Sharp AF-S50CX, AF-S55CX, AF-S60CX Service Manual

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Page 1

SER VICE MANU AL

AIR CONDITIONER

AF-S50CX AF-S55CX

AF-S50CX AF-S55CX AF-S60CX

S3207AFS06CX/

MODELS

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

EXTERNAL DIMENSIONS ................................................................................................................................... 4

HOW TO OPERATE ............................................................................................................................................. 5

INSTALLATIOIN INSTRUCTIONS ......................................................................................................................13

DISASSEMBLING PROCEDURE....................................................................................................................... 16

HOW TO REPAIR REFRIGERATION ................................................................................................................ 20

ELECTRICAL COMPONENT TEST .................................................................................................................... 23

MICROCOMPUTER CONTROL SYSTEM ..........................................................................................................24

TROUBLESHOOTING GUIDE ............................................................................................................................28

COOLING LOAD ESTIMATE FORM ...................................................................................................................33

RUNNING CONDITION .......................................................................................................................................35

PACKING AND ACCESSORIES ......................................................................................................................... 36

REPLACEMENT PARTS LIST ............................................................................................................................37

AF-S60CX

Page

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

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

Page 2

AF-S50CX AF-S55CX AF-S60CX

SPECIFICATIONS

Models AF-S50CX, AF-S55CX AF-S60CX Cooling capacity BTU/h 5000 6000 Moisture removal Pints/h 1.2 1.5

ELECTRICAL DATA

Phase Single Rared frequency Hz 60 Rated voltage Volts 115 Rated current Amps 4.2 5.2 Rated input Watts 455 545 Power factor % 94 91 EER BTU/Wh 11.0 11.0

COMPRESSOR

Type (Hermetically sealed rotary type) Model, Motor output

39R121AA-C4P, 390W

39R141AA-04P

, 460W

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 600 x 1 2.7 x 1.2 x 700 x 1 (Capillary tube) Refrigerant volume R-22(OZ) 11.1 11.8 (Factory change)

NET DIMENSIONS

Width Height Depth

inches(mm)

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

Net Weight lbs 47 48

GROSS DIMENSIONS

Width Height Depth

inches(mm)

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

Gross Weight lbs 53 54

FAN SYSTEM

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

195 / 175 / 150

OTHERS

Safety devices Compressor: Overload relay

Fan motor: Internal thermal protector Air filter Polypropylene net Power cord length ft 6.0 Power plug type 125V, 10A

Page 3

ELECTRICAL PARTS

Models

AF-S50CX, AF-S55CX

AF-S60CX Running capacitor 250V-35µF 250V-25µF Fan capacitor 250V-6µF Thermistor 15kΩ at 78˚F Fan motor OBM-2016K1

(MLA998)

Overload relay B210-130-241A B200-130-141E

WIRING DIAGRAM

AF-S50CX AF-S55CX AF-S60CX

POWER SUPPLY CORD

115V 60Hz

NON RIBBED

RIBBED

RUNNING CAPACITOR 250V 35µF

FAN MOTOR CAPACITOR 250V 6µF BL

123654

THERMAL PROTECTOR

COMPRESSOR

GYREOR

M.C

OUT

OVERLOAD PROTECTOR

A.C

RE OR WH

CONNECTOR

FAN MOTOR

EARTH

MOTOR

3A 125V

MRY

FU1 CONTROL BOARD UNIT

CNR1 CNR2

8 7 1 3 5

BCN1

CNR3

BCN2

RY1 RY2 RY3

BCN3

WIRE COLOR

: BLACK

: BLUE

: RED

: WHITE

: GREEN

: GRAY

: ORANGE

THERMISTOR

CN1

(

ROOM TEMP

YELLOW TH1

CN2

CN3

DISPLAY BOARD UNIT

Figure W-1. Wiring diagram for AF-S50CX, AF-S55CX

POWER SUPPLY CORD

115V 60Hz

NON RIBBED

RIBBED

RUNNING CAPACITOR 250V 25µF

FAN MOTOR CAPACITOR 250V 6µF BL

123654

THERMAL PROTECTOR

COMPRESSOR

GYREOR

M.C

OUT

OVERLOAD PROTECTOR

A.C

RE OR WH

CONNECTOR

FAN MOTOR

EARTH

MOTOR

3A 125V

MRY

FU1 CONTROL BOARD UNIT

CNR1 CNR2

8 7 1 3 5

BCN1

CNR3

BCN2

RY1 RY2 RY3

BCN3

WIRE COLOR

: BLACK

: BLUE

: RED

: WHITE

: GREEN

: GRAY

: ORANGE

THERMISTOR

CN1

(

ROOM TEMP

YELLOW TH1

CN2

CN3

DISPLAY BOARD UNIT

)

Figure W-2. Wiring diagram for AF-S60CX

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AF-S50CX AF-S55CX AF-S60CX

EXTERNAL DIMENSIONS.

17-23/32"

33-7/16" (full opened)

21-21/32" (full closed)

4-1/8"

Fig. E-1

15-1/4"

1-15/32"

13-5/8"

15-11/16"

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PARTS NAMES

UNIT

HOW TO OPERA TE

AF-S50CX AF-S55CX AF-S60CX

CONTROL PANEL

AF-S50CX, S60CX

1Front Cabinet 2Air Inlet (Indoor Side) 3Horizontal Louvers 4Vertical Louvers

5Air Outlet (Indoor Side) 6Control Panel 7Rear Cabinet

8Air Inlet (Outdoor side) 9Filter (Pull the filter handle

to the right to remove.)

0Filter Handle qPower Cord

AF-S55CX

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

POWER

ON/OFF

ENERGY

SAVER

1Receiver window for remote control signal 2Display 3SELECTOR indicator 4SELECTOR pad 5TEMPERATURE setting pad

----Lower temp. ----Raise temp.

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

POWER

ON/OFF

ENERGY

SAVER

6TIMER ON/OFF pad 7TIMER indicator 8ENERGY SAVER pad 9ENERGY SAVER indicator 0POWER ON/OFF pad qPOWER indicator

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AF-S50CX AF-S55CX AF-S60CX

COOLING OPERATION

SELECTOR indicator

POWER indicator

Touch POWER ON/OFF pad.

• The unit is preset at 74°F and HIGH COOL. This will show in the display when the power is first turned on.

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

POWER

ON/OFF

ENERGY

SAVER

• POWER indicator and SELECTOR indicator (COOL) will light.

To turn off the unit, touch POWER

ON/OFF pad again

• POWER indicator and SELECTOR

POWER ON/OFF pad

indicator will go off.

TO CHANGE TEMPERATURE SETTING

During cooling operation

Touch the TEMPERATURE setting pad to adjust the temperature setting.

---Lower temp.

---Raise temp.

