Sanyo C2432 User's Manual
Contents
1. Ambient temperature 68 F Source Coil resistance BRW WHT 1110 ORG YEL 167 440 V 1 5 uF SR4X 51A6P No of pole r p m 230 V High 1 187 WHT VLT 35 4 BLK PNK 23 9 VLT ORG 13 4 YEL BLK 136 6 Operating temperature 266 144 1742 27 Heat exchanger ENE Coil Aluminum plate fin Copper tube Face area C Auto louver motor A A NEN MM Model No DATA SUBJECT TO CHANGE WITHOUT NOTICE Rows Fins per inch 3 14 9 SM830060 1 2 Major Component Specifications B Outdoor Unit Compressor Rotary Hermetic KC C 2R170H6S 230 208 V 1 phase 60 Hz 1 700 Compressors o o f w E Coil resistance Ambient temperature 77 F Q C R 0 885 C S 1 773 Internal type 00 Operating temperature Open F 297 9 198 20 F Safety device Operating ampere at 77 F E A ee 1l VAC u 400 V 40 uF R22 5 3 2 4 Refrigerant amount charged at shipment lbs kg High pressure switch ACB 1UB11 Set pressure OFF kg cm 30 33 ON kg cm 24 2 0 1 18 3 32 460 2 AUTO SL KFO6T 91D6P 230 208 V 1 phase 60 Hz No of pole mpm 230V High pm 6 879 Nmmiupt oo w p MH TT Coil resistance Q BRW WHT 67 14 VLT YEL 11 42 Ambient temperature 68 F A WHT VLT 64 85 YEL PNK 10 602. SM830060 Unit Specifications 1 1 Outdoor Unit POWER SOURCE PERFORMANCE Moisture removal High ELECTRICAL RATINGS Outdoor Hi REFRIGERANT TUBING Limit of elevation difference ft m between the two units Refrigerant tube Narrow tube in mm outer diameter Wide tube in mm Refrigerant amount at shipment lbs kg DIMENSIONS amp WEIGHT TS2432 Microprocessor Built in O F ON OFF 24 hours amp Program 3 and Automatic control 3 Auto Manual Automatic Washable easy access RCS 5PS4U Capillary tube Flare type Rotary 39 37 33 Outdoor unit is higher than indoor unit 132 40 Outdoor unit is lower than indoor unit 83 25 Outdoor unit Cooling 7 15 32 51 3 16 28 15 16 735 3 940 26 3 8 670 13 3 8 340 in 9 14 32 240 32 17 32 826 in mm in mm 75 ei Shipping volume 12 3 0 349 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 Unit dimensions 190 1 300 Package dimensions SM830060 7 1 2 Major Component Specifications A Indoor Unit Souce Le 290 208V iphase 60Hz Remote controller Accessory Controller P C B Ass y Control circuit fuse Switch Ass y
3. Check high pressure switch Does high pressure switch actuate 63PH Is outdoor heat exchanger coil dirty or are there Clean heat exchanger coil obstacles near air suction or remove obstacles 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 1033 X 5 SM830060 35 F Check auxiliary relay 1Y or 2Y Check coil resistance of auxiliary relay 1Y or 2Y 0620 X S G Check fuse on the P C B Ass y in the indoor unit Check fuse on the P C B Check coil of compressor Ass y in the indoor unit motor magnetic contactor for continuity 52C When the fuse blows Check resistance of primary and secondary winding of transformer TR P C B Ass y is defective Check resistance of indoor fan motor winding FMI Check resistance of louver motor winding LM 1079 X 5 36 SM830060 AOON 3 Outdoor Unit does not Run A Check COOL FAN selector switch in the remote control unit set to COOL B Check set temperature Try to lower set temperature by Temperature setting button COOLER Set Operation selector switch to TEST in the indoor unit Is room temperature too low Try to run both indoor and outdoor units with an
