Sharp AY-X10CR Service Manual
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Sharp AY-X10CR Service Manual

Sharp AY-X10CR Service Manual

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New Refrigerant : R-410A
SPECIFICATIONS ............................................................................................................................................. 2
EXTERNAL DIMENSIONS ................................................................................................................................. 3
WIRING DIAGRAMS ......................................................................................................................................... 5
ELECTRICAL PARTS ......................................................................................................................................... 6
BLOCK DIAGRAM .............................................................................................................................................. 6
MICROCOMPUTER CONTROL SYSTEM ......................................................................................................... 8
FUNCTIONS .................................................................................................................................................... 12
FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES ............................................................... 18
BREAKDOWN DIAGNOSIS PROCEDURE .................................................................................................... 20
REFRIGERATION CYCLE ............................................................................................................................. 23
PERFORMANCE CURVES ............................................................................................................................. 24
DISASSEMBLING PROCEDURE .................................................................................................................... 25
OPTION ........................................................................................................................................................... 32
REPLACEMENT PARTS LIST ........................................................................................................................ 33
REFRIGERANT PIPING INSTALLATION/SERVICE MANUAL FOR AIR CONDITIONERS USING R-410A .. 39
SERVICE MANUAL
ROOM AIR CONDITIONERS
INDOOR UNIT
AY-X10CR
MODELS
AY-X10CR-N
OUTDOOR UNIT
AE-X10CR
AE-X10CR-N
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.
TABLE OF CONTENTS
SHARP CORPORATION
1
S8236AYX10CRN
SPLIT TYPE
(FOR SWEDEN ONLY)
(FOR SWEDEN ONLY)
AY-X10CR
AE-X10CR
AY-X10CR-N
AE-X10CR-N
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  • Page 1 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N SERVICE MANUAL S8236AYX10CRN SPLIT TYPE ROOM AIR CONDITIONERS INDOOR UNIT AY-X10CR MODELS (FOR SWEDEN ONLY) AY-X10CR-N OUTDOOR UNIT AE-X10CR (FOR SWEDEN ONLY) AE-X10CR-N 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 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N SPECIFICATIONS INDOOR UNIT OUTDOOR UNIT MODEL ITEMS AY-X10CR-N, AY-X10CR AE-X10CR-N, AE-X10CR 2.8(0.9 _ 3.3) Cooling capacity(Min. ~ Max.) kW 3.7(0.9 _ 5.0) Heating capacity(Min. ~ Max.) kW Moisture removal(at cooling) Liters/h Electrical data Phase Single Rated frequency...
  • Page 3 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N EXTERNAL DIMENSIONS 18.5 Length unit (mm) INVERTER AIR CONDITIONER Remote controller Figure E-1. INDOOR UNIT 37.5 179.5 182.5 Figure E-2. OUTDOOR UNIT...
  • Page 4 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 815 (unit size) Ceiling More than 50mm Center of wall hole: Leftward piping Center of wall hole: Backward piping Outline of indoor unit Figure E-3. INSTALLATION DIMENSIONS WIRING DIAGRAMS OUTDOOR UNIT INDOOR UNIT TERMINAL BOARD 1...
  • Page 5 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 6 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N ELECTRICAL PARTS For INDOOR UNIT DESCRIPTION MODEL REMARKS Indoor fan motor ML-A915 220 - 240V, 50Hz Indoor fan motor capacitor – 430V, 2µF Transformer – Primary; AC 220 - 240V, 50Hz Secondary; AC19V, 50Hz WPE1 –...
  • Page 7 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N OUTDOOR UNIT 15 A protection Unit-unit wiring (AC power Power supply circuit Smoothing Active filter Filter circuit circuit circuit and serial signals) CPU oscillator circuit DC overvoltage detection circuit protection Outdoor fan relay drive circuit Outdoor fan...
  • Page 8 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N MICROCOMPUTER CONTROL SYSTEM TO TERMINAL " 2 " OF TERMINAL BOARD 4P (RED) C3 (CN8) QPWBFB389JBZZ JP33 RATE TO TERMINAL " N " OF 1 2 3 COOL JP31 JP10 TERMINAL BOARD 4P HEAT FAN H...
  • Page 9 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 10 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 11 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 12 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N FUNCTIONS Cooling Heating 1. INDOOR UNIT Room Frequency Room Frequency Room Frequency 1-1 Temperature Adjustment temp. Code temp. Code temp. Code zone zone zone a. Normal control Proportional control (P control) (Hot keep fan) When the temperature zone changes, this control changes the frequency by one rank to move closer to the set value.
  • Page 13 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N (1) Control for indoor freezing prevention If the temperature of the indoor heat exchanger stays below approximately 0°C for four minutes during cooling or dry, this control stops the compressor. Over 2˚C the compressor will run again.
  • Page 14 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N compressor chamber temperature rises above 25°C. 1-5 OFF-timer Preheat does not operate for 2 hours after heating The OFF-timer is set by pressing the OFF-timer is stopped. After that, it goes on for 180 minutes button. Operation is as follows: and then stops for 30 minutes, repeatedly.
  • Page 15 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N informed by the flashing number as well as the 1-13 Auto Restart lighting pattern of the operation lamp which When power failure occures, after power is flashes with the timer lamp.(For details, refer to recovered, the unit will automatically restart in the Error diagnostic method.)
