Sharp AF-05CML Service Manual

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Page 1

SER VICE MANU AL

AIR CONDITIONER

AF-05CML

S3209AF05CML/

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 identical to those specified should be used.

TABLE OF CONTENTS

SPECIFICATIONS ................................................................................................................................................ 2

EWIRING DIAGRAM ............................................................................................................................................ 3

EXTERNAL DIMENSIONS ................................................................................................................................... 3

HOW TO OPERATE ............................................................................................................................................. 4

INSTALLATIOIN INSTRUCTIONS ........................................................................................................................5

DISASSEMBLING PROCEDURE......................................................................................................................... 7

HOW TO REPAIR REFRIGERATION ................................................................................................................ 10

ELECTRICAL COMPONENT TEST .................................................................................................................... 12

TROUBLESHOOTING GUIDE ............................................................................................................................13

COOLING LOAD ESTIMATE FORM ...................................................................................................................16

RUNNING CONDITION .......................................................................................................................................18

PACKING AND ACCESSORIES ......................................................................................................................... 19

REPLACEMENT PARTS LIST ............................................................................................................................20

AF-05CML

Page

SHARP CORPORATION This document has been published to be used for after

sales service only. The contents are subject to change without notice.

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AF-05CML

SPECIFICATIONS

Models AF-05CML Cooling capacity BTU/h 5000 Moisture removal Pints/h 1.0

ELECTRICAL DATA

Phase Single Rared frequency Hz 60 Rated voltage Volts 115 Rated current Amps 4.6 Rated input Watts 500 Power factor % 95 EER BTU/Wh 10.0

COMPRESSOR

Type (Hermetically sealed rotary type) Model, Motor output

REFRIGERANT SYSTEM

Evaporator Louver fin, Grooved tube, 7mm, Hair pin Condenser Louver fin, Grooved tube, 7mm, Hair pin Control O.D. x I.D. x Length x Q'ty(mm) 2.7 x 1.1 x 400 x 1 (Capillary tube) Refrigerant volume R-22(OZ) 8.5 (Factory change)

NET DIMENSIONS

Width Height Depth

inches(mm)

Net Weight lbs 47

GROSS DIMENSIONS

Width Height Depth

inches(mm)

Gross Weight lbs 52

FAN SYSTEM

Indoor side(Evaporator) Centrifugal fan Outdoor side(Condenser) Propeller fan Air flow rate(indoor side) CFM High / Med / Low

OTHERS

Safety devices Compressor: Overload relay

Air filter Polypropylene net Power cord length ft 6.0 Power plug type 125V, 10A

ELECTRICAL PARTS

Running capacitor 250V-40µF Fan capacitor 250V-6µF Selector switch 2109 Thermistor No. APPLI- COLD COLD WARM WARM

Fan motor OBM-2016K1 (MLA998) Overload relay MRA99484

RM5455GQ86, 400W

17-23/32(450) x 14-9/16(370) x 14-7/8(378)

20-7/8(530) x 18-1/8(460) x 18-3/8(467)

195 / 175 / 150

Fan motor: Internal thermal protector

. CAUTION CUT-IN CUT-OUT CUT-IN CUT-OUT

MM1-A001 Cooling 66.2˚F 61.7˚F 86.0˚F 82.5˚F

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BLACK

BLUE

RED

WHITE

:ORANGE :

GRAY

: GREEN

RIBBED

WIRING DIAGRAM

POWER SUPPLY CORD

115V 60Hz

NON RIBBED

EARTH

OVERLOAD

RELAY

COMPRESSOR

THERMOSTAT

MOTOR

RUNNING CAPACITOR 250V 40µF

CONNECTOR

PROTECTOR

THERMAL

EARTH

M.C

SELECTOR SWITCH

OFF FAN LOW-COOL MED-COOL HIGH-COOL

642 RE

214563

FAN MOTOR

CAPACITOR 250V 6µF

A.C

FAN MOTOR

AF-05CML

EXTERNAL DIMENSIONS

17-23/32"

33-7/16" (full opened)

21-21/32" (full closed)

Figure W-1

14-7/8"

4-1/8"

1-15/32"

13-5/8"

15-11/16"

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AF-05CML

SELECTOR

WAIT THREE MINUTES BEFORE RESTARTING

THERMOSTAT

COOLER

SELECTOR

COOLER

HOW TO OPERA TE

HOW TO OPERATE

PARTS NAMES

UNIT CONTROL PANEL

1 Front Cabinet 2 Air Inlet (Indoor Side) 3 Horizontal Louvers 4 Vertical Louvers 5 Air Outlet (Indoor Side) 6 Control Panel 7 Rear Cabinet 8 Air Inlet (Outdoor Side) 9 FiIter (Pull the filter handle to the right to remove.) 0 Filter Handle q Power Cord

1 Thermostat Knob 2 Selector Knob

THERMOSTAT

OFF

COOLER

WAIT THREE MINUTES BEFORE RESTARTING

FAN

SELECTOR

LOW COOL

MED COOL

HIGH COOL

SELECTOR KNOB

Both the fan and cooling operationare off.

This setting can be used to circulate air whenever cooling is not desired. The fan will operate at medium speed.

Cooling for sleeping comfort with low fan speed.

Fan operates at medium speed; cooling power at medium.

Fan and cooling at maximum performance.

