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AEXM24HR

5 – 1

AEXM24HR

Service Manual

CHAPTER 5.

DISASSEMBLING PROCEDURE

[1] OUTDOOR UNIT

1) Remove the 5 screws fixing the front panel R and slide

the front panel R down.

2) Remove the 10 screws fixing the top cover.

3) Remove the 6 screws fixing thefront panel L.

4) Remove the 6 screws fixing the rear guard.

5) Remove the 11 screws fixing the side cover R.

6) Remove the 6 screws fixing the side cabinet L.

7) Cut the insulators.

8) Remove the 2 screws fixing the control box cover.

Caution: Discharge electrytic capacitor before

touching this capacitor or other components or wirings.

Screws

Cut

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Summary of Contents for AE-XM24HR

Page 1: ...HAPTER 2 EXPLANATION OF CIRCUIT AND OP ERATION 1 BLOCK DIAGARM 2 1 2 FUNCTION 2 2 CHAPTER 3 FUNCTION AND OPERATION OF PRO TECTIVE PROCEDURES 1 PROTECTIVE FUNCTIONS AND OPERA TIONS 3 1 2 TROUBLESHOOTING GUIDE 3 3 CHAPTER 4 REFRIGERATION CYCLE 1 REFRIGERATION SYCLE 4 1 2 PERFORMANCE CURVES 4 3 CHAPTER 5 DISASSEMBLING PROCEDURE 1 OUTDOOR UNIT 5 1 Parts Guide TopPage MULTI SPLIT TYPE ROOM AIR CONDITIO...

Page 2: ...Evaporator Slit Fin and Grooved tube type Condenser Corrugate Fin and Grooved tube type Control Expansion valve Name of refrirerant R410A Refrigerant volume 2300g Noise level at cooling dB A Hi Low Soft High Med Low 7FR 37 34 28 49 9FR 39 36 28 12FR 40 37 29 Fan system Drive Direct drive Air flow quantity at cooling m3 min Hight Med Low 7FR 8 0 7 4 5 4 43 9FR 8 6 7 9 5 6 12FR 9 8 8 5 6 9 Fan Cross...

Page 3: ... Units Indoor Units 7 AY XPM7FR GS XPM7FR 9 AY XPM9FR GS XPM9FR GS XPM9FGR 12 AY XPM12FR GS XPM12FR GS XPM12FGR AE XM24HR 9 9 9 9 12 9 7 7 9 9 9 7 12 7 7 7 9 9 7 7 9 7 7 7 7 7 7 7 320 37 890 361 383 800 590 150 51 3 16 75 150 52 52 52 52 389 284 210 151 26 940 50 26 Figure OUTDOOR UNIT ...

Page 4: ... OFF OFF 2 0 OFF OFF OFF 2 0 1 6 2 7 2 3 1 8 3 2 500 400 700 Oper ating Status Combination of Indoor Units Heating Capacity kW Running Current A Power Consumption W A B C D A B C D RATING Min Max RATING Min Max RATING Min Max 4 Room 09 09 09 09 2 00 2 00 2 00 2 00 8 0 3 0 9 2 9 2 2 6 11 7 2000 560 2560 12 09 07 07 2 74 2 06 1 60 1 60 8 0 3 0 9 2 9 2 2 6 11 7 2000 560 2560 09 09 09 07 2 12 2 12 2 1...

Page 5: ...AEXM24HR 1 4 5 WIRING DIAGRAMS 1 FOR MODEL AEXM24HR CC373 ...

Page 6: ...OMP T HEAT EXCHANGER TEMP OUT DOOR TEMP SUCTION TEMP from THERMISTOR SUCTION from HEAT SINK THERMISTOR from CONTROL BOX from DIODE BRIDGE DB1 from DIODE BRIDGE DB1 from DC FAN MOTOR from DC FAN MOTOR QPWBFB630JBZZ QPWBFB630JBZZ from 4 WAY VALVE from TERMINAL BOARD from TERMINAL BOARD from SHORT CIRCUIT CONNECTOR from TERMINAL BOARD from EXPANSION VALVE B from EXPANSION VALVE C from EXPANSION VALVE...

