Durastar Split-Style Air Conditioner Installation Manual

Introduction

This manual provides essential information for the installation of Durastar Wall Mounted Indoor Unit Split-Style Air Conditioners. Before contacting customer service, users are advised to:

• Contact the retailer or dealer immediately if the product is received damaged.
• Read and follow this manual carefully for proper use and maintenance.
• Refer to the troubleshooting section for diagnosing and solving common issues.
• Visit www.durastar.com for product guides and updates.
• For warranty service, contact customer service via email at questions@durastar.com or by phone at 1-888-320-0706.

Warnings and Symbols

The following symbols are used in this manual:

• ⚠️ Warning Symbol: Indicates cautionary information for the user. Extra care and precautions are necessary to ensure user safety.
• ✏️ Pencil Symbol: Indicates manufacturer notes, clarifications, or call-outs related to surrounding content.
• ? Light Bulb Symbol: Indicates suggested manufacturer tips for optimizing the use of Durastar equipment and enhancing the user experience.

Important Safety Precautions

Improper handling can cause serious damage or injury. Please read the following safety information carefully.

Operation, Cleaning, and Maintenance Safety Precautions

• Children and individuals with reduced physical, sensory, or mental capabilities, or lacking experience, should only use the air conditioner under supervision or with clear instructions, understanding the hazards involved.
• Children should not play with the air conditioner.
• Never insert fingers or other body parts into the air conditioner openings, as the internal fan may be rotating at high speeds, potentially causing injury.
• After removing the filter, avoid touching the fins to prevent injury.
• Maintenance must be performed by qualified professionals to avoid personal injury or damage to the unit and property.
• Do not attempt to repair the air conditioner yourself; contact a qualified service representative for assistance to prevent electric shock or damage.
• Do not block the air outlet or air inlet, as this can cause a malfunction.
• Avoid spilling water on the remote control, as this can permanently damage it.
• In case of the following issues, turn off the unit, disconnect power at the circuit breaker, and contact a dealer or qualified professional:
  • Overheating or damaged power cord.
  • Abnormal operating sounds.
  • Frequent tripping of the circuit breaker.
  • Burning smell from the unit.
  • Indoor unit leaking.
• Operating the unit under abnormal conditions may lead to malfunctions, electric shock, or fire hazards.
• When using the emergency operation switch, use an insulated object (not metal) to press it.
• Do not step on or place heavy objects on the top panel of the unit to prevent damage or injury.
• Children should not perform cleaning or user maintenance without supervision.
• Do not spray water on the indoor unit, as this can cause electric shock or malfunction.
• Do not use flammable materials like hair spray or lacquer near the air conditioner, as they may catch fire.
• Do not operate the unit near combustible gases, as accumulation may cause an explosion.
• Do not use fire or a hair dryer to dry the filter; this can cause deformation or fire hazard.
• Do not wash the air conditioner with water, as this can cause electric shock.
• Always disconnect power at the circuit breaker when cleaning the unit to avoid electric shock.

Electrical Safety

• Do not modify the power supply cord or use an extension cord.
• If the supply cord is damaged, it must be replaced by the manufacturer, a service agent, or a similarly qualified person.
• Do not share electrical outlets with other appliances; insufficient power supply can cause fire or electric shock.
• Ensure the product is properly grounded during installation to prevent electric shock.
• Follow all local and national wiring standards and regulations for electrical work. Connect cables tightly and clamp them securely to prevent damage. Improper connections can cause overheating, fire, or shock. All connections must follow the Electrical Connection Diagram on the unit panels.
• Arrange wiring properly to ensure the control board cover closes correctly. An improperly closed cover can lead to corrosion and overheating of terminals, causing fire or electric shock.
• The air conditioner's circuit board (PCB) has a fuse for overcurrent protection, with specifications printed on the board.

