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AE-X12PU
SERVICE MANUAL
SB212AEX12PU/T
SPLIT TYPE
ROOM AIR CONDITIONER
(OUTDOOR UNIT)
MODEL
AE-X09PU
AE-X12PU
In the interests of user-safety (Required by safety regulations in some countries) the set should be restored to its original condition and only parts identical to those specified should be used.
CONTENTS
CHAPTER 1. SPECIFICATION
[1] SPECIFICATION............................................ 1-1
[2] EXTERNAL DIMENSION............................... 1-2
[3] WIRING DIAGRM ..................................
........ 1-2
[4] ELECTRICAL PARTS................................... 1-4
[6] MALFUNCTION(PARTS) CHECK
METHOD.....................................................3-8
[7] OUTDOOR UNIT CHECK METHOD...........3-9
[8] TROUBLESHOOTING GUIDE....................3-12
[9] CHART........................................................3-13
CHAPTER 2. ELECTROIC CIRCUIT
[1] BLOCK DIAGRAMS...................................... 2-1
....... 2-2
[3] FUNCTION ................................................... 2-6
CHAPTER 3. FUNCTION AND OPERATION
OF PROTECTIVE PROCEDURES
[1] PROTECTION DEVICE FUNCTIONS
AND OPERATIONS......................................3-1
[2] AIR CONDITIONER OPERATION IN
THERMISTOR ERROR................................3-3
[3] THERMISTOR TEMPERATURE CHARACT-
ERISTICS......................................................3-5
[4] HOW TO OPERATE THE OUTDOOR
UNIT INDEPENDENTLY...............................3-5
[5] GENERAL TROUBLESHOOTING
CHART..........................................................3-6
CHAPTER 4. REFRIGERATION CYCLE
[1] SCHEMATIC DIAGRAM...............................4-1
[2] STANDARD CONDITION.............................4-1
[3] CURRENT OF HEAT CONTROLLER..........4-1
[4] TEMPERATURE AT EACH PART AND
PRESSURE IN 3-WAY VALVE.....................4-1
[5] FLOW CHART OF REFRIGERANT
CYCLE...........................................................4-3
[6] CHARACTERISTIC OF COOLING AND
HEATING OPERATION ...............................4-3
CHAPTER 5. DISASSEMBLY PROCEDURE
[1] OUTDOOR UNIT..........................................5-1
[2] DISASSEMBLY OF CONTROL BOX...........5-4
CHAPTER 6. INSTALLATION MANUAL.............6-1
Parts List
Parts marked with " " are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.
This document has been published to be used for after sales service only.
The contents are subject to change without notice.
CHAPTER 1.
SPECIFICATION
[1] SPECIFICATION
ITEMS
Power supply
Phase
Rated voltage
Rated frequency
System
Indoor units numder
Maximum length (per unit)
Maximum height difference
Performance
Capacity (Min.-Max.)
Rated
(Cooling)
Rated
(Heating)
Moisture removal (Liters/h)
Power input
Running current
Capacity (Min.-Max.)
Power input
Running current
Noise level
Air flow quantity
Fan speed
OUTDOOR MODEL
V
Hz ft (m) ft (m)
Btu/h
1/h
W
A
Btu/h
W
A
Cooling dB(A)
Heating dB(A)
Cooling m3/min
Heating m3/min
Cooling rpm
Heating rpm
Compressor system
Compressor
Oil
Type
Fan system
Fan motor
AE-X09PU
Single
208/230
60
65.6 (20)
32.8 (10)
8500(3500 - 11000)
-
1
650
-
10000(3000 - 14000)
750
-
48
49
28.5
30.6
850
850
GMCC(8.9CC)ASM89D15UFZ
695W
VG74 ( 480cc )
Single Rotary
GMCC(8.9CC)ASM89D15UFZ
695W
VG74 ( 480cc )
Single Rotary
CMOTLB537JBEZ
8poles,43W
Propeller fan Φ400, 3-wing
AE-X12PU
Single
208/230
60
-
-
1
65.6 (20)
32.8 (10)
11500(4000 - 13500)
960
14000(3500 - 18000)
1200
-
49
50
27.2
29.1
860
860
CMOTLB537JBEZ
8poles,43W
Propeller fan Φ400, 3-wing
Fan
Refrigerant system
Condenser
Refrigerant control
Refrigerant
Refrigerant filling
Connections
Refrigerant coupling
Refrigerant tube size
(A:Gas line,B:Liquid line)
Drain joint [inch(mm)]
Others
Louver fin and Grooved tube type
Expansion valve FUJIKOKI Φ1.8
R410A
39.5 oz (1120g)
Flare type
A: 3/8" (Flared connection 3/8")
B: 1/4" (Flared connection 1/4")
Connected part O.D.
Φ0.63(16)
Louver fin and Grooved tube type
Expansion valve FUJIKOKI Φ1.8
R410A
42.3 oz (1200g)
Flare type
A: 3/8" (Flared connection 3/8")
B: 1/4" (Flared connection 1/4")
Connected part O.D.
Φ0.63(16)
Net dimensions
Net weight
Width inch(mm)
Height inch(mm)
Depth inch(mm) lb (kg)
30 23/32 (780)
21 1/4 (540)
10 19/32 (269)
79 (35.5)
30 23/32 (780)
21 1/4 (540)
10 19/32 (269)
83 (37.5)
NOTE:Test conditions are based on AHRI 210/240. (Refrigerant piping length [per unit] : 25ft [7.6m])
[TEST CONDITIONS COOLING]
INDOOR DB80 ℉ (26.7
℃)/WB66.9
℉( 19.4
℃)
OUTDOOR DB95
℉( 35.0
℃)/WB --
1 – 1
AE-X12PU
AE-X12PU
[2] EXTERNAL DIMENSION
21.3 (540) 6.2 (158)
2.8 (70)
30.7 (780)
0.5 (12)
1.5 (37.5)
0.2 (4.5)
2.3 (58)
0.6 (16) 10.6 (269)
Length unit: inch (mm)
7.1 (179.5)
7.2 (182.5)
[3] WIRING DIAGRAM
WIRING DIAGRAM
208/230V
1 phase
60Hz
L1
L2
2
(Outdoor Unit)
L1
L2
2
FUSE
102℃
BL
BT2
BT1
BN
RD
FU1
250V/20A
SA1
BT3
NR1
BT4
3
4
1
2
5
6
G(Y)
Diagnosis
EXPANSION
VALVE
X
1 time
X 2 times
X 5 times
X 6 times
X 7 times
Serial signal error
Short circuit of the thermistor
DC current error
AC current error
DANGER
CE004
CT1
250V/3.15A
FU2
NR2
RY1
R180
C129
CN12
CN4
7
8
No
LED pattern
X 9 times
X 10 times
9
10
11
High voltage at C(electrolytic capacitor) on outdoor unit.
For maintenance, discharge C to prevent electric shock.
If the fuse FU5 has blown out,the voltage is kept high at C.
Usually LED shows that the charge of C is still high,too.
MRY
REACTOR
PTC
4-WAY
X 11 times
DB1
DB2
C
Q5
FAN
MOTOR
IC
250V/20A
FU3
FU5
CN3
Diagnosis
Thermistor or 4-way valve
EEPROM error
Outdoor fan motor error
IPM
U
V
W
T7
T8
T9
RD
WT
COMPRESSOR
W
OR
CN8
TH1 (RD)
TH2 (OR)
TH3 (GN)
TH4 (BK)
V
U
TH1: COMPRESSOR .TEMP.
TH2: HEAT EXCHANGE .TEMP.
TH3: OUTDOOR .TEMP.
TH4: SUCTION .TEMP.
LED blinking
LED turns on
Slow flashing(1times for 2seconds)
Quick flashing(3times for 2seconds)
X 13 times
X 14 times
Rotation error or lock
PAM voltage or PAM clock error
Do not touch the electric components as it may result in eletric shock.
high voltage, because the circuit shares the same GND line of high voltage.
Do not earth oscilloscope,etc., as it may become damaged.
AE-X12PU/AE-X09PU
1 – 2
[4] ELECTRICAL PARTS
AE-X12PU / AE-X09PU
P a
Compressor
r t N a m e
F
F a n u 1 m o t o r
F u 2
F u 3
F u 5
M o d e l
ASM89D15VFZ
SHA-52FV-D843-2
-
-
-
-
R e m a r k s
GMCC (8.9 CC) (FCMPRA362JBKZ)
D
Q
C
F m
S o t o
G A r
0 9
( C M O T
0 J B Z Z
L B
(
5
2 0 A
3 7 J B
2 5 0
E
V
Z
)
)
Q F
QF
S -
S -
G
G
A
A
0
0
7
7
8
7
J B
J B
Z Z
Z Z
( 3
( 2
.
1 5 A
A 2 5 0
2 5
V )
0 V
QFS-GA090JBZZ (20A 250V)
)
AE-X12PU
1 – 3
CHAPTER 2.
ELECTROIC CIRCUIT
[1] BLOCK DIAGRAMS
1. Outdoor unit
20A
Expansion valve circuit Expansion valve
20A
AE-X12PU
2 – 1
AE-X12PU
[2] MICROCOMPUTER CONTROL SYSTEM
1 Electronic control circuit diagram: AE-X12PU/AE-X09PU
2 – 2
2. Printed wiring board: AE-X12PU/AE-X09PU
AE-X12PU
2 – 3
AE-X12PU
[3] FUNCTION
1. Function
1.1. Restart control
Once the compressor stops operating, it will not restart for 180 seconds to protect the compressor.
Therefore, if the operating compressor is shut down from the remote control and then turned back on immediately after, the compressor will restart after a preset delay time.
(The indoor unit will restart operation immediately after the ON switch is operated on the remote control.)
1.5. Peak control
If the current flowing in the air conditioner exceeds the peak control current (see the table below), the operation frequency is decreased until the current value drops below the peak control current regardless of the frequency control demand issued from the indoor unit based on the room temperature.
Model
AE-X09PU
AE-X12PU
Mode
Cooling
Heating
Cooling
Heating
Peak Control
Current(A)
5.8
6.8
6.9
9.1
Overload Current
Compensation(A)
0
0
0
-2.0
1.2. Outdoor unit 2-way valve freeze prevention control
If the temperature of the outdoor unit 2-way valve remains below 32
℉(
0 ℃) for 10 consecutive minutes during cooling or dehumidifying operation, the compressor operation stops temporarily in order to prevent freezing.
When the temperature of the 2-way valve rises to 50 operation.
℉(
10 ℃) or higher after about 180 seconds, the compressor restarts and resumes normal
1.3. Outdoor unit overheat prevention control
During cooling operation, if the temperature of the outdoor unit heat exchanger exceeds the outdoor unit heat exchanger overheat prevention temperature (about 131
℉(
54
℉(
℃) or lower.
55 ℃)), the operating frequency is decreased by about 4 to 15 Hz. Then, this operation is repeated every 60 seconds until the temperature of the outdoor unit heat exchanger drops to about 129.2
Once the temperature of the outdoor unit heat exchanger drops to about 129.2
℉(
54 ℃) or lower, the operating frequency is increased by about 4 to 10 Hz every 60 seconds until the normal operation condition resumes.
If the temperature of the outdoor unit heat exchanger exceeds the outdoor unit heat exchanger overheat protection temperature for (120 sec. : outdoor temperature ≥ 104
104
℉(
40
℉(
40 ℃), 60 sec : outdoor temperature <
℃)) at minimum operating frequency, the compressor stops operating and then restarts after about 180 seconds, and the above mentioned control is repeated.
