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Everwell CIP12CA-EL Service Manual

Inverter air conditioner
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Air Conditioner Service Manual
Inverter air conditioner
Service Manual
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CIP12CA-EL
CIP12CD-EL
CIP18CD-EL
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Summary of Contents for Everwell CIP12CA-EL

  • Page 1 Air Conditioner Service Manual Inverter air conditioner Service Manual Models CIP12CA-EL CIP12CD-EL CIP18CD-EL CIP24CD-EL CIP36CD-EL...

  • Page 2: Table Of Contents

    Air Conditioner Service Manual CONTENTS Part Ⅰ Technical Information ..........................3 1. Important Notice ............................3 2. Refrigeration cycle diagram ..........................4 3. Electric Diagram ............................5 3.1 Wiring diagram ............................5 3.2 PCB LAOUT ..............................5 4. Electronic Controller Introduction ........................9 4.1 Electronic Controller ..........................

  • Page 3: 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 4: Refrigeration Cycle Diagram

    Air Conditioner Service Manual 2. Refrigeration cycle diagram Cool only Liquid side 2-way valve Capillary Heat exchange Heat exchange (Evaporator) (condenser) Gas side 3-way valve Accumulator Compressor Liquid side 2-way valve Electronic expansion valve Heat exchange Heat exchange (Condenser) (Evaporator) Gas side 3-way valve 4-way valve...

  • Page 5: Electric Diagram

    Air Conditioner Service Manual 3. Electric Diagram 3.1 Wiring diagram The wiring diagram can be found near the PCB inside the unit. 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 9K,12K,18K,24K(AC motor type) PCB type: A010268...
  • Page 6 Air Conditioner Service Manual A010283 PCB type: 9K,12K,18K,24K(DC motor ) PCB type: A010283 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 10 Up-Down swing connector 11 Display...
  • Page 7 Air Conditioner Service Manual PCB type: A010403 Outdoor unit 9K, 12K A010313 Mainly relay Fuse L, N & 1 (communication) wiring 4-way valve Heater motor connector Electronic expansion valve Discharge sensor connector OAT/OPT sensor connector LED5...

  • Page 8: Electronic Controller Introduction

    Air Conditioner Service Manual A010386 18,24K A010286 DRED(OPTION) OAT/OPT connector Discharge sensor connector Electronic expansion valve AC/DC motor connector Heater 4-way valve LED5 Communication wiring Fuse L , N line Mainly relay LED1-LED4 Note: OAT: Outdoor Ambient Temperature OPT: Outdoor pipe temperature 4.
  • Page 9 Air Conditioner Service Manual 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 10 Air Conditioner Service Manual If 5℃≤IPT＜6 ℃ , the compressor frequency forbidden to increase 3). Normal Frequency Decreasing (NFD): If 3℃≤IPT＜4 ℃ , the frequency decreasing rate is 8Hz/90s, until to the lower frequency limit. 4). Fast Frequency Decreasing (FFD): If 2℃≤IPT＜3 ℃...
  • Page 11 Air Conditioner Service Manual for the motor should be less than 160s. 2). When switch on unit on heating mode, ODU fan motor will delay 5s after compressor starts up 3). in the process of defrosting, the fan motor will stop operation 48s delay after compressor stopped. 4).
  • Page 12 Air Conditioner Service Manual a. If ITP＞31℃ while compressor works for 5 min, fan motor will work according to preset fan speed. b. If IPT≤31℃, fan motor stops working while compressor operation within 2min, if IPT≥27℃, fan motor works in low speed 2 min, then change to preset speed.
  • Page 13 Air Conditioner Service Manual 4.1.8 Emergency switch When the EMERGENCY switch is pressed one time, COOLING mode is selected and if it pressed again within 3s, HEATING mode selected, while press once again, the unit will be switched off. When the remote controller out of function, batteries lost power, for example, the EMERGENCY button in the front of indoor unit can be used for function test.
  • Page 14 Air Conditioner Service Manual for over current protection. 2. When unit A/C working current more than Stopped current (I ), AC unit stops working. Only when the compressor stops for 3 min can the unit be recovered operation. 3. If unit have 6 times of over current stop-working protection continuously, this protection can’t be recovered unless press ON/OFF button.

  • Page 15: 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 16: 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 17 Air Conditioner Service Manual Improper installation may lead to fire hazard, explosion, electric shock or injury. Safety precautions for Installing and Relocating the unit. To ensure safety, please be mindful of the following precautions. Warnings When installing or relocating the unit, be sure to keep the refrigerant circuit free from air or substances other than the specified refrigerant.
  • Page 18 Air Conditioner Service Manual Where: is the allowable maximum charge in a room, in kg; M is the refrigerant charge amount in appliance, in kg; is the required minimum room area, in m2; A is the room area, in m2; LFL is the lower flammable limit, in kg/m3;...
  • Page 19 Air Conditioner Service Manual 3) Installation Safety Installation Safety Principles Site Safety Open Flames Prohibited Ventilation Necessary Operation Safety Open Flames Prohibited Mind Static Electricity Must wear protective clothing and anti-static gloves Don`t use mobile phone Installation Safety  Refrigerant Leak Detector ...
  • Page 20 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 vacuum degree should be lower than 10Pa. Mini Vacuum Pump It should be a special explosion-proof filling device; have certain precision and its filling deviation should be less than 5g.
  • Page 21 Air Conditioner Service Manual  It is necessary to ensure that the air conditioner is in reliable ground connection before maintenance.  Make sure powered supply to air conditioner is off. Before maintenance, it is necessary to cut off the power and discharge the capacitor power which used in the air conditioner.
  • Page 22 Air Conditioner Service Manual 6). Requirements for fill the refrigerants  It is necessary to use nitrogen to clear the cyclic system before operating the refrigerating system and vacuumize the outdoor unit for 30 minutes at least.  It is necessary to ensure that there is no cross contamination among different refrigerants when the refrigerant filling device is used.

