Maxon MXI 18HC001, MXO-18HC001, MXI 09HC001, MXI 12HC001, MXO-09HC001 Service Manual

Splitairconditioner

WallmountedType

Servicemanual

MXI 18HC001- /MXO-18HC001

MBFRIGOGrupad.o.o.,Bani81,10010 Zagreb,tel:01/6608002,fax:01/6608005

www.maxon.com.hr,e-mail:[e-mail]

1

CONTENTS

11

Contents

Safety precautions

Installation

Block diagram

Trouble shooting

Fault diagnosis by symptom

Control specification

To disassemble mechanical parts

Exploded views and parts list

Wiring diagrams

22

22

1111

1212

1313

1717

2121

2525

4141

The following safety precautions must be taken when using your air
conditioner.

SAFETY PRECAUTIONS

1. Warning: Prior to repair, disconnect the power cord.

2. Use proper parts: use only exact replacement parts. (Also, we recommend replacing parts rather
than repairing them.)

3. Use the proper tools: use the proper tools and test equipment, and know how to use them. Using
defective tools or test equipment may cause problems later-intermittent contact, for example.

4. Power cord: prior to repair, check the power cord and replace it if necessary.

5. Avoid using an extension cord, and avoid tapping into a power cord. This practice may result in
malfunction or fire.

6. After completing repairs and reassembly, check the insulation resistance.
Procedure: prior to applying power, measure the resistance between the power cord and the ground
terminal. The resistance must be greater than 30 megohms.

7. Make sure that the grounds are adequate.

8. Make sure that the installation conditions are satisfactory. Relocate the unit if necessary.

9. Keep children away from the unit while it is being repaired.

10. Be sure to clean the unit and its surrounding area.

1

2

Location of indoor unit

A place solid enough to bear the weight of the unit and not cause any shake.
Good ventilation, less dust, far from direct rain and sunshine.

Avoid places close to inflammable gas leakage.

Keep the air inlet and outlet at a far distance from the blockage.

Keep the height distance between the indoor and outdoor unit at most 5m.

Mount on the wall solid enough to bear the weight of the unit and not cause any shake.

Avoid direct sunshine.

A place easy for condensate drain and easy for connecting with the outdoor unit.

Keep a far distance away from the fluorescent lamp, it may influence the operation of remote controller.

Location of outdoor unit

Keep at least 1m away from the TV radio and other home appliances.

A place where the air discharged out of the outdoor unit or the operation noise will not annoy your
neighbours.
No blockage near the outdoor unit.

Avoid places close to inflammable gas leakage.

Selecting area for installation

INSTALLATION

Select an area for installation that is suitable to the customer’s needs.

It is harmful to the air conditioner if it is used in the following environments: greasy areas (including area
near machines). Salty area such as coastal areas, areas where sulfuric gas is present such as hot spring
areas. Contact your dealer for advice.

Caution:

2

front

right

back

Underside

Left-back

back

Notice: do not elevate the
drain hose.

The copper pipe can be led
from back, right, underside,
or left-back side.

Cover connecting pipe with
adiabatic material.

Sponge plastic adiabatic
material with the
thickness of 8mm.

While installing the pipeline on the
thin armor plate or on the wall of
metal mesh, you should use the
wooden board to clamp between
the wall and the pipeline, or wrap
up the pipeline with 7-8 layers of
insulating plastic tape.

left

100

mm

ÒÔÉÏ

above 300m

m

above

500m

m

above 300mm

above 500mm

above 500mm

INSTALLATION

Installation diagram of indoor unit and outdoor unit

Confirm the installation position by the mark of the indoor mounting plate.

or

or or

above 155mm

above 250mm

Above 20mm

above 105mm

3

Securing the mounting plate and drill on the wall

1

Secure the mounting plate

The mounting plate should be attached to the structural part of wall (post etc).

fasten string at the central hole

10

5

m

m

o

r

m

o

r

e

f

r

om

s

i

d

ewa

ll

155

m

m

or

m

or

e

at

l

e

a

s

t 2

5

0

m

m

fr

o

m

si

d

e

w

al

l

Tapping screw
ST4 25(5)

mounting plate

NOTICE:

The holes at solid arrow position must be secured to avoid the shake of mounting plate.
When the expansion bolts are used, two holes ( 11 20 or 11 26 ) that the distance
between them is 450mm should be adopted.

