Sanyo C3032 User's Manual

 SERVICE MANUAL | SANYO
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| FILE NO.
KS3032/ C3032, CL3032
KS3632/ C3632, CL3632
SPLIT SYSTEM AIR CONDITIONER Section
INDOOR MODEL No. PRODUCT CODE No. OUTDOOR MODEL No. PRODUCT CODE No. a. 1
KS3032 854 014 59 C3032 854 014 61
CL3032 854 014 60
KS3632 854 014 50 C3632 854 014 54
CL3632 854 014 52
Indoor Unit Outdoor Unit
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KS3032 — C3032
KS3632 CL3032
| C3632
CL3632
©
| 85464849169000 REFERENCE NO. SMa30069
Please Read Before Starting
This air conditioning system meets strict safety and operating
standards. As the installer or service person, it is an important
part of your job to install or service the system so it it operates
safely and efficiently.
For safe installation and trouble-free operation, you must :
® Carefully read this instruction booklet before beginning.
® Follow each installation or repair step exactly as shown.
e Observe all local, state, and national electrical codes.
e Pay close attention to all warning and caution notices
given in this manual.
This symbol refers to a hazard or
WN={N{{\[eJl unsafe practice which can result in
severe personal injury or death.
This symbol refers to à hazard or
CAUTION | unsafe practice which can result in
personal injury or product or
property damage.
If Necessary, Get Help
These instructions are all you need for most installation sites
and maintenance conditions. If you require help for a special
problem, contact our sales/service outiet or your certified dealer
for additional instructions. |
In Case of Improper Installation
The manufacturer shall in no way be responsible for i improper
installation or maintenance service, including failure to follow
the instructions in this document.
SPECIAL PRECAUTIONS
When Wiring |
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.
Do not supply power to the unit until all wiring and tubing are
completed or reconnected and checked.
Highly dangerous electrical voltages are used in this system.
Carefully refer to the wiring diagram and these instructions
when wiring. improper connections and inadequate ground-
ing can cause accidental injury or death.
* Ground the unit following local electrical codes.
* Connect all wiring tightly. Loose wiring may cause overheat-
ing at connection points and a possible fire hazard.
When Transporting
LE LY YE
Be careful when picking up and moving the indoor and outdoor
units. Get a partner to help, and bend your knees when lifting to
reduce strain on your back. Sharp edges or thin aluminum fins
on the air conditioner can cut your fingers.
When Installing
lt a Room
Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to walls
and floors.
...In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents water
damage and abnormal vibration.
ln an area with High Winds
Securely anchor the outdoor unit down with bolts and a metal
frame. Provide a suitable air baffle.
ln a Snowy Area (for Heat Pump-type Sys-tems)
Install the outdoor unit on a raised platform that is higher than
drifting show. Provide snow vents.
When Connecting Refrigerant Tubing
PRR ANE RE ENS AEA REA FFA AAS RE FAR nr RA ET FRE PAE ARR AA FN ANA NR ERE FARA NAGE SNF ARSE
* Ventilate the room well, in the event that refrigerant gas
leaks during the installation. Be careful not to allow contact
of the refrigerant gas with a flame as this will cause the
generation of poisonous gas.
*+ Keep all tubing runs as short as possible.
« Use the flare method for connecting tubing.
Apply refrigerant lubricant to the matching surfaces of the
flare and union tubes before connecting them, then tighten
the nut with a torque wrench for a leak-free connection.
* Check carefully for leaks before starting the test run.
[NOTE]
Depending on the system type, liquid and gas lines may be
either narrow or wide. Therefore, to avoid confusion the
refrigerant tubing for your particular model is specified as either
“narrow” or “wide” rather than as “liquid” or “gas”.
When Servicing
LEAT RS YEE EER NY ERE FEY PR EL EY NY EE EE PFE EE EE FT RF RAY RATNER YRS NSE NT RE FY NEY YE Fe
* Tum the power OFF at the main power box (mains) before
opening the unit to check or repair electrical parts and
wiring.
+ Keep your fingers and clothing away from any moving parts.
Ciean up the site when installation is finished. Check that no
metal scraps or bits of wiring have been left inside the unit.
CAUTION
» Ventilate any enclosed areas when installing or testing the
refrigeration system. Contact of refrigerant gas with fire or
heat can produce poisonous gas.
+ Confirm after installation that no refrigerant gas is leaking. If
the gas comes in contact with a burning stove, gas water
heater, electric room heater or other heat source, it can
cause the generation of poisonous gas.
SM830069
This service manual is made to assist the service technician apply his knowledge and training
to this model air conditioner. This manual is written both for experienced service persons
and those who are new to air conditioning service. To help those with less experience or who
are new to this kind of unit we have included more explanations of basic procedures in simple
language than is usual in some service manuals. The experienced technician will of course
find he knows many of these things already and can go directly to the procedures and infor-
mation he needs; the less experienced technician will better understand what to do even
before he arrives on the job, and therefore be better able to work by himself as well as assist
the more experienced technician.
TEE
À. SPECIFICATIONS oes eee eee eee eee eee eee ree 5
1-1 Unit Specifications ..….....…...…..….…..….eerenenemençentencennençsennnnnnnnnnnnnnnnnnnnnnnbnûnnann 6
1-2 Major Component Specifications .......................-........ e... ....... e... nena reee ene. 10
(A) Indoor UNit ..............e=.e..ee=sesececaorencanno neo caen arnsormemennsenenentenccnneacenavenceneses 10
(B) Outdoor Unit .................ee=esascccacansconanaoccananane eenoruecananananan anna ooeenanana acen ancanecaco 12
1-3 Other Component Specifications .….….….......….….…....…..….…cesenceenmeeneenennannnetensansences 16
(A) Indoor Unit ...................e-eee=eerenesooocareaacenananeranaronenenoaciceconeceerecenoenonennon enero. 16
(8) Outdoor Unit ................e.=eee=.ecececerneca nora eee nee. nenannonone RG 17
1-4 Dimensional Data...................e...ee0cscrcoccooconscacaconanaen acen nena enan en cone reenenanenceneene 21
(A) Indoor Unit N 21
(B) Outdoor Unit ............... ненееовеечетесозиенетьесозезееессввееетевечзеееееввеазеенсв. conseneananonananenoa 22
1-5 Refrigerant Flow Diagram .............-e-ee.emmncoccacncornenenncan nana ree anece tenen nene naeenaceca 23
1-6 Operating Range ...............e....—......eeee ere ear Leen eee reee nee 24
2. PROCESSES AND FUNCTIONS ....................e.eeeceuecocenccctocacceononear one ae noo ena near encon. 25
2-1 Room Temperature Control .................-.e=<.es=ececenonccnrone cananea no renaeceneecaac eee RTG 26
2-2 Freeze Prevention ............ e... ....erecenncecocoarneaooneecanoreaeane cancer recanonaananneca naa eocenonane 27
2-3 Outdoor Fan Speed Control ...........-.......e=cnoceocenerceonenea enana eee nacen 28
3. ELECTRICAL DATA -.......................eoenceoocnconorcanconecconocracarneeconananenenoenoc enero ZO
3-1 Indoor Unit ................. eeneenoeaeeoaoeeeneere enero enana nece nn osea ene encon ercer er eee. 30
3-2 Outdoor UNit.................e=eecernereoar recen reaacon aerea acen enneneeeae PO 32
4. SERVICE PROCEDURES ....................csemcessencconseconaosaceneoaneaconenaanaancacercaneacan enana 37
4-1 Troubleshooting ............. cerereerestecssasearreneeranssranannes erasteenastteeartrnnnsnsreennmasnnarenannsans 38
4-2 A Sensor is Defective.......................smeereconerecaneeo one ner e reee reneanananacanene 49
4-3 Operation of Major Electrical Parts ..................ee.eeceneconecsarreconeee reee nene ee 49
4-4 Checking the Electrical Components ................ e eeee=ee==erreceourconr DT 50
SMB30069 -
— 3 —-
Introduction: Read Me First!
This manual will help you understand and service the air conditioner. To help you find the information you need,
we have divided it into 5 main sections. Each section is divided into chapters with charts, tables and explana-
tions to help you find and repair problems.
Q Section 1: Specifications, tells you about the physical and electrical make up of the unit, as well
as its heating and cooling capacities. Look in this section to find the correct values for
components and functions. |
Q Section 2: Processes and Functions, explains each different part of the cooling and heating
cycle, and how each control function reacts to changing conditions to keep the room at the set
temperature range.
Q Section 3: Electrical Data, which has fold-out schematic and wiring diagrams so you can find
the parts you need to check when something is wrong, and see how they should be connected.
D Section 4: Service Procedures, has two main parts, a diagnostic chapter to help you find the
specific component to replace or adjust, and a chapter with specific procedures and values to
guide you in checking the electrical components in the unit.
