Sharp AY-XP12ZU1 Service Manual
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Sharp AY-XP12ZU1 Service Manual

Sharp AY-XP12ZU1 Service Manual

Split type room air conditioner
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SPLIT TYPE ROOM AIR CONDITIONER
[1] SPECIFICATION ...............................................1-1
[2] EXTERNAL DIMENSION ..................................1-4
[3] WIRING DIAGRAM ...........................................1-6
[4] ELECTRICAL PARTS ........................................1-7
[1] BLOCK DIAGRAMS ..........................................2-1
[1] FUNCTION ........................................................3-1
[2] PAM Circuit ........................................................3-3
[3] IPM Drive Circuit ................................................3-5
[4] 180deg. Energizing Control ...............................3-6
OPERATIONS ....................................................4-1
THERMISTOR ERROR .....................................4-3
CHARACTERISTICS ........................................4-5
INDEPENDENTLY .............................................4-6
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.
"Vertical louver (V-louver)" in this document means "horizontal air flow louver" in the operation manual.
"Horizontal louver (H-louver)" in this document means "vertical air flow louver" in the operation manual.
SERVICE MANUAL
12K Btu/h models
15K Btu/h models
18K Btu/h models
24K Btu/h models
In the interests of user-safety (Required by safety regulations in some countries) the set should be re-
stored to its original condition and only parts identical to those specified should be used.
CONTENTS
[7] OUTDOOR UNIT CHECK METHOD .................4-11
[8] TROUBLESHOOTING GUIDE ..........................4-13
[1] SCHEMATIC DIAGRAM ....................................5-1
[2] STANDARD CONDITION ..................................5-1
PRESSURE IN 3-WAY VALVE ...........................5-1
[4] PERFORMANCE CURVES ...............................5-3
AY-XP18ZU1, AY-XP24ZU1 models) .................6-6
AY-XP18ZHU1 models) .....................................6-11
OPERATION MANUAL
INSTALLATION MANUAL
PARTS LIST
FAILURE DIAGNOSIS FLOW CHART
S7305AYXPC2ZUT
INDOOR UNIT
OUTDOOR UNIT
AY-XP12ZU1
AY-XP12ZHU1
AY-XP15ZU1
AY-XP18ZU1
AY-XP18ZHU1
AY-XP24ZU1
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.
AY-XP12ZU1
AE-X12ZU1
AE-X12ZHU1
AE-X15ZU1
AE-X18ZU1
AE-X18ZHU1
AE-X24ZU1

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Summary of Contents for Sharp AY-XP12ZU1

  • Page 1: Table Of Contents

    [2] MICROCOMPUTER CONTROL SYSTEM ..2-3 [4] PERFORMANCE CURVES .......5-3 CHAPTER 3. FUNCTION CHAPTER 6. DISASSEMBLY PROCEDURE [1] FUNCTION ............3-1 [1] INDOOR UNIT(For AY-XP12ZU1 model) ..6-1 [2] PAM Circuit ............3-3 [2] INDOOR UNIT(For AY-XP15ZU1, [3] IPM Drive Circuit ..........3-5 AY-XP18ZU1, AY-XP24ZU1 models) ....6-6 [4] 180deg.

  • Page 2: Revision Record

    REVISION RECORD Date Page Change contents Reason...

  • Page 3: Chapter 1. Product Specification

    AY-XP12ZU1 CHAPTER 1. PRODUCT SPECIFICATION [1] SPECIFICATION MODEL INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT AY-XP12ZU1 AE-X12ZU1 AY-XP12ZHU1 AE-X12ZHU1 ITEMS Service Manual 12000 ( 2800 - 13600 ) 12000 ( 3500 - 14000 ) Rated cooling capacity (Min. - Max.) Btu/h Rated heating capacity (Min.
  • Page 4 AY-XP12ZU1 MODEL INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT AY-XP15ZU1 AE-X15ZU1 AY-XP18ZU1 AE-X18ZU1 ITEMS Service Manual Rated cooling capacity (Min. - Max.) Btu/h 15000 ( 5000 - 17000 ) 18000 ( 6000 - 21600 ) Rated heating capacity (Min. - Max.)
  • Page 5 AY-XP12ZU1 MODEL INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT AY-XP18ZHU1 AE-X18ZHU1 AY-XP24ZU1 AE-X24ZU1 ITEMS Service Manual 18000 ( 6000 - 21600 ) 22000 ( 6000 - 23000 ) Rated cooling capacity (Min. - Max.) Btu/h 21600 ( 5500 - 30000 ) 24000 ( 5500 - 27100 ) Rated heating capacity (Min.

