Fujitsu AB*30LBAG series Service Instruction Download Page 4 | Manualshive

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1-1-1  PARTS LAYOUT DRAWING...............................................................................
1-1-2  WIRING................................................................................................................
1-1-3  DISASSEMBLY PROCESS.................................................................................

1-1 For AO*30/ 36LMBWL.............................................................................................

1 REPLACEMENT PARTS ( For OUTDOOR UNIT )

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10. REPLACEMENT PARTS

10-01
10-01
10-01

10-04

10-03

2-1 PARTS LAYOUT DRAWING...................................................................................

2 REPLACEMENT PARTS ( For INDOOR UNIT )

........................................................... 10-29

10-29

1-1-4 ASSEMBLY PROCESS of INVERTER UNIT....................................................... 10-09

1-2-1  PARTS LAYOUT DRAWING...............................................................................
1-2-2  WIRING................................................................................................................
1-2-3  DISASSEMBLY PROCESS.................................................................................
1-2-4  ASSEMBLY PROCESS of INVERTER UNIT......................................................

1-2 For AO*45LJBYL..................................................................................................... 10-14

10-14

10-18

10-16

10-24

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Summary of Contents for AB*30LBAG series

Page 1: ...SPLIT TYPE ROOM AIR CONDITIONER Large Ceiling type Models Indoor unit Outdoor unit AB 30LBAG AB 36LBAG AB 45LBAG AO 30LMBWL AO 36LMBWL AO 45LJBYL INVERTER SERVICE INSTRUCTION R410A ...

Page 2: ...ING CAPACITY CONTROL 5 2 HEATING OPERATION 05 02 05 02 5 3 1 INDOOR UNIT CONTROL 5 3 DRY OPERATION 05 03 05 03 05 04 05 05 05 07 05 08 5 8 COMPRESSOR CONTROL 05 10 5 9 TIMER OPERATION CONTROL 05 11 5 10 ELECTRONIC EXPANSION VALVE CONTROL 05 13 5 11 TEST OPERATION CONTROL 05 13 5 12 PREVENT TO START FOR 3 MINUTES 3 MINUTES ST 05 13 5 13 4 WAY VALVE EXTENSION SELECT 05 13 5 14 AUTO RESTART 05 13 5 1...

Page 3: ...CAPACITY TABLE 08 01 8 2 OPERATION RANGE 08 02 8 3 ELECTRIC CHARACTERISTICS 08 03 8 4 SAFETY DEVICE 08 04 8 5 FUNCTION SETTING 08 05 7 1 2 OUTDOOR UNIT DISPLAY 7 1 1 INDOOR UNIT DISPLAY 7 1 ERROR DISPLAY 7 TROUBLE SHOOTING 7 2 TROUBLE SHOOTING WITH ERROR CODE 7 3 TROUBLE SHOOTING WITH NO ERROR CODE 7 4 SERVICE PARTS INFORMATION 07 01 07 01 8 5 1 INDOOR UNIT 08 05 8 5 2 OUTDOOR UNIT AO 30 36LMBWL 0...

Page 4: ... 10 REPLACEMENT PARTS 10 01 10 01 10 01 10 04 10 03 2 1 PARTS LAYOUT DRAWING 2 REPLACEMENT PARTS For INDOOR UNIT 10 29 10 29 1 1 4 ASSEMBLY PROCESS of INVERTER UNIT 10 09 1 2 1 PARTS LAYOUT DRAWING 1 2 2 WIRING 1 2 3 DISASSEMBLY PROCESS 1 2 4 ASSEMBLY PROCESS of INVERTER UNIT 1 2 For AO 45LJBYL 10 14 10 14 10 18 10 16 10 24 ...

Page 5: ...1 SPECIFICATIONS R410A INVERTER Large Ceiling type ...

Page 6: ...ture of 20 CDB 15 CWB and outdoor temperature of 7 CDB 6 CWB Pipe length 7 5 m Height difference 0 m Outdoor unit Indoor unit CEILING MODELS INVERTER HEAT PUMP 230V 50Hz STARTING METHOD FAN TYPE x Q ty FAN MOTOR OUTPUT W COMPRESSOR TYPE FAN SPEED COOL HEAT DRAIN PIPE kg lbs MATERIAL SIZE CONNECTION METHOD SIZE mm WEIGHT NET GROSS MAX HEIGHT HEAT EXCHANGER TYPE INDOOR Coil OUTDOOR Coil Fin mm mm PI...

Page 7: ... GAS 15 88 5 8 inc m 70 chargeless 20 m 30 R410A CHARGE g 3400 POE COOLING 15 to 43 HEATING 15 to 24 WIRELESS ABS mm Outer diameter 25 6 Inner diameter 22 0 Note Specifications are based on the following conditions Cooling Indoor temperature of 27 CDB 19 CWB and outdoor temperature of 35 CDB 24 CWB Heating Indoor temperature of 20 CDB 15 CWB and outdoor temperature of 7 CDB 6 CWB Pipe length 7 5 m...

Page 8: ...2 DIMENSIONS R410A INVERTER Large Ceiling type ...

Page 9: ...Unit mm 30 30 Suspension bolt pitch 1 600 INDOOR UNIT TOP VIEW 10 155 300 INDOOR UNIT Suspension bolt should extend outward 30 to 75 Refrigerant piping flare connection Gas Refrigerant piping flare connection Liquid Drain piping connection Drain pipe I D 22 O D 25 6 Knock out hole for fresh air Knock out hole for refrigerant piping Hole for lifting bolt Use M10 screw bolt ...

Page 10: ...0 30 Suspension bolt pitch 1 600 INDOOR UNIT TOP VIEW 10 155 300 INDOOR UNIT Suspension bolt should extend outward 30 to 75 Refrigerant piping flare connection Gas Refrigerant piping flare connection Liquid Drain piping connection Drain pipe I D 22 O D 25 6 Knock out hole for fresh air Knock out hole for refrigerant piping Hole for lifting bolt Use M10 screw bolt ...

Page 11: ...3 REFRIGERANT SYSTEM DIAGRAM R410A INVERTER Large Ceiling type ...