FAN

OFF

SELECTOR

LOW COOL

MED COOL

HIGH COOL

OFF

FAN

LOW COOL

MED COOL

HIGH COOL

THERMOSTAT KNOB

This knob is used to adjust the desired room temperature.

You can adjust the cooling performance of

COOLER

your air conditioner by resetting the thermostat control to a higher number for maximum cooling. The lower the number, the warmer the room temperature.

You will need to experiment to find the setting which suits you best.

CHANGING AIR DIRECTION

The horizontal louvers are used to adjust the UP/DOWN direction of air flow, and the vertical louvers are used to adjust the LEFT/RIGHT direction of air flow for uniform and efficient cooling of the room.

Horizontal louvers

Adjusts UP / DOWN air flow.

Vertical louvers

Adjusts LEFT / RIGHT air flow.

Lever

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INSTALLATION INSTALLATIONS

ACCESSORIES

No. Accessories

Right closure assembly

Left closure assembly

Window sash foam seal

(adhesive type) Bottom gasket

Screws(L=1",25.4mm)

Screws(L=

Base pan angle

SUGGESTED TOOLS

1. Screw driver (medium size Phillips)

2. Tape measure or ruler

3. Knife or scissors

/32",10mm)

Q'ty

1 1 1 1

1 7 6 2

AF-05CML

INSTALLATION

WARNING: Make sure the unit is turned off and unplugged before working.

1. Cut the window sash foam seal (adhesive type) to the proper length and attach it to the underside of the window sash.

Jamb

Window sash foam seal (adhesive type)

Sill

Sash

2. Insert the right closure assembly and the left closure assembly into the top angle and the bottom channels. Secure the right and left closure to the cabinet with six of the provided screws. (L= 13/32",10mm)

Closure assembl

3. Open the window sash and place the air conditioner on the sill. Balance the unit on the sill and close the window sash securely behind the top angle.

WARNING:

At this step, make sure the unit is inclinedapproximately 1 cm (3/8") to the back. If the unit is not properly inclined, the water collected in the bottom tray during operation will not drain properly and may flow into the room where the air conditioner is installed.

4. Insert the bottom gasket into the space between the window sill and the bottom of the unit to seal outside air. If there is space between the bottom channel and the sill, fill the gap with a thin board or other hard filler.

Sill

Unit

incline backwards about 1cm

/8")

(

Bottom gasket

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AF-05CML

Window sash foam seal

5. Insert the closure assemblieson both sides into the rails of the jamb.

Closure assembly (Left)

Indoor

Jamb (Left)

Closure assembly (Left)

Sill

side

Indoor side

Stool

/2 inches

(13mm)

6. Loosen screws on both sides of the cabinet, then hang the base pan angle on and secure the screws again.

8. Secure the top angle of the unit and the top of the closure assemblies to the sash with three of the provided screws. (L=1",25.4mm) And secure the bottom of the closure assemblies to the sill with two of theprovided screws. (L=1",25.4mm)

Top angle

9. Cut the window sash foam seal to the proper length and seal the opening between the top of the inside window sash and the outside window sash.

7. Secure the base pan angle to the sill by using the hole of the front side on the angle with one screw. (L=1",25.4mm)

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DISASSEMBLING PROCEDURE

AF-05CML

1. Unscrew the 2 screws holding the front panel on each side.

2. Remove the front panel by pulling the front panel at the lower corner toward you about one inch. Next lift up and pull it toward you.

5. Remove the control knob and control panel.

6. Unscrew the 5 screws. 3 screws are holding the control box at the top and right side. 1 screw is holding the power supply cord. 1 screw each screw on the evaporator.

3. Unscrew the 9 screws holding the cabinet. 2 screws are on each side. 4 screws are on back side. 3 screws are on top side.

4. Remove the thermostat.

7. Take off the fan motor connector.

8. Cut the wire fixing band, slide the control box rightward and remove.

SLIDE

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AF-05CML

9. Unfasten the one nut at the top of the compressor holding the terminal cover. Then remove the wiring connector of the compressor cord.

10. Unscrew the 6 screws holding the condenser. 2 screws are on right side.

2 screws are on left side. 2 screws are on back side. And remove the condenser from the unit.

13. Unscrew the 5 screws. 2 screws are holding the evaporator on each side. 3 screws are holding the bulkhead to the base pan on

each side and back side.

14. Lift up and take out the bulkhead.

11. Unfasten the nut holding the propeller fan by rotating it counter-clockise. And remove the propeller fan.

12. Unscrew the 3 screws holding the condenser shround. And remove the condenser shround.

15. Unscrew the 2 screws holding the orifice.

16. Unscrew the screw holding the centrifugal fan. (Remove by using a driver or a wrench)

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17. Remove the caseing. 18. Unscrew the 4 screws holding fan motor.

DISASSEMBLING THE CONTROL BOX

AF-05CML

1 Unscrew the 2 screws holding the control box cover.

CAUTION: DISCHARGE THE FAN MOTOR CAPACITOR AND RUNNING CAPACITOR BEFORE TOUCHING THOSE CAPACITORS OR OTHER COMPONENTS OR WIRING.

2 Cut the wire fixing bands holding the fan motor lead

wires, the compressor cord and the power supply cord.

3 Unscrew the 3 screw holding the selector switch and

thermostat. And take off the wiring connector of the compressor cord, the fan motor cord and the power supply cord.

