General ABG36A, ABG36ABA3W, AOG36ACG3L, ABG45A, ABG45ABA3W Service Manual

SPLIT TYPE

ROOM AIR CONDITIONER

CEILING type (50Hz)

Models Indoor unit	Outdoor unit
ABG36ABA3W	AOG36ACG3L
ABY36ABA3W	AOY36ACG3L
ABT36ABA3W	AOT36ACG3L
ABG45ABA3W	AOG45ACA3L
ABY45ABA3W	AOY45ACA3L
ABT45ABA3W	AOT45ACA3

C O N T E N T S

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OUTLINE AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REFRIGERANT SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . 3

ERROR CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INDOOR PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM . . . . . 7

REMOTE CONTROL UNIT CODE SWITCHING . . . . . . . . . . . . . . . 8

DISASSEMBLY ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2003.07.29

S P E C I F I C A T I O N S

TYPE				COOL
INDOOR UNIT		AB	36ABA3W		AB 45ABA3W
OUTDOOR UNIT		AO	36ACG3L		AOG45ACA3L, AOY45ACA3L, AOT45ACA3
COOLING CAPACITY	(kW)	10.3 - 10.5			12.4 - 12.7

ELECTRICAL DATA

POWER SOURCE	(V)			380 - 415
FREQUENCY	(Hz)			3ø / 50
RUNNING CURRENT	(A)	7.0	- 7.2		7.5	- 7.5
INPUT WATTS	(kW)	3.80	- 3.90		4.45	- 4.57
E.E.R.	(kW/kW)	2.71	- 2.69		2.79	- 2.78
MOISTURE REMOVAL	( /hr)	4.0			5.5
AIR CIRCULATION-Hi	(m3/hr)	1,660			1,850

COMPRESSOR

TYPE			Hermetic type, 2 pole, 3-phase,		Induction motor
CODE			CR47KQ-TFD		CRPQ-0450-TFD
REFRIGERANT	R-22	(g)	2,350		3,150

FAN MOTOR

POWER SOURCE		(V)		220 - 240
	TYPE			MFA-45DZM
INDOOR	HI-SPEED	(r.p.m.)	1,000		1,100
UNIT	MED-SPEED	(r.p.m.)	900		1,000
	LO-SPEED	(r.p.m.)	750		850
OUTDOOR	TYPE			MFB-362FT
UNIT	HI-SPEED	(r.p.m.)		790

DIMENSIONS

	INDOOR UNIT	H x W x D	(mm)	240 x 1,660 x 700
	OUTDOOR UNIT			1,152 x 940 x 370

WEIGHT

INDOOR UNIT	GROSS / NET	(kg)		61 / 48
OUTDOOR UNIT			108 / 94		116 / 102

ADDITIONAL REFRIGERANT R-22

7.5 m (25 ft )	2,350 g (82.9 oz)		3,150 g (111.1 oz)
10.0 m (33 ft )	2,350 g (82.9 oz)		3,150 g (111.1 oz)
20.0 m (66 ft )	2,350 g (82.9 oz)		3,150 g (111.1 oz)
25.0 m (82 ft )	2,550 g (89.9 oz)		3,350 g (118.2 oz)
30.0 m (98 ft )	2,750 g (97.0 oz)		3,550 g (125.2 oz)
40.0 m (131 ft )	3,150 g (111.1 oz)		3,950 g (139.3 oz)
50.0 m (164 ft )	3,550 g (125.2 oz)		4,350 g (153.4 oz)
ADDITIONAL CHARGE		40 g (0.43 oz) / 3.3 ft (1 m)
CHARGELESS		20 m (66 ft )
MAX PIPE LENGTH		50 m (164 ft )
MAX ELEVATATION		30 m (98 ft )

Note : • Between 7.5 m and 50 m, when using a connection pipe other than in the table, charge additional refrigerant with 40 g (1.41 oz) / 1 m (3.3 ft) as the criteria.

