Comfort Star ADA24-410, ADH24-410, ADA30-410, ADH30-410, ADA36-410 Installation & Operation Instructions

1

Installation &Operation Instructions

For R410A (ADA & ADH) Series

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION

ATTENTION INSTALLING PERSONNEL

Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings.

During installation or repair, caution is to be observed

It is your responsibility to install the product safely and to educate the customer on its safe use

Eair LLC

12201 N.W. 107

th

Avenue, Medley, FL 33178

www.comfortstarusa.com

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TABLE OF CONTENTS

Safety Considerations............................................................................................. 3

Physical Dimension.................................................................................................3

2.1 Outdoor Unit....................................................................................................................................... ..................... 3

2.2 Indoor Unit .............................................................................................................................................................. 4

Installation Recommendations .............................................................................. 5

Installation...............................................................................................................6

STEP 1 —Check Equipment & Jobsite.........................................................................................................................6

STEP 2 —Install on a Solid, Level Mounting Pad........................................................................................................ 6

STEP 3 —Clearance Requirements............................................................................................................................... 6

STEP 4 —Operating Ambient ....................................................................................................................................... 6

STEP 5 —Elevate Unit.................................................................................................................................................. 7

STEP 6 —Check Piston................................................................................................................................................. 7

STEP 7 —Make Piping Connections............................................................................................................................. 8

STEP 8 —Make Electrical Connections...................................................................................................................... 13

STEP 10 —Start-Up....................................................................................................................................................16

STEP 11 —Final Checks ............................................................................................................................................. 18

CARE AND MAINTENANCE............................................................................ 18

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Safety Considerations

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire,
electrical shock, or other conditions which may cause death, personal injury, or property damage.
Consult a qualified installer, service agency, or your distributor or branch for information or
assistance. The qualified installer or agency must use factory--authorized kits or accessories when
modifying this product. Refer to the individual instructions packaged with the kits or accessories
when installing. Follow all safety codes. Wear safety glasses, protective clothing, and work gloves.

Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult
local building codes and National Electrical Code (NEC) for special requirements. Recognize safety

information. This is the safety--alert symbol

.When you see this symbol on the unit and in

instructions or manuals, be alert to the potential for personal injury. Understand these signal words;
DANGER, WARNING, and CAUTION. These words are used with the safety--alert symbol.

DANGER identifies the most serious hazards which will result in severe personal injury or death.

WARNING signifies hazards which could result in personal injury or death. CAUTION is used

to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is

used to highlight suggestions which will result in enhanced installation, reliability, or operation.

Physical Dimension

2.1 Outdoor Unit

TABLE 1—Dimension of Outdoor Unit

DIMENSION

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ELECTRICAL SHOCK HAZARD

Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out
and tag switch with a suitable warning label.

Failure to follow this warning could result in personal
injury or death

WARNING

MODEL

A B C

ADA18-410/ADH18-410

24

1/2" 24" 24"

ADA24-410/ADH24-410

24

1/2" 24" 24"

ADA30-410/ADH30-410

29" 28" 28"

ADA36-410/ADH36-410

29" 28" 28"

ADA42-410/ADH42-410

29" 28" 28"

ADA48-410/ADH48-410

33

1/2" 28" 28"

ADA60-410/ADH60-410

33

1/2" 291/2" 291/2"

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Fig.1—Outdoor Unit

2.2 Indoor Unit

TABLE 2—Dimension of Indoor Unit

DIMENSION MODEL

A B C D E

HD18 21" 215/16” 105/8" 113/16" 431/2"
HD24 21"

21

5/16”

10

5/8"

11

3/16"

43

1/2"

HD30 21"

21

5/16”

12"

113/16"

49

3/8"

HD36 21"

21

5/16”

12"

113/16" 493/8"

HD42 21"

21

5/16”

12"

113/16" 493/8"

HD48 24½”

21

5/16”

13

3/4"

11

3/16" 493/8"

HD60 24½”

215/16”

13

3/4"

11

3/16" 493/8"

5

B

C

D

A

E

Fig.2—Indoor Unit

Installation Recommendations

NOTE:

In some cases noise in the living area has been traced to gas pulsations from improper

installation of equipment.

