Sanyo CH2432, XHS3632, CH3632, XHS2432 User Manual

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SERVICE MANUAL

XHS2432 / CH2432 XHS3632 / CH3632

SPLIT SYSTEM AIR CONDITIONER

FILE NO.

Section

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

XHS2432 CH2432

XHS3632 CH3632

85464849176000 REFERENCE NO. SM830076

Important

Please Read Before Starting

This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently.

For safe installation and trouble-free operation, you must :

ⓦ Carefully read this instruction booklet before beginning. ⓦ Follow each installation or repair step exactly as shown. ⓦ Observe all local, state, and national electrical codes. ⓦ Pay close attention to all warning and caution notices

given in this manual.

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

This symbol refers to a hazard or

CAUTION

unsafe practice which can result in personal injury or product or property damage.

If Necessary, Get Help

These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to follow the instructions in this document.

SPECIAL PRECAUTIONS

When Wiring

……………………………………………………………………

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.

• Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.

• Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death.

• Ground the unit following local electrical codes.

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

When Transporting

…………………………………………………………………… Be careful when picking up and moving the indoor and outdoor

units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers.

When Installing

……………………………………………………………………

…In a Room

Properly insulate any tubing run inside a room to prevent “sweating” that can cause dripping and water damage to walls and floors.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration.

…In an area with High Winds

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

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

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

When Connecting Refrigerant Tubing

……………………………………………………………………

• Ventilate the room well, in the event that refrigerant gas leaks during the installation. Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas.

• Keep all tubing runs as short as possible.

• Use the flare method for connecting tubing.

• Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leak-free connection.

• Check carefully for leaks before starting the test run.

NOTE

Depending on the system type, liquid and gas lines may be either narrow or wide. Therefore, to avoid confusion the refrigerant tubing for your particular model is specified as either “narrow” or “wide” rather than as “liquid” or “gas”.

When Servicing

……………………………………………………………………

• Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring.

• Keep your fingers and clothing away from any moving parts.

• Clean up the site when installation is finished. Check that no metal scraps or bits of wiring have been left inside the unit.

CAUTION

• Ventilate any enclosed areas when installing or testing the refrigeration system. Contact of refrigerant gas with fire or heat can produce poisonous gas.

• Confirm after installation that no refrigerant gas is leaking. If the gas comes in contact with a burning stove, gas water heater, electric room heater or other heat source, it can cause the generation of poisonous gas.

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SM830076

WHO SHOULD USE THIS MANUAL

This service manual is made to assist the service technician apply his knowledge and training to this model air conditioner. This manual is written both for experienced service persons and those who are new to air conditioning service. To help those with less experience or who are new to this kind of unit we have included more explanations of basic procedures in simple language than is usual in some service manuals. The experienced technician will of course find he knows many of these things already and can go directly to the procedures and information he needs; the less experienced technician will better understand what to do even before he arrives on the job, and therefore be better able to work by himself as well as assist the more experienced technician.

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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SM830076

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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SM830076

Introduction:

Read 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 explanations to help you find and repair problems.

❑ Section 1: Specifications, tells you about the physical and electrical make up of the unit, as well

as its heating and cooling capacities. Look in this section to find the correct values for components and functions.

❑ Section 2: Processes and Functions, explains each different part of the cooling and heating

cycle, and how each control function reacts to changing conditions to keep the room at the set temperature range.

❑ Section 3: Electrical Data, which has fold-out schematic and wiring diagrams so you can find

the parts you need to check when something is wrong, and see how they should be connected.

❑ Section 4: Service Procedures, has two main parts, a

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.

WHAT IS IN THIS MANUAL

diagnostic

chapter to help you find the

HOW TO USE THIS MANUAL

You can use this manual both as a reference to find specific information about the capacity, functions and construction of this unit, and as a source of information to help you set up and maintain the unit. When this unit is not working properly, and the cause is not known, you can use the procedures in Section 3: Servicing Procedures to find the problem, fix it, and restore the unit to its proper functioning.

This air conditioner has many helpful self diagnostic features to help you identify problem areas quickly.

So you will be ready when a problem happens, we suggest you look this manual over and become familiar with it by following these steps:

1. Look at the TABLE OF CONTENTS to get an idea of what is in this manual and where to find it.

2. Look at the chapter about TROUBLE SHOOTING, so you are familiar with the way the flow

charts work. They are designed to guide you quickly through the possible causes for each kind of problem that is likely to happen to the Unit. Particularly read the introduction to this section, and the parts about the self-diagnosis and error codes which show on the display.

