Model Number: DRA2H18M1A, DRA3H28M1A, DRA4H36M1A, DRA5H48M1A,
DRA5H55M1A
Serial Number: [insert serial number]
Purchase Date: [insert purchase date]
Installing Contractor Company Name: [insert company name]
For any questions or concerns, contact Durastar customer
service via email ([email protected]) or by telephone
(1-888-320-0706)

Product Usage Instructions

Before installing the Durastar Multi-Zone Outdoor Unit
Split-Style Air Conditioner, it is important to read through the
safety precautions and installation instructions provided in the
manual.

Important Safety Precautions

Improper handling can cause serious damage or injury. Please
read and follow the safety information provided in the manual.

Operation, Cleaning, and Maintenance Safety Precautions:

Do not use the air conditioner near flammable gases or
combustibles
Do not touch the power plug with wet hands
Do not insert fingers or objects into the air inlet or
outlet
Turn off the power supply before cleaning or servicing the air
conditioner
Do not use water hotter than 40°C to clean the air
conditioner
Do not touch the outdoor unit during operation as it may be
hot

Electrical Safety:

Do not modify or extend the power cord
Do not use an extension cord or multi-outlet adapter
Ensure the power supply voltage and frequency match the
specifications on the air conditioner

Installation Safety:

Only a qualified installer or service technician should
install, repair, or service the air conditioner
Do not install the air conditioner in a potentially hazardous
location
Ensure the installation location can support the weight of the
outdoor unit

Operating Temperatures

The Durastar Multi-Zone Outdoor Unit Split-Style Air Conditioner
is designed to operate in specific indoor and outdoor temperatures.
When used outside of these temperature ranges, safety features may
activate and turn off the unit to protect it from damage.

	Indoor Air Temperature	Outdoor Air Temperature
Note	16°C – 32°C	-15°C – 50°C

Accessories Included

The Durastar Multi-Zone Outdoor Unit Split-Style Air Conditioner
comes with the following installation accessories:

Installation Manual
Refrigerant Pipe Adapters (quantity 2-3)
Drain Joint
Refrigerant Pipe Adapter (3/8-1/2)
Drain Joint Seal
Refrigerant Pipe Adapter (1/2-3/8)
Rubber Foot (quantity 4)
Refrigerant Pipe Adapter (1/2-5/8)
Refrigerant Pipe Adapter (1/4-3/8)

Tools Needed for Installation

The following tools may be required for installation:

Drill and drill bit set
Flaring tool
Torque wrench
Pipe cutter
Level

View Fullscreen

INSTALLATION MANUAL
MULTI-ZONE OUTDOOR UNIT
SPLIT-STYLE AIR CONDITIONER
DRA2H18M1A, DRA3H28M1A, DRA4H36M1A, DRA5H48M1A, DRA5H55M1A

Model Number:
Serial Number:
Purchase Date:
Installing Contractor Company Name:
TIP
Capture relevant information about your Durastar mini-split equipment before it is installed and write it above for future reference.

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TABLE OF CONTENTS
INTRODUCTION ………………………………………………………………………………………………………. 3 WARNINGS ……………………………………………………………………………………………………………….. 3 IMPORTANT SAFETY PRECAUTIONS ……………………………………………………………… 4 OPERATING TEMPERATURES……………………………………………………………………………..7 ACCESSORIES………………………………………………………………………………………………………….. 8 PARTS IDENTIFICATION ……………………………………………………………………………………….. 9 OUTDOOR UNIT INSTALLATION……………………………………………………………………… 10 STEP 1: SELECT INSTALLATION LOCATION ……………………………………………….. 10 STEP 2: INSTALL THE DRAIN JOINT ………………………………………………………………..11 STEP 3: MOUNT THE OUTDOOR UNIT…………………………………………………………… 12 STEP 4: CONNECT THE SIGNAL & POWER CABLES ………………………………… 13 REFRIGERANT PIPING CONNECTIONS…………………………………………………………. 15 STEP 1: CUT PIPES………………………………………………………………………………………………….17 STEP 2: REMOVE BURRS……………………………………………………………………………………..17 STEP 3: FLARE PIPE ENDS ………………………………………………………………………………… 18 STEP 4: CONNECT PIPES……………………………………………………………………………………. 19 SYSTEM EVACUATION …………………………………………………………………………………………20 FINAL CHECKS………………………………………………………………………………………………………..22 TEST RUN …………………………………………………………………………………………………………………23 TROUBLESHOOTING……………………………………………………………………………………………24 WIRING DIAGRAMS……………………………………………………………………………………………….28 ERROR AND OPERATING CODES ……………………………………………………………………32 JOB SITE INFORMATION SHEET………………………………………………………………………33

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INTRODUCTION
To better serve you, please do the following before contacting customer service: · If you received a damaged product, immediately contact the retailer or dealer that sold you the
product. · Read and follow this owner’s manual carefully to help you use and maintain your air conditioner. · Read the troubleshooting section of this manual as it will help you diagnose and solve common
issues. · Visit us on the web at www.durastar.com to download product guides and up-to-date
information. · If you need warranty service, our friendly customer service representatives are available via
email at [email protected] or by telephone at 1-888-320-0706.
WARNINGS
Symbols Used in This Manual
The warning symbol indicates cautionary information for the user. Extra care and precautions should be taken to ensure the user’s safety.
The pencil indicates any manufacturer notes relating to surrounding content. These may include further clarifications or call-outs.
A light bulb symbol indicates suggested manufacturer tips for the user to get the most out of the Durastar equipment and to accommodate the best user experience.

