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Welcome
Module
1
RAC
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Jason RobertsTraining Manager
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SAFETY
Mobile Phones
Fire Alarm
Exits
Toilets
Practical Testing Workshop
Awareness
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Support Manual
2 x Books Residential (RAC)
Commercial (PAC)
25 Codes across all products
Quick access to rectification
A5 Convenience
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CERTIFICATE
On line questionnaire One submission attempt
Certificate if passed
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Recommended
Tools
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Multimeter
Diode test function is
essential
Sharp or needlepoint
probes are recommended.
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Clamp Meter
True RMS
To monitor current draw to unit
and compressor.
A frequency function is
HIGHLY RECOMMENDED
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Inverter Checker
Connect to the inverter in placeof a DC Compressor, LEDsflash ON and OFF to indicateswitching of Inverter.
A quick visual check of Inverterfunction
DOES NOT test Inverter underload.
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Thermometer
Who has a Digitemp?
Thermometer with bead typethermocouple or touch probe
Can be attached to a pipe with a cabletie.
Can be slipped in with the factory pipetemperature sensor.
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Serial signal test lead
A serial signal test lead is used
to measure the indoor and
outdoor communication signal.
Easily made with a spare
multimeter lead and a 1000Vdiode
We will even give you a diode for
free
Invaluable for working on Fujitsu
General units
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A device that converts normal alternating
current to an adaptable voltage & frequency.
This in turn allows a motor speed to
increase or slow down.
What is an inverter?
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Inverter Benefits
Compressor speed is controlled
automatically to reduce energy consumption.
The target temperature can be achieved
more rapidly as the compressor can increase
its output to meet peak demand.
The control temperature is more accuratelycontrolled improving customer comfort.
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Inverter Block Diagram
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Power / Filter PCB
Visually check the varistors for signs of
physical damage such as splitting or burning.
A varistor will fail or blow if an excess
voltage is applied, its normally a sign of amains power supply issue.
Check for AC Voltage IN and OUT of the
Power PCB
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Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
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Posistor / Power relay
The Posistor is a safety device used to preventsubsequent damage after a component in the inverterhas failed.
The initial fault will occur and usually trip the powersupply circuit breaker to the system.
When the power supply is reset the Posistor detects theover current as the outdoor unit powers up and opencircuits preventing power flow into the inverter and anyfurther damage.
The Posistor itself does not actually fail, it is similar to aself resetting fuse and will open circuit when excesscurrent flows through it. Once the fault downstream hasbeen corrected the Posistor will reset.
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Inverter Block DiagramPOWER FACTOR
CORRECTION CIRCUIT
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Diode Bridge / Bridge Rectifier
The AC Voltage enters theDiode Bridge and is
converted into DC Voltage
240 VAC in = ~240 VDC
OUT
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Diode b r idge checks II
Multimeter lead connections
Negative lead
(BLACK)
Positive lead
(RED)
Normal / Expected
values
DIODE BRIDGE WIRE
CONNECTIONS (if
discrete module)
orSOLDER PADS (if part of
PCB)
+ (Red) ~ (Grey) All readings should
be similar
(~0.5v)+ (Red) ~ (White)
- (Black)
~ (Grey)
All readings should
be open (OL)- (Black) ~ (White)
~ (Grey) - (Black) All readings should
be similar
(~0.5v)~ (White) - (Black)
~ (Grey) + (Red)All readings should
be open (OL)
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
Disconnect wires to component if possible
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Heat sin k paste
If there was white paste on the components you removed
then a new coating must be applied to the replacement
components
The old paste must be cleaned off the heat sink, Methylatedspirits and some rag or paper towel works well
A small artists palette knife is very handy to apply an even
coating and keeps you and the machine free from mess
Heatsink paste must be used
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ACTPM / Act ive Fi lter Modu le Check
Black
Red
White
Brown
Blue N1
Yellow P
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ACTPM / Choke Coil
Most systems have a separate power factor correction device that maybe called the ACTPM or ACTIVE FILTER MODULE.On small systems where there is only one inverter / controller pcb in theoutdoor unit, the power factor correction circuit is part of the main inverterPCBThe power factor correction circuit includes a large coil of copper wirereferred to as the Reactor, Inductor or Choke coil.
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Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
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Smoothing Capacitor
Capacitors store energy and are used to smooth out any ripplesin the DC Voltage.
Beware they BITE !
At this stage the DC power has now been boosted, correctedand smoothed and is ready to be used to drive the compressor.
