Professional Documents
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AY/AE-A099E
SERVICE MANUAL
S2915AYA099E/
SPLIT SYSTEM
ROOM AIR CONDITIONERS
INDOOR UNIT
MODELS AY-A079E
AY-A099E
OUTDOOR UNIT
AE-A079E
AE-A099E
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
Page
SPECIFICATIONS ........................................................................................................................................... 2
EXTERNAL DIMENSIONS ............................................................................................................................... 3
WIRING DIAGRAMS ....................................................................................................................................... 4
ELECTRICAL PARTS ...................................................................................................................................... 5
MICROCOMPUTER CONTROL SYSTEM ...................................................................................................... 8
FUNCTIONS ................................................................................................................................................... 9
TROUBLESHOOTING OF THE CONTROL CIRCUIT .................................................................................. 17
REFRIGERATION CYCLE ........................................................................................................................... 21
PERFORMANCE CURVES .......................................................................................................................... 23
REFRIGERANT PIPE AINSTALLATION WORKS ......................................................................................... 24
DISASSEMBLING PROCEDURE ................................................................................................................. 25
REPLACEMENT PARTS LIST ....................................................................................................................... 29
SHARP CORPORATION
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AY/AE-A079E
AY/AE-A099E
SPECIFICATIONS
ITEMS INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT
AY-A079E AE-A079E AY-A099E AE-A099E
Cooling capacity kW 2.1 2.6
Heatpump kW 2.4 3.0
Heating capacity
Moisture removal Liters/h 0.9 1.2
Electrical data
Phase – Single
Rated frequency Hz 50
Rated voltage range V 198 to 264
Rated voltage V 220 - 240
Rated current Cool A 3.2 - 3.1 4.1 - 3.9
Heat A 2.9 - 2.8 4.0 - 3.9
Rated input Cool W 680 - 720 890 - 920
Heat W 630 - 670 880 - 920
Power factor Cool % 97 - 97 99 - 98
Heat % 99 - 99 99 - 98
Compressor Type Hermetically sealed rotary type
Model 2PS134D5AA01 RH174VHET
Oil charge 270cc (SUNISO 4GDID) 300cc (DIAMOND MS56)
Refrigerant system Evaporator Louver fin and Grooved tube type(7mm tube)
Condenser Corrugate Fin and Grooved tube type
Control Capillary tube
Refrigerant volume 690g 730g
De-lce system Micro computer controled reverse sysetm
Noise level High dB(A) 33 43 38 43
(at cooling) Med. dB(A) 29 – 31 –
Low dB(A) 26 – 27 –
Fan system
Drive Direct drive
Air flow quantity High m3/min. 5.8 20 7.1 20
3
(at cooling) Med. m /min. 4.9 – 5.3 –
Low m3/min. 4.3 – 4.4 –
Fan Cross flow fan Propeller fan Cross flow fan Propeller fan
Connections
Refrigerant coupling Flare type
Refrigerant tube size Gas, Liquid 3/8", 1/4"
Refrigerant pipe sets No. AZ-24H5E; 5m(16.4ft), AZ-24H7E; 7m(23ft)
Drain piping mm(Inches) O.D ø 18(45/64)
Others
Safety device Compressor: Overload protector(MRA98589) Compressor: Overload protector(Internal)
Fan motors: Thermal fuse
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 790 720 790 720
Height mm 270 535 270 535
Depth mm 155 236 155 236
Net weight kg 7 27 7 31
Note: The condition of star ( ) marked item are ‘IEC 378’.