4. 41E S26 Coil resistance 50 F 9 7 23 F 18 8 04 68 F 6 5 32 F 15 0 86 F 4 4 41 F 12 1 104 F 3 1 113 F 2 6 emmer len DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830060 13 1 4 Dimensional Data A Indoor Unit TS2432 12 7 32 Holes in the rear unit View from front Hole for wall through piping View from front Suspension bolt hole pitch 12 12 Air outlet or more 51 3 16 or more Service space Service space Air intake 24 or more Dimension inch lt Remote controller Accessory O Drain connection Drain connection for left side E O Refrigerant liquid line 1 4 Flare connection a O Refrigerant gas line 3 4 Flare connection o ap O Hole for rear side refrigerant tubing O Hole for through the wall refrigerant tubing 23 15 16 hole O Hole for upper side refrigerant tubing Knockout hole 8 Hole for right side refrigerant tubing Knockout hole Hole for left side drain connection Knockout hole 243 32 23 32 Hole for power supply cord Knockout hole 97 8 Infrared rays receiver for wireless remote controller C il 6 25 32 1078 X SM830060 442 1 4 Dimensional Data B Outdoor Unit C2432 CL2432 28 15 16 Dimension inch D Hole for anchor bolt 4 61 2 Refrigerant tube joint n
5. Safety device Operating temperature 248 41 171 59 F Heat exchanger 2 14 VAC u 440 V 4 uF Aluminum plate fin Copper tube Rows Fins per inch Face area m 6 63 0 616 DATA SUBJECT TO CHANGE WITHOUT NOTICE ft SM830060 1 2 Major Component Specifications B Outdoor Unit Controller P C B Ass y CR CL2432 Microprocessor E EE el 290 208V iphasee80Hz GR 012432 Microprocesso Compressor Modelers Nominatoupat a Compressor el 300 _Coilresistance Ambient temperature 77 F 2 C R 0885 C S 1773 EX Safety device internal type Overload relay models Operating temperature 297 9 198 20 400 V 40 uF V W lbs Crank case neater VW 230 V 30 W Refrigerant amount charged at shipment kg R22 5 5 2 5 High pressure switch ACB 1UB11 Set pressure OFF kg cm 30 6 ON kg cm 24 2 0 1 18 9 32 460 3 AUTO Mil KFOBT 91D6P Source 230 208 V 1 phase 60 Hz No of pole rpm 230 V High Nominal output NI Coil resistance Ambient temperature 68 F Safety device BRN WHT 67 14 VLT YEL 11 42 WHT VLT 64 85 YEL PNK 10 60 Operating temperature Run capacitor Heat exchange Coil Rows Fins per inch E DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830060 10 1 3 Other Component Sp
6. and repair problems Section 1 Specifications tells you about the physical and electrical make up of the unit as well as its heating and cooling capacities Look in this section to find the correct values for components and functions Section 2 Processes and Functions explains each different part of the cooling and heating cycle and how each control function reacts to changing conditions to keep the room at the set temperature range Section 3 Electrical Data which has fold out schematic and wiring diagrams so you can find the parts you need to check when something is wrong and see how they should be connected Section 4 Service Procedures has two main parts a diagnostic chapter to help you find the specific component to replace or adjust and a chapter with specific procedures and values to guide you in checking the electrical components in the unit HOW TO USE THIS MANUAL You can use this manual both as a reference to find specific information about the capacity functions and construction of this unit and as a source of information to help you set up and maintain the unit When this unit is not working properly and the cause is not known you can use the procedures in Section 3 Servicing Procedures to find the problem fix it and restore the unit to its proper functioning f This air conditioner has many helpful self diagnostic features to help you identify problem areas quickly So you will be ready when a problem ha
7. foreign matter or repair Fan motor burnout or foreign matter Repair or replace 0601 X SM830060 6 Outdoor Fan does not Run Check fan casing for foreign matter on the inside Remove foreign matter or repair Fan cannot Check fan rotation be rotated Rotate the fan gently once or twice by hand Fan motor burnout or foreign matter in bearing Repair or replace Check resistance of fan motor winding Check fan motor capacitor Check continuity between terminals on the compressor motor magnetic contactor 0633 X S 7 Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F C2432 Type Check the thermostat 23S 1037 X S 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 CL2432 Type Check outdoor unit P C B Ass y Check resistance of outdoor temp sensor om X5 SM830060 40 9 Outdoor Fan does not Run for CL2432 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 Wait for 30 minutes until com
