ComfortStar CPK3 Series Air Handler Fan Coil Owner's Manual

Model Numbers: CPK3-18-SG3, CPK3-24-SG3, CPK3-30-SG3, CPK3-36-SG3

IMPORTANT NOTE: Read this manual carefully before installing or operating your new air conditioning unit. Make sure to save this manual for future reference.

Contents

Inside you'll find many helpful hints on how to use and maintain your air conditioner properly. Just a little preventive care on your part can save you a great deal of time and money over the life of your air conditioner. These instructions may not cover every possible condition of use, so common sense and attention to safety is required when installing, operating and maintaining this product.

Safety Precautions

It is really important that you read Safety Precautions Before Operation and Installation. Incorrect installation due to ignoring instructions can cause serious damage or injury. The seriousness of potential damage or injuries is classified as either a WARNING or CAUTION.

The following safety guidelines are intended to prevent unforeseen risks or damage from unsafe or incorrect operation of the appliance. Please check the packaging and appliance on arrival to make sure everything is intact to ensure safe operation. If you find any damage, please contact the retailer or dealer. Please note modifications or alterations to the appliance are not allowed for your safety. Unintended use may cause hazards and loss of warranty claims.

Explanation of Symbols

[Warning Symbol] This symbol indicates the possibility of personnel injury or loss of life.

[Caution Symbol] This symbol indicates the possibility of property damage or serious consequences.

Read these operating instructions carefully and attentively before using/commissioning the unit and keep them in the immediate vicinity of the installation site or unit for later use!

WARNING

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

WARNING FOR PRODUCT USE

ELECTRICAL WARNINGS

Cleaning and Maintenance Warnings

CAUTION

WARNING FOR USING FLAMMABLE REFRIGERANTS

For R454B refrigerant charge amount and minimum room area:

The machine you purchased may be one of the types in the table below. The indoor and outdoor units are designed to be used together. Please check the machine you purchased. The minimum room area of operating or storage should be as specified in the following table:

ModelIndoor unitOutdoor unitIndoor unitOutdoor unitIndoor unitOutdoor unitIndoor unitOutdoor unit
Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]
Regular Heat Series
18K(208/230V)CPK3-18-SG3CPR3-18CD(O)
24K(208/230V)CPK3-24-SG3CPR3-24CD(O)
30K(208/230V)CPK3-30-SG3CPR3-30CD(O)
36K(208/230V)CPK3-36-SG3CPR3-36CD(O)
Hyper Heat Series
18K(208/230V)CPK3-18-SG3CPH3-18CD(O)
24K(208/230V)CPK3-24-SG3CPH3-24CD(O)
30K(208/230V)CPK3-30-SG3CPH3-30CD(O)
36K(208/230V)CPK3-36-SG3CPH3-36CD(O)
Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]Mc or MREL [oz/kg]TAmin [ft²/m²]
<=62.7/1.77612/1.1134/3.8126/11.67211.6/6.0198/18.43289.2/8.2271/25.18
63.5/1.860/5.53141.1/4132/12.29218.7/6.2205/19.04296.3/8.4278/25.8
70.5/266/6.14148.1/4.2139/12.9225.8/6.4212/19.66303.4/8.6284/26.41
77.6/2.273/6.76155.2/4.4145/13.51232.8/6.6218/20.27310.4/8.8291/27.63
84.6/2.479/7.37162.2/4.6152/14.13239.9/6.8225/20.88317.5/9.0298/27.64
91.7/2.686/7.99169.3/4.8159/14.74246.9/7.0231/21.5324.5/9.2304/28.26
98.8/2.893/8.6176.4/5165/15.36254/7.2238/22.11331.6/9.4311/28.87
105.8/399/9.21183.4/5.2172/15.97261/7.4245/22.73338.6/9.6317/29.48
112.9/3.2106/9.83190.5/5.4179/16.58268.1/7.6251/23.34345.7/9.8324/30.10
119.9/3.4112/10.44197.5/5.6185/17.2275.1/7.8258/23.96352.7/10.0331/30.71
127/3.6119/11.06204.6/5.8192/17.81282.2/8.0264/24.57

TAmin is the required minimum room area in ft²/m²

Mc is the actual refrigerant charge in the system in oz/kg

MREL is the refrigerant releasable charge in oz/kg

hinst is the height of the bottom of the appliance relative to the floor of the room after installation.