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EXTERNAL DIMENSIONS
790
155
270
58 19.5
Remote control
Figure E-1. INDOOR UNIT for AY-A079E and AY-A099E
58
245
236
228
535
20˚
WIRING DIAGRAMS
N N
RE THERMAL
UNIT TO UNIT CORD
N BL FUSE C
L
FAN VALVE COMPRESSOR
MOTOR COIL MOTOR
TERMINAL R S
BORAD 1 RE WH
BK BL
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N N
RE THERMAL
MOTOR
ELECTRICAL PARTS
For Model AY-A079E and AE-A079E
DESCRIPTION MODEL REMARKS SITE
Compressor 2PS134D5AA01 220/240V, 50Hz, 650W AE
Indoor fan motor ML-A411 220/240V, 50Hz AY
Outdoor fan motor ML-A592 220/240V, 50Hz AE
Indoor fan motor capacitor – 400V, 1µF AY
Outdoor fan motor capacitor – 400V, 1.5µF AE
Running capacitor – 370V, 25µF AE
Transformer – Primary; AC 220V,50Hz AY
Secondary; AC16.1V, 50Hz
Fuse 250V, 2.5A AY
Reverse valve MMB-26A 240V AE
Reverse valve coil RSV-10 – AE
FUSE
5V 12V C D
THERMAL FUSE 1 5
CT
7812 C1 2.5A 250V
AY/AE-A099E
AY/AE-A079E
29
28
27
26
25
24
23 NC
22 NC
21
20
50v
50v 50v
JP10
KH
12V
P60
P61
P62
P63
P64
P65
P66
P40
12H/24H
GND
TEST 32
OCS IN 30
PHOTO DETECTOR UNIT 5V 5V
OCSOUT 31 NC
JP9
D. FAN OFF 5V
JP7
33 P27 P41 19 OFF WIDEH
R30 JP5 BZ D8
+ C101 CN101 CN6 10k 34 P26 P42 18 DEICE B
33µ JP4 R5 R15
– 10v 35 P25 P43 17 DEICE A 2.7k 2.7k(F) D7
1 1 Q1
(C102) 36 P24 P44 16 3
0.1µ R26 C23
680 1000P 2 5V
25v 37 P23 P45 15 1
2 2 50v 3 IC5 1 + R14
C20 R16 C9 R13
38 P22 P46 14 2k(F)
2 50V 13.7k(F) 16V 10k(F)
3 3 39 P21 F 13 1 C15 1000P 220µ –
3 0.1µ
40 P20 RESET 12 50v
(YELLOW) LED102 4 4 OCS
R29 330 41 K1 SM8313 CK1 11
(RED) LED101 5 5 42 P17 CK2 10 2 8MHz 5V
R28 680 43 P16 AGND 9 JP6 5V
IC1 10k R31
6
BCN1 BCN2 NC 44 P15 P30 8
2 Q2 SWEAT
2 3 NC 45 P14 P31 7 JP3 1
SSR D5 7 7 10k R32 TEST
RY2 46 P13 P32 6 RPM PLUSE
3 1 2
6 6 47 P12 P33 5 JP1 R19
RY1 RY3 10k R33 TH1 15k(25˚C)
R6 48 P11 P50 4 10k 3
PREHEAT
470 1 1 49 P10 P51 3 R21 10k
1/2w 10k R34 JP2 ROOM TEMP.
50 P07 P52 2 + 4
8 8 WIRELESS C21 R18 C11
51 P06 P53 1 1000P 15kF 10µ TH2 15k(25˚C)
22k(F) R35 R10 50v – 16v 5
FAN L R20 10k
12V PIPE TEMP.
12V + 6
VR
5 5 C22
P05
P04
P03
P02
P01
P00
P57
P56
P55
P54
22k(F) R36 R9 R17 C10
VDD
GND
FAN M 1000P 15kF 10µ
50v – 16v CN4
BCN1 BCN2 9
52
53
58
59
60
61
62
63
5 64 22k(F) R37 R8
FAN H
NC 54
NC 55
NC 56
NC 57
4 5V
NONE R38 R12
MODEL B
3 +
C8 C7 R39
10µ 0.1µ 22k(F) R11
2 IC4 10v – 50v MODEL A
1
LOUVER MOTOR 8
CN3
D. FAN OFF OFF WIDEH SWEAT RPM PREHEAT WIRELESS FAN L FAN M FAN H MODEL MODEL DE. FAN DE. FAN FREEZE FREEZE POWER ON
DEICE DEICE
FUNCTION 12H / 24H PLUSE CHANG/ B A B A B A
B A
OFF/ON 3/5min. ON/OFF 1/3 OFF/ON NORMAL ON/OFF
19 17 16 15 14 8 7 6 5 4 3 2 1 64 33 34 35 36 40
IC1 PIN NO. (P41) (P43) (P44) (P45) (P46) (P30) (P31) (P32) (P33) (P50) (P51) (P52) (P53) (P54) (P27) (P26) (P25) (P24) (P20)
SYMBOL JP10 JP9 JP7 JP5 JP4 JP6 JP3 JP1 JP2 R10 R9 R8 R12 R11 JP14 JP13 JP12 JP11 JP8
AY-A079E X NONE X NONE X NONE X NONE X NONE USE USE USE X NONE X NONE 140k(F) 24.9k(F) 22k(F) 133k(F) X NONE X NONE X NONE X NONE X NONE
