replace air filter Low vapor cool Operating below 65 F outdoors Add low
19. ecial port inside the accumulator 9 Refrigerant vapor flows through the suction line to the intake of the compressor The cycle then repeats Electrical The operation cycle as follows 1 The thermostat calls for cooling 2 This sends a 24 voltage signal through the Y terminal to the compressor start kit after 3 minutes the compressor contactor in the outdoor unit are closed The compressor and outdoor fan start 3 At the same time a 24 Voltage signal flows through the G Terminal to the indoor blower relay The indoor blower starts 4 the cooling system is now in operation The thermostat satisfies and ends the call for cooling This ends the 24 Voltage signal to the compressor start kit and the outdoor unit stops 5 6 7 This ends the 24 voltage signal to the indoor blower relay and this indoor blower strips 8 The system is now off 6 Defrost Cycle During heat pump mode If the compressor continually running for 44 minutes and the outdoor coil temperature drop below 23 oF for more than 1 minute the defrost cycle start outdoor fan stop reversing valve energized meanwhile the indoor auxiliary heater come on The maximum time for defrost cycle is 10 minutes When defrost cycle is terminated the outdoor fan come back on reversing valve de energized and the indoor auxiliary heater turn off When switch system from heat pump mode to cooling mode the defrost cycle will be terminated immediately Outdoor defrost con
20. ed in an area where contaminants are likely to be a problem special attention should be given to the equipment location and exposure Avoid having lawn sprinkler heads spray directly on the unit cabinet In coastal areas locate the unit on the side of the building away from the waterfront Shielding provided by fence or shrubs may give some protection Regular maintenance will reduce the buildup of contaminants and help to protect the unit s finish WARNING Disconnect all electrical power to the unit before servicing Disconnect power to both the indoor and outdoor units NOTE There may be more than one electrical disconnect switch Failure to shut off power can cause electrical shock resulting in personal injury or death Frequent washing of the cabinet fan blade and coil with fresh water Regular cleaning and waxing of the cabinet with good automobile polish A good liquid cleaner may be used several times a year to remove matter that will not wash off with water The best protection is frequent cleaning maintenance and minimal exposure to contaminants 5 3 Installation The Position of Installation The Air Conditioner shall be installed in accordance with national and local wiring regulation Quality of installation can affect its operation It is forbidden to fix the unit by users themselves please contact dealer for repair It must be fixed and adjusted by the qualified person Switch on ater all the fixing work had been f
21. en heat This is heat held in the humidity in the air 1 Comfortstar Service manual for 13seer Heatpump Condensing Removing this heat does not affect a thermometer However removing the heat held in the moisture in the air greatly increase comfort A properly sized unit removes both forms of heat producing a comfortable living space An oversized system cycles on and off too quickly and does not properly remove humidify producing an uncomfortable living space Select the indoor and outdoor equipment combination based on the manufacturer s engineering data After the proper equipment combination has been selected satisfying both sensible and latent conditioning requirements the system must be properly installed Only then can the unit provide the comfort the manufacturer built into it There are several factors that installers must consider Outdoor unit location Proper equipment evacuation Outdoor unit refrigerant charge Indoor unit air flow Indoor unit blower speed Supply and return air duct design and sizing System air balancing Diffuser and return air grille location and sizing Working U RUE en o S Max cooling function 86 15 SE HB 5 Min cooling function Lee Low ambient control kit should be installed when temperature lower men 55 Max heating function 86 PB SEY Min heating function 61 20 Auxiliary heater shoud be installed when below 20 Table1 Unit Dimensions Da a fe m 283
