Sanyo C4232 Technical Data & Service Manual Download

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SM830078

12. SERVICE PROCEDURES

Some Part does not Operate.

A. Indoor fan does not run.

Indoor Unit does not Run.

(Indoor fan and louver motor do not run.)

B. Louver motor does not run.

• Check resistance of fan
motor winding.

• Check fan motor capacitor.

Relay RY1 or RY2 on the
P.C.B. Ass’y is defective.

• Check fan rotation.
Rotate the fan gently once
or twice by hand.

0631_X_S

Check fan casing
for foreign matter
on the inside.

Remove foreign
matter or repair.

Repair or replace.

Fan cannot
be rotated.

Fan motor burnout
or foreign matter
in bearing.

• Check resistance of
louver motor winding.

P.C.B. Ass’y or remote
control unit is defective.

0632_X_S

0630_X_S

P.C.B. Ass’y is defective.

Summary of Contents for C4232

Page 1: ...ERVICE MANUAL FILE NO INDOOR MODEL No PRODUCT CODE No OUTDOOR MODEL No PRODUCT CODE No XS4232 854 016 10 C4232 854 016 12 CL4232 854 016 11 TS4232 854 016 09 C4232 854 016 12 CL4232 854 016 11 TS4232 XS4232 C4232 CL4232 Indoor Unit Outdoor Unit XS4232 C4232 CL4232 TS4232 C4232 CL4232 ...

Page 2: ... to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers Important CAUTION 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 o...

Page 3: ...HARTS 25 1 Operating Current 25 2 High and Low Pressure 29 6 AIR THROW DISTANCE CHART 31 7 REFRIGERANT FLOW DIAGRAM 32 8 INSTALLATION INSTRUCTIONS 33 9 ELECTRICAL DATA 38 10 ELECTRICAL WIRING DIAGRAMS 39 1 Indoor Unit 39 2 Outdoor Unit 43 11 PROCESSES AND FUNCTIONS 47 1 Room Temperature Control 47 2 Freeze Prevention 48 3 Drain Pump Control 48 4 Outdoor Fan Speed Control 49 12 SERVICE PROCEDURES 5...

Page 4: ...o 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 f...

Page 5: ...S4232 CL4232 Temperature Indoor Air Intake Temp Outdoor Air Intake Temp Maximum 95 F DB 71 F WB 115 F DB Minimum 67 F DB 57 F WB 67 F DB Temperature Indoor Air Intake Temp Outdoor Air Intake Temp Maximum 95 F DB 71 F WB 115 F DB Minimum 67 F DB 57 F WB 0 F DB ...

Page 6: ... m 165 50 Limit of tubing length at shipment ft m 50 15 Limit of elevation difference ft m Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52 outer diameter Wide tube in mm 3 4 19 05 Refrigerant amount at shipment lbs kg R22 9 7 4 4 DIMENSIONS WEIGHT Indoor unit Outdoor unit Unit dimensions ...

Page 7: ... tubing length ft m 165 50 Limit of tubing length at shipment ft m 50 15 Limit of elevation difference ft m Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52 outer diameter Wide tube in mm 3 4 19 05 Refrigerant amount at shipment lbs kg R22 9 7 4 4 DIMENSIONS WEIGHT Indoor unit Outdoor unit...

Page 8: ...6 7 mm Compressor Scroll Operation sound Indoor Hi Me Lo dB A 42 40 35 Outdoor Hi dB A 56 REFRIGERANT TUBING Limit of tubing length ft m 165 50 Limit of tubing length at shipment ft m 50 15 Limit of elevation difference ft m Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52 outer diameter W...

Page 9: ...ade size 3 4 in 26 7 mm Compressor Scroll Operation sound Indoor Hi Me Lo dB A 42 40 35 Outdoor Hi dB A 56 REFRIGERANT TUBING Limit of tubing length ft m 165 50 Limit of tubing length at shipment ft m 50 15 Limit of elevation difference ft m Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52...

