Welcome

Module
1
RAC
Jason Roberts
Training Manager
SAFETY
Mobile Phones
Fire Alarm
Exits
Toilets

Practical Testing
Workshop
Awareness
Why training in service?
Technology Advancements
Better understanding of what is actually happening during
operation and diagnostic
Product problems are dealt with efficiently by you.
Less incorrect warranty diagnosis
Opportunity for two way feedback

What we are going to cover today?
Support Manual
Equipment
Basic Theory
Control Functions
Checking testing
Introduction
Support Manual
2 x Books Residential (RAC)
Commercial (PAC)
25 Codes across all products
Quick access to rectification
A5 Convenience
CERTIFICATE
On line questionnaire
One submission attempt
Certificate if passed
Recommended
Tools
Multimeter
Diode test function is
essential
Sharp or needlepoint
probes are recommended.
Clamp Meter
True RMS
To monitor current draw to unit
and compressor.
A frequency function is
HIGHLY RECOMMENDED
Inverter Checker
Connect to the inverter in place
of a DC Compressor, LEDs
flash ON and OFF to indicate
switching of Inverter.
A quick visual check of Inverter
function
DOES NOT test Inverter under
load.
Insulation tester

Commonly known as a
Megger
Used to test compressor
windings for shorts to
earth
A multimeter IS NOT an
Insulation tester

Thermometer
Who has a Digitemp?
Thermometer with bead type
thermocouple or touch probe
Can be attached to a pipe with a cable
tie.
Can be slipped in with the factory pipe
temperature sensor.
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 1000V
diode
We will even give you a diode for
free
Invaluable for working on Fujitsu
General units
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?
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 accurately
controlled improving customer comfort.
Inverter Block Diagram
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 a
mains power supply issue.
Check for AC Voltage IN and OUT of the
Power PCB
Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
POSISTOR
By passes Power Relay,
allowing initial power up as
the power relay is not
energised by default. It
Only allows low current to
pass through it. The
Posistor goes open circuit if
abnormal current flow is
detected on power up.
Posistor / Power Relay Circuit
POWER RELAY
Energised by outdoor
control PCB
Posistor / Power relay
The Posistor is a safety device used to prevent
subsequent damage after a component in the inverter
has failed.
The initial fault will occur and usually trip the power
supply circuit breaker to the system.
When the power supply is reset the Posistor detects the
over current as the outdoor unit powers up and open
circuits preventing power flow into the inverter and any
further damage.
The Posistor itself does not actually fail, it is similar to a
self resetting fuse and will open circuit when excess
current flows through it. Once the fault downstream has
been corrected the Posistor will reset.

Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
Diode Bridge / Bridge Rectifier
The AC Voltage enters the
Diode Bridge and is
converted into DC Voltage
240 VAC in = ~240 VDC
OUT
Diode bridge checks II
Multimeter lead connections
Negative lead
(BLACK)
Positive lead
(RED)
Normal / Expected
values
DIODE BRIDGE WIRE
CONNECTIONS (if
discrete module)
or
SOLDER 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
Heat sink 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, Methylated
spirits 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

ACTPM / Active Filter Module Check
Black
Red
White
Brown
Blue N1
Yellow P
ACTPM / Active Filter Module 2
Before starting test, ensure outdoor unit is isolated
All wires must be disconnected from the Active Filter to do the tests
Multimeter must be set to Resistance.
ACTPM / Choke Coil
Most systems have a separate power factor correction device that may
be called the ACTPM or ACTIVE FILTER MODULE.
On small systems where there is only one inverter / controller pcb in the
outdoor unit, the power factor correction circuit is part of the main inverter
PCB
The power factor correction circuit includes a large coil of copper wire
referred to as the Reactor, Inductor or Choke coil.
Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
Smoothing Capacitor
Capacitors store energy and are used to smooth out any ripples
in the DC Voltage.
Beware they BITE !
At this stage the DC power has now been boosted, corrected
and smoothed and is ready to be used to drive the compressor.

Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT




Intelligent Power Module (IPM)
S1

S2

S3

S4

S5

S6
U V
V W
W U
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.
Intelligent Power Module Check
Intelligent Power Module Check II
Negative
positive
U Phase
V Phase
W Phase
This procedure performs a static test of the component only and will identify a
shorted transistor which is one of the causes of an IPM error.

Before starting test, ensure outdoor unit is isolated
Use a digital multimeter set to Diode Check mode
Disconnect wires to component if possible
Multimeter lead connections
Normal values
Negative 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 should
be similar
(~0.35-0.4v)
V (White) N (Blue)
W (Black) N (Blue)
U (Red) P (Yellow)
All readings should
be open (OL)
V (White) P (Yellow)
W (Black) P (Yellow)
Intelligent Power Module Checks III
Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
Inverter Checker
The Inverter phase checker may be used to check the switching
operation of the Intelligent power Module.
It is plugged into the compressor harness connector or at the
compressor terminals, depending on model to simulate the
compressor
The lights will flash on and off in sequence to indicate correct
switching of the IPM.
If any lights do not light to the same brightness as the others or
if any lights stay permanently ON or OFF then the IPM is
defective or it is being given incorrect switching signals from the
controller PCB.
Inverter Compressor testing
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 measure
compressor winding resistances.
Most compressor winding resistances are stated at 20 or 25 C,
the compressor must be at the stated temperature for the reading
to be accurate.
Insulation resistance MUST be checked using an INSULATION
TESTER (Megger) at 500V not a normal multimeter.
Inverter Block Diagram
POWER FACTOR
CORRECTION CIRCUIT
Main- Inverter- Controller PCB
The Controller PCB functions:
Low voltage power supply
Microprocessor
Serial communication
Thermistors
Outdoor fan motor, AC or DC
Electronic expansion valve
Break
Practical Session
WARNING
Some of the equipment being demonstrated today will be LIVE
Please make sure all due care and attention is taken, there will
be 240 VAC present and up to 400V DC.
Please watch others as they are watching you!