8. of the remote control unit The set temperature is too low lt Is the remote control unit installed Change installation at a place where it can position of the remote control unit detect the room temperature properly SM830060 42 4 2 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 opens b Short Freeze Prevention does not operate when dehumidified water is indoor coil 2 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 4 3 Operation of Major Electrical Parts Indoor unit and Remote Control unit Operation Indicator lamps Fan Room Night setback Operation Mode Function ThemoON O O lol Thermo oFF O O lol Nm pen ojo o 2 Cool setback Tthermo orF O JO o 9 timer ONTimer dol f set LoFF Timer_ ooo lol Freeze prevention Loo o Fan post PR p AO swo LOL a Fa Joj JJ Jol so E poto o o Fan Eu s A O NOTE O Refer to Cooling Mode 43 frozen on the Fel o SER SM830060 4 4 Checking the Electrical Components Measurement of Insulation R
9. 1 CL2432 mes zee a 3 D m N 63PH SM830060 29 SM830060 30 4 SERVICE PROCEDURES AAA A 32 1 Check before and after Troubleshooting ecce 32 2 Air Conditioner does not Operate cessere 33 3 Outdoor Unit does not Run eese 37 4 Indoor Unit does not Run see 39 5 Some Part does not Operate essences 39 6 Outdoor Fan does not Run aaneen treten tennis 40 7 Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F C2432 Type aana 40 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 CL2432 Type 40 9 Outdoor Fan does not Run for CL2432 nnee 41 10 Compressor does not Run nnee nennen ensen 41 e ieden te nae eeen ee Te 42 12 Excessive Cooling aote eee oett de imt tiec ced Toast 42 4 2 A Sensor is Defective A reis creat cro etd utei eld 43 4 3 Operation of Major Electrical Parts aenema nnen eenen 43 4 4 Checking the Electrical Components nennen eenen 44 1 Measurement of Insulation Resistance nn 44 2 Checking the Protective Devices nnen nnen ennen 45 3 Checking the Electrical Parts E 46 4 Thermistor Characteristic Curve aaa 47 SM830060 31 4 1 Troubles
10. 12 1 4 Dimensional Data zannnaaaaaaaaanaannannnannunsnnannnnnnnnnnanannnnnnunnununnnnnnnnnnnannannnannnnnani 14 A Indoor Unit aaannaaaaannzaxa anannnnnnnnnnnnnannannnnannnnnunnsnannn anannnnnnnnanunannnnnnnnnnnunnannnnanna 14 B Outdoor Unit MM 15 1 5 Refrigerant Flow Diagram aa2aananaaaaansananananansnnnnnnnnnnnnannnnnnnnunnanannnnnnnnunnaanannni 16 1 6 Operating Range anaanaannaaaaasaaaaannananannnnnnnannannnnnnannunnananannanaaannananananananananannnn 17 2 PROCESSES AND FUNCTIONS eneen 19 2 1 Room Temperature Control EEN 20 2 2 Freeze Prevention a naaannnannnnannnanannnsvt si ssssssnssninatta annunununannanannnnunannananaa 21 2 3 Outdoor Fan Speed Control 22 3 ELECTRICAL DATA ENEE 23 A 24 3 2 Outdoor Unit een 26 4 SERVICE PROCEDURES AANEREN 31 4 1 Troubleshooting aaiaaaaxzaz annannnnananannnnnonnunnnninnnnnannnaunnnnunnnnsannnnanannnnnnnnnnnnnnnnananunanuna 32 4 2 A Sensor is Defective ENEE 43 4 3 Operation of Major Electrical Parts aaaaaaaaaaaavnvaaaannnnnnnanasnnnsnannnnnnunannannnannna 43 4 4 Checking the Electrical Components essen eene 44 SM830060 Introduction Read Me First A 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 heip you find
11. 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 In Case of Improper Installation The manufacturer shall in no way be responsible for improper installation or maintenance service including failure to follow the instructions in this document SPECIAL PRECAUTIONS When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ONLY A QUALIFIED EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM Do not supply power to the unit until all wiring and tu
