Sanyo CH2432 Service Manual Download Page 24

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1. Specifications

– 24 –

SM830076

1-5

Refrigerant Flow Diagram

Outdoor Unit: CH3632

Indoor Unit: XHS3632

1-6

Operating Range

Temperature

Indoor Air Intake

Outdoor Air Intake

Cooling

Maximum

F DB, 71

F WB

115

F DB

Minimum

F DB, 57

F WB

F DB

Heating

Maximum

F DB, 67

F WB

F DB, 65

F WB

Minimum

-DB / -WB

F DB / 15

F WB

High
pressure
switch

Compressor

Accumulator

Heat exchanger

4-way valve

Heat exchanger

Distributor

Electronic
ref.control
valve

Strainer

Liquid line
nipple

Liquid line
service
valve

O.D.
3/8"
(9.52mm)

O.D.
3/4"
(19.05mm)

Gas line
nipple

Gas line
service
valve

Distributor

Sub-heat exchanger

Cooling Cycle
Heating Cycle

Strainer

1398_THS_I

Muffler

Summary of Contents for CH2432

Page 1: ...EM AIR CONDITIONER SERVICE MANUAL FILE NO XHS2432 CH2432 XHS3632 CH3632 INDOOR MODEL No PRODUCT CODE No OUTDOOR MODEL No PRODUCT CODE No XHS2432 854 013 40 CH2432 854 013 42 XHS3632 854 015 45 CH3632 854 014 57 Indoor Unit Outdoor Unit XHS3632 CH3632 XHS2432 CH2432 ...

Page 2: ...train 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 outdoor unit ...

Page 3: ... 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 ...

Page 4: ...ctronic 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 P...

Page 5: ...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 an...

Page 6: ...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 ...

Page 7: ... 2 450 17 F 2 150 2 020 Buck up heater kW Maximum fuse size A 30 FEATURES Controls Microprocessor Fan speeds Indoor Outdoor 3 and Automatic control 2 Auto Timer ON OFF 24 hours Program Air deflection Horizontal Vertical Automatic Air filter Washable easy access long life fiter 2 500 hr Operation sound Indoor dB A 37 35 31 Hi Me Lo Outdoor Hi dB A 53 Refrigerant control Electronic Refrigerant Contr...

Page 8: ...mensions Width in mm 32 14 32 824 40 1 016 Depth in mm 32 25 32 833 16 12 32 416 Shipping weight lbs kg 60 27 170 77 Shipping volume cu ft m3 6 9 0 195 12 3 0 349 Indoor grille Height in mm 4 3 32 104 Package dimensions Width in mm 38 2 32 967 PNR XHS2432 Depth in mm 39 11 32 999 Shipping weight lbs kg 18 8 Shipping volume cu ft m3 3 5 0 100 DATA SUBJECT TO CHANGE WITHOUT NOTICE Cooling Rating con...

Page 9: ...50 3 750 17 F 3 150 2 950 Buck up heater kW Maximum fuse size A 30 FEATURES Controls Microprocessor Fan speeds Indoor Outdoor 3 and Automatic control 2 Auto Timer ON OFF 24 hours Program Air deflection Horizontal Vertical Automatic Air filter Washable easy access long life fiter 2 500 hr Operation sound Indoor dB A 43 40 36 Hi Me Lo Outdoor Hi dB A 56 Refrigerant control Electronic Refrigerant Con...

Page 10: ...imensions Width in mm 43 27 32 1 114 40 1 016 Depth in mm 32 25 32 833 16 12 32 416 Shipping weight lbs kg 71 32 227 103 Shipping volume cu ft m3 10 3 0 293 19 8 0 56 Indoor grille Height in mm 4 3 32 104 Package dimensions Width in mm 49 16 32 1 257 PNR XHS3632 Depth in mm 39 11 32 999 Shipping weight lbs kg 29 13 Shipping volume cu ft m3 4 6 0 131 DATA SUBJECT TO CHANGE WITHOUT NOTICE Cooling Ra...

Page 11: ... 0 ORG YEL 66 4 Ambient temperature 68 F WHT VLT 23 9 WHT PNK 77 4 VLT ORG 12 4 YEL BLK 82 1 Safety device Operating temperature Open F 266 14 4 Close F 174 2 27 Run capacitor VAC µF 440 V 4 µF Electronic expansion valve Coil DKV MOZS582E0 Coil resistance at 20 C Ω ORG GRY 46 YEL GRY 46 RED GRY 46 BLK GRY 46 Valve body IKV 24D12 Heat exchanger Coil Aluminum plate fin Copper tube Rows Fins per inch...

