Sharp AY-XP24PU, Service Manual

Page 1: ...T AND OPERATION 1 BLOCK DIAGRAMS 2 1 2 MICROCOMPUTER CONTROL SYSTEM 2 2 3 FUNCTION 2 3 4 OPERATION MANUAL 2 6 CHAPTER 3 TROUBLE SHOOTING GUIDE 1 SELF DIAGNOSIS FUNCTION 3 1 2 THERMISTOR TEMPERATURE CHAR ACTERISTICS 3 8 3 8 3 9 CHAPTER 4 DISASSEMBLING PROCEDURE 1 INDOOR UNIT INDOOR UNIT 4 1 CHAPTER 5 INSTALLATION INSTRUCTION 1 5 1 2 5 4 Parts Guide TopPage CONTENTS SPLIT TYPE AIR CONDITIONER INDOOR...

Page 2: ...ed part O D Φ0 63 16 Rated frequency Reted voltage 27 Net weight 208 230 60 60 CRMC A868JBEZ 1060 750 620 1130 800 650 Cross flow fan Φ118 254 7 2 9 8 250 28 7 13 CMOT A561JBKZ 8poles 40W 503 14 3 Air flow quantity Heating Fan speed Cooling ITEMS Phase INDOOR MODEL AY XPC15PU Single Single 38 0 965 12 3 313 44 Cluster generator Rmote controller Refrigerant system Sound Presure Level Cooling Sound ...

Page 3: ... R l e d o M e m a N t r a P Fan motor Louver motor 1 u F DC motor CMOT A561JBKZ SHA 37CVJ F440 1 DC12V RMOT A223JBZZ 24BYJ48 1373 V 0 5 2 A 5 1 3 Z Z B J 8 7 0 A G S F Q 3 ELECTRICAL PARTS 4 WIRING DIAGRM FAN MOTOR DISPLAY BOARDUNIT MAINCONTROLBOARDUNIT 1 2 3 4 5 6 THERMISTOR PIPETEMP THERMISTOR ROOMTEMP THERMISTOR VALVETEMP ORANGE YELLOW BLACK ...

Page 4: ...TEMP THERMISTOR ROOMTEMP THERMISTOR VALVETEMP ORANGE YELLOW BLACK s k r a m e R l e d o M e m a N t r a P Fan motor Louver motor 1 u F DC motor CMOT A561JBKZ SHA 37CVJ F440 1 DC12V RMOT A223JBZZ 24BYJ48 1373 V 0 5 2 A 5 1 3 Z Z B J 8 7 0 A G S F Q 1 3 3 ELECTRICAL PARTS 4 WIRING DIAGRM AY XPC15PU ...

Page 5: ...2 1 AHXPC12LV 6HUYLFH 0DQXDO CHAPTER 2 EXPLAMATION OF CIRCUIT AND OPERATION 1 BLOCK DIAGRAMS AY XPC15PU ...

Page 6: ...1 8 9 9 9 5 N 5 N 5 N S 9 9 S 9 X 9 X 9 X 3 5 N 9 9 5 N 5 5 9 X N 5 5 9 X 5 9 X 9 X 0 5 0 5 17 15 9 6 9 X 9 X 5 N 75 3 33 02725 289 5 N 5 N 5 5 872 2 8 32 5 5 N 9 X 9 X 9 X 1 6 1 1 P 8 5 2 5 1 52 1 9 X 9 9 X 5 N 287 1 3 3 722 5 6 7 3 7 3 3 5 966 966 9 9 3 173 57 3 7 72 3 7 72 3 5 3 5 3 5 3 5 173 3 5 173 3 5 173 3 5 173 3 7 72 173 3 3 3 173 3 173 3 3 3 3 3 7 72 3 7 72 173 3 62 7 3 6 5 3 6 3 1 3 1 3...

Page 7: ...d by pressing the ON timer button When the ON timer is activated the operation start time is adjusted based on fuzzy logic calculations 1 hour before the set time so that the room temperature reaches the set temperature at the set time AY XPC15PU 4 OFF Timer Sleep Operation The OFF timer can be activated by pressing the OFF timer button When the OFF timer is set the operation stops after the set t...

