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AH-X127E
AU-X127E

AY-X127E
AE-X127E

1

SHARP CORPORATION

S4709AYX127E/

SPLIT TYPE

ROOM AIR CONDITIONERS

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.

SERVICE MANUAL

Page

SPECIFICATIONS ................................................................................................................................................. 2
EXTERNAL DIMENSIONS ..................................................................................................................................... 4
WIRING DIAGRAMS .............................................................................................................................................  5
ELECTRICAL PARTS ............................................................................................................................................ 8
BLOCK DIAGRAM ..................................................................................................................................................9
MICROCOMPUTER CONTROL SYSTEM ..........................................................................................................  11
FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES ...................................................................  26
BREAKDOWN DIAGNOSIS PROCEDURE ........................................................................................................  29
REFRIGERATION CYCLE .................................................................................................................................  31
PERFORMANCE CURVES ................................................................................................................................  34
DISASSEMBLING PROCEDURE .......................................................................................................................  35
OPTION ...............................................................................................................................................................  45
REPLACEMENT PARTS LIST ............................................................................................................................. 47

TABLE OF CONTENTS

MODELS

INDOOR UNIT

AH-X127E
AY-X127E

AU-X127E
AE-X127E

OUTDOOR UNIT

1
2
3
...
»

Summary of Contents for AE-X127E

Page 1: ...cal to those specified should be used SERVICE MANUAL Page SPECIFICATIONS 2 EXTERNAL DIMENSIONS 4 WIRING DIAGRAMS 5 ELECTRICAL PARTS 8 BLOCK DIAGRAM 9 MICROCOMPUTER CONTROL SYSTEM 11 FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES 26 BREAKDOWN DIAGNOSIS PROCEDURE 29 REFRIGERATION CYCLE 31 PERFORMANCE CURVES 34 DISASSEMBLING PROCEDURE 35 OPTION 45 REPLACEMENT PARTS LIST 47 TABLE OF CONTENTS MODELS I...

Page 2: ...tube Refrigerant volume 720g Noise level High dB A 41 49 at cooling Med dB A 37 Low dB A 33 Fan system Drive Direct drive Air flow High m3 min 9 8 28 3 quantity Med m3 min 8 5 at cooling Low m3 min 7 0 Fan Close flow fan Propeller fan Connections Refrigerant coupling Flare type Refrigerant tube size Gas Liquid 1 2 1 4 Refrigerant pipe sets No AZ 24H5E 5m 16 4 ft AZ 24H7E 7m 23ft Drain pipng mm Inc...

Page 3: ...ol Capillary tube Refrigerant volume 790g De Ice system Micro computer controled reverse system Noise level High dB A 41 49 at cooling Med dB A 37 Low dB A 33 Fan system Drive Direct drive Air flow High m3 min 9 8 28 3 quantity Med m3 min 8 5 at cooling Low m3 min 7 0 Fan Close flow fan Propeller fan Connections Refrigerant coupling Flare type Refrigerant tube size Gas Liquid 1 2 1 4 Refrigerant p...

Page 4: ... AY X127E AE X127E 4 EXTERNAL DIMENSIONS Figure E 1 INDOOR UNIT Figure E 2 OUTDOOR UNIT 790 188 270 800 58 18 19 5 182 Length unit mm 250 280 304 525 10 5 38 58 5 76 5 141 5 515 530 15 728 98 60 59 5 69 5 Length unit mm ...

Page 5: ...R COMPRESSOR UNIT TO UNIT CORD CONTROL BOARD UNIT 1 1 2 2 N N L N SERIAL SIGNAL CIRCUIT LED INDICATION FOR SELF DIAGNOSIS Abnormal conditions Short circuit of the outdoor thermistor Overheat of the compressor Abnormal AC current Compressor lock Open circuit of the outdoor thermistor DC overcurrent or over heat of the IPM AC overcurrent Open circuit of serial signal line Short circuit of serial sig...

Page 6: ...times for 2 seconds Example NO 2 Compressor lock on off 1 0sec 1 0sec 1 0sec 0 6sec 0 6sec 0 6sec 1 0sec 1 0sec 0 6sec 0 6sec 0 6sec 0 6sec NO 3 Overheat of the compressor NO 1 2 3 4 Normal Abnomal signal line Compressor lock Overheat of the compressor DC overcurrent or overheat of the IPM Short circuit of the thermistor Open circuit of the thermistor AC abnormal current AC overcurrent LED indicat...

