Sharp Plasmacluster AE-X12FR User manual

CHAPTER 1. SPECIFICATION
[1] SPECIFICATION............................................1-1
[2] EXTERNAL DIMENSION...............................1-4
[3] WIRING DIAGRM ..........................................1-5
[4] ELECTRICAL PARTS ....................................1-6
CHAPTER 2. EXPLAMATION OF CIRCUIT AND OP-
ERATION
[1] BLOCK DIAGRAMS.......................................2-1
[2] MICROCOMPUTER CONTROL SYSTEM........2-3
[3] FUNCTION.....................................................2-8
CHAPTER 3. FUNCTION AND OPERATION OF PRO-
TECTIVE PROCEDURES
[1] PROTECTIONDEVICEFUNCTIONSAND
OPERATIONS................................................3-1
[2] AIR CONDITIONER OPERATION IN
THERMISTOR ERROR .................................3-3
[3] THERMISTOR TEMPERATURE CHAR-
ACTERISTICS ...............................................3-5
[4] HOW TO OPERATE THE OUTDOOR
UNIT INDEPENDENTLY................................ 3-6
[5] GENERAL TROUBLESHOOTING CHART........3-6
[6] MALFUNCTION (PARTS) CHECK METH-
OD .................................................................3-8
[7] OUTDOOR UNIT CHECK METHOD...........3-10
[8] TROUBLESHOOTING GUIDE....................3-13
CHAPTER 4. REFRIGERATION CYCLE
[1] FLOW FOW REFRIGERANT........................4-1
[2] STANDARD CONDITION..............................4-1
[3] TEMPERATURE AT EACH PART AND
PRESSURE IN 3-WAY VALVE......................4-1
[4] PERFORMANCE CURVES...........................4-2
CHAPTER 5. DISASSEMBLING PROCEDURE
[1] DISASSEMBLY OF INDOOR UNIT...............5-1
[2] DISASSEMBLY OF OUTDOOR UNIT...........5-7
REPLACEMENT PARTS LIST
SERVICE MANUAL
AYXP7FR
S6512AYXP7FR/T
SHARP CORPORATION
CONTENTS
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.
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
SPLIT TYPE
ROOM AIR CONDITIONER
OUTDOOR UNIT
AE-X7FR
AE-X9FR
AE-X12FR
MODELS INDOOR UNIT
AY-XP7FR
AY-XP9FR
AY-XP12FR
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.

AYXP7FR
1 – 1
AYXP7FR Service Manual
CHAPTER 1. SPECIFICATION
[1] SPECIFICATION
1. AY-XP7FR – AE-X7FR
MODEL INDOOR UNIT OUTDOOR UNIT
ITEMS AY-XP7FR AE-X7FR
Cooling capacity(Min. > Max.) kW 2.1 (0.9 - 2.5)
Heating capacity(Min. > Max.) kW 2.4 (0.9 - 3.4)
Moisture removal(at cooling) Liters/h
Electrical data
Phase Single
Rated frequency Hz 50
Rated voltage V 230
Rated current ✩
(Min - Max.) Cool A 2.5 (1.0 - 4.1)
Heat A 2.4 (0.9 - 4.5)
Rated input ✩
(Min - Max.) Cool W 530 (200 - 760)
Heat W 510 (160 - 1100)
Power factor ✩Cool % 92
Heat % 92
Compressor Type Hermetically sealed rotary type
Model DA89X1F-23F
Oil charge 370cc (VG74)
Refrigerant system Evaporator Louver Fin and Grooved tube type
Condenser Corrugate Fin and Grooved tube type
Control Expansion valve
Refrigerant (R410A) 830g
De-lce system Micro computer controled reversed systems
Noise level
(at cooling) High dB(A) 37 45
Low dB(A) – –
Soft dB(A) 28 –
Fan system
Drive Direct drive
Air flow quantity
(at cooling) High m3/min. 8.0 23.2
Low m3/min. 6.8 –
Soft m3/min. 5.5 –
Fan Cross flow fan Propeller fan
Connections
Refrigerant coupling Flare type
Refrigerant tube size Gas, Liquid 3/8", 1/4"
Drain piping mm O.D φ18
Others
Safety device Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 790 730
Height mm 278 540
Depth mm 198 250
Net weight kg 10 33