3. Look at the chapter about CHECKING ELECTRICAL COMPONENTS. You already know

about most of these procedures. This chapter gives you the specific values and methods for these components. If you don’t know some of these procedures, you can easily learn them here.

4. Read the Instruction Manual! The Instruction Manual is included here because it helps you help

the user to set the temperature controls properly and know how to take care of any simple problems that may happen, as well as know when to call for service. The Instruction Manual also has illustrations, care, and installation information not found in the rest of the service manual. It is short, and if you read it carefully, you will be able to answer the customers questions easily, and also know the most efficient ways for setting times and temperatures.

Please use this manual to make your work easier, keep the air conditioner functioning well, and keep your customers satisfied.

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SM830076

1. SPECIFICATIONS

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

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

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

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

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

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

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

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

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

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

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

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

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SM830076

1. Specifications

1-1 Unit Specifications

MODEL No. Indoor Unit XHS2432

Outdoor Unit CH2432 POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz PERFORMANCE Cooling Heating

Capacity* BTU / h 24,000 23,400 25,000 24,300 Moisture removal (High) Pints / h 8.6 8.4 —

Air circulation (Hi) S.E.E.R. (H.S.P.F.)

ELECTRICAL RATINGS

Voltage rating VAC 230 208 230 208 Available voltage range VAC 187 - 253 187 - 253 Running amperes A 11.2 11.6 11.7 12.3 Max. running amperes A — — — — Power input* W 2,450 2,350 2,500 2,450

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 Control Valve

REFRIGERANT PIPING

Limit of piping length ft. (m) 165 (50) Limit of piping length at shipment ft. (m) 100 (30) Limit of elevation difference ft. (m) Outdoor unit is higher than indoor unit: 165 (50)

between the two units Outdoor unit is lower than indoor unit: 100 (30) Refrigerant piping Narrow pipe in. (mm) 1 / 4 (6.35)

Flare type Wide pipe in. (mm) 3 / 4 (19.05)

(17°F)** 16,400 15,800

cu.ft. / min.

BTU / Wh

(17°F)** 2,150 2,020

10.0 10.2 (7.0) (7.0)

540 / 510

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SM830076

1. Specifications

1-1 Unit Specifications

DIMENSIONS & WEIGHT Indoor unit Outdoor unit

Unit dimensions Height in. (mm) 9-27/32 (250) 28-30/32 (735)

Width in. (mm) 29-29/32 (760) 37 (940) Depth in. (mm) 29-29/32 (760) 13-12/32 (340)

Net weight lbs. (kg) 49 (22) 157 (71)

Indoor grille dimensions Height in. (mm) 3-1/16 (78)

PNR-XHS2432 Width in. (mm) 33-27/32 (860)

Depth in. (mm) 33-27/32 (860)

Net weight lbs. (kg) 11 (5)

Indoor / Outdoor unit Height in. (mm) 11-6/32 (284) 32-17/32 (826)

Package dimensions 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)

Cooling :

Rating conditions (*) : Room temperature 80 °F DB / 67 °F WB, Ambient temperature 95 °F DB / 75 °F WB

Heating :

Rating conditions (*) : Room temperature 70 °F DB / 60 °F WB, Ambient temperature 47 °F DB / 43 °F WB Low temp conditions (**): Room temperature 70 °F DB / 60 °F WB, Ambient temperature 17 °F DB / 15 °F WB

DATA SUBJECT TO CHANGE WITHOUT NOTICE

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SM830076

1. Specifications

1-1 Unit Specifications

MODEL No. Indoor Unit XHS3632

Outdoor Unit CH3632 POWER SOURCE 230 - 208 VAC / 1 Phase / 60 Hz PERFORMANCE Cooling Heating

Capacity* BTU / h 34,500 33,500 37,500 36,500 Moisture removal (High) Pints / h 11.1 11.1 —

Air circulation (Hi) S.E.E.R. (H.S.P.F.)