HOW TO USE THIS MANUAL
You can use this manual both as a reference to find specific information about the capacity, functions and
construction of this unit, and as a source of information to help you set up and maintain the unit.
When this unit is not working properly, and the cause is not known, you can use the procedures in
Section 3: Servicing Procedures to find the problem, fix it, and restore the unit to its proper functioning.
This air conditioner has many helpful self diagnostic features to help you identify problem areas quickly.
So you will be ready when a problem happens, we suggest you look this manual over and become familiar with it
by following these steps:
1. Look at the TABLE OF CONTENTS to get an idea of what is in this manual and where to find it.
2. Look at the chapter about TROUBLE SHOOTING, so you are familiar with the way the flow
charts work. They are designed to guide you quickly through the possible causes for each kind of
problem that is likely to happen to the Unit. Particularly read the introduction to this section, and
the parts about the self-diagnosis and error codes which show on the display.
3. Look at the chapter about CHECKING ELECTRICAL COMPONENTS. You already know
about most of these procedures. This chapter gives you the specific values and methods for
these components. If you don’t know some of these procedures, you can easily learn them here.
4. Read the Instruction Manual! The Instruction Manual is included here because it helps you help
the user to set the temperature controls properly and know how to take care of any simple
problems that may happen, as well as know when to call for service. The Instruction Manual also
has illustrations, care, and installation information not found in the rest of the service manual. It is
short, and if you read it carefully, you will be able to answer the customers questions easily, and
also know the most efficient ways for setting times and temperatures.
Please use this manual to make your work easier, keep the air conditioner functioning well, and keep your
customers satisfied.
SM830069
1-4
1-5
1-6
1. SPECIFICATIONS
Unit Specifications ..............e-.....eesrercevecooroonrconrcan cenoansecarecaaanenacacennaananena enana 6
Major Component Specifications .............e.«....« <a... nnennenanacenn nece nenannaan aa anecos 10
(A) Indoor UNit ....................ee=nessececncaareeoeneaa aa eaneeea naa rerecen ee eneeneecancenenarnerenee 10
(B) Outdoor UNit ...................resesecosscansenenenonooacacencenaneanae aa anceaan acen e necanen nece 12
Other Component Specifications ....................e..e===eeorreccenrescecinene sen cerrecceo 16
(A) Indoor Unit ....... auconenenencanenananaarcencanarreneercaacane encon ne nene ecanananerecenarcarenrree aman e 16
(B) Outdoor Unit .................. peoeacereeneneneone cenneronnnanenea rentar enenneneenecos cocsessranees 17
Dimensional Data............... eesnaotena nano eee reooeecac enana renenacan core n bears be ses ean enanne 21
(A) Indoor Unit ...........—e...—e.e.ee==ecscenanrenacovs anecononeanoneaeaananennonoeeneoneneaenannceneenen 21
(B) Outdoor Unit ene reenenean carece encens 22
Refrigerant Flow Diagram ...............e-e==.ceocccaacoceanocoanonaoocanrona recae nenerenaetaenonee 23
Operating Range ...................—w..esmeceoner nene enee nene ee enano enanos 24
SM830069
1-1 Unit Specifications
MODEL No. Indoor Unit KS3032
Outdoor Unit C3032
POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz
PERFORMANCE Cooling
Capacity BTU/h 30,000 29,000
kW 8.8 8.5
Air circulation (Hi) -cu.ft, / min. 840 760
Moisture removal (High) Pints / h 10.0 9.9
ELECTRICAL RATINGS IE
Voltage rating Vv 230 | 208
Available voltage range Vv 187 - 253
Running amperes" A 13.0 13.6
Max. running amperes™ A 15.1 16.1
Power input W 2,880 2,770
Power factor % 96 98
S.E.E.R BTU/Wh 10.4 10.7
[ Max. starting amperes A 79.6 72.5
| Maximum fuse size A 30
| FEATURES
Controls Microprocessor
Timer ON / OFF 24-hours 8 Program
Fan speed indoor / Qutdoor 3 and Automatic contro! / 2 (Auto)
Air defiection Horizontal / Vertical Manual / Automatic (>
Air filter Washable, easy access
Remote controller (Accessory) RCS - 5PS4U
Refrigerant control Capillary tube
Refrigerant tubing connections Flare type
Drain pipe trade size 3/4 in. (26.7 mm)
Compressor Rotary
Operation sound Indoor - Hi/Me/Lo| dB-A 46 / 42 / 38
Outdoor - Hi de -A 56
REFRIGERANT TUSING
Limit of tubing length ft. (m) 165 (50)
Limit of tubing length at shipment ft. (m) 50 (15)
Limit of elevation difference ft. (m) Outdoor unit is higher than indoor unit: 165 (50)
between the two units Outdoor unit is lower than indoor unit: 100 (30)
Refrigerant tube Narrow tube in. (mm) 3/8 (9.52)
outer diameter Wide tube in. (mm) 3/4 (19.05)
Refrigerant amount at shipment Ibs. (kg) R22 :8.6 (3.9)
DIMENSIONS & WEIGHT Indoor unit Outdoor unit
Unit dimensions Height in. (mm) 14-9/16 (370) 48-5/8 (1,235)
Width in. (mm) 59-1/16 (1,500) 37 (940)
Depth in. (mm) 9-7/16 (240) 13-3/8 (340)
Package dimensions Height . in. (mm) 18-6/32 (462) 52-7/32 (1,326)
Width in. (mm) 629/16 (1,589) 40 (1,016)
Depth in. (mm) 11-5/8 (295) 16-12/32 (416)
Net weight Ibs. (kg) 64 (29) 198 (90)
Shipping weight lbs. (kg) 82 (37) 223 (101)
Shipping volume cu.ft. (md) 7.7 (0.217) 19.8 (0.56) E,
Cooling : DATA SUBJECT TO CHANGE WITHOUT NOTICE |
Rating conditions (*) : Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 95 °F DB / 75 °F WB
Full load conditions (**) : Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 115 °F DB
SM830069
— 6 —
m 1-1 Unit Specifications
MODEL No. indoor Unit KS3032
| Outdoor Unit CL3032
POWER SOURCE | - 280 - 208 V / 1 Phase / 60 Hz
PERFORMANCE Cooling
Capacity BTU/h 30,000 29,000
kW 8.8 8.5
Air circulation (Hi) ‘cu.ft. / min. 840 760
Moisture removal (High) Pints / h 10.0 9.9
ELECTRICAL RATINGS
Voltage rating \ 230 208
Available voltage range V 187 - 253
Running amperes* A 13.0 13.6
Max. running amperes** A 15.1 16.1
Power input W 2,880 2,770
Power factor. % 96 98
S.E.E.R BTU/Wh 10.4 10.7
Max. starting amperes A 79.6 72.5
Maximum fuse size A 30
FEATURES
Controls Microprocessor
Low ambient contro! Built-in 0 °F
Timer ON / OFF 24-hours & Program
(> Fan speed Indoor / Outdoor 3 and Automatic control / 3 (Auto)
; | Air deflection Horizontal / Vertical | Manual / Automatic
Air filter Washable, easy access
Remote controller (Accessory) RCS - 5PS4U
Refrigerant contro! Capillary tube
Refrigerant tubing connections Flare type
Drain pipe trade size
3/4 in. (26.7 mm)
Compressor Rotary
Operation sound Indoor - Н1/ Ме / 09| dB-A 46 / 42 / 38
Outdoor - Hi dB-A 56
~ REFRIGERANT TUBING
Limit of tubing length ft. (m) 165 (50)
Limit of tubing length at shipment ft. (m) 50 (15)
Limit of elevation difference ft. (m) Outdoor unit is higher than indoor unit: 165 (50)
between the two units | Outdoor unit is lower than indoor unit: 100 (30)
Refrigerant tube Narrow tube in. (mm) 3/8(9.52)
outer diameter Wide tube in. (mm) 3 / 4 (19.05)
Refrigerant amount at shipment bs. (kg) R22 : 8.6 (3.9)
DIMENSIONS & WEIGHT Indoor unit Outdoor unit
Unit dimensions Height in. (mm) 14-916 (370) 48-5/8 (1,235)
Width in. (mm) 59-1/16 (1,500) 37 (940)
Depth in. (mm) 9-7/16 (240) 13-3/8 (340)
Package dimensions Height in. (mm) 18-6/32 (462) 52-7/32 (1,326)
| Width in. (mm) 62-9/16 (1,589) 40 (1,016)
Depth in. (mm) 11-5/8 (295) 16-12/32 (416)
Net weight №5. (kg) 64 (29) 198 (90)
O Shipping weight lbs. (kg) 82 (37) 223 (101)
Shipping volume cu.ft. (m°) 7.7 (0.217) 19.8 (0.56)
Cooling : DATA SUBJECT TO CHANGE WITHOUT NOTICE
Rating conditions (*) : Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 95 °F DB / 75 °F WB
Full load conditions (**) : Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 115 °F DB
- 7 —
SM830069
