Sharp AH-PG21 User manual

SPECIFICATIONS.............................................................................................................................................. 1
SERVICE MANUAL
CONTENTS
TopPage
OUTDOOR UNIT
AU-PG21
INDOOR UNIT
AH-PG21
SPLIT SYSTEM
ROOM AIR CONDITIONER
MODEL
MODEL
EXTERNAL DIMENSIONS................................................................................................................................. 2
WIRING DIAGRAMS.......................................................................................................................................... 3
ELECTRICAL PARTS........................................................................................................................................ 4
MICROCOMPUTER CONTROL SYSTEM......................................................................................................... 5
FUNCTIONS....................................................................................................................................................... 7
PRINTING WIRING DIAGRAM.......................................................................................................................... 6
TROUBLESHOOTING GUIDE OF CONTROL CIRCUIT................................................................................... 11
REFRIGERATION CYCLE................................................................................................................................. 14
PERFORMANCE CURVES............................................................................................................................... 15
DISASSEMBLING PROCEDURE...................................................................................................................... 16
REPARTMENT PARTS LIST............................................................................................................................. 26
SERVICE MANUAL

CHAPTER 1. PRODUCT SPECIFICATION
[1] SPECIFICATION
1. AH-PG21 / AU-PG21
ITEMS INDOOR UNIT OUTDOOR UNIT
A
H-PG21 AU-PG21
Cooling capacity kW 5.30
Moisture removal Liters/h –
Electrical data
Phase Single
Rated frequency Hz 50
Rated voltage V 220
Rated current A7.9
Rated input * W 1720
Power factor % 92 - 98
Compressor Type Hermetically sealed rotary type
Model PH31VNET
Oil charge 670cc ,DIAMOND MS32(N-1)
Refrigerant system Evaporator Louver fin and Grooved tube type
Condenser Louver fin and Grooved tube type
Control Capillary tube
Refrigerant volume R22 1300g
Noise level
(at cooling) High dB(A) 44 53
Mid. dB(A) 37 –
Low dB(A) 35 –
Fan s
y
stem
Drive Direct drive
Air flow quantity Hi
g
hm
3
/
m
i
n. 17.5 44
(at cooling) Med. m
3
/
m
i
n. 13.4
Low m
3
/
m
i
n. 11.9
Fan Cross flow fan Propeller fan
Connections
Refri
g
erant cou
p
lin
g
Flare t
yp
e
Refri
g
erant tube size Gas, Li
q
uid 1
/
2" , 1
/
4"
Drain piping mm O.D 20
Others
Safety device Compressor : Internal protector
Fan motor : Thermal protector(Internal)
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 1040 (1155) 890 (1020)
Height mm 325 (300) 645 (735)
Depth
Net weight kg
mm 220 (385)
19 (21) 55 (59)
327 (398)
1
φ

[2] EXTERNAL DIMENSION
1. Indoor unit (AH-PG21)
2. Outdoor unit (AU-PG21)
2

[3] WIRING DIAGRAM
Indoor Unit (AH-PG21)
Outdoor Unit (AU-PG21)
3
%%
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CHAPTER 2. ELECTRIC CIRCUIT
[1] ELECTRIC PARTS
1. INDOOR UNIT (AH-PG21)
PART NO. PART NAME ITEM SPECIFICATION
1Terminal Board Rating 300V,25A
2Fan motor Capacitor Rating 450V, 2µF
3Relay-1 Rating AC250V,20A
(RY1) Coil Volt: 12V
4Printed Wiring Board Material Paper Base Phenolic Resin (UL 94V-0)
5Transformer Rating Pri 220-240VAC
6Fan motor Rating 220 - 240VAC 50Hz 41W 4-Pole
Type MLA999
Thermal Protector Cut off 135 10 C
(Internal)
7Power Supply Cord Rating 3 x 1.5 mm2
Type H05VV-F
8Louver Motor Rating DC12V
Type 24BYJ48
1. OUTDOOR UNIT (AU-PG21)
PART NO. PART NAME ITEM SPECIFICATION
1Terminal Board Rating 300V,25A
2Fan motor Capacitor Rating 450V, 3µF
3Running Capacitor Rating 400V, 45µF
4Compressor Rating AC220V 50Hz 1730W
Type PH31VNET
5Protector Rating -
Type (INTERNAL)
6Fan motor Rating 220 - 240VAC 50Hz 71W 6-Pole
Type MLA002
Thermal Protector Cut off 135 5 C
(Internal)
4
±°
±°