ELECTRICAL RATINGS

Voltage rating VAC 230 208 230 208 Available voltage range VAC 187 - 253 187 - 253 Running amperes A 15.4 15.8 18.2 19.3 Max. running amperes A — — — — Power input* W 3,350 3,200 3,850 3,750

Buck-up heater kW — — — — Maximum fuse size A 30

FEATURES

Hi / Me / Lo Outdoor - Hi dB - A 56 Refrigerant control Electronic Refrigerant Control Valve

REFRIGERANT PIPING

Limit of piping length ft. (m) 165 (50) Limit of piping length at shipment ft. (m) 100 (30) Limit of elevation difference ft. (m) Outdoor unit is higher than indoor unit: 165 (50)

between the two units Outdoor unit is lower than indoor unit: 100 (30) Refrigerant piping Narrow pipe in. (mm) 3 / 8 (9.52)

Flare type Wide pipe in. (mm) 3 / 4 (19.05)

(17°F)** 25,000 23,500

cu.ft. / min.

BTU / Wh

(17°F)** 3,150 2,950

10.7 11.0 (7.0) (7.0)

980 / 880

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SM830076

1. Specifications

1-1 Unit Specifications

DIMENSIONS & WEIGHT Indoor unit Outdoor unit

Unit dimensions Height in. (mm) 11-1/32 (280) 48-20/32 (1,235)

Width in. (mm) 41-11/32 (1,050) 37 (940) Depth in. (mm) 29-29/32 (760) 13-12/32 (340)

Net weight lbs. (kg) 60 (27) 203 (92)

Indoor grille dimensions Height in. (mm) 3-1/6 (78)

PNR-XHS3632 Width in. (mm) 33-27/32 (1,150)

Depth in. (mm) 33-27/32 (860)

Net weight lbs. (kg) 15 (7)

Indoor / Outdoor unit Height in. (mm) 12-14/32 (316) 52-7/32 (1,326)

Package dimensions 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)

Cooling :

Rating conditions (*) : Room temperature 80 °F DB / 67 °F WB, Ambient temperature 95 °F DB / 75 °F WB

Heating :

DATA SUBJECT TO CHANGE WITHOUT NOTICE

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SM830076

1. Specifications

1-2 Major Component Specifications

(A) Indoor Unit

MODEL No. XHS2432 Source 230 - 208 VAC / 1 phase / 60 Hz Remote controller (Accessory) RCS - 5HPS4U Controller P. C. B Ass'y CR - THS2432 Control circuit fuse 250 VAC, 3 A Controller Ass'y CR - 3XHS Fan (Number … diameter) in. (mm) Turbo (1…19-9/32 (490)) Fan motor

Model SFG6X - 41A5P Source 230 - 208 V / 1 phase / 60 Hz No. of pole … r.p.m. (230 V, High) rpm 6 … 451 Nominal output W 40 Coil resistance Ω BRW - WHT : 114.0 , 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 °F266± 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 2 … 14.9 Face area ft.

Panel

Model No. PNR - XHS2432 Indicator Lamp Ass'y IND - 3THS Auto louver motor MT8 - 3C Auto louver motor … Rated V, W, rpm 240 VAC , 3 W , 3 rpm Coil resistance (Ambient temperature 77 °F) Ω 16.430 Ω ± 8 %

(m2) 3.18 (0.295)

DATA SUBJECT TO CHANGE WITHOUT NOTICE

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SM830076

1. Specifications

1-2 Major Component Specifications

(A) Indoor Unit

MODEL No. XHS3632 Source 230 - 208 VAC / 1 phase / 60 Hz Remote controller (Accessory) RCS - 5HPS4U Controller P. C. B Ass'y CR - THS2432 Control circuit fuse 250 VAC, 3 A Controller Ass'y CR - 3XHS Fan (Number … diameter) in. (mm) Turbo (1…19-9/32 (490)) Fan motor

Model SFG6X - 61A3P Source 230 - 208 V / 1 phase / 60 Hz No. of pole … r.p.m. (230 V, High) rpm 6 … 560 Nominal output W 60 Coil resistance Ω BRW - WHT : 71.1 , ORG - YEL : 22.7 (Ambient temperature 68 °F) WHT - VLT : 8.7 , VLT - PNK : 43.2

VLT - ORG : 13.3 , YEL - BLK : 54.32

Safety device

Operating temperature Open °F266± 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 2 … 14.9 Face area ft.