Page 12: ... 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 Electronic expansion valve Coil EKV MOZS584E0 Coil resistance at 20 C Ω ORG GRY 46 YEL GRY 46 RED GRY 46 BLK GRY 46 Valve body HKV 30D16 Heat exchanger Coil Aluminum plate fin Copper tube Rows Fins per inch...

Page 13: ...0 µF Crank case heater VAC W 230 VAC 30 W Refrigerant amount charged at shipment lbs kg R22 6 17 2 8 High pressure switch ACB 1UB11 Set pressure OFF lb in2 kg cm2 426 6 30 ON lb in2 kg cm2 341 3 28 44 24 2 0 Fan Propeller Number diameter in mm 1 18 3 32 460 Fan speeds 2 AUTO Fan motor Model KFC6T 91D6P Source 230 208 VAC 1 phase 60 Hz No of pole rpm 230 V High 6 879 Nominal output W 110 Coil resis...

Page 14: ...F Crank case heater VAC W 230 VAC 30 W Refrigerant amount charged at shipment lbs kg R22 8 82 4 0 High pressure switch ACB 1UB11 Set pressure OFF lb in2 kg cm2 426 6 30 ON lb in2 kg cm2 341 3 28 44 24 2 0 Fan Propeller Number diameter in mm 2 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 6 879 Nominal output W 110 2 Coil resist...

Page 15: ...rmistor Coil sensor TH2 3 PBC 41E S26 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 sensor TH1 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 230 208 VAC 12 5 W Float switch FS 0218 102 MAX Rated Contact rated 50 W DC 5V 0 1 mA Solenoid control valve or c...

Page 16: ... TH2 3 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 sensor TH1 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 230 208 VAC 12 5 W Float switch FS 0218 103 MAX Rated Contact rated 50 W DC 5V 0 1 mA Solenoid control valve or coil Solenoid contro...

Page 17: ...pacity 5 6 VA Coil resistance at 73 F Ω WHT WHT 395 5 BRN BRN 2 19 Thermal cut off temperature F 266 Thermistor Coil sensor TH6 7 PBC 41E S4 PBC 41E S26 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 3 1 113 F 2 6 Thermistor Comp discharge gas sensor TH8 PTC 51H S1 Coil resistance kΩ 140 F 13 8 194 F 5 1 158 F 9 7 212 F 3 8 167 F 8 2 230 F 2 8 176 F 7 0...

Page 18: ...apacity 5 6 VA Coil resistance at 73 F Ω WHT WHT 395 5 BRN BRN 2 19 Thermal cut off temperature F 266 Thermistor Coil sensor TH6 7 PBC 41E S4 PBC 41E S36 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 3 1 113 F 2 6 Thermistor Comp discharge gas sensor TH8 PTC 51H S1 Coil resistance kΩ 140 F 13 8 194 F 5 1 158 F 9 7 212 F 3 8 167 F 8 2 230 F 2 8 176 F 7 ...

Page 19: ... 4 Suspention bolt pitch Grille center 23 7 32 Suspention bolt pitch 13 2 4 1 3 8 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 14 X view X 1024_X_S 12 13 3 8 14 5 29 32 10 1 32 7 7 8 Dimension inch 2 13 32 23 32 6 25 32 Remote controller Accessory 4 29 32 29 29 32 1 2 1 2 3 15 16 8 21 32 8 1 16 19 32 4 ...

Page 20: ...pention bolt pitch Panel center 23 7 32 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 1346_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...

Page 21: ... 1 3 16 1 31 32 28 15 16 11 12 1 16 37 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 Flare connection 3 4 in 19 05 mm Refrigerant tubing inlet Power supply inlet 1131_THS_I 1 31 32 13 3 8 4 21 64 26 6 11 16 ...

Page 22: ...32 37 Dimension 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 1581_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 23: ... DB Heating Maximum 80 F DB 67 F WB 75 F DB 65 F WB Minimum DB WB 17 F DB 15 F WB HP High pressure switch Compressor Accumulator Accumulator EC P Heat exchanger 4 way valve EC P Heat exchanger Distributor Electronic ref control valve Strainer Liquid line nipple Liquid line service valve O D 1 4 6 35mm O D 3 4 19 05mm Gas line nipple Gas line service valve Distributor Sub heat exchanger Cooling Cyc...

