Sanyo C3032 User's Manual
Contents
1. 6 1 2 Major Component Specifications 10 A Indoor Uni t 10 B Outdoor Unit 12 1 3 Other Component Specifications 16 A Indoor Unit 16 B Outdoor Unit MEM 17 1 4 Dimensional Data 21 Indoor Unit 21 B Outdoor Unit 22 1 5 Refrigerant Flow Diagram 23 1 6 Operating Range 24 SM830069 x 1 1 Unit Specifications MODEL No 2 POWER SOURCE 230 208 1 Phase 50 Hz PERFORMANGE Capacity BTU h2. 52 4 Thermistor Characteristic Gurve 53 SM830069 37 4 1 Troubleshooting 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 D Check power supply wiring a Single phase Check that power supply wires are correctly connected to terminal No 1 through No 4 on the 4P terminal plate in the indoor unit and L1 and L2 on the 6P terminal in the outdoor unit Check inter unit wiring Q Check that inter unit control wiring AC 230 208 V Line voltage is cor rectly connected between the indoor unit and outdoor unit Single phase outdoor unit Indoor Unit Outdoor Unit B Inter Unit Wiring Line voltage Fig 4 MT Check power supply Q Check that voltage is within the specified range 10 of the rating Check that power is being supplied KE If the following troubleshooting must be done with power being supplied be careful not to touch any uninsulated live part that can cause ELECTRIC HOCK Check the lead wires and connectors in indoor and outdoor units Q Check that the sheath of lead wires is not damaged Q Check that the lead wires are firmly connected at the terminal plate
3. 45 6 Outdoor Fan does not P 46 7 Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F C3032 C3632 Type 46 8 Outdoor Fan Speed is not Switched from High to Med even when the Outdoor Temperature Falls below 77 F Outdoor Fan Speed is not Switched from Med to Low even when the Outdoor Temperature Falls below 59 F CL3032 CL3632 Type 46 9 Outdoor Fan does not Run for CL3032 CL3632 47 10 Compressor does not Run 47 11 Poor Cooling 48 12 Excessive Cooling 48 4 2 Sensor is Defective 49 4 3 Operation of Major Electrical Parts 49 4 4 Checking the Electrical Components 50 1 Measurement of Insulation Resistance 50 2 Checking the Protective 51 3 Checking the Electrical Parts
4. 27 2 3 Outdoor Fan Speed Control 28 3 ELECTRICAL DATA 29 3 1 Indoor Unit 30 3 2 Outdoor Uni 32 4 SERVICE PROCEDURES 37 4 1 Troubleshooting 38 4 2 Sensor iS Defective 49 4 3 Operation of Major Electrical Parts 49 4 4 Checking the Electrical Components 50 3 SM830069 Introduction Head Me First This manual will help you understand and service the air conditioner To help you find the information you need we have divided it into 5 main sections Each section is divided into chapters with charts tables and explana tions to help you find and repair problems Section 1 Specifications tells you about the physical and electric
5. el TE Safety device internal type Overload relay models _____ G Operating temperature 189 20 Operating ampere at 77 F AL bs Kg High pressure switch Set pressure riget _ 0 0 ON kgom 2422 Number diameter Fan speeds Pp Fan motor 222 71 KFC6T 91D6P x 2 230 208 1 phase 60 Hz No of pole rpm 230 V High 6 879 OO OSOE Coil resistance BRN WHT 67 14 VLT YEL 11 42 Ambient temperature 68 F WHT VLT 6485 YEL PNK 10 60 Safety device Internal type Operating temperature 248 9 m o on TE Ss Face area NIS DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 15 1 3 Other Component Specifications A Indoor Unit MODEL No Power Transformer Rated AC 220 V 60 Hz Secondary 1 1 13V12A 0 Coil resistance Primary WHT WHT 146 15 Ambient temprature 77 F Secondary BRN BRN 0 5 15 96 Thermistor cut off temperature 259 F 2 A 250 V Thermistor Coil sensor PBC 41E 54 Coil resistance 14 F 237 i 41 F 12 1 23 F 18 8 50 F 9 7 Thermistor Room or coil sensor 32 F 15 0 Coil resistance M2EA24ZA01 DATA SUBJECT TO CHANGE WITHOUT NOTICE Synchronized Motor SM83
6. 9 171 27 2 12 16 45 8 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 10 1 2 Major Component Specifications A Indoor Unit sowe 290 208V tphase e0Hz O Controller P C B Ass y F 4 Number Dia and length 1 O D 4 13 18 120 146 1 170 Fan motor Noopoe rpm Q30V Hig Nominal output pw Coil resistance WHT GRY 1182 WHT VLT Ambient temperature 68 F 13 6 YEL PNK 31 4 VLT YEL Safety device 171 27 Heat exchanger ee Rows k _ 835039 M2EA24ZA01 771 oma Courses Ambon temes sss a 771 1 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 11 1 2 Major Component Specifications B Outdoor Unit MODEL No Compressor Rotary Hermetic C RI91H6L Some 230 208 V 1 phase 60 Hz 230 208 V 1 phase 60 Hz Nomina output 1 900 Compressor ot e 1 Coil resistance Ambient temperature 77 F a C R 0 697 C 1 656 Safety device Overload relay models Internal type Operating temperature 203 9 Operating ampere at 77 F AL Runcapactor VAC 400 V 40 uF Refrigerant amount charged at shipment ibs kg R22 8 6 3 9 High pressure switch ACB 10811 Set pressure OFF karem TS ON kg