1.4. Compressor overheat prevention control
If the temperature of the compressor exceeds the compressor overheat prevention temperature 230 ℉ (110 decreased by about 4 to 10 Hz. Then, this operation is repeated every
60 seconds until the temperature of the compressor drops below the overheat protection temperature 212 ℉
℃), the operation frequency is
(100 ℃).
Once the temperature of the compressor drops below the overheat protection temperature, the operating frequency is increased by about
4 to 10 Hz every 60 seconds until the normal operation condition resumes.
If the temperature of the compressor exceeds the overheat protection temperature (for 120 seconds in cooling operation or 60 seconds in heating operation) at minimum operating frequency, the compressor stops operating and then restarts after about 180 seconds, and the above mentioned control is repeated.
1.6. Outdoor unit fan delay control
The compressor stops immediately after cooling, dehumidifying or heating operation is shut down, but the outdoor unit fan continues operation for 50 seconds before it stops.
1.7. Defrosting
1.7.1 Reverse defrosting
The defrost operation starts when the compressor operating time exceeds 10 minutes during heating operation, as shown below, and the outside air temperature and the outdoor unit heat exchanger temperature meet certain conditions. When the defrost operation starts, the indoor unit fan stops. The defrost operation stops when the outdoor unit heat exchanger temperature rises to about 15°C or higher or the defrosting time exceeds 9 minutes.
10 min or more 10 min or more 10 min or more
Start of heating operation
Defrosting
Max. 9min
Defrosting
Max. 9min
1.8. Self-diagnostic malfunction code display of Outdoor unit
If a malfunction occurs, LED1 on the outdoor unit flashes in 0.2-seco nd intervals as shown below.
0.5
When reading the result of self-diagnosis, you shall combine it with indoor unit indication in order to get a correct conclusion.
For details, please refer to the troubleshooting section.
2 – 4
1.9. AUTOMATIC AIR CONDITIONING
In the AUTO mode, the unit will automatically select COOL or HEAT mode by comparing the room temperature and your desired temperature.
The unit will automatically switch between HEAT and COOL mode to keep the desired temperature.
COANDA and MULTI SPACE button will be inactivated during AUTO mode.
1.10. INACTIVATE 5°F(-15°C) AUTO STOP FUNCTION
During the heating operation, the unit will automatically stop when the outdoor temperature drops below 5°F(-15°C) to prevent the outdoor unit from the damage caused by the freezing of the drained water. The unit will stop its operation for 4 hour and then resume the operation when the outdoor temperature rises above 7°F(-13.9°C).
AE-X12PU
If the customer do not want to use this function, this function can be inactivated by cutting JPA on outdoor PWB.
1. Power off.
2. Cut the JPA cut JPA
2. Outline of PAM circuit
2.1. PAM (Pulse Amplitude Modulation)
The PAM circuit varies the compressor drive voltage and controls the rotation speed of the compressor.
The IGBT shown in the block diagram charges the energy (electromotive force) generated by the reactor to the electrolytic capacitor for the inverter by turning ON and OFF.
208 or
230V
When the IGBT is ON, an electric current flows to the IGBT via the reactor (L1) and diode bridge (DB2).
When the IGBT turns OFF, the energy stored while the IGBT was ON is charged to the voltage capacitor via the diode bridge (DB1).
As such, by varying the ON/OFF duty of the IGBT, the output voltage is varied.
2 – 5
AE-X12PU
2.2. High power factor control circuit
This circuit brings the operating current waveform closer to the waveform of commercial power supply voltage to maintain a high power factor.
Because of the capacitor input, when the PAM circuit is OFF, the phase of the current waveform deviates from the voltage waveform as shown below.
To prevent this deviation, a current is supplied during the periods indicated by "O" in the diagram.
To determine the length of period to supply a current, the zero-cross timing of the AC input voltage is input to the microcomputer via the clock circuit.
The power source frequency is also determined at the same time.
The IGBT turns ON after the time length determined by the zero-cross point to supply a current to the IGBT via the reactor.
This brings the current waveform closer to the voltage waveform in phase.
As described above, the ON/OFF operation of the IGBT controls the increase/decrease of the compressor power supply voltage (DC voltage) to improve the compressor efficiency and maintain a high power factor by keeping the current phase closer to that of the supply voltage.
2.2.1 Detailed explanation of PAM drive circuit sequence
60 about 9 mS
1300uS
0.004 1.7ms
2.2.2 AC clock (zero-cross) judgment
• The clock circuit determines the time from one rising point of the clock waveform to the next rising point.
The detected clock waveform is used to judge the power source frequency (60Hz).
• The zero-cross of the AC voltage is judged as the rising of the clock waveform, as shown in the diagram above.
2.2.3 IGBT ON start time (delay time B)
• Based on the zero-cross of the AC voltage, the IGBT turns ON after a delay time set according to the power source frequency.
2.2.4 IGBT ON time (C)
• After the above delay time, the IGBT turns ON to supply a current to the reactor.
• The ON time of the IGBT determines the amount of energy (level of DC voltage rise) supplied to the reactor.
DC voltage level in each operation mode (varies depending on external load conditions)
– Cooling operation --- 220 to 290 V
– Heating operation --- 260 to 290 V
C9 C10
2.3. PAM protection circuit
560
To prevent excessive voltage of PAM output from damaging the IPM and electrolytic capacitor as well as the control printed wiring board (PWB), this circuit monitors the PAM output voltage and turns off the PAM control signal and PAM drive immediately when an abnormal voltage output is generated. At the same time, it shuts off the compressor operation.
The protection voltage level is as follows.
2 – 6
AE-X12PU
2.3.1 Details of troubleshooting procedure for PAM
1) PAM shutdown due to error
1) When the DC voltage detection circuit sends a signal exceeding the specified voltage to the microcomputer
DC voltage of 400 V or higher (detection circuit input voltage of about 4.6 V or higher) [IC1 69 pin]
– When an error is detected
• PAM IGBT turns OFF.
• Compressor turns OFF.
• All units shut down completely when the error occurs four times.
2) When the outdoor unit clock waveform differs from the specified value immediately before the PAM IGBT turns ON
When there is no clock waveform input
When a clock signal of other than specified power source frequency (60Hz) is input
– When an error is detected
• PAM IGBT does not turn ON.
• Compressor operates normally.
• Complete shutdown does not occur.
2) PAM error indication
In case of error “1)”
– An error signal is sent to the indoor unit as soon as an error is generated.
• Malfunction No. 14-0 is indicated when the error code is called out by the indoor unit's self-diagnosis function.
– The LED on the outdoor unit flashes 14 times when an error is generated.
• The LED continues flashing in the 14-time cycle even after the compressor stops operating.
• The LED turns off (data is deleted from the memory) when the outdoor unit power is turned off.
In case of error “2)”
– An error signal is sent to the indoor unit as soon as an error is judged.
• Malfunction No. 14-1 is indicated when the error code is called out by the indoor unit's self-diagnosis function.
– The LED on the outdoor unit flashes 14 times when an error is judged.
• The LED on the outdoor unit flashes in normal pattern when the compressor stops operating.
(Compressor OFF or Thermostat OFF from remote control)
* When a user complains that the air conditioner does not provide sufficient cool air or warm air
In addition to conventional error-generating reasons, there is a possibility that the PAM IGBT does not turn ON even if the compressor is operating.
In that case, the DC voltage does not rise even though the compressor is operating, and lowers to the 180-VDC level.
– Check items
• Clock circuit check
• PAM IGBT check
2 – 7
AE-X12PU
3. Explanation of IPM drive circuit
The IPM for compressor drive is made by Mitsubishi Electric.
The power supply for the IPM drive, the shunt resistance for over current detection, etc., are provided outside the IPM (control PWB).
3.1. IPM drive power supply circuit
The power supply for the upper-phase IGBT (HU, HV, HW) drive employs a bootstrap system, and provides power to the upper-phase IC.
The 15-V power supply for the lower-phase IC is provided by the control printed wiring board (PWB).
3.1.1 Brief explanation of bootstrap system (single power drive system)
To supply power to the upper-phase IC, the microcomputer (IC1) turns ON the lower-phase IGBT (LU, LV, LW).
This results in a charging current that flows to the electrolytic capacitor of each upper-phase IC input and charges the bootstrap capacitor with a 15V current.
The power supply for the subsequent stages is charged while the lower-phase IGBT is ON in ordinary compressor drive control.
2 – 8
AE-X12PU
3.1.2 DC over current detection circuit
When a current of about 20 A or higher flows through the shunt resistance [AE-X09PU/AE-X12PU(R49A~R49E)] on the control printed wiring board
(PWB), the voltage at this resistance is input to IPM CIN pin (15). Then, the gate voltage of the lower-phase IGBT (LU, LV, LW) inside the IPM turns
OFF to cut off the over current. At the same time, an L output of more than 20 μs is generated from IPM from pin (14), and this results in an L input to over current detection input pin (17) of the microcomputer (IC1) and turns OFF the PWM signal output (IC1 pins (20) through (25)) to the IGBT gate.
AE-X09PU(R49A~R49E),
AE-X12PU(R49A~R49E)
2 – 9
AE-X12PU
4. 180° energizing control
This is the control system to moderate the speed by the current phase difference for higher efficiency and lower noise of the compressor. The current phase difference control is the control system paid attention to the interrelation between efficiency and phase gap generated by the applied voltage of motor and current in the coil of motor as shown in the figure below.
This control is the forced magnetization system independent of the location of rotor, detecting the phase difference between driving voltage phase and line current phase flowing in motor coil, and controls the modulation rate data to get the phase difference at the best efficiency.
2 – 10
AE-X12PU
CHAPTER 3.
FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES
[1] PROTECTION DEVICE FUNCTIONS AND OPERATIONS
* These models have following thermistors.
OUTDOOR UNIT
AE-X09PU, AE-X12PU TH1, TH2, TH3, TH4, TH6
The errors for the thermistors that are not mentioned above are irrelevant.
These indoor units don’t have power relay.
F u n c t i o n O p e r a t i o n
Description Detection period
1 Indoor unit fan lock Operation stops if there is no input of rotation pulse signal from indoor unit fan motor for 1 minute.
Indoor unit fan rotation speed error
Operation stops if rotation pulse signal from indoor unit fan indicates abnormally low speed
(about 300 rpm or slower).
2 2-way valve freeze prevention
3 Outdoor unit heat exchanger overheat shutdown
Compressor stops if temperature of outdoor unit 2-way valve remains below 32
℉(
0
℃) for 10 continuous minutes during cooling or dehumidifying operation.
Operation frequency lowers if outdoor unit heat exchanger temperature exceeds about 131
℉(
55
℃) during cooling operation.Compressor stops if outdoor unit heat exchanger temperature exceeds about 131
℉(
55
℃) for 120 seconds at minimum frequency.
When indoor unit fan is in operation
When indoor unit fan is in operation
When in cooling or dehumidifying operation
When in cooling or dehumidifying operation
4 Compressor discharge overheat shutdown
Operating frequency lowers if temperature of compressor chamber thermistor (TH1) falls below about 230
℉
(110
℃). Compressor stops if temperature of compressor chamber ther-mistor (TH1) remains at about 230
℉
(110
℃) (for 120 seconds in cooling operation, or 60 seconds in heat-ing operation) at minimum fre-quency.
