Sharp AE-X4M30PU Service Manual Download Page 33 | Manualshive

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AE-X4M30PU

33

How to disassemble the control box assembly

1.

Remove the 3 screws fixing the PFC PWB.

2.

Remove the 4 screws fixing the MAIN PWB.

3. Unlock the 2 spacer’s lock.

4.

Remove the 2 screws fixing the FILTER PWB.

5. Unlock the 2 spacer’s lock.

The position of setting Ferrite core (FC1-FC11)

FC1

FC2

FC3

FC5

FC4

FC8

FC9

FC10

FC11

FC7

FC6

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Summary of Contents for AE-X4M30PU

Page 1: ...ING PROCEDURE 29 PROCEDURE 29 Position of the thermistors 32 How to disassemble the control box assembly 33 SERVICE MANUAL 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 This document has been published to be used for after sales service only The content...

Page 2: ...ge type FV50S oz cc 27 4 700 Refrigerant system Evaporator Louver Fin and Grooved tube type Condenser Corrugate Fin and Grooved tube type Control Expansion valve Refrigerant type R410A oz g 88 2 2500 Noise level at cooling High Soft 53 07PU dB A 38 26 09PU 39 26 12PU 44 27 15PU 44 32 18PU 45 33 Noise level at heating High Soft 55 07PU dB A 39 28 09PU 40 28 12PU 43 29 15PU 44 34 18PU 46 35 Fan syst...

Page 3: ...49 15 Additional charge oz ft g m 0 16 15 Drain pipe O D inch mm 5 8 16 Others Safety device Compressor Thermal protector Fan motors Thermal fuse Fuse Micro computer control Pressure switch Air fillters Polypropylene net Washable Net dimensions Width x Height x Depth 07PU 09PU 12PU inch mm 36 7 32 x 11 13 32 x 9 7 16 920 x 290 x 240 35 x 31 1 2 x 12 19 32 890 x 800 x 320 15PU 18PU inch mm 38 x 12 ...

Page 4: ...NSION Length unit inch mm 0 6 16 2 51 3 3 75 14 2 361 15 1 383 5 9 150 5 9 150 23 2 590 R0 3 8 5 37 940 31 5 800 35 890 37 941 1 26 2 8 3 210 5 9 151 1 1 3 32 7 12 6 320 2 9 73 6 2 52 7 178 6 2 52 11 2 283 6 2 52 2 52 15 3 388 6 ...

Page 5: ...7 6 767 29 000 12 000 31 000 3 080 640 3 530 15 1 3 7 17 2 13 6 3 3 15 6 7 7 7 7 7 050 7 050 7 050 7 050 28 200 12 000 30 400 2 950 640 3 330 14 4 3 7 16 2 13 0 3 3 14 7 3 indoor unit operation 18 18 9 11 600 11 600 5 800 29 000 12 000 31 000 3 080 620 3 530 15 1 3 6 17 2 13 6 3 2 15 6 18 18 7 12 140 12 140 4 721 29 000 12 000 31 000 3 080 620 3 530 15 1 3 6 17 2 13 6 3 2 15 6 18 15 12 11 600 9 66...

Page 6: ...18 9 9 7 13 814 6 907 6 907 5 372 33 000 12 000 37 000 2 860 800 3 250 13 9 4 1 15 8 12 6 3 7 14 3 18 9 7 7 14 488 7 244 5 634 5 634 33 000 12 000 37 000 2 860 800 3 250 13 9 4 1 15 8 12 6 3 7 14 3 18 7 7 7 15 231 5 923 5 923 5 923 33 000 12 000 37 000 2 860 800 3 250 13 9 4 1 15 8 12 6 3 7 14 3 15 15 7 7 11 250 11 250 5 250 5 250 33 000 12 000 37 000 2 860 800 3 250 13 9 4 1 15 8 12 6 3 7 14 3 15...

Page 7: ...7 11 845 11 845 6 910 30 600 12 000 32 400 2 940 780 3 250 14 3 4 0 15 8 13 0 3 6 14 3 12 9 9 12 240 9 180 9 180 30 600 12 000 32 400 2 940 780 3 270 14 3 4 0 15 9 13 0 3 6 14 4 12 9 7 13 114 9 836 7 650 30 600 12 000 32 400 2 940 780 3 280 14 3 4 0 16 0 13 0 3 6 14 5 12 7 7 14 123 8 238 8 238 30 600 12 000 32 400 2 940 780 3 290 14 3 4 0 16 0 13 0 3 6 14 5 9 9 9 10 200 10 200 10 200 30 600 12 000...

