Sharp AE-X09TU Service Manual
Sharp AE-X09TU Service Manual

Sharp AE-X09TU Service Manual

Split type room air conditioner (outdoor unit)

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TopPage
[1]
SPECIFICATION.................................... . ....... 1-1
[2]
EXTERNAL DIMENSION....................... . ....... 1-2
[3]
WIRING DIAGRM ..................................
[4]
ELECTRICAL PARTS................................... 1-3
[1]
BLOCK DIAGRAMS............................... . ...... 2-1
[2]
[3]
FUNCTION ................................................... 2-4
CHAPTER 3. FUNCTION AND OPERATION
OF PROTECTIVE PROCEDURES
[1]
AND OPERATIONS......................................3-1
[2]
THERMISTOR ERROR................................3-3
[3]
ERISTICS......................................................3-5
[4]
UNIT INDEPENDENTLY...............................3-5
[5]
CHART..........................................................3-6
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
ROOM AIR CONDITIONER
(OUTDOOR UNIT)
AE-X09TU
MODEL
AE-X12TU
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
[6]
METHOD.....................................................3-8
[7]
........ 1-2
[8]
TROUBLESHOOTING GUIDE....................3-12
[9]
CHART........................................................3-13
[1]
SCHEMATIC DIAGRAM...............................4-1
....... 2-2
[2]
STANDARD CONDITION.............................4-1
[3]
CURRENT OF HEAT CONTROLLER..........4-1
[4]
PRESSURE IN 3-WAY VALVE.....................4-1
[5]
CYCLE...........................................................4-3
[6]
HEATING OPERATION ...............................4-3
[1]
OUTDOOR UNIT..........................................5-1
[2]
DISASSEMBLY OF CONTROL BOX...........5-4
CHAPTER 6. INSTALLATION MANUAL.............6-1
Parts List
S1606AEX12TU/T
SPLIT TYPE
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.
AE-X12TU

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Summary of Contents for Sharp AE-X09TU

  • Page 1: Table Of Contents

    S1606AEX12TU/T SPLIT TYPE ROOM AIR CONDITIONER (OUTDOOR UNIT) AE-X09TU MODEL AE-X12TU 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. Specification

    AE-X12TU CHAPTER 1. SPECIFICATION AUX3M24LV [1] SPECIFICATION AE-X09TU OUTDOOR MODEL AE-X12TU ITEMS Power supply Phase Single Single Rated voltage 208/230 208/230 Rated frequency System Indoor units number Maximum length (per unit) 65.6 (20) 65.6 (20) ft (m) Maximum height difference ft (m) 32.8 (10)
  • Page 3: External Dimension

    AE-X12TU [2] EXTERNAL DIMENSION 21.3 (540) 6.2 (158) 2.8 (70) Length unit: inch (mm) 0.5 (12) 1.5 (37.5) 2.3 (58) 0.6 (16) 10.6 (269) 30.7 (780) 7.1 (179.5) 7.2 (182.5) [3] WIRING DIAGRAM AE-X12TU/AE-X09TU 1 – 2...
  • Page 4: Electrical Parts

    AE-X12TU [4] ELECTRICAL PARTS AE-X12TU / AE-X09TU Compressor 43A26MWM-PJKF RECHI(10.4CC)(PCMPRA770JBEZ) SHA-52FV-D843-2 QFS-GA090JBZZ (20A 250V) 1 – 3...
  • Page 5: Chapter 2. Electroic Circuit Block Diagrams

    AE-X12TU CHAPTER 2. ELECTROIC CIRCUIT [1] BLOCK DIAGRAMS 1. Outdoor unit Expansion valve circuit Expansion valve 2 – 1...
  • Page 6: Microcomputer Control System

    AE-X12TU [2] MICROCOMPUTER CONTROL SYSTEM 1 Electronic control circuit diagram: AE-X12TU/AE-X09TU 2 – 2...
  • Page 7 AE-X12TU 2. Printed wiring board: AE-X12TU/AE-X09TU 2 – 3...
  • Page 8: Function

    Peak Control Overload Current (The indoor unit will restart operation immediately after the ON switch Model Mode is operated on the remote control.) Current(A) Compensation(A) Cooling 7.47 AE-X09TU Heating 8.31 -0.5 Cooling 8.72 AE-X12TU Heating 9.88 -2.1 1.2. Outdoor unit 2-way valve freeze prevention control If the temperature of the outdoor unit 2-way valve remains below 32 ℉( 0℃)
  • Page 9: Outline Of Pam Circuit