7. 10 A Indoor Uni t 10 B Outdoor Uni t 12 1 3 Other Component Specifications 16 A Indoor Uniit 16 B Outdoor Unit 17 1 4 Dimensional Data 21 A Indoor Unit 21 B Outdoor Unit 22 1 5 Refrigerant Flow Diagram 23 1 6 Operating Ranoe JJ u u uuu 24 2 PROCESSES AND FUNCTIONS 25 2 1 Room Temperature Control 26 2 2 Freeze Prevention
8. SM830069 19 i 1 1 3 Other Component Specifications B Outdoor Unit Compressor Motor Magnetic Contactor OBE Contact rated Main 240 V 26 A Contact rated Auxiliary AC 240 V 3 A Power Relay AC 240 V 60 Hz Goitresistance at 77 F AC 220 V 6A Power Transformer ATR 135B LLL Colresistance at78 F WHT 4825 BRN 3 95 Thermal cut ofi temperature Thermistor Outdoor Temp sensor Coil resistance Thermistor PTC TDK 101YV AC 400 V 115A Resistance at 77 F 100 2 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 20 C 1 4 Dimensional Data Indoor Unit KS3032 KS3632 14 9 16 Remote controller Accessory 6 25 32 23 32 21 2 3 4 9 7 16 D Refrigerant gas line Wide tubing 3 4 Refrigerant liquid line narrow tubing 3 8 Drain hose OD 1 1 4 Dimension inch _X S SM830069 1 4 Dimensional Data B Outdoor Unit C3032 CL3032 C3632 CL3632 SS CER MoN S Z Im N WS ZO S B SAR R 2 S WS SEES 2 Z 2 o Wes Dimension inch D Hole for anchor bolt 4 213 Refrigerant tube joint narrow tube Flare c
9. When the outdoor temperature falls below 78 F the outdoor fan is set from HIGH to LOW automatically When the outdoor temperature rises to 82 F the outdoor fan is set from LOW to HIGH automatically 2 CL3032 CL3632 Type n low outdoor temperature the outdoor fan is set automatically from HIGH to MED LOW to prevent the indoor heat exchanger from freezing When the outdoor temperature falls below 77 F the outdoor fan is set from HIGH to MED automatically When the outdoor temperature rises to 81 F the outdoor fan is set from MED to HIGH automatically When the outdoor temperature falls below 59 F the outdoor fan is set from MED to LOW automatically When the outdoor temperature rises to 63 F the outdoor fan is set from LOW to MED automatically When the outdoor temperature falls below 47 F the outdoor upper fan is set from LOW to OFF and Lower fan is set from LOW to MED antomatically When the Lm outdoor temperature rises to 50 F the outdoor upper fan is set from OFF to LOW and Lower fan is set from MED to LOW antomatically 80 4 4 Upper fan H Lower fan H 380 171 7777 Upper fan OFF Lower fan M Upper fan M Lower fan M FAN ROTATION RPM 230 Upper fan L Lower fan L 47 50 59 63 77 81 OUTDOOR AIR TEMPERATURE F DB 1344 X Fig 3 SM830069 28 3 1 Indoor Unit Electric Wiring Diagram Sche
10. Air circulation H 8 1270 Moisture removal High _ t3 _ ELECTRICAL RATINGS LLL LLL Voltage rating Availabe voltage range Running amperes A s 155 Max running amperes A v 18 9 Power input w 330 Aj a 8 c z 10 8 11 0 886 17 7 Power factor Max starting amperes Maximum fuse size Controls Microprocessor Timer ON OFF 24 hours amp Program Fan speed Indoor Outdoor 3 and Automatic control 2 Auto Remote canal Accesso Refrigerant conr Refrigerant tubing connections Drain pipo rade size Compressor Outdoor Hi dB A 56 REFRIGERANT TUBING Umi of wing length m Limit of tuting length at shipment e Limit of elevation difference m Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52 outer diameter Wide tube in mm 3 4 19 05 Refrigerant amount at shipment Ibs kg R22 9 48 4 3 DIMENSIONS amp WEIGHT indoorunit Outdoor unit Height in m 14 916 370 48 5 8 1 235 Width in m 59 1 16 1 500 37 940 Depth in mm 9 76 240 13 3 8 340 Package dimensions Height in 18 6 32 462 52 7 32 1 326 62 9 16 1 589 40 1 016 11 5 8 295 16 12 32 416 P Unit dimensions 5
11. 88 s Moisture removal tign Pmsm 1 I s ELECTRICAL RATINGS UU S 29 Tp Rewnpamees Mex inning amperes wm s SER _ 34 Maxmumtusese AL p 77 bamboo RDE ET 1 Manual Automatic Are SS Washable easy access Remote controler Remote controller Accessory RCS 5PS4U Dunppewdesm comes tay CCC Outdoor Hi dB A 56 REFRIGERANT TUBING EEL Limit of elevation difference Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 outer diameter Wide tube 3 4 19 05 DIMENSIONS amp WEIGHT Unit dimensions mmm Gro 4858 1 235 Wien m mn 7 a0 13 38 340 52 182 1 326 40 1 016 Depth mm 16 12 32 416 Net weight Ibs ko 198 90 Shipping weight Ibs ka 223 101 Shipping volume cu ft m 7 7 0 217 19 8 0 56 Cooling DATA SUBJECT TO CHANGE WITHOUT NOTICE Rating conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 95 F DB 75 F WB Package dimensions Full load conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 115 F DB 5 830069 7 1 1 Unit Specifications POWER SOURCE PERFORMANCE Capacity