22. iately and make leak hunting Processing 1 Charge Nitrogen 20 0kgf cm into the system 2 Check the joint of the pipes with suds mark the leaking point 3 When all of the checking finished charge more Nitrogen 1 0 3 0kgf em then welding the leaking point 4 After the welding charge high pressure Ntrogen 25 0kgf cm and check the Press after 48 hours calculate the Press Decline with the Formula below the result should be less han 1 of Testing Press lf not pls recheck the system to find out the leakage joint 2P P4 P2 273 T 273 T2 In the formula P the Press Decline MPa P4 P2 Press of Nitrogen at the beginning and the finishing MPa Ta Ta Tempreture of the Nitrogen at the beginning and the finishing C If possible test the leakage with Halogen Testing Instrument at the beginning of the leakage 8 4 Vacuumizing for the pipeline after maintenance Vacuum pipeline can keep the system running naturally and high efficiently So vacuumizing after leak hunting is necessary Processing 1 Discharge the Nitrogen first 2 Connect the pressure gauge to the service vavle you can get the result of the vacuum from the lower pressure gauge 3 Turn on the vacuum pump 4 When the vacuum reaching 1 0kgf cm continue 0 5 1 0 hour then turn the pump off 5 Connect the tube to the Refrigeration Pot after discharging the air in the tube charge Refrigeration into the system until the pressure reach 0 0kgf cm 6 Change the tube to conne
23. ing units are charged with refrigerant Condensing unit liquid and suction valves are closed to contain the charge within the unit Do not force the valve stem against the retaining ring If the valve stem is backed out past the retaining ring system pressure could force the valve stem out of the valve body and possibly cause personal injury Comfortstar Service manual for 13seer Heatpump Condensing Instructions on the field tubing connections and valve opening procedure are as follow 1 Tubing should be cut square Make sure it is round and free of burrs at the connecting ends Clean the tubing to prevent contamination from entering the system 2 Make sure that both refrigerant shutoff valves at the outdoor unit are closed 3 Push the tubing into the fitting until it stops This prevents flux from getting into the system 4 Remove the cap and Schrader valve core from the service port to protect the valve seals 5 Wrap a wet rag around the valve stub before brazing 6 Braze the joints of interconnecting tubing Flow dry nitrogen into the shutoff valve port and through the tubing while brazing 7 After brazing quench with a wet rag to cool the joint Reinstall the Schrader core in the valve if removed for brazing 8 Pressurize the lines to 150 psi maximum with dry nitrogen Check for leaks at all joints with liquid detergent If a leak is found repair it after removing the nitrogen Repeat the process and re check 9 Do not purge the lines
24. inished Outdoor Unit must be fixed on stable and solid surface of floor Don t install Outdoor Unit under window or between buildings and prevent the operation noise from entering into room There should be no obstructions at both air intake and outlet vents for indoor and outdoor units for maintaining well air ventilation When installing indoor unit make sure that the hanging parts at top are strong enough to stand the weight of unit Do not install the Air Conditioner in place with flammable and explosive things or in some dusty place Make sure to lessen the length of connecting pipe between the indoor and outdoor unit and the number of bends Don t connect duct to inlet outlet of outdoor unit When indoor unit in heating mode condensing water will drop from the chassis of outdoor unit The condensing water will freeze when the outdoor temp below 0C 32F lt gt The Installation Position of Outdoor Unit Ensure the place where is well ventilated and there is sufficient space for maintenance It s shown as follow Comfortstar Service manual for 13seer Heatpump Condensing Fig 3 Installation Position of Outdoor Unit When removing the outdoor unit two ropes are needed to hang the unit along the four directions In order to avoid the excursion the angle between the ropes should be less than 40 It is shown as follow Below 400 NZ T Fig 4 Condensing Unit Hoisting Sketch 5 4 Refrigerant Piping
25. ist the tubing Refrigerant piping should not be installed in a cement slab as this limits access to the refrigerant should a leak be suspected To ensure good oil return to the compressor it is important to pitch the horizontal suction line toward the compressor approximately 1 2 for every 10 of line 5 5 Line Insulation Suction line requires insulation in order to prevent condensation from forming on the piping and to prevent heat gain caused by surrounding air Generally 3 8 wall thickness of Arm flex or equivalent is satisfactory In severe application hot high humidity areas greater thickness may be required Apply the line insulation by sliding it on the sealed tubing before cutting and making connections Liquid line does not necessarily need insulation however if they are exposed to high ambient temperatures i e kitchen boiler rooms hot attics amp rooftop surface then they should be insulated Make sure to use the proper size tubing for the liquid line to prevent liquid refrigerant flashing to a vapor within the liquid line Do not allow the vapor line and liquid line to touch together This would cause an undesirable heat transfer resulting in capacity loss and increased power consumption Refrigerant Line Sizing Check the following table for correct suction and liquid line sizes for any 6 Comfortstar Service manual for 13seer Heatpump Condensing combination of the unit size and the maximum refrigerant line length