Page 10: ...hase 60 Hz No of pole r p m 230 V High rpm 6 560 Nominal output W 60 Coil resistance Ω BRW WHT 71 1 ORG YEL 22 7 Ambient temperature 68 F WHT VLT 8 7 VLT PNK 43 2 VLT ORG 13 3 YEL BLK 54 32 Safety device Operating temperature Open F 266 14 4 Close F 174 2 27 Run capacitor VAC µF 440 V 6 µF Heat exchanger Coil Aluminum plate fin Copper tube Rows Fins per inch 2 14 9 Face area ft 2 m2 5 17 0 48 Pane...

Page 11: ...of pole r p m 230 V High rpm 1 015 Nominal output W 100 Coil resistance Ω BRW WHT 61 05 ORG YEL 13 23 Ambient temperature 68 F WHT VLT 9 955 YEL BLK 19 25 VLT ORG 9 576 BLK PNK 10 81 Safety device Operating temperature Open F 266 14 4 Close F 174 2 27 Run capacitor VAC µF 440 V 4 µF Heat exchanger Coil Aluminum plate fin Copper tube Rows Fins per inch 3 14 9 Face area ft 2 m2 3 51 0 326 Auto louve...

Page 12: ...ere at 77 F A Run capacitor VAC µF 400 V 50 µF Refrigerant amount charged at shipment lbs kg R22 9 7 4 4 High pressure switch ACB 1UB11 Set pressure OFF kg cm2 30 ON kg cm2 24 2 0 Fan Propeller Number diameter in mm 1 18 3 32 460 Fan speeds 2 AUTO Fan motor Model KFC6T 91D6P 2 Source 230 208 V 1 phase 60 Hz No of pole rpm 230 V High rpm 6 879 Nominal output W 110 2 Coil resistance Ω BRW WHT 67 14 ...

Page 13: ... VAC µF 400 V 50 µF Crank case heater V W 230 V 30 W Refrigerant amount charged at shipment lbs kg R22 9 7 4 4 High pressure switch ACB 1UB11 Set pressure OFF kg cm2 30 ON kg cm2 24 2 0 Fan Propeller Number diameter in mm 1 18 3 32 460 Fan speeds 3 AUTO Fan motor Model KFC6T 91D6P 2 Source 230 208 V 1 phase 60 Hz No of pole rpm 230 V High 6 879 Nominal output W 110 2 Coil resistance Ω BRN WHT 67 1...

Page 14: ...F 266 Thermistor Coil sensor PBC 41E S36 Coil resistance kΩ 14 F 23 7 41 F 12 1 23 F 18 8 50 F 9 7 32 F 15 0 59 F 8 0 Thermistor Room or coil sensor KTEC 35 S6 Coil resistance kΩ 32 F 16 5 104 F 2 7 41 F 12 8 113 F 2 2 50 F 10 0 122 F 1 8 68 F 6 3 131 F 1 5 86 F 4 0 Drain pump WP20SL 21 Rated AC 200 V 14 7 W Float switch FS 0218 103 MAX Rated Contact rated AC 200 V 50 W Switch Ass y SW X363GS Indi...

Page 15: ...bient temprature 77 F Thermistor cut off temperature F 266 Thermistor Coil sensor PBC 41E S36 Coil resistance kΩ 14 F 23 7 41 F 12 1 23 F 18 8 50 F 9 7 32 F 15 0 59 F 8 0 Thermistor Room or coil sensor KTEC 35 S6 Coil resistance kΩ 32 F 16 5 104 F 2 7 41 F 12 8 113 F 2 2 50 F 10 0 122 F 1 8 68 F 6 3 131 F 1 5 86 F 4 0 Switch Ass y SW X363GS Indicator Lamp Ass y IND TS2432 Synchronized Motor MT8 3C...

Page 16: ...tance at 68 F Ω 350 10 Contact rated Main AC 240 V 35 A Contact rated Auxiliary AC 240 V 3 A Power Relay HH62S Coil rated AC 240 V 60 Hz Coil resistance at 77 F kΩ 17 2 Contact rated AC 220 V 5 A Thermostat Coil sensor YTB 4U305F Operating Temperature F 79 3 OFF 75 ON Contact rated 200 to 240 V 1 A 3 1 DATA SUBJECT TO CHANGE WITHOUT NOTICE 2 SPECIFICATIONS ...

