IVT AE-X12GR-N Service Manual Download Page 1

 

SERVICE MANUAL

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............................................ 1-1
[2] EXTERNAL 

DIMENSION............................... 1-2

[3] WIRING 

DIAGRM .......................................... 1-3

[4] ELECTRICAL 

PARTS .................................... 1-3

CHAPTER 2. EXPLAMATION OF CIRCUIT AND OP-
ERATION

[1] BLOCK 

DIAGRAMS....................................... 2-1

[2]  MICROCOMPUTER CONTROL SYSTEM

........ 2-3

[3] FUNCTION..................................................... 2-8

CHAPTER 3. FUNCTION AND OPERATION OF PRO-
TECTIVE PROCEDURES

[1]  PROTECTION DEVICE FUNCTIONS AND 

OPERATIONS................................................ 3-1

[2]  AIR CONDITIONER OPERATION IN 

THERMISTOR ERROR ................................. 3-3

[3] THERMISTOR 

TEMPERATURE 

CHAR-

ACTERISTICS ............................................... 3-5

[4]  HOW TO OPERATE THE OUTDOOR 

UNIT INDEPENDENTLY................................ 3-5

[5] GENERAL 

TROUBLESHOOTING 

CHART

........ 3-6

[6]  MALFUNCTION (PARTS) CHECK METH-

OD .................................................................3-8

[7]  OUTDOOR UNIT CHECK METHOD...........3-10
[8] TROUBLESHOOTING 

GUIDE ....................3-13

CHAPTER 4. REFRIGERATION CYCLE

[1] FLOW 

FOW 

REFRIGERANT ........................4-1

[2] STANDARD 

CONDITION ..............................4-1

[3]  TEMPERATURE AT EACH PART AND 

PRESSURE IN 3-WAY VALVE ......................4-1

[4] PERFORMANCE 

CURVES...........................4-2

CHAPTER 5. DISASSEMBLING PROCEDURE

[1]  DISASSEMBLY OF INDOOR UNIT...............5-1
[2]  DISASSEMBLY OF OUTDOOR UNIT...........5-7

Parts Guide

TopPage

CONTENTS

SPLIT TYPE

ROOM AIR CONDITIONER

INDOOR UNIT

AY-XP12GR-N

OUTDOOR UNIT

AE-X12GR-N

MODELS

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.

Summary of Contents for AE-X12GR-N

Page 1: ...R CONDITIONER OPERATION IN THERMISTOR ERROR 3 3 3 THERMISTOR TEMPERATURE CHAR ACTERISTICS 3 5 4 HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY 3 5 5 GENERAL TROUBLESHOOTING CHART 3 6 6 MALFUNCTION PARTS CHECK METH OD 3 8 7 OUTDOOR UNIT CHECK METHOD 3 10 8 TROUBLESHOOTING GUIDE 3 13 CHAPTER 4 REFRIGERATION CYCLE 1 FLOW FOW REFRIGERANT 4 1 2 STANDARD CONDITION 4 1 3 TEMPERATURE AT EACH PART AND PRESS...

Page 2: ...111A1F22F Oil charge 450mL Ester oil VG74 Refrigerant system Evaporator Louver Fin and Grooved tube type Condenser Corrugate Fin and Grooved tube type Control Expansion valve Refrigerant R410A 1050g De lce system Micro computer controled reversed systems Noise level at cooling heating High dB A 40 44 47 49 Low dB A 38 38 Soft dB A 27 34 Fan system Drive Direct drive Air flow quantity at cooling he...

Page 3: ...AEX12GRN 1 2 2 EXTERNAL DIMENSION 1 Indoor unit 2 Outdoor unit 278 198 790 22 0 58 18 5 175 INVERTER AIR CONDITIONER 265 780 540 14 165 540 299 72 58 37 5 12 4 5 324 135 81 136 ...

Page 4: ...Indoor fan motor capacitor Transformer FUSE1 QFS GA062JBZZ 250V 3 15A FUSE2 QFS GA063JBZZ 250V 2A DESCRIPTION MODEL REMARKS Compressor DA111A1F22F D C brush less motor Outdoor fan motor ML A902 DC Motor Outdoor fan motor capacitor Fu4 QFS GA064JBZZ 250V 1A Fu3 QFS GA051JBZZ 250V 2A Fu2 QFS GA052JBZZ 250V 3 15A Fu1 QFS CA001JBZZ 250V 20A Fu5 6 QFS CA002JBZZ 250V 15A ...