Page 7: ...G BOARD from ELECTROLYTIC CAPACITOR C10 from ELECTROLYTIC CAPACITOR C10 from COMPRESSOR W ORANGE from COMPRESSOR V WHITE from COMPRESSOR TERMINAL U RED from CONTROL PWB CN14 from CONTROL PWB BCN1 figure IPM P W B TERMINAL TERMINAL ...

Page 8: ...㨗㧾㧞㧟㧜㧾㧞㧞㧥㧾㧞㧞㧤㧾㧞㧝㧥㧾㧞㧝㧣㧾㧞㧝㧢㧾㧥㧤㧭㧙㧥㧤㧴㧦㧢㧚㧤㨗㧲㧾㧥㧤㧴㧾㧥㧤㧲㧾㧥㧤㧱㧾㧥㧤㧰㧾㧥㧤㧯㧾㧥㧣㧭㧙㧾㧥㧣㧴㧦㧝㧜㨗㧾㧥㧤㧮㧾㧥㧤㧭㧾㧥㧣㧱㧾㧥㧣㧰㧾㧥㧣㧯㧾㧥㧣㧮㧾㧥㧣㧭㧾㧥㧣㧲㧾㧥㧣㧳㧾㧥㧣㧴㧾㧥㧜㧯㧾㧥㧜㧮㧾㧥㧜㧭㧞㨃㧝㨗㧝㨗㧞㨃㧞㨃㧝㨗㧾㧤㧥㧾㧤㧤㧡㧢㨗㧠㧚㧣㨗㧾㧤㧢㧝㧠㧟㧞㧠㧝㧞㧟㧾㧤㧡㧯㧾㧤㧡㧮㧾㧤㧡㧭㧞㨃㧝㨗㧝㨗㧞㨃㧝㨗㧞㨃㧟㧚㧟㨗㧾㧤㧠㧾㧤㧞㧡㧢㨗㧠㧚㧣㨗㧾㧤㧝㧝㧟㧠㧞㧠㧝㧾㧤㧜㧯㧾㧤㧜㧮㧾㧤㧜㧭㧞㨃㧝㨗㧞㨃㧝㨗㧝㨗㧞㨃㧟㧚㧟㨗㧾㧣㧥㧡㧢㨗㧠㧚㧣㨗㧾㧣㧣㧾㧣㧢㧰㧝㧤㧞㨃㧾㧣㧡㧯㧝㨗㧝㨗㧞㨃㧾㧣㧡㧮㧝㨗㧾㧣㧡㧭㧞㨃㧠㧞㧝㧟㧞㧠㧝㧟㧟㧚㧟㨗㧾㧣㧠㧾㧣...

Page 9: ...ansion valve A Expansion valve B Expansion valve C CPU oscillator circuit AC overcurrent detection circuit DC overcurrent detection circuit Power transistor module overheat LED Heat exchanger pipe thermistor Compressor thermistor Current transformer Compressor Power transistor module Outdoor fan motor Smoothing circuit Active filter circuit Filter circuit AC power Unit unit wiring AC power and ser...

Page 10: ...the frequency is lowered approximately 5Hz once every 60 seconds or approximately 15Hz once every 90 seconds When the temperature of all of indoor heat exchangers go below the overheating prevention line 1 the frequency is raised by approximately 5Hz once every 60 seconds and normal operation is restored If the condition that the frequency is minimum lasts for 2 minutes the compressor will be stop...

Page 11: ...or units indoor units after 90 seconds have passed it will be turned on and the expansion valve corresponding to the requesting indoor unit will be opened When the indoor unit of a room requests for the cooling operation to the outdoor unit and it runs responding to the request requests for the heating can t be accepted if the indoor units in other rooms send individual requests If the indoor unit...

Page 12: ...ped At the same time the outdoor fan go ON The compressor is reactivated in the heating cycle 1 minutes after it was stopped and normal control resumes 1 12 Power factor module Output voltage If a voltage error over 450V is detected at power factor module output voltage the compressor is stopped for 3 minutes In this case the out door fan does not stop for 3 minutes and another try will be made Th...