• Additional gas charge is not necessary with pipe length up to 20 m.

2003.07.29

- 1 -

	O U T L I N E A N D D I M E N S I O N S
INDOOR UNIT	(Unit : mm)

700

1,660

240

1,600

OUTDOOR UNIT

1,152

23

300

130

370

425

400

650

940

- 2 -

2003.07.29

R E F R I G E R A N T S Y S T E M D I A G R A M

Models : AB 36ABA3W / AO 36ACG3L

INDOOR UNIT	OUTDOOR UNIT
Refrigerant pipe
.52mm (3/8")
Capillary tube	Dryer
Distributor

Charging valve

Condenser

Evaporator

Accumulator

	Refrigerant pipe	Muffler
	19.05mm (3/4")
		Compressor
	Charging valve
	Models : AB 45ABA3W / AO 45ACA3L
	ABT45ABA3W / AOT45ACA3
	INDOOR UNIT	OUTDOOR UNIT
	Refrigerant pipe
	9.52mm (3/8")
		Capillary tube
	Distributor	Dryer
	Charging valve

Condenser

Evaporator

Thermistor (Discharge gas)

Charging valve

Muffler

Compressor

Refrigerant pipe 19.05mm (3/4")

Accumulator

2003.07.29

- 3 -

E R R O R C O N T E N T S

INDOOR UNIT

Operation can be checked by lighting and flashing of the display section OPERATION, TIMER, and VERTICAL SWING lamps.

Perform judgment in accordance with the following.

VERTICAL SWING lamp (Orange)

TIMER lamp (Green)

OPERATION lamp (Red)

MANUAL

AUTO

SWING SWING TIMER OERATION

TEST RUNNING

When the air conditioner is run by pressing the remote control unit test run button, the OPERATION, TIMER, and VERTICAL SWING lamps flash slowly at the same time.

ERROR

The OPERATION, TIMER, and VERTICAL SWING lamps operate as follows (Table 1) according to the error contents.

Table 1

Error contents	Error display
	OPERATION	TIMER	VERTICAL SWING
	lamp	lamp	lamp
Indoor EEPROM abnormal
Outdoor EEPROM abnormal
Indoor room temperature sensor	(2 times)
open
Indoor room temperature sensor	(2 times)
short-circuited
Indoor heat exchanger	(3 times)
temperature sensor open
Indoor heat exchanger	(3 times)
temperature sensor short-circuited
Float switch operated	(4 times)
Indoor signal abnormal	(5 times)
Outdoor signal abnormal	(5 times)
Indoor fan abnormal	(6 times)
Outdoor power source connection		(2 times)
abnormal
Outdoor heat exchanger		(3 times)
temperature sensor open
Outdoor heat exchanger		(3 times)
temperature sensor short-circuited
Outdoor temperature sensor open		(4 times)
Outdoor temperature sensor		(4 times)
short-circuited
Outdoor discharge pipe		(5 times)
temperature sensor open
Outdoor discharge pipe		(5 times)
temperature sensor short-circuited
Outdoor high pressure abnormal		(6 times)
Outdoor discharge pipe		(7 times)
temperature abnormal
: 0.1s ON / 0.1s OFF (flash)	: OFF
: 0.5s ON / 0.5s OFF (flash)

