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Sharp AH-AP18DR Service Manual

Room air conditioners
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SPECIFICATIONS ............................................................................................................................................. 2
EXTERNAL DIMENSIONS ............................................................................................................................... 4
WIRING DIAGRAMS ......................................................................................................................................... 5
ELECTRICAL PARTS ....................................................................................................................................... 9
MICROCOMPUTER CONTROL SYSTEM .....................................................................................................11
FUNCTIONS ................................................................................................................................................... 19
TROUBLESHOOTING GUIDE OF CONTROL CIRCUIT ................................................................................ 27
REFRIGERATION CYCLE .............................................................................................................................. 32
PERFORMANCE CURVES ............................................................................................................................ 34
REFRIGERANT PIPE INSTALLATION WORKS ............................................................................................. 35
DISASSEMBLING PROCEDURE ................................................................................................................... 37
REPLACEMENT PARTS LIST ........................................................................................................................46
SERVICE MANUAL
ROOM AIR CONDITIONERS
INDOOR UNIT
AH-AP18DR AY-AP18DR
AH-AP24DR AY-AP24DR
MODELS
OUTDOOR UNIT
AU-A18DR AE-A18DR
AU-A24DR AE-A24DR
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
SPLIT SYSTEM
AH/AY-AP18DR
AH/AY-AP24DR
S5305AYAP24DR
Page

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  Summary of Contents for Sharp AH-AP18DR

  • Page 1: Table Of Contents

    AH/AY-AP18DR AH/AY-AP24DR SERVICE MANUAL S5305AYAP24DR SPLIT SYSTEM ROOM AIR CONDITIONERS INDOOR UNIT AH-AP18DR AY-AP18DR AH-AP24DR AY-AP24DR MODELS OUTDOOR UNIT AU-A18DR AE-A18DR AU-A24DR AE-A24DR 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: Specifications

    AH/AY-AP18DR AH/AY-AP24DR SPECIFICATIONS ITEMS INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT AY-AP18DR AE-A18DR AY-AP24DR AE-A24DR Cooling capacity Heating capacity Moisture removal Liters/h Electrical data Phase – Single Rated frequency Rated voltage 220 – 240 Rated current Cool 9.2 – 9.3 12.7 –...
  • Page 3 AH/AY-AP18DR AH/AY-AP24DR ITEMS INDOOR UNIT OUTDOOR UNIT INDOOR UNIT OUTDOOR UNIT AH-AP18DR AU-A18DR AH-AP24DR AU-A24DR Cooling capacity Moisture removal Liters/h Electrical data Phase – Single Rated frequency Rated voltage 220 – 240 Rated current 9.2 – 9.3 12.7 – 13.1 Rated input 1.99 –...
  • Page 4: External Dimensions

    AH/AY-AP18DR AH/AY-AP24DR EXTERNAL DIMENSIONS 1040 18.5 Power supply cord (AY-AP18DR, AH-AP18DR only) INVERTER AIR CONDITIONER MODE TEMP. TIMER TEMP. SAVE MODE [Length unit : mm] FULL POWER SWING CANCEL Remote controller Figure E-1. INDOOR UNIT 46.3 ø4.5 10.5 Figure E-2. OUTDOOR UNIT...
  • Page 5: Wiring Diagrams

    AH/AY-AP18DR AH/AY-AP24DR WIRING DIAGRAMS Figure W-1. Wiring Diagram for AY-AP18DR Figure W-2. Wiring Diagram for AE-A18DR...
  • Page 6 AH/AY-AP18DR AH/AY-AP24DR Figure W-3. Wiring Diagram for AY-AP24DR Figure W-4. Wiring Diagram for AE-A24DR...
  • Page 7 AH/AY-AP18DR AH/AY-AP24DR Figure W-5. Wiring Diagram for AH-AP18DR Figure W-6. Wiring Diagram for AU-A18DR...
  • Page 8 AH/AY-AP18DR AH/AY-AP24DR Figure W-7. Wiring Diagram for AH-AP24DR Figure W-8. Wiring Diagram for AU-A24DR...
  • Page 9: Electrical Parts