Page 13: ...er By adding ON signal to the gate of IGBT from the control IC IGBT turns ON and the collector current Ic flows This current flows from the side of the diode bridge DB to the Choke coil the side of the diode bridge DB through IGBT from the Choke coil L At this time energy is stored in the choke coil L Next when gate signal of IGBT turned OFF IGBT will be turned OFF and the energy stored in L durin...

Page 14: ... comparing with reference voltage When the output voltage of active filter reaches 450V or higher the 4th pin of IC5 will be higher than the reference voltage at the 5th pin the output of comparator will be reversed H L the L signal will be entered at the 52nd pin of microcomputer IC1 and the operation of the active filter will be stopped 2 5 Explanation of IPM drive circuit The power supply for t...

Page 15: ... L level input to overcurrent detection input pin 53 of the microcomputer IC1 and then turns OFF the compressor driving signal output IC1 from pins 65 to 70 to the IGBT gate 2 6 2 6 1 120 energizing control digital position detection control This control system detects the digital position detection signal and adjusts the rate of acceleration deceleration accordingly The motor s induced voltage wa...

Page 16: ... 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 7 DC Current Detection Sensor Circuit Control of current phase difference is made by reading in the phase difference generated at the both edges...

Page 17: ...0V 0V 15V N CIN P TU TV TW Y Z Y Z IPM IC1 C121 D8 C96 1000P C119 ZD101 R200 1K R201 100KF IC9 C97 0 1μ 1 R202 20KF R113 18KF R203 2 0KF R204 200KF R205 200KF 3 2 4 8 S R C FC1 Inverter current detection circuit 630v 0 33Ǵ 1000p 0 015 R100 ...

Page 18: ...r operation During compressor operation During compressor operation During compressor operation During compressor operation Restart condition Automatically restarts after safety time 180 seconds Automatically restarts after safety time 180 seconds Automatically restarts after safety time 180 seconds Automatically restarts when thermistor TH1 temperature falls below 99 approximately 30 minutes Auto...

Page 19: ...n is continued OUTDOOR Closes the expansion valve of the corresponding room if the outdoor unit does not receive a serial signal from one or more indoor unit for 30 seconds Compressor is stopped if the out door unit does not receive a serial signal from all indoor units Lowers the operating frequency if the temperature of any of indoor heat exchanger rises high temper ature during heating Stops th...

Page 20: ...re indicated by the Operation Timer and Plasmacluster Ion LE Ds on the indoor unit 2 The self diagnosis display function of the outdoor unit indicates the error information by flashing LE D1 on the outdoor unit according to the content of self diagnosis The self diagnosis display function of the outdoor unit is active only for about 3 to 10 minutes after self diagnosis is performed during operatio...

Page 21: ... rotation 4 No abnormality found in above inspections 1 through 3 5 No abnormality found in above inspections 1 through 4 1 Replace the outdoor unit IPM PCB assembly 2 Correct the installa tion tighten the screws Apply silicon grease 3 Replace the outdoor unit fan motor 4 Replace the outdoor unit IPM PCB assembly 5 Replace the compressor Indoor outdoor units in complete shutdown 7 time Outdoor uni...

Page 22: ...between units 2 Check voltage between N and 1 the indoor outdoor unit terminal boards 1 Connect stable power supply 2 Replace the outdoor unit control PCB assembly 1 Check the wires between units 2 Check the outdoor unit fuse 3 Check 15 V 13 V and 5 V voltages on the PCB Check resistance between IPM terminals 4 Check pins No 5 and 8 of connector CN3A of the outdoor unit fan motor for short circuit...

Page 23: ... 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 R...

Page 24: ...rating only the outdoor unit cooling 55 Hz fixed mode To make only the outdoor unit run in cooling mode and apply a voltage of 220 240V AC to L and N on the terminal board and push the PUMP DOWN SWITCH SW1 Avoid operating the outdoor unit alone for long periods of time ...

