SONY AFR100CX Service Manual

SER VICE MANU AL

AIR CONDITIONER

AF-R100CX AF-R120CX

S3203AFR12CX/

MODELS

AF-R100CX AF-R120CX

In the interest of user-safety the air conditioner should be restored to its original condition and only parts identical to those specified should be used.

TABLE OF CONTENTS

Page

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

WIRING DIAGRAM................................................................................................................................................3

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

OPERATION INSTRUCTIONS............................................................................................................................. 4

INSTALLATION INSTRUCTIONS ........................................................................................................................ 6

DISASSEMBLING PROCEDURE......................................................................................................................... 8

HOW TO REPAIR REFRIGERATION ................................................................................................................ 12

ELECTRICAL COMPONENT TEST .................................................................................................................... 14

MICROCOMPUTER CONTROL SYSTEM ..........................................................................................................15

TROUBLESHOOTING GUIDE ............................................................................................................................19

COOLING LOAD ESTIMATE FORM ...................................................................................................................24

RUNNING CONDITION .......................................................................................................................................26

PACKING AND ACCESSORIES ......................................................................................................................... 27

REPLACEMENT PARTS LIST ............................................................................................................................28

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

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

AF-R100CX AF-R120CX

SPECIFICATIONS

Models AF-R100CX AF-R120CX Cooling capacity BTU/h 10000 12000 Moisture removal Pints/h 2.7 3.3

ELECTRICAL DATA

Phase Single Rated frequency Hz 60 Rated voltage Volts 115 Rated current Amps 9.0 11.5 Rated input Watts 1000 1200 Power factor % 97 91 EER BTU/Wh 10.0 10.0

COMPRESSOR

Type (Hermetically sealed rotary type) Model, Remarks 44R251AC-AJS, 840 W 44B124HX1EF, 1000W

REFRIGERANT SYSTEM

Evaporator Slit fin, Grooved tube, Ø 9.53 mm Hair pin Condenser Louver fin, Control O.D. x I.D. x Length x Q'ty(mm)

Capillary tube 2.7 x 1.4 x 400 x 1 Capillary tube 2.7 x 1.2 x 800 x 2

Refrigerant volume R-22(OZ) 18.3(Factory charged) 19.4(Factory charged)

Grooved

tube, 7mm Hair pin

NET DIMENSIONS

Width Height Depth

inches(mm)

22-1/16(560) x 14-3/4(375) x 24-5/16(617)

Net Weight lbs 83 85

GROSS DIMENSIONS

Width Height Depth

inches(mm)

25-25/32(655) x 18-29/32(480) x 27-7/8(708)

Gross Weight lbs 94 96

FAN SYSTEM

Indoor side(Evaporator) Centrifugal fan Outdoor side(Condenser) Propeller fan Air flow rate(indoor side) CFM (High/Med/Low) 304 / 254 / 223 (High/Med/Low) 318 / 254 / 219

OTHERS

Safety devices Compressor: Overload relay

Fan motor: Internal thermal protector Air filter Polypropylene net Power cord length ft 4.3 Power plug type 125V, 15A

ELECTRICAL PARTS

Running capacitor 250V-60µF 370V-50µF Fan capacitor

250V-6µF x 2 250V-6µF x 2 Thermistor 15k at 78˚F

Fan motor ARS030ZUEA/SHP(MLA895) ARS030ZUEA/SHP(MLA895) Overload relay MRA4789-9053 MRA98693-12007

WIRING DIAGRAM

AF-R100CX AF-R120CX

POWER SUPPLY CORD

115V 60Hz

RUNNING CAPACITOR

RIBBED

AF-R100CX AF-R120CX 250V 60µF 370V 50µF

FAN MOTOR CAPACITOR 250V 6µF x 2

NON RIBBED

OVERLOAD PROTECTOR

COMPRESSOR

MOTOR

RUNNING CAPACITOR

123654

GYREOR

THERMAL PROTECTOR

M.C

A.C

MRY

OUT

RE OR WH

CONNECTOR

FAN MOTOR

8 7 1 3 5

3A 125V

FU1 CONTROL BOAD UNIT

CNR1 CNR2 CNR3

BCN1

RY1 RY2 RY3

WIRE COLOR

GR GY OR

THERMISTOR

CN1

(

ROOM TEMP

YELLOW TH1

CN2

CN3

: BLACK : BLUE : RED : WHITE : GREEN : GRAY : ORANGE

)

BCN2

DISPLAY BOARD UNIT

BCN3

Figure W-1

EXTERNAL DIMENSIONS

22-1/16"

38-19/32"

27-5/32"

24-5/16"

5-3/16"

1-3/8"

14-3/4"

16-23/32"

19/32"

AF-R100CX AF-R120CX

OPERATION INSTRUCTIONS

UNIT

Front panel

Air inlet (Indoor side) Louvers

Air outlet (Indoor side)

Exhaust lever

Control panel Cabinet

Air outlet (Outdoor side)

Air inlet (Outdoor side)

Filter (Pull the filter handle to the right to remove.)