  • Page 6: External Dimension

    AY-XP12ZU1 [2] EXTERNAL DIMENSION 1. Indoor unit Length unit: mm AY-XP12ZU1 AY-XP12ZHU1, AY-XP15ZU1, AY-XP18ZHU1, AY-XP18ZU1, AY-XP24ZU1...
  • Page 7 AY-XP12ZU1 2. Outdoor unit Length unit: mm AY-XP12ZU1, AY-XP12ZHU1, AY-XP15ZU1 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) AY-XP18ZHU1, AY-XP18ZU1, AY-XP24ZU1 Length unit: inch (mm) 0.6 (16)

  • Page 8: Wiring Diagram

    AY-XP12ZU1 [3] WIRING DIAGRAM 1. Indoor unit 2. Outdoor unit...

  • Page 9: Electrical Parts

    AY-XP12ZU1 [4] ELECTRICAL PARTS 1. Indoor unit DESCRIPTION MODEL REMARKS DAI239P-H030A-3207/ZKFP-30-8-277L Indoor fan motor 30W,Class E Transformer TE20SMSW-G08V/BCK-19-0701 DC 5V,12V,19V 2010 T3.15A 250V 3.15A,250V 2. Outdoor unit DESCRIPTION MODEL REMARKS KSN98D42UFZA (For AE-X12ZU1) KTN150D63UFZR3 Compressor (For AE-X12ZHU1, AE-X18ZHU1, AE-X15ZU1, AE-X18ZU1, AE-X24ZU1)

  • Page 10: Chapter 2. Explanation Of Circuit And Operation [1] Block Diagrams

    AY-XP12ZU1 CHAPTER 2. EXPLANATION OF CIRCUIT AND OPERATION [1] BLOCK DIAGRAMS 1. Indoor unit 3.15A FUSE Humidity detect circuit Humidity sensor Pipe temp. detect circuit Pipe temp. thermistor motor Horizontal louver (H-louver) motor drive circuit Horizontal louver (H-louver) WLAN module drive circuit...
  • Page 11 AY-XP12ZU1 2. Outdoor unit AC clock circuit Pulse amplitube modulation circuit IGBT FUSE protection Power supply Unit-unit wiring (AC power Smoothing Power factor Filter circuit circuit and serial signals) converter circuit circuit FUSE protection CPU oscillator circuit FUSE DC overvoltage detection circuit...

  • Page 12: Microcomputer Control System

    AY-XP12ZU1 [2] MICROCOMPUTER CONTROL SYSTEM 1.Indoor unit Printed wiring board louver Vertical Horizontal Louver PCI (Center) LED PCI unit (V-louver) (H-louver) Thermistor Terminal board WLAN module Motion sensor DC fan motor...
  • Page 13 AY-XP12ZU1 2.Outdoor unit 2.1. Printed wiring board 12K,15K Btu/h models...
  • Page 14 AY-XP12ZU1 18K,24K Btu/h models...

  • Page 15: Chapter 3. Function [1] Function

    AY-XP12ZU1 CHAPTER 3. FUNCTION AE-X18ZU1 10.5 12.6 10.6 [1] FUNCTION AE-X24ZU1 12.5 13.0 10.6 AE-X12ZHU1 12.0 1 Restart control AE-X18ZHU1 10.5 13.0 10.6 Once the compressor stops operating, it will not restart for 180 seconds to protect the compressor. Therefore, if the operating compressor is shut down from the re- 6.

  • Page 16: Save Operation

    AY-XP12ZU1 2) Setting not memorized • Timer setting • Full power setting • Self cleaning • Multi Space setting • ECO setting 3) Disabling auto restart function By removing (cutting) jumper (JP0) on the printed circuit board(PCB), the auto restart function can be disabled.
  • Page 17 AY-XP12ZU1 1. PAM (Pulse Amplitude Modulation) The PAM circuit varies the compressor drive voltage. The IGBT shown in the block diagram charges the energy (electromotive force) generated by the reactor to the electrolytic capacitor for the inverter by turning ON and OFF.

  • Page 18: Pam Circuit

    AY-XP12ZU1 2) AC clock (zero-cross) judgment • The clock circuit determines the time from one rising point of the clock waveform to the next rising point. The detected clock waveform is used to judge the power source frequency (60Hz). • The zero-cross of the AC voltage is judged as the rising of the clock waveform, as shown in the diagram above.