Page 5: ...rive circuit CPU reset circuit CPU oscillator circuit Room temp detect circuit Heat exchanger pipe thermo circuit EEPROM Select circuit Serial I O circuit Power supply relay drive circuit Auto restart circuit Test run circuit Auxiliary mode Power on circuit Cluster generator drive circuit Indoor fan motor Fan motor pulse detect Wireless remote control operation Audible operation confirmation Room ...

Page 6: ...drive circuit Serial I O circuit CPU reset circuit Position detection circuit AC overcurrent detection circuit Compressor thermo circuit Heat exchanger pipe thermo circuit Outdoor temp thermo circuit LED drive circuit Test mode circuit Power factor converter circuit Filter circuit Smoothing circuit Pulse amplitube modulation circuit EEPROM AC clock circuit DC overcurrent detection circuit IGBT Uni...

Page 7: ... 7K R69 100K R68 4 7K 100μ DC15V D2SBA60 5V C24 25V 0 1μ R46 DB1 C1 3 3 450V 120μ 1M R2 RF 1 2W 1M 1 2W 4 3 2 1 5V PC817XP3 3 3K R66 100K R73 35V C46 25V C50 0 1μ 0 1μ 50V C47 R28 R31 56k 2A 250V 1 4 2 3 1 4 5V FU2 5W R1 47k R67 10k R50 0 1μ C52 25V C37 0 1μ 25V 5V JPW JPP R87 R86 10K 10K C26 4 7μ IC2 RESET 0V ZD1 ST03D 200 5V 1 4W 100 R56 1 4W 100 R51 C39 16V 0 01μ C36 0 01μ 16V 10K 10K 10K CN4 R...

Page 8: ...N105A CN104B CN104A a b c d e f g SG201 Q102 Q101 Q104 KRC106S Q103 CN105B CN105C 1 2 3 25V R201 47 IC201 RECEIVER CIRCUIT SUB MICRO COMPUTER PWB CIRCUIT DAIGRAM 1 2 3 4 5 LOUVER MOTOR BOTTOM LOUVER MOTOR TOP SERIAL SIGNALS REMOTE CONTROLLER SIGNALS ERROR SIGNAL OF SERIAL POWER SUPPLY OF SUB MICRO COMPUTER 5V LINE GND for 12V LINE GND for 7 SEG LED RECEIVER PWB GND for 12V LINE GND for 5V LINE 12V...

Page 9: ...AEX12GRN 2 5 1 3 Printed wiring board ...

Page 10: ...AEX12GRN 2 6 2 Outdoor unit 2 1 Electronic control circuit diagram ...

Page 11: ...AEX12GRN 2 7 2 2 Printed wiring board ...

Page 12: ... 4 to 15 Hz Then this operation is repeated every 60 seconds until the temperature of the indoor unit heat exchanger drops below the overheat protection temperature Once the temperature of the indoor unit heat exchanger drops below the overheat protection temperature the operating frequency is increased by about 4 to 10 Hz every 60 seconds until the normal oper ation condition resumes If the tempe...

Page 13: ...oor unit control printed circuit board control PCB connecting the power cord to an AC outlet starts the air conditioner in either cooling or heating mode which is determined automatically by the room temper ature sensor When a circuit breaker is used to control the ON OFF operation please insert a jumper as described above 1 17 Self diagnostic malfunction code display 1 17 1 Indoor unit 1 When a m...

Page 14: ...perates at a very low speed and the upper louver is angled upward and the lower louver remains horizontal The airflow volume and direction can be changed by using the remote control 1 24 Hot keep When the room temperature rises above the set temperature by 0 6 C or more the ON OFF operation of the compressor and indoor unit fan is controlled in order to lower the room temperature The values indica...

Page 15: ...oom by the air flow created by the blower fan indoor unit fan motor in the air conditioner unit 1 When microcomputer output turns H the IC6 output changes to Lo turning ON the SSR and applying 230 V to the cluster unit for the genera tion of cluster ions positive and negative ions 3 Outline of PAM circuit 3 1 PAM Pulse Amplitude Modulation The PAM circuit varies the compressor drive voltage and co...

Page 16: ...ease 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 3 2 1 Detailed explanation of PAM drive circuit sequence 3 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 detect...

Page 17: ...ot 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 flashin...

Page 18: ...circuit board PCB 4 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 15 V current The power supply for the subsequent stages is charge...