Drill on the wall

Center of hole( 65mm)

Confirm the position of holes, and drill holes on the wall.

NOTICE:

Fasten string at the central hole

105mm or m

ore

from

sidew

al

l

455m

m or m

ore

at le

as

t 2

50mm

fr

om

sid

ew

al

l

Tapping screw
ST4 25(5)

mounting plate

plumb

40mm

a

t

l

e

as

t

2

4

m

m

plumb

fasten string at the central hole

105mm

45mm

Center of hole( 65mm)

plumb

NOTICE:

The holes at solid arrow position must be secured to avoid the shake of mounting plate.

When the expansion bolts are used, two holes ( 11 20 or 11 26 ) that the distance
between them is 450mm should be adopted.

Confirm the position of holes, and drill holes on the wall.

INSTALLATION

440mm

fasten string at the central hole

at least250mm

230mm

440mm

at least 120mm

at least 120mm

90mm

plumb

90mm

Pipe hole

40mm

Pipe hole

plumb

fasten string at the central hole

at least 250mm

at least 180mm

at least 140mm

120mm

Center of hole( 65mm)

Center of hole( 65mm)

4

Wiring

2

Open the front grille;
Remove the screw from electrical box cover, pull the
electrical box cover away from the unit and set aside.
Remove the screw from fastener, pull the fastener
away from the unit and set aside.
Connect the cable.
Replace the fastener and electrical box cover.

Indoor unit terminal

Screw

Connecting cable

Diagram

INSTALLATION

The drain hose must be arranged beneath the copper pipe.
The drain hose must not be hunched or twisted.
While wrapping up the drain hose, do not pull it.
The drain hose through the room must be wrapped up by the
thermal insulation materials.
The copper pipe and the drain hose must be wrapped up by felt
strip. Adiabatic pad should be used at where the pipe contacts
the wall.

NOTE:

1

2

3

ROUTE OF PIPE

If pipe comes out of the right side of the indoor unit, cut part

1 of the unit;
If pipe comes out of the lower-right side of the indoor unit, cut
part 2 of the unit;
If pipe comes out of the left side of the indoor unit, cut part 3
of the unit.

Installation of the drain hose

3

Drain hose

gas pipe

Liquid pipe

felt

Adiabatic
underlay

drain hose

If pipe comes out of the left side of the indoor unit, the drain hose
must be refitted, otherwise water leakage may occur.
Refit methods: Interchange the position of drain hose and drain
rubber plug.
Clearance is not allowed after refit, it would lead to water leakage.

Drain rubber
plug

REFIT OF DRAIN HOSE

5

NOTE:

The appliance shall be installed in accordance with national wiring regulations.
The appliance must not be installed in the laundry.
The appliance must be installed 2.3m above the floor.

The appliance must be positioned so that the plug is accessible.

For some models whose cooling capacity are above 4600W (17000BTU/h),
an all-pole disconnection device which has at least 3mm separation distance in
all pole and a residual current device(RCD)with the rating of above 10mA shall

be incorporated in the fixed wiring according to the national rule.

Arrangement of the drain hose

To drain the condensate water easily, the drain hose should be declined downwards.

The following 5 arrangement methods are incorrect.

Decline
downward

(Fig. 1)

(Fig. 2)

(Fig. 3)

(Fig. 4)

Water
leak

Standing water

air

Dip hose
into water

(Fig. 5)

50mm or less
above floor

Decline
downward

Water
leak

Water
leak

If you find the drain hose not long enough to connect with the indoor
unit, you can extend it with the hoses in the accessory box.
The drain hose through the room must be wrapped up with the special
adiabatic material.