Page 24: ... DB Heating Maximum 80 F DB 67 F WB 75 F DB 65 F WB Minimum DB WB 17 F DB 15 F WB HP High pressure switch Compressor Accumulator Accumulator EC P Heat exchanger 4 way valve EC P Heat exchanger Distributor Electronic ref control valve Strainer Liquid line nipple Liquid line service valve O D 3 8 9 52mm O D 3 4 19 05mm Gas line nipple Gas line service valve Distributor Sub heat exchanger Cooling Cyc...

Page 25: ... 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 ...

Page 26: ...When the room temperature is 2 F below the set temperature T Compressor OFF 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 thermo...

Page 27: ...ature 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 THERMO ON THERMO ON 2 F OFF OFF 2 1 Refer to 2 4 Outdoor Fan Speed Control OFF SET SPEED ON ON ON ON REVERSING CYCLE ON TEMP OPERATION REMOTE CONTROL SENSOR Only for wireless remote controller BODY SENSOR OFF OFF SET SPE...

Page 28: ...inutes 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 Chart Summary and Explanations 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...

Page 29: ...wn below B Heating Fig 5 INDOOR FAN SPEED L H M M H 0433_M_S ROOM TEMP deg SET TEMP 3 2 1 H M High Middle L LL Low Very low 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 INDOOR FAN SPEED H L M M H 0434_M_S ROOM TEMP deg SET TEMP 2 4 H M High Middle L LL Low Very low Chart ...

Page 30: ...times 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 Outdoor unit coil Outdoor fan temperature C2 motor FMo or more 77 F H less than 77 F M OUTDOOR T...

Page 31: ...cycle is controlled by the lower temperature sensed at either of the two sensors Chart Explanations and notes 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...

Page 32: ...peed 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 140 131 OUTDOOR UNIT COIL TEMP C2 F O...

Page 33: ...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 F ELECTRONIC REF CONTROL VALVE INDOOR ...

Page 34: ...low 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 c...

Page 35: ...o 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 Fig 12 COOLING SELECTION TEMP 5 deg SHIFT SET TEMP 4 deg REMOTE CONTROLLED SET TEMP SHIFT ...

Page 36: ...eating 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 usin...

Page 37: ... ON ON ON ON STANDBY APPEARS 0442_M_S Time Chart for Defrosting During the defrost cycle STANDBY appears on the remote controller Cold Draft Prevention may operate occasionally 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 Refer to time chart Minimum continuous operating time by defrostin...

Page 38: ... 15 OFF OFF OFF OFF OFF 3 MINUTES OFF TURN ON TURN OFF THERMO OFF THERMO ON THERMO OFF THERMO ON 2 2 2 1 1 1 1 OFF SOLENOID COIL 4 WAY VALVE COMPRESSOR COOL MODE BUTTON HEAT OPERATION BUTTON POWER SOURCE 1 More than 5 minutes 2 More than 3 minutes ON ON HEAT ON ON ON HEAT COOL ON ON ON ON 0443_M_S Chart Summary and Explanations For the first 3 minutes after power is applied the 4 way valve remains...

Page 39: ...ower failure recovery function 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 SOLENOID COIL 4 WAY VALVE COMPRESSOR COOL AUTO MODE CONTROL HEAT OFF OFF OFF OFF POWER SOURCE OPERATION BUTTON OFF MORE THAN 10 MINUTES THERMO OFF MORE THAN 10 MINUTES THERMO OFF 3 MINUTES THERMO OFF THERMO ...

Page 40: ... of temperature fan speed etc These control circuits work automatically to send just the right amount of refrigerant through the Electronic Refrigerant Control Valve 2 14 Compressor Discharge Gas Temperature A Cooling Indoor temp F 68 77 79 82 84 90 Outdoor temp F 55 or below 57 61 81 95 97 109 Compressor discharge gas temp F 104 176 104 194 140 212 158 221 B Heating Except During Defrosting Indoo...

Page 41: ...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 Thermo...

Page 42: ...trol 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 un...

Page 43: ... 43 SM830076 2 Processes and functions 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 ...

Page 44: ...1 2 3 4 Section 44 SM830076 2 Processes and functions ...

Page 45: ...3 Electrical data 1 2 3 4 Section 45 SM830076 3 ELECTRICAL DATA 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram 46 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram 48 ...

