Download SERVICE MANUAL

SERVICE MANUAL
SPLIT SYSTEM
ROOM AIR CONDITIONER
INDOOR UNIT
AH-MP20
OUTDOOR UNIT
AU-MP20
CONTENTS
Page
SPECIFICATIONS..............................................................................................................................................2
EXTERNAL DIMENSIONS.................................................................................................................................3
WIRING DIAGRAMS..........................................................................................................................................4
ELECTRICAL PARTS........................................................................................................................................5
MICROCOMPUTER CONTROL SYSTEM.........................................................................................................6
PRINTED WIRING DIAGRAM............................................................................................................................7
FUNTIONS..........................................................................................................................................................8
TROUBLESHOOTING......................................................................................................................................12
REFRIGERATION CYCLE AND PERFORMANCE CURVES..........................................................................15
DISASSEMBLING PROCEDURE.....................................................................................................................17
REPLACEMENT PARTS LIST..........................................................................................................................27
SHARP CORPORATION
1
CHAPTER 1. PRODUCT SPECIFICATION
[1] SPECIFICATION
1. AH-MP20 / AU-MP20
ITEMS
Cooling capacity
Moisture removal
Electrical data
Phase
Rated frequency
Rated voltage
Rated current
Rated input *
Power factor
Compressor
Refrigerant system
Noise level
(at cooling)
Fan system
Drive
Air flow quantity
(at cooling)
kW
Liters/h
Net weight
OUTDOOR UNIT
AU-MP20
Single
50
220
7.9
1720
92 - 98
Type
Hermetically sealed rotary type
Model
PH31VNET
Oil charge
670cc ,DIAMOND MS32(N-1)
Evaporator
Louver fin and Grooved tube type
Condenser
Louver fin and Grooved tube type
Control
Capillary tube
Refrigerant volume R22 1300g
High
44
dB(A)
53
Mid.
37
dB(A)
–
Low
35
dB(A)
–
Hz
V
A
W
%
High
Med.
Low
m3/min.
m3/min.
m3/min.
Fan
Connections
Refrigerant coupling
Refrigerant tube size Gas, Liquid
mm
Drain piping
Others
Safety device
Air filters
Net dimensions
INDOOR UNIT
AH-MP20
5.30
–
Width
Height
Depth
mm
mm
mm
kg
17.5
13.4
11.9
Cross flow fan
Direct drive
44
Propeller fan
Flare type
1/2" , 1/4"
O.Dφ 20
Compressor : Internal protector
Fan motor : Thermal protector(Internal)
Fuse, Micro computer control
Polypropylene net (Washable)
1040 (1155)
890 (1020)
325 (300)
645 (735)
220 (385)
327 (398)
19 (21)
55 (59)
2
[2] EXTERNAL DIMENSION
1. Indoor unit (AH-MP20)
2. Outdoor unit (AU-MP20)
3
[3] WIRING DIAGRAM
Indoor Unit (AH-MP20)
25A
450v
CC064
Outdoor Unit (AU-MP20)
UNIT TO UNIT CORD
45
CC097
4
CHAPTER 2. ELECTRIC CIRCUIT
[1] ELECTRIC PARTS
1. INDOOR UNIT (AH-MP20)
PART NO.
PART NAME
ITEM
SPECIFICATION
1
Terminal Board
Rating
2
Fan motor Capacitor
Rating
450V, 2µF
3
Relay-1
Rating
AC250V,20A
4
Printed Wiring Board
Material
Paper Base Phenolic Resin (UL 94V-0)
5
Transformer
Rating
Pri 220-240VAC
6
Fan motor
Rating
220 - 240VAC 50Hz 41W 4-Pole
Type
MLA999
(RY1)
300V,25A
Coil Volt: 12V
± °
Thermal Protector Cut off 135 10 C
(Internal)
7
Power Supply Cord
8
Louver Motor
Rating
3 x 1.5 mm2
Type
H05VV-F
Rating
DC12V
Type
24BYJ48
1. OUTDOOR UNIT (AU-MP20)
PART NO.