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

POWER

ON/OFF

ENERGY

SAVER

• Temperature can be set within the range of 64°F to 86°F.

TEMPERATURE setting pad

• Display will change as you touch the pad.

NOTE:

• The latest temperature setting will be memorized and will appear on the display the next time

the unit is turned on.

• In cases of power outages or when the unit is disconnected; when the power is restored or the unit is plugged in, the unit and display will return to the preset conditions of 74°F and HIGH COOL. The unit will not automatically turn back on. The user must touch POWER ON/OFF to resume opertion.

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TO CHANGE FAN SPEED AND OPERATION MODE

AF-S50CX AF-S55CX AF-S60CX

SELECTOR indicator

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

POWER

ON/OFF

ENERGY

SAVER

SELECTOR pad

NOTES ON OPERATION MODE:

MODE

HIGH COOL

SELECTOR DISPLAY

COOL

During operation

Touch SELECTOR pad and select the operation mode and fan speed.

• SELECTOR indicator and display will light in order as you touch.

HIGH COOL MED COOL

MED FANLOW FAN

Cooling operation with high fan speed.

LOW COOL

HIGH FAN

MED COOL

LOW COOL

HIGH FAN

MED FAN

LOW FAN

COOL

FAN

Cooling operation with medium fan speed.

Cooling operation with low fan speed.

Fan only operation with high fan speed.

Fan only operation with medium fan speed.

Fan only operation with low fan speed.

• The latest operation mode will be memorized and the selector indicator and display will light when the unit is turned on.

• In fan only operation, the temperature display will go off.

• When the SELECTOR is changed to fan only operation from cooling operation, it will take 5

seconds for the compressor to stop.

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AF-S50CX AF-S55CX AF-S60CX

ENERGY SAVER

During normal operation, the thermostat automatically controls cooling and the fan runs continuously. When the ENERGY SAVER is selected, the thermostat automatically controls cooling and the fan automatically stops when the compressor is not operating. (Fan will stop 30 seconds after the compressor stops. After the fan stops, the fan is programmed to rotate for approx. 2 minutes to detect room temperature. This will occur within a 20 min time span.)

ENERGY SAVER indicator

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

POWER

ON/OFF

ENERGY

SAVER

During cooling operation

Touch ENERGY SAVER pad.

• ENERGY SAVER indicator will light.

To cancel, touch ENERGY SAVER

pad again.

• ENERGY SAVER indicator will go off.

ENERGY SAVER pad

NOTE: ENERGY SAVER cannot be set during fan only (HIGH FAN, MED FAN, LOW FAN)

operation.

TO CHANGE AIR FLOW 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

Adjust UP/DOWN air flow

Vertical louvers

Lever

Adjust LEFT/RIGHT air flow

Page 9

ON TIMER OPERA TION

• This unit has a built-in timer that can be programmed to start the unit up to 12 hours in advance. You can set the timer to start in increments of 30 minutes (0.5 hours) up to 9.5 hours in advance of the start time, or in 1 hour increments from 10 to 12 hours in advance of the start time.

• The unit will start automatically according to your setting.

When the unit is not operating

SELECTOR indicator

Touch the TIMER ON/OFF pad to set the delayed start time.

POWER

ON/OFF

• The time setting will change as you touch the pad. The display will change as follows;

AF-S50CX AF-S55CX AF-S60CX

COOL / FAN TEMP

SELECTOR

TIMER ON/OFF pad

TIMER indicator

TIMER

ON/OFF

(If you wish to start the operation 6 hours and 30 minutes later, set the delay time as shown above.)

ENERGY

SAVER

Preset(0.5h)

Previous setting

0.5h

CL(cancel)

1.0h

1.5h 10h 11h12h

• The timer will be set, 5 seconds after the TIMER ON/OFF pad is touched for the last time.

• SELECTOR indicator and TIMER indicator will light.

• The time display will count down the remaining time.

• The unit will start when the set time expires. The temperature setting will be displayed.

TO CANCEL THE TIMER SETTING

Touch the TIMER ON/OFF pad again after the timer is set, or press the TIMER ON/OFF pad until CL(cancel) appears on the display.

NOTES FOR TIMER SETTING AND OPERATION:

• After setting the TIMER, change the temperature and fan speed settings as shown on pages 11 and 12. When the temperature is set in the timer mode, the temperature will show in the display for 5 seconds and then return to the time display.

• The last setting used will be memorized and will appear on the display the next time you operate the unit with the TIMER function.

• If a power failure occurs while the ON or OFF TIMER is set, the TIMER memory will be cancelled and will not resume even after power is reinstated. The unit will not automatically start.

• OFF TIMER OPERATION can also be set with the REMOTE CONTROL.

Page 10

AF-S50CX AF-S55CX AF-S60CX

OFF TIMER OPERA TION

• T

his unit has a built-in timer that can be programmed to shut the unit off up to 12 hours in advance. You can set the timer to stop in increments of 30 minutes (0.5 hours) up to 9.5 hours in advance of the stop time, or in 1 hour increments from 10 to 12 hours in advance of the stop time.

• The unit will stop automatically according to your setting.

When the unit is operating

POWER

ON/OFF

Touch the TIMER ON/OFF pad to set the delayed stop time.

• The time setting will change as you touch the pad. The display will change as follows;

COOL / FAN TEMP

SELECTOR

TIMER

ON/OFF

ENERGY

SAVER

TIMER ON/OFF pad

TIMER indicator

(If you wish to stop the operation 10 hours later, set the delay time as shown above.)

Preset(0.5h)

Previous setting

0.5h

CL(cancel)

1.0h

1.5h 10h 11h12h

• The timer will be set, 5 seconds after the TIMER ON/OFF pad is touched for the last time.

• TIMER indicator will light.

• The time display will count down the

remaining time.

• The unit will stop when the set time expires. All indicators and displays will go out.

TO CANCEL THE TIMER SETTING

Touch the TIMER ON/OFF pad again after the timer is set or, press the TIMER ON/OFF pad until CL(cancel) appears on the display.

Page 11

USING THE REMOTE CONTROL

INSTALLING BATTERIES

Use two size-AAA (R03) batteries.

Remove the battery compartment cover.

Insert the batteries in the compartment,

making sure the and polarities are properly aligned.

Replace the cover.

NOTES:

• The battery life is approximately one year with normal use.

• When you replace the batteries, always use two new ones of the same type.

• If the remote control does not operate normally after replacing the batteries, take out the

batteries and replace them again after 30 seconds.

• If you will not be using the unit for a long time, remove the batteries from the remote control.

Battery compartment cover

AF-S50CX AF-S55CX AF-S60CX

ATTACHING THE REMOTE CONTROL HOOK

• Remove the backing from the remote control hook.

• Attach the hook onto the left side of the unit's front

cabinet.