  • Page 19: Ipm Drive Circuit

    AY-XP12ZU1 [3] IPM Drive Circuit The IPM is used for compressor drive. The power supply for the IPM drive, the shunt resistance for over current detection, etc., are provided outside the IPM (control PWB). 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: 180Deg. Energizing Control

    AY-XP12ZU1 [4] 180deg. 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 21: Chapter 4. Function And Operation Of Protective Procedures [1] Protection Device Functions And Operations

    AY-XP12ZU1 CHAPTER 4. FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES [1] PROTECTION DEVICE FUNCTIONS AND OPERATIONS * These models have following thermistors INDOOR UNIT OUTDOOR UNIT TH1, TH2 TH1, TH2, TH3, TH4, TH5 The errors for the thermistors that are not mentioned above are irrelevant.
  • Page 22 AY-XP12ZU1 Self-diagnosis Operation result display Function Indoor Indoor Outdoor Description Detection period Reset condition unit error unit unit display Outdoor unit heat Compressor stops if there is shortcircuit in outdoor At compressor Operation OFF or exchanger thermistor Yes ☆ 1 unit heat exchanger thermistor (TH2).

  • Page 23: Air Conditioner Operation In Thermistor Error

    AY-XP12ZU1 [2] AIR CONDITIONER OPERATION IN THERMISTOR ERROR * These models have following thermistors INDOOR UNIT OUTDOOR UNIT TH1, TH2 TH1, TH2, TH3, TH4, TH5 The errors for the thermistors that are not mentioned above are irrelevant. These indoor units don’t have power relay.
  • Page 24 AY-XP12ZU1 When resistance is When resistance is low high (temperature Item Mode Control operation (temperature judged Short-circuit Open-circuit judged lower than higher than actual) actual) Outside air tem- Auto Operation mode Cooling mode is activat- Outdoor unit Heating mode is ac-...

  • Page 25: Thermistor Temperature Characteristics

    AY-XP12ZU1 [3] THERMISTOR TEMPERATURE CHARACTERISTICS 1.Indoor unit To measure the resistance, first remove the connector from the board. BCN7 100K Room temperature thermistor TH1 20ºC resistance 1 2.65 Ω Heat exchange temperature thermistor TH2 (Orange) 25ºC resistance 15 k Ω...

  • Page 26: How To Operate The Outdoor Unit Independently

    AY-XP12ZU1 [4] HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY 1.Cooling in 40 Hz fixed mode To operate the outdoor unit independently, short-circuit the sections indicated by arrows in the diagram below with an adapter, and apply 230 VAC between (L1) and (L2) on the terminal board of the outdoor unit. This allows the outdoor unit to be operated in cooling mode independently.

  • Page 27: Louvers Do Not Move

    AY-XP12ZU1 Main cause Inspection method Normal value/condition Remedy Use Sevick light (Hitachi). Check if Sevick light (Hitachi) is Signal may not be received Replace light or change position. used. sometimes due to effect of Se- vick light. Operating position/angle are inappro-...

  • Page 28: Malfunction (Parts) Check Method

    AY-XP12ZU1 9.Operation stops after a few minutes and restarts, and this process repeats Main cause Inspection method Normal value/condition Remedy Dried-up electrolytic capacitor. Measure 290-VDC line voltage. 250 V or higher. Replace outdoor unit PWB. Layer short-circuit in expansion Measure resistance.

  • Page 29: Ipm Check Method

    AY-XP12ZU1 Inverter electrolytic capacitor (C5,C6: For 12K,15K Btu/h models; C8,C9: For 18K,24K Btu/h models) check method Turn off the power, let the inverter electrolytic capacitor (C5,C6: For 12K,15K Btu/h models; C8,C9: For 18K,24K Btu/h models) discharge completely, and remove the capacitor from the control printed circuit board (PWB). First, check the case for cracks, deformation and other damages. Then, using a needle-type tester, check continuity.
  • Page 30 AY-XP12ZU1 6.Motion sensor trouble-shooting ! CAUTION ! • Sometimes, the buzzer sound is not stable for 3 minutes at just after pluging the power supply. • Sometimes, the buzzer sound lags behind movement. Press the ON/OFF bu�on. The air condi�oner starts opera�on.