PART NAME
ITEM
SPECIFICATION
1
Terminal Board
Rating
300V,25A
2
Fan motor Capacitor
Rating
450V, 3µF
3
Running Capacitor
Rating
400V, 45µF
4
Compressor
Rating
AC220V 50Hz 1730W
Type
PH31VNET
Rating
-
5
6
Protector
Fan motor
Type
(INTERNAL)
Rating
220 - 240VAC 50Hz 71W 6-Pole
Type
MLA002
Thermal Protector Cut off 135
(Internal)
5
±5°C
I
DEF.
JP1
1
2
3
5
6
7
JP3
SWEAT
HOT
KEEP
CN3
CN2
CN1
WIRE
LESS
JP4
3
3
NONE
1
5
3
1
1
BL
BL
JP2
FAN
MOTOR
INTERNAL
THERMOSTAT
NONE
CLUSTER
SYMBOL
N
TERMINAL
BOARD
TO
OUTDOOR
UNIT
1
TERMINAL
BOARD
CT1
BL
L1
2∝
C1
6.8K
R1
2W
6.8K
R2
2W
D12
+
NR1
PWR
ON
JP5
JP6
JP7
TEST
JP8
NONE NONE NONE NONE
D14
NF1
400V
R7
1K(F)
DEIC
E1
JP9
2
1
R8
10K(F)
D6
3
Q8
R39
10K
DEIC
E2
C3
2
1
0.1∝
4
3
2
1
3
Q7
R6
20K
TR1
+ C9
16V
220∝
DRY
FAN
JP11
5
6
7
8
PIPE
1
JP12
D1?4
16V
C10
0.01∝
R4
22K
PIPE
2
JP13
25V
C11
NONE NONE
R40
10K
JP10
JP18
SINGLE
PHASE
0.01 ∝
275V
C2
A
JP9
0.1 ∝
JP8
275V
JP7
N
JP19
1
JP12
POWER
SUPPLY
8
WPE1
3A
250V
T
OUT
FAN
JP18
1 2
Q2
22K
C4
35V
1000∝
+
CLUS
TER
JP19
FAN1
HEAT
R19
IC2
R9
2.7K(F)
C5
50V
0.1∝
NONE 15K
R5
3.3K
R13
JP11
OUT
BK RY1
BR
SSR1
100
R41
1W
0.1 ∝
6
SSR2
275V
C31
0.033 ∝
C28
275V
C29
47 ∝
25V
JP13
IC8
JP1
JP2
JP3
16V
16V
16V
16V
P31
P32
P33
P34
P35
Vcc
P36
P37
P40
P41
P42
P43
P44
JP21
13K
R37
MODE MODE
L2
L1
R38
9.1K
R16
10K
15K
R15
R23
NC
0.01∝
0.01∝
0.01∝
0.01∝
10K
R14
22.6K(F)
C13
C14
C15
C27
52
53
54
55
56
57
58
59
60
61
62
63
64
FAN2 LOUV
COOL ER
R21
15K
7812
D7
+ C6
25V
47∝
C7
25V
0.1∝
IC3
+ C8
10V
100∝
(PATTERN SIDE)
IC1
MB89537A
13K
13K
13K
NC
NC
3
+
R37
R38
R23
R21
R22
R19
JP5
JP4
16V 0.01∝
R25
16V 0.01∝
50V 1000p
R24
R20
32
31
30
29
28
27
26
25
24
23
22
21
20
R18
C19
10K
C18
C17
680
P21
P22
P23
P24
P25
P26
P27
Vss
X1
X0
MOD1
MOD0
RST
1
OSC1
10MHz
R17
3.3K
R26
10K
10K
R27
C22
16V
0.01 ∝
8
9
IC5
IC4
1/2W
BZ1
IN
D8
D9
JP10
47K
R11
1K
R10
6.8K
R12
0.01 ∝
16V
C12
7805
NC
NC
NC
NC
C16
25V
25V
C20
0.1 ∝
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
0.1 ∝
8
9
1.8K
R29
R28
P30
NC
P00
P01
P02
P03
P04
P05
P06
P07
P10
P11
P12
P13
P14
P15
P16
P17
P20
P45
P46
P47
AN0
AN1
AN2
AN3
AN4
AN5
AN6
AN7
AVcc
AVR
AVss
P60
P61
P62
P63
P64
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
50V
IC6
C21
1∝
470
3
3
R30
470
1/2W
RY1
CLEANING
SWITCH 2
3
1
1
SSR1
CN9
2
Q5
2
Q6
SSR2
2
GND
5V
12V
R35
3.3K
47