    AH/AY-AP18DR AH/AY-AP24DR ELECTRICAL PARTS Part Part Name Items Specifications AY-AP18DR AY-AP24DR Terminal Board Rating 300V 25A Fan motor Rating 400V 2µF Capacitor Relay-1 Rating AC250V 20A – (RY1) Coil Volt.; 12V Relay-2 Rating AC250V 3A (RY2, RY3, RY4) Coil Volt.; 12V Printed Wiring Material Paper Base Phenolic Resin (UL 94V-0)
  • Page 10 AH/AY-AP18DR AH/AY-AP24DR Part Part Name Items Specifications AH-AP18DR AH-AP24DR Terminal Board Rating 300V 25A Fan motor Rating 400V 2µF Capacitor Relay-1 Rating AC250V 20A – (RY1) Coil Volt.; 12V Relay-2 Rating – AC250V 5A (RY4) Coil Volt.; 12V Printed Wiring...
  • Page 11: Microcomputer Control System

    AH/AY-AP18DR AH/AY-AP24DR MICROCOMPUTER CONTROL SYSTEM...
  • Page 12 AH/AY-AP18DR AH/AY-AP24DR...
  • Page 13 AH/AY-AP18DR AH/AY-AP24DR...
  • Page 14 AH/AY-AP18DR AH/AY-AP24DR...
  • Page 15 AH/AY-AP18DR AH/AY-AP24DR TO TERMINAL BOARD TO TERMINAL BOARD BOTTOM " N " TOP " N " FROM TERMINAL BOARD BOTTOM " L " " BROWN " FROM CLEANING SWITCH 2 TO TERMINAL BOARD TOP " 3 " TO TERMINAL BOARD TOP "...
  • Page 16 AH/AY-AP18DR AH/AY-AP24DR TO TERMINAL BOARD TO TERMINAL BOARD BOTTOM " N " TOP " N " TO TERMINAL BOARD TOP " 1 " FROM CLEANING SWITCH 2 TO TERMINAL BOARD TOP " 4 " TO TERMINAL BOARD TOP " 3 " TO TERMINAL BOARD TOP "...
  • Page 17 TO TERMINAL BOARD TOP " N " BCN101(BCN201) FROM TERMINAL BOARD TOP " 1 " " BLACK " FROM FAN MOTOR FROM THERMISTOR FROM CLUSTER GENERATOR FROM CLEANING SWITCH 1 FROM LOUVER MOTOR Figure L-7. Printed Wiring Diagram for AH-AP18DR...
  • Page 18 AH/AY-AP18DR AH/AY-AP24DR TO TERMINAL BOARD TO TERMINAL BOARD BOTTOM " N " TOP " N " TO TERMINAL BOARD TOP " 1 " FROM CLEANING SWITCH 2 TO TERMINAL BOARD TOP " 2 " FROM CLUSTER GENERATOR FROM FAN MOTOR FB441 FB441 FB441...
  • Page 19: Functions

    AH/AY-AP18DR AH/AY-AP24DR FUNCTIONS HEAT operation AH-AP18DR/AP24DR are noty provided with the In the “HEAT” mode, the thermostat circuit is heating function controlled by six thermostat lines (H01 thru H4). Temperature control characteristic 37.0 COOL operation 36.0 In the “COOL” mode, the thermostat circuit is 35.0...
  • Page 20 AH/AY-AP18DR AH/AY-AP24DR DRY operation Table Y-1 On the switch on, the compressor always starts to Compressor Fan speed operate for 2 minutes with fan speed "DL" . The microcomputer reads the room temperature 2 Cooling zone "DH" minutes after this first compressor operation. Dehumidifying zone "DL"...
  • Page 21 AH/AY-AP18DR AH/AY-AP24DR 4. Hot-Keep 6. Overheating protection system This function automatically controls the on-off operation When overloading occurs during the heating operation, of the indoor fan motor in accordance with the ON-OFF this system controls the outdoor fan motor according to operation of the compressor during the heating the indoor pipe temperature to prevent the overloading operation, thereby preventing the air conditioner from...
  • Page 22 AH/AY-AP18DR AH/AY-AP24DR Current control Defrost start This system, in order to prevent overcurrent 60sec. 60sec. during heating operation, controls the outdoor fan Compressor motor and changes the indoor fan motor speed by detecting total current. When the current exceeds MAX. 7min. Reverse P2, the outdoor fan motor is automatically turned Valve...
  • Page 23 AH/AY-AP18DR AH/AY-AP24DR Automatic air conditioning Outputs in each operation mode automatic air conditioning is selected, the operation mode and preset temperature are set Table Y-5 automatically according to the room temperature Compressor Outdoor Indoor Valve on starting operation. Mode Fan Motor Fan Motor Coil Table Y-4...
  • Page 24 AH/AY-AP18DR AH/AY-AP24DR...
  • Page 25 AH/AY-AP18DR AH/AY-AP24DR...
  • Page 26 AH/AY-AP18DR AH/AY-AP24DR Diagnosis procedure When indoor fan motor is out of order or compressor lock occurs, the compressor, 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.
  • Page 27: Troubleshooting Guide Of Control Circuit