• To prevent loss, hook the remote control on the front cabinet when not in use.

Remote control hook

Rear Cabinet

Front Cabinet

HOW TO USE THE REMOTE CONTROL

Point the remote control towards the unit's receiver window and press the desired button. A beep will sound when the unit receives the signal.

• Make sure no objects, such as curtains, block the receiver window.

• The remote control operates from up to 20 feet (6 meters) away.

• The beep will also sound when each pad on the control panel is touched.

CAUTION:

• Do not expose the receiver window to direct sunlight. This can adversely affect its operation. In such case, close the curtains to block the sunlight.

• Use of a fluorescent lamp in the same room may interfere with the transmission of the signal.

• The unit may be affected by signals emitted from the remote control of a television, VCR or other

equipment used in the same room.

• Do not leave the remote control exposed to direct sunlight or near a heater. Protect the remote control from moisture and shock which can discolor or damage it.

Page 12

AF-S50CX AF-S55CX AF-S60CX

OPERATING WITH THE REMOTE CONTROL

TRANSMITTER

POWER

ON/OFF

TEMP.

POWER ON/OFF button

Push to start or stop the operation.

TEMP.

SELECTOR

SET TIMER/OFF

TEMP. TEMP.

SELECTOR button

Push to change fan speed and operation mode. Fan speed and operation mode selections are shown to the right.

SET TIMER/OFF button

---Raise temp. setting 1°F at a time.

---Lower temp. setting 1°F at a time.

HIGH COOL MED COOL LOW COOL HIGH FAN

MED FAN LOW FAN

Push to set delay "OFF" timer during operation.

• The time setting will change as you push the button. The display will change as follows;

Preset(0.5h)

Previous setting

0.5h

CL(cancel)

• The last OFF time setting is memorized by the unit and will appear on the display when the button is pushed.

• The timer will be set, 5 seconds after the SET TIMER/OFF button is pushed for the last time.

• If you wish to cancel the timer, push the SET TIMER/OFF button again after the time is set or, push the SET TIMER/OFF button until CL (cancel) appears on the display. A double beep will sound when the timer is cancelled.

• The "ON" TIMER cannot be set with the remote control. It can only be activated by the TIMER ON/OFF pad on the unit's control panel ( See page 9 ).

1.0h

1.5h 10h 11h12h

To change temperature setting when ON/OFF timer is in use

1. Push a TEMPERATURE setting button. The current set temperature will be recalled on the unit's display.

2. Use the TEMPERATURE setting buttons to set the new temperature. The new set temperature will show on the display for 5 seconds and return to the time display.

Page 13

ACCESSORIES

No.

Accessories Q'ty

INSTALLATION INSTRUCTIONS

AF-S50CX AF-S55CX AF-S60CX

1 2

6 7 8 9

10 11

Right closure assembly 1 Left closure assembly 1 Window sash foam seal 1 Window sash foam seal 1

(adhesive type) Bottom gasket 1 Screws (L=1", 25.4mm) 7 Screws (L=

/32", 10mm) 6 Base pan angle 2 Remote control 1 Battery 2 Remote control hook 1

SUGGESTED TOOLS

1. Screw driver (medium size Phillips)

2. Tape measure or ruler

3. Knife or scissors

Page 14

AF-S50CX AF-S55CX AF-S60CX

INSTALLATION

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

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

the underside of the window sash.

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.

/32", 10mm)

(L=

Jamb

Sill

Sash

Window sash foam seal (adhesive type)

Closure assembly

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 inclined approximately 1 cm ( 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.

Insert the bottom gasket into the space between the window sill and the bottom of

the unit to seal outside air.

/8") to the back.

sill

unit

incline backwards approximately 1cm (3/8")

If there is space between the bottom channel and the sill, fill the gap with a thin board or other hard filler.

Bottom gasket

Page 15

Insert the closure assemblies on both sides into the rails of the jamb.

Jamb (Left)

Closure assembly (Left)

Sill

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

Indoor side

Closure assembly (Left)

1/2 inches (13mm)

Stool

AF-S50CX AF-S55CX AF-S60CX

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)

Top angle

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 the provided screws. (L=1", 25.4mm)

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.

Window sash foam seal

Page 16

AF-S50CX AF-S55CX AF-S60CX

DISASSEMBLING PROCEDURE

CAUTION: DISCONNECT THE ROOM AIR CONDITIONER FROM THE POWER SUPPLY BEFORE ANY SERVICE

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 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 thermistor holder.

7. Take off the fan motor connector.

8. Unscrew the 1 screw holding the compressor cord.

Page 17

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

SLIDE

AF-S50CX AF-S55CX AF-S60CX

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

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

11. 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.

14. 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.

15. Lift up and take out the bulkhead.

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

16. Unscrew the 2 screws holding the orifice.

Page 18

AF-S50CX AF-S55CX AF-S60CX

17. Unscrew the 1 screw holding the centrifugal fan.

18. Remove the caseing.

19. Unscrew the 4 screws holding fan motor.

Page 19

DISASSEMBLING THE CONTROL BOX

AF-S50CX AF-S55CX AF-S60CX

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. Unscrew the 3 screws holding the printed wiring board.

5. Unscrew the 1 power supply cord grounding screw. Unscrew the earth screw. Unscrew the 1 screw holding the capacitor clamp.

6. Detach each connector by using long-noise pliers.

3. Cut the wire fixing bands holding the fan motor lead wires, the compressor cord and the power supply cord.

4. Unscrew the 1 screw holding the fan motor capacitor.

7. Unscrew the 2 screws holding the transformer.

8. Remove the control board with unhooking the 2 spacers.

Page 20

AF-S50CX

AF-S55CX AF-S60CX

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.

GOOD FIT

PROPER JOINT FIT CLEARANCE

0.01" TO 0.03"

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 swaging 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.

Joint Clearance.

Figure 1

EMERY CLOTH

Cleaning Tubing.

ure 2

POOR FIT

KEEP TUBE IN DOWNWARD POSITION

Page 21

PROPER FLUXING

OUTER CONE

HOTTEST PART OF FLAME

INNER CONE

TORCH STEM

Figure 4

Composition of Torch Flame.

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.

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 calor 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.

3/8"

INNER CONE

TORCH STEM

SILVER ALLOY

Directing Torch Flame to Copper Tubing.

Figure 3

AF-S50CX AF-S55CX AF-S60CX

DEHYDRATING SEALED SYSTEM

Many servicers 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.

Page 22

AF-S50CX AF-S55CX AF-S60CX

Type of evacuation methods

1. Piston Type Compressor No good.

System parts must be above 110˚F.

2. Rotary Vacuum Pump Disavantages. 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.

TO RELATED SERVICE VALVE OR PROCESS TUBES OF THE UNIT.