1. Locate unit away from windows, patios, decks, etc. where unit operation sound may disturb
customer.

2. Ensure that vapor and liquid tube diameters are appropriate for unit capacity.

3. Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends.

4. Leave some slack between structure and unit to absorb vibration.

5. When passing refrigerant tubes through the wall, seal opening with RTV or other pliable
silicon--based caulk.(See Fig. 3.)

6. Avoid direct tubing contact with water pipes, duct work, floor joists, wall studs, floors, and walls.

7. Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in
direct contact with tubing. (See Fig. 3.)

8. Ensure that tubing insulation is pliable and completely surrounds vapor tube.

9. When necessary, use hanger straps which are 1 in. wide and conform to shape of tubing insulation.
(See Fig. 3.)

10. Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of
insulation.

When outdoor unit is connected to factory--approved indoor unit, outdoor unit contains system
refrigerant charge good for 25 ft.
For proper unit operation, check refrigerant charge using charging information located on control box
cover and/or in the Check Charge section of this instruction.

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Fig.3 – Connecting Tubing Installation

Installation

STEP 1 —Check Equipment & Jobsite

Unpack Unit

Move to final location. Remove carton taking care not to damage unit.

Inspect Equipment

File claim with shipping company prior to installation if shipment is damaged or incomplete. Locate
unit rating plate. It contains information needed to properly install unit. Check rating plate to be sure
unit matches job specifications.

STEP 2 —Install on a Solid, Level Mounting Pad

For hurricane tie downs, contact distributor for details and PE Certification (Professional Engineer), if
required.
On rooftop applications, mount on level platform or frame. Place unit above a load--bearing wall and
isolate unit and tubing set from structure. Arrange supporting members to adequately support unit and
minimize transmission of vibration to building. Consult local codes governing rooftop applications.

NOTE: Unit must be level to within ±2° (±3/8 in./ft.) per compressor manufacturer specifications.

STEP 3 —Clearance Requirements

When installing, allow sufficient space for airflow clearance, wiring, refrigerant piping, and service.
Allow 30--in. clearance to service end of unit and 48 in. above unit. For proper airflow, a 6--in.
clearance on 1 side of unit and 12 in. on all remaining sides must be maintained. Maintain a distance
of 24 in. between units. Position so water, snow, or ice from roof or eaves cannot fall directly on unit.
On rooftop applications, locate unit at least 6 in. above roof surface.

STEP 4 —Operating Ambient

The minimum outdoor operating ambient in cooling mode is 55°F, and the maximum outdoor

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operating ambient in cooling mode is 125°F. The maximum outdoor operating ambient in heating
mode is 66 °F.

STEP 5 —Elevate Unit

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UNIT OPERATION HAZARD

Failure to follow this caution may result in equipment
damage or improper operation.

Unit must be kept free of an accumulation of water
and/or ice in the basepan.

CAUTION

Elevate unit per local climate and code requirements to provide clearance above estimated snowfall
level and ensure adequate drainage of unit. If using accessory support feet, use installation instructions
from kit for installation.

STEP 6 —Check Piston

There is a piston located in outdoor condensing unit, please verify the piston size based on the below
table. When matching with ComfortStar HD air handler, please make sure replace this piston

in HD air

handler.

OUTDOOR UNIT INDOOR UNIT

PISTON KIT

PART NO.

ADA18-410 HD18

054
ADA24-410 HD24 060
ADA30-410 HD30 070
ADA36-410 HD36

073

ADA42-410 HD42

079

ADA48-410 HD48

100

ADA60-410 HD60

091

ADH18-410 HD18

054

ADH24-410 HD24

058

ADH30-410 HD30

071

ADH36-410 HD36

066

ADH42-410 HD42

079

ADH48-410 HD60

094

ADH60-410 HD60

100

Ta ble 3 —Piston Chart

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STEP 7 —Make Piping Connections

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UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage or improper operation.