    AH/AY-AP18DR AH/AY-AP24DR TROUBLESHOOTING GUIDE OF CONTROL CIRCUIT The machine does not function at all with remote controller and switch on the indoor unit. Check the cleaning FAIL switch 2(1), CN9, CN8 and lead wires. Replace the cleaning switch 2(1). (or reset connector) Using a tester, measure the measure the secondary voltage voltage between anodes of D1...
  • Page 28 AH/AY-AP18DR AH/AY-AP24DR The machine does not function with remote controller Push button "O/I" on the wireless remote controller. Is transmitting Are batteries of the indicator of the remote wireless remote controller controller active ? proper ? Replace the batteries with new ones. Replace the wireless remote controller.
  • Page 29 AH/AY-AP18DR AH/AY-AP24DR For AY-AP18DR/AE-A18DR, AH-AP18DR/AU-A18DR The room is not cooled at all or not cooled. The compressor does not operate. Fig. 1 Temperature properties of indoor thermistors Room temperature Heat exchange thermistor TH1 thermistor TH2 Thermistor Color Connector Push the button "AUX." on...
  • Page 30 AH/AY-AP18DR AH/AY-AP24DR For AY-AP24DR/AE-A24DR, AH-AP24DR/AU-A24DR The room is not cooled at all or not cooled. The compressor does not operate. Push the button "AUX." on the indoor unit, for more than 5 sec. Using a tester, measure voltage at the terminals on the terminal board. Is the voltage between terminal of black lead...
  • Page 31 AH/AY-AP18DR AH/AY-AP24DR For AY-AP24DR/AE-A24DR, AY-AP18DR/AE-A18DR The room is not heated at all or not heated. The compressor does not operate. Select HEAT MODE with remote controller. And then start operation. Push the button of "AUX" on the indoor unit, for more than 5 sec. Using a tester, measure voltages at the terminals on the terminal board.
  • Page 32: Refrigeration Cycle

    AH/AY-AP18DR AH/AY-AP24DR REFRIGERATION CYCLE Indoor unit Evaporator Flare coupling Flare coupling 3-way 2-way valve valve Outdoor unit Capillary tube Compressor Condenser Accumulator Figure R-1. Refrigeration Cycle for AH-AP18CE/AH-AP24CE Indoor unit Evaporator Flare coupling Flare coupling 3-way 2-way valve valve Heating Cooling Silencer Strainer...
  • Page 33 0.77MPa ISO condition Indoor side Outdoor side Temperature (˚C) Relative humididity (%) Temperature (˚C) Relative humididity (%) Cooling Dimension of Capillary tube For AH-AP18DR For AH-AP24DR O.D. I.D. O.D. I.D. Capillary tube Capillary tube ø 3.2 ø 1.8 ø 3.5...
  • Page 34: Performance Curves

    AH/AY-AP18DR AH/AY-AP24DR PERFORMANCE CURVES Indoor air temp. : 27˚C Indoor humidity : 47RH% Indoor air temp. : 20˚C Indoor fan speed : Hi Indoor fan speed : Hi 19000 22000 20000 18000 18000 17000 16000 14000 16000 12000 2500 2500 2000 2000 1500...
  • Page 35: Refrigerant Pipe Installation Works

    AH/AY-AP18DR AH/AY-AP24DR Indoor air temp. : 27˚C Indoor humidity : 47RH% Indoor air temp. : 20˚C Indoor fan speed : Hi Indoor fan speed : Hi 24000 30000 28000 23000 26000 22000 24000 22000 21000 20000 3500 3000 3000 2500 2500 2000 2000...
  • Page 36 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 0 Outside air temp.(˚C) Outside air temp.(˚C) Figure P-5. At Cooling for AH-AP18DR Figure P-6. At Cooling for AH-AP24DR REFRIGERANT PIPE INSTALLATION WORKS Refrigerant pipe length and level difference between the indoor and outdoor units.
  • Page 37: Disassembling Procedure

