ComfortStar CHT-23 Series Service Manual
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ComfortStar CHT-23 Series Service Manual

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SPLIT AIR CONDITIONERS
Service Manual
INVERTER CHT-23 SERIES
Models
CHT09CA-23(I)
CHT12CA-23(I)
CHT09CD-23 (I)
CHT12CD-23 (I)
CHT18CD-23 (I)
CHT24CD-23 (I)
IMPORTANT NOTE:
Read this manual carefully before operating your
new air conditioning unit. Make sue to save this
manual for future reference.
Please check the applicable models, technical data,
F-GAS(if any) and manufacturer information from the "Owner's
Manual - Product Fiche " in the packaging of the outdoor unit.
CHT09CA-23(O)
CHT12CA-23(O)
CHT09CD-23 (O)
CHT12CD-23 (O)
CHT18CD-23 (O)
CHT24CD-23 (O)
1W

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Summary of Contents for ComfortStar CHT-23 Series

  • Page 1 SPLIT AIR CONDITIONERS Service Manual INVERTER CHT-23 SERIES Models CHT09CA-23(I) CHT09CA-23(O) CHT12CA-23(I) CHT12CA-23(O) CHT09CD-23 (I) CHT09CD-23 (O) CHT12CD-23 (I) CHT12CD-23 (O) CHT18CD-23 (I) CHT18CD-23 (O) CHT24CD-23 (I) CHT24CD-23 (O) IMPORTANT NOTE: Read this manual carefully before operating your new air conditioning unit. Make sue to save this manual for future reference.

  • Page 2: Table Of Contents

    Air Conditioner Service Manual CONTENTS Part Ⅰ Technical Information ....................4 1. Important Notice ........................4 2. Refrigeration cycle diagram ......................5 3. Electric Diagram .......................... 6 3.1 Wiring diagram ........................6 3.2 PCB LAOUT ........................... 10 4. Controller Introduction ...................... 15 4.1 Electronic controller ......................
  • Page 3 Air Conditioner Service Manual...

  • Page 4: Part Ⅰ Technical Information

    Air Conditioner Service Manual Part Ⅰ Technical Information 1. Important Notice This service manual is intended for use by individuals possessing adequate backgrounds of electrical, electronic and mechanical experience. Any attempt to repair the appliance may result in personal injury and property damage.

  • Page 5: Refrigeration Cycle Diagram

    Air Conditioner Service Manual 2. Refrigeration cycle diagram Heat pump Check valve Liquid side 2-way valve Capillary Heat exchange Heat exchange (Condenser) (Evaporator) Gas side 3-way valve 4-way valve Muffler Muffler Heating Cooling Compressor Liquid side 2-way valve Electronic expansion valve Heat exchange Heat exchange (Condenser)

  • Page 6: Electric Diagram

    Air Conditioner Service Manual 3. Electric Diagram 3.1 Wiring diagram MODEL: CHT09CA-23，CHT12CA-23 INDOOR UNIT： OUTDOOR UNIT:...
  • Page 7 Air Conditioner Service Manual MODEL: CHT09CD-23 INDOOR UNIT： OUTDOOR UNIT：...
  • Page 8 Air Conditioner Service Manual MODEL: CHT12CD-23, CHT18CD-23 INDOOR UNIT： OUTDOOR UNIT：...
  • Page 9 Air Conditioner Service Manual MODEL: CHT24CD-23 INDOOR UNIT： OUTDOOR UNIT：...

  • Page 10: Pcb Laout

    Air Conditioner Service Manual 3.2 PCB LAOUT Note: the PCB type is printed on the PCB, please inquire the PCB layout via the PCB type information. Indoor PCB Model 9K, 12K, 18K, 24K _ AC motor type PCB type: A010283 PCB type: A010268 Transformer IN ODU AC power output...
  • Page 11 Air Conditioner Service Manual PCB type: A010412 Model 9K, 12K, 18K, 24K _ DC motor PCB type: A010270 10 11 ODU AC power output Fuse ODU AC power input DC fan motor connection IDU/ODU wiring connection --N connector Power supply --N connector Anion connector IDU/ODU communication wiring Left-Right swing connector...
  • Page 12 Air Conditioner Service Manual A010403 PCB type:...
  • Page 13 Air Conditioner Service Manual outdoor unit 9K, 12K A010332 PCB type: ODU PCB Mainly relay Fuse L, N & 1 4-way valve Heater DC fan motor connector Electronic expansion valve Discharge sensor connector/ OAT/OPT connector LED5 PCB type: A010386...
  • Page 14 Air Conditioner Service Manual A010331 PCB type: LED5 Discharge sensor connector/ OAT/OPT connector Electronic expansion valve AC/DC fan motor connector 4-way valve Heater Communication wiring L line Fuse N line ODU PCB Mainly relay LED1-LED4 A010350 PCB type: LED5 OAT/OPT connector Discharge sensor connector Electronic expansion...