AYXP7FR
1 – 2
2. AY-XP9FR – AE-X9FR
MODEL INDOOR UNIT OUTDOOR UNIT
ITEMS AY-XP9FR AE-X9FR
Cooling capacity(Min. > Max.) kW 2.64 (0.9 - 3.0)
Heating capacity(Min. > Max.) kW 3.1 (0.9 - 4.8)
Moisture removal(at cooling) Liters/h
Electrical data
Phase Single
Rated frequency Hz 50
Rated voltage V 230
Rated current ✩
(Min - Max.) Cool A 3.7 (1.0 - 4.8)
Heat A 3.5 (0.9 - 6.1)
Rated input ✩
(Min - Max.) Cool W 780 (200 - 960)
Heat W 730 (160 - 1400)
Power factor ✩Cool % 92
Heat % 91
Compressor Type Hermetically sealed rotary type
Model DA89X1F-23F
Oil charge 370cc (VG74)
Refrigerant system Evaporator Louver Fin and Grooved tube type
Condenser Corrugate Fin and Grooved tube type
Control Expansion valve
Refrigerant (R410A) 830g
De-lce system Micro computer controled reversed systems
Noise level
(at cooling) High dB(A) 39 45
Low dB(A) – –
Soft dB(A) 28 –
Fan system
Drive Direct drive
Air flow quantity
(at cooling) High m3/min. 8.6 23.3
Low m3/min. 7.3 –
Soft m3/min. 5.5 –
Fan Cross flow fan Propeller fan
Connections
Refrigerant coupling Flare type
Refrigerant tube size Gas, Liquid 3/8", 1/4"
Drain piping mm O.D φ18
Others
Safety device Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 790 730
Height mm 278 540
Depth mm 198 250
Net weight kg 10 33

AYXP7FR
1 – 3
3. AY-XP12FR – AE-X12FR
NOTE: The condition of star”✩” marked item are ‘ISO5151’ : 1994(E), contition T1.
MODEL INDOOR UNIT OUTDOOR UNIT
ITEMS AY-XP12FR AE-X12FR
Cooling capacity(Min. > Max.) kW 3.5 (0.9 - 3.8)
Heating capacity(Min. > Max.) kW 4.0 (0.9 - 6.0)
Moisture removal(at cooling) Liters/h
Electrical data
Phase Single
Rated frequency Hz 50
Rated voltage V 230
Rated current ✩
(Min - Max.) Cool A 5.0 (1.1 - 8.2)
Heat A 4.8 (1.0 - 8.0)
Rated input ✩
(Min - Max.) Cool W 1090 (210 - 1300)
Heat W 1030 (180 - 1900)
Power factor ✩Cool % 95
Heat % 93
Compressor Type Hermetically sealed rotary type
Model 5RS102XBE01
Oil charge 320cc (RB68A or Freol Alpha 68M)
Refrigerant system Evaporator Louver Fin and Grooved tube type
Condenser Corrugate Fin and Grooved tube type
Control Expansion valve
Refrigerant (R410A) 1030g
De-lce system Micro computer controled reversed systems
Noise level
(at cooling) High dB(A) 40 48
Low dB(A) – –
Soft dB(A) 28 –
Fan system
Drive Direct drive
Air flow quantity
(at cooling) High m3/min. 9.8 26.7
Low m3/min. 8.5 –
Soft m3/min. 6.9 –
Fan Cross flow fan Propeller fan
Connections
Refrigerant coupling Flare type
Refrigerant tube size Gas, Liquid 3/8", 1/4"
Drain piping mm O.D φ18
Others
Safety device Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 790 730
Height mm 278 540
Depth mm 198 250
Net weight kg 10 37

AYXP7FR
1 – 4
[2] EXTERNAL DIMENSION
1. Indoor unit
2. Outdoor unit
278
198790
22.0
58 18.5
175
INVERTER AIR CONDITIONER
250
165
167.5
136
81
730
72
540
299 324
515
12
37.5
4.5
58
135
14

