Sharp AF-06CSL User manual

1
AF-06CSL
S3210AF06CSL/
SERVICE MANUAL
Page
SPECIFICATIONS ................................................................................................................................................ 2
EXTERNAL DIMENSIONS ................................................................................................................................... 3
WIRING DIAGRAM............................................................................................................................................... 3
HOW TO OPERATE ............................................................................................................................................. 4
OPERATION INSTRUCTUINS ............................................................................................................................. 5
INSTALLATIOIN INSTRUCTIONS ......................................................................................................................12
DISASSEMBLING PROCEDURE....................................................................................................................... 14
HOW TO REPAIR REFRIGERATION ................................................................................................................ 18
ELECTRICAL COMPONENT TEST ....................................................................................................................21
MICROCOMPUTER CONTROL SYSTEM ..........................................................................................................22
TROUBLESHOOTING GUIDE ............................................................................................................................26
COOLING LOAD ESTIMATE FORM ...................................................................................................................31
RUNNING CONDITION .......................................................................................................................................33
PACKING AND ACCESSORIES .........................................................................................................................34
REPLACEMENT PARTS LIST ............................................................................................................................35
TABLE OF CONTENTS
AIR CONDITIONER
MODEL
Intheinterestsofuser-safety(Requiredbysafetyregulationsinsome
countries)theset should berestoredtoits original conditionandonly
parts identical to those specified should be used.
AF-06CSL
SHARP CORPORATION This document has been published to be used for after
sales service only.
The contents are subject to change without notice.

2
AF-06CSL
SPECIFICATIONS
Models AF-06CSL
Cooling capacity BTU/h 6000
Moisture removal Pints/h 1.5
ELECTRICAL DATA
Phase Single
Rared frequency Hz 60
Rated voltage Volts 115
Rated current Amps 5.2
Rated input Watts 545
Power factor % 91
EER BTU/Wh 11.0
COMPRESSOR
Type (Hermetically sealed rotary type)
Model, Motor output 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 1.2 x 700 x 1
(Capillary tube)
Refrigerant volume R-22(OZ) 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 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 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
ELECTRICAL PARTS
Running capacitor 250V-25µF
Fan capacitor 250V-6µF
Thermistor 15kΩat 78˚C
Fan motor OBM-2016K1 (MLA998)
Overload relay B200-130-141E

3
AF-06CSL
WIRING DIAGRAM
Figure W-1
EXTERNAL DIMENSIONS
Figure E-1
17-23/32"
33-7/16" (full opened)
21-21/32" (full closed)
14-7/8"
13-5/8"
1-15/32"
15-11/16"
4-1/8"
GR
OVERLOAD
PROTECTOR
A.C
EARTH
M.C
CONNECTOR
HML
FAN MOTOR
CAPACITOR
250V 6µF
FAN MOTOR
RUNNING
CAPACITOR
250V 25µF
THERMAL
PROTECTOR
BL
BL
BLBK
BK
BK
GY RE OR WH
COMPRESSOR
MOTOR
BK
BL
RE
WH
GR
GY
OR
: BLACK
: BLUE
: RED
: WHITE
: GREEN
: GRAY
: ORANGE
POWER SUPPLY CORD
115V 60Hz
3A 125V
IN
GR MRY CONTROL
BOARD UNIT
NR C1
CN1
BCN2
BCN3
TR
OUT
RIBBED
NON RIBBED
BK
BK
C
R
RE WH
GY
BCN1
CN2
CN3
WH
OR
RE
GY
S
FU1
123654
WIRE COLOR
YELLOW TH1
RY3
RY2
RY1
CNR3
CNR2
CNR1
THERMISTOR
(ROOM TEMP)
8
7
1
3
5
DISPLAY
BOARD
UNIT

4
AF-06CSL
HOWTO OPERATE
1Receiver window for remote
control signal
2Display
3SELECTOR indicator
4SELECTOR pad
5TEMPERATURE setting pad
----Lower temp.
----Raise temp.
6TIMER ON/OFF pad
7TIMER indicator
8ENERGY SAVER pad
9ENERGY SAVER indicator
0POWER ON/OFF pad
qPOWER indicator
34567
8
9
10
11
1
2
PARTS NAMES
UNIT
CONTROL PANEL
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
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
12
3
4 5 6 7 8 9
10
11