    AE-X12TU 1.9. INACTIVATE -4°F(-20°C) AUTO STOP FUNCTION During the heating operation, the unit will automatically stop when the outdoor temperature drops below -4°F(-20°C) to prevent the outdoor unit from the damage caused by the freezing of the drained water. The unit will stop its operation for 4 hour and then resume the operation when the outdoor temperature rises above -2°F(-18.9°C).
  • Page 10 AE-X12TU 2.2. 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 11 AE-X12TU 2.3.1 Details of troubleshooting procedure for PAM 1) PAM shutdown due to error 1) When the DC voltage detection circuit sends a signal exceeding the specified voltage to the microcomputer DC voltage of 400 V or higher (detection circuit input voltage of about 4.6 V or higher) [IC1 69 pin] –...
  • Page 12: Explanation Of Ipm Drive Circuit

    AE-X12TU 3. 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 PWB). 3.1. 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 13 3.1.2 DC over current detection circuit When a current of about 20 A or higher flows through the shunt resistance [AE-X09TU/AE-X12TU(R49A ~R49E)] on the control printed wiring board (PWB), the voltage at this resistance is input to IPM CIN pin (15). Then, the gate voltage of the lower-phase IGBT (LU, LV, LW) inside the IPM turns OFF to cut off the over current.
  • Page 14 AE-X12TU 4. 180° energizing control This is the control system to moderate the speed by the current phase difference for higher efficiency and lower noise of the compressor. The current phase difference control is the control system paid attention to the interrelation between efficiency and phase gap generated by the applied voltage of motor and current in the coil of motor as shown in the figure below.
  • Page 15: Function And Operation Of Protective Procedures

    [1] PROTECTION DEVICE FUNCTIONS AND OPERATIONS * These models have following thermistors. OUTDOOR UNIT AE-X09TU, AE-X12TU TH1, TH2, TH3, TH4, TH6 The errors for the thermistors that are not mentioned above are irrelevant. These indoor units don’t have power relay.
  • Page 16 AE-X12TU Self-diagnosis Operation result display Function Description Detection period Reset condition Indoor Indoor Outdoor unit unit unit error display Thermistor installa- Compressor stops if high and low 3 minutes after com- Operation OFF or ON Yes I1 tion error or 4-way values of temperatures detected pressor startup valve error...
  • Page 17: Air Conditioner Operation In Thermistor Error

    [2] AIR CONDITIONER OPERATION IN THERMISTOR ERROR * These models have following thermistors. OUTDOOR UNIT AE-X09TU, AE-X12TU TH1, TH2, TH3, TH4, TH6 The errors for the thermistors that are not mentioned above are irrelevant. These indoor units don’t have power relay.
  • Page 18 AE-X12TU 1. 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 19: Thermistor Temperature Characteristics

    AE-X12TU [3] THERMISTOR TEMPERATURE CHARACTERISTICS 1. Outdoor unit thermistor temperature characteristics To measure the resistance, first remove the connector from the board. Thermistor No. Connector Color 1 - 2 Compressor thermistor 3 - 4 Heat exchanger pipe thermistor Orange 5 - 6 Outdoor temp.
  • Page 20: General Troubleshooting Chart

    AE-X12TU [5] GENERAL TROUBLESHOOTING CHART * These models have following thermistors. OUTDOOR UNIT AY-XPC09TU(AE-X09TU)/AY-XPC12TU(AE-X12TU) TH1, TH2, TH3, TH4, TH6 The errors for the thermistors that are not mentioned above are irrelevant. These indoor units don’t have power relay. 1. Indoor unit does not turn on...
  • Page 21: Louvers Do Not Move

    AE-X12TU 5. Louvers do not move Main cause Inspection method Normal value/condition Remedy Caught in sliding section. Operate to see if louvers are Louvers should operate smoothly. Remove or correct catching sec- caught in place. tion. Disconnected connector Inspect connectors. Connectors or pins should not be Install correctly.
  • Page 22: Malfunction(Parts) Check Method

    AE-X12TU [6] MALFUNCTION (PARTS) CHECK METHOD 1. Procedure for determining defective outdoor unit IPM/compressor The following flow chart shows a procedure for locating the cause of a malfunction when the compressor does not start up and a DC overcurrent indi- cation error occurs.
  • Page 23: Ipm Check Method

    AE-X12TU 4. IPM check method Turn off the power, let the large capacity electrolytic capacitor (C9, 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 ∞...
  • Page 24: Troubleshooting Of Outdoor Unit Electric Components