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IMPORTANT SAFETY PRECAUTIONS
Improper handling can cause serious damage or injury. Please read the following safety information in its entirety.
Operation, Cleaning, and Maintenance Safety Precautions
· Children and people with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, should only use this air conditioner if they are given supervision or instructions concerning use of the air conditioner in a safe way and understand the hazards involved.
· Children should not play with the air conditioner. · Never stick fingers or any other body parts into the air conditioner openings. The internal fan
may be rotating at high speeds, and may result in injury. · After removing the filter, do not touch the fins in order to avoid injury. · Maintenance must be performed by qualified professionals. Otherwise, you may experience
personal injury or damage to the air conditioner and surrounding property. · Do not repair the air conditioner by yourself. It may cause electric shock or damage. Please
contact a qualified service representative when you need to repair the air conditioner. · Do not block the air outlet or air inlet. This could cause a malfunction. · Do not spill water on the remote control as this can permanently damage the remote. · If the below problems occur, please turn off the air conditioner and disconnect power at the
circuit breaker immediately. Then contact your dealer or a qualified professional for service. · The power cord is overheating or damaged. · There is an abnormal sound during operation. · The circuit breaker trips frequently. · The air conditioner gives off a burning smell. · The indoor unit is leaking.
· If the air conditioner operates under abnormal conditions, it may cause malfunctions, electric shock, or fire hazard.
· When turning the unit on or off via the emergency operation switch, press the switch with an insulated object other than metal.
· Do not step on the top panel of the unit, or put heavy objects on the top panel. This could cause damage or personal injury.
· Cleaning and user maintenance should not be performed by children without supervision. · Do not spray water on the indoor unit. This could cause electric shock or a unit malfunction. · Do not use flammable materials such as hair spray, lacquer, or paint near the air conditioner as
they may catch fire. · Do not operate the air conditioner in places near combustible gases. Emitted gases may
collect around the air conditioner and cause an explosion. · Do not use fire or a hair dryer to dry the filter. This could cause a deformation or fire hazard. · Do not wash the air conditioner with water as this could cause an electric shock. · Disconnect the power supply by turning it off at the circuit breaker when cleaning the air
conditioner. Otherwise, you could risk electric shock.

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Electrical Safety
· Do not modify the length of the power supply cord or use an extension cord to power the unit. · If the supply cord is damaged, it must be replaced by the manufacturer, a service agent, or a
similarly qualified person in order to avoid a safety hazard. · Do not share the electrical outlet with other appliances. Improper or insufficient power supply
can cause fire or electrical shock. · The product must be properly grounded at the time of installation, or electrical shock may
occur. · For all electrical work, follow all local and national wiring standards and regulations. Connect
cables tightly, and clamp them securely to prevent external forces from damaging the terminal. Improper electrical connections can overheat and cause fire, and may also cause shock. All electrical connections must be made according to the Electrical Connection Diagram located on the panels of the indoor and outdoor units. · All wiring must be properly arranged to ensure that the control board cover can close properly. If the control board cover is not closed properly, it can lead to corrosion and cause the connection points on the terminal to heat up, catch fire, or cause electrical shock. · The air conditioner’s circuit board (PCB) is designed with a fuse to provide overcurrent protection. The specifications of the fuse are printed on the circuit board.

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Installation Safety
· Installation must be performed by an authorized dealer or specialist. Improper installation can cause water leakage, electrical shock, or fire. (In North America, installation must be performed in accordance with NEC and CEC requirements by authorized personnel only.)
· Installation must be performed according to the installation instructions. Improper installation can cause water leakage, electrical shock, or fire.
· This air conditioner shall be installed in accordance with national and local wiring regulations. · Contact an authorized service technician for repair or maintenance of this unit. · Only use the included accessories, parts, and specified parts for installation. Using non-
standard parts can cause water leakage, electrical shock, fire, and can cause the unit to fail. · Install the unit in a firm location that can support the unit’s weight. If the chosen location
cannot support the unit’s weight, or the installation is not done properly, the unit may fall and cause serious injury and damage. · Install drainage piping according to the instructions in the installation manual. Improper drainage may cause water damage to your home and property. · For units that have an auxiliary electric heater, do not install the unit within 3 feet (1 meter) of any combustible materials. · Do not install the unit in a location that may be exposed to combustible gas leaks. If combustible gas accumulates around the unit, it may cause a fire. · Do not turn on the power until all work has been completed. · When moving or relocating the air conditioner, consult experienced service technicians for disconnection and re-installation of the unit. · Be careful when opening or closing valves below freezing temperatures. Refrigerant may spurt out from the gap between the valve stem and the valve body, resulting in injuries.
Additional Precautions
· Turn off the air conditioner and disconnect the power if you are not going to use it for a long time.
· Turn off and unplug the unit during storms. · Make sure that water condensation can drain unhindered from the unit. · Do not operate the air conditioner with wet hands. This may cause electric shock. · Do not use this device for any other purpose than its intended use. · Do not climb onto or place objects on top of the outdoor unit. · Do not allow the air conditioner to operate for long periods of time with doors or windows
open, or if the humidity is very high.

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OPERATING TEMPERATURES
Your air conditioner is designed to operate in the following indoor and outdoor temperatures. When your air conditioner is used outside of the following temperature ranges, certain safety features may activate and turn off the unit to protect it from damage.

TEMPERATURE RANGES

Indoor Air Temperature
Outdoor Air Temperature

COOL mode 62°F – 90°F (17°C – 32°C) 5°F – 122°F (-15°C – 50°C)

HEAT mode 32°F – 86°F (0°C – 30°C) -22°F – 75°F (-30°C – 24°C)

DRY mode 50°F – 90°F (10°C – 32°C) 32°F – 122°F (0°C – 50°C)

To further optimize the performance of your unit, do the following: · Keep doors and windows closed. · Limit energy usage by using TIMER ON and TIMER OFF features. · Do not block air inlets or outlets. · Regularly inspect and clean air filters.

NOTE
Your Durastar air conditioner’s outdoor unit is equipped with a base pan heater, allowing it to continue to operate at freezing temperatures as low as -22°F (-30°C). When outdoor air temperatures are at or below 32°F (0°C), we strongly recommend keeping the unit plugged in at all times to ensure smooth ongoing performance.
NOTE
Keep the room’s relative humidity below 80%. If the air conditioner operates in excess of this, the surface of the air conditioner may attract condensation. To help prevent condensation from forming and dripping, set the vertical airflow louver to its maximum angle (vertically to the floor) and set the fan to HIGH.