ELECTRIC VACUUM GAUGE

LARGE DIAMETER BRAIDED VACUUM HOSES

HIGH VACUUM MANIFOLD

DIAL-CHARGE CHARGING CYLINDER

LOW SIDE GAUGE

HIGH SIDE GAUGE

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.

HIGH VACUUM PUMPHook up for Evacuation and charging

Figure 5

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 calor. 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 hermeticly sealed condition.

Page 23

AF-S50CX AF-S55CX AF-S60CX

ELECTRICAL COMPONENT TEST

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.

FAN CAPACITOR

INSULATION TEST

RUNNING CAPACITOR

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.

Page 24

AF-S50CX AF-S55CX AF-S60CX

MICROCOMPUTER CONTROL SYSTEM

1. Temperature control characteristic

1-1 COOL operation

In the “COOL” mode, the thermostat circuit is controlled by two thermostat lines (C1, C2).

Room temperature (°F)

64 86

Preset temperature (°F)

("THERMO" switch)

Figure Y-1

2. Operation mode

2-1 COOL operation

The compressor turns on or off, at thermostat lines C1 and C2. The fan motor is also controlled with the compressor.

States 1 & 3 States 2

: Compressor ON : Compressor OFF

3. Fan speed

Fan speeds are given by the fan motor, “H”, “M” and “L”, which are available in the following operation

mode.

Table Y-1

Selector Fan motor HIGH COOL H MED COOL M LOW COOL L HIGH FAN H MED FAN M LOW FAN L

4. 12-hours timer

4-1 OFF-TIMER operation

Set the delay timer during operation. The unit will turn off automatically according to your setting. Timer duration can be set by 0.5 hours to maximum 12 hours. Up to 9.5 hours, you can set by 0.5 hours increments and from 10 to 12 hours, by 1 hour increment. If you touch button “POWER ON/OFF” during OFFTIMER operation, then the unit turns off and OFFTIMER operation is cancelled.

4-2 ON-TIMER operation

Set the delay timer when unit is not operating. The unit will turn on automatically according to your setting. Timer duration can be set by 0.5 hours to maximum 12 hours. Up to 9.5 hours, you can set by

0.5 hours increments and from 10 to 12 hours, by 1 hour increment. If you touch button “POWER ON/OFF” during ONTIMER operation, then the unit turns on and ON-TIMER operation is cancelled. ON-TIME and OFF-TIME display will count down the remaining time.

Room temperature (°C)

Room temperature transition

Preset temperature (°C)

Figure Y-2

2-2 FAN ONLY operation

The fan motor always turns on.

from 0.5 to 9.5 ..... 0.5 hours

from 10 to 12 ....... 1 hour

5. Energy saver

During normal operation, the thermostat automatically

controls cooling and the fan runs continuously whenever the air conditioner is in operation. When the ENERGY SAVER is set, the thermostat automatically controls cooling and the fan automatically stop when compressor is not operating. (Fan will stop in 30 seconds after the compressor stops.)

Compressor

Fan

OFF

30 seconds

Figure Y-3

Page 25

6. Safety start

When you turn the air conditioner OFF and restart again soon, wait at least 3 minutes before the cooling operation starts.

7. Test mode

Keep pushing both buttons “POWER ON/OFF” and “ " ” and supply the power, the system will go to the test mode. In this mode, the output operation is switched by pushing buttons. Normal outputs are shown in Table Y-2.

AF-S50CX AF-S55CX AF-S60CX

For selfdiagnosis check mode

No. PUSH KEY (SWITCH)

PLUG IN the power supply cord

while pushing power ON/OFF key and (down) key.

TIMER

<SW6>

3 4

ENERGY SAVER

5 6 7 8

1) If thermistor is normal (nether short nor open), LED is ON.

2) When A/D (R42) bit 7 = 1, LED is ON.

2) When A/D (R42) bit 6 = 1, LED is ON.

2) When A/D (R42) bit 5 = 1, LED is ON.

ON/OFF

POWER ON/OFF by REMOTE CONTROL

POWER SUPPLY OFF

BEPP

SOUND

1SELECTOR <SW3> 1

1 1 1 1 1

LED1

<LED2>

8.8 ON

OFF

02 03 04 05 05

OFF

FAN

HIGH

OFF OFF

2) 3) 4)

ON OFF OFF

ON OFF OFF OFF OFF OFF OFF OFF OFF OFF

Table Y-2

FAN

MID

<LED3>

ON ON ON ON ON ON ON OFF

OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

OFF OFF ON OFF OFF ON OFF

ON OFF OFF ON OFF OFF ON OFF ON OFF OFF ON OFF OFF OFF OFF ON OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF

Table Y-3

LED LIGHTING CHECK ITEM

FAN

LOW

<LED4>

COOL

<LED9>

<LED5>

TIMER

<LED7>

ENERGY

SAVER

<LED8>

POWER ON/OFF <LED6>

FAN

OUTPUT

LOW

MIDDLE

HIGH

OFF

LOW HIGH MIDDLE

OFF

COMP

OUTPUT

OFF

OFF OFF

OFF OFF OFF

ON OFF OFF

and REMARK

LED ALL ON

LED ALL OFF

FAN CHECK

COMPRESSOR CHECK REMOTE CONTROL CHECK

T(˚C) T(˚F) R(kΩ)

V(volts) 0 32.0 49.33 1.17 1 33.8 46.86 1.21 2 35.6 44.53 1.26 3 37.4 42.33 1.31 4 39.2 40.25 1.36 5 41.0 38.29 1.41 6 42.8 36.44 1.46 7 44.6 34.68 1.51 8 46.4 33.02 1.56 9 48.2 31.45 1.61

10 50.0 29.96 1.67 11 51.8 28.55 1.72 12 53.6 27.22 1.78 13 55.4 25.96 1.83 14 57.2 24.76 1.89 15 59.0 23.62 1.94 16 60.8 22.56 2.00 17 62.8 21.52 2.05 18 64.4 20.55 2.11 19 66.2 19.63 2.17 20 68.0 18.76 2.22

T(˚C) T(˚F) R(kΩ) V(volts)

21 69.8 17.93 2.28 22 71.6 17.14 2.33 23 73.4 16.39 2.39 24 75.2 15.68 2.44 25 77.0 15.00 2.50 26 78.8 14.36 2.55 27 80.6 13.74 2.61 28 82.4 13.16 2.66 29 84.2 12.60 2.71 30 86.0 12.07 2.77 31 87.8 11.57 2.82 32 89.6 11.09 2.87 33 91.4 10.63 2.93 34 93.2 10.19 2.98 35 95.0 9.78 3.03 36 96.8 9.38 3.08 37 98.6 9.00 3.13 38 100.4 8.64 3.17 39 102.2 8.30 3.22 40 104.0 7.97 3.27

V ....... Input the voltage of microcomputer (No. 10-port).