  • Page 31: Outdoor Unit Check Method

    AY-XP12ZU1 [7] OUTDOOR UNIT CHECK METHOD After repairing the outdoor unit, conduct the following inspection procedures to make sure that it has been repaired completely. Then, operate the com- pressor for a final operation check. 1. Troubleshooting of outdoor unit electric components...

  • Page 32: Caution In Checking Printed Circuit Boards (Pwb)

    AY-XP12ZU1 2. Caution in checking printed circuit boards (PWB) 2.1. 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 33: Troubleshooting Guide

    AY-XP12ZU1 [8] TROUBLESHOOTING GUIDE 1. Self-Diagnosis Function 1.1 Indoor unit • At below situation, the operation lamp (Green), timer lamp (Orange) and WLAN lamp(Green) flash to indicate the information of malfunction. Error code main sub OPERATION Lamp (flash 2 times)
  • Page 34 AY-XP12ZU1 1.2. Outdoor unit • The self-diagnosis is indicated the error information by flashing LED1 on the outdoor unit. • The self-diagnosis of outdoor unit is displayed for about 3-10 minutes. Then, the LED1 returns to normal display. LED1 2. Self-Diagnosis Function <Error code display on remote control >...
  • Page 35 AY-XP12ZU1 3.Chart for Reading Self-Diagnosis Outdoor Malfunction Content of diagnosis unit No.* Problem indica- Check point Action symptom tion Main Main (LED1) Normal Normal Normal condition blinking Indoor and 1-time Outdoor unit Heat exchanger 1) Measure the resistanceof 1) Replace the outdoor unit...
  • Page 36 AY-XP12ZU1 Outdoor Malfunction Content of diagnosis unit No.* Problem indica- Check point Action symptom tion Main Main (LED1) Indoor unit 2-time Cycle Compressor dis- 1) (Temporary stop for cycle operates. temperature charge overheat. protection) Outdoor Outdoor unit heat unit does...
  • Page 37 AY-XP12ZU1 Outdoor Malfunction Content of diagnosis unit No.* Problem indica- Check point Action symptom tion Main Main (LED1) Indoor and 7-time Outdoor unit AC AC over current 1) Check the outdoor unit air 1) Ensure unobstructed air outdoor Current error outlet for blockage.
  • Page 38 AY-XP12ZU1 Outdoor Malfunction Content of diagnosis unit No.* Problem indica- Check point Action symptom tion Main Main (LED1) Indoor and 11-time Outdoor unit Outdoor unit DC 1) Check if the fan IPM termi- 1) Replace the outdoor unit outdoor DC fan...
  • Page 39 AY-XP12ZU1 Outdoor Malfunction Content of diagnosis unit No.* Problem indica- Check point Action symptom tion Main Main (LED1) Compressor error Compressor winding Indoor and 13-time Replace Compressor. short circuit outdoor units do not Compressor wind- operate. ing open etc. compressor Lock...
  • Page 40 AY-XP12ZU1 Outdoor Malfunction Content of diagnosis unit No.* Problem indica- Check point Action symptom tion Main Main (LED1) Indoor and Normal Indoor unit Indoor unit fan 1) Check the indoor fan mo- 1) Replace the indoor fan outdoor blinking or...
  • Page 41 AY-XP12ZU1 4.OTHER MALFUNCTION ERROR INDICATIONS / BUZZERS 4.1 LED lamp indications during malfunction Blinking LED Lamps *Any LED lamp keeping lit and is not blinking indicates normal operation and setting MALFUNCTION OPERATION TIMER WLAN PLASMACLUSTER Main error code and details...
  • Page 42 AY-XP12ZU1 Malfunction indications due to wiring error during installation. Inter-unit wiring error mode Symptoms The unit stops operation. Malfunction diagnosis displays nothing. (Remote control also displays nothing when malfunction code is called out.) Indoor Outdoor unit unit The unit stops operation.

  • Page 43: Chapter 5. Refrigeration Cycle [1] Schematic Diagram

    AY-XP12ZU1 CHAPTER 5. REFRIGERATION CYCLE [1] SCHEMATIC DIAGRAM Indoor unit Evaporator Flare coupling Flare coupling 3-way 2-way valve valve Heating Cooling Silencer Strainer Outdoor unit Accumulator Antifreeze pipe* Expansion Comp- valve ressor Coil Reverse valve Condenser [2] STANDARD CONDITION Indoor side Outdoor side Dry-bulb Temp.
  • Page 44 AY-XP12ZU1 AY-XP15ZU1 Model Cooling Heating Mode Max *1 Test Run *2 Max *1 Test Run *2 AC Current (A) 3-way valve pressure (MPaG) Outlet Air Temp. on (5) °F(℃ ) Temp. on (1) °F(℃ ) Temp. on (2) °F(℃ ) Temp.