STAY SAFE!
The serial signal is used for the indoor unit and outdoor unit to communicate
with each other
The serial signal is modulated on an AC sine wave
Outdoor Unit
INFORMATION 1
Forward Serial signal

INFORMATION 2
Reverse Serial signal
Example of Serial Signal of ASY24PBA-W/AOY24PMAL
Indoor Unit
Serial signal Communication
Communication Signal
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 outdoor
unit. 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 indoor
unit. If the signal is 0 to 5 VDC start checking the outdoor unit for defective
components.

Communication Serial signal testing
DC Fan motors
DC fan motors are self contained
inverter driven variable speed
motors.
DC Fan motors are becoming more
common in Outdoor units and in
many Indoor units.
Distinguished by a Multi pin
connector with 5 leads
Controlled by a speed signal from
Main PCB based on compressor
speed and outdoor ambient temp.
The DC motor provides a Feedback
signal to Main PCB.
NEVER
DISCONNECT OR
RE-CONNECT
WHILST POWER
APPLIED
DC Fan Motor Checks
Before disconnecting or reconnecting ANY DC Fan motors
the power supply must be isolated and the DC voltage
within the unit drained below 40VDC
High Voltage DC
330-380 VDC (RED)
DC Ground (BLACK)
DC Control Power
15VDC (WHITE)
Fan motor speed signal
(YELLOW)
Fan motor feedback
signal (BLUE)
(Or Brown)
Model
Multi-Meter Lead Connection
Values
Negative 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 MOTOR
USING 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
Values
Negative 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 MOTOR
USING 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
Values
Negative
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 MOTOR
USING 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
Values
Negative
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
Model
Multi-Meter Lead Connection
Values
Negative 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 MOTOR
USING 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
Values
Negative lead
(BLACK)
Positive lead
(RED)
ASTA-B09 BLACK ORANGE 460 Ohms
ASTA-B09 BLACK WHITE 203 Ohms
ASTA-B09
WHITE ORANGE
258 Ohms
OUTDOOR MOTOR
USING 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
Model
Multi-Meter Lead Connection
Values
Negative 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 MOTOR
USING 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
Values
Negative 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 MOTOR
USING 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
Electronic expansion valve
The EEV is a motor driven needle
valve powered by an external step
motor coil. Full valve operating range
is 0 to 480 pulses.
On initialisation the valve is driven fully
closed then fully open. The valve will
remain fully open until the compressor
is required to start. It then drives
closed to a pre-set start position
determined by the ambient
temperature & the mode.
During operation the EEV is
modulated to maintain a target
compressor discharge temperature,
which is calculated from the
compressor speed, outdoor ambient
and unit operating mode.

EEV Tests Checks
Check for the tick-tick-tick noise as the valve
is driven fully closed then opened to its
maximum position.
The EEV coil must be seated correctly on the
body of the valve, it is held in place either by
a clip over the inlet pipe or a tab screwed to
the body of the valve.
The winding resistances of the coils of the
expansion valve can be measured. Consult
the service instructions for each model as the
resistances can vary.
Thermistors
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 the
TIMER 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.
Wired remote control Error Display

0:01E
Communication
error (Serial reverse
transfer error)
Testing and Checking Inverters
Initial power up checks
Serial Communication checks
Power PCB
Power Relay / Posistor
DC Fan motors
EEV
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
All compressors have a frequency range
Depending on the mode
SELECTION
Cooling mode
Heating Mode
Step 1.

Maximum frequency limit set
Cooling

Cooling Mode
Maximum frequency limit
Measure outside air temp
Temp
falling
Temp
rising

Cooling Mode
Maximum frequency limit
Check indoor fan speed setting
Step 2.

Capacity Control Cooling

Cooling Mode
Capacity Control

If the Room Temperature is 2C or higher than the set
temperature, the compressor will ramp up to the maximum
frequency in step 1.

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 unit
to work at maximum output, the compressor will be
controlled within the frequency range.
Step 1.

Maximum frequency limit set
Heating
Heating Mode
Outside air temp
Indoor fan speed setting
Step 2.

Capacity Control Heating

Heating Mode
Capacity Control
If the Room Temperature is 3C or more lower than the set
temperature, the compressor will ramp up to the maximum
frequency in step 1.

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 the
frequency range.
FREQUENCY CONTROL
AFTER START-UP
Total Time 6.8min (ASTA18LCC)
Heat Exchanger Temperature Control
DEFROST CYCLE
OTHER NEW
PRODUCT FEATURES
New Wall Mounted Option Parts
Wired Remote Controller
Optional kit - UTY-XCBXE (Communication box kit)
Controller UTB-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.
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 unit
operation 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
Additional Features
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