26. nual for 13seer Heatpump Condensing 3 Warning Before operating the Air Conditioner read this manual thoroughly and operate accordingly lt gt CAUTION and DANGER have the following meanings with these instructions DANGER This mark indicates improper operation might lead to serious injury for the users CAUTION This mark indicates improper operation might possibly result in personal harm to the user or damage to property DANGER Do not use or place combustible and explosive gas or liquid near the air conditioner Do not attempt to install Air Conditioner by yourself to guarantee the Air Conditioner can be permanent use In the event of a malfunction burning smell etc stop operating immediately and turn off the power switch Do not insert fingers or objects into the outlet port or intake grilles Do not check or repair the Air Conditioner when it is running Do not sprinkle water on the Air Conditioner or operate it with wet hands CAUTION e Before install ensure the power supply is corresponding to that listed in nameplate and check the security of the power source Before use ensure the wire connections are proper for avoiding electric shock or fire The Air Conditioner should not be operated by children Please turn off the power before cleaning the Air Conditioner or replacing the filters Turn off power source when not using the Air Conditioner for extended periods Do not climb on or place objects on the
27. ok 10378211 ss pp Axialflowtan 1035821 gt gt GasmiquidSeparator_ 0722822 1 sp Compressor 00202206 1 pe Base Plate Sub Assy 0120822007 1 k o way Vale 4300807 1 way Valve Accessary 43008214 1 a Fite 07210056 a oa Bidirection Strainer 03410107 1 Pp Tube Clip 0214000585 1 sa pp Cutoff Vave1 1 8 07138236 1 o cutoftvawei 07138235 o Thermal Expansion Vae 07332208 1 a OnewayVave 07138202 1 e po Cabinet 01318206 1 20 Tubeexitplate 01388208 1 S k Af Af af A Af klk lk lA lk lA lA lk A Comfortstar Service manual for 13seer Heatpump Condensing Side Plate 10 5 60K 10 5 1Explosive view 10 5 2 Spare parts list O diseription PartNo Bolt M8x 25 70210084 4 7 l Gas liquid Separator 07228272 1 Compressor 00202205 1 BasePlateSub Assy 01192205P 1 a Away Vale 43000407 1 DOM wayValeAccessay 4300824 1 Mo Fie 07219056 1 o a BidirectionStraner______ 03410107 Cd Pp Tube Clip 021400085 1 k Af Af Af All Al A Comfortstar Service manual for 13seer Heatpump Condensing i 1 Thermal Expansion Valve 07130324 1 ARA MM l 02140001 Capacitor Clamp Capacitor CBB65 15uF 450V 33010045 AC Contactor GC6 45S 01C1 44010253 Terminal Board 42011242
28. phere It is a violation of federal law to do so If the refrigerant needs to be removed from a system to correct the charge inside always use a recovery or recycling device WARNING To prevent personal injury wear safety glasses and gloves when handling Refrigerant 1 Fully open both shutoff valves 2 Connect service gage manifold to the valve service ports being sure to evacuate lines 3 Startup the system Run system at least 10 minutes to allow pressure to stabilize 8 Comfortstar Service manual for 13seer Heatpump Condensing 4 Temporarily install thermometer on suction large line near condensing unit Be sure of good contact between thermometer and line Wrap thermometer with insulating material to assure accurate reading 5 Refer to Table 5 for proper system superheat Add charge to lower superheat Remove charge to raise superheat Carefully remove gage lines System Superheat Ambient Return Air Temperature F Temperature At 50 2 2 Table5 System charging table by superheat 5 7 Electrical Wiring WARNING A means of strain relief must be installed to this appliance at the electrical service entrance Make sure that interconnecting wires between indoor and outdoor units meet the standards codes and regulations Incomplete connection or fixing of the wire could result in a fire Do not use intermediate connection of the power cord or the extension cord and do not connect many devices to one AC ou
29. tlet It could cause a fire or an electric shock due to defective contact defective insulation exceeding the permissible current etc Perform electrical work according to the installation manual and be sure to use an exclusive circuit If the capacity of the power circuit is insufficient or there is incomplete electrical work it could result in a fire or an electric shock Ground the unit Do not connect the ground to a gas pipe water pipe lighting rod or telephone ground Defective grounding could cause an electric shock Electrical installation will consists of power supply wiring to the condensing unit and control wiring between thermostat indoor unit and the condensing unit All wiring must be in accordance with National Electrical Code and or local ordinances that may apply See unit wiring diagram furnished with this instruction The condensing unit rating plate and the tables of Physical and Electrical Specifications provide pertinent data necessary for the selection of proper size electrical service and over current protection devices Table 6 provides data on the minimum copper wire size as a function of supply wire length and 9 Comfortstar Service manual for 13seer Heatpump Condensing circuit ampacity Copper Wire Size AWG 1 Voltage Drop Supply Circuit Supply Wire Length Ft ae Table6 Minimum Wire Size Based on N E C for 60 C Type Copper Conductors Below 100 Ampacity The owner should be made familiar
