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IVT AE-X12GR-N Service Manual

Room air conditioner
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TopPage
CHAPTER 1. SPECIFICATION
[1]
SPECIFICATION.................................... . ....... 1-1
[2]
EXTERNAL DIMENSION....................... . ....... 1-2
[3]
WIRING DIAGRM .................................. . ....... 1-3
[4]
ELECTRICAL PARTS ............................ . ....... 1-3
ERATION
[1]
BLOCK DIAGRAMS............................... . ....... 2-1
[2]
[3]
FUNCTION............................................. . ....... 2-8
[1]
OPERATIONS........................................ . ....... 3-1
[2]
THERMISTOR ERROR ......................... . ....... 3-3
[3]
ACTERISTICS ....................................... . ....... 3-5
[4]
UNIT INDEPENDENTLY........................ . ....... 3-5
[5]
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.

SERVICE MANUAL

SPLIT TYPE
ROOM AIR CONDITIONER
MODELS
CONTENTS
........ 2-3
........ 3-6

INDOOR UNIT

AY-XP12GR-N
OUTDOOR UNIT
AE-X12GR-N
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.
[6]
OD .................................................................3-8
[7]
[8]
TROUBLESHOOTING GUIDE ....................3-13
[1]
FLOW FOW REFRIGERANT ........................4-1
[2]
STANDARD CONDITION ..............................4-1
[3]
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
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.

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  • Page 1: Table Of Contents

    ROOM AIR CONDITIONER INDOOR UNIT MODELS AY-XP12GR-N OUTDOOR UNIT AE-X12GR-N 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.

  • Page 2: Specification

    AEX12GRN CHAPTER 1. AEX12GRN SPECIFICATION Service Manual [1] SPECIFICATION 1. AY-XP12GR-N – AE-X12GR-N MODEL INDOOR UNIT OUTDOOR UNIT ITEMS AY-XP12GR-N AE-X12GR-N Cooling capacity(Min.–Max.) 3.5 (0.9 - 4.0) Heating capacity(Min.– Max.) 4.6 (0.9 - 6.5) Moisture removal(at cooling) Liters/h Electrical data...

  • Page 3: External Dimension

    AEX12GRN [2] EXTERNAL DIMENSION 1. Indoor unit 18.5 INVERTER AIR CONDITIONER 22.0 2. Outdoor unit 37.5 1 – 2...

  • Page 4: Wiring Diagrm

    AEX12GRN [3] WIRING DIAGRM 1. Indoor unit 2. Outdoor unit [4] ELECTRICAL PARTS 1. Indoor unit DESCRIPTION MODEL REMARKS Indoor fan motor MLB084 DC Motor Indoor fan motor capacitor – – Transformer – – FUSE1 – QFS-GA062JBZZ (250V, 3.15A) FUSE2 –...

  • Page 5: Chapter 2. Explamation Of Circuit And Op

    AEX12GRN CHAPTER 2. AEX12GRN EXPLAMATION OF CIRCUIT AND OPERATION Service Manual [1] BLOCK DIAGRAMS 1. Indoor unit DC power supply circuit Rectification circuit AC power 3.15A Fuse Fuse Fan motor PWM control circuit Indoor fan motor Rotation pulse input circuit Fan motor pulse detect AC clock circuit Remote controller signal reception circuit...
  • Page 6 AEX12GRN 2. Outdoor unit AC clock circuit protection Pulse amplitube modulation circuit IGBT protection Unit-unit wiring (AC power Power supply circuit Smoothing Power factor Filter circuit converter circuit circuit and serial signals) CPU oscillator circuit 3.15A DC overvoltage detection circuit protection Outdoor fan drive circuit Outdoor fan...

  • Page 7: Microcomputer Control System

    AEX12GRN [2] MICROCOMPUTER CONTROL SYSTEM 1. Indoor unit 1.1. Electronic control circuit diagram 2 – 3...
  • Page 8 AEX12GRN 1.2. Display circuit diagram 1 2 3 4 5 2 – 4...
  • Page 9 AEX12GRN 1.3. Printed wiring board 2 – 5...
  • Page 10 AEX12GRN 2. Outdoor unit 2.1. Electronic control circuit diagram 2 – 6...
  • Page 11 AEX12GRN 2.2. Printed wiring board 2 – 7...

