IVT AY-XP12FR-N Service Manual
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IVT AY-XP12FR-N Service Manual

Split type room air conditioner
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TopPage
[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
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

INDOOR UNIT

AY-XP12FR-N
OUTDOOR UNIT
AE-X12FR-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.
[3]
ACTERISTICS...............................................3-5
[4]
UNIT INDEPENDENTLY ...............................3-7
[5]
[6]
OD .................................................................3-9
[7]
[8]
TROUBLESHOOTING GUIDE ....................3-14
[1]
FLOW FOW REFRIGERANT ........................4-1
[2]
STANDARD CONDITION ..............................4-1
[3]
PRESSURE IN 3-WAY VALVE ......................4-1
[4]
PERFORMANCE CURVES...........................4-2
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.
AYXP12FRN
........3-7

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Summary of Contents for IVT AY-XP12FR-N

  • Page 1: Table Of Contents

    SERVICE MANUAL SPLIT TYPE ROOM AIR CONDITIONER INDOOR UNIT MODELS AY-XP12FR-N OUTDOOR UNIT AE-X12FR-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.

  • Page 2: Chapter 1. Specification

    AYXP12FRN CHAPTER 1. AYXP12FRN SPECIFICATION Service Manual [1] SPECIFICATION 1. AY-XP12FR-N – AE-X12FR-N MODEL INDOOR UNIT OUTDOOR UNIT ITEMS AY-XP12FR-N AE-X12FR-N Cooling capacity(Min. > Max.) 3.5 (0.9 - 4.0) Heating capacity(Min. > Max.) 4.2 (0.9 - 6.0) Moisture removal(at cooling)

  • Page 3: External Dimension

    AYXP12FRN [2] EXTERNAL DIMENSION 1. Indoor unit 18.5 INVERTER AIR CONDITIONER 22.0 2. Outdoor unit 37.5 1 – 2...

  • Page 4: Wiring Diagrm

    AYXP12FRN [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- Od

    AYXP12FRN CHAPTER 2. AYXP12FRN 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 AYXP12FRN 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

    AYXP12FRN [2] MICROCOMPUTER CONTROL SYSTEM 1. Indoor unit 1.1. Electronic control circuit diagram 2 – 3...
  • Page 8 AYXP12FRN 1.2. Display circuit diagram 1 2 3 4 5 2 – 4...
  • Page 9 AYXP12FRN 1.3. Printed wiring board 2 – 5...
  • Page 10 AYXP12FRN 2. Outdoor unit 2.1. Electronic control circuit diagram 2 – 6...
  • Page 11 AYXP12FRN 2.2. Printed wiring board 2 – 7...

  • Page 12: Function

    AYXP12FRN [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 Model Peak control current Cooling operation Heating operation 1.16. Power ON start AY-XP12FR-N Approx. 6.4 A Approx. 7.5 A If a jumper cable is inserted in the location marked with HAJP on the 1.12. Outdoor unit fan delay control indoor unit control printed circuit board (control PCB), connecting the...
  • Page 14 AYXP12FRN 1.18. Information about auto mode 1.19. Airflow control In the AUTO mode, the temperature setting and mode are automati- The airflow control holds the two upper and lower louvers at special cally selected according to the room temperature and outdoor temper- positions during operation to prevent discharged air from directly blow- ature when the unit is turned on.
  • Page 15 AYXP12FRN 1.25. Winter cool • Fan setting • Air flow direction Cooling operation is available during the winter season by the built in winter cool function. • Power ON/OFF Lower limit of outdoor temperature range is -10°C DB. • Automatic operation mode setting When the outside air temperature is low, the outdoor unit fan operates •...
  • Page 16 AYXP12FRN 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 AYXP12FRN 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

    AYXP12FRN 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 AYXP12FRN 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 AYXP12FRN 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

    AYXP12FRN CHAPTER 3. AYXP12FRN 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 unit unit error display Indoor unit fan lock Operation stops if there is no When indoor unit fan Operation OFF or ON ✩2...
  • Page 22 AYXP12FRN Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit unit unit error display AC overcurrent Operating frequency lowers if When compressor is Operation OFF or ON Yes ✩1 error compressor AC current exceeds in operation peak control current value.