Page 17: ... Coil rated AC 240 V 60 Hz Coil resistance at 77 F kΩ 17 2 Contact rated AC 220 V 5 A Power Transformer ATR I35B Rated Primary AC 220 V 60 Hz Secondary 14 V 0 2 A Capacity 2 8 VAC Coil resistance at 78 F Ω WHT WHT 482 5 BRN BRN 3 95 Thermal cut off temperature F 266 Thermistor Outdoor Temp sensor PBC 41E S4 Coil resistance kΩ 14 F 23 7 50 F 9 7 23 F 18 8 68 F 6 5 32 F 15 0 86 F 4 4 41 F 12 1 104 F...

Page 18: ... Suspention bolt pitch 19 9 32 1 9 16 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 X view 1813_X_S 8 19 32 5 23 32 1 3 8 8 9 32 2 3 8 29 29 32 2 3 4 6 1 2 11 7 32 8 9 32 3 15 16 3 15 16 9 13 15 32 19 32 15 32 1 7 8 15 32 Dimension inch 2 13 32 23 32...

Page 19: ...2 Infrared rays receiver for wireless remote controller Cutting position for fresh air intake 1341_TS_I Dimension inch Air intake Air outlet 2 ft or more Hole for wall through piping View from front 2 13 32 23 32 9 7 8 6 25 32 9 7 16 8 7 16 62 26 3 8 11 1 32 12 7 32 61 7 32 7 3 4 12 19 32 6 5 16 5 15 16 Remote controller Accessory 5 1 2 7 3 4 6 11 16 4 1 2 7 1 4 7 3 4 1 3 32 6 5 16 3 5 32 4 3 4 5 ...

Page 20: ...nsion inch Hole for anchor bolt 4 ø13 Refrigerant tube joint narrow tube Flare connection 3 8 in 9 52 mm Refrigerant tube joint wide tube Flare connection 3 4 in 19 05 mm Refrigerant tubing inlet Power supply inlet 1342_C_S 15 3 4 14 31 32 13 32 1 3 16 1 31 32 1 31 32 13 3 8 4 21 64 26 6 11 16 ...

Page 21: ...2 22 2 SHC 21 050 20 190 19 250 18 240 17 160 67 76 24 4 SHC 24 160 23 300 22 360 21 350 20 270 19 4 80 26 7 SHC 27 410 26 550 25 610 24 600 23 520 84 28 9 SHC 30 520 29 660 28 720 27 710 26 630 88 31 1 SHC 33 630 32 770 31 830 30 820 29 740 TC 48 260 46 580 44 770 42 800 40 610 CI 3 1 3 39 3 73 4 14 4 56 72 22 2 SHC 17 040 16 320 15 550 14 720 13 830 71 76 24 4 SHC 20 150 19 420 18 650 17 830 16 ...

Page 22: ...250 TC 44 190 42 440 40 500 38 350 36 000 CI 3 02 3 31 3 62 4 05 4 48 72 22 2 SHC 20 400 19 550 18 620 17 620 16 560 67 76 24 4 SHC 23 250 22 390 21 470 20 470 19 400 19 4 80 26 7 SHC 26 220 25 370 24 450 23 450 22 380 84 28 9 SHC 29 070 28 220 27 290 26 290 25 230 88 31 1 SHC 31 920 31 060 30 140 29 140 28 070 TC 46 530 44 910 43 170 41 270 39 160 CI 3 06 3 35 3 67 4 11 4 55 72 22 2 SHC 16 690 15...

Page 23: ...2 22 2 SHC 21 110 20 260 19 330 18 330 17 260 67 76 24 4 SHC 24 280 23 430 22 500 21 500 20 430 19 4 80 26 7 SHC 27 590 26 750 25 820 24 810 23 740 84 28 9 SHC 30 760 29 920 28 990 27 980 26 910 88 31 1 SHC 33 930 33 090 32 160 31 150 30 080 TC 48 260 46 580 44 770 42 800 40 610 CI 3 1 3 39 3 73 4 14 4 56 72 22 2 SHC 17 050 16 330 15 570 14 750 13 870 71 76 24 4 SHC 20 220 19 500 18 740 17 920 17 ...

