Durastar Single Zone Outdoor Unit Split-Style Air Conditioner Installation Manual

Introduction

To ensure proper installation and operation of your Durastar air conditioner, please read this manual carefully. If you received a damaged product, contact the retailer immediately. For warranty service, contact Durastar customer service via email at QUESTIONS@DURASTAR.COM or by phone at 1-888-320-0706. Additional product guides and information are available at WWW.DURASTAR.COM.

Symbols Used in this Manual

• WARNING: Indicates potential personal injury or loss of life. Exercise extra care.
• CAUTION: Indicates potential property damage or serious consequences.
• NOTE: Provides manufacturer notes for clarification.
• TIP: Offers suggested manufacturer tips for optimal user experience.

Refrigerant Warning: R-454B is a flammable material. Follow handling instructions carefully and comply with national regulations.

Explanation of Symbols on the Unit:

• CAUTION: Read the operation manual carefully.
• CAUTION: Service personnel should refer to the installation manual.
• i: Information is available in the operating or installation manual.

Important Safety Precautions

WARNING: Turn off the air conditioner and disconnect the power before installing, cleaning, or repairing to avoid electric shock.

Improper handling can cause serious damage or injury. Follow these safety guidelines:

• Children and individuals with reduced capabilities should only use, clean, or maintain the unit under supervision.
• Maintenance and repair must be performed by qualified professionals.
• Disconnect power at the circuit breaker before cleaning or maintenance.
• Use an insulated object when operating the emergency switch.
• If the power cord is overheating, the unit makes abnormal sounds, the circuit breaker trips frequently, there is a burning smell, or the indoor unit is leaking, turn off the unit and contact a professional.
• Do not block air outlets or inlets.
• Never insert body parts into the unit's openings.
• Do not spill water on the remote control.
• Do not spray water on the indoor unit.
• Do not clean the unit with excessive water or combustible cleaning agents.
• After removing the filter, do not touch the fins.
• Do not use fire or a hair dryer to dry the filter.
• Do not step on the unit or place heavy objects on it.
• Do not use flammable materials near the unit.
• Do not operate in areas with combustible gases.
• Do not operate in wet rooms like bathrooms.
• Ensure adequate ventilation when using the unit with burners or heating devices.

Electrical Safety:

• Do not modify the power cord or use extension cords.
• If the supply cord is damaged, it must be replaced by the manufacturer or a qualified person.
• Keep the power plug clean.
• Do not pull the power cord to unplug; grip the plug firmly.
• Do not share the electrical outlet with other appliances.
• Ensure the product is properly grounded.
• Follow all local and national wiring standards. Connect cables tightly.
• Ensure the control board cover is properly closed to prevent corrosion.
• For fixed wiring, use an all-pole disconnection device and consider an RCD if leakage current exceeds 10mA.
• The circuit board has a fuse for over-current protection.

Installation Safety:

• Installation must be performed by an authorized dealer or specialist.
• Follow installation instructions and local/national wiring regulations.
• Contact an authorized service technician for repair or maintenance.
• Use only included or specified parts.
• Install the unit in a firm location that can support its weight.
• Ensure proper drainage piping installation.
• For units with auxiliary electric heaters, maintain a 3-foot clearance from combustible materials.
• Do not install near combustible gas leaks.

Refrigerant Safety (A2L)

WARNING: Do not use means to accelerate defrosting or cleaning other than recommended. Store the appliance in a room without ignition sources. Do not pierce or burn. Be aware that flammable refrigerants may not have an odor. Comply with national refrigerant regulations.

A2L Refrigerant Safety Precautions:

• Personnel working with refrigerant circuits must hold a valid certificate.
• Maintenance and repair should be done by competent persons.
• Minimize and protect pipe-work from physical damage.
• Ensure pipe-work complies with national gas regulations.
• Mechanical connections must be accessible for maintenance.
• Prevent foreign matter from entering piping. Seal piping openings securely.
• All safety procedures must be performed by competent persons.
• Store appliances in a well-ventilated area.
• Joints must be tested with detection equipment (0.18 oz/5g per year sensitivity). Detachable joints are not recommended for the indoor side.
• Ensure ventilation openings are kept clear of obstruction.
• The unit has a leak detection system. If leakage is detected, an error code will display, a buzzing sound will occur, and the compressor will stop. The refrigerant sensor has a service life of 15 years and must be replaced by the manufacturer if it malfunctions.