Panel

Model No. PNR - XHS3632 Indicator Lamp Ass'y IND - 3THS Auto louver motor MT8 - 3C Auto louver motor … Rated V, W, rpm 240 VAC , 3 W , 3 rpm Coil resistance (Ambient temperature 77 °F) Ω 16.430 Ω ± 8 %

(m2) 5.17 (0.48)

DATA SUBJECT TO CHANGE WITHOUT NOTICE

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SM830076

1-2 Major Component Specifications

(B) Outdoor Unit

MODEL No. CH2432 Source 230 - 208 VAC / 1 phase / 60 Hz Controller P.C.B. Ass'y CR - CH2432 (Microprocessor)

Control circuit fuse 250 VAC, 3 A

Compressor Rotary (Hermetic)

Model C - 2R160H6T Source 230 - 208 VAC / 1 phase / 60 Hz Nominal output W 1,700 Compressor oil cc 800 Coil resistance (Ambient temperature 77 °F) Ω C – R : 0.885 , C – S : 1.773

Safety device Internal type

Overload relay models — Operating temperature Open °F 297 ± 9

Close °F 198 ± 20

Operating ampere (at 77 °F) A — Run capacitor VAC, µF 400 VAC, 40 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 resistance Ω BRN – WHT : 67.14 , VLT – YEL : 11.42

(Ambient temperature 68 °F) WHT – VLT : 64.85 , YEL – PNK : 10.60 Safety device Internal type

Operating temperature Open °F 248 ± 9

Close °F 171 ± 27

Run capacitor VAC, µF 440 VAC, 4 µF

Heat exchange

Coil Aluminum plate fin / Copper tube

Rows ..... Fins per inch 2 ... 14.1

Face area ft.

(m2) 6.78 (0.63)

+ 28.44 + 7.11

DATA SUBJECT TO CHANGE WITHOUT NOTICE

+ 2.0 + 0.5

1. Specifications

– 13 –

SM830076

1-2 Major Component Specifications

(B) Outdoor Unit

MODEL No. CH3632 Source 230 - 208 VAC / 1 phase / 60 Hz Controller P.C.B. Ass'y CR - CH2432 (Microprocessor)

Control circuit fuse 250 V, 3 A

Compressor Rotary (Hermetic)

Model C - R221H6R Source 230 - 208 VAC / 1 phase / 60 Hz Nominal output W 2,200 Compressor oil cc 1,500 Coil resistance (Ambient temperature 77 °F) Ω C – R : 0.549 , C – S : 1.525

Safety device Internal type

Overload relay models —

Operating temperature Open °F 320 ± 9

Close °F 189 ± 20

Operating ampere (at 77 °F) A — Run capacitor VAC, µF 400 VAC, 40 µF 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 resistance Ω BRN – WHT : 67.14 , VLT – YEL : 11.42

(Ambient temperature 68 °F) WHT – VLT : 64.85 , YEL – PNK : 10.60 Safety device Internal type

Operating temperature Open °F 248 ± 9

Close °F 171 ± 27

Run capacitor VAC, µF 440 VAC, 4 µF × 2

Heat exchange

Coil Aluminum plate fin / Copper tube

Rows ..... Fins per inch 2 ... 14.1

Face area ft.

(m2) 11.63 (1.08)

+ 28.44 + 7.11

DATA SUBJECT TO CHANGE WITHOUT NOTICE

+ 2.0 + 0.5

1. Specifications

– 14 –

SM830076

1. Specifications

1-3 Other Component Specifications

(A) Indoor Unit

MODEL No. XHS2432 Power Transformer ATR – II174B

Rated Primary 220 VAC, 60 Hz

Secondary 14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA Capacity —

Coil resistance (Ambient temprature 77 °F)

Thermistor cut off temperature °F277

Thermistor (Coil sensor) : TH2, 3 PBC - 41E - S26

Coil resistance kΩ 14 °F : 23.7 , 41 °F : 12.1

Thermistor (Room sensor) : TH1 KTEC - 35 - S6

Coil resistance kΩ 32 °F : 16.5 , 104 °F : 2.7

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 coil

Solenoid control valve IKV - 24D12 Solenoid coil DKV - MOZS582E0

Indicator Lamp Ass'y IND - 3THS Synchronized Motor MT8 - 3C

Ω WHT - WHT : 101 , BRN - BRN : 0.42

23 °F : 18.8 , 50 °F : 9.7 32 °F : 15.0 , 59 °F : 8.0

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 ,

– 15 –

SM830076

1. Specifications

1-3 Other Component Specifications

(A) Indoor Unit

MODEL No. XHS3632 Power Transformer ATR – II174B

Rated Primary 220 VAC, 60 Hz

Secondary 14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA Capacity —

Coil resistance (Ambient temprature 77 °F)