When compressor is in operation
Reset condition Indoor unit error display
Operation OFF or ON I2
Operation OFF or ON
I2
Automatic reset when temperature of 2-way valve rises above
50
℉(
10
℃).
Automatic reset after safety period (180 sec).
Automatic reset after safety period (180 sec).
None
None
None
Yes
Yes
Yes
Yes
Yes
S e l f d i a g n o s i s result display
Indoor unit
Outdoor unit
None
None
Yes
Yes
Yes
Yes Yes 5 Dehumidifying operation temporary stop
6 DC over current error
7 AC over current error
8 AC over current error in compressor
OFF status
9 AC maximum current error
10 AC current deficiency error
Compressor stops if outside air temperature thermistor is lower than about 60.8
℉
(16
℃) during dehumidifying operation.
Compressor stops if electric current of about 20 A or higher flows in IPM.
Operating frequency lowers if compressor AC current exceeds peak control current value. Compressor stops if compressor AC current exceeds peak control current value at minimum frequency.
Indoor and outdoor units stop if
AC current exceeds about 3 A while compressor is in non-operation status.
Compressor stops if compressor
AC current exceeds 17 A.
Compressor stops if operating frequency is 50 Hz or higher and compressor AC current is about
2.0 A or lower.
When in dehumidifying operation
When compressor is in operation
When compressor is in operation
When compressor is in non-operation
When compressor is in operation
When compressor is in operation
Automatic reset when outside air tempera-
None ture rises above
60.8
℉
(16
℃)
Operation OFF or ON YesI1
Operation OFF or ON YesI1
Replacement of defective parts such as IPM
YesI2
Operation OFF or ON Yes I1
Operation OFF or ON Yes I1
3 – 1
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
AE-X12PU
F u n c t i o n
Description
O p e r a t i o n
Detection period
11 Thermistor installation error or 4-way valve error
Compressor stops if high and low values of temperatures detected by outdoor unit heat exchanger thermistor (TH2) do not match operating cycle.
3 minutes after compressor startup
Reset condition Indoor unit error display
Operation OFF or ON Yes
I1
Yes
S e l f d i a g n o s i s result display
Indoor unit
Outdoor unit
Yes
12 Compressor high temperature error
13 Outdoor unit heat exchanger thermistor short-circuit error
14 Outdoor unit outside air temperature thermistor short-circuit error
15 Outdoor unit suction thermistor short-circuit error
16 Outdoor unit heat exchanger thermistor open-circuit error
17 Outdoor unit outside air temperature thermistor open-circuit error
18 Outdoor unit suction thermistor open-circuit error
19 Outdoor unit discharge thermistor open-circuit error
20 Serial signal error
Compressor stops if compressor chamber thermistor (TH1) exceeds about 237.2
℉(
114
℃), or if there is short-circuit in TH1.
Compressor stops if there is short-circuit in outdoor unit heat exchanger thermistor (TH2).
Compressor stops if there is short-circuit in outdoor unit outside air temperature thermistor
(TH3).
Compressor stops if there is short-circuit in outdoor unit suction thermistor (TH4).
Compressor stops if there is open-circuit in outdoor unit heat exchanger thermistor (TH2).
Compressor stops if there is open-circuit in outdoor unit outside air temperature thermistor
(TH3).
Compressor stops if there is open-circuit in outdoor unit suction thermistor (TH4).
Compressor stops if there is open-circuit in outdoor unit discharge thermistor (TH1).
Power relay turns OFF if indoor unit cannot receive serial signal from outdoor unit for 8 minutes.
When in operation
At compressor startup
At compressor startup
At compressor startup
At compressor startup
At compressor startup
At compressor startup
At compressor startup
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
Operation OFF or ON Yes
I1
When in operation Operation OFF or ON
(Automatic reset when less than 8 minutes)
Reset after reception of serial signal
None
21 Compressor startup error
22 Compressor rotation error (at 120
° energizing)
23 Outdoor unit DC fan error
24 PAM over voltage error
Compressor stops if outdoor unit cannot receive serial signal from indoor unit for 30 seconds.
Compressor stops if compressor fails to start up.
Compressor stops if there is no input of position detection signal from compressor or input is abnormal.
Operation stops if there is no input of rotation pulse signal from outdoor unit fan motor for 30 seconds.
Compressor stops if DC voltage is
350 V or higher.
When in operation
At compressor startup
Compressor operating at 120
° energizing
When outdoor unit fan is in operation
When in operation
Operation OFF or ON Yes
I3
Operation OFF or ON Yes
I3
Operation OFF or ON
Operation OFF or ON
Yes
Yes
I1
I1
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
None
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
None
None
Yes
Yes
Yes
Yes
3 – 2
AE-X12PU
F u n c t i o n O p e r a t i o n
Description Detection period Reset condition
25 PAM clock error
26 Outdoor unit thermal fuse error in the
Terminal board
When power source frequency cannot be determined (at startup), or when power source clock cannot be detected for 1 continuous second (at startup).
Compressor stops if outdoor unit cannot receive serial signal from indoor unit for 30 seconds.
At compressor startup, when in operation
When in operation
Compressor continues operation without stopping.
Reset after reception of serial signal
I1—The outdoor unit restarts four times before the indoor unit error is displayed (complete shutdown).
I2—A single error judgment results in the display of the indoor unit error (complete shutdown).
I3—The outdoor unit restarts eight times before the indoor unit error is displayed (complete shutdown).
Indoor unit error display
None
None
S e l f d i a g n o s i s result display
Indoor unit
Yes
None
Outdoor unit
Yes
None
[2] AIR CONDITIONER OPERATION IN THERMISTOR ERROR
* These models have following thermistors.
OUTDOOR UNIT
AE-X09PU, AE-X12PU
The errors for the thermistors that are not mentioned above are irrelevant.
These indoor units don’t have power relay.
TH1, TH2, TH3, TH4, TH6
3 – 3
AE-X12PU
1. Outdoor unit
Item
Compressor chamber thermistor (TH1)
Heat exchanger thermistor (TH2)
Cooling
Dehumidifying
Outside air temperature thermistor (TH3)
Cooling
Dehumidifying
Heating
Heating
Auto
Mode
Cooling
Dehumidifying
Heating
Suction pipe thermistor (TH4)
Cooling
Dehumidifying
Heating
Control operation
Expansion valve control and compressor protection
Outdoor unit heat exchanger overheat prevention
Expansion valve control
Defrosting
Operation mode judgment
Operation not affected
Rating control
Defrosting
When resistance is low
(temperature judged higher than actual)
Compressor operates, but room does not become cool or warm (expansion valve is open).
Short-circuit
Compressor high temperature error indication.
Compressor operates at low speed or stops.
Defrosting operation is not activated as needed, and frost accumulates on outdoor unit (expansion valve is closed).
Outdoor unit thermistor short-circuit error indication.
Outdoor unit thermistor short-circuit error indication.
Cooling mode is activated even if room temperature is low.
Outdoor unit thermistor short-circuit error indication.
Normal operation.
Outdoor unit thermistor short-circuit error indication.
Defrosting operation is activated unnecessarily.
Outdoor unit thermistor short-circuit error indication.
When resistance is high
(temperature judged lower than actual)
Layer short-circuit or open-circuit may result in compressor in normal operation.
Expansion valve control
Expansion valve control
Compressor operates, but room does not become cool
(expansion valve is open).
Compressor operates, but room does not become warm
(expansion valve is open).
Outdoor unit thermistor short-circuit error indication.
Outdoor unit thermistor short-circuit error indication.
Open-circuit
Outdoor unit thermistor open-circuit error indication.
Normal operation.
Outdoor unit thermistor open-circuit error indication.
Defrosting operation is activated unnecessarily, and room does not become warm
(expansion valve is open).
Outdoor unit thermistor open-circuit error indication.
Heating mode is activated even if room temperature is high.
Outdoor unit thermistor open-circuit error indication.
Normal operation.
Outdoor unit thermistor open-circuit error indication.
Defrosting operation is not activated, and frost accumulates on outdoor unit.
Frost accumulates on evaporator inlet section, and room does not become cool
(expansion valve is closed).
Outdoor unit thermistor open-circuit error indication.
Outdoor unit thermistor open-circuit error indication.
Frost accumulates on expansion valve outlet section, and room does not become warm (expansion valve is closed).
Outdoor unit thermistor open-circuit error indication.
3 – 4
AE-X12PU
[3] THERMISTOR TEMPERATURE CHARACTERISTICS
1. Outdoor unit thermistor temperature characteristics
To measure the resistance, first remove the connector from the board.
T h e r m i s t o r
Compressor thermistor
Heat exchanger pipe thermistor
Outdoor temp. thermistor
Suction temp. thermistor
No. Connector
TH1
TH2
TH3
TH4
1 - 2
3 - 4
5 - 6
7 - 8
C o l o r
Red
Orange
Green
Black
500K
TH1: compressor thermistor
400K
300K
Connector
(CN8)
77
℉(25ºC ) resistance
45 K
1
200K
100K
5.78K
3.06K
4.17K 2 28K
1.72K
Tester
0
-20 0 20 60 80 100 120
Temperature
℉(ºC)
8
40K
30K
20K
10K
TH2: Heat exchange thermistor
TH3: Outdoor temp. thermistor
TH4: Suction pipe thermistor
32
℉(0ºC ) resistance14.5 K
Connector
CN8
77
℉(25ºC ) resistance
4.431 K
1
TH2, TH3, TH4
0
-20 0 20 40 60
Temperature
℉(ºC)
Tester
8
[4] HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY
1. Cooling in 40 Hz fixed mode
To operate the outdoor unit independently, short-circuit the sections indicated by arrows in the diagram below with an adapter, and apply rated VAC between (L1) and (L2) on the terminal board of the outdoor unit. This allows the outdoor unit to be operated in cooling mode independently.
(Do not operate the outdoor unit in this condition for an extended period of time.)
Soldering Side
L3 L4
C9 C10 f these pads are connected and Power is applied to L1 and L2 on terminal board.
hen the outdoor unit operate in "TEST COOL 40Hz" mode.
3 – 5
AE-X12PU
[5] GENERAL TROUBLESHOOTING CHART
* These models have following thermistors.
OUTDOOR UNIT
AY-XPC09PU(AE-X09PU)/AY-XPC12PU(AE-X12PU)
The errors for the thermistors that are not mentioned above are irrelevant.
These indoor units don’t have power relay.
1. Indoor unit does not turn on
TH1, TH2, TH3, TH4, TH6
Main cause
Cracked PWB.
(Cracked pattern)
Inspection method
Check visually.
Open-circuit in FU1 (250 V, 2.5A). Check melting of FU1.
2. Indoor unit fan does not operate
Normal value/condition
There should be no cracking in
PWB or pattern.
Remedy
Replace PWB.
There should be no open-circuit.
Replace PWB.
Main cause
Open-circuit in heat exchanger thermistor (TH2) (in heating operation)
Inspection method
Measure thermistor resistance
(dismount for check)
Disconnected heat exchanger thermistor (TH2) (in heating operation)
Inspect connector on PWB.
Check thermistor installation condition.
Normal value/condition
Refer to THERMISTOR TEPER-
ATURE CHARACTERISTICS-1
There should be no open-circuit or faulty contact.