1/2W
2
R45
+
+
1
Q1
R31
10K
R33
10K
3
25V
C24
3
C25
10∝
16V
C26
10 ∝
16V
6
0.1∝
25V
C23
0.1∝
CN7
CN8
CN10
BCN1
R32
10K
(F)
T
ON
FR
R34
10k
(F)
1
3
4
5
6
7
3
4
5
6
7
3
2
1
4
5
4
3
2
1
3
2
1
4
3
GR
56
CN5
CN6
HOLE
IC
1
2
3
SW101
TH1
PIPE TEMP
10k ! (25ыC).
TH2
PIPE TEMP
15k ! (25ыC).
FAN
MOTOR
CN103
LOUVER
MOTOR
(TIMER)
LED102
(OPERATION)
LED101
BL
4
5
LED107
(CLUSTER)
R101
R102
R103
R104
R105
2
2
CLEANING
SWITCH 1
3
3
(FAN AUTO)
LED106
(FAN H)
LED105
(FAN M)
LED104
(FAN L)
LED103
C102
25V
0.1∝
IC101
6
+
C101
10V
33∝
R106
CN102
BCN102
R108
R107
2.7K
620
1/2W
620
1/2W
620
1/2W
620
1/2W
3K
56
BCN101
CN101
SW1 : AUX.(TEST RUN)
5
2
2
1
1
2
10
10
1
9
9
8
2
2
8
1
1
3
2
2
3
1
1
1
1
[2] MICRO-COMPUTER CONTROL SYSTEM
1. Electronic Control Diagram
Indoor unit (AH-MP20)
2. PRINTED WIRING DIAGRAM
1 Indoor (AH-MP20)
7
CHAPTER 3. FUNCTIONS
[1] FUNCTION
1. TEMPERATURE CONTROL CHARACTERISTIC
2.2. DRY
1.1. COOL operation
On the switch on, the compressor always starts to operate for 2
minutes with fan speed "DL".
The microcomputer reads the room temperature 2 minutes after this
first compressor operation.
In the "COOL" mode, the thermostat circuit is controlled by five
thermostat lines (C1 thru C5).
This room temperature is set as the preset temperature
t preset
ti lltemperature ranges from 18° C to 32°C. When the room
The
temperature is below 18 °C, the preset temperature is set to 18° C,
and when the room temperature is over 32 ° C, the preset
temperature is set to 32°C.
Dry operation is divided into three zones (Cooling zone,
Dehumidifying zone and Circulating zone) by thermostat lines (D1 to
D3), and the compressor and the fan motor are controlled in each
zone as shown in Table.
18 32
Preset temperature (C° )
1.2. DRY
In the "DRY" mode, the thermostat circuit is controlled by three
thermostat lines (D1 thru D3).
18 32
Preset temperature (C° )
Compressor
ON
ON
OFF
Cooling zone
Dehumidifying zone
Circulating zone
18 32
Preset temperature (C° )
2. OPERATION MODES
2.1.
Fan speed
"DH"
"DL"
"DL" or OFF
3. FAN SPEED
Fan speeds are given by the indoor fan motor, "DL"~"HH" which are
available in the following operation mode.
COOL operation
The compressor turns on or off, at the thermostat lines C3 and C4.
The outdoor fan motor is also controlled with the compressor.