AY-A099E X NONE X NONE X NONE USE USE USE USE USE X NONE 140k(F) 15k(F) 15k(F) 1.87k(F) 107k(F) X NONE X NONE X NONE X NONE X NONE
Figure L-1. Electronic Control Circuit Diagram for AY-A079E and AY-A099E
Fan motor capacitor Fan motor capacitor
Louver motor Indoor fan motor(R.P.M. Signal)
Indoor fan motor CN201
CN101 Thermistor
CN3 CN5
2 CN1 FAN MOTOR
COIL
2.550V CNR2 1 5 LOUVER MOTOR RPM SIGNAL
A
VALVE
IN
IC2
ORANGE
CNR1
(E) 2
(D)
PURPLE
SE
FU
FAN MOTOR
CAPACITOR
THERMISTOR CN4
R25
5 3 1
JP49
OUT
(B)
C12
OUT DOOR
FAN MOTOR(F)
C4 IN
IC3 C3
R14 QPWBFA652JBE0
NR
C5OUT FPWBFA013JBK0
Terminal board L 6 R17 1
D9
L
CT C6 C11
R13 C9 JP44 12V SW201 SW202
GND
IN
D8
3
D7 JP46
JP 27
RY2
C1
R30
R28
R29
9 C10 R18
3 Q1 1
JP42
3 CN7 1 5 1
R5 CN7
RY3 TEST AUX.
CN6
CNR3 JP48
1
RUN
CN201
OUT
16
(C1)
JP43
8
7
C8
(A1)
BLUE
JP47
13 JP41 R11 MODEL A RECEIVER UNIT
7
IC4
R16
R8
5
64 FAN M
DPWBFA
Terminal board " 1 " 2 R9
D5
JP38
JP39
R39
C20
51
C21
R38
1 R36
R37
QPWBFB252JBE0(C)
R35
CN2 5
C101
S
R26 CN6
FAN L
CN101
D4
D2
D1 SR
JP1
IC1
C13 R34
2
1
(TRANSFORMER)
PREHEAT
GND JP2
R41 WIRELESSL
R33
1
R40 R32
C15
POWER ON
1
JP34 LED102
JP8 JP12
IC5 JP6
Q2
3
8 FPWBFA134JBK0
JP50
R4
JP36 5
R7
FREEZE A
DE.FAN A
D3
FREEZE B
JP14
R6
JP10
R19
C16
C19
BCN1
JP33
R24
13
C14
DE.FAN B
R23
FSGY-A141JBK0
8
BCN2 JP35
DEICE B
DEICE A
12H / 24H
C18
OFF WIDEH
R22
QPWBFB124JBE0
5V
Q3
JP37
JP5
JP7
JP4
1
1
IC6 4
1
DIP DIP
Microcomputer (IC1)
The microcomputer is a CMOS, one chip, 8-bit microcomputer.
Microcomputer port allocation is as follows.
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AY/AE-A099E
FUNCTIONS
1. Temperature control characteristic 1-3 HEAT operation
1-1 COOL operation In the “HEAT” mode, the thermostat circuit
In the “COOL” mode, the thermostat circuit is is controlled by six thermostat lines (H01 thru
controlled by four thermostat lines (C1 thru C4). H4).
34.5 C1 40 H01
38 H02
33.5 C2 36 H1
Room temperature (˚C)
32.5 C3 35 H2
Room temperature(˚C)
33 H3
31.5 C4 31 H4
26
20.5
24
19.5 22
21
18.5
19
17.5 17
18 32 18 32
Preset temperature (˚C) Preset temperature (˚C)
31.5 D3
C3
Room temperature
C4
3
1
19.5
18.5
Room
temperature
17.5 transition
2
18 32
Preset temperature (˚C)
Figure Y-4
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Room temperature
H1
The preset temperature ranges from 18˚C to
32˚C. When the room temperature is below 18˚C, H2
the preset temperature is set to 18˚C, and when 2
the room temperature is over 32˚C, the preset
temperature is set to 32˚C.
Dry operation is divided into three zones (Cooling Room
temperature
zone, Dehumidifying zone and Circulating zone) 3 transition
by thermostat lines (D1 to D3), and the 1
compressor and the fan motor are controlled in
each zone as shown in Table Y-1. Preset temperature
5 3. Fan speed
1 D3 Fan speeds are given by the indoor fan motor, "H",
4 “M”, “L”, “UL” and "D" which are available in the
following operation mode.
