Sony AS18A6RC Service Manual

ROOM AIR CONDITIONER

INDOOR UNIT

AS24A2RC AS18A6RC AS18A0RCD

SERVICE

OUTDOOR UNIT

US24A2RC US18A6RC US18A0RCD

Manual

CONTENTSAIR CONDITIONER

1. Installation

2. Disassembly and Reassembly

3. Troubleshooting

4. Exploded Views and Parts List

5. Refrigerating Cycle Block Diagrams

6. PCB Diagrams

7. Wiring Diagrams

E DB81-00189A(3)

8. Schematic Diagrams

1. Installation

1-1 Refrigerant Refill Procedure

• Refill an air-conditioner with refrigerant when refrigerant has been leaked at installing or using

1. Purge air(for new installation only).

2. Turn the 3-way valve clockwise to close, connect the pressure gauge(low pressure side) to the service valve, and open the 3-way valve again.

Suspension hook

3. Connect the tank to refill with Refrigerant

4. Set the unit to cool operation mode.

5. Check the pressure indicated by the pressure

gauge(low pressure side).

* Standard pressure is should be 4.5~5.5kg/cm

regular, high operation mode.

6. Open the refrigerant tank and fill with refrigerant until the rated pressure is reached.

* It is recommended not to pour the refrigerant in too

quickly, but gradually while operating a pressure valve.

7. Stop operation of the air conditioner.

in a

Compound gauge

For mounting other and of hose when not in use

High pressure gauge

Hand wheel

Finger tight fittings

Connected to high pressure side

Charging line

R-22

8. Close the 3-way valve, disconnect the pressure gauge, and open the 3-way valve again.

9. Close the cap of each valve.

1-2 “Pump down” Procedure

Pump down' shall be carried out when an evaporator is replaced or when the unit is relocated in another area.

1. Remove the caps from the 2-way valve and the 3-way valve.

2. Turn the 3-way valve clockwise to close and connect a pressure gauge(low pressure side) to the service valve, and open the 3-way valve again.

3. Set the unit to cool operation mode. (Check if the compressor is operating.)

4. Turn the 2-way valve clockwise to close.

5. When the pressure gauge indicates "0" turn the 3-way valve clockwise to close.

6. Stop operation of the air conditioner.

7. Close the cap of each valve.

Relocation of the air conditioner

• Refer to this procedure when the unit is

relocated.

1. Carry out the pump down procedure

(refer to the details of 'pump down').

2. Remove the power cord.

3. Disconnect the assembly cable from the

indoor and outdoor units.

4. Remove the flare nut connecting the

indoor unit and the pipe. At this time, cover the pipe of the indoor unit and the other pipe using a cap or vinyl plug to avoid foreign material entering.

2-Way Valve

3-Way Valve

5. Disconnect the pipe connected to the outdoor unit. At this time, cover the valve of the outdoor unit and the other pipe using a cap or vinyl plug to avoid foreign material entering.

6. Make sure you do not bend the connection pipes in the middle and store together with the cables.

7. Move the indoor and outdoor units to a new locatioon.

8. Remove the mounting plate for the indoor unit and move it to a new location.

2. Disassembly and Reassembly

Stop operation of the air conditioner and remove the power cord before repairing the unit.

2-1 Indoor Unit

No Parts Procedure Remark

Front Grille 1) Stop the air conditioner operation and block the

main power.

2) Seperate tape of front panel upper.

3) Contract the second finger to the left, and right handle and pull to open the inlet grille.

4) Take the left and right filter out.

* Take the Deodorizing and Electrostatic filter

out. (Optional)

5) Loosen one of the right fixing screw and seperate the terminal cover.

6) Loosen three fixing screws of front grille.

7) Pull the upper left, right and Center of discharge softly for the outside cover to be pulled out.

8) Pull softly the lower part of discharge and push it up.

Caution;

Assemble the front panel and fix the hooks of left, right and Center

No Parts Procedure Remark

Ass’y Tray Drain.

Electrical Parts

(Main PCB)

1) Do “1” above. Separate the drain hose from the extension drain hose.

2) Take the display PCB out. (Center of indoor unit)

3) Loosen two fixing screws of left and right

4) Pull tray drain out from the back body.

1) Do “1”, “2”, above

2) Take all the connector of PCB upper side out. (Inclusion Power cord)

Heat Exchanger

3) Separate the outdoor unit connection wire from the terminal block.

4) Pulling the Main PCB up. it will be taken out. (Separate the TRANS hook. it before).

1) Do “1” and “2”, “3”, above

2) Loosen two fixing earth screws of right side.

3) Separate the connection pipe.

4) Separate the bush body at the upper side and holder at the rear side.

5) Loosen the two fixing screws of left side.

6) Lifting the heat exchanger up a little to push the up side for separation from the indoor unit.

No Parts Procedure Remark

Fan Motor and

Cross Fan

1) Do “1” “2” ”3” “4”, above.

2) Loosen the fixing three screws and separate the motor holder.

3) Loosen the fixing screw of fan motor. (By use of M3 wrench)

4) Separate the fan motor from the fan.

5) Separate the fan from the left holder bearing.

2-2 Outdoor Unit

No Parts Procedure Remark

Cabinet

Fan Motor & Propeller Fan

1) Turn off the unit and remove the power cable

2) Remove the top cover.

3) Remove the control box cover.

4) Unplug the ass'y cable.

5) Remove the cabi-side.

6) Remove the cabi-front.

* When you assemble the parts, check if the

each parts and electric connectors are fixed firmly.

1) Do Procedure 1 above.

2) Remove the nut flange. (Turn to the right to remove as it is a left turned screw)

3) Disassemble the propeller fan.