Fan
Fan switch
speed
DL
DH
CL
CAL
CM
CAH
CH
18 32
Preset temperature (C° )
8
Fan switch
(AUTO)
—
—
COOL SOFT
—
COOL LOW
—
COOL HIGH
DRY
—
COOL
—
AH-MP20
(r.p.m)
800
890
800
840
980
1020
1170
4. TEST
OUTPUTS IN EACH OPERATION MODE
If the "AUX" button on the unit is pressed for 5 seconds or more during
operation, cool test operation starts. The operation LED (red) flickers
during test run.
Mode
To put the system in the heating test run mode, start the cooling
operation and select the heating mode on the remote control. In cool
and heat mode continuous compressor on operation is performed. In
dry mode the operation is in dehumidifiying zone. In fan only mode the
indoor fan motor runs continusly.
Compressor
Outdoor
Indoor
Fan Motor Fan Motor
ON
ON
OFF
ON
Valve Coil
O Cooling
ON
OFF
Cooling
} Dehumidiflying
ON
ON
ON
ON
L/UL
UL/D
OFF
OFF
OFF
OFF
D/OFF
OFF
O CirculatU ing
OFF
OFF
o
5. TIMER
5.1. ON/OFF Timer
Circulating
When the unit operates during one hour after the OFF-time is set, therin
mostart setting is automatically shifted (
operation and dry operation). When the ON-timer is set in cool
operation, operation starts before 0 to 30 minutes(depends on the room
temperature) so that preset temperature is obtaind at set time.
POWER ON START
If the connecting wire "POWER ON" (JP99) is cut on the PWB
ass'y, when the power is supplied by turning on a circuit breaker,
the air conditioner automatically starts of operation in "AUTO".
5.2. hour timer
(Refer to Printed Wiring Board.)
When ONE-HOUR timer is set, the unit turns off automatically after one
hour. The one hour timer operation has priority over other time
operation, such as the TIMER ON and TIMER OFF. If the ONE-HOUR
TIMER button is pressed again during operation, the unit will operate
additionally for another one hour.
AUTO RESTART 11.1.
When JP5 is ON
Power failuer occurs during operation, the unit will restart in the
same operation mode as before recovery.
AUTOMATIC AIR CONDITIONING
When automatic air conditioning is selected, the operation mode and
preset temperature are set automatically according to the room
temperature on starting operation.
11.2. When JP5 is OFF
Auto restart function is not available.
Room temperature
at operation start
Above 28°C
26°C > 28°C
24°C > 26°C
Below 24°C
Operation Mode
Preset Temperature
COOL
DRY
Room temperature at
operation start
26°C
25°C
24°C
When DRY mode is selected by the micro computer with AUTO
operation, the fan speed lamps on the indoor unit panel will indicate
identically with the fan speed symbols on the remote control dispaly, as
the FAN speed setting is changed accordingly. Despite,as the FAN
speed setting is changed accordingly. Despite, the actual fan speed will
not change, as it is determined autometically by the micro computer.
AUTOMATIC FAN SPEED
When the automatic fan speed is selected in cool operation, the fan
speed is automatically changed by the thermostat lines C1 to C3 in
cool operation.
9
[2] TEST MODE
Keep pushing the "AUX." buttons and supply the power, the system will go to the test mode. In this mode, the output of operation is switched by
pushing the ""AUX." button in the unit or the "OI" button in the remote controller. Normal outputs are shown in Table.
2.1 PLASMA CLUSTER
Plasma cluster ion mode
SSR2 : ON
Relay (Cluster unit inside) : OFF
Minus ion mode
SSR2 : ON
Relay (Cluster unit inside) : ON
1) Cluster generator checking (STEP 1)
Time LED
ON
(Yellow)
Judgement
Normal
(Generator OK)
OFF
Failure
(Check circuit)
10
[3] DIAGNOSIS PROCEDURE
When indoor fan motor is out of order or compressor lock occurs, indoor fan motor, outdoor fan motor, and louver are all stopped and the
operation LED(red) turns on or off synchronously 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 synchrnoously with the
timing of the timer LED by pushing continously for more than 5 seconds "AUX." button during suspension of operation.