4 Unscrew the 1 screw holding the capacitor clamp and

the fan motor capacitor, and take off each connector. And unscrew 2 earth screws.

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AF-05CML

INNER CONE

TORCH STEM

SILVER ALLOY

Figure 3

Directing Torch Flame to Copper Tubing.

3/8"

;;

HOW TO REPAIR REFRIGERATION

Before sealed system work can be preformed a refrigerant recovery EPA and LOCALLY approved certification is required, additionally, EPA and LOCALLY approved refrigerant recovery equipment is required.

SEALED SYSTEM REPAIR

Sealed system repairs should be properly diagnosed before entering into a repair of the system. It is important to follow proper procedures when doing a system repair for safety reasons and that the repair will result in a restoration of the system to proper factory standards.

SAFETY REMINDERS

1) Do not heat any system component with an open flame for any reason.

2) Do not solder until you are sure that all refrigerant has been removed from the system.

3) Do not heat the charging cylinder with an open flame. Use warm water only and do not exceed 125˚F (not too hot to keep your hand in.)

4) Do not over fill any charging cylinders, as they could explode when over filled.

5) Use proper wrenches.

6) Use safety goggles when working with refrigerants.

7) Keep a fire extinguisher within easy reach.

8) Watch flame direction when soldering so as not to burn clothing, wiring or other components.

9) Solder in a well ventilated area. If a high concentration of freon is present, an open flame will create phosgene gas which can be harmful.

PROPER SOLDERING

Joint clearances should be maintained so that the brazing alloy will flow between the closely mated surfaces rather than forming large fillets. This films make the strongest joints, capillary attraction also work best with close tolerance. The best clearance is between 0.01" to 0.03", the amount of lap will be approximately 3/8" depending on the sweging tool used. (Figure 1.)

CLEANING TUBING

To make a sound, leak tight joint, the brazing alloy when raised to brazing temperature, must wet and flow freely over the entire surface of the tubing in the joint area. To assure this, the tubing surfaces must be free of all dirt, grease, oil and oxides otherwise the alloy will not wet and flow properly over any surface with these elements present. Cleaning can be done with an abrasive cloth or steel wool. Never blow into the tubing because this will introduce a lot of moisture into the system. Open tubing joints should be covered if exposed for long periods of time.

GOOD FIT

PROPER JOINT FIT CLEARANCE .001"TO .003"

Joint Clearance.

Figure 1

EMERY CLOTH

KEEP TUBE IN DOWNWARD POSITION

Cleaning Tubing.

Figure 2

POOR FIT

PROPER FLUXING

Flux is necessary when using silver solder; it is not required when using silfos on copper to copper joints. To do a good job the flux should cover the tube surface completely. Be careful not to introduce any flux inside the tubing. Fluxing should be done after the tubing is mated together and just before brazing is done. Do not allow it to dry out. When brazing, the flux should become entirely liquid and clear, like water. The temperature will be at 1100˚F and only a little more heat will allow the alloy to flow freely into the joint.3

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AF-05CML

HEATING THE TUBING

Direct the torch flame so that the larger tube receives most of the heat. Silver solder flows at 1200˚F and silfos flows at 1300˚F. Heat all around the tubing. The flame is composed of two cones, a smaller inner cone (pale blue) in colour and a much larger outer cone. The hottest part of the flame is at the tip of the inner cone. The flame should be directed at the joint with the tip of the cone just touching the surface of the tubing. Figure 3 and 4.

OUTER CONE

HOTTEST PART OF FLAME

INNER CONE

TORCH STEM

Composition of Torch Flame.

Figure 4

DEHYDRATING SEALED SYSTEM

Many services feel that since air conditioners run with evaporator temperatures above 33˚F, moisture will not present a problem. Nothing is further from the truth. Oxygen in moisture plus the heat produced during compression will react with the refrigerant oil to produce harmful acids in the system which will break down motor winding insulation, create sludge and pit component parts, reducing efficiency of the air conditioner and shortening the life of compressors. There it becomes mandatory that good dehydrating practices be adhered to at all times. Proper hook up procedures as shown in Figure 5 must be used in order to pull and good vacuum from the system. The use of a good vacuum pump is very important so that the boiling point of any water in the system will be lowered to a point where it will vaporize and be expelled from the system in the form of vapour.

Type of evacuation methods

1. Piston Type Compressor No good.

System parts must be above 110 ˚F.

2. Rotary Vacuum Pump Disadvantages. Low CFMC. 4 oil gets dirty.

3. Single State Vacuum Pump will not clean oil. Oil must be changed often.

4. Two Stage Vacuum Pump will reach 50 microns. First stage is below atmospheric pressure. Moisture is removed into second stage which works up to atmospheric pressure thus keeping oil clean. Manometer cannot be read to 1/2 mm. Micron gauge reads from 25,400 microns to 0.

ELECTRIC VACUUM GAUGE

TO RELATED SERVICE VALVE OR PROCESS TUBES OF THE UNIT.