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ACCESSORIES

INCLUDED INSTALLATION ACCESSORIES
The air conditioning system comes with the following accessories. They may vary by model.

Accessory

Quantity

Image

Accessory

Quantity

Image

Installation

Manual

Refrigerant

2-3

Pipe Adapter

(3/8″-1/2″)

Drain Joint

Refrigerant

0-2

Pipe Adapter

(1/2″-3/8″)

Drain Joint Seal

Refrigerant

0-2

Pipe Adapter

(1/2″-5/8″)

Rubber Foot

Refrigerant

0-2

Pipe Adapter

(1/4″-3/8″)

FIELD SUPPLIED INSTALLATION ACCESSORIES
The following installation accessories may be required and must be purchased separately. · Refrigerant lines · Indoor and outdoor connection wire · Outdoor power supply cord · Drain hose · Pipe and cable wrapping tape · Wall hole sleeve and cover · Putty · Suspension bolts and necessary hardware
to hang indoor unit (if necessary) · Wiring u-lugs

TOOLS NEEDED
The following tools may be required for installation.
· Phillips screwdriver · Drill with 2 1/2″ or 3 1/2″ core bit
(indoor unit model depending) · Vacuum pump · HVAC manifold gauge set · Refrigerant leak detector · Copper pipe cutter · Flaring tool

· Burr reamer · Crescent or spanner wrench · Hexagonal wrench set · Torque wrench · Hammer · Wire strippers · Wire crimper

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PARTS IDENTIFICATION
NOTE
The installation must be performed in accordance with the required local and national standards. The installation may be slightly different in different areas.

DRA5H48M1A, DRA5H55M1A DRA4H36M1A
DRA3H28M1A
DRA2H18M1A

Air Inlets

Signal Cable, Refrigerant Pipes, and Drain Pipe
Power Supply

Air Outlet

Wiring Terminal Refrigerant Valves

NOTE
Illustrations in this manual are for explanatory purposes. The actual shape of your minisplit equipment may vary slightly. Indoor units may also vary in configuration.

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OUTDOOR UNIT INSTALLATION
Installation Instructions
Install the unit following local codes and regulations. These may differ slightly between regions.

24″ (610) above

12″ on

(305) left

12″ (b3a0c5k) wall from

79″in(2f0ro0n7t)

o2n4″rig(6h1t0)

STEP 1: SELECT INSTALLATION LOCATION
Before installing the outdoor unit, you must choose an appropriate location. The following are standards that will help you choose an appropriate location for the unit.
Proper installation locations meet the following standards: · Meets all spatial requirements shown in installation space requirements above. · Good air circulation and ventilation. · Firm and solid location –the location can support the unit’s weight and will not vibrate. · Noise from the unit will not disturb others. · Protected from prolonged periods of direct sunlight or rain. · Where snowfall is anticipated, raise the unit above the base pad to prevent ice buildup and coil
damage. Mount the unit high enough to be above the average accumulated area snowfall. The minimum height must be 18 inches.
DO NOT install unit in the following locations: · Near an obstacle that will block air inlets and outlets. · Near a public street, crowded areas, or where noise from the unit will disturb others. · Near animals or plants that will be harmed by hot air discharge. · Near any source of combustible gas. · In a location that is exposed to large amounts of dust. · In a location exposed to an excessive amount of salty air. · Install the unit at least 10 ft. (3 m) away from TV or radio antennas. Operation of the unit may
interfere with antenna reception in areas where the signal is weak. An amplifier may be needed for affected devices.

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Special considerations for extreme weather If the unit is exposed to heavy wind, install unit so that air outlet fan is at a 90° angle to the direction of the wind. If needed, build a barrier in front of the unit to protect it from extremely heavy winds. See figures below.

Strong wind

Wind Baffle

Strong wind
If the unit is frequently exposed to heavy rain or snow Build a shelter above the unit to protect it from rain or snow. Be careful not to obstruct airflow around the unit.
STEP 2: INSTALL THE DRAIN JOINT 1. Fit the rubber seal on the end of the drain joint that will connect to the outdoor unit. 2. Insert the drain joint into the hole in the base pan of the unit. 3. Rotate the drain joint 90° until it clicks in place facing the front of the unit. 4. Connect a drain hose extension (not included) to the drain joint to redirect water from the unit
during heating mode.

Base pan hole of outdoor unit Seal
Seal
Drain joint
NOTE
In cold climates, make sure that the drain hose is as vertical as possible to ensure swift water drainage. If water drains too slowly, it can freeze in the hose and flood the unit.

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STEP 3: MOUNT THE OUTDOOR UNIT
Anchoring the Unit The outdoor unit can be anchored to the ground or to a wall-mounted bracket (sold separately) with bolts (M10). Mount the unit on a cement slab, condenser mounting pad, or other level surface able to support the unit’s weight. Do not place the unit directly on the ground. If using a wallmounting bracket, make sure the attached structure can support at least four times the unit’s weight.
Unit Mounting Dimensions The distance between their mounting feet varies by outdoor unit. Prepare the installation base of the unit according to the dimensions below. In most cases, it may be easier to place the outdoor unit in its correct location and mark the exact placement for the anchor holes.
A
Air inlet
Air inlet

Air outlet

Outdoor Unit – Dimensions W x H x D inches (mm)

Mounting Dimensions Dist. A inches (mm) Dist. B inches (mm)

DRA2H18M1A 37-3/16 x 31-15/16 x 16-1/2 (946x810x410)

26-1/2″ (673)

15-7/8″ (403)

DRA3H28M1A 37-3/16 x 31-15/16 x 16-1/2 (946x810x410

26-1/2″ (673)

15-7/8″ (403)

DRA4H36M1A 37-1/2 x 52-1/2 x16-5/16 (952x1333x415)

24-15/16″ (634)

15-15/16″ (404)

DRA5H48M1A 37-1/2 x 52-1/2 x16-5/16 (952x1333x415) DRA5H55M1A 37-1/2 x 52-1/2 x16-5/16 (952x1333x415)

24-15/16″ (634) 24-15/16″ (634)

15-15/16″ (404) 15-15/16″ (404)

Installing multiple outdoor units If installing multiple outdoor units, refer to the diagram below for proper clearances.

