Table of Contents
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AIR CONDITIONER
SYSTEM AIR CONDITIONER
OUTDOOR UNIT
AM072/096/120/144/168/216/240BXV***
CONTENTS
1. Precautions .............................................1
2. Product Specifications ......................... 3
3. Disassembly and Reassembly ...........27
4. Troubleshooting ................................. 63
5. PBA Diagram and Parts List .............176
6. Wiring Diagram ................................. 192
7. Piping Diagram ..................................202
8. Key Options .......................................283
9. Test Operation ...................................304
10. Nomenclature ................................. 319
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Table of Contents
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Summarization of Contents
1. Precautions
1-1 Precautions for the Service
Guidelines for safe and correct service procedures.
1-2 Precautions for the Static Electricity and PL
Safety measures for handling static sensitive components and preventing damage.
1-3 Precautions for the Safety
General safety guidelines to prevent electric shock and hazards.
1-4 Precautions for Handling Refrigerant for Air Conditioner
Safety and environmental precautions for handling refrigerants.
1-5 Precautions for Welding the Air Conditioner Pipe
Safety guidelines for welding refrigerant pipes.
1-6 Precautions for Additional Supplement of Air Conditioner Refrigerant
Precautions for adding refrigerant to the air conditioner system.
1-7 Other Precautions
General precautions not covered in previous sections.
2. Product Specifications
2-1 Feature of Product
Overview of innovative features and technological advances.
2-1-3 Structure of product (AM***BXV*F*)
Explains the internal structure of the AM***BXV*F* model units.
2-1-3 Structure of product (AM***BXV*J*)
Details the internal structure of the AM***BXV*J* model units.
2-2 Model names of Indoor/Outdoor Unit
Lists and categorizes indoor and outdoor unit model names.
2-2-1 Outdoor unit combination
Details the combinations and specifications for outdoor units.
2-3 Combination and Connection Ratio limitation
Outlines limitations for combining indoor and outdoor units.
2-5-1 Outdoor Unit
Provides detailed specifications for outdoor units.
2-6 Accessory and Option Specifications
Lists specifications for accessories and optional components.
2-6-1 Controller
Details various controller options and their specifications.
2-6-2 Piping
Specifies piping requirements and specifications for installation.
2-6-3 Controller & control Accessory Compatibility
Outlines compatibility between controllers and accessories.
3. Disassembly and Reassembly
3-1 Necessary Tools
Lists essential tools required for refrigerant pipe installation and work.
3-2 Disassembly and Reassembly
Provides step-by-step instructions for disassembling and reassembling the unit.
3-2-1 Checking the Device Condition
Outlines procedures for checking the unit's condition before disassembly.
3-2-2 Removal Instructions for Cabinet
Details the process for removing the unit's cabinet.
3-2-3 Disconnecting the Power Supply
Crucial safety steps for disconnecting the power supply before service.
3-2-4 Removal Instructions for Guard Fan
Step-by-step guide for removing the guard fan.
3-2-5 Removal Instructions for Fan and Motor
Instructions for safely removing the fan and motor components.
3-2-6 Removal Instructions for Compressor
Detailed procedure for removing the compressor, a major component.
3-2-7 Compressor exchange order
Provides a step-by-step guide for exchanging a compressor.
3-2-8 Removal Instructions for the Accumulator
Details the removal process for the accumulator.
3-2-9 Removal Instructions for the Control PBA
Instructions for removing the control Printed Circuit Board Assembly.
3-2-10 Removal Instructions for the Control Panel Assy
Guide for removing the control panel assembly.
3-2-11 Removal Instructions for the Inverter PBA
Steps for removing the inverter Printed Circuit Board Assembly.
3-2-12 Removal Instructions for the Fan PBA
Instructions for removing the fan Printed Circuit Board Assembly.
3-2-13 Removal Instructions for the DC Reactors and EMI PBA
Guide for removing DC reactors and EMI PBA.
3-2-14 MCU
Instructions for disassembling the Micro Controller Unit (MCU).
3-2-15 EEV kit
Steps for disassembling the Electronic Expansion Valve (EEV) kit.
4. Troubleshooting
4-1 Check-up Window Description
Explains the display indicators and their functions for diagnostics.
4-2 Service Operation
Details various service operation modes for diagnostics and testing.
4-2-1 Special Operation
Covers specific operational modes for service technicians.
4-2-2 DVM S Models EEPROM Code Table
Table mapping DVM S models to their Inverter and EEPROM codes.