If AN

Y refrigerant tubing is buried, provide a 6-in,

vertical rise at service valve.
Refrigerant tubing lengthens up to 36-in, may be buried

without further special consideration. Do not bury lines
longer than 36 in

CAUTION

！

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage or improper operation.

To prevent damage to unit or service valves, observe the
following:

Use a brazing shield.

Wrap service valves with wet cloth or use a heat sink
material

CAUTION

Outdoor units may be connected to indoor section using accessory tubing package or field--supplied
refrigerant grade tubing of correct size and condition. For tubing requirements beyond 80 ft., substantial
capacity and performance losses can occur. Follow the recommendations in the Long Line
Guideline for long line application. Refer to Table 4 for accessory requirements. Refer to Table 5 for
field tubing diameters. If refrigerant tubes or indoor coil are exposed to atmosphere, they must be
evacuated to 500 microns to eliminate contamination and moisture in the system.

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Table 4—Accessory Usage

Accessory

Required for low-ambient
applications(below 55°
F)

Required for long line
applications(Over 80 ft.)

Required for sea coast
applications(within 2
miles)

Crankcase Heater Yes Yes No
Evaporator Freeze
Thermostat

Yes No No

Winter Start Control Yes No No
Accumulator No No No
Compressor Start Assist
Capacitor and Relay

Yes Yes No

Motor Master Control Yes No No
Support Feet Recommended No Recommended

Table5—Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters(In.)

Liquid Vapor UNIT SIZE

Connection Diameter Tube Diameter Connection Diameter Rated Tube Diameter

18,24 3/8 3/8 5/8 5/8
30,36,42 3/8 3/8 3/4 3/4
48,60 1/2 1/2 1-1/8 1-1/8

Outdoor Unit Connected to Factory Approved Indoor Unit

These outdoor units are carefully evaluated and listed with specific indoor coils for proper system
performance.

IMPORTANT: Do not apply indoor coils which are not factory approved to these units.
IMPORTANT: DO

not apply piston which is in R22 indoor unit to these units. Must use R410a piston which

in the accessories replacing the existent R22 piston.

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！

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

Service valves must be wrapped in a heat-sinking
material such as a wet cloth.

damage or improper operation.

CAUTION

！

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

Installation of filter drier in liquid line is required.

damage or improper operation.

CAUTION

Install Liquid Line Filter Drier Indoor

Refer to Fig. 3 and install filter drier as follows:

1. Braze 5 in. liquid tube to the indoor coil.

2. Wrap filter drier with damp cloth.

3. Braze filter drier to 5 in. long liquid tube from step 1.

4. Connect and braze liquid refrigerant tube to the filter drier.

Fig.3—Liquid Line Filter Drier

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Leak Testing

Leak test all joints indoors, outdoors, and refrigerant tubing.

Evacuate Refrigerant Tubing and Indoor Coil

！

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

Never use this system compressor as a vacuum pump.

damage or improper operation.

CAUTION

Refrigerant tubes and indoor coil should be evacuated using the recommended the recommended deep
vacuum method of 500 microns. The alternate triple evacuation method may be used if the procedure
outlined below is followed.

IMPORTANT: Always break a vacuum with dry nitrogen.

Deep Vacuum Method

The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a
vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most
positive way of assuring a system is free of air and liquid water. See Fig. 4.

Fig.4- Deep Vacuum Graph

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Fig.5—Triple Evacuation Method

Triple Evacuation Method

The triple evacuation method should only be used when vacuum pump is only capable of pumping
down to 28 in. of mercury vacuum, and system does not contain any liquid water. Refer to Fig. 5 and
proceed as follows:

1. Pump system down to 28 in. of mercury and allow pump to continue operating for an additional 15
minutes.

2. Close service valves and shut off vacuum pump.

3. Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig.