1-1 Unit Specifications
MODEL No. Indoor Unit KS3632
Outdoor Unit C3632
POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz
PERFORMANCE Cooling
Capacity BTU/h 34,000 33,000
kW 9.96 9.67
Air circulation (Hi) “cuit. / min. 830 750
Moisture removal (High) Pints / h 11.1 - 11.1
ELECTRICAL RATINGS
Voltage rating Vv 230 208
Available voltage range Vv 187 - 253
Running amperes* A 14.9 15.5
Max. running amperes"” A 17.7 18.9
Power input W 3,300 3,110
Power factor % 96 96
S.E.E.R BTU/Wh 10.8 11.0
Max. starting amperes A 97.6 88.6
Maximum fuse size A 35
FEATURES
Controls Microprocessor
Timer ON / OFF 24-hours & Program
Fan speed Indoor / Outdoor 3 and Automatic control / 2 (Auto)
Air deflection Horizontal / Vertical Manual / Automatic
Air filter Washable, easy access
Remote controller (Accessory) RCS - 5PS4U
Refrigerant control Capillary tube
Refrigerant tubing connections Flare type
Drain pipe trade size 3/4in. (26.7 mm)
Compressor Rotary
Operation sound indoor - Hi/ Me/Loj| dB-A 48 / 44 / 40
Outdoor - Hi de -A | 56
REFRIGERANT TUBING
Limit of tubing length ft. (m) 165 (50)
Limit of tubing length at shipment ft. (m) 50 (15)
Limit of elevation difference ft. (m) Outdoor unit is higher than indoor unit: 165 (50)
between the two units Outdoor unit is lower than indoor unit: 100 (30)
Refrigerant tube Narrow tube in. (mm) 3/8 (9.52)
outer diameter Wide tube in. (mm) 3 / 4 (19.05)
Refrigerant amount at shipment bs. (kg) R22 : 9.48 (4.3)
DIMENSIONS & WEIGHT indoor unit Outdoor unit
Unit dimensions Height in. (mm) 14-9/16 (370) 48-5/8 (1,235)
Width in. (mm) 59-1/16 (1,500) 37 (940)
Depth in. (mm) 9-7/16 (240) 13-3/8 (340)
Package dimensions Height in. (mm) 18-6/32 (462) 52-7/32 (1,326)
Width in. (mm) 62-9/16 (1,589) 40 (1,016)
Depth in. (mm) 11-5/8 (295) 16-12/32 (416)
Net weight Ibs. (kg) 68 (31) 198 (90)
Shipping weight Ibs. (kg) 86 (39) 223 (101)
Shipping volume cu.ft. (m3) 7.7 (0.217) 19.8 (0.56)
Cooling : DATA SUBJECT TO CHANGE WITHOUT NOTICE
: Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 95 *F DB / 75 °F WB
: Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 115 °F DB
Rating conditions (*)
Full load conditions (**)
SM830069
—8-
O 1-1 Unit Specifications
MODEL No. indoor Unit KS3632
Outdoor Unit CL3632
POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz
PERFORMANCE Cooling
Capacity BTU/h 34,000 33,000
| kW , — 9.96 9.67
Air circulation (Hi) “cu.ft. / min. 830 750
Moisture removal (High) Pints / h | 11.1 - 11.1
ELECTRICAL RATINGS ‘
Voltage rating \ 230 208
Available voltage range Vv 187 - 253
Running amperes" A 14.9 15.5
Max. running amperes** A 17.7 18.9
Power input W 3,300 3,110
Power factor % 96 - 96
SEER BTU/Wh 10.8 11.0
Max. starting amperes A 97.6 88.6
Maximum fuse size A | | 35
FEATURES ; |
Controls Microprocessor
Low ambient control — Built-in 0 °F
Timer | ON / OFF 24-hours & Program
( Fan speed Indoor / Outdoor 3 and Automatic control / 3 (Auto)
' Air deflection Horizontal / Vertical Manual / Automatic
Air filter — Washable, easy access
Remote controller (Accessory) | RCS - 5PS4U
Refrigerant control | Capillary tube
Refrigerant tubing connections | Flare type
Drain pipe trade size | 3/4in. (26.7 mm)
Compressor | Rotary
‘ Operation sound — Indoor-Hi/Me/Loi dB-A 48/44/40
Outdoor - Hi dB-A 56
REFRIGERANT TUBING
Limit of tubing length ft. (m) | 165 (50)
Limit of tubing length at shipment ft. (m) 50 (15)
Limit of elevation difference ft. (m) Outdoor unit is higher than indoor unit: 165 (50)
between the two units Outdoor unit is lower than indoor unit: 100 (30)
Refrigerant tube Narrow tube in. (mm) 3/8 (9.52)
outer diameter Wide tube in. (mm) 3 / 4 (19.05)
Refrigerant amount at shipment ibs. (kg) R22 : 9.48 (4.3)
DIMENSIONS 4 WEIGHT Indoor unit Outdoor unit
Unit dimensions Height in. (mm) 14-9/16 (370) 48-5/8 (1,235)
Width in. (mm) 59-1/16 (1,500) 37 (940)
Depth in. (mm) 9-7/16 (240) 13-3/8 (340)
Package dimensions Height in. (mm) 18-6/32 (462) 52-7/32 (1,326)
Width in. (mm) 62-9/16 (1,589) 40 (1,016)
Depth in. (mm) 11-5/8 (295) 16-12/32 (416)
Net weight — !bs. (kg) 68 (31) 198 (90)
( Shipping weight | 165. (Ка) 86 (39) 223 (101)
; Shipping volume cu.ft. (m°) 7.7 (0.217) 19.8 (056)
Cooling : DATA SUBJECT TO CHANGE WITHOUT NOTICE
Rating conditions (*) : Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 95 °F DB / 75 °F WB
Full load conditions (**) : Indoor air temperature 80 °F DB / 67 °F WB, Outdoor air temperature 115 °F DB SM830069
-0
1
|
1-2 Major Component Specifications
(A) Indoor Unit
MODEL No. KS3032
Source 230 - 208 V / 1 phase / 60 Hz
Remote controller (Accessory) RCS -5PS4U
Controller P. C. B Ass'y POW - KS2412BN
| Control circuit fuse 250V,3 A
Fan
Type Cross-flow
Number ... Dia. and length | in. (mm) 1... 0.D. 4-13/18 (120), L46 (1,170)
Fan motor
Model SFG4T - 41A6P
Source 230 - 208 V / 1 phase / 60 Hz
No. of pole ... r.p.m. (230 V, High) rpm 4... 1,260
Nominal output W 40
Coil resistance Q WHT - GRY : 1755 , WHT - VLT : 16.9
(Ambient temperature 68 °F) YEL - PNK : 350 , VLT - YEL : 114
Safety device Internal
Operating temperature Open °F 248 + 9
Close °F 171 + 27
Run capacitor VAC, pF 440V ,4.5uF
Heat exchanger
Coil Aluminum plate fin / Copper tube
Rows ... 2... 12.7
Расе агеа ft.2 (m?) 3.33 (0.309)
Louver Motor |
Model M2EA24ZA01
Rating 208 to 230 V, 60 Hz
No. of pole … rpm 8...3
Output W 2.5
Coil resistance (Ambient temperature 68 °F) КО 16.45 + 8 %
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
-10-
1-2 Major Component Specifications
(A) Indoor Unit
MODEL No. KS3632
Source 230 - 208 V / 1 phase / 60 Hz
Remote controller (Accessory) RCS - 5PS4U
Controller P. C. B Ass'y POW - KS2412BN
| Control circuit fuse 250V,3 A
Fan
Type | Cross-flow
Number ... Dia. and length lin. (mm) 1... 0.D. 4-13/18 (120), L46 (1,170)
Fan motor
Model SFG4T - 51A6P
Source | 230 - 208 Y / 1 phase / 60 Hz
No. of pole … r.p.m. (230 V, High) rom 4... 1,329
Nomina! output W 50 |
Coil resistance Q WHT - GRY : 1182 , WHT - VLT : 155
(Ambient temperature 68 °F) YEL - PNK : 314 , VLT - YEL : 136
Safety device Internal
Operating temperature Open °F 248 + 9
| Close °F 171 + 27
Run capacitor VAC, uF 440 V , 4 uF
Heat exchanger
Coil Aluminum plate fin / Copper tube
Rows ... 3...127
Face area | | #2 (m?) 3.33 (0.309)
Louver Motor
Model M2EA24ZA01
Rating 208 to 230 V, 60 Hz
No. of pole ... rpm 8...3
Output W 25
Coil resistance (Ambient temperature 68 *F) kQ 16.45 + 8 %
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
-11-
1-2 Major Component Specifications
(B) Outdoor Unit
MODEL No. C3032
Source 230 - 208 V / 1 phase / 60 Hz
Compressor Rotary (Hermetic)
Model С - R191H6L
Source 230 - 208 V / 1 phase / 60 Hz
Nomina! output W 1,900
Compressor oil cc 1,350
Coil resistance (Ambient temperature 77 °F) Q C-R:0.697,0C-5: 1.656
Safety device | Internal type
Overload relay models —
Operating temperature Open °F 329 + 9
Close °F 203 + 9
Operating ampere (at 77 °F) A —
Run capacitor VAC, uF 400 Y, 40 uF
Refrigerant amount charged at shipment bs. (kg) R22 : 8.6 (3.9)
High pressure switch ACB - 1UB11
Set pressure OFF kg/cm? 30:55
ON kg/cm? 24 + 2.0
Fan Propeller
| Number...diameter | in. (mm) 2... 18-3/32 (460)
Fan speeds 2 (AUTO)
Fan motor
Model KFC6T - 91DEP x 2
Source 230 - 208 V / 1 phase / 60 Hz
No. of pole ... mm (230 Y, High) rpm 6...879
Nominal output W 110x2
Coil resistance Q BRW - WHT 67.14 , VLT — YEL 11.42
(Ambient temperature 68 °F) WHT — VLT 64.85 , YEL — PNK 10.60
Safety device
Operating temperature Open °F 248 + 9
Close °F 171 + 27
Run capacitor VAC, uF 440 V, 4 uF x 2
Heat exchanger
Coil Aluminum plate fin / Copper tube
Rows ... Fins per inch | 2... 12.7
Face area rz my 11.63 (1.08)
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
—12—
1-2 Major Component Specifications
(B) Outdoor Unit
MODEL No.