4-2-3 Number Display Method (Outdoor Unit, MCU, Cable remote control, wall-mount, etc.)
Explains how to interpret numbers displayed on various units and controls.
4-3 Appropriate Measures for Different Symptom
Provides solutions for various system symptoms and errors.
4-3-1 Outdoor Unit Test Operation Flow
A flowchart detailing the process for performing outdoor unit test operations.
4-3-2 Main PBA has no power phenomenon
Troubleshooting steps for when the Main PBA shows no power.
4-3-3 Communication Error between Indoor and Outdoor Units during Tracking
Addresses communication errors occurring during system tracking.
4-3-4 Communication Error between Indoor and Outdoor Units after Tracking
Troubleshooting for communication errors that appear after tracking.
4-3-5 Communication error between main and sub Unit of outdoor unit or between outdoor units
Solves communication errors between outdoor units or main/sub units.
4-3-6 Internal Communication error of the Outdoor Unit C-Box
Troubleshoots internal communication errors within the outdoor unit's C-Box.
4-3-7 Internal PBA Communication error of the Outdoor Unit C-Box
Addresses internal PBA communication errors in the outdoor unit's C-Box.
4-3-8 MCU branch part setup error – inconsecutive connection with the use of 2 branch parts
Solves MCU branch setup errors related to non-consecutive connections.
4-3-9 MCU branch part setup error – Repeated setup for the same address over 3 times
Troubleshoots MCU branch setup errors caused by repeated address assignments.
4-3-10 MCU branch part setup error – non-installed address setup
Addresses MCU branch setup errors when addresses are not installed.
4-3-11 Setup Error for MCU Branch part – Setup Error for MCU Quantity Used
Solves MCU branch setup errors related to incorrect MCU quantity.
4-3-12 MCU branch part setup error – Overlapping Indoor unit Address setup
Troubleshoots MCU branch setup errors due to overlapping indoor unit addresses.
4-3-13 MCU branch part setup error – Set as being used without connection to an Indoor unit
Addresses MCU branch setup errors where a branch is used without an indoor unit.
4-3-14 MCU branch part setup error – Connect an Indoor unit to a branch part not being used
Solves MCU branch setup errors from connecting to unused branch parts.
4-3-15 MCU branch part setup error – Connect more Indoor units than what is actually set up in MCU
Troubleshoots MCU branch setup errors when more units are connected than configured.
4-3-16 MCU/MCU subcooler entrance/exit sensor error (Open/Short)
Addresses open/short errors for MCU/subcooler sensors.
4-3-17 Outdoor Temperature Sensor Error
Troubleshooting for outdoor temperature sensor issues.
4-3-18 Cond Out Temperature Sensor Error (Open/Short)
Addresses open/short errors for the Cond Out temperature sensor.
4-3-19 Outdoor Cond Out sensor breakaway error
Troubleshooting for breakaway errors in the Outdoor Cond Out sensor.
4-3-20 Compressor Discharge or Top 1/2 Temperature sensor error
Addresses errors related to compressor discharge or top temperature sensors.
4-3-21 Compressor Discharge or Top temperature sensor breakaway error
Troubleshooting for breakaway errors in compressor discharge/top sensors.
4-3-22 Suction Temperature sensor breakaway error
Troubleshooting for suction temperature sensor breakaway errors.
4-3-23 High Pressure sensor error (Open/Short)
Addresses open/short errors for the high pressure sensor.
4-3-24 Low Pressure sensor error (Open/Short)
Troubleshooting for open/short errors in the low pressure sensor.
4-3-25 Suction Temperature sensor error (Open/Short)
Addresses open/short errors for the suction temperature sensor.
4-3-26 Liquid Pipe Temperature sensor error (Open/Short)
Troubleshooting for open/short errors in the liquid pipe temperature sensor.
4-3-27 EVI In Temperature sensor error (Open/Short)
Addresses open/short errors for the EVI In temperature sensor.
4-3-28 EVI Out Temperature sensor error (Open/Short)
Troubleshooting for open/short errors in the EVI Out temperature sensor.
4-3-29 Suction-2 Temperature Sensor Error (OPEN/SHORT)
Addresses open/short errors for the Suction-2 temperature sensor.
4-3-30 Measures of other outdoor unit error
Provides measures for various other outdoor unit errors.
4-3-31 Comp. Down due to High Pressure Protection Control
Troubleshooting for compressor shutdown due to high pressure protection.