  • Page 15: Controller Introduction

    Air Conditioner Service Manual 4. Controller Introduction RT-------Room Temperature. IPT------Indoor Pipe (Coil) Temperature. ST------Indoor Setting Temperature. OPT---Outdoor Pipe Temperature. OAT---Outdoor Ambient Temperature. ODT---Outdoor Discharge Temperature. CRT---Compensated Room Temperature. IDU--- Indoor unit ODU---Outdoor unit. Note: When AC finishing installation, because of the air ventilation and the distance of temperature test sensor to different location of the house, the temperature for IDU PCB control need compensation.
  • Page 16 Air Conditioner Service Manual c. to the set temperature. After compressor ceased, the fan motor stops working according to the temperature of OPT and OAT, the max delay for the motor should be less than 160s. 2). When switch on unit on cooling mode, ODU fan motor will delay 5s after compressor starts up. 4.
  • Page 17 Air Conditioner Service Manual The compressor stops operation. 3). The compressor frequency control: Based on relation of RT & ST, and the changing speed of RT. 4). The compressor will also stop working while unit: a. switched off. b. under protection. c.
  • Page 18 Air Conditioner Service Manual a. t1≥t2, or b. t3≤t1＜t2. and also the temperature (related to OAT & OPT) tested 3 min continuously meets for defrosting. 1) Defrosting start up: Compressor stops working, and re-starts to working after 50s delay; 2) Conditions for quitting defrosting a.
  • Page 19 Air Conditioner Service Manual 4.1.5 Fan mode 1. The temperature setting: 16~31℃, Fan speed and vane position: as preset. The function for remote controller 58E only. 2. For above function, when unit preset to be auto fan mode, the fan motor will change its operation speed based on the temperature difference of ambient and preset temperature.
  • Page 20 Air Conditioner Service Manual Note: The function setting: Within 3 min while power on unit, set the unit on cooling mode, set temperature 30℃, and mid fan speed, press the ECO button 10 times within 8s, the AUTO-RESTART will be activated. 4.1.10 Protection 4.1.10.1 Overload protection 1.
  • Page 21 Air Conditioner Service Manual Note: For different models, I and I have different programmed value. 4.1.10.4 IPM overheating protection 1. When IPM temperature T ≥87℃, the compressor will be frequency limited / reduced for IPM over temperature protection. 2. When T ≥95℃, the AC unit stops working for AC system protection.

  • Page 22: Wifi Operation Maual

    Air Conditioner Service Manual 4.2 WIFI OPERATION MAUAL 4.2.1 The WIFI control logic Comfortstar CLOUD Internet controller Home wireless router Comfortstar IDU WIFI AC APP module IDU PCB Remote controller 4.2.2 Download and installation Customer can scan the QR in the user manual or from appliance APP store to download the APP and install it in the cell phone, while installation achieved, there would be an icon as picture created on the desktop.