[2] MICRO-COMPUTER CONTROL SYSTEM
1. Electronic Control Diagram
Indoor unit (AH-PG21)
5
MODE
13K
R37
L2
NC NC
56
L 1
9.1K
R45
1/2W
10K
D14
25V
47
∝
C29
+
NF1
6.8K 6.8K
R41
100
L1
SSR1
C31 1W 275V
0.033
∝
Q8 Q7
Q6 Q5
JP21
3 1 3 1
NR1
CN9
THERMOSTAT
INTERNAL
CN8 CN7
CN6 CN5
CN3
CN2 CN1
1
23
1
CLUSTER
R35
3.3K
R40 R39 10K
CLEANING SWITCH 1
SWITCH 2 CLEANING
31
D8D9
32
12
3 32
2
0.01
∝
C22
16V
2
0.01∝
C10
16V
22K
R6 20K
Q2
1
R5
22K R4
R27
2
1/2W
9
470
R30 SSR2
3
12V
5V
10
9
25V
C24
SW101
2 11
2
8
IC4
10K
R29
R28
1.8K
BZ1
RY1
SSR1
1/2W 470
IC5
8
9
Q1
16V 220∝
10K(F)
+
D6
25V
0.1∝
1 2 4 5 3
MOTOR LOUVER
3 2 1 5 4
1 2 3
HOLE
IC
FAN
MOTOR
2
3
JP3 JP2 JP1
NC
MB89537A
1
IC6
3
10K
13K 13K
25V
0.1
∝
1 ∝
50V
IC1
(PATTERN SIDE)
400V
0.01∝16V
JP5 JP4
1K
0.01
∝
OSC1
FRONT
P21 P22 P23 P24 P25 P26 P27 X1 X0
MOD1 MOD0
RST
32 31 30 29 28 27 26 25 24 23 22 21 20
Vcc
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
P45
P46
P47
AN0
AN1
AN2
AN3
AN4
AN5
AN6
AN7
AVR
P60
P61
P62
P63
P64
P31 P32 P33 P34 P35 P36 P37 P40
P41 P42 P43 P44
52 53 54 55 56 57 58 59 60 61 62 63 64
P30
NC
P00
P01
P02
P03
P04
P05
P06
P07
P10
P11
P12
P13
P14
P15
P16
P17
P20
49
50
51
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
AVcc
AVss
Vss
50V 1000p
+
680
10K 10K
10
∝
16V16V
10
∝
10k
(F) 10K
(F)
4 3 2 1TH2
PIPE TEMP 15k!(25ыC).
TH1 PIPE TEMP 10k!(25ыC).
FAN
MOTOR
2∝
1 3 5
2.7K(F)
D7
+
35V
1000∝
50V
0.1∝
7812
IC2
+
25V 47∝
7805
0.1∝
IC3
25V 10V
100∝
+
C7
D1?4
GND
22.6K(F)
3.3K
45
IC8
1 2 3
8 7 6
0.1∝25V
16V 0.01∝
TR1
C1
C2
C3
C4 C5
C6 C8
C9
C11
C13 C14 C15 C17
C18 C19
C20
C21
C23
C25
R7 R8
R9
R10
R13 R14
R15
R16
R18 R19 R20 R21 R22 R23
R24 R25
R26
R32
R34
10K
16V 16V 16V
0.01∝ 0.01∝ 0.01∝
6.8K
R12
47KR11
10MHz
JP10
JP11
JP12
JP13
JP18
10K
10K
0.01∝16V
0.01 ∝ 16V
R17
3.3K
13K
C27
C12
SW1 : AUX.(TEST RUN)
C16
25V0.1
∝
1
R31R33
+
+
C26
3 2 1 1
BCN1
2 3 4 5 6 7 8
R37
6 7 1 3 5
1K(F)
1
0.1∝
D12
3
R108
10
32
(TIMER)
LED102 LED101
(OPERATION)
1
12
BL
GR LED107
(CLUSTER)
134256
9
R107
(FAN L) (FAN M) (FAN H)
(FAN AUTO)
LED106 LED105 LED104 LED103
3K
2.7K
R102 R101
1/2W 1/2W
C102
C101
0.1∝
25V
33∝
10V
+
IC101
BCN101
R103 R104 R105 R106
620 620
1 2 3 1 8 7 6 5 4 3 2
620 620
1/2W 1/2W
56
CN10
CN103
BCN102
CN102
CN101
275V
275V
0.1
∝
0.1 ∝
275V C28
86
SSR2
2W 2W
R1 R2
NC
NC
NC
NC
JP9
JP8
JP7
JP19
DEIC E 1
DEIC E 2
DRY FAN
PIPE 1
PIPE 2
NONENONENONENONE
JP7 JP8 JP9 JP10 JP11 JP12 JP13
TEST
NONE
JP6
NONE 15K 15K 15K
JP18 JP19
LOUVOUT
FAN
CLUS TER ER
R19 R21 R23
FAN2FAN1
HEAT COOL
MODE
R38
R38
ON PWR
LESS WIRE
AT SWE-
KEEP HOT
DEF. SYMBOL
I
JP2 JP3 JP4 JP5JP1
IN OUT
RY1
WPE1
T
250V 3A
1 N
BOARD TERMINAL
1 N
PHASE SINGLE SUPPLY POWER
TERMINAL BOARD
A
BL
BK
BR
UNIT OUTDOOR TO
NONENONENONE
47
CT1
BL
BL