12. OUTDOOR FAN ROOM TEMPERATURE WITHIN 3 MINUTE MORE THAN 3 MINUTES MORE THAN 3 MINUTES 5 MINUTES 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 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 T 1 F Compressor ON Thermo OFF When the room temperature is equal to or below the set temperature T Compressor OFF SM830069 26 2 2 Freeze Prevention Freeze Prevention keeps the indoor heat exchange coil from freezing Freezing reduces the efficiency of the unit and frost buildup on the coil blocks cool air circulation from the indoor unit s fan FREEZE FREEZE PREVENTION PREVENTION MORE THAN 10 MINUTES 6 MINUTES 10 MINUTES 6 MINUTES INDOOR COIL TEMPERATURE 3 THERMO ON COMPRESSOR OUTDOOR FAN INDOOR FAN kt Reo ed 2 1029 X 5 Fig 2 SM830069 27 2 3 Outdoor Fan Speed Control 1 C3032 C3632 Type n low outdoor temperature the outdoor fan is set automatically from HIGH to LOW to prevent the indoor heat exchanger from freezing
13. Look at the TABLE OF CONTENTS to get an idea of what is in this manual and where to find it 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 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 Read the Instruction Manual The Instruction Manual is included here because it helps you help the user to set the temperature controls properly and know how to take care of any simple problems that may happen as well as know when to call for service The Instruction Manual also has illustrations care and installation information not found in the rest of the service manual It is short and if you read it carefully you will be able to answer the customers questions easily and also know the most efficient ways for setting times and temperatures Please use this manual to make your work easier keep the air conditioner functioning well and keep your customers satisfied SM830069 1 SPECIFICATIONS 1 1 Unit Specifications
14. unit directly Is wide tube between indoor unit and outdoor unit insulated YES Change installation position of remote control unit Insulate wide tube and then execute taping with narrow tube Temperature difference is small Possibility of refrigerant shortage Charge refrigerant R22 Measure temperatures of suction and discharge air of indoor unit Temperature difference between suction and discharge air is large enough Approx 10 deg or more Check clogging of air filter Clean filter Air filter is clogged YES Set fan speed to either Is fan speed set to LOW HIGH or MEDIUM Review cooling load estimate Reduce cooling load or if performance of air conditioner replace the unit with is normal higher cooling capacity 1040 X S Excessive Cooling Set the temperature to higher value using temperature setting button of the remote control unit The set temperature is too low Is the remote control unit installed M hange installation at a place where it can Change installatio position of the remote control unit detect the room temperature properiy SM830069 4 2 4 3 A Sensor is Defective D Indoor heat exchanger coil temp Sensor is defective a Open No continuity in sensor Compressor and outdoor fan repeat ON for 10 minutes and OFF for 6 minutes when sensor o
15. Ass y is defective 0628 X 5 E Check outdoor unit P C B CL3032 CL3632 Type Check P C B Ass y Check voltage between terminals L1 and L2 at terminal plate No voltage appears P C B Ass y is defective 1036 X 5 SM830069 4 Indoor Unit does not Run Indoor fan and louver motor do nol run P C B Ass y is defective 0630 X S 5 Some Part does not Operate A Indoor fan does not run Check fan rotation Rotate the fan gently once or twice by hand Check resistance of fan motor winding OK Check fan motor capacitor OK Relay RY1 or RY2 on the P C B Ass y is defective B Louver motor does not run Check resistance of louver motor winding OK P C B Ass y or remote contro unit is defective 9332 XS for foreign matter Fan cannot be rotated Check fan casing Remove foreign on the inside matter or repair Fan motor burnout or foreign matter in bearing Repair or replace 0631 X 5 SM830069 6 Outdoor Fan does not Run Check fan casing i i for foreign matter Remove foreign Fan cannot on the inside matter or repair Check fan rotation be rotated Rotate the fan gently once or twice by hand Fan motor burnout or foreign matter Repair or replace in bearing Check resistance of fan motor winding Check fan motor