Thermistor cut off temperature °F277

Thermistor (Coil sensor) : TH2, 3 PBC - 41E - S36

Coil resistance kΩ 14 °F : 23.7 , 41 °F : 12.1

Thermistor (Room sensor) : TH1 KTEC - 35 - S6

Coil resistance kΩ 32 °F : 16.5 , 104 °F : 2.7

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 control valve HKV - 30D16 Solenoid coil EKV - MOZS728E0

Indicator Lamp Ass'y IND - 3THS

Synchronized Motor MT8 - 3C

Ω WHT - WHT : 101 , BRN - BRN : 0.42

23 °F : 18.8 , 50 °F : 9.7 32 °F : 15.0 , 59 °F : 8.0

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 ,

DATA SUBJECT TO CHANGE WITHOUT NOTICE

– 16 –

SM830076

1. Specifications

1-3 Other Component Specifications

(B) Outdoor Unit

MODEL No. CH2432 Compressor Motor Magnetic Contactor FMCA - 1UL

Coil rated 240 VAC, 60 Hz Coil resistance (at 77 °F) Ω 580 ± 15 % Contact rated (Main) 230 VAC, 20 A Contact rated (Auxiliary) 230 VAC, 3 A

Power Relay HH62S

Coil rated 240 VAC, 60 Hz Coil resistance (at 77 °F) kΩ 17.2 Contact rated 220 VAC, 5 A

Power Transformer ATR - I65C

Rated

Primary 220 VAC, 60 Hz

Secondary 14 V, 0.4 A Capacity 5.6 VA Coil resistance (at 73 °F ) Ω WHT – WHT : 395.5 , BRN – BRN : 2.19 Thermal cut off temperature °F266

Thermistor (Coil sensor) : TH6, 7

Coil resistance kΩ 14 °F : 23.7 , 50 °F : 9.7

Thermistor (Comp. discharge gas sensor) : TH8

Coil resistance kΩ 140 °F : 13.8 , 194 °F : 5.1

Solenoid control valve or coil

Solenoid control valve V 389100 Solenoid coil LB 59005

Thermistor (PTC) TDK – 101YV

Rated

Max. voltage 400 VAC Max. ampere 11.5 A

Resistance (at 77 °F) Ω 100 %

PBC - 41E - S4 , PBC - 41E - S26

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

PTC - 51H - S1

158 °F : 9.7 , 212 °F : 3.8 167 °F : 8.2 , 230 °F : 2.8 176 °F : 7.0 , 248 °F : 2.2 185 °F : 5.9 , 266 °F : 1.7

+ 30 – 20

DATA SUBJECT TO CHANGE WITHOUT NOTICE

– 17 –

SM830076

1. Specifications

1-3 Other Component Specifications

(B) Outdoor Unit

MODEL No. CH3632

Compressor Motor Magnetic Contactor FMCA - 1SUL

Coil rated 240 VAC, 60 Hz Coil resistance (at 68 °F) Ω 588 ± 10 % Contact rated (Main) 240 VAC, 26 A Contact rated (Auxiliary) 240 VAC, 3 A

Power Relay HH62S

Coil rated 240 VAC, 60 Hz Coil resistance (at 77 °F) kΩ 17.2 Contact rated 220 VAC, 5 A

Power Transformer ATR - I65C

Rated

Primary 220 VAC, 60 Hz

Secondary 14 V, 0.4 A Capacity 5.6 VA Coil resistance (at 73 °F ) Ω WHT – WHT : 395.5 , BRN – BRN : 2.19 Thermal cut off temperature °F266

Thermistor (Coil sensor) : TH6, 7

Coil resistance kΩ 14 °F : 23.7 , 50 °F : 9.7

Thermistor (Comp. discharge gas sensor) : TH8

Coil resistance kΩ 140 °F : 13.8 , 194 °F : 5.1

Solenoid control valve or coil

Solenoid control valve V 389100 Solenoid coil LB 59005

Thermistor (PTC) TDK – 101YV

Rated

Max. voltage 400 VAC Max. ampere 11.5 A

Resistance (at 77 °F) Ω 100 %

PBC - 41E - S4 , PBC - 41E - S36

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

PTC - 51H - S1

158 °F : 9.7 , 212 °F : 3.8 167 °F : 8.2 , 230 °F : 2.8 176 °F : 7.0 , 248 °F : 2.2 185 °F : 5.9 , 266 °F : 1.7

+ 30 – 20

DATA SUBJECT TO CHANGE WITHOUT NOTICE

– 18 –

SM830076

1-4 Dimensional Data

(A) Indoor Unit: XHS2432

4-29/32

1. Specifications

8-21/32

8-1/16

• Remote controller (Accessory)

