AYXP7FR
SERVICE MANUAL
S6512AYXP7FR/T
SPLIT TYPE
ROOM AIR CONDITIONER
INDOOR UNIT
OUTDOOR UNIT
MODELS
AY-XP7FR AE-X7FR
AY-XP9FR AE-X9FR
AY-XP12FR AE-X12FR
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
CHAPTER 1. SPECIFICATION
[5] GENERAL TROUBLESHOOTING CHAR...T.....3-6
[1] SPECIFICATION........................................... 1-1
[2] EXTERNAL DIMENSION.............................. 1-4
[3] WIRING DIAGRM ......................................... 1-5
[4] ELECTRICAL PARTS ................................... 1-6
[6] MALFUNCTION (PARTS) CHECK METH-
OD .................................................................3-8
[7] OUTDOOR UNIT CHECK METHOD...........3-10
[8] TROUBLESHOOTING GUIDE....................3-13
CHAPTER 2. EXPLAMATION OF CIRCUIT AND OP-
ERATION
[1] BLOCK DIAGRAMS...................................... 2-1
[2] MICROCOMPUTER CONTROL SYSTE..M...... 2-3
[3] FUNCTION.................................................... 2-8
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 3. FUNCTION AND OPERATION OF PRO-
TECTIVE PROCEDURES
CHAPTER 5. DISASSEMBLING PROCEDURE
[1] DISASSEMBLY OF INDOOR UNIT...............5-1
[2] DISASSEMBLY OF OUTDOOR UNIT...........5-7
[1] PROTECTION DEVICE FUNCTIONS AND
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
REPLACEMENT PARTS LIST
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.
SHARP CORPORATION
AYXP7FR
2. AY-XP9FR – AE-X9FR
MODEL
INDOOR UNIT
AY-XP9FR
OUTDOOR UNIT
AE-X9FR
ITEMS
Cooling capacity(Min. > Max.) kW
Heating capacity(Min. > Max.) kW
2.64 (0.9 - 3.0)
3.1 (0.9 - 4.8)
Moisture removal(at cooling)
Electrical data
Phase
Liters/h
Single
Rated frequency
Rated voltage
Hz
V
50
230
Rated current ✩
(Min - Max.)
Cool
A
3.7 (1.0 - 4.8)
3.5 (0.9 - 6.1)
780 (200 - 960)
730 (160 - 1400)
92
Heat
A
Rated input ✩
(Min - Max.)
Cool
W
W
%
%
Heat
Power factor ✩
Cool
Heat
91
Compressor
Type
Hermetically sealed rotary type
DA89X1F-23F
Model
Oil charge
370cc (VG74)
Refrigerant system Evaporator
Louver Fin and Grooved tube type
Corrugate Fin and Grooved tube type
Expansion valve
Condenser
Control
Refrigerant (R410A) 830g
De-lce system Micro computer controled reversed systems
Noise level
(at cooling)
High
Low
Soft
dB(A)
39
–
45
–
dB(A)
dB(A)
28
–
Fan system
Drive
Direct drive
Air flow quantity
(at cooling)
High
Low
Soft
m3/min. 8.6
m3/min. 7.3
m3/min. 5.5
23.3
–
–
Fan
Cross flow fan
Propeller fan
Connections
Refrigerant coupling
Refrigerant tube size Gas, Liquid
Drain piping mm
Others
Flare type
3/8", 1/4"
O.D φ18
Safety device
Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Polypropylene net (Washable)
Air filters
Net dimensions
Width
Height
Depth
mm
mm
mm
kg
790
278
198
10
730
540
250
33
Net weight
1 – 2
AYXP7FR
3. AY-XP12FR – AE-X12FR
MODEL
INDOOR UNIT
AY-XP12FR
OUTDOOR UNIT
AE-X12FR
ITEMS
Cooling capacity(Min. > Max.) kW
Heating capacity(Min. > Max.) kW
3.5 (0.9 - 3.8)
4.0 (0.9 - 6.0)
Moisture removal(at cooling)
Electrical data
Phase
Liters/h
Single
Rated frequency
Rated voltage
Hz
V
50
230
Rated current ✩
(Min - Max.)
Cool
A
5.0 (1.1 - 8.2)
4.8 (1.0 - 8.0)
1090 (210 - 1300)
1030 (180 - 1900)
95
Heat
A
Rated input ✩
(Min - Max.)