Drain hose

Hose(ID 15cm)

PVC hard

INSTALLATION

5

Pipe Connection

DIAMETER OF PIPE

6.35mm ( 1/4 )

9.52mm ( 3/8 )

12.7mm ( 1/2 )

TORQUE(N m)

13.7---17.6

34.3---41.2

49.0---56.4

Align the centre of joint in line with that of flare and tighten the nut of connecting pipe with wrench.

Put some seal oil to cover the joint and the flare.

15.88mm ( 5/8 )

73.0---78.0

The number of bent position of the pipe in the indoor unit should not exceed 10.

The number of bent position of the pipe in the indoor unit and the outdoor unit should not exceed 15.

The radius of bent position should be more than 10cm.

Evaporator
craft tube

Do not exhaust the inside air just by loosing the nut since there is the air of certain pressure

inside the tube of indoor unit. Please do not make extra effort for fear of damaging the flare.

Attention:

Please break the evaporator craft tube with pincers before connecting. After exhausting the inside air,

use the wrench to twist down the nut of connecting tube of the evaporator.

Installation of the indoor unit

Let pipe go through the wall hole and attach the indoor
unit to the mounting plate.(Press the rib of indoor unit
inside the hook of the mounting plate.)

the rib of indoor unit

the mounting plate

Bottom

Indoor unit

4

Wall sealing and Pipe fastening

Use putty to seal the wall hole.
Use clamp (pipe fastener) to secure the pipe at specified position.

Indoor unit

clamp

screw

get rid of unwanted part

seal with putty

secure the connecting
pipe with clamp

6

6

INSTALLATION

Connecting
cable

Outdoor unit terminal

1

Wiring

1 Remove the self-tapping screws (2 pcs)
on the maintenance board and take out the
maintenance board.

Maintenance
board

Terminal board

Fix the cable wire
with anchor cable

Piping cover

Please utilize outdoor pipe support when
the cable wire is led from the backside.

Outdoor pipe support
(Outdoor pipe support is not required
when leading the cable wire from other places).

The cable wire can be led from the back hole
of the piping hole or ejecting hole.

Maintenance
board

Piping cover

Ejecting hole

Right wiring

Back wiring

Sponge

Piping cover

2 Loosen the self-tapping screws (2 pcs) on
the fixing clip to loosen the fixing clip.

5 Install the maintenance board. After the pipes
and cable wire are installed, please seal the
sponge block as per drawing indication.

3 Loosen the fixing screw of the wire terminal
board, pass the power wire and signal wire
through the fixing clip. Then firmly fix the
power wire and signal wire on the terminal
board with the fixing screw. (Earth wire
must be connected firmly.)

4 Tighten the self-tapping screw on the fixing clip.

Wiring For Above 6000W Model (Above 21000BTU/h Model)

Connecting
cable

Outdoor unit terminal

or

Installation diagram of indoor unit and outdoor unit

7

INSTALLATION

8

If the interconnection cord for power supply has to be replaced, please see the
following table for reference.

Notice:

If the signal wire has to be bought separately, choose electric wire above 0.75mm.

MODEL

SPECS (Interconnection cord)

2700W(10000BTU/h)

1.0mm

3000W(11000BTU/h)

-4000W(15000BTU/h)

4500W(18000BTU/h)

-8000W(28000BTU/h)

2.5mm

1.5mm

2

2

2

2

WARNING:

Special cable must be used to connect indoor unit and outdoor unit. It should be ensured
that the terminals are not influenced by external force. Poor connection may cause fire.

The electric box cover must be mounted and secured in position, otherwise fire or electrical
shock may occur because of dust or moisture.

The connecting cables must be clipped together.

Please take the electric circuit diagram attached to the indoor/outdoor units as major
reference while installing.