Page 7: ... times for 2 seconds Example NO 2 Compressor lock on off 1 0sec 1 0sec 1 0sec 0 6sec 0 6sec 0 6sec 1 0sec 1 0sec 0 6sec 0 6sec 0 6sec 0 6sec NO 3 Overheat of the compressor NO 1 2 3 4 Normal Abnomal signal line Compressor lock Overheat of the compressor DC overcurrent or overheat of the IPM Short circuit of the thermistor Open circuit of the thermistor AC abnormal current AC overcurrent LED indica...

Page 8: ...or fan motor capacitor 430V 2 0µF AU WPE1 QFS GA014JBE0 20A 250V AU WPE2 QFS GA019JBE0 20A 250V AU WPE3 QFS GA008JBE0 3A 250V AU For Model AY X127E and AE X127E DESCRIPTION MODEL REMARKS SITE Indoor fan motor ML A486 220 240V 50Hz AY Indoor fan motor capacitor 430V 1 5µF AY Transformer Primary AC 230V 50Hz AY Secondary AC14 6V 50Hz Fuse 250V 2 5A AY Compressor KHV127FEM 3 PHASE Induction motor AE ...

Page 9: ...circuit Serial I O circuit Compressor relay drive circuit LED drive circuit Auto restart circuit Test run circuit Power on circuit Flow direction control louver motor Wireless remote control operation Audible operation confirmation Room fan motor Fan motor pulse detect Room temp thermistor Heat exchanger pipe thermistor Blower temperature fan speed model select Outdoor ratings Wireless preheat Ind...

Page 10: ...ircuit built into IPM CPU oscillator circuit AC overcurrent detection circuit DC overcurrent detection circuit LED Heat exchanger pipe thermistor Compressor thermistor Current transformer Outdoor temperature thermo circuit Outdoor temperature thermistor Compressor Power transistor module 4 way valve except for the AU X127E Outdoor fan Smoothing circuit Passive filter circuit Filter circuit Unit un...

Page 11: ...44 5v 5v R7 20k R6 3 3k 3 1 2 Q1 C7 50v 1000P 45 14 15 9 7 5 4 3 2 1 13 12 11 JP5 JP6 JP7 JP9 JP10 SIGNAL IN SIGNAL OUT MODEL 5 MODEL 6 MODEL 7 WIRELESS PREHEAT 1 2 3 OSC 8MHz 6 5v 5v 1 2 3 Q2 C16 16v 0 01µ C15 16v 0 01µ 16 D5 R22 1 2k R21 3 3k R18 2 7k R20 33k R19 4 7k IC1 TRANSFORMER 46 D1 D2 D3 D4 47 TR C21 250VAC 0 01µ C1 430VAC 1 5µ NR1 55 50 48 49 67 66 68 56 54 NF1 FU1 2 5A 250v T CNR1 13 1...

Page 12: ...NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC 0 1µ 25v R38 10k 5v 5v IC3 2 3 1 PST993D 5v OSC1 1µ 50v C23 R10 6 49kF C15 10v 220µ 5v D3 D2 1 00kF R9 JP1 1 80kF R8 BL BL BCN12 DTD113ZS Q3 JP4 JP3 KRC106M Q1 Q2 RY2 D5 RY1 D6 13v T5 T6 BK DB1 OR BCN13 BL PTC1 GR GR MRY1 BL PTC Thermistor Reactor C10 C6 RE 1 2 3 4 400v 150µ 400v 150µ L2 Reactor RE RE BK C5 200v 50µF WH C8 CMP YL BL DB2 GR GR BL BR GR W...

Page 13: ... R6 3 3k 3 1 2 Q1 C7 50v 1000P 45 14 15 9 7 5 4 3 2 1 13 12 11 JP5 JP6 JP7 JP9 JP10 SIGNAL IN SIGNAL OUT MODEL 5 MODEL 6 MODEL 7 WIRELESS PREHEAT 1 2 3 OSC 8MHz 6 5v 5v 1 2 3 Q2 C16 16v 0 01µ C15 16v 0 01µ 16 D5 R22 1 2k R21 3 3k R18 2 7k R20 33k R19 4 7k IC1 TRANSFORMER 46 D1 D2 D3 D4 47 TR C21 250VAC 0 01µ C1 430VAC 1 5µ NR1 55 50 48 49 67 66 68 56 54 NF1 FU1 2 5A 250v T CNR1 13 11 S201D01 SSR1 ...

