Sharp AE-Z40KR Service Manual
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Sharp AE-Z40KR Service Manual

Split type air-to-air heat pump
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TopPage
[1]
SPECIFICATION.................................... . ....... 1-1
[2]
EXTERNAL DIMENSION....................... . ....... 1-2
[3]
WIRING DIAGRM .................................. . ....... 1-3
[4]
ELECTRICAL PARTS ............................ . ....... 1-4
[1]
BLOCK DIAGRAMS............................... . ....... 2-1
[2]
[3]
FUNCTION............................................. . ....... 2-7
[1]
OPERATIONS........................................ . ....... 3-1
[2]
THERMISTOR ERROR ......................... . ....... 3-3
[3]
ACTERISTICS ....................................... . ....... 3-5
[4]
UNIT INDEPENDENTLY........................ . ....... 3-5
[5]
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.

SERVICE MANUAL

SPLIT TYPE
AIR-TO-AIR HEAT PUMP
MODEL
INDOOR UNIT
AY-ZP40KR
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.
CONTENTS
........ 2-3
........ 3-6
OUTDOOR UNIT
AE-Z40KR
[6]
OD .................................................................3-7
[7]
[8]
TROUBLESHOOTING GUIDE ....................3-13
[9]
CHART ........................................................3-14
[1]
SCHEMATIC DIAGRAM ................................4-1
[2]
STANDARD CONDITION ..............................4-1
[3]
PRESSURE IN 3-WAY VALVE ......................4-1
[4]
PERFORMANCE CURVES...........................4-1
[1]
INDOOR UNIT...............................................5-1
[2]
TER) ..............................................................5-4
[3]
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.
AYZP40KR
S9928AYZP40KRT

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  • Page 1: Table Of Contents

    AIR-TO-AIR HEAT PUMP MODEL OUTDOOR UNIT INDOOR UNIT AE-Z40KR AY-ZP40KR 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.

  • Page 2: Chapter 1. Product Specification

    AYZP40KR CHAPTER 1. AYZP40KR PRODUCT SPECIFICATION Service Manual [1] SPECIFICATION 1. AYZP40KR – AEZ40KR MODEL INDOOR UNIT OUTDOOR UNIT ITEMS AYZP40KR AEZ40KR Rated cooling capacity (Min– Max.) 3.5 (0.9 - 4.0) Rated heating capacity (Min–Max.) 4.0 (0.9 - 6.0) Moisture removal (at cooling) Liters/h Electrical data Phase...

  • Page 3: External Dimension

    AYZP40KR [2] EXTERNAL DIMENSION 1. Indoor unit Length unit [mm] Remote controller 2. Outdoor unit Length unit [mm] 37.5 167.5 1 – 2...

  • Page 4: Wiring Diagrm

    AYZP40KR [3] WIRING DIAGRM 1. Indoor unit 2. Outdoor unit 1 – 3...

  • Page 5: Electrical Parts

    AYZP40KR [4] ELECTRICAL PARTS 1. Indoor unit DESCRIPTION MODEL REMARKS Indoor fan motor MLA508 AC Motor Indoor fan motor capacitor DS401155BLSA RC-HZA512JBZZ(400V-1.5F) Transformer DB–EI41–5167–290mA RTRNPA045JBZZ – QFS-IA001JBZZ (250V, 2.5A) 2. Outdoor Unit DESCRIPTION MODEL REMARKS Compressor DA111A1F22F D.C. brush-less motor Outdoor fan motor MLB078 DC Motor...

  • Page 6: Chapter 2. Explamation Of Circuit And Op- Eration Block Diagrams

    AYZP40KR CHAPTER 2. AYZP40KR EXPLAMATION OF CIRCUIT AND OPERATION Service Manual [1] BLOCK DIAGRAMS 1. Indoor unit 5VDC regulation 12V DC regulation AC power 2.5A Fuse Fan motor phase control circuit Indoor fan motor Rotation pulse input circuit Fan motor pulse detect AC clock circuit Remote controller signal reception circuit Wireless remote control operation...
  • Page 7 AYZP40KR 2. Outdoor unit AC clock circuit protection Pulse amplitube modulation circuit IGBT protection Unit-unit wiring (AC power Power supply circuit Smoothing Power factor Filter circuit converter circuit circuit and serial signals) CPU oscillator circuit 3.15A DC overvoltage detection circuit protection Outdoor fan drive circuit Outdoor fan...