Thermistor should not be disconnected.
Remedy
Replace thermistor.
Replace thermistor.
Install correctly.
3. Indoor unit fan speed does not change
Main cause
Remote control not designed to allow fan speed change.
Inspection method
Check operation mode.
Normal value/condition
Fan speed should change except during dehumidifying operation, ventilation, light dehumidifying operation, internally normal operation
Remedy
Explain to user.
4. Remote control signal is not received
Main cause
Batteries at end of service life.
Batteries installed incorrectly.
Lighting fixture is too close, or fluorescent lamp is burning out.
Use Sevick light (Hitachi).
Defective light receiving unit.
Dew condensation on light receiving unit.
Turn off light and check.
Check if Sevick light (Hitachi) is used.
Inspection method
Measure battery voltage.
Check battery direction.
Operating position/angle is inappropriate.
Open-circuit or short-circuit in wiring of light receiving section.
Operate within range specified in manual.
Check if wires of light receiving section are caught.
Check signal receiving circuit
(measure voltage between terminals 9 and 10 of connector CN7).
Check for water and rust.
Normal value/condition
2.5 V or higher (two batteries in series connection)
As indicated on battery compartment.
Signal should be received when light is turned off.
Signal may not be received sometimes due to effect of Sevick light.
Signal should be received within range specified in manual.
Wires of light receiving section should not have any damage caused by pinching.
Tester indicator should move when signal is received.
Remedy
Install new batteries.
Install batteries in indicated direction.
Change light position or install new fluorescent lamp.
Replace light or change position.
Explain appropriate handling to user.
Replace wires of light receiving section.
Replace PWB.
Signal should be received within range specified in manual.
Take moisture-proof measure for lead wire outlet of light receiving section.
3 – 6
AE-X12PU
5. Louvers do not move
Main cause
Caught in sliding section.
Disconnected connector
Contact of solder on PWB
(connector section on PWB)
6. There is noise in TV/radio
Check visually.
Main cause
Grounding wires not connected properly.
TV/radio is placed too close to outdoor unit.
Other than above.
Inspection method
Operate to see if louvers are caught in place.
Inspect connectors.
Normal value/condition
There should not be solder contact.
Remedy
Louvers should operate smoothly.
Remove or correct catching section.
Connectors or pins should not be disconnected.
Install correctly.
Correct contacting section.
Inspection method
Check grounding wire connections.
Check distance between TV/radio and outdoor unit.
Check for radio wave interference.
Normal value/condition
Grounding wires should be connected properly.
If TV/radio is placed too close, it may become affected by noise.
Remedy
Connect grounding wires properly.
Move TV/radio away from outdoor unit.
7. Malfunction occurs
Main cause
Malfunction caused by noise.
Inspection method
Check for radio wave interference.
8. Compressor does not start
Normal value/condition Remedy
Main cause
Erroneous inter-unit connection.
D a m a g e d I P M .
Dried-up electrolytic capacitor.
Blown outdoor unit fuse.
Power supply voltage is too low.
Compressor lock.
Inspection method
Check wiring between indoor and outdoor units.
Normal value/condition
Terminal board 1-N: 230 VAC, 60
Hz
Terminal board 2: serial signal
C h e c k I P M c o n t i n u i t y .
Check electrolyt i c c a p a c i t o r .
Check 20-A fuse.
Fuse should not be blown.
Measure power supply voltage during startup.
Supply current and touch compressor cover (sound absorbing material) to check if operation starts.
230
±10 VAC, 60 Hz
Compressor should start normally.
Remedy
Correct wiring.
R e p l a c e I P M .
R e p l a c e e l ectrolytic capacitor.
Replace fuse/diode bridge.
Replace fuse.
Replace outdoor unit PWB assembly.
Make sure that power supply voltage is 180 V or higher.
Apply external impact to compressor.
Replace compressor.
9. Operation stops after a few minutes and restarts, and this process repeats
Main cause
Dried-up electrolytic capacitor.
Layer short-circuit in expansion valve coil.
Inspection method
Measure 290-VDC line voltage.
Measure resistance.
Normal value/condition
250 V or higher.
46
±3Ω in each phase (at 68 ℉
(
20
℃) )
Remedy
Replace electrolytic capacitor.
Replace coil.
CAUTION: If fuse FU1/FU5 (outdoor unit control circuit board) is blown, be careful of charging voltage in inverter electrolytic capacitor C9, C10.
To discharge stored electricity, unplug the power cord and connect the plug of a soldering iron (230VAC, 30W) between the positive and negative terminals of inverter electrolytic capacitor C9, C10.
3 – 7
AE-X12PU
[6] MALFUNCTION (PARTS) CHECK METHOD
1. Procedure for determining defective outdoor unit IPM/compressor
The following flow chart shows a procedure for locating the cause of a malfunction when the compressor does not start up and a DC overcurrent indication error occurs.
208/
L1 L2
2. Diode bridge check method
Turn off the power and let the inverter electrolytic capacitor (C9, C10) discharge completely. Then use a tester and check continuity.
When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed.
3. Inverter electrolytic capacitor (C9, C10) check method
Turn off the power, let the inverter electrolytic capacitor (C9, C10) discharge completely, and remove the capacitor from the control printed circuit board
(PWB). First, check the case for cracks, deformation and other damages. Then, using a needle-type tester, check continuity.
Determination of normal condition
The tester needle should move on the scale and slowly returns to the original position. The tester needle should move in the same way when polarities are reversed. (When measurement is taken with the polarities reversed, the tester needle exceeds the scale range. Therefore, let the capacitor discharge before measurement.)
3 – 8
AE-X12PU
4. IPM check method
Turn off the power, let the large capacity electrolytic capacitor (C9, C10) discharge completely, and dismount the IPM. Then, using a tester, check leak current between C and E.
When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed.
P
Needle-type tester Normal resistance value
(-) (+)
N
U
∞
(several M
Ω)
V
W
V
Needle-type tester Normal resistance value
(-) (+)
U N
∞
(several M
Ω)
W
Values in ( ) are for digital tester.
[7] OUTDOOR UNIT CHECK METHOD
After repairing the outdoor unit, conduct the following inspection procedures to make sure that it has been repaired completely. Then, operate the compressor for a final operation check.
1. Checking procedures
No
.
1 Preparation
I t e m
2
3
4
5
6
C h e c k m e t h o d N o r m a l v a l u e / c o n d i t i o n R e m e d y
Inverter DC power supply voltage check
IPM circuit check
Compressor check
Expansion valve check
Final check
Disconnect compressor cords (white, orange, red: 3 wires) from compressor terminals, and connect simulated load (lamp used as load).
Operate air conditioner in cooling or heating test operation mode.
Measure DC voltage between IPM pins (20) and (24).
3 2 0 V D C R e p l a c e c o n t r o l P W B .
Replace diode bridge.
Correct soldered section of Fasten tabs (BT1, BT2, BT5,BT6) on control PWB and IPM (U, V, W).
(Repair solder cracks.)
Replace control PWB.
Check that 3 lamps (load) light.
Check position detection voltage (+15
V, 5 V) on control PWB.
Measure compressor coil resistance
(for each phase of U, V and W).
Use multi-meter or digital tester capable of displaying two digits right of the decimal point (0.01
Ω).
Measure expansion valve coil resistance.
Turn off power, and connect compressor cords to compressor.
Operate air conditioner.
Measure DC voltage between IPM pins (20) and (24).
Each voltage should be normal.
All 3 lamps (load) should light with same intensity.
Resistance value at 68
--- 0.65
Ω
℉(
20
℃)
Each phase 46
±3Ω (at 68
Compressor should operate normally.
200 VDC or higher.
Correct connections at compressor terminals.
Replace compressor.
℉(
20
℃))Replace expansion valve.
Replace control PWB.
Replace outdoor unit thermistor.
Replace compressor (in case of compressor lock).
3 – 9
AE-X12PU
2. Troubleshooting of outdoor unit electric components
Is 230 V applied between L1 and
L2 on outdoor unit terminal board?
Check outdoor unit.
2
3
3
3 – 10
AE-X12PU
3. Caution in checking printed wiring boards (PWB)
3.1. Non-insulated control circuit
The GND terminals of the low-voltage circuits (control circuits for microcomputer and thermistors and drive circuits for expansion valve and relays) on the control printed wiring board (PWB) are connected to the compressor drive power supply (320-VDC negative terminal). Therefore, exercise utmost caution to prevent electric shock.
If a measuring instrument used for the test is grounded, its chassis (ground) has the same electric potential as the 0-V probe. Since non-insulated circuits have the following voltage potential difference from the ground, connection of the grounding wire results in a short-circuit between the 0-V line and the ground, thus allowing an excessive current to flow to the tester to cause damage.
If the sheaths of the thermistor lead wires or expansion valve lead wires inside the outdoor unit become damaged due to pinching by the front panel or other metal parts or contacting a pipe, a high voltage can flow and destroy the circuits. To prevent these problems, carefully conduct assembly work.
L1
208/230V
L2
3 – 11
AE-X12PU
[8] TROUBLESHOOTING GUIDE
1. Self-Diagnosis Function
1.1. Indoor unit
• To display the self-diagnosis, hold down the AUX button for over 5 seconds on the indoor unit when the indoor unit is not operating.
• The operation lamp (green), timer lamp (orange) and Plasmacluster lamp (blue) flash to indicate the information of malfunction.
AUX
Plasmacluster lamp(Blue)
Operation lamp(Green)
Timer lamp(orange)
• Even if the power supply to the air conditioner is cut off, the latest malfunctioncode will remain in the memory until the malfunction is
repaired.
<Display of self-diagnosis result>
The operation lamp (green) and the Plasmacluster lamp (blue) flash in synchronization with the timer lamp (orange).
Timer lamp (1 cycle)
1st
1-second
ON
2nd
1-second
ON
3rd
1-second
ON
4th
1-second
ON
5th
1-second
ON
ON
OFF
1-second
OFF
1-second
OFF
1-second
OFF
1-second
OFF
5-second OFF
1.2. Outdoor unit
• The self-diagnosis is indicated the error information by flashing LED1 on the outdoor unit.
• The self-diagnosis of outdoor unit is displayed for sbout 3-10 minutes.Then ,the LED1 returns to normal display.
3 – 12
AE-X12PU
[9] CHART
<INDOOR UNIT> ○:1-second ON / 1-second OFF
Problem symptom
Normal condition
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
Outdoor unit indication
(LED1)
Indoor unit
M alfunction
No.*
Content of diagnosis Check point Action
→
Lamp
Normal blinking
1-time
2-time
O O O O O Timer (Orange)
Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O
O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
O O Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
Plasmacluster (Blue)
Main Sub
0 0
Main
Normal
1
2
0 Outdoor unit thermistor short-circuit
1
2
3
0 Cycle temperature
Sub
Heat exchanger thermistor short circuit error
1) Measure the resistance of the outdoor unit thermistors.
Outdoor temperature thermistor short circuit error
2) Check the lead wire of the outdoor unit thermistor for torn sheath and shortcircuit.
Suction hermistor short circuit error
Suction hermistor
(for unit A, B, C) short circuit error
Compressor high temperature error
3) 1) 2):Normal
1) Replace the outdoor unit thermistor assembly.
2) Replace the outdoor unit thermistor assembly.
3) Replace the outdoor unit control PCB assembly.
1) Check the outdoor unit air outlet for blockage.