16. Aluminum plate fin Copper tube 11 63 1 08 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 13 1 2 Major Component Specifications B Outdoor Unit MODEL No EJ 230 208 1 phase 60 Hz Compressor Rotary Hermetic Mot C R221H6R 230 208 V 1 phase 60 Hz Compressori e _ 1 500 Coll resistance Ambient temperature 77 F C R 0 549 C S 1 525 Safety device Internal type Overload relay models Operating temperature Open F 320 9 189 20 Operating ampere at 77 F VAC pF 400 V 40 pF Refrigerant amount charged at shipment 165 kg R22 9 48 4 3 High pressure switch ACB 1UB11 Set pressure Ia Propeller 2 19 332 460 2 AUTO K KFCBT 91D6P 2 230 208 V 1 phase 60 Hz No of pole rpm 230 V High 6 879 w 110x2 F Coil resistance EE BRW WHT 6714 VLT YEL 1142 Ambient temperature 68 F WHT VLT 64 85 YEL PNK Safety device 171 27 440 V 4 pF x 2 Heat exchanger Aluminum plate fin Copper tube 2 127 tt 11 63 1 08 DATA SUBJECT TO CHANGE WITHOUT NOTICE lr SM830069 14 C 1 2 Major Component Specifications B Outdoor Unit 230 208 V 1 phase 60 Hz Controller P C B Ass y CR CL2432 Microprocessor Cowmodomuttse Compressor Rotary Hermetic MeT emme ET w
17. Q Check that the wiring is correct 5 Reference Condition of general cooling operation Thermo ON SWEEP ON Indoor fan speed HIGH j SM830069 38 C 2 Air Conditioner does not Operate D Circuit breaker trips or fuse blows a When the circuit breaker is set to ON it is tripped soon There is a possibility of ground fault Check insulation resistance If resistance value is 1 MQ or less it is a defect of insulation Example supply cords Ground power line Set the circuit breaker to OFF D Remove power supply cords from the terminal plate in the outdoor unit Check insulation resistance of power supply cords Execute rewiring Remove inter unit power line from the terminal plate in the outdoor unit Check insulation resistance of outdoor unit insulation of outdoor unit is defective Remove inter unit power line from the termina plate in the indoor unit Check insulation resistance of indoor unit Inter unit power lines are Execute defective rewiring Insulation of indoor unit is defective electrical parts in the indoor unit Check insulation resistance of electrical parts in the outdoor unit Check insulation resistance of b Circuit breaker trips in several minutes after turning the air conditioner on There is possibility of short circu
18. capacitor Check continuity between terminals on the compressor motor magnetic contactor 7 Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F C3032 C3632 Type Check the thermostat 235 8 Outdoor Fan Speed is not Switched from High to Med even when the Outdoor Temperature Falis below 77 F Outdoor Fan Speed is not Switched from Med to Low even when the Outdoor Temperature Falls below 59 F CL3032 CL3632 Type Check outdoor unit P C B Ass y OK Check resistance of outdoor temp sensor 8 830069 46 9 Outdoor Fan does not Run for CL3632 Check fuse on PCB Ass y in outdoor unit for continuity If fuse blows Check resistance of primary winding of transformer TR 1038 X S 10 Compressor does not Run Check compressor motor capacitor RC1 OK Check PTC OK Check resistance of compressor motor winding 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 1039 X 5 SM830069 47 11 12 Poor Cooling Check installation position of remote control unit Does cool air from air condi tioner reach remote control
19. s 2 Net weight 6 en 195 90 Shipping weight tos kg 223 101 Shipping volume m Cooling DATA SUBJECT TO CHANGE WITHOUT NOTICE Rating conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 95 F DB 75 F WB Full load conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 115 F DB SM830069 8 xac 1 1 Unit Specifications QOutdorunt O POWER SOURCE 230 208 V 1 Phase 60 Hz kW 9 67 mm 7 Moisture removal High Pins h 11 1 ELECTRICAL RATINGS FI ET 188 sam and ss ES lsix i i cmm 117 Low ambient control Built in 0 F wanden OO C maal Ae eee a 4 Remote mole Accesso LEET Drain pipe trade size Compressor Operation sound Indoor Hi Me Loj dB A 48 44 40 Outdoor Hi dB A 56 REFRIGERANT TUBING ys Limit of tubing length 165 50 Limit of tubing length at shipment t m 50 15 Limit of elevation difference f 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 3 8 9 52 outer diameter Wide tube 3 4 19 05 Refrigerant amount at shipment ibs kg R22 9 48 4 3 3 4in