L H L > H

L 1/2H

9 13/16″ (250mm)

1/2H < L H 11 13/16″ (300mm) Can not be installed

(2590m13m/1)6″ (2590m13m/1)6″
H

L A
118″ (3000mm)
(155090″mm) 2(63050/m8″m)

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Pipe length and unit height difference maximums When installing multiple indoor units with a single outdoor unit, ensure that the length of the refrigerant pipe and the drop height between the outdoor and indoor units, and between indoor units, meets the requirements below.

Max. length for all rooms

DRA2H18M1A DRA3H28M1A
131′ (40m) 197′ (60m)

DRA4H36M1A, DRA5H48M1A DRA5H55M1A
262′ (80m)

Max. length for one indoor unit 82′ (25m)

98′ (30m)

115′ (35m)

Max. height difference between outdoor and indoor unit Max. height difference between indoor units
Outdoor unit

49′ (15m) 33′ (10m)

Indoor unit Max. Height difference

Indoor unit 49′ (15m)

33′ (10m)
49′ (15m)
Indoor unit
STEP 4: CONNECT THE SIGNAL & POWER CABLES The outside unit’s terminal block is protected by an electrical wiring cover on the side of the unit. A comprehensive wiring diagram is printed on the inside of the wiring cover.
WARNING
Before performing any electrical or wiring work, turn off the main power to the system.
USE THE RIGHT CABLE · Indoor Power/ Signal Cable: 14/4 stranded, unshielded · Outdoor Power Cable: Determined by amperage of system and the local codes in your area.

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Choose the Correct Size of Cable The size of the power supply cable, signal cable, fuse, and switch needed is determined by the maximum current of the unit. The maximum current is indicated on the nameplate located on the side panel of the unit. Refer to this nameplate to choose the right cable (stranded wire preferred), fuse, or switch.
Prepare the cable and wires for connection: · Using wire strippers, strip the rubber jacket from both ends of cable to reveal about 1.5″ (38-
40mm) of the wires inside. · Strip the insulation from the ends of the wires. · Using a wire crimper, crimp u-lugs on the ends of the wires.
WARNING
Pay attention to the live wire. While crimping wires, make sure you clearly distinguish the Live (“L”) Wire from other wires.
WARNING
All wiring work must be performed strictly in accordance with the wiring diagram located inside the terminal cover of the outdoor unit.
1. Remove the electrical wiring cover. 2. Remove the caps on the conduit panel. 3. Temporarily mount the conduit tubes (sold separately) onto the conduit panel. 4. Properly connect both the power supply and low voltage lines to the corresponding terminals
on the terminal block. 5. Ground the unit in accordance with local codes. 6. Be sure to cut the wire several inches longer than the required length for future maintenance. 7. Permanently secure the conduit tubes to the conduit panel. 8. Replace the wire cover on the side of the unit, and screw it in place.

Terminal block Over 1.57in.(40mm)

Connecting cable
G
Power supply cord
Conduit panel

Wire Cover
Select the appropriate holes to feed the wires through according to their diameter.

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REFRIGERANT PIPING CONNECTIONS

WARNING
When connecting refrigerant piping, do not let substances or moisture other than specified refrigerant enter the unit or pipes. The presence of foreign materials will lower the unit’s capacity and can cause abnormally high pressure in the refrigeration system. This can result in explosion and personal injury.

REFRIGERANT PIPE LENGTH The length of refrigerant piping will affect the performance and efficiency of the unit. Nominal efficiency is tested with a pipe length of 25 feet (7.6 meters). A minimum pipe run of 10 feet (3 meters) is required to minimize vibration and excessive noise.

Refer to the table on page 13 for specifications on the maximum length and drop height of refrigerant piping.

Note on refrigerant valve selection for indoor units
For DRA3H28M1A and DRA4H36M1A: If installing a 24,000 BTU indoor unit, only connect the unit with the valve ports labeled “A” on the outdoor unit.
For DRA5H48M1A and DRA5H55M1A: If installing one 24,000 BTU indoor unit, only connect the unit with the valve ports labeled “A” on the outdoor unit. If installing two 24,000 BTU indoor units, only connect the units with the valve ports labeled “A” and “B” on the outdoor unit.
Master Valves

Refrigerant connecting pipe sizes

for indoor units

Indoor Unit capacity (Btu/h)

Liquid

6K/9K/12K

1/4″

12K &18K

1/4″

24K

3/8″

Gas
3/8″ 1/2″ 5/8″

“A” and “B” valve ports.

Note on master valves
For DRA3H28M1A, DRA4H36M1A, DRA5H48M1A, and DRA5H55M1A:
Initial startup Once installation is complete, open all zone valves connected to an indoor unit. Connect the high side hose of the manifold gauge to the gas side master valve to gain access to all connected zones. Perform leak check procedures. Afterwards, remove the high side hose and attach the low side hose from the manifold to evacuate all connected zones.

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Once a vacuum is maintained, open both master valves to release the refrigerant charge into the entire system. After all the refrigerant is released, both master valves and all zone valves connected to an IDU must remain open for proper operation.
WARNING
After startup, the master valves and all zone valves connected to an IDU must remain open for proper operation.
Post start-up and servicing Once the system is operational, the master valves can be used to access the entire system for servicing and troubleshooting. If a repair requires the entire refrigerant charge to be removed, the master valves will allow the recovery of all system refrigerant. Simply connect the low side hose of the manifold gauge directly to the gas side master valve to recover refrigerant. Once repair is complete, use the high side hose of the manifold to leak check. Then, connect the low side hose again to pull a vacuum and charge the system. After service is complete, both master valves and all zone valves connected to an IDU must remain open for proper operation.
WARNING
After servicing, the master valves and all zone valves connected to an IDU must remain open for proper operation.