2) Check if the power supply voltage is AC
230V at full power.
3) Check the pipe connections for refrigerant leaks.
4) Measure resistance of the outdoor unit compressor thermistor.
5) Check the expansion valve for proper opera ion.
1) Ensure unobstructed outdoor unit air ou let.
2) Connect power supply of proper voltage.
amount of refrigerant.
4) Replace he outdoor unit compressor thermistor assembly.
5) Replace he expansion valve coil, expansion valve or outdoor unit control
PCB assembly.
Indoor unit operates.
Outdoor unit does not operate temporarily
Indoor and outdoor units do not operate.
Indoor unit operates.
Outdoor unit does not operate temporarily.
3-time
O O O O O Timer (Orange)
O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
O O Plasmacluster (Blue)
O O O O O Timer (Orange)
O
O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O
O Operation (Green)
O Plasmacluster (Blue)
O O O O O
O O
Timer (Orange)
Operation (Green)
Plasmacluster (Blue)
1
2
3
4
5
Compressor discharge overheat.
(Temporary stop for cycle protection)
Outdoor unit heat exchanger overheat.
(Temporary stop for cycle protection)
Indoor unit heat exchanger overheat.
(Temporary stop for cycle protection)
IPM high temperature error
Measure resistance of the heat-sink hermistor.
IPM high temperature error
Replace the outdoor unit control PCB assembly.
-
-
-
-
-
3 0 Dry operation
Heat operation
Temporary stop due to dehumidifying opera ion
5
℉/-15℃
AUTO OFF
(Temporary stop for cycle protection)
-
Measure the resistance of outdoor temperature thermister.
Replace the outdoor unit thermister assembly.
3 – 13
AE-X12PU
Problem symptom
Outdoor unit indication
(LED1)
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
5-time
6-time
7-time
8-time
Indoor unit
Malfunction
No.*
Content of diagnosis Check point Action
→
Lamp
O O O O O Timer (Orange)
O O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O
O
O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O O Operation (Green)
O Plasmacluster (Blue)
Main Sub
5
Main Sub
0 Outdoor unit thermistor open-circuit
Heat exchanger thermistor open circuit error
6
7
1
2
3
4
5
0
1
0
1
2
Outdoor unit
DC Current
Outdoor unit
AC Current
1) Check connector of outdoor unit thermistor for secure installa ion.
Outdoor temperature
2) Measure resistance of thermistor open outdoor hermistors circuit error
Suction thermistor open circuit error
Discharge thermistor open circuit error
Heat sink thermistor open circuit error
DC over current error
IPM pin level error
3) Check the lead wires of hermistors on the outdoor unit control
PCB for open-circuit.
Suction thermistor open circuit error
4) 1) 2) 3):Normal
2) Replace the outdoor unit thermistor assembly.
3) Replace the outdoor unit thermistor assembly.
Go to “DC Over Current Error (6-0 error)”.
Check the IPM is attached correctly to the outdoor unit
IPM PWB.
AC over current error 1) Ensure unobstructed air
AC current error when OFF unit air outlet.
2) Check the outdoor unit fan motor.
1) IPM con inuity check
1) Correct the installaion
4) Replace the outdoor unit control PWB assembly.
Replace the outdoor unit IPM PWB assembly.
1) Ensure unobstructed outdoor unit air outlet.
2) Check the outdoor unit fan motor.
1) Replace the outdoor
PWB
O O O O O Timer (Orange)
O O O Operation (Green)
O O Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
Plasmacluster (Blue)
8
3
0 Abnormal wire check
AC maximum current 1) Ensure unobstructed air error unit air outlet.
2) Check the outdoor unit fan motor.
1) Ensure unobstructed outdoor unit air outlet.
2) Check the outdoor unit fan motor.
AC current 1) Replace the outdoor unit control PCB assembly.
1) Replace the outdoor unit control PCB assembly.
amount of refrigerant.
3) Correct refrigerant clogs.
(Stop valve, pipe, expansion valve) amount of refrigerant.
3) Correct refrigerant clogs. (Stop valve, pipe, expansion valve)
Abnormal wire check 1) Check the expansion error valve.
2) Are four expansion valves connected by mistake.
3) Check the wiring between units.
1) Replace the outdoor control board assembly.
2) Reattach
3) Check the wiring between units.
3 – 14
AE-X12PU
Problem symptom
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
Outdoor unit indication
(LED1)
9- ime
Indoor unit
→
Lamp
O O O O O Timer (Orange)
O O Operation (Green)
Plasmacluster (Blue)
Malfunction
No.*
Main Sub
9
O O O O O Timer (Orange)
O
O
O Operation (Green)
Plasmacluster (Blue)
10
Content of diagnosis
Main Sub
Check point Action
0
4
0
Cycle temperature
Cycle temperature
EEPROM error
Thermistor installation error or 4-way valve error.
1)Check the thermistor (heat exchanger) and (2way valve) are installed in correct positions.
2)Check resistance of hermistors (heat exchanger and 2way valve).
3)Check the 4-way valve for proper operation.
4)No abnormality found in above inspections (1), (2),
(3).
1)Correct the installa ion.
2)Change he specified amount of refrigerant.
3)Replace the 4way valve.
4)Replace the outdoor unit control
PWB assembly.
4 way valve error or
Gas leak error
1) Check the unit thermistor 1) Correct the
TH2 (exchange) and
TH3 (pipe temperature) installation.
2) Change the are installed in correct portions.
refrigerant.
2) Check if the refrigerant volume is abnormally low.
3) Replace the 4-way valve.
EEPROM (outdoor) data error
-
3) Check the 4-way valve for proper operation.
Replace the outdoor unit control PWB assembly.
10-time O O O O O Timer (Orange)
O O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
11-time O O O O O Timer (Orange)
10
11
1
2 EEPROM error
EEPROM (outdoor) data error
EEPROM (outdoor) data error
Replace the outdoor unit control PWB assembly.
O O O Operation (Green)
Plasmacluster (Blue)
0 Outdoor unit
DC fan
Outdoor unit DC fan rotation error
1) Check connector CN3 of the outdoor unit DC fan motor for secure installation.
2) Check the outdoor unit fan motor for proper rotation.
3) Check fuse FUSE5.
4) Outdoor unit control
PWB
1) Correct the installation.
2) Replace the outdoor unit fan motor.
3) Replace the outdoor unit control PWB assembly.
4) Replace the outdoor unit control PWB assembly.
O O O O O Timer (Orange)
O O O Operation (Green)
O Plasmacluster (Blue)
1
O O O O O Timer (Orange)
O O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O
O O O O O Timer (Orange)
O
O
O O Operation (Green)
O O Plasmacluster (Blue)
O O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O
O
O O Operation (Green)
O Plasmacluster (Blue)
2
3
4
5
Outdoor unit DC fan driver IC error
1) Check if the fan IPM terminal resistance values are uniform.
2) Outdoor unit fan motor continuity check.
Outdoor unit DC fan lock error
1) Check the outdoor unit fan motor for proper rotation.
2) 1): Normal
-
1) Replace the outdoor unit control PWB assembly.
2) Replace the outdoor unit fan.
1) Replace the outdoor unit control PWB assembly.
2) Replace the outdoor unit fan.
Detection error of DC (Temporary stop for DC fan nega ive rotation before compressor is fan circuit protection) driven
Detection error of inverter current for
DC fan
Replace the outdoor unit control PWB assembly.
Outdoor unit DC fan open connector error
1) Check connector CN3 of the outdoor unit DC fan motor for secure installation.
2) No abnormality found in above inspection 1).
1) Correct the installation.
2) Replace the outdoor unit control PWB assembly.
3 – 15
AE-X12PU
Problem symptom
Indoor and outdoor units do not operate.
Indoor and outdoor units do not operate.
Outdoor unit indication
(LED1)
Indoor unit
→
Lamp
12- ime O O O O O Timer (Orange)
O O Operation (Green)
Plasmacluster (Blue)
Malfunction
No.*
Main Sub
12
13- ime O O O O O Timer (Orange)
O O
O
O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O O Operation (Green)
Plasmacluster (Blue)
13
Content of diagnosis
Main Sub
Check point Action
0 Thermal fuse in terminal board
Thermal fuse error in terminal board (for power supply)
1) Check he thermal fuse in terminal board (for
Power supply)
1) Replace terminal board for Power supply.
2) Check connector CN5 of the outdoor unit.
2) Correct he installation.
3) 1) 2): Normal 3) Replace the outdoor unit control PCB assembly.
0
1
2
DC compressor
Compressor startup error
Compressor rota ion error.
(at 120° energizing)
Compressor rota ion error
(at 180° energizing)
1) Check he colors (red, white, orange) of the compressor cords for proper connection.
1) Correct the installation.
(U: Red, V: White, W:
Orange)
(PWB side, compressor side)
2) Check if he IPM terminal resistance values are uniform.
2) Replace the outdoor unit control PWB assembly.
3) Replace the outdoor unit control PWB assembly.
3) Check if outdoor main relay (MRY1) turns on and voltage of both end of the condenser (C8 or C9) has become
DC290-330V.
4) Replace the compressor.
4) 1) 2) 3) : Normal
Indoor and outdoor units operate.
O O O O O Timer (Orange)
O O O Operation (Green)
O O Plasmacluster (Blue)
3 Detection error of inverter current
Check the circuit of detection of inverter current.
Replace the outdoor unit control PWB assembly.
Indoor and outdoor units do not operate.
Indoor unit operates.
Outdoor unit does not operate.
Lighting or
OFF
Indoor unit operates.
Outdoor unit does not operate.
Indoor and outdoor units do not operate.
14- ime
Lighting or
OFF
O O O O O Timer (Orange)
O O O Operation (Green)
Plasmacluster (Blue)
14
O O O O O Timer (Orange)
O
O
O O O Operation (Green)
O Plasmacluster (Blue)
O O O O O Timer (Orange)
O O O Operation (Green)
O
O
Plasmacluster (Blue)
O O O O O Timer (Orange)
O Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
Operation (Green)
Plasmacluster (Blue)
O O O O O Timer (Orange)
O O Operation (Green)
O Plasmacluster (Blue)
17
18
0 Outdor unit
PAM
PAM over voltage error
1 PAM clock error
1) Check the AC power supply voltage for
1) Correct he installation.
2) No abnormality found in above inspection.
2) Replace the PWB assembly.
Check the PAM clock for proper input.
Replace the outdoor unit control PWB assembly.
2
0
0
Wiring between units
Wiring between units
PAM under voltage error
Serial opencircuit
Serial short-circuit
1) Check the AC power supply voltage for
2) No abnormality found in above inspection.
1) Correct he installation.
2) Replace the PWB assembly.
1) Check he wires between 1) Connect stable units.
power supply.
2) Check voltage between
L1 and L2 the indoor/ outdoor unit terminal boards.
Correct the wiring.
2) Replace the outdoor unit control PWB assembly.
3) Check the outdoor unit fuse.
3) Replace the fuse/ outdoor unit control
PWB assembly.
4) Check 15-V,12-V and
5-V voltages on the
PCB.
4) Replace the outdoor unit control PWB assembly.
Check resistance between
IPM terminals.
5) Check pins No 3 and 5 of connector CN3 of he outdoor unit fan motor for shortcircuit.
5) Replace the outdoor unit fan motor.
6) Replace the outdoor unit control PWB.
6) Outdoor unit control
PCB.