  • Page 45: Performance Curves

    AY-XP12ZU1 [4] PERFORMANCE CURVES NOTE 1) Indoor fan speed: High 2) Indoor air temp.: Cooling 80°F 3) Power source: 230V, 60Hz AY-XP12ZU1 COOLING HEATING 1200 1100 1100 1000 1000 OUTSIDE TEMPERATURE（℉） OUTSIDE TEMPERATURE ( ℉ 14.0 18.0 15.0 13.0 12.0 12.0...
  • Page 46 AY-XP12ZU1 AY-XP12ZHU1 COOLING HEATING 1250 1150 1050 OUTSIDE TEMPERATURE（℉） OUTSIDE TEMPERATURE ( ℉ 20.0 14.5 17.0 13.5 14.0 12.5 11.0 11.5 10.5 OUTSIDE TEMPERATURE （℉） OUTSIDE TEMPERATURE ( ℉ 63.0 102.0 61.5 100.5 60.0 99.0 58.5 97.5 96.0 57.0 OUTSIDE TEMPERATURE （℉）...
  • Page 47 AY-XP12ZU1 AY-XP15ZU1 COOLING HEATING 1450 1250 1350 1150 1250 1050 1150 1050 OUTSIDE TEMPERATURE（℉） OUTSIDE TEMPERATURE ( ℉ 17.5 22.0 16.5 19.0 16.0 15.5 13.0 14.5 10.0 13.5 OUTSIDE TEMPERATURE （℉） OUTSIDE TEMPERATURE ( ℉ 104.0 60.0 102.5 58.5 101.0 57.0...
  • Page 48 AY-XP12ZU1 AY-XP18ZU1 COOLING HEATING 1600 1700 1450 1550 1300 1400 1150 1250 1000 1100 OUTSIDE TEMPERATURE（℉） OUTSIDE TEMPERATURE ( ℉ 22.0 28.0 20.5 24.0 19.0 20.0 17.5 16.0 12.0 16.0 OUTSIDE TEMPERATURE （℉） OUTSIDE TEMPERATURE ( ℉ 59.0 104.0 57.5 102.5...
  • Page 49 AY-XP12ZU1 AY-XP18ZHU1 COOLING HEATING 1700 1600 1550 1450 1400 1300 1250 1150 1100 1000 OUTSIDE TEMPERATURE（℉） OUTSIDE TEMPERATURE ( ℉ 22.0 28.0 24.0 20.5 20.0 19.0 16.0 17.5 12.0 16.0 OUTSIDE TEMPERATURE （℉） OUTSIDE TEMPERATURE ( ℉ 104.0 59.0 102.5 57.5...
  • Page 50 AY-XP12ZU1 AY-XP24ZU1 COOLING HEATING 2050 2500 1900 2300 1750 2100 1600 1900 1450 1700 OUTSIDE TEMPERATURE（℉） OUTSIDE TEMPERATURE ( ℉ 30.0 26.0 26.0 24.5 22.0 23.0 18.0 21.5 14.0 20.0 OUTSIDE TEMPERATURE （℉） OUTSIDE TEMPERATURE ( ℉ 57.0 108.0 55.5 106.5...

  • Page 51: Chapter 6. Disassembly Procedure

    After the air conditioner is repaired or parts are replaced, measure insulation resistance of the equipment using an insulation resistance meter. If the measured resistance is lower than 1MΩ, inspect parts and repair or replace defective parts. [1] INDOOR UNIT(For AY-XP12ZU1 model) 1. INDOOR UNIT 1) Push the handles up to remove Air filter .
  • Page 52 AY-XP12ZU1 Pull this side to release these hooks. 5) Remove Horizontal Louver. - Take the center Bearing out. Press below position to unfasten the hooks in side of Front Panel, then take the Front Panel out. - Take the left side Louver Bushing out.
  • Page 53 AY-XP12ZU1 9) Take off the Contorl Box Cover. 13) Release the hook of PCI Cover, take PLASMACLUSTER Unit out. Then remove the connecter. 14) Remove the screw of Louver Motor, then take the Motor out. 10) Cut the wire fixing band and remove all the connectors.
  • Page 54 AY-XP12ZU1 17) Remove 1 screw between Cross Flow Fan and Fan Motor. 20) Remove 2 screws fixing Side Cover L. 18) Hold and press the Cross Flow Fan to left side as much as possible, meanwhile, take Fan Motor out.
  • Page 55 AY-XP12ZU1 REPLACE WIRELESS ADAPTER Maintenance shall be made by service personnel full of knowl- edge about wireless LAN. Please contact SHARP for replacement. 1) Remove the Connector of Wireless adapter, and take it off from Control unit. Wireless adapter 2) Replace the Wireless adapter by S-B01 WLAN PWB UNIT.