Page 8: ... automatically determined based on the outside air temperature In addition the air conditioner operation differs from the operation in the Manual mode as explained below 11 Full Power Operation Temperature setting method Auto mode Cooling Heating Heating Automatic temperature setting based on outside air temperature Can be changed within 2 using remote control Dehumidifying Manual mode Cooling Can...

Page 9: ...tion Temperature setting Fan setting Air flow direction Power ON OFF Automatic operation mode setting Swing louvre Plasmacluster mode 14 2 Setting not memorized Timer setting Powerful Jet setting Internal cleaning 14 3 Disabling auto restart function By removing cutting jumper JP on the printed circuit board PCB the auto restart function can be disabled 15 Explanation of cluster circuit The cluste...

Page 10: ...N OFF NOTE TIPS ABOUT AUTO MODE n e AUTO mode e unit will automatically select COOL or HEAT mode by comparing e room temperature and your desired temperature e unit will automatically switc between HEAT and COOL mode to keep e desired temperature COANDA and MULTI SPACE button will be inactivated during AUTO mode VERTICAL AIR FLOW DIRECTION 1 Press the SWING button e vertical louver will swing 2 Pr...

Page 11: ...et obliquely upward to de liver cool air to the ceiling in order to avoid direct 1 During operation press the COAN DA AIFLOW button HEAT mode The remote control will display COOL DRY mode The remote control will display TO CANCEL Press the COANDA AIFLOW button again NOTE If you want COANDA AIRFLOW operation in FULL POWER mode press COANDA AIR FLOW button during FULL POWER operation The COANDA AIRF...

Page 12: ...d AUTO op eration press the SILENT button The speed icon on the remote control will display SILENT TO CANCEL Press the SILENT button again 1 FULL POWER OPERATION SILENT OPERATION 1 When the 1 2 3 5h OFF TIMER is set the unit will automatically turn off after the set ting hours 1Press the 1 2 3 5h OFF TIMER but ton to set the desired time The orange TIMER lamp will light up The remaining time will ...

Page 13: ... set the desired time The time can be set in 10 minute incre ments 3Press the SET C button The orange TIMER lamp will light up 4Select the mode temperature and fan speed as desired Press below buttons to select mode HEAT COOL AUTO DRY Press the TEMPERATURE button or to set the desired temperature Press the FAN button to set the desired fan speed CANCEL TO CHANGE TIME SETTING Cancel the TIMER setti...

Page 14: ... eliminated by this operation SELF CLEAN OPERATION 1 Press the DISPLAY button when the lamps on the unit are too bright The green OP ERATION lamp and the orange TIMER lamp cannot be turned off 1During operation press the DIS PLAY button The blue PLASMACLUSTER lamp 5 F 15 C AUTO OFF lamp and or the green FULL POWER lamp will turn off TO LIGHT UP Press the DISPLAY button again DISPLAY BUTTON 1 Use t...

Page 15: ...esult of self diagnosis you shall combine it with outdoor unit indication in order to get a correct conclusion LED1 Ma f o Normal condition Normal blinking O O O O O Timer Orange 0 0 Normal Operation Green Plasmacluster Blue Indoor and outdoor units do not oper ate 1 time O O O O O Timer Orange 1 0 Outdoor unit thermistor short circuit Heat exchanger thermistor short circuit error 1 Measure the re...

Page 16: ...units do not operate O O O O O O O O O O O O Timer Orange 5 IPM high temperature error Replace the outdoor unit control PCB assembly O Operation Green O O Plasmacluster Blue Plasmacluster Blue AY XPC15PU _ Q Q Q Indoor unit operates Outdoor unit does not operate temporarily 3 time Timer Orange tion Temporary stop due to dehumidi fying operation Temporary stop for cycle protection Operation Green 3...