Page 8: ...IRING DIAGRAM CAUTION Power factor PFC module error Compressor rotation error Thermal fuse error of terminal board Rotation error of the fan motor EEPROM error Overheat error Compressor Power module Example No 3 Overheat error Compressor Power module Cycle temperature error Abnormal wire check Abnormal AC current Abnormal signal line Abnormal comments Normal Short circuit of the thermistor Open ci...

Page 9: ...9 ZD3 R250 C100 C21 C25 C94 C101 C102 C104 C77 C124 IC5 C123 C16 C37D R35D C125 C54D C74 C90 C138 C130 C132 C131 R247 JP24 C33 JP94 R243 R17 R103 R109 R49 R240 R241 R242 JP23 JP22 JP21 R263 D23B D24D D23C D24C CN12A JP7 1 2 CN15B 1 2 CN15A 12V JP93 C137 R258 R259 1 3 CN4 BT15 C27 D5 FU6 R50 R262 CN11 1 10 C136 CN12D CN8M CN8A R100 R101 C99 C129 R180 FU2 NR2 R237 CT1 R235 Q6 R105 R236 D16 2 4 1 3 P...

Page 10: ... 20A FU1 C11C R1 R2 T4 BT4 C12B R4 C13B L5 C13C BT22 BT20 BT21 BT23 T21 C14B SA1 C1 C2 C3 C4 T23 L6 L3 C5 C12C NR1 L4 T22 T11 T20 from Control Box Green Yellow from Terminal Board AB L1 Brown from Terminal Board L2 Brown from Terminal Board AB L2 Blue from Terminal Board L1 Blue from Main PWB T14 Blue from Main PWB T13 Brown to Main PWB CN11 from Main PWB MRY1 OUT Black from Main PWB BCN13 from Ma...

Page 11: ... C15 1μF C17 50V C56 50V 1000pF R51 R53 10KΩ R263 C50 100μF 25V 100μF 25V C52 1 4W 33Ω R161 R162 1 4W 33Ω 33Ω R47 1 4W R48 1 4W 33Ω C30 100μF 10V F 3 9KΩ R249 IC11 A 1 3 2 8 4 JP93 Q5B C E B Q5C C E B Q5D C E B R93A 1 4W 2 2k R93B 2 2k 1 4W R93C 1 4W 2 2k R93D 1 4W 2 2k R92A 1 4W 1k R92B W 4 1 k 1 R92C 1k 1 4W R92D 1k 1 4W D24A D25A R153 1KΩ R154 4 7KΩ 0 1μF 25V C300 100Ω R180 1W 0 1μF C60 25V R24...

Page 12: ...lve D drive circuit Expansion valve D Expansion valve A Expansion valve B Expansion valve C CPU oscillator circuit AC overcurrent detection circuit DC overcurrent detection circuit Power transistor module overheat LED Heat exchanger pipe thermistor OR Compressor thermistor RED Current transformer Compressor Power transistor module Outdoor fan motor Smoothing circuit PFCM module Filter circuit AC p...

Page 13: ...5Hz once every 60 seconds or approxi mately 15Hz once every 90 seconds When the temperature of all of indoor heat exchangers go below the overheating prevention line 1 45 5 F 7 5 C the frequency is raised by approximately 5Hz once every 60 seconds and normal operation is restored If the condition that the frequency is minimum lasts for 2 minutes the compressor will be stopped When ON When OFF Over...

Page 14: ...an t be accepted if the indoor units in other rooms send individual requests If the indoor unit in another room sends a request for the heating operation the operation lamp and timer lamp of the indoor unit in that room start flashing in turn to inform that the unit is in the standby mode If the operation in one room is stopped while the indoor unit in another room is in the stand by mode the oper...

Page 15: ...n the heating cycle 1 minutes after it was stopped and normal control resumes 12 5 F 15 C AUTO STOP FUNCTION During the heating operation the unit will automatically stop when the outdoor temperature drops below 5 F 15 C to prevent the outdoor unit from the damage caused by the freezing of the drained water The unit will stop its operation for 4 hour and then resume the operation when the outdoor ...

Page 16: ... flash in synchronization with the timer lamp orange Timer lamp 1 cycle ON OFF 5 second OFF 1 second OFF 1 second OFF 1 second OFF 1 second OFF 1 second ON 1 second ON 1 second ON 1 second ON 1 second ON 1st 2nd 3rd 4th 5th 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 T...