LARGE DIAMETER BRAIDED VACUUM HOSES

Hook up for Evacuation and charging

HIGH VACUUM MANIFOLD

HIGH VACUUM PUMP

Figure 5

DIAL-CHARGE CHARGING CYLINDER

LOW SIDE GAUGE

HIGH SIDE GAUGE

Page 12

AF-05CML

It becomes clear that good equipment and maintained properly must be used in order to remove air and moisture from the system. When a vacuum of 1,000 to 500 microns is reached, block off the vacuum pump from the system. This is done by closing the value between the pump and system. If the micron gauge does not increase above 1,000, the system is free of moisture and no leak exists. If the micron gauge increases to higher levels moisture or a leak exists.

LEAKS

Several methods are used to detect leaks in systems.

Electronic Leak Detectors are very sensitive and are able to detect leaks down to 1/2 ounce per year. A good electronic leak detector is generally far better in locating very small leaks. Halide Torch be sure the room is free from refrigerant vapours. Watch the flame for the slightest change in colour. A very faint green indicates a small leak. The flame will be unmistakably changed to green or purple when large leaks are encountered. To simplify leak detection pressurize the system to approximately 75 lbs. Some leaks can be located by a visual inspection of the system components and solder joints and if oil is found at any given location it generally is a sign that a leak exists at that point due to the fact that flame does carry oil with it travels through the system.

Soap Bubbles

Liquid detergents can sometimes assist in finding small leaks by brushing detergent on the suspect area and watching for bubbles. Before applying detergent be sure that the system is pressurized.

Tap line devices are permissible for diagnosis only they are not suitable when evacuating the system. After the diagnosis has been made they must be removed so that the system will be restored to a hermetical sealed condition.

ELECTRICAL COMPONENT TEST

SELECTOR SWITCH

(1) Remove the lead wires from the selector switch. (2) Using a volt-ohm-meter set on resistance range, check continuity

between terminals as indicated below. FAN OPERATION 1-4

LOW-COOL OPERATION 1-2, 1-8 MED-COOL OPERATION 1-4, 1-8 HIGH-COOL OPERATION 1-6, 1-8

OFF FAN LOW-COOL

MED-COOL HIGH-COOL

2468

INSULATION TEST Check the resistance between the terminal and SWITCH shaft. Reading must be more than 10MΩ at DC 500V.

THERMOSTAT

(1) Take the wires off the thermostat terminals.

2 6 8

(2) Set the selector switch of a volt-ohm-meter (or a tester) on the

resistance range. (3) Connect the probes to the thermostat terminals and check continuity between terminals. (4) Turn the shaft of the thermostat clockwise. Continuity between terminals: OFF ON

Turn the shaft of the thermostat counter-clockwise. Continuity between terminals: ON OFF

(When ambient temperature is more than 86˚F, continuity between terminals may not change to OFF.)

INSULATION TEST

Check the resistance between the terminals and thermostat shaft. Reading must be more than 10MΩ at DC 500V.

2468

RUNNING CAPACITOR AND FAN CAPACITOR CAUTION:DISCHARGE THE RUNNING CAPACITOR AND FAN CAPACITOR BEFORE TOUCHING CAPACITOR

OR WIRING.

(1) Discharge capacitor by shorting terminals. (2) Take the wires off the capacitor terminals. (3) Set the selector switch of a volt-ohm-meter (or a tester) on the resistance range. (4) Connect the probes to the capacitor terminals and watch the indicator swing.

The indicator does not swing at all ..... Open.

The indicator swings but does not return ..... Shorted.

The indicator swings, then returns a moment later ..... Good.

Page 13

INSULATION TEST

RUNNING CAPACITOR

FAN CAPACITOR

Neither fan motor not compressor operate

In sufficient cooling

No cooling

1) Check power supply switch or plug and measure the voltage

1) Fuse open or circuit braker open

1) If fuse or breaker are normal, ask the power supply company for check.

2) Plug disconnected

3) Plug connected properly but contact defective.

2) Connect properly.

1) Knob position not properly adjusted

3) Change power supplym cord with plug.

1) Move thermostat knob to a higher number (toward 10).

2) Defective thermostat 2) Replace

2) Change compressor

2) Outside air too high temp.

1) Equipment defective if no temp. difference

3) Air conditioner normal but heat leak excessive

1) Change or repair defect

2) Improve ventilation, avoid sunshine

3) Calculate cooling load and change or remove heat source

1) Change capillary tube

2) Check for gas leak and repair, recharge

1) Capillary tube restricted

2) Gas leak

1) Gas leak

2) Compressor defective

2) Check if temp.difference between inlet and outlet air of indoor unit is over 14˚F

1) No temperature difference between discharge pipe and suction pipe of compressor

3) Check indoor exchanger inlet/outlet piping temp. Sweat is less than half of coil or frost sticks to capillary tube

2) Check air filter

1) Check thermostat

Air filter clogged Clean

3) Check for a high heat source

4) Check doors and windows

5) Check if condenser and evaporator are clean

6) Check if any object is restricting heat radiation from the condenser.

7) Undersized air conditioner

8) Sealed system

Remove the added heat source Windows and doors must be

kept closed Clean them with steam cleaner

or another method Remove the object or move the

air conditioner Use Cooling Load Estimate

Form (Refer to page 16). Check sealed system

1) Repair gas leak

Symptom Check Defect Remedy

Check the resistance between the terminals and case. Reading must be more than 10MΩ at DC 500V.

OVERLOAD RELAY

Check continuity between terminals with volt-ohm-meter.

INSULATION TEST

Check resistance between terminals and the relay case. Reading must be more than 10MΩ at DC 500V.