WARNING: The minimum room area or minimum room area of conditioned space is based on releasable charge and total system refrigerant charge.

When the unit detects a refrigerant leak, the minimum airflow of the indoor unit is as follows:

ModelNominal air volume
18K400CFM (680m³/h)
24K400CFM (680m³/h)
30K453CFM (770m³/h)
36K529CFM (900m³/h)

Installation

1. Installation (where refrigerant pipes are allowed)

2. When a FLAMMABLE REFRIGERANT is used, the requirements for installation space of appliance and /or ventilation requirements are determined according to

a. The minimum test pressure for the low side of the system shall be the low side design pressure and the minimum test pressure for the high side of the system shall be the high side design pressure, unless the high side of the system cannot be isolated from the low side of the system in which case the entire system shall be pressure tested to the low side design pressure.

b. The test pressure after removal of pressure source shall be maintained for at least 1 h with no decrease of pressure indicated by the test gauge, with test gauge resolution not exceeding 5% of the test pressure.

c. During the evacuation test, after achieving a vacuum level specified in the manual or less, the refrigeration system shall be isolated from the vacuum pump and the pressure shall not rise above 1500 microns within 10 min. The vacuum pressure level shall be specified in the manual, and shall be the lessor of 500 microns or the value required for compliance with national and local codes and standards, which may vary between residential, commercial and industrial buildings.

field-made refrigerant joints indoors shall be tightness tested according to the following requirements: The test method shall have a sensitivity of 5 grams per year of refrigerant or better under a pressure of at least 0,25 times the maximum allowable pressure. No leak shall be detected.

Any servicing shall be performed only as recommended by the manufacturer.

3. Qualification of workers

Any maintenance, service and repair operations must be required qualification of the working personnel. Every working procedure that affects safety means shall only be carried out by competent persons that joined the training and achieved competence should be documented by a certificate. The training of these procedures is carried out by national training organizations or manufacturers that are accredited to teach the relevant national competency standards that may be set in legislation. All training shall follow the ANNEX HH requirements of UL 60335-2-40 4th Edition.

Examples for such working procedures are:

Information Servicing

1. Checks to the area

Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimised. For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system.

2. Work procedure

Works shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapour being present while the work is being performed.

3. General work area

All maintenance staff and others working in the local area shall be instructed on the nature of work being carried out. Work in confined spaces shall be avoided.

4. Checking for presence of refrigerant

The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with flammable refrigerants, i.e., no sparking, adequately sealed or intrinsically safe.

5. Presence of fire extinguisher

If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry power or CO2 fire extinguisher adjacent to the charging area.

6. No ignition sources

No person carrying out work in relation to a REFRIGERATING SYSTEM which involves exposing any pipe work shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation, repairing, removing and disposal, during which refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. "No Smoking" signs shall be displayed.

7. Ventilated area

Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.

8. Checks to the refrigeration equipment

Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer's maintenance and service guidelines shall be followed. If in doubt consult the manufacturer's technical department for assistance. The following checks shall be applied to installations using FLAMMABLE REFRIGERANTS:

9. Checks to electrical devices

Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, and adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised. Initial safety checks shall include:

10. Sealed electrical components shall be replaced if it's damaged

11. Intrinsically safe components must be replaced if it's damaged

12. Cabling

Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.

13. Detection of flammable refrigerants

Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used.

The following leak detection methods are deemed acceptable for refrigerant systems. Electronic leak detectors may be used to detect refrigerant leaks but, in the case of FLAMMABLE REFRIGERANTS, the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed, and the appropriate percentage of gas (25 % maximum) is confirmed.

Leak detection fluids are also suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work.