Page 17: ...y stop for cycle protection O Operation green O Plasmacluster blue O O O O O Timer Orange 2 Outdoor unit heat exchanger overheat Temporary stop for cycle protection O Operation green O Plasmacluster blue O O O O O Timer Orange 3 Indoor unit heat exchanger overheat Temporary stop for cycle protection O Operation green O O Plasmacluster blue O O O O O Timer Orange 4 IPM high temperature error Measur...

Page 18: ...ot operate 9 time O O O O O Timer Orange 9 4 Cycle temperature 4 way valve error or Gas leak error 1 Check the unit thermistor TH2 exchange and TH3 pipe temperature are installed in correct portions 2 Check if the refrigerant volume is abnormally low 3 Check the 4 way valve for proper operation 1 Correct the installation 2 Change the specified amount of refrigerant 3 Replace the 4 way valve O O Op...

Page 19: ...ion green Plasmacluster blue O O O O O Timer Orange 1 PFC Module clock error O O O Operation green O Plasmacluster blue O O O O O Timer Orange 2 PFC Module low voltage error O O O Operation green O Plasmacluster blue O O O O O Timer Orange 4 PFC Module error O O O Operation green O Plasmacluster blue Indoor unit operates Outdoor unit does not operate Lighting or OFF O O O O O Timer Orange 17 0 Wir...

Page 20: ...e properties of indoor thermistors kΩ To measure the resistance first remove the soldering as shown at right Room temperature thermistor TH1 Yellow 77ºF 25ºC resistance 10 kΩ Heat exchange thermistor TH2 Orange TH3 Black 77ºF 25ºC resistance 4 431 kΩ CAUTION When attaching or removing the board When operating only the outdoor unit cooling 40 Hz fixed mode To make only the outdoor unit run in cooli...

Page 21: ...thermistor TH2 CN8A Orange No 3 to 4 Outdoor temp thermistor TH3 CN8A Green No 5 to 6 Suction thermistor TH4 CN8A Black No 7 to 8 Thermistor unit A suction TH6 CN8M Blue No 1 to 2 Thermistor unit B suction TH7 CN8M White No 3 to 4 Thermistor unit C suction TH8 CN8M Brown No 5 to 6 Thermistor unit D suction TH9 CN8M Yellow No 7 to 8 1 How to distinguish the defective parts 1 When all rooms are not ...

Page 22: ...tched off Is CN6 connected The cycle is abnormal The compressor is abnormal P U N U P V N V P W N W A Is the resistance value of the ther mistor for the com pressor TH1 heat ex changer TH2 or outdoor temper ature TH3 or suc tion TH4 TH6 9 correct Is each of the resist ance values among the terminals of the IPM PWB 0 P U N U P V N V P W N W Is each of the resistance values among the termi nals of t...

Page 23: ...nd L2 of the indoor unit is AC 230V Repair the wiring between the units Replace the indoor control PWB Replace the thermistor Check the failure symptom with the failure diagnosis mode Replace the outdoor control PWB or the expansion valve UNIT A or the expansion valve UNIT B or the expansion valve UNIT C or the expansion valve UNIT D Is the resistance value of the winding in the fan motor Between ...

Page 24: ...ied between the connector CN4 1 and 3 of the 4 way valve Replace the 4 way valve Pressure check The heating cycle is normal Refer to 1 All rooms are not cooled Press the ON switch on the remote control to run the air conditioner Set the temperature to 86ºF 30ºC in the heating mode and start operation Is the outdoor compressor running Yes Yes T o No No Yes Yes No No A ...

Page 25: ...oor thermistor opens Close the expansion valve of the corresponding room if some suction thermistor shorts or opens When the room turns ON and the compressor starts Operation OFF 1 time Yes Yes 8 AC abnormal cur rent Compressor is stopped if the operating frequen cy is above 70Hz and the compressor current is below 0 8A During compressor operation Automatically re starts after safety time 180 sec ...

Page 26: ...changer Heat exchanger UNIT C UNIT B UNIT A Expansion valve D STOP valve Liquid Compressor 4 way valve Accumulator STOP valve Gas Expansion valve C Expansion valve B Expansion valve A 1 4 2 3 3 3 3 15K 18K can t be connected 2 Flow of refrigerant INDOOR UNIT OUTDOOR UNIT AE X4M30PU UNIT D UNIT C UNIT B UNIT A Cooling heating 15K 18K can t be connected ...