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Inverter B lock Diagram
POWER FACTOR
CORRECTION CIRCUIT
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Intel l igent Pow er Module (IPM)
S1
S2
S3
S4
S5
S6
UV
VW
WU
time
ON
OFF
S1 S3 S5
S4 S6 S2
U
V W
+
-
S1 S3 S5
S4 S6 S2
U
V W
+
-
S1 S3 S5
S4 S6 S2
U
V W
+
-
S1 S3 S5
S4 S6 S2
U
V W
+
-
By changing the ON-OFF cycle of the switch, the
rotation of the motor can be varied at the desired
frequency. If the DC voltage is changed, the input
voltage of the motor can be also varied.
Practically, the motor is rotated by using 6pcs
of transistors instead of a switch, and the transistor
is alternately turned ON-OFF.
MOTOR
P
N
The IPM takes the High Voltage DC power and switches it to each phase of the
compressor creating artificial three phase power.
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Intel ligent Power Module Check
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In tel l igent Power Modu le Check II
Negative
positive
U Phase
V Phase
W Phase
This procedure performs a static test of the component only and will identify ashorted transistor which is one of the causes of an IPM error.
Before starting test, ensure outdoor unit is isolatedUse a digital multimeter set to Diode Check modeDisconnect wires to component if possible
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Multimeter lead connections
Normal valuesNegative lead
(BLACK)
Positive lead
(RED)
IPM POWER WIRE
CONNECTIONS (if discrete
module)
or
SOLDER PADS(if part of Inverter PCB)
P (Yellow) U (Red)All readings should
be similar
(~0.35-0.4v)
P (Yellow) V (White)
P (Yellow)
W (Black)
N (Blue) U (Red)All readings should
be open (OL)N (Blue) V (White)
N (Blue) W (Black)
U (Red) N (Blue)
All readings shouldbe similar
(~0.35-0.4v)
V (White) N (Blue)
W (Black) N (Blue)
U (Red) P (Yellow)All readings shouldbe open (OL)
V (White) P (Yellow)
W (Black)
P (Yellow)
In tell igent Power Modu le Checks III
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Inverter B lock Diagram
POWER FACTOR
CORRECTION CIRCUIT
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Inverter Checker
The Inverter phase checker may be used to check the switchingoperation of the Intelligent power Module.
It is plugged into the compressor harness connector or at thecompressor terminals, depending on model to simulate thecompressor
The lights will flash on and off in sequence to indicate correctswitching of the IPM.
If any lights do not light to the same brightness as the others orif any lights stay permanently ON or OFF then the IPM isdefective or it is being given incorrect switching signals from thecontroller PCB.
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Inverter Compressor test ing
Winding resistance between phases vary depending on model,they range from 0.188 Ohm (AOT54LJBYL) to 1.41 ohms(AOT24LMADL) between phases.
A Dedicated milliohm meter is the only way to accurately measurecompressor winding resistances.
Most compressor winding resistances are stated at 20 or 25 C,the compressor must be at the stated temperature for the readingto be accurate.
Insulation resistance MUST be checked using an INSULATIONTESTER (Megger) at 500V not a normal multimeter.
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Inverter B lock DiagramPOWER FACTOR
CORRECTION CIRCUIT
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Main- Inverter- Contro l ler PCB
The Controller PCB functions:
Low voltage power supply
Microprocessor Serial communication
Thermistors
Outdoor fan motor, AC or DC
Electronic expansion valve
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Break
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Practical Session
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WARNING
Some of the equipment being demonstrated today will be LIVE
Please make sure all due care and attention is taken, there willbe 240 VAC present and up to 400V DC.
Please watch others as they are watching you!
STAY SAFE!
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The serial signal is used for the indoor unit and outdoor unit to communicate
with each otherThe serial signal is modulated on an AC sine wave
Outdoor Unit
INFORMATION 1
Forward Serial signal
INFORMATION 2
Reverse Serial signalExample of Serial Signal of ASY24PBA-W/AOY24PMAL
Indoor Unit
Serial signal Communication
C S
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Communication Signal
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Diode Lead Signal Check
This test is to check the indoor unit is communicating to the outdoor unit
Place the diode lead on to the signal line
Place the black lead on to the neutral line
If the reading is approx 30 to 60 VDC the indoor unit is communicating to the outdoorunit. If the signal is 0 to 5 VDC start checking the indoor unit for defective
components.
This test is to check the outdoor unit is communicating to the indoor unit
Place the diode lead on to the neutral line
Place the black lead on to the signal line
If the reading is approx 30 to 60 VDC the outdoor unit is communicating to the indoorunit. If the signal is 0 to 5 VDC start checking the outdoor unit for defectivecomponents.
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Communication Serial signal testing
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DC Fan motors DC fan motors are self contained
inverter driven variable speedmotors.
DC Fan motors are becoming morecommon in Outdoor units and inmany Indoor units.