4. Close service valve and allow system to stand for 1 hour. During this time, dry nitrogen will be able
to diffuse throughout the system absorbing moisture.

5. Repeat this procedure as indicated by Fig. 5. System will then be free of any contaminants and water
vapor.

Final Tubing Check

IMPORTANT: Check to be certain factory tubing on both indoor and outdoor unit has not shifted during shipment.

Ensure tubes are not rubbing against each other or any sheet metal. Pay close attention to feeder tubes, makings sure
wire ties on feeder tubes are secure and tight.

Refrigerant Charge Determination and Adjustment

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！

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death

Do not supply power to unit with compressor terminal
box cover removed.

WARNING

Weight in Charge Method

The unit was pre-charged good for 25 ft application, if the line set longer than 25ft, please refer to the following table
for additional charge
Liquid line size (inch) Additional charge for every

additional foot (oz)
3/8 0.62
1/2 0.82

Superheat Method

STEP 8 —Make Electrical Connections

Be sure field wiring complies with local and national fire, safety, and electrical codes, and voltage to
system is within limits shown on unit rating plate. Contact local power company for correction of
improper voltage. See unit rating plate for recommended circuit protection device.

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！

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault
should occur.

The ground may consist of electrical wire or metal conduit
when installed in accordance with existing electrical codes.

WARNING

NOTE:

Operation of unit on improper line voltage constitutes abuse and could affect unit reliability. See

unit rating plate. Do not install system where voltage may fluctuate above or below permissible limits.

NOTE:

Use copper wire only between disconnect switch and unit.

NOTE:

Install branch circuit disconnect of adequate size per NEC to handle unit starting current. Locate

disconnect within sight from and readily accessible from unit, per Section 440—14 of NEC.

Model Number ADA18-410 ADA24-410 ADA30-410 ADA36-410 ADA42-410 ADA48-410 ADA60-410

Minimum Circuit Ampacity -MCA(amps) 9.8 13.3 16.8 22.5 28.2 27.9 33.3

Minimum Circuit Ampacity-MCA(amps)

13.7 20 20.9 20.9 26.3 32.1 38.7

Maximum Over Current Protective device-MOCP(amps)

15 20 25 35

45

55

Compressor LRA/RLA

39/6.9 48/9.7 70/12.4 96.7/17 105/21.5 115/21 150/25

Model Number ADH18-410 ADH24-410 ADH30-410 ADH36-410 ADH42-410 ADH48-410 ADH60-410

Maximum Over Current Protective device-MOCP(amps)

20 30 35 35 45 55 65

Compressor LRA/RLA

48/10.0 58.3/15 73.0/15.7

77.0/15.7 112/20.0 117/24.3 134/29.3

Route Ground and Power Wires

Remove access panel to gain access to unit wiring. Extend wires from disconnect through power wiring
hole provided and into unit control box.

45

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Wiring Diagram:

Pig6A. COOL ONLY Wiring Diagram of Condense Unit (only for reference)

Pig6B. Heat Pump Wiring Diagram of Condense Unit (only for reference)

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！

PERSONAL INJURY HAZARD

Failure to follow this caution may result in personal
injury.
Wear safety glasses, protective clothing, and gloves when
handling refrigerant and observe the following:

CAUTION

Front seating service valves are equipped with Schrader
valves.

！

ENVIROMENTAL HAZARD

Failure to follow this caution may result in environmental
damage.

Federal regulations require that you do not vent refrigerant
to the atmosphere. Recover during system repair or final unit
disposal.

CAUTION

STEP 10 —Start-Up

！

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this caution may result in minor personal
injury, equipment damage or improper operation.

To prevent compressor damage or personal injury,

observe the following:
Do not overcharge system with refrigerant.
Do not operate unit in a vacuum or at negative pressure.
Do not disable low pressure switch in scroll compressor

applications.
Dome temperatures may be hot.
In 3 phase applications, incorrect phasing will cause reverse

rotation, resulting in elevated noise levels, equalized
pressures and reduced current draw.Correct by reversing
power connections L1 and L2 on contactor.