OIL TRAPS Oil traps are necessary for the continued performance of the system if the indoor and outdoor units are installed at significantly different heights.

Refer to the diagram below for proper installation of any required oil traps.

Gas Pipe Oil Trap

Indoor Unit

Gas Pipe Oil Trap

Outdoor Unit

Liquid Pipe

32′ 10″ (10m)

Indoor Unit

Liquid Pipe

19′ 9″ (6m)

Required distance between oil traps when the indoor unit is installed higher than the
outdoor unit.

Required distance between oil traps when the outdoor unit is installed higher than the
indoor unit.

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If the indoor unit is installed higher than the outdoor unit: Oil may flow back into the outdoor unit’s compressor and cause liquid compression. This will lead to deterioration of performance and shorten the life of the compressor. Oil traps in the rising gas piping can prevent this and should be installed every 32’10” (10m) of vertical rise.
If the outdoor unit is installed higher than the indoor unit: Proper oil return to the compressor must be maintained with the suction gas velocity. If velocities drop below 1500fpm, oil return will be decreased and lead to deterioration of performance and shorten the life of the compressor. Oil traps in the rising gas piping can prevent this and should be installed every 19’9″ (6m) of vertical rise.
REFRIGERANT PIPE CONNECTION INSTRUCTIONS
STEP 1: CUT PIPES When preparing refrigerant pipes, take extra care to cut and flare them properly. This will ensure efficient operation and minimize leaks and the need for future maintenance. 1. Measure the distance between the indoor and outdoor units. 2. Using a pipe cutter, cut the pipe length a little longer than the measured distance. 3. Make sure that the pipe is cut at a perfect 90o angle. 4. Do not damage, deform, or dent the pipe while cutting.

90°

Oblique Rough Warped

STEP 2: REMOVE BURRS Burrs can affect the airtight seal of the refrigerant piping connection and must be completely removed. 1. Hold the pipe at a downward angle to prevent burrs from falling into the pipe. 2. Using a reamer or deburring tool, remove all burrs from the cut section of the pipe.
Pipe Reamer
Point downward

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STEP 3: FLARE PIPE ENDS Proper flaring is essential to achieve an airtight seal. 1. After removing burrs from cut pipe, seal the ends with PVC tape to prevent foreign materials
from entering the pipe. 2. Sheath pipe with insulating material. 3. Place flare nuts on both ends of the pipe. Make sure they are facing in the right direction as
you cannot change their orientation after flaring.
Flare nut
Copper pipe
4. Remove PVC tape from ends of pipe when ready to perform flaring. 5. Clamp flare form on the end of pipe. The end of the pipe must extend beyond the edge of the
flare form in accordance with the pipe extension table.

PIPE EXTENSION BEYOND FLARE FORM

Outer Diameter of Pipe Inches (mm)
Ø 0.25″ (6.35mm) Ø 0.375″ (9.52mm)
Ø 0.5″ (12.7mm) Ø 0.63″ (16mm) Ø 0.75″ (19mm) Ø 0.875″ (22mm)

“A” Minimum Extension Inches (mm)
0.0275″ (0.7mm) 0.04″ (1.0mm) 0.04″ (1.0mm) 0.078″ (2.0mm) 0.078″ (2.0mm)

“A” Maximum Extension Inches (mm) 0.05″ (1.3mm)
0.063″ (1.6mm) 0.07″ (1.8mm) 0.086″ (2.2mm) 0.094″ (2.4mm)

Flare form

A Pipe

TIP: THICKNESS COMPARISON
· 0.0275″ = A Thumbnail · 0.04″ = A Dime · 0.078″ = A Nickle

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6. Place flaring tool onto the form. 7. Turn the handle of the flaring tool clockwise until the pipe is fully flared. 8. Remove the flaring tool and flare form, then inspect the pipe for cracks and even flaring.
STEP 4: CONNECT PIPES When connecting refrigerant pipes, be careful not to use excessive torque or to deform the piping in any way. You should first connect the low-pressure pipe, then the high-pressure pipe.
When bending connective refrigerant piping, the minimum bending radius is 4 inches (10cm). Do not leave coils in the refrigerant line sets. Remove excess line length to ensure proper system operation.
Radius ~4″ (10cm)
Radius 4″ (10cm)

WARNING
Do not leave coils in the refrigerant line sets. All excess line length must be removed to ensure proper system operation.
CONNECTING PIPING TO INDOOR UNIT 1. Align the center of the two pipes that you will connect.

Indoor unit tubing

Flare nut Pipe

2. Tighten the flare nut as tightly as possible by hand. 3. Using a spanner, grip the nut on the unit tubing. 4. While firmly gripping the nut on the unit tubing, use a torque wrench to tighten the flare nut
according to the torque values in the table on the next page. Loosen the flaring nut slightly, then tighten again.

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Outer Diameter of Pipe Inches (mm) Ø 0.25″ (6.35mm) Ø 0.375″ (9.52mm)
Ø 0.5″ (12.7mm) Ø 0.63″ (16mm) Ø 0.75″ (19mm)

Tightening Torque Nm (lb-ft)
18~20 (13.3~14.8) 32~39 (23.6~28.8) 49~59 (36.1~43.5)
57~71 (42~52.4) 67~101 (49.4~74.5)

Flare Dimension “B” Inches (mm)
0.33~0.34 (8.4~8.7) 0.52~0.53 (13.2~13.5) 0.64~0.65 (16.2~16.5) 0.76~0.78 (19.2~19.7) 0.91~0.93 (23.2~23.7)

Flare Shape
90 °± 4 45 °±2
B
R 0.4~0.8

WARNING
Do not use excessive torque. Excessive force can break the nut or damage the refrigerant piping. You must not exceed the torque requirements shown in the table above.
CONNECTING PIPING TO OUTDOOR UNIT
1. Remove the valve cover on the side of the outdoor unit. 2. Remove the protective caps from the ends of the valves. 3. Align flared pipe end with each valve and tighten the flare nut as tightly as possible by hand. 4. Using a spanner, grip the body of the valve. Do not grip the nut that seals the service valve. 5. While firmly gripping the body of the valve, use a torque wrench to tighten the flare nut
according to the correct torque values in the table above. 6. Loosen the flare nut slightly, then tighten again. 7. Repeat steps 3-6 for the remaining pipe.