NOTE Examples of leak detection fluids are:

If a leak is suspected, all naked flames shall be removed/extinguished.

If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak. See the following instructions of removal of refrigerant.

14. Removal and evacuation

When breaking into the refrigerant circuit to make repairs - or for any other purpose conventional procedures shall be used. However, for flammable refrigerants it is important that best practice be followed, since flammability is a consideration. The following procedure shall be adhered to:

The refrigerant charge shall be recovered into the correct recovery cylinders if venting is not allowed by local and national codes. For appliances containing flammable refrigerants, the system shall be purged with oxygen-free nitrogen to render the appliance safe for flammable refrigerants. This process might need to be repeated several times. Compressed air or oxygen shall not be used for purging refrigerant systems.

For appliances containing flammable refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the system with oxygen-free nitrogen and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum (optional for A2L). This process shall be repeated until no refrigerant is within the system (optional for A2L). When the final oxygen-free nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. The outlet for the vacuum pump shall not be close to any potential ignition sources, and ventilation shall be available.

15. Charging procedures

In addition to conventional charging procedures, the following requirements shall be followed:

16. Decommissioning

Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refrigerants are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of recovered refrigerant. It is essential that electrical power is available before the task is commenced.

a) Become familiar with the equipment and its operation.

b) Isolate system electrically

c) Before attempting the procedure ensure that:

d) Pump down refrigerant system, if possible.

e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.

f) Make sure that cylinder is situated on the scales before recovery takes place.

g) Start the recovery machine and operate in accordance with instructions.

h) Do not overfill cylinders (no more than 80 % volume liquid charge)

i) Do not exceed the maximum working pressure of the cylinder, even temporarily.

j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.

k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.

17. Labelling

Equipment shall be labelled stating that it has been de-commissioned and emptied of refrigerant. The label shall be dated and signed. For appliances containing FLAMMABLE REFRIGERANTS, ensure that there are labels on the equipment stating the equipment contains FLAMMABLE REFRIGERANT.

18. Recovery

When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely. When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge is available. All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant (i.e., special cylinders for the recovery of refrigerant). Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.

The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of the flammable refrigerant. If in doubt, the manufacturer should be consulted. In addition, a set of calibrated weighing scales shall be available and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition.

The recovered refrigerant shall be processed according to local legislation in the correct recovery cylinder, and the relevant waste transfer note arranged. Do not mix refrigerants in recovery units and especially not in cylinders.

If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The compressor body shall not be heated by an open flame or other ignition sources to accelerate this process. When oil is drained from a system, it shall be carried out safely.

19. Transportation, marking and storage for units

Explanation of symbols displayed on the indoor unit or outdoor unit

A2L WARNING: This symbol shows that this appliance used a flammable refrigerant. If the refrigerant is leaked and exposed to an external ignition source, there is a risk of fire.

CAUTION: This symbol shows that the operation manual should be read carefully.

CAUTION: This symbol shows that a service personnel should be handling this equipment with reference to the installation manual.

CAUTION: This symbol shows that information is available such as the operating manual or installation manual.

Unit Specifications and Features

Indoor unit display

Note: Different models have different display panels. Not all the indicators describing below are available for the air conditioner you purchased. Please check the indoor display panel of the unit you purchased. Illustrations in this manual are for explanatory purposes. The actual shape of your indoor unit may be slightly different. The actual shape shall prevail. This display panel on the indoor unit can be used to operate the unit in case the remote control has been misplaced or is out of batteries.

A diagram shows the indoor unit of the ComfortStar CPK3 Series air handler fan coil. It indicates the air inlet, air outlet, drain hose, and refrigerant connecting pipe. The electric control cabinet is also visible.

Indoor Unit Parts and Major Functions

1.1 UNIT PARTS

1.2 OPERATING CONDITIONS

Use the system under the following temperatures for safe and effective operation. If the air conditioner is used under different conditions, it may malfunction or become less efficient.