Distinguished by a Multi pinconnector with 5 leads
Controlled by a speed signal fromMain PCB based on compressorspeed and outdoor ambient temp.
The DC motor provides a Feedbacksignal to Main PCB.
NEVERDISCONNECT ORRE-CONNECTWHILST POWERAPPLIED
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DC Fan Motor Checks
Before disconnecting or reconnecting ANY DC Fan motorsthe power supply must be isolated and the DC voltage
within the unit drained below 40VDC
High Voltage DC330-380 VDC (RED)
DC Ground(BLACK)
DC Control Power15VDC (WHITE)
Fan motor speed signal
(YELLOW)
Fan motor feedbacksignal (BLUE)
(Or Brown)
INDOOR MOTOR
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Model
Multi-Meter Lead Connection
ValuesNegative lead
(BLACK)
Positive lead
(RED)
ASTA-B09 RED BLACK 1.05V
ASTA-B09 BLACK RED OPEN
ASTA-B09 WHITE BLACK 0.57V
ASTA-B09 BLACK WHITE 1.32V
INDOOR MOTORUSING TOPTRONIC T9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
The fan motor must be disconnected and the check carried out at the fan motor plug
INDOOR MOTOR
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Model
Multi-Meter Lead Connection
ValuesNegative lead
(BLACK)
Positive lead
(RED)
ASTA-B18 RED BLACK 1.04V
ASTA-B18 BLACK RED OPEN
ASTA-B18 WHITE BLACK 0.57V
ASTA-B18 BLACK WHITE 1.47V
INDOOR MOTORUSING TOPTRONIC T9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
The fan motor must be disconnected and the check carried out at the fan motor plug
INDOOR MOTOR
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Model
Multi-Meter Lead
Connection
ValuesNegative
lead(BLACK)
Positive
lead(RED)
ASTA-
B18RED BLACK 1.04V
ASTA-
B18
BLACK REDOPEN
ASTA-
B18
WHITE BLACK
0.57V
ASTA-
B18
BLACK WHITE1.47V
INDOOR MOTORUSING TOPTRONIC T9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
The fan motor must be disconnected and the check carried out at the fan motor plug
Model
Multi-Meter Lead
Connection
ValuesNegative
lead(BLACK)
Positive
lead(RED)
ASTA-
B24RED BLACK 0.81V
ASTA-
B24
BLACK REDOPEN
ASTA-
B24
WHITE BLACK
0.23V
ASTA-
B24
BLACK WHITE0.23V
INDOOR MOTOR
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Model
Multi-Meter Lead Connection
ValuesNegative lead
(BLACK)
Positive lead
(RED)
ASTA-B24 RED BLACK 0.81V
ASTA-B24 BLACK RED OPEN
ASTA-B24 WHITE BLACK 0.23V
ASTA-B24 BLACK WHITE 0.23V
INDOOR MOTORUSING TOPTRONIC T9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
The fan motor must be disconnected and the check carried out at the fan motor plug
OUTDOOR MOTOR
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Model
Multi-Meter Lead Connection
ValuesNegative lead
(BLACK)
Positive lead
(RED)
ASTA-B09 BLACK ORANGE 460 Ohms
ASTA-B09 BLACK WHITE 203 Ohms
ASTA-B09 WHITE ORANGE 258 Ohms
OUTDOOR MOTORUSING TOPTRONIC 9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Ohms Resistance mode
The fan motor must be disconnected and the check carried out at the fan motor plug
OUTDOOR MOTOR
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Model
Multi-Meter Lead Connection
ValuesNegative lead
(BLACK)
Positive lead
(RED)
ASTA-B18 RED BLACK 0.82V
ASTA-B18 BLACK RED OPEN
ASTA-B18 WHITE BLACK 0.22V
ASTA-B18 BLACK WHITE 0.23V
OUTDOOR MOTORUSING TOPTRONIC T9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
The fan motor must be disconnected and the check carried out at the fan motor plug
OUTDOOR MOTOR
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Model
Multi-Meter Lead Connection
ValuesNegative lead
(BLACK)
Positive lead
(RED)
ASTA-B24 RED BLACK 0.79V
ASTA-B24 BLACK RED OPEN
ASTA-B24 WHITE BLACK 0.24V
ASTA-B24 BLACK WHITE 0.23V
OUTDOOR MOTORUSING TOPTRONIC T9005
Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
The fan motor must be disconnected and the check carried out at the fan motor plug
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Electronic expansion valve
The EEV is a motor driven needlevalve powered by an external stepmotor coil. Full valve operating rangeis 0 to 480 pulses.