Valve cover

SYSTEM EVACUATION
PREPARATIONS AND PRECAUTIONS
Air and foreign matter in the refrigerant system can cause abnormal rises in pressure, which can damage the air conditioner, reduce energy efficiency, and cause injury. Use a vacuum pump and manifold gauge to evacuate the refrigerant system, removing any non-condensible gas and moisture from the system. Evacuation should be performed upon initial installation and if unit is relocated.

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BEFORE PERFORMING EVACUATION
1. Check to make sure the refrigerant pipes connecting the indoor and outdoor units are connected properly and leak free.
2. Check to make sure all wiring is connected properly.
EVACUATION INSTRUCTIONS
1. Connect the high pressure side hose of the manifold gauge to the service port on the outdoor unit’s service valve.
2. Connect the hose from the auxiliary port of the manifold gauge to the nitrogen tank. 3. Open the high pressure side of the manifold gauge. Keep the low pressure side closed. 4. Open the nitrogen tank valve and pressurize the system to 600PSIG. 5. Close nitrogen tank valve and high pressure side of the manifold gauge. 6. Wait 15 minutes, then check that there has been no change in pressure. 7. If pressure loss is greater than 5PSIG, a leak may be present. Using the Soap and Bubble
Method, locate and fix all leaks. Start back at step 1 once all leaks have been fixed. 8. If there is no change in pressure, remove the auxiliary port of the manifold gauge from the
nitrogen tank. 9. Release the pressure in the system by opening up the high side of the manifold gauge. 10. Once pressure has been released, remove the high pressure side hose of the manifold gauge
from the service port and replace it with the low pressure side hose. 11. Connect the hose of the auxiliary port of the manifold gauge to the vacuum pump and a
MICRON GAUGE. 12. Turn on the vacuum pump to evacuate the system. 13. Run the vacuum until the micron gauge reads 250 microns. 14. Once the micron gauge reads 250 microns, close the low pressure side of the manifold gauge
and turn off the vacuum pump. System must hold below 500 microns for 15 minutes with the vacuum pump off. 15. If there is a change in pressure, a leak may be present. Using the Soap and Bubble Method, locate and fix all leaks. Start back at step 1 once all leaks have been fixed. 16. If there is no change in pressure, remove the manifold gauge auxiliary hose from the vacuum pump. 17. Remove the caps from the unit’s valve bodies, and open the system’s valves gently with a hex wrench by turning it counterclockwise until they reach their stopping point. Do not try to force the valves to open further.

Manifold Gauge
Low pressure gauge

Low pressure valve
Low pressure hose

High pressure valve Auxiliary hose
Vacuum pump

Flare nut
Cap Valve body
Valve stem

Low pressure valve

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NOTE ON ADDING ADDITIONAL REFRIGERANT
Each outdoor unit is factory charged with enough refrigerant to support up to 25′ (7.5m) per zone. This is based on a one way liquid line measurement from the outdoor unit to the indoor unit. For example, (N x 25′ = T) where “T” is the total length of line set that can be supported by the units factory charge and “N” is the number of zones available for use (eg. The DRA3 outdoor system has zone A, B, and C available or 3 zones [3 x 25′ = 75′] So the total length of line set that the DRA3 can support in one direction is 75′ distributed between the 3 (or less) zones available.) Systems with line sets that exceed this length will require additional refrigerant (see the following chart). The refrigerant should be charged from the service port on the outdoor unit’s low pressure valve. Additional refrigerant information can be found in the SUBMITTALS DOCUMENTS at WWW.SERVICE.DURASTAR.COM. Additional refrigerant can be calculated using the following formula:

Liquid Side Ø 1/4″ (6.35mm)
(Actual pipe length – Standard pipe length) x 0.16oz/ft or
(Actual pipe length – Standard pipe length) x 15g/m

Liquid Side Ø 3/8″ (9.52mm)
(Actual pipe length – Standard pipe length) x 0.32oz/ft or
(Actual pipe length – Standard pipe length) x 30g/m

WARNING
DO NOT mix refrigerant types.

FINAL CHECKS
BEFORE THE TEST RUN Only perform the test run after you have completed the following steps: · Electrical Safety Checks – Confirm that the unit’s electrical system is connected and operating
correctly. · Gas Leak Check – Check all flare nut connections and confirm the system is not leaking. · Confirm that the low and high pressure valves are fully open. · Check grounding work by measuring the grounding resistance by visual detection and with a
multimeter. The grounding resistance must be less than 0.1 .

ELECTRICAL SAFETY CHECKS After installation, confirm that all electrical wiring is installed in accordance with local and national regulations, and according to this installation manual.

DURING TEST RUN Using your multimeter, verify the voltage of the main power entering the system. If the main power voltage is greater than ±10% of the name plate voltage, turn off the unit and immediately call a licensed electrician to find and resolve the cause.

WARNING
RISK OF ELECTRICAL SHOCK – All wiring must comply with local and national electrical codes, and must be installed by a licensed electrician.

GAS LEAK CHECK There are two methods to check for gas leaks: 1. Soap and Water Method – Using a soft brush, apply a soapy water or liquid detergent to all
pipe connection points on the indoor and outdoor unit. The presence of bubbles indicates a leak.

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2. Leak Detector Method – If using a leak detector, refer to the device’s operation manual for proper usage instructions.