Page 26

AF-S50CX AF-S55CX AF-S60CX

GREEN

RED

LED6

LED2~LED5, LED7~LED9

YELLOW

LED7, LED8

AF-S55CX AF-S50CX/S60CX

LED2~LED5, LED9 GREEN

D17

HEATSINK

RED

LED6

7812

IN OUT

D1 - D4

KRA101M

(DTA143ES)

COM

IC2

+++

C2 C3 C4 C5 C6 C7

LED2 COOL/H

LED3 COOL/M

25V

0.1µ

15K

ZD1

HZ4A-2

25V

0.1µ

10V

100µ

OUT

COM

IC3

25V

47µ

25V

0.1µ

25V

0.1µ

25V

1000µ

D3 D4

250V

0.1µF

LED4 COOL/L

LED5 FAN

LED6 ON/OFF

LED1

79L05

12V

10K

KRC101M

(DTC143ES)

22K

271

LED7 TIMER

LED8 ENERGY

SAVER

Q10

C11

C12

C10

16V

0.01µ

20k

LED9 COOL

Q8 ~ Q10

KRA222M

(DTB123EA)

7654321

BCN2

16V

10µ

C20

C21

25V

0.1µ

Q7: KRA106M

(DTA143ZS)

2.7K

IC4

R23 47Ω 1/2W

C22

Q1: KRA105M

(DTA123JS)

D5D8

D7 D6

R18

C18

C17

25V

50V

R17

47µ

0.1µ

10K R24

OSC

COMP

R16

R15

R14

PHOTO

DETECTOR

UNIT

CN2

10K

R5 10K 10K

10K R28

28272625242322212019181716

HOLD

OUT dd

4MHz

1X V

2345678

MRY

RY1

RY2

RY3

FAN H

FAN M

FAN L

R13

R12

SW6

QWN-KEY

SW5

UP-KEY

SW4

POWER

SW3

SELECTOR

SW2

TIMER

SW1

E/SAVER

C19 16V 10µF

1000P 50V

C15

R92

R91

R90

RESET

R70

R71

Q2, Q3, Q4

KRA106M

(DTA143ZS)

12V

R11 ~ R18

150Ω x 8

R11

C16

R83

INT1

R81

INT2

R72

R40

R41

R42 9

TEST

D15

D14

D13 D12 D11

D10

BCN3CA1 CN3

R63

R62

R61

R60

R53

TMP47C443N

R43

R50

R51

R52

1011121314

R10

15K(F)

R22

C14

432

2134567

IC1

-5V

16V

10µ

CN1

RA1

CA1: 1000pF x 8

RA1: 10kΩ x 8

SW1: ENERGY SAVER

SW2: TIMER

SW3: SELECTOR

SW4: POWER

SW5: UP-KEY

SW6: DOWN-KEY

Electronic Control Circuit Diagram

FU1

125V

MRY

POWER SUPPLY

115V AC

60Hz

OVERLOARD

PROTECTOR

COMPRESSOR

MOTOR

250V 35µF

RUNNING CAPACITOR

AF-S50CX

AF-S55CX

AF-S60CX 250V 25µF

RUNNING

CAPACITOR

GRAY

BCN1

671

FAN MOTOR

CAPACITOR

250V 6µF

RY1

GRAY

BL BK

CNR1

RED

RY2

CNR2

ORANGE

RY3

CNR3

WHITE

CNR1 - CNR3

CONNECTOR

GR RE GY BK

123654

YELLOW

(15k)

ROOM

Temp

TH1

GREEN

NO INSERT PART

FAN

MOTOR

IF NOT SPECIFIED 1/5W, ±5% (RESISTOR)

IF NOT SPECIFIED 50V 1000pF (CAPACITOR)

IF NOT SPECIFIED 1SS133T-72 (DIODE)

: INDICATED POSITION IS FUNCTION TEST POINT

CA1: 1000pF x 8 (CAPACITOR ARRAY)

RA1: 10kΩ x 8 (RESISTOR ARRAY)

Page 27

AF-S50CX AF-S55CX AF-S60CX

DPWBFA244JBKZ (AF-S55CX)

DPWBFA278JBKZ

QPWBFB475JBZZ

QPWBFB438JBZZ (AF-S55CX)

R15

BCN2

DPWBFA278JBKZ

QPWBFB475JBZZ

DPWBFA244JBKZ (AF-S55CX)

Printed Wiring Board

QPWBFB438JBZZ (AF-S55CX)

Page 28

AF-S50CX AF-S55CX AF-S60CX

No cooling (Operation not at all.)

TROUBLESHOOTING GUIDE

Measure the power supply voltage at receptacle.

120V(over 100V)

Is it sufficient current capacity of power equipment ? Is it small wiring for power supply equipment ?

sufficient

Is plug disconnecting ?

connecting

Check the power supply cord.

under 100V

The house fuse or circuit breaker open ?

open

Is it proper current capacity of the house fuse or the circuit breaker ?

Change the house fuse and the circuit breaker turn on.

insufficient

Ask the power supply company for check.

disconnecting

Connect plug properly.

imperfect contact

Change the power supply cord.

not open.

Ask the power supply company for check.

Check the fuse on PWB ass'y.

Measure the secondary voltage of transformer.

over 14V(AC)

Measure the voltage between

-12V and GND on PWB ass'y. OK(12V, DC)

Measure the voltage between

-5V and GND on PWB ass'y. OK(5V, DC)

If unit operate, dose the house fuse or the circuit breaker open ?

open

Change the fuse on PWB ass'y.

under 14V(AC)

Change PWB ass'y.

YES

Measure the insulation resistance of compressor.

OK(over 10MΩ)

Measure the insulation resistance of fan motor.

OK(over 10MΩ)

NG(under 10MΩ)

Change the compressor.

NG(under 10MΩ)

Change the fan motor.

Checking complete.

Can the Compressor operate ?

can operate

can't operate

Change the compressor.

Page 29

No cooling (Fan operate but the compressor doesn't operate.)

AF-S50CX AF-S55CX AF-S60CX

Measure the power supply voltage at receptacle.

120V(over 100V)

s it sufficient current capacity of power equipment ? Is it small wiring for power supply equipment ?

sufficient

Measure the current in compressor circuit.

current

Check the overload relay.

Check the running capacitor.

under 100V

Ask the power supply company for check.

insufficient

Ask the power supply company for check.

no current

imperfect contact

Change the overload relay.

Change the running capacitor.

Check the overload relay.

short

Is the connector disconnecting ?

connecting

Check the compressor relay.(MRY on PWB)

open

Change the overload relay.

disconnecting

Connect properly.

Change PWB ass'y.

Measure the resistance of compressor coil.