5
AF-06CSL
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
POWER
indicator
SELECTOR indicator
POWER ON/OFF pad
---Lower temp.
---Raise temp.
Touch POWER ON/OFF pad.
•The unit is preset at 74°F and HIGH
COOL. Thiswillshowinthedisplaywhen
the power is first turned on.
•POWER indicator and SELECTOR
indicator (COOL) will light.
Toturnofftheunit,touchPOWER
ON/OFF pad again.
•POWER indicator and SELECTOR
indicator will go off.
Touch the TEMPERATURE setting
pad to adjust the temperature
setting.
•Temperature can be set within the range
of 64°F to 86°F.
•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.
2
1
During cooling operation
COOLING OPERATION
TO CHANGETEMPERATURE SETTING
HOWTO OPERATE
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
TEMPERATURE setting pad

6
AF-06CSL
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
SELECTOR indicator
SELECTOR pad
TO CHANGE FAN SPEED AND OPERATION MODE
During operation
TouchSELECTORpadandselectthe
operation mode and fan speed.
•SELECTORindicatoranddisplaywilllight
in order as you touch.
NOTES ON OPERATION MODE:
SELECTOR DISPLAY
HIGH COOL
MED COOL
LOW COOL
HIGH FAN
MED FAN
LOW FAN
•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.
COOL
COOL
COOL
FAN
FAN
FAN
MODE
Cooling operation with high fan speed.
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.
HIGH COOL MED COOL
MED FANLOW FAN
LOW COOL
HIGH FAN

7
AF-06CSL
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
ENERGY SAVER indicator
ENERGY SAVER pad
ENERGY SAVER
TO CHANGE AIR FLOW DIRECTION
Horizontal louvers
Adjust UP/DOWN air flow
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.
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.)
2Tocancel,touchENERGYSAVER
pad again.
•ENERGY SAVER indicator will go
off.
NOTE: ENERGY SAVER cannot be set during fan only (HIGH FAN, MED FAN, LOW FAN)
operation.
During cooling operation
1
Adjust LEFT/RIGHT air flow
Lever
Touch ENERGY SAVER pad.
•ENERGY SAVER indicator will light.
Vertical louvers

8
AF-06CSL
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
SELECTOR indicator
TIMER ON/OFF pad
TIMER indicator
ONTIMER OPERATION
(If you wish to start the operation
6 hours and 30 minutes later, set
the delay time as shown above.)
1Touch the TIMER ON/OFF pad to set
the delayed start time.
•Thetimesettingwillchangeasyoutouchthe
pad. The display will change as follows;
•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.
•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.
NOTES FOR TIMER SETTING AND OPERATION:
•AftersettingtheTIMER,changethetemperatureandfan speedsettingsasshownonpages11
and12. Whenthetemperatureissetinthetimermode, thetemperaturewillshow inthedisplay
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.
When the unit is not operating
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.
0.5h 1.0h 1.5h 10h
Preset(0.5h)
Previous setting
11h12h
CL(cancel)

9
AF-06CSL
POWER
ON/OFF
F
hr
SELECTOR
TIMER
ON/OFF
ENERGY
SAVER
COOL / FAN TEMP
TIMER ON/OFF pad
TIMER indicator
OFFTIMER OPERATION
•This 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.
1Touch the TIMER ON/OFF pad to set
the delayed stop time.
•Thetimesettingwillchangeasyoutouchthe
pad. The display will change as follows;
•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.
(If you wish to stop the
operation 10 hours later, set
the delay time as shown
above.)
TO CANCEL THE TIMER SETTING
Touch the TIMER ON/OFF pad again after the
timerissetor,presstheTIMERON/OFFpad until
CL(cancel) appears on the display.
When the unit is operating
0.5h 1.0h 1.5h 10h
Preset(0.5h)
Previous setting
11h12h
CL(cancel)

10
AF-06CSL
Remove the battery compartment cover.
Insert the batteries in the compartment,
making sure the and polarities
are properly aligned.
Replace the cover.
INSTALLING BATTERIES
Use two size-AAA (R03) batteries.
Batterycompart-
ment 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.
•Ifyouwillnotbeusingtheunitforalongtime,removethebatteriesfromtheremotecontrol.
ATTACHINGTHE REMOTE CONTROL HOOK
•Remove the backing from the remote control hook.
•Attach the hook onto the left side of the unit's front
cabinet.
•Topreventloss,hooktheremotecontrolonthefront
cabinet when not in use. Front Cabinet
Remote control hook
Rear Cabinet
HOWTO USETHE REMOTE CONTROL
Point the remote control towards the unit's re-
ceiver 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.
•Theunitmaybeaffectedbysignalsemittedfromtheremotecontrolofatelevision,VCRorother
equipment used in the same room.
•Donotleave theremote control exposedto directsunlightor neara heater. Protect the remote
control from moisture and shock which can discolor or damage it.
2
1
3
USINGTHE REMOTE CONTROL