- 4 -

2003.07.29

Models : AB 36ABA3W AB 45ABA3W

C I R C U I T D I A G R A M
		THERMISTOR (ROOM TEMP.)
		THERMISTOR (PIPE TEMP.)
							GRAY
							GRAY	1 2							FAN MOTOR
								GRAY	GRAY	BLACK	BLACK				CAPACITOR
															WHITE
				1	CN 15	1	2	1	2	1	2		CN 4	1
						CN 6		CN 7		CN 8
				2
														2
				3
CN 201
			BROWN												WHITE
	1	1		1
DISPLAY BOARD	2	2	RED	2											STEP MOTOR
	3	3	ORANGE	3
	4	4	YELLOW	4	CN 13			CONTROL BOARD						1	(UP/DOWN)
	5	5	WHITE	5											BROWN	1
			BLUE											2	RED	2
	6	6		6									CN 10				M
			PURPLE											3	ORANGE	3
	7	7		7
	8	8	GRAY	8										4	YELLOW	4
														5	WHITE	5
															STEP MOTOR
		1	GRAY	1											(LEFT/RIGHT)
FAN MOTOR					16
			PURPLE											1	BROWN	1
		2	BLUE	2	CN									2	RED	2
FM		3	BLACK	3									11	3	ORANGE	3	M
		2	WHITE	1	5								CN	4	YELLOW	4
		1		2	CN										WHITE
		3	RED	3			CN 19		CN 1					5		5
							1	2	2	1
									WHITE	BLACK					Use T3.15A-250V
															Fuse on F101
											FILTER	BOARD			GREEN
									N	L
							GRAY		WHITE	BLACK
							1		2	3
				TERMINAL				(N)

Model : AO

36ACG3L

FAN MOTOR

FAN MOTOR

COMPRESSOR

(UPPER)

THERMAL

(LOWER)

INTERNAL

PROTECTOR

OVERLOAD

T1

T3

PROTECTOR

BLACK

RED

T2

BLUE

CONNECTOR

CONNECTOR

WHITE

THERMOSTAT (DISCHARGEPIPE)

RED WHITE

BLACK

WHITEWHITE

BLACK

RELAYMAGNETIC

COMPOSITECR

HEATERCRANKCASE

2

4

6

32

A/A1

FAN

FAN

CAPACITOR

CAPACITOR

WHITE

BLUE

1

3

5

31

B/A2

BLACK

WHITE

RED

BROWN

WHITE

BLACK

WHITE

BLUE

GRAY

L

H

OUTDOOR

TERMINAL

THERMOSTAT

BLUE

BLACK

BLACK

BLUE

C

FUSE

GREEN / YELLOW

RED

5A

R

S

T

N

3

2

1

BLACK

TERMINAL

(N)

TO POWER SUPPLY

TO INDOOR UNIT

2003.07.29

- 5 -

Models : AOG45ACA3L

AOY45ACA3L

FAN MOTOR

FAN MOTOR

COMPRESSOR

(UPPER)

THERMAL

(LOWER)

INTERNAL

OVERLOAD

PROTECTOR

T1

T3

PROTECTOR

BLACK

RED

T2

BLUE

THERMOSTAT (DISCHARGE PIPE)

CONNECTOR

CONNECTOR

BLACK

BLACK

2

4

6

32

A

WHITE

WHITE

CRANKCASE HEATER

FAN

FAN

CAPACITOR

CAPACITOR

RED

WHITE

WHITEWHITE

MAGNETICRELAY

COMPOSITECR

1

5

31

B

BLUE

3

BLACK

RED

BROWN

WHITE

BLACK

WHITE

OUTDOOR THERMOSTAT

BLUE

GRAY

L

H

TERMINAL

BLUE

BLACK

BLUE

C

BLACK

FUSE

GREEN/YELLOWWHITE

RED

5A

TERMINAL

R S

T N

3

2

1

BLACK

(N)

TO POWER SUPPLY

TO INDOOR UNIT

Model : AOT45ACA3

FAN MOTOR

FAN MOTOR

COMPRESSOR

(UPPER)

THERMAL

(LOWER)

INTERNAL

OVERLOAD

PROTECTOR

T1

T3

PROTECTOR

BLACK

RED

T2

CONNECTOR

CONNECTOR

2

4

6

32

A

WHITE

FAN

FAN

WHITE

(DISCHARGEPIPE)