Page 14: ...NC NC NC NC NC NC NC NC NC 0 1µ 25v R38 10k 5v 5v IC3 2 3 1 PST993D 5v OSC1 1µ 50v C23 R10 6 49kF C15 10v 220µ 5v D3 D2 1 00kF R9 JP1 1 80kF R8 BL BL BCN12 DTD113ZS Q3 JP4 JP3 KRC106M Q1 Q2 RY2 D5 RY1 D6 13v T5 T6 BK DB1 OR BCN13 BL PTC1 GR GR MRY1 BL PTC Thermistor Reactor C10 C6 RE 1 2 3 4 400v 150µ 400v 150µ L2 Reactor RE RE BK C5 200v 50µF WH C8 CMP YL BL DB2 GR GR BL BR GR WH C7 YL 63v 4700µ ...

Page 15: ...OR CAPACITOR JP12 R27 R25 3 4 2 2 4 3 R6 R21 D7 R44 R24 R4 R5 CN4 TH1 R43 R42 R41 R40 1 SW1 C9 R29 IC80 8 CN1 CN2 1 1 3 R1 CN3 LOUVER M 5 JP1 JP2 JP3 JP7 JP9 JP10 JP8 C80 JP4 DSGY A827 JBK0 3 R9 R28 JP99 R12 3 CN8 R18 4 1 3 Q1 R7 R19 C12 C6 R3 C11 R15 R14 C15 C16 R81 5 MEMORY JP5 JP6 D5 R11 32 33 20 POWER ON R10 IC2 8 C17 JP19 JP18 JP17 52 51 1 IC1 16 1 19 C10 R31 64 R39 R37 R35 R33 R38 C14 R36 R3...

Page 16: ...9 WPE3 CT1 D2 3A 250V T5 C1 MRY1 BLACK R3 R7 R17 R16 R24 R23 R22 R34 JP9 JP14 Q1 RY1 C24 R40 JP34 E C B D3 D6 BCN12 Q3 E C B LED1 JP8 JP4 C13 R4 D1 C12 NR1 T4 T3 SAI 20A 250V JP21 T1 WPE1 JP22 L3 C4 C3 T6 JP26 T2 JP25 C14 60 55 50 45 40 35 33 64 5 10 R29 R31 R33 OUT IN R32 R18 C2 IC1 R30 R28 15 20 32 IC3 R37 R35 CN8 4 1 JP11 C28 OSC1 1 3 1 DSGY A830JBK0 UX127E BLUE BROWN G Y RED BLUE F DIP MRY1 BC...

Page 17: ...OR CAPACITOR JP12 R27 R25 3 4 2 2 4 3 R6 R21 D7 R44 R24 R4 R5 CN4 TH1 R43 R42 R41 R40 1 SW1 C9 R29 IC80 8 CN1 CN2 1 1 3 R1 CN3 LOUVER M 5 JP1 JP2 JP3 JP7 JP9 JP10 JP8 C80 JP4 DSGY A826 JBK0 3 R9 R28 JP99 R12 3 CN8 R18 4 1 3 Q1 R7 R19 C12 C6 R3 C11 R15 R14 C15 C16 R81 5 MEMORY JP5 JP6 D5 R11 32 33 20 POWER ON R10 IC2 8 C17 JP19 JP18 JP17 52 51 1 IC1 16 1 19 C10 R31 64 R39 R37 R35 R33 R38 C14 R36 R3...

Page 18: ...D2 3A 250V T5 C1 MRY1 BLACK R3 R7 R17 R16 R24 R23 R22 R34 JP9 JP14 Q1 Q2 RY1 C24 R40 JP34 E C B E C B D3 D6 JP3 BCN12 Q3 E C B LED1 JP8 JP4 C13 R4 D1 C12 NR1 T4 T3 SAI 20A 250V JP21 T1 WPE1 JP22 L3 C4 C3 T6 JP26 T2 JP25 C14 60 55 50 45 40 35 33 64 5 10 R29 R31 R33 OUT IN R32 R18 C2 IC1 R30 R28 15 20 32 IC3 R37 R35 CN8 4 1 JP11 C28 OSC1 1 3 1 CN4 1 3 DSGY A829JBK0 EX127E BLUE BROWN G Y RED BLUE F D...

Page 19: ...h 1 Heating If the room temperature is in the z zone when operation begins proportional integral control is not performed and the machine runs at frequency code c full power until the h zone is reached When the h zone is reached the frequency changes to the frequency code determined by fuzzy calculation and after that proportional integral control is performed 2 Cooling If the room temperature is ...

Page 20: ... exchanger reaches 26 C It also stops the fan if the temperature goes below 23 C during operation 4 Indoor fan and operating frequency The indoor fan has 12 speeds and changing is done in four stages Auto High Med and Low The relations between the indoor fan speed air quantity setting operating frequency and indoor heat exchanger are shown in the following charts Operating frequency Over 50 Hz Ove...

