Comfort Star CDP Series User manual

SPLIT AIR CONDITIONERS
Seice Manual
Comfo Sta 恁）
CDP SERIES
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Service Manual
Service Manual
PART 1 Product instructions
PART 2 System Instruction ………………………………………………….……………………………………… 3
2.1 Refrigerant Circuit ……………………………………………………………….………………………………… 3
2.2 Functional Parts Layout ………………………………………………….……………………………………… 4
2.3 Refrigerant Flow ……………………………………………………………..…………………………………… … 6
PART 3 Function and Control ………………….……………………………………………………………… 7
3.1 Function General …………………………………………………………………………..……………………… 8
3.1.1 Unit Shutdown Control ………………………………………..…………………………………….…….… 9
3.1.2 Unit Standby Control ………………………………………………………………..……………….…….… 9
3.1.3 Unit Normal Operation …………………………………………………………….…………….……….…… 10
3.1.4 Unit Special Control ……………………………………………………………………..………………..…… 10
3.1.5 Unit Protection Control or Restart……………………….……………………………..…….…………… 11
3.1.6 Fault of Main Board ………………………………….……………………………….………..………………… 12
3.1.7 Unit Fault Control or Restart ………………………………………………………..……….………. …. 13
PART 4 Field settings ……………………………………………………………………………….…………….…… 15
4.1 Test Operation ……………………………………………………………………………….…….……………… 16
4.1.1 Checks before Test Operation ……………………………………………………………….…….………… 16
4.1.2 Turn Power on …………………………………………………………………………………….……..………… 17
4.1.3 Manual Defrost …………………………………………………………………………….……………..………… 18
4.2 Setting by DIP Switches …………………………………………………………….……………..………..… 19
4.3 Thermostat ……………………..……………………………………………………….……………...…………… 20
PART 5 Intelligent Troubleshooting …………….…………………………………………..……………… 21
5.1 Diagnosis System Introduction ………………………….……………………………………..……..… 22
5.2 Symptom-based Troubleshooting ……………………….……………………………………..…… … 23
5.3 Troubleshooting by Main board Fault code……………….…………………………………………… 26
PART 6 Check ………………………………………………………………………………………………....………… 29
6.1 Check for Causes of Rise in High Pressure ……………………………………………….……..…… 30
6.2 Check for Causes of Dropping Low Pressure in Cooling …………….………….….………… 31
6.3 Check for Causes of Dropping Low Pressure in Heating ………………………….….……… 32
6.4 Check for Causes of Refrigeration cycling Blocked …………………………………..………… 33
6.5 Check for Temperature Sensor (T3/T4) …………………………………………..……….…………… 34
6.6 Check for High Pressure Switch (HPS) …………………………………………….….….………… … 35
6.7 Check for Low Pressure Switch (LPS) ……………………………………….…….…….………… … 36
6.8 Check for Discharge Temperature Switch (T5) ………………….…………………….…………… 37
6.9 Check for Compressor Check ……………………………………..……………………………………… 38
PART 7 Appendix…………………………………………………………………………………….……………….. 39
7.1 Wiring Diagrams ……………………………………………………………………………………………………… 40
7.2 Temperature and Resistance Relationship Tables …………………………………………………… 44
1

2. Refrigerant Circuit
2
PART 2 System Instruction ……………………………………………………………………………… 3
2.1 Refrigerant Circuit ……………………………………………………………………………………… 3
2.2 Functional Parts Layout ……………………………………………………………………………… 4
2.3 Refrigerant Flow ……………………………………………………………………………………… … 6

2. System Instruction
2.1 Refrigerant Circuit
3
No. in
diagram
Symbol Part Name Major function
AComp. Compressor Compresses and drives the refrigerant.
BT5 Compressor dischare temperature
sensor Used to discharge temperature protection
CHPS High pressure switch Used to high pressure protection when up to 609 PSIG and
recovery when below to 464 PSIG.
DFan Fan of outdoor Used to help heat exchange by PSC motor.
ET3 Condenser coil temperature sensor Used to discharge temperature protection and defrost control.
FT4 Ambient temperature sensor Used to ambient protection and defrost control.
GRV The Reversing Valve Used to switch mode between cooing and heating.
HAccumulator Accumulator Store the liquid component of the refrigerant and reduce the
load of the condenser.
ILPS Low pressure switch Used to low pressure protection when below to 20 PSIG and
recovery when up to 44 PSIG.