  • Page 23: Part Ⅱ Installation And Maintenance

    Air Conditioner Service Manual PART Ⅱ Installation and Maintenance 1. Notes for installation and maintenance Safety Precautions Important! Please read the safety of precautions carefully before installation and maintenance. The following contents are very important for installation and maintenance. Please follow the instructions bellow. ●...
  • Page 24 Air Conditioner Service Manual 3) When installing the indoor unit and outdoor unit, a sufficient fixing bolt must be installed, make sure the installation supporter is firm. 4) Ware safety belt if the height of working is above 2m. 5) Use equipped components or appointed components during installation. 6) Make sure no foreign objects are left in the unit after finishing installation.
  • Page 25 Air Conditioner Service Manual Compared with ordinary refrigerants, Refrigerants R32 & R290 are environmentally friendly and do not destroy the ozone sphere and that their values of greenhouse effect are also very low. 2) R32/R290 air conditioner installation area requirement m1=(4m )×LFL, m2=(26m ) ×LFL, m3=(130m...
  • Page 26 Air Conditioner Service Manual conditioner. When filling the combustible refrigerant, any of your rude operations may cause serious injury or injuries  to human body or bodies and object or objects. A leak test must be done after the installation is completed. ...
  • Page 27 Air Conditioner Service Manual Special tools: Tool Name Requirement(s) for Use It should be an explosion-proof vacuum pump; can ensure certain precision and its Mini Vacuum Pump vacuum degree should be lower than 10Pa. It should be a special explosion-proof filling device; have certain precision and its filling deviation should be less than 5g.
  • Page 28 Air Conditioner Service Manual of the refrigerant leak detector should not exceed 25% of the lower explosion limit (LEL), the refrigerant leak detector must be working during maintenance. 2) Inspection of air conditioner  It is necessary to ensure that the air conditioner is in reliable ground connection before maintenance. ...
  • Page 29 Air Conditioner Service Manual  It is necessary to provide firefighting devices such as dry powder or carbon dioxide fire extinguisher appropriate for extinguishing the electrical fire and keep such firefighting devices in a usable condition.  Temporary wires and sockets are prohibited on the maintenance location. 6).
  • Page 30 Air Conditioner Service Manual precautionary measures in work. For example, it is prohibited to enter the location with any kindling material and it is prohibited to wear clothing or shoes which easily produce static. Handling suggestions when a large amount of combustible refrigerant leaks: It is necessary to immediately operate the ventilating equipment while cutting off other power supply and ...

  • Page 31: Installation

    Air Conditioner Service Manual 2 Installation 2.1 Installation Dimension Diagram S p a c e t o t h e w a l l A t l e a s t 1 5 c m A t l e a s t 1 5 c m S p a c e t o t h e w a l l S p a c e t o t h e o b s t r u c t i o n S p a c e t o t h e f l o o r...

  • Page 32: Accessory

    Air Conditioner Service Manual 2.2 Accessory Remote controller Remote Batteries Vinyl tape controller supporter Drain hose Hole cover Screw Insulation material 2.3 Tools Picture Picture Picture Tool name Tool name Tool name Standard Pipe Vacuum Pump Wrench Cutter Screw Adjustable/ drivers Crescent (Phillips &...

  • Page 33: Position

    Air Conditioner Service Manual 1） Must follow the electric safety regulations when 2.4 Position installing the unit. Indoor unit 2） According to the local safety regulations, use  Install the indoor unit level on a strong wall that is qualified power supply circuit and air switch. not subject to vibrations 3）...
  • Page 34 Air Conditioner Service Manual 9K(770T) The hole must slope downwards towards the exterior. Note: Keep the drain pipe down towards the direction of the wall hole, otherwise leakage may occur. 4.2.1 Electrical connections---Indoor unit 1).Lift the front panel. 2).Take off the cover as indicated in the picture (by removing a screw or by breaking the hooks).
  • Page 35 Air Conditioner Service Manual Wrap the insulation material around the connecting portion.  Overlap the connection pipe insulation material and the indoor unit pipe insulation material. Bind them together with vinyl tape so that there is no gap. Shape the connection pipe 4.2.2 Connecting the pipes.

  • Page 36: Odu Installation

    Air Conditioner Service Manual 1) Fasten the drain port in the 25mm hole placed in the part of the unit as shown in the picture. 2) Connect the drain port and the drain pipe. Pay attention that water is drained in a suitable place.

  • Page 37: Vacuum And Gas Leakage Test

    Air Conditioner Service Manual 2.9 Final test 2.8 Vacuum and gas leakage test 1. Use vacuum Pump 1 Preparation of test operation. 1) Air and humidity left inside the refrigerant circuit can  The client approves the air conditioner cause compressor malfunction. After having connected installation.