  • Page 16 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N (4) Defrost stop When defrosting time exceeds 13 minutes When the temperature of the outdoor heat exchanger rises above approximately 7˚C Defrost stop is determined by either of the above conditions, and the compressor is stopped. At the same time, the outdoor fan go ON.
  • Page 17 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 2-3 Overcurrent protection (1) AC overcurrent detection To protect against overcurrent due to sudden changes in load, the compressor is stopped if the set value AC : 12.5A is exceeded in the AC section. In this case, the outdoor fan does not stop, and 170 seconds after operation is stopped, another try will be made.
  • Page 18 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES Operation Self diagnostic display Function Description Detection Restart Restart Indoor Outdoor time condition times Indoor fan Stops operation if no rotation pulse signal When indoor Operation OFF No limit lock...
  • Page 19 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N Operation Self diagnostic display Function Description Detection Restart Restart Indoor Outdoor time condition times Outdoor heat Lowers the operating frequency if the During Automatically No limit exchanger temperature of the outdoor heat exchanger compressor restarts after safety overheating rises above 55°C during cooling.
  • Page 20 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 21 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 22 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 23 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N REFRIGERATION CYCLE Indoor unit Evaporator Flare coupling Flare coupling 3-way 2-way valve valve Heating Cooling Silencer Strainer Outdoor unit Capillary Compressor tube A Capillary tube B Silencer Capillary Coil tube C Condenser (2 pieces) Reverse valve Figure R-1.
  • Page 24 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 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 (Running frequency: 63Hz) 1000 Outside air temp.(˚C) Figure P-1. At Cooling...
  • Page 25 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N DISASSEMBLING PROCEDURE FOR INDOOR UNIT SERVICING CAUTION : DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY 1. Open the opne panel, and remove 2 air filters. 5. Pull the front panel up. 2. Remove 4 screws fixing the front panel.
  • Page 26 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 9. Remove the thermistor of the evaporator. 13. Remove the screw fixing the pipe holder. 10. Remove 4 connectors. 14. Remove 3 screws fixing the control box, and remove the control box. 11. Remove the thermistor holder from the evaporator.
  • Page 27 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 17. Remove the drain cover from the evaporator. Note: During reassembly, verify that the dew on the pipe is led to the drain pan. 20. Remove 2 screws fixing the motor cover, and pull up the fan.
  • Page 28 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N How to remove the display cover 1. Push the center of display cover from the back. 2. Remove the screw fixing the terminal board. 2. Slide the display cover to the right. How to assemble the display cover 1.
  • Page 29 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N Drain pan and related 1. Remove 3 screws fixing motors. Drain Hose Drain pan Projection Groove To disconned To reconnect 2. Turn the cap area of the drain hose counterclockwise, and remove it from the drain pan.
  • Page 30 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N FOR OUTDOOR UNIT SERVICING CAUTION : DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY Right side view Left side view 1. Loose a screw fixing the side cover. Front view 2. Loose the unit to unit cord.
  • Page 31 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N DISASSEMBLING PROCEDURE OF THE FAN Loose 8. Remove the terminal cover of compressor. 1. Loose the fan nut and fan can take out. 9. Remove 3 terminals of compressor.. 2. Fan motor is secured by 4 screws.
  • Page 32 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N OPTION HOW TO REPLACE THE AIR PURIFYING FILTER (AZ-F900B; (2-sheet package) Electrostatic Type Precautions The filters are sealed in a plastic bag to keep thier dust collection effect. Do not open the bag until using the filters.
  • Page 33 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N REPLACEMENT PARTS LIST [AY-X10CR-N / AY-X10CR] REF. NO. PART NO. DESCRIPTION Q'TY CODE CONTROL BOX PARTS 1- 1 CMOT-A397JBKZ Fan motor sub assembly 1- 2 PGUMSA046JBE0 Damper rubber 1- 3 CHLD-A067JBK0 Bearing assembly 1- 4 DCHS-A401JBKZ...
  • Page 34 PACKING PARTS 6- 1 CPADBA038JBKZ Packing pad assembly 6- 2 SPAKCB168JBEZ Packing case [AY-X10CR-N] 6- 2 SPAKCA947JBEZ Packing case [AY-X10CR] HOW TO ORDER REPLACEMENT PARTS To have your order filled prompty and correctly, please furnish the following information. 1. MODEL NUMBER 2.
  • Page 35 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N INDOOR UNIT 4-10 1-29 4-11 4-12 4-43 1-23 1-35 1-38 1-39 1-41 1-40 1-26 1-12 1-42 2-11 1-41 1-22 1-32 2-18 2-13 1-18 2-14 2-12 1-21 1-33 1-31 2-10 1-25 2-19 1-28 1-14 1-36 1-37 1-20...
  • Page 36 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N REPLACEMENT PARTS LIST [AE-X10CR-N / AE-X10CR] REF. NO. PART NO. DESCRIPTION Q'TY CODE CONTROL BOX PARTS 1- 1 CMOTLA902JBEZ Fan motor 1- 2 RTRN-A256JBE0 Current transformer CT1 1- 3 DPWBFA252JBKZ Electric control board 1- 4 QTANZA001JBZZ...
  • Page 37 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N REF. NO. PART NO. DESCRIPTION Q'TY CODE 2-20 TLABKD184JBEZ Number card [AE-X10CR-N] 2-20 TLABKC996JBRZ Number card [AE-X10CR] 2-21 TSPC-E267JBRZ Name badge [AE-X10CR-N] 2-21 TSPC-E033JBRZ Name badge [AE-X10CR] 2-22 PSEL-C051JBEZ Side cover seal 2-23 FFTA-A014JBKZ Side cover assembly...
  • Page 38 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 2-25 OUTDOOR UNIT 4-13 2-27 2-28 2-31 2-32 2-24 4-13 2-33 2-30 2-26 2-15 2-34 4-13 1-14 2-23 2-18 2-35 2-21 1-10 2-22 2-37 1-22 2-14 4-10 2-36 1-12 4-12 4-14 2-38 1-18 1-19 1-23 1-18...