Installation Safety

• Installation must be performed by an authorized dealer or specialist to prevent water leakage, electric shock, or fire. In North America, installation must comply with NEC and CEC requirements by authorized personnel only.
• Improper installation can cause water leakage, electric shock, or fire.
• Install the air conditioner according to national and local wiring regulations.
• Contact an authorized service technician for repair or maintenance.
• Use only included, specified parts for installation. Non-standard parts can cause leaks, shock, fire, or unit failure.
• Install the unit in a firm location capable of supporting its weight. Failure to do so may result in the unit falling and causing injury or damage.
• Install drainage piping correctly to prevent water damage.
• Do not install the unit where combustible gas leaks may occur, as accumulated gas can cause a fire.
• Do not turn on power until all work is completed.
• Consult experienced service technicians for moving or relocating the unit.

Additional Precautions

• Turn off and disconnect power if the unit will not be used for an extended period.
• Turn off the unit during electrical storms to prevent damage.
• Ensure water condensation can drain freely.
• Do not operate the unit with wet hands to avoid electric shock.
• Use the device only for its intended purpose.
• Do not climb on or place objects on the outdoor unit.
• Avoid operating the unit for long periods with doors/windows open or in high humidity.

Operating Temperatures

The air conditioner is designed for specific indoor and outdoor temperatures. Exceeding these ranges may activate safety features to protect the unit.

* The minimum operating temperature in heat mode depends on the outdoor unit; low ambient models operate down to -22°F (-30°C).

To optimize performance:

• Keep doors and windows closed.
• Use TIMER ON and TIMER OFF features to limit energy usage.
• Do not block air inlets or outlets.
• Regularly inspect and clean air filters.

Accessories

Included Installation Accessories

Field Supplied Installation Accessories

The following are required and must be purchased separately:

• Refrigerant piping (line set)
• Indoor and outdoor connection wire
• Outdoor power supply cord
• Drain pipe
• Pipe and cable wrapping tape
• Wall hole sleeve and cover
• Putty
• Wiring u-lugs

Tools Needed

The following tools are required for installation:

• Phillips screwdriver
• Drill with 2 1/2" or 3 1/2" (indoor unit model depending) core bit
• Vacuum pump
• HVAC manifold gauge set
• Micron Gauge
• Refrigerant leak detector
• Copper pipe cutter
• Flaring tool
• Burr reamer
• Crescent or spanner wrench
• Hexagonal wrench set
• Torque wrench
• Multimeter
• Electroprobe
• Level
• Hammer
• Wire strippers
• Wire crimper

Parts Identification

The indoor and outdoor units consist of the following parts:

• 1. Wall Mounting Plate
• 2. Front Panel
• 3. Air Flow Louver
• 4. Air Freshness (Carbon) Filter
• 5. Drain Pipe
• 6. Signal Cable
• 7. Refrigerant Piping
• 8. Remote Controller
• 9. Remote Controller Holder
• 10. Outdoor Unit Power Cable

Installation Overview - Indoor Unit

The installation process involves the following key steps:

1. Select Installation Location: Ensure proper clearances (e.g., 6" from ceiling, 4 3/4" from walls).
2. Determine Wall Hole Position: Mark the location for piping.
3. Attach Mounting Plate: Secure the mounting plate to the wall, ensuring it is level.
4. Drill Wall Hole: Drill a hole through the wall for connective piping, angled slightly downwards for drainage.
5. Connect Piping: Connect refrigerant and drain pipes.
6. Connect Wiring: Connect the signal cable and power supply.
7. Prepare Drain Pipe: Ensure proper drainage and insulation.
8. Wrap Piping and Cable: Bundle and insulate the pipes and cable.
9. Mount Indoor Unit: Securely attach the indoor unit to the mounting plate.

Indoor Unit Installation

STEP 1: SELECT INSTALLATION LOCATION

Choose an appropriate location based on the following standards:

• Good air circulation.
• Convenient drainage.
• Minimal noise disturbance to occupants.
• Firm and solid mounting surface, free from vibration.
• Sufficient strength to support the unit's weight.
• At least three feet (one meter) away from other electrical devices (TV, radio, computer).

DO NOT install the unit in the following locations:

• Near heat, steam, or combustible gas sources.
• Near flammable items like curtains or clothing.
• Where obstacles might block air circulation.
• Near a doorway.
• In direct sunlight.

Ensure proper clearances from walls and ceiling:

• 6" (15cm) or more from the ceiling.
• 4 3/4" (12cm) or more from side walls.
• 6' (1.83m) or more from the front.