Page 24: ...400 TC 44 190 42 440 40 500 38 350 36 000 CI 3 02 3 31 3 62 4 05 4 48 72 22 2 SHC 20 430 19 580 18 660 17 660 16 600 67 76 24 4 SHC 23 290 22 450 21 530 20 530 19 470 19 4 80 26 7 SHC 26 290 25 450 24 520 23 530 22 470 84 28 9 SHC 29 160 28 310 27 390 26 400 25 340 88 31 1 SHC 32 030 31 180 30 260 29 270 28 210 TC 46 530 44 910 43 170 41 270 39 160 CI 3 06 3 35 3 67 4 11 4 55 72 22 2 SHC 16 690 15...

Page 25: ...e humidity 50 Indoor fan speed High 230V 208V 1792_X_S Operating current A 21 22 23 17 16 18 19 20 59 68 77 86 95 104 15 20 25 30 35 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Low High 70 21 85 30 80 27 75 24 1793_X_S Operating current A 59 68 77 86 95 104 15 20 25 30 35 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Low High 70 21 85 30 80 27 75 24 21 22 23 17 16...

Page 26: ...e humidity 50 Indoor fan speed High 230V 208V 1794_X_S Operating current A 21 22 23 17 16 18 19 20 59 68 77 86 95 104 15 20 25 30 35 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Low High 70 21 85 30 80 27 75 24 1795_X_S Operating current A 59 68 77 86 95 104 15 20 25 30 35 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Low High 70 21 85 30 80 27 75 24 21 22 23 17 16...

Page 27: ...ing current A 21 22 23 17 16 15 18 19 20 23 32 41 50 59 68 5 0 5 10 15 20 77 25 86 30 95 35 104 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Upper Lower STOP Med Low Low Med Med High High 70 21 85 30 80 27 75 24 1797_X_S Operating current A 23 32 41 50 59 68 5 0 5 10 15 20 77 25 86 30 95 35 104 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Upper Lower STOP Med Low ...

Page 28: ...ing current A 21 22 23 17 16 15 18 19 20 23 32 41 50 59 68 5 0 5 10 15 20 77 25 86 30 95 35 104 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Upper Lower STOP Med Low Low Med Med High High 70 21 85 30 80 27 75 24 1799_X_S Operating current A 23 32 41 50 59 68 5 0 5 10 15 20 77 25 86 30 95 35 104 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Upper Lower STOP Med Low ...

Page 29: ...eristics versus outdoor ambient temperature and indoor temperature Indoor relative humidity 50 Indoor fan speed High 230V 208V 1442_X_S Discharge pressure psig 280 300 320 340 200 180 160 220 240 260 59 68 77 86 95 104 15 20 25 30 35 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Low High 70 21 85 30 80 27 75 24 1800_X_S Suction pressure psig 100 60 50 40 70 80 90 59 68 77 86 95 104...

Page 30: ...ature Indoor relative humidity 50 Indoor fan speed High 230V 208V 1444_X_S Discharge pressure psig 300 320 340 220 200 180 160 140 240 260 280 23 32 41 50 59 68 5 0 5 10 15 20 77 25 86 30 95 35 104 40 Outdoor ambient temp F C Indoor temp F C Outdoor fan speed Upper Lower STOP Med Low Low Med Med High High 70 21 85 30 80 27 75 24 1801_X_S Suction pressure psig 80 70 60 50 40 90 100 23 32 41 50 59 6...

Page 31: ...ITY ft sec VERTICAL DISTANCE ft AXIS AIR VELOCITY FAN SPEED COOLING ROOM AIR TEMP LOUVER ANGLE HIGH 80 F 30 COOLING 1428_X_S MODEL TS4232 COOLING FAN SPEED HIGH ROOM AIR TEMP 80 F LOUVER ANGLE 7 5 Horizontal distance ft 10 15 5 0 10 0 15 20 25 30 33 Axis air velocity ft sec Vertical distance ft 1454_X_S Axis air velocity ...