20. 0069 16 1 3 Other Component Specifications B Outdoor Unit ET k Compressor Motor Magnetic Contactor o 1 0 Power Relay Collresistance ka ft Thermostat Coll sensor 7513 ON Thermistor PTO msuwwmrv Tel DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 17 1 3 Other Component Specifications B Outdoor Unit Compressor Motor Magnetic Contactor Coilresistance at77 F o OO Power Relay k Coilresistance at 77 F ko 172 AC 220 V 5 A Power Transformer ATR I35B Coil resistance at78 F o WHT WHT 425 BRN BRN 395 Thermal cut off temperature F 2800 02 Thermistor Outdoor Temp sensor Coil resistance 97 2 6 TDK 101YV AC 400 V 115A Resistance at 77 F o 100 3 96 DATA SUBJECT TO CHANGE WITHOUT NOTICE Thermistor PTC SM830069 18 C 1 3 Other Component Specifications B Outdoor Unit MODELNo Compressor Motor Magnetic Contactor Colessame ues o Power Relay _Collresistance at7 F ko 000 0 0 0 0 m2 Thermostat Coil sensor Operating Temperature 79 OFF 75 3 ON 200 to 240 V 1 A Thermistor PTC TDK 101YV AC 400 V Resistance at 77 F o 100 DATA SUBJECT TO CHANGE WITHOUT NOTICE
21. 1Y or 2Y Check coil resistance of auxiliary relay 1Y or 2Y 0620 X 5 G Check fuse on the P C B Ass y in the indoor unit Check fuse on the P C B Check coil of compressor Ass y in the indoor unit motor magnetic contactor for continuity 52 When the fuse blows P C B Ass y is defective Check resistance of primary and secondary winding of transformer Check resistance of indoor fan motor winding FMI 1052 X 5 SM830069 42 C 3 Outdoor Unit does not Run o A Check COOL FAN selector switch in the remote control unit Is COOL FAN selector switch NO set to COOL Set to COOL 0623 X B Check set temperature Try to lower set temperature by Temperature setting button COOLER Set Operation selector switch to TEST in the indoor unit Outdoor unit runs Is room temperature too low Try to run both indoor and outdoor units with another remote control unit The other remote control unit is defective Room sensor in the remote control unit is defective 0624 X SM830069 C Check compressor motor magnetic contactor on Check coil resistance of compressor motor magnetic contactor 52C 1035 X D Check indoor unit P C B Check P C B Ass y Check voltage between terminals No 2 and No 4 at terminal plate No voltage appears P C B
22. 26 7 mm DIMENSIONS amp WEIGHT Indoor unit Outdoor unit Unit dimensions Height in mm 14 9 16 370 48 5 8 1 235 Width in mm 9 1 16 1 500 37 940 Depth in m 13 3 8 340 Package dimensions Height in mm 52 7 32 1 326 40 1019 Depth 14588 299 16 12 32 416 Net weight Ibs kg 198 90 Shipping weight Ibs kg 223 101 Shipping volume cu ft m 19 8 0 56 Cooling DATA SUBJECT TO CHANGE WITHOUT NOTICE Rating conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 95 F DB 75 F WB x Full load conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 115 F DB SM830069 9 1 2 Major Component Specifications A Indoor Unit i 1 Kem k Fan Number Dia and length in mm 1 O D 4 13 18 120 146 1 170 KE SFGAT 41A6P Sore 04020222 230 208 1 phase 60 Hz No of pole r p m 230 V High O _ 200 2 Coil resistance WHT GRY 1755 WHT VLT 169 Ambient temperature 68 F E YEL PNK 350 VLT YEL 114 Safety device 00 Heat exchanger Ros 2 47 wm 2 Louver Motor sss C Noopde mm 88 oma w 48 2 Coil resistance Ambient temperature 68 F
23. 29 000 Air circulation Hi 760 Moisture removal High Pints h ELECTRICAL RATINGS pt Volage rating v Rawgaweee 7 Mecnmmoamem 6 t j wer ee Em LT Drain pipe trade size Outdoor Hi dB A 56 REFRIGERANT TUBING Limit of tubing length f Limit of tubing length at shipment T EJ Outdoor unit is higher than indoor unit 165 50 Limit of elevation difference 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 tbs ko R22 8 6 3 9 DIMENSIONS amp WEIGHT Unit dimensions wan mmm seus 3 MO Depth in mm Height imm width 62916 9 40 Shpphgwe be p Te 22 Shipping volume cu ft 7 7 0 217 Cooling DATA SUBJECT TO CHANGE WITHOUT NOTICE Rating conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 95 F DB 75 F WB Full toad conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 115 F DB Package dimensions SM830069 6 C 1 1 Unit Specifications Outdoor Unit POWER SOURCE PERFORMANCE Capacly BTU R 29 000 m