2. Refrigerant Circuit
2.2 Functional Part
13.4HP 71/105
4
13.4HP 140/160
1
2
3
6
7
9
8
4
5
1
2
3
4
5
6
7
8

2. Refrigerant Circuit
2.2 Functional Part
5

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
6

3. Function and Control
7
PART 3 Function and Control …………………………………………………………………………… 7
3.1 Function General …………………………………………………………………………………………… 8
3.1.1 Unit Shutdown Control ……………………………………………………………………….…….… 9
3.1.2 Unit Standby Control ………………………………………………………………………….…….… 9
3.1.3 Unit Normal Operation …………………………………………………………………………….…… 10
3.1.4 Unit Special Control ………………………………………………………………………………..…… 10
3.1.5 Unit Protection Control or Restart……………………….…………………………….…………… 11
3.1.6 Fault of Main Board ………………………………….……………………………….…………………… 12
3.1.7 Unit Fault Control or Restart ………………………………………………………….………. …. 13

3. Function and Control
3.1 Function General
8
3.1.1 Unit shutdown control：
(1) Protection shutdown
(2) System stops
3.1.2 Unit standby control：
(1) Standby control
(2) Crankcase heater control
3.1.3 Unit normal operation：
(1) Reversing valve control
3.1.5 Unit protection control or restart
(1) T3 Protection
(2) T5(Discharge Temp.) Protection
(3) Low Pressure Switch Protection
(4) High Pressure Switch Protection
3.1.4 Unit special control：
[dF]Defrost control
Normal Protection
3.1.6 Fault of Main board Fault ：
(1) 1 Flash/cycle: T3 sensor not reading
correctly
(2) 2 Flash/cycle: T4 sensor not reading
correctly or High pressure switch not reading
correctly or T5 sensor not reading correctly
(3) 3 Flash/cycle: Low pressure switch not
reading correctly
Fault of Main board

3. Function and Control
3.1.1 Unit shutdown control
9
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≥44.6℉
T4＜41℉
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 would show the fault code when fault present.
⑵Thermostat satisfied shutdown
Anytime system is in unit standby, LED will flash slowly (2s ON and 2s off).
Crankcase heater
power on
or

3. Function and Control
3.1.3 Unit normal operation
10
(1) Reversing valve 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
[Cooling]
Symbol Part Name Major function
RV The Reversing Valve ON
[Heating]
3.1.4 Unit special control
[dF] Defrost control
●The Demand Defrost Control (DDC) monitors the 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 of three conditions is required to enter defrost:
—— T3<32 ℉and lasted for 60 minutes
—— T4<37℉and lasted for 80 minutes
—— ”Standby time” is 2 hours, T3<28℉when starting and lasted for 15 minutes

3. Function and Control
11
3.1.5 Unit protection control or restart：
⑴T3 Protection in cooling
⑵T5(Discharge Temp.) Protection
Normal operation
System standby
T3 sensor ≥147.2 ℉
Outputting the LED code
” 1 Flash/cycle” ..
Normal operation
System standby
T5 sensor ≥239 ℉(71/105)
⑶High Pressure Switch Protection
Normal operation
System standby
T3 sensor <125.6 ℉
Outputting the LED code
” 2 Flash/cycle” ..
T5 sensor <167 ℉(71/105)
HPC <464 psi
HPC >638 psi
Outputting the LED code
” 2 Flash/cycle ” ..
T5 sensor ≥275 ℉(140/160) T5 sensor <194 ℉(140/160)

