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Sharp AE-X15PU, Service Manual

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Sharp AE-X15PU Service Manual Download Page 14

AE-X15PU

2 – 10

3. Explanation of IPM drive circuit

The IPM for compressor drive is made by Mitsubishi Electric.

The power supply for the IPM drive, the shunt resistance for over current detection, etc., are provided outside the IPM (control PWB).

3.1. IPM drive power supply circuit

The power supply for the upper-phase IGBT (HU, HV, HW) drive employs a bootstrap system, and provides power to the upper-phase IC.

The 15-V power supply for the lower-phase IC is provided by the control printed wiring board (PWB).

3.1.1 Brief explanation of bootstrap system (single power drive system)

To supply power to the upper-phase IC, the microcomputer (IC1) turns ON the lower-phase IGBT (LU, LV, LW).

This results in a charging current that flows to the electrolytic capacitor of each upper-phase IC input and charges the bootstrap capacitor with a 15V
current.

The power supply for the subsequent stages is charged while the lower-phase IGBT is ON in ordinary compressor drive control.

Summary of Contents for AE-X15PU

Page 1: ...TER 4 REFRIGERATION CYCLE 1 SCHEMATIC DIAGRAM 4 1 2 STANDARD CONDITION 4 1 CHAPTER 5 DISASSEMBLY PROCEDURE 1 OUTDOOR UNIT 5 1 2 DISASSEMBLY OF CONTROL BOX 5 4 Parts List TopPage CONTENTS SPLIT TYPE ROOM AIR CONDITIONER OUTDOOR UNIT AE X15PU MODEL 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 iden...

Page 2: ... 19000 22000 6000 22000 1 h 3 2 Fan motor Twin Rotary W 1120 8poles 43W SIAM 13 0cc SNB130FGBMT 900W FV50S 350cc Single Single Maximum length per unit Maximum height difference Indoor units number ft m ft m Rated frequency Reted voltage 1 1 65 6 20 98 4 30 Refrigerant tube size A Gas line B Liquid line Net dimensions Net weight lb kg Condenser A Drain joint Fan Refrigerant control Refrigerant ITEM...

Page 3: ...AL DIMENSION Length unit inch mm 3 WIRING DIAGRAM AE X15PU AE X18PU 14 9 379 28 0 710 5 6 143 3 3 83 0 8 20 7 0 6 16 36 2 920 14 3 363 13 0 330 8 3 210 9 35 6 905 33 5 850 21 9 557 4 5 6 141 3 0 2 4 5 2 0 50 2 8 72 15 6 395 ...

Page 4: ...a N t r a P Compressor SNB130FGBMT DC motor FCMPRA333JBKZ Fan motor RDN 280 60 8C DC motor CMOTLB488JBEZ V 0 5 2 A 0 2 0 E B J 4 1 0 A G S F Q 1 u F V 0 5 2 A 5 1 3 Z Z B J 8 7 0 A G S F Q 2 u F V 0 5 2 A 5 2 Z Z B J 7 7 0 A G S F Q 3 u F V 0 5 2 A 0 2 0 E B J 9 1 0 A G S F Q 5 u F SHA 52FV D843 2 s k r a m e R l e d o M e m a N t r a P Compressor SNB130FGBMT DC motor FCMPRA333JBKZ Z E B J 7 3 5 B...

Page 5: ...AE X15PU 2 1 CHAPTER 2 ELECTROIC CIRCUIT 1 BLOCK DIAGRAMS 1 Outdoor unit Expansion valve circuit Expansion valve 20A 25A for AE X24PU 20A ...

Page 6: ...6 1 10W 100KJ R104B R104A R205 10K R202 0K R204 10K R129 10K C33 25V 4 7u C32 25V 0 1u R79 100J R80 100K R78 270 R77 270 C31 25V 0 1u R105 1 10W 22KJ R90 1 10W 1KF R91 1 10W 6 49KF R124 100 R186 10K F R188 2K F R 89 20K F R187 2KF R196 20K F R195 20K F R194 2K F R193 2KF R182 10K F R183 10K F R178 10K F R179 10K F R177 13KF CN3 1 3 5 R94 1KJ R143 2KF 10KJ R122 50V 0 01uF C107 C49 0 1u 25V 25V C51 ...