CL3032
Source
230 - 208 Y / 1 phase / 60 Hz
Controller P.C.B. Ass'y
CR - CL2432 (Microprocessor)
Control circuit fuse 250V,3 A
Compressor Rotary (Hermetic)
Model C-R191H6L
Source 230 - 208 V / 1 phase / 60 Hz
Nominal output W 1,900
Compressor oil ce 1,350
Coil resistance (Ambient temperature 77 °F) Q C-R:0.697,C~-S: 1.656
Safety device internal type
Overload relay models —
Operating temperature Open °F 329 + 9
Close °F 203 + 9
Operating ampere (at 77 *F) A —
Run capacitor VAC, uF 400 V, 40 pF
Crank case heater \, W 230 V, 30 W
Refrigerant amount charged at shipment Ibs. (kg) R22 : 8.6 (3.9)
High pressure switch ACB - 1UB11
Set pressure OFF kg/cm? 30 + 50
ON kg/cm? 24 + 2.0
Fan Propeller
| Number... diameter lin. (mm) 2... 18 - 3/32 (460)
Fan speeds 3 (AUTO)
Fan motor
Model KFC6T - 91D6P x 2
Source 230 - 208 V / 1 phase / 60 Hz
No. of pole ..... rpm (230 V, High) 6..879
Nominal output W 110x2
Coil resistance Q | BAN - WHT : 67.14 , VLT — YEL : 11.42
(Ambient temperature 68 °F) WHT — VLT : 6485 , YEL - PNK : 10.60
Safety device Internal type
Operating temperature Open °F 248 + 9
Close °F 171 + 27
Run capacitor VAC, uF 440V, 4 uF x 2
Heat exchange
Coil Aluminum plate fin / Copper tube
Rows ..... Fins per inch 2... 12.7
Face area If? (m?) 11.63 (1.08)
— 13 —
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
1-2 Major Component Specifications
(B) Outdoor Unit
MODEL No. C3632
Source 230 - 208 V / 1 phase / 60 Hz
Compressor Rotary (Hermetic)
Model C-R221H6R
Source 230 - 208 V / 1 phase / 60 Hz
Nominal output W 2,200
‘Compressor oil сс — 1,500
Coil resistance (Ambient temperature 77 °F) Q C-R:0549,C-8:1.525
Safety device Internal type
Overload relay models —
Operating temperature Open °F 320 + 9
Close °F 189 + 20
Operating ampere (at 77 °F) A —
Run capacitor VAC, pF 400V, 40 pF
Refrigerant amount charged at shipment Ibs. (kg) R22 : 9.48 (4.3)
High pressure switch ACB - 1UB11
Set pressure OFF kg/cm? 30 $55
ON kg/cm? 24 + 2.0
Fan Propeller
Number...diameter lin. (mm) 2... 18-3/32 (460)
Fan speeds 2 (AUTO)
Fan motor
Model KFC6T - 91D6P x 2
Source 230 - 208 V / 1 phase / 60 Hz
No. of pole ... rpm (230 V, High) rpm 6... 879
Nomina! output уу 110 х 2
Coil resistance Q BRW —- WHT 67.14 , VLT - YEL 11.42
(Ambient temperature 68 °F) WHT — VLT 6485 , YEL - PNK 10.60
Safety device
Operating temperature Open °F 248 + 9
Close °F 171 + 27
Run capacitor VAC, uF 440 V, 4 pF x2
Heat exchanger
Coil Aluminum plate fin / Copper tube
Rows ... Fins per inch 2... 12.7
Расе агеа [rz mM 11.63 (1.08)
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
—14—
1-2 Major Component Specifications
(B) Outdoor Unit
MODEL No. CL3632
Source 230 - 208 V / 1 phase / 60 Hz
Controller P.C.B. Ass'y CR - CL2432 (Microprocessor)
Control circuit fuse 250 V, 3 A
Compressor Rotary (Hermetic)
Model C - R221H6R
Source 230 - 208 V / 1 phase / 60 Hz
Nomina! output W — 2,200
Compressor oil ec 1,500
Coil resistance (Ambient temperature 77 °F) Q C-R:0.5419,C-5:1.525
Safety device internal type
Overload relay models —
Operating temperature Open °F 320 + 9
Close °F 189 + 20
Operating ampere (at 77 °F) A —
Run capacitor VAC, pF 400 V, 40 uF
Crank case heater V, W 230 V,30 W
Refrigerant amount charged at shipment 165. (kg) R22 : 9.48 (4.3)
High pressure switch АСВ - 1UB11
Set pressure OFF kg/cm? 30 : 22
ON kg/cm? 24 + 2.0
Fan Propeller
| Number...diameter lin. (mm) 2... 18 - 3/32 (460)
Fan speeds 3 (AUTO)
Fan motor
Model KFC6T - 91D6P x 2
Source 230 - 208 V / 1 phase / 60 Hz
No. of pole ..... rpm (230 V, High) 6... 879
Nominal output W 110x2
Coil resistance Q | BAN - WHT : 67.14 , VLT - YEL : 11:42
(Ambient temperature 68 °F) WHT — VLT : 64.85 , YEL - PNK : 10.60
Safety device Internal type
Operating temperature Open °F 248 + 9
Close °F 171 + 27
Run capacitor VAC, uF 440 V, 4 uF x 2
Heat exchange
Coil Aluminum plate fin / Copper tube
Rows ..... Fins per inch 2... 12.7
Face area ft.2 (m°) 11.63 (1.08)
-15 ~
DATA SUBJECT TO CHANGE WITHOUT NOTICE
1-3 Other Component Specifications
(A) Indoor Unit
MODEL No. KS3032
- Power Transformer ATR — H122U
Rated Primary AC 220 V, 60 Hz
Secondary 10V,12A
Capacity 12 VA
Coil resistance Q Primary (WHT - WHT) : 146 + 15 %
(Ambient temprature 77 °F) Secondary (BRN - BRN) : 0.5 + 15 %
Thermistor cut off temperature 259 °F, 2 À, 250 V
Thermistor (Coil sensor) РВС - 41Е - 54
Coil resistance ко 14 °F : 23.7 , 41 °F : 12.1
23 °F : 18.8 , 50% : 9.7
32 *F : 15.0 , 59% : 8.0
Thermistor (Room or coil sensor) KTEC - 35 - S6
Coil resistance kQ 32 °F : 16.5 , 104 °F: 2.7
41°F : 12.8 , 113% : 2.2
50 °F : 10.0 , 122 F : 1.8
68°F: 6.3 , 131%: 1.5
| 86°F: 4.0 ,
| Switch Ass'y SW - KS3012W
Synchronized Motor M2EA24ZA01
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
-16—
O
1-3 Other Component Specifications
(B) Outdoor Unit
MODEL No. C3032
Compressor Motor Magnetic Contactor FMCA - 1UL
Coil rated AC 240 V, 60 Hz
Coil resistance (at 77 °F) | Q 580 + 15%
Contact rated (Main) AC 240 V, 20 À
Contact rated (Auxiliary) AC 240 V, 3 A
Power Relay HH62S
Coil rated AC 240 V, 60 Hz
Coil resistance (at 77 °F) | kQ 17.2
Contact rated AC 220 V, 5 À
Thermostat (Coil sensor) YTB - 4U305F
Operating Temperature °F 79+ 3 OFF
7527 ON
Contact rated 200t0240V,1 A
Thermistor (PTC) TDK - 101YV
Rated
Max. voltage AC 400 V
Max. ampere 11.5A
Resistance (at 77 °F) | a 10018 %
—17-
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
-18-—
1-3 Other Component Specifications и
(B) Outdoor Unit
MODEL No. CL3032
Compressor Motor Magnetic Contactor FMCA - 1UL
Coil rated AC 240 V, 60 Hz
Coil resistance (at 77 °F) | Q 580 + 15%
Contact rated (Main) АС 240 М, 20 А
Contact rated (Auxiliary) AC240V,3 A
Power Relay HH62S
Coil rated AC 240 V, 60 Hz
Coil resistance (at 77 °F) | kQ 17.2
Contact rated AC220V,5A
Power Transformer ATR - 135B
Rated
Primary AC 220 V, 60 Hz
Secondary 14 V, 0.2 À
Capacity 2.8 VAC В
Coil resistance (at 78 °F ) Q WHT — WHT : 4825 ‚, BAN — BRN : 3.95
Thermal cut off temperature °F 266
Thermistor (Outdoor Temp. sensor) РВС - 41Е - 54
Coil resistance kQ 14 °F : 23.7 , 50 °F : 9.7
23 °F : 18.8 ‚ 68°F: 6.5
32 °F : 15.0 | 86 °F : 4.4 a
41% : 12.1 , 104 °F : 3.1 |
113% : 2.6
Thermistor (PTC) TDK - 101YV
Rated
Max. voltage AC 400 V
Max. ampere 115A
Resistance (at 77 °F) Q 100°% %
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
e
1-3 Other Component Specifications
(B) Outdoor Unit
MODEL No. C3632
Compressor Motor Magnetic Contactor FMCA - 1SUL
Coil rated AC 240 V, 60 Hz
Coil resistance (at 68 °F) Q 588 + 10%
Contact rated (Main) — AC 240V,26A
Contact rated (Auxiliary) AC240V,3 A
Power Relay HH62S
Coil rated AC 240 V, 60 Hz
Coil resistance (at 77 °F) | ко 17.2
Contact rated AC 220 V, 5A
Thermostat (Coil sensor) YTB - 4U305F
Operating Temperature °F 79+ 3 OFF
75:3 ON
Contact rated 200 to 240 V, 1 A
Thermistor (PTC) ТОК - 101YV
Rated |
Max. voltage AC 400 V
Max. ampere 11.5A
Resistance (at 77 °F) | a 100 23 %
— 19-
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
1-3 Other Component Specifications и
(B) Outdoor Unit
MODEL No. CL3632
Compressor Motor Magnetic Contactor FMCA - 1SUL
Coil rated AC 240 V, 60 Hz
Coil resistance (at 68 °F) | Q 588 + 10 %
Contact rated (Main) AC 240 V, 26 À
Contact rated (Auxiliary) : АС 240 М, ЗА
Power Relay HH62S
Coil rated AC 240 V, 60 Hz
Coil resistance (at 77 °F) kQ 17.2
Contact rated ; AC 220 V,5A
Power Transformer ATR - 135B
Rated
Primary AC 220 V, 60 Hz
Secondary 14 V, 0.2 A
| Capacity | 2.8 VAC
Coil resistance (at 78 °F) Q WHT — WHT : 4825 , BRN — BRN : 3.95
Thermal cut off temperature °F 266
Thermistor (Outdoor Temp. sensor) | PBC - 41E - $54
Coil resistance kQ 14 °F : 23.7 , 50°F: 9.7
2 | 150 | 06 Fl aa —
41 °F : 12,1 , 104 °F : 3.1
113 °F : 2.6
Thermistor (PTC) TDK — 101YV
Rated
Max. voltage | AC 400 V
Max. ampere 11.5A
Resistance (at 77 *F) | a 100 :2 %
DATA SUBJECT TO CHANGE WITHOUT NOTICE
SM830069
— 20 —
1-4 Dimensional Data
(A) Indoor Unit: KS3032, KS3632
ON
1-49/64
* Remote controller (Accessory)
6-25/32 |
añ
ay
14-9/16
@ Refrigerant gas line (Wide tubing 3/4")
@ Refrigerant liquid line (narrow tubing 3/8")
Drain hose OD 1-1/4
Dimension : inch
1-4 Dimensional Data
(B) Outdoor Unit: C3032, CL3032, C3632, CL3632
6-11/16, 26 „4-21/64
1-31/32 1-31/32_
AY Y
LL 13-38.
В
1 a
14-31/32
_ 15394 _
. 37
<
Ve <
е 7
O
q = I 1 ^^
a y
© © <
В y 8 a <
O oN oN
- +
a 6
Y Y 1 | © o
"a — LT = co” LV
Dimension : inch
© Hole for anchor bolt (4-213)
O Refrigerant tube joint (narrow tube)
Flare connection 3/8 in (8.52 mm)
® Refrigerant tube joint (wide tube)
— Flare connection 3/4 in (19.05 mm)
(O) Refrigerant tubing inlet
(© Power supply inlet
1347 CS
SM830069
1-5 Refrigerant Flow Diagram
Indoor Unit: KS3032
Outdoor Unit: C3032, C3632
KS3632 CL3032, CL3632
Wide tube
Г service valve
в
. D. o
Sr Accumulator ©
|5 | (9.05 тт) - Ss
5 © ‚8
=. = © 5
S Des y!
LU ica
D
5 5
, ri 2
© o
о Narrow tube O
Strainer service valve
O. D. — =
3/8" Sub-condenser
(9.52 mm)
1345 X_5
— 23 —
SM830069
1-6 Operating Range
- KS3032, KS3632 / C3032, C3632
Temperature Indoor Air Intake Temp. | Outdoor Air Intake Temp.
Maximum 95 °F DB / 71 °F WB
115°FDB .
Minimum 67 °F DB / 57 °F WB
67 °F DB
KS3032, KS3632 / CL3032, CL3632
Temperature Indoor Air Intake Temp. | Outdoor Air intake Temp.
Maximum 95 °F DB /71 °F WB
115 °F DB
Minimum 67 °F DB / 57 °F WB
0 °F DB
— 24 —
SM830069
EEN NN
2-1 Room Temperature Control ..................... e... onaeeneeeeeee reee neeananeneeeanenane 26
2-2 Freeze Prevention.................... eee eee re eones cer eee eneroeeeceaaeees ‚27
2-3 Outdoor Fan Speed Control ............... e... eee. eones cerrenc renacer. 28
SM830069
— 25 —
2-1 Room Temperature Control =
The Unit adjusts room temperature by turning the outdoor unit's compressor ON and OFF.
This process is controlled by the thermostat located in the remote control unit.
The figures on this and the next pages show how each part of the system performs when the
room temperature changes and the thermostat activates the compressor to start (thermo ON)
or stop (thermo OFF). Fig. 1 shows about the cooling cycle.
ROOM TEMPERATURE
MORE THAN 3 MINUTES
WITHIN 3 MINUTE
S.T.+1°F | Tee RO Tee TIT 7 CII KN
SET TEMP. T*F THERMO ON THERMO ON
(S.T.) |
THERMO OFF MORE THAN THERMO OFF
3 MINUTES 5 MINUTES
COMPRESSOR
INDOOR FAN
OUTDOOR FAN
Chart Summary and Explanations
О Once the compressor starts, it keeps running for 5 minutes.
Q Once the compressor stops, it will not start running again for 3 minutes.
Q If you change the operation mode during the cooling cycle, the control circuit stops the
compressor for 3 minutes.
О For 5 minutes after the compressor is first turned on, and for 3 minutes after it is turned off,
the compressor is not controlled by the room sensor.
O Thermo ON: When room temperature rises 1 °F above the set temperature T*, (T “+1 °F):
Compressor — ON
Q Thermo OFF: When the room temperature is equal to or below the set temperature T°:
Compressor ~ OFF
SM830069
— 26 —
2-2 Freeze Prevention
Freeze Prevention keeps the indoor heat exchange coil from freezing. Freezing reduces the
efficiency of the unit, and frost buildup on the coil blocks cool air circulation from the indoor
units fan.
FREEZE FREEZE
PREVENTION PREVENTION
MORE THAN 10 MINUTES |6 MINUTES 1OMINUTES | 6 MINUTES
INDOOR COIL >
TEMPERATURE
30°F ) temo —
(THERMO OFF)
COMPRESSOR
OUTDOOR FAN
INDOOR FAN
1029 X 5
Fig. 2
SM830069
— 97 —
2-3 Outdoor Fan Speed Control
(1) C3032, C3632 Type
In low outdoor temperature, the outdoor fan is set automatically from HIGH to LOW
to prevent the indoor heat exchanger from freezing.
When the outdoor temperature falls below 78 °F, the outdoor fan is set from HIGH to
LOW automatically. When the outdoor temperature rises to 82 °F, the outdoor fan is
set from LOW to HIGH automatically.
(2)
CL3032, CL3632 Type
In low outdoor temperature, the outdoor fan is set automatically from HIGH to MED,
LOW to prevent the indoor heat exchanger from freezing.
When the outdoor temperature falls below 77 °F, the outdoor fan is set from HIGH to
MED automatically. When the outdoor temperature rises to 81 °F, the outdoor fan is
set from MED to HIGH automatically.
When the outdoor temperature falls below 59.°F, the outdoor fan is set from MED to -
LOW automatically. When the outdoor temperature rises to 63 °F, the outdoor fan 15
set from LOW to MED automatically.
When the outdoor temperature falls below 47 °F, the outdoor upper fan is set from
LOW to OFF and Lower fan is set from LOW to MED antomatically. When the (7
outdoor temperature rises to 50 °F, the outdoor upper fan is set from OFF to LOW
and Lower fan is set from MED to LOW antomatically.
870 - = = = — —=|- — - — — - Le Le =
Upper fan: H
Lower fan: H
E Y A
oc
«<
o
<
E 8806 —— 17
or Upper fan: OFF v Ÿ Upper fan: M
= Lower fan: M ` 2 Lowerfan:M
u
230 Upper fan: L
Lowerfan: L
47 50 59 63 77 81
OUTDOOR AIR TEMPERATURE °F DB ых
Fig. 3
SM830069
— 28 -
— 29 —
SM830069
Indoor Uni
M KS3032, KS3632
3-1
(CE9ESH ‘ZEOESH) 0-00-819-892S-2-758 Y)
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yun oopmno ol
WeDelg Du 9.93 +
SM830069
—30—
Indoor Unit
@ KS3032, KS3632
« Schematic Diagram
-31—
© 854-2-5268-618-00-0 (KS3032, KS3632)
SM830069
„еее POLI sees Whey ene
Terminal Plate(4P) ! :
— F1 ' '
— 1 + -6 e 4 !
- e > + AC250V3A НОР : ’
| PAY ?
I Rv4 5] [5] : :
et | | r=
se | |
4 i THUCOIL)
| [1 Wy
, | =F
| a
| | TH2(ROOM)
| 9 —
| 2
O ET Y E WEEE Е 1 “e Mii р ml |
| COM а
|
D = mue = се = сете = сое = сана < «оно с» ие de TEO de aras qe MANDO ве ша qe amar q ава у Lx x E ___ J )
Symbols Description
FMI Indoor Fan Motor
RC1 Running Capacitor
LM Auto Louver Motor
F1 Fuse
NF Noise Filter
TRI Power Transformer
RY1,2,3,4 | Auxiliary Relay
TH1 Thermistor (Indoor Coil)
TH2 Room Thermistor
POW-KS2412BN Indoor Controller
e Terminal! Plate
Connector
Terminal
3-2 Outdoor Uni
MD C3032, C3632
(25959 ‘26050) 0-00-029-8925-2-v58 M
TINNED TIA/NHD
20-467 10169
<<<MDO UD ¡BURLO
TABLE que3
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(LHM) d9 1814 |9
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yueg
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Jun Joopus ol A OEC/ A 802 Hdl 7H09
Aiddng semod
weibeiq Bury 0110913 +
SM830069
— 32 —
Fr
3-2 Outdoor Unit
© C3032, C3632
Terminal Plate (6P)
: 2Y
e
Symbols __ Description
CM Compressor Motor
FMO1,2 Outdoor Fan Motor
ja9F01,2 | Outdoor Fan Motor Thermal Protector
52C Compressor Motor Magnetic Contactor
63PH High Pressure Switch
238 Fan Speedcontroi Thermostat
RC1, 2,3 Running Capacitor
PTC PTC Thermistor
1Y, 2Y Auxiliary Relay
CI Connector
Terminal! Plate
© 854-2-5268-620-00-0 (C3032, C3632)
-33 —
SM830069
3-2 Outdoor Uni
@ CL3032, CL3632
(2€9€10 ‘2€0€1D) 1-00-619-8925-2-v58 à
(Z£PZ19-H) 19/10:3U09
revuno |
pun JOOPULOL AQEZ/A SO0Z Hd! ZHOS
Arddns Jamog
we1Be1q Bunny auoa|3 +
SM830069
— 34 —
a mee a
3-2 Outdoor Unit
@ CL3032, CL3632
Terminal
Plate (6P)
« Schematic Diagram
POT Controller 7
« F1(A)
в
|
sec
32
81
F2 (3A)
a o a ma tó mo mt ma ms ms o e o ns o a mo ml
CR-CL2432
8
i
Temperature
Symbols Description Symbols Description
CM Compressor Motor F1,2 Fuse
CH Crankcase Heater ESPH High Pressure Switch
FMO1, 2 Outdoor Fan Motor © Termina! Plate
49F01,2 Outdoor Fan Motor Thermal Protector |] Connector
520 Compressor Motor Magnetic Contactor Terminal
PTC PTC Thermistor
TR Power Transformer
TH Thermistor (Qutdoor Temperature)
RC1,2,3 Running Capacitor
RY1,2,3 Auxiliary Relay
1Y~4Y Auxiliary Relay
CR-CL2432 | Outdoor Controller
© 854-2-5268-619-00-1 (CL3032, CL3632)
— 35 —
SM830069
(
4-1 Troubleshooting .................—....weeesseirneea een carre neon nneen aereo ene een eee 38
(1) Check before and after Troubleshooting .....................ee.....sccrennas neneacanes 38
(2) Air Conditioner does not Operate ......................e.emeneconecone nene ee 39
(3) Outdoor Unit does not Run .....................ececernessveorae oo ee neon nencenecanoneno 43
(4) Indoor Unit does not Run ...............ece=eeeeesensnssecerenena nene ranane eee een eeoecec ene 45
(5) Some Part does not Operate ..........................eemeer eee ...45
(6) Outdoor Fan does not Run .....................escecscerracanenone nacen near rene 46
(7) Outdoor Fan Speed is not Switched from High to Low even when the
Outdoor Temperature Falls below 78 °F (C3032, C3632 Type) ............. 46
(8) Outdoor Fan Speed is not Switched from High to Med even when the
Outdoor Temperature Falls below 77 °F
Outdoor Fan Speed is not Switched from Med to Low even when the
Outdoor Temperature Falls below 59 °F (CL3032, CL3632 Type) ......... 46
(9) Outdoor Fan does not Run for CL3032, CL3632 .................e..e..enencoronoas 47
(10) Compressor does not Run ....................ercrcrccacacacananace tenen eee rre recen 47
(11) Poor Cooling ..................e««-=e-eseecsrenar e error ee neerneencaanener eee eee eeenees 48
(12) Excessive Cooling ...................e-e-sreserenerre ee eecaceece narra nenaaan ea anaoe nene. 48
4-2 A Sensor is Defective..................eascoancscacononesacoronan eee necenee nea eee oeenocanenaananenos 49
4-3 Operation of Major Electrical Parts .....................===.e0eesosannarrcanaconenercene recen. 49
4-4 Checking the Electrical Componenits ....................<.<=eaueccraaricac enero 50
(1) Measurement of Insulation Resistance .............e..e..esemscocconancaon enero 50
(2) Checking the Protective Devices.........................ess0cccarooorneee Dee 51
(3) Checking the Electrical Parts .........................eeccerecece aer. 52
(4) Thermistor Characteristic Curve.....................eeeesoasmecraceroo eee 53
SM830069
— 37 -
4-1 Troubleshooting ВЕ и
(1) Check before and after Troubleshooting
Many problems may happen because of wiring or power supply problems, so you
should check these areas first. Problems here can cause false results in some of
the other tests, and so should be corrected first.
© Check power supply wiring
(a) Single-phase
QO Check that power supply wires are correctly connected to terminal No. 1
through No. 4 on the 4P terminal plate in the indoor unit and L1 and L2 on
the 6P terminal in the outdoor unit.
@ Check inter-unit wiring
U Check that inter-unit contro! wiring (AC 230 - 208 V Line voltage) is cor-
rectly connected between the indoor unit and outdoor unit.
Single-phase outdoor unit
indoor Unit Outdoor Unit
B
ES
1070: e
(ist te ; |
1070! a) ower supply
===" A
on © |
Wiri
(Line voltage) © 7 —
Oj Ground
Fig. 4 1037 MI
® Check power supply
OQ Check that voltage is within the specified range (+10 % of the rating).
Q Check that power is being supplied.
NET
If the following troubleshooting must be done with power being supplied, be
careful not to touch any uninsulated live part that can cause ELECTRIC
SHOCK. |
@ Check the lead wires and connectors in indoor and outdoor units.
Q Check that the sheath of lead wires is not damaged.
OQ Check that the lead wires are firmly connected at the terminal plate.
Q Check that the wiring is correct.
® Reference
« Condition of general cooling operation (Thermo. ON)
SWEEP ON
Indoor fan speed .... HIGH
SM830069
— 38 —
(2) Air Conditioner does not Operate
@ Circuit breaker trips (or fuse blows).
(a) When the circuit breaker is set to ON, it is tripped soon.
* There is a possibility of ground fault.
* Check insulation resistance.
If resistance value is 1 MQ or less, it is a defect of insulation.
(Example)
© Outdoor © © Indoor]
unit unit
— Circuit XL1——1 | © x11
xj L2——2 |x x| 2
— breaker Power © С С
supply 4 | х x| 4
cords Inter-unit
|
Ground power line
*Set the circuit breaker to OFF.
@ Remove power supply cords
from the terminal plate in
the outdoor unit.
» Check insulation resistance
of power supply cords.
Execute
rewiring.
OK
» Check insulation
resistance of
electrical parts
in the outdoor unit.
@ Remove inter-unit power line |
from the termina! plate in NO Insulation of
the outdoor unit. —— | outdoor unit
+ Check insulation resistance is defective.
of outdoor unit.
OK.
® Remove inter-unit power line | NO
from the terminal plate in Insulation of
the indoor unit. ——® | indoor unit
» Check insulation resistance is defective.
of indoor unit.
OK
Inter-unit power lines are
defective.
Execute
rewiring.
» Check insulation
resistance of
electrical parts
in the indoor unit.
39 —
1340 XS
SM830069
(b) Circuit breaker trips in several minutes after turning the air conditioner on.
* There is a possibility of short circuit.
* Check capacity of circuit
breaker.
Is capacity of circuit
breaker sufficient ?
NO
Replace it with a
* Check resistance of
outdoor fan motor winding.
+ Check resistance of
compressor motor winding.
* Check resistance of louver
motor winding.
suitable one.
(= larger capacity)
® Neither indoor unit nor outdoor unit runs.
A.
Power is not supplied
* Check power supply.
Is power being supplied
to outdoor unit ?
Check remote control un
* Try to run both indoor and
outdoor units with another
remote contro! unit.
y OK
The other remote control
unit is defective.
Circuit breaker
is tripped.
1055 X_S
Reset the breaker.
NO
Power failure.
it.
NO
— 40 —
Wait for recovery
or consult power
supply company.
0615 X $
—l- Refer to item C.
0616_X_S
SM830069
( ~ C. Check “Operation selector” switch in the indoor unit.
+ Has “Operation selector” Ive а IND. LAMP Ass'y or P.C.B.
switch been set to ON pe! Ass’y in the indoor unit
position ? | is defective.
y No
Set “Operation selector”
switch to ON.
Y But neither unit runs.
Switch Ass'y or P.C.B.
Ass'y in the indoor unit
is defective. |
D. Check compressor motor protectors.
(a) High pressure switch (63PH)
Disconnect the socket from 2P (WHT) connector.
* Check high pressure switch. Check the continuity between No.1 No.2 pol
( Does high pressure switch | —®» {the socket “muy Deween No.1 and No.2 poles
a actuate ? (63PH)
y YES
* ls outdoor heat exchanger
coil dirty or are there
obstacies near air suction
inlet of outdoor unit ?
y NO
* Check if outdoor fan rotates.
Refer to “Only outdoor fan
does not run.”
YES Clean heat exchanger coil
№ or remove obstacles.
E. Transformer in indoor unit.
* Check resistance of
transformer winding. (TR1)
1033. $
SM830069
— 41 —
( ~ C. Check “Operation selector” switch in the indoor unit.
+ Has “Operation selector” Ive а IND. LAMP Ass'y or P.C.B.
switch been set to ON pe! Ass’y in the indoor unit
position ? | is defective.
y No
Set “Operation selector”
switch to ON.
Y But neither unit runs.
Switch Ass'y or P.C.B.
Ass'y in the indoor unit
is defective. |
D. Check compressor motor protectors.
(a) High pressure switch (63PH)
Disconnect the socket from 2P (WHT) connector.
* Check high pressure switch. Check the continuity between No.1 No.2 pol
( Does high pressure switch | —®» {the socket “muy Deween No.1 and No.2 poles
a actuate ? (63PH)
y YES
* ls outdoor heat exchanger
coil dirty or are there
obstacies near air suction
inlet of outdoor unit ?
y NO
* Check if outdoor fan rotates.
Refer to “Only outdoor fan
does not run.”
YES Clean heat exchanger coil
№ or remove obstacles.
E. Transformer in indoor unit.
* Check resistance of
transformer winding. (TR1)
1033. $
SM830069
— 41 —
F. Check. auxiliary relay. (1Y or 2Y) —
» Check coil resistance of
auxiliary relay. |
(1Y or 2Y)
0620 X_S
G. Check fuse on the P.C.B. Ass’y in the indoor unit. -
» Check fuse on the P.C.B. + Check coil of compressor
Ass'y in the indoor unit motor magnetic contactor.
for continuity. — (520)
Y When the fuse blows. Y OK
* Check resistance of * P.C.B. Ass'y is defective.
primary and secondary
winding of transformer.
' (TR) —
OK OT
* Check resistance of indoor
fan motor winding.
(FMI)
OK
1057 xs
Fann
SM830069
_42-
(3) Outdoor Unit does not Run. Ш
A. Check COOL / FAN selector switch in the remote control unit.
+ Is COOL/FAN selector switch | NO
set to COOL ?
B. Check set temperature.
Try to lower set
temperature by Temperature
setting button “COOLER”.
y YES
* Set “Operation selector”
switch to TEST in the
indoor unit.
Y Outdoor unit runs.
( \ Is room temperature too
low ?
Y NO
* Try to run both indoor and
outdoor units with another
remote control unit.
y OK
The other remote control
unit is defective.
(Room sensor in the remote
control unit is defective.)
0624 X $
Set to COOL.
0623 X 5
SM830069
C. Check compressor motor magnetic contactor. —
* Check coil resistance of
compressor motor magnetic
contactor. (520)
1035 X_S
D. Check indoor unit P.C.B.
* Check P.C.B. Ass'y.
Y
* Check voltage between
terminals No.2 and No.4 at
terminal plate.
Y No voltage appears.
P.C.B. Ass'y is defective. a
0628 X 5
E. Check outdoor unit P.C.B. (CL3032, CL3632 Type)
* Check P.C.B. Ass'y.
Y
* Check voltage between
terminals L1 and L2 at
terminal plate.
Y No voltage appears.
P.C.B. Ass’y is defective.
1036_X_5
SM830069
(4) Indoor Unit does not Run.
(Indoor fan and louver motor do not run.)
P.C.B. Ass'y is defective.
0630_X_S
Indoor fan does not run.
(5) Some Part does not Operate.
+ Check fan rotation.
Rotate the fan gently once
or twice by hand.
Fan cannot
be rotated.
* Check resistance of fan
motor winding.
y OK
* Check fan motor capacitor.
y OK
Relay RY1 or RY2 on the
Р.С.В. Ass'y is defective.
B. Louver motor does not run.
Check resistance of
louver motor winding.
y OK
P.C.B. Ass'y or remote
contro! unit is defective.
0632 X_S
Check fan casing
for foreign matter
on the inside.
== |
Remove foreign
matter or repair.
Fan motor burnout
or foreign matter
in bearing.
—
Repair or replace.
0631_X 5
SM830069
(6) Outdoor Fan does not Run.
* Check fan casing )
for foreign matter |-#-| Remove foreign
Fan cannot on the inside. matter or repair.
- Check fan rotation. be rotated. |
Rotate the fan gently once
or twice by hand. Fan motor bumout
or foreign matter [—»] Repair or replace.
in bearing.
* Check resistance of fan
motor winding.
y OK
* Check fan motor capacitor
« Check continuity between
terminals on the compressor
motor magnetic contactor.
0633 X 5
(7) Outdoor Fan Speed is not Switched from High to Low even when the Outdoor
Temperature Falls below 78 °F. (C3032, C3632 Type)
» Check the thermostat (23S).
1037 X 5
(8) Outdoor Fan Speed is not Switched from High to Med even when the Outdoor
Temperature Falis below 77 °F.
Outdoor Fan Speed is not Switched from Med to Low even when the Outdoor
Temperature Falls below 59 °F. (CL3032, CL3632 Type)
» Check outdoor unit P.C.B.
Ass'y
Y OK
* Check resistance of outdoor
temp sensor.
0722 XS
SM830069
— 46 —
(9) Outdoor Fan does not Run for CL3632.
* Check fuse on PCB Ass'y in
outdoor unit for continuity.
| If fuse blows,
* Check resistance of primary —
winding of transformer. (TR)
1038_X_S
(10) Compressor does not Run.
* Check compressor motor capacitor
(RC).
| OK
1
» Check resistance of compressor
motor winding.
» Check PTC.
—47—
Wait for 30 minutes until com-
pressor has cooled.
| Compressor runs.
Compressor internal thermal
protector is operated.
|
* Check power supply voltage.
Is voltage abnormally low?
y
* Is outdoor heat exchanger coil dirty
or are there obstacies near air
suction inlet?
1039 X 5
SM830069
(11) Poor Cooling.
Check installation position
of remote control unit.
* Does cool air from air condi-
tioner reach remote control
unit directiy ?
YES
Change installation
position of remote
* ls wide tube between indoor unit
and outdoor unit insulated ?
NO
control unit.
_ | Insulate wide tube and
—p then execute taping with
| YES
Temperature
difference
« Measure temperatures of suction
and discharge air of indoor unit.
is small.
Temperature difference between
suction and discharge air is
large enough (Approx. 10 deg. or more).
« Check clogging of air
filter.
narrow tube.
Possibility of Charge
refrigerant refrigerant
shortage. (R22).
+ Is fan speed set to LOW ?
YES
Air filter is clogged.
1 Clean filter.
Set fan speed to either
Review cooling load estimate,
if performance of air conditioner
is normal.
HIGH or MEDIUM.
Reduce cooling load or
(12) Excessive Cooling.
* The set temperature is too low.
YES
replace the unit with
higher cooling capacity.
1040 X 5
| Set the temperature to
p= higher value using
- Is the remote control unit installed
at a place where it can
detect the room temperature
properly ?
NO
temperature setting
button of the remote
control unit.
Change installation
position of the remote
control unit.
0637 Х 5
SM830069
e
a
4-2 A Sensor is Defective.
OD Indoor (heat exchanger) coil temp. Sensor is defective.
(a) Open (=No continuity in sensor)
Compressor and outdoor fan repeat ON for 10 minutes and OFF for 6 minutes
when sensor opens.
(b) Short
“Freeze Prevention” does not operate when dehumidified water is frozen on the
indoor coil.
+
(a) Open (=No continuity in sensor)
Neither outdoor fan nor compressor runs.
(b) Short
Room temp. Sensor (in the remote contro! unit) is defective.
Outdoor fan and compressor do not stop. — Excessive cooling.
4-3 Operation of Major Electrical Parts
| Operation Mode Operation Indoor unit and Remote Control unit Oudoor unit
Indicator lamps Fan | Fan | Compressor
(Function) Temp. Cool | Timer Cry saver Sweep
Manuel Thermo.ON O O O O O
| Thermo.OFF O O O
Night Thermo.ON O O _0 о | © O
Cool | setback Thermo.OFF O O O
„Ing Timaer ON Timer O
(set) OFF Timer O O O о | © O
Freeze prevention O O | O
Fan O O
Sweep Cool O | ©* Oo" O O" O"
Fan O O
Flap
Stop Cool O | ©* or O O" Oo"
Fan O O
NOTE O" Refer to Cooling Mode.
—-49—
SM830069
4-4 Checking the Electrical Components
(1) Measurement of Insulation
Resistance
« The electrical insulation is acceptable when the
resistance exceeds 1 MQ.
© Power Supply Wires
Clamp the earthed wire of the Power Supply wires
with a lead clip of the insulation resistance tester and
measure the resistance by placing a probe on either
of the power wires. (Fig. 5) |
Then measure the resistance between the earthed
wire and the other power wires. (Fig. 5)
@ Indoor Unit
Clamp an aluminum plate fin or copper tube with the
lead clip of the insulation resistance tester and
measure the resistance by placing a probe on the
terminal plate (Fig. 6)
@ Outdoor Unit
Measure the resistance by placing a probe on the
terminal plate in the same manner as explained
above ©. (Fig. 6)
@ Measurement of Insulation Resistance for
Electrical parts
» Disconnect the connector of the desired electric
part from terminal plate, P.C.B. Ass'y, etc. (Fig. 7)
- Similarly, disconnect the lead wires from
compressor, capacitor, etc. (Fig. 8)
« Measure the resistance in the same manner as
illustrated on the right.
Refer to Electrical Wiring Diagram.
If the probe does not enter the hole because the
hole is too narrow, use a probe with a thinner pin.
Earthed wire
Probe
insulation
tester ‚ |
0638_X_S
Terminal plate |
olle
Clip
Copper
tube or
metallic part
о 0639 _X $
| CG E =<
Clip | |
``”
Copper
tube or —
metallic part |
tester ‚ |
060_X_5
From fan motor,
compressor and other.
parts.
Metallic
part
Ci p
Insulation
tester 0641 _X.S x ;
SM830069
— 50 —
= (2) Checking the Protective Devices
» Disconnect the connector, which consists of P (plug) and S (socket) when you want to
check the protective device.
- Then check continuity among plug's (and/or socket's) terminal as in Fig. 9.
* Normality of the protective device can be judged by the following table.
The Protective Device is proved normal if there is a continuity between terminals.
Multimeter
<
Ri
0642 X_5
Fig. 9
O © Indoor fan motor thermal protector (49FI) ...... Indoor unit
o « Disconnect the connector which leads to the indoor fan motor (FMI).
e Check the socket's terminais.
@ Compressor motor thermal protector ...... Outdoor unit
+ Disconnect the wires from terminals of compressor.
» Check the terminals of compressor.
© Outdoor fan motor thermal protector (49FO) ...... Outdoor unit
- Disconnect both the connector which leads to the outdoor fan motor (FMO).
* Check sockets terminal.
SM830069
— 51 —
(3)
Checking the Electrical Parts
Power transformer (TR1) ................. Indoor unit *Measure the coil resistance.
- Primary 230-208 V ; Measure the resistance between two WHT lead wire terminals
of socket connected to power transformer.
- Secondary 10.6 V ; Measure the resistance between two BRN lead wires.
Refer to “1-3—(A) Other component specifications”.
Power transformer (TR) ................. Outdoor unit *Measure the coil resistance.
- Primary 230-208 V ; Measure the resistance between two WHT lead wire terminals
of socket jointed to power transformer.
* Secondary 14V Measure the resistance between two BRN lead wires.
Refer to “1-3-(B) Other component specifications”.
Indoor fan motor (FMI) ............... Indoor unit *Measure the coil resistance.
« Measure the resistance between each terminal of the socket connected to the
indoor fan motor.
Refer to “1-2—(A) Major component specifications”.
Outdoor fan motor (FMO) ........... Outdoor unit *Measure the coil resistance.
« Measure the resistance in the same manner as explained above ©.
Refer to “1-2-—(B) Major component specifications”.
Motor capacitor ............ Both in indoor and outdoor unit
Remove the lead wires from the
capacitor terminals, and then place a
probe on the capacitor terminals as
shown in Fig. 10. Observe the
deflection of the pointer, setting the
resistance measuring range of the Les
multimeter to the maximum value. /
* The capacitor is “good” if the pointer
bounces to a great extent and then
gradually returns to its original posi-
tion.
NOTE
The range of deflection and the deflection
time differ according to the capacity of the
capacitor.
Multimeter
322
Li
à
re 2
Compressor motor
capacitor
Fan motor
capacitor
Fig. 10 xs
SM830069
= 52 —
a ® Continuity of fuse on P.C.B. Ass'y
he
* Check for continuity using a multimeter as
shown in Fig. 11.
NOTE
Method Used to Replace Fuse on PCB Ass'y
1.
Remove the PCB Ass'y from the electrical compo-
nent box.
. Remove the fuse from PCB Ass'y using pliers while
heating the soldered leads on the back side of the
PCB Ass'y with a soldering iron (30W or 60W).
(Fig. 12) |
. For replacement, insert a fuse of the same rating to
the intended position and solder it.
(Allow time to radiate heat during soldering so that
the fuse does not melt.)
When replacing the fuse, be
CAUTION sure not to break down the
varistor.
( > (4) Thermistor Characteristic Curve
M Room temp. sensor
(KTEC - 35)
—
>
Resistance (ko)
N © E a © N O ©
«=
50 59 68 77 86 95 104
r—si o
Temperature (*F)
1044 M!
Resistance (kQ)
40
35
30
25
20
15
10
Soldering iron
Pliers
Fuse
1042 X_S
Fig. 11
Varistor
1043 X_S
Fig. 12
@ Coil sensor
(PBC-41E)
\
N
I
- 53 —
A
5
14 23 32 41 50 59 68
——]——];].— ie
Temperature (°F) 1045_M 1
SM830069
SANYO FISHER Service Company
CENTRAL REGION
1165 Aligood Road, Suite 22
Marietta, GA 30062
Phone: (770) 509-5230
Fax: (770) 579-2860
Jan. / '99 Printed in U.S.A.