4-3-32 Suspension of starting due to Compressor discharge temperature sensor / Top temperature sensor
Addresses startup suspension caused by discharge/top temperature sensors.
4-3-33 3-phase Input Wiring error
Troubleshooting for 3-phase input wiring errors.
4-3-34 Suspension of starting by abnormal compression ratio
Troubleshooting for startup suspension due to abnormal compression ratio.
4-3-35 EVI EEV Open error
Troubleshooting for EVI EEV open errors.
4-3-36 Refrigerant leakage error
Troubleshooting for refrigerant leakage and shortage.
4-3-37 Prevention of heating / cooling operation due to outdoor temperature
Troubleshooting operational constraints related to outdoor temperature.
4-3-38 Prevention of heating refrigerant charge due to outdoor temperature
Troubleshooting operational constraints for heating refrigerant charge.
4-3-39 CCH wire breaking error
Troubleshooting for CCH wire breaking errors.
4-3-40 Fan motor starting error
Troubleshooting for fan motor starting errors.
4-3-41 Fan motor locking error
Troubleshooting for fan motor locking errors.
4-3-42 Momentary Blackout error
Troubleshooting for momentary blackout errors.
4-3-43 Outdoor Fan Motor overheating
Troubleshooting for outdoor fan motor overheating.
4-3-44 Fan PBA IPM overheating error
Troubleshooting for Fan PBA IPM overheating errors.
4-3-45 Compressor starting error
Troubleshooting for compressor starting errors.
4-3-46 COMP Overcurrent error
Troubleshooting for compressor overcurrent errors.
4-3-47 Overvoltage / Low voltage error
Troubleshooting for overvoltage or low voltage errors.
4-3-48 DC Link voltage sensor error
Troubleshooting for DC Link voltage sensor errors.
4-3-49 Fan Motor Overcurrent error
Troubleshooting for fan motor overcurrent errors.
4-3-50 Input / Output Current sensor error
Troubleshooting for input/output current sensor errors.
4-3-51 Outdoor Fan PBA Overvoltage / Low voltage error
Troubleshooting for outdoor fan PBA overvoltage/low voltage errors.
4-3-52 Hall IC connection/Two motor parameter difference error
Addresses Hall IC connection and motor parameter difference errors.
4-3-53 Inverter PBA IPM overheating error
Troubleshooting for Inverter PBA IPM overheating.
4-3-54 Option setting error of outdoor unit
Troubleshooting errors related to outdoor unit option settings.
4-3-55 Error due to using single type outdoor unit in a module installation
Troubleshooting errors from single type outdoor units in module installations.
4-3-56 Indoor unit and MCU address duplication error
Troubleshooting errors from indoor unit and MCU address duplication.
4-3-57 Refrigerant leakage check alarm in operaiton
Troubleshooting refrigerant leakage alarms during operation.
4-3-58 Main EEV leakage Error
Troubleshooting errors related to Main EEV leakage.
4-4 Case study for trouble shoots
Provides practical examples of troubleshooting common issues.
4-4-1 Electric discharge mode
A case study on handling electric discharge mode, emphasizing safety.
4-4-2 Pump down operation
Details the procedure for performing pump down operation.
4-4-3 Pump out operation
Provides steps for pump out operation for repair purposes.
4-4-4 Vacuum
Explains the vacuum operation procedure for outdoor unit repair.
4-4-5 Case study – E201 (Communication error between indoor & outdoor unit)
Troubleshooting example for communication errors between indoor and outdoor units.
4-4-6 Case study – E205 (Internal communication error of the outdoor unit C-box)
Troubleshooting example for internal C-Box communication errors.
4-4-7 Case study – E206 (Internal communication error of the outdoor unit C-box)
Troubleshooting example for internal PBA communication errors in C-Box.
4-4-8 Case study – E108 (Error due to repeated address setting)
Troubleshooting example for repeated indoor unit address setting errors.
4-4-9 Case study – E108, E604, E613
Troubleshooting examples for communication and address errors.
4-4-10 Case study – E461, E361 (Error due to operation failure of inverter compressor)
Troubleshooting example for inverter compressor operation failure.
4-4-11 Case study – Inverter PBA error
Troubleshooting examples related to inverter PBA errors.
4-4-12 Case study – E461/361 & E464/364 & E466/366
Troubleshooting examples for compressor and PBA errors.
4-4-13 Case study – Poor cooling caused by IPM overheated
Troubleshooting example for poor cooling due to IPM overheating.
4-4-14 Case study – Related error with IPM
Troubleshooting examples for errors related to IPM.