2. PRINTED WIRING DIAGRAM
1 Indoor (AH-PG21)
6

CHAPTER 3. FUNCTIONS
[1] FUNCTION
1. TEMPERATURE CONTROL CHARACTERISTIC
1.1. COOL operation
2.2. DRY
On the switch on, the compressor always starts to operate for 2
minutes with fan speed "DL".
In the "COOL" mode, the thermostat circuit is controlled by five
thermostat lines (C1 thru C5). The microcomputer reads the room temperature 2 minutes after this
first compressor operation.
This room temperature is set as the preset temperature
The preset temperature ranges from 18 C to 32 C. When the room
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.
ttill
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 tem
p
erature
(
C
)
Compressor Fan speed
Cooling zone ON "DH"
Dehumidifying zone ON "DL"
Circulating zone OFF "DL" or OFF
18 32
Preset tem
p
erature
(
C
)
3. FAN SPEED
Fan speeds are given by the indoor fan motor, "DL"~"HH" which
are available in the following operation mode.
2. OPERATION MODES
2.1. COOL operation
Fan
speed
Fan switch Fan switch
(AUTO)
AH-PG21
(r.p.m)
The compressor turns on or off, at the thermostat lines C3 and
C4. The outdoor fan motor is also controlled with the compressor. DL —DRY 800
DH —890
CL COOL SOFT — 800
CAL —COOL 840
CM COOL LOW 980
CAH —1020
CH COOL HIGH — 1170
18 32
Preset tem
p
erature
(
C
)
7
°°
°
°
°
°
°
°
°
°

ing
r
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 Compressor Outdoor
Fan Motor
Indoor
Fan Motor Valve Coil
OCooling ON ON ON OFF
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.
O
U
Circulat-
ing OFF OFF ON OFF
Cooling ON ON L/UL OFF
}
oDehu-
midiflying ON ON UL/D OFF
5. TIMER
5.1. ON/OFF Timer
Circulat- OFF OFF D/OFF OFF
When the unit operates during one hour after the OFF-time is set, ther-
mostart setting is automatically shifted ( in
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 afte
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 o
p
eration start
Operation Mode Preset Temperature
Above 28°C26°C
26°C > 28°C COOL 25°C
24°C > 26°C24°C
Below 24°C DRY Room temperature at
operation start
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.
8

AH-PG21
9
11. 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.
12. Turbo operation
When turbo operation is started by remote-controller, indoor fan and setting temperature change following.
OUTPUT "O" : ON, "X" : OFF
NO.
BUZZER
LED 107
(BLUE)
LED 103
(RED)
LED 104
(ORANGE)
LED 105
(GREEN)
CLUSTER
FAN M.
LOUVER
OUTDOOR
AH-PG21 AH-AP24GMY
*1 : 7°C < (Room Tenp.) < 42°C
STEP0 BEEP2 *9 O
*1 O *2 O *3 XXX X*2 : -2°C < (Pipe Temp.) < 45°C
*3 : CLEANING SW1 ON
STEP1 BEEP1 X X
*4 *5 MDL *6 MDL X O OPEN O *4 : (AN2 INPUT VOLTAGE) < 0.3V, OR 4.5V < (AN2 INPUT VOLTAGE)
*5:O
*6:X *5:O *6:X
STEP2 BEEP1 *9 O
RPM *7 MDL *8 MDL O O X X *7:X *8:O *7:O *8:O
*10:X
*11:O *10:X *11:X
STEP3 BEEP1 X X
H.K. O P.ON *10 FAN C. O O X X *12:O *13:O *12:O *13:O
STEP4 BEEP1 X O
IC8 O JP8 *11 FAN C. X O X X *9:O *9:O
STEP5 BEEP1 X X
A.RES. O *12 FAN C. XOX X
STEP6 BEEP1 X X
R.C. X *13 FAN C. XOX X
*14:X
*15:O *14:X *15:O
STEP7 BEEP1 X *14
DATA *18 DATA *22 FAN H X O X X *16:O *17:O*16:X *17:O
*18:O
*19:X *18:X *19:X
STEP8 BEEP1 X *15
DATA *19
DATA *23 FAN H X O X X *20:X *21:X *20:X *21:O
*22:X
*23:O *22:X *23:O
STEP9 BEEP1 X *16
DATA *20 DATA *23 FAN H X O X X *24:O *25:O *24:O *25:O
STEP10 BEEP1
X *17
DATA *21 DATA *25 H.F. XXCLOSEX
Turbo fan Setting temp.
COOL for 30 minutes Turbo fan 15°C
after 30 minutes CH 18°C

[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
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.
PROCEDURE
10

CHAPTER 4. TROUBLESHOOTING
11

12

CHAPTER 5. TROUBLESHOOTING
13

CHAPTER 6. REFRIGERANTION CYCLE AND PERFORMANCE CURVES
[1] REFRIGERANT CYCLE
Capillary tube O.D I.D L
3.5 2.0 800
14

[2] PERFORMANCE CURVES
1 – 14
15

MODEL: AH-PG21
[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.
16

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.
17

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
18

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.
19