Page 19: ...an L output of about 1 8 ms is generated from IPM Fo pin 24 and this results in an L input to overcurrent detection input pin 34 of the microcomputer IC1 and turns OFF the PWM signal output IC1 pins 51 through 56 to the IGBT gate SET RESET About 22 A SC SC reference voltage Delay by CR time constant circuit About 1 8 ms a1 Protection circuit status Output current Ic A Sense voltage relative to shu...

Page 20: ... internal processing so that detection is enabled only when it is ON Based on the detected position signal actual PWM waveform output timing is determined Since it does not use a filter circuit the detection accuracy is high The microcomputer performs internal processing to cancel spike voltage during the regenerative process Furthermore even if the induced voltage is low position detection is sti...

Page 21: ...verheat tem perature during heating operation Compressor stops if indoor unit heat exchanger temperature exceeds overheat temperature for 60 seconds at minimum fre quency Overheat temperature setting value indoor unit heat exchanger thermistor temperature about 45 to 54 C When in heating operation Automatic reset after safety period 180 sec None Yes Yes 5 Outdoor unit heat exchanger over heat shut...

Page 22: ...star tup Operation OFF or ON Yes 1 Yes Yes 17 Outdoor unit suction thermistor short cir cuit error Compressor stops if there is short circuit in outdoor unit suc tion thermistor TH4 At compressor star tup Operation OFF or ON Yes 1 Yes Yes 18 Outdoor unit 2 way valve thermistor short circuit error Compressor stops if there is short circuit in outdoor unit 2 way valve thermistor TH5 At compressor st...

Page 23: ... Yes 1 Yes Yes Item Mode Control opera tion When resistance is low temperature judged higher than actual Short circuit When resistance is high tempera ture judged lower than actual Open circuit Room tempera ture thermistor TH1 Auto Operation mode judgment Cooling mode is acti vated even if room temperature is low Cooling mode is acti vated in most cases Heating mode is activated even if room tempe...

Page 24: ...uit error indication Cooling Dehumidifying Operation not affected Normal operation Outdoor unit ther mistor short circuit error indication Normal operation Outdoor unit ther mistor open cir cuit error indication Heating Rating control Defrosting Defrosting operation is activated unneces sarily Outdoor unit ther mistor short circuit error indication Defrosting opera tion is not acti vated and frost...

Page 25: ...om temperature thermistor TH2 Heat exchanger thermistor Before measuring resistance disconnect connectors as shown above TH2 TH5 500K 400K 300K 200K 100K 0 20 0 20 60 80 100 120 Tester 1 10 Connector CN8 Resistance at 25 52 76 k 5 8K 40K 30K 20K 0 10K 20 0 20 60 40 3 06K 4 17K 1 72K 2 28K Tester In case of TH2 heat exchanger thermistor 1 10 Connector CN8 Thermistor Compressor thermistor Heat excha...

Page 26: ... indicated on battery compartment Install batteries in indicated direc tion Lighting fixture is too close or flu orescent lamp is burning out Turn off light and check Signal should be received when light is turned off Change light position or install new fluorescent lamp Use Sevick light Hitachi Check if Sevick light Hitachi is used Signal may not be received some times due to effect of Sevick lig...

Page 27: ...eck for radio wave interfer ence See page Main cause Inspection method Normal value condition Remedy Erroneous inter unit connection Check wiring between indoor and outdoor units Terminal board 1 N 230 VAC 50 Hz Terminal board 2 serial signal Correct wiring Damaged IPM Check IPM continuity Refer to IPM check method 3 Replace IPM Dried up electrolytic capacitor Check electrolytic capacitor Refer to...

Page 28: ...arts up Does LED1 indicate DC overcurrent error Does LED1 indicate rotation error Outdoor unit PWB 15 5 V display section Voltage OK Replace compressor Check inter unit wiring Check indoor unit PWB Does LED1 remain lit Serial signal error Check inter unit wiring Check indoor and outdoor unit PWBs Replace outdoor unit PWB Check compressor 2 3 way valve closed Refrigerant shortage Replace outdoor un...

Page 29: ...en 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 Measure resistance in expansion valve coil Normal resistance between red terminal of expansion valve lead wire and each terminal about 46 at 20 Insert checker shown at left into connector CN12 on control PWB and operate...

Page 30: ...MΩ V W No Item Check method Normal value condition Remedy 1 Preparation Disconnect compressor cords white orange red 3 wires from compres sor terminals and connect simulated load lamp used as load Operate air conditioner in cooling or heating test operation mode 2 Inverter DC power supply voltage check Measure DC voltage between IPM pins 31 and 35 320 VDC Replace control PWB Replace diode bridge C...