  • Page 8: Microcomputer Control System

    AYZP40KR [2] MICROCOMPUTER CONTROL SYSTEM 1. Indoor unit 1.1. Electronic control circuit diagram 2 – 3...
  • Page 9 AYZP40KR 1.2. Printed wiring board 2 – 4...
  • Page 10 AYZP40KR 2. Outdoor unit 2.1. Electronic control circuit diagram 2 – 5...
  • Page 11 AYZP40KR 2.2. Printed wiring board To Terminal Board To Terminal Board To Control Box (2) (Red) (N)(Blue) (Green/Yellow) To Terminal Board (1) (Brown) From Four way Valve From Expansion Valve From Thermistor To Reactor L5 (Gray) From Fan Motor To Reactor L6 (White) From Compressor To Reactor L6...

  • Page 12: Function

    AYZP40KR [3] FUNCTION 1. Function 1.1. Startup protection control 1.6. Indoor unit overheat prevention control The main relay remains off during the first 45 seconds (first safety During heating operation, if the temperature of the indoor unit heat time) immediately after the power cord is plugged into an AC outlet in exchanger exceeds the indoor unit heat exchanger overheat preven- order to disable outdoor unit operation and protect outdoor unit electric tion temperature (about 45 to 54C) which is determined by the operat-...
  • Page 13 AYZP40KR 1.10. Peak control 1.15. Power ON start If the current flowing in the air conditioner exceeds the peak control If a jumper cable is inserted in the location marked with HAJP on the current (see the table below), the operation frequency is decreased indoor unit control printed circuit board (control PCB), connecting the until the current value drops below the peak control current regardless power cord to an AC outlet starts the air conditioner in either cooling or...
  • Page 14 AYZP40KR 1.18. Airflow control CAUTION: Never attempt to adjust the louvres manually. Manual adjustment on the louvres can cause the unit to malfunction. Position in the COOL or DRY mode for an extended period of time, When the vertical adjustment louvre is positioned at the lowest condensation may result.
  • Page 15 AYZP40KR minutes, and then shift to “HIGH” fan speed. The vertical adjustment Press the SPOT AIR button to select louvre will be set obliquely downward. the desired air flow direction.  You can not set the temperature or fan speed during the FULL POWER operation.
  • Page 16 AYZP40KR 1.31. Program Eco Operation 1.31.2 Heat Operation By pressing Program Eco button during Heat operation, set tempera- 1.31.1 Cool/Dry Operation ture will vary in -2 degree C ~ +1 degree C range, and will correspond By pressing Program Eco button during Cool/Dry operation, the set to lowering the set temperature -1 degree C in calculation.
  • Page 17 AYZP40KR Reactor Stored energy IGBT ON IGBT OFF IGBT 3.2. High power factor control circuit This circuit brings the operating current waveform closer to the waveform of commercial power supply voltage to maintain a high power factor. Because of the capacitor input, when the PAM circuit is OFF, the phase of the current waveform deviates from the voltage waveform as shown below. To prevent this deviation, a current is supplied during the periods indicated by “O”...
  • Page 18 AYZP40KR 3.3. PAM protection circuit To prevent excessive voltage of PAM output from (Overvoltage detection) damaging the IPM and electrolytic capacitor as well as the control printed circuit board (PCB), this circuit monitors the PAM output voltage and turns off the R112 R114 255K...
  • Page 19 AYZP40KR 4. Explanation of IPM drive circuit The IPM for compressor drive is made by Mitsubishi Electric. The power supply for the IPM drive, the shunt resistance for over current detection, etc., are provided outside the IPM (control PCB). 4.1. IPM drive power supply circuit The power supply for the upper-phase IGBT (HU, HV, HW) drive employs a bootstrap system, and provides power to the upper-phase IC.
  • Page 20 AYZP40KR Protection circuit status RESET (Lower phase) Internal IGBT gate (About 25 A) Output current Ic (A) SC reference voltage Sense voltage relative to shunt resistance Delay by CR time constant circuit About 1.8 ms Error output Fo Shunt resistance Overcurrent overcurrent detection...
  • Page 21 AYZP40KR 5. 120 energizing control (digital position detection control) This control system detects the digital position detection signal and adjusts the rate of acceleration/deceleration accordingly. The motor's induced voltage waveform is input to the comparator in the form of PWM-switched pulse waveform, and a position detection signal is generated as a reference voltage equaling 1/2 of 280 VDC.

  • Page 22: Chapter 3. Function And Operation Of Pro- Tective Procedures Protection Device Functions And Operations

    AYZP40KR CHAPTER 3. AYZP40KR FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES Service Manual [1] PROTECTION DEVICE FUNCTIONS AND OPERATIONS Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit unit unit error display Indoor unit fan lock Operation stops if there is no When indoor unit fan Operation OFF or ON ☆...
  • Page 23 AYZP40KR Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit unit unit error display AC overcurrent Operating frequency lowers if When compressor is Operation OFF or ON Yes ☆ 1 error compressor AC current exceeds in operation peak control current value.