  • Page 56: Indoor Unit(For Ay-Xp12Zu1 Model)

    AY-XP12ZU1 [2] INDOOR UNIT (For AY-XP15ZU1, AY-XP18ZU1, AY-XP24ZU1 models) 3) Remove a scerw fixing the Cord Holder, then take the Cord 1. INDOOR UNIT Holder out. 1) Push the handles up to remove Air filter . 2) Remove Open Panel as below step.
  • Page 57 AY-XP12ZU1 Pull this side to release these hooks. 5) Remove Horizontal Louver. - Take the center Bearing out. Press below position to unfasten the hooks in side of Front Panel, then take the Front Panel out. - Take the left side Louver Bushing out.
  • Page 58 AY-XP12ZU1 9) Take off the Contorl Box Cover. 13) Remove a screws of Side Cover R. 14) Remove 2 screws fixing Side Cover L. 10) Cut the wire fixing band and remove all the connectors. 15) Push the Pipe Holder to remove Pipe Holder.
  • Page 59 AY-XP12ZU1 17) Release 2 hooks of Stabilizer R, and take Stabilizer R Ass’y 20) Remove 2 screw fixing the Fan Motor Cover, then remove out. Release the hook of PCI Cover, take PLASMACLUSTER Fan Motor Cover. Unit out. Then remove the connecter.
  • Page 60 23) Take Corss Flow Fan out. REPLACE WIRELESS ADAPTER Maintenance shall be made by service personnel full of knowl- edge about wireless LAN. Please contact SHARP for replacement. 1) Remove the Connector of Wireless adapter, and take it off from Control unit. Wireless adapter 2) Replace the Wireless adapter by S-B01 WLAN PWB UNIT.

  • Page 61: Indoor Unit(For Ay-Xp15Zu1, Ay-Xp18Zu1, Ay-Xp24Zu1 Models)

    AY-XP12ZU1 [3] INDOOR UNIT (For AY-XP12ZHU1, AY-XP18ZHU1 models) 1. INDOOR UNIT 3) Remove a scerw fixing the Cord Holder, then take the Cord Holder out. 1) Push the handles up to remove Air filter . 2) Remove Open Panel as below step.
  • Page 62 AY-XP12ZU1 Pull this side to release these hooks. 5) Remove Horizontal Louver. - Take the center Bearing out. Press below position to unfasten the hooks in side of Front Panel, then take the Front Panel out. - Take the left side Louver Bushing out.
  • Page 63 AY-XP12ZU1 9) Take off the Contorl Box Cover. 13) Remove PCI UNIT. - Press the hook to rotate the PCI LOCK - Slide the PCI cover to right side, then lift it to take it out 10) Cut the wire fixing band and remove all the connectors.
  • Page 64 AY-XP12ZU1 Remove Center LED UNIT. 14) Remove the screw of Louver Motor, then take the Motor out. - Release the hook of Stabilizer R Ass’Y, rolate Stabilizer R Ass’Y out. 15) Release Arm Auto/Manual from Louver Link R. - Release a hook, take out the LED CASE, then take the center LED CASE out.
  • Page 65 AY-XP12ZU1 18) Remove 2 screw fixing the Fan Motor Cover, then remove 22) Remove 2 screws fixing Side Cover L. Fan Motor Cover. 19) Remove 1 screw between Cross Flow Fan and Fan Motor. 23) Push the Pipe Holder to remove Pipe Holder.
  • Page 66 AY-XP12ZU1 REPLACE WIRELESS ADAPTER Maintenance shall be made by service personnel full of knowl- edge about wireless LAN. Please contact SHARP for replacement. 1) Remove the Connector of Wireless adapter, and take it off from Control unit. Wireless adapter 2) Replace the Wireless adapter by S-B01 WLAN PWB UNIT.

