Comfort Star BAR5 Series User manual

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

Service Manual
Service Manual
PART 1 Product instructions
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
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 Start Up Control ……………………………………………………………………………….…….… 13
3.1.4 Unit Normal Operation …………………………………………………………………………….…….… 15
3.1.5 Unit Protection Control or Restart ……………………………………………………………………… 16
3.1.6 Fault of Main board ………………………………….……………………………….……….……………16
3.1.7 Unit Fault Control or Restart ………………………………………………………….…….….….… 17
3.1.8 Fault of Motor driver module ………………………………………………….………………….…… 20
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
4.1.5 Check Parameter …………………………………………………………………………………..….…….… 28
4.2.1 Setting by DIP Switches ………………………………………………………………………….…..….… 30
4.2.2 DIP Switch Position Indication ………………………………………………………………..….….… 31
4.3 Thermostat ……………………………………………………………………………………………..….….… 32
4.3.1 Control Wiring …………………………………………………………………………………….….….….… 32
PART 5 Intelligent Troubleshooting …………………………………………………………………….… 33
5.1 Diagnosis System Introduction …………………………………………………………….…..…….… 33
5.2 Symptom-based Troubleshooting ………………………………………………………….….…….… 34
5.3 Troubleshooting by Diagnosis Code …………………………………………………….…….….… 37
5.4 Troubleshooting by Fault Code ……………………………………………………………….….….… 43
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 ………………………….…….… 53
6.4 Check for Causes of Refrigeration Cycling Blocked ………………………………….……… 54
6.5 Check for Control Board …………………………………………………………………………..….… 55
6.6 Check for Temperature Sensor (T3/T4) ………………………………………………………..… 56
6.7 Check for High Pressure Switch (HPS) ……………………………………………………………... 57
6.8 Check for High Pressure Switch (LPS) ………………………………...…………………………… 58
6.9 Check for Discharge Temperature Switch (T5) ……………………………………….………… 59
6.10 Check for Condenser Fan Motor ……………………………………………………………………… 60
6.11 Check for Compressor Check ………………………………………………………………………… 61
6.12 Check for Indoor Air Flow ………………………………………………………………………….…… 62
PART 7 Appendix ………………………………………………………………………………………………… 63
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
1

2. Refrigerant Circuit
2
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

2. System Instruction
2.1 Refrigerant Circuit
3
No. in
diagram Symbol Part Name Major function
ARotary
Comp. Rotary Compressor Inverter compressor is operated in multi-steps according to PT.
B HPS High pressure switch Used to high pressure protection when up to 580 PSIG and
recovery when below to 435PSIG.
C Fan Fan of outdoor Used to help heat exchange by 10-speeds ECM motor.
DT3 Condenser coil temperature sensor Used to discharge temperature protection and Fan control in
cooling mode, and defrost control.
ET4 Ambient temperature sensor Used to ambient protection and Fan control in cooling mode,
and defrost control.
FRV The Reversing Valve Used to switch mode between cooing and heating.
GCV Check Valve Open during cooling and shutoff during heating by itself.
HPEV Pressure Equalizer Valve To ensure pressure balance before compressor starts
I LPS Low pressure switch Used to low pressure protection when below to 20 PSIG and
recovery when up to 43.5PSIG.
AC system with Rotary compressor

2. System Instruction
2.1 Refrigerant Circuit
4
HP system with Scroll compressor
AC system with Scroll compressor

2. Refrigerant Circuit
2.2 Functional Part
13.4 AC 53/71/90/105, 14.3AC 53/71/90
5
13.4 AC 160

2. Refrigerant Circuit
2.2 Functional Part
6
14.3 AC 160
13.4 AC 120/140

2. Refrigerant Circuit
2.2 Functional Part
7
14.3 HP 53/71/90
14.3 HP 105/120/140/160

2. Refrigerant Circuit
2.2 Functional Part
8

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
9

3. Function and Control
10
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……………………….…………………………….…………… 16
3.1.6 Fault of Main Board ………………………………….……………………………….…………………… 16
3.1.7 Unit Fault Control or Restart ………………………………………………………….………. …. 17
3.1.8 Fault of Motor driver module ………………………………………………………….…………… 20

3. Function and Control
3.1 Function General
11
3.1.1 Unit shutdown control：
⑴Protection shutdown
⑵System stops
3.1.2 Unit standby control：
⑴Standby control
⑵Crankcase heater control
3.1.3 Unit normal operation：
⑴List of functions in normal
operation
⑵Reversing valve control
⑶Fan control
⑷PEV control
3.1.5 Unit protection control or restart
⑴T3 Protection in cooling
⑵T5(Discharge Temp.) Protection
⑶Low Pressure Switch Protection
3.1.4 Unit special control：
⑴[dF]Defrost control
3.1.8 Fault of Motor driver module：
(1) 0.2S ON/ 0.2S OFF: Inter integrated
circuit communication error
(2) 1 Flash/cycle: Motor current error
(3) 2 Flash/cycle: Inverter module
temperature error
(4)3 Flash/cycle: Dc bus voltage error
Low pressure switch not reading correctly
(5)4 Flash/cycle: Motor parameter error
(6) 5 Flash/cycle: Motor startup failure
(7) 6 Flash/cycle: Phase sequence error
Normal Protection
Fault of Motor driver module
3.1.6 Fault of Main board Fault ：
⑴1 Flash/cycle: T3 sensor not reading
correctly in cooling
⑵2 Flash/cycle: T4 sensor not reading
correctly
⑶3 Flash/cycle: Low pressure switch not
reading correctly
⑷5 Flash/cycle: DC fan motor fault
⑸6 Flash/cycle: No machine type
Fault of Main board