Page 32: ...ant Tubing IMPORTANT When installing CL models insulate both wide and narrow tube When outdoor temperature is low condensation can also from on a narrow tube So always insulate both wide and narrow tubes After a tube has been insulated never try to bend it into a narrow curve because it can casue the tube to break or crack Insulation Thickness Min 5 16 in Wide tube Narrow tube Thickness Min 5 16 i...

Page 33: ...o additional charge of compressor oil is necessary 1 If total tubing length becomes 50 to 165 ft charge additional refrigerant R22 by 0 86 oz ft Model C4232 Tubing Data CL4232 Tubing size Narrow tube in mm 3 8 9 52 outer dia Wide tube in mm 3 4 19 05 Limit of tubing length ft 165 Outdoor unit is higher ft 165 Limit of elevation difference than indoor unit between the 2 units Outdoor unit is lower ...

Page 34: ... uniformly cooled ã select a location where the ceiling is strong enough to support the weight of the unit ã select a location where tubing and drain pipe have the shortest run to the outdoor unit ã allow room for operation and maintenance as well as unrestricted air flow around the unit ã install the unit within the maximum elevation difference above or below the outdoor unit and within a total t...

Page 35: ... the unit and decreased service life Fig 4 ã use lug bolts or equivalent to bolt down unit reducing vibration and noise In case of multiple installations Air in Air in Air discharge Concrete block 4 inch 1 ft 4 inch beams or equal Anchor bolts 4 pieces Min 6 inch 0934_C_I Unit spacing if air discharge chamber is not used Unit spacing when air discharge chamber is used Min 4 ft Min 4 ft Min 5 ft Mi...

Page 36: ...air temperature in winter wind shield must be installed on the outdoor unit This unit is designed so that the fan of the outdoor unit runs at low speed when the air conditioner is operated at low outdoor air temperatures When the outdoor unit is ex posed to strong wind the system pressure drops because of the freeze protector For outer dimensions of wind shield please see Fig 7 Air discharge 0426_...

Page 37: ...CAL CODES before beginning You must ensure that installation complies with all relevant rules and regulations 8 To prevent malfunction of the air condi tioner caused by electrical noise care must be taken when wiring as follows ã The inter unit control wiring and the remote control wiring option should be wired apart from the inter unit power wiring ã It is recommended that shielding wires or twis...

Page 38: ...del XS4232 Outdoor model C4232 CL4232 Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230 208 V 1 phase 60 Hz 230 208 V 1 phase 60 Hz Rating conditions A 0 7 0 7 1 8 1 8 18 1 18 5 20 6 21 0 kW 0 16 0 14 0 36 0 34 3 67 3 62 4 19 4 10 Full load conditions A 0 7 0 7 1 8 1 8 21 44 22 7 23 9 25 2 kW 0 16 0 16 0 36 0 34 4 49 4 48 5 01 4 96 Starting amperes A 1 1 2 2 ...

Page 39: ...YEL GRN YEL Earth Terminal Earth Terminal Earth Terminal Earth Terminal ORG VLT WHT BRN BRN PNK BRN GRN YEL GRY BLK BLK GRY FMI LM Controller CR TS2432 E 2P RED TH1 TH2 Room 2 1 BLK BLK 2P YEL TH2 3P GRN LM 2 1 TR1 P S 2 1 PRY 2P WHT SEC 2P WHT DP 3P BLU FS 3P RED 3P WHT 49FMI FM COM SUP 5P WHT GRY BLK BLK BLK BLK WHT WHT RED WHT BRN BRN BRN 7P WHT M H L 7P WHT W LESS 3P WHT SW ASSY 7 1 7 1 IND La...