  • Page 38: Maintenance

    Air Conditioner Service Manual 3. Maintenance 3.1 Failure code Code Reason Remark IDU & ODU Communication failure The IDU & ODU wiring connection correct? IDU Room Temperature sensor failure.（IDU IDU sensor and PCB. RT failure） IDU Coil temperature sensor failure.（IDU IPT IDU sensor and PCB.
  • Page 39 Air Conditioner Service Manual Cooling system gas flow abnormal Please check the troubleshooting for detail. PROTECTION.. PFC PROTECTION Please check the troubleshooting for detail. The Compressor lack of phase / Anti-phase Please check the troubleshooting for detail. PROTECTION. IPM Module temperature PROTECTION Please check the troubleshooting for detail.

  • Page 40: Trouble Shooting

    Air Conditioner Service Manual 3.2 Trouble shooting 3.2.1 E0 ---IDU & ODU communication failure Start Display E0 IDU wiring Check and re- E0 disappear? connection correct? connect Check communication Replace/ re- E0 disappear? wiring and the connection, connect in good condition? ODU wiring Check and re- E0 disappear?
  • Page 41 Air Conditioner Service Manual 3.2.2 E1, E2 ---IDU Room temperature sensor and/or coil temperature sensor failure. Start Display E1or E2 Is the sensor well Re-connect connected to PCB E1/E2 disappear? Multi-meter check the Replace the sensor sensor, is it open or short circuit? The malfunction eliminated?
  • Page 42 Air Conditioner Service Manual 3.2.3 E4 --- AC Cooling system abnormal (Gas not enough) Start Display E4 Check the pressure AC pressure correct? Check the sensor short or (cooling:0.8-1.3Mpa,/ open? heating 2.0-3.6Mpa) Replace the sensor Check the valves open or Replace the main PCB Open the valves Lower than 0.8 Mpa in...
  • Page 43 Air Conditioner Service Manual 3.2.4 E6----IDU ventilation failure (PG and DC fan motor only) Start Display E6 Turn the fan blades by hand while power-off condition Adjust the motor and blade Can the fan blades run assembly so that rotor can smoothly? run smoothly.
  • Page 44 Air Conditioner Service Manual 3.2.5 E3, E7 or E8----ODU Coil temperature sensor, Ambient temperature sensor or Discharge temperature sensor failure. When any of the sensor resistance open or short circuit , unit will display failure code as E3/E7 or E8, IDU and ODU turns off.
  • Page 45 Air Conditioner Service Manual 3.2.6 E9---ODU IPM /Compressor drive fault If unit have 6 times stopping works for IPM protection (P0) continuously, it will display E9 error, and unit can’t be recovered to operation, except press ON/OFF button. Display E9 Display F9 or FA first Replace ODU PCB then E9...
  • Page 46 Air Conditioner Service Manual 3.2.7 EF---ODU DC fan motor failure Shut off Check the fan blade by Re install the DC motor hand, can it rotate freely Works normal? Fan motor well Re-connect connect to PCB Works normal? 1. For built-in control (5pins) motor: check the V =310V? =15V?
  • Page 47 Air Conditioner Service Manual 3.2.8 EU---ODU voltage test sensor failure After power relay works, when tested voltage effective value less than 50V for 3s continuously, unit will display EU. Start Display EU Test voltage btw ODU Check while voltage terminal L/N, more than become normal 50V~? Unit works?
  • Page 48 Air Conditioner Service Manual 3.2.9 P0---IPM protection When overheat or overcurrent for IPM, AC unit will display P0protection. Display P0 Restart unit. It works normal? Wiring connection Re-connect U/V/W correct? P0 disappear? ODU fan motor no Replace ODU Can compressor works or too slowly? fan motor start up?
  • Page 49 Air Conditioner Service Manual 3.2.10 P1--- Over / under voltage protection 1. Test voltage between L &N, When the power supply V＞AC260V or V＜AC150V, AC will display P1 protection, unit will recover back to previous status while V＞AC155V. 2. Test voltage on the big size electrolytic capacitor of ODU PCB, When DC busbar voltage V＞DC420V or V ＜DC150V, unit will recover back to previous status while DC190V＜V＜DC410V Display P1 Wait until the AC...