CAPACITORBLACK

CAPACITORBLACK

RED

WHITE

WHITEWHITE

MAGNETICRELAY

CRCOMPOSITE

BLACK

THERMOSTAT

WHITE

1

5

31

B

3

OUTDOOR THERMOSTAT

L

H

BLACK

WHITE

RED

GRAY

FUSE 5A

BLUE

BLACK

C

BROWN

RED

BLUE

GREEN/YELLOW

BLACK

R S

T N

3

2

1

TERMINAL

(N)

TO POWER SUPPLY

TO INDOOR UNIT

- 6 -

2003.07.29

Models : AB 36ABA3W AB 45ABA3W

I N D O O R P R I N T E D C I R C U I T B O A R D

C I R C U I T D I A G R A M

CONTROLLER PCB ASSEMBLY ( MAIN PCB )

EZ-0020GWSE-C

5V

C6	R5
4700P	62K
600V	<2W>

						R4 330K			D5
							1SR139-600
						<2W>
								D10
			R1 3.3				1SR139-600
			<5W>					C7
					Q1
								0.047		R6	100
					2SC4236
								50V		<1/2W>
			D1					D2
							D1FL20U
			D3SB60		R3 100
					<1/10W>			D3		D4
						Q2	MTZJ5.1B			D1FL20U
				C5 +		2SC1815
					R2 1.5			R7		C8
			100/450V		<2W>
							330		+	100
							<1/4W>			/6.3V
											JM6
POWER SOURCE
220 - 240V
50Hz		FH101	BET FH102
		TM101 L	F101				C103		C105
							0.01		0.01
			3.15A	VA102
		<250V>					<F>		<F>		C101
				470V
							C104		C106		0.22
		N					0.01		0.01		275V
							<F>		<F>
						LF101
		TM102			ELF20N018A
		SA101		VA101
		3600V		470V
					POWER SUPPLY PCB
		E101	W103	W104	EZ-002THSE-P
		AWG16 GREEN			CN1 B2P3-VH-B-C			BLACK
						AC IN
		UL1015		UL1015 AWG18		BLACK	CN1-1
				UL1015 AWG18		WHITE	CN1-2
							CN4
				UL1015 AWG20			B2P3-VH-B-Y YELLOW
						WHITE	CN4-1
BLACK	WHITE	FAN CAPACITOR
				UL1015 AWG20		WHITE	CN4-2
AWG18	AWG18			UL1015 AWG20		BLACK	CN5-1
UL1015	UL1015
			F M	UL1015	AWG20	WHITE	CN5-2
				UL1015 AWG20		RED	CN5-3	JM5		JM8
		FAN MOTOR					CN5
							B3P5-VH-B WHITE
					CN6				K4
					B2P3-VH-B-E				G5NB-1A
					BLUE		CN6-2
				DRAIN PUMP				C3 0.22 <275V>
								R88 120 <1/2W>
							CN6-1
								K8
				UL1015 AWG18		GRAY	CN19-1	G5NB-1A

R15 - R17

10K <1/10W> x 3

NOT USED

JM1

R18 1.0K <1/10W>

1

P15

P10

76

REMOTE CONTROL CUSTOM CODE

JM2

R19 1.0K <1/10W>

2

P16

SWITCHING (R1)

REMOTE CONTROL CUSTOM CODE

JM3

R20 1.0K <1/10W>

3

P17

SWITCHING (R2)