The power wire and signal wire between the indoor/outdoor units must be connected
one by one as per corresponding number on the wiring terminal board.

All the models shall be connected with the mains which has system impedance limitations.
While installing the unit, please see the following table for impedance information or
consult with the supply authority.

The temperature of refrigerant circuit will be high, please keep the interconnection cable away
from the copper tube.

3500W (12000BTU/h)

0.219

5100W (18000BTU/h)

0.186

R410A
series

6800W (18000BTU/h)

0.124

Burr

Oblique

Copper pipe

90

Roughness

Reamer

Burr

Outer diameter

A(mm)

2.0--2.5

3.0--3.5

3.5--4.0

6.35mm ( 1/4 )

9.52mm ( 3/8 )

12.7mm ( 1/2 )

15.88mm(5/8 )

4.0--4.5

Air exhausting

4

Installation of the drain joint(only for heat pump type)

Bottom

Double-channel
drain joint

Drain hose

Joint of the connecting pipe

Put some seal oil to cover the joint and the flare.

Align the centre of joint in line with that of flare and tighten the nut of connecting pipe
with wrench. ( Adjust the torque by the same method of connecting pipe for indoor unit.)

Insert the outdoor double-channel drain joint in one of the
bottom holes of the suitable size then connect drain hose
and joint together.

2

3

gas shut-off
valve

liquid shut-off valve

service port

gas connecting
pipe

liquid connecting pipe

valve nuts

service port cap

allen wrench

Screw down the cap of both gas shut-off valve and
liquid shut-off valve as well as the nut of service port.

Use Allen wrench to turn the valve cork of liquid side
at 90 counter-clockwise, and close it after 10 seconds.
Use soapy water to check the gas leakage especially
at all joint. If there is no gas leakage, please turn the
valve cork of liquid side at 90 counter-clockwise again.

Press the cork of service port at gas shut-off valve, 10
seconds later, when you see foggy gas discharged, that
means inner air is exhausted out.

Use Allen wrench to turn the valve cork of both liquid
shut-off valve and gas shut-off valve counter-clockwise
until they are completely open and then replace the
valve caps and tighten them.

Process of flared tube

5

Use the pipe cutter to cut off the broken part of flare.

Remove burrs at the cut of the flare.

Insert a nut into the connecting pipe and do flaring
with specified flaring tools, reamers for example.

Check the quality of flaring technique.

INSTALLATION

Remove burrs at the cut of the flare.

9

Screw the gas shut-off valve to close, connect

charging hose(low pressure) to the service valve

and then open gas shut-off valve again.

Connect the refrigerant bottle to the charging hose

and then convert it.

Disconnect the manifold gauge after turning off the

shut-off valve, and then open gas shut-off valve again.

Exhaust the air as the above-mentioned method.

Tighten nuts and caps of each valve.

Fill in liquid refrigerant as the above table.

Service port

Manifold gauge

Low pressure
valve

High pressure
valve

Pressure meter

Charging line

Adding refrigerant

If the connecting pipe is longer than 7 metres, add refrigerant as needed. (Cool only type) added

amount A=(Lm-7m) 15g/m ; (Heat pump type)added amount A= (Lm-7m) 50g/m. ( A: amount

of added refrigerant, L: the length of connecting pipe)

6

7

0

0

8

15

50

9

30

100

10

45

150

The length of connecting pipe (m)

(Cool only type)added amount (g)

(Heat pump type)added amount (g)

INSTALLATION

Set the unit to cool operation mode.

Stop operation of the air conditioner.

Relocation of the air conditioner.

Refer to this procedure when the unit is relocated.

1. Carry out the pump down procedure.

2. Remove the power cord.

3. Disconnect the assembly cable from the indoor and outdoor units.

4. Remove the flare nut connecting the indoor unit and the pipe.

At this time, cover the pipe of the indoor unit and the other pipe using a cap or vinyl plug to avoid foreign

material entering.