Page 46: ...U1 U2 GRN YEL G GRN YEL 49FI BLK BLK BLK BLK BLK BLK PNK RED RED BRN BRN RED WHT YEL ORG VLT WHT GRY GRY PNK BRN BLK GRY BLK GRN YEL WHT WHT BLK GRN YEL GRY VLT FMI ORG RED BLK BLK BLK BLK YEL BLK GRY DP PNK BRN BRN BLK Coil E2 RED Coil E1 YEL Room Temp Controller CR THS2432 T6 WHT DP BLU FS RED E R SUP BLK N R SEC WHT PRY WHT N COM YEL H L LL FMI WHT HH 2 1 4 3 12V SG CD WL BLU G LM GRN 49FI GRY ...

Page 47: ... 1 4P 2 RY1 LM LL L HH H COM F2 3A MOV Symbols Description FMI 49FI RC1 F1 2 DP LM TR1 1X 3X RY1 RY2 MOV FS 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 TH3 CR THS2432 CONT IND Room Thermistor Thermistor Indoor Coil E1 Thermistor Ind...

Page 48: ... YEL C R S PTC RC1 WHT BLK BLK BLK WHT RED To Indoor Unit U1 U2 Terminal Plate 2P 52C 8 7 1Y 2 1 W 854 2 5268 582 00 2 CH2432 BRN GRN YEL RED BLK BLK BLU PNK ORG GRY BRN BRN RED GRY BLK WHT VLT PNK GRY BRN BLK BLK BRN BLK BLK BRN RED WHT WHT 49FO WHT RED GRN YEL 2 1 1 2 20S 3P RED 63PH 3P YEL 20S 3P BLK 52C 9P WHT CN24 3P WHT CT1 3P WHT PRY 2P WHT BLK C1 RED C2 Discharge Gas GRN CN2 2P BLU 3 1 SUP...

Page 49: ...8 PTC CR CH2432 RY1 RY4 1Y Thermistor Outdoor Coil C1 Thermistor Outdoor Coil C2 Thermistor Discharge Gas PTC Thermistor Outdoor Controller Auxiliary Relay Auxiliary Relay Terminal Plate Terminal Connector Schematic Diagram FMO 2 1 3 1 1 2 2 1 2 1 2 1 3 1 TR AC 208V 230V AC 14V TH8 TH7 TH6 2P 2 2P 1 3 7 3 1 4 RC2 RY3 RY4 RY2 RY1 2 1 1 52C 20S 1 9 2 1 3 3 1 7 6 5 5 3 H L M 49FO RY2 63PH 1 RY1 RY3 R...

Page 50: ...621 00 0 CH3632 BRN RED BLK BLK BLU PNK ORG GRY BRN BRN RED GRY WHT VLT PNK 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 BRN GRY GRY WHT VLT PNK GRY BRN BLK BLK BLK BLK BRN RED WHT WHT WHT RED 2 1 1 2 20S 3P RED 63PH 3P YEL 20S 3P BLK 52C 9P WHT CN24 3P WHT PRY 2P WHT BLK C1 RED C2 Discharge Gas GRN CN2 2P BLU 3 1 SUP 3P BLU 3 1 CT1 3P WHT E SEC Con...

Page 51: ... RY4 1Y Thermistor Outdoor Coil C1 Thermistor Outdoor Coil C2 Thermistor Discharge Gas PTC Thermistor Outdoor Controller Auxiliary Relay Auxiliary Relay Terminal Plate Terminal Connector Schematic Diagram FMO2 2 1 3 1 1 2 2 1 2 1 2 1 3 1 TR AC 208V 230V AC 14V TH8 TH7 TH6 2P 2 2P 1 3 7 3 1 4 RC3 RY3 RY4 RY2 RY1 2 1 1 52C 20S 1 9 2 1 3 3 1 7 6 5 5 3 H L M FMO1 RC2 2 1 7 6 5 H L M 49FO1 RY2 63PH 1 R...

Page 52: ...3 Electrical data 1 2 3 4 Section 52 SM830076 ...

Page 53: ...rvice 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 Out...

Page 54: ...s 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 pro...

Page 55: ...or unit and outdoor unit Power Supply 60 Hz single phase 230 208 V 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 be done with power being supplied be careful not to touch any uninsulated live part that can cause ELECTRIC SHOCK 4 4 4 4 4 Check the lead wires and connectors in in...