  • Page 50 Air Conditioner Service Manual 3.2.11 P2---Over Current protection When the AC unit running current more than I , it will stop and display P2 protection. Note: for different AC model, I has difference valve. Display P2 ODU fan motor Replace fan motor works? P2 disappear? IDU filter or ODU...
  • Page 51 Air Conditioner Service Manual 3.2.12 P4 ---ODU Discharge temperature overheating protection Display P4 ODU temperature Normal protection higher than 60℃? ODU location Adjust ODU Enough space for Unit operate? installation acceptable? ventilation? Condenser too Clean IDU filter or P4 disappear? dirty? or filter ODU condenser.
  • Page 52 Air Conditioner Service Manual 3.2.13 P5---Sub-cooling protection on Cooling/Dry mode On Cooling or Dry mode, when IDU evaporator coil temperature IPT＜1℃ continuously for 3 min after compressor start up for 6 min, CPU will switch off outdoor unit and show P5 failure code. Display P5 Switch on unit after minutes...
  • Page 53 Air Conditioner Service Manual 3.2.14 P6---Overheating protection on Cooling mode On Cooling or Dry mode, when ODU condenser coil temperature OPT≥62℃ , MCU will switch off outdoor unit and show P6 failure code. Display ODU fan motor Fan motor Replace fan motor works normal? broken? P6 disappear?
  • Page 54 Air Conditioner Service Manual 3.2.15 P7---Overheating protection on Cooling mode ℃ On heating mode, when IDU evaporator coil temperature IPT≥62 , ODU PCB will switch off outdoor unit and show P7 failure code. Display P7 ODU fan motor Fan motor Replace fan motor works normal? broken?
  • Page 55 Air Conditioner Service Manual 3.2.16 P8---Outdoor Overtemperature/Under-temperature protection When environment temperature as below condition, the compressor will stop working, after 200s delay, the IDU will show P8 failure code. (1). On Cooling or Dry mode: ODU ambient temperature: OAT＜-20℃ or OAT＞63℃; (2).
  • Page 56 Air Conditioner Service Manual 3.2.17 P9---The compressor driving protection (the compressor load abnormal) When compressor start up or in the process of operation, if: (1). MCU can’t test the feedback signal from compressor, or (2). Tested a abnormal signal from compressor, or (3).
  • Page 57 Air Conditioner Service Manual 3.2.18 F4---Cooling system Gas flow abnormal protection When compressor startup, unit will check the variation of IDU coil temperature. If there is mistake installer forgetting to open the 2-way or 3-way valve on ODU, the gas can’t flow in the cooling system, it will show F4 protection. Start Display F4 Check the 2-way...
  • Page 58 Air Conditioner Service Manual 3.2.19 F5---PFC Protection PFC Overcurrent protection F5 Code Check the power supply, Display F5 by is it abnormal? (this is random? normal protection) Display F5 frequently Switch off the unit for 3 Still F5? minutes and re-switch on Still F5? Replace ODU PCB...
  • Page 59 Air Conditioner Service Manual 3.2.20 F6 The Compressor Lack of phase / Anti-phase protection. If ODU PCB can’t test one, or even three phase of compressor current, it will show F6 protection. Display F6 Check compressor Re-connect wiring connector, is it well connected? Problem solved? The Compressor...
  • Page 60 Air Conditioner Service Manual 3.2.21 F7---Module temperature protection. IPM overtemperature protection, when IPM temperature more than 95℃, it will show F7. Display F7 Clean or adjust the gap IPM well contact Any dust or gap btw btw IPM and heat sink to heat sink? IPM &...
  • Page 61 Air Conditioner Service Manual 3.2.22 F8---4-Way Value Reversing abnormal On heating mode, if IDU Coil temperature tested lower than Room temperature 5℃ or even more after compressor works for 8min, unit will show F8 code. Display F8 the 4-way valve Re-connect wiring connection correct?
  • Page 62 Air Conditioner Service Manual 3.2.23 Fy--- Gas leakage protection After compressor works in high frequency for 9 min, if the temperature on IDU evaporator & ODU condenser has only a little variation comparing previous, but, the compressor discharge temperature on high level, then the unit will show Fy failure code.