4-4-15 Case study – E455 (Fan IPM overheat error)
Troubleshooting example for Fan IPM overheat errors.
4-4-16 Case study – Temperature sensor open/short
Troubleshooting examples for temperature sensor open/short faults.
4-4-17 Case study – Pressure sensor open/short
Troubleshooting examples for pressure sensor open/short faults.
5. PBA Diagram and Parts List
5-1 Main PBA DC
Diagram and parts list for the Main PBA (DC).
5-2 Main PBA AC
Diagram and parts list for the Main PBA (AC).
5-3 EMI PF8
Diagram and parts list for the EMI PF8 module.
5-4 EMI PF9
Diagram and parts list for the EMI PF9 module.
5-5 EMI PF9 OLD
Diagram and parts list for the EMI PF9 OLD module.
5-6 Dual FAN
Diagram and parts list for the Dual FAN module.
5-7 Safety 2FAN
Diagram and parts list for the Safety 2FAN module.
5-8 PF8 Inv.Integration J POWER
Diagram and parts list for the PF8 Inv.Integration J POWER module.
5-9 PF8 Inv.Integration F POWER
Diagram and parts list for the PF8 Inv.Integration F POWER module.
5-10 PF8_20C INV J POWER
Diagram and parts list for the PF8_20C INV J POWER module.
5-11 PF9_20C INV F POWER
Diagram and parts list for the PF9_20C INV F POWER module.
6. Wiring Diagram
6-1 AM072BXVGF*/AA, AM072BXVGJ*/AA
Wiring diagram for AM072BXVGF*/AA and AM072BXVGJ*/AA models.
6-2 AM096/120/144BXVGF*/AA, AM096/120/144/168BXVGJ*/AA
Wiring diagrams for AM096-168 BXVGF*/AA and BXVGJ*/AA models.
6-3 AM162BXVGF*/AA
Wiring diagram for the AM162BXVGF*/AA model.
6-4 AM192BXVGJ*/AA
Wiring diagram for the AM192BXVGJ*/AA model.
6-5 AM216/240BXVGF*/AA, AM216/240BXVGJ*/AA
Wiring diagrams for AM216-240 BXVGF*/AA and BXVGJ*/AA models.
6-6 Field Wiring
Instructions and diagrams for field wiring.
7. Piping Diagram
7-1 Piping Diagram
Diagrams illustrating the refrigerant flow paths.
7-1-1 AM072BXVGFH/AA, AM072BXVGJH/AA
Piping diagram for AM072BXVGFH/AA and AM072BXVGJH/AA models.
7-1-2 AM096/120/144BXVGFH/AA, AM096/120/144/168BXVGJH/AA
Piping diagrams for AM096-168 BXVGFH/AA and BXVGJH/AA models.
7-1-3 AM192BXVGFH/AA, AM192BXVGJH/AA
Piping diagram for AM192BXVGFH/AA and AM192BXVGJH/AA models.
7-1-4 AM216/240BXVGFH/AA, AM216/240BXVGJH/AA
Piping diagrams for AM216-240 BXVGFH/AA and BXVGJH/AA models.
7-1-5 AM072BXVGFR/AA, AM072BXVGJR/AA
Piping diagram for AM072BXVGFR/AA and AM072BXVGJR/AA models.
7-1-6 AM096/120/144BXVGFR/AA, AM096/120/144/168BXVGJR/AA
Piping diagrams for AM096-168 BXVGFR/AA and BXVGJR/AA models.
7-1-7 AM192BXVGFR/AA, AM192BXVGJR/AA
Piping diagram for AM192BXVGFR/AA and AM192BXVGJR/AA models.
7-1-8 AM216/240BXVGFR/AA, AM216/240BXVGJR/AA
Piping diagrams for AM216-240 BXVGFR/AA and BXVGJR/AA models.
7-2 Refrigerant Flow for Each Operation Mode
Illustrates refrigerant flow for different operation modes.
7-2-1 DVM S Heat Pump – Cooling operation
Details refrigerant flow for DVM S Heat Pump in cooling mode.
7-2-2 DVM S Heat Pump – Heating operation
Details refrigerant flow for DVM S Heat Pump in heating mode.
7-2-3 DVM S Heat Recovery – Cooling operation
Details refrigerant flow for DVM S Heat Recovery in cooling mode.
7-2-4 DVM S Heat Recovery – Main cooling operation
Details refrigerant flow for DVM S Heat Recovery main cooling operation.