    AH/AY-AP18DR AH/AY-AP24DR DISASSEMBLING PROCEDURE FOR INDOOR UNIT MODEL [AH-AP18DR/AP24DR, AY-AP18DR/AP24DR] CAUTION:DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY SERVICING Open the Opne panel, remove 2 Air Filters. Remove 6 screws fixing the Front panel. Remove the screw fixing the Cord holder.
  • Page 38 AH/AY-AP18DR AH/AY-AP24DR Remove a screw fixing the Control box cover. Close the Open panel. pushing the nail of the Front panel, and lift the Front panel up. Cut the fixing band and Remove the Cover B. Remove the unit-to-unit wiring from the Terminal board.
  • Page 39 AH/AY-AP18DR AH/AY-AP24DR Cut the fixing band and Remove the Holder. Remove the Thermistor of the Evaporator. Remove Connectors. Remove 2 screws fixing the Control box and remove it.
  • Page 40 AH/AY-AP18DR AH/AY-AP24DR Remove the Evaporator from the Cabinet. Remove a screw fixing the drain pan and pull Drain pan toward you. Remove 4 screws fixing the Side cover R, and pull up the Cross flow fan. Remove the Drain cover from the Evaporator. Loose a screw fixing Cross flow fan.
  • Page 41 AH/AY-AP18DR AH/AY-AP24DR The Electric Control box. Remove a screw fixing the Cord holder and 2 screws fixing the Terminal board. Remove the screw fixing the Receiving filter. Remove 2 screws fixing the Transformer and pull Remove the 2 Switch and Photo detector unit. the Control board unit.
  • Page 42 AH/AY-AP18DR AH/AY-AP24DR The LOUVER FRAME UNIT and related The DRAIN PAN and related Remove the screw fixing the FRAME GUIDE on Remove the screw fixing the Drain pan on both both side and take off the LOUVER UNIT. side. Turn left the Drain hose. Remove 2 screws fixing Cover-L and Cover-R and take off them.
  • Page 43 AH/AY-AP18DR AH/AY-AP24DR How to remove the Hi Voltage UNIT. Remove the connector of Louver motor and take off the Wire and Holder. Remove 2 screws fixing Holder. Push the one of the Vertical louver. Take off the HIGH VOLTAGE UNIT ASS’Y from How to remove the DISPLY COVER.
  • Page 44: Disassembling Procedure Of The Control Box

    AH/AY-AP18DR AH/AY-AP24DR FOR OUTDOOR UNIT MODEL AE-A18DR/AE-A24DR DISASSEMBLING PROCEDURE OF THE CONTROL BOX Loose 1 screw fixing the cabinet (rear side). Loose 3 screws fixing the control cover. Loose 1 screw fixing the side cover. Loose 3 screw fixing the cabinet (right side). Loose 8 screws fixing the side cover R.
  • Page 45 AH/AY-AP18DR AH/AY-AP24DR Loose 1 screw fixing the rear cabinet (left side). Remove 3 terminals. Loose 3 screws fixing the bulkhead. Cut nylon band. DISASSEMBLING PROCEDURE OF THE FAN Loose the fan nut and fan can take out. Loose 1 screw fixing the control box. Loose 2 screw fixing the fan motor angle Remove the terminal cover.
  • Page 46: Replacement Parts List