    AE-X12TU 2. Troubleshooting of outdoor unit electric components Is 230 V applied between L1 and L2 on outdoor unit terminal board? Check outdoor unit. 3 – 10...
  • Page 25 AE-X12TU 3. Caution in checking printed wiring 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 wiring board (PWB) are connected to the compressor drive power supply (320-VDC negative terminal). Therefore, exercise utmost caution to prevent electric shock.
  • Page 26: Troubleshooting Guide

    AE-X12TU [8] TROUBLESHOOTING GUIDE 1. Self-Diagnosis Function 1.1. Indoor unit • To display the self-diagnosis, hold down the AUX button for over 5 seconds on the indoor unit when the indoor unit is not operating. • The operation lamp (green), timer lamp (orange) and Plasmacluster lamp (blue) flash to indicate the information of malfunction. Plasmacluster lamp(Blue) Operation lamp(Green) Timer lamp(orange)
  • Page 27: Chart

    AE-X12TU [9] CHART <INDOOR UNIT> ○:1-second ON / 1-second OFF Malfunction Indoor unit Content of diagnosis Check point Action Outdoor No.* Problem unit symptom indication (LED1) → Lamp Main Sub Main Normal Normal Normal O O O O O Timer (Orange) condition blinking Operation (Green)
  • Page 28 AE-X12TU Malfunction Indoor unit Content of diagnosis Check point Action Outdoor No.* Problem unit symptom indication (LED1) Lamp Main Sub Main → Indoor and 5-time O O O O O Timer (Orange) Outdoor unit Heat exchanger 1) Check connector of 1) Correct the installa- outdoor thermistor...
  • Page 29 AE-X12TU Malfunction Indoor unit Content of diagnosis Check point Action Outdoor No.* Problem unit symptom indication (LED1) → Lamp Main Sub Main O O O O O Timer (Orange) Thermistor 1)Check the ther- 1)Correct the instal- Cycle Indoor and 9- ime temperature mistor (heat la ion.
  • Page 30 AE-X12TU Malfunction Indoor unit Content of diagnosis Check point Action Outdoor No.* Problem unit symptom indication (LED1) → Lamp Main Sub Main Indoor and 12- ime O O O O O Timer (Orange) Thermal fuse Thermal fuse error 1) Check he thermal fuse 1) Replace terminal outdoor in terminal...
  • Page 31 AE-X12TU Malfunction Indoor unit Content of diagnosis Check point Action Outdoor No.* Problem unit symptom indication (LED1) → Lamp Main Sub Main Indoor and Normal O O O O O Timer (Orange) Indoor unit Indoor unit fan error 1) Check the indoor fan 1) Replace the indoor outdoor blinking or...
  • Page 32: Chapter 4. Refrigeration Cycle

    [3] PEAK OPERATION CURRENT PEAK CURRENT (A) Cooling Heating AE-X09TU AE-X12TU [4] TEMPERATURE AT EACH PART AND PRESSURE IN 3-WAY VALVE ( AY-XPC09TU / AE-X09TU ) n i l Mode Test Run Test Run 61 or More 42 Fixed 70 or More...
  • Page 33 AE-X12TU AY-XPC12TU / AE-X12TU n i l Mode Test Run Test Run 81 or More 42 Fixed 89 or More 42 Fixed ITEM 163 (73) 138 (59) 185 (85) 126 (52) Temp. on (1) ゜F(℃) 100 (38) 99 (37) 39 (4) 39 (4) Temp.
  • Page 34: Flow Chart Of Refrigerant Cycle

    5-1 COOLING & DEFROSTING 5-2 HEATING [6] CHARACTERISTIC OF COOLING AND HEATING OPERATION 6-1 AY-XPC09TU / AE-X09TU CAUTION: Indoor fan speed is set to [HIGH]. Airflow direction is initial. Air inlet temperature of is 80℉ (26.7℃) during COOLING operation, and 70℉ (21.1℃) during HEATING operation.
  • Page 35 AE-X12TU 6-2 AY-XPC12TU / AE-X12TU CAUTION: Indoor fan speed is set to [HIGH]. Airflow direction is initial. Temperature of inlet is 80℉ (26.7℃) during COOLING operation, and 70℉ (21.1℃) during HEATING operation. COOLING HEATING 1050 1350 1300 1000 1250 1200 1150 1100 1050...
  • Page 36: Chapter 5. Disassembly Procedure