STEP 2: ATTACH MOUNTING PLATE TO WALL

1. Remove the screw securing the mounting plate to the back of the indoor unit.
2. Secure the mounting plate to the wall using the provided anchors and screws. Ensure the plate is flat and level.

Diagram Description: Shows correct orientation of mounting plate with checkmarks and incorrect orientations with crosses.

STEP 3: DRILL WALL HOLE FOR CONNECTIVE PIPING

1. Determine the wall hole location based on the mounting plate dimensions, using the installation template or the provided illustrations.
2. Drill the wall hole using a 2 1/2" (65mm) core drill for pipes up to 5/8" (16mm) or a 3 1/2" (90mm) drill for pipes 5/8" (16mm) or larger. The hole should be drilled at a slight downward angle (3/16" – 1/4" or 5mm – 7mm) from indoor to outdoor for proper water drainage.
3. Insert the protective wall hole sleeve into the drilled hole to protect pipes and cables from sharp edges and seal the opening. Attach the wall hole cover to the sleeve on the outside wall, ensuring it is flush.

Diagram Description: Shows dimensions for wall hole placement for Model 9K and 12K, and Model 18K and 24K.

STEP 4: PREPARE REFRIGERANT PIPING

1. Choose the side (left or right) for piping exit based on the wall hole position relative to the mounting plate.
2. If the wall hole is behind the unit, do not remove the knock-out panel. If the hole is to the side, remove the plastic knock-out panel from that side to create an exit slot for the piping. Use pliers if the panel is difficult to remove; grooves are provided for easier cutting. The size of the removed piece depends on the piping diameter.
3. If pre-existing piping is in the wall, proceed to Step 5. If not, connect the indoor unit's refrigerant piping to the connective piping for the outdoor unit, referring to the outdoor unit's installation manual for details.
4. Position the piping to align with the wall hole. Piping can exit from the left-hand side, right-hand side, left rear, or right rear.

STEP 5: CONNECT THE DRAIN PIPE

The drain pipe is typically attached to the left-hand side of the unit (facing the back) but can be moved to the right. Attach the drain pipe on the same side as the refrigerant piping exit for proper drainage. Attach any extension pipe (5/8" inner diameter) securely to the existing drain pipe.

• Wrap the connection point with Teflon tape for a good seal and to prevent leaks.
• Wrap the indoor portion of the drain pipe with foam pipe insulation to prevent condensation.
• Remove the air filter and pour a small amount of water into the drain pan to check for smooth water flow.
• Arrange the drain pipe correctly: ensure no kinks or dents.

Diagram Description: Shows correct drain pipe routing (no kinks/dents) and incorrect routing (kinks create water traps, placing end in water prevents drainage).

STEP 6: CONNECT SIGNAL CABLE

BEFORE PERFORMING ANY ELECTRICAL WORK, READ THESE REGULATIONS:

1. All wiring must comply with local/national electrical codes and be installed by a licensed electrician.
2. Electrical connections must follow the Electrical Connection Diagram on the unit panels.
3. If there is a serious safety issue with the power supply, stop work and contact a licensed electrician.
4. Power voltage should be within 90-110% of rated voltage. Insufficient supply can cause malfunction, shock, or fire.
5. For fixed wiring, install a surge protector and main power switch rated 1.5 times the unit's maximum current.
6. For fixed wiring, a switch or circuit breaker with at least 1/8" (3mm) contact separation must be used.
7. Connect the unit only to an individual branch circuit outlet; do not connect other appliances to it.
8. Properly ground the air conditioner.
9. Ensure all wires are firmly connected. Loose wiring can cause overheating, malfunction, or fire.
10. Keep wires away from refrigerant tubing, the compressor, or moving parts.
11. If the unit has an auxiliary electric heater, install it at least 40" away from combustible materials.
12. To avoid electric shock, wait at least 10 minutes after turning off power before touching electrical components.

The signal cable enables communication between indoor and outdoor units. Choose the correct cable size and run a continuous length, avoiding splices.

CABLE SIZING

• Indoor Power/Signal Cable: 14/4 stranded, unshielded.
• Outdoor Power Cable: Determined by system amperage and local codes.

The required power supply cable, fuse, and switch size depend on the unit's maximum current, indicated on the nameplate.