Page 12: ... THPO THD THR THR THPI THPI THD THC THPO COMPRESSOR ACCUMULATOR EXPANSION VALVE STRAINER STRAINER 4 Way valve THERMISTOR DISCHARGE TEMP THERMISTOR ROOM TEMP THERMISTOR PIPE TEMP THERMISTOR OUTDOOR TEMP THERMISTOR PIPE TEMP THERMISTOR COMP TOP TEMP Refrigerant Pipe Refrigerant Pipe COOL HEAT EVAPOLATOR Charging Valve Charging Valve 3 REFRIGERANT CIRCUIT ...

Page 13: ...THPO THD THR THPI THR THPI THD THC THPO COMPRESSOR ACCUMULATOR EXPANSION VALVE STRAINER STRAINER STRAINER 4 Way valve THERMISTOR DISCHARGE TEMP THERMISTOR ROOM TEMP THERMISTOR PIPE TEMP THERMISTOR OUTDOOR TEMP THERMISTOR PIPE TEMP THERMISTOR COMP TOP TEMP Refrigerant Pipe Refrigerant Pipe COOL HEAT EVAPOLATOR Charging Valve Charging Valve MUFFLER ...

Page 14: ...4 CIRCUIT DIAGRAM R410A INVERTER Large Ceiling type ...

Page 15: ...ORANGE YELLOW WHITE WHITE BLACK BLUE BLUE PURPLE PURPLE GRAY GRAY BROWN RED ORANGE YELLOW WHITE GREEN WHITE WHITE 1 2 3 4 5 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 1 2 1 2 3 4 5 1 2 3 1 2 3 1 2 3 2 1 3 1 2 3 4 5 1 2 3 4 5 1 2 1 2 1 2 3 2 1 1 2 CN4 CN10 CN15 CN13 CN16 CN5 CN11 CN7 CN6 CN1 CN201 CN8 CONTROL BOARD DISPLAY BOARD N L FILTER BOARD Use T 3 15A 250V Fuse on F101 4 CIRCUIT DI...

Page 16: ...BOARD MAIN RED BLACK BLACK BROWN BLUE BLACK BROWN BLACK BLACK WHITE WHITE YELLOW YELLOW BROWN BROWN BLUE ORANGE RED RED RED RED BLACK WHITE WHITE BLACK BLACK ORANGE BROWN RED RED RED WHITE WHITE BLACK BLACK ORANGE YELLOW YELLOW BLUE WHITE BROWN ORANGE RED BLACK BROWN RED 4WV FM EV HIGH PRESSURE SW SOLENOID COIL EXPANSION VALVE COIL FAN MOTOR THERMISTOR HEAT SINK THERMISTOR DISCHARGE THERMISTOR PIP...

Page 17: ...W BROWN BROWN BLUE ORANGE RED RED BLACK WHITE YELLOW BROWN RED RED RED BLACK WHITE WHITE WHITE WHITE BROWN YELLOW BLUE VIOLET BLACK ORANGE BROWN RED RED RED WHITE WHITE BLACK BLACK ORANGE YELLOW ORANGE BLACK BROWN RED 4WV FM FM EV HIGH PRESSURE SW SOLENOID COIL EXPANSION VALVE COIL FAN MOTOR 1 FAN MOTOR 2 THERMISTOR HEAT SINK THERMISTOR DISCHARGE THERMISTOR PIPE THERMISTOR OUTDOOR THERMISTOR COMPR...

Page 18: ...5 DESCRIPTION OF EACH CONTROL OPERATION R410A Large Ceiling type INVERTER ...

Page 19: ...he compressor frequency is controlled within the range shown in Table1 However the maximum frequency is limited in the range shown in Figure 1 based on the fan speed mode and the outdoor temperature minimum frequency maximum frequency 20Hz 20Hz 20Hz 90Hz 90Hz 92Hz AB 30LBAG AB 36LBAG AB 45LBAG Outdoor air temperature A zone 31 C B zone C zone D zone Hi Me Lo A zone 90Hz 70Hz 65Hz 55Hz 90Hz 92Hz 72...

Page 20: ... be stopped When the room temperature is between 2 degC to 3 degC of the setting temperature the compressor frequency is controlled within the range shown in Table2 However the maximum frequency is limited in the range shown in Figure 2 based on the outdoor temperature Table 2 Compressor Frequency Range Fig 2 Limit of Maximum Frequency based on Outdoor Temperature 05 02 Outdoor air temperature C z...

Page 21: ...detected as shown in the Table 3 Room temperature Room temperature Compressor ON Ts 1 5 degC Ts 1 degC Compressor OFF Compressor ON ON OFF Indoor fan air flow mode Air flow mode Lo OFF 30 5 30 120 5 sec 180 180 Table 3 Compressor frequency Fig 3 Compressor Control based on Room Temperature Fig 4 Indoor Fan Control 05 03 Operating frequency 45Hz 45Hz 30Hz AB 30LBAG AB 36LBAG AB 45LBAG Ts Setting te...

Page 22: ...utdoor unit s operarion mode the operation mode is selected in accordance with the table below Table 4 Operation mode selection table When COOLING was selected at the same operation as COOLING OPERATION is performed When HEATING was selected at the same operation as HEATING OPERATION is performed When the compressor was stopped for 6 consecutive minutes by the temperature control function after th...

Page 23: ... to a room temperature as shown in Figure 5 On the other hand if switched in HIGH LOW the indoor motor will run at a constant airflow of COOL operation modes LOW MED HIGH as shown in Table 5 Fig 5 Airflow change over Cooling AUTO When the room temperature rises When the room temperature drops TR Room temperature Ts Setting temperature TR Ts 2 degC 1 degC TR Ts 2 degC TR Ts 1 degC TR Ts 3 degC 2 de...

Page 24: ...ONTROL Heating mode 6 DRY OPERATION Refer to the Figure 4 During the dry mode operation the fan speed setting can not be changed 47 C 41 C SETTING FAN MODE LO mode S LOW mode 33 C 30 C 30 C Indoor heat exchanger temperature Indoor heat exchanger temperature Indoor heat exchanger temperature The maximum value of the indoor fan speed is set as shown in Figure 7 based on the detected temperature by t...