    AH/AY-AP18DR AH/AY-AP24DR REPLACEMENT PARTS LIST [ AY-AP18DR/AY-AP24DR/AH-AP18DR/AH-AP24DR] REF. NO. PART NO. DESCRIPTION Q'TY CODE CABINET AND UNIT PARTS 1- 1 CMOT-A405JBKZ Fan moter sub assembly 1- 2 PFPFPC188JBEZ Gap seal 1- 3 GWAK-A270JBFA Front panel 1- 4 CHLD-A067JBK0 Bearing assembly...
  • Page 47 Flare nut assembly (1/2") 3- 4 PVLV-0341JBE0 Flare union (1/4") 3- 5 PVLV-A259JBEZ Flare union (1/2") 3- 6 DEVA-A204JBKZ Evaporator sub assembly [AH-AP18DR, AY-AP18DR] 3- 6 DEVA-A205JBKZ Evaporator sub assembly [AH-AP24DR, AY-AP24DR] ACCESSORY PARTS 4- 1 CRMC-A561JBEZ Remote control [AH-AP18DR, AY-AP24DR] 4- 1...
  • Page 48 AH/AY-AP18DR AH/AY-AP24DR INDOOR UNIT FOR AY-AP18CE / AY-AP24CE / AH-AP18CE / AH-AP24CE 1-45 4-10 4-11 4-12 1-28 (AY-AP18DR, AY-AP24DR only) 1-31 1-36 1-42 1-30 1-31 1-31 1-26 1-42 1-31 1-18 1-37 1-38 2-13 2-12 2-17 2-16 1-41 1-29 2-15 2-20 2-10 1-40 2-14...
  • Page 49 Compressor cover [AU-A24DR] 1-13 PSEL-C017JBEZ Cabinet seal 1-14 TSPC-E471JBRZ Name label [AU-A18DR] 1-14 TSPC-E474JBRZ Name label [AU-A24DR] 1-15 TLABBA100JBRA SHARP badge 1-16 CCHS-A844JBTA Base pan assembly [AU-A18DR] 1-16 CCHS-A781JBTA Base pan assembly [AU-A24DR] 1-17 PSEL-C585JBEZ Angle seal [AU-A18DR] 1-18 PSEL-C264JBEZ...
  • Page 50 AH/AY-AP18DR AH/AY-AP24DR REF. NO. PART NO. DESCRIPTION Q'TY CODE 3-12 LX-NZA002JBE0 Special nut 3-13 PSEL-C287JBE0 Terminal gasket 3-14 GLEG-A115JBEZ Compressor cushion [AU-A18DR] 3-14 GLEG-A093JBE0 Compressor cushion [AU-A24DR] 3-15 PPIPCG335JB1Z Discharge tube [AU-A18DR] 3-15 PPIPCG346JB1Z Discharge tube [AU-A24DR] 3-16 CPIPCA848JBKZ Suction tube assembly [AU-A18DR] 3-16 PPIPCG337JB1Z Suction tube [AU-A24DR]...
  • Page 51 AH/AY-AP18DR AH/AY-AP24DR OUTDOOR UNIT FOR AU-A18CE / AU-A24CE 2-10 1-14 1-23 1-20 1-30 1-24 1-31 1-22 2-1 6-8 1-17 3-11 6-10 1-11 1-19 1-12 3-12 1-27 3-16 3-12 3-13 1-18 3-15 1-21 1-10 1-28 1-16 1-26 3-14 1-25 1-13 3-10 1-15 1-29 i d e...
  • Page 52 Compressor cover [AE-A24DR] 1-13 PSEL-C017JBEZ Cabinet seal 1-14 TSPC-E463JBRZ Name label [AE-A18DR] 1-14 TSPC-E472JBRZ Name label [AE-A24DR] 1-15 TLABBA100JBRA SHARP badge 1-16 CCHS-A844JBTA Base pan assembly [AE-A18DR] 1-16 CCHS-A781JBTA Base pan assembly [AE-A24DR] 1-17 PSEL-C585JBE0 Angle seal 1-18 GCAB-A221JBTA Rear cabinet [AE-A18DR]...
  • Page 53 AH/AY-AP18DR AH/AY-AP24DR REF. NO. PART NO. DESCRIPTION Q'TY CODE 3-14 GLEG-A093JBE0 Compressor cushion rubber [AE-A24DR] 3-15 PMUF-A042JBE0 Muffler [AE-A24DR] 3-16 CCIL-A122JBEZ Coil 3-17 PVLVXA061JBEZ Reverse valve 3-18 PCOV-A379JBE0 Terminal cover [AE-A18DR] 3-18 PCOV-A762JBEZ Terminal cover [AE-A24DR] 3-19 LX-NZA002JBE0 Special nut 3-20 PSEL-A150JBE0 Gasket washer [AE-A24DR]...
  • Page 54 AH/AY-AP18DR AH/AY-AP24DR OUTDOOR UNIT FOR AE-A18CE / AE-A24CE 2-10 1-18 1-14 1-23 1-20 1-30 1-24 1-31 1-22 2-1 6-8 1-17 6-10 3-11 1-19 3-19 1-12 3-20 3-18 1-27 3-21 3-12 3-17 1-11 3-16 1-21 6-11 3-15 1-10 1-28 1-26 3-14 1-25 1-13 3-10...
  • Page 55 AH/AY-AP18DR AH/AY-AP24DR...
  • Page 56 AH/AY-AP18DR AH/AY-AP24DR '2003 05 SHARP CORP.