AYXP7FR
1 – 5
[3] WIRING DIAGRM
1. Indooa unit
2. Outdooa unit
2.1. AE-X7FR / AE-X9FR
2.2. AE-X12FR
420V
750μF 420V 750μF

AYXP7FR
3 – 13
[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).
The display of malfunction No. differs from that of the 2001 cooling unit models. To show detailed malfunction information, two types of numbers
flash alternately. (example: "21" ←→ "-0")
1) The content of the self-diagnosis memory can be called out and displayed on the seven-segment display section on the indoor unit. (The error
data cannot be called out for display by the LED on the outdoor unit.)
2) If the power cord is unplugged from the AC outlet or the circuit breaker is turned off, the self-diagnosis memory loses the stored data.
a) The self-diagnosis display function of the indoor unit indicates the content of diagnosis by showing the error main category (number) and the
error sub-category (-number) alternately in 1-second intervals on the seven-segment display section of the indoor unit.
Example of self-diagnosis display on indoor unit: Compressor high-temperature error
b) The self-diagnosis display function of the outdoor unit indicates the error information by flashing LED1 on the outdoor unit according to the con-
tent of self-diagnosis.
The self-diagnosis display function of the outdoor unit is active only for about 3 to 10 minutes after self-diagnosis is performed during operation,
and the display returns to normal condition after this display period.
The content of self-diagnosis cannot be called out by the self-diagnosis display function of the outdoor unit.
Example of self-diagnosis display on outdoor unit: Compressor high-temperature error
c) The content of diagnosis is transferred to the indoor unit via serial communication, but it does not trigger a complete shutdown operation.
: Flashes in 2-sec intervals (normal), : On, : Off, : Flashes 3 times in 0.2-sec intervals (When LED1 on the outdoor unit flashes in 2-sec
intervals, the outdoor unit is in normal condition.)
Status of
indoor/
outdoor
units
Indication
by LED1
on out-
door unit
*2
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis Inspection location/method Remedy
Main
cate-
gory
Sub-
cate-
gory
Main category Sub-category
Indoor/
outdoor
units in
operation
Nor-
mal
flash-
ing
00 Normal – –
Indoor/
outdoor
units in
complete
shutdown
1 time 1 -0 Outdoor unit
thermistor
short-circuit
Heat exchanger
thermistor short-cir-
cuit error
(1) Measure resistance of the
outdoor unit thermistors.
(TH2 to TH5: Approx. 4.4
kΩat 25°C)
(1) Replace the outdoor
unit thermistor assem-
bly.
-1 Outside tempera-
ture thermistor
short-circuit error
(2) Check the lead wire of the
outdoor unit thermistor for
torn sheath and short-cir-
cuit.
(2) Replace the outdoor
unit thermistor assem-
bly.
-2 Suction thermistor
short-circuit error (3) No abnormality found in above inspections (1) and
(2).
(3) Replace the outdoor
unit control PWB
assembly.
-3 2-way valve ther-
mistor short-circuit
error
'TTQTOCKPECVGIQT[ 'TTQTUWDECVGIQT[
1 sec 1 sec 1 sec 1 sec 1 sec1 sec0.6 sec 0.6 sec0.6 sec 0.6 sec 1 sec
ON
OFF
1 sec 1 sec