Page 56: ...ion 3 A Cooling Poor cooling Is setting temp suitable Change the setting temp Is cooling load too heavy Review cooling load estimate 4 way valve is defective Replace the 4 way valve Refrigerant shortage Charge refrigerant gas Refrigerant flow failure Electronic refrigerant control valve is defective Service valves are not fully open Replace the compressor Compressor is defective Open the valves fu...

Page 57: ...ully open Replace the compressor Compressor is defective Open the valves fully Air filter is clogged Clean the filter Not enough air circulation Is fan speed set to LOW Set the fan speed to either MEDIUM or HIGH Refrigerant tubes between indoor and outdoor units are not insulated Insulate wide and narrow tubes separately Replace the valve 4 way valve is defective Replace the valve Cold air is disc...

Page 58: ...O Heat stand by lamp Error receiving of serial communications signal Error transmitting of serial communications signal Indoor unit address setting is duplicated Remote controller address RCU ADR is duplicated Error transmitting of serial communications signal Error receiving of serial communications signal When using flexible combination control main indoor unit address setting is duplicated judg...

Page 59: ... device for compressor is activated 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 Compressor motor is overloaded Compressor motor is ...

Page 60: ...voltage SW activates Negative phase protector activates Sensor is abnormal Open or short Abnormal compressor current value is detected Auto address failure Auto address is in operation NOTE v LED lamps OFF V LED lamps ON lights up LED lamps ON flashes v v No message v V E06 E07 L04 v No message V v P02 V V P04 P05 V F04 F09 v H01 H02 E15 E16 SETTING flashes Flash at the same time REFRIGERANT SHORT...

Page 61: ...repair Replace the indoor unit PCB Is there 230 208 V AC between R and S of the indoor PCB Is the LED D80 on the indoor unit PCB lit Is there 12 V DC between R2 and R3 on the 8P terminal plate of the indoor unit Is the primary side of the indoor power transformer shorted Is there 230 208 V AC between U1 and U2 of the 8P terminal plate Are the connections for the 4P connector for the indoor unit s ...

Page 62: ...he No 1 line of the remote controller wiring from the indoor unit terminal plate Replace the indoor unit PCB OK No No No Yes Yes Yes NG 1145_THS_I Start Remote controller judges itself with self diagnostic functions Replace the remote controller Correct the wiring Correct the setting Open the inspection pin Is there an open or a contact defect in the No 1 line of the remote controller Is the indoo...

Page 63: ...he connections No Correct the connections Replace the indoor unit PCB Replace the indoor unit PCB Indoor outdoor unit control lines are cut off Correct the wiring 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 C...

Page 64: ...of INSTALLATION INSTRUCTION concerning with controlling remote controller switches when there are two remote controllers No No Yes Yes 0337_M_I Start Correct the setting Correct wiring Influenced by external noise Is the setting for the indoor address on the indoor unit PCB inappropriate Is there a cut line or contact defect between an indoor and outdoor unit s control line No Yes 0338_M_I Start I...

Page 65: ...ion warning No No No Yes Yes Yes 1146_THS_I Start Is there 230 208 V AC between S4 and T20 3 on the indoor unit PCB Is there 230 208 V AC between T20 3 and S4 after T20 1 and T20 3 on the indoor unit PCB shorted Is the indoor fan wire winding protection thermostat 49FI off Replace the indoor fan Correct the connection Replace the indoor unit PCB ...

Page 66: ...CB Correct the connection Yes No No No Replace the outdoor unit PCB Is there 230 208 V AC between CN19 9 and CN19 1 on the outdoor unit PCB Yes Replace the outdoor unit PCB Is the high voltage switch 63 PH off Yes Replace the fuse Is the fuse on the outdoor unit PCB blown F1 and F2 Is the compressor protection thermostat 49C off except 48 type No refrigerant High load 4 way valve defect Clogged re...

Page 67: ...ic refrigerant control valve defect indoor unit No Yes No Yes 0344_M_I Start Are there connection defects in the wiring High pressure switch defect Repair the wiring The system does not operate again 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 O...

Page 68: ...nit operate when two of the three phases are changed Actuation of negative phase protector Is there a contact defect in the 3P connector No Yes Replace the fuse Is the fuse F1 F2 on the indoor unit PCB blown No No No Yes Yes Yes 0646_M_S Start Repair the wiring Select an indoor unit which matches with the outdoor capacity Check the contact Perform the same as CHECK E04 When the group of the units ...