Cool
W
W
%
%
Heat
Power factor ✩
Cool
Heat
93
Compressor
Type
Hermetically sealed rotary type
5RS102XBE01
Model
Oil charge
320cc (RB68A or Freol Alpha 68M)
Louver Fin and Grooved tube type
Corrugate Fin and Grooved tube type
Expansion valve
Refrigerant system Evaporator
Condenser
Control
Refrigerant (R410A) 1030g
De-lce system Micro computer controled reversed systems
Noise level
(at cooling)
High
Low
Soft
dB(A)
40
–
48
–
dB(A)
dB(A)
28
–
Fan system
Drive
Direct drive
Air flow quantity
(at cooling)
High
Low
Soft
m3/min. 9.8
m3/min. 8.5
m3/min. 6.9
26.7
–
–
Fan
Cross flow fan
Propeller fan
Connections
Refrigerant coupling
Refrigerant tube size Gas, Liquid
Drain piping mm
Others
Flare type
3/8", 1/4"
O.D φ18
Safety device
Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Polypropylene net (Washable)
Air filters
Net dimensions
Width
Height
Depth
mm
mm
mm
kg
790
278
198
10
730
540
250
37
Net weight
NOTE: The condition of star”✩” marked item are ‘ISO5151’ : 1994(E), contition T1.
1 – 3
AYXP7FR
[2] EXTERNAL DIMENSION
1. Indoor unit
790
198
18.5
58
INVERTER AIR CONDITIONER
22.0
2. Outdoor unit
515
135
72
12
37.5
4.5
58
14
250
730
165
167.5
1 – 4
AYXP7FR
[3] WIRING DIAGRM
1. Indooa unit
2. Outdooa unit
2.1. AE-X7FR / AE-X9FR
420V 420V
750μF 750μF
2.2. AE-X12FR
1 – 5
AYXP7FR
[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
'TTQTꢀOCKPꢀECVGIQT[
'TTQTꢀUWDꢁECVGIQT[
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
1 sec 1 sec 0.6 sec 1 sec 0.6 sec 1 sec 1 sec 1 sec 0.6 sec 1 sec 0.6 sec 1 sec 1 sec
ON
OFF
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 Indication
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis
Inspection location/method
Remedy
indoor/
outdoor
units
by LED1
on out-
door unit
*2
Main Sub- Main category
cate- cate-
Sub-category
gory gory
Indoor/
outdoor
units in
Nor-
mal
flash-
ing
0
0
Normal
–
–
operation
Indoor/
outdoor
units in
complete
shutdown
1 time
1
-0
-1
Outdoor unit
thermistor
short-circuit
Heat exchanger
thermistor short-cir-
cuit error
(1) Measure resistance of the (1) Replace the outdoor
outdoor unit thermistors.
(TH2 to TH5: Approx. 4.4
kΩ at 25°C)
unit thermistor assem-
bly.
Outside tempera-
ture thermistor
short-circuit error
(2) Check the lead wire of the (2) Replace the outdoor
outdoor unit thermistor for
torn sheath and short-cir-
cuit.
unit thermistor assem-
bly.
-2
-3
Suction thermistor
short-circuit error
2-way valve ther-
mistor short-circuit
error
(3) No abnormality found in
above inspections (1) and
(2).
(3) Replace the outdoor
unit control PWB
assembly.
3 – 13
AYXP7FR
Status of Indication
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis
Inspection location/method
Remedy
indoor/
outdoor
units
by LED1
on out-
door unit
*2
Main Sub- Main category
cate- cate-
Sub-category
gory gory
Indoor/
2 times
2
-0
Cycle tempera- Compressor high-
(1) Check the outdoor unit air (1) Ensure unobstructed
outdoor
units in
ture
temperature error
outlet for blockage.
air flow from the out-
door unit air outlet.
complete
shutdown
(2) Check if the power supply (2) Connect power sup-
voltage is 90 V or higher at
full power.
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 (4) Replace the outdoor
outdoor unit compressor
thermistor.
unit compressor ther-
mistor assembly.
(TH1: Approx. 53 kΩ at
25°C)
(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
-1
-2
Temporary stop due (Temporary stop for cycle pro-
–
to compressor dis-
charge overheat *3
tection)
operation
Outdoor
unit in
tempo-
rary stop
Temporary stop due (Temporary stop for cycle pro-
–
–
to outdoor unit heat
exchanger overheat
*3
tection)
-3
Temporary stop due (Temporary stop for cycle pro-
to outdoor unit heat
exchanger overheat
*3
tection)
-4
-0
Temporary stop due (Temporary stop for cycle pro-
–
–
to 2-way valve
freeze *3
tection)
Indoor
unit in
3 times
5 times
3
5
Dry operation
Temporary stop due (Temporary stop for cycle pro-
to dehumidifying
operation *3
tection)
operation
Outdoor
unit in
tempo-
rary stop
Indoor/
outdoor
units in
complete
shutdown
-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
-2
Outside tempera-
ture thermistor
open-circuit error
Suction thermistor
open-circuit error
(2) Measure resistance of out- (2) Replace the outdoor
door thermistors TH1 to
TH5.
unit thermistor assem-
bly.