A diagram illustrates two types of split systems, labeled A and B, showing air inlets and outlets. The following table details operating conditions for the INVERTER SPLIT TYPE:

COOL modeHEAT modeDRY modeSingle on electric heating
Room TemperatureOutdoor TemperatureRoom TemperatureOutdoor TemperatureRoom TemperatureOutdoor Temperature18K+10kwothers
16°C - 32°C (60°F - 90°F)-30°C - 50°C (-22°F - 122°F) (For Hyper Heat Series)
-25°C - 50°C (-13°F - 122°F) (For Regular Heat Series)
0°C - 30°C (32°F - 86°F)-30°C - 24°C (-22°F - 75°F) (For Hyper Heat Series)
-25°C - 24°C (-13°F - 75°F) (For Regular Heat Series)
10°C - 32°C (50°F - 90°F)0°C - 50°C (32°F - 122°F)Highest: 24°C(75°F)Highest: 27°C(80.6°F)

FOR OUTDOOR UNITS WITH AUXILIARY ELECTRIC HEATER

When outside temperature is below 0°C (32°F), we strongly recommend keeping the outdoor unit powered at all times to prevent damage to equipment.

NOTICE

Room relative humidity less than 80%. If the air conditioner operates in excess of this figure, the surface of the air conditioner may attract condensation.

TO FURTHER OPTIMIZE THE PERFORMANCE OF YOUR UNIT, DO THE FOLLOWING:

1.3 FEATURES

Refrigerant Leak Detection System

In the event of a refrigerant leak, the LCD screen will display "ELOC" or "EHC1" or "EHC2" and the LED indicator light will flash. The default temperature of the first power-on is set to 60 °F for refrigeration and 86 °F for heating. When the temperature stops, the temperature is set at the room temperature at that time.

NOTICE

1.4 ENERGY SAVING TIPS

A diagram shows curtains being closed to retain heat. Another diagram shows doors and windows should be kept closed.

Care and Maintenance

CLEANING YOUR INDOOR UNIT

BEFORE CLEANING OR MAINTENANCE

CAUTION FOR ALL PIPES INSTALLATION

Only use a soft, dry cloth to wipe the unit clean. If the unit is especially dirty, you can use a cloth soaked in warm water to wipe it clean.

Step 1

Loosen the 12 screws on the protective net and remove the protective net.

A diagram shows the indoor unit with screws indicated for removing the protective net.

Step 2

Loosen the screw on the cover plate of the electric control box and remove the cover of the electric control box.

A diagram shows the indoor unit's electric control box cover with a screw indicated for removal.

Step 3 Repair electronic controller

Loosen the screws on both sides of the electric control box assembly and remove the electric control box.

A diagram shows the electronic controller assembly with screws indicated for removal.

Step 4 Repair fan and motor

Remove product backplane.

Remove the screws that secure the fan, and loosen three screws on each side.

A diagram shows the backplane of the unit with screws indicated for fan removal.

Step 5 Repair sensors

Disassemble the left panel of the product and connect the drain pipe.

A diagram shows the internal components, including the drain pipe connection.

Maintenance your AC.

Maintenance - Long Periods of Non-Use

If you plan not to use your air conditioner for an extended period of time, do the following:

Maintenance - Pre-Season Inspection

After long periods of non-use, or before periods of frequent use, do the following:

Troubleshooting

SAFETY PRECAUTIONS

If any of the following conditions occurs, turn off your unit immediately!

DO NOT ATTEMPT TO FIX THESE YOURSELF! CONTACT AN AUTHORIZED SERVICE PROVIDER IMMEDIATELY!

Common Issues

The following problems are not a malfunction and, in most situations, will not require repairs.