Is there high heat source near the unit.

there isn't

Is the outdoor temperature too high ?

under 43ûC

Check the outdoor heat exchanger.

not dirty

Change the compressor.

there is

Remove the high heat source or stop.

over 43ûC

Avoid sun light and ventilate well for outdoor heat exchanger.

dirty

Clean them with steam cleaner or another method.

Check the thermister.

Change the thermistor.

Checking method for the compressor relay. (MRY on PWB)

Turn off the power supply.

Measure the resistance of its coil.

OK(160Ω at 20ûC)

Turn on the power supplty as operating the compressor.

Measure the voltage to its coil.

OK(12V, DC)

Can the compressor operate ?

can operate

Checking complete.

can't operate

Change the compressor.

Page 30

AF-S50CX AF-S55CX AF-S60CX

No cooling (The compressor operate but the fan motor doesn't operate)

crack at the solder part

Check BNC1 on PWB

disconnecting the connector

ass'y

Repair with over solder. Connect the connector

Check the fan motor

properly.

capacitor.

Change the fan motor capacitor

Measure the resistance

of compressor coil.

Is the fan locked ?

Change the fan motor.

locked

Is the fan touched to another parts ?

no touch

Change the fan motor.

touch

Change fan or another parts, or adjust.

The compressor doesn't turn off.

Check the thermister connector.

Check the thermister resistance.

Check the compressor relay.

Checking complete.

Checking complete

disconnecting

Connect the connector properly.

Change the thermister.

Change PWB ass'y.

Checking method for the compressor relay. (MRY and PWB)

Turn off the power supply.

Measure the contact resistance.

open

OK NG

short

Page 31

Insufficient cooling(Both compressor and compressor operate)

Check the temperature setting.

too high

Set the lower temperature.

AF-S50CX AF-S55CX AF-S60CX

Check the air filter.

not dirty

Is there high heat source or any object restricting heat radiation near the unit.

there isn't

Check doors and windows.

Check the outdoor and indoor heat exchanger.

not dirty

Calculate heat load wit using Cooling load estimate form.

Check rotating direction of centrifugal fan.(to clockwise)

Check changing fan speed properly.

dirty

Clean the air filter.

there is

Remove the high heat source or stop.

open

Doors and windows must be kept closed.

dirty

Clean them with steam cleaner or another method.

Undersized air conditioner

Change unit to proper sized air conditioner.

Check the fan motor connector.

Measure the resistance of fan motor coil.

Change the fan motor.

Connect properly.

Is the outdoor temperature

over 40ûC

too high ?

under 40ûC

Check the thermister.

Measure temperature difference between inlet and outlet air at indoor.

over 10ûC

Checking complete.

Avoid sun light and ventilate well for outdoor heat exchanger.

Change the thermister.

under 10ûC

Is frost sticking to capillary tube ? Or is indoor heat exchanger no cold ?

YES

Is the refrigerant leaked ?

The capillary tube restrict, and change the capillary tube.

Measure the emperature difference between discharge tube and suction tube.

temperature difference

YES

Repair leakage and recharge the refrigerant.

No temperature difference

The compressor is defective.

Change the compressor.

Page 32

AF-S50CX AF-S55CX AF-S60CX

Excessive vibration or Abnormal noise

At fan only mode, Excessive vibration or Abnormal noise

YES

Check the air filter

Check rotating direction of centrifugal fan.(to clockwise)

Is the fan deformed or broken.

Is loosened screw and nut fixing fan ?

not dirty

dirty

Clean the air filter.

Check the fan motor connector.

Measure the resistance of fan motor coil.

deform or broken

Change the fan

loosened

Tighten up.

Connect properly.

Change the fan motor.

Is each screws loosened ?

Is pipe touching to another parts.

Check mounting of compressor.

Check compressor noise and vibration.

Checking complete

loosen

Tighten up

touching

Repair with adjusting shape of pipes.

Repair mounting or change compressor cushion.

too big

Change compressor.

Page 33

AF-S50CX AF-S55CX AF-S60CX

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 34

AF-S50CX AF-S55CX AF-S60CX

HEAT GAIN FROM QUANTITY

1. WINDOWS: Heat gain from sun. Northeast Southeast South Southwest

Southeast West Northwest North

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

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

a. Outside walls Noth exposure Other than North exposure

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

4. ROOF OR CEILING: (Use one 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

5. FLOOR: (Disregard if floor is directly

on ground or over basement.)

6. NUMBER OF PEOPLE:

7. LIGHTS AND ELECTRICAL

EQUIPMENT IN USE

(Area a Factor)

Use

only

the

largest

load Use only

BTU/Hr (Quantity x Factor)

FACTORS

DAY

Shades

sq ft sq ft sq ft

60 80 75

75 110 150 120

sq ft

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.

sq ft sq ft

Inside

Shades

25 40 30 35 45 65 50

Outside Shades

20 30 45 35

only

Light Construction Heavy Construction

20 30

sq ft sq ft sq ft

sq ft sq ft

sq ft

ft ft

30 60

8 3

600

watts

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).)

EUGENE

RENO

SACRAMENT

FRESNO

LAS VEGAS

x x x x x x x x x x

(Item 9) x (Factor from Map) =

FARGO

GREEN BAY

WICHITA

PUEBLO

PHOENIX

SAN ANTONIO

BIRMINGHAM

300

ROCHESTER

ALBANY

NEW HAVEN

COLUMBIA

ATLANTA

Page 35

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.

AF-S50CX AF-S55CX AF-S60CX

600

500

400

300

Line current(Amp.) Power input (W)

(86)

RUNNING CONDITION FOR

MODEL AF-S50CX / AF-S55CX

PERFORMANCE CURVE

40%RH

70%RH

40%RH

70%RH

700

600

500

400

Line current(Amp.) Power input (W)

(86)

RUNNING CONDITION FOR

MODEL AF-S60CX

PERFORMANCE CURVE

40%RH

70%RH

40%RH

70%RH

(68)

(50)

Outlet air temp˚C (˚F)

25 30 35

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

Outside air temp.˚C (˚F)

40%RH

(68)

40%RH

(50)

Outlet air temp˚C (˚F)

25 30 35

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

Outside air temp.˚C (˚F)

Page 36

AF-S50CX AF-S55CX AF-S60CX

PACKING AND ACCESSORIES

TOP PAD ASSEMBLY (DPADBA004JBFZ)

Top pad L

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 Remote control Battery Remote control hook

"Front side" mark

Enegry card TLAB-C213JBEZ: AF-S50CX TLAB-C270JBEZ: AF-S55CX TLAB-C214JBEZ: AF-S60CX

Front side

Packing case SPAKCA996JBEZ: AF-S50CX SPAKCB050JBEZ: AF-S55CX SPAKCA997JBEZ: AF-S60CX

Protect (SSAKHA009JBEZ)