Page 40: ... FMI 1 2 1 9 8 7 3 5 4 5 6 RY1 RY2 RY2 H L M 1 3 49FMI RY3 RY4 Symbols Description FMI 49FI RC1 F1 DP LM TR1 RY1 RY5 FS Indoor Fan Motor Indoor Motor Thermal Protector Running Capacitor Fuse Drain Pump Auto Louver Motor Power Transformer Auxiliary Relay Float Switch Symbols Description TH1 TH2 CR TS2432 IND SW Thermistor Indoor Coil Room Thermistor Indoor Controller Indicator Lamp Assy Switch Assy...

Page 41: ...N YEL GRN YEL Earth Terminal Earth Terminal Earth Terminal ORG VLT WHT BRN BRN PNK BRN BLK WHT FMI LM Controller CR TS2432 E 2P RED TH1 TH2 Room 2 1 BLK BLK 2P YEL TH2 3P GRN LM 2 1 TR1 P S 2 1 PRY 2P WHT SEC 2P WHT DP 3P BLU FS 3P RED 3P WHT 49FMI FM COM SUP 5P WHT GRY BLK BLK BLU WHT WHT RED WHT BRN BRN BRN 7P WHT M H L 7P WHT W LESS 3P WHT SW ASSY 7 1 7 1 IND Lamp Assy Switch Assy RED ORG BRN 1...

Page 42: ... 2 1 9 8 7 3 5 4 5 6 RY1 RY2 RY2 H DP L M 1 3 49FMI RY3 RY4 Symbols Description FMI 49FI RC1 F1 DP LM TR1 RY1 RY5 FS Indoor Fan Motor Indoor Motor Thermal Protector Running Capacitor Fuse Drain Pump Auto Louver Motor Power Transformer Auxiliary Relay Float Switch Symbols Description TH1 TH2 CR TS2432 IND SW Thermistor Indoor Coil Room Thermistor Indoor Controller Indicator Lamp Assy Switch Assy Te...

Page 43: ... 4 5 4 7 6 7 6 2 1 2 1 3 3 8 8 Earth Terminal Connector 8P WHT Connector 8P WHT CM C R S BLK RED WHT Connector 2P WHT 63PH P S 1 1 2 2 GRY WHT WHT 3 8 7 1 4 5 2Y 2 6 3 8 7 1 4 5 1Y 2 6 41 42 13 14 T W H L 23S C S V R U A1 A2 52C WHT VLT GRY GRY BRN PNK L1 L2 1 2 4 G L1 L2 Terminal Plate 6P Earth Terminal Earth Terminal Power Supply 60Hz 1PH 208 V 230 V To Indoor Unit RED RED GRY BRN BRN WHT RED RE...

Page 44: ...late 6P 49FO2 63PH 2Y 4 1 2Y 2 2Y 52C T W 52C 1 L2 L1 4 G 2 Schematic Diagram S 854 2 5268 896 00 0 C4232 Symbols Description CM FMO1 2 49FO1 2 52C 63PH 23S RC1 2 3 1Y 2Y Compressor Motor Outdoor Fan Motor Outdoor Fan Motor Thermal Protector Compressor Motor Magnetic Contactor High Pressure Switch Fan Speedcontrol Thermostat Running Capacitor Auxiliary Relay Connector Terminal Plate ...

Page 45: ... 5 9 3 1 6 5 8 7 8 P Connector 8P WHT RC3 S 7 BRN BLK WHT PNK 49FO2 Earth Terminal GRN YEL GRN YEL FMO1 PNK BRN GRY GRY WHT VLT YEL 2 1 2 1 4 3 4 3 6 5 6 5 8 7 8 P Connector 8P WHT RC2 S 7 BRN GRY GRY WHT VLT YEL PNK 49FO1 63PH Earth Terminal 1 3 5 2 4 6 8 7 4Y 1 3 5 2 4 6 8 7 3Y 1 3 5 2 4 6 8 7 2Y 1 3 5 2 4 6 8 7 1Y 1 3 1 3 3P BLU MGSW 3P RED SUP E Earth Terminal TH TR 1 2 BLK BLK 2P WHT TEMP 9P ...