Page 25: ...an motors For AB 30 36LBAG It runs at 500rpm for 20 seconds after starting up the outdoor fan When the outdoor heat exchanger tenperature is lower than 2 C the fan speed switches to 900rpm on heating mode For AB 45LBAG It runs at 500rpm for 20 seconds after starting up the outdoor fan When the outdoor heat exchanger tenperature is lower than 2 C the fan speed switches to 850rpm Upper fan and 750rp...

Page 26: ...controller the vertical louver starts to swing The range of swing depends on the set airflow direction When the indoor fan is either at S Lo or Stop mode the swinging operation is interrupted and the louver stops at the memorized position 05 08 The indoor fan motor starts after the louver reaches to the setting position At the start of operation if the setting louver position is or the setting pos...

Page 27: ...ir Direction Range Operation Range 2 1 SWING OPERATION When the swing signal is received from the remote controller the horizontal louver starts to swing The range of swing depends on the set airflow direction When the indoor fan is either at S Lo or Stop mode the swinging operation is interrupted and the louver stops at the memorized position 05 09 Stop mode means Operation stop 1 2 3 4 5 1 2 3 3...

Page 28: ... 10 Compressor Control at Start up Frequency Frequency 05 10 AB 30LBAG 20Hz 20Hz 20Hz 90Hz 90Hz 92Hz AB 36LBAG AB 45LBAG 20Hz 20Hz 20Hz 95Hz 95Hz 92Hz 45Hz 45Hz 30Hz Time A Time B Time C Time E Time D Hold 1 2 Frequency Time Frequency Frequency AB 30LBAG AB 36LBAG AB 45LBAG 180sec 60sec 120sec 120sec 720sec 180sec 80sec 180sec 180sec 720sec 40Hz 56Hz 56Hz 70Hz AB 30LBAG AB 36LBAG AB 45LBAG Time A ...

Page 29: ...Remote Controller ON TIMER OFF TIMER PROGRAM TIMER SLEEP TIMER The program timer allows the OFF timer and ON timer to be used in combination one time Operation mode Operation will start from the timer setting either OFF timer or ON timer whichever is closest to the clock s current timer setting The order of operations is indicated by the arrow in the remote control unit s display SLEEP timer opera...

Page 30: ...n the cooling operation mode When the sleep timer is set the setting temperature is increased 1 degC It increases the setting temperature another 1 degC after 1 hour After that the setting temperature is not changed and the operation is stopped at the time of timer setting Ts 1degC 2degC 2degC 1degC 4degC 3degC Set 60min In the heating operation mode When the sleep timer is set the setting tempera...

Page 31: ...rupted by a power failure etc during operation the operation contents at that time are memorized and when power is recovered operation is automatically resumed with the memorized operation contents When the power is interrupted and recovered during timer operation timer operation is canceled but only setting time is memorized Operation contents memorized when the power is interrupted Operation mod...

Page 32: ... valve gas within 1minute after operations stops 4 The LED will go out 3minutes after it stops Disconnect the power supply after confirming that the LED has gone out Perform the following procedures to collect the refrigerant when moving the indoor unit or the outdoor unit When the outdoor heat exchanger temperature is lower than Operation temperature Refer to Table 8 and the heating operation has...

Page 33: ... Operation lamp 9 sec ON 1 sec OFF Outdoor heat exchanger temperature Over 12 C or Compressor ON time Over 15 minutes Defrost end Compressor integrating operation 45 minutes and over Outdoor heat exchanger temperarure Below 10 C Outdoor heat exchanger temperarure Below 8 C Outdoor temp 1 C Outdoor temp 1 C Compressor integrating operation 45 minutes and over Outdoor temp Outdoor heat exchanger tem...

Page 34: ...oor side will detect discharge gas temperature When the discharge temperature becomes higher than Temperature the compressor frequency is decreased 10 Hz and it continues to decrease the frequency for 10 Hz every 120 seconds until the temperature becomes lower than Temperature When the discharge temperature becomes lower than Temperature the control of the compressor frequency is released When the...

Page 35: ...T0 13 C 38 C T0 19 C T0 Outdoor temperature 780 rpm 850 rpm 400 rpm 250 rpm 170 rpm 10 0A 9 5A 14 0A 13 5A 14 0A 13 5A 15 0A 14 5A 18 0A 17 5A 10 0A 9 5A 10 0A 9 5A 15 0A 14 5A 7 0A 6 5A 12 0A 11 5A 5 5A 5 0A 7 0A 6 5A 9 5A 9 0A Outdoor unit fan speed The compressor frequency is controlled so that the outdoor unit input current does not exceeds the current limit value that was set up with the outd...

Page 36: ...lled as following based on the detection value of the indoor heat exchanger temperature sensor Fig 12 Heating Overload Protection Control 05 18 63 C 54 C 50 C Compressor is OFF The compressor frequency is decreased 10Hz every 60seconds Compressor OFF Release of protection Compressor ON The compressor frequency is increased 10Hz every 60seconds Hold Indoor heat exchange temperature 3 C 6 C 12 C The...

Page 37: ...6 REFRIGERANT CAUTION R410A R410A INVERTER Large Ceiling type ...

Page 38: ...and the ser vice port side are possible to open and close at the same time Thermistor vacuum gauge Fig 4 15 To remove moisture from the refrigerating cycle complete ly it is necessary to perform appropriate vacuum drying For that reason vacuum conditions can be confirmed cer tainly Vacuum valve Fig 4 16 This valve builts in a check valve and it is easily possible to vacuum a refrigerating cycle or...

Page 39: ...del with HFC R407C R410A model If you use existing pipes it may cause resolution of compressor oil by remaining mineral oil 3 8 15 88mm R410A 22 29 19 7 25 R22 R407C R22 R407C R22 R407C 19 4 23 20 27 3 4 19 05mm R410A 24 36 24 29 R22 R407C 23 7 29 24 Material Nominal diameter in 1 4 3 8 1 2 5 8 3 4 7 8 1 1 8 1 1 4 1 1 2 1 3 8 1 6 35 9 52 12 70 15 88 19 05 22 22 28 58 31 75 38 10 34 92 25 40 Outsid...