  • Page 63: Disassembly Idu & Odu

    Air Conditioner Service Manual 4. Disassembly IDU & ODU 4.1. IDU Disassembly Steps Reference photo 1. Before disassembly The original status. 2. Disassemble Front Panel, Display Board. Display A. Open front panel. B. Remove one screw and take the display box out from panel. C.
  • Page 64 Air Conditioner Service Manual Unfix one screw on the cover of electric box, and remove 5. Disassemble the Bottom Plate. Force apart the bottom plate left and right sides with hands towards as RED arrow, you can easily disassemble the bottom plate.
  • Page 65 Air Conditioner Service Manual Buckles * 2 There are 2 buckles on filter assembly, bring it upwards slightly by hands to take it out from unit. 8. Disassemble the Mid Frame Buckles A. unfix 2 screws between mid frame and base plate. B.
  • Page 66 Air Conditioner Service Manual A. Unfix screw btw mounting plate and base plate. B. Press buckles shown as RED arrow, you can loose the mounting plate from Clip unit base. Clip C. Press pipes cover on locker points and force upwards by hand to take the cover out from base.
  • Page 67 Air Conditioner Service Manual After remove the motor cover, you can take both the cross fan and motor out in the same time. 14. Disassemble Cross Fan and Motor. Unfix the lock screw btw cross motor, separate the both parts. 4.2 ODU Assembly Step Reference picture...
  • Page 68 Air Conditioner Service Manual Unfix screws btw the top cover with front panel, left and right plate, then you can take the top cover out. step2：Disassemble the Fan Guard and Front Panel Unfix screws on front panel with fan guard. ODU middle separate plate and base plate, uplift...
  • Page 69 Air Conditioner Service Manual Unfix screws btw Right Plate and the Electric Box assembly, Valve Plate , Base Plate, then you can take the Right plate out. Unfix screws btw Left Plate, Base plate and Condenser plate, you can take the left plate out.
  • Page 70 Air Conditioner Service Manual Unfix screw btw Electric Box and motor supporter etc. loosen the wiring clamp, then you can take the control box out. step6：take out the noise cotton Shown as picture to take the cotton out step7：Disassemble the separate plate Unfix the screw btw separate plate and unit, and take it out...
  • Page 71 Air Conditioner Service Manual Unfix screw btw Valve plate and base, you can take the 2-way and 3-way valve out by welding. Note: 1). The welding can only place while no gas in the unit. 2). Pay attention to the fire to prevent any injury.
  • Page 72 Air Conditioner Service Manual Unfix screws btw fan motor with supporter, and supporter with base plate. Note: Pay attention to the motor wiring, it can’t be taken out by force.

  • Page 73: Appendix

    Air Conditioner Service Manual APPENDIX 1．Appendix The comparison table of Celsius-Fahrenheit temperature Fahrenheit Fahrenheit Fahrenheit Celsius Celsius Celsius diplay Fahrenheit diplay Fahrenheit diplay Fahrenheit temperature ℃ temperature ℃ temperature ℃ (℉) (℉) (℉) (℉) (℉) (℉) 60.8 69/70 69.8 78/79 78.8 62/63 62.6...

  • Page 74: Appendix Pipes Flaring

    Air Conditioner Service Manual 3. Appendix Pipes Flaring Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the following procedure. A. Cut the pipes and the cable. 1) Use the piping kit accessory or the pipes purchased locally. 2) Measure the distance between the indoor and the outdoor unit.

  • Page 75: 4．Appendix Thermistor Temperature Characteristics

    Air Conditioner Service Manual 4．Appendix THERMISTOR TEMPERATURE CHARACTERISTICS 1). Indoor unit and outdoor exchange temperature and outside air temperature sensor temperature characteristics TEMP. Resistance Voltage of TEMP. Resistance Voltage of TEMP. Resistance Voltage of ℃ ℃ ℃ (k Ohm) resistance (k Ohm) resistance (k Ohm)
  • Page 76 Air Conditioner Service Manual TH1: indoor room temperature sensor and outside air temperature sensor TH2: indoor exchange temperature sensor and outside exchange temperature sensor Before measuring resistance, disconnect connectors as shown above. Outdoor unit sensor temperature characteristics TEMP. R min R(t) R max TEMP.
  • Page 77 Air Conditioner Service Manual 63.74 70.48 77.87 6.309 6.655 7.013 1.073 1.12 1.168 60.69 67.05 6.08 6.409 6.748 1.042 1.089 1.136 57.81 63.8 70.34 5.861 6.173 6.495 1.013 1.058 1.104 55.08 60.72 66.88 5.651 5.947 6.253 0.9833 1.028 1.074 52.49 57.81 63.61 5.449...

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