Page 46: ...L 12V PRY SEC Temp 3 4 1 1 1 3 2 4 3 3 52C 1 2 3 CH 1 2 G 4 L1 L2 Terminal Plate 6P CR CL2432 Controller S 854 2 5268 897 00 0 CL4232 Symbols Description CM CH FMO1 2 49FO1 2 52C TR TH RC1 2 3 RY1 2 3 1Y 4Y CR CL2432 Compressor Motor Crankcase Heater Outdoor Fan Motor Outdoor Fan Motor Thermal Protector Compressor Motor Magnetic Contactor Power Transformer Thermistor Outdoor Temperature Running Ca...

Page 47: ... Once the compressor stops it will not start running again for 3 minutes If you change the operation mode 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 1 F above the set temperature...

Page 48: ...OR FAN OFF OFF OFF OFF INDOOR COIL TEMPERATURE MORE THAN 10 MINUTES FREEZE PREVENTION 6 MINUTES 10 MINUTES FREEZE PREVENTION 6 MINUTES THERMO ON 30 F ON ON ON ON ON ON 1029_X_S SET SPEED THERMO OFF 3 Drain Pump Control Drain pump operates when compressor starts to operate or when Float Switch turns off ON ON ON ON ON ON ON ON ON ON SET SPEED OFF OFF OFF OFF OFF OFF FLOAT SWITCH ON low water level ...

Page 49: ...outdoor fan is set from HIGH to MED automatically When the outdoor temperature rises to 81 F the outdoor fan is set from MED to HIGH automatically When the outdoor temperature falls below 59 F the outdoor fan is set from MED to LOW automatically When the outdoor temperature rises to 63 F the outdoor fan is set from LOW to MED automatically When the outdoor temperature falls below 47 F the outdoor ...

Page 50: ...n the indoor unit and L1 and L2 on the 6P terminal in the outdoor unit 2 2 2 2 2 Check inter unit wiring Check that inter unit control wiring AC 230 208 V Line voltage is cor rectly connected between the indoor unit and outdoor unit 3 3 3 3 3 Check power supply Check that voltage is within the specified range 10 of the rating Check that power is being supplied If the following troubleshooting must...

Page 51: ...ords OK NO NO Insulation of outdoor unit is defective Execute rewiring Remove inter unit power line from the terminal plate in the outdoor unit Check insulation resistance of outdoor unit OK Remove inter unit power line from the terminal plate in the indoor unit Check insulation resistance of indoor unit OK Inter unit power lines are defective NO Insulation of indoor unit is defective Check insula...

Page 52: ...plied to outdoor unit Circuit breaker is tripped Power failure Reset the breaker Wait for recovery or consult power supply company NO Check capacity of circuit breaker NO Check resistance of outdoor fan motor winding 0614_X_S Is capacity of circuit breaker sufficient Check resistance of compressor motor winding Replace it with a suitable one larger capacity 0616_X_S Try to run both indoor and outd...

Page 53: ...indoor unit is defective IND LAMP Ass y or P C B Ass y in the indoor unit is defective 0618_X_S Check high pressure switch Does high pressure switch actuate 63PH YES YES Clean heat exchanger coil or remove obstacles Is outdoor heat exchanger coil dirty or are there obstacles near air suction inlet of outdoor unit Check if outdoor fan rotates Refer to Only outdoor fan does not run NO Disconnect the...

Page 54: ..._X_S Check fan rotation Rotate the fan gently once or twice by hand Check fan casing for foreign matter on the inside Remove foreign matter or repair Repair or replace Fan cannot be rotated OK Check fan motor capacitor Fan motor burnout or foreign matter in bearing 1034_X_S Check fuse on the P C B Ass y in the indoor unit for continuity Check transformer TR1 Check resistance of indoor fan motor wi...

Page 55: ...e by Temperature setting button COOLER Set Operation selector switch to TEST in the indoor unit YES Outdoor unit runs Is room temperature too low NO Try to run both indoor and outdoor units with another remote control unit OK The other remote control unit is defective Room sensor in the remote control unit is defective 0623_X_S Is COOL FAN selector switch set to COOL NO Set to COOL ...