Page 17: ... Stop valve pipe expansion valve O O O Operation Green O O Plasmacluster Blue Indoor and outdoor units do not operate 8 time O O O O O Timer Orange 8 0 0 Abnormal wire check Abnormal wire check error 1 Check the expansion valve 2 Are four expansion valves connected by mistake 3 Check the wiring between units 1 Replace the outdoor control board assembly 2 Reattach 3 Check the wiring between units O...

Page 18: ...ntrol PWB assembly O O O Operation Green O Plasmacluster Blue O O O O O Timer Orange 5 Outdoor unit DC fan open connector error 1 Check connector CN3 of the outdoor unit DC fan motor for secure installation 2 No abnormality found in above inspection 1 1 Correct the installa tion 2 Replace the outdoor unit control PWB assembly O O O Operation Green O O Plasmacluster Blue Indoor and outdoor units do...

Page 19: ... unit control PCB 1 Connect stable power supply Correct the wiring 2 Replace the outdoor unit control PWB assembly 3 Replace the fuse outdoor unit control PWB assembly 4 Replace the outdoor unit control PWB assembly 5 Replace the outdoor unit fan motor 6 Replace the outdoor unit control PWB O O Operation Green Plasmacluster Blue Indoor unit operates Outdoor unit does not operate Lighting or OFF O ...

Page 20: ...hermistor 1 Check connector of thermistor for secure installation 1 Replace the ther mistor 2 Check the tempera ture properties of the thermistor 2 Replace the ther mistor Problem symptom Outdoor unit indi cation LED1 Indoor unit Malfunc tion No Content of diagnosis Check point Action Lamp Main Sub Main Sub o Remark The malfunction No is calculated using the following way Example Indoor unit lamp ...

Page 21: ...s securely Modify or replace termistor Are stop valves liquid and gas close Does compressor rotate Check IPM lead wire Check short circuit Check compressor terminal Does compressor rotate Does compressor rotate more than 30 seconds Is IPM PWB floating from the heat sink Check the AC power supply voltage when compressor rotate rated voltage 10 Cooling mode Check indoor heat exchanger termistor and ...

Page 22: ...ature is low Cooling mode is acti vated in most cases Heating mode is activated even if room temperature is high Heating mode is always activated Cooling Frequency control Room becomes too cold Air conditioner oper ates in full power even when set tem perature is reached Room does not become cool Compressor does not operate Dehumidifying Room temperature memory Frequency control Normal operation R...

Page 23: ...urn off light and check Signal should be received when light is turned off Change light position or install new fluorescent lamp Use Sevick light Hitachi Check if Sevick light Hitachi is used Signal may not be received sometimes due to effect of Sevick light Replace light or change position Operating position angle is inap propriate Operate within range specified in manual Signal should be receive...

Page 24: ...1 MΩ inspect parts and repair or replace defective parts 1 INDOOR UNIT 1 Open the open panel to the horizontal position and remove with pulling it forward 2 Remove the 2 air filters 3 Unscrew the screw fixing cable cover and remove it Cable cover 4 Unscrew the 2 screws and remove the cable holder Cable holder 5 Remove the connecting cable and power supply cable from termi nal board 6 Remove the gr...

Page 25: ...move it Front cover Control box side cover 9 Unscrew the screw fixing the front panel R and remove it Front panel R Front panel R Remove the front panel R with pushing the 2 hooks 1 2 15 Cut the 2 fixing bands and disconnect the connectors from the con trol board unit Connectors Fixing bands 14 Release the hook of the control box top cover and slide it up to remove Control box top cover ...

Page 26: ...acket ertical louvre 21 Release the hook of the motor cover from cabinet 1 Remove the control box b releasing the upper hook and pulling out ook 22 ake out the motor and cross flow fan 23 Unscrew the screw of the cross flow fan and remove it otor and cross flow fan 24 Remove the pipe holder Push the hook of the pipe holder and remove it b pulling lower part ook of the pipe holder pull e d i s k c ...