CAUTION

Follow these steps to properly start up system:

1. After system is evacuated, fully open liquid and vapor service valves.

2. Unit is shipped with valve stem(s) closed and caps installed. Replace stem caps after system is
opened to refrigerant flow (back seated). Replace caps finger—tight and tighten with wrench an

17

！

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this caution may result in minor personal
injury, equipment damage or improper operation.

To prevent compressor damage or personal injury,

Do not overcharge system with refrigerant.

Do not operate unit in a vacuum or at negative pressure.

Do not disable low pressure switch in scroll compressor
applications.

Dome temperatures may be hot.

In 3 phase applications, incorrect phasing will cause reverse
rotation, resulting in elevated noise levels, equalized pressures
and reduced current draw.Correct by reversing power
connection L1 and L2 on contactor.

CAUTION

additional 1/12 turn.

3. Close electrical disconnects to energize system.

4. Set room thermostat at desired temperature. Be sure set point is below indoor ambient
temperature.

5. Set room thermostat to HEAT or COOL and fan control to ON or AUTO mode, as desired.
Operate unit for 15 minutes. Check system refrigerant charge.

Setting on Defrost Control PCB (for Heat Pump unit only)

There are 8 different defrost control setting you can choose by change the dip switch located on
Defrost Control PCB.

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Note: ADH unit do not have outdoor ambient sensor installed, the defrost cycle only based on the
outdoor coil sensor. Therefore, “100”, “101”, “110” and “111” do not apply to ADH units.

T-----------Outdoor ambient temperature
t-----------Accumulation of compressor running time
T1----------Initiation Coil Temperature
T2---------Termination Coil Temperature

The factory default setting is “0 0 0”. After the compressor consecutively runs for 30 minutes, the
defrost cycle will be initiated if the sensor detects the coil temperature ≤ 32F for consecutive 1 minute.
The defrost cycle will be terminated either the coil temperature reach 68F or the defrost cycle reach 15
minutes.

Defrost Cycle：when the system running in heat pump mode, after the compressor has been
running for “t” minutes continuously, the defrost cycle start if the defrosting temp sensor has been in T1
degree or under T1 degree for 1 minute continuously. During the defrost cycle, the reversing valve is
energized, the outdoor fan stops running and the auxiliary electric heating is energized. The defrost
cycle will be terminated if defrost cycle reach 15 minutes or the coil sensor detects the coil temperature
over T2 degree.

Manually Defrost Cycle

There is a Manually Defrost Button located on the Defrost Control PCB, by press this button , the
system will go to defrost cycle right away to melt the ice on the coil.

STEP 11 —Final Checks

IMPORTANT: Before leaving job, be sure to do the following:

1. Ensure that all wiring is routed away from tubing and sheet metal edges to prevent rub--through or
wire pinching.

2. Ensure that all wiring and tubing is secure in unit before adding panels and covers. Securely fasten all
panels and covers.

3. Tighten service valve stem caps to 1/12--turn past finger tight.

4. Leave Users Manual with owner. Explain system operation and periodic maintenance requirements
outlined in manual.

5. Fill out Dealer Installation Checklist and place in customer file.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible equipment failure, periodic maintenance
must be performed on this equipment. Frequency of maintenance may vary depending upon geographic
areas, such as coastal applications.

Without Outdoor Ambient Sensor

installed With Outdoor Ambient Sensor Installed

Dip Switch

Setting 000 001 010 011 100 101 110 111

T - - - - >26F <26F >26F <26F >26F <26F >26F <26F

t 30 min 44 min 60min 90min 30min 60min 44min 60min 60min 90min 90min 120min
T1 32F 28F 32F 32F 28F 14F 28F 14F 28F 5F 28F 5F
T2 68F 68F 68F 68F 68F 60F 68F 60F 68F 60F 68F 60F

66129902760