COMPRESSOR

(1) Take the wires off compressor terminals. (2) Set selector switch of volt-ohm-meter on the resistance range. (3) Put the probes on the terminals of the compressor and check continuity between each terminal.

INSULATION TEST

Check the resistance between the terminals and the copper tube. Reading must be more than 10MΩ at DC 500V.

TROUBLESHOOTING GUIDE

AF-05CML

Page 14

AF-05CML

Symptom Check Defect Remedy

Fan motor runs but compressor doesn't operate

1) No current runs. (Compressor circuit)

1) Slector switch defective

2) Thermostat defective

3) Overload relay defective

4) Compressor coil burnt out

5) Wiring disconnected or burnt

1) Change switch

1) Change thermostat

2) Change overload relay

3) Change compressor

4) Connect or change wiring

out

2) Current runs. (Below operating current, capacitor normal)

3) High current draw

1) Compressor (main winding) burn out

2) Switch contact defective

1) Compressor locked

2) Compressor (Auxiliary

1) Change compressor

2) Change switch

1) Change compressor

2) Change compressor

winding) burn out

3) Overload relay contact burn

3) Change overload relay

out

4) High current draw compressor operates but stops immediately

4) Capacitor defective

5) Compressor winding short

1) Compressor winding short

2) Heat source near to air conditioner

3) Partial restriction in sealed

4) Change capacitor

5) Change compressor

1) Change compressor

2) Remove heat source

3) Check sealed system

system

Compressor trys to start

With switch set for cooling, fuse or circuit breaker open

1) Check power source voltage, start voltage drop

1) Check power line fuse or circuit breaker

2) Check power source voltage

1) Power source voltage too low

2) Wiring for power supply equipment too small

1) Insufficient capacity of fuse

2) Circuit breaker "OFF"

Power source cut off or contact

1) Improve the power supply equipment

2) Improve the power supply equipment

1) Change to rated fuse

2) Circuit breaker "ON" Repair

defective

3) Check compressor

1) Compressor locked

2) One connection terminal of

1) Change compressor

2) Solder

compressor burn out

3) One core of lead wire of

3) Change lead wire

compressor burn out

Fan motor doesn't operate with "Selector switch" set at "Fan only"

4) Insulation test on compressor

5) Insulation test on switch

1) Check select switch or micro switch contact

Insulation defective Insulation defective

1) Switch contact burn out

2) Switch contact defective

3) Switch cam defective

4) Wiring to terminal defective

Change compressor Change switch

1) Change switch

2) Polish contact

3) Change switch

4) Change or correct wiring

or improper

2) Check a. Fan capacitor b. Power cord c. Fan motor

3) Check a. Current exceeds rated one

1) Fan capacitor defective

2) Power supply voltage is too low

3) Fan motor defective

1) Fan motor bearing locked

2) Fan motor lead wire burn out

1) Change capacitor

2) Improve power supply

equipment

3) Change fan motor

1) Change motor

2) Change or repair lead wire

b. Motor lead wire

Page 15

Symptom Check Defect Remedy

Fan motor operates but supplies no air when "Selector switch" set at "Fan"

Compressor starts but stops soon

Check motor rotating direction

1) Check air filter and fan elements

1) Measure power supply voltage

Motor rotating wrong

1) Dirty air filter

2) Fan screw or nut loose and only motor rotating

1) Voltage is low and overcurrent runs, overload relay or

Change motor

1) Clean

2) Tighten up

1) Improve the power supply equipment

internal thermostat operates

2) Improve the power supply equipment

1) Change switch Check electric circuit (fan)

2) Tighten up

2) Check if air is delivered

2) Wiring for power supply

equipment too small

1) Overload relay operates as

fan is not rotating

2) Overload relay operates as

fan nut is loose

3) Check the temp. of air at condensor

1) Overload relay operates as

outdoor air temp. is too high

1) Ventilate well for outdoor exchanger, avoid sun light, remove heat source from around outdoor unit

AF-05CML

Compressor operates in cooling but fan doesn't rotate

Noise

Excessive vibration and noise

4) Rated current is normal but overload relay or internal thermostat cuts out

1) Check switch mechanism

2) Check fan capacitor

3) Check fan motor

1) Vibrating noise

2) Metallic sound

3) Noise created by fan

4) Check mounting of compressor

Check noise source

2) Improper ventilation for

outdoor heat exchanger. Overload relay operates as the temp. of outdoor unit is too high

Overload relay defective

Switch defective Capacitor defective

Fan motor defective

1) Insulation unstable

2) Cabinet screw loose

Piping touches cabinet or other parts

1) Fan cracked or deformed

2) Screw or nut loose causing

vibrating noise

Compressor mounts defective

1) Compressor

2) Electric parts

3) Piping touched

4) Cabinet or parts set-screws

loosened

5) Fan touching

6) Insulation unstable

2) Clean the outdoor unit Improve ventilation for outlet port of outdoor exchanger

Change overload relay

Change switch Change capacitor Change motor

1) Secure

2) Tighten up Repair

1) Change fan

2) Secure

Replace

1) Change compressor

2) Repair or change

3) Repair

4) Tighten up

5) Adjust

6) Secure

Page 16

AF-05CML

COOLING LOAD ESTIMATE FORM

INSTRUCTIONS FOR USING COOLING LOAD ESTIMATE FORM FOR ROOM AIR CONDITIONERS

(AHAM PUB. NO. RAC-1)

A. This cooling load estimate form is suitable for estimating the cooling load for comfort air conditioning installations

which do not require specific conditions of inside temperature and humidity.