Page 25: ...N8A Green 25 resistance 45 k Resistance Resistance 0 resistance 14 5 k 25 resistance 4 431 k To measure the resistance first remove the connector from the board 4 17k 500 400 300 200 100 0 20 0 20 40 Temperature 80 100 3 25k 60 12 3k 6 14k Resistance k Thermistor Heatsink Color Black To measure the resistance first remove the connector as shown at right Signal CN8B Heatsink thermistor TH5 black 25...

Page 26: ...e indoor units in all rooms flashing Check the failure symptom with the failure diagnosis mode The cooling cycle is abnormal Check the pressure Check that the power between the terminal board N and L of the indoor unit is AC 230V 50Hz Repair the wiring between the units Press the OPERATION button to start operating the air condi tioner One room operation ON Set the cooling mode to 18 㧕 Check the f...

Page 27: ...Is CN6 connected The cycle is abnormal The compressor is abnormal P U N U P V N V P W N W A Is the resistance value of the ther mistor for the com pressor TH1 heat ex changer TH2 or outdoor temper ature TH3 or suc tion TH4 TH6 9 correct Is each of the resist ance values among the terminals of the IPM PWB 0 P U N U P V N V P W N W Is each of the resistance values among the termi nals of the IPM PWB...

Page 28: ...board N and 1 of the indoor unit is AC 230V R epair the wiring between the units R eplace the indoor control P W B R eplace the thermistor C heck the failure symptom with the failure diagnosis mode R eplace the outdoor control P WB or the expansion valve UNIT A or the expansion valve UNIT B or the expansion valve UNIT C or the expansion valve UNIT D Is the resistance value of the winding in the fa...

Page 29: ... between the connector CN4 1 and 3 of the 4 way valve Replace the 4 way valve Pressure check The heating cycle is normal Refer to 1 All rooms are not cooled Press the ON switch on the remote control to run the air conditioner Set the temperature to 32 in the heating mode and start operation Is the outdoor compressor running Ye s Ye s To No No Ye s Ye s No No A ...

Page 30: ...TDOOR UNIT UNIT D Heat exchanger Heat exchanger Heat exchanger Heat exchanger Heat exchanger UNIT C UNIT B UNIT A E xpansion valve D S TOP valve Liquid C ompres s or 4 way valve Accumulator S TOP valve Gas E xpansion valve C E xpansion valve B E xpansion valve A 1 4 2 3 3 3 3 Figure Flow of Refrigerant INDOOR UNIT OUTDOOR UNIT UNIT D UNIT C UNIT B UNIT A Cooling heating ...

Page 31: ...lve pressure 0 90MPa abs 1 08MPa abs 3 54MPa abs 2 17MPa abs Frequency Frequency 60Hz 30Hz 85Hz 40Hz 1 65 57 83 55 09 2 37 37 18 7 1 unit 3 11 14 40 24 4 6 12 3 6 stop valve pressure 0 96MPa abs 1 14MPa abs 3 50MPa abs 2 10MPa abs Frequency Frequency 45Hz 25Hz 75Hz 30Hz 1 71 63 72 48 07 2 31 35 13 7 1 unit 3 11 14 32 25 4 16 21 4 7 stop valve pressure 1 03MPa abs 1 18 MPa abs 3 07MPa abs 1 93MPa a...

Page 32: ...service port cap and both valve shaft caps tightly Turn until thetorque suddenly increases Now tighten a 1 6 turn more NOTE Use a gauge manifold and hoses exclusive for R410A After air removal check the tubeconnections for gas leak using a leakage detector or soapy water Regarding leakage detector use high sensitivity type designed specially for R410A Fig At Cooling for AY XPM7FR for AE XM24HR Fig...

Page 33: ... flash and three BEEP will be emitted 6 After 5 10 minutes fully close the stop valve liquid side by turning the hexagon socket screw key clockwise 7 After2 3minutes immediately close the stop valve gas side fully 8 Press the PUMP DOWN SWITCH SW1 on the display board unit for 5 seconds or more The operation of indoor outdoor unit will stop 9 Replace the service port cap and both valve shaft caps t...

Page 34: ...amp on the indoor unit will flash and three BEEP will be emitted Miswiring of unit to unit wiring will be self corrected 4 Wrong piping works cannot be corrected and will be detected as an error When an error is detected during checking all LED will show triple flash for eight times The indoor and outdoor operation will stop Turn the circuit breaker OFF and check and correct the miswiring mispipin...