Check the wiring between units.
Correct the wiring.
1 Serial erroneous wiring
Check the wiring between units.
Correct the wiring.
3 – 16
AE-X12PU
Problem symptom
Outdoor unit indication
(LED1)
Indoor unit
Malfunction
No.*
Content of diagnosis Check point Action
→
Lamp
Indoor and outdoor units do not operate.
Normal blinking or
OFF
O O O O O Timer (Orange)
O O O Operation (Green)
Plasmacluster (Blue)
Main Sub
19
Main Sub
0 Indoor unit fan
Indoor unit fan error 1) Check the indoor fan motor for proper rotating operation.
(Check fan lock.)
1) Replace the indoor fan motor.
2) Replace the indoor fan motor.
2) Check the lead wire of the indoor fan motor for open-circuit.
3) Correct the installation of the indoor fan motor connector.
3) Check connector ofthe indoor unit fanmotor for secureinstallation.
4) Replace the indoorunit control PCB.
4) 1) 2) 3): Normal
Indoor and outdoor units do not operate.
Indoor and outdoor units operate.
Normal blinking or
OFF
Normal blinking or OFF
O O O O O Timer (Orange)
O O Operation (Green)
Plasmacluster (Blue)
Timer (Orange)
Operation (Green)
Plasmacluster(Blue)
20
Timer (Orange)
Operation (Green)
Plasmacluster(Blue)
Timer (Orange)
Operation (Green)
Plasmacluster(Blue)
0 Indoor unit control PCB
EEPROM data error (EEPROM read data error) Replace the indoor unit control PWB.
26 1 Indoor unit room temperature thermistor
2 Indoor unit pipe temperature thermistor
3 Indoor unit valve temperature thermistor
Indoor unit room temperature thermistor
Indoor unit pipe temperature thermistor
Indoor unit valve temperature thermistor
(1)Check connector of thermistor for secure installation.
(2)Check the temperature properties of the thermistor.
(1)Check connector of thermistor for secure installation.
(2)Check the temperature properties of the thermistor.
(1)Check connector of thermistor for secure installation.
(2)Check the temperature properties of the thermistor.
(1)Replace the thermistor.
(2)Replace the thermistor.
(1)Replace the thermistor.
(2)Replace the thermistor.
(1)Replace the thermistor.
(2)Replace the thermistor.
*Remark
The malfunction No. is calculated using the following way.
Example)
Indoor unit lamp
Timer (orange)
Operation (Green)
Plasmacluster (blue)
→Lamp
16 8 4 2 1
O O O O O
O O
O
Calculation
4+1=5
2
Main
5
Sub
2
3 – 17
CHAPTER 4.
REFRIGERATION CYCLE
Service Manual
The content of this section is currently under revision.
Will be released after approval.
[1] SCHEMATIC DIAGRAM
Indoor unit Evaporator
(3)
Flare union
Flare union
Outdoor unit
Mini 3-way valve
Mini 2-way valve
Strainer
S
Expansion valve silencer
Compressor
(4)
(1)
Strainer
S
Reverse valve s
Condenser
(2)
[2] STANDARD CONDITION
Temperature of each part and presure of 3-way valve are acquired in standard condition, and would change with condition around. The standard condition is as follows:
Cooling
Heating
Dry-bulb Temp.
80 (26.7)
I n d o o
℉
(℃)
70 (21.1)
r s i d e
Relative Humidity (%)
51.1
ー
O u
Dry-bulb Temp. (℃)
95 (35.0)
t d
47 (8.33)
o o r s i d e
Relative Humidity (%)
ー
73
* R EFRIGERANT PIPE LENGTH 25feet (7.6m).
[3] PEAK OPERATION CURRENT
AE-X09PU
AE-X12PU
Cooling
5.8 A
6.9 A
PEAK CURRENT
Heating
6.8 A
9.0 A
AE-X12PU
[4] TEMPERATURE AT EACH PART AND PRESSURE IN 3-WAY VALVE
(AY-XPC09PU / AE-X09PU)
MODE
COOLING
MAX
HEATING
MAX
COOLING
TEST RUN
HEATING
TEST RUN
Hz
No.
Temp. on (1)
℉ (℃)
Temp. on (2)
℉ (℃)
Temp. on (3)
℉
(℃)
Temp. on (4)
℉
(℃)
3-way valve pressure (MPaG)
67 OR MORE 77 OR MORE
160.9 (71.6)
102.2 (39)
52.9 (11.6)
54.0 (12.2)
0.892
172.4 (78.0)
37.0 (2.8)
105.6 (40.9)
35.8 (2.1)
2.977
42 FIXED
143.8 (62.1)
102.9 (39.4)
56.3 (13.5)
62.6 (17.0)
1.045
42 FIXED
134.8 (57.1)
37.9 (3.3)
84.7 (29.3)
40.6 (4.8)
2.228
4 – 1
AE-X12PU
(AY-XPC12PU / AE-X12PU)
0.822
3.443
142.0 (61.1)
99.1 (37.3)
58.8 (14.9)
61.2 (16.2)
1.047
133.0 (56.1)
38.7 (3.7)
80.1 (26.7)
42.0 (5.5)
2.158
3-way valve pressure (MPaG)
“Hz” in the table above is converted by frequency, and has nothing to do with power supply frequency.
Note: For COOLING/HEATING max, please set the temperature to low/high limit (COOLING 61 ℉[16℃], HEATING 86℉[30℃]).
However, it is possible that the COOLING/HEATING max operation can not be obtained depending on the circumambient
condition.
4 – 2
[5] FLOW CHART OF REFRIGERANT CYCLE
5-1 COOLING & DEFROSTING 5-2 HEATING
AE-X12PU
[6] CHARACTERISTIC OF COOLING AND HEATING OPERATION
6-1 AY-XPC09PU / AE-X09PU
CAUTION: Indoor fan speed is set to [HIGH].
Airflow direction is initial.
Air inlet temperature of is 80 ℉ (26.7℃) during COOLING operation, and 70℉ (21.1℃) during HEATING operation.
COOLING
800
750
700
650
600
550
65 75 85 95
OUTSIDE TEMPERATURE(℉)
105 115
HEATING
850
800
750
700
650
600
550
23 31 39 47 55
OUTSIDE TEMPERATURE(℉)
63
10.0
9.5
9.0
8.5
8.0
7.5
65 75 85 95 105
OUTSIDE TEMPERATURE(℉)
115
12.5
11.5
10.5
9.5
8.5
7.5
6.5
5.5
23 33 43 53
OUTSIDE TEMPERATURE(℉)
63
4 – 3
AE-X12PU
6-2 AY-XPC12PU / AE-X12PU
CAUTION: Indoor fan speed is set to [HIGH].
Airflow direction is initial.
Temperature of inlet is 80 ℉ (26.7℃) during COOLING operation, and 70℉ (21.1℃) during HEATING operation.
COOLING HEATING
1100
1050
1000
950
900
850
800
750
65 75 85 95
OUTSIDE TEMPERATURE(℉)
105 115
1350
1300
1250
1200
1150
1100
1050
1000
950
23 31 39 47 55
OUTSIDE TEMPERATURE(℉)
63
13.5
13.0
12.5
12.0
11.5
11.0
10.5
10.0
65 75 85 95 105
OUTSIDE TEMPERATURE(℉)
115
17.0
16.0
15.0
14.0
13.0
12.0
11.0
10.0
9.0
8.0
23 31 39 47 55
OUTSIDE TEMPERATURE(℉)
63
4 – 4
AE-X12PU
CHAPTER 5.
DISASSEMBLING PROCEDURE
If, in carrying out repairs and modifications, the work requires the use of arc- and flame-producing apparatus, such as welding, brazing and soldering equipment, this work shall only be started after the rooms have been thoroughly ventilated. While the work is being carried out, the mechanical ventilation, if any, shall be kept in constant operation and all windows and doors kept open. In the case of repairs to parts of the refrigerant circuit, it may be necessary that not only the workman but also a second person shall be present for observation and assistance. Necessary protective equipment shall be available and, in the case of open flames or arcs, fire extinguishing apparatus shall be ready to hand. Welding and brazing shall be carried out by qualified workmen. Be sure to disconnect the power cord from the AC power outlet before starting the disassembly procedure. When reassembling the unit after repairing, be sure to install screws to their original positions. The screws used are not the same in specifications such as corrosionresistant treatment, tip shape and length. After the air conditioner is repaired or parts are replaced, measure insulation resistance of the equipment using an insulation resistance meter. If the measured resistance is lower than 1 M
Ω, inspect parts and repair or replace defective parts.
[1] OUTDOOR UNIT
Be sure to disconnect the power cord from the AC power outlet before starting the disassembly procedure. When reassembling the unit after repairing, be sure to install screws to their original positions.
The screws used are not the same in specifications such as corrosion-resistant treatment, tip shape and length.
After the air conditioner is repaired or parts are replaced, measure insulation resistance of the equipment using an insulation resistance meter. If the measured resistance is lower than 1 M
Ω, inspect parts and repair or replace defective parts.
1. MAIN UNIT
1) Unscrew 2 screws fixing the Valve Cover and remove it.
3)
Loosen the screws fixing the Power Supply and connecting cable, then remove them.
Valve Cover
2)
Unscrew 2 screws fixing the Cable Cover and remove it.
4)
Unscrew 1 screw fixing the Cable Holder and remove it.
Cable Cover
Cable Holder
5 – 1
AE-X12PU
5) Unscrew 5 screws fixing the Top Cover and remove it.
7) Remove 2 pcs Compressor Cover.
Compressor Cover
Top Cover
6) Unscrew 6 screws fixing the Front Panel and remove it.
8) Unscrew the Nut fixing the Terminal Cover and remove it , then disconnet the Compressor cable.
Terminal Cover
Compressor cable
Front Panel
5 – 2
9) Cut the 4 pcs band and disconnect the connectors.
AE-X15PU
11) Unscrew 2 screws fixing the Bulkhead and remove it.
Band
Bulkhead
10) Unscrew 4 screws fixing the Control Unit and remove it.
12) Unscrew 2 screws fixing the Motor Angle and remove it.
Motor Angle
Control Unit
5 – 3
AE-X12PU
13) Unscrew the Nut fixing the propeller fan and remove it.
16) Disconnect the cable and unscrew 1 screw fixing the earth cable.
14) Cut fixing band, and unscrew 4 screws fixing the Fan
Motor and remove it.
17) Remove Control Box and Box Cover.
[2] DISASSEMBLY OF CONTROL UNIT
15) Cut the band fixing the cable.
18) Remove Heat Sink Holder.
Heat Sink Holder
Band
5 – 4
AE-X12PU
CHAPTER 6. INSTALLATION MANUAL
This manual describes the installation of outdoor unit only.
For the installation of the indoor unit, see the installation manual accompanying indoor unit.
SAFETY PRECAUTIONS
• Installation must be made in accordance with the installation manual by qualifi ed service personnel.
Incorrect work will cause electric shock, water leak, fi re.
• Be sure to use the attached accessories parts and specifi ed parts
Use of other parts will cause electric shock, water leak, fi re, the unit falling.
• The appliance shall be installed and wired in accordance with
Wrong connection can cause overheating or fi re.
• After installation has complete, check that there is no leakage of refrigerant gas.
If the refrigerant gas contact with fi re, it may generate toxic gas.
• Ventilate the room if refrigerant gas leaks during installation.