24. SERVICE MANUAL SAN Y O KS3032 C3032 CL3032 KS3632 C3632 CL3632 Section SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No PRODUCT CODE No OUTDOOR MODEL No PRODUCT CODE No asa 014 59 6032 85401461 85401460 eun 7 Indoor Unit Outdoor Unit KS3032 C3032 KS3632 CL3032 C3632 CL3632 85464849169000 REFERENCE NO 5 830069 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 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 I
25. al 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
26. ate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on the terminal plate Fig 6 Outdoor Unit Measure the resistance by placing a probe on the terminal plate in the same manner as explained above 2 Fig 6 Measurement of Insulation Resistance for Electrical parts Disconnect the connector of the desired electric part from terminat plate P C B Ass y etc Fig 7 Similarly disconnect the lead wires from compressor capacitor etc Fig 8 Measure the resistance in the same manner as illustrated on the right Refer to Electrical Wiring Diagram If the probe does not enter the hole because the hole is too narrow use a probe with a thinner pin Earthed wire insulation tester 0638 X 5 Terminal plate Clip Copper Insulation tube or tester metallic part 0639 X 5 Clip Copper tube or metallic part Insulation tester 0600 X 5 From fan motor compressor and other parts E ZN Metallic A Probe part A F Q Clip 2 oe Insulation tester 0641 X S 50 Fig 5 Fig 6 Fig 7 ir Fig 8 SM830069 r 2 Checking the Protective Devices Disconnect the connector which consists of P plug and S socket when you want to check the protective device Then check continuity among plug s and or socket s terminal as in Fig 9 Normality of the protective device can be
27. cm 24 t 2 0 2 18 3 32 460 2 AUTO sss KFOST 9IDPx2 EJ 23 209V tpwse e0Hz No otpole pm 230V Hio mm 689 Coil resistance BRW WHT 67 14 VLT YEL 11 42 Ambient temperature 68 F WHT VLT 6485 YEL 10 60 Safety device Heat exchanger Rows Fins per inch CE 11 63 1 00 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830069 12 _ _ _ 1 2 Major Component Specifications B Outdoor Unit EJ 230 208 1 phase 60 Hz Controller P C B Ass y CR CL2432 Microprocessor Control circuit fuse r Compressor Mel Sows compressor o Coil resistance Ambient temperature 77 F o c R 0697 C 8 1656 Satety device L Overloadrelaymadels Operating temperature pn ae F 400 V 40 pF High pressure switch ACB 1UB11 Set pressure OFF kgo ON ke OO Propeller Number dameter mm 2 18 3 32 460 3 AUTO No of pole rpm 230 V High LNmmaops Coil resistance BRN WHT 67 14 VLT YEL 11 42 Ambient temperature 68 F WHT VLT 6485 YEL 10 60 Interna type 248 9 440 V 4 pF x 2
28. easure the resistance between each terminal of the socket connected to the indoor fan motor Refer to 1 2 Major component specifications Outdoor fan motor FMO Outdoor unit Measure the coil resistance Measure the resistance the same manner as explained above Refer to 1 2 B Major component specifications Motor capacitor Both in indoor and outdoor unit Remove the lead wires from the capacitor terminals and then place a probe on the capacitor terminals as shown in Fig 10 Observe the deflection of the pointer setting the resistance measuring range of the multimeter to the maximum value The capacitor is good if the pointer bounces to a great extent and then gradually returns to its original posi tion NOTE The range of deflection and the deflection time differ according to the capacity of the capacitor Multimeter Compressor motor capacitor Fan motor capacitor Fig 10 ions SM830069 52 Continuity of fuse P C B Ass y Check for continuity using a multimeter as shown in Fig 11 NOTE Method Used to Replace Fuse on PCB Ass y 1 Remove the PCB Ass y from the electrical compo nent box 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 S0W or 60W Fig 12 3 For replacement insert a fuse of the same rating to the intended pos
29. it Check capacity of circuit breaker Replace it with a suitable one Is capacity of circuit larger capacity breaker sufficient f Check resistance of outdoor fan motor winding Check resistance of compressor motor winding Check resistance of louver motor winding 1056 X 5 Neither indoor unit nor outdoor unit runs A Power is not supplied Circuit breaker is tripped Reset the breaker Check power supply Is power being supplied NO to outdoor unit Wait for recovery Power failure or consult power supply company 9845 X S B Check remote control unit Try to run both indoor and NO outdoor units with another remote control unit Refer to item C The other remote control unit is defective 0516 X S SM830069 40 Has Operation selector switch been set to ON position NO Set Operation selector switch to ON Switch Ass y or P C B Ass y in the indoor unit is defective Check high pressure switch Does high pressure switch actuate 63PH 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 E Transformer in indoor unit Check resistance of transformer winding TR1 108 X But neither unit runs C Check Operation selecto