  • Page 67: Outdoor Unit(12K/15K Btu/H Models)

    AY-XP12ZU1 [4] OUTDOOR UNIT (12K/15K Btu/h models) 1) Remove the screw fixing the Cover, then take the cover out. Valve Cover 2) Remove the screw fixing Terminal Cover 5) Remove six screws fixing the Front Panel, and Cord Clamp, then take them out.
  • Page 68 AY-XP12ZU1 6) Cut the Wire Fixing Band. Remove two terminals from the Reator and all connectors on the Control Board Unit, and remove compressor conector. 10) Disconnect three terminals on the Compressor. 7) Remove four screws fixing the Control Box, then take it out.
  • Page 69 AY-XP12ZU1 13) Unscrew the nut, take out the Propeller 3) Lift up to remove the metal cover. Fan carefully. 4) Remove the screw fixing the earth wire. 14) Remove all screws, take out the Motor. 5) Move out the Heat Sink Holder.

  • Page 70: Outdoor Unit(18K/24K Btu/H Models)

    AY-XP12ZU1 [5] OUTDOOR UNIT (18K/24K Btu/h models) Be sure to disconnect the power cord from the AC power outlet before starting the disassembly procedure. When reassembling the unit after repair- ing, be sure to install screws to their original positions.
  • Page 71 AY-XP12ZU1 AE-X15TU 9) Unscrew the 2 screws fixing the angle and remove it. 5) Unscrew the 2 screws fixing the cable holdor and remove it Angle 6) Unscrew the 6 screws fixing the top plate and remove it. 10) Unscrew the 4 screws fixing the front panel and remove it.
  • Page 72 AY-XP12ZU1 AE-X15TU 17)Unscrew the 2 screws fixing the bu khead and remove it. 13).Cut 1pcs Fixing Band. Unscrew the 3 screws fixing control unit and remove it. Contol unit Bulkhead 14)Remove the 2 compressor covers. 18)Unscrew the 2 screws fixing the motor angle and remove it.
  • Page 73 AY-XP12ZU1 AE-X15TU 1. Control unit box’s Approach to decomposition 5) Remove 2 screws and the 3 metal covers. 1) Unscrew the 3 screws and remove the terminal board. Metal cover 2) Unscrew the 2 screws fixing the terminal angle and remove it.
  • Page 74 AY-XP12ZU1 Failure diagnosis flowchart Table of contents Contents Error code Short circuit of ODU thermistor Overheat error (Compressor or cycle) Open circuit of ODU thermistor DC current error AC current error Cycle error EEPROM mutual memory Error ODU fan motor error...
  • Page 75 AY-XP12ZU1 ·The lead wire sheath of the ODU thermistor has been damaged due to edge or long-time 　 friction by vibration, and the wire toches the pipe, etc. Check if the resistance of each ODU thermistor is correct as shown in graph below.

  • Page 76: Overheat Error (Compressor Or Cycle)

    AY-XP12ZU1 2-0 Compressor high temperature error Error Code 2-1 Compressor discharge overheat Overheat error (Compressor or cycle) 2-2 Outdoor unit overheat 2-3 Indoor unit overheat 2-5 IPM high temperature error Check the failure of compressor Main cause ·Temperature of compressor or cycle parts becomes too high.
  • Page 77 AY-XP12ZU1 · The lead wire of ODU thermistor has broken due to the edge or vibration. · The attachment of connector has broken by inside tension due to unsuitable wiring process. Check if ODU thermistors are firmly installed and connected with ODU PWB properly.

  • Page 78: Dc Current Error

    AY-XP12ZU1 6-0 DC current error 6-1 DC current error 1 6-2 DC current error 2 6-3 DC current error 3...
  • Page 79 AY-XP12ZU1 Check if the power supply voltage during comperessor operating is within rated voltage ±10%. Correct the cable between IDU and ODU , or connect air conditioner to stable power source. Check if the air filter and heat exchanger of IDU has been blocked by dust etc, or the ODU air outlet has been blocked.

  • Page 80: Cycle Error

    AY-XP12ZU1 cycle temperature error * This error is judged by the temperature of thermistor. Check if all ODU thermistor are at the correct position. resistance Connect air conditioner to stable power source. Please see Appendix ① (ODU thermister R-T) Check if the resistance of each ODU thermistor is correct.
  • Page 81 AY-XP12ZU1 cycle temperature error Check if the temperature of ODU heat exchanger pipe and 2-way valve changes properly. (Refer to below method.) In cooling mode: Whether the ODU heat exchanger pipe has higher temperature and the 2-way valve pipe has lower one.
  • Page 82 AY-XP12ZU1 cycle temperature error Measure if the pressure of refrigerant is proper by gauge manifold for checking the refrigerant volume.