GAS LEAK CHECK POINTS

Check-point of indoor unit

Check-point of outdoor unit
D

A: Low pressure stop valve B: High pressure stop valve C & D: Indoor unit flare nuts

TIP
Use the Durastar Job Site Information Sheet at the end of this manual as a commissioning report to record your start up readings.

TEST RUN

TEST RUN INSTRUCTIONS You should perform the test run for at least 30 minutes. 1. Connect power to the unit. 2. Press the ON/OFF button on the remote controller or wired thermostat to turn the unit on. 3. Press the MODE button to scroll through the following functions, one at a time:
· COOL – Select lowest possible temperature. · HEAT – Select highest possible temperature. 4. Let each function run for 5 minutes and perform the following checks:

LIST OF CHECKS TO PERFORM

[ X ]

Unit is Properly Grounded

[ ]

All Electrical Terminals are Properly Covered

[ ]

Indoor and Outdoor Units are Solidly Installed

[ ]

All Pipe Connection Points Do Not Leak

[ ]

Water Drains Properly from Drain Hose

[ ]

All Piping is Properly Insulated

[ ]

Unit Performs COOL Function Properly

[ ]

Unit Performs HEAT Function Properly

[ ]

Indoor Unit Louvers Move Properly

[ ]

Indoor Unit Responds to Remote Controller or Thermostat

[ ]

5. Double check all pipe connections. During operation, the pressure of the refrigerant system will increase. This may reveal leaks that were not present during the initial leak check. Take time during the test run to recheck all pipe connection points. Refer to Gas Leak Check section for instructions.

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TROUBLESHOOTING
SAFETY PRECAUTIONS
If ANY of the following conditions occurs, turn off your unit immediately! · The power cord is damaged or abnormally warm · You smell a burning odor · The unit emits loud or abnormal sounds · A power fuse blows or the circuit breaker frequently trips · Water or other objects fall into or out of the unit 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.

ISSUE

POSSIBLE CAUSES

Unit does not turn on The Unit has a 3-minute protection feature that prevents the unit from

when pressing ON/OFF overloading. The unit cannot be restarted within three minutes of being

button

turned off.

The unit changes from The unit may change its setting to prevent frost from forming on the

COOL/HEAT mode to unit. Once the temperature increases, the unit will start operating in

FAN mode

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 In humid regions, a large temperature difference between the room’s

white mist

air and the conditioned air can cause white mist.

Both the indoor and outdoor units emit white mist

When the unit restarts in HEAT mode after defrosting, white mist may be emitted due to moisture generated during the defrosting process.

The indoor unit makes A rushing air sound may occur when the louver resets its position.

noises

A squeaking sound may occur after running the unit in HEAT mode due

to expansion and contraction of the unit’s plastic parts.

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ISSUE

POSSIBLE CAUSES

Both the indoor unit and Low hissing sound during operation: This is normal and is caused by outdoor unit make noises 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 The unit will make different sounds based on its current operating

noises

mode.

Dust is emitted from either the indoor or outdoor unit

The unit may accumulate dust during extended periods of nonuse, 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 odor

The unit may absorb odors from the environment (such as furniture, cooking, cigarettes, 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 operate
Operation is erratic, unpredictable, or unit is unresponsive

During operation, the fan speed is controlled to optimize product operation.
Interference from cell phone towers and remote boosters may cause the unit to malfunction. In this case, try the following: · Disconnect the power, then reconnect. · Press ON/OFF button on remote control to restart operation.

NOTE
If problem persists, contact a local dealer or your nearest customer service center. Provide them with a detailed description of the unit malfunction as well as your model number.

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

PROBLEM Poor Cooling Performance
Poor Heating Performance
The unit starts and stops frequently

POSSIBLE CAUSES

SOLUTION

Temperature setting may be higher Lower the temperature setting than ambient room temperature

The heat exchanger on the indoor Clean the affected heat exchanger or outdoor unit is dirty

The air filter is dirty

Remove the filter and clean it according to instructions

The air inlet or outlet of either unit is Turn the unit off, remove the obstruction

blocked

and turn it back on

Doors and windows are open

Make sure that all doors and windows are closed while operating the unit

Excessive heat is generated by sunlight

Close windows and curtains during periods of high heat or bright sunshine

Low refrigerant due to leak or long- Check for leaks, re-seal if necessary and

term use

top off refrigerant

Excessive heat is generated by sunlight

Block sunlight in installation area

Too many sources of heat in the room (people, computers, electronics, etc.)

Reduce amount of heat sources

The outdoor temperature is extremely low

This model is designed to work down to -13°F, however, heating performance is impacted at temperatures below freezing

Cold air is entering through doors Make sure that all doors and windows are

and windows

closed during use

Low refrigerant due to leak or long-term use

Check for leaks, re-seal if necessary, and top off refrigerant

There’s too much or too little refrigerant in the system

Check for leaks and recharge the system with refrigerant

Incompressible gas or moisture has Evacuate and recharge the system with

entered the system

refrigerant

The compressor is broken

Replace the compressor

The voltage is too high or too low Install a manostat to regulate the voltage

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PROBLEM POSSIBLE CAUSES

SOLUTION

The unit is not Power failure

working

The power is turned off

Wait for the power to be restored Turn on the power

The fuse is burned out

Replace the fuse

Remote control batteries are dead Replace batteries

The Unit’s 3-minute protection has Wait three minutes after restarting the

been activated

unit

Timer is activated

Turn timer off

Indicator lamps continue flashing or error code appears

The unit may stop operation or continue to run safely. If the indicator lamps continue to flash or error codes appear, wait for about 10 minutes. The problem may resolve itself. If not, disconnect the power, then connect it again. Turn the unit on. If the problem persists, disconnect the power and contact your nearest customer service center.

NOTE
If your problem persists after performing the checks and diagnostics above, turn off your unit immediately and contact an authorized service center.