  • Page 23: Air Conditioner Operation In Thermistor Error

    AYXP12FRN Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit unit unit error display 25 Compressor star- Compressor stops if compressor At compressor star- Operation OFF or ON Yes ✩3 tup error fails to start up. 26 Compressor rota- Compressor stops if there is no Compressor operat-...
  • Page 24 AYXP12FRN Item Mode Control opera- When resis- Short-circuit When resis- Open-circuit tion tance is low tance is high (temperature (temperature judged higher judged lower than actual) than actual) Heat exchanger Cooling Freeze preven- Indoor unit evap- Indoor unit evap- Compressor Compressor does thermistor (TH2) Dehumidifying...

  • Page 25: Thermistor Temperature Characteristics

    AYXP12FRN Item Mode Control opera- When resis- Short-circuit When resis- Open-circuit tion tance is low tance is high (temperature (temperature judged higher judged lower than actual) than actual) 2-way valve ther- Cooling Expansion valve Frost accumu- Outdoor unit ther- Compressor Outdoor unit ther- mistor (TH5) Dehumidifying...
  • Page 26 AYXP12FRN 2. Outdoor unit thermistor temperature characteristics Connector Connector 500K Tester Tester Resistance 400K Resistance at 0 Resistance (K ) (In case of TH2 heat exchanger thermistor) 14.57 k (K ) 300K Resistance at 25 Resistance at 25 52.76 k 4.431 k 200K 5.8K...

  • Page 27: How To Operate The Outdoor Unit Independently

    AYXP12FRN [4] HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY 1. Cooling in 40 Hz fixed mode To operate the outdoor unit independently, short-circuit the sections indicated by arrows in the diagram below with an adapter, and apply 230 VAC between (1) and (N) on the terminal board of the outdoor unit. This allows the outdoor unit to be operated in cooling mode independently. (Do not operate the outdoor unit in this condition for an extended period of time.) Short-circuit negative terminal of capacitor (C33) and jumper wire...
  • Page 28 AYXP12FRN Main cause Inspection method Normal value/condition Remedy Dew condensation on light receiv- Check for water and rust. Signal should be received within Take moisture-proof measure for ing unit. range specified in manual. lead wire outlet of light receiving section. 5.

  • Page 29: Malfunction (Parts) Check Method

    AYXP12FRN [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 30 AYXP12FRN 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 31: Outdoor Unit Check Method

    AYXP12FRN 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 32 AYXP12FRN Item Check method Normal value/condition Remedy Compressor check Measure compressor coil resistance Resistance value at 20°C --- 0.65Ω 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 33 AYXP12FRN 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 34: Troubleshooting Guide

    AYXP12FRN [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 35 AYXP12FRN 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 36 AYXP12FRN 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 37 AYXP12FRN 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/ Outdoor unit DC Outdoor unit DC fan (1) Check connector CN3 of...
  • Page 38 AYXP12FRN 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/ Indoor unit fan Indoor unit fan error (1) Check the indoor fan...
  • Page 39 AYXP12FRN Malfunction indications due to erroneous wiring during air conditioner installation Inter-unit wiring error mode Symptom Indoor unit relay Turns On momentarily, then turns Off. Malfunction diagnosis display "18-1" Indoor Outdoor unit unit Indoor unit relay Relays turns Off after about 30 minutes. Malfunction diagnosis display None (Displays "18-0"...

  • Page 40: Chapter 4. Refrigeration Cycle

    Relative Humidity (%) Dry-bulb Temp. (°C) Relative Humidity (%) Cooling Heating – * REFRIGERANT PIPE LENGTH 5.0m [3] TEMPERATURE AT EACH PART AND PRESSURE IN 3-WAY VALVE Model AY-XP12FR-N MAX. TEST RUN Operation model Cool Heat Cool Heat more than 93 3-way valve pressure (MPaG) 1.08...

  • Page 41: Performance Curves

    AYXP12FRN [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-XP9FR-N 1.1. At Cooling 1.2. At Heating 1000 1100 1000...

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