Page 40: ...efrigerant charge Do it always from the liquid phase side Don t charge from the gas phase side Compressor oil is changed Be careful to handle synthetic oil since it resolves easily by moisture and contamination Don t mix new synthetic oil and mineral oil It may cause trouble We developed new synthetic oil since HFC refrigerant doesn t dissolve in mineral for R22 oil 06 03 ...

Page 41: ... It is necessary to use the vacuum pump which can obtain the high vacuum condition Precaution on Tools Feature 2 New Refrigerant has Approx 1 6 times higher pressure than previous refrigerant R410A High Pressure Different point from previous one Diameter of Service port has been changed from 1 4 Flare to 5 16 Flare It requires the gauge manifold and charge hose exclusively for R410A It requires th...

Page 42: ...hase out schedule of HCFC according to Montreal protocol 1996 2010 2000 2004 2015 2020 2030 60 40 20 100 Year 80 HCFC consumption of 1989 CFC consumption of 1989 x 2 8 65 35 10 0 5 started control only service use total abolition 100 0 06 05 ...

Page 43: ...emical compound including chlorine and hydrogen ODP 0 02 01 HCFC Hydro Chloro Fluoro Carbon For example R22 for air conditioner R134a for Car air conditioner HFC3 Hydro Fluoro Carbon R407C for air conditioner Refrigerant characteristics R22 Composition wt R22 100 Boiling Point 40 8 Behavior Pressure at 54 5 C kPa 2 151 Temperature Glide deg 0 ODP 0 055 R407C R32 R125 R134a 23 25 52 43 6 zeotrope 2...

Page 44: ... Pressure Mpa 39 2 27 40 2 32 41 2 38 42 2 44 44 2 57 45 2 63 46 2 69 47 2 76 48 2 83 49 2 90 51 3 04 52 3 11 53 3 18 54 3 26 56 3 41 57 3 49 58 3 57 59 3 65 61 3 82 62 3 90 63 3 99 64 4 08 Desighed pressure of R410A refrigerant Pressure Temp Relation between R410A condensing temperature and saturated pressure Temp Pressure Advantage Disadvantage Suitable for R410A higher system performance Near A...

Page 45: ... Use better grade of material for sliding parts for securing good lubrication of sliding part as HFC refrigerant does not contain chloride Review insulating materials Increase pressure resistance strength CAUTION During storage due care must be taken so that foreign matters such as dust and water do not enter HEAT EXCHANGER Review the water contaminants controlling level Use thinner tube to increa...

Page 46: ...7 TROUBLE SHOOTING R410A INVERTER Large Ceiling type ...

Page 47: ...5sec ON OFF 0 1sec 0 1sec ON OFF 1 ERROR DISPLAY 2 ERROR DISPLAY METHOD Error Contents 2 times blink 2 times blink 3 times blink 3 times blink 5 times blink 6 times blink 5 times blink 3 times blink 4 times blink 5 times blink 8 times blink 9 times blink 10 times blink 11 times blink 12 times blink 13 times blink 14 times blink OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Trouble sh...

Page 48: ...Forward transfer signal error 1 time blink 2 times blink 3 times blink 4 times blink 7 times blink 8 times blink 9 times blink 12 times blink 13 times blink 14 times blink 15 times blink 1 2 3 4 5 6 7 8 9 10 11 Outdoor heat exchanger temperature sensor error Outdoor temperature sensor error Outdoor discharge pipe temperature sensor error Outdoor unit fan motor error upper fan Pressure switch abnor...

Page 49: ...emoved connection line of Indoor unit and Outdoor unit If there is an abnormal condition correct it by referring to Installation Manual or Data Technical Manual Check connection between Outdoor Unit Main PCB and Filter PCB If there is loose connector or open cable Check Point 3 Check the voltage of power supply Check the voltage of power supply Check if AC198 264V appears at Outdoor Unit Terminal ...

Page 50: ...LACK BLACK CN7 CN8 1 2 1 2 Room Temperature Sensor Error Indoor Unit Controller PCB Circuit Room Temperature Thermistor When Room Temperature Thermistor open or short circuit is detected at power ON 1 Connector connection failure 2 Thermistor failure 3 Controller PCB failure Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon correcting the removed conne...

Page 51: ...ermistor failure 3 Controller PCB failure Check Point 1 Check connection of Connector Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon correcting the removed connector or mis wiring reset the power Check Point 2 Remove connector and check Thermistor resistance value Thermistor Characteristics Approx value If Thermistor is either open or shorted replac...

Page 52: ...Temperature Thermistor open or short circuit is detected at power ON or while running the compressor 1 Connector connection failure 2 Thermistor failure 3 Main PCB failure Check Point 1 Check connection of Connector Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon correcting the removed connector or mis wiring reset the power Check Point 2 Remove conn...

Page 53: ... Thermistor When Outdoor Temperature Thermistor open or short circuit is detected at power ON or while running the compressor 1 Connector connection failure 2 Thermistor failure 3 Main PCB failure Check Point 1 Check connection of Connector Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon correcting the removed connector or mis wiring reset the power ...

Page 54: ...it Discharge Pipe Temperature Thermistor When Discharge Pipe Temperature Thermistor open or short circuit is detected at power ON or while running the compressor 1 Connector connection failure 2 Thermistor failure 3 Main PCB failure Check Point 1 Check connection of Connector Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon correcting the removed conn...

Page 55: ...ircuit Momentary power failure Check if there is a defective contact or leak current in the power supply circuit Noise Check if there is any equipment causing harmonic wave near electric line Neon bulb or electric equipment that may cause harmonic wave Check the complete insulation of grounding Note EEPROM EEPROM Electronically Erasable and Programmable Read Only Memory is a non volatile memory wh...

Page 56: ...by hand when operation is off Check if fan is caught dropped off or locked motor If Fan or Bearing is abnormal replace it Check Indoor Fan motor PARTS INFORMATION 5 If Fan motor is abnormal replace it Check excessively high temperature around the motor If there is any surrounding equipment that causes heat Upon the temperature coming down restart operation Check continuity of motor capacitor If it...

Page 57: ...mplete insulation of the grounding Check if there is any equipment that causes harmonic wave near the power cable Neon light bulb or any electronic equipment which causes harmonic wave Check the voltage of power supply Check if AC198 264V appears at Outdoor Unit Terminal L N Check if Indicated value swings between AC70V and AC130V at Outdoor Unit Terminal 2 3 Check any loose or removed connection ...