12. ES 10 MINUTES 6 MINUTES INDOOR COIL TEMPERATURE apie THERMO ON THERMO OFF COMPRESSOR Krama cer OUTDOOR FAN INDOOR FAN 1029 X Fig 2 SM830060 291 2 3 Outdoor Fan Speed Control 1 C2432 Type lt In low outdoor temperature the outdoor fan is set automatically from HIGH to LOW to prevent the indoor heat exchanger from freezing When the outdoor temperature falls below 78 F the outdoor fan is set from HIGH to LOW automatically When the outdoor temperature rises to 82 F the outdoor fan is set from LOW to HIGH automatically 2 CL2432 Type In low outdoor temperature the outdoor fan is set automatically from HIGH to MED LOW to prevent the indoor heat exchanger from freezing When the outdoor temperature falls below 77 F the outdoor fan is set from HIGH to MED automatically When the outdoor temperature rises to 81 F the outdoor fan is set from MED to HIGH automatically When the outdoor temperature falls below 59 F the outdoor fan is set from MED to LOW automatically When the outdoor temperature rises to 63 F the outdoor fan is set from LOW to MED automatically 70 4 41 FAN ROTATION RPM HGBV HOT GAS BYPASS VALVE 47 50 59 63 77 81 1030 X 5 OUTDOOR AIR TEMPERATURE F DB SM830060 SOD 3 ELECTRICAL DATA 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram 24 3 2 Outdoor Unit Electric Wiring Diagram S
13. RCT pressor has cooled Compressor runs Check PTC Compressor internal thermal protector is operated Check resistance of compressor motor winding Check power supply voltage Is voltage abnormally low Is outdoor heat exchanger coil dirty or are there obstacles near air suction inlet 1039 X S SM830060 41 11 Poor Cooling Check installation position Change installation of remote control unit position of remote Does cool air from air condi control unit tioner reach remote control unit directly Insulate wide tube and then execute taping with narrow tube Is wide tube between indoor unit and outdoor unit insulated 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 HIGH or MEDIUM Is fan speed set to LOW 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 12 Excessive Cooling Set the temperature to higher value using temperature setting button
14. SERVICE MANUAL SANYO TS2432 C2432 CL2432 SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No PRODUCT CODE No OUTDOOR MODEL No PRODUCT CODE No C2432 854 013 43 TS2432 854 013 38 CL2432 854 013 39 Indoor Unit Outdoor Unit Ss JJ In SCH N AN Z zz Ez S ST SI S A P Mt Ni WS Mi di quM ti IN ON ma R E 152432 u C2432 CL2432 85464849160000 REFERENCE NO SM830060 2 Air Conditioner does not Operate Circuit breaker trips or fuse blows a When the circuit breaker is set to ON it is tripped soon There is a possibility of ground fault Check insulation resistance If resistance value is 1 MQ or less it is a defect of insulation Example Set the circuit breaker to OFF Remove power supply cords from the terminal plate in the outdoor unit Check insulation resistance of power supply cords 2 Remove inter unit power line from the terminal plate in the outdoor unit Check insulation resistance of outdoor unit Remove inter unit power line from the termina plate in the indoor unit Check insulation resistance of indoor unit Inter unit power lines are defective 33 Execute rewiring Insulation of outdoor unit is defective Insulation of outdoor unit is defective Execute rewiring Check insulation resistance of electrical parts in the outdoor uni