3. Function and Control
3.1.6 Fault of Main board：
12
No. Operation LED Protection code Protection control
description Supposed cause
1LED2 1 Flash/cycle T3 sensor not reading
correctly in cooling
T3 sensor is not properly placed/High pressure
switch fault
2LED2 2 Flash/cycle T4 sensor not reading
correctly
T4 sensor is not properly placed/High pressure
switch fault/ Discharge temp. switch open
3LED2 3 Flash/cycle Low pressure switch not
reading correctly
Low
pressure switch is not properly connected.
⑶Low Pressure Switch Protection
Normal operation
System standby
LPC <29 psi LPC >44 psi
Outputting the LED code
” 3 Flash/cycle ” ..
3.1.5 Unit protection control or restart：

3. Function and Control
3.1.7 Unit Fault Control or Restart ：
(1) T3 sensor not reading correctly in cooling
(2) T4 sensor not reading correctly
13
Normal operation
T3 is seated fault
standby and restart
Outputting the LED code
”1 Flash/cycle ” .
Normal operation
T4 is seated fault
standby and restart
Outputting the LED code
”2 Flash/cycle ” .
Automatic restart
T3 is shorted or open
T4 is shorted or open
(3) T5 sensor not reading correctly
Normal operation
T5 is seated fault
standby and restart
Outputting the LED code
”2 Flash/cycle ” .
T5 is shorted or open

3. Function and Control
3.1.7 Unit Fault Control or Restart：
14
(5) LPC open
Normal operation
LPC is opened
standby and restart
Outputting the LED code
”3 Flash/cycle ”.
Automatic restart
LPC is opened when the
compressor is power on
(4) HPC open
Normal operation
HPC is opened
standby and restart
Outputting the LED code
”2 Flash/cycle ”.
Automatic restart
HPC is opened when the
compressor is power on

4. Field settings
PART 4 Field settings ……………………………………………………………………………….………… 15
4.1 Test Operation …………………………………………………………………………….……………… 16
4.1.1 Checks before Test Operation …………………………………………………………….………… 16
4.1.2 Turn Power on …………………………………………………………………………………..………… 17
4.1.3 Manual Defrost …………………………………………………………………………….…….………… 18
4.2 Setting by DIP Switches …………………………………………………………….…….…………… 19
4.3 Thermostat ……………………..……………………………………………………….……..…………… 20
15

4. Field settings
4.1 Test operation
No. Checkpoints Cautions or warnings
1Are all units securely installed? Dangerous for turning over during storm
Possible damage to pipe connections
2Is the earth wire installed according to the applicable
local standard? Dangerous if electric leakage occurs
3Are the condenser unit installed according to location
restrictions requirement?
Poor capacity
abnormal operation
4Are all air inlets and outlets of the indoor and outdoor
units unobstructed?
Poor cooling
Poor heating
5Does the drain flow out smoothly? Pipeline water leak
6Is piping adequately heat-insulated? Pipeline water leak
Poor capacity
7Do the supply power wirings connected Normally?
Including the earth wiring. Dangerous if electric leakage occurs
8Does the earth leakage circuit breaker connected
normally? Dangerous if electric leakage occurs
9
Do the wirings of 24V signal connected according to
wiring diagram? Including the thermostat wiring and
setting.
abnormal operation
10 Is the supply voltage conform to the specifications on
the name plate?
abnormal operation
Damage unit
11 Are the cable sizes as specified and according to local
regulations? Damage of cables
4.1.1 Checks before test operation
16

4. Field settings
4.1.2 Turn power on
Settings of outdoor unit
Supply power to the indoor and
outdoor units
Set system thermostat ON
Set system thermostat OFF
Note:
Make field setting if needed.
(For the setting procedure, refer to
information in “4.2 Setting by DIP
switches”)
Note:
In a normal condition, the LED flesh slowly .
Check for normal operations Note:
Check operations
Check for the 24V signal from thermostat
Check for operation mode
17
4.1 Test operation

4. Field settings
4.1.3 Manual defrost
Step 1
Starting the system in heating mode for more
than 10 minutes.
Step 3
The system defrost
Step 2
Set the SW3-1 switch to “ON” .
Note:
Defrost will exit automatically.
Step 4
If needed, repeat step 2 again after a few
minutes.
18
4.1 Test operation

4. Field settings
4.2 Setting by DIP switches
19