3. Function and Control
3.1.1 Unit shutdown control
12
⑴Standby control
When compressor stopped, the outdoor fan would stop immediately.
Before compressor start, the outdoor fan motor will run at least 15 seconds.
3.1.2 Unit standby control
Crankcase heater
power off
Standby up to 3 hours T4≥43.6℉
T4＜37.4℉
⑵Crankcase heater control
Here is the condition for crankcase heater control.
First time power on
and
T4 is the Ambient temperature .
⑴Unit 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.
⑵Thermostat satisfied shutdown
Anytime system is in unit standby, LED 1 (Red) will flash slowly (2s ON and 2s off).
Crankcase heater
power on
or

3. Function and Control
3.1.3 Unit normal operation
13
⑴List of functions in normal
⑵Reversing valve control control
The heat pump need “B” signal of 24V wires.
●Cooling:
The reversing valve is off during cooling.
●Heating:
The reversing valve is on during heating and heating standby.
▲Special control: The reversing valve will delay about 1 minute when the first heating
starting for reversing reliability.
Symbol Part Name Major function
RV The Reversing Valve OFF
Fan Outdoor fan motor 10 speeds ECM motor.
Controlled by T3.
[Cooling]
Symbol Part Name Major function
RV The Reversing Valve ON
Fan Outdoor fan motor 10 speeds ECM motor.
Controlled by T4 and compressor speed
[Heating]
Anytime the compressor is operating, the digital tube will show the frequency of compressor.
⑶Fan control
Initial
speed Keeping speed
+1 speed
-1 speed
T3≥97 ℉
T3<84 ℉
[Cooling]
Note: ±1 speed/25 seconds,10 speeds ECM motor.
[Heating]
Fan when heating maintains 10 speed

3. Function and Control
⑷PEV control
14
3.1.3 Unit Normal operation
PEV
power off
Continue 2 minutes
Compressor
stopped over 30s
PEV
power on
Compressor stopped over 3 minutes
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.

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.
●Any one of three conditions is required to enter defrost:
1. After T3 is achieved.
--T4≥19℉T3<32 ℉and lasted for 60 minutes
2. After T4 is achieved.
--T3<28℉and lasted for 65 minutes
_”Standby time” is 2 hours, T3<28℉when starting and lasted for 15 minutes
15

3. Function and Control
16
3.1.7 Unit protection control or restart：
⑴T3 Protection in cooling
⑵T5(Discharge Temp.) Protection
Normal operation
System standby
T3 sensor ≥143.6 ℉
Outputting the LED 1 code
”2S ON/2S OFF” ..
Normal operation
System standby
T5 sensor ≥239 ℉
⑶Low Pressure Switch Protection
Normal operation
System standby
T3 sensor <125.6 ℉
Outputting the LED 1 code
”2 Flash/cycle” ..
T5 sensor <167 ℉
LPS <21 psi LPS >44 psi
Outputting the LED 1 code
”3 Flash/cycle ” ..

3. Function and Control
3.1.6 Fault of Main board：
17
No.
Operation LED
Protection code
Protection control
description Supposed cause
1 LED2
1 Flash/cycle
T3 sensor
not reading
correctly in cooling
T3 sensor is
not properly
placed/High pressure
switch
fault
2 LED2 2 Flash/cycle
T4 sensor not reading
correctly
T4 sensor is not properly placed/High pressure
switch fault/ Discharge temp. switch open
3 LED2 3 Flash/cycle
Low
pressure switch
not
reading
correctly
Low
pressure switch
is not properly connected.
4 LED2 5 Flash/cycle
DC fan motor fault
Motor fault/severe weather (fan rpm too
low
due to wind)
5 LED2 6 Flash/cycle
Phase sequence error
Speed
message isn’t wrote in main board

3. Function and Control
3.1.7 Unit protection control or restart：
⑴T3 sensor not reading correctly in cooling
⑵T4 sensor not reading correctly
18
Normal operation
T3 is seated fault
standby and restart
Outputting the LED 2 code
”1 Flash/cycle ” .
Normal operation
DC fan motor fault
standby and restart
Outputting the LED 2 code
”2 Flash/cycle ” .
⑶LPC open
Normal operation
T5 is seated fault
standby and restart
Outputting the LED 2 code
”3 Flash/cycle ”.
Automatic restart
Automatic restart
T3 is shorted or open
T4 is shorted or open
LPC is opened when the
compressor is power off