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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

O u

Dry-bulb Temp. ()

95 (35.0)

t d

47 (8.33)

o o r s i d e

Relative Humidity (%)

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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