Page 7: ...R98 1KJ R99 1KJ C25 25V 0 1u R22 10K C19 35V 150u C89 25V 0 1u R62 10K R66 10K R65 0K R64 10K R63 10K C125 10V 100u C126 25V 0 1u 50V C87 0 01u C128 10V 100u C127 0 1u 25V R146 1 10W 100KJ R104B R104A R205 10K R202 10K R204 10K R129 10K C33 25V 4 7u C32 25V 0 1u R79 100J R80 100K R78 270 R77 270 C31 25V 0 1u R105 1 10W 22KJ R90 1 0W 1KF R91 1 10W 6 49KF R124 100 R82 10K R186 10K F R188 2K F R189 2...

Page 8: ...330Ω R109 PC5 2 1 3 BT15 BT16 R111 1 4W 1KJ 50V C202 1000p 50V 1000p C199 TH6 R110 1 4W 150J 25V C52 10u T13 IC7 ULN200 L D 6 T 8 1 16 9 2 3 5 6 7 10 11 2 13 1 15 CN 2 1 2 3 5 CN 1 1 2 3 BT14 D5 800V 1A R92 1K C31 0 1u 25V C126 25V 0 1u C125 10V 100u 0 1u 25V C127 C128 100u 10V IC1 VCC 1 M X 6 PM1 8 PM2 9 PM3 10 PP0 12 PP1 13 PP2 1 PP3 15 PP 16 PP5 17 VSS 18 VCC 19 PQ0 20 PQ1 21 PQ2 22 PQ3 23 PQ 2...

Page 9: ...AE X15PU 2 5 2 Printed wiring board AE X15PU This PCB is common for AE X15PU X18PU X24PU but for AE X24PU there will be a sub board Will be released after approval ...

Page 10: ...rature of the outdoor unit heat exchanger drops to about 54 C or lower the operating frequency is increased by about 4 to 10 Hz every 60 seconds until the normal operation condition resumes If the temperature of the outdoor unit heat exchanger exceeds the out door unit heat exchanger overheat protection temperature for 120 sec outdoor temperature 40 C 60 sec outdoor temperature 40 C at minimum ope...

Page 11: ... HEAT mode by comparing the room temperature and your desired tempera ture The unit will automatically switch between HEAT and COOL mode to keep the desired temperature COANDA and MULTI SPACE button will be inactivated during AUTO mode During operation if the outdoor temperature changes the temperature settings will automatically slide as shown in the chart Modes and Temperature Settings the figur...

Page 12: ...tion of PAM drive circuit sequence 2 2 2 AC clock zero cross judgment The clock circuit determines the time from one rising point of the clock waveform to the next rising point The detected clock waveform is used to judge the power source frequency 60Hz The zero cross of the AC voltage is judged as the rising of the clock waveform as shown in the diagram above 2 2 3 IGBT ON start time delay time B...

Page 13: ...r code is called out by the indoor unit s self diagnosis function The LED on the outdoor unit flashes 14 times when an error is generated The LED continues flashing in the 14 time cycle even after the compressor stops operating The LED turns off data is deleted from the memory when the outdoor unit power is turned off In case of error 2 An error signal is sent to the indoor unit as soon as an erro...

Page 14: ...er to the upper phase IC The 15 V power supply for the lower phase IC is provided by the control printed wiring board PWB 3 1 1 Brief explanation of bootstrap system single power drive system To supply power to the upper phase IC the microcomputer IC1 turns ON the lower phase IGBT LU LV LW This results in a charging current that flows to the electrolytic capacitor of each upper phase IC input and ...

Page 15: ...stance is input to IPM CIN pin 15 Then the gate voltage of the lower phase IGBT LU LV LW inside the IPM turns OFF to cut off the over current At the same time an L output of more than 20μs is generated from IPM from pin 14 and this results in an L input to over current detection input pin 17 of the microcomputer IC1 and turns OFF the PWM signal output IC1 pins 20 through 25 to the IGBT gate AE X15...

Page 16: ...ention to the interrelation between efficiency and phase gap generated by the applied voltage of motor and current in the coil of motor as shown in the figure below This control is the forced magnetization system independent of the location of rotor detecting the phase difference between driving voltage phase and line current phase flowing in motor coil and controls the modulation rate data to get...

Page 17: ...ompressor chamber ther mistor TH1 remains at about 110 for 120 seconds in cooling operation or 60 seconds in heat ing operation at minimum fre quency When compressor is in operation Automatic reset after safety period 180 sec None Yes Yes 5 Dehumidifying oper ation temporary stop Compressor stops if outside air temperature thermistor is lower than about 16 during dehumidi fying operation When in d...