Page 35: ... fixing the top cover 3 Remove the 6 screws fixing thefront panel L 4 Remove the 6 screws fixing the rear guard 5 Remove the 11 screws fixing the side cover R 6 Remove the 6 screws fixing the side cabinet L 7 Cut the insulators 8 Remove the 2 screws fixing the control box cover Caution Discharge electrytic capacitor before touching this capacitor or other components or wirings Screws Cut ...

Page 36: ...ssor cover 11 Remove the terminal cover and disconnect 3 terminals note Caution to the connectors position when reinstalling 12 Remove the 5 screws fixing the controlbox assembly 13 Cut the2 insulators 14 Remove the 3 screws fixing the bulkhead Compressor cover White C thermistor Red Compressor Red s Orenge R C ut ...

Page 37: ...ller fan 16 remove the 2 screws fixing the motor angle 17 Cut the fixing bands 18 Remove the 4 screws fixing the fan motor 19 Position of the thermistors Note Caution to the position when reinstalling Loos e Green Orange Black Yellow Brown White Blue ...

Page 38: ... to disassemble the control box assembly 1 Cut the wire fixing band 3 points 2 Remove the 4 screws fixing the PWB 3 Unlock the spacer s lock Instal this SHORT CIRCUIT CONNECTOR in a new CONTROL PWB at CONTROL PWB exchange ...

Page 39: ...AEXM24HR 5 5 ...

Page 40: ...AEXM24HR 5 6 ...

Page 41: ... 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 AEXM24HR AE XM24HR OUTDOOR UNIT MALTI SPLIT TYPE ROOM AIR CONDITIONERS MODELS PartsGuide 1 CONTROL BOX PARTS 2 CABINET AND PARTS 3 CYCLE PARTS 4 OTHER PARTS 5 PACKING PARTS 6 ACCESSORY PARTS INDEX ...

Page 42: ... 1 15 QFS GA062JBZZ AF FUSE 3 15A 250V 1 16 QFS GA063JBZZ AE FUSE 2A 250V 1 17 QFS GA064JBZZ AF FUSE 1A 250V 1 18 QSPGCA006JBZZ AH SURGE ABSORBER 1 22 FW VZA073JBKZ AV LEAD WIRE DB AF1 1 29 RRLYDA008JBZZ AH RELAY 1 30 RRLYDA012JBZZ AR RELAY 1 37 QW VZF823JBZZ AF LEAD WIRE AF1 L2 COIL 1 38 QW VZF824JBZZ AF LEAD WIRE AF1 L1 COIL 1 41 QW VZF827JBZZ AL LEAD WIRE MRY1 DB1AC1 1 42 QW VZF828JBZZ AL LEAD ...

Page 43: ...6 4 1 2 17 1 11 2 36 1 60 1 36 1 63 1 52 1 62 1 46 1 65 1 613 15 2 21 1 70 1 62 2 41 1 59 1 58 2 37 2 40 2 20 2 20 2 55 2 49 2 48 2 39 2 31 1 69 2 46 2 14 2 15 2 57 2 47 2 22 2 10 2 52 2 53 2 62 2 61 2 13 2 12 2 56 2 28 2 24 2 25 2 19 2 23 2 26 2 38 1 66 1 76 1 66 1 12 4 3 2 9 4 3 4 3 4 3 4 3 1 45 1 44 1 48 1 71 2 70 4 1 ...

Page 44: ...JBTA BE FRONT PANEL R 2 9 JHNDPA016JBFA AE HANDLE 2 10 PSEL C637JBEZ AD FRONT PANEL SEAL A 2 12 GCAB A247JBTB BE FRONT PANEL L 2 13 GGADFA028JBTA AZ FAN GUARD 2 14 CCHS A862JBKZ BK BASE PAN ASS Y 2 15 GLEGMA043JBTB AX BASE STAND 2 17 GPLTMA062JBTB AX SIDE CABINET L 2 19 GPLTMA066JBTA BC SIDE COVER R 2 20 PSEL C641JBEZ AD SIDE COVER R SEAL 2 21 PSEL C597JBEZ AC BULKHEAD INSULATOR 2 22 PSKR A327JBWZ...