Page 21: ... timer button Operation is as follows During Heating 1 3 Hot keep If the room temperature is in the j or k zone during heating the compressor is turned on and off to prevent overheating 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 e f zone g zone h zone i zone Dry Operating frequency code Fan speed 12 11 10 9 8 7 6 5 4 3 2 1 0 High Circulation Operating frequency code Fan speed Med Low Heating 24 C Heatin...

Page 22: ...2 hours after heating is stopped After that it goes on for 165 minutes and then stops for 15 minutes repeatedly 1 12 Power ON start If a jumper wire is inserted into the place indicated power ON on the indoor control board and the power plug is inserted cooling or heating will be automatically determined by the room temperature sensor on the main unit and operation will begin 1 13 Compressor relay...

Page 23: ...not enabled the machine waits until defrosting is enabled Defrost mask times is 20 minutes The defrosting zone is decided by outdoor temperature and outdoor heat exchanger temperature 3 During defrosting When defrosting begins the compressor stops Approximately 1 minutes later the compressor reactivates in the refrigeration cycle and the outdoor heat exchanger is defrosted Each mode is as follows ...

Page 24: ...red to minimum frequency without the temperature of the outdoor heat exchanger decreasing and this condition lasts for 1 minute the compressor will be stopped 4 Control for prevention of discharge overheating If the discharge temperature exceeds approximately 105 107 C during compressor operation the operating frequency is lowered by approximately 5 Hz After that the frequency is lowered by approx...

Page 25: ...ctor control If the temperature of the compressor chamber exceeds 114 C the compressor is stopped In this case the outdoor fan does not stop and when the compressor chamber temperature decreases to 100 C three minutes after operation is stopped another try will be made Three retries are allowed On the fourth retry a complete stop request signal is sent to the indoor unit and the outdoor unit will ...

Page 26: ...ration 51 C to 54 C During full power operation 54 C to 58 C Stops the compressor if a current of approximately 30 A or more flows in the power transistor module Also stops the compressor if the temperature of the power transistor module is exceeds 105 C Lowers the operating frequency if the compressor AC current exceeds Peak control level 11 3A heating 10 4A cooling Stops the compressor if the cu...

Page 27: ...s the compressor if the circuit of an outdoor thermistor breaks Except for the AU X127E Stops the compressor if if the operating frequency is above 70 Hz and the compressor current is below 1 0 A Turns the compressor relay off if the indoor unit does not receive a serial signal from the outdoor unit for 8 minutes Stops the compressor if the outdoor unit does not receive a serial signal from the in...

Page 28: ...AH X127E AU X127E AY X127E AE X127E 28 ...

Page 29: ...AH X127E AU X127E AY X127E AE X127E 29 ...

Page 30: ...AH X127E AU X127E AY X127E AE X127E 30 ...

Page 31: ...r Evaporator Indoor unit Compressor Flare coupling Flare coupling Silencer 4 valve valve Accumulator Figure R 1 Refrigeration Cycle for AH X127E 1 4 C 2 Accumulator 3 Strainer Outdoor unit Condensor Evaporator Reverse valve Comp ressor Valve Valve Silencer Cooling Heating Coil Capillary tube A Capillary tube B Flare coupling Indoor unit Flare coupling s ...

Page 32: ... side Dry bulb Temp C Relative Humidity 35 40 AH X127E Temperature at each part and pressure in 3 way valve Operation mode Cool Max Cool 1 2 3 4 3 way valve pressure kg cm2 G 107 C 48 C 12 C 8 C 4 3 67 C 44 C 14 C 11 C 6 0 111 50 settle AH X127E No Hz Capillary tube O D I D L ø3 2 ø1 8 900 AH X127E Dimension of Capillary tube ...

Page 33: ...27E Temperature at each part and pressure in 3 way valve Operation mode Cool Max Heat Max Cool Heat 1 2 3 4 3 way valve pressure kg cm2 G 107 C 46 C 13 C 5 C 4 2 103 C 0 C 39 C 1 C 20 0 69 C 44 C 14 C 12 C 6 0 55 C 2 C 32 C 2 C 12 7 111 more than120 50 settle 50 settle AY X127E No Hz Capillary tube A O D I D L ø3 2 ø1 8 1100 Capillary tube B ø3 2 ø1 8 500 AY X127E Dimension of Capillary tube ...