(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
-4
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.
Discharge ther-
mistor open-circuit
error
3 – 14
AYXP7FR
Status of Indication
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis
Inspection location/method
Remedy
indoor/
outdoor
units
by LED1
on out-
door unit
*2
Main Sub- Main category
cate- cate-
Sub-category
gory gory
Indoor/
outdoor
units in
6 times
6
-0
Outdoor unit DC DC overcurrent error (1) IPM continuity check
(1) Replace the outdoor
unit control PWB
assembly.
complete
shutdown
(2) Check the IPM and heat
sink for secure installation.
(2) Correct the installa-
tion (tighten the
screws).
(3) Check the outdoor unit fan (3) Replace the outdoor
motor for proper rotation.
(4) No abnormality found in
above inspections (1)
through (3).
unit fan motor.
(4) Replace the outdoor
unit control PWB
assembly.
(5) No abnormality found in
above inspections (1)
through (4).
(5) Replace the compres-
sor.
-1
-0
IPM pin level error
Check the IPM is attached
correctly to the outdoor
unit control PWB.
Replace the outdoor
unit control PWB
assembly.
Indoor/
7 times
7
Outdoor unit AC AC overcurrent error (1) Check the outdoor unit air (1) Ensure unobstructed
outdoor
units in
outlet for blockage.
air flow from the out-
door unit air outlet.
complete
shutdown
(2) Check the outdoor unit fan (2) Check the outdoor unit
for proper rotation.
AC overcurrent error (1) IPM continuity check
in OFF status
fan motor.
-1
-2
(1) Replace the outdoor
unit control PWB
assembly.
AC maximum cur-
rent error
(1) Check the outdoor unit air (1) Ensure unobstructed
outlet for blockage.
air flow from the out-
door unit air outlet.
(2) Check the outdoor unit fan (1) Check the outdoor unit
for proper rotation. fan motor.
(1) Check if there is an open- (1) Replace the outdoor
-3
-0
-3
AC current defi-
ciency error
circuit in the secondary
winding of the current
transformer of the outdoor
unit control PWB.
unit control PWB
assembly.
(2) Check if the refrigerant
volume is abnormally low.
(3) Check if the refrigerant
flows properly.
(2) Charge the specified
amount of refrigerant.
(3) Correct refrigerant
clogs.
(2-way valve, 3-way
valve, pipe, expan-
sion valve)
Indoor/
9 times
9
Outdoor unit
Thermistor installa-
cooling/heating tion error or 4-way
switchover 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.
outdoor
units in
complete
shutdown
(2) Measure resistance of
thermistors TH1 and TH5.
(2) Replace the ther-
mistor assembly.
(3) Check the 4-way valve for (3) Replace the 4-way
proper operation.
(4) No abnormality found in
above inspections (1)
through (3).
valve.
(4) Replace the outdoor
unit control PWB
assembly.
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 (2) Replace the 4-way
proper operation.
(3) check to see compressor
type is correct.
valve.
(3) Replace the compres-
sor with the correct
part.
3 – 15
AYXP7FR
Status of Indication
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis
Inspection location/method
Remedy
indoor/
outdoor
units
by LED1
on out-
door unit
*2
Main Sub- Main category
cate- cate-
Sub-category
gory gory
Indoor/
outdoor
units in
complete
shutdown
11
times
11
-0
Outdoor unit DC Outdoor unit DC fan (1) Check connector CN3 of
(1) Correct the installa-
tion.
fan
rotation error
the outdoor unit DC fan
motor for secure installa-
tion.
(2) Check the outdoor unit fan (2) Replace the outdoor
motor for proper rotation.
(3) Check fuse FU3.
unit fan motor.
(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
-1
DC compressor Compressor startup (1) Check the colors (red,
(1) Correct the installa-
tion.
error
white, orange) of the com-
pressor cords for proper
connection. (PWB side,
compressor side)
(U: Red, V: White, W:
Orange)
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- (1) Connect stable power
ply voltage for fluctuation.
(2) No abnormality found in
above inspection (1).
supply.
(2) Replace the outdoor
unit control PWB
assembly.
Indoor/
-1
-0
PAM clock error
(1) Check the PAM clock for
proper input.
(1) Replace the outdoor
unit control PWB
assembly.
outdoor
units in
operation
Indoor
17
Wires between
units
Serial open-circuit
(1) Check the wires between
units.