30. ition 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 i 4042 5 Soldering iron 4 Thermistor Characteristic Curve D Room temp sensor D Coil sensor KTEC 35 PBC 41E Resistance Resistance ko 50 59 68 77 86 95 104 Temperature F 53 4 5 14 23 32 41 A Temperature F Fig 11 i l 1043 XS Fig 12 50 59 68 1045 M 1 SM830069 SANYO FISHER Service Company CENTRAL REGION 1165 Allgood Road Suite 22 Marietta G 30062 Phone 770 509 5230 Fax 770 579 2860 Jan 99 Printed in U S A
31. judged by the following table The Protective Device is proved normal if there is a continuity between terminals Socket h Multimeter Fig 9 D Indoor fan motor thermal protector 49FI Indoor unit Disconnect the connector which leads to the indoor fan motor FMI Check the socket s terminals Compressor motor thermal protector Outdoor unit Disconnect the wires from terminals of compressor Check the terminals of compressor Outdoor fan motor thermal protector 49FO Outdoor unit Disconnect both the connector which leads to the outdoor fan motor FMO Check socket s terminal 51 3 Checking the Electrical Parts Power transformer TR1 Indoor unit Measure the coil resistance e Primary 230 208 V Measure the resistance between two WHT lead wire terminals of socket connected to power transformer Secondary 10 6 V Measure the resistance between two BRN lead wires Refer to 1 3 Other component specifications Power transformer TR Outdoor unit Measure the coil resistance Primary 230 208 V Measure the resistance between two WHT lead wire terminals of socket jointed to power transformer Secondary 14 V Measure the resistance between two BRN lead wires Refer to 1 3 B Other component specifications Indoor fan motor FMI Indoor unit Measure the coil resistance M
32. matic Diagram 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram 29 SM830069 Indoor Uni 3 1 D KS3032 KS3632 229653 ZEOESH 0 00 819 892G 2 v 39 8 2 3 Je jooeH 40j 04 u 0 88V MS omeen WOHL 1 yeg MeT kun 01 5 830069 30 C 8 1 Indoor Unit D KS3032 KS3632 Schematic Diagram ns POW KS2412BN Controller Terminal Plate 4P B THY COIL FMI Indoor Fan Motor RC1 Running Capacitor TRI Auto Louver Motor RY1 2 3 4 Auxiliary Relay Teminat Piate connector 854 2 5268 618 00 0 KS3032 KS3632 Symbols SM830069 31 3 2 Outdoor Unit D C3032 C3632 Electric Wiring Diagram PNK WHT Terminal Plate 6P COOS r oL A 082 7 A 80Z Hdi 2 09 IddnS 32 Connector 5 xz gt gt Earth Terminal i ome GRN YEL 49FO1 u 9 854 2 5268 620 00 0 C3032 C3632 SM830069 C 3 2 Outdoor Unit C3032 C3632 Terminal Plate 6P Schematic Diagram T 2 4103 aD Ry Compressor motor 2 Compressor Motor Magnetic Contactor 3PH High Pressure Switch 23s Fan Speedcontrol Thermostat Running Capacitor PTC Thermistor Auxiliary Relay Connec
33. n 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 ground ing can cause accidental injury or death Ground the unit following loca electrical codes Connect ail wiring tightly Loose wiring may cause overheat ing 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 a Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors 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 vibra
34. onnection 3 8 in 9 52 mm Refrigerant tube joint wide tube Flare connection 3 4 in 19 05 mm Refrigerant tubing inlet amp Power supply inlet 142 C SM830069 1 5 Refrigerant Flow Diagram Indoor Unit KS3032 Outdoor Unit C3032 C3632 KS3632 CL3032 CL3632 9 0 Accumulator H 5 19 05 mm 8 E 8 1 i E I 5 Narrow tube 8 Strainer Service valve MN Sub condenser om be mem 1345 5 SM830069 23 1 6 Operating Range KS3032 53632 C3032 C3632 Indoor Air Intake Temp Outdoor Air Intake Temp 95 F DB 71 F WB 115 FDB Minimum 67 F DB 57 F WB 67 F DB KS3032 KS3632 CL3032 CL3632 Indoor Air Intake Temp Outdoor Air intake Temp Maximum 95 FDB 71 FWB 115 F DB Minimum 67 F DB 57 F WB 0 F DB SM830069 24 aaa 2 1 Room Temperature Control gt 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 S T TF SET TEMP T F COMPRESSOR INDOOR FAN