11
AF-06CSL
POWER
TEMP.
TEMP.
SELECTOR
SET TIMER/OFF
ON/OFF
•Thetimesettingwillchangeasyoupushthebutton. Thedisplay
will change as follows;
•The last OFF time setting is memorized by the unit and will
appear on the display when the button is pushed.
•Thetimerwillbeset,5secondsaftertheSETTIMER/OFFbutton
is pushed for the last time.
•Ifyouwishtocancelthetimer,pushtheSETTIMER/OFFbutton
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 8).
TEMP.
TEMP. ---Raise temp. setting 1°F at a time.
---Lower temp. setting 1°F at a time.
OPERATING WITHTHE REMOTE CONTROL
TRANSMITTER
TEMPERATURE setting button
POWER ON/OFF button
Push to start or stop the operation.
SELECTOR button
Push to change fan speed and operation
mode.
Fan speed and operation mode selec-
tions are shown to the right.
SET TIMER/OFF button
Push to set delay "OFF" timer during operation.
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.
HIGH COOL
MED COOL
LOW COOL
HIGH FAN
MED FAN
LOW FAN
0.5h 1.0h 1.5h 10h
Preset(0.5h)
Previous setting
11h12h
CL(cancel)

12
AF-06CSL
11
10
9
8
6
7
3
45
1
2
11
10
9
8
7
6
5
4
3
2
1
ACCESSORIES
No. Accessories Q'ty
Right closure assembly 1
Left closure assembly 1
Window sash foam seal 1
1. Screw driver (medium size Phillips)
2. Tape measure or ruler
3. Knife or scissors
6 7
2
2
SUGGESTEDTOOLS
Window sash foam seal 1
(adhesive type)
Bottom gasket 1
Screws (L=1", 25.4mm) 7
Screws (L= 13/32", 10mm) 6
Base pan angle 2
Remote control 1
Battery 2
Remote control hook 1
INSTALLATION
WARNING: Make sure the unit is turned off and unplugged before working.
1. Cut the window sash foam seal (adhesive type) to the
proper length and attach it to the underside of the
window sash.
2. Insert the right closure assembly and the left closure
assembly into the top angle and the bottom channels.
Secure the right and left closure to the cabinet with
six of the provided screws.
(L= 13/32", 10mm)
INSTALLATION INSTRUCTIONS
Closure assembly
Sash
Jamb
Sill
Window sash foam seal
(adhesive type)

13
AF-06CSL
3. Open the window sash and place the airconditioner
on the sill.
Balance the unit on the sill and close the window
sash securely behind the top angle.
Indoor
side
1/2 inches
(13mm)
Indoor
side
WARNING:
Atthis step, makesure theunit
is inclined approximately 1 cm
(3/8") to the back.
If the unit is not properly in-
clined, the water collected in
the bottom tray during opera-
tion will not drain properly and
may flow into the room where
the air conditioner is installed.
4. Insert the bottom gasket into the space between the
window sill and the bottom of the unit to seal outside
air.
If there is space between the bottom channel and
the sill, fill the gap with a thin board or other hard
filler.
5. Insert the closure assemblies on both sides into the
rails of the jamb.
6. Loosen screws on both sides of the cabinet, then
hang the base pan angle on and secure the screws
again.
7. Secure the base pan angle to the sill by using the hole
of the front side on the angle with one screw. (L=1",
25.4mm)
8. Secure the top angle of the unit and the top of the
closureassembliestothesashwiththreeoftheprovided
screws. (L=1", 25.4mm)
And secure the bottom of the closureassemblies to
the sill with two of the provided screws. (L=1",
25.4mm)
9. Cut the window sash foam seal to the proper length
and seal the opening between the top of the inside
window sash and the outside window sash.
Bottom gasket
Jamb
(Left)
Sill
Stool
Closure assembly
(Left)
Closure assembly
(Left)
unit
sill incline backwards approximately
1cm (3/8")
Top angle
Window sash foam seal

14
AF-06CSL
DISASSEMBLING PROCEDURE
CAUTION: DISCONNECT THE ROOM AIR CONDITIONER FROM THE POWER SUPPLY BEFORE ANY SERVICE
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.
5. Remove the control panel.
6. Unscrew the 5 screws.
3screws are holding thecontrolboxat the top andright
side.
1 screw is holding the power supply cord.
1 screw each screw on the evaporator.
7. Take off the fan motor connector.
8. Unscrew the 1 screw holding the compressor cord.
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.