If the refrigerant gas contact with fi re, it may generate toxic gas.
• Use the specifi ed electrical cable.
Make sure the cable is secured in place and that the terminals are free of any excess force from the cable. Otherwise overheating or fi re may result.
• Form the cable so that the control box cover, the cord holder and
• Tighten the fl are nut with a torque wrench according to the specifi ed method.
If the fl are nut is tightened too hard, the fl are nut may be broken after a long time and cause refrigerant gas leakage.
• When installing the unit, take care not to enter air substance other than the specifi ed refrigerant(R410A) in the refrigerant cycle.
Otherwise, it will cause burst and injury as a result of abnormal high pressure in the refrigerant cycle.
• Be sure to connect the refrigerant pipe before running the compressor.
Otherwise, it will cause burst and injury as a result of abnormal high pressure in the refrigerant cycle.
Incomplete ground may cause electrical shock.
Insuffi cient drainage may cause wetting of the room, furniture etc.
Use the pipe, fl are nut and tools exclusively for R410A.
ACCESSORIES
AE-X09PU, AE-X12PU
ITEMS
1 Base pan cap 1
Q’ty
1
ITEMS
4 Manual
INSTALL
2 Base pan cap 3
3
3 Drain joint
1
Q’ty
1
NOTES ON LOCATIONS
1. Place the outdoor unit on a stable base.
2. Provided
3. The unit should not be exposed to strong wind nor splashed with rain water.
4. Water drain from the unit should be let out without problem. Lay a drain hose if required. In cold regions, installation of the drain pipe is not advisable as freezing could result.
5. Keep TV set, radio and the like 1 m or more away from the unit.
6. Avoid locations exposed to machine oil vapor, salty air (facing the seashore, for example), hot spring vapor sulfur gas, etc. Such location can cause breakdown.
7. Avoid locations exposed to muddy water (along a road, for example) or where the unit can be tampered with.
8. Select a location where the outgoing air or operating noise cannot annoy others.
9. Keep the air outlet opening free of any obstacle. This could affect the performance of the unit and create loud noises.
10. For colder climate, install the unit in area not affected by snowfall or icefalls
(example roof houses). Unit should be installed minimum 10 inches from your country average snowfall accumulation.
INSTALLATION DIAGRAM
4 in (100 mm) or more
7.9 in (200 mm) or more
Coating tape
(Commercially available)
2 in (50 mm) or more
7.9 in (200 mm) or more
Provide as much installation space as possible for
PIPING
Model
Max. piping length:A
Max. height difference:B
65.6 ft (20 m) 32.8 ft (10 m)
Min. piping length
9.8 ft (3 m)
Additional refrigerant
(piping length exceeds ft/m)
0.22 oz/ft (20 g/m)
Chargeless max pipe length
32.8 ft (10 m) AE-X09PU, AE-X12PU
1. Standard piping length is 25ft(7.6 m).
2. When the outdoor unit is placed at a higher level than the indoor unit, provide a trap near the hose’s lead-in port.
Use the refrigerant pipes shown in the table below.
P i p e s i z e
Liquid side
1/4" (ø 6.35 mm)
Gas side
AE-X09PU, AE-X12PU 3/8" (ø 9.52 mm)
P i p e t h i c k n e s s
0.03 inch (0.8 mm)
T h e r m a l i n s u l a it o n
Thickness: 0.24 inch (6 mm) or thicker
Material: Polyethylene foam
• The thermal insulation should cover both the gas and liquid pipes.
B
6 – 1
A
B
Trap
AE-X12PU
1 OUTDOOR UNIT INSTALLATION
A
Installation dimension
Referring to the fi gure, fi rmly fasten the outdoor unit with bolts.
Model
AE-X09PU
AE-X12PU
A
21.3 inch
(540 mm)
B
12.2 inch
(310 mm)
2 CONNECTING THE REFRIGERANT PIPES
Flaring the pipe end
(1) Cutting with a pipe cutter
Cut at a right angle.
(2) Deburring
Allow no cuttings in the pipe.
(3) Putting in the fl are nut
90° (4) Flaring
Flare processing dimensions(A)
(5) Checking
To be fl ared perfectly circular.
Flare nut not missing.
A
Connecting the pipes
Connect the pipes for the indoor unit fi rst and then for the outdoor unit.
(1) Tighten the fl are nuts by hand for the fi rst 3-4 turns.
(2) Use a wrench and torque wrench to tighten up the pipes.
• Do not over tighten the pipes; it may be deformed or damaged.
Notes:
• Bend the pipes carefully as not to damage them.
• Lay the drain hose below the pipes.
Wrench
Gas side
Flare nut
Torque wrench
Flare nut tightening torque
P i p e s i z e
Liquid side 1/4" (ø 6.35 mm)
Tool
R410A tool
A
0 - 0.02 inch
(0 - 0.5 mm)
T o r q u e
11.8 ± 1.5 ft·lbs (16 ± 2 N·m)
3/8" (ø 9.52 mm) 28 ± 3 ft·lbs (38 ± 4 N·m)
3 AIR REMOVAL
Use a vacuum pump, gauge manifold and hoses exclusively for R410A.
(1) Remove both valve shaft caps of the 2 and 3-way valves.
(2) Remove the service port cap of the 3-way valve.
(3) Connect the gauge manifold hose to the service port and the vacuum pump.
Be sure that the hose end to be connected to the service port has a valve core pusher.
(4) Open the gauge manifold low-pressure valve(Lo) and operate the vacuum pump for 10-15 minutes.
Make sure the compound gauge reads -0.1 MPa(-76 cmHg).
(5) Close the gauge manifold valve.
(6) Turn off the vacuum pump.
Leave as it for 1-2 minutes and make sure the needle of the compound gauge does not go back.
(7) Open the 2-way valve 90° counterclockwise by turning the hexagon wrench.
Close it after 5 second, and check for gas leakage.*
(8) Disconnect the gauge manifold hose from the service port.
(9) Fully open the 2-way valve with hexagon wrench.
(10) Fully open the 3-way valve with hexagon wrench.
(11) Firmly tighten the service port cap and both valve shaft caps with a torque wrench at the specifi ed tightening torque.
2-way valve
3-way valve
Service port
Service port cap
Hexagon wrench
4mm
Gauge manifold
Compound gauge
Valve shaft cap
Service port
Lo Hi
Vacuum pump
* Check the pipe connections for gas leak using a leakage detector or soapy water. Regarding leakage detector, use high-sensitivity type designed specially for R410A.
OPEN
Valve shaft cap
Valve shaft cap tightening torque
P i p e s i z e
Liquid side 1/4" (ø 6.35 mm)
T o r q u e
17.7±2.1 ft·lbs (24±3 N·m)
Service port cap tightening torque
Torque
8.1±0.74 ft·lbs (11±1 N·m)
Gas side 3/8" (ø 9.52 mm) 17.7±2.1 ft·lbs (24±3 N·m)
6 – 2
AE-X12PU
4 CONNECTING THE CABLE TO THE OUTDOOR UNIT
Connecting wires and the ground wire
• Use solid conductor AWG14 or stranded conductor AWG14.
• Use double insulated copper wire with 600 V insulation.
• Use copper conductors only.
• Follow local electrical codes.
(1) Process the end of the Connecting Cable for the outdoor unit.
• For power supply cable, securely clamp a round terminal to
each end of the stripped cable.
(2) Remove the Side Cover and Cable Cover.
(3) Attach the Connection Holder to Cable Holder with Lock Nut.
Adjust the length of Connecting Cable and then connect it to
Terminal Board. Be sure that the terminal connections are as specifi ed.
(4) Attach the Cable Cover with the screws.
(5) Attach the Side Cover with the screws.
(6) Double-check that the Connecting Cable is securely in place.
Refer to
HOW TO CONNECT THE CONNECTING CABLE.
Caution:
• Be sure to put the Connecting Cable leads deep into the Terminal
Board and tighten up the screws. Poor contact can cause overheating or fi re, or malfunction.
• Be sure to connect the Connecting Cable to match the markings on the outdoor unit’s Terminal Board and those of the indoor unit.
• A Disconnect Switch is required. Check the local code.
Power supply cable and ground wire
• Use solid or stranded conductor AWG14.
• Use copper conductors only.
• Follow local electrical codes.
Cross section area
Connecting cable
14 AWG or larger if required
by local electrical code.
(2.1
mm
2
)
0.3in (8mm)
Connecting cable
2.6in (65mm)
2.2in (55mm)
0.3in (8mm)
Power supply
208/230 V AC,
1phase 2 wires.
60Hz
Power supply cable
14 AWG or larger if required
by local electrical code.
Ground wire
(2.1
mm
OUTDOOR UNIT
Terminal board 2
2 )
2in (50mm)
1.6in (40mm)
Disconnect switch
Cross section area
Power supply cable
Ground wire
INDOOR UNIT
Ground
HOW TO CONNECT THE CONNECTING CABLE
Lock Nut
Cable Cover
Cable holder
L1
L1
L2
L2
2
Terminal Board
Ground Wire
Side Cover
Connection Holder
(For Wire Conduit)
Power supply
Connecting cable
Control Box Cover
• Attach Wire conduit to Cable holder with Lock nut.
The thread of the installed Wire conduit should be less than 3/8 in. (10 mm) Fig. 1
• In order to connect the Connecting Cable correctly, please refer to the fi gure for proper length. Fig.2
Cable Holder
Lock Nut
Less than 3/8 in.
(10 mm)
Connection Holder
Wire Conduit
Fig. 1
7 in (177.8mm)
7 in (177.8mm)
Connecting Cable
Power supply
Fig. 2
6 – 3
AE-X12PU
5 POWER CABLING
Prepare a dedicated power supply circuit. For the connections, see below.
AE-X09PU
Supply power
Guaranteed voltage
Circuit breaker
15A
AE-X12PU
208/230 V, single-phase
187-253 V
• Fit a disconnect switch, having a contact separation of at least
3mm in all poles, to the electricity power line.
6 TEST RUN
See the installation manual accompanying indoor unit.
9 ITEMS TO CHECK
Is the specifi ed power supply voltage used?
Is the connecting cable fi xed to terminal board fi rmly?
Is the ground wire connected properly arranged?
Is the drainage properly?
Is there any gas leakage at the pipe connection?
Confi rm with the customers whether the 5°F/-15°C AUTO
OFF function will be used or not.
DRAIN WORK
EXPLANATION TO CUSTOMER
• Explain to the customer how to use and maintain the system, referring to the operation manual.
• Ask the customer to carefully read the operation manual.
• When the system has been set up, hand the installation manual to the customer.
• In the heating mode, the outdoor unit discharges water due to defrosting from its drain port and drain hole. Perform drain work if water drops are a problem.
• In very cold areas where the water in the drain hose could freeze, connecting the drain hose is not recommended.
(1) Insert the base pan caps into their matching drain hole on the bottom of the outdoor unit.
(2) Fit the drain joint into the drain tray and insert drain tray to the drain port.
(3) Connect commercial drain hose to the drain joint.
2 Base pan cap 3
Drain port
1 Base pan cap 1
2 Base pan cap 3
2 Base pan cap 3
Drain port
Drain joint 3
Drain hose
PUMP DOWN
Pump down is adopted in the case of unit removal for re-installation, abandonment, repair etc. Pump down is to collect the refrigerant into the outdoor unit.