5. Disconnect the pipe connected to the outdoor unit.

6. Make sure you do not bend the connection pipes in the middle and store together with the cables.

7. Move the indoor and outdoor units to a new location.

8. Remove the mounting plate for the indoor unit and move it to a new location.

7

10

Operation test

8

INSTALLATION

Before test operation, wiring safety inspection must be carried out carefully again.

1. Emergency switch operation: Every press of emergency switch, the

air conditioner runs as in the following order:

Cool

only type:

Cool

Shut off

Heat pump type: Cool

Heat

Shut off

2. Remote controller operation: If the indoor unit sounds like Di, Di when pressing I/O button,

that indicates the air conditioner is under the operation of remote controller. After that, press

every button to test their functions.

3. operation: Open the front grille and press the check button. Switch on the powerCheck switch

source and then the operation test is activated. If the indicator lamps light up at first and then

go out in succession or the LED window of the indoor unit illuminates at first and then goes out,

the system is under normal operation. If one of the indicator lamps is flashing at all times, or

failure codes are displayed on the LED window of the indoor unit, the system has something

wrong and please check malfunction immediately.

Check valve

Capillary tube

Capillary tube

Liquid side

2-way valve

Gas side

3-way valve

Accumulator

Compressor

4-way valve

Cross fan

Heat
exchanger
(Condenser)

Propeller fan

Heat
exchanger
(Evaporator)

INDOOR UNIT OUTDOOR UNIT

Cooling
Heating
Gas leak check point

BLOCK DIAGRAM

Refrigerant Cycle Block Diagram

11

TROUBLE SHOOTING

Items to be checked first

1. Is the voltage of the power correct?
The input voltage shall be rating voltage 10%.
The air conditioner may not operate properly if the voltage is out of this range.

2. Is the link cable connecting the indoor unit and the outdoor unit linked properly?
Please refer to the “wiring diagram”
Check the terminals if the indoor unit and outdoor unit are properly linked by the same number of cables.

3. When a problem occurs due to the contents illustrated in the table below, it is symptom not related to the
malfunction of the air conditioner.

Operation of air conditioner

In COOL operation mode, the compressor does not operate
at a room temperature higher than the setting temperature
that the indoor fan should operate.
In a HEAT operation mode, the compressor does not
operate at a room temperature lower than the setting
temperature that indoor fan should operate.

It happens after a delay of 3 minutes when the compressor is
reoperated. The same phenomenon occurs when a power is on.
As a phenomenon that the compressor is reoperated after a
delay of 3 minutes, the indoor fan is adjusted automatically with
reference to a temperature of the air blow.

Fan speed setting is not allowed in AUTO or DRY mode.

The speed of the indoor fan is set to low in DRY mode.
Fan speed of 3 steps is selected automatically in AUTO mode.

Explanation

Compressor stops operation intermittently in DRY mode.

Compressor operation is automatically controlled in DRY mode
depending on the room temperature and humidity.

Compressor of the outdoor unit is operating although it is
turned off in HEAT mode.

When the unit is turned off while de-ice is activated, the
compressor continues operation for up to 10 minutes(maximum)
until the deice is completed.

Timer indicator lamp lights up and the air conditioner does
not operate.

Timer is being activated and the unit is in ready mode.
The unit operates normally if the timer operation is cancelled.

The compressor and indoor fan stop intermittently in HEAT
mode.

The compressor and indoor fan stop intermittently if room
temperature exceeds a setting temperature in order to protect
the compressor from overheated air in HEAT mode.

Indoor fan and outdoor fan stop intermittently in HEAT mode.

The compressor operates in a reverse cycle to remove exterior
ice in HEAT mode, and indoor fan and outdoor fan do not
operate intermittently for within 20% of the total heat operation.

The compressor stops intermittently in COOL mode or DRY
mode, and fan speed of the indoor unit decreases.

The compressor stops intermittently or the fan speed of the
indoor unit decreases to prevent inside/outside air frozen
depending on the inside/outside air temperature.