P11

77

C19 - C21

I C 1

0.01 x 3

T1

<F>

uPD780058BGC

-057-8BT

SWITCHING TRANSFORMER

ZFT29B01

P57

35

D6

14V

R59

10K <1/10W>

54

P122

D2FL20U

R97

10K <1/10W>

R810K

<1/10W>

55

P123

C6

R98

10K <1/10W>

65

P04

+

R98

10K <1/10W>

66

P05

1000

P56

34

/25V

74

VDD0

PRIMARY SECONDARY

IC3

5V

68

VDD1

75

AVRF0

P50

27

7805

I

O

7

AVRF1

P27

18

G

P26

17

C54

C13

C14

+

C15

C47

P25

16

0.01

0.1

100/

0.1

0.1

<F>

<F>

6.3V

<F>

<F>

4

AVSS

67

VSS0

P22

13

5V

33

VSS1

P21

12

P20

11

NC

72

XT2

P130

5

R29 - R32

R33 - R36

1.0K <1/10W> x 4

56

P124

10K <1/10W> x 4

57

P125

58

P126

59

P127

P51

28

R11 56K

P52

29

C26 - C29

P53

30

<1.0W>

0.01 <F> x 4

P54

31

D8

P55

32

D1F60

5V

IC9

5V

R10

R9

390

TLP621

10K

<1/10W>

<GB>

<1/10W>

63

P02

P01

62

R12 1.0K

<1/10W>

CR6

R13 10K

C18

C17

0.01

<F>

<1/10W>

0.01

0.01

Q3

5V

<F>

<F>

DTC124EKA

R93 - R96

P70

8

10K <1/10W> x 4

P71

9

42

P66

P72

10

CR1 10K

P131

6

14V

IC5 (5/7)

<1/10W>

SSR1

uPA2003GR

G3MC-202PL-VD

11

6

40

P64

DC12V

+

12

5

39

P63

50

-

P36

13

4

38

P62

14

3

37

P61

P14

80

VA2

P13

79

470V

K 4

15

2

36

P60

P12

52

P120

78

12

5

P00

61

13

4

51

P37

P47

26

14

3

49

P35

P46

25

K 8

15

2

48

P34

P45

24

8

IC6 (4/7)

P44

23

uPA2003GR

P43

22

						5V	B2B-XASK-1-A WHITE		ROOM TEMPERATURE THERMISTOR
						CN8
							CN8-1	BLACK
							CN8-2	BLACK
C32	R44 1.0K		R43	C34		CN7	B2B-XAKK-1-A BLACK			PIPE TEMPERATURE THERMISTOR
1000P	<1/10W>		10K (1%)	0.1			CN7-1 UL1430 AWG24		GRAY	GRAY
<R>			<1/10W>	<F>			CN7-2 UL1430 AWG24		GRAY	GRAY
C35	R46 1.0K		R45	C37
1000P			49.9K (1%)	0.1			CN14
	<1/10W>
<R>			<1/10W>	<F>		Q4
							B4B-XH-AM
						DTC124EKA	WHITE	CN14-4
							5V
					5V			CN14-3
							R47 390			HA
						R48
								CN14-2		JEM-A
							<1/10W>
				R49 1.0K		10K
				<1/10W>		<1/10W>		CN14-1
				C38		CN10
						B5B-XASK-1-A
				0.01	14V
		IC5 (1/7)				WHITE
	14V			<F>		CN10-1
		uPA2003GR					BROWN	BROWN
	9	16				CN10-2	RED	RED
	1										LOUVER
7	10					CN10-3	ORANGE	ORANGE		M
	6	11				CN10-4	YELLOW	YELLOW			( UP / DOWN )
5	12					CN10-5	WHITE	WHITE

14V

CN11-1

BROWN

BROWN

9

13

CN11-2

RED

RED

4

LOUVER

3

14

CN11-3

ORANGE

ORANGE

M

2

15

CN11-4

YELLOW

YELLOW

( RIGHT / LEFT )

1

16

CN11-5

WHITE

WHITE

CN11

UL1430 AWG28

B5B-XARK-1-A

IC4 (7/7)