Energy star label (TLAB-C277JBRZ)

Power supply cord

Detail is assembling Energy card

Bottom pad assembly (CPADBA046JBKZ)

Page 37

AF-S50CX AF-S55CX AF-S60CX

REPLACEMENT PARTS LIST

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

CABINET AND UNIT PARTS

1- 1 DCHS-A441JBTA Base pan ass’y 1 BA 1- 2 CCAB-A316JBKZ Cabinet ass’y 1 BB 1- 3 LANG-A503JBTA Top inst. angle 1 AP 1- 4 PSEL-C357JBEZ Cabinet insulator 1 AE 1- 5 HPNLCA802JBFA Control panel [AF-S50CX] 1 AE 1- 5 HPNLCA802JBFA Control panel [AF-S60CX] 1 AE 1- 5 HPNLCA802JBFB Control panel [AF-S55CX] 1 AE 1- 6 HPNLCA811JBEA Key sheet [AF-S50CX] 1 AS 1- 6 HPNLCA811JBEA Key sheet [AF-S60CX] 1 AS 1- 6 HPNLCA810JBEA Key sheet [AF-S55CX] 1 AN 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 [AF-S50CX] 1 AH 1-15 PKESSA066JBFA Orifice [AF-S60CX] 1 AH 1-15 PKESSA066JBFB Orifice [AF-S55CX] 1 AR 1-16 MLOV-A321JBFA Vertical louver A [AF-S50CX] 1 AC 1-16 MLOV-A321JBFA Vertical louver A [AF-S60CX] 1 AC 1-16 MLOV-A321JBFB Vertical louver A [AF-S55CX] 1 AC 1-17 MLOV-A322JBFA Vertical louver B [AF-S50CX] 3 AC 1-17 MLOV-A322JBFA Vertical louver B [AF-S60CX] 3 AC 1-17 MLOV-A322JBFB Vertical louver B [AF-S55CX] 3 AC 1-18 MJNTPA089JBFA Louver joint [AF-S50CX] 1 AC 1-18 MJNTPA089JBFA Louver joint [AF-S60CX] 1 AC 1-18 MJNTPA089JBFB Louver joint [AF-S55CX] 1 AC 1-19 MLOV-A323JBFA Horizontal louver [AF-S50CX] 4 AC 1-19 MLOV-A323JBFA Horizontal louver [AF-S60CX] 4 AC 1-19 MLOV-A323JBFB Horizontal louver [AF-S55CX] 4 AC 1-20 MJNTPA090JBFA Louver link [AF-S50CX] 1 AC 1-20 MJNTPA090JBFA Louver link [AF-S60CX] 1 AC 1-20 MJNTPA090JBFB Louver link [AF-S55CX] 1 AC 1-21 MSPR-A148JBEZ Louver spring 2 AF 1-22 GWAKPA150JBFA Front panel [AF-S50CX] 1 AV 1-22 GWAKPA150JBFA Front panel [AF-S60CX] 1 AV 1-22 GWAKPA150JBFB Front panel [AF-S55CX] 1 AV 1-23 PFILMA162JBEA Air filter [AF-S50CX] 1 AK 1-23 PFILMA162JBEA Air filter [AF-S60CX] 1 AK 1-23 PFILMA162JBEB Air filter [AF-S55CX] 1 AK 1-24 PSEL-C254JBEZ Tube insulator 1 AC 1-25 LHLDW0364JBE0 Wire holder 1 AA 1-26 LHLDW0366JBE0 Wire holder 2 AA 1-27 TSPC-E073JBRZ Name badge [AF-S50CX] 1 AC 1-27 TSPC-E140JBRZ Name badge [AF-S55CX] 1 AC 1-27 TSPC-E074JBRZ Name badge [AF-S60CX] 1 AC 1-28 TLAB-C213JBEZ Energy card [AF-S50CX] 1 AC 1-28 TLAB-C270JBEZ Energy card [AF-S55CX] 1 AC 1-28 TLAB-C214JBEZ Energy card [AF-S60CX] 1 AC 1-29 TLABBA110JBRA Sharp badge 1 AB 1-30 TLABKA564JBE0 Number card 1 AC 1-31 TLABMA326JBRZ Feature card 1 AE 1-32 LBND-A042JBE0 Wire fixing band 2 AC 1-33 TLAB-C277JBRZ Energy star label 1 AB 1-34 DSKR-A126JBKZ Bulkhead ass'y 1 AW 1-35 DKES-A029JBKZ Orifice ass'y [AF-S50CX] 1 AW 1-35 DKES-A029JBKZ Orifice ass'y [AF-S60CX] 1 AW 1-35 DKES-A030JBKZ Orifice ass'y [AF-S55CX] 1 AV

CONTROL BOX PARTS

2- 1 DPLT-A057JBWZ Cont. box cover ass’y 1 AH 2- 2 DPLT-A058JBWZ Cont. box angle ass’y 1 AM 2- 3 LBNDKA104JBWZ Capacitor clamp 1 AG 2- 4 QACC-A260JBZZ Power supply cord 1 AS 2- 5 RH-HXA006JBZZ Thermistor 1 AK 2- 6 QW-VZC561JBE0 Lead wire 1 AD

Page 38

AF-S50CX AF-S55CX AF-S60CX

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

2- 7 RC-HZA256JBE0 Fan motor capacitor 1 AM 2- 8 RC-HZA136JBZ0 Running capacitor [AF-S50CX] 1 AU 2- 8 RC-HZA136JBZ0 Running capacitor [AF-S55CX] 1 AU 2- 8 RC-HZA393JBE0 Running capacitor [AF-S60CX] 1 AW 2- 9 TLABCB587JBRZ Wiring diagram [AF-S50CX] 1 AB 2- 9 TLABCB587JBRZ Wiring diagram [AF-S55CX] 1 AB 2- 9 TLABCB582JBRZ Wiring diagram [AF-S60CX] 1 AA 2-10 DPWBFA278JBKZ Control board unit [AF-S50CX] 1 BL 2-10 DPWBFA278JBKZ Control board unit [AF-S60CX] 1 BL 2-10 DPWBFA244JBKZ Control board unit [AF-S55CX] 1 BF 2-11 PSPA-A158JBZZ PWB Spacer 2 AD 2-12 PSPA-A159JBZZ PWB Spacer 1 AD 2-13 QFS-AA048JBE0 Fuse 1AB 2-14 LBND-A042JBE0 Wire fixing band 3 AC 2-15 QW-IZA038JBZZ Comp. wiring 1 AS 2-16 PPLT-A299JBEZ Insulator sheet 1 AG 2-17 PPLT-A301JBEZ Insulator sheet 1 AA