30. trol board display Both LED1 and LED2 will blink when units working under normal condition during defrost cycle both LED1 and LED2 will be continually on Comfortstar Service manual for 13seer Heatpump Condensing 7 Maintenance Instructions Warning Make sure to turn off the power before maintenance The heat exchanger of Outdoor unit must be cleaned regularly At least clean it for once every two months you can clean the dust and sundries on its surface with vacuum and nylon brush or blow them by using compressing air Check connecting pipe and connector if there is oil leakage repair it in time tis forbidden to wash the unit by water or it may cause electric shock Inspection at the beginning of the using 1 Remove any block near the outdoor 2 Proper grounding 3 Proper circuitry Maintenance after the using season 4 Clean the body of the outdoor 5 Proper protection of the outdoor 6 Turn off the power supply Notice When testing the piping system do not mix the Oxygen and Acetylene into the piping system Pls use Nitrogen or Refrigeration to keep the testing safe 8 Service And Troubleshooting 8 1 Fill more oil into Compressor Processing 1 Collecting the refrigeration under cooling model fasten up the big and small vavles 2 Disconnecting the bigger copper pipe and valve with welding torch 3 Filling the oil to the copper pipe 4 Welding the copper pipe together with the vavle 5 Vacuumi
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32. with refrigerant Evacuate the lines and indoor coil Evacuation All new installations must be evacuated to a deep vacuum in order that all noncondensible gases and moisture are removed prior to charging the system Air in a system causes high condensing pressure which increases power consumption and reduces performance The presence of moisture in a system can render it inoperable in a very short time Proper evacuation assures a dry uncontaminated system Here is the recommended evacuation procedure 1 Connect vacuum pump to both liquid and suction valve service ports 2 Evacuate the interconnecting tubing and indoor coil to 500 microns or less for a minimum of 30 minutes Close the valve to the vacuum pump and wait 15 minutes Vacuum should not rise above 800 microns If unable to obtain 500 microns or vacuum rises above 800 microns over 15 minutes period discontinue evacuation pressurize and check for leaks Repair any leaks found and repeat the step 2 3 Close valve to the vacuum pump and stop pump 4 When sure of a tight well evacuated system charge with refrigerant 5 6 Charging the System For systems with capillary tube or expansion valve or fixed orifice metering device Before checking the system charge make sure that the outdoor unit and indoor coil must be an approved match per the unit specification The indoor conditions should be within 2 F of the desired comfort conditions WARNING Do not vent refrigerant to the atmos
33. zing then keep pressure for 30 minutes 6 Open the two valves 7 Turn on the unit 8 2 Compressor replacement Processing 1 Switching off the power supply of the outdoor unit make marks for each wires when removing the power cord of the compressor 2 Loosening the bolts of the compressor 3 Disengage the Discharge pipe from the vent of the Compressor 4 Disengage the suction pipe from the inspiratory end of the compressor 5 Put the new compressor on the right place pull out all of the rubber plugs and connect the pipes after that first the discharge pipe then the suction pipe Pls do weld the pipes immediately after you 12 Comfortstar Service manual for 13seer Heatpump Condensing pull out the rubber plugs or else the water vapor may enter into the compressor When welding the pipes pls be with Nitrogen and the pressure of the Nitrogen is 1 0 3 0kgf cm2 o 6 Resume the system as the condition before the compressor replacement When connect the power cord of the compressor turn it on once to test whether it rolls back If rollback there will be depressing sound from it XIP there is any leakage of the lubricating oil pls fill more Notice Usually the discharge pipe is thin and there is at least one U bend in the pipe so we disengage this pipe first when replace the compressor 8 3 Maintenance when Refrigeration leakage Best hermetic system is the base of the reliable function When there is leakage turn off the system immed
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