Flammable Refrigerant Requirements

Installation space and ventilation requirements depend on refrigerant mass charge, installation location, and ventilation type. Piping material, routing, and installation must comply with codes and standards (e.g., ASHRAE 15, IAPMO, ICC, CSA B52). Field joints must be accessible for inspection. Protection devices, piping, and fittings should be protected from environmental effects. Piping should minimize hydraulic shock. Steel pipes require corrosion protection. Precautions against vibration and pulsation are necessary. Minimum floor area requirements must be met.

Pressure Testing:

1. Pressure test the refrigerant piping to 500 PSI with OXYGEN-FREE NITROGEN (OFN).
2. Maintain test pressure for at least 1 hour with no pressure decrease.
3. During evacuation, the system must hold below 500 microns for 15 minutes after vacuum pump is off.

Field-made Refrigerant Joints: Must be tightness tested with a sensitivity of 0.18 oz (5 g) per year of refrigerant or better.

Qualifications of Workers:

• Maintenance, service, and repair operations must be performed by qualified personnel.
• Workers must have completed necessary training and obtained certification.
• Training should follow ANNEX HH requirements of UL 60335-2-40 4th Edition.
• Examples of procedures requiring qualified personnel include breaking into the refrigerating circuit, opening sealed components, and opening ventilated enclosures.

Ventilated Area

Ensure adequate ventilation before working on the system to disperse any released refrigerant.

Cabling

Check wiring for wear, corrosion, excessive pressure, vibration, sharp edges, and other adverse environmental effects.

Detection of Flammable Refrigerants

Do not use sources of ignition when searching for leaks. Electronic leak detectors are acceptable, but sensitivity may need adjustment for flammable refrigerants. Ensure detectors are not ignition sources and are suitable for the refrigerant. Leak detection fluids are also suitable, but avoid those containing chlorine.

Note: Examples of leak detection fluids include bubble method and fluorescent method agents.

If a leak is suspected, remove all naked flames. If brazing is required for a leak, recover all refrigerant or isolate the system.

Evacuation

When breaking into the refrigerant circuit, follow best practices for flammable refrigerants:

• Safely remove refrigerant according to regulations.
• Purge the circuit with NITROGEN.
• Evacuate.
• Continuously flush or purge with NITROGEN when using flame.
• Open the circuit.

Refrigerant charge must be recovered into correct cylinders. Purge the system with OXYGEN-FREE NITROGEN (OFN) to render it safe. Compressed air or oxygen must not be used. Vent the system to atmospheric pressure after the final OFN charge.

Recovery

When removing refrigerant for servicing or decommissioning, recover it safely. Ensure correct recovery cylinders are used.

Charging Procedures

Follow these requirements for charging:

• Use appropriate tools.
• Ensure no contamination of refrigerants.
• Use short hoses to minimize refrigerant volume.
• Keep cylinders upright.
• Ground the system before charging.
• Label the system upon completion.
• Avoid overfilling.
• Pressure test with OFN before recharging.
• Leak test after charging but before commissioning.
• Perform a follow-up leak test before leaving the site.

Additional Precautions:

• Turn off and disconnect power if not using the unit for a long time.
• Turn off the unit during electrical storms.
• Ensure condensation can drain freely.
• Do not operate with wet hands.
• Use the device only for its intended purpose.
• Do not climb on or place objects on the outdoor unit.
• Do not operate with doors or windows open for extended periods, especially in high humidity.

Refrigerant Pipe Length

The length of refrigerant piping affects performance and efficiency. Nominal efficiency is tested with 25 ft (7.6m) of piping. A minimum of 10 ft (3m) is required.

Oil Traps

Oil traps are necessary when indoor and outdoor units are installed at significantly different heights.

• Indoor unit higher than outdoor unit: Install oil traps in the rising gas piping every 32'10" (10m) of vertical rise to prevent oil from flowing back to the compressor.
• Outdoor unit higher than indoor unit: Install oil traps in the rising gas piping every 19'9" (6m) of vertical rise to maintain proper oil return.

Diagrams illustrating oil trap placement for different height configurations are provided.

Refrigerant Pipe Connection Instructions

Step 1: Cut Pipes

1. Measure the distance between the indoor and outdoor units.
2. Cut the pipe length slightly longer than the measured distance.
3. Ensure the pipe is cut at a perfect 90° angle.
4. Do not damage, deform, or dent the pipe while cutting.

Step 2: Remove Burrs

• Burrs affect the airtight seal and must be removed.
• Hold the pipe at a downward angle to prevent burrs from falling in.
• Use a reamer or deburring tool to remove burrs.

Step 3: Flare Pipe Ends

• Seal pipe ends with PVC tape to prevent foreign materials.
• Sheath pipe with insulating material.
• Place flare nuts on both ends of the pipe, ensuring correct orientation.
• Remove PVC tape before flaring.
• Clamp the flare form on the pipe end, ensuring proper extension.
• Use the flaring tool to flare the pipe.
• Inspect the flare for cracks and evenness.