AYXP7FR
3 – 14
Indoor/
outdoor
units in
complete
shutdown
2 times 2 -0 Cycle tempera-
ture Compressor high- temperature error (1) Check the outdoor unit air outlet for blockage. (1) Ensure unobstructed air flow from the out-
door unit air outlet.
(2) Check if the power supply
voltage is 90 V or higher at
full power.
(2) Connect power sup-
ply of proper voltage.
(3) Check the pipe connec-
tions for refrigerant leaks. (3) Charge the specified amount of refrigerant.
(4) Measure resistance of the
outdoor unit compressor
thermistor.
(TH1: Approx. 53 kΩat
25°C)
(4) Replace the outdoor
unit compressor ther-
mistor assembly.
(5) Check the expansion
valve for proper operation. (5) Replace the expan- sion valve coil, expan-
sion valve or outdoor
unit control PWB
assembly.
Indoor
unit in
operation
Outdoor
unit in
tempo-
rary stop
-1 Temporary stop due
to compressor dis-
charge overheat *3
(Temporary stop for cycle pro-
tection) –
-2 Temporary stop due
to outdoor unit heat
exchanger overheat
*3
(Temporary stop for cycle pro-
tection) –
-3 Temporary stop due
to outdoor unit heat
exchanger overheat
*3
(Temporary stop for cycle pro-
tection) –
-4 Temporary stop due
to 2-way valve
freeze *3
(Temporary stop for cycle pro-
tection) –
Indoor
unit in
operation
Outdoor
unit in
tempo-
rary stop
3 times 3 -0 Dry operation Temporary stop due
to dehumidifying
operation *3
(Temporary stop for cycle pro-
tection) –
Indoor/
outdoor
units in
complete
shutdown
5 times 5 -0 Outdoor unit
thermistor
open-circuit
Heat exchanger
thermistor open-cir-
cuit error
(1) Check connector CN8 of
the outdoor unit ther-
mistor for secure installa-
tion.
(1) Correct the installa-
tion.
-1 Outside tempera-
ture thermistor
open-circuit error
(2) Measure resistance of out-
door thermistors TH1 to
TH5.
(2) Replace the outdoor
unit thermistor assem-
bly.
-2 Suction thermistor
open-circuit error (3) Check the lead wires of thermistors TH1 through
TH5 on the outdoor unit
control PWB for open-cir-
cuit.
(3) Replace the outdoor
unit thermistor assem-
bly.
-3 2-way valve ther-
mistor open-circuit
error
(4) No abnormality found in
above inspections (1)
through (3).
(5) Replace the outdoor
unit control PWB
assembly.
-4 Discharge ther-
mistor open-circuit
error
Status of
indoor/
outdoor
units
Indication
by LED1
on out-
door unit
*2
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis Inspection location/method Remedy
Main
cate-
gory
Sub-
cate-
gory
Main category Sub-category

AYXP7FR
3 – 15
Indoor/
outdoor
units in
complete
shutdown
6 times 6 -0 Outdoor unit DC DC overcurrent error (1) IPM continuity check (1) Replace the outdoor
unit control PWB
assembly.
(2) Check the IPM and heat
sink for secure installation. (2) Correct the installa- tion (tighten the
screws).
(3) Check the outdoor unit fan
motor for proper rotation. (3) Replace the outdoor unit fan motor.
(4) No abnormality found in
above inspections (1)
through (3).
(4) Replace the outdoor
unit control PWB
assembly.
(5) No abnormality found in
above inspections (1)
through (4).
(5) Replace the compres-
sor.
-1 IPM pin level error Check the IPM is attached
correctly to the outdoor
unit control PWB.
Replace the outdoor
unit control PWB
assembly.
Indoor/
outdoor
units in
complete
shutdown
7 times 7 -0 Outdoor unit AC AC overcurrent error (1) Check the outdoor unit air
outlet for blockage. (1) Ensure unobstructed air flow from the out-
door unit air outlet.
(2) Check the outdoor unit fan
for proper rotation. (2) Checktheoutdoorunit fan motor.
-1 AC overcurrent error
in OFF status (1) IPM continuity check (1) Replace the outdoor unit control PWB
assembly.
-2 AC maximum cur-
rent error (1) Check the outdoor unit air outlet for blockage. (1) Ensure unobstructed air flow from the out-
door unit air outlet.
(2) Check the outdoor unit fan
for proper rotation. (1) Checktheoutdoorunit fan motor.
-3 AC current defi-
ciency error (1) Check if there is an open- circuit in the secondary
winding of the current
transformer of the outdoor
unit control PWB.
(1) Replace the outdoor
unit control PWB
assembly.
(2) Check if the refrigerant
volume is abnormally low. (2) Charge the specified amount of refrigerant.
(3) Check if the refrigerant
flows properly. (3) Correct refrigerant clogs.
(2-way valve, 3-way
valve, pipe, expan-
sion valve)
Indoor/
outdoor
units in
complete
shutdown
9 times 9 -0 Outdoor unit
cooling/heating
switchover
Thermistor installa-
tion error or 4-way
valve error
(1) Check to make sure out-
door unit thermistor TH2
(heat exchanger) and TH5
(2-way valve) are installed
in correct positions.
(1) Correct the installa-
tion.
(2) Measure resistance of
thermistors TH1 and TH5. (2) Replace the ther- mistor assembly.
(3) Check the 4-way valve for
proper operation. (3) Replace the 4-way valve.
(4) No abnormality found in
above inspections (1)
through (3).
(4) Replace the outdoor
unit control PWB
assembly.
-3 Torque control error (1) Check if the refrigerant
volume is abnormally low. (1) Change the specified amount of refrigerant.
(2) Check the 4-way valve for
proper operation. (2) Replace the 4-way valve.
(3) check to see compressor
type is correct. (3) Replace the compres- sor with the correct
part.
Status of
indoor/
outdoor
units
Indication
by LED1
on out-
door unit
*2
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis Inspection location/method Remedy
Main
cate-
gory
Sub-
cate-
gory
Main category Sub-category