Page 18: ...ermistor TH3 At compressor star tup Operation OFF or ON Yes I1 Yes Yes 19 Outdoor unit suction thermistor open cir cuit error Compressor stops if there is open circuit in outdoor unit suc tion thermistor TH4 At compressor star tup Operation OFF or ON Yes I1 Yes Yes 20 Outdoor unit 2 way valve thermistor open circuit error Compressor stops if there is open circuit in outdoor unit 2 way valve thermi...

Page 19: ... At compressor star tup when in opera tion Compressor contin ues operation with out stopping None Yes Yes 28 Outdoor unit ther mal fuse error in the Terminal board Compressor stops if outdoor unit cannot receive serial signal from indoor unit for 30 seconds When in operation Reset after reception of serial signal None None None s i s o n g a i d f l e S n o i t a r e p O n o i t c n u F result dis...

Page 20: ...it error indication Cooling Dehumidifying Operation not affected Normal operation Outdoor unit ther mistor short cir cuit error indication Normal operation Outdoor unit ther mistor open cir cuit error indication Heating Rating control Defrosting Defrosting opera tion is activated unnecessarily Outdoor unit ther mistor short cir cuit error indication Defrosting opera tion is not acti vated and fros...

Page 21: ...Green Black 25ºC resistance 45 K Resistance 40K 30K 20K 10K 0 20 0 20 60 40 1 8 Connector CN8 TH2 Heat exchange thermistor TH3 Outdoor temp thermistor TH4 Suction pipe thermistor TH2 TH3 TH4 Temperature ºC Tester Resistance 0ºC resistance 14 5 K 25ºC resistance 4 431 K To operate the outdoor unit independently short circuit the sections indicated by arrows in the diagram below with an adapter and ...

Page 22: ...tteries in series connection Install new batteries Batteries installed incorrectly Check battery direction As indicated on battery compart ment Install batteries in indicated direc tion Lighting fixture is too close or flu orescent lamp is burning out Turn off light and check Signal should be received when light is turned off Change light position or install new fluorescent lamp Use Sevick light H...

Page 23: ...and outdoor units Terminal board 1 N 230 VAC 60 Hz Terminal board 2 serial signal Correct wiring M P I e c a l p e R y t i u n i t n o c M P I k c e h C M P I d e g a m a D Dried up electrolytic capacitor Check electrolyt l e e c a l p e R r o t i c a p a c c i ectrolytic capacitor Blown outdoor unit fuse Check 20 A fuse Fuse should not be blown Replace fuse diode bridge Replace fuse Replace outdo...

Page 24: ... be reversed 3 Inverter electrolytic capacitor C8 C9 check method Turn off the power let the inverter electrolytic capacitor C8 C9 discharge completely and remove the capacitor from the control printed circuit board PWB First check the case for cracks deformation and other damages Then using a needle type tester check continuity Determination of normal condition The tester needle should move on th...

Page 25: ...ion mode 2 Inverter DC power supply voltage check Measure DC voltage between IPM pins 20 and 24 B W P l o r t n o c e c a l p e R C D V 0 2 3 Replace diode bridge Correct soldered section of Fas ten tabs BT1 BT2 BT5 BT6 on control PWB and IPM S C R Repair solder cracks 3 IPM circuit check Check that 3 lamps load light Check position detection voltage 15 V 5 V on control PWB Each voltage should be ...

Page 26: ...AE X15PU 3 10 2 Troubleshooting of outdoor unit electric components 2 3 3 ...

Page 27: ... test is grounded its chassis ground has the same electric potential as the 0 V probe Since non insulated cir cuits have the following voltage potential difference from the ground connection of the grounding wire results in a short circuit between the 0 V line and the ground thus allowing an excessive current to flow to the tester to cause damage If the sheaths of the thermistor lead wires or expa...

Page 28: ... not operating The operation lamp green timer lamp orange and Plasmacluster lamp blue flash to indicate the information of malfunction If the power cord is unplugged or the circuit breaker is turned off the self diagnosis memory is lost Display of self diagnosis result The operation lamp green and the Plasmacluster lamp blue flash in synchronization with the timer lamp orange Timer lamp 1 cycle ON...

Page 29: ...nections for refrigerant leaks 4 Measure resistance of the outdoor unit compressor thermistor 5 Check the expansion valve for proper opera ion 1 Ensure unobstructed outdoor unit air ou let 2 Connect power supply of proper voltage amount of refriger ant 4 Replace he outdoor unit compressor thermistor assem bly 5 Replace he expan sion valve coil expansion valve or outdoor unit control PCB assembly O...