Page 27: ...the wire guard to right and remove it ertical louvre 5 Remove the 2 screw covers nsert a flat t pe screw driver to hole of screw cover Unscrew 2 screws lide Plasmacluster cover to the back Replace the Plasmacluster unit isconnect the connector and replace Plasmacluster unit Plasmacluster cover Plasmacluster unit Connector pen panel ...

Page 28: ... 5 Keep TV set radio and other similar appliances at least 1 m or more away from the unit and the remote control 6 Keep the air inlet clear of obstacles that could block incoming air 7 The remote control may not function properly in a room equipped lighting 8 Select a location that does not cause loud operation noise and extreme vibrations Tighten the nut with a torque wrench according to the meth...

Page 29: ... double insulated copper wire with 600 V insulation Use copper conductors only Follow local electrical codes 1 Process the end of the connecting cable for the indoor side 2 T f 3 T ff the Connection Holder from the Wire Conduit and attach the Con r 5 Attach the Cable Holder and Connection Holder to Cabinet with screw _ to ATTACH THE CABLE HOLDER AND CONNECTION HOLDER Fig 3 and Fig 4 6 7 Open the O...

Page 30: ...oor unit 4 Push the unit and apply the bottom hooks to the mounting plate s support 5 in place For left side piping 1 Reverse the positions of the drain hose and drain cap Refer to Exchange the drain hose 2 Connect the pipes and wrap tape around the insulation of the piping joints tightly not to become thick 3 Pass the pipes connecting cable and the drain hose through the piping hole 4 Hook the un...

Page 31: ...on use polyethylene foam 6 mm or thicker Flare nut Wrench Torque wrench AUX 7 TEST RUN 1 Start the operation with the remote control 2 To start test run in cooling hold down the AUX button on the unit for over 5 seconds until a beep sound is heard and an operation 3 Make sure the system runs well To stop the operation press the AUX button again 8 ITEMS TO CHECK Is the earth wire connected properly...

Page 32: ...hout notice AY XPC15PU AY XPC15PU AY XPC18PU AY XP24PU HOW TO ORDER REPLACEMEN Parts of AY XPC18PU and AY XP24PU are still under revision may change for reliability improvement New edition of this manual will be issued after revision is completed T PARTS To have your order filled promptly and correctly please furnish the following information 1 MODEL NUMBER 2 REF NO 3 PART NO 4 DESCRIPTION PartsGu...

Page 33: ...AY XPC15PU 2 1 INDOOR UNIT PARTS ...

Page 34: ...FA AC N SCREW COVER 5 3 3 QW VZG595JBZZ AK LEAD WIRE 5 3 4 LHLD B211JBFA AG N HOLDER 5 3 5 LHLD B212JBFA AG N COVER 5 4 DCOV A390JBKZ AV N FRONT PANEL ASS Y 5 5 DSRA A403JBKZ BC N DRAIN PAN SUB ASS Y 5 6 GGAD A076JBTA AT N WIRE GUARD 5 7 MARMPA078JBFA AD N ARM 5 8 MJNTPA191JBFA AE N LOUVER LINK 5 9 MLOV A574JBFA AQ N HORAIZONTAL LOUVER 5 10 MLOV A562JBFA AE VERTICAL LOUVER 5 11 NBRG A026JBFA AB LO...

Page 35: ...N INSTALLATION MANUAL 1 6 TINSEA760JBRZ AF N OPERATION MANUAL 1 7 UBATUA027JBE0 AE BATTERY PACK 2 ACCESSORY PARTS NO PARTS CODE PRICE RANK NEW MARK PART RANK DESCRIPTION 2 1 SPADBA579JBEZ AP PACKING PAD L 2 2 SPADBA580JBEZ AP PACKING PAD R 2 3 SPAKCE212JBEZ AS PACKING CASE 2 4 TLABMB224JBRZ AE N PRODUCT LABEL AY XPC15PU 2 4 TLABMB225JBRZ AE N PRODUCT LABEL AY XPC18PU 2 4 TLABMB301JBRZ AE N PRODUCT...