Page 69: ...e the total capacities of indoor units to that of outdoor units more than 107 16 Symptom LCD on the remote controller displays CHECK L13 No Yes 0648_M_S Start Repair the wiring When the group of the units are installed is there any mis cross between inter unit control wiring and refrigerant tubing Check the capacity of the indoor unit by remote controller See Test Run Manual 17 Check P9 is display...

Page 70: ... unit and correct it Normal No Failure in the electronic control valve activation No Replace the sensor Operate the unit in cooling mode 30 minutes after its operation 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 Does each indoor coil sensor detect the temperature correctly Is there any ...

Page 71: ...of fan motor winding Replace the fan motor Replace the capacitor Replace the P C B Ass y in the indoor unit No Yes Out 0650_M_S 2 Flaps in indoor unit s air outlet does not operate when you press SWEEP button Is 2P connector socket WHT attached to panel connected firmly with 2P plug No Yes Replace P C B Ass y in the indoor unit Yes No Replace the motor Connect firmly Check the louver motor resista...

Page 72: ...or motor magnetic contactor Check resistance of compressor motor winding Replace the compressor NG 0461_M_I No Yes No Yes Is fan motor capacitor normal No Is there voltage output of P C B Ass y for fan motor Yes Check resistance of fan motor winding NG Replace the fan motor Replace the relays Replace the capacitor Replace P C B Ass y in the outdoor unit Are auxiliary relays 1Y normal 1148_THS_I ...

Page 73: ...ration 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 ON OFF RCU ADR switch ON OFF RCU CK switch 0354_M_I The followings are the correct switch setting...

Page 74: ... 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 fi...

Page 75: ...me for more than 4 seconds SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No UNIT No No CODE SET TEMP C TIMER SET AIM SWEEP A SETTING TEST CHK 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 ...

Page 76: ...dress and the location of the sensor In case there are no sensor equipped with the unit is shown on the display 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 prob...

Page 77: ...n order of Past È Present 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 0360_M_I SERVICE R C No CHECK UN...

Page 78: ...e 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 ...

Page 79: ...ODE 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 fo...

Page 80: ... 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 Ex R C No 3 is selected Indoor No 2 is the smallest indoor No of the R C No 3 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 0362_M_I SET CL MODE F...

Page 81: ...he 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 ato h in the same way SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET No CODE TIMER SET DATA SETTING TEST CHK 0364_M_I 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 N...

Page 82: ... than 4 seconds 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 e Press the SET button CODE No 06 SET DATA and SETTING change from flashin...

Page 83: ...m 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 c Set the CODE No 12 to set the No of R C with the SET TEMP button NOTE SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET UNIT No No CODE TIMER SE...

Page 84: ...hich you want to set with the button Ex Indoor unit No 4 will be set In this example indoor unit address UNIT No will be set 2 4 Ex No of R C will be set 2 h Press the SET button UNIT No CODE No 13 SETTING and SET DATA 0004 change from flashing to ON state SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET UNIT No No CODE TIMER SET DATA SETTING TEST CHK 0369_M_I SET CL MODE FAN SP...

Page 85: ... 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 ...

Page 86: ...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 e Press the SET button CODE No 06 SET DATA and SETTING change from flashing to ON state f If you made a mistake pres...

Page 87: ...hen measure the resistance between the earthed wire and the other power wires Fig 21 2 2 2 2 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 3 3 3 3 Outdoor Unit Measure the resistance by placing a probe on the terminal plate in the same manner as explained a...

Page 88: ...ice is 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 pr...

Page 89: ... 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 Refer to 1 3 Other component specifications 3 Indoor fan motor FMI Indoor unit Measure the coil resistance Measure the resistance between each termina...

Page 90: ...and solder it Allow time to radiate heat during soldering so that the fuse does not melt When replacing the fuse be sure not to break down the varistor NOTE CAUTION 1042_X_S Fuse Fig 27 1043_X_S Soldering iron PCB Ass y Fuse Varistor Pliers 5 5 5 5 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 ...

Page 91: ...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 Refer to 1 3 Other component specifications Check the continuity between contactors 0 Solenoid coil of 4 way valve 20S Outdoor unit Measure the resistan...

Page 92: ... SM830076 Indoor Unit XHS2432 4 Sensor and Solenoid Layout Diagram Outdoor Unit CH2432 1154_THS_I TH6 C1 BLK 20S 63PH TH7 C2 RED TH8 GRN TH6 7 8 CM CH TH8 GRN Discharge gas 1153_THS_I TH2 E1 RED TH3 E2 BLK Electronic expansion valve 1582_X_I ...