Filter handle

Power cord

CONTROL PANEL

8 9

2 1

SELECTOR indicator Receiver window for remote control

signal Display

SELECTOR pad

TIMER ON/OFF pad

TIMER indicator

TEMPERATURE setting pad

----Lower temp.

----Raise temp.

ENERGY SAVER pad

ENERGY SAVER indicator

POWER ON/OFF pad

POWER indicator

COOLING OPERATION

Procedure Pad Display / Indicator

HOW TO OPERATE

1 2 3

HIGH COOL MED COOL LOW COOL FAN ONLY

SELECTOR

TIMER

ON/OFF

4 5 6 7 8 9

TEMP

ENERGY

SAVER

POWER

ON/OFF

10 11

1. 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.

2. To turn off the unit, touch POWER ON/

OFF pad again.

POWER

ON/OFF

POWER

ON/OFF

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

• POWER indicator and SELECTOR indicator will go off.

TO CHANGE TEMPERATURE SETTING

MED COOL

LOW COOL

Procedure Pad Display / Indicator

AF-R100CX AF-R120CX

During cooling operation

TEMP

Touch the TEMPERATURE setting pad to adjust the temperature setting.

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

---Lower temp.

---Raise temp.

• Display will change as you touch the pad.

The latest temperature setting will be memorized and will appear on the display the next time the unit is turned on. NOTE: 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 operation.

TO CHANGE FAN SPEED

Procedure Pad Display / Indicator

During operation

• SELECTOR indicator will light in order as you touch.

Touch SELECTOR pad and select the desired fan speed.

SELECTOR

HIGH COOL

MED COOL

NOTES ON FAN SPEED

HIGH COOL

MED COOL

LOW COOL

Fan and cooling at maximum performance. Unit is preset to HIGH COOL when first turned on after unit is plugged in.

Fan operates at medium speed; cooling power at medium. Cooling for sleeping comfort with low fan speed.

FAN ONLY OPERATION

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

Procedure Pad Display / Indicator

During operation

• SELECTOR indicator FAN ONLY will light, and the temperature display will

Touch SELECTOR pad and select FAN ONLY.

SELECTOR

go off. After 5 seconds, the compressor will stop and the unit will operate in FAN ONLY mode.

LOW COOL

FAN ONLY

When the unit is turned off, the last fan speed will be stored in memory. The next time the air conditioner is used, the memorized fan speed will start automatically.

AF-R100CX AF-R120CX

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.)

Procedure Pad Display / Indicator

During cooling operation

1. Touch ENERGY SAVER pad.

ENERGY

SAVER

• ENERGY SAVER indicator will light.

2. To cancel, touch ENERGY SAVER pad again.

ENERGY

SAVER

• ENERGY SAVER indicator will go off.

NOTE: ENERGY SAVER cannot be set during FAN ONLY mode operation.

TO CHANGE AIR FLOW DIRECTION

Adjust the louvers to change the direction of air flow for uniform and efficient cooling of the room.

Vertical louvers

EXHAUST

If air in your room is stale, set the EXHAUST lever to the OPEN position. This will exhaust stale air to the outside. The EXHAUST lever should normally be kept in the CLOSED position during cooling for maximum efficiency.

Adjusts LEFT/RIGHT air flow

Horizontal louvers Adjusts UP/DOWN air flow

EXHAUST Lever

CLOSED OPEN

INSTALLATION INSTRUCTIONS

ITEMS PACKED WITH THIS UNIT

No.

1 2

6 7

8 9

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

(adhesive type) Bottom gasket 1 Screws(L=1", 25.4mm) 8 Screws(L= 13/ 32", 10mm) 6 Remote control 1 Battery 2 Remote control hook 1

Accessories Q'ty

AF-R100CX AF-R120CX

SUGGESTED TOOLS

1. Screw driver (medium size Phillips)

2. Tape measure or ruler

3. Knife or scissors

INSTALLATION

These models can also be installed through the wall with the optional through the wall mounting kit, model AZ80WK. To order this kit either contact your dealer or call 1-800-BE-SHARP. The wall opening dimensions for through the wall installation are:

25" (635mm) (W) x 17 -1/ 4 " (438mm) to 17-3/ 4"

(451mm) (H) x 4" (102mm) minimum (D). Complete instructions are included with the wall mounting kit.