AYXP7FR
3 – 16
Indoor/
outdoor
units in
complete
shutdown
11
times 11 -0 OutdoorunitDC fan Outdoor unit DC fan rotation error (1) Check connector CN3 of the outdoor unit DC fan
motor for secure installa-
tion.
(1) Correct the installa-
tion.
(2) Check the outdoor unit fan
motor for proper rotation. (2) Replace the outdoor unit fan motor.
(3) Check fuse FU3. (3) Replace the outdoor
unit control PWB
assembly.
(4) Outdoor unit control PWB (4) Replace the outdoor
unit control PWB
assembly.
Indoor/
outdoor
units in
complete
shutdown
13
times 13 -0 DC compressor Compressor startup error (1) Check the colors (red, white, orange) of the com-
pressor cords for proper
connection. (PWB side,
compressor side)
(1) Correct the installa-
tion.
(U: Red, V: White, W:
Orange)
-1 Compressor rota-
tion error
(120°energizing
error)
(2) Check if the IPM terminal
resistance values are uni-
form.
(2) Replace the outdoor
unit control PWB
assembly.
(3) No abnormality found in
above inspections (1) and
(2).
(3) Replace the outdoor
unit control PWB
assembly.
(4) No abnormality found in
above inspections (1)
through (3).
(4) Replace the compres-
sor.
Indoor/
outdoor
units in
complete
shutdown
14
times 14 -0 Outdoor unit PAM PAM over voltage error
Compressor rota-
tion error
(1) Check the AC power sup-
ply voltage for fluctuation. (1) Connect stable power supply.
(2) No abnormality found in
above inspection (1). (2) Replace the outdoor unit control PWB
assembly.
Indoor/
outdoor
units in
operation
-1 PAM clock error (1) Check the PAM clock for
proper input. (1) Replace the outdoor unit control PWB
assembly.
Indoor
unit in
operation
Outdoor
unit in
complete
shutdown
17 -0 Wires between
units Serial open-circuit (1) Check the wires between units. (1) Connect stable power supply.
(2) Check voltage between
Nos. 1 and 2 on the
indoor/outdoor unit termi-
nal boards.
(2) Replace the outdoor
unit control PCB
assembly.
Outdoor unit does
not turn on due to
erroneous wiring
(1) Check the wires between
units. (1) Correct the wiring.
(2) Check the outdoor unit
fuse. (2) Replace the fuse/out- door unit control PCB
assembly.
(3) Check 15-V, 13-V and 5-V
voltages on the PWB.
Checkresistancebetween
IPM terminals.
(3) Replace the outdoor
unit control PCB
assembly.
(4) Check pins No. 5 and 7 of
connector CN3 of the out-
door unit fan motor for
short-circuit.
(4) Replace the outdoor
unit fan motor.
(5) Outdoor unit control PCB (5) Replace the outdoor
unit control PCB
board.
18 -0 Serial short-circuit (1) Check the wires between
units. (1) Correct the wiring.
-1 Serial erroneous wir-
ing (1) Check the wires between units. (1) Correct the wiring.
Status of
indoor/
outdoor
units
Indication
by LED1
on out-
door unit
*2
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis Inspection location/method Remedy
Main
cate-
gory
Sub-
cate-
gory
Main category Sub-category