SONY AFR100CX Service Manual
AF-R100CX
AF-R120CX
SERVICE MANUAL
S3203AFR12CX/
AIR CONDITIONER
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.
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TABLE OF CONTENTS |
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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.
1
AF-R100CX
AF-R120CX
SPECIFICATIONS
Models |
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AF-R100CX |
AF-R120CX |
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Cooling capacity |
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BTU/h |
10000 |
12000 |
Moisture removal |
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Pints/h |
2.7 |
3.3 |
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ELECTRICAL DATA |
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Phase |
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Single |
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Rated frequency |
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Hz |
60 |
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Rated voltage |
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Volts |
115 |
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Rated current |
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Amps |
9.0 |
11.5 |
Rated input |
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Watts |
1000 |
1200 |
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Power factor |
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% |
97 |
91 |
EER |
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BTU/Wh |
10.0 |
10.0 |
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COMPRESSOR |
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Type |
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(Hermetically sealed rotary type) |
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Model, Remarks |
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44R251AC-AJS, 840 W |
44B124HX1EF, 1000W |
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REFRIGERANT SYSTEM |
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Evaporator |
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Slit fin, Grooved tube, Ø 9.53 mm Hair pin |
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Condenser |
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Louver fin, Grooved tube, 7mm Hair pin |
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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 |
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Refrigerant volume R-22(OZ) |
18.3(Factory charged) |
19.4(Factory charged) |
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NET DIMENSIONS |
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Width Height Depth |
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inches(mm) |
22-1/16(560) x 14-3/4(375) x 24-5/16(617) |
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Net Weight |
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lbs |
83 |
85 |
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GROSS DIMENSIONS |
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Width Height Depth |
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inches(mm) |
25-25/32(655) x 18-29/32(480) x 27-7/8(708) |
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Gross Weight |
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lbs |
94 |
96 |
FAN SYSTEM |
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Indoor side(Evaporator) |
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Centrifugal fan |
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Outdoor side(Condenser) |
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Propeller fan |
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Air flow rate(indoor side) |
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CFM |
(High/Med/Low) 304 / 254 / 223 |
(High/Med/Low) 318 / 254 / 219 |
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OTHERS |
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Safety devices |
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Compressor: Overload relay |
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Fan motor: Internal thermal protector |
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Air filter |
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Polypropylene net |
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Power cord length |
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ft |
4.3 |
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Power plug type |
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125V, 15A |
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ELECTRICAL PARTS |
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Running capacitor |
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250V-60µF |
370V-50µF |
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Fan capacitor |
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250V-6µF x 2 |
250V-6µF x 2 |
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Thermistor |
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15k at 78˚F |
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Fan motor |
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ARS030ZUEA/SHP(MLA895) |
ARS030ZUEA/SHP(MLA895) |
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Overload relay |
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MRA4789-9053 |
MRA98693-12007 |
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2
AF-R100CX
AF-R120CX
WIRING DIAGRAM
RUNNING CAPACITOR
AF-R100CX AF-R120CX
250V 60 F 370V 50 F
POWER SUPPLY CORD |
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3A 125V |
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WIRE COLOR |
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115V 60Hz |
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BK : BLACK |
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IN |
FU1 |
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NON RIBBED |
BL : BLUE |
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GR |
MRY |
CONTROL |
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RE : RED |
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OUT |
BOAD UNIT |
WH : WHITE |
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BK |
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GR : GREEN |
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NR |
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GY : GRAY |
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OVERLOAD |
C1 |
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PROTECTOR |
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OR : ORANGE |
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COMPRESSORC |
BK |
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TR |
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THERMISTOR |
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RIBBED |
MOTOR |
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CN1 |
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(ROOM TEMP) |
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RUNNING |
R |
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S |
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YELLOW |
TH1 |
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CAPACITOR |
RE |
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WH |
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CNR1 |
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FAN MOTOR |
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CNR2 |
CN2 |
BCN2 |
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CAPACITOR |
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GY |
8 |
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250V 6 F x 2 |
GY |
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CNR3 |
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DISPLAY |
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BL |
BK |
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7 |
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RE |
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RY1 |
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1 |
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BOARD |
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OR |
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RY2 |
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UNIT |
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3 |
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WH |
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RY3 |
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BL |
BK |
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5 |
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CN3 |
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1 2 3 6 5 4 CONNECTOR |
BCN1 |
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BCN3 |
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BL BK GY RE OR WH |
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H |
M L |
FAN MOTOR |
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THERMAL |
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PROTECTOR |
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BK |
M.C |
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BL |
A.C |
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Figure W-1
EXTERNAL DIMENSIONS
22-1/16" |
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38-19/32" |
5-3/16" |
3/8"-1 |
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27-5/32" |
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24-5/16" |
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14-3/4" |
16-23/32" |
19/32" |
3
AF-R100CX
AF-R120CX
OPERATION INSTRUCTIONS
1
2
3
4
5
6
7
8
9
10
11
12
UNIT
Front panel |
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5 |
6 |
Air inlet (Indoor side) |
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4 |
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Louvers |
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7 |
Air outlet (Indoor side) |
3 |
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8 |
Exhaust lever |
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9 |
Control panel |
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10 |
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Cabinet |
2 |
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Air outlet (Outdoor side) |
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Air inlet (Outdoor side) |
1 |
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Filter (Pull the filter handle to the right to remove.) |
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12 |
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11
Filter handle
Power cord
CONTROL PANEL
1SELECTOR indicator
2Receiver window for remote control signal
3Display
4SELECTOR pad
5TIMER ON/OFF pad
6TIMER indicator
7TEMPERATURE setting pad 
----Lower temp.