2
Room Table Y-2
temperature
3 transition
FAN Switch HEAT COOL FAN ONLY
HIGH H M M
Preset temperature
LOW M L L
Figure Y-5
SOFT L UL UL
Table Y-1
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Pipe temperature(˚C)
30
29
24
OFF
UL Preset UL OFF UL
Fan speed
Figure Y-8
11
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7. Current control
This system, in order to prevent overcurrent during Switch ON Defrost Defrost
heating operation, controls the outdoor fan motor and
changes the indoor fan motor speed by detecting total
current.
When the current exceeds P2, the outdoor fan motor is Heating Heating Heating
automatically turned off, and when the current falls
below P4, the outdoor fan motor is turned on. Min. Max. Min. Max.
40min. 11min. 30min. 11min.
When the current exceeds P3 and the indoor fan speed
shifts down because of cold air (5. Preheat air flow), the Figure Y-11
changes in the indoor fan speed shifts up as follows, Defrost start 50sec. 10sec. 50sec. 10sec.
from "off" to "UL", or from "UL" to "L". And when the
current falls bellow P5, the indoor fan speed shift up is Compressor ON
canceled. OFF
ON MAX. 9min.
AY- AY-
Reverse
Current transition A079E A099E
Valve
OFF
P1 5.3A 6.9A ON
P2 4.5A 6.1A Outdoor
Fan Motor OFF
P3 4.0A 5.4A
ON
Input current
Time
Figure Y-12
Outdoor Indoor Compressor
Fan motor Fan motor OFF 10. Delayed operation of the reverse valve
OFF Shift UP When the heat operation is shut down or the operating
mode is switched from heat to cool or dry, or vice versa,
Figure Y-10 the reverse valve is switched after 3 minutes.
2 18.Test mode
Room 18-1 TEST 1 (For control circuit operation checking)
temperature Make terminals 1 and 2 of connector CN4 short-
3 transition circuited and supply the power.
Hereby the timer's period becomes shortened.
Preset temperature In this test mode, the control times are shortend
as follows.
Figure Y-13
The operation LED flicker's period
b. HEAT operation
not
in Test run shortened
States 1 & 7 : "H" The protector timer
States 2 & 6 : "M"
States 3 & 5 : "L"
The defrost timer
States 4 : "L"/"UL"/OFF
H1 Other controls; 1/60 (ex.; 3 min. to 3 sec.)
Room temperature
4 H2
18-2 TEST 2 (For output of each operation checking)
H3 Keep pushing both the buttons, "AUX." and
3
5 H4 "TEST RUN", and supply the power, the system
2 will go to the test 2 mode. In this mode, the
6 output of operation is switched by pushing the
1 Room
7
temperature
"TEST RUN" button in the unit or the "OI" button
transition in the remote controller. Use the "AUX." button
to back to step 1.
Preset temperature Normal outputs are shown in Table Y-6 and Y-7.
Figure Y-14
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19.Diagnosis procedure
When indoor fan motor is out of order or compressor lock occurs, the compressor, inddor fan motor, outdoor fan
motor, and louver are all stopped and the operation LED(red) turns on or off syncronously with the timimg of the
timer LED.
When the thermistor for room temperature or pipe temperature is open or short state, the operation LED turns on
or off syncrnoously with the timing of the timer LED by pushing continously for more than three seconds both
"TEST" button and "AUX." button.
1sec. 1sec.
ON
Timer 4sec.
LED
OFF
Indoor Operation ON
fan motor LED
OFF
ON
Comp.-lock Operation
LED
OFF
Thermistor Operation ON
short state LED
OFF
Thermistor Operation ON
open state LED
OFF
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Table Y-7[AY-A099E]
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YES
NO
Replace the PWB with a new Is the 2.5A fuse down ?
one.
YES
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Is transmitting NO NO
Are batteries of the
indicator of the remote wireless remote controller
controller active ? proper ?
NO
YES
Connect the Replace the
connector PWB with a
properly. new one.
Using a tester,
measure the voltage When the signal is NO
between terminals received, does the voltage
of resistor R15 change ?
on the PWB ass'y.
Replace the display unit
YES with a new one.