Page 45: ...3 13 3 11 3 22 2 67 2 34 3 21 2 68 2 69 3 12 4 6 3 7 3 9 3 8 2 66 2 30 2 63 3 30 3 28 3 28 3 31 3 32 3 33 3 34 2 64 2 16 3 2 4 5 1 73 3 24 3 17 3 1 1 1 69 1 78 3 30 3 5 3 5 1 3 5 2 3 34 3 34 3 32 3 32 3 30 3 30 2 30 2 30 3 1 1 3 17 2 33 3 34 3 32 3 29 3 28 2 30 3 1 1 3 17 ...

Page 46: ... 3 5 2 LX NZA227JBEZ AF BONNET 3 7 DVLV A847JBKZ BD REVERSE VALVE ASS Y 3 8 CCIL A112JBEZ AX COIL 3 9 LX BZA268JBEZ AB SPECIAL SCREW 3 10 PACU A043JBEZ BW ACCUMULATOR 3 11 GLEG A029JBE0 AK CPMPRESSOR CUSHION 3 12 LBSHCA005JBE0 AD TERMINAL BUSHING 3 13 PCMPRA563JBEZ CT COMPRESSOR 3 14 PCOV 0562JBE0 AG TERMINAL COVER 3 17 RMOTSA031JBZZ BC COIL 3 21 PVLVXA061JBEZ BD REVERSE VALVE 3 22 PGUMSA319JBEZ A...

Page 47: ...C381JBEZ BE PACKING CASE 6 ACCESSORY PARTS 6 1 TINS B107JBRZ AC INSTALLATION MANUAL 6 1 TINS B108JBRZ AH INSTALLATION MANUAL 6 1 TINS B109JBRZ AH INSTALLATION MANUAL 6 5 LX BZA140JBE0 AB SPECIAL SCREW 6 6 GFTASA002JBFA AM CABLE COVER 6 7 LBND A046JBE0 AE WIRE FIXING BAND 6 8 LPFT A134JBFZ AF DRAIN JOINT 6 9 LPFT A135JBFZ AH DRAIN TRAY 6 10 PTUB A218JBEZ AB TUBE INSULATOR 6 10 6 7 6 5 6 1 6 6 6 10 ...

Page 48: ...EZ 3 3 13 CT PCON A553JBPZ 2 3 15 CC PCOV 0562JBE0 3 3 14 AG PCOV A940JBWZ 2 2 37 AP PDAI A177JBTB 3 2 16 BB PGUM A119JBEZ 3 2 67 AG PGUM A120JBEZ 3 2 68 AG PGUM A121JBEZ 3 3 24 AG PGUM A122JBEZ 3 3 25 AG PGUMSA319JBEZ 3 3 22 AF PMUF A081JBEZ 3 3 23 AY PRDAFA206JBEZ 2 1 52 BA PRDAFA207JBEZ 2 1 36 BC PSEL C006JBEZ 3 2 66 AC PSEL C282JBEZ 2 2 38 AD PSEL C373JBEZ 2 2 39 AC PSEL C597JBEZ 2 2 21 AC PSE...

Page 49: ...TLAB B709JBRA 3 2 64 AH TLABBA146JBRA 2 2 52 AP TLAB C770JBRA 3 2 63 AR TLAB C773JBRZ 2 2 62 AN TLABCC373JBRZ 2 2 53 AF TLAB D231JBRZ 4 1 90 AF TLAB D234JBRZ 2 2 61 AR TLAB D247JBRZ 4 1 86 AF TLAB D257JBEZ 2 2 70 AF TSPC F845JBRZ 2 2 55 AL V VHDD25VB60 1 2 1 45 AN PARTS CODE No PRICE RANK NEW MARK PART RANK ...

Page 50: ...roduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without prior written permission of the publisher COPYRIGHT XXXX BYSHARP CORPORATION ALL RIGHTS RESERVED ...

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