Page 58: ...ressor Temperature Thermistor When Compressor Temperature Thermistor open or short circuit is detected at power ON or while running the compressor 1 Connector connection failure 2 Thermistor failure 3 Main PCB failure Check Point 1 Check connection of Connector Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon correcting the removed connector or mis wi...

Page 59: ...it Pressure Switch 1 Connector connection failure 2 Pressure Switch failure 3 Main PCB failure When pressure switch open is detected in 10 seconds after the power is turned on Does abnormal LED indication show again Make sure circuit diagram of outdoor unit and check terminal voltage at Pressure Switch DC5 0V If the voltage does not appear replace Main PCB Check if connector is loose or cable is o...

Page 60: ...heck if cable is open Upon correcting the removed connector or mis wiring reset the power Check Point 2 Check Outdoor Fan Heat Exchanger Is there anything obstructing the air distribution circuit Is there any clogging of Outdoor Heat Exchanger Is the Fan rotating by hand when operation is off Check Outdoor Fan Motor Refer to Trouble shooting 17 If the Fan Motor is locked replace it If the Fan Moto...

Page 61: ...he same circuit Momentary power failure Check if there is a defective contact or leak current in the power supply circuit Noise Check if there is any equipment causing harmonic wave near electric line Neon bulb or electric equipment that may cause harmonic wave Check the complete insulation of grounding Check Point 1 1 Reset Power Supply and operate Does Error indication show again When Input Curr...

Page 62: ...PARTS INFORMATION 3 If Active Filter Module is abnormal replace it Check Point 4 Replace Main PCB If Check Point 1 2 do not improve the symptom change Main PCB Check Point 1 Check external cause at Indoor and Outdoor Voltage drop or Noise Instant drop Check if there is a large load electric apparatus in the same circuit Momentary power failure Check if there is a defective contact or leak current ...

Page 63: ...1 do not improve the symptom change Main PCB Check if connector is removed Check erroneous connection Check if cable is open Upon correcting the removed connector or mis wiring reset the power Refer to PARTS INFORMATION 2 For Compressor Terminal Main PCB While running the compressor if the detected rotor location is out of phase with actual rotor location more than 90 degrees the compressor stops ...

Page 64: ...n the temperature coming down restart operation When outdoor fan rotation speed is less than 100rpm in 20 seconds after fan motor starts fan motor stops After fan motor restarts if the same operation within 60sec is repeated 3 times in a row compressor and fan motor stops If and repeats 5 times in a row compressor and fan motor stops permanently 07 18 Indoor Unit Operation LED Blink Timer LED 14 t...

Page 65: ...Error Outdoor Unit Main PCB Circuit Heat Sink Temperature Thermistor When Heat Sink Temperature Thermistor open or short circuit is detected at power ON or while running the compressor 1 Connector connection failure 2 Thermistor failure 3 Main PCB failure Check Point 1 Check connection of Connector Check if connector is removed Check erroneous connection Check if thermistor cable is open Upon corr...

Page 66: ...me operation is repeated within 40sec the compressor stops again If and repeats 5 times the compressor stops permanently Outdoor Unit Main PCB Circuit 1 Defective connection of electric components 2 Main PCB failure Check Point 1 Check connection of around the Compressor components OK OK Check Point 2 Replace Main PCB If Check Point 1 do not improve the symptom replace Main PCB Check if connector ...

Page 67: ...ctive contact or leak current in the power supply circuit Noise Check if there is any equipment causing harmonic wave near electric line Neon bulb or electric equipment that may cause harmonic wave Check the complete insulation of grounding Check Point 3 Check Electrical Components Check Voltage of power supply Check AC198 264V appears at Indoor Unit Terminal 1 2 Power Supply Check Fuse F101 in Fi...

Page 68: ...ve contact or leak current in the power supply circuit Noise Check if there is any equipment causing harmonic wave near electric line Neon bulb or electric equipment that may cause harmonic wave Check the complete insulation of grounding Check the voltage of power supply Check if AC198 264V appears at Outdoor Unit Terminal L N YES YES Check Fuse F2 F4 in Main PCB If Fuse is open check loose termin...

Page 69: ... manual and Data Technical Manual Turn off Power and check correct followings Is there loose or removed communication line of Indoor Unit and Outdoor Unit Instant drop Check if there is a large load electric apparatus in the same circuit Momentary power failure Check if there is a defective contact or leak current in the power supply circuit Noise Check if there is any equipment causing harmonic w...

Page 70: ...22 Check any objects that obstruct the air flow route Check clogged Heat Exchanger Is the Valve open Is capacity of Indoor Unit fitted to Room size Any windows open Or direct sunlight Check connection pipe specified pipe length Pipe diameter Check any loose or removed communication line If there is an abnormal condition correct it by referring to Installation Manual or Data Technical Manual Check ...

Page 71: ...t panel normal Is Fan broken or deformed Is the screw of Fan loose Is there any object which obstruct the Fan rotation Is Main Unit installed in stable condition Is Fan Guard installed normally Check if vibration noise by loose bolt or contact noise of piping is happening Is Compressor locked Check Compressor PARTS INFORMATION 1 2 Water Leaking 1 Erroneous installation 2 Drain hose failure Diagnos...

Page 72: ... compressor due to clogged dirt or less oil Replace Compressor Replace Compressor Replace Compressor Stops soon after starting up Is there open or loose connection cable Is Gas Pipe Valve open Low Pressure is too low Check if Refrigerant is leaking Recharge Refrigerant Check if Strainer is clogged PARTS INFORMATION 4 If there is no failure the defect of Compressor can be considered Compression par...

Page 73: ...TM305 W303 TM303 RED WHITE BLACK Compressor Inverter Compressor Check terminal connection of Compressor loose or incorrect wiring Check connection of Main PCB Loose or incorrect wiring Check winding resistance of each terminal If the resistance value is 0 or infinite replace Compressor If the symptom does not change with above Check 1 2 replace Main PCB Resistance Value 0 88 For AB 30 36LBAG 0 188...