B. The form is based on an outside design temperature of 95˚F dry bulb and 75˚F wet bulb. It can be used for areas in

the continental United States having other outside design temperature by applying a correction factor for the particular locality as determined from the map.

C. The form includes "day" factors for calculating cooling loads in rooms where daytime comfort (such as living rooms,

offices, etc.).

D. The numbers of the following paragraphs refer to the correspondingly numbered item on the form:

1. Multiply the square feet of window area for each exposure by the applicable factor. The window area is the area of the wall opening in which the window is installed. For windows shaded by inside shades or venetian blinds, use the factor for "Inside Shades". For windows shades by outside awnings or by both outside awnings and inside shades (or venetian blinds), use the factor for "Outside Awnings". "Single Glass" includes all types of single thickness windows, and "Double Glass" includes sealed air space types, storm windows, and glass block. Only one number should be entered in the right-hand column for item 1, and this number should represent only the exposure with the largest load.

2. Multiply the total square feet of all windows in the room by the applicable factor.

3a. Multiply the total length (linear feet) of all walls exposed to the outside by the applicable factor. Doors should be

considered as being part of the wall. Outside walls facing due north should be calculated separately from outside walls facing other directions. Walls which are permanently shaded by adjacent structures should be considered as being "North Exposure". Do not consider trees and shrubbery as providing permanent shading. An insulated frame wall or a masonry wall 8 inches or less in thickness is considered "Light Construction". An insulated frame wall or a masonry wall over 8 inches in thickness is considered "Heavy Construction".

3b. Multiply the total length (linear feet) of all inside walls between the space to be conditioned and any unconditioned

spaces by the given factor. Do not include inside walls which separate other air conditioned rooms.

4. Multiply the total square feet of roof or ceiling area by the factor given for the type of construction most nearly describing the particular application. (Use one line only.)

5. Multiply the total square feet of floor area by the factor given. Disregard this item if the floor is directly on the ground or over a basement.

6. Multiply the number of people who normally occupy the space to be air conditioned by the factory given. Use a minimum of 2 people.

7. Determine the total number of watts for lights and electrical equipment, except the air conditioner itself, that will be in use when the room air conditioning is operating. Multiply the total wattage by the factor given.

8. Multiply the total width (linear feet) of any doors or arches which are continually open to an unconditioned space by the applicable factor. NOTE: Where the width of the doors or arches is more than 5 feet, the actual load may exceed the calculated

value. In such cases, both adjoining rooms should be considered as a single large room, and the room air conditioner unit or units should be selected according to a calculation made on this new basis.

9. Total the loads estimated for the foregoing 8 items.

10. Multiply the sub total obtained in item 9 by the proper correction factor, selected from the map, for the particular locality. The result is the total estimated design cooling load in BTU per hour.

E. For best results a room air conditioner unit or units having a cooling capacity rating (determined in accordance with

the NEMA Standards Publication for Room Air Conditioners, CN 1-1960) as close as possible to the estimated load should be selected. In general, a greatly oversized unit which would operate intermittently will be much less satisfactory than one which is slightly undersized and which would operate more nearly continuously.

F. Intermittent loads such as kitchen and laundry equipment are not included in this form.

Page 17

AF-05CML

HEAT GAIN FROM QUANTITY

FACTORS

DAY

BTU/Hr (Quantity x Factor)

1. WINDOWS: Heat gain from sun. Southeast

Northeast South

Southwest Southeast

West Northwest North

sq ft sq ft sq ft

sq ft sq ft sq ft sq ft

Shades

Inside

Shades

Outside

Shades

(Area a Factor)

75 110 150 120

35 45 65 50

20 25 20 20 30 45 35

Use only

the

largest

load Use only

only

These factors are for single glass only. For glass block, multiply the above factors by 0.5: for double-glass or storm windows, multiply the above factors by 0.8.

2. WINDOWS: Heat gain by conduction. (Total of all windows) Single glass Double glass or glass block

sq ft sq ft

sq ft sq ft sq ft

sq ft sq ft

sq ft

ft ft

watts

30 60

20 30

8 3

600

300

Light Construction Heavy Construction

x x x x x x x x x x

(Item 9) x (Factor from Map) =

3. WALLS: (Based on linear feet of wall.)

4. ROOF OR CEILING: (Use one only.)

5. FLOOR: (Disregard if floor is directly

on ground or over basement.)

6. NUMBER OF PEOPLE:

7. LIGHTS AND ELECTRICAL

EQUIPMENT IN USE

8. DOORS AND ARCHES

CONTINUOUSLY OPENED TO UNCONDITIONED SPACE: (Linear feet of width.)