35. pens b Short Freeze Prevention does not operate when dehumidified water is frozen on the indoor coil Room temp Sensor in the remote control unit is defective a Open No continuity in sensor Neither outdoor fan nor compressor runs b Short Outdoor fan and compressor do not stop Excessive cooling Operation of Major Electrical Parts indoor unit and Remote ERE UI RN unit Operation Indicator indeatrlamp Fan Fan Compressor Room mer Nh setback IE jorn O O meses po Remon olol o tolol Gool setback memoor o o 799 mme ponme L L 1 o Freeze prevention 010 o ol o T ol Fa T O c Tole etH H NOTE O Refer to Cooling Mode Operation Mode Function SM830069 49 4 4 Checking the Electrical Components 1 Measurement of Insulation Resistance The electrical insulation is acceptable when the resistance exceeds 1 MO D Power Supply Wires Clamp the earthed wire of the Power Supply wires with a lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the power wires Fig 5 Then measure the resistance between the earthed wire and the other power wires Fig 5 Indoor Unit Clamp an aluminum pl
36. r switch in the indoor unit D Check compressor motor protectors a High pressure switch 63PH IND LAMP Ass y or P C B Ass y in the indoor unit is defective 0617 X S Disconnect the socket from 2P WHT connector Check the continuity between No 1 and No 2 poles of the socket 41 Clean heat exchanger coil or remove obstacles 0518 X SM830069 Has Operation selector switch been set to ON position NO Set Operation selector switch to ON Switch Ass y or P C B Ass y in the indoor unit is defective Check high pressure switch Does high pressure switch actuate 63PH 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 E Transformer in indoor unit Check resistance of transformer winding TR1 108 X But neither unit runs C Check Operation selector switch in the indoor unit D Check compressor motor protectors a High pressure switch 63PH IND LAMP Ass y or P C B Ass y in the indoor unit is defective 0617 X S Disconnect the socket from 2P WHT connector Check the continuity between No 1 and No 2 poles of the socket 41 Clean heat exchanger coil or remove obstacles 0518 X SM830069 F Check auxiliary relay
37. s when installing or testing the refrigeration system Contact of refrigerant gas with fire or heat can produce poisonous gas Confirm after installation that no refrigerant gas is leaking If the gas comes in contact with a burning stove gas water heater electric room heater or other heat source it can cause the generation of poisonous gas SM830069 MUS This service manual is made to assist the service technician apply his knowledge and training to this model air conditioner This manual is written both for experienced service persons and those who are new to air conditioning service To help those with less experience or who are new to this kind of unit we have included more explanations of basic procedures in simple language than is usual in some service manuals The experienced technician will of course find he knows many of these things already and can go directly to the procedures and infor mation he needs the less experienced technician will better understand what to do even before he arrives on the job and therefore be better able to work by himself as well as assist the more experienced technician TABLE OF CONTENTS 1 SPECIFICATIONS naan u u uuu 5 1 1 Unit Specifications 6 1 2 Major Component Specifications
38. tion 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 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 Tum the power OFF at the main power box mains before opening the unit to check or repair electrical parts and wiring Keep your fingers and clothing away from any moving parts Clean up the site when installation is finished Check that no metal scraps or bits of wiring have been left inside the unit Ventilate any enclosed area
39. tor Terminal Plate 5 854 2 5268 620 00 0 C3032 C3632 SM830069 32 3 2 Outdoor Unit CL3032 CL3632 Electric Wiring Diagram amp BS E of 5 062 802 Hd 2HO9 Aiddng 24 854 2 5268 619 00 1 CL3032 CL3632 8 830069 3 2 Outdoor Unit E re 2 CL3032 CL3632 Schematic Diagram 777 7 7 7 5 7 s Controller 3 L ee i v ou Compressormoor rz re lo crancase Heater Hion Pressure swn emona OudoorFanwoor 9 Temmiae eronz Outdoor Fan Moor cme mo Pre Tl m mwrmmeme 11 ouzo Ruming Capector 2 12 71 ayna O O OO owocne LC C C 854 2 5268 619 00 1 CL3032 CL3632 35 SM830069 4 SERVICE PROCEDURES 4 1 Troubleshooting aaaaaaanaanaanananannanunnannanannuanannanannnnannanannaunnannnanaanasununanannnnauna 38 1 Check before and after Troubleshooting 38 2 Air Conditioner does not Operate 39 3 Outdoor Unit does not Run 43 4 indoor Unit does not Run 45 5 Some Part does not Operate
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