Pipe Extension Beyond Flare Form: A table provides minimum and maximum extension dimensions for different pipe diameters.

Tip: Thickness Comparison: Provides visual aids for thickness measurements.

Step 4: Connect Pipes

• Connect pipes carefully, avoiding excessive torque.
• Connect the low-pressure pipe first, then the high-pressure pipe.
• Maintain a minimum bending radius of 4 inches (10cm).
• Remove excess line length.

Connecting Piping to Indoor Unit: Align pipes and tighten flare nuts by hand, then with a torque wrench according to the provided table. A table specifies tightening torque and flare dimensions for different pipe sizes.

Caution: Do not use excessive torque.

Connecting Piping to Outdoor Unit: Remove the valve cover and protective caps. Align flared pipe ends and tighten flare nuts by hand, then with a torque wrench. Repeat for the remaining pipe.

System Evacuation

Preparations and Precautions: Air and foreign matter can cause system damage. Use a vacuum pump and manifold gauge to evacuate the system. Evacuation is required for initial installation and relocation.

Before Performing Evacuation:

• Check refrigerant pipe connections for leaks.
• Check wiring connections.

Evacuation Instructions:

1. Connect manifold gauge hoses.
2. Pressurize the system to 600 PSIG with nitrogen.
3. Wait 15 minutes and check for pressure changes.
4. If pressure loss is greater than 5 PSIG, locate and fix leaks.
5. If no pressure change, remove the nitrogen tank connection.
6. Release system pressure.
7. Connect the vacuum pump and micron gauge.
8. Evacuate the system until the micron gauge reads 250 microns.
9. Close the low pressure side and turn off the vacuum pump. The system must hold below 500 microns for 15 minutes.
10. If pressure changes, locate and fix leaks.
11. Remove the manifold gauge auxiliary hose.
12. Open the system's valves gently.

Note on Adding Additional Refrigerant: Each outdoor unit is factory charged for up to 25 ft (7.5m). Systems with longer line sets require additional refrigerant. Refer to the submittal documents at WWW.DURASTAR.COM for calculations. Do not mix refrigerant types.

Final Checks

Before the Test Run:

• Confirm electrical system is connected and operating correctly.
• Check all flare nut connections for leaks.
• Confirm low and high pressure valves are fully open.
• Check grounding resistance (must be less than 0.1 Ω).

Electrical Safety Checks: Ensure all electrical wiring complies with local and national regulations.

During Test Run:

• Verify main power voltage with a multimeter. If voltage deviates by more than ±10%, turn off the unit and call an electrician.

Warning: All wiring must comply with electrical codes and be installed by a licensed electrician.

Test Run

Perform the test run for at least 30 minutes.

1. Connect power to the unit.
2. Turn the unit on using the remote controller or wired thermostat.
3. Press the MODE button to select COOL (lowest temperature) and HEAT (highest temperature) modes.
4. Run each function for 5 minutes and perform the following checks:

Double-check all pipe connections during operation. If the ambient temperature is below 60°F (16°C), use the MANUAL CONTROL button on the indoor unit to test the COOL function.

Troubleshooting

Safety Precautions: If the power cord is damaged, the unit emits abnormal sounds or a burning odor, a fuse blows, or water/objects fall into/out of the unit, turn off the unit immediately and contact an authorized service provider.

Common Issues:

Troubleshooting Table:

Note: If problems persist after checks, turn off the unit and contact an authorized service center.

Wiring Diagrams

Wiring diagrams are provided for various Durastar models, including:

• DRA1H06S2A, DRA1U09S2A, DRA1H09S2A, DRA1U12S2A, DRA1H12S2A
• DRA1U18S2A, DRA1H18S2A, DRA1U24S2A
• DRA1H24S2A
• DRA1H33S2A

These diagrams illustrate the connections for the main control board, indoor unit, outdoor unit, power supply, sensors, motors, compressor, and other components.

Error and Operating Codes

A comprehensive list of error and operating codes is provided, along with their corresponding operation or malfunction descriptions. This includes codes related to defrost, cooling, fan speed, sensors, communication errors, refrigerant leaks, pressure protection, overcurrent, and temperature protection.

Job Site Information Sheet

A Job Site Information Sheet is included for recording site, contractor, outdoor unit (ODU), and indoor unit (IDU) information, as well as refrigerant line size and length. It also includes sections for outdoor and indoor electrical readings, and outdoor and indoor thermal readings.