9. SUB-TOTAL

10. TOTAL COOLING LOAD: (BTU per hour to be used for selection of room air conditioner(s).)

a. Outside walls Noth exposure Other than North exposure

b. Inside Walls (between conditioned and unconditioned spaces only)

a. Roof, uninsulated b. Roof, 1 inch or more insulation

c. Ceiling, occupied space above. d. Ceiling, insulated with attic space above e. Ceiling, uninsulated, with attic space above

FARGO

EUGENE

RENO

SACRAMENT

FRESNO

LAS VEGAS

PHOENIX

PUEBLO

WICHITA

SAN ANTONIO

GREEN BAY

BIRMINGHAM

ATLANTA

COLUMBIA

ROCHESTER

ALBANY

NEW HAVEN

Page 18

AF-05CML

RUNNING CONDITION

Note:

1. Select mode of the Running Condition of a Room Air Conditioner.

SELECTOR .................................................................................................... HIGH COOL

THERMOSTAT .............................................................................................. 64˚F

2. Data of Performance Curve is measured between 40%RH and 70%RH.

If you measure the Room Air Conditioner above or below this rating, the data may miss the range of the

performance curve.

3. Outlet air temp. is influenced by the method of measurement. Measurement examples are shown.

4. Use power input data when checking the Running Condition.

RUNNING CONDITION FOR

PERFORMANCE CURVE

600

40%RH

500

400

300

Line current(Amp.) Power input (W)

(86)

(68)

(50)

Outlet air temp˚C (˚F)

25 30 35

(77) (86) (95) (104)

Outside air temp.˚C (˚F)

70%RH

40%RH

70%RH

40%RH

Page 19

PACKING AND ACCESSORIES

TOP PAD ASSEMBLY (DPADBA004JBFZ)

Top pad L

AF-05CML

Top pad R

Accessories Operation manual Window sash foam seal Window sash seal Bottom gasket

Screws Base pan angle Right closure assembly Left closure assembly

Enegry card (TLAB-C217JBEZ)

"Front side" mark

Packing case (SPAKCB001JBEZ)

Front side

Protect (SSAKHA245YDE0)

Power supply cord

Detail is assembling Energy card

Bottom pad assembly (CPADBA046JBKZ)

Page 20

AF-05CML

REPLACEMENT PARTS LIST

REF. NO. PART NO. DESCRIPTION Q'TY CODE

CABINET AND UNIT PARTS

1- 1 DCHS-A439JBTA Base pan ass’y 1 AZ 1- 2 CCAB-A316JBKZ Cabinet ass’y 1 BB 1- 3 LANG-A503JBTA Top inst. angle 1 BP 1- 4 PSEL-C357JBEZ Cabinet insulator 1 AC 1- 5 HPNLCA812JBRA Control panel 1 AK 1- 6 JKNB-A045JBKZ Control knob ass’y 2 AE 1- 7 PKESPA091JBFZ Condenser shroud 1 AS 1- 8 PSEL-C351JBEZ Condenser indulator 1 AC 1- 9 NFANPA106JBFZ Propeller fan 1 AR 1-10 CMOTLA998JBEZ Fan motor 1 BK 1-11 PSEL-A828JBE0 Motor insulator 1 AB 1-12 PSKR-A239JBFA Bulkhead 1 AX 1-13 PKESSA067JBFZ Caseing 1 AH 1-14 NFANSA027JBF0 Centrifugal fan 1 AU 1-15 PKESSA066JBFA Orifice 1 AH 1-16 MLOV-A321JBFA Vertical louver A 1 AC 1-17 MLOV-A322JBFA Vertical louver B 3 AC 1-18 MJNTPA089JBFA Louver joint 1 AC 1-19 MLOV-A323JBFA Horizontal louver 4 AC 1-20 MJNTPA090JBFA Louver link 1 AC 1-21 MSPR-A148JBEZ Louver spring 2 AF 1-22 GWAKPA150JBFA Front panel 1 AV 1-23 PFILMA162JBEA Air filter 1 AK 1-24 PSEL-C254JBEZ Tube insulator 1 AC 1-25 LHLDW0364JBE0 Wire holder 1 AA 1-26 LHLDW0366JBE0 Wire holder 1 AA 1-27 TSPC-E077JBRZ Name badge 1 AC 1-28 TLAB-C217JBEZ Energy card 1 AC 1-29 TLABBA110JBRA Sharp badge 1 AB 1-30 TLABKA564JBE0 Number card 1 AC 1-31 LBND-A042JBE0 Wire fixing band 2 AC 1-32 DSKR-A126JBKZ Bulkhead ass'y 1 AW 1-33 DKES-A029JBKZ Orifice ass'y 1 AW

CONTROL BOX PARTS

2- 1 DPLT-A057JBWZ Cont. box cover ass’y 1 AH 2- 2 DPLT-A059JBWZ Cont. box angle ass’y 1 AG 2- 3 LBNDKA109JBWZ Capacitor clamp 1 AC 2- 4 QACC-A260JBZZ Power supply cord 1 AS 2- 5 QW-VZC561JBE0 Lead wire 1 AD 2- 6 RC-HZA256JBE0 Fan motor capacitor 1 AM 2- 7 RC-HZA418JBZZ Running capacitor 1 AV 2- 8 TLABCB588JBRZ Wiring diagram 1 AB 2- 9 QSW-RA021JBE0 Selector switch 1 AS 2-10 RTHM-A190JBE0 Thermostat 1 BB 2-11 QW-VZD336JBE0 Lead wire 1 AG 2-12 QW-VZE252JBZZ Lead wire 1 AN 2-13 QW-IZA039JBZZ Comp. wiring 1 AS 2-14 LBND-A042JBE0 Wire fixing band 3 AC