SELF DIAGNOSIS FUNCTION

Our company provides the end-users with thoughtful services by installing various diagnostic systems to
indicate the following irregular performances.

Check code

Diagnosis of malfunction

FAULT F7

FAULT F8

FAULT F9

Indoor TEMP sensor faults

Indoor coil pipe TEMP sensor faults

Outdoor coil pipe TEMP sensor faults

FAULT F6

PG motor faults

12

FAULT DIAGNOSIS BY SYMPTOM

No cooling
effect at all

Fan motor
error

Fan motor or its capacitor faults.

Loose connection or badly contact.

compressor
does not operate

Control circuit error.

Voltage may appear a little lower or higher.

Loose or wrong connection.

Compressor faults or jumps for overloading.

Control circuit error.

Leakage of
refrigerant

Recharge the refrigerant at leaking place.

Block of the cooling
system

Poor cooling

efficiency

Insufficient
refrigerant

Some cracks, welding failure in the system.

Air filter is
blocked

No periodical cleaning.

Accumulated lampblack, dust or

Accumulated lampblack, dust or contaminated
ambient environment.

Too high ambient

temperature

The outdoor unit gets exposed to the sun for too
long period.

Air conditioning burden
is not adequate for the
room

The capillary, pipeline are blocked or the valve

is not open or the connecting tube is folded flat.

The doors and windows are not closed well;
too weak of input cooling power or too many

heat resources in the room.

Some leakage in the valve.

No cooling

The four-way

valve error

Blockage in
the system

The valve is not completely open; the capillary or
Pipeline is half blocked.

Connecting tube is folded flat.

The distributing air of the four-way valve may have mixed

together; the valve core or solenoid valve faults.

Low airflow volume

Low fan motor frequency or capacitor is not

functional.

Low fan speed or the fan motor faults.

Extra fluorin is added during mounting.

Mounting location is not suitable, such as near the wall.

Air outlet is blocked or accumulated lampblack
or dust is attached to the vane.

Poor efficiency of
heat dissipating on
the outdoor unit

Not for residential use.

13

No heating
effect at all

Fan motor
error

Fan motor or its capacitor faults.

Loose connection or badly contact.

compressor
does not operate

Control circuit error.

Voltage may appear a little lower or higher.

Loose or wrong connection.

Compressor faults or jumps for overloading.

Control circuit error.

Leakage of
refrigerant

Recharge the refrigerant at leaking place.

Block of the cooling
system

Poor heating

efficiency

Insufficient
refrigerant

Some cracks, welding failure in the system.

Air filter is
blocked

No periodical cleaning.

contaminated ambient environment.

Too low ambient

temperature

Below 0 .

Too thick frost
generated on the

condenser.

The condenser does not defrost, no smooth air

circulation.

Extra refrigerant or
mixing air in the system

Discharge the redundant refrigerator recharge
the refrigerant after vacuum extraction.

The condenser is too dirty

Air conditioning burden
is not adequate for the
room

Accumulated lampblack or dust is attached

to the vane.

The capillary, pipeline are blocked or the valve

is not open or the connecting tube is folded flat.

The doors and windows are not closed well;
too weak of input cooling/heating power.

Some leakage in the valve.

No heating

The four-way valve
or solenoid valve faults.

The four-way valve did not commutate or the
distributing air of the four-way valve may
have mixed together.

The electric heater is
not working

Not satisfy the conditions for electric heater

running.

Plug cords may be loose.

The four-way

valve error

Blockage in

the system

The valve is not completely open; the capillary or
Pipeline is half blocked.

Connecting tube is folded flat.

The distributing air of the four-way valve may have mixed

together; the valve core or solenoid valve faults.

Low airflow volume

Low fan motor frequency or capacitor is not

functional.

Low fan speed or the fan motor faults.

Extra fluorin is added during mounting.

FAULT DIAGNOSIS BY SYMPTOM

14