PROCEDURE USING GAUGE MANIFOLD
(Recommended procedure)
(1) Connect the gauge manifold hose to the service port of the 3-way valve.
(2) Run the air conditioner at cooling test run mode (Refer to 6 TEST RUN).
(3) After 5-10 minutes, close the 2-way valve.
(4) Close the 3-way valve when the compound gauge reading becomes almost 0 MPa(0 cmHg).
(5) Stop the test run operation.
(6) Disconnect the gauge manifold hose from the service port.
(7) Disconnect both refrigerant pipes.
PROCEDURE WITHOUT USING GAUGE MANIFOLD
(1) Run the air conditioner at cooling test run mode (Refer to 6 TEST RUN).
(2) After 5-10 minutes, fully close the 2-way valve by turning the hexagon wrench clockwise.
(3) After 2-3 minutes, immediately close the 3-way valve fully.
(4) Stop the test run operation.
(5) Disconnect both refrigerant pipes.
2-way valve
3-way valve
Service port
Compound gauge
Gauge manifold
Lo Hi
Caution:
• Make sure that the compressor is turned off before removing the refrigerant pipes. Otherwise, it will cause burst and injury.
• Do not perform PUMP DOWN when refrigerant is leaking or there is no refrigerant in the refrigerant cycle. Otherwise, it will cause burst and injury.
TINS-B405JBRZ
6 – 4
PartsGuide
AE-X12PU
PARTS GUIDE
SPLIT TYPE
ROOM AIR CONDITIONER
SPLIT TYPE
ROOM AIR CONDITIONER
(OUTDOOR UNIT)
MODEL
AE-X09PU
AE-X12PU
[1] OUTDOOR UNIT PARTS
In the interests of user-safety (Required by safety regulations in some countries) the set should be restored to its original condition and only parts identical to those specified should be used.
CONTENTS
[2]
OUTDOOR UNIT STRUCTURE
AND CYCLE PARTS
[3] OTHER OUTDOOR UNIT
ELECTRIC PARTS
[4] OUTDOOR PACKING PARTS
“HOW TO ORDER REPLACEMENT PARTS”
To have your order filled promptly and correctly, please furnish the following information.
1. MODEL NUMBER
3. PART NO.
2. REF. No.
4. DESCRIPTION
★
MARK: SPARE PARTS-DELIVERY SECTION
Parts marked with " " are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.
This document has been published to be used for after sales service only.
The contents are subject to change without notice.
AE-X12PU
[1] OUTDOOR UNIT PARTS FOR AE-X09PU, AE-X12PU
2
PSEL-E465JBEZ
LHLD-B217JBFA
LHLD-B221JBTA
MSPR-A026JBE0
LX-NZA428JBEZ
MSPR-A027JBE0
NFANPA150JBEZ
PCOV-C018JBFA
PCOV-C019JBTA
PSPF-B332JBEZ
PSPF-B333JBEZ
RCILZA042JBZZ
RH-HXA187JBZZ
TLAB-F635JBRA
TLAB-F672JBRA
TLAB-F696JBRZ
TLAB-F748JBRZ
TLABBA291JBRA
TLABMA849JBRA
TLABMB245JBRZ
TLABMB250JBRZ
TSPC-H662JBRZ
TSPC-H694JBRZ
TLABKG063JBEZ
TLABKG064JBEZ
XTTS740P14000
PFPFPE338JBEZ
LBND-A042JBE0
XTTWW40P16000
CMOTLB537JBEZ
LANGKA327JBTA
CCAB-A588JBKZ
GCAB-A472JBTA
GGADFA050JBFA
PSEL-C048JBEZ
PSEL-C049JBEZ
PSEL-C050JBEZ
PSEL-D146JBEZ
PSEL-E341JBEZ
PSPF-B395JBEZ
DCAB-A182JBKZ
GCAB-A470JBTA
PSEL-C119JBEZ
PSEL-C133JBEZ
CPLT-A219JBKZ
JHNDPA031JBFA
PPLT-A939JBTA
PSEL-E396JBEZ
PSPF-B393JBEZ
CSKR-A571JBKZ
PCOV-C026JBFZ
PSEL-C680JBEZ
PSEL-C681JBEZ
PSKR-A411JBTA
PSPF-B394JBEZ
CCHS-B377JBTA
PSEL-E463JBEZ
PSEL-E464JBEZ
1-18
1-19
1-20
1-21
1-22
1-23
1-23
1-24
1-10-3
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-25
1-26
1-27
1-28
1-28
1-29
1-29
1-30
1-30
1-31
1-9-1
1-9-2
1-9-3
1-9-4
1-9-5
1-10
1-10-1
1-10-2
1-7-2
1-7-3
1-8
1-8-1
1-8-2
1-8-3
1-8-4
1-9
1-6-3
1-6-4
1-6-5
1-6-6
1-6-7
1-6-8
1-7
1-7-1
1-1
1-2
1-3
1-4
1-5
1--6
1-6-1
1-6-2
NO.
PARTS CODE
PRICE
RANK
NEW
MARK
PART
RANK
[1] OUTDOOR UNIT STRUCTURE AND CYCLE PARTS (AE-X09PU,AE-X12PU)
DESCRIPTION
AY
AH
AH
AF
AN
AG
AN
BC
AC
AB
AZ
AS
AC
AE
AG
AB
AC
AH
AH
AC
AF
AK
AM
AC
AC
AC
AH
BD
AH
AF
AD
AA
AA
AU
BD
AC
AL
AW
AE
AC
BF
AF
AC
AN
AY
AY
AC
AC
AG
AF
AT
BK
BB
BA
AD
AC
AC
BL
3
CUSHION
WIRE FIXING BAND
TAPPING SCREW
FAN MOTOR
FAN MOTOR ANGLE
FRONT PANEL ASS'Y
FRONT PANEL
FAN GUARD
F.PANEL INSULATOR
F.PANEL INSULATOR
BULKHEAD INSULATOR
SEAL
INSULATOR L
FRONT-P IIR SHEET
TOP COVER ASS'Y
TOP COVER
BOX INSULATOR
BOX INSULATOR
REAR CABINET ASSY
HANDLE
REAR CABINET
REAR CABINET SEAL A
REAR CABI IIR SHEET
BULKHEAD ASS'Y
COVER
SEAL A
SEAL B2
BULKHEAD
BULKHEAD IIR SHEET
BASE PAN SUB ASS'Y
BASE PAN SEAL A
BASE PAN SEAL B
BASE PAN SEAL C
THERMISTOR HOLDER
CABLE HOLDER
SPRING
SPECIAL NUT
THERMISTOR SPRING
PROPELLER FAN
VAVLE COVER
CABLE COVER
COMPRESSOR TOP COVER
COMPRESSOR COVER
REACTOR
THERMISTOR
ENERGY LABEL(AE-X12PU)
ENERGY LABEL(AE-X09PU)
CAUTION LABEL UL
UL COPPER WIRE LABEL
PCI LABEL
INVERTER LABEL
PRODUCT LABEL(AE-X12PU)
PRODUCT LABEL(AE-X09PU)
NAME LABEL(AE-X12PU)
NAME LABEL(AE-X09PU)
NUMBER CARD(AE-X12PU)
NUMBER CARD(AE-X09PU)
TAPPING SCREW
AE-X12PU
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
AE-X12PU
4-5
4-6
4-7
4-8
4-1
4-2
4-3
4-4
4-9
4-10
4-11
4-12
4-13
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
2-13
2-14
2-15
2-16
2-17
3-1
3-2
3-2
2-7-1
2-7-2
2-8
2-9
2-9
2-10
2-11
2-12
2-4
2-5
2-6
2-7
2-1
2-2
2-3
2-3
PSEN-A044JBKZ
PSEN-A045JBKZ
DCON-A757JBPZ
DCON-A758JBPZ
DVLV-B073JBKZ
DVLV-B353JBKZ
PDAI-A297JBTA
DVLV-B349JBKZ
PGUMSA068JBE0
PGUM-0034JBE0
CCIL-A185JBKZ
DVLV-B371JBKZ
DVLV-B347JBKZ
PGUMS0170JBE0
LX-NZA313JBEZ
RMOTSA037JBZZ
GLEG-099JBE0
LX-NZA476JBEZ
PCMPRA717JBEZ
PCOV-B149JBEZ
PGUM-A250JBEZ
DBOX-A086JBYZ
DSGY-F031JBKZ
DSGY-F082JBKZ
LHLD-B227JBFA
LHLD-B231JBFA
PCOV-B716JBWZ
PDAI-A295JBWZ
QTANZA091JBZZ
RFIL-A064JBE0
TLABCE004JBRZ
TLABNA002JBRZ
[2] OUTDOOR UNIT ELECTRIC PARTS (AE-X09PU,AE-X12PU)
AU
AF
AD
AF
AQ
AH
AR
AH
AC
AT
BQ
BQ
AD
AD
CD
AD
BF
AE
AE
BC
AD
AF
AU
BL
AY
AY
AK
BN
AG
AK
CP
CP
FLARE NUT ASS'Y
FLARE NUT ASS'Y
CONDENSER(AE-X12PU)
CONDENSER(AE-X09PU)
2WAY VALVE UNIT
3WAY VALVE UNIT
FLARE COUPLING BASE
REVERSE VALVE ASS'Y
DAMPER RUBBER
DAMPER RUBBER
COIL ASS'Y
EXPAN.VALVE ASS'Y(AE-X12PU)
EXPAN.VALVE ASS'Y(AE-X09PU)
DAMPER RUBBER
SPECIAL NUT
COIL
COMPRESSOR CUSHION
FRANGE NUT
COMPRESSOR
TERMINAL COVER
TERMINAL GASKET
CONTROL BOX ASS'Y
CONTROL BOARD UNIT(AE-X12PU)
CONTROL BOARD UNIT(AE-X09PU)
CONTROL BOX HOLDER
HEAT SINK HOLDER
COVER
TERMINAL HOLDER
TERMINAL BOARD
FERRITE CORE
WIRING DIAGRAM
LABEL
QFS-GA077JBZZ
QFS-GA078JBZZ
QFS-GA090JBZZ
QSPGCA006JBZZ
QW-VZG714JBZZ
QW-VZG715JBZZ
QW-VZG712JBZZ
QW-VZG713JBZZ
QW-VZG040JBZZ
QW-VZE711JBZZ
QW-VZG364JBZZ
RC-EZA463JBZZ
VHVTVR10511-B+
AE
AF
AE
AF
AD
AD
AG
AH
AK
AD
AF
AY
AD
Fuse (FU3)
Fuse (FU2)
Fuse (FU5)
Surge absorb (SA1)
Lead wire(BT2)
Lead wire (BT1)
Lead wire (BT6)
Lead wire (BT5)
Lead wire (BT4)
Lead wire (BT10-BT11)
Lead wire (BT3)
Capacitor(C9,C10)
Varistot(NR1,NR2)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
3
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
2
4
[4] OUTDOOR UNIT PACKI NG PARTS
7-2
7-3
7-1
NO.
PARTS CODE
PRICE
RANK
NEW
MARK
[4] OUTDOOR UNIT PACKING PARTS
7-1 CPADBA152JBKZ
7-2 CPADBA032JBKZ
7-3 SPAKCE236JBEZ
AR
AL
AW
PART
RANK
Bottom Pad Assembly
Packing Pad Assembly
Packing Case
DESCRIPTION
AE-X12PU
5
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