Timing chart of Timer LED and Operation LED of DIAGNOSIS PROCEDURE.
When "OI" button the remote controller or "AUX." button in the unit is pushed, the unit is free from DIAGNOSIS
PROCEDURE
When the louver unit is not properly installed, all lamps on the indicator panel will blink operation are all stop and Remote signal is not accept.
11
CHAPTER 4. TROUBLESHOOTING
12
13
14
CHAPTER 5. REFRIGERANTION CYCLE AND PERFORMANCE CURVES
[1] REFRIGERANT CYCLE
Capillary tube
O.D
3.5
15
I.D
2.0
L
80
[2] PERFORMANCE CURVES
1 – 14
16
MODEL: AH-MP20
[1] INDOOR UNIT
1. Disassembling procedure of the indoor unit
1) Open the open panel, remove 2 Air Filters.
4) Remove the screw fixing the Cord holder.
2) Open the Louver frame, unlooks the hooks, pull the unit.
5) Close the Open panel. pushing the nail of the Front panel, and
lift the Front panel up.
6) Remove the unit-to-unit wiring from the Terminal board.
3) Remove 6 screws fixing the Front panel.
17
7) Remove a screw fixing the Control box cover.
10) Remove the Thermistor of the Evaporator.
11) Remove Connector.
8) Cut the fixing band and remove the Cover B.
12) Cut the fixing band and remove the Holder.
9) Remove a screw fixing the ground wire.
18
13) Remove 2 screws fixing the Control box and remove it.
16) Remove 3 screws fixing the Evaporator.
17) Remove the Evaporator from the Cabinet.
14) Remove a screw fixing the drain pan and pull Drain pan
toward you.
18) Remove 4 screws fixing the Side cover R, and pull the Cross flow fan
19) Loose a screw fixing Cross flow fan.
15) Remove the Drain cover from the Evaporator
19
2. The Electric Control box.
1) Remove the screw fixing the Receiving filter.
4) Remove a screw fixing the Cord holder and 2 screw
fixing the Terminal board.
2) Remove the 2 Switch and Photo detector unit.
5) Remove 2 screws fixing the Transformer and pull the
Control board unit.
3) Remove a screw fixing the Cord holder.
20
3. The Drain pan and related.
1) Remove the screw fixing the Drain pan on both side.
2) Turn left the Drain hose.
21
4. The Louver frame unit and related
1) Remove the screw fixing the frame guide on both side
3) Remove the connector of louver motor and take off the
and take off the louver unit.
wire and holder.
4) Put the one of the vertical louver.
2) Remove 2 screws fixing cover-l and cover-r and take off them.
22
5. How to remove the display cover
1) Put the center of the front panel under the display cover.
2) Side it to one side.
6. How to remove the hi voltage unit.
1) Remove 2 screws fixing holder.
2) Take off the high voltage unit ass'y from the holder.
3) Remove the connector of high voltage unit ass'y.
23
MODEL: AU-MP20
[2] OUTDOOR UNIT
1. Disassembling procedure of the control box
1) Loose 3 screws fixing the control cover.
5) Loose 1 screw fixing the cabinet (rear side).
2) Loose 1 screw fixing the side cover.
6) Loose 3 screw fixing the cabinet (right side).
3) Loose 8 screws fixing the side cover R.
7) Loose 1 screw fixing the cabinet (front side).
4) Loose 2 screws fixing the cabinet.
8) Loose 7 screws fixing the rear cabinet.
24
9) Loose 1 screw fixing the rear cabinet (left side).
12) Remove the terminal cover.
10) Cut nylon band.
13) Remove 3 terminal.
11) Loose 1 screw fixing the control box.
14) Loose 3 screws fixing the bulkhead.
25
2. Disassembling procedure of the fan
1) Loose the fan nut and fan can take out.
2) Loose 2 screw fixing the fan motor angle.
3) Cut the nylon band and loose 4 screws fixing the fan motor
26