CYCLE PARTS

3- 1 PCMPRA319JBEZ Compressor 1 BZ 3- 2 GLEG-A089JBE0 Compressor cushion 3 AR 3- 3 PPIPCF488JB1Z Discharge tube 1 AM 3- 4 PCON-A473JBEZ Condenser 1 BG 3- 5 PPIPCF491JB1Z Lead tube 1 AF 3- 6 DCPY-A258JBKZ Capillary tube ass’y 1 AR 3- 7 PEVA-A454JBEZ Evaporator 1 BD 3- 8 CPIP-A027JBKZ Suction tube ass’y 1 AR 3- 9 PSEL-B183JBE0 Terminal gasket 1 AC 3-10 RHOG-A177JBZZ Overload relay 1 AW 3-11 MSPR-A117JBE0 Protector spring 1 AE 3-12 PCOV-A382JBE0 Terminal cover 1 AE 3-13 PSEL-A691JBE0 Gasket washer 1 AF 3-14 PGUM-A113JBE0 Damper rubber 1 AH 3-15 LBND-A046JBEO Wire fixing band 1 AE 3-16 PSEL-C250JBEZ Evaporator insulator 1 AB 3-17 LBND-A042JBE0 Wire fixing band 1 AC 3-18 QW-VZD775JBZZ Overload relay wire 1 AD

Page 21

AF-05CML

REF. NO. PART NO. DESCRIPTION Q'TY CODE

ACCESSORY PARTS

4- 1 TINSEA299JBRZ Operation manual 1 AE 4- 2 LANGAA011JBFE Left closure frame 1 AH 4- 3 LANGAA012JBFE Right closure frame 1 AH 4- 4 PPLTPA016JBFB Closure 2 AK 4- 5 PSEL-A931JBE0 Window insulator 1 AH 4- 6 PSEL-A932JBE0 Window insulator 1 AE 4- 7 PSEL-C251JBEZ Window insulator 1 AC 4- 8 DX-BZA016JBK0 Screws kit 1 AW 4- 9 SSAKAA018YDE0 Bag 1AB 4-10 XCTSD40P10000 Tapping screw 6 AA 4-11 XMPSD40P25000 Wood screw 7 AA 4-12 LANGAA030JBTA Base pan angle 2 AD 4-13 SPADBA163JBEZ Card board 1 AC 4-14 SSAKHA009JBEZ Bag 1AC 4-15 CFZK-B935JBKZ Closure ass’y 1 AX

PACKING PARTS

5- 1 DPADBA004JBFZ Top pad ass’y 1 AH 5- 2 CPADBA046JBKZ Bottom pad ass’y 1 AN 5- 3 SPAKCB001JBEZ Packing case 1 AP 5- 4 SSAKHA245YDE0 Protect 1 AB 5- 5 SSAKAA053YDE0 Bag 1AB

SCREWS AND NUTS

6- 1 XTTSD40P20000 Tapping screw 4 AA 6- 2 XCTWJ40P16000 Tapping screw 2 AA 6- 3 XTTSD40P14000 Tapping screw 7 AA 6- 4 XTTSD40P12000 Tapping screw 13 AA 6- 5 XHTSD40P10000 Tap tight screw 6 AA 6- 6 XHTSD40P08000 Tap tight screw 5 AA 6- 7 XBPSD40P06J00 Machine screw 3 AB 6- 8 LX-BZA236JBE0 Special screw 1 AC 6- 9 LX-CZA038WRE0 Special screw 4 AA 6-10 LX-HZA001JBE0 Special screw 1 AB 6-11 LX-BZA140JBE0 Special screw 2 AB 6-12 LX-NZA074JBE0 Special nut 1 AB 6-13 LX-NZA103JBE0 Frange nut 1 AF 6-14 LX-NZA026JBE0 Special nut 3 AC

To have your order filled prompty and correctly, please furnish the following information.

1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION

HOW TO ORDER REPLACEMENT PARTS

Page 22

AF-05CML

12345

CABINET PARTS

6-4

4-12

1-11

1-32

4-9

1-10

4-10

4-11

6-4

4-3

6-1

4-7

4-5

6-1

4-6

6-10

4-4

6-5

4-2

6-11

1-4

6-4

1-9

6-14

1-3

6-9

1-2

6-11

1-8

5-3

4-13

4-14

4-15

4-8

4-1

6-5

6-9

6-2

1-22

1-12

1-21

1-13

1-19

1-17

1-20

1-33

1-18

1-26

1-16

1-31

1-24

1-25

6-4

6-3

1-14

1-7

1-15

5-1

2-4

5-5

6-8

6-4

6-3

1-30

5-2

5-4

1-29

6-4

1-28

1-27

6-2

123456

1-23

1-1

6-3

Page 23

AF-05CML

12345

CONTROL BOX PARTS

1-6

6-5

2-3

2-7

1-5

6-6

6-4

2-4

6-6

6-7

2-5

2-10

2-2

2-9

2-6

6-5

2-12

3-8

3-1

3-5

3-6

2-1

3-18

6-4

3-14

2-8

2-13

3-15

2-13

2-11

2-14

6-6

CYCLE PARTS

3-16

6-3

3-7

6-14

6-13 3-13

3-12

3-11 3-10

3-9

3-4

3-3

123456

6-5

3-17

6-14

3-2

Page 24

AF-05CML

No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.

’02 SHARP CORP. (3S0.85E) Printed in U.S.A.