X-view

13-3/8

4-29/32

5-29/32 7-7/8

10-1/32

32-9/32 (Ceiling opening)

23-7/32 (Suspention bolt pitch)

Grille center

13-2/4 1-3/8

32-9/32 (Ceiling opening)

28-3/4(Suspention bolt pitch)

11-23/32 1-3/16

8-1/16

6-1/2

1-7/8

3-15/16

29-29/32

3-15/16

19/32

1/2

33-27/32

19-11/16

2-13/32 23/32

33-27/32 19-11/16

6-25/32

Min. 2-3/8

3-1/32

4-29/32

29-29/32

– 19 –

1/2

Dimension : inch

Air intake Air outlet Narrow tube (1/4") Wide tube (3/4") Drain connection Power line (conduit size : 1/2") For discharge duct Suspention bolt mounting

1024_X_S

SM830076

1-4 Dimensional Data

(A) Indoor Unit: XHS3632

8-19/32

1. Specifications

2-13/32

32-9/32 (Ceiling opening)

23-7/32 (Suspention bolt pitch)

13-15/32 19/32

X-view

19-9/32 1-9/16

5-23/321-3/8

29-29/32

2-3/4

8-9/32

6-1/2

11-7/32

12-29/32

8-19/32

4-29/32

2-3/8

1-3/16

15/32

33-27/32 19-11/16

Panel center

41-11/32

43-11/16 (Ceiling opening)

40-5/32 (Suspention bolt pitch)

3-15/16 3-15/16

1-7/8

8-9/32

45-9/32

31-3/32

15/32

Dimension : inch

Air intake grille Air outlet Refrigerant liquid line (ø3/8") Refrigerant gas line (ø3/4") Drain connection Power supply entry For discharge duct Humidifier (option) mounting hole Suspension bolt mounting

1346_X_S

– 20 –

SM830076

1-4 Dimensional Data

(B) Outdoor Unit: CH2432

1-31/32

1. Specifications

4-21/64266-11/16

1-31/32

1-3/16

13-3/8

28-15/16

14-31/32 13/32

15-3/4

12-1/16

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

– 21 –

SM830076

1-4 Dimensional Data

(B) Outdoor Unit: CH3632

1-31/32 1-31/32

1. Specifications

4-21/64266-11/16

1-3/16

13-3/8

48-5/8

15-3/4

14-31/32 13/32

22-27/32

23-29/32

– 22 –

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

SM830076

1-5 Refrigerant Flow Diagram

Outdoor Unit: CH2432 Indoor Unit: XHS2432

1. Specifications

Compressor

Accumulator

High pressure switch

Sub-heat exchanger

Cooling Cycle Heating Cycle

Accumulator

4-way valve

Heat exchanger

Distributor

Muffler

Gas line service valve

Liquid line service valve

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

O.D. 1/4" (6.35mm)

Gas line nipple

Heat exchanger

Distributor

Strainer

Electronic ref.control valve

Liquid line nipple

Strainer

1132_THS_I

1-6 Operating Range

Temperature Indoor Air Intake Outdoor Air Intake

Cooling

Heating

Maximum 95 °F DB, 71 °F WB 115 °F DB

Minimum 67 °F DB, 57 °F WB 23 °F DB

Maximum 80 °F DB, 67 °F WB 75 °F DB, 65 °F WB

Minimum -DB / -WB 17 °F DB / 15 °F WB

SM830076

– 23 –

1-5 Refrigerant Flow Diagram

Outdoor Unit: CH3632 Indoor Unit: XHS3632

1. Specifications

Compressor

Accumulator

High pressure switch

Sub-heat exchanger

Cooling Cycle Heating Cycle

Accumulator

4-way valve

Heat exchanger

Distributor

Muffler

Gas line service valve

Liquid line service valve

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

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

Gas line nipple

Heat exchanger

Distributor

Strainer

Electronic ref.control valve

Liquid line nipple

Strainer

1398_THS_I

1-6 Operating Range

Temperature Indoor Air Intake Outdoor Air Intake

Cooling

Heating

Maximum 95 °F DB, 71 °F WB 115 °F DB

Minimum 67 °F DB, 57 °F WB 23 °F DB

Maximum 80 °F DB, 67 °F WB 75 °F DB, 65 °F WB

Minimum -DB / -WB 17 °F DB / 15 °F WB

– 24 –

SM830076

2. Processes and functions

1. Specifications

2. PROCESSES AND FUNCTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section

– 25 –

SM830076

Section

2. Processes and functions

2-1 Room Temperature Control

The Unit adjusts room temperature by turning the outdoor unit’s compressor ON and OFF. This process is controlled by the thermostat located in the remote control unit. The figures on this and the next pages show how each part of the system performs when the room temperature changes and the thermostat activates the compressor to start (thermo ON) or stop (thermo OFF). Fig. 1 shows about the cooling cycle, and Fig. 2 shows about the heating cycle.