Page 74: ...s less than the output voltage of compressor stopping Active Filter Module is detective Replace Active Filter Module 07 28 Terminal Resistance value L2 L1 L1 L2 P P Control Box N1 N1 Tester Tester Check the open or short circuit L2 P P N2 L2 L2 Check the diode 0 360k 720k 1 65M 20 360k 20 20 Ref value 1 1 14M Ref value 2 1 01M Ref value 1 761k Ref value 2 Terminal Resistance value Tester Tester 1 ...

Page 75: ...ITE 1 2 3 4 5 6 at 20 C Outdoor unit Electronic Expansion Valve EEV Check connection of connector CN27 Loose connector or open cable Remove connector check each winding resistance of Coil If Resistance value is abnormal replace EEV Remove Connector and check Voltage DC12V If it does not appear replace Main PCB Turn on Power and check operation noise If an abnormal noise does not show replace Main ...

Page 76: ...t 22 8 10 31 9 10 Resistance value AC Thermal protector 115 125 C Pr 1 1 3 2 3 The connector inserting numbers 2 3 at 20 C Indoor Unit Fan Motor Check each winding resistance of the motor If Resistance value is abnormal replace motor 07 30 ...

Page 77: ...8 APPENDING DATA R410A INVERTER Large Ceiling type ...

Page 78: ...B Outdoor temperature Indoor temperature 16 CDB 18 CDB 20 CDB 23 CDB 25 CDB 27 CDB COOLING HEATING AFR 33 3 CDB CWB TC PI TC PI TC PI TC PI TC PI TC PI TC PI 15 16 8 53 3 78 8 35 3 84 8 24 4 14 7 86 4 14 7 75 4 60 7 45 4 60 7 07 4 60 10 11 10 50 4 20 10 28 4 27 10 03 4 34 9 68 4 46 9 55 4 60 9 17 4 60 8 71 4 60 4 6 12 45 4 38 12 18 4 47 11 91 4 54 11 42 4 60 11 06 4 60 10 71 4 60 10 12 4 60 1 1 14...

Page 79: ...ng Dry 18 to 32 C About 80 or less 10 to 43 C Heating 16 to 30 C 10 to 24 C Operation Range Mode MODEL AB 45LBAG AO 45LJBYL Indoor temperature Indoor humidity Outdoor temperature Cooling Dry 18 to 32 C About 80 or less 15 to 43 C Heating 16 to 30 C 15 to 24 C Operation Range Mode 8 2 OPERATION RANGE ...

Page 80: ...an Motor 0 13 0 13 19 30 Indoor unit Outdoor unit Voltage V Frequency Hz Cooling Heating Current A 19 5 18 5 Input kW 4 45 4 25 Max Operating Current A 22 6 20 0 Starting Current A Main Fuse Circuit breaker Current A Power Cable mm 2 2 Limited wiring length m Input kW Full Load Amp A Input kW Full Load Amp A 1 Wiring Spec Selected Sample Selected based on Japan Electrotechnical Standard and Codes ...

Page 81: ...HERMAL PROTECTOR OFF 130 5 C ON 80 5 C OFF 130 5 C ON 80 5 C FUSE ON MAIN PCB INDOOR UNIT PROTECTION FORM AB 30LBAG AB 36LBAG PCB FUSE FAN MOTOR PROTECTION PROTECTION FORM AO 45LJBYL FUSE SIDE OF INDOOR UNIT TERMINAL 10A 250V 3 15A 250V 3 15A 250V 5A 250V FAN MOTOR PROTECTOR THERMAL PROTECTOR 150 5 C OFF 120 5 C OFF HIGH PRESSURE PROTECTION PRESSURE SWITCH OFF 4 2 0 1MPa ON 3 2 0 15MPa DISCHARGE T...

Page 82: ...tart validity invalidity Room temperature correct coefficient Room temperature correct coefficient Forbidden Remote control unit signal code INDOOR UNIT DIP SW 3 JM3 Jumper Wire JM1 JM2 SW1 1 2 SW1 SW1 ON OFF 3 2 1 JM1 JM2 JM3 8 5 FUNCTION SETTING 8 5 1 INDOOR UNIT ...

Page 83: ...URE CORRECTION SW1 2 1 3 Room temperature correct coefficient of heating Factory setting SW 1 1 SW state OFF Invalidity ON Validity 0 deg 0 deg 0 deg cooling 2 deg SW 1 2 SW 1 3 0 deg heating dry 2 deg 2 deg ON ON ON OFF OFF 2 deg 2 deg OFF SW state 2 deg OFF ON 0 deg 4 deg Factory setting Remote control unit signal code JM 1 2 3 setting forbidden Jumper wire JM2 JM3 connect connect A connect Disc...

Page 84: ...07 Pump down switch Change current capacity No use OFF 1 OUTDOOR UNIT 2 3 DIP SW 1 PUSH SW PUSH SW 1 DIP SW 1 OFF ON 2 3 Outdoor unit control circuit board SWITCH POSITION 8 5 2 OUTDOOR UNIT AO 30 36LMBWL ...

Page 85: ...s factory setting AO 36LMBWL 2 30000BTU model s factory setting AO 30LMBWL 13 5A 12 0A DIP SW1 CURRENT MAX 18 0A 1 15 0A 2 OFF OFF OFF ON ON OFF ON OFF 1 OFF ON 2 3 OFF OFF PUSH SWITCH SETTING Press the push button switch and PUMP DOWN OPERATION is starting SW2 setting ...

Page 86: ...8 09 Pump down switch Change current capacity No use OFF 1 OUTDOOR UNIT 2 3 DIP SW 1 PUSH SW PUSH SW 1 DIP SW 1 OFF ON 2 3 Outdoor unit control circuit board SWITCH POSITION 8 5 3 OUTDOOR UNIT AO 45LJBYL ...

Page 87: ...odel s factory setting 2 45000BTU model s factory setting AO 45LJBYL 18 0A 15 5A DIP SW1 CURRENT MAX 23 5A 1 20 0A 2 OFF OFF OFF ON ON OFF ON OFF 1 OFF ON 2 3 OFF OFF PUSH SWITCH SETTING Press the push button switch and PUMP DOWN OPERATION is starting SW2 setting ...

Page 88: ...9 INSTALLATION MANUAL R410A INVERTER Large Ceiling type ...