  • Page 12: Function

    AEX12GRN [3] FUNCTION 1. Function 1.1. Startup control 1.6. Outdoor unit 2-way valve freeze prevention control The main relay remains off during the first 45 seconds (first safety If the temperature of the outdoor unit 2-way valve remains below 0°C time) immediately after the power cord is plugged into an AC outlet in for 10 consecutive minutes during cooling or dehumidifying operation, order to disable outdoor unit operation and protect outdoor unit electric...
  • Page 13 AEX12GRN 1.10. Startup control 1.16. Power ON start When the air conditioner starts in the cooling or heating mode, if the If a jumper cable is inserted in the location marked with HAJP on the room temperature is 2°C higher than the set temperature (in cooling indoor unit control printed circuit board (control PCB), connecting the operation) or 3.5°C lower (in heating operation), the air conditioner power cord to an AC outlet starts the air conditioner in either cooling or...
  • Page 14 AEX12GRN 1.19. Airflow control 1.23. Plasmacluster Ion function The airflow control holds the two upper and lower louvers at special Operating the Plasmacluster Ion button while the air conditioner is in positions during operation to prevent discharged air from directly blow- operation or in non-operation allows the switching of the operation mode in the following sequence: “Air Clean operation”...
  • Page 15 AEX12GRN 1.26. Auto restart • Automatic operation mode setting • Swing louvre When power failure occures, after power is recovered, the unit will automatically restart in the same setting which were active before the • Plasmacluster mode power failure. 1.26.2 Setting not memorized 1.26.1 Operating mode (Cool, Heat, Dry) •...
  • Page 16 AEX12GRN When the IGBT is ON, an electric current flows to the IGBT via the reactor (L5), (L6) and diode bridge (DB2). When the IGBT turns OFF, the energy stored while the IGBT was ON is charged to the voltage doubler capacitor via the diode bridge (DB1). As such, by varying the ON/OFF duty of the IGBT, the output voltage is varied.
  • Page 17 AEX12GRN 3.3. PAM protection circuit To prevent excessive voltage of PAM output from (Overvoltage detection) damaging the IPM and electrolytic capacitor as well as the control printed circuit board (PCB), this circuit monitors the PAM output voltage and turns off the R112 R114 255K...

  • Page 18: Explanation Of Ipm Drive Circuit

    AEX12GRN 4. 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 overcurrent detection, etc., are provided outside the IPM (control PCB). 4.1. 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.
  • Page 19 AEX12GRN 4.1.2 DC overcurrent detection circuit When a current of about 25 A or higher flows through the shunt resistance (R49) on the control printed circuit board (PCB), the voltage at this resis- tance is input to IPM CIN pin (26). Then, the gate voltage of the lower-phase IGBT (LU, LV, LW) inside the IPM turns OFF to cut off the overcurrent. At the same time, 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.
  • Page 20 AEX12GRN 5. 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 waveform is input to the comparator in the form of PWM-switched pulse waveform, and a position detection signal is generated as a reference voltage equaling 1/2 of 280 VDC.

  • Page 21: Chapter 3. Function And Operation Of Pro- Tective Procedures Protection Device Functions And Operations

    AEX12GRN CHAPTER 3. AEX12GRN FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES Service Manual [1] PROTECTION DEVICE FUNCTIONS AND OPERATIONS Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit error unit unit display Operation OFF or ON ✩2 Indoor unit fan lock Operation stops if there is no When indoor unit fan...
  • Page 22 AEX12GRN Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit error unit unit display Operation OFF or ON Yes ✩1 AC overcurrent Operating frequency lowers if When compressor is error compressor AC current exceeds in operation peak control current value.

  • Page 23: Air Conditioner Operation In Thermistor Error

    AEX12GRN Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit error unit unit display Operation OFF or ON Yes ✩3 25 Compressor star- Compressor stops if compressor At compressor star- tup error fails to start up. Operation OFF or ON Yes ✩3 26 Compressor rota- Compressor stops if there is no...
  • Page 24 AEX12GRN 2. Outdoor unit Item Mode Control opera- When resistance is Short-circuit When resistance Open-circuit tion low (temperature is high (tempera- judged higher than ture judged lower actual) than actual) Compressor Cooling Expansion valve Compressor oper- Compressor high Layer short-circuit Outdoor unit ther- chamber ther- Dehumidifying...

  • Page 25: Thermistor Temperature Characteristics

    AEX12GRN [3] THERMISTOR TEMPERATURE CHARACTERISTICS 1. Indoor unit thermistor temperature characteristics Resistance (K ) Tester Tester Heat exchanger thermistor TH2 (orange) Thermistor Symbol Color Before measuring resistance, Resistance at 25 : 15 k disconnect connectors as shown above. Room temperature Yellow Room temperature thermistor TH1 (yellow) (CN4)

  • Page 26: General Troubleshooting Chart

    AEX12GRN [5] GENERAL TROUBLESHOOTING CHART 1. Indoor unit does not turn on Main cause Inspection method Normal value/condition Remedy Cracked PWB. Check visually. There should be no cracking in PWB Replace PWB. (Cracked pattern) or pattern. Open-circuit in FU1 (250 V, 3 Check melting of FU1, FU2.
  • Page 27 AEX12GRN 6. There is noise in TV/radio Main cause Inspection method Normal value/condition Remedy Grounding wires not connected Check grounding wire connec- Grounding wires should be connected Connect grounding wires prop- properly. tions. properly. erly. TV/radio is placed too close to Check distance between TV/radio If TV/radio is placed too close, it may Move TV/radio away from outdoor...