  • Page 83: Eeprom Mutual Memory Error

    AY-XP12ZU1 EEPROM mutual memory Error Identify whether the cause is outdoor unit data error or indoor unit data error. Rewrite the outdoor EEPROM data. Does the error improve? Rewrite the indoor EEPROM data. Complete Since this failure is an abnormality of the EEPROM data and not a failure of the board,...

  • Page 84: Odu Fan Motor Error

    AY-XP12ZU1 11-1 DC fan driver IC error Error Code 11-2 DC fan lock error ODU fan motor error 11-3 Detection error of negative rotation before compressor start 11-4 Detection error of inverter current 11-5 open connector error Check the cause due to PWB or DC fan motor.
  • Page 85 AY-XP12ZU1 Error Code 13-0 compressor motor short error 13-1 compressor motor open or PWB short error 13-2 compressor motor lock error Main Cause Compressor motor winding has abnormality. (Short or open) PWB has abnormality. (IPM Shunt resistor is short) Air conditioner operation stopped...

  • Page 86: Ac Voltage Error

    AY-XP12ZU1 AC voltage error 14-2 Abnormal AC power supply voltage or DC low voltage error Check if the AC power supply voltage is within rated voltage±10%. Connect air conditioner to power supply with proper voltage. Check if the power supply is fluctuant or has momentary power failure.

  • Page 87: Serial Open Circuit Error

    AY-XP12ZU1 Error Code Serial open error Serial open error Determine why serial communication is not possible. Defective PWB of IDU Serial circuit failure, power supply circuit operation failure, etc. Defective PWB of ODU Serial circuit failure, power supply circuit operation failure, etc.
  • Page 88 AY-XP12ZU1 Error Code Serial open error Serial open error Determine why serial communication is not possible. Defective PWB of IDU Serial circuit failure, power supply circuit operation failure, etc. Defective PWB of ODU Serial circuit failure, power supply circuit operation failure, etc.

  • Page 89: Serial Short Circuit Error

    AY-XP12ZU1 Error Code Serial short error Serial　short Incorrect wiring Determine if the units connecting cable is incorrectly inserted or the control board is defective. Main causes of serial shorts ・ Incorrect insertion of units connecting cable ・ Indoor unit serial circuit failure ・...
  • Page 90 AY-XP12ZU1 Please see Appendix ⑤ to confirm AC FAN or DC FAN Check if fan motor connector (CN8) on IDU PWB is connected properly. Connect the CN8 correctly. Check if the IDU fan could physically rotates smoothly by turning it with finger.

  • Page 91: Eeprom Mutual Memory Error

    AY-XP12ZU1 EEPROM mutual memory Error 20-4 Identify whether the cause is outdoor unit data error or indoor unit data error. 20-4 Rewrite the indoor EEPROM data. Does the error improve? Rewrite the outdoor EEPROM data. Complete Since this failure is an abnormality of the EEPROM data and not a failure of the board,...

  • Page 92: Ac Clock Error

    AY-XP12ZU1 AC Clock Error 25-1 25-1 Replace the IDU main PCB.
  • Page 93 AY-XP12ZU1 Please see Appendix ④ (IDU thermister ) Check if the room temperature thermistor is firmly installed and connected with IDU PWB properly. Correct the installation of the thermistor and the connector on IDU PWB. Check if the lead wire of the room temperature thermistor is broken or the sheath of it is damaged leading to short circuit.
  • Page 94 AY-XP12ZU1 Please see Appendix ④ (IDU thermister ) Check if the pipe temperature thermistor is firmly installed and connected with IDU PWB properly. Correct the installation of the thermistor and the connector on IDU PWB. Check if the lead wire of the pipe temperature thermistor is broken or the sheath of it is damaged leading to short circuit.
  • Page 95 AY-XP12ZU1 APPENDIX ① ODU thermister 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 Outdoor temp. thermistor 5 - 6 Green Suction temp.

  • Page 96: Compressor Check

    AY-XP12ZU1 APPENDIX Compressor check ③ IDU thermistor ④ To measure the resistance, first remove the connector from the board. BCN7 100K Room temperature thermistor TH1 20ºC resistance 1 2.65 Ω Heat exchange temperature thermistor TH2 (Orange) 25ºC resistance 15 k Ω...

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