----Raise temp.
8 ENERGY SAVER pad
9 ENERGY SAVER indicator
10POWER ON/OFF pad
11POWER indicator
1 |
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2 |
3 |
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HIGH COOL |
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MED COOL |
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F |
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LOW COOL |
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hr |
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FAN ONLY |
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TEMP |
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SELECTOR |
TIMER |
ENERGY |
POWER |
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ON/OFF |
SAVER |
ON/OFF |
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4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
HOW TO OPERATE
COOLING OPERATION
Procedure |
Pad |
Display / Indicator |
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1. Touch POWER ON/OFF pad. |
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F |
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POWER |
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hr |
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• The unit is preset at 74°F and HIGH |
ON/OFF |
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• POWER indicator and SELECTOR |
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COOL. This will show in the display |
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indicator (HIGH COOL) will light. |
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when the power is first turned on. |
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2. To turn off the unit, touch POWER ON/ |
POWER |
• POWER indicator and SELECTOR |
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indicator will go off. |
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OFF pad again. |
ON/OFF |
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4
AF-R100CX
AF-R120CX
TO CHANGE TEMPERATURE SETTING
Procedure |
Pad |
Display / Indicator |
During cooling operation |
TEMP |
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F |
Touch the TEMPERATURE setting pad to |
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hr |
adjust the temperature setting. |
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• It can be set within the range of |
---Lower temp. • Display will change as you touch the |
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64°F to 86°F. |
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pad. |
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---Raise temp. |
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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 |
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light in order as you touch. |
Touch SELECTOR pad and select |
SELECTOR |
the desired fan speed. |
HIGH COOL |
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MED COOL |
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LOW COOL |
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FAN ONLY |
NOTES ON FAN SPEED |
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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 |
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• SELECTOR indicator FAN ONLY will |
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light, and the temperature display will |
Touch SELECTOR pad and select FAN |
SELECTOR |
go off. After 5 seconds, the compressor |
ONLY. |
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will stop and the unit will operate in |
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FAN ONLY mode. |
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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.
5
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.)
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Procedure |
Pad |
Display / Indicator |
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During cooling operation |
ENERGY |
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• ENERGY SAVER indicator will light. |
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1. |
Touch ENERGY SAVER pad. |
SAVER |
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2. |
To cancel, touch ENERGY SAVER pad |
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again. |
ENERGY |
• ENERGY SAVER indicator will go off. |
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SAVER |
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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.
EXHAUST |
Vertical louvers |
Adjusts LEFT/RIGHT air flow |
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.
Horizontal louvers
Adjusts UP/DOWN air flow
EXHAUST Lever
CLOSED
OPEN
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INSTALLATION INSTRUCTIONS |
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ITEMS PACKED WITH THIS UNIT |
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No. |
Accessories |
Q'ty |
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1 |
6 |
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1 |
Right closure assembly |
1 |
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8 |
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2 |
Left closure assembly |
1 |
2 |
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3 |
Window sash foam seal |
1 |
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7 |
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Window sash foam seal |
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4 |
1 |
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6 |
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(adhesive type) |
3 |
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5 |
Bottom gasket |
1 |
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6 |
Screws(L=1", 25.4mm) |
8 |
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8 |
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7 |
Screws(L= 13/ 32", 10mm) |
6 |
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4 |
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8 |
Remote control |
1 |
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5 |
9 |
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2 |
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9 |
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Battery |
2 |
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10 |
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10 |
Remote control hook |
1 |
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6
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.
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
Front |
Exhaust Lever |
panel |
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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.
AF-R100CX
AF-R120CX
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
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") |
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7
AF-R100CX
AF-R120CX
6.Insert the closure assemblies on both sides into the rails of the jamb.
Jamb (Left)
Closure assembly
(Left)
Closure assembly (Left)
Sill |
1/2 inch |
(13mm) |
Stool |
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).
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 |
Exhaust Lever |
Panel |
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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.
8
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.
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.
7.Unscrew the one screw holding the wire holder. Pull out thermistor holder.
AF-R100CX
AF-R120CX
8. Unscrew the one screw holding earth wire .
9. Cut the fixing band holding the wires.
10.Remove the control unit.
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.
9
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.
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 .
17.Remove the condenser by liftting up about 1 inch and pull it toward you and move to right.
18.Unfasten the one nut holding propeller fan by rotating it clockwise. And remove the propeller fan.
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.
21.Remove the evaporator.
10
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