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WIRING DIAGRAMS
DRA2H18M1A

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DRA3H28M1A

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DRA4H36M1A

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DRA5H48M1A/DRA5H55M1A

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ERROR AND OPERATING CODES

Display Malfunction & protection indication

EL01

Communication malfunction between indoor and outdoor units

FL14

Capability dismatch between indoor unit and outdoor unit

EC50

Outdoor temp. sensor error

EC51

Outdoor EEPROM error

EC52

Condenser coil temperature sensor (T3) malfunction

EC53

Outdoor ambient temperature sensor (T4 ) malfunction

EC54

Compressor discharge temperature sensor TP is in open circuit or has short circuited

EC55

Outdoor IPM module temperature sensor malfunction

EC56

Outdoor T2B sensor error

EC57

Refrigerant pipe temperature sensor error

EC07

Outdoor DC fan motor malfunction/fan speed out of control

EC71

Over current failure of outdoor DC fan motor

EC72

Lack phase failure of outdoor DC fan motor

PC00

Inverter module (IPM) protection

PC02

Top temperature protection of compressor

PC06

Discharge temperature protection of compressor

PC08

Outdoor overcurrent protection

PC0A High temperature protection of condenser

PC0F

PFC module protection

PC0L

Low temperature protection of outdoor unit

PC10

Outdoor unit low AC voltage protection

PC11

Outdoor unit main control board DC bus high voltage protection

PC12

Outdoor unit main control board DC bus high voltage protection /341 MCE error

PC30

System high pressure protection

PC31

System low pressure protection

PC40

Communication error between outdoor main chip and compressor driven chip

PC42

Compressor start failure of outdoor unit

PC43

Outdoor compressor lack phase protection

PC44

Outdoor unit zero speed protection

PC45

Outdoor unit IR chip drive failure

PC46

Compressor speed has been out of control

PC49

Compressor overcurrent failure

PCA1 Condensation protection of refrigerant pipe

PH90 High temperature protection of Evaporator

PH91 Low temperature protection of Evaporator

LC06

High temperature protection of Inverter module (IPM)

Note: DF (defrost) and FC (forced cooling) are normal operating codes, not malfunctions. [ ] Applicable to some units only.

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JOB SITE INFORMATION SHEET
Site Information Job Name: _____________________________________________ Installation Date: _________________ Address: ______________________________ City: _____________________ State: ______ Zip: ________ Phone: ________________________ Email: ____________________________________________________
Contractor Information Contractor Name: _____________________________ Technician Name: __________________________ Address: ______________________________ City: _____________________ State: ______ Zip: ________ Phone: ________________________ Email: ____________________________________________________
Outdoor Unit Information Model #: _________________________________ Serial #: _______________________________________ Unit Location: ____________________________________________________________________________ _________________________________________________________________________________________
Outdoor Electrical Readings Line Power Wire Color: L1 __________________ L2 __________________ G _____________________ Line Voltage (Power Off): L1 to L2 _____________ L1 to G _____________ L2 to G ________________ Line Voltage (Power On): L1 to L2 _____________ L1 to G _____________ L2 to G ________________
Outdoor Thermal Readings Discharge: _________°F Ambient: _________°F

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Indoor System Information

Unit Information Model #: _________________________________ Serial #: _______________________________

Type: ____________________ Location: _____________________________________________

Refrigerant Line Size 1/4″ 3/8″ 1/2″ 5/8″ Line Set Length: _______________ (Circle Liquid and Gas Line):

Electrical Readings

Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________

Voltage Readings: 1-2 ___________ AC

2-3 ___________DC

Thermal Readings

Return Air: _________°F Supply Air: _________°F Room Air: _________°F

Gas Line Saturation: _________°F

Liquid Line Saturation: _________°F

B Unit Information
DRA2 Model #: _________________________________ Serial #: _______________________________ Type: ____________________ Location: _____________________________________________

Refrigerant Line Size 1/4″ 3/8″ 1/2″ 5/8″ Line Set Length: _______________ (Circle Liquid and Gas Line):

Electrical Readings

Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________

Voltage Readings: 1-2 ___________ AC

2-3 ___________DC

Thermal Readings

Return Air: _________°F Supply Air: _________°F Room Air: _________°F

Gas Line Saturation: _________°F

Liquid Line Saturation: _________°F

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C Unit Information
DRA3 Model #: _________________________________ Serial #: _______________________________

Type: ____________________ Location: _____________________________________________

Refrigerant Line Size 1/4″ 3/8″ 1/2″ 5/8″ Line Set Length: _______________ (Circle Liquid and Gas Line):

Electrical Readings

Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________

Voltage Readings: 1-2 ___________ AC

2-3 ___________DC

Thermal Readings

Return Air: _________°F Supply Air: _________°F Room Air: _________°F

Gas Line Saturation: _________°F

Liquid Line Saturation: _________°F

D Unit Information
DRA4 Model #: _________________________________ Serial #: _______________________________

Type: ____________________ Location: _____________________________________________

Refrigerant Line Size 1/4″ 3/8″ 1/2″ 5/8″ Line Set Length: _______________ (Circle Liquid and Gas Line):

Electrical Readings

Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________

Voltage Readings: 1-2 ___________ AC

2-3 ___________DC

Thermal Readings

Return Air: _________°F Supply Air: _________°F Room Air: _________°F

Gas Line Saturation: _________°F

Liquid Line Saturation: _________°F

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E Unit Information
DRA5 Model #: _________________________________ Serial #: _______________________________
Type: ____________________ Location: _____________________________________________

Refrigerant Line Size 1/4″ 3/8″ 1/2″ 5/8″ Line Set Length: _______________ (Circle Liquid and Gas Line):

Electrical Readings

Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________

Voltage Readings: 1-2 ___________ AC

2-3 ___________DC

Thermal Readings

Return Air: _________°F

Supply Air: _________°F

Room Air: _________°F

Gas Line Saturation: _________°F Liquid Line Saturation: _________°F

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NOTES: