Sanyo CH2432 Service manual

SERVICE MANUAL

XHS2432 / CH2432

XHS3632 / CH3632

FILE NO.

SPLIT SYSTEM AIR CONDITIONER

INDOOR MODEL No.

XHS2432

XHS3632

PRODUCT CODE No.

854 013 40

854 015 45

OUTDOOR MODEL No.

CH2432

CH3632

PRODUCT CODE No.

854 013 42

854 014 57

Indoor Unit Outdoor Unit

XHS2432 CH2432

Section

1

2

3

4

85464849176000

XHS3632 CH3632

REFERENCE NO. SM 830076

Important

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 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.

ⓦ

Observe all local, state, and national electrical codes.

ⓦ

Pay close attention to all warning and caution notices given in this manual.

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION

This symbol refers to a hazard or 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 outlet or your certified dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for 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 grounding can cause accidental injury or death.

• Ground the unit following local electrical codes.

• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

When Transporting

……………………………………………………………………

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

……………………………………………………………………

…In 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.

…In an area with High Winds

Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle.

…In a Snowy Area (for Heat Pump-type Sys-tems)

Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

……………………………………………………………………

• 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

……………………………………………………………………

• Turn 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.

• Clean 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.

SM830076

– 2 –

WHO SHOULD USE THIS MANUAL

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 information 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.

TABLE OF CONTENTS

1. SPECIFICATIONS ......................................................................................................... 6

1-1 Unit Specifications ................................................................................................ 7

1-2 Major Component Specifications ........................................................................11

(A) Indoor Unit ..................................................................................................... 11

(B) Outdoor Unit .................................................................................................. 13

1-3 Other Component Specifications ........................................................................15

(A) Indoor Unit ..................................................................................................... 15

(B) Outdoor Unit .................................................................................................. 17

1-4 Dimensional Data ................................................................................................ 19

(A) Indoor Unit ..................................................................................................... 19

(B) Outdoor Unit .................................................................................................. 21

1-5 Refrigerant Flow Diagram ................................................................................... 23

1-6 Operating Range ................................................................................................. 23

2. PROCESSES AND FUNCTIONS ................................................................................25

2-1 Room Temperature Control ................................................................................26

(A) Cooling .......................................................................................................... 26

(B) Heating .......................................................................................................... 27

2-2 Cold Draft Prevention (Heating Cycle) ................................................................28

2-3 Automatic Fan Speed (Indoor Unit) .....................................................................29

(A) Cooling .......................................................................................................... 29

(B) Heating .......................................................................................................... 29

2-4 Outdoor Fan Speed Control ................................................................................30

(A) Cooling .......................................................................................................... 30

(B) Heating .......................................................................................................... 30

2-5 Freeze Prevention (Cooling) ............................................................................... 31

2-6 Condensing Temperature Control (Cooling) ...................................................... 32

2-7 Overload Protection (Heating)............................................................................. 33

2-8 Discharge Temperature Control (Cooling and Heating) ..................................... 34

SM830076

– 3 –

2-9 Auto. Mode for Automatic Heating/Cooling Switching ........................................ 35

2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating).............................. 37

2-11 4-Way Valve, Solenoid Control ...........................................................................38

(A) Normal Control Mode .................................................................................... 38

(B) AUTO Control Mode ...................................................................................... 39

2-12 Automatic Restart after Power Interruption ........................................................ 39

2-13 Electronic Expansion Valve ................................................................................40

2-14 Compressor Discharge Gas Temperature ......................................................... 40

(A) Cooling .......................................................................................................... 40

(B) Heating (Except During Defrosting) ...............................................................40

2-15 Compressor Current Detection Circuit ................................................................41

2-16 Electronic Expansion Valve Control ....................................................................42

2-17 Voltage Detection Control ................................................................................... 43

3. ELECTRICAL DATA .................................................................................................... 45

3-1 Indoor Unit (Electric Wiring Diagram, Schematic Diagram) ............................... 46

3-2 Outdoor Unit (Electric Wiring Diagram, Schematic Diagram)............................. 48

4. SERVICE PROCEDURES ........................................................................................... 53

4-1 Troubleshooting .................................................................................................. 54

4-2 Checking the Electrical Components ..................................................................87

– 4 –

SM830076

Introduction: Read Me First!

WHAT IS IN THIS MANUAL

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 explanations to help you find and repair problems.

❑ 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.

❑ 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.

❑ 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.

❑ 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.

SM830076

– 5 –

1. SPECIFICATIONS

1-1 Unit Specifications ...........................................................................................7

1-2 Major Component Specifications .................................................................. 11

(A) Indoor Unit ................................................................................................11

(B) Outdoor Unit .............................................................................................13

1-3 Other Component Specifications .................................................................. 15

(A) Indoor Unit ................................................................................................15

(B) Outdoor Unit .............................................................................................17

1-4 Dimensional Data ...........................................................................................19

(A) Indoor Unit ................................................................................................19

(B) Outdoor Unit .............................................................................................21

1-5 Refrigerant Flow Diagram ............................................................................. 23

1-6 Operating Range ............................................................................................23

1

– 6 –

SM830076

1. Specifications

1-1 Unit Specifications

MODEL No.

Indoor Unit

Outdoor Unit

POWER SOURCE

PERFORMANCE

Capacity* BTU / h

(17

°

F)**

Moisture removal (High)

Air circulation (Hi)

S.E.E.R. (H.S.P.F.)

ELECTRICAL RATINGS

Voltage rating

Available voltage range

Running amperes

Max. running amperes

Power input*

Pints / h cu.ft. / min.

BTU / Wh

(17

°

F)**

Buck-up heater

Maximum fuse size

FEATURES

Controls

Fan speeds Indoor / Outdoor

Timer

Air deflection

Air filter

Horizontal / Vertical

Operation sound

Hi / Me / Lo

Refrigerant control

REFRIGERANT PIPING

Limit of piping length

Indoor

Outdoor - Hi

Limit of piping length at shipment

Limit of elevation difference between the two units

Refrigerant piping

Flare type

Narrow pipe

Wide pipe ft.

kW

A dB - A dB - A

(m) ft.

(m) ft.

(m) in. (mm) in. (mm)

VAC

VAC

A

A

W

24,000

8.6

10.0

XHS2432

CH2432

230 - 208 V / 1 Phase / 60 Hz

Cooling Heating

23,400 25,000

16,400

24,300

15,800

8.4

—

540 / 510

10.2

(7.0) (7.0)

230

11.2

—

2,450

208

187 - 253

11.6

—

2,350

— —

230

11.7

—

2,500

2,150

—

208

187 - 253

12.3

—

2,450

2,020

—

30

Microprocessor

3 and Automatic control / 2 (Auto)

ON / OFF 24-hours & Program

— / Automatic

Washable, easy access, long life fiter (2,500 hr)

37 / 35 / 31

53

Electronic Refrigerant Control Valve

165 (50)

100 (30)

Outdoor unit is higher than indoor unit: 165 (50)

Outdoor unit is lower than indoor unit: 100 (30)

1 / 4 (6.35)

3 / 4 (19.05)

1

2

3

4

– 7 –

SM830076



1

2

DIMENSIONS & WEIGHT

Unit dimensions

Net weight

Indoor grille dimensions

PNR-XHS2432

Net weight

Indoor / Outdoor unit

Package dimensions

Shipping weight

Shipping volume

Indoor grille

Package dimensions

PNR-XHS2432

Shipping weight

Shipping volume

Height

Width

Depth

Height

Width

Depth

Height

Width

Depth

Height

Width

Depth in. (mm) in. (mm) in. (mm) lbs. (kg) in. (mm) in. (mm) in. (mm) lbs. (kg) in. (mm) in. (mm) in. (mm) lbs. (kg) cu.ft. (m 3 ) in. (mm) in. (mm) in. (mm) lbs. (kg) cu.ft. (m 3 )

Indoor unit

9-27/32 (250)

29-29/32

29-29/32

49

3-1/16

33-27/32

(760)

(760)

(22)

(78)

(860)

33-27/32

11

11-6/32

32-14/32

32-25/32

60

6.9

4-3/32

38-2/32

39-11/32

18

3.5

(0.195)

(104)

(967)

(999)

(8)

(0.100)

(860)

(5)

(284)

(824)

(833)

(27)

Outdoor unit

28-30/32 (735)

37

13-12/32

157

(940)

(340)

(71)

32-17/32

40

16-12/32

170

12.3

(826)

(1,016)

(416)

(77)

(0.349)

DATA SUBJECT TO CHANGE WITHOUT NOTICE

Cooling :

Rating conditions (*) : Room temperature 80

°

F DB / 67

°

F WB, Ambient temperature 95

°

F DB / 75

°

F WB

Heating :


°

F DB / 60

°


°

F DB / 43

°

F WB

Low temp conditions (**) : Room temperature 70 ° F DB / 60 ° F WB, Ambient temperature 17 ° F DB / 15 ° F WB

3

4

– 8 –

SM830076



MODEL No.

Indoor Unit

Outdoor Unit

POWER SOURCE

PERFORMANCE

Capacity* BTU / h

(17

°

F)**

Moisture removal (High)

Air circulation (Hi)

S.E.E.R. (H.S.P.F.)

ELECTRICAL RATINGS

Voltage rating

Available voltage range

Running amperes

Max. running amperes

Power input*

Pints / h cu.ft. / min.

BTU / Wh

(17

°

F)**

Buck-up heater

Maximum fuse size

FEATURES

Controls

Fan speeds Indoor / Outdoor

Timer

Air deflection

Air filter

Horizontal / Vertical

Operation sound

Hi / Me / Lo

Refrigerant control

REFRIGERANT PIPING

Limit of piping length

Indoor

Outdoor - Hi

Limit of piping length at shipment

Limit of elevation difference between the two units

Refrigerant piping

Flare type

Narrow pipe

Wide pipe ft.

kW

A dB - A dB - A

(m) ft.

(m) ft.

(m) in. (mm) in. (mm)

VAC

VAC

A

A

W

34,500

11.1

10.7

XHS3632

CH3632

230 - 208 VAC / 1 Phase / 60 Hz

Cooling Heating

33,500 37,500

25,000

36,500

23,500

11.1

—

980 / 880

11.0

(7.0) (7.0)

230

15.4

—

3,350

208

187 - 253

15.8

—

3,200

— —

230

18.2

—

3,850

3,150

—

208

187 - 253

19.3

—

3,750

2,950

—

30

Microprocessor

3 and Automatic control / 2 (Auto)

ON / OFF 24-hours & Program

— / Automatic

Washable, easy access, long life fiter (2,500 hr)

43 / 40 / 36

56

Electronic Refrigerant Control Valve

165 (50)

100 (30)

Outdoor unit is higher than indoor unit: 165 (50)

Outdoor unit is lower than indoor unit: 100 (30)

3 / 8 (9.52)

3 / 4 (19.05)

1

2

3

4

– 9 –

SM830076



1

2

DIMENSIONS & WEIGHT

Unit dimensions

Net weight

Indoor grille dimensions

PNR-XHS3632

Net weight

Indoor / Outdoor unit

Package dimensions

Shipping weight

Shipping volume

Indoor grille

Package dimensions

PNR-XHS3632

Shipping weight

Shipping volume

Height

Width

Depth

Height

Width

Depth

Height

Width

Depth

Height

Width

Depth in. (mm) in. (mm) in. (mm) lbs. (kg) in. (mm) in. (mm) in. (mm) lbs. (kg) in. (mm) in. (mm) in. (mm) lbs. (kg) cu.ft. (m 3 ) in. (mm) in. (mm) in. (mm) lbs. (kg) cu.ft. (m 3 )

Indoor unit

11-1/32 (280)

41-11/32

29-29/32

60

3-1/6

33-27/32

(1,050)

(760)

(27)

(78)

(1,150)

33-27/32

15

12-14/32

43-27/32

32-25/32

71

10.3

4-3/32

49-16/32

39-11/32

29

4.6

(860)

(7)

(316)

(1,114)

(833)

(32)

(0.293)

(104)

(1,257)

(999)

(13)

(0.131)

Outdoor unit

48-20/32 (1,235)

37

13-12/32

203

(940)

(340)

(92)

52-7/32

40

16-12/32

227

19.8

(1,326)

(1,016)

(416)

(103)

(0.56)


Cooling :


°

F DB / 67

°


°

F DB / 75

°

F WB

Heating :


°

F DB / 60

°


°

F DB / 43

°

F WB

Low temp conditions (**) : Room temperature 70 ° F DB / 60 ° F WB, Ambient temperature 17 ° F DB / 15 ° F WB

3

4

– 10 –

SM830076


1-2 Major Component Specifications

(A) Indoor Unit

MODEL No.

Source

Remote controller (Accessory)

Controller P. C. B Ass'y

Control circuit fuse

Controller Ass'y

Fan (Number … diameter)

Fan motor

Model

Source

No. of pole … r.p.m. (230 V, High)

Nominal output

Coil resistance

(Ambient temperature 68

°

F) in.

(mm) rpm

W

Ω

Safety device

Operating temperature Open

°

F

Close

°

F

VAC,

µ

F Run capacitor

Electronic expansion valve

Coil

Coil resistance (at 20

°

C)

Ω

Valve body

Heat exchanger

Coil

Rows … Fins per inch

Face area

Panel

Model No.

Indicator Lamp Ass'y

Auto louver motor

Auto louver motor … Rated

Coil resistance (Ambient temperature 77

°

F) ft.

2 (m 2 )

V, W, rpm

Ω

XHS2432

230 - 208 VAC / 1 phase / 60 Hz

RCS - 5HPS4U

CR - THS2432

250 VAC, 3 A

CR - 3XHS

Turbo (1…19-9/32 (490))

SFG6X - 41A5P

230 - 208 V / 1 phase / 60 Hz

6 … 451

40

BRW - WHT : 114.0

, ORG - YEL : 66.4

WHT - VLT : 23.9

, WHT - PNK : 77.4

VLT - ORG : 12.4

, YEL - BLK : 82.1

266

±

14.4

174.2

±

27

440 V , 4

µ

F

DKV - MOZS582E0

ORG - GRY : 46

RED - GRY : 46 ,

, YEL

BLK

IKV - 24D12

- GRY

- GRY

:

:

46

46

Aluminum plate fin / Copper tube

2 … 14.9

3.18 (0.295)

PNR - XHS2432

IND - 3THS

MT8 - 3C

240 VAC , 3 W , 3 rpm

16.430

Ω ±

8 %


1

2

3

4

SM830076

– 11 –


1

2

3

4


(A) Indoor Unit

MODEL No.

Source

Remote controller (Accessory)

Controller P. C. B Ass'y

Control circuit fuse

Controller Ass'y

Fan (Number … diameter)

Fan motor

Model

Source

No. of pole … r.p.m. (230 V, High)

Nominal output

Coil resistance


°

F) in.

(mm) rpm

W

Ω

Safety device

Operating temperature Open

°

F

Close

°

F

VAC,

µ

F Run capacitor

Electronic expansion valve

Coil


°

C)

Ω

Valve body

Heat exchanger

Coil

Rows … Fins per inch

Face area

Panel

Model No.


Auto louver motor

Auto louver motor … Rated


°

F) ft.

2 (m 2 )

V, W, rpm

Ω

XHS3632

230 - 208 VAC / 1 phase / 60 Hz

RCS - 5HPS4U

CR - THS2432

250 VAC, 3 A

CR - 3XHS

Turbo (1…19-9/32 (490))

SFG6X - 61A3P

230 - 208 V / 1 phase / 60 Hz

6 … 560

60

BRW - WHT : 71.1

WHT - VLT : 8.7

,

,

ORG - YEL

VLT - PNK

:

:

22.7

43.2

VLT - ORG : 13.3

, YEL - BLK : 54.32

266

±

14.4

174.2

±

27

440 V , 6

µ

F

EKV - MOZS584E0

ORG - GRY : 46

RED - GRY : 46 ,

, YEL

BLK

HKV - 30D16

- GRY

- GRY

:

:

46

46


2 … 14.9

5.17 (0.48)

PNR - XHS3632

IND - 3THS

MT8 - 3C

240 VAC , 3 W , 3 rpm

16.430

Ω ±

8 %


SM830076

– 12 –



(B) Outdoor Unit

MODEL No.

Source

Controller P.C.B. Ass'y

Control circuit fuse

Compressor

Model

Source

Nominal output

Compressor oil


°

F)

Safety device

Overload relay models

Operating temperature

Operating ampere (at 77

°

F)

Run capacitor

Crank case heater

Refrigerant amount charged at shipment

High pressure switch

Set pressure

Open

°

F

Close

°

F

A

VAC,

µ

F

VAC, lbs.

W

(kg)

OFF lb/in 2 (kg/cm 2 )

ON lb/in 2 (kg/cm 2 )

W cc

Ω

Fan

Number...diameter

Fan speeds

Fan motor

Model

Source

No. of pole ..... rpm (230 V, High)

Nominal output

Coil resistance


°

F)

Safety device

Operating temperature in.

(mm)

W

Ω

Open

°

F

Close

°

F

VAC,

µ

F Run capacitor

Heat exchange

Coil

Rows ..... Fins per inch

Face area ft.

2 (m 2 )

CH2432

230 - 208 VAC / 1 phase / 60 Hz

CR - CH2432 (Microprocessor)

250 VAC, 3 A

Rotary (Hermetic)

C - 2R160H6T

230 - 208 VAC / 1 phase / 60 Hz

1,700

800

C – R : 0.885 , C – S : 1.773

Internal type

—

297

±

9

198

±

20

—

400 VAC, 40

µ

F

230 VAC, 30 W

R22 : 6.17 (2.8)

ACB - 1UB11

426.6

+ 28.44

+ 7.11

+ 2.0

(30 )

341.3

±

28.44 (24

±

2.0)

Propeller

1 ... 18 - 3/32 (460)

2 (AUTO)

KFC6T - 91D6P

230 - 208 VAC / 1 phase / 60 Hz

6 ... 879

110

BRN – WHT : 67.14 , VLT – YEL : 11.42

WHT – VLT : 64.85 , YEL – PNK : 10.60

Internal type

248

±

9

171

±

27

440 VAC, 4

µ

F


2 ... 14.1

6.78 (0.63)


1

2

3

4

SM830076

– 13 –


1

2

3

4



MODEL No.

Source

Controller P.C.B. Ass'y

Control circuit fuse

Compressor

Model

Source

Nominal output

Compressor oil


°

F)

Safety device

Overload relay models

Operating temperature

Operating ampere (at 77

°

F)

Run capacitor

Crank case heater

Refrigerant amount charged at shipment

High pressure switch

Set pressure

Open

°

F

Close

°

F

A

VAC,

µ

F

VAC, lbs.

W

(kg)

OFF lb/in 2 (kg/cm 2 )

ON lb/in 2 (kg/cm 2 )

W cc

Ω

Fan

Number...diameter

Fan speeds

Fan motor

Model

Source

No. of pole ..... rpm (230 V, High)

Nominal output

Coil resistance


°

F)

Safety device

Operating temperature in.

(mm)

W

Ω

Open

°

F

Close

°

F

VAC,

µ

F Run capacitor

Heat exchange

Coil

Rows ..... Fins per inch

Face area ft.

2 (m 2 )

CH3632

230 - 208 VAC / 1 phase / 60 Hz

CR - CH2432 (Microprocessor)

250 V, 3 A

Rotary (Hermetic)

C - R221H6R

230 - 208 VAC / 1 phase / 60 Hz

2,200

1,500

C – R : 0.549 , C – S : 1.525

Internal type

—

320

±

9

189

±

20

—

400 VAC, 40

µ

F

230 VAC, 30 W

R22 : 8.82 (4.0)

ACB - 1UB11

426.6

+ 28.44

+ 7.11

+ 2.0

(30 )

341.3

±

28.44 (24

±

2.0)

Propeller

2 ... 18 - 3/32 (460)

2 (AUTO)

KFC6T - 91D6P

×

2

230 - 208 V / 1 phase / 60 Hz

6 ... 879

110

×

2

BRN – WHT : 67.14 , VLT – YEL : 11.42

WHT – VLT : 64.85 , YEL – PNK : 10.60

Internal type

248

±

9

171

±

27

440 VAC, 4

µ

F

×

2


2 ... 14.1

11.63 (1.08)


SM830076

– 14 –


1-3 Other Component Specifications

(A) Indoor Unit

MODEL No.

Power Transformer

Rated Primary

Secondary

Capacity

Coil resistance

(Ambient temprature 77

°

F)

Thermistor cut off temperature

Ω

°

F

Thermistor (Coil sensor) : TH2, 3

Coil resistance k

Ω

Thermistor (Room sensor) : TH1

Coil resistance

Drain pump

Rated

Float switch

MAX Rated (Contact rated)

Solenoid control valve or coil

Solenoid control valve

Solenoid coil


Synchronized Motor k

Ω

WHT - WHT : 101 , BRN - BRN : 0.42

14

°

F : 23.7

23

°

F : 18.8

32

°

F : 15.0

32

°

F : 16.5

41

°

F : 12.8

50

°

F : 10.0

68

°

F : 6.3

86

°

F : 4.0

XHS2432

ATR – II174B

220 VAC, 60 Hz

14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA

—

277

PBC - 41E - S26

,

,

,

KTEC - 35 - S6

41

50

59

°

°

°

F : 12.1

F :

F :

9.7

8.0

,

,

,

,

,

WP20SL - 21

230 / 208 VAC, 12.5 W

104

°

F : 2.7

113

°

F : 2.2

122

°

F : 1.8

131

°

F : 1.5

FS - 0218 - 102

50 W, DC 5V, 0.1 mA

IKV - 24D12

DKV - MOZS582E0

IND - 3THS

MT8 - 3C

1

2

3

4

– 15 –

SM830076


1

2

3


(A) Indoor Unit

MODEL No.


Rated Primary

Secondary

Capacity

Coil resistance

(Ambient temprature 77

°

F)

Thermistor cut off temperature

Ω

°

F


Coil resistance k

Ω

Thermistor (Room sensor) : TH1

Coil resistance

Drain pump

Rated

Float switch

MAX Rated (Contact rated)



Solenoid coil


Synchronized Motor k

Ω

WHT - WHT : 101 , BRN - BRN : 0.42

14

°

F : 23.7

23

°

F : 18.8

32

°

F : 15.0

32

°

F : 16.5

41

°

F : 12.8

50

°

F : 10.0

68

°

F : 6.3

86

°

F : 4.0

XHS3632

ATR – II174B

220 VAC, 60 Hz

14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA

—

277

PBC - 41E - S36

,

,

,

KTEC - 35 - S6

41

50

59

°

°

°

F : 12.1

F : 9.7

F : 8.0

,

,

,

,

,

WP20SL - 21

230 / 208 VAC, 12.5 W

104

°

F : 2.7

113

°

F : 2.2

122

°

F : 1.8

131

°

F : 1.5

FS - 0218 - 103

50 W, DC 5V, 0.1 mA

HKV - 30D16

EKV - MOZS728E0

IND - 3THS

MT8 - 3C


4

– 16 –

SM830076




MODEL No.

Compressor Motor Magnetic Contactor

Coil rated


°

F)

Contact rated (Main)

Ω

Contact rated (Auxiliary)

Power Relay

Coil rated


°

F)

Contact rated k

Ω


Rated

Primary

Secondary

Capacity


°

F )

Thermal cut off temperature


Coil resistance k

°

Ω

F

Ω

Thermistor (Comp. discharge gas sensor) : TH8

Coil resistance k

Ω

CH2432

FMCA - 1UL

240 VAC, 60 Hz

580

±

15 %

230 VAC, 20 A

230 VAC, 3 A

HH62S

240 VAC, 60 Hz

17.2

220 VAC, 5 A

ATR - I65C

220 VAC, 60 Hz

14 V, 0.4 A

WHT – WHT : 395.5

5.6 VA

, BRN – BRN : 2.19

PBC - 41E - S4

14

°

F : 23.7

23

°

F : 18.8

32

°

F : 15.0

41

°

F : 12.1

266

,

,

,

,

,

PBC - 41E - S26

50

°

F : 9.7

68

°

F : 6.5

86

°

F : 4.4

104

°

F : 3.1

113

°

F : 2.6

140

158

167

176

185

°

°

°

°

°

F : 13.8

F :

F :

F :

F :

9.7

8.2

7.0

5.9

PTC - 51H - S1

,

,

,

,

, 194

212

230

248

266

°

°

°

°

°

F : 5.1

F : 3.8

F : 2.8

F : 2.2

F : 1.7



Solenoid coil

Thermistor (PTC)

Rated

Max. voltage

Max. ampere

Resistance (at 77

°

F)

Ω

V 389100

LB 59005

TDK – 101YV

400 VAC

11.5 A

+ 30

100 %


1

2

3

4

SM830076

– 17 –


1

2

3

4



MODEL No.

Compressor Motor Magnetic Contactor

Coil rated


°

F)

Contact rated (Main)

Ω

Contact rated (Auxiliary)

Power Relay

Coil rated


°

F)

Contact rated k

Ω


Rated

Primary

Secondary

Capacity


°

F )

Thermal cut off temperature


Coil resistance k

°

Ω

F

Ω

Thermistor (Comp. discharge gas sensor) : TH8

Coil resistance k

Ω

CH3632

FMCA - 1SUL

240 VAC, 60 Hz

588

±

10 %

240 VAC, 26 A

240 VAC, 3 A

HH62S

240 VAC, 60 Hz

17.2

220 VAC, 5 A

ATR - I65C

220 VAC, 60 Hz

14 V, 0.4 A

WHT – WHT : 395.5

5.6 VA

, BRN – BRN : 2.19

PBC - 41E - S4

14

°

F : 23.7

23

°

F : 18.8

32

°

F : 15.0

41

°

F : 12.1

266

,

,

,

,

,

PBC - 41E - S36

50

°

F : 9.7

68

°

F : 6.5

86

°

F : 4.4

104

°

F : 3.1

113

°

F : 2.6

140

158

167

176

185

°

°

°

°

°

F : 13.8

F :

F :

F :

F :

9.7

8.2

7.0

5.9

PTC - 51H - S1

,

,

,

,

, 194

212

230

248

266

°

°

°

°

°

F : 5.1

F : 3.8

F : 2.8

F : 2.2

F : 1.7



Solenoid coil

Thermistor (PTC)

Rated

Max. voltage

Max. ampere

Resistance (at 77

°

F)

Ω

V 389100

LB 59005

TDK – 101YV

400 VAC

11.5 A

+ 30

100 %


SM830076

– 18 –


1-4 Dimensional Data

(A) Indoor Unit: XHS2432

4-29/32

8-21/32

8-1/16

4-29/32

32-9/32 (Ceiling opening)

23-7/32 (Suspention bolt pitch)

14

Min. 2-3/8

3-1/32

• Remote controller (Accessory)

1

2-13/32 23/32

5-29/32

7-7/8

10-1/32

11-23/32

8-1/16

6-1/2

1-3/16

1-7/8

33-27/32

19-11/16

4-29/32

– 19 –

Dimension : inch

Air intake

Air outlet

Narrow tube (1/4")

Wide tube (3/4")

Drain connection

Power line (conduit size : 1/2")

For discharge duct

Suspention bolt mounting

1024_X_S

SM830076

4

2

3



(A) Indoor Unit: XHS3632

8-19/32

8-9/32

2-3/8

1

2

3

4

2-13/32

32-9/32 (Ceiling opening)

23-7/32 (Suspention bolt pitch)

13-15/32 19/32

2-3/4

6-1/2

11-7/32

12-29/32

8-19/32

4-29/32

1-3/16 33-27/32

19-11/16

1-7/8

8-9/32

– 20 –

Dimension : inch

Air intake grille

Air outlet

Refrigerant liquid line (ø3/8")

Refrigerant gas line (ø3/4")

Drain connection

Power supply entry

For discharge duct

Humidifier (option) mounting hole

Suspension bolt mounting

1346_X_S

SM830076



(B) Outdoor Unit: CH2432

6-11/16

1-31/32

26

1-31/32

4-21/64

37

1

2

Dimension : inch

Hole for anchor bolt (4-ø1/2)

Refrigerant tube joint (narrow tube)

Flare connection 1/4 in (6.35 mm)

Refrigerant tube joint (wide tube)


Refrigerant tubing inlet

Power supply inlet

1131_THS_I

3

4

– 21 –

SM830076


1

2

3

4


(B) Outdoor Unit: CH3632

6-11/16

1-31/32

26

1-31/32

4-21/64

37

Dimension : inch

Hole for anchor bolt (4-ø13)

Refrigerant tube joint (narrow tube)


Refrigerant tube joint (wide tube)


Refrigerant tubing inlet

Power supply inlet

1581_C_S

SM830076

– 22 –


1-5 Refrigerant Flow Diagram

Outdoor Unit: CH2432 Indoor Unit: XHS2432

Compressor Accumulator

Accumulator

Gas line service valve

O.D.

3/4"

(19.05mm)

Gas line nipple

High pressure switch

HP

P

EC

Heat exchanger

Distributor

Muffler

4-way valve

Liquid line service valve

O.D.

1/4"

(6.35mm)

EC

Heat exchanger

Distributor

P

Strainer

Electronic ref.control

valve

M

Liquid line nipple

Strainer

Sub-heat exchanger

Cooling Cycle

Heating Cycle

1132_THS_I

1

2

3

1-6 Operating Range

Cooling

Heating

Temperature

Maximum

Minimum

Maximum

Minimum

Indoor Air Intake Outdoor Air Intake

95

°

F DB, 71

°

F WB 115

°

F DB

67

°

F DB, 57

°

F WB 23

°

F DB

80

°

F DB, 67

°

F WB 75

°

F DB, 65

°

F WB

-DB / -WB 17

°

F DB / 15

°

F WB

4

SM830076

– 23 –


1

2

3

1-5 Refrigerant Flow Diagram

Outdoor Unit: CH3632 Indoor Unit: XHS3632

Compressor Accumulator

Accumulator

Gas line service valve

O.D.

3/4"

(19.05mm)

Gas line nipple

High pressure switch

HP

P

EC

Heat exchanger

Distributor

Muffler

4-way valve

Liquid line service valve

O.D.

3/8"

(9.52mm)

EC

Heat exchanger

Distributor

P

Strainer

Electronic ref.control

valve

M

Liquid line nipple

Strainer

Sub-heat exchanger

Cooling Cycle

Heating Cycle

1398_THS_I

4 1-6 Operating Range

Cooling

Heating

Temperature

Maximum

Minimum

Maximum

Minimum

Indoor Air Intake Outdoor Air Intake

95

°

F DB, 71

°

F WB 115

°

F DB

67

°

F DB, 57

°

F WB 23

°

F DB

80

°

F DB, 67

°

F WB 75

°

F DB, 65

°

F WB

-DB / -WB 17

°

F DB / 15

°

F WB

SM830076

– 24 –

2. PROCESSES AND FUNCTIONS

2-1 Room Temperature Control .......................................................................... 26

(A) Cooling .....................................................................................................26

(B) Heating .....................................................................................................27

2-2 Cold Draft Prevention (Heating Cycle) .......................................................... 28

2-3 Automatic Fan Speed (Indoor Unit) ............................................................... 29

(A) Cooling .....................................................................................................29

(B) Heating .....................................................................................................29

2-4 Outdoor Fan Speed Control .......................................................................... 30

(A) Cooling .....................................................................................................30

(B) Heating .....................................................................................................30

2-5 Freeze Prevention (Cooling) ......................................................................... 31

2-6 Condensing Temperature Control (Cooling) ................................................. 32

2-7 Overload Protection (Heating)....................................................................... 33

2-8 Discharge Temperature Control (Cooling and Heating) ................................ 34

2-9 Auto. Mode for Automatic Heating/Cooling Switching ................................... 35

2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating)......................... 37

2-11 4-Way Valve, Solenoid Control ..................................................................... 38

(A) Normal Control Mode ...............................................................................38

(B) AUTO Control Mode .................................................................................39

2-12 Automatic Restart after Power Interruption ................................................... 39

2-13 Electronic Expansion Valve .......................................................................... 40

2-14 Compressor Discharge Gas Temperature .................................................... 40

(A) Cooling .....................................................................................................40

(B) Heating (Except During Defrosting) ......................................................... 40

2-15 Compressor Current Detection Circuit .......................................................... 41

2-16 Electronic Expansion Valve Control .............................................................. 42

2-17 Voltage Detection Control ............................................................................. 43

Section

1

2

3

4

– 25 –

SM830076

2. Processes and functions

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, and Fig. 2 shows about the heating cycle.

Section

1

(A) Cooling

2

THERMO. OFF

(THERMO. ON)

BODY SENSOR

T+2

°

F

SET TEMP . T

°

F

T–2

°

F

COMPRESSOR

1

OUTDOOR FAN

(H OR M)

MORE THAN

5 MINUTES 3 MINUTES

ON OFF

ON OFF

5 MINUTES

ON

ON

3

4

(THERMO. OFF)

ROOM TEMP.

THERMO. ON

MORE THAN

3 MINUTES

OFF

OFF

MORE THAN

5 MINUTES

ON

ON

INDOOR FAN SET SPEED

1. Refer to 2-4 Outdoor Fan Speed Control

Fig. 1

1133_THS_I

Chart Summary and Explanations

❑ Once the compressor starts, it keeps running for 5 minutes.

❑ Once the compressor stops, it will not start running again for 3 minutes.

❑ If you change the operation mode (HEAT, COOL, or FAN) during the cooling cycle, the control circuit stops the compressor for 3 minutes.

❑ 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.

❑ Thermo ON: When room temperature rises 2°F (4°F when set on body sensor) above the set temperature T˚, (T˚+2°F or T˚+4°F when set on body sensor):

Compressor ➞ ON

❑ Thermo OFF: When the room temperature is –2°F below the set temperature T˚:

Compressor ➞ OFF

SM830076

– 26 –

(B) Heating

REMOTE CONTROL

SENSOR

(Only for wireless remote controller)

SET. +2

°

F

SETTING TEMP.

SET. –2

°

F

THERMO. ON

THERMO. OFF

THERMO. ON

THERMO. OFF

THERMO. ON

BODY SENSOR

+2

°

F

SET TEMP.+7

°

F SHIFT

–2

°

F

SET TEMP.

THERMO. ON

THERMO. OFF

THERMO. ON

THERMO. OFF

THERMO. ON

5 MINUTES 3 MINUTES

MORE THAN

5 MINUTES

MORE THAN

3 MINUTES

COMPRESSOR

1

OUTDOOR FAN

(H OR M)

OFF ON OFF ON OFF ON

2

INDOOR FAN

OFF ON

OFF

3 SECONDS

L LL L

SET SPEED

OFF

LL

ON

SET SPEED

2

STANDBY

OFF ON OFF ON OFF

(88

°

F)

INDOOR HEAT

EXCH.

COIL

81

°

F

TEMP.

E2

SOLENOID

COIL (4-WAY)

77

°

F

TEMP.

OPERATION

BUTTON

OFF

ON (REVERSING CYCLE)

ON

1. Refer to 2-4 Outdoor Fan Speed Control

2. Refer to 2-2 Cold Draft Prevention (Heating)


OFF

LL

ON

ON

SET SPEED

OFF

1134_THS_I

❑ Once the compressor starts, it keeps running for 5 minutes.

❑ Once the compressor stops, it will not start running again for 3 minutes.

❑ If you change the operation mode (HEAT, COOL or FAN) during the heating cycle, the control circuit stops the compressor for 3 minutes.

❑ 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.

When set on remote control sensor

Thermo ON: When room temperature is –2°F below the set temperature T˚.

Compressor ➞ ON

Thermo OFF: When the room temperature is 2°F above the set temperature T˚, (T˚+2°F)

Compressor ➞ OFF

When set on body sensor

NOTE: In case of Body sensor, operating temperature is shifted to setting temperature +7°F.

Fig. 2

SM830076

– 27 –

Section

1

2

3

4


2-2 Cold Draft Prevention (Heating Cycle)

Section

1

The cold draft prevention function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coils have warmed up.

❑ STANDBY shows on the remote controller when the indoor fan speed is LL (very low) or OFF. This condition occurs in the following 3 cases:

• During Thermo OFF (refer to 2-1 B). Room Temperature Control, Heating)

• During the defrosting operation (refer to 2-10 Defrosting Control, Heating)

• Until either the coil temperature E2 reaches 81°F or when a maximum of 6 minutes has past.

❑ The indoor fan motor operates in L instead of LL for 3 seconds as it starts to give the fan an initial boost.

2

3

4

92

88

INDOOR UNIT

COIL TEMP.

E2 (

°

F)

81

77

MAX. 6 MINUTES

50

SET

FAN

SPEED

AUTO OR H

M

LL

LL

L LL

“STANDBY”

INDICATOR

LL/OFF

LL/OFF

LL/OFF

LL

LL

LL

“STANDBY” APPEARS

LL= Very low speed

L= Low speed

L

L

L

M

M

L

M= Medium speed

H= High speed

H

M

L

1135_THS_I

Fig. 3


❑ The main idea of this chart is to show that the indoor fan speed increases and gets closer to the set fan speed as the coil temperature E2 rises.

❑ The indoor unit’s coil temperature is taken from sensor E2 located in the middle of the indoor heat exchange coil.

❑ The dotted line shows that the indoor fan motor is OFF. When the temperature at sensor E2 falls below 50°F, the indoor fan motor stops running.

SM830076

– 28 –

2-3 Automatic Fan Speed (Indoor Unit)

By pressing the FAN SPEED button on the remote controller, the fan speed can be set at one of four steps: AUTO., HI., MED., or LO. When set at AUTO. the indoor unit fan speed will be automatically adjusted to the room temperature as the two charts shown below.

(A) Cooling

ROOM TEMP.

(deg)

+3

+2

+1

SET TEMP.

INDOOR FAN

SPEED H H

M M

L

H : High

M : Middle

L : Low

LL : Very low

0433_M_S

Chart Explanations and notes

❑ When the fan speed changes, it keeps the speed step for at least 3 minutes, even if the temperature changes to another speed step during the time.

Fig. 4

(B) Heating

ROOM TEMP.

(deg)

SET TEMP.

–2

–4

INDOOR FAN

SPEED H

M M

H

L

H

M

: High

: Middle

L : Low

LL : Very low

0434_M_S


❑ When the fan speed changes, it keeps the speed step for at least 1 minute, even if the temperature changes to another speed step during the time.

Fig. 5

SM830076

– 29 –

Section

1

2

3

4


2-4 Outdoor Fan Speed Control

Section

1

To optimize the performance of air conditioner, the outdoor fan speed is selected automatically according to the outdoor temperature.

❑ Note that in both Cooling and Heating modes, the fan comes on at first at high speed (H mode) for 5 seconds. Since outdoor conditions sometimes make it difficult for the fan to start, this sudden surge of power may be necessary.

❑ The outdoor fan operates in H mode for 3 minutes after the compressor stops

(excluding defrosting operation period).

❑ Charts below show how the outdoor fan speed changes with the change in outdoor temperature.

(A) Cooling

2

Outdoor unit coil temperature [C2] or more 77°F less than 77°F

Outdoor fan motor (FMo)

H

M 77

H

3

M

Fig. 6

4

(B) Heating

Outdoor coil temperature [C2] or more 57°F less than 57°F

Outdoor fan motor (FMo)

M

H

57

M

H

Fig. 7

SM830076

– 30 –

2-5 Freeze Prevention (Cooling)

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 unit's fan.

MIN. VALUE OF

EITHER E1 OR E2

INDOOR UNIT

TEMP.

34

32

31

(

°

F)

30

ELECTRONIC REF.

CONTROL

VALVE SIGNAL

COMPRESSOR

OPEN OPEN

CONTINUOUS

DETECTION

FOR 2 MINUTES

ON

MINIMUM 3

MINUTES

ON

1138_THS_I

Fig. 8

Note: Freeze prevention is controlled by the temperature at the indoor heat exchanger coil as sensed by either sensor E1 (located at the entrance of the coil) or sensor E2 (located on the middle of the coil). Freeze prevention cycle is controlled by the lower temperature sensed at either of the two sensors.


❑ This chart shows when the electronic refrigerant control valve opens to regulate the temperature of the indoor unit coil to prevent freezing.

❑ If the refrigerant control is not effective and the temperature continues to drop and stays below 30°F for 2 minutes continuously, the control circuit stops the compressor. The compressor does not start again until the temperature rises above 34°F.

The compressor stops for 3 minutes minimum.

Section

1

2

3

4

SM830076

– 31 –


Section

1

2-6 Condensing Temperature Control (Cooling)

Condensing temperature is controlled by the outdoor heat exchanger coil temperature as sensed by sensor C2.

140

OUTDOOR UNIT

COIL TEMP. C2

(

°

F)

131

OUTDOOR FAN

SPEED

ELECTRONIC REF.

CONTROL VALVE

H, M

FORCED

H

OPEN

H, M

2

1139_THS_I

Fig. 9

3


❑ This chart shows how the outdoor fan speed and the electronic refrigerant control valve react to coil temperature to control condensing temperature.

❑ Sensor C2 is located in the middle of the outdoor unit heat exchange coil.

❑ When C2 rises above 140°F the electronic refrigerant control valve opens at 50 steps/30 seconds, and the outdoor fan speed is forced to change to high (H) until C2 falls below

131°F.

4

– 32 –

SM830076

2-7 Overload Protection (Heating)

This function prevents the air conditioner from overloading.

(

°

F)

147

144

140

INDOOR UNIT COIL

TEMP. (E2)

138

131

127

OVERLOAD

PROTECTION

FUZZY CONTROL

OVERLOAD PROTECTION

FUZZY CONTROL

ELECTRONIC REF.

CONTROL VALVE

OUTDOOR FM

OPEN

H OR M

OPEN

START UP

COMPENSATION

OFF

H M H OR M

1140_THS_I

Fig. 10


❑ This chart shows how the outdoor fan speed and the electronic refrigerant control valve react to coil temperature to keep the indoor heat exchanger coil from overloading.

❑ When sensor E2 rises above 140°F the electronic refrigerant control valve opens at 50 steps/30 seconds until E2 falls below 138°F.

❑ Sensor E2 is located in the middle of the indoor unit heat exchange unit.

❑ When sensor E2 rises above 144°F, the control circuit stops the outdoor fan motor till the temp. drops to 131°F

❑ Fuzzy control controls the electronic refrigerant control valve.

Section

1

2

3

4

SM830076

– 33 –


2-8 Discharge Temperature Control (Cooling and Heating)

Section

1

This function prevents the compressor motor from burnout by overheating.

239

221

203

200

DISCHARGE GAS

TEMP. (

°

F)

194

185

2

3

4

OUTDOOR

FAN SPEED

COMPRESSOR

ELECTRONIC REF.

CONTROL VALVE

(DISCHARGE TEMP.)

H OR M

OPEN

M

ON

H OR M

OPEN

TRIP IS OPERATED.

1141_THS_I

Fig. 11


❑ Discharge temperature is sensed by TH8 (discharge gas sensor).

❑ When the temperature rises above 203°F the electronic refrigerant control valve opens at

50 steps/30 seconds until the temperature falls below 200°F.

❑ During HEATING operation, when the temperature rises above 221°F, the control circuit stops the outdoor fan motor until the temperature falls below 194°F. Please note that this control does not function during COOLING operation.

❑ For both COOLING and HEATING modes, if the temperature reaches 239°F the operation shuts down and alarm P3 appears on the remote controller.

❑ The outdoor fan speed is controlled on discharge temp. at heating mode.

SM830076

– 34 –

2-9 Auto. Mode for Automatic Heating/Cooling Switching

❑ When the AUTO mode is selected, the microprocessor calculates the difference between the set temperature and the room temperature, and automatically switches to the COOLING or HEATING mode to maintain the desired temperature.

Room temp.

] Set temp.

➔ COOLING

Room temp.

<

Set temp.

➔ HEATING

This means that if the room temperature is higher or equal to the set temperature,

COOLING operation starts. If the room temperature is lower than the set temperature, HEATING operation starts.

Section

1

COOLING SELECTION TEMP.

+5 deg

SHIFT SET TEMP.

+4 deg

A

REMOTE CONTROLLED

SET TEMP.

B

2

SHIFT SET TEMP.

–4 deg

HEATING SELECTION TEMP.

–6 deg

C

3

HEATING COOLING HEATING

1142_THS_I

Fig. 12

4

– 35 –

SM830076

2

3

Section

1


Chart summary and Explanations

❑ This chart shows how the Operation Mode (COOLING or HEATING) is determined by the microprocessor taking the room temperature into consideration. It also shows the temperature points at which the cooling or heating mode is switched, when the AUTO mode is selected.

❑ After operation starts, the set temperature shifts automatically by +4 deg. at cooling and by -4 deg. at heating. For example, if cooling is selected, the set temperature changes from

68°F to 72°F.

(The display of the remote controller remains 68°F.)

❑ The change of the operation mode (heating to cooling, cooling to heating) by the change of the room temperature during the operation is as follows.

Heating to Cooling; Room temp.

≥

Shifted temp +1.0 deg.

Cooling to Heating; Room temp.

≤

Shifted temp -2.0deg.

For example, if the room temperature rises above 73°F (=72+1) during the cooling operation at the room temperature 68°F set by the remote controller, the operation changes to cooling. When the room temperature lowers below 63°F (=65-2) thereafter, the operation changes to heating again.

❑ In heating operation, using the body sensor, room temperature control is designed so that room air temp. is sensed as 8 deg. lower than suctioned air at indoor unit taking into account of the temperature gap between upper part and lower part of the room.

❑ Within 10 minutes after the compressor turns OFF, the operation does not change to cooling (heating), even when the room temperature changes from C to A (A to C).

❑ When switching from cooling (heating) to heating (cooling), the actuation of the 4 way valve will delay about 30-50 seconds after the compressor turns ON.

4

– 36 –

SM830076

2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating)

When the outdoor temperature is low, frost may form on the outdoor heat exchanger coil.

When this occurred, the defrosting system operates. The microprocessor in the outdoor unit monitors the relationship between the temperature of the outdoor heat exchanger coil and the outdoor temperature so it can defrost when necessary.

Flow of Defrosting

Heating operation

OUTDOOR COIL

TEMP. C1 (

°

F)

Y

“RELEASE OF

50

DEFROSTING”

RANGE

No counting time for detecting frost : 15 minutes

7.3

OUTDOOR AIR TEMP.

50

(

°

F)

X

27

18

Detecting the frost

–4

The area below the heavy line is the frost detection area.

Stand by time for defros:

25 minutes

Either continuous 8 minutes or cumulative 60 minutes are required to detect frost in the “Frosting” range.

Section

1

2

Defrosting

Release of defrosting

Refer to time chart.

*Minimum continuous operating time by defrosting is 48 minutes (= 15 + 8 + 25).

Occurs either when the temperature of C1 (the outdoor heat exchanger coil) has reached 50

°

F or above, or when the maximum defrosting time (9 minutes) has elapsed.

1143_THS_I

Fig. 13

Time Chart for Defrosting

1 MINUTE MAX. 9 MINUTES 1 MINUTE

COMPRESSOR ON ON ON

3

4

SOLENOID COIL

(4 WAY VALVE)

OUTDOOR FAN

(H OR L)

ON

ON

INDOOR FAN

(SET SPEED) OFF OR LL

OFF

OR LL

“STANDBY”

INDICATOR

“STANDBY” APPEARS

Defrosting

Start

Release of

Defrosting

❑ During the defrost cycle, STANDBY appears on the remote controller.

❑ *......Cold Draft Prevention may operate occasionally

ON

ON

0442_M_S

Fig. 14

SM830076

– 37 –


2-11 4-Way Valve, Solenoid Control

The basic function of the 4-way valve is to direct the refrigerant in the correct direction according to the Operation Mode (COOLING or HEATING) selected.

The following two charts show conditions of the controls and functions listed in the left hand column when the solenoid is ON or OFF. Chart (A) on this page shows the relationships when the temperature control is in NORMAL mode, and Chart (B) on the next page shows the relationships when the remote controller is set to AUTO mode.

Section

1

(A) Normal Control Mode

POWER SOURCE OFF ON

OPERATION

BUTTON

ON OFF ON

2

3

4

MODE

COOL

BUTTON HEAT

COMPRESSOR

SOLENOID COIL

(4-WAY VALVE)

OFF

HEAT

3 MINUTES

2

TURN ON

TURN OFF

ON

1

ON

1. . . More than 5 minutes

OFF

COOL

ON

HEAT

THERMO OFF

THERMO

ON

THERMO OFF

THERMO

ON

OFF ON OFF ON

2 2

1 1 1

OFF

2. . . More than 3 minutes

ON

0443_M_S

Fig. 15


❑ For the first 3 minutes after power is applied, the 4–way valve remains OFF and the compressor will not operate, even if the ON button is pushed.

❑ If the 4–way valve is turned OFF with the compressor operating, the air conditioner operates in COOLING mode. See Table below.

❑ If the 4–way valve is turned ON with the compressor operating, the air conditioner operates in HEATING mode. See Table below.

Operation Mode

COOLING

HEATING

4-way valve

Compressor solenoid

OFF

ON

ON

SM830076

– 38 –

(B) AUTO Control Mode

POWER SOURCE OFF ON

OPERATION

BUTTON

AUTO

MODE

COOL

CONTROL HEAT

COMPRESSOR OFF

SOLENOID COIL

(4-WAY VALVE)

OFF

MORE THAN 10 MINUTES

(THERMO. OFF)

ON

MORE THAN 10 MINUTES

(THERMO. OFF)

COOL

HEAT

3 MINUTES

ON OFF ON OFF

HEAT

THERMO. OFF

THERMO. ON

ON

MORE THAN

3 MINUTES

OFF ON

MORE THAN

30 – 50 SECONDS

MORE THAN

30 – 50 SECONDS

ON OFF ON

0445_M_S

Fig. 16

When the Compressor has stopped while in AUTO mode, the 4-way valve switches on

(heating) or off (cooling) within 1 minute according to the following conditions:

Compressor has stopped under the operation of

“AUTO mode” condition.

4-way valve delays its switching for 30 – 50 seconds after compressor has been turned ON.

0446_M_S

Fig. 17

2-12 Automatic Restart after Power Interruption

This air conditionner has a power failure recovery function.

Section

1

2

3

4

SM830076

– 39 –


Section

1

2-13 Electronic Expansion Valve

❑ This valve allows very precise and smooth control of the amount of refrigerant flow in the system. Since the valve is operated by a step motor, the control circuits can open or close it in very exact amounts, so the degree of heating or cooling can be changed by just a little, or changed very quickly or slowly.

(Completely close …… 0 step)

(Full open ................ 480 step)

Model

24 type

36 type

Heating

100 step

90 step

Min. open

Cooling

120 step

90 step

Max. open

480 step

480 step

2

❑ Fuzzy Control

Fuzzy Control is a controlling system to control electronic refrigerant control valve using fuzzy logic. It regulates the functions of heating and cooling, as well as some of the processes inside the unit, by taking account of many different conditions of temperature, fan speed, etc. These control circuits work automatically to send just the right amount of refrigerant through the Electronic Refrigerant Control Valve.

3

4

2-14 Compressor Discharge Gas Temperature

(A) Cooling

Indoor temp. (°F)

Outdoor temp. (°F)

Compressor discharge gas temp. (°F)

55 or below

68 – 77

57 – 61

104 – 176 104 – 194

79 – 82

81 – 95

140 – 212

84 – 90

97 – 109

158 – 221

(B) Heating (Except During Defrosting)

Indoor temp. (°F)

Outdoor temp. (°F)

Compressor discharge gas temp. (°F)

64 – 70 72 – 77 79 – 86

32 or below 34 – 50 32 or below 34 – 50 52 – 70 32 or below 34 – 50 52 – 70

104 – 176 122 – 194 122 – 194 122 – 212 140 – 221 122 – 194 140 – 212 158 – 221

❑ Operate the unit at least 30 minutes to stabilize the discharge temperature.

❑ The above discharge temperature was measured with a 15m tubing length.

The temperature may vary with tubing length.

– 40 –

SM830076

2-15 Compressor Current Detection Circuit

❑ The Compressor Current Detection Circuit detects the compressor current and, depending on the current range, can stop the compressor motor so it will not be damaged by overcurrent.

❑ Overcurrent can be caused by several factors, particularly mechanical seizing of the compressor or liquid backflow. Either of these conditions can hold the compressor to run, and thus drawing so much current that the motor can burn out.

Comp. Amps.(A)

Locked Comp. Cut-off Range

Overload Protection Range

Normal Operation Range Is

Rated Current value

Outdoor Model

CH2432

CH3632

Rated Current Value ls (A)

17.1

27.5

Overload Protection ls x 1.17 (A)

20.0

32.0

0447_M_S

Fig. 18

Locked Compressor Cut-off

Is x 1.4 (A)

23.9

38.5


❑

❑

❑

Overload Protection

• When the detected current is 1.17 – 1.4 times greater than the rated current value (Is) and continues for 30 seconds, both compressor and outdoor fan stop (Thermostat OFF).

• After 3-minute pause, if the air conditioner is ready for Thermostat ON, it starts again. However, if the condition mentioned above repeats twice within 30 minutes, the remote controller displays the alarm message H01, compressor overload.

Locked Compressor Cut-off

• When the detected current is 1.4 times greater than the rated current value (ls) and continues for 2

seconds, both compressor and outdoor fan stop (Thermostat OFF).

• After 3-minute pause, if the air conditioner is ready for Thermostat ON, it starts again. However, if the condition mentioned above repeats twice, the remote controller displays the alarm message H02,

compressor locked.

Failure of Compressor Current Detection

• When the Compressor Current Detection Circuit fails to detect the compressor current within 2

seconds after compressor starts, both compressor and outdoor fan stop (Thermostat OFF).

• After 3-minute pause, if the air conditioner is ready for Thermostat ON, it starts again. However, when the circuit fails to detect the current twice in a row, the remote controller displays alarm message H03,

Failure of compressor Current Detection.

Section

1

2

3

4

SM830076

– 41 –


2-16 Electronic Expansion Valve Control

The circulation volume of the refrigerant is controlled by a pulse type electronic control valve.

When the power is switched ON, the opening degree of the electronic control valve is controlled between 90 and 480 steps after setting the initial step at the time when the thermostat is ON.

Section

1

Contents and Order of control

Cooling

Start

Discharge gas temperature control

Heating

Start

Discharge gas temperature control

Outdoor unit coil temperature control High load prevention control

2 Freeze prevention control

Refrigerant flow distribution control

Discharge gas target temperature control (Fuzzy control)

Heating start up control

Refrigerant flow distribution control

*

Discharge gas target temperature control (Fuzzy control)

3

*

* Repeat control in accordance with the priority order.

0451_M_S

4

Even though the operation is performed every 30 seconds, the control of discharge gas temperature, high load prevention, outdoor unit coil temperature and freeze prevention activates when it occurs.

(1) Refrigerant flow distribution control

At the control of flexible combination (a plural number of indoor units are set), the opening degree of the electronic control valve is controlled by the indoor unit coil temperature.

Cooling: indoor unit coil E2 temperature (located at the middle of coil)

Heating: indoor unit coil E1 temperature (located at the outlet of coil)

(2) Fuzzy control (optimal refrigerant flow rate control)

By outputting the fuzzy estimation result corresponding to the fuzzy input variables (the indoor unit coil temp., the deviation between the actual discharge gas temp. and the target discharge gas temperature calculated from the outdoor unit coil temperature and the change thereof), the electronic refrigerant valve is controlled so that the unit can perform its maximum ability in accordance with the indoor and outdoor temperature conditions at the operation.

SM830076

– 42 –

2-17 Voltage Detection Control

When the power voltage falls below 160 V or rises above 260 V, operation lamp and stand-by lamp flash alternately to protect the compressor and electrical components.

Section

1

2

3

4

– 43 –

SM830076


Section

1

2

3

4

– 44 –

SM830076

3. Electrical data

3. ELECTRICAL DATA

3-1 Indoor Unit (Electric Wiring Diagram, Schematic Diagram) ............................... 46

3-2 Outdoor Unit (Electric Wiring Diagram, Schematic Diagram)............................. 48

Section

1

2

3

4

– 45 –

SM830076


Section

1

2

3

4

3-1 Indoor Unit

1 XHS2432, XHS3632

BLK

GRY

GRN/YEL

GRY

WHT

GRY

BLK

YEL

ORG

BRN

PNK

VLT

BRN

BRN

PNK

ORG

VLT

BLK

YEL

BRN

RED

BLU

PNK

WHT

RED

GRY

BLK

GRN/YEL

ORG

WHT

BLK

YEL

RED

WHT

WHT

BRN

BRN

RED

RED

BLK

YEL

GRY

RED

ORG

BLK

BLK

BLK

BLK

BLK

BLK

BLK

BLK

BLK

BLK

GRN/YEL

GRN/YEL

SM830076

– 46 –


3-1 Indoor Unit

1 XHS2432, XHS3632

4P-1

4P-2

N

3

1

R

F1(3A)

3X

1X

2X

LL

7

L

5

H

3

HH

1

COM

1

FMI

RC1

1 2

3X

LL

3

L

4 5

H HH

6 7

HT

8

49FI

RY2

DP

1

• Schematic Diagram

DP

RY1

LM

1

1

LM

2

49FI

1

IND

CR-THS2432

Controller

1

6

CONT

TR1

49FI

3

1

3

1

2

3

4

1

2

3

4

CD

SG WL

12V

G

SG

RC 12V

G

1

2

3

SEC

PRY

T6

1

4

5

2

3

PNL

1

2

3

1X

FS

1

3

2X

3X

RY2

RY1 LM

DP

DC12V

MOV

1

2

1

2

1

2

Room Thermistor

Indoor Coil

TH1

E1

Indoor Coil

TH2

E2

TH3

FS

9

F2(3A)

3

COM

3 3

SG1

SG1

SG2

1

2

4P4P-

U2 U1

To Outdoor Unit

Symbols

FMI

49FI

RC1

F1,2

DP

LM

TR1

1X-3X

RY1-RY2

MOV

FS

Description

Indoor Fan Motor

Indoor Motor Thermal Protector

Running Capacitor

Fuse

Drain Pump

Auto Louver Motor

Power Transformer

Auxiliary Relay

Auxiliary Relay

Motor Operated Valve

Float Switch

Symbols Description

TH1

TH2

Room Thermistor

Thermistor (Indoor Coil E1)

TH3 Thermistor (Indoor Coil E2)

CR-THS2432 Indoor Controller

CONT

IND

Controller

Indicator Lamp Assy

Terminal Plate

Connector

Terminal

S 854-2-5268-772-00-0 (XHS)

Section

1

2

3

4

SM830076

– 47 –

Section

1

2

3

4

3-2 Outdoor Unit

1 CH2432

RED

WHT

BRN

WHT

WHT

RED

GRY

BLK

BLK

BRN

BRN

RED

BLK

BLK

RED

BRN

VLT

WHT

PNK

BRN

BLK

GRY

YEL

VLT

WHT

BRN

PNK

GRY

GRY

Relay

YEL

BRN

WHT

WHT

BLK

RED

BLK

WHT

– 48 –


SM830076



1 CH2432

Terminal

Plate (5P)

-1

-2

-G

-L1

-L2

CT

52C

C

R

S

CM

63PH

RC1

PTC

1

1

CH

2

52C

F1(3A)

1Y


RY1 RY2

63PH

1

RY3

1Y

RY4

H

3 5

LL

3

20S 52C

3

3

49

FO

7

2 3

H

5

M

6

L

7

20S

FMO

52C

RC2

1 2 1

49

C

9

4

49FO

RY1

RY2

RY3

RY4

CR-CH2432

Controller

(U1) (U2)

2P-1 2P-2

CN2

PRY

1

3

1

2

AC 208V

230V

TR

SEC

20S

52C

Outdoor

Coil C1

1

2

FM1

FM2

DC12V

N1

Outdoor

Coil C2

Discharge

Gas

CT1

1

3

1

2

1

2

2

1

AC 14V

TH6

TH7

TH8

3 1 1 1

F2(3A)

Section

1

2

Symbols

CM

FMO

52C

49FO

63PH

CT

RC1, RC2

TR

CH

20S

F1, F2

Description Symbols

Compressor Motor

Outdoor Fan Motor

Compressor Motor Magnetic Contactor

Outdoor Fan Motor Thermal Protector

High Pressure Switch

Current Transmitter

Running Capacitor

Power Transformer

Crank Case Heater

Four Way Valve

Fuse

TH6

TH7

TH8

PTC

CR-CH2432

RY1~RY4

1Y

Description

Thermistor (Outdoor Coil C1)


Thermistor (Discharge Gas)

PTC Thermistor

Outdoor Controller

Auxiliary Relay

Auxiliary Relay

Terminal Plate

Terminal

Connector

S 854-2-5268-582-00-2 (CH2432)

3

4

SM830076

– 49 –

Section

1

2

3

4


2 CH3632

WHT

WHT

RED

GRY

BLK

BLK

BRN

BRN

VLT

WHT

BRN

RED

BRN PNK

BRN

VLT

WHT

GRY

GRY

BRN

GRY

YEL

VLT

WHT

PNK

RED

WHT

BLK

BLK

BRN

VLT

WHT

GRY

BRN

GRY

PNK

YEL

VLT

WHT

GRY

BRN

PNK

GRY

YEL

BRN

WHT

WHT

RED

WHT

– 50 –

BLK

RED

BLK

WHT


SM830076



2 CH3632

Terminal

Plate (5P)

-1

-2

-G

-L1

-L2

CT

52C

C

R

S

CM

1

1

F1(3A)


RY1 RY2

63PH

1

RY3 1Y

2

63PH

52C

RY4

H

3 5

LL

3

20S 52C

3

2

3

49

FO

7

3

1Y

49FO1

1

H

5

M

6

L

7

H

5

M

6

L

7

20S 52C

CH 1Y

FMO1 FMO2

4

3

49FO2

RC1

PTC

2

RC2

1 2

RC3

1 2 1

49

C

9

4

3 1 1 1

F2(3A)

RY1

RY2

RY3

RY4

CR-CH2432

Controller

(U1) (U2)

2P-1 2P-2

CN2

PRY

1

3

1

2

AC 208V

230V

TR

SEC

2

1

20S

52C

Outdoor

Coil C1

1

2

FM1

FM2

DC12V

N1

Outdoor

Coil C2

Discharge

Gas

CT1

1

3

1

2

1

2

AC 14V

TH6

TH7

TH8

Section

1

2

Symbols

CM

FMO1, 2

52C

49FO1, 2

63PH

CT

RC1, 2, 3

TR

CH

20S

F1, F2

Description Symbols

Compressor Motor

Outdoor Fan Motor

Compressor Motor Magnetic Contactor

Outdoor Fan Motor Thermal Protector

High Pressure Switch

Current Transmitter

Running Capacitor

Power Transformer

Crank Case Heater

Four Way Valve

Fuse

TH6

TH7

TH8

PTC

CR-CH2432

RY1~RY4

1Y

Description



Thermistor (Discharge Gas)

PTC Thermistor

Outdoor Controller

Auxiliary Relay

Auxiliary Relay

Terminal Plate

Terminal

Connector

S 854-2-5268-621-00-0 (CH3632)

3

4

SM830076

– 51 –


Section

1

2

3

4

– 52 –

SM830076

4. Service procedures

4. SERVICE PROCEDURES

4-1 Troubleshooting .............................................................................................54

(1) Check before and after Troubleshooting ................................................ 55

(2) General Troubleshooting Flow Chart: Diagnosis and Remedy .............. 56

(3) Meanings of alarm messages ................................................................ 58

(4) LED Indication on the Outdoor Unit’s P.C.B. Ass’y ................................ 60

(5) Symptoms and parts to inspect .............................................................. 61

(6) Procedures When a Specific Component Does Not Work ..................... 71

(7) Service Functions of Optional Wired Remote Controller ........................ 73

4-2 Checking the Electrical Components ............................................................ 87

(1) Measurement of Insulation Resistance .................................................. 87

(2) Checking the Protective Devices............................................................ 88

(3) Checking the Electrical Parts ................................................................. 89

(4) Sensor and Solenoid Layout Diagram.................................................... 92

(5) Thermistor Characteristic Curve............................................................. 94

(6) P.C.B. Setting ..........................................................................................95

(7) R.C Address Setting Method .................................................................. 96

(8) Automatic Address Setting Method ........................................................ 97

(9) Displaying Indoor / Outdoor Unit Combination Numbers ....................... 97

(10) Items to Check Prior to Test Run ........................................................... 98

(11) Test Run.................................................................................................. 99

(12) P.C.B. and Parts Location .................................................................... 102

(13) Checking procedure for each PC Board............................................... 104

(14) Check Pins ............................................................................................105

Section

1

2

3

4

– 53 –

SM830076


4-1 Troubleshooting

This section explains:

❑ What the LED codes mean

❑ What the remote control unit display screen messages mean

❑ How to use the flow charts to find and solve problems

❑ How to use the self-diagnostic tests to find parts that aren’t working right

Section

1

2

3

4

This unit is made to be trouble free, and not need much service. However, with time, moving parts wear out, electronic components break down, and sometimes misuse damages the unit.

The purpose of this section is to help you when the unit is not working properly. Sometimes your experience will tell you right away where to look for a problem, and when you find it you will know how to fix it at once.

Often, however, all you have is a symptom like “poor cooling” or “outside fan doesn’t come on.” Now you must find out the cause of the problem, and then how to fix it. This section provides several ways to help you go from the symptom to the cause and then the solution.

The first chart, General Troubleshooting Flow Chart is divided into two sections: Poor heating and Poor Cooling. Under each heading you will find the main things that can go wrong and cause either of these problems. Sometimes you can start with this chart and find the problem right away, but often you will come here for more suggestions after you have looked at the error code on the remote control unit display. This chart gives you the "big picture" of problems and solutions.

The other main tool we explain here is the use of the Alarm Messages. When a certain part fails or a safety device has shut the unit down, any alpha-numeric codes appears on the display to guide you to the problem.

By understanding the code you can often go right to the problem area and then, with this manual and your knowledge of air conditioning, find the solution.

– 54 –

SM830076


(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.

1 . Check power supply wiring

❑ Check the power supply wires are correctly connected between terminal

No. 1 & 2 on the 5P terminal plates in the indoor unit and the outdoor unit.

2 . Check inter-unit wiring

❑ Check that inter-unit control wiring (DC low voltage) is correctly connected between the indoor unit and outdoor unit.

Power Supply: 60 Hz, single-phase, 230/208 V

Section

1

Disconnect SW

(Field supply)

Inter unit power line

230/208 V

1

B

2

G

Ground

U1

C

U2

Indoor

Inter unit control line

Unit

DC 5 V

U1

U2 L2

G

Outdoor

Unit

1

2

G

L1

Power supply single phase

230/208 V

L1

A

L2

Ground

1103_M_I

Fig. 19

3 .

Check power supply

❑ Check that voltage is within the specified range (±10% of the rating).

❑ Check that power is being supplied.

2

3

4

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.

4 . Check the lead wires and connectors in indoor and outdoor units.

❑ Check that the sheath of lead wires is not damaged.

❑ Check that the lead wires are firmly connected at the terminal plate.

❑ Check that the wiring is correct.

SM830076

– 55 –


(2) General Troubleshooting Flow Chart: Diagnosis and Remedy

When you have found a major problem, such as refrigerant not flowing in the system or reduced air circulation, come to this section and find the box listing the problem. Connected to the box are the main causes of the problem and their remedies. To find out which malfunction is happening in your case, check the remote controller for an Alarm Message, and follow the steps in section 3).

Section

1

(A) Cooling a. Cooling

Poor cooling

Is setting temp.

suitable ?

Is cooling load too heavy ?

Change the setting temp.

Review cooling load estimate.

2

3

4

Refrigerant flow failure

4-way valve is defective.

Refrigerant shortage

Electronic refrigerant control valve is defective.

Compressor is defective.

Service valves are not fully open.

Replace the 4-way valve.

Charge refrigerant gas.

Replace the valve.

Replace the compressor.

Open the valves fully.

Not enough air circulation

Air filter is clogged.

Is fan speed set to LOW ?

Refrigerant tubes between indoor and outdoor units are not insulated.

Clean the filter.

Set the fan speed to either MEDIUM or HIGH.

Insulate wide and narrow tubes separately.

0458_M_I

SM830076

– 56 –


(B) Heating b. Heating

Poor heating

Refrigerant flow failure

Not enough air circulation

Cold air is discharged.

Cold draft prevention is not working.

Is setting temp.

suitable ?

Is heating load too large ?


Refrigerant shortage

Electronic refrigerant control valve is defective.

Compressor is defective.

Service valves are not fully open.

Air filter is clogged.

Is fan speed set to LOW ?

Refrigerant tubes between indoor and outdoor units are not insulated.


“ STANDBY ” is displayed.

Indoor coil sensor E2 is defective.

Change the setting temp.

Review heating load estimate.

Replace the valve.

Charge with refrigerant.

Replace the valve.


Open the valves fully.

Clean the filter.

Set the fan speed to either MEDIUM or HIGH.

Insulate wide and narrow tubes separately.

Replace the valve.

Replace indoor

P.C.B. Ass'y.

Replace the sensor.

0459_M_I

SM830076

Section

1

2

3

4

– 57 –


Section

1

2

3

4

(3) Meanings of alarm messages

If an error occurred in the air conditioner, the error condition is presented by indicating the error code in the wired remote controller display or by the combination of lamp statuses for operation, timer and heat stand-by (OFF status and flashing status).

Possible causes of troubles

Remote controller is detecting unusual signal from indoor unit.

Error transmitting of serial communications signal.

• Indoor unit is detecting unusual signal from the remote controller and group control.

(No serial communications signal)

Improper setting of indoor unit or remote controller.

Indoor unit is detecting unusual signal from signal option.


Indoor unit is detecting unusual signal from outdoor unit.

Outdoor unit is detecting unusual signal from indoor unit.

Auto. address setting is not correct.

Error receiving of serial communications signal.

Indoor unit address setting is duplicated.

Remote controller address (RCU.ADR) is duplicated.

Error transmitting of serial communications signal


When using flexible combination control, main indoor unit address E14 setting is duplicated. (judged by outdoor unit.)


E11

E04



(Confirmation error of unit numbers included)

Wired remote controller display

Wireless remote controller display

E01

E02

Operation lamp flashes

E03

E08

E09

O : Operation lamp v

: Timer lamp v

:Heat stand-by lamp

E10

E05

E06

Error transmitting of serial communications signal.

E07

No. of judged indoor units or total capacity of indoor units is small.

E15

Heat stand-by lamp flashes v

:Operation lamp v : Timer lamp

O

: Heat stand-by lamp

Indoor unit is detecting unusual signal from another indoor unit.

No. of judged indoor units or total capacity of indoor units is large.

E16



E17

E18


Indoor unit group address is not correct.

Model setting of indoor unit is not matching the outdoor unit.

Indoor unit address (or group address) is not set.

Capacity code of indoor unit is not set.

Improper wiring of group control wiring.

L01

L02

When using group control, main indoor unit address setting is duplicated.

(judged by indoor unit.)

L03

Outdoor unit address is duplicated.

Improper wiring between indoor units.

(There is a group connection wiring in case of individual control.)

L04

L07

L08

L09

L11

Operation lamp and heat stand-by lamp flash at the same time.

O : Operation lamp v

: Timer lamp

O


Indoor unit model setting is improper (capacity)

Improper wiring connections of ceiling panel.

Protective device in indoor unit is activated.

Thermal protector in indoor fan motor is activated.

Float switch is activated.

Protective device in outdoor unit is activated.

• Thermal protector in outdoor fan motor is activated.

• Compressor thermal protector is activated.

• Power supply voltage is unusual. (The voltage is more than

260 V or less than 160 V.)

Discharge gas temperature of comp. is unusual.

High pressure switch is activated.

Voltage drops.

Other indooor unit is warning.

L13

P09

P01

P10

P02

P03

P04

P05

P31 v

: Operation lamp

O

: Timer lamp

O


Operation lamp and heat stand-by lamp flash alternately.

O

: Operation lamp v

: Timer lamp

O : Heat stand-by lamp

SM830076

– 58 –

Possible causes of troubles

Indoor thermistor is either open or short.

Outdoor thermistor is either open or short.

Indoor coil temp. (E1) cannot be detected.

Indoor coil temp. (E2) cannot be detected.

Indoor room temperature cannot be detected.

Discharge gas temp. cannot be detected.

Outdoor coil liquid temp. (C1) cannot be detected.

Outdoor coil gas temp. (C2) cannot be detected.

• Non volatile memory IC (EEPROM) is abnormal (Indoor control panel)

Protective device for compressor is activated.

Compressor motor is overloaded.

Compressor motor is locked.

Compressor current detection circuit is defective.

Power supply voltage between phases is unbalanced.

Standard comp. contactor (Mg SW)is chattering.

O

: flashes v : OFF


Wired remote controller display

Wireless remote controller display

F01

F02

F10

F04

F06

Operation lamp and heat stand-by lamp flash alternately.

O

: Operation lamp

O

: Timer lamp v :Heat stand-by lamp

F07

F29

H01

H02

H03 v

:Operation lamp

O

: Timer lamp v

:Heat stand-by lamp

H17

H18

Section

1

2

3

4

– 59 –

SM830076


(4) LED Indication on the Outdoor Unit’s P.C.B. Ass’y

If something goes wrong with the outdoor unit, LED lamps on the outdoor P.C.B. Ass’y light up to show the cause of the trouble, in addition to the Alarm message on the remote controller.

Section

1

2

LED 2 on

P.C. board v

LED 1 on

P.C. board v

Remote controller

No message v V

Possible cause of trouble

Normal

E06, E07, L04

Outdoor unit serial communication signal is abnormal.

Outdoor unit address is duplicated.

v

V

* v

No message

P02

Other outdoor units are performing auto address and detecting refrigerant shortage.

FMo • CM thermal protection is in operation.

Power supply voltage is abnormal.

V

V

*

V

* v

P04, P05

F04~F09

H01, H02

* *

Flash at the same time

E15, E16

High voltage SW activates

Negative phase protector activates.

Sensor is abnormal. (Open or short)

Abnormal compressor current value is detected.

Auto address failure

* *

Flash alternately

“SETTING” flashes.

Auto address is in operation.

3 NOTE v : LED lamps OFF V : LED lamps ON (lights up) * : LED lamps ON (flashes)

LED 2 (D12)

LED 1 (D11)

4

1125_C_I

Fig. 20

CAUTION

* REFRIGERANT SHORTAGE

Note particularly that a shortage of refrigerant is only shown by the outdoor P.C.B. Ass’y

LEDs and the Alarm Message does not appear on the Indoor Remote Controller . The compressor keeps running even when the refrigerant is less, so when you find the LED indication on the outdoor P.C.B. Ass’y, stop the air conditioner immediately to avoid the compressor damage.

SM830076

– 60 –


(5) Symptoms and parts to inspect

1) Symptom: LCD on the remote controller does not display and remote controller does not operate.

Start

Is the LED (D80) on the indoor unit PCB lit?

Yes

No

Section

1

Is there 12 V DC between R2 and R3 on the 8P terminal plate of the indoor unit?

Yes

No

Is there 12 V DC between 2 and 3 of the remote controller?

Yes

No

Repair the remote controller wiring.

2

Miswiring of power supply wires and indoor/outdoor control lines

Yes Is there 230-208 V AC between U1 and U2 of the 8P terminal plate?

No

No Is there 230-208 V AC between R and S of the indoor PCB?

Yes

Replace the remote controller.

3

Correct the wiring. Remove the socket connected to the OC plug on the

PCB and connect to the EMG plug instead.

Check and repair the power breaker etc.

Correct the connections

Replace the indoor unit power transformer.

No

Are the connections for the 4P connector for the indoor unit’s

PCB power transformer good?

Yes

No

Has the indoor unit PCB fuse blown?

Yes

No Is there 15 V AC between 1 and 2 of the 4P connector for the indoor unit’s power transformer?

Yes

Is the primary side of the indoor power transformer shorted?

Yes

No

Is the 230-208 V AC circuit shorted?

No

Yes

Replace the indoor unit PCB.


Replace the indoor unit’s power transformer.

Replace or repair.

– 61 –

1144_THS_I

SM830076

4


2) Symptom: LCD on the remote controller displays “CHECK E01”.

(Unusual communication between remote controller and indoor unit.)

Start

Section

1

Remote controller judges itself with self-diagnostic functions

OK

NG


Is there an open or a contact defect in the No. 1 line of the remote controller?

No

Yes

Correct the wiring.

Is there 230 -208 V AC between

U1 and U2 of 8 P terminal plate?

No

Yes

Mis-wiring between the power supply line and indoor/ outdoor unit operation lines.

Yes

Correct the wiring, and pull out the socket connected to the OC plug to replace with the EMG plug.

2

Is the indoor unit PCB’s non-volatile memory IC setting (“CHECK F29” displayed) wrong?

Yes

No

Correct the setting.

3 Is the indoor unit PCB’s inspection pin shorted?

Yes

No

Open the inspection pin.

4



(Unusual communication between remote controller and indoor unit)

1145_THS_I

Start

Is the No. 1 line wire (red) for the remote controller connected to another line (2 or 3) or are No. 1 and No. 3 (black) wired reversed?

No

Yes

Remote controller judges itself with self-diagnostic functions.

(To avoid misjudgment, always remove the No. 1 line of the remote controller wiring from the indoor unit terminal plate.)

OK

NG


Repair the wiring.


0334_M_I

SM830076

– 62 –


4) Symptom: LCD on the remote controller is displaying “CHECK E04”.

(Unusual communication between the indoor and outdoor units.)

Start

Cut the breaker and remove the indoor/outdoor unit control lines connected to U1 and U2 of the indoor unit 8P terminal plate.

After shorting the test pin (CN2) on the indoor unit PCB, switch the breaker on. Does the LED

(red) on the PCB light up?

No

Yes

Is the contact good at the 2P connector for indoor serial communications on the outdoor unit PCB?

Yes

No


Correct the connections.

Cut the breaker, remove the indoor/outdoor unit control lines connected to U1 and U2 of the outdoor unit 8P terminal plate.

After shorting the test pin (CN11) on the outdoor unit PCB, switch the breaker on. Do the LEDs (red,

×

2) on the PCB flash?

No

Yes

Indoor/outdoor unit control lines are cut off

Correct the wiring.

Is the contact good at the 2P connector for indoor serial communications on the outdoor unit PCB?

No


Correct the connections.

0335_M_I

Section

1

2

3


(Unusual communication between the indoor and outdoor units)

Start

Indoor unit PCB transmission/ reception circuit defect


0336_M_I

4

SM830076

– 63 –



(Unusual communication between the indoor and outdoor units)

Start

Section

1

2

Is the setting for the indoor address on the indoor unit PCB inappropriate?

Yes

No

Yes

Is there a cut line or contact defect between an indoor and outdoor unit’s control line?

No


Correct wiring.

Influenced by external noise 0337_M_I

* See the section of INSTALLATION INSTRUCTION concerning with flexible combination system.


(Duplicate indoor unit address setting)

Start

3

4

Is the setting for the non-volatile memory IC on the indoor unit PCB inappropriate? If the setting is appropriate, “F29” is displayed.

(Are there two units with the same address?)

No

Yes


Influenced by external noise

0338_M_I

* See the section of INSTALLATION INSTRUCTION concerning with flexible combination system.


(Duplicate setting of RCU address switch of remote controllers)

Start

Are there two remote controllers

(master-slave) installed with both remote controllers set as masters?

No

Yes


*


0339_M_I

* See the section of INSTALLATION INSTRUCTION concerning with controlling remote controller switches when there are two remote controllers.

SM830076

– 64 –


9) Symptom: LCD on the remote controller displays “CHECK P01”.

(Indoor fan protection thermostat operation warning)

Start

Yes

Is there 230-208 V AC between S4 and T20-3 on the indoor unit PCB?

No

Is there 230-208 V AC between

T20-3 and S4 after T20-1 and T20-3 on the indoor unit PCB shorted?

No

Yes

Is the indoor fan wire winding protection thermostat (49FI) off?

Yes

No

Replace the indoor fan.


Correct the connection

Section

1

1146_THS_I

2

3

4

– 65 –

SM830076

Section

1

2

3

4



(Compressor / outdoor fan protection thermostat operation warning / power supply voltage abnormality)

Start

Is the power supply to the outdoor unit normal?

(Voltage / defective phase?)

No

Yes

Is the fuse on the outdoor unit

PCB blown (F1 and F2)?

No

Yes

Yes

Is the high voltage switch

(63 PH) off?

No

Is there 230-208 V AC between

CN19-9 and CN19-1 on the outdoor unit PCB?

No

Yes

Check the power breaker etc. and repair.

Replace the fuse.

Replace the outdoor unit PCB.


Is the outdoor fan wire winding protection thermostat (49FO) off?

Yes

No

Replace the outdoor fan.

Is the compressor protection thermostat (49C) off except 48 type?

Yes

No

• No refrigerant

• High load

• 4-way valve defect

• Clogged refrigerant circuit

• Electronic refrigerant control valve

defect (indoor unit)

Is there connector contact defect?

No

Yes



1147_THS_I

SM830076

– 66 –


11) Symptoms: LCD on the remote controller displays “CHECK P03”.

(Alarm for unusual discharge temp. of compressor)

Start

Unusual discharge gas temperature

• Refrigerant shortage

• Clogged refrigerant circuit

• Electronic refrigerant control valve defect (indoor unit)

0343_M_I

Section

1


(High-pressure switch activation warning)

Start

The system does not operate again.

Yes

No

High-pressure switch activation

(Both cooling and heating)

• Electronic refrigerant control valve defect

• Refrigerant over-charged

(Cooling)

• Outdoor unit, heat exchanger dirty, clogged

• Outdoor unit air short

• Outdoor fan stopped

(Heating)

• Outdoor unit air short

• Indoor unit, heat exchanger dirty, clogged

• Large pipe side service valve closed

• Indoor fan stop

• Air filter clogged

Are there connection defects in the wiring?

No

High-pressure switch defect

Yes

Repair the wiring.

0344_M_I

2

3

4

SM830076

– 67 –


(Negative phase detection operation warning)

Start


Section

1

2

Is the power supply to the outdoor unit normal?

(Voltage defective phase?)

Yes

No

Does the outdoor unit operate when two of the three phases are changed?

(Actuation of negative phase protector)

No

Yes

Is the fuse (F1, F2) on the indoor unit PCB blown?

No

Yes

Is there a contact defect in the

3P connector?

No

Yes

Check the power breaker etc. and repair

No problem

Replace the fuse.


3

Replace the outdoor PCB


0345_M_I

Start

4

When the group of the units are installed, is there any mis-cross between interunit control wiring and refrigerant tubing?

No

Yes

Are the total capacities of indoor units to that of outdoor units less than 93%?

No

Yes

Repair the wiring.

Select an indoor unit which matches with the outdoor capacity.

Are there no contact failure between outdoor and indoor units?

Yes

No

Perform the same as “CHECK E04”.

Check the contact.

0646_M_S

– 68 –

SM830076



Start

When the group of the units are installed, is there any mis-cross between inter unit control wiring and refrigerant tubing?

Yes

No

Are the total capacities of indoor units to that of outdoor units more than 107%?

Yes

No

Repair the wiring.

Select indoor units which match with the outdoor capacity.

Confirm less than 5 indoor units are connected.

No

16) Symptom: LCD on the remote controller displays “CHECK L13”.

0647_M_S

Start

When the group of the units are installed, is there any mis-cross between inter unit control wiring and refrigerant tubing?

Yes

No

Check the capacity of the indoor unit by remote controller.

See Test Run Manual.

17) “Check P9” is displayed on the remote control unit.

Start

Repair the wiring.

0648_M_S

Is 15P connector socket (RED) being attached to panel connected firmly with 15P plug?

Yes

Yes

Replace P.C.B. Ass’y in the indoor unit.

Connect firmly.

0649_M_S

– 69 –

SM830076

Section

1

2

3

4

Section

1


18) Symptom: LCD on the remote controller displays “CHECK H01, H02, H03”.

(compressor current detection)

* Please check the related part described in the following chart after confirming the code setting (S4) of the outdoor unit’s capacity on the PCB in the outdoor unit.

Start

“CHECK H01” display

Compressor overload detection


Compressor lock detection


Compressor current detection circuit defect

2

• Insufficient voltage

• Comp. motor magnetic contactor

defect

• Refrigerant over-charged

Compressor lock • L3 phase wire disconnected

• Comp. motor magnetic contactor

defect

• Outdoor unit PCB defect

0346_M_I

3

19) Check the indoor unit (When the alarm of communication failure is not activated)

¶

If the electronic control valve failure occurred in Flexible Combination system

(simultaneous operation system), one indoor unit would not be operated normally, then the other units won’t be operated either. Due to this, try to detect the troubled unit and correct it.

Operate the unit in cooling mode.

(30 minutes after its operation)

4

• Cooled air comes out.

• Is the temperature of each indoor coil sensor almost

the same? (Refer to the sensor temperature

display function of the remote controller.)

No

Yes

Normal

• Does each indoor coil sensor detect the temperature

correctly? (Is there any leakage from the pipe of the

temperature detection section?)

No

Replace the sensor.

Yes

Failure in the electronic control valve activation.

0460_M_I

SM830076

– 70 –


(6) Procedures When a Specific Component Does Not Work

1) Indoor fan does not operate.

No

Is fan motor capacitor normal ?

Replace the capacitor.

Yes

Is there voltage output of P.C.B. Ass'y for fan motor ?

Yes

No Replace the P.C.B. Ass'y in the indoor unit.

• Check resistance of

fan motor winding.

Out

Replace the fan motor.

0650_M_S

2) Flaps in indoor unit’s air outlet does not operate, when you press SWEEP button.

No

Check the louver motor resistance.

Is auto louver motor normal?

Yes

Replace the motor.

Is 2P connector socket (WHT) attached to panel connected firmly with 2P plug ?

Yes

No

Replace P.C.B. Ass'y in the indoor unit.

Connect firmly.

1200_M_S

Section

1

2

3

4

– 71 –

SM830076

3) Compressor motor does not operate.

Does compressor motor magnetic contactor (52C) actuate ?

No

Yes

Check resistance of compressor motor winding.

NG

Section

1


2

4) Outdoor fan does not operate.

Are auxiliary relays (1Y) normal ?

Yes

No

3

Is fan motor capacitor normal ?

Yes

No

4

Is there voltage output of

P.C.B. Ass’y for fan motor ?

Yes

No

Check resistance of fan motor winding.

NG

Replace the fan motor.


Replace the compressor motor magnetic contactor.

Replace the relays.

0461_M_I

Replace the capacitor.

Replace P.C.B. Ass’y in the outdoor unit.

1148_THS_I

SM830076

– 72 –


(7) Service Functions of Optional Wired Remote Controller

(Temperature displayed on the screen is not °F but °C.)

From the remote controller you can control both the operation and settings of the unit as well as perform several useful service checks. This section explains how to use the remote controller on the following items from (A) to (J).

(A) Set service check switches.

(B) Use the test run procedure.

(C) Check the sensor temperature readings.

(D) Find out about past service problems.

(E) Check the remote controller itself for correct operation.

(F) Excute the auto. address operation.

(G) Confirm and change the indoor unit address.

(H) Change the shift temperature in heating mode

( I ) Set the indoor unit address.

(J) Change the period of the filter timer

(A) Set service check switches

The service check switch (RCU.CK) is located on the back of the remote controller’s P.C.B.

Ass’y as follows :

Section

1

2

3

4

0354_M_I

The followings are the correct switch settings for ordinary use of the unit. Only change the settings temporarily for making service checks. When you finish the settings, be sure to

return them to the standard settings shown here.

❏ RCU.CK switch - Refer to section (E) “ Checking the remote controller for correct

operation”

(Remote Control Unit, Check)

❏ RCU.ADR switch - Keep the switch OFF all the time except in case of sub remote controller

(Remote Control Unit, Address)

SM830076

– 73 –


Section

1

2

3

(B) Use the test run procedure

❏ The purpose of the test run function is to let you control the operation of the unit directly without turning the unit on or off by thermostat. As indicated in the following procedure, be sure to stop test run operation when you finish the procedure, or the air conditioner may be damaged.

❏ To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes after power is applied or the unit is turned OFF.

a Press the TEST / CHK button at the bottom right on the remote controller.

b Press the ON / OFF operation button to start the test run.

c Press the MODE button to select either COOLING or HEATING mode.

d When the test run starts, “TEST” shows on the remote controller’s display.

e During the test run, the air conditioner runs continuously and the thermostat does not control the system.

f After the test run, be sure to press the

TEST / CHK button once again to finish this mode and make sure “TEST” is not shown on the display.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

A

°

C

TEST

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK

Alarm message

TEST RUN / CHECK button

ON / OFF operation button

1152_THS_I

4

CAUTION

The TEST RUN button is used only for servicing the air conditioner. Do not press this button in normal operation, or the system may be damaged.

SM830076

– 74 –


(C) Check the sensor temperature readings

The air conditioner has thermo sensors which are used to control the unit.

❏ Each sensor has an address which is made up of the indoor unit address, and the sensor address. The indoor unit address is used only when several units are hooked up to one remote controller (group control). If there is only one unit, made up of one indoor and one outdoor unit, then only the sensor address should be put in, as shown in the procedure below.

Follow this procedure to display the temperature of each sensor: a On the remote controller, press both TEST / CHK and CL buttons at the same time for more than 4 seconds.

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

A

R.C.

AIM

No.

CODE No.

°

C

SWEEP

SET TEMP.

SETTING

MODE

SET TEMP.

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

Section

1

2

0356_M_I b The UNIT No., the address and temperature of the sensors instead of its usual information will flash on the display.

❏ Following example shows the UNIT No. (Indoor unit address) is fixed at 01– 01.

❑ In case of group control, select the UNIT NO. (Indoor unit address) which you want to check with UNIT button.

❏ Each time you press the , (SET TEMP.) button you can select a different sensor, and the display shows the sensor address and temperature as shown below.

3

UNIT No. (Indoor unit address)

4

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

MODE

SET TEMP.

SETTING

DATA

FAN SPEED

MONITOR

SET CL

ON

OFF

•

•

TEST / CHK

Sensor address

Sensor temperature

°

C

0357_M_I

NOTE

Do not press TIMER SET button during the procedure.

SM830076

– 75 –


Section

1

2

Refer to the table below for the relationship between the sensor address and the location of the sensor.

Relationship between the sensor address and the location of sensor

Sensor Address

(CODE No.)

Location of Sensor (Themistor)

Indoor Unit 01 —

02 TH1 Indoor air suction Temp.

03 TH2 Indoor coil Temp. (E1)

04 TH3 Indoor coil Temp. (E2)

05 —

06

07

08

—

—

Electronic expansion valve open

09 —

Outdoor Unit 0A TH8 Discharge gas Temp.

0B —

0C —

0D TH7 Outdoor coil liquid Temp. (C2)

0E TH6 Outdoor coil liquid Temp. (C1)

0F

10

11

—

—

—

12

13

14

—

—

—

NOTE

In case there are no sensor equipped with the unit, “- - -” is shown on the display.

3

4

C Resetting the remote controller display to previous mode.

❏ To reset the display, press TEST / CHK button, then the remote controller will return to previous mode.

(D) Find out about past service problems

The remote controller can memorize the max. 4 most recent alarm messages, so you can see problems the unit has had, if any. Knowing what has already occurred and been fixed helps you to know what to check at present.

❏ This function is usable even if the unit is not working.

❏ To display the past error codes, follow the procedure below.

Procedure: a On the remote controller, press both TEST / CHK and SET buttons at the same time for more than 4 seconds.

b Once in this mode, display changes from the normal display to service check display as shown in the table below:

NORMAL DISPLAY

Display Change

( È )

SERVICE CHECK DISPLAY

Set temp.

UNIT No.

Hours, Minutes

È

È

È

Code No.

UNIT No. (Indoor unit address)

Alarm Message

SM830076

– 76 –


This picture shows the service check display.

UNIT No.

UNIT No.

1–1

No.

Refrigerant

Circuit No.

R.C.

No.

CODE No.

CODE No.

CHECK

Alarm message

SERVICE

0358_M_I c . A maximum of 4 alarm messages can be accessed by pressing either SET TEMP button or as follows.

MODE

Section

1

SET TEMP.

Past

Present

Present

NOTE Pressing CL (Clear) button will clear all the service history.

Past

... accessed in order of “Past È Present”.

FAN SPEED

0359_M_I

... accessed in order of “Present È Past”.

For example, if the last four alarm messages were, in order of occurrence from oldest to most recent, P01, P02, P04, and most recently E01, then the display will be shown as below when you press button four times. The 5th time you press button you can repeat the display, then the first message will be shown again.

1 2 3 4

UNIT No.

R.C.

No.

CODE No.

UNIT No.

R.C.

No.

CODE No.

UNIT No.

R.C.

No.

CODE No.

UNIT No.

R.C.

No.

CODE No.

2

3

4

CHECK

SERVICE

CHECK

SERVICE

CHECK

SERVICE

CHECK

SERVICE

If there are no alarm messages, the display shows:

Alarm message

UNIT No.

R.C.

No.

CODE No.

CHECK

SERVICE

– 77 –

0360_M_I

SM830076


Important

Never press CL (clear) button unless you want to erase the accessed data in memory. Follow the procedure below only when erasing is necessary.

❏ To erase accessed data, press the CL button.

❏ When erasing is finished,“----” mark appears on the controller’s display.

CAUTION

Section

1

2

After checking the alarm messages, be sure to press the TEST / CHK button.

(E) Check the remote controller itself for correct operation

The remote controller has a self-diagnostic function to check if it works properly. Use this procedure to find out if the remote controller itself is in trouble.

a Turn ON the RCU.CK switch on the back of the P.C.B. Ass’y in the remote controller. See section (A) for exact location.

b The appearance of the display will tell you whether or not the remote controller is working correctly or not.

❏ Normal condition – All displays appear for 10 seconds, then disappear.

❏ Unusual condition – All displays flash ON and OFF for 10 seconds, then disappear.

3

CAUTION

After checking the panel, be sure to set the RCU.CK switch to this original OFF position.

4

– 78 –

SM830076


(F) Execute the auto. address operation

❏ Auto. address operation is executed by pressing the A. ADD (S1) button of outdoor unit’s PCB usually.

For your convenience it can be executed by remote controller also.

a Press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds.

b Set CODE No. A1 with , (SET TEMP) button.

AIR FLOW

UNIT

FLAP

TIMER SET

R.C.

CODE No.

SETTING

MODE

SET TEMP.

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

In this mode, the auto. address operation is executed at each R.C.

(Refrigerant Circuit) line one by one.

Section

1

2

0361_M_I c Select R.C. No. which you want to execute the auto. address operation with UNIT button.

d Press the SET button. The auto. address operation will start. CODE No. changes from flashing to ON state.

e If an error occurs during operation, the alarm message will be displayed. Check and remove the cause. If you want to stop the operation, press the CL button then the unit stands in waiting mode (Press the SET button again.) f If the automatic address operation finishes, the display will disappear.

g Execute the operation of the other R.C. line in the same way by following the above steps c to d .

h Complete the automatic address operation by pressing the TEST / CHK button.

3

4

SM830076

– 79 –


(G) Confirm and change the indoor unit address

❏ The purpose of the above function is to let you confirm the indoor unit address after the auto. address operation, and change the indoor unit address if it is needed.

a Press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds.

Section

1

AIR FLOW

UNIT

FLAP

TIMER SET

R.C.

MODE

CODE No.

SET TEMP.

SETTING

SET DATA

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

2

3

4

0362_M_I b Select the R.C. No. which you want to change with the UNIT (up) or FLAP (down) buttons.

c Press the SET button (to confirm the R.C. No.).

The smallest registered indoor No. and the selected R.C. No. will be displayed.

AIR FLOW

UNIT UNIT No.

MODE

Ex:

R.C. No. 3 is selected.

Indoor No. 2 is the smallest indoor No. of the R.C. No. 3.

R.C.

No.

FLAP

SET TEMP.

CODE No.

TIMER SET

FAN SPEED

SETTING

SET DATA

SET CL

ON

OFF

•

•

TEST / CHK

0363_M_I d Select the indoor No. which you want to change with UNIT button. Once in this mode, the fan motor of selected indoor unit will turn on and let you confirm the indoor unit address.

SM830076

– 80 –

4. Service procedures e Set the required new indoor unit’s No. by pressing the , ( ) button.

AIR FLOW

UNIT

FLAP

TIMER SET

R.C.

No.

CODE No.

MODE

SET TEMP.

SETTING

SET DATA

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

Ex: UNIT No. 3-6: currently registered indoor unit address

Required new indoor No.8: SET DATA

* In this case, UNIT No. 3 – 6 (current)

=

3 – 8 (NEW : after pressin the

TEST / CHK button)

0364_M_I f Press the SET button.

UNIT No, SET DATA (0008) and

SETTING changes from flashing to ON state.

g If you made a mistake, press the CL button.

h Finally, press the TEST / CHK button.

i If you want to change the indoor unit address of the other R.C. No., follow the step a to h in the same way.

Section

1

2

3

4

– 81 –

SM830076


(H) Change the shift temperature in heating mode

❏ If the indoor unit is installed at high location (ex. ceiling level), the thermostat tends to turn off at heating mode because of the hot air temperature around ceiling level. In order to solve the problem, the shift temp. (valid while heating only) is set when shipped from factory.

❏ If the shift temp. is not enough (ex. the indoor unit is installed at position higher than 3 m), the shift temp. can be set with remote controller from +1 to +10 deg (°C) <from +2 to 20 deg (°F)>.

manually as follows: a Press the TEST / CHK button for more than 4 seconds.

Section

1 AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

SETTING

SET DATA

SET CL

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK 2

3

4

0365_M_I b In case of group control, if you want to change all units in group control collectively, proceed next step remaining ALL displayed.

If you want to change a unit individually, select the indoor unit address (UNIT No.) with

UNIT button.

c Select the CODE No. 06 with , (SET TEMP) button.

d Choose the shift temp with , ( ) button.

AIR FLOW

UNIT

FLAP

UNIT No.

R.C.

No.

CODE No.

MODE

SET TEMP.

EX:

UNIT No. 1–6

CODE No. 06

Shift temp. +5 deg (°C)

<+10 deg (°F)>

TIMER SET

SET TEMP.

SETTING

SET DATA

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

0366_M_I e Press the SET button.

CODE No. 06, SET DATA and

SETTING change from flashing to ON state.

f If you made a mistake, press the CL button.

g Finally, press the TEST / CHK button.

– 82 –

SM830076


( I ) Set the indoor unit address

❏ This function is usable if the auto. address operation is not available.

Indoor unit address can be set one by one by remote controller in such case.

NOTE

1) In case of group control, branch wiring for group control should be removed temporarily.

2) In case of remote controllerless system, remote controller should be connected with the indoor unit temporarily.

a Short the two terminals of DISP PIN on indoor unit PCB.

(DISP PIN : Refer to P. VI–2) b Press the TEST / CHK , SET and CL buttons at the same time for more than 4 seconds.

Section

1

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

SETTING

SET DATA

SET CL

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0367_M_I c Set the CODE No. 12 to set the No. of R. C. with the , (SET TEMP) button.

2

3

4

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

SETTING

SET DATA

SET CL

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0368_M_I

SM830076

– 83 –

4. Service procedures d Set the No. of R. C. which you want to set with , ( ) button.

Ex. No. of R. C. will be set 2.

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

SETTING

SET DATA

SET CL

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK

Section

1

2

0369_M_I e Press the SET button.

UNIT No., CODE No. 12,

SETTING and SET DATA (0002) change from flashing to ON state.

f Select the CODE No. 13 to set the indoor unit No. with the , (SET TEMP) button.

g Set the indoor unit No. which you want to set with the , ( ) button.

3

Ex. Indoor unit No. 4 will be set.

In this example, indoor unit address

(UNIT No.) will be set 2–4.

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

MODE

SET TEMP.

SETTING

SET DATA

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

4

0370_M_I h Press the SET button.


SETTING and SET DATA (0004) change from flashing to ON state.

SM830076

– 84 –

4. Service procedures i Select the code No. 14 to set group setting with the , (SET TEMP) button.

j Set the No. of group setting as shown below with the , ( ) button.

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

SETTING

SET DATA

SET CL

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK

Nos. of group setting.

0 : Standard system (except group control)

1 : Main indoor unit in case of group control

2 : Sub indoor unit in case of group control

99: No setting (at factory shipment)

Section

1

0371_M_I k Press the SET button.


SETTING and SET DATA change from flashing to ON state.

l If you made a mistake, press the CL button so that setting returns to the initial state.

m Press the TEST / CHK button to finish this mode.

The display is disappeared.

n Confirm the indoor unit address (UNIT No.) with the UNIT button after pressing the ON /

OFF button.

o Finally, remove the short circuit of DISP PIN.

And in case of group control, be sure to restore the branch wiring to its original wiring. In case of remote controller–less system, remove the remote controller.

2

3

4

– 85 –

SM830076


Section

1

(J) Change the period of the filter timer

❏ If the period of filter timer is not suitable (for example in case of dirty environment), the period can be shortened to half as follows: a Press the TEST / CHK button for more than 4 seconds.

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

SETTING

SET DATA

SET CL

ON

OFF

•

•

MODE

SET TEMP.

FAN SPEED

TEST / CHK

2

3

0213_M_I b In case of group control, if you want to change all units in group control collectively, proceed next step remaining “ALL” displayed.

If you want to change a unit individually, select the indoor unit address (UNIT No.) with

UNIT button.

c Select the CODE No. 02 with , (SET TEMP) button.

d Change the No. from 0 to 1 with , ( ) button.

EX:

UNIT No. 1–6

CODE No. 02

K type 150 hr → 75 hr

4

AIR FLOW

UNIT

FLAP

TIMER SET

UNIT No.

R.C.

No.

CODE No.

MODE

SET TEMP.

SET TEMP.

SETTING

SET DATA

FAN SPEED

SET CL

ON

OFF

•

•

TEST / CHK

0214_M_I e Press the SET button.

CODE No. 06, SET DATA and

SETTING change from flashing to ON state.

f If you made a mistake, press the CL button.

g Finally, press the TEST / CHK button.

SM830076

– 86 –


4-2 Checking the Electrical Components

Earthed wire

(1) Measurement of Insulation

Resistance

• The electrical insulation is acceptable when the resistance exceeds 1 M

Ω

.

1 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. 21)

Then measure the resistance between the earthed wire and the other power wires. (Fig. 21)

2 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. 22)

3 Outdoor Unit

Measure the resistance by placing a probe on the terminal plate in the same manner as explained above 2 . (Fig. 22)

4 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. 23)

• Similarly, disconnect the lead wires from compressor, capacitor, etc.

(Fig. 24)

• Measure the resistance in the same manner as illustrated on the right.

Refer to Electrical Wiring Diagram.

Probe

Clip

Copper tube or metallic part

Clip

Copper tube or metallic part

Clip

Terminal plate

Insulation tester

0638_X_S

Probe

Insulation tester

0639_X_S

Probe

Insulation tester

0640_X_S

From fan motor, compressor and other parts.

NOTE

If the probe does not enter the hole because the hole is too narrow, use a probe with a thinner pin.

Metallic part

Clip

Probe

Fig. 21

Fig. 22

Fig. 23

Section

1

2

3

4

Insulation tester

0641_X_S

Fig. 24

SM830076

– 87 –


Section

1

(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. 25.

• 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.

socket

Multimeter

Ω

2

0642_X_S

Fig. 25

3

4

1 Indoor fan motor thermal protector (49FI) . . . . . . Indoor unit

• Disconnect the connector which leads to the indoor fan motor (FMI).

• Check the socket’s terminals.

2 Compressor motor thermal protector . . . . . . Outdoor unit

• Disconnect the wires from terminals of compressor.

• Check the terminals of compressor.

3 Outdoor fan motor thermal protector (49FO) . . . . . . Outdoor unit

• Disconnect both the connector which leads to the outdoor fan motor (FMO).

• Check socket’s terminal.

– 88 –

SM830076


(3) Checking the Electrical Parts

1 Power transformer (TR1) ..................... Indoor unit *Measure the coil resistance.

• Primary 230-208V ; Measure the resistance between No.1 and No.3

(WHT lead wires) terminals of 3P (WHT) socket connected to power transformer.

• Secondary 14.8V ; Measure the resistance between No.1 and No.2

(RED lead wires).

14.8V ; Measure the resistance between No.3 and No.4

(BRN lead wires).

Refer to “1-3 Other component specifications”.

2 Power transformer (TR) .................... Outdoor unit *Measure the coil resistance.

• Primary 230-208V ; Measure the resistance between No.1 and No.3

(WHT lead wires) terminals of 3P(WHT) socket jointed to power transformer.

• Secondary 14 V ; Measure the resistance between No.1 and No.2

(BRN lead wires).


3 Indoor fan motor (FMI) ......................... Indoor unit *Measure the coil resistance.

• Measure the resistance between each terminal of 7P (WHT) socket and 3P (YEL) socket connected to the indoor fan motor.

Refer to “1–2–(A) Major component specifications”.

4 Outdoor fan motor (FMO) .....................Outdoor unit *Measure the coil resistance.

• Measure the resistance in the same manner as explained above 3 .

Refer to “1–2–(B)Major component specifications”.

Section

1

2

3

4

– 89 –

SM830076


5 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. 26. Observe the deflection of the pointer, setting the resistanc measuring range of the multimeter to the maximum value.

• The capacitor is “good” if the pointer bounces to a great extent and then gradually returns to its original position.

Section

1

NOTE

The range of deflection and the deflection time differ according to the capacity of the capacitor.

Multimeter

Ω

2

3

4

6 Continuity of fuse on P.C.B. Ass’y

• Check for continuity using a multimeter as shown in Fig. 27.

NOTE

Method Used to Replace Fuse on PCB Ass’y

1. Remove the PCB Ass’y from the electrical component box.

2. 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. 28)

3. 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.)

CAUTION

When replacing the fuse, be sure not to break down the varistor.

– 90 –

Compressor motor capacitor

Pliers

Fan motor capacitor

1041_X_S

Fig. 26

Fuse

Soldering iron

1042_X_S

Fig. 27

PCB Ass’y

Fuse Varistor

1043_X_S

Fig. 28

SM830076


7 Solenoid coil of the electronic refrigerant control valve (ERCV) ………… Indoor unit

*Measure the coil resistance.

• Measure the resistance between No. 5 (GRY lead wire) and other terminals (another color of lead wires) of 5P (WHT) plug connected to the solenoid coil.

Refer to “1-2-(A) Major component specifications”.

8 Compressor motor (CM) ……… Outdoor unit

• In case of single -phase compressor

*Measure the coil resistance.

Remove the cover of compressor terminal and measure the resistance between terminals.

Refer to “1-2 Major component specifications”.

9 Compressor motor magnetic contactor (52C) ………… Outdoor unit

• Measure the resistance between A (ORG lead wire) and B (GRY lead wire) terminals on the compressor motor magnetic contactor.


• Check the continuity between contactors.

MODEL FMCA–1UL

Push button on the magnetic contactor R – U

Pair of terminals

S – V T – W 31 – 32

–––– –––– –––– YES no press press YES YES YES ––––

0 Solenoid coil of 4-way valve (20S) … Outdoor unit *Measure the coil resistance.

• Measure the resistance between No.1 (BLK lead wire) and No.2 (BLK lead wire) terminals of 2P (BLK) socket connected to the solenoid coil.

Refer “1-3 Other component specifications”.

Section

1

2

3

4

– 91 –

SM830076

(4) Sensor and Solenoid Layout Diagram

Indoor Unit

• XHS2432

Electronic expansion valve


Section

1

TH2 (E1), (RED)

TH3 (E2), (BLK)

1582_X_I

2

Outdoor Unit

• CH2432

TH6, 7, 8

3

TH8 (GRN)

( Discharge gas)

4

CM

CH

1153_THS_I

63PH

20S

TH8

(GRN)

TH6 (C1), (BLK)

TH7 (C2), (RED)

1154_THS_I

SM830076

– 92 –

(4) Sensor and Solenoid Layout Diagram

Indoor Unit

• XHS3632

Electronic expansion valve

TH2

(E1), (RED)

TH3 (E2), (BLK)


Section

1

1583_X_I

Outdoor Unit

• CH3632

2

TH6, 7, 8

3

TH7 (C2), (RED)

20S

63PH

TH8 (GRN)

( Discharge gas)

4

TH6 (C1), (BLK)

CM

CH

0585_C_S

0584_C_S

SM830076

– 93 –


Section

1

2

3

(5) Thermistor Characteristic Curve

(1) Room temp. sensor : TH1 (KTEC-35)

5

4

7

6

3

10

9

8

2

1

50 59 68 77 86

Temperature (

°

F)

95 104

1044_M_I

(2) Indoor heat exch.

coil sensor : TH2(E1), TH3(E2)

Outdoor heat exch. coil sensor : TH6(C1), TH7(C2)

30

25

20

15

10

5

0

( PBC-41E)

40

35

–4 5 14 23 32 41 50 59 68

Temperature (

°

F)

1045_M_I

(3) Compressor discharge gas temp. sensor : TH8 (PTC-51H)

4

5

4

3

2

1

7

6

176 194 212 230

Temperature (

°

F)

248 266

1149_THS_I

SM830076

– 94 –


(6) P.C.B. Setting

● Setting of outdoor control P.C.B.

(A) Standard control (single outdoor unit)

In case of single outdoor unit installation, no indoor unit’s setting is necessary for twin, triple or quartet types (2, 3 or 4 indoor units).

Leave R.C. address setting at “0” as factory shipment state.

In this case, auto. address operation is performed automatically for the first time when the power is switched on. This operation takes about a few minutes.

(B) Group control (Multiple outdoor units)

In case of group control (up to 8 indoor units can be connected with one *wired remote controller), before turning on the power supply, set the R.C. address with S2, S3 on the outdoor control P.C.B..

R.C. address: Refrigerant circuit address 1 ~ 30.

Regarding the example of R.C. address for group control, please refer to R.C. Address

Setting Method.

(C) Central control (when using the *system controller)

In case of central control (when using the system controller,that is, when linking outdoor units in a network),

(a) Before turning the power supply on, set the R.C. address with S2, S3 on the outdoor control P.C.B..

(b) Remove the short plug (CN4, 2P Black) from all outdoor units except one outdoor unit.

Regarding the example of R.C. address for central control and the position of CN4, please refer to R.C. Address Setting Method.

* Temperature displaed on both controllers are not °F but °C.

● Setting of indoor control P.C.B.

No setting is necessary.

Each indoor unit address (UNIT No.: R.C. – No.) is decided after auto. address operation.

Indoor unit No.

Refrigerant Circuit No. (R.C. address)

Manual setting for indoor unit address can be performed also by remote controller.

Section

1

2

3

4

SM830076

– 95 –


(7) R.C. Address Setting Method

Section

1

Outdoor unit R.C. address setting method

In case of group control or central control, set the R.C. address to 1, 2, 3, ... according to the

No. of outdoor units.

Outdoor control PCB

CN4 (2P Black)

Refrigerant circuit address

(factory setting = 0)

Refrigerant circuit address (black)

0

: S2

Refrigerant circuit address

(2P DIP switch, green or Blue)

10 20 position position

ON ON side

: S3

1 2

OFF side

A. ADD (S1):

Automatic address setting start button

Used for central control (link system) and group control (Normally, not used)

1126_C_I 2

3

4

R.C. address

00 auto address

(“0” when shipped from factory)

R.C. address R.C. address

(S3: 2P dip switch, green or Blue) (S2: Rotary switch, Black)

ON ON side

0

Both OFF Set to 0

1

ON

2

OFF side

ON side

2

02 (In case of No. 2 outdoor unit) Both OFF Set to 2

1

ON

2

OFF side

ON side

03 (In case of No. 3 outdoor unit) Both OFF Set to 3

1

ON

2

OFF side

ON side

1

11 (In case of No. 11 outdoor unit) 10’s SW is ON

1

ON

2

OFF side

ON side

21 (In case of No. 21 outdoor unit) 20’s SW is ON

30 (In case of No. 30 outdoor unit)

Both 10’s and 20’s switches are ON

1

ON

2

OFF side

ON side

1 2

OFF side

0

1

Set to 1

Set to 1

Set to 0

SM830076

– 96 –


(8) Automatic Address Setting Method

— For group control and central control with multiple outdoor units —

Carry out automatic address setting with the remote controller.

1) All auto. address operation

1 Press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds.

2 Press the SET button after confirming the CODE No. AA (CODE

No. AA: All Auto. address operation).

After addresses are automatically set in order for the outdoor units from

No. 1 to No. 30, the system returns to the normal stopped state.

2) Individual auto. address operation for each refrigerant circuit

1 To select each refrigerant circuit individually and set addresses automatically, press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds, then press the , (SET TEMP) button once to set CODE No. A1.

(CODE No. A1: Auto. address operation)

2 Select R.C. No. which you want to execute the auto. address operation with UNIT button.

3 Press the SET button. The auto. address operation will start. CODE No. changes from flashing to ON state.

4 If the error occurred during the operation, the alarm message will be displayed. Check and remove the cause. If you want to interrupt the operation, press the CL button then the unit stands in waiting mode

(Press the SET button).

5 If the auto. address operation finishes, the display will disappear.

6 Execute the operation of the other

R.C. line in the same way by following the above steps 2 to 3 .

7 Complete the auto. address operation by pressing the TEST / CHK button.

NOTE

Required time for auto. address operation:

In case of group control : a few minutes for each R.C.

In case of central control : max. about 20 min. for each

R.C.

(9) Displaying Indoor / Outdoor Unit

Combination Numbers

Display the indoor / outdoor unit address after automatic address setting.

1) When installing multiple units, match the indoor unit address numbers and the outdoor R.C. address numbers and display them at an easy-to-check location

(near the nameplate) with an oil-based magic marker or other indelible marker so that the individual indoor and outdoor unit combinations can be checked.

Example:

Outdoor Unit 1 – Indoor Units 1-1, 1-2,

1-3, ....

Outdoor Unit 2 – Indoor Units 2-1, 2-2,

2-3, ....

2) Displaying indoor / outdoor unit address is necessary for maintenance. Always label numbers.

*Check indoor unit address with the remote controller. Press the TEST / CHK button for at least 4 seconds and check the indoor unit address with the UNIT button. (Each time you press the UNIT button, the address changes 1-1, 1-2, ...

2-1, 2-2, ...) The fan for only the selected indoor unit turns on at high speed, so check which indoor unit runs and label the indoor unit address.

(If there is 1 outdoor unit, the addresses are 1-1, 1-2, ...)

When you press the TEST / CHK button again, the system returns to normal remote control mode.

Section

1

2

3

4

SM830076

– 97 –

(10) Items to Check Prior to Test Run

Section

1

1) Turn on the power supply switch more than 5 hours before in order to charge the crank case heater.

2) Fully open the outdoor service valve after making the leak inspection of field connected tubing, vacuuming, and gas charging if necessary.

3) Check the capacity code setting.

* The factory setting is as shown in the table below check it.

* The capacity code is set by S4 (green or Blue 4P DIP switch) on outdoor control P.C.B..

2

Outdoor control PCB


3

4

S4 (green or Blue) capacity code

(4P DIP switch)

ON ON side

1 2 3 4

OFF side

S4. Capacity code

Model No.

No.

1

Outdoor PCB

2 3 4

24 type (1 phase) ON ON ON OFF

36 type (1 phase) OFF ON OFF ON

1127_C_I

SM830076

– 98 –


(11) Test Run

(11)-1. Preparing for Test Run

Before starting the air conditioner, check the followings:

(1) Remove all loose matter from the cabinet especially metal filings, bits of wire, and clips.

(2) Connect the control wiring correctly and tighten all electrical connections.

(3) Remove the protective spacer for the compressor used for transportation.

(4) Connect the power to the unit for at least 5

hours before starting the compressor. The bottom of the compressor should be warm to the touch and the crankcase heater around the feet of the compressor should be hot to the touch. For

Ceiling mounted and Recessed Type indoor units, the flap(s) move(s) for one minute when the power is connected to the unit.

This is not the malfunction.

(5) Open both the wide and narrow tube service valves after air purge.

(6) Remove the transportation cardboard protection for the indoor fan.

(11)-2. Performing Test Run

CAUTION

Be careful since the fan will start when performing Test

Run.

For XHS models

(1) For XHS models, the Operation Selector is located above the electrical component box inside the indoor unit. To access the Operation Selector, press the two latches of the air intake grille in the direction of the arrow to open the grille. Open the air intake grille downward. (Fig. 11-1)

(2) Set the TEST RUN switch of the SERVICING switches on the Operation Selector (housed inside the indoor unit) to the ON position. (Fig. 11-1)

(3) Press the ON/OFF operation button on the remote control unit and start the air conditioner in

Cooling or Heating mode.

(4) Let the unit run for about 30 minutes and check that the unit operates normally.

(5) After the test run, be sure to set the TEST RUN switch back to the OFF position to cancel the test run mode. Then stop the air conditioner.

– 99 –

All OFF for

ON

OFF

1 2 3 4

1. TEST RUN(ON)

2. PCB CHK.(ON)

3. RCU MAIN(OFF)

/ SUB(ON)

4. OFF

ADDRESS

1 2 3 NORM. HOLD

SWEEP

ON • I

OFF•O

Operation selector

1 2 3 4

1. TEST RUN

2. (OFF)

3. (OFF)

4. (ON)

Air filter

Fig. 11-1

Air intake grille

1584_M_I

SM830076

Section

1

2

3

4

Important

Set the Operation Selector at the “ON” position. Otherwise the unit will stop or will not run correctly.

CAUTION

The TEST RUN switch is used only for servicing the air conditioner. DO NOT use this switch for normal operation.

Otherwise, it may put stress on the system.

Section

1

2

NOTE

● During the test run, all of the 3 indicator lamps on the indoor unit will flash.

● During the test run, the air conditioner runs continuously and the thermostat does not control the system.

● To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes after power is applied or the air conditioner is turned off and then back on.

● When the air conditioner fails to start the test run, 1 or more of the 3 alarm indicator lamps on the indoor unit will flash.

3

4


– 100 –

SM830076


(11)-3. Test Run Procedure

Start

Yes

Multiple remote control?

No

Yes Turn on RCU address SW of sub remote control unit

Recheck the test items before test operation.

Check the indoor and outdoor unit combination (wiring).

Single type?

(One indoor unit and one remote controller for one outdoor unit)

Group control

for multiple outdoor units?

No

Yes

No

Yes

Go to next

R.C. line

No

Finish all

R.C. line?

Multiple indoor units for one outdoor units?

Yes

No

Turn on power supply for indoor units side first. Then turn on power supply for outdoor unit side.

Set the outdoor unit R.C. address.

Turn on power supply switch.

or

Press A. ADD (S1) button.

Execute auto. address operation with the remote controller.

Central control for multiple outdoor units?

No

Yes

Yes

Go to next

R.C. line

No

Finish all

R.C. line?

or

CN4: Open (*)

Set the outdoor unit R.C. address.

Turn on power supply switch.

Press A. ADD (S1) button.

Execute auto. address operation with the remote controller.

Display the combination number.

Section

1

2

3

4

Set the remote controller to test operation.

Does the unit work?

No Check according the self-diagnostics function table, and if you find defective parts, repair them according to

Service Manual.

Note: Check the indoor side drain water.

Yes

Return the remote controller to normal.

End

1585_M_I

NOTE

1) One of CN4 of all linked outdoor units shold be short.

2) In case of using system controller, zone registration is required after finishing Test run.

Regarding the zone registration, please refer to Installation Instructions attached with system controller.

SM830076

– 101 –


Section

1

(12) P.C.B. and Parts Location

● P.C.B. (CR-THS2432) FOR INDOOR UNITS

CN78 (BLU) : DP

CN85 (BLU) : DPH

CN81 (GRY) : 49FI

CN84 (YEL) : COM

CN80 (RED) : 26H

CN77 (GRN) : LM

F2 : Fuse 250V / 3A

CN74 (WHT) : PRY

CN73 (BLK) : SUP

F1 : Fuse 250V / 3A

CN75 (WHT) : SEC

CN83 (WHT) : FMI

2

3

4

JP1 (Jumper wire)

: For sellecting the

signal of T10.

Shipment state

: Pulse signal

Jumper cut

: Static signal

CN71 (YEL) T10

: External input and

output terminal

E

2

P-ROM

CN30 (BRN) : COIL E3

CN6 (RED) EXCT

: Forced thermostat

OFF input terminal

CN32 (BLK) : COIL E2

CN31 (RED) : COIL E1

CN33 (YEL) : ROOM TEMP

CN1 (WHT) : DISP PIN

CN2 (WHT) : CHECK PIN

CN3 (WHT) : TEST PIN

CN5 (WHT) : FORCED OPR

CR-THS2432

CN9 (RED) : FS

CN70 (WHT) : T6

CN41 (BLU) : Wired remote controller

CN42 (BLU) : For wireless remote controller

CN35 (GRN) : PNL

– 102 –

CN44 (BRN) : SG2

CN40 (BLU) : SG1

F3 : Fuse 125V / 0.5A

1128_THS_I

SM830076


(12) P.C.B. and Parts Location

● P.C.B. (CR-CH2432) FOR OUTDOOR UNITS

CN21 (YEL) : 20S

CN22 (BLK) : 52C

S2 (BLK)

: R.C. address

S3 (GRN or BLU)

: R.C. address

S4 (GRN or BLU)

: Capacity code

S1 (A. ADD)

: AUTO ADDRESS

BUTTON

0

CN11 (YEL)

: TEST PIN

CN13 (BLK) : C1

CN14 (RED) : C2

CN15 (GRN) : DISCHARGE

CR-CH2432

CN23 (RED) : 63PH

CN20 (WHT) : PRY

Section

1

F2 : Fuse 250V / 3A

F1 : Fuse 250V / 3A

CN19 (BLU) : SUP

2

CN3 (BRN) : SG2

CN2 (BLU) : SG1

F3 : Fuse 125V / 0.5A

D11, D12 (RED)

: MESSAGE LAMP

CN4 (BLK) : LINK SYSTEM

CN12 (WHT) : CT1

D14 (RED) : POWER LAMP

3

4

CN1 (WHT) : SEC

CN7 (RED) : CHECK PIN

CN8 (WHT) : CK.L PIN

CN9 (WHT) : CK.H PIN

1129_THS_I

SM830076

– 103 –


Section

1

(13) Checking procedure for each P.C.B.

The indoor and outdoor P.C.B. have functions to check the signal transmission and reception of the serial circuit and to check the microcomputer operation. (Self-diagnosis function)

● Precautions required when checking

1. After turning off the power to the indoor (outdoor) unit, remove the inter-unit control wiring (U1-U2) and create a short-circuit between U1 and U2.

2. Short the CHECK PIN on the PC board of the indoor (outdoor) unit and turn on the power.

3. When checking the Outdoor controller, remove the compressor wiring from the compressor electromagnetic contactor.

4-1. Checking the serial circuit

Indoor controller: A lighted LED indicates normal. A blinking LED indicates abnormal.

Outdoor controller: Blinking LEDs (D11 and D22) indicate normal. If one of the LEDs (D11 and D22) goes off, it indicates abnormal.

2

3

4

4-2. Checking microcomputer operation

When the microcomputer works normally, the relays are switched in sequence as below.

Indoor controller

Output ON time

Indoor fan Very high fan speed (HH) 0.5 seconds

Indoor fan High fan speed (H) 0.5 seconds

Indoor fan Low fan speed (L) 0.5 seconds

Indoor fan Very low fan speed (LL) 0.5 seconds

Flap motor

Drain pump

Operation order Electric heater

Operation signal

In a lump

Electronic control valve A

Electronic control valve B

Electronic control valve.A

Electronic control valve B

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

Operation order

Outdoor controller

Output

Outdoor fan High fan speed (H)

Outdoor fan Low fan speed (L)

4-way valve

Compressor

ON time

0.5 seconds

0.5 seconds

0.5 seconds

0.5 seconds

SM830076

– 104 –


(14) Check Pins

When shorting check pins on the indoor and outdoor PCBs, operations shown on the above table will be performed on each indoor and outdoor unit. Use check pins to perform a quick check.

NOTE

• When checking pin operation, stop the indoor and outdoor units with the remote control unit.

(14)-1. FORCED OPR pin of the indoor controller

● Switch the pin from normal operation to check operation

• Relay RY6 turns ON ➞ Indoor fan motor operates at the “H” fan speed.

• Relay RY2 turns ON ➞ Dew prevention heater (DPH) turns ON.

➞ Indoor flap motor moves to the F1 position.

• Electronic control valve opens fully. (480 steps)

NOTE

• Even if the remote control unit is not connected, the indoor unit operates independently.

(14)-2. Shorting CK.L or CK.H pin of the outdoor PCB

● When shorting the cooling pin (CN8) with normal operation

• Relay RY3 is turned ON for 3 seconds

• Relay RY4 is turned ON for 3 seconds

➞ The outdoor fan motor operates at the “LL” fan speed.

➞ The outdoor fan motor oprates at the “H” fan speed.

• Turn ON relay RY2 under the above condition ➞ The magnet switch (52C) turns ON.

It will take about 18 seconds before cooling operation begins.

● Shorting the heating pin (CN9) with normal operation

• Relays RY3 and RY4 are turned ON for 3 seconds ➞ The outdoor fan motor operates at the “H” fan speed.

• Relay RY3 is turned ON for 3 seconds ➞ The outdoor fan motor operates at the “LL” fan speed.

• Turn ON relay RY2 under the above conditions ➞ The magnet switch (52C) turns ON. If relay RY1 is turned ON, the 4-way valve (20S) turns ON.

It will take about 18 seconds before heating operation begins.

NOTE

• The outdoor unit operates independently regardless of the indoor unit’s operation. However, the outdoor unit does not defrost.

• The indoor and outdoor units stop when the outdoor protection apparatus activates during the checking operation, and automatically restarts, unlike in normal operation.

Section

1

2

3

4

SM830076

– 105 –

• The specifications, designs, and information in this brochure are subject to change without notice.

SANYO FISHER Service Company

CENTRAL REGION

1739 Sands Place, Suite G

Marietta, GA 30067

Phone: (770) 951-8284

Fax: (770) 951-2077

Jan. / 2000 Printed in U.S.A.

Sanyo CH2432 Service manual

SERVICE MANUAL

SPLIT SYSTEM AIR CONDITIONER

Important

Introduction: Read Me First!

WHAT IS IN THIS MANUAL

2-1 Room Temperature Control

2-2 Cold Draft Prevention (Heating Cycle)

2-3 Automatic Fan Speed (Indoor Unit)

2-4 Outdoor Fan Speed Control

2-5 Freeze Prevention (Cooling)

2-6 Condensing Temperature Control (Cooling)

2-7 Overload Protection (Heating)

2-8 Discharge Temperature Control (Cooling and Heating)

2-9 Auto. Mode for Automatic Heating/Cooling Switching

2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating)

2-11 4-Way Valve, Solenoid Control

2-12 Automatic Restart after Power Interruption

2-13 Electronic Expansion Valve

2-14 Compressor Discharge Gas Temperature

2-15 Compressor Current Detection Circuit

2-16 Electronic Expansion Valve Control

2-17 Voltage Detection Control

3-1 Indoor Unit

3-1 Indoor Unit

3-2 Outdoor Unit

3-2 Outdoor Unit

3-2 Outdoor Unit

3-2 Outdoor Unit

4-1 Troubleshooting

4-2 Checking the Electrical Components

Key Features

Related manuals

Frequently Answers and Questions

What is the operating voltage of the Sanyo CH2432?

What is the cooling capacity of the Sanyo CH2432?

What is the heating capacity of the Sanyo CH2432?

What are the dimensions of the Sanyo CH2432?

What is the weight of the Sanyo CH2432?

Table of contents

Sanyo CH2432 Service manual

SERVICE MANUAL

SPLIT SYSTEM AIR CONDITIONER

Important

Introduction: Read Me First!

WHAT IS IN THIS MANUAL

2-1 Room Temperature Control

2-2 Cold Draft Prevention (Heating Cycle)

2-3 Automatic Fan Speed (Indoor Unit)

2-4 Outdoor Fan Speed Control

2-5 Freeze Prevention (Cooling)

2-6 Condensing Temperature Control (Cooling)

2-7 Overload Protection (Heating)

2-8 Discharge Temperature Control (Cooling and Heating)

2-9 Auto. Mode for Automatic Heating/Cooling Switching

2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating)

2-11 4-Way Valve, Solenoid Control

2-12 Automatic Restart after Power Interruption

2-13 Electronic Expansion Valve

2-14 Compressor Discharge Gas Temperature

2-15 Compressor Current Detection Circuit

2-16 Electronic Expansion Valve Control

2-17 Voltage Detection Control

3-1 Indoor Unit

3-1 Indoor Unit

3-2 Outdoor Unit

3-2 Outdoor Unit

3-2 Outdoor Unit

3-2 Outdoor Unit

4-1 Troubleshooting

4-2 Checking the Electrical Components

Key Features

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387106944

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387106941

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621

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SAP- FR99EH

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387106968

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Frequently Answers and Questions

What is the operating voltage of the Sanyo CH2432?

What is the cooling capacity of the Sanyo CH2432?

What is the heating capacity of the Sanyo CH2432?

What are the dimensions of the Sanyo CH2432?

What is the weight of the Sanyo CH2432?

Table of contents