15. arrow tube Flare connection 1 4 in 6 35 mm Refrigerant tube joint wide tube Flare connection 3 4 in 19 05 mm O Refrigerant tubing inlet Power supply inlet 1025 C S SM830060 1 5 Refrigerant Flow Diagram Indoor Unit TS2432 Outdoor Unit C2432 op j 5 3 4 Zi i 19 05mm S E S q 5 9 o y gt b pressure switch 5 g Narrow tube 8 service valve 0 0 od 1 4 Sub condenser 6 35 mm EN aks AA 1026 X S Indoor Unit TS2432 Outdoor Unit CL2432 Wide tube 1 service valve 1 gt z Accumulator O Compressor Evaporator pressure switch Narrow tube service valve Condenser 1027_X_S SM830060 ESTA 1 6 Operating Range TS2432 C2432 Indoor Air Intake Temp Outdoor Air Intake Temp Maximum 95 FDB 71 F WB 115 F DB Minimum 67 FDB 57 FWB 67 F DB lt TS2432 CL2432 Indoor Air Intake Temp Outdoor Air Intake Temp Maximum 95 FDB 7 FWB 115 F DB 67 F DB 57 F WB 0 F DB SM830060 17 SM830060 18 2 PROCESSES AND FUNCTIONS 2 1 Room Temperature Control ee EEN 20 2 2 Freeze Prevention sistance A neede 21 2 3 Outdoor Fan Speed Control annen ENNEN 22 SM830060 19 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 contr
16. bing are completed or reconnected and checked Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequate ground ing can cause accidental injury or death Ground the unit following local electrical codes Connect all wiring tightly Loose wiring may cause overheat ing at connection points and a possible fire hazard When Transporting 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 Ina Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors In Moist or Uneven Locations Use a raised concrete pad or concrete blocks to provide a solid level foundation for the outdoor unit This prevents water damage and abnormal vibration In an area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame Provide a suitable air baffle In a Snowy Area for Heat Pump type Sys tems Install the outdoor unit on a raised platform that is higher than drifting snow Provide snow vents When Connecting Refrigerant Tubing Ventilate the room well in the event that refrigerant gas leaks during the installation Be caref
17. chematic Diagram aaa 26 SM830060 23 3 1 Indoor Unit O TS2432 TH1 Coil al D 2 amp 0 Earth Terminal e Electric Wiring Diagram TH2 Room S2432 BLK BLK vj Connector 2P BLK o o Connector 2P WHT Qo o BLK TTS PSN 0000 Terminal Plate 4P To Outdoor Unit Terminal W 854 2 5268 593 00 0 TS2432 SM830060 3 1 Indoor Unit O TS2432 Schematic Diagram CR TS2432 854 2 5268 593 00 0 TS2432 SM830060 25 3 2 Outdoor Unit D C2432 Electric Wiring Diagram Terminal Plate 6P PS WHT 41 1 WHT RED 2 2 RED Connector 2P WHT 63PH Power Supply H 208V 230V To Indoor Unit 60Hz 1 Terminal GRN YEL 5 Di o O Earth Terminal Terminal v 49FO GRN YEL W 854 2 5268 594 00 0 C2432 SM830060 26 3 2 Outdoor Unit D C2432 Schematic Diagram eu mes 854 2 5268 594 00 0 C2432 27 SM830060 3 2 Outdoor Uni ZEPZ19 1 00 049 8929 3 488 A uwa yeg UHM dz JOJ99LUOD d aw Nyga aja I NH8 WIE je NE euwe yue3 LUS ID DuulM 91110913 e CL2432 euwe eg 49 eyed jeuruue Hdl ZH09 Ajddng semod yun 100pu OL ADEZ ABOS SM830060 28 3 2 Outdoor Unit CL2432 Schematic Diagram CR CL2432 Controller Lan rm e e a a erc EXT 854 2 5268 570 00
18. ecifications A Indoor Unit MODEL No Power Transformer Rated o EE 9 85 VAC Coil resistance T WHT 101 BRN BRN 0 42 Ambient temprature 77 F Thermistor out off temperature EE in ee Thermistor Coil sensor PBC 41E S14 kQ 14 F 23 7 41 F 12 1 23 F 18 8 50 F 97 32 F 15 0 59 F 8 0 Coil resistance KTEC 35 S6 32 F 16 5 104 F 2 7 41 F 12 8 113 22 50 F 10 0 122 F 1 8 68 F 6 3 131 15 86 F 4 0 Switch Ass y SW X363GS indicator Lamp Ass y i IND 152432 Synchronized Motor MT8 3C Thermistor Room or coil sensor Coil resistance DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830060 11 1 3 Other Component Specifications B Outdoor Unit MOEN EN Compressor Motor Magnetic Contactor Coi resistance t779 o HIE Power Relay Thermostat Coil sensor 75 ON Thermistor PTC Rated AC 400 V 11 5 A Resistance at 77 F 100255 96 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830060 4o 1 3 Other Component Specifications B Outdoor Unit Compressor Motor Magnetic Contactor Coliresistance at77 F o smoers Power Relay Coi resistance sg ke a O Power Transformer Rated Do Secondary ECKE Coil resistance gr o wer wers BRN BAN 395 Trematowoftemperue v T Thermistor Outdoor Temp sensor PBC