Page 34: ...r front 3 Indoor air temp Colling 27 C NOTE Running frequency 99HZ Figure P 1 At Cooling for AH X127E 25 30 35 40 3 1 3 3 3 5 3 7 3 9 10 12 14 1200 1400 1600 1800 Running frequency 99Hz Cooling capacity kW Outside air temp C Input W Outlet air temp C 5 0 5 10 3 0 3 5 4 0 4 5 4 7 35 40 45 1200 1400 1600 1800 Running frequency 102Hz Heating capacity kW Outside air temp C Input W Outlet air temp C Fi...

Page 35: ... a Press the top of the screw cover with the flat tipped screwdriver or nail etc b Insert the flat tipped screwdriver or nail etc into the lower clearance and pull and lift it toward you for removal 2 Remove two screws from the front panel 5 Remove the fastening screw which retains the cable and remove the cord Note During reassembly install the holder after installing the front panel This will ma...

Page 36: ...l parallel to the cabinet When pressing it in take care to prevent the top of the blow out portofthedrainpanfrombeingcaughtbythefrontpanel 7 Remove the unit to unit wiring from the terminal board Loosen the screw with the screwdriver and pull out the wiring 8 Remove one fastening screw from the control box cover 9 Remove the control box cover Holding its bottom pull and disengage the upper hook to...

Page 37: ...e band of the lead wire 14 Remove two connectors of the fan motor and one of louver motor 15 Remove the indicator assembly Push up the lower hook and the indicator will be ready for removal 16 Remove four fastening screws of the control box and remove the control box 17 Remove the fastening screws of the drain pan One screw on the left side ...

Page 38: ...move them together If it is tried to remove the fan alone it will damagetheinnersurfaceofthemetaltopreventremoving the fan During installation turn the drain hose to the state of the engagement position After reinstallation verify that it is securely fastened 19 Pull down the drain pan toward you for removal 20 Remove two fastening screws of the side cover L Drain hose Drain pan Groove Projection ...

Page 39: ...ectric control box 1 Remove the fastening screw of the 4 poles terminal board Motor shaft Fan Fan boss 23 To remove the evaporator remove the tube holder on the rear side of the cabinet pull the side cover L of left side with the side cover R of right side toward yourself and lift it up and remove it from cabinet pulling it toward you 3 Remove the receiver unit Press and spread the upper hook and ...

Page 40: ...in pan and related How to remove the louver motor Remove two screws which fasten the louver motor How to remove the horizontal adjustment louver Slightly fall down the hinge area deflect the louver and remove it at one place Remove the shaft from each of the left and right sides How to remove the side clamp assembly Left the edge of the drain pan to the arrow marked direction and ditach the side c...

Page 41: ...over 3 Remove two screws which are fixing right side of the front panel And disconnect the wiring from the terminal board 6 Take off the three hooks of back side of the front panel And pull it toward you 1 Remove one screw which is fixing the control box cover 4 Remove two screws which are fixing left side of the front panel 5 Remove one screw which is fixing front part of the front panel BLACK CO...

Page 42: ...e rear cabinet 10 Remove three screws which are fixing condenser box cover 11 Remove two screws which are fixing the control box 9 Remove four screws which are fixing back side of the rear cabinet And take out the rear cabinet 12 Disconnect following connectors AU X127E Fan motor Thermistor AE X127E Fan motor Thermistor Reverse valve Above Figure is AE X127E ...

Page 43: ...wires To capacitor three wires 16 Remove two screws which are fixing heat insulator assembly And take it out 17 Remove two screws which are fixing bulkhead And take it out Fixing the bottom part is used special screw 15 Take out the control box and put it just under The compressor cord is still wired 18 Disconnect the compressor cord Three wires ...

Page 44: ...mistor from the holder AE X127E only Reactor 22 Disconnect the wires from the reactor to the condenser box 4 wires 23 Remove one screw which is fixing the reactor cover And take it out 24 Remove two screws which are fixing the reactor And take it out Fan motor angle 25 Remove two screws which are fixing the fan motor And take it out ...

Page 45: ...r Purifying Filter for Air Conditioner 2 sheet package Panel Air filter Hooks 2 Replace the old air purifying filters with new ones Unhook the filter frame Snap out in the arrow marked direction Place the new filter Snap the filter frame back into position 4 Close the panel Push the arrow marked position firmly to lock it in place Be careful not to get injured with the metallic edge Replacement in...

Page 46: ...reful not to get injured with the metallic edge R Type How to Set Up AH X127 series AY X127 series Replacement filter Type AZ F1207 Replace the air purifying filters at the intervals of 3 6 months The filter frames are reusable Replace the dirty filters only The dirty filters are not washable for reuse The filters are available at your nearest dealer Replacement intervals guideline Snap the filter...

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