3. Troubleshooting

3-1 Items to be checked first

1) The input voltage should be rating voltage 10% range. The airconditioner may not operate properly if the voltage is out of this range.

2) Is the link cable linking the indoor unit and the outdoor unit linked properly? The indoor unit and the outdoor unit shall be linked by 6 cables. Check the terminals if the indoor unit and outdoor unit are properly linked by the same number of cables. Otherwise the airconditioner may not operate properly.

3) When a problem occurs due to the contents illustrated in the table below it is a symptom not related to the malfunction of the airconditioner.

1 The STD operation indication LED blinks when a

power plug of the indoor unit is plugged in for the first time.

2 In a COOL operation mode, the compressor does not

operate at a room temperature higher than the setting temperature that the INDOOR FAN should operate.

3 Fan speed setting is not allowed in AUTO or DRY mode.

4 Compressor stops operation intermittently in DRY mode.

5 The compressor stops intermittently in a COOL mode or DRY

mode, and fan speed of the indoor unit decreases.

4) Indoor unit observes operation condition of the air conditioner, and displays self diagnosis details on the display panel.

1 STD LED blinking (1Hz) 2 TIMER LED blinking (1Hz) 3 STD and TIMER LED blinking (1Hz) 4 BIO LED blinking (1Hz) 5 STD, BIO and TIMER LED blinking(1Hz) 6 All LED blinking(1Hz)

Operation of air conditioner

Display

Explanation

It indicates power is on. The LED stops blinking if the operation ON/OFF button on the remote control unit is pushed.

In happens after a delay of 3 minutes when the compressor is reoperated. The same phenomenon occurs when a power is on. As a phenomenon that the compressor is reoperated after a delay of 3 minutes, the indoor fan is adjusted automatically with reference to a temperature of the air blew

The speed of the indoor fan is set to LL in DRY mode. Fan speed is 5 steps is selected automatically in AUTO mode.

Compressor operation is controlled automatically in DRY mode depending on the room temperature and humidity.

The compressor stops intermittently or the fan speed of the indoor unit decreases to prevent inside/outside air frozen depending on the inside/outside air temperature.

Self Diagnosis

Restore from power failure (input initial power) Indoor unit Room sensor Error (open or short) Indoor unit heat exchanger temperature sensor Error (open or short) Indoor fan malfunctioning (for spead is Below 450rpm) EEPROM Error Option Error (option wasn’t setup or option data error)

3-2 Fault Diagnosis by Symptom

3-2-1 No Power(completely dead)-Initial diagnosis

1) Checklist : (1) Is input voltage normal? (rating voltage ±10% range) (2) Is AC power linked correctly? (3) Are connections between primary side, secondary side of the power transformer and PCB good. (4) Is input voltage of DC regulator IC KA7805 (IC02) normal? (11VDC-12.5VDC) (5) Is output voltage of DC regulator IC KA7805 (IC02) normal? (4.5VDC-5.5VDC)

2) Troubleshooting procedure

Remove power cord and plug in again

in approx. 5 seconds

YES

Replace PCB

display

Is DC voltage of PCB

display normal?

Is the rating Voltage ±10%

range applied to the

between #1 and #3 of CN78

•Check linkage between power cord and

terminal tap

•Check fuse

Is 11~12.5VDC appear in

the input side of the DC

regulator IC KA7805(IC02)?

refer to replace

PCB module

Replace resonator (X501)

Is operation normal?

YES

YESNO

Is operation lamp blinking?

Does operation start when

run/stop button on the remote

controller unit pushed?

Is transmission display of the remote

controller unit blinking?

Is "beep"sound heard from the main

Is DC voltage of the PCB module

Are voltages of #8 (compressor), and#6 (outdoor fan) of the micom normal? ; 5VDC Is voltage of #60 (indoor fan) of the micom

DC5V

Is voltage at #33 terminal of the Micom normal? Is voltage at #18 terminal of the Micom normal?

Is voltage at #52 terminal of the micom

Are voltage at #48 and #49 of the

YES

unit?

YES

normal?

YES

normal?

10ms

YES

normal?

10ms

YES

micom normal?

YES

Replace

micom

100ns

;

0VDC

;

5VDC

YES

Normal

Refer to remote control

unit fault diagnosis

Refer to Replace PCB

module.

Are voltages at RY71(Compressor)

and RY72 (Outdoor fan)

Is voltage at SS71(indoor fan)

YES

Check connections

compressor, outdoor

fan and indoor fan.

Is output voltage of ICO2 normal?(DC5V)

YES

Refer to replace PCB

module

Is voltage output terminal of D101~D105(IN4007) normal?

YES

normal? ; DC12V

Replace

RY71, RY72

and SS71

Replace ICO2

Replace IN4007

3-2-2 When the Indoor Unit Fan Does Not Operate. (Initial Diagnosis)

1) Checklist : (1) Is the indoor unit fan motor properly connected with the connector (CN73)? (2) Is the AC voltage correct? (3) Is HALL IC in indoor fan motor properly connected with the connector (CN43)? (4) Is the running capacitor properly connected with the solder part of the PCB?

2) Troubleshooting procedure

After unplugging out the power cord should

Does the operating lamp(Green) blink?

Does the Solid State Relay(SS71) work properly?

SS71+

PCB CN73

pin3, pin5

be reconnected within five seconds.

YES

Test rod location

SS71-

YES

Is the supply voltage of the fan

motor sufficient?

Test rod location

Condition

Fan operate

12V

Normal

Voltage

Normal voltage

= AC 180V

Check as in the procedur “NO power parts”

Refer to page 8.

Microcomputer is out of order.

PCB is

out of order.

Refer to replace

PCB module

YES

Fan motor

is out of order.

MF-C is out of order

Replace MFC

Fan motor

should be replaced.

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