On initialisation the valve is driven fullyclosed then fully open. The valve will
remain fully open until the compressoris required to start. It then drivesclosed to a pre-set start positiondetermined by the ambienttemperature & the mode.
During operation the EEV ismodulated to maintain a targetcompressor discharge temperature,which is calculated from thecompressor speed, outdoor ambientand unit operating mode.
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EEV Tests Checks Check for the tick-tick-tick noise as the valve
is driven fully closed then opened to itsmaximum position.
The EEV coil must be seated correctly on thebody of the valve, it is held in place either by
a clip over the inlet pipe or a tab screwed tothe body of the valve.
The winding resistances of the coils of theexpansion valve can be measured. Consultthe service instructions for each model as theresistances can vary.
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Thermistors
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ASTA / ASTB series error display
The OPERATION and TIMER light flash a coded message.
The number of flashes of each light must be counted as the
OPERATION light is the first digit of the error display and theTIMER light is the second digit of the error display
The OPERATION light may not always be lit
eg Operation = OFF, Timer = 2 x ON indicates Reverse serial
communication error at start-up.
Wi d t t l E Di l
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Wired remote control Error Display
0:01E
Communication
error (Serial reverse
transfer error)
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Testing and Checking Inverters
Initial power up checks
Serial Communication checks
Power PCB
Power Relay / Posistor
DC Fan motors
EEV
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Initial power up checks
Stop Look and Listen
When power is applied, the power relay in the outdoor unit will
be energised.
You will hear a Click sound
The Electronic Expansion valve will go through its initialisation
sequence.
You will hear a Tick, Tick, Tick sound
Double check by placing your hand on the body of the valve or
at the side of the outdoor unit near the liquid service valve Sometimes the serial communication chip will make a sound,
listen for the Crickets
The only wildlife that should ever find inside an inverter assembly
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All compressors have a frequency range
Depending on the mode
SELECTION
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Cooling mode
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Heating Mode
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Step 1.
Maximum frequency limit set
Cooling
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Cooling Mode
Maximum frequency limitMeasure outside air temp
Tempfalling
Temp
rising
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Cooling Mode
Maximum frequency limitCheck indoor fan speed setting
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Step 2.
Capacity Control Cooling
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Cooling Mode
Capacity Control
If the Room Temperature is 2C or higher than the set
temperature, the compressor will ramp up to the maximumfrequency in step 1.
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Cooling Mode
Capacity Control
If the Room Temperature is 2.5C lower than the
set temperature, the compressor will be stopped.
If the Room Temperature does not require the unitto work at maximum output, the compressor will be
controlled within the frequency range.
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Step 1.
Maximum frequency limit set
Heating
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Heating Mode
Outside air temp
Indoor fan speed setting
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Step 2.
Capacity Control Heating
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Heating Mode
Capacity Control
If the Room Temperature is 3C or more lower than the settemperature, the compressor will ramp up to the maximum
frequency in step 1.
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Heating Mode
Capacity Control
If the Room Temperature is 2.5C higher than the set
temperature, the compressor will be stopped.
If the Room Temperature does not require the unit to work at
maximum output, the compressor will be controlled within thefrequency range.
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FREQUENCY CONTROL
AFTER START-UP
Total Time 6.8min (ASTA18LCC)
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Heat Exchanger Temperature Control
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DEFROST CYCLE
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OTHER NEW
PRODUCT FEATURES
New Wall Mounted Option Parts
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e a ou ted Opt o a tsWired Remote Controller
Optional kit - UTY-XCBXE (Communication box kit)
ControllerUTB-TUD
Please Note: ET Chassis is the only one that requires this option part. All other chassis
shown has this control ability already on the circuit board inside indoor unit, These units
do not need above optional kit.
Additional Features
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External input
Pump down function
Low noise mode
Peak cut function
Suppresses night time operating sound.
Suppresses maximum capacity and performs
energy-saving operation and can prevent
breaker tripping.
Refrigerant recovery is performed with one
button when moving, etc.
Valve close timing can also be easily
confirmed by LED display and outdoor unit
damage can be prevented.
External output
ON/OFF
ERROR
This output indicates the outdoor unitoperation status's On / Off.
This output indicates the outdoor unit and
connected indoor unit's Normal / Error.
Blue fin heat exchanger
Corrosion-resistance of the heat exchanger
even in coastal areas has been improved by
blue fin treatment of the outdoor unit heat
exchanger.
Blue fin heat exchanger
Cobalt Blue protection
Standard chromate protection
Aluminium base material
Hydrophilic coating
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www.fujitsugeneral.co.nz
Service / Technical Manuals
Bulletins
Operating Manuals
Glossy sales leaflets
News
Plus much more
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THANK YOU.
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