Wiring the Indoor Unit

1. Open the front panel of the indoor unit.
2. Using a screwdriver, open the wire box cover on the right side to access the terminal block.
3. Unscrew the cable clamp below the terminal block and set it aside.
4. Remove the plastic panel on the bottom left-hand side (facing the back of the unit).
5. Feed the signal wire through this slot from the back to the front.
6. Connect a spade u-lug onto the end of each wire.
7. Facing the front, connect the wires to the terminal block according to the indoor unit's wiring diagram, screwing each lug firmly.
8. After ensuring all connections are secure, use the cable clamp to fasten the signal cable to the unit, screwing it down tightly.
9. Replace the wire cover on the front and the plastic panel on the back.

STEP 7: PREPARE REFRIGERANT PIPING

1. If pre-existing refrigerant piping is embedded in the wall, skip to Step 9 and begin outdoor unit installation, referring to the outdoor unit's manual for Refrigerant Piping Connections.
2. If no pre-existing piping, connect the indoor unit's refrigerant piping to the connective piping that will join the indoor and outdoor units, again referring to the outdoor unit's manual.

STEP 8: WRAPPING THE CABLES

Bundle the drain pipe, refrigerant pipes, and signal cable together before passing them through the wall hole to save space, protect them, and insulate them.

1. Bundle the components as shown in the diagram.
2. Using adhesive vinyl tape, attach the drain pipe to the underside of the refrigerant pipes.
3. Using insulation tape, wrap the signal wire, refrigerant pipes, and drain pipe tightly together. Double-check that all items are bundled.

STEP 9: MOUNT INDOOR UNIT

If new connective piping was installed to the outdoor unit:

1. If refrigerant piping is already through the wall, proceed to step 4.
2. Double-check that the ends of the refrigerant pipes are sealed to prevent dirt or foreign materials from entering.
3. Slowly pass the wrapped bundle of refrigerant pipes, drain pipe, and signal wire through the wall hole.
4. Hook the top of the indoor unit onto the upper hook of the mounting plate.
5. Check that the unit is firmly mounted by applying slight pressure to the sides; it should not jiggle or shift.
6. Using even pressure, push down on the bottom half of the unit until it snaps onto the lower hooks of the mounting plate.
7. Re-check that the unit is firmly mounted.

If refrigerant piping is already embedded in the wall:

1. Hook the top of the indoor unit onto the upper hook of the mounting plate.
2. Use a bracket or wedge to prop up the unit, providing room to connect the refrigerant piping, signal cable, and drain pipe.
3. Connect the drain pipe and refrigerant piping (refer to the outdoor unit's installation manual).
4. Keep the pipe connection point exposed for the leak test (refer to the outdoor unit's installation manual).
5. After the leak test, wrap the connection point with insulation tape.
6. Remove the bracket or wedge.
7. Push down on the bottom half of the unit until it snaps onto the lower hooks of the mounting plate.

Diagram Description: Shows adjustment range for left/right positioning.

Troubleshooting

Safety Precautions

If any of the following occur, turn off the unit immediately:

• Damaged or abnormally warm power cord.
• Burning odor.
• Loud or abnormal sounds.
• Blown fuse or frequently tripping circuit breaker.
• Water or other objects entering or exiting the unit.

DO NOT attempt to fix these issues yourself! Contact an authorized service provider immediately!

Common Issues

Additional Troubleshooting

Troubleshooting - Performance and Operation

Troubleshooting - Unit Not Working / Indicator Lamps

Wiring Diagram

Wiring diagrams are provided for different model series:

• DRAW06F1B: Provides a detailed schematic of the main board connections, including optional components indicated by dotted lines.
• DRAW09F1B and DRAW12F1B: Shows connections for these models, illustrating the main board, multi-function control board, display board, and optional components.
• DRAW18F1B and DRAW24F1B: Details the wiring for these larger models, highlighting the main board and optional features.

Diagram Description: The diagrams illustrate the electrical connections between the indoor unit, outdoor unit, main board, and various sensors and control modules. Optional components are indicated by dotted lines.

Error and Operating Codes

The following table lists common operating codes and error codes displayed by the unit:

* Normal operating codes, not malfunctions.