(A) Cooling

THERMO. OFF

(THERMO. ON)

(THERMO. OFF)

ROOM TEMP.

THERMO. ON

BODY SENSOR

SET TEMP

COMPRESSOR

OUTDOOR FAN

T+2 °F

. T °F

T–2 °F

(H OR M)

INDOOR FAN

MORE THAN 5 MINUTES

ON ON ON

1. Refer to 2-4 Outdoor Fan Speed Control

3 MINUTES

OFF OFF

5 MINUTES

SET SPEED

MORE THAN 3 MINUTES

MORE THAN 5 MINUTES

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 (HEAT, COOL, or FAN) during the cooling cycle, the

control circuit stops the compressor for 3 minutes.

❑ For 5 minutes after the compressor is first turned on, and for 3 minutes after it is turned off,

the compressor is not controlled by the room sensor.

❑ Thermo ON: When room temperature rises 2°F (4°F when set on body sensor) above

the set temperature T˚, (T˚+2°F or T˚+4°F when set on body sensor):

Compressor ➞ ON

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

Compressor ➞ OFF

1133_THS_I

– 26 –

SM830076

2. Processes and functions

1. Specifications

(B) Heating

REMOTE CONTROL

SENSOR (Only for wireless remote controller)

SETTING TEMP.

BODY SENSOR

SET TEMP.+7°F SHIFT

COMPRESSOR

1 OUTDOOR FAN (H OR M)

INDOOR FAN

SET. +2°F SET. –2°F

+2°F

–2°F

SET TEMP.

OFF

THERMO. ON

ONOFF

3 SECONDS

THERMO. OFF

3 MINUTES

OFF

THERMO. ON

THERMO. OFF

MORE THAN

5 MINUTES5 MINUTES

ON OFF ONOFFOFF ON

ON OFF ON

SET SPEEDSET SPEED

MORE THAN 3 MINUTES

THERMO. ON

THERMO. ONTHERMO. ON

Section

SET SPEED

STANDBY

INDOOR HEAT EXCH. COIL TEMP. E2 SOLENOID COIL (4-WAY)

TEMP. OPERATION BUTTON

(88°F)

81°F 77°F

OFF

ON ON ON

OFF

1. Refer to 2-4 Outdoor Fan Speed Control

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

OFF OFF

ON (REVERSING CYCLE)

Chart Summary and Explanations

control circuit stops the compressor for 3 minutes.

❑ For 5 minutes after the compressor is first turned on, and for 3 minutes after it is turned off,

the compressor is not controlled by the room sensor.

When set on remote control sensor

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

Compressor ➞ ON

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

Compressor ➞ OFF

When set on body sensor

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

OFF

1134_THS_I

Fig. 2

– 27 –

SM830076

2. Processes and functions

2-2 Cold Draft Prevention (Heating Cycle)

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

❑ STANDBY shows on the remote controller when the indoor fan speed is LL (very

low) or OFF. This condition occurs in the following 3 cases:

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

Section

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

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

❑ The indoor fan motor operates in L instead of LL for 3 seconds as it starts to give

the fan an initial boost.

MAX. 6 MINUTES

INDOOR UNIT

COIL TEMP.

E2 (°F)

SET FAN SPEED

❑ The main idea of this chart is to show that the indoor fan speed increases and gets closer to

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

❑ The dotted line shows that the indoor fan motor is OFF. When the temperature at sensor E2

AUTO OR H

“STANDBY” INDICATOR

the set fan speed as the coil temperature E2 rises.

heat exchange coil.

falls below 50°F, the indoor fan motor stops running.