Page 27: ...7 ºF 3 3 49 ºF 9 55 ºF 13 112 ºF 45 91 ºF 33 4 56 ºF 14 66 ºF 19 36 ºF 2 39 ºF 4 Stop valve pressure gas side 107 psig 134 psig 467 psig 349 psig Frequency 61Hz 34Hz 80Hz 49Hz AY XPC12PU 1 unit only on operation 1 166 ºF 74 149 ºF 65 167 ºF 75 124 ºF 51 2 95 ºF 35 95 ºF 35 38 ºF 3 37 ºF 3 3 54 ºF 12 59 ºF 15 103 ºF 40 78 ºF 25 4 56 ºF 14 68 ºF 20 38 ºF 3 45 ºF 7 Stop valve pressure gas side 121 ps...

Page 28: ...t W Outside air temp Outside air temp 2400 2600 2800 3000 3200 Total input W 58 60 62 64 66 68 Outlet air temp 78 80 82 84 86 88 90 92 Outlet air temp ºF ºF 9 7 4 1 2 4 7 10 13 ºC 15 20 25 30 35 40 45 50 55 Outside air temp ºF 9 7 4 1 2 4 7 10 13 ºC 15 20 25 30 35 40 45 50 55 Outside air temp ºF 9 7 4 1 2 4 7 10 13 ºC 18 21 24 27 29 32 35 38 41 43 46 49 ºC 65 70 75 80 85 90 95 100 105 110 115 120 ...

Page 29: ...ews fixing the front panel R 2 Remove the ten 10 screws fixing the top cover 3 Remove the two 2 screws fixing the side cover 4 Remove the one 1 screw fixing the cable cover 5 Remove the six 6 screws fixing the front panel L 6 Remove the four 4 screws fixing the rear guard ...

Page 30: ...2 points 9 Remove the two 2 screws fixing the control box cover Cut 10 Cut the six 6 fixing bands 11 Disconnect the nine 9 connectors 12 Remove the two 2 compressor covers Compressor covers 13 Remove the one 1 nut fixing the terminal cover 14 Disconnect the three 3 terminals RED WHITE ORANGE ...

Page 31: ...he five 5 screws fixing the control box assembly 16 Remove the one 1 nut fixing the propeller fan 17 Remove the two 2 screws fixing the motor angle 18 Cut the two 2 fixing bands 19 Remove the four 4 screws fixing the fan motor ...

Page 32: ...32 AE X4M30PU Position of the thermistors Green Orange Black Red Yellow Brown White Orange Blue Green ...

Page 33: ... the 3 screws fixing the PFC PWB 2 Remove the 4 screws fixing the MAIN PWB 3 Unlock the 2 spacer s lock 4 Remove the 2 screws fixing the FILTER PWB 5 Unlock the 2 spacer s lock The position of setting Ferrite core FC1 FC11 FC1 FC2 FC3 FC5 FC4 FC8 FC9 FC10 FC11 FC7 FC6 ...

Page 34: ...34 AE X4M30PU ...

Page 35: ...se 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 AEX4M30PU OUTDOOR UNIT AE X4M30PU PartsGuide 1 OUTDOOR UNIT PARTS 1 2 OUTDOOR UNIT PARTS 2 3 OTHER OUTDOOR PARTS 4 PACKING PARTS INDEX CONTENTS ...

Page 36: ...31 2 39 2 20 2 22 2 61 2 58 2 62 2 53 2 57 2 50 2 47 2 51 2 46 2 48 2 2 2 4 2 5 4 1 4 1 4 1 4 1 4 1 2 3 2 10 2 5 2 1 2 60 2 11 2 36 4 8 1 1 4 15 2 7 2 23 2 24 2 26 2 25 2 20 2 40 1 44 3 15 2 37 1 44 1 60 4 11 1 49 1 12 4 11 1 66 1 66 4 13 1 52 1 61 1 61 1 5 1 1 4 4 1 4 1 4 1 4 16 1 46 4 17 4 34 1 65 4 18 4 1 2 17 1 11 1 36 2 13 4 3x4 2 8 2 9 2 52 2 70 2 55 2 12 2 56 2 6 2 6 4 35 2 21 ...