5V

RED

uPA2003GR

R53

R52

5V

10K

10K

<1/10W>

<1/10W>

CN13-1

BROWN

BROWN

1

R201 330 <1/4W>

D201 SLR-325 <RED>

OPERATE

CN13-2

RED

RED

2

R202 330 <1/4W>

D202 SLR-325 <GRN>

TIMER

CN13-3

ORANGE

ORANGE

3

R203 330 <1/4W>

D203 SLR-325 <ORG>

LOUVER

CN13-4

YELLOW

YELLOW

4

R204 330 <1/4W>

D204 SLR-325 <ORG>

LOUVER

CN13-8

WHITE

WHITE

8

C201

0.1

C40

R51 1.0K

5V

CN13-5

BLUE

BLUE

5

SW201

+C202

OUT

0.01

<1/10W>

C41 +

C42

MANUAL AUTO

10/

<F> PHA201

25V

<F>

R54 47

10/

0.01

7

SWITCH

SBX1810

25V

<F>

PURPLE

PURPLE

-22

<1/10W>

CN13-7

6

EVQ PEE 04R

GRAY

GRAY

CR5

CN13-6

CN201

CN13

UL1430 AWG28

1000P

8P-SCN

INDICATOR PCB

R50 10K

5V

WHITE

<R>

B8B-XASK-1-A

EZ-097JHSE-D

<1/10W>

4

D0

VCC

8

3

D1

NC

7

C39

2

SK

NC

6

0.1

1

CS

GND

5

<F>

R77 - R79

IC7

10K <1/10W> x 3

BR93LC46RF

14V

R56 1.0K

R57 1.0K 14V

6

9

<1/10W>

<1/10W>

11

IC6 (1/7)

CR2

10K <1/10W>

uPA2003GR

B Z

CR3

10K <1/10W>

BZ1

PKM13EPY-4000

CR4

10K <1/10W>

JM11

5V

R100

10K <1/10W>

R58

10K <1/10W>

R81	1.0K	<1/10W>	R80	10K <1/10W>
R72	1.0K	<1/10W>	R69	10K	<1/10W>	5V
R71	1.0K <1/10W>		R70	10K	<1/10W>

CR8

10

7

53

P121

C43

C16

C31

R68

C1

5V

R67 1.0K

10K

0.1

UL1430 AWG22 GRAY

TA120033

IC6 (2/7)

CN16-1

CN19-2

uPA2003GR16

47

P33

0.01

0.01

0.01

<1/10W>

<1/10W>

<F>

CN16-2

UL1430 AWG22

F M

TERMINAL BOARD

R21 - R24

1

PURPLE

CN19

<F>

<F>

<F>

CN16-3

UL1430 AWG22 BLUE

3

B2P3-VH-B-R

10K <1/10W> x 4

IC5 (1/7) 10

7

41

P65

CR7

0.01

RED

CN9

uPA2003GR

P03

64

CN16

FEED BACK

<F>

2(N)

B5P-SHF-1AA

CN9-1

43

P67

XT1

5V

B3P-VH-B

73

WHITE

CN9-2

44

P30

WHITE

1

I C

71

RJ2 10K

TEST

CN9-3

45

P31

P24

15

5V

CN9-4

46

P32

<1/10W>

P23

14

RJ1 10K

CN9-5

R25 - R28

C22 - C25

<1/10W>

CN15-1

5V

1.0K <1/10W> x 4

0.01 x 4 <F>

5V

R76

R75 10K

C49

CN15-2

FLOAT SWITCH

5V

R55

10K

<1/10W>

0.01

CN15-3

R39

R38 R37

19

P40

10K

1

<1/10W>

<F>

CN15

20

P41

RESET

60

<1/10W>

C45 JM10

10K <1/10W> x 3

3

B3B-XARK-1-A

21

P42

C44

0.1

RED

NO.1

R42 1.0K

<1/10W>

X2

2

AUTO RESTARTE SWITCHING

X1

0.1

<F>

OUTDOOR UNIT

ROOM TEMPERATURE CORRECTION

NO.2

R41 1.0K

<1/10W>

C10 C12

C30

1

70

69

3

<F>

IC8

( HEATING OPERATION )

NO.3

R40 1.0K

<1/10W>

PST600C

ROOM TEMPERATURE CORRECTION

X1

CSTS0500MG03-T

( HEATING OPERATION )

SW1

2

DSS803

0.01 <F> x 3

2003.07.29

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