Page 93: ...ion 93 SM830076 Indoor Unit XHS3632 4 Sensor and Solenoid Layout Diagram Outdoor Unit CH3632 TH6 7 8 CM CH TH8 GRN Discharge gas 63PH 20S 0584_C_S 0585_C_S TH6 C1 BLK TH7 C2 RED TH3 E2 BLK TH2 E1 RED Electronic expansion valve 1583_X_I ...

Page 94: ...mistor Characteristic Curve 1 Room temp sensor TH1 KTEC 35 4 5 14 23 32 41 50 59 68 0 5 10 15 20 25 30 35 40 Temperature F Resistance kn 1045_M_I Resistance kn 50 59 68 77 86 95 104 10 9 8 7 6 5 4 3 2 1 Temperature F 1044_M_I 3 Compressor discharge gas temp sensor TH8 PTC 51H 176 194 212 230 248 266 1 2 3 4 5 6 7 Temperature F Resistance kn 1149_THS_I ...

Page 95: ...ess 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 ...

Page 96: ... or Blue S2 Rotary switch Black 00 auto address Both OFF Set to 0 02 In case of No 2 outdoor unit Both OFF Set to 2 03 In case of No 3 outdoor unit Both OFF Set to 3 11 In case of No 11 outdoor unit 10 s SW is ON Set to 1 21 In case of No 21 outdoor unit 20 s SW is ON Set to 1 30 In case of No 30 outdoor unit switches are ON Set to 0 1 ON 10 position 20 position ON side S2 S3 OFF side Refrigerant ...

Page 97: ...ress 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 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 Uni...

Page 98: ...on 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 1 ON ON side 1127_C_I OFF side S4 green or Blue capacity code 4P DIP switch Outdoor control PCB 2 3 4 S4 Capacity code No Outdoor PCB Model No 1 2 3 4 24...

Page 99: ... 2 Performing Test Run 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...

Page 100: ...n the system During the test run all of the 3 indicator lamps on the indoor unit will flash During the test run the air conditioner runs continu ously and the thermostat does not control the sys tem 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 condition...

Page 101: ... 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 Recheck the test items before test operation Check the indoor and outdoor unit combination wiring Return the remote controller to normal Display the combination number Set the remote controller to test operation No No No Yes Yes Yes Yes Yes Y...

Page 102: ...T DISP PIN CN33 YEL ROOM TEMP CN31 RED COIL E1 CN32 BLK COIL E2 CN30 BRN COIL E3 E2 P ROM CN6 RED EXCT Forced thermostat OFF input terminal CN71 YEL T10 External input and output terminal CN83 WHT FMI CN84 YEL COM CN81 GRY 49FI CN85 BLU DPH CN78 BLU DP CN41 BLU Wired remote controller Shipment state Pulse signal Jumper cut Static signal JP1 Jumper wire For sellecting the signal of T10 CR THS2432 F...

Page 103: ...F3 Fuse 125V 0 5A F1 Fuse 250V 3A F2 Fuse 250V 3A CN2 BLU SG1 CN3 BRN SG2 CN19 BLU SUP CN4 BLK LINK SYSTEM CN15 GRN DISCHARGE CN14 RED C2 CN13 BLK C1 CN11 YEL TEST PIN S3 GRN or BLU R C address S2 BLK R C address CN22 BLK 52C CN21 YEL 20S CN7 RED CHECK PIN CN8 WHT CK L PIN CN9 WHT CK H PIN S4 GRN or BLU Capacity code S1 A ADD AUTO ADDRESS BUTTON D11 D12 RED MESSAGE LAMP CN20 WHT PRY CN23 RED 63PH ...

Page 104: ...D indicates abnormal Outdoor controller Blinking LEDs D11 and D22 indicate normal If one of the LEDs D11 and D22 goes off it indicates abnormal 4 2 Checking microcomputer operation When the microcomputer works normally the relays are switched in sequence as below 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 seco...

Page 105: ...elay RY3 is turned ON for 3 seconds The outdoor fan motor operates at the LL fan speed Relay RY4 is turned ON for 3 seconds 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 ...

Page 106: ...ompany 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 The specifications designs and information in this brochure are subject to change without notice ...

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Sanyo CH2432, Service Manual

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