  • Page 24: Air Conditioner Operation In Thermistor Error

    AYZP40KR Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor Indoor Outdoor unit unit unit error display 25 Compressor star- Compressor stops if compressor At compressor star- Operation OFF or ON Yes ☆ 3 tup error fails to start up. 26 Compressor rota- Compressor stops if there is no Compressor operat-...
  • Page 25 AYZP40KR 2. Outdoor unit Item Mode Control opera- When resis- Short-circuit When resis- Open-circuit tion tance is low tance is high (temperature (temperature judged higher judged lower than actual) than actual) Compressor Cooling Expansion valve Compressor Compressor high Layer short-cir- Outdoor unit ther- chamber ther- Dehumidifying...

  • Page 26: Thermistor Temperature Characteristics

    AYZP40KR [3] THERMISTOR TEMPERATURE CHARACTERISTICS 1. Indoor unit thermistor temperature characteristics Resistance (K ) Tester Tester Heat exchanger thermistor TH2 (orange) Thermistor Symbol Color Before measuring resistance, Resistance at 25 : 15 k disconnect connectors as shown above. Room temperature Yellow Room temperature thermistor TH1 (yellow) (CN2)

  • Page 27: General Troubleshooting Chart

    AYZP40KR [5] GENERAL TROUBLESHOOTING CHART 1. Indoor unit does not turn on Main cause Inspection method Normal value/condition Remedy Cracked PWB. Check visually. There should be no cracking in Replace PWB. (Cracked pattern) PWB or pattern. Open-circuit in FU1 (250 V, 2.5A). Check melting of FU1.

  • Page 28: Malfunction (Parts) Check Method

    AYZP40KR Main cause Inspection method Normal value/condition Remedy TV/radio is placed too close to Check distance between TV/radio If TV/radio is placed too close, it Move TV/radio away from outdoor outdoor unit. and outdoor unit. may become affected by noise. unit.
  • Page 29 AYZP40KR Connect power cord to AC outlet. Using remote control, operate air conditioner that compressor starts. After about 20 seconds there Check inter-unit wiring. between (1) and (N) Check indoor unit PWB. Check posistor (PTC1) on outdoor unit PWB (about 40 at 25 ).
  • Page 30 AYZP40KR 2. Procedure for determining defective expansion valve Measure resistance in expansion valve coil. Normal resistance between red terminal of expansion valve lead wire and each terminal: about 46 (at 20 (red) Checker Insert checker shown at left into connector (CN12) on control PWB, and operate air conditioner.

  • Page 31: Outdoor Unit Check Method

    AYZP40KR 5. IPM check method Turn off the power, let the large capacity electrolytic capacitor (C10) discharge completely, and dismount the IPM. Then, using a tester, check leak current between C and E. When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed. Needle-type tester Normal resistance value Needle-type tester...
  • Page 32 AYZP40KR Item Check method Normal value/condition Remedy Compressor check Measure compressor coil resistance Resistance value at 20C --- 0.65 Correct connections at compres- (for each phase of U, V and W). sor terminals. Use multi-meter or digital tester capa- Replace compressor. ble of displaying two digits right of the decimal point (0.01).
  • Page 33 AYZP40KR 3. Caution in checking printed circuit boards (PWB) 3.1. Non-insulated control circuit The GND terminals of the low-voltage circuits (control circuits for microcomputer and thermistors and drive circuits for expansion valve and relays) on the control printed circuit board (PWB) are connected to the compressor drive power supply (320-VDC negative terminal). Therefore, exercise utmost caution to prevent electric shock.

  • Page 34: Troubleshooting Guide

    AYZP40KR [8] TROUBLESHOOTING GUIDE 1. SELF-DIAGNOSIS FUNCTION AND DISPLAY MODE 1) To call out the content of the self-diagnosis memory, hold down the emergency operation button for more than five seconds when the indoor unit is not operating. a) According to the content of the self-diagnosis memory, the Operation LED (main category) and the Plasmacluster Ion LEDs (sub-category) flash in sync with the Timer LED on the indoor unit.

  • Page 35: Chart

    AYZP40KR [9] CHART 3 – 14...
  • Page 36 AYZP40KR 3 – 15...
  • Page 37 AYZP40KR 3 – 16...
  • Page 38 AYZP40KR 3 – 17...