19. esistance 1 lt The electrical insulation is acceptable when the resistance exceeds 1 MQ 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 Power Supply Wires Then measure the resistance between the earthed wire and the other power wires Fig 5 Clamp an aluminum plate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on the terminal plate Fig 6 Indoor Unit 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 terminal plate P C B Ass y etc Fig 7 Similarly disconnect the lead wires from compressor capacitor etc Fig 8 Measure the resistance in the same manner as illustrated on the right Refer to Electrical Wiring Diagram If the probe does not enter the hole because the hole is too narrow use a probe with a thinner pin Earthed wire ET N A Insulation tester Fig 5 0638 X S Terminal plate Probe Ba Copper tube or metallic part 0639 X S Fig 6 KL I L Copper tube or metallic part Insulation 3 tester Fig 7 0640_X_S From fan motor compres
20. hooting 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 Q 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 A 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 Disconnect SW Field supply Outdoor Unit Inter Unit Wiring Line voltage Fig 4 Check power supply A Check that voltage is within the specified range 10 of the rating Q Check that power is being supplied AN Urra If the following troubleshooting must be done with power being supplied be careful not to touch any uninsulated live part that can cause ELECTRIC SHOCK Check the lead wires and connectors in indoor and outdoor units O Check that the sheath of lead wires is not damaged Q Check that the lead wires are firmly connected at the terminal plate Q Check that the wiring is correct Reference Condition of general cooling operation Thermo ON SWEEP ON Indoor fan speed HIGH SM830060 32 Please Read
21. itioner on There is a possibility of short circuit lt Check capacity of circuit breaker Replace it with a hak suitable one Is capacity of circuit larger capacity breaker sufficient Check resistance of outdoor fan motor winding Check resistance of compressor motor winding Check resistance of louver motor winding 1056 X S 2 Neither indoor unit nor outdoor unit runs A B Power is not supplied Circuit breaker is tripped Reset the breaker Check power supply Is power being supplied to outdoor unit NO Wait for recovery or consult power supply company Power failure 0615 X S 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 0616 X S SM830060 34 C Check Operation selector switch in the indoor unit Has Operation selector IND LAMP Ass y or P C B switch been set to ON Ass y in the indoor unit position is defective Set Operation selector switch to ON But neither unit runs Switch Ass y or P C B Ass y in the indoor unit is defective 0617 X S D Check compressor motor protectors a High pressure switch 63PH Disconnect the socket from 2P WHT connector Check the continuity between No 1 and No 2 poles of the socket