  • Page 28: Malfunction (Parts) Check Method

    AEX12GRN [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 indi- cation error occurs.
  • Page 29 AEX12GRN 2. Procedure for determining defective expansion valve Measure resistance in expansion valve coil. Normal resistance between red terminal of expansion valve lead wire and each terminal: about 46 (at 20 (red) Checker Insert checker shown at left into connector (CN12) on control PWB, and operate air conditioner.

  • Page 30: Outdoor Unit Check Method

    AEX12GRN 5. IPM check method Turn off the power, let the large capacity electrolytic capacitor (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. Needle-type tester Normal resistance value Needle-type tester...
  • Page 31 AEX12GRN Item Check method Normal value/condition Remedy Compressor check Measure compressor coil resistance Resistance value at 20°C --- 1.13Ω Correct connections at compres- (for each phase of U, V and W). sor terminals. Use multi-meter or digital tester capa- Replace compressor. ble of displaying two digits right of the decimal point (0.01Ω).
  • Page 32 AEX12GRN 3. Caution in checking printed circuit 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 circuit board (PWB) are connected to the compressor drive power supply (320-VDC negative terminal). Therefore, exercise utmost caution to prevent electric shock.

  • Page 33: Troubleshooting Guide

    AEX12GRN [8] TROUBLESHOOTING GUIDE 1. Self-Diagnosis Function and Display Mode To call out the content of the self-diagnosis memory, hold down the emergency operation button for more than 5 seconds when the indoor unit is not operating. • The number of indications displayed by the LEDs on the outdoor unit differs from that for the 2001 cooling unit models (for detailed display of mal- function information).
  • Page 34 AEX12GRN Status of Indication Malfunction Content of diagnosis Inspection location/method Remedy indoor/ by LED1 No. dis- outdoor on out- played on units door unit main unit display sec- tion *1 Main Sub- Main category Sub-category cate- cate- gory gory Indoor/ 2 times Cycle tempera- Compressor high-...
  • Page 35 AEX12GRN Status of Indication Malfunction Content of diagnosis Inspection location/method Remedy indoor/ by LED1 No. dis- outdoor on out- played on units door unit main unit display sec- tion *1 Main Sub- Main category Sub-category cate- cate- gory gory Indoor/ 6 times Outdoor unit DC DC overcurrent error (1) IPM continuity check (1) Replace the outdoor...
  • Page 36 AEX12GRN Status of Indication Malfunction Content of diagnosis Inspection location/method Remedy indoor/ by LED1 No. dis- outdoor on out- played on units door unit main unit display sec- tion *1 Main Sub- Main category Sub-category cate- cate- gory gory Indoor/ 9 times Outdoor unit Thermistor installa-...
  • Page 37 AEX12GRN Status of Indication Malfunction Content of diagnosis Inspection location/method Remedy indoor/ by LED1 No. dis- outdoor on out- played on units door unit main unit display sec- tion *1 Main Sub- Main category Sub-category cate- cate- gory gory Indoor Wires between Serial open-circuit (1) Check the wires between...
  • Page 38 AEX12GRN Inter-unit wiring error mode Symptom Indoor unit relay Relays turns Off after about 30 minutes. Malfunction diagnosis display None Indoor Outdoor (Displays "18-0" when malfunction code is called out.) unit unit Indoor unit relay Relays turns Off after about 30 minutes. Malfunction diagnosis display None (Displays "18-0"...

  • Page 39: Chapter 4. Refrigeration Cycle

    AEX12GRN CHAPTER 4. AEX12GRN REFRIGERATION CYCLE Service Manual [1] FLOW FOW REFRIGERANT Indoor unit Evaporator Flare coupling Flare coupling 3-way 2-way valve valve Heating Cooling Strainer Muffler Outdoor unit Accumulator Expansion valve Comp- ressor Coil Condenser Reverse valve [2] STANDARD CONDITION Indoor side Outdoor side Dry-bulb Temp.

  • Page 40: Performance Curves

    AEX12GRN [4] PERFORMANCE CURVES NOTE: 1) Indoor fan speed: Hi 2) Vertical adjustment louver "45°", Horizontal adjustment louver "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 1000 1200 1100...

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