  • Page 39: Chapter 4. Refrigeration Cycle

    AYZP40KR CHAPTER 4. AYZP40KR REFRIGERATION CYCLE Service Manual [1] SCHEMATIC DIAGRAM Indoor unit Evaporator Flare coupling Flare coupling 3-way 2-way valve valve Heating Cooling Silencer Strainer Outdoor unit Accumulator Expansion valve Comp- ressor Strainer Coil Condenser Reverse valve [2] STANDARD CONDITION Indoor side Outdoor side Dry-bulb Temp.
  • Page 40 AYZP40KR 1. AY-ZP40KR 1.1. At Cooling 1200 1100 1000 Outside air temp.(ºC) 1.2. At Heating 1200 1100 1000 Outside air temp.(ºC) 4 – 2...

  • Page 41: Chapter 5. Disassembling Procedure

    AYZP40KR CHAPTER 5. AYZP40KR DISASSEMBLING PROCEDURE Service Manual If, in carrying out repairs and modifications, the work requires the use of arc- and flame-producing apparatus, such as welding, brazing and soldering equipment, this work shall only be started after the rooms have been thoroughly ventilated. While the work is being carried out, the mechanical venti- lation, if any, shall be kept in constant operation and all windows and doors kept open.
  • Page 42 AYZP40KR Pull the front panel toward in the direction shown the picture. 12)Remove the center shaft of the horizontal louver from louver holder with lifting the louver holder, and remove the horizontal louver from cabinet while warping. 8) Remove the thermistor cover and the thermistor wire. Remove a screw fixing the earth wire.
  • Page 43 AYZP40KR When assembling them, insert the motor shaft in the boss of the cross flow fan to the ring position. Screw Catch Ring Screw b) Remove the tube cover. • Insert the (–) screwdriver to A hole and then lean it to the right as lifting B part.

  • Page 44: How To Remove Plasmacluster Unit(For The Models With Plasmacluster)

    AYZP40KR 20)Remove 2 screws fixing on the rear side of control box. Remove the control board unit from the control box while unfixing 2 hooks. [2] HOW TO REMOVE PLASMACLUSTER UNIT(For the models with PLASMACLUSTER) 1) Take the tape off and cut the fixing band 2) Insert the thin board to center of gap and remove the hook of holder.

  • Page 45: Disassembly Of Outdoor Unit

    AYZP40KR [3] DISASSEMBLY OF OUTDOOR UNIT 4) The screw on the right-hand side of front panel is removed 1) The fixed screw of control box cover is removed and control box cover is removed. 5) The screw on the right-hand side of front panel is removed 2) The 2 screws on the right-hand side of top plate ass’y is removed.
  • Page 46 AYZP40KR 8) The 2 screws on the right-hand side of side cover L is removed. 12)A bulkhead plate fixed 2 screws is removed. 9) The 7 screws of the side cover L and side cover R back is removed. 13)The conp cover top is removed. 10)The connectors in the control box BOX and reactor is removed.
  • Page 47 AYZP40KR 15)A lead wire, a thermistor, and a cover gasket are removed. 18)An outdoor fan is removed. 16)A comp cover is removed. 19)The fixed 2 screws of a motor angle is removed. 17)A thermistor is removed. (1 place) 5 – 7...
  • Page 48 AYZP40KR – Disassembly of Heater(CHET-A025JBKZ) Unit 1) Cut the band fixing the bi-metal thermostat. 2) Powercord for bi-metal thermostat. 3) Cut the band which holds together the thermistor cords and power cord for bi-metal thermostat. 4) Remove screw NK-8K 5) Purr out the heater wire from beneath the heat exchanger 5 –...
  • Page 49 AYZP40KR — MEMO— 5 – 9...
  • Page 50 AYZP40KR 5 – 10...