  • Page 39: Table Of Contents

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N Refrigerant Piping Installation / Servicing Manual for Air Condioners Using R-410A TABLE OF CONTENTS Page 1. Outline ................................. 40 1.1 Refrigerant R410A ..........................40 1.2 Safety during Installation / Servicing ...................... 40 2. Refrigerant Piping Installation ........................41 2.1 Pipng Materials and Joint Used ......................

  • Page 40: Outline

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 1. Outline 1. 1 Refrigerant R410A (1) Adoption of R410A in Air Conditioners In 1974, it was pointed out that ozone layer in the upper stratosphere (about 20 ~ 40 km above ground) might have been damaged by the ozone depleting substances such as CFC (chlorofluorocarbon) and HCFC (hydrochlorofluorocarbon).

  • Page 41: Safety During Installation/Servicing

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N (3) Lubricationg Oils for R410A As the lubricating oils for R22, mineral oils, alkylbenze synthetic oils, etc. have so far been used. As R410A features less solubility with these conventional lubricating oils such as mineral oils, the lubricating oils tend to stay within the refrigeration cycle.

  • Page 42: Processing Of Piping Materials

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 2.2 Processing of Piping Materials When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner is used, and that refrigerant does not leak.
  • Page 43 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N Table 7. Flare and Flare Nut Dimensions for R22 [Unit: mm] Norminal Norminal Thickness Dimension (mm) Flare nut diameter diameter (mm) width (mm) 6.35 9.52 13.0 13.5 12.70 16.2 16.0 12.9 15.88 19.4 19.0 16.0 Fig. 4 Relations between Flare Nut and Flare Seal Surface (2) Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc.

  • Page 44: Storage Of Piping Materials

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 2.3 Storage of Piping Materials (1) Types and Storage of Piping Materials Refrigerant piping materials for air conditioners are broadly classified into the following types. Refrigerant piping General name materials with heat with flare processing : (a) Piping set...
  • Page 45 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N Table 10. Differences in Port Size between Conventional Manifold and That for R410A Conventional manifold Manifold for R410A 7/16 UNF 1/2 UNF Port size 20 threads per inch 20 threads per inch b) Charge Hose As R410A is characterized by high pressure, the pressure resistance of the charge hose has been increased.

  • Page 46: New Installation Work (When Using New Refrigerant Piping)

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N h) Refrigerant Cylinder A refrigerant cylinder exclusive for R410A comes identified with refrigerant name and is coated with pink paint as designated by the ARI, U. S. A Charge Port and Packing for Refrigerant Cylinder According to the charge hose's cap size, a charge port with 1/2 UNF 20 threads per inch and corresponding packing are required.
  • Page 47 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N h) After securing the caps on the control valves, check the caps periphery if there is any gas leakage. 3 4 7 Compound pressure gauge Gauge manifold 76cmHg Handle Lo Handle Hi (always closed) Charge hose...

  • Page 48: Removal (When Using New Refrigerant Piping)

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N h) After securintg the caps on the service port and control valve, check the capsÅfperiphery to see if there is any gas leakage. (Liquid side) (Indoor unit) (Outdoor unit) Control valve (2-way) Opened (Gas side) Refrigerant cylinder...

  • Page 49: Refrigerant Recharging At Servicing

    AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N 3.6 Refrigerant Recharging at Servicing When it becomes necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. (For details, see the instruction manual prepared by the equipment manufacturer) 1) Connect the charge hose to the outdoor unit's service port.
  • Page 50 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 51 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N...
  • Page 52 AY-X10CR AE-X10CR AY-X10CR-N AE-X10CR-N '02 SHARP CORP. (8U0.10E) Printed in Germany...

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