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140
120
Push the button "TEST RUN" on
the indoor unit, and wait 3 minutes. 100
80
25˚C
60 15K
Using a tester, measure voltage at
the terminals on the terminal board. 40
20
0
-10 0 10 20 30 40˚C
Fig. 1
Is the voltage
between terminal "N" and NO
"1" of the terminal board the
power supply voltage ?
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Is the voltage
between terminal "N" and NO
"1" of the terminal board the
power supply voltage ?
YES
Is the voltage
between terminal "N" and NO
"2" of the terminal board the NO
power supply voltage ?
YES
Is the voltage
between terminal "N" and NO
"3" of the terminal board the
power supply voltage ?
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REFRIGERATION CYCLE
3
Flare coupling Flare coupling
Strainer S
Compressor Capillary
tube A
1
Capillary
tube B Check
valve
Accumulator
4 Condenser 2
S
Reverse Strainer
valve
At Cooling At Heating
21
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PERFORMANCE CURVES
11900 3.5
Cooling capacity (BTU/h)
(KW)
8500 2.5 8500 2.5
6800 2.0
6800 2.0
5100 1.5
1000
1000
Input(W)
Input(W)
500
500
0
15 50
14
Outlet air temp.(˚C)
45
Outlet air temp.(˚C)
13
40
12
11 35
10
30
9
25
8
7 20
30 31 32 33 34 35 36 37 38 39 40 –10 –8 –6 –4 –2 0 2 4 6 8 10
Outside air temp.(˚C) Outside air temp.(˚C)
Figure P-1. At Cooling for AY-A079E Figure P-2. At Heating for AY-A079E
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11900 3.5
Cooling capacity(BTU/h)
Cooling capacity(BTU/h)
10200 3.0
10200 3.0
(KW)
(KW)
8500 2.5
8500 2.5
5100
1.5 1.5
5100
3400
1.0
1000 1000
Input(W)
15
14 0
13 50
Outlet air temp.(˚C)
12 45
11 40
10 35
9 30
8 25
7 2-
30 31 32 33 34 35 36 37 38 39 40 -10 -8 -6 -4 -2 0 2 4 6 8 10
Outside air temp.(˚C) Outside air temp.(˚C)
Figure P-3. At Cooling for AY-A099E Figure P-4. At Heating for AY-A099E
The shorter refrigerant pipe, the highter the machine capabillity. Keep the pipeline as short as possible.
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DISASSEMBLING PROCEDURE
FOR INDOOR UNIT MODEL AY-A079E/AY-A099E
CAUTION: DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY SERVICING
1. Remove the 2 screw covers in the front panel. 4. Close the open panel softly, and then press " B " and
" C " of it securely.
Remove the front panel ass'y as to lift up.
B B
C
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7.Take the thermistor holder from evaporator. 11.Loosen 4 screws fixing control box and take out control
ass'y.
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15.When assembling make sure that O-ring is fitted to 19.Loosen 2 screws fixing evaporator.
the drain hose.
O-ring
Drain hose
O-ring
(Section)
16.Take out the drain pan ass'y. 20.Take out the fan bearing ass'y.
17.Loose a screw fixing cross flow fan to motor. 21.Take out the cross flow fan while slightly lifting the
evaporator.
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CAUTION: DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY SERVICING
1 Remove the three (3) screws holding the right side 3 Remove the another screws holding the cabinet and
plate and take it out. take it out..
2 Remove the three (3) screws holding the left side
plate and take it out.
2
Left side plate
NOTE: Number as shown in following
figure is the moval order.
Condenser
Compressor
Fan motor
To have your order filled prompty and correctly, please furnish the following information.
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1 2 3 4 5 6
A
INDOOR UNIT FOR AY-A079E AND AY-A099E A
4-3
4-10
4-6
1-30 4-4
B 4-7 B
4-5
4-1
4-2
1-41 4-8
1-16
1-20 6-2
F 1-26 F
1-38
1-24
1-34
2-17
1-39
G 1-40 G
1-22 1-32
1-21
1-23
H H
1 2 3 4 5 6
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1 2 3 4 5 6
A
OUTDOOR UNIT FOR AE-A079E AND AE-A099E A
1-6
B 3-2 B
1-16
3-23
3-21
1-12
E 6-1 E
1-2
6-5
1-9
1-8
F
2-8 2-4 F
2-5
2-9 2-10
2-6
1-7
1-1
G G
2-2 2-7
1-10 1-14
1-15
H H
1 2 3 4 5 6
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