(1) Connect stable power
supply.
unit in
operation
Outdoor
unit in
complete
shutdown
(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 (3) Replace the outdoor
voltages on the PWB.
Check resistance between
IPM terminals.
unit control PCB
assembly.
(4) Check pins No. 5 and 7 of (4) Replace the outdoor
connector CN3 of the out-
door unit fan motor for
short-circuit.
unit fan motor.
(5) Outdoor unit control PCB
(5) Replace the outdoor
unit control PCB
board.
18
-0
-1
Serial short-circuit
(1) Check the wires between
units.
(1) Correct the wiring.
Serial erroneous wir- (1) Check the wires between
ing units.
(1) Correct the wiring.
3 – 16
AYXP7FR
Status of Indication
Malfunction
No. dis-
played on
main unit
display sec-
tion *1
Content of diagnosis
Inspection location/method
Remedy
indoor/
outdoor
units
by LED1
on out-
door unit
*2
Main Sub- Main category
cate- cate-
Sub-category
gory gory
Indoor/
outdoor
units in
19
-0
Indoor unit fan
Indoor unit fan error (1) Check the indoor fan
motor for proper rotating
operation.(Check fan
(1) Replace the indoor fan
motor.
complete
shutdown
lock.)
(2) Check the lead wire of the (2) Replace the indoor fan
indoor fan motor for open-
circuit.
motor.
(3) Check CN1 of the indoor
unit fan motor for secure
installation.
(3) Correct the installa-
tion of CN1 of the
indoor fan motor.
(4) No abnormality found in
above inspections (1)
through (3).
(4) Replace the indoor
unit control PWB.
Indoor/
20
88
-0
Indoor unit con- EEPROM data error
trol PCB
(EEPROM read data
error)
Replace the indoor
unit control PWB.
outdoor
units in
operation
Indoor/
outdoor
units in
operation
Control and dis- Communication
(1) Check for disconnected
connector between control
PCB and display PCB,
and open-circuit in lead
wires.
(1) Insert connectors cor-
rectly, or replace con-
trol PWB.
play PCB
error
(2) Check that control PCB
outputs signals correctly.
(2) Replace control PWB.
3 – 17
AYXP7FR
Malfunction indications due to erroneous wiring during air conditioner installation
Inter-unit wiring error mode
Symptom
Turns On momentarily, then turns Off.
Malfunction diagnosis display "18-1"
1
2
3
4
5
Indoor unit relay
1
1
Outdoor
unit
Indoor
unit
N
2
N
2
Indoor unit relay
Malfunction diagnosis display None
Relays turns Off after about 30 minutes.
1
1
(Displays "18-0" when malfunction code is called out.)
Outdoor
unit
Indoor
unit
N
2
N
2
Indoor unit relay
Malfunction diagnosis display None
(Displays "18-0" when malfunction code is called out.)
Relays turns Off after about 30 minutes.
1
1
Outdoor
unit
Indoor
unit
N
2
N
2
Indoor unit relay
Malfunction diagnosis display "18-1"
Turns On momentarily, then turns Off.
1
1
Outdoor
unit
Indoor
unit
N
2
N
2
Indoor unit relay
Turns On momentarily, then turns Off.
Malfunction diagnosis display "18-1"
1
1
Outdoor
unit
Indoor
unit
N
2
N
2
3 – 18
AYXP7FR
[4] PERFORMANCE CURVES
NOTE
1) Indoor fan speed: Hi
2) Vertical adjustment louver "45°”, Horizontal adjustment louver "front"
3) Indoor air temp. : Cooling 27°C, Heating 20°C
4) Power source : 230V, 50Hz
1. AY-XP7FR
1.1. At Cooling
1.2. At Heating
600
500
400
300
600
500
400
3.0
2.5
2.0
1.5
2.6
2.4
2.2
2.0
25
30
35
40
-5
0
5
7
10
Outside air temp.(ºC)
Outside air temp.(ºC)
2. AY-XP9FR
2.1. At Cooling
2.2. At Heating
800
700
600
900
800
700
600
3.2
3.0
2.8
2.6
2.4
3.5
3.0
2.5
2.0
-5
0
5
7
10
25
30
35
40
Outside air temp.(ºC)
Outside air temp.(ºC)
4 – 2
AYXP7FR
3. AY-XP12FR
3.1. At Cooling
3.2. At Heating
1200
1100
1000
900
1200
1100
1000
900
800
4.0
3.8
3.6
3.4
3.2
4.5
4.0
3.5
3.0
2.5
25
30
35
40
-5
0
5
7
10
Outside air temp.(ºC)
Outside air temp.(ºC)
4 – 3
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