Page 56: ...inal plate Check P C B Ass y No voltage appears P C B Ass y is defective E Check outdoor unit P C B CL3632 Type Check coil resistance of compressor motor magnetic contactor 52C 1035_X_S 0628_X_S Check voltage between terminals No 2 and No 4 at terminal plate Check P C B Ass y No voltage appears P C B Ass y is defective 0629_X_S Is drainage prevented from flowing Check drain hose YES Check float sw...

Page 57: ...capacitor OK Relay RY1 or RY2 on the P C B Ass y is defective Check fan rotation Rotate the fan gently once or twice by hand 0631_X_S Check fan casing for foreign matter on the inside Remove foreign matter or repair Repair or replace Fan cannot be rotated Fan motor burnout or foreign matter in bearing OK Check resistance of louver motor winding P C B Ass y or remote control unit is defective OK 06...

Page 58: ...door Temperature Falls below 59 F CL4232 Type Check resistance of fan motor winding Check fan motor capacitor OK Check continuity between terminals on the compressor motor magnetic contactor Check fan rotation Rotate the fan gently once or twice by hand 0633_X_S Check fan casing for foreign matter on the inside Remove foreign matter or repair Repair or replace Fan cannot be rotated Fan motor burno...

Page 59: ...ransformer TR 1038_X_S If fuse blows Check PTC Check compressor motor capacitor RC1 Wait for 30 minutes until com pressor has cooled Compressor runs Compressor internal thermal protector is operated Check power supply voltage Is voltage abnormally low NO Is outdoor heat exchanger coil dirty or are there obstacles near air suction inlet Check resistance of compressor motor winding 1039_X_S OK OK ...

Page 60: ...R22 Temperature difference is small YES Check clogging of air filter Temperature difference between suction and discharge air is large enough Approx 10 deg or more Clean filter Air filter is clogged Set fan speed to either HIGH or MEDIUM Is fan speed set to LOW Reduce cooling load or replace the unit with higher cooling capacity Review cooling load estimate if performance of air conditioner is nor...

Page 61: ... No continuity in sensor Neither outdoor fan nor compressor runs b Short Outdoor fan and compressor do not stop Excessive cooling 3 Operation of Major Electrical Parts Oudoor unit Indicator lamps Cool Room Temp Fan Compressor Function Operation Mode Operation Indoor unit and Remote Control unit Sweep Fan Night setback Energy saver Timer Manual Thermo ON V V V V V Thermo OFF V V V Night Thermo ON V...

Page 62: ...tdoor Unit Measure the resistance by placing a probe on the terminal plate in the same manner as explained above 2 Fig 14 4 4 4 4 4 Measurement of Insulation Resis tance for Electrical parts Disconnect the connector of the de sired electric part from terminal plate P C B Ass y etc Fig 15 Similarly disconnect the lead wires from compressor capacitor etc Fig 16 Measure the resistance in the same man...

Page 63: ...proved normal if there is a continuity between terminals 1 1 1 1 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 2 2 2 2 Compressor motor thermal protector Outdoor unit Disconnect the wires from terminals of compressor Check the terminals of compressor 3 3 3 3 3 Outdoor fan motor thermal protector...

Page 64: ...il resistance Measure the resistance between each terminal of the socket connected to the indoor fan motor Refer to 1 2 A Major component specifications 4 4 4 4 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 5 5 5 5 5 Motor capacitor Both in indoor and outdoor unit Remove ...

Page 65: ... Fig 20 3 For replacement insert a fuse of the same rating to the intended position and solder it Allow time to radiate heat during sol dering so that the fuse does not melt When replacing the fuse be sure not to break down the varis tor 4 Thermistor Characteristic Curve Fig 19 1043_X_S Soldering iron PCB Ass y Fuse Varistor Pliers Fig 20 1042_X_S Fuse NOTE CAUTION 1 Room temp sensor KTEC 35 1 Coi...

Page 66: ...ompany CENTRAL REGION 1739 Sands Place Suite G Marietta GA 30067 Phone 770 951 8284 Fax 770 951 2077 Jun 2000 Printed in U S A The specifications designs and information in this brochure are subject to change without notice ...

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