15
AF-06CSL
9. Cut the wire fixing band, slide the control box rightward
and remove.
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.
12. Unfasten the nut holding the propeller fan by rotating it
counter-clockise. And remove the propeller fan.
13. Unscrew the 3 screws holding the condenser shround.
And remove the condenser shround.
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.
16. Unscrew the 2 screws holding the orifice.
SLIDE

16
AF-06CSL
17. Unscrew the screw holding the centrifugal fan.
(Remove by using a driver or wrench)
18. Remove the caseing.
19. Unscrew the 4 screws holding fan motor.

17
AF-06CSL
DISASSEMBLING THE CONTROL BOX
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.
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.
5. Unscrew the 1 power supply cord grounding screw.
Unscrewtheearthscrew.Unscrew the 1 screwholding
the capacitor clamp.
6. Detach each connector by using long-noise pliers.
7. Unscrew the 2 screws holding the transformer.
8. Remove the control board with unhooking the 2
spacers.

18
AF-06CSL
4) Do not over fill any charging cylinders, as they could explode when over
filled.
5) Use proper wrenches.
6) Use safety goggles when working with refrigerants.
7) Keep a fire extinguisher within easy reach.
8) Watch flame direction when soldering so as not to burn clothing, wiring or
other components.
9) Solder in a well ventilated area. If a high concentration of freon is present,
an open flame will create phosgene gas which can be harmful.
PROPER SOLDERING
Joint clearances should be maintained so that the brazing alloy will flow
between the closely mated surfaces rather than forming large fillets.
This films make the strongest joints, capillary attraction also work best with
close tolerance.
The best clearance is between 0.01" to 0.03" , the amount of lap will be
approximately 3/8" depending on the 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
oxidesotherwisethealloywill notwetandflowproperlyoverany surface with
theseelementspresent.Cleaningcanbedone with an abrasiveclothorsteel
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.
HOWTO 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) Donotheatthechargingcylinderwithan open flame. Use warm water only and do not exceed 125˚F(nottoohottokeep
your hand in.)
Figure 1
Fi
g
ure 2
GOOD FIT
POOR FIT
Joint Clearance.
PROPER
JOINT FIT
CLEARANCE
0.01" TO 0.03"
EMERY CLOTH
KEEP TUBE IN
DOWNWARD POSITION
Cleaning Tubing.

19
AF-06CSL
PROPER FLUXING
Flux is necessary when using silver solder; it is not required
when using silfos on copper to copper joints.
To do a good job the flux should cover the tube surface
completely. Be careful not to introduce any flux inside the
tubing.
Fluxing should be done after the tubing is mated together
and just before brazing is done. Do not allow it to dry out.
When brazing, the flux should become entirely liquid and
clear,likewater.Thetemperaturewillbeat1100˚Fandonly
alittlemoreheatwillallowthealloytoflowfreelyintothejoint.
INNER CONE
TORCH STEM
SILVER ALLOY
Figure 3
Directing Torch Flame to Copper Tubing.
3/8"
OUTER CONE
HOTTEST PART
OF FLAME
INNER CONE
TORCH STEM
Figure 4
Composition of Torch Flame.
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
(paleblue)incalorandamuchlargeroutercone.Thehottest
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.
DEHYDRATING SEALED SYSTEM
Many servicers feel that since air conditioners run with evaporator temperatures above 33˚F, moisture will not present a
problem.Nothingisfurtherfromthetruth.Oxygen in moisture plus the heatproducedduringcompressionwillreactwiththe
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.

20
AF-06CSL
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.
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.
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.
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.
HIGH VACUUM PUMPHook up for Evacuation and charging
TO RELATED SERVICE
VALVE OR PROCESS
TUBES OF THE UNIT.
LARGE DIAMETER
BRAIDED VACUUM
HOSES
HIGH VACUUM
MANIFOLD
DIAL-CHARGE
CHARGING CYLINDER
HIGH SIDE
GAUGE
LOW SIDE
GAUGE
ELECTRIC
VACUUM
GAUGE
Figure 5