Page 37: ...insulator 2 22 PSKR A414JBTA AY Bulkhead 2 23 GCAB A477JBTA BA Top cover 2 24 PSEL C598JBEZ AK Top cover seal A 2 25 PSEL C640JBEZ AG Top cover seal B 2 26 PSEL C702JBEZ AE Top cover seal C 2 28 GGADRA001JBTA AV Rear guard 2 31 LHLD B239JBFA AD Thermistor holder 2 36 NFANPA152JBEZ AY Propeller fan 2 37 PCOV A940JBWZ AP Control box cover 2 39 PSEL C373JBEZ AC Seal 2 40 PSEL C634JBEZ AE Panel seal A...

Page 38: ...UTDOOR UNIT PARTS 1 2 68 2 66 2 30 2 63 3 28 3 28 3 32 2 16 3 5 3 5 2 3 2 3 32 3 39 3 39 3 40 3 40 3 37 3 35 2 30 2 29 2 29 3 5 1 4 6 4 7 2 67 1 79 1 73 3 6 3 10 6 12 6 11 1 78 1 73 3 7 3 21 3 8 3 3 6 3 3 4 3 14 3 1 3 9 3 30 3 11 4 5 2 72 4 5 3 22 1 54 3 12 3 13 1 73 3 17 2 69 6 7 6 10 6 8 6 9 6 1 3 33 3 33 3 33 3 34 3 33 3 34 3 38 3 29 3 29 3 36 3 31 3 31 3 31 3 31 ...

Page 39: ... Flare union unit 2S C 3 36 DVLV B365JBKZ AT Flare union unit 2S A 3 37 DVLV B366JBKZ AT Flare union unit 2S B 3 38 DVLV B368JBKZ AT Flare union unit 2S D 3 39 LX NZA280JBEZ AG Flare nut 4 3 40 PCAP A103JBEZ AF Nut bonnet 4 5 LX BZA494JBEZ AE Special Screw 4 6 XNFS760 50000 AE Nut 4 7 LX WZA057JBEZ AC Washer 22 6 1 TINS B434JBRZ AG Installation manual 6 3 MSPR A026JBE0 AB Spring 6 7 LBND A046JBE0 ...

Page 40: ... B237JBFZ AG Heat sink holder Sub 4 21 PCOV C027JBWZ AH Holder cover 4 26 TLAB F836JBRZ AH Label Terminal CDP 4 27 TLAB F685JBRZ AH Label Terminal AB 4 29 TLAB F689JBRZ AH Label 6 11 CPIPCB666JBKZ AX JOINT 1 2 3 8 assembly 4 PACKING PARTS 5 1 CPADBA072JBKZ AR Bottom pad ass y 5 2 CPADBA073JBKZ AH Packing pad ass y 5 3 SPAKCE269JBEZ AZ Packing case 5 4 SPADBA707JBEZ AF Packing pad 3 OTHER OUTDOOR P...

Page 41: ... AB MSPR A036JBE0 2 1 79 AB MSPR A129JBE0 2 2 69 AD N NFANPA152JBEZ 1 2 36 AY P PACU A054JBEZ 2 3 10 BG PCAP A083JBEZ 2 3 33 AC PCAP A084JBEZ 2 3 34 AC PCAP A103JBEZ 2 3 40 AF PCMPRA718JBEZ 2 3 13 CU PCOV A940JBWZ 1 2 37 AP PCOV B887JBEZ 2 3 14 AR PCOV C027JBWZ 3 4 21 AH PCOV C028JBFA 1 2 72 AN PCOV C029JBTA 1 2 71 AL PDAI A298JBTA 2 2 16 AX PGUM A008JBE0 2 3 4 AE PGUM A120JBEZ 2 2 68 AG PGUM A121...

Page 42: ...89JBRZ 3 4 29 AH TLAB F690JBRA 2 2 72 AR TLAB F691JBRA 2 2 63 AS TLAB F692JBRZ 1 2 61 AH TLAB F693JBRZ 1 2 62 AM TLAB F694JBEZ 1 2 70 AH TLAB F696JBRZ 1 2 58 AF TLAB F697JBRZ 1 2 59 AH TLAB F748JBRZ 1 2 74 AF TLAB F836JBRZ 3 4 26 AH TLABMA819JBRA 1 2 52 AV TSPC H712JBRZ 1 2 55 AH X XBPS740P08K00 1 4 17 AK XBPS740P20J00 1 4 10 AF XCPS740P25000 1 4 12 AD XCTS740P30000 1 4 16 AF XJTS740P10000 1 4 13 ...

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