    AE-X12TU CHAPTER 5. DISASSEMBLING PROCEDURE 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 37 AE-X12TU 7) Remove 2 pcs Compressor Cover. 5) Unscrew 5 screws fixing the Top Cover and remove it. Compressor Cover Top Cover 8) Unscrew the Nut fixing the Terminal Cover and remove it , then disconnet the Compressor cable. 6) Unscrew 6 screws fixing the Front Panel and remove it. Terminal Cover Compressor cable Front Panel...
  • Page 38 AE-X12TU 9) Cut the 4 pcs band and disconnect the connectors. 11) Unscrew 2 screws fixing the Bulkhead and remove it. Bulkhead Band 10) Unscrew 4 screws fixing the Control Unit and remove it. 12) Unscrew 2 screws fixing the Motor Angle and remove it. Motor Angle Control Unit 5 –...
  • Page 39 AE-X12TU 13) Unscrew the Nut fixing the propeller fan and remove it. 16) Disconnect the cable and unscrew 1 screw fixing the earth cable. Propeller Fan Propeller Fan Propeller Fan Propeller Fan Propeller Fan Propeller Fan 14) Cut fixing band, and unscrew 4 screws fixing the Fan 17) Remove Control Box and Box Cover.
  • Page 40: Chapter 6. Installation Instruction

    AE-X12TU CHAPTER 6. INSTALLATION INSTRUCTION AHXPC12LV Service Manual Carefully read and follow these instructions for smooth and trouble-free installation. This manual describes the installation of outdoor unit only For the installation of the indoor unit, see the installation manual accompanying indoor unit. SAFETY PRECAUTIONS •...
  • Page 41: Connecting The Pipes

    AE-X12TU OUTDOOR UNIT INSTALLATION Installation dimension Referring to the fi gure, 21.3 inch 12.2 inch fi rmly fasten the outdoor (540 mm) (310 mm) unit with bolts. CONNECTING THE REFRIGERANT PIPES Flaring the pipe end (1) Cutting with a pipe cutter (4) Flaring 90°...
  • Page 42 AE-X12TU CONNECTING THE CABLE TO THE OUTDOOR UNIT Power supply cable and ground wire Connecting wires and the ground wire • Use solid conductor AWG14 or stranded conductor AWG14. • Use solid or stranded conductor AWG14. • Use double insulated copper wire with 600 V insulation. •...
  • Page 43: Power Cabling

    TEST RUN POWER CABLING Prepare a dedicated power supply circuit. For the connections, see below. See the installation manual ac- companying indoor unit. AE-X09TU AE-X12TU • Fit a disconnect switch, having Supply power 208/230 V, single-phase a contact separation of at least...
  • Page 44: Parts Guide

    ROOM AIR CONDITIONER SPLIT TYPE ROOM AIR CONDITIONER (OUTDOOR UNIT) AE-X09TU MODEL AE-X12TU 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 45 AE-X12TU [1] OUTDOOR UNIT PARTS FOR AE-X09TU, AE-X12TU...
  • Page 46 COMPRESSOR TOP COVER 1-20 PSPF-B333JBEZ COMPRESSOR COVER 1-21 RCILZA042JBZZ REACTOR 1-22 RH-HXA187JBZZ THERMISTOR 1-23 TLAB-G567JBRA ENERGY LABEL(AE-X12TU) 1-23 TLAB-G568JBRA ENERGY LABEL(AE-X09TU) 1-24 TLAB-F696JBRZ CAUTION LABEL UL 1-25 TLAB-F748JBRZ UL COPPER WIRE LABEL 1-26 TLABBA291JBRA PCI LABEL 1-27 TLABMA849JBRA INVERTER LABEL...
  • Page 47 TERMINAL COVER 2-17 PSEL-E001JBEZ TERMINAL GASKET 2-18 PGUM-A121JBEZ DAMPER RUBBER DBOX-A086JBYZ CONTROL BOX ASS'Y DSGY-G082JBKZ CONTROL BOARD UNIT(AE-X12TU) DSGY-G083JBKZ CONTROL BOARD UNIT(AE-X09TU) LHLD-B227JBFA CONTROL BOX HOLDER LHLD-B231JBFA HEAT SINK HOLDER PCOV-B716JBWZ COVER PDAI-A295JBWZ TERMINAL HOLDER QTANZA091JBZZ TERMINAL BOARD RFIL-A064JBE0 FERRITE CORE...
  • Page 48 [3] OUTDOOR UNIT PACKING PARTS [ ] OUTDOOR UNIT PAC KING PAR TS CPADBA242JBKZ Bottom Pad Assembly CPADBA032JBKZ Packing Pad Assembly SPAKCE236JBEZ Packing Case...

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