Page 89: ... the indoor unit pipe until immediately before connecting the connection pipe 2 Centering the pipe against port on the indoor unit turn the flare nut with your hand To prevent gas leakage coat the flare surface with alkylbenzene oil HAB Do not use mineral oil 3 Remove the filter guide Indoor unit Filter guide 4 Attach the connection pipe Connection pipe Liquid Indoor unit Connection pipe Gas For 2...

Page 90: ...N TIMER and VERTICAL SWING lamps Perform judgment in accordance with the following FRESH AIR INTAKE 1 Open up the knockout hole for the fresh air intake as shown in the figure If using half concealed installation open up the top knockout hole instead For half concealed installation Indoor unit CAUTION 1 When removing the cabinet iron plate be careful not to damage the indoor unit internal parts an...

Page 91: ...m pump for R410A exclusively 9 Using the same vacuum pump for different refrigerants may damage the vacuum pump or the unit 0 Use a clean gauge manifold and charging hose for R410A exclusively A If refrigerant leaks while work is being carried out ventilate the area If the refrigerant comes in contact with a flame it produces a toxic gas Be careful not to scratch the air conditioner when handling ...

Page 92: ...wire 2 Using a screwdriver remove the terminal screw s on the terminal board 3 Using pliers bend the solid wire to form a loop suitable for the terminal screw 4 Shape the loop wire properly place it on the terminal board and tighten securely with the terminal screw using a screwdriver B For strand wiring 1 Cut the wire end with a wire cutter or wire cutting pliers then strip the insulation to abou...

Page 93: ...10 REPLACEMENT PARTS R410A INVERTER Large Ceiling type ...

Page 94: ...or Heat sink Fan motor Fan Heat Exchanger Accumulator Compressor 4 way valve Solenoid Thermistor Compressor temp Thermistor Discharge temp VIEW A A Choke coil 1 1 1 PARTS LAYOUT DRAWING 1 1 For AO 30 36LMBWL 10 01 1 REPLACEMENT PARTS For OUTDOOR UNIT ...

Page 95: ...Thermistor Heat exchanger temp Coil Expansion valve Expansion valve Check valve Pressure SW 3 way valve Liquid 3 way valve Gas 10 02 Thermo Holder Thermistor Outdoor Temp ...

Page 96: ...Expansion valve BIND Compressor wire Solenoid wire CLAMP BIND Thermistor Discharge temp wire Thermistor Outdoor temp wire Thermistor Compressor temp wire Thermistor Heat exchanger temp wire Coil Expansion valve wire Pressure SW wire Thermistor Heat exchanger temp BIND Thermistor Heat exchanger temp Coil Expansion valve Pressure SW Thermistor Outdoor temp ENLARGED DETAIL ENLARGED DETAIL VIEW B B 1 ...

Page 97: ...Remove the 7 mounting screws Remove the TOP PANEL upward FRONT VIEW REAR VIEW 1 1 3 DISASSEMBLY PROCESS For AO 30 36LMBWL 10 04 Replaceable Component Compressor Accumulator 4 way valve Solenoid Thermistor Compressor temp Thermistor Discharge temp Thermistor Outdoor temp Thermistor Heat exchanger temp Pressure SW Coil Expansion valve ...

Page 98: ...crews Remove the connectors and cords Refer to VIEW C D Remove the INVERTER BOX upward 10 05 G G Remove power supply Connection cord Remove the connectors Remove the connectors C D VIEW C VIEW D Choke coil Terminal REAR VIEW FRONT VIEW INVERTER BOX ...

Page 99: ...ve the INVERTER BOX COVER upward Remove the connector and cords 10 06 Hook 2 places INVERTER BOX COVER CN1 Black Brown Red W6 Black W4 Black W7 White W5 White Twist W6 and W7 4 times or more Twist W4 and W5 2 times or more E F VIEW E ...

Page 100: ... 07 BIND W12 P Yellow W13 N1 Blue CN407 CN407 P Yellow N1 Blue Black Red L1 White Twist 4 times or more 2 turn the Wire this way L2 Brown Thermistor Heat sink Remove the connector and cords VIEW F DETAIL ...

Page 101: ...rd 10 08 INVERTER BOX A REAR VIEW LEFT SIDE VIEW 1 3 3 4 4 5 5 6 6 2 Main PCB Remove the 1 mounting screw Remove the Main PCB upward Filter PCB Remove the 2 mounting screws Remove the Filter PCB upward Screw Screw Hook 3 places Hook 2 places Main PCB Filter PCB ...

Page 102: ...ig 3 temporarily fix MAIN PCB to INVERTER BOX A After it is temporary fix of MAIN PCB As shown in the Fig 4 7 pull out the wires of MAIN PCB 1 1 4 ASSEMBLY PROCESS of INVERTER UNIT For AO 30 36LMBWL 10 09 Screw 2 places Hook 2 places Fig 1 Fig 3 Fig 2 FILTER PCB INVERTER BOX A W12 Yellow W13 Blue Screw Fig 5 Fig 4 Fig 6 7 Hook 3 places MAIN PCB ...

Page 103: ...wires As shown in Fig 5 pull out the wires and fix them 10 10 W16 Red W17 Black Thermistor Heat sink CN407 W303 Black W304 White W305 Red Fig 4 Fig 5 W12 Yellow W13 Blue W17 Black W16 Red W303 Black W304 White W305 Red Hook 2 places ...

Page 104: ...As shown in Fig 6 pull out the wires As shown in Fig 7 pull out the wires 10 11 Fig 6 Fig 7 W200 Red CN1 CN1 wire with connector W200 Red A DETAIL A HYIC1 Don t come in contact with HYIC1 ...

Page 105: ...As shown in Fig 8 connect wires As shown in Fig 9 connect wires 10 12 Fig 8 Fig 9 CN1 White CN34 Yellow Through this hole W21 Orange W22 Orange TM102 White line TM101 Black line PTC Thermistor ...

Page 106: ...n the figures set wire with connector and bind it to INVERTER BOX A 10 13 Fig 10 Fig 11 Thermistor Heat sink Hook 3 places Pull out the wire through this opening CN407 W303 Black W304 White W305 Red Through the hole Through the guide Bind wire to INVERTER BOX A ...