IssuePossible Causes
Unit does not turn on when pressing ON/OFF buttonThe Unit has a 3-minute protection feature that prevents the unit from overloading. The unit cannot be restarted within three minutes of being turned off.
Cooling and Heating Models: If the Operation light and PRE-DEF (Pre-heating/Defrost) indicators are lit up, the outdoor temperature is too cold and the unit's anti-cold wind is activated in order to defrost the unit.
In Cooling-only Models: If the "Fan Only" indicator is lit up, the outdoor temperature is too cold and the unit's anti-freeze protection is activated in order to defrost the unit.
The unit changes from COOL/HEAT mode to FAN modeThe unit may change its setting to prevent frost from forming on the unit. Once the temperature increases, the unit will start operating in the previously selected mode again.
The set temperature has been reached, at which point the unit turns off the compressor. The unit will continue operating when the temperature fluctuates again.
The indoor unit emits white mistIn humid regions, a large temperature difference between the room's air and the conditioned air can cause white mist.
Both the indoor and outdoor units emit white mistWhen the unit restarts in HEAT mode after defrosting, white mist may be emitted due to moisture generated from the defrosting process.
The indoor unit makes noisesA squeaking sound is heard when the system is OFF or in COOL mode. The noise is also heard when the drain pump (optional) is in operation.
A squeaking sound may occur after running the unit in HEAT mode due to expansion and contraction of the unit's plastic parts.
Both the indoor unit and outdoor unit make noisesLow hissing sound during operation: This is normal and is caused by refrigerant gas flowing through both indoor and outdoor units.
Low hissing sound when the system starts, has just stopped running, or is defrosting: This noise is normal and is caused by the refrigerant gas stopping or changing direction.
Squeaking sound: Normal expansion and contraction of plastic and metal parts caused by temperature changes during operation can cause squeaking noises.
The outdoor unit makes noisesThe unit will make different sounds based on its current operating mode.
Dust is emitted from either the indoor or outdoor unitThe unit may accumulate dust during extended periods of non-use, which will be emitted when the unit is turned on. This can be mitigated by covering the unit during long periods of inactivity.
The unit emits a bad odorThe unit may absorb odors from the environment (such as furniture, cooking, cigarette, etc.) which will be emitted during operations. The unit's filters have become moldy and should be cleaned.
The fan of the outdoor unit does not operateDuring operation, the fan speed is controlled to optimize product operation.

NOTICE

If problem persists, contact a local dealer. Provide them with a detailed description of the unit malfunction as well as your model number.

Troubleshooting

When troubles occur, please check the following points before contacting a repair company.

ProblemPossible CausesSolution
Poor Cooling PerformanceTemperature setting may be higher than ambient room temperatureLower the temperature setting
The heat exchanger on the indoor or outdoor unit is dirtyClean the affected heat exchanger
The air inlet or outlet of either unit is blockedTurn the unit off, remove the obstruction and turn it back on
Doors and windows are openMake sure that all doors and windows are closed while operating the unit
Excessive heat is generated by sunlightClose windows and curtains during periods of high heat or bright sunshine
Too many sources of heat in the room (people, computers, electronics, etc.)Reduce amount of heat sources
Low refrigerant due to leak or long-term useCheck for leaks, re-seal if necessary and top off refrigerant
The unit is not workingPower failureWait for the power to be restored
The power is turned offTurn on the power
The fuse is burned outReplace the fuse
The Unit's 3-minute protection has been activatedWait three minutes after restarting the unit
Timer is activatedTurn timer off
The unit starts and stops frequentlyThere's too much or too little refrigerant in the systemCheck for leaks and recharge the system with refrigerant.
Incompressible gas or moisture has entered the system.Evacuate and recharge the system with refrigerant
System circuit is blockedDetermine which circuit is blocked and replace the malfunctioning piece of equipment
Poor heating performanceThe compressor is brokenReplace the compressor
The voltage is too high or too lowInstall a manostat to regulate the voltage
The outdoor temperature is extremely lowUse auxiliary heating device
Cold air is entering through doors and windowsMake sure that all doors and windows are closed during use
Low refrigerant due to leak or long-term useCheck for leaks, re-seal if necessary and top off refrigerant
Models: CPK3-18-SG3, CPK3-24-SG3, CPK3-30-SG3, CPK3-36-SG3, CPR3 Series Air Handler Fan Coil, CPR3 Series, Air Handler Fan Coil, Handler Fan Coil, Fan Coil

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