Page 30: ...ion Green Plasmacluster Blue O O O O O Timer Orange 1 IPM pin level error Check the IPM is attached correctly to the outdoor unit IPM PWB Replace the outdoor unit IPM PWB assembly O O Operation Green O Plasmacluster Blue Indoor and outdoor units do not operate 7 time O O O O O Timer Orange 7 0 Outdoor unit AC Current AC over current error 1 Ensure unobstructed air unit air outlet 2 Check the outdo...

Page 31: ...ation Green O Plasmacluster Blue Indoor and outdoor units do not operate 11 time O O O O O Timer Orange 11 0 Outdoor unit DC fan Outdoor unit DC fan rotation error 1 Check connector CN3 of the outdoor unit DC fan motor for secure installation 2 Check the outdoor unit fan motor for proper rotation 3 Check fuse FUSE5 4 Outdoor unit control PWB 1 Correct the installa tion 2 Replace the outdoor unit f...

Page 32: ...ndoor and outdoor units do not operate 14 ime O O O O O Timer Orange 14 0 Outdor unit PAM PAM over voltage error 1 Check the AC power supply voltage for 2 No abnormality found in above inspection 1 Correct he installa tion 2 Replace the PWB assembly O O O Operation Green Plasmacluster Blue O O O O O Timer Orange 1 PAM clock error Check the PAM clock for proper input Replace the outdoor unit contro...

Page 33: ...oor and outdoor units oper ate Normal blinking or OFF Timer Orange room tem perature thermistor Indoor unit room temperature thermistor 1 Check connector of thermistor for secure installation 1 Replace the ther mistor Operation Green Plasmacluster Blue Operation Green Plasmacluster Blue Operation Green Plasmacluster Blue 2 Check the tempera ture properties of the thermistor 2 Replace the ther mist...

Page 34: ...ng PEAK CURRENT Cooling Heating AE X15PU 7 6 A 9 5 A 10 3 A 12 0 A 7 7 A 11 8 A AE X18PU AE X24PU The content of this section is currently under revision Will be released after approval 1 2 Expansion valve Strainer 3 Outdoor unit silencer Condenser Evaporator Indoorunit Compressor Flare coupling Flare coupling 4 3 way valve 2 way valve Reverse valve S s Strainer S Temp on 1 165 2 74 194 5 90 3 Tem...

Page 35: ...OOLING MAX HEATING MAX COOLING TEST RUN MODE HEATING TEST RUN MODE Hz No 65 OR MORE 88 OR MORE 42 FIXED 42 FIXED Temp on 1 Temp on 2 Temp on 3 Temp on 4 3 way valve pressure MPaG MODE COOLING MAX HEATING MAX COOLING TEST RUN HEATING TEST RUN Hz No 105 OR MORE 97 OR MORE 42 FIXED 42 FIXED Hz in the table above is converted by frequency and has nothing to do with power supply frequency Note For COOL...

Page 36: ...r inlet temperature of is 80 26 7 during COOLING operation and 70 21 1 during HEATING operation 800 900 1000 1100 1200 1300 65 75 85 95 105 115 POWER CONSUMPTION W OUTSIDE TEMPERATURE 1100 1250 1400 1550 1700 1850 23 31 39 47 55 63 OUTSIDE TEMPERATURE 12 0 13 0 14 0 15 0 16 0 17 0 65 75 85 95 105 115 COOLING CAPABILITY kBTU 6 0 10 0 14 0 18 0 22 0 26 0 18 28 38 48 58 68 HEATING CAPABILITY kBTU OUT...

Page 37: ...MPERATURE 10 0 14 0 18 0 22 0 26 0 30 0 23 31 39 47 55 63 HEATING CAPABILITY kBTU OUTSIDE TEMPERATURE 6 3 AY XP24PU AE X24PU CAUTION Indoor fan speed is set to HIGH Airflow direction is initial Temperature of inlet is 80 26 7 during COOLING operation and 70 21 1 during HEATING operation 6 3 1 COOLING 1800 2000 2200 2400 2600 2800 65 75 85 95 105 115 OUTSIDE TEMPERATURE 1600 1800 2000 2200 2400 260...