7-2-5 DVM S Heat Recovery – Heating operation
Details refrigerant flow for DVM S Heat Recovery in heating mode.
7-2-6 DVM S Heat Recovery – Main heating operation
Details refrigerant flow for DVM S Heat Recovery main heating operation.
7-3 Functions
Explains various functions and controls of the system.
7-3-1 Basics
Covers fundamental concepts related to the system.
7-3-1-1 P-h Diagram
Explains the Psychrometric (P-h) diagram for refrigerant properties.
7-3-1-2 Refrigeration Cycle
Describes the basic refrigeration cycle.
7-3-2 Control
Details the control mechanisms for various system operations.
7-3-2-1 Actuator
Explains the function and control of system actuators.
7-3-2-6 Indoor unit control
Details the control logic for indoor unit operations.
7-3-2-2 Start-up modes
Explains different start-up modes for compressors.
7-3-2-3 Normal operation modes
Describes normal operation modes for cooling and heating.
7-3-2-4 Special operation modes
Details special operation modes like defrost and oil return.
7-3-2-5 Protective control
Explains protective controls for system and compressor safety.
7-3-2-6 Indoor unit control
Details control logic for indoor unit operations.
7-3-2-6 Indoor unit control (cont.)
Further details on indoor unit control logic.
7-3-2-6 Indoor unit control (cont.)
Details on Thermo On/Off control for indoor units.
7-3-2-6 Indoor unit control (cont.)
Explains temperature compensation settings for indoor units.
7-3-2-6 Indoor unit control (cont.)
Details fan speed control settings for various modes.
7-3-2-6 Indoor unit control (cont.)
Explains Electronic Expansion Valve (EEV) control.
7-3-2-6 Indoor unit control (cont.)
Details drain pump control operations.
7-3-2-6 Indoor unit control (cont.)
Explains cold air prevention measures for indoor units.
7-3-3-1 Field Setting
Covers field setting options for system customization.
7-3-3-1 Field Setting (cont.)
Details field setting options for cooling capacity correction.
7-3-3-1 Field Setting (cont.)
Details field setting options for heating capacity correction.
7-3-3-1 Field Setting (cont.)
Explains current restriction rate settings for operation.
7-3-3-1 Field Setting (cont.)
Details settings for snow accumulation prevention control.
7-3-3-1 Field Setting (cont.)
Details fan speed correction settings for outdoor units.
7-3-3-1 Field Setting (cont.)
Explains silent mode settings for night-time operation.
7-3-3-1 Field Setting (cont.)
Details high-head condition setting options.
7-3-3-1 Field Setting (cont.)
Explains settings for long-piping conditions.
7-3-3-1 Field Setting (cont.)
Details energy control (ECO) operation settings.
7-3-3-1 Field Setting (cont.)
Explains Power mode settings for cooling operation.
7-3-3-1 Field Setting (cont.)
Details rotation defrost settings for HR units.
7-3-3-1 Field Setting (cont.)
Explains expand operational temperature range settings for cooling (HR only).
7-3-3-1 Field Setting (cont.)
Details channel address settings for controller connection.
8. Key Options
Covers key options for system configuration and operation.
8-1 System Configuration
Provides an overview of system configuration and display indicators.
8-2 List of Field Setting Items
Lists and explains various field setting items.
8-3 Outdoor unit option switch settings
Details the option switch settings for outdoor units.
8-4 How to check the view mode using a tact switch
Explains how to use tact switches to check view modes and settings.
8-5 Applications
Covers application examples for system features.
8-5-1 Application of Night Silent
Details the application of the night silent mode for noise reduction.
8-5-2 Application of External Contact Interface Module
Instructions for applying the external contact interface module.
8-5-3 Application of Auxiliary Heat Module
Details the application of the auxiliary heat module.
8-5-4 Application of Mode select Switch
Explains the application of the mode select switch for system operation.
9. Test Operation
Covers procedures for testing system operation.
9-1 Auto Trial Operation
Details the auto trial operation for system inspection.
9-1-1 Overview of Auto Trial Operation
Explains the purpose and overview of the auto trial operation.
9-1-2 Auto Trial Operation Flow Chart
A flowchart detailing the auto trial operation process.
9-1-3 How to resolve NG items
Provides steps to resolve NG (Not Good) items found during testing.
9-2 Amount of refrigerant automatically checking
Describes the automatic procedure for verifying refrigerant amount.
10. Nomenclature
Provides definitions and naming conventions for system components.
10-1 Model Naming
Explains the structure and meaning of model names.
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