CYCLE PARTS

3- 1 PCMPRA364JBEZ Compressor [AF-S50CX] 1 BZ 3- 1 PCMPRA364JBEZ Compressor [AF-S55CX] 1 BZ 3- 1 PCMPRA362JBEZ Compressor [AF-S60CX] 1 BZ 3- 2 GLEG-A103JBE0 Compressor cushion 3 AG 3- 3 PPIPCF683JB1Z Discharge tube 1 AM 3- 4 PCON-A485JBEZ Condenser 1 BQ 3- 5 PPIPCF491JB1Z Lead tube 1 AF 3- 6 DCPY-A274JBKZ Capillary tube ass’y [AF-S50CX] 1 AR 3- 6 DCPY-A274JBKZ Capillary tube ass’y [AF-S55CX] 1 AR 3- 6 DCPY-A273JBKZ Capillary tube ass’y [AF-S60CX] 1 AV 3- 7 PEVA-A454JBEZ Evaporator [AF-S50CX] 1 BD 3- 7 PEVA-A454JBEZ Evaporator [AF-S55CX] 1 BD 3- 7 PEVA-A461JBEZ Evaporator [AF-S60CX] 1 BM 3- 8 CPIP-A028JBKZ Suction tube ass’y [AF-S50CX] 1 AV 3- 8 CPIP-A028JBKZ Suction tube ass’y [AF-S55CX] 1 AV 3- 8 CPIP-A029JBKZ Suction tube ass’y [AF-S60CX] 1 AX 3- 9 PSEL-B160JBE0 Terminal gasket 1 AH 3-10 RHOG-A201JBZZ Overload relay [AF-S50CX] 1 AU 3-10 RHOG-A201JBZZ Overload relay [AF-S55CX] 1 AU 3-10 RHOG-A200JBZZ Overload relay [AF-S60CX] 1 AU 3-11 MSPR-A114JBE0 Protector spring 1 AF 3-12 PCOV-A371JBE0 Terminal cover 1 AF 3-13 PSEL-B161JBE0 Gasket washer 1 AH 3-14 PGUM-A113JBE0 Damper rubber [AF-S50CX] 1 AH 3-14 PGUM-A113JBE0 Damper rubber [AF-S55CX] 1 AH 3-15 LBND-A046JBE0 Wire fixing band [AF-S50CX] 1 AE 3-15 LBND-A046JBE0 Wire fixing band [AF-S55CX] 1 AE 3-16 LHLD-A315JBF0 Thermistor holder 1 AE 3-17 PSEL-C250JBEZ Evaporator insulator [AF-S50CX] 1 AB 3-17 PSEL-C250JBEZ Evaporator insulator [AF-S55CX] 1 AB 3-17 PSEL-C289JBEZ Evaporator insulator [AF-S60CX] 1 AC 3-18 LBND-A042JBE0 Wire fixing band 1 AC

ACCESSORY PARTS

4- 1 TINSEA326JBRZ Operation manual 1 AC 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 TCAD-A351JBEZ Consummer card 1 AB 4- 9 DX-BZA016JBK0 Screws kit 1 AW 4-10 SSAKAA018YDE0 Bag 1AB 4-11 XCTSD40P10000 Tapping screw 6 AA 4-12 XMPSD40P25000 Wood screw 7 AA 4-13 LANGAA030JBTA Base pan angle 2 AD 4-14 CRMC-A526JBEZ Remote control 1 AT 4-15 LHLD-A389JBFB Controller holder 1 AC 4-16 SPADBA163JBEZ Card board 1 AC 4-17 SSAKHA009JBEZ Bag 1AC 4-18 UBATUA027JBE0 Battery pack 1 AE 4-19 CFZK-C019JBKZ Closure ass’y 1 BB

Page 39

AF-S50CX AF-S55CX AF-S60CX

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

PACKING PARTS

5- 1 DPADBA004JBFZ Top pad ass’y 1 AH 5- 2 CPADBA046JBKZ Bottom pad ass’y 1 AN 5- 3 SPAKCA996JBEZ Packing case [AF-S50CX] 1 AP 5- 3 SPAKCB050JBEZ Packing case [AF-S55CX] 1 AR 5- 3 SPAKCA997JBEZ Packing case [AF-S60CX] 1 AP 5- 4 SSAKHA245YDE0 Protect 1 AB 5- 5 SSAKAA053YDE0 Bag 1AB 5- 6 TLABMA331JBRZ Color label [AF-S55CX] 1 AH

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 14 AA 6- 5 XHTSD40P10000 Tap tight screw 6 AA 6- 6 XHTSD40P08000 Tap tight screw 4 AA 6- 7 XTPSD40P08000 Tapping screw 3 AA 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 XBPSD40P12J00 Machine screw 2 AB 6-13 LX-NZA074JBE0 Special nut 1 AB 6-14 LX-NZA148JBE0 Frange nut 1 AD 6-15 LX-NZA026JBE0 Special nut 3 AC

HOW TO ORDER REPLACEMENT PARTS

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

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

Page 40

AF-S50CX AF-S55CX AF-S60CX

12345

CABINET PARTS

4-19

6-4

4-16

4-17

4-9

4-10

4-11

4-12

4-3

4-4

1-3

6-9

4-8

4-14

4-1

4-5

4-6

4-2

6-11

1-4

6-9

4-7

4-15

4-18

6-5

4-13

6-4

6-10

6-13

1-2

6-11

1-26

6-1

1-32

1-24

6-1

1-26

6-4

1-7

1-34

6-5

1-10

1-11

1-12

6-3

1-13

1-25

1-9

6-4

5-1

5-6 [AF-S55CX only]

2-4

1-8

5-3

5-2

1-30

5-4

1-35

5-5

1-14

1-21

1-19

1-17

6-8

1-16

1-22

6-2

1-20

1-18

6-3

1-15

6-3

6-4

1-29

6-4

1-33

1-28

1-31

6-2

1-27

1-23

1-1

6-3

123456

Page 41

AF-S50CX AF-S55CX AF-S60CX

12345

CONTROL BOX PARTS

1-6

2-17

1-5

6-7

2-10

2-12

6-12

6-7

6-6

2-11

2-7

6-4

2-16

2-10

2-5

2-3

6-5

2-8

2-6

2-2

2-4

6-5

2-13

6-6

2-14

2-9

2-1

6-4

6-6

123456

Page 42

AF-S50CX AF-S55CX AF-S60CX

12345

CYCLE PARTS

6-14 3-13

3-12

3-11 3-10

3-9

2-15

3-3

3-4

3-17

6-15

3-8

6-3

3-1

3-15

[AF-S50CX/S55CX, only]

3-5

3-6

3-14 [AF-S50CX/S55CX, only]

3-7

3-16

6-15

3-18

6-5

3-2

123456

Page 43

AF-S50CX AF-S55CX AF-S60CX

Page 44

AF-S50CX AF-S55CX AF-S60CX

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.