Page 38: ... same in specifications such as corrosion resistant treatment tip shape and length After the air conditioner is repaired or parts are replaced measure insulation resistance of the equipment using an insulation resistance meter If the measured resistance is lower than 1 MΩ inspect parts and repair or replace defective parts 1 OUTDOOR UNIT Be sure to disconnect the power cord from the AC power outle...

Page 39: ...service panel then slide the panel downward and remove it 8 Unscrew the 4 screws fixing the motor angle T and remove it Service panel Motor angle T 9 Unscrew the 2 screws fixing the angle and remove it 10 Unscrew the 4 screws fixing the front panel and remove it 1 2 Angle 11 Disconnect the 4 connectors and the 2 terminals Terminal Connector 12 Cut the fixing band ...

Page 40: ...er and remove it Nut Terminal cover 16 Disconnect the 3 terminal connected with the compressor 17 Unscrew the 2 screws fixing the bu khead and remove it 18 Unscrew the 2 screws fixing the motor angle and remove it 19 Unscrew the nut fixing the fan and remove it 20 Unscrew the 4 screws fixing the motor and cut the fixing band and then remove the motor Nut Fixing band Bulkhead ...

Page 41: ...ve 1 screw and the 2 metal covers 7 Unscrew the 4 screws fixing the Heatsink and remove it from Heatsink holder Heat sink holder Metal cover control cover 1 Unscrew the 2 screws and remove the terminal board 2 Unscrew the 2 screws fixing the terminal angle and remove it 3 Remove the metal cover 4 Unscrew the 8 screws fixing the control board unit and remove it ...

Page 42: ... have your order filled promptly and correctly please furnish the following information 1 MODEL NUMBER 2 REF No 3 PART NO 4 DESCRIPTION MARK SPARE PARTS DELIVERY SECTION SPLIT TYPE ROOM AIR CONDITIONER MODEL In the interests of user safety Required by safety regulations in some countries the set should be restored to its original condi ion and only parts identical to those specified should be used...

Page 43: ...AE X15PU 2 1 OUTDOOR UNIT PARTS FOR AE X15PU AE X18PU AE X24PU ...

Page 44: ...1 1 21 PSEL E389JBEZ N SIDE COVER SEAL 1 1 22 PCOV C030JBFA N VALVE COVER 1 1 23 DCAB A185JBKZ N TOP PLATE ASS Y 1 1 23 1 GCAB A478JBTA N TOP PLATE 1 1 23 2 PSEL E129JBEZ TOP PLATE SEAL A 1 1 23 3 PSEL E130JBEZ TOP PLATE SEAL B 1 1 23 4 PSEL E131JBEZ TOP PLATE SEAL C 1 1 23 5 PSEL E284JBEZ TOP PLATE SEAL E 1 1 24 CSKR A569JBKZ N BULKHEAD ASS Y 1 1 24 1 PSKR A410JBTA N BULKHEAD 1 1 24 2 PSEL E285JB...

Page 45: ...Z AG FLARE NUT ASS Y 1 2 17 PSEN A053JBKZ AN FLARE NUT ASS Y 1 2 18 CCIL A185JBKZ AU N COIL ASS Y 1 2 19 RMOTSA037JBZZ BC COIL 1 2 20 PGUMS0170JBE0 AE DAMPER RUBBER 1 3 1 PCOV B888JBWZ AL COVER 1 3 2 DSGY F029JBKZ CA N CONTROL BOARD UNIT AE X15PU 1 3 2 DSGY F033JBKZ CA N CONTROL BOARD UNIT AE X18PU 1 3 2 DSGY F122JBKZ CA N CONTROL BOARD UNIT AE X24PU 1 3 3 LHLD B240JBFZ AT N HOLDER 1 3 4 LHLD B241...

Page 46: ... 3 5 1 5 2 NO PARTS CODE PRICE RANK NEW MARK PART RANK DESCRIPTION Qty 4 11 QW VZG615JBZZ AG Lead wire BT14 BT15 BT16 1 4 12 QW VZG713JBZZ AF Lead wire BT5 1 4 13 QW VZG762JBZZ AE Lead wire BT4 1 4 14 QW VZG772JBZZ AE Lead wire JPL1A JPL1B 1 4 15 QW VZG773JBZZ AE Lead wire JPL2C JPL2D 1 4 16 QW VZG775JBZZ AE Lead wire BT3 1 4 17 RC EZA371JBZZ BB Capacitor C8 C9 C10 2 4 18 VHVTVR10511 B AD Varistot...

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