22. ndoor unit Measure the coil resistance Measure the resistance between each terminal of the socket connected to the indoor fan motor Refer to 1 2 A Major component specifications Outdoor fan motor FMO Outdoor unit Measure the coil resistance lt Measure the resistance in the same manner as explained above Refer to 1 2 B Major component specifications Motor capacitor Both in indoor and outdoor unit Remove the lead wires from the capacitor terminals and then place a probe on the capacitor terminals as shown in Fig 10 Observe the deflection of the pointer setting the resistance measuring range of the multimeter to the maximum value The capacitor is good if the pointer bounces to a great extent and then gradually returns to its original position The range of deflection and the deflection time differ according to the capacity of the capacitor Multimeter Compressor motor capacitor Fan motor capacitor 1041 X 5 Fig 10 SM830060 46 amp Continuity of fuse on P C B Ass y Check for continuity using a multimeter as shown in Fig 11 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 30W or 60W Fig 12 3 For replacement insert a fuse of
23. ol unit The figures on this and the next pages show how each part of the system performs when the room temperature changes and the thermostat activates the compressor to start thermo ON or stop thermo OFF Fig 1 shows about the cooling cycle ROOM TEMPERATURE MORE THAN 3 MINUTES WITHIN 3 MINUTE S T 1 F a gt SET TEMP TF s THERMO ON THERMO OFF RMO OFF S MORE THAN THER DE 3 MINUTES 5 MINUTES COMPRESSOR INDOOR FAN OUTDOOR FAN 1028 X S Fig 1 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 T vi F Compressor ON Thermo OFF When the room temperature is equal to or below the set temperature T Compressor OFF A SM830060 20 2 2 Freeze Prevention Freeze Prevention keeps the indoor heat exchange coil from freezing Freezing reduces the efficiency of the unit and frost buildup on the coil blocks cool air circulation from the indoor units fan FREEZE FREEZE PREVENTION PREVENTION MORE THAN 10 MINUTES 6 MINUT
24. other remote control unit The other remote control unit is defective Room sensor in the remote control unit is defective 0624 X 5 Is COOL FAN selector switch NO Outdoor unit runs 237 Set to COOL SM830060 C Check compressor motor magnetic contactor Check coil resistance of compressor motor magnetic contactor 520 1035 X S D Check indoor unit P C B Check P C B Ass y Check voltage between terminals No 2 and No 4 at terminal plate No voltage appears P C B Ass y is defective 0628 X S E Check outdoor unit P C B CL2432 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 38 SM830060 4 Indoor Unit does not Run Indoor fan and louver motor do not run P C B Ass y is defective 0630 X S 5 Some Part does not Operate A Indoor fan does not run Fan cannot be rotated Check fan rotation Rotate the fan gently once or twice by hand lt Check resistance of fan motor winding Check fan motor capacitor 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 P C B Ass y or remote control unit is defective 39 Check fan casing for foreign matter on the inside Remove
25. p your customers satisfied SM830060 1 SPECIFICATIONS ded Unit Specifications island 6 1 2 Major Component Specifications esee 8 AJindo r Unit esmee iaa 8 By OHIO Urbs dee O OA 9 1 3 Other Component Specifications giga gege See See added 11 A O 11 IB Outdoor UM st inicias 12 1 4 Dimensional Date airoso acid 14 E ele ee EE 14 B Outdoor UM ee eege 15 1 5 Refrigerant Flow Diagram eege ENEE 16 156 Operating RANGE An neden edere ended neee equ Re M e 17 _SM830060 1 1 Unit Specifications Le EESC aa Powertacor le WUw ros D Max starting amperes Al Operation sound Indoor Hi Me Lo dB A 39 37 33 Outdoor Hi dB A 53 REFRIGERANT TUBING eee O a Limit of tubing length 132 40 Limit of tubing length at shipment 50 15 Outdoor unit is higher than indoor unit 132 40 between the two units Outdoor unit is lower than indoor unit 83 25 outer diameter Wide tube in mm 3 4 19 05 R22 53 24 Unit dimensions 2638 870 Package dimensions Height in mm 9 14 32 240 32 17 32 826 Shipping weight bs ka Shipping volume cu ft m 8 9 0 253 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