  • Page 23: Installation

    Air Conditioner Service Manual evacuating the affected personnel urgently from the location. It is necessary to inform near residents of evacuating for over 20 meters from the location, make an  alarm call, set the emergency area and prohibit irrelevant personnel and vehicles from approaching. The professional firefighters should wear anti-static clothing to handle the emergency on the site and cut ...
  • Page 24 Air Conditioner Service Manual Space to the wall At least 15cm At least 15cm Space to the wall Space to the obstruction Space to the floor Space to the obstruction Drainage pipe Connecting wire...

  • Page 25: Accessory

    Air Conditioner Service Manual 2.2 Accessory Remote Batteries Vinyl tape controller supporter Remote controller 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 26: 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 27 Air Conditioner Service Manual 9K(770X) 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. 1.6.3 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 28 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 1.6.4 Connecting the pipes.

  • Page 29: Odu Installation

    Air Conditioner Service Manual the drain pipe. unit during heating operation can be drained away through the drain pipe. 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.

  • Page 30: Vacuum And Gas Leakage Test

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

  • Page 31: 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 32 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 33: 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 E0 disappear? connection correct? re-connect Check communication Replace/ E0 disappear? wiring and the connection, re-connect in good condition? ODU wiring Check and E0 disappear? Connection correct?
  • Page 34 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 35 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 36 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 Adjust the motor and blade Can the fan blades run assembly so that rotor can smoothly? run smoothly.
  • Page 37 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 38 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 39 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 40 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 41 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 42 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.
  • Page 43 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 44 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 45 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 46 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 47 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 48 Air Conditioner Service Manual 3.2.16 P8---Outdoor Over temperature/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 49 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 50 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 51 Air Conditioner Service Manual 3.2.19 F5---PFC Protection PFC Over current 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 52 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 53 Air Conditioner Service Manual 3.2.21 F7---Module temperature protection. IPM over temperature protection, when IPM temperature more than 95℃, it will show F7. Display F7 Clean or adjust the gap IPM well contact to Any dust or gap btw btw IPM and heat sink heat sink? IPM &...
  • Page 54 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 wiring connection Re-connect correct?
  • Page 55 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 56: 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. Disassembly front panel, display board and WIFI module. 显示盒 Display box A. Open front panel. B. Remove one screw and take the display box out from the panel.
  • Page 57 Air Conditioner Service Manual 4. Remove the electric control box cover 固 定 Unfix one screw on the cover of 螺 electric box, and remove the cover. screw 钉 5. Remove the filter Push the filter upwards a little, you can take it out from unit.
  • Page 58 Air Conditioner Service Manual 7. Disassembly the electric control box. 电控盒 Electric control box A. Remove the RT & IPT out from evaporator; B. Unscrew all the earth ground wirings on the evaporator. C. Take all the connectors out from PCB.
  • Page 59 Air Conditioner Service Manual 9. Disassembly the evaporator screws Screws + motor 螺钉/卡扣 螺钉 cover A. Unfix 2 screws of left side shown as picture. B. Unfix 2 screws of right side on motor cover/right support plate. C. Take the evaporator out from unit by uplifting the IUPUT/OUTPUT pipes slightly.

  • Page 60: Odu Assembly

    Air Conditioner Service Manual 4.2 ODU Assembly Step Reference picture step1：Remove the PCB Cover , valve Cover and top cover 1). Unfix one screw on the PCB cover, you can take the cover out from unit. 2). Unfix one screw on the valve cover, you can take it out easily.
  • Page 61 Air Conditioner Service Manual ODU middle separate plate and base plate, uplift front panel you can take it out from unit. step3：Disassemble the Left and Right plate. Unfix screws btw Right Plate and the Electric Box assembly, Valve Plate , Base Plate, then you can take the Right plate out.
  • Page 62 Air Conditioner Service Manual Unfix screws btw Left Plate, Base plate and Condenser plate, you can take the left plate out. step4：Disassemble the Axis Fan Blade Unscrew the fan blade nut, and take the blade out. step5：Disassemble the electric box...
  • Page 63 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...
  • Page 64 Air Conditioner Service Manual Unfix the screw btw separate plate and unit, and take it out step8：Disassemble the 2 and 3-way valve Unfix screw btw Valve plate and base, you can take the 2-way and 3-way valve out by welding. Note: 1).
  • Page 65 Air Conditioner Service Manual step10：Disassemble the compressor. Unscrew the nuts and take the compressor out. step11：Remove the fan motor and fan supporter. 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 66: Appendix

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

  • Page 67: Appendix 3 Pipes Flaring

    Air Conditioner Service Manual Appendix 3 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 68: Appendix 4 Thermistor Temperature Characteristics

    Air Conditioner Service Manual Appendix 4 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 ℃...
  • Page 69 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 70 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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