Page 31: ... Item Check method Normal value condition Remedy Does LED light NO YES YES NO Does LED flash Normal NO YES NO YES NO YES NO YES Is 230 V applied between 1 and N on outdoor unit terminal board Is voltage between IPM pins 31 and 35 320 V or higher 5 Short circuit in DC fan motor Short circuit in IPM Short circuit in diode bridge Blown fuse Defective electrolytic capacitor Wire disconnection PWB patt...

Page 32: ...e 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 Ground voltage 320 VDC line 0 V line 0 V line voltage point F Voltage at point E 320V 160V 160V Terminal board Ground 0 V l...

Page 33: ...to 10 minutes after self diagnosis is performed during operation and the display returns to normal condition after this display period The content of self diagnosis cannot be called out by the self diagnosis display function of the outdoor unit Example of self diagnosis display on outdoor unit Compressor high temperature error c The content of diagnosis is transferred to the indoor unit via serial...

Page 34: ...ion 4 Temporary stop due to 2 way valve freeze 3 Temporary stop for cycle pro tection Indoor unit in operation Outdoor unit in tempo rary stop 3 times 3 0 Dry operation Temporary stop due to dehumidifying operation 3 Temporary stop for cycle pro tection Indoor outdoor units in complete shutdown 5 times 5 0 Outdoor unit thermistor open circuit Heat exchanger thermistor open cir cuit error 1 Check c...

Page 35: ...nit air outlet 2 Check the outdoor unit fan for proper rotation 2 Check the outdoor unit fan motor 1 AC overcurrent error in OFF status 1 IPM continuity check 1 Replace the outdoor unit control PWB assembly 2 AC maximum cur rent error 1 Check the outdoor unit air outlet for blockage 1 Ensure unobstructed air flow from the out door unit air outlet 2 Check the outdoor unit fan for proper rotation 1 ...

Page 36: ...Correct the installa tion 2 Check the outdoor unit fan motor for proper rotation 2 Replace the outdoor unit fan motor 3 Check fuse FU3 3 Replace the outdoor unit control PWB assembly 4 Outdoor unit control PWB 4 Replace the outdoor unit control PWB assembly Indoor outdoor units in complete shutdown 13 times 13 0 DC compressor Compressor startup error 1 Check the colors red white orange of the com ...

Page 37: ...n 19 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 Check the lead wire of the indoor fan motor for open circuit 2 Replace the indoor fan motor 3 Check CN1 of the indoor unit fan motor for secure installation 3 Correct the installation of CN1 of the indoor fan motor 4 No abnormality found in above i...

Page 38: ...out 30 minutes None Displays 18 0 when malfunction code is called out 4 Indoor unit relay Malfunction diagnosis display Turns On momentarily then turns Off 18 1 5 Indoor unit relay Malfunction diagnosis display Turns On momentarily then turns Off 18 1 Inter unit wiring error mode Symptom Indoor unit Outdoor unit 1 N 2 1 N 2 Indoor unit Outdoor unit 1 N 2 1 N 2 Indoor unit Outdoor unit 1 N 2 1 N 2 ...

Page 39: ...idity Cooling 27 47 35 40 Heating 20 7 87 Model AY XP12GR N Operation model MAX TEST RUN Cool Heat Cool Heat Hz 69 90 42 42 No rpm 4150 5400 2500 2500 1 75 C 87 C 61 C 60 C 2 40 C 2 C 38 C 3 C 3 12 C 36 C 13 C 30 C 4 10 C 3 C 13 C 5 C 3 way valve pressure MPaG 0 87 3 29 1 04 2 34 s 1 4 C 2 Accumulator 3 Strainer Expansion valve Heating Cooling Outdoor unit Condenser Evaporator Indoor unit Reverse ...

Page 40: ...er front 3 Indoor air temp Cooling 27 C Heating 20 C 4 Power source 230V 50Hz 1 AY XP12GR N 1 1 At Cooling 1 2 At Heating 25 30 35 40 4 0 3 8 3 6 3 4 3 2 1000 900 800 700 Cooling capacity kW Outside air temp ºC Input W 5 0 7 5 10 Heating capacity kW Outside air temp ºC Input W 5 0 4 5 4 0 3 5 3 0 2 5 1200 1100 1000 900 ...

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