WARNING: Make sure the unit is turned off and

unplugged before working.

1-1. Cut the window sash foam seal (adhesive type) to the

proper length and attach it to the underside of the window sash.

1-2. Attach the bottom gasket to the outer side of the

window sill.

CAUTION Do not remove any material (ex.

styrofoam, etc.) from inside the unit.

4. 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 6 of the provided screws. (L= 13/ 32 ", 10 mm)

Closure assembly

window sash foam seal (adhesive type)

bottom gasket

2-1. Unscrew the 2 screws at the corners of the front panel.

Keep them as they will be used later.

2-2. Remove the front panel by pulling the front panel at the

lower corners towards you about an inch. Next lift it up and pull it towards you.

CAUTION: Take care not to damage the exhaust

lever when removing the front panel.

Horizontal Louver

Front panel

3-1. Unscrew the 6 stopper screws of the cabinet. Keep

the 4 screws from the top and front , as they will be used later.

3-2. Slide the chassis out from the cabinet by pulling on the

hand hold located at the bottom center of the chassis.

Exhaust Lever

5. Open the window sash and place the cabinet on the sill. Close the window sash securely behind the top angle.If there is space between the bottom channel and the sill, fill the gap with a thin board or other hard filler.

WARNING: At this step, make sure the cabinet is inclined approximately 1 cm (3/8”) to the back. If the cabinet 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.

Cabinet

sill

incline backwards about 1cm (3/8")

AF-R100CX AF-R120CX

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

Jamb (Left)

Closure assembly

Closure assembly (Left)

(Left)

Sill

Stool

1/2 inch (13mm)

7-1. Secure the cabinet to the window stool with 3 screws

(L=1", 25.4 mm), working from the inside of the cabinet.

7-2. Secure the top angle and the closure assemblies to

the window sash with 3 screws (L=1", 25.4 mm).

7-3. Secure the closure assemblies to the sill with 2 screws

(L=1", 25.4 mm).

Top angle

8-1. Slide the chassis back into the cabinet. 8-2. Replace the 4 screws removed in

step 3 to the top

and side of the cabinet .

9-1 Replace the front panel. Slip the exhaust lever through

the opening between the horizontal louver and the front panel then, hook the cabinet top.

CAUTION:Take care not to damage the exhaust lever with

the front panel.

9-2. Screw the front cabinet on at the bottom corners with

2 screws removed in step 2.

Horizontal Louver

Front Panel

Exhaust Lever

10.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

DISASSEMBLING PROCEDURE

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

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

2. Remove the front panel by pulling it at the lower corner toward you about 1 inch and next lift up and pull it toward you.

AF-R100CX AF-R120CX

3. Unscrew the four screws holding the cabinet. Two screws are on top side. Two screws are on each side.

4. Slide the chassis away from the cabinet by pulling on each corner of the base pan.

8. Unscrew the one screw holding earth wire .

9. Cut the fixing band holding the wires.

10.Remove the control unit.

5. Unscrew the four screws holding the control unit. Two screws are on front side. Two screws are on right side.

6. Unscrew the one screw holding the power supply cord.

11.Unscrew the four screws holding control box cover. Two are on the right side, one is on the left side, one is on the back side.

CAUTION: DISCHARGE THE FAN MOTOR CAPACITOR

AND RUNNING CAPACITOR BEFORE TOUCHING THOSE CAPACITORS OR OTHER COMPONENTS OR WIRING.

12.Detach each terminals of fan motors by using long-nose pliers.

7. Unscrew the one screw holding the wire holder. Pull out thermistor holder.

AF-R100CX AF-R120CX

13.Remove the putty and unfasten the one nut at the top of compressor holding the terminal cover. Then remove the wiring connector of the compressor cord.

14.Unscrew the five screws holding the connecting stay.

18.Unfasten the one nut holding propeller fan by rotating it clockwise. And remove the propeller fan.

15.Unscrew the two screws holding the shroud cover.

16.Unscrew the six screws holding the condenser and condenser shroud. Two screws are on the back side. Four screws are on the each side. Unscrew the two screws holding the condenser cover .

19.Unscrew the three screws holding condenser shroud.

Note: Seal three female screws with siliconsealer

before re-installing.

20.Unscrew the four screws holding the evaporator. Two are on left side. Two are on right side.

17.Remove the condenser by liftting up about 1 inch and pull it toward you and move to right.

21.Remove the evaporator.

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