  • Page 51: Parts Guide

    OUTDOOR UNIT INDOOR UNIT MODEL AY-ZP40KR AE-Z40KR 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. CONTENTS INDOOR UNIT PARTS...
  • Page 52 AYZP40KR [1] INDOOR UNIT PARTS 2-27 2-23 2-14 2-3-1 2-10 3-10 2-3-2 2-15-2 2-41 2-43 2-11 3-11 2-46 2-13 2-15-1 2-28 2-40 2-13-2 3-1-1 2-16 2-44 2-19 1-10 2-25 2-5-2 2-47 2-17 2-18 2-5-1 2-24 1-11 2-57 2-58 2-33 2-21 2-22 2-34 2-21-1...
  • Page 53 AYZP40KR PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [1] INDOOR UNIT PARTS LEAD WIRE PC QW-VZF644JBZZ POWER SUPPLY CORD QACC-A341JBZZ TERMINAL BOARD QTANZA039JBZZ TERMINAL BOARD QTANZA040JBZZ LEAD WIRE QW-VZF891JBZZ LEAD WIRE QW-VZF895JBZZ QW-VZF896JBZZ LEAD WIRE LEAD WIRE QW-VZF897JBZZ THERMISTOR RH-HXA070JBZZ 1-10 CONTROL BOARD UNIT...
  • Page 54 AYZP40KR [2] ACCESSORY PARTS 4-12 4-11 PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [2] ACCESSORY PARTS PURIFY FILTER ASS'Y CFIL-A124JBKZ REMOTE CONTROL CRMC-A788JBEZ SPECIAL SCREW LX-BZA357JBEZ SPECIAL NUT LX-NZA207JBEZ XTTS740P20000 TAPPING SCREW XTTS745P30000 TAPPING SCREW LHLD-A849JBFA CORD HOLDER INSTALLATION MANUAL TINS-B219JBRZ 4-11 OPERATION MANUAL...
  • Page 55 AYZP40KR [4] OUTDOOR UNIT PARTS 2-48-1 2-17 2-34 2-61 2-46-2 2-30 2-46-1 2-48-2 2-26 2-7-1 2-7-4 2-33 2-7-2 2-46-3 2-25 2-60 2-22 2-31 2-7-5 2-39-5 2-39-3 2-39-4 2-37 2-7-3 2-20 2-7-6 1-2-6 2-56 2-19 1-2-7 3-12 2-45 2-18 2-47-1 1-10 2-10 2-39 2-39-7...
  • Page 56 AYZP40KR PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [4] OUTDOOR UNIT PARTS FAN MOTER CMOTLB078JBEZ CONTROL BOARD UNIT[With 2-9 Holder] DSGY-C917JBKZ 1-2-6 RH-IXA903JBZZ 1-2-7 DIODE BRIDGE VHDD25XB60+-F LEAD WIRE(REACTOR) QW-VZF245JBZZ RCILZA009JBZZ REACTOR THERMISTOR RTHM-A022JBE0 TERMINAL BOARD QTANZA001JBZZ WIRE FW-VZA070JBKZ 1-10 FERRITE CORE RFIL-A064JBE0...
  • Page 57 AYZP40KR PARTS CODE P R I C E N E W P A R T DESCRIPTION RANK MARK RANK [4] OUTDOOR UNIT PARTS 3-6-4 WIRE FIXING BAND LBND-A014JBE0 CONTROL VALVE ASS'Y DVLV-A662JBKZ 3-7-1 COIL RMOTSA023JBZZ 3-7-2 CONTROL VALVE PVLVRA036JBEZ 3-7-3 DAMPER RUBBER PGUMSA386JBEZ CCIL-A142JBKZ...
  • Page 58 AYZP40KR INDEX PRICE PART PRICE PART PARTS CODE PARTS CODE RANK MARK RANK RANK MARK RANK NFANCA113JBEZ 1-2-16 [ C ] NFANPA145JBEZ 4-2-25 CANG-A165JBKZ 4-2-30 CCAB-A408JBKZ 4-2-2 [ P ] CCHS-A931JBTA 4-3-1 PBOX-A511JBFZ 1-2-19 CCIL-A142JBKZ 4-3-8 PCOV-A300JBF0 1-2-44 CCYC-C270JBKZ PCOV-A594JBPZ 4-2-7-1 CFIL-A124JBKZ 2-4-1...
  • Page 59 AYZP40KR PRICE PART PARTS CODE RANK MARK RANK QFS-CA002JBZZ 5-1-2-4 QFS-GA051JBZZ 5-1-2-2 QFS-GA052JBZZ 5-1-2-3 QFS-GA064JBZZ 5-1-2-5 QTANZA001JBZZ 4-1-6 QTANZA039JBZZ 1-1-3 QTANZA040JBZZ 1-1-4 QW-VZF245JBZZ 4-1-3 QW-VZF644JBZZ 1-1-1 QW-VZF891JBZZ 1-1-5 QW-VZF895JBZZ 1-1-6 QW-VZF896JBZZ 1-1-7 QW-VZF897JBZZ 1-1-8 [ R ] RCILZA009JBZZ 4-1-4 RFIL-A064JBE0 4-1-10 RH-HXA029JBZZ 4-1-11...
  • Page 60 COPYRIGHT © 2009 BY SHARP CORPORATION ALL RIGHTS RESERVED. © COPYRIGHT XXXX BYSHARP CORPORATION No part of this publication may be reproduced, stored ALL RIGHTS RESERVED. in retrieval systems, or transmitted in any form or by any means, electronic, mechanical, photocopying, re-...

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