Page 107: ...ge Active Filter Module Thermistor Heat sink Fan motor Fan Heat Exchanger Accumulator Compressor 4 way valve Solenoid Thermistor Compressor temp Thermistor Discharge temp Choke coil 1 2 1 PARTS LAYOUT DRAWING 10 14 1 2 For AO 45LJBYL ...

Page 108: ...Thermistor Heat exchanger temp Coil Expansion valve Expansion valve Check valve Pressure SW 3 way valve Liquid 3 way valve Gas 10 15 Thermo Holder Thermistor Outdoor Temp ...

Page 109: ...ND Thermistor Discharge temp Thermistor Compressor temp Thermistor Heat exchanger temp Coil Expansion valve ENLARGED DETAIL 1 2 2 WIRING For AO 45LJBYL 10 16 CLAMP BIND Thermistor Discharge temp wire Thermistor Outdoor temp wire Thermistor Compressor temp wire Thermistor Heat exchanger temp wire Coil Expansion valve wire Pressure SW wire ...

Page 110: ...Thermistor Outdoor temp Thermistor Heat exchanger temp Coil Expansion valve CLAMP with U PIPE Thermistor Heat exchanger temp Coil Expansion valve ENLARGED DETAIL 10 17 ...

Page 111: ... sliding downward 1 2 3 DISASSEMBLY PROCESS AO 45LJBYL 10 18 Replaceable Component Compressor Accumulator 4 way valve Solenoid Thermistor Compressor temp Thermistor Discharge temp Thermistor Outdoor temp Thermistor Heat exchanger temp Pressure SW Coil Expansion valve Hook 3 places ...

Page 112: ...2 TOP PANEL removal Remove the 7 mounting screws Remove the TOP PANEL upward FRONT VIEW REAR VIEW 10 19 ...

Page 113: ...crews Remove the connectors and cords Refer to VIEW C D Remove the INVERTER BOX upward G G VIEW C REAR VIEW C D FRONT VIEW Remove power supply Connection cord Remove the connectors INVERTER BOX Remove the connectors VIEW D Choke coil Terminal 10 20 ...

Page 114: ... 1 mounting screw Remove the INVERTER BOX COVER upward Remove the connector and cords 10 21 Hook 2 places INVERTER BOX COVER E F VIEW E W6 Black W7 White W200 Red W2 White W1 Black Twist W6 and W7 2 times or more ...

Page 115: ...10 22 P Yellow N1 Blue Black Red L1 White L2 Brown Gray Thermistor Heat sink White D Power Bridge BIND P Yellow N1 Blue CN407 CN407 Remove the connector and cords VIEW F ...

Page 116: ...rd 10 23 INVERTER BOX A REAR VIEW LEFT SIDE VIEW 1 3 3 4 4 5 5 6 6 2 Main PCB Remove the 1 mounting screw Remove the Main PCB upward Filter PCB Remove the 2 mounting screws Remove the Filter PCB upward Screw Screw Hook 3 places Hook 2 places Main PCB Filter PCB ...

Page 117: ... Fig 3 temporarily fix MAIN PCB to INVERTER BOX A After it is temporary fix of MAIN PCB As shown in the Fig 4 6 pull out the wires of MAIN PCB 1 2 4 ASSEMBLY PROCESS of INVERTER UNIT For AO 45LJBYL 10 24 Screw 2 places Hook 2 places Fig 1 Fig 3 Fig 2 FILTER PCB INVERTER BOX A Fig 5 Fig 4 Fig 6 Hook 3 places MAIN PCB W14 Yellow W15 Blue Screw ...

Page 118: ...he wires As shown in Fig 5 pull out the wires and fix them 10 25 CN407 W303 Black W304 White W305 Red W303 Black W304 White W305 Red Fig 4 Fig 5 Thermistor Heat sink Thermistor Heat sink CN407 W107 White W108 Violet Hook 2 places ...

Page 119: ...As shown in Fig 6 pull out the wires As shown in Fig 7 connect wires 10 26 Fig 6 Fig 7 VIEW A Don t come in contact with HYIC1 W200 Red CN34 Yellow CN1 White CN1 wire with connector A HYIC1 ...

Page 120: ...As shown in Fig 8 connect wires 10 27 Fig 8 W108 Violet W107 White Through this hole Twist 5 times or more Gray line TM102 White line TM101 Black line Make White line on Black line ...

Page 121: ...n the figures set wire with connector and bind it to INVERTER BOX A 10 28 Fig 9 Fig 10 Thermistor Heat sink Hook 3 places Pull out the wire through this opening CN407 Bind wire to INVERTER BOX A Through the guide Through the hole W303 Black W304 White W305 Red ...

Page 122: ...al Remove the 2 AIR FILTERS INTAKE GRILLE Tapping screw AIR FILTER INTAKE GRILLE 2 places AIR FILTER 2 places 2 1 PARTS LAYOUT DRAWING SIDE COVER A RIGHT SIDE COVER B RIGHT SIDE COVER B LEFT 2 REPLACEMENT PARTS For INDOOR UNIT ...

Page 123: ...10 30 2 INTAKE GRILLE removal Remove the 6 mounting screws Remove the 2 INTAKE GRILLES INTAKE GRILLE 2 places 1 2 ...

Page 124: ...nting screws Left side and Right side Remove the SIDE COVER A and B 4 CONTROL BOX removal Remove the 2 mounting screws Pull the CONTROL BOX downward 1 1 2 2 1 1 2 2 1 2 SIDE COVER A LEFT SIDE COVER B LEFT Hook 2 places Hook 3 places CONTROL BOX ...

Page 125: ... PCB CONTROLLER PCB BIND Wire with connector For Display Thermistor Pipe temp Wire with connector For Stepping motor BIND Wire with connector For Fan motor Wire with connector For Capacitor BIND Wire with connector For Power Supply PCB Wire with connector For ACIN BIND Wire with connector For Display Thermistor Pipe temp Thermistor Room temp Power Supply PCB Capacitor Plastic BLACK WHITE RED Therm...

Page 126: ...1116 Suenaga Takatsu ku Kawasaki 213 8502 Japan May 2006 Printed in Japan ...

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