26. ppens we suggest you look this manual over and become familiar with it by following these steps 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 kee
27. sor and other parts K 7 Metallic part Clip Insulation t tester osti X 8 Fig 8 SM830060 44 2 Checking the Protective Devices Disconnect the connector which consists of P plug and S socket when you want to check the protective device Then check continuity among plug s and or socket s terminal as in Fig 9 Normality of the protective device can be judged by the following table The Protective Device is proved normal if there is a continuity between terminals socket i Multimeter Fig 9 D Indoor fan motor thermal protector 49Fl Indoor unit e 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 SM830060 45 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 lt Secondary 10 6 V Measure the resistance between two BRN lead wires Refer to 1 3 A Other component specifications Indoor fan motor FMI I
28. t Check insulation resistance of electrical parts in the indoor unit 10322 X SM830060 WHO SHOULD USE THIS MANUAL This service manual is made to assist the service technician apply his knowledge and training to this model air conditioner This manual is written both for experienced service persons and those who are new to air conditioning service To help those with less experience or who are new to this kind of unit we have included more explanations of basic procedures in simple language than is usual in some service manuals The experienced technician will of course find he knows many of these things already and can go directly to the procedures and 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 EEN 1 1 Unit Specifications anna enseeenvenserevennneeennneeennnnereenenenreernnnnverenensenveene 1 2 Major Component Specifications nae vans eonvenennenensenveveerevensenserrrenvenenn A Indoor Unit aaaaaaaaaaaaaannnanannunnnnunsnnnnnannnnnnnnonnnnnnnnananatannnnnn aa annannnnnnnnnnnnnunnna B Outdoor Unit REM 1 3 Other Component Specifications EEN 11 A Indoor Unit aaaaaaaaaaaaaaavananasaannnannannaannannnnnnnnnnnnnnannnnnnnnnnnnnnnnnnunanunnnanannnnnnnnanana 11 B Outdoor Unit ee
29. the same rating to the intended position and solder it Allow time to radiate heat during soldering so that the fuse does not melt When replacing the fuse be CAUTION sure not to break down the varistor 4 Thermistor Characteristic Curve D Room temp sensor KTEC 35 10 9 3 S TM 8 S 6 5 D E 4 a 3 2 VEJ 50 59 68 77 86 95 104 Temperature F 1044 MI 47 Fuse 1042 X S Fig 11 Soldering iron Varistor 1043 X Fig 12 D Coil sensor PBC 41E EX TEE NEER ENAERE CEN EAS A H gt M MERTE 0 4 5 14 23 32 41 50 59 68 Temperature F siii SM830060 SANYO FISHER Service Company CENTRAL REGION 1739 Sands Place Suite G Marietta GA 30067 Phone 770 951 8284 Fax 770 951 2077 Apr 98 Printed in U S A
30. ul 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 Turn the power OFF at the main power box mains before opening the unit to check or repair electrical parts and wiring Keep your fingers and clothing away from any moving parts Clean up the site when installation is finished Check that no metal scraps or bits of wiring have been left inside the unit Ventilate any enclosed areas when installing or testing the refrigeration system Contact of refrigerant gas with fire or heat can produce poisonous gas Confirm after installation that no refrigerant gas is leaking If the gas comes in contact with a burning stove gas water heater electric room heater or other heat source it can cause the generation of poisonous gas SM830060 b Circuit breaker trips in several minutes after turning the air cond
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