LL LL/OFF LL L M H

LL LL/OFF LL L M M

L LL LL/OFF LL L L L

“STANDBY” APPEARS

LL= Very low speed L= Low speed

Chart Summary and Explanations

– 28 –

M= Medium speed H= High speed

1135_THS_I

Fig. 3

SM830076

2. Processes and functions

1. Specifications

2-3 Automatic Fan Speed (Indoor Unit)

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

(A) Cooling

❑ When the fan speed changes, it keeps the speed step for at least 3 minutes, even if the

(B) Heating

ROOM TEMP.

(deg)

+3 +2

SET TEMP.

INDOOR FAN

SPEED

HM: High

: MiddleLLL

: Low : Very low

Chart Explanations and notes

temperature changes to another speed step during the time.

Section

0433_M_S

Fig. 4

ROOM TEMP.

(deg)

SET TEMP.

–2 –4

INDOOR FAN

SPEED H

HM: High

: MiddleLLL

: Low : Very low

0434_M_S

Chart Explanations and notes

❑ When the fan speed changes, it keeps the speed step for at least 1 minute, even if the

temperature changes to another speed step during the time.

– 29 –

Fig. 5

SM830076

2. Processes and functions

2-4 Outdoor Fan Speed Control

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

❑ Note that in both Cooling and Heating modes, the fan comes on at first at high

speed (H mode) for 5 seconds. Since outdoor conditions sometimes make it difficult for the fan to start, this sudden surge of power may be necessary.

Section

❑ 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 TEMPERATURE (°F)

Fig. 6

(B) Heating

Outdoor coil Outdoor fan temperature [C2] motor (FMo)

or more 57°F M less than 57°F H

OUTDOOR TEMPERATURE (°F)

Fig. 7

SM830076

– 30 –

2. Processes and functions

1. Specifications

2-5 Freeze Prevention (Cooling)

Freeze Prevention keeps the indoor heat exchange coil from freezing. Freezing reduces the efficiency of the unit, and frost buildup on the coil blocks cool air circulation from the indoor unit's fan.

MIN. VALUE OF EITHER E1 OR E2

INDOOR UNIT TEMP.

ELECTRONIC REF.

CONTROL

VALVE SIGNAL

COMPRESSOR

(°F)

OPEN

CONTINUOUS DETECTION FOR 2 MINUTES

OPEN

ON ON

MINIMUM 3 MINUTES

Fig. 8

1138_THS_I

Note: Freeze prevention is controlled by the temperature at the indoor heat

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

Chart Explanations and notes

Section

❑ This chart shows when the electronic refrigerant control valve opens to regulate the

temperature of the indoor unit coil to prevent freezing.

❑ If the refrigerant control is not effective and the temperature continues to drop and stays

below 30°F for 2 minutes continuously, the control circuit stops the compressor. The compressor does not start again until the temperature rises above 34°F. The compressor stops for 3 minutes minimum.

– 31 –

SM830076

Section

2. Processes and functions

2-6 Condensing Temperature Control (Cooling)

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

140

OUTDOOR UNIT

COIL TEMP. C2

(°F)

131

OUTDOOR FAN

SPEED

ELECTRONIC REF.

CONTROL VALVE

❑ This chart shows how the outdoor fan speed and the electronic refrigerant control valve

react to coil temperature to control condensing temperature.

❑ Sensor C2 is located in the middle of the outdoor unit heat exchange coil. ❑ When C2 rises above 140°F the electronic refrigerant control valve opens at 50 steps/30

seconds, and the outdoor fan speed is forced to change to high (H) until C2 falls below 131°F.

H, M H, M

Chart Explanations and notes

FORCED

OPEN

1139_THS_

Fig. 9

– 32 –

SM830076

2-7 Overload Protection (Heating)

This function prevents the air conditioner from overloading.

(°F)

147

144

2. Processes and functions

1. Specifications

INDOOR UNIT COIL TEMP. (E2)

ELECTRONIC REF. CONTROL VALVE

OUTDOOR FM

140

138 131

127

OVERLOAD PROTECTION OVERLOAD PROTECTION

OPEN

H OR M H OR MH M

OPEN

START UP

COMPENSATION

OFF

FUZZY CONTROLFUZZY CONTROL

Chart Explanations and notes

❑ This chart shows how the outdoor fan speed and the electronic refrigerant control valve

react to coil temperature to keep the indoor heat exchanger coil from overloading.

❑ When sensor E2 rises above 140°F the electronic refrigerant control valve opens at 50

steps/30 seconds until E2 falls below 138°F.

❑ Sensor E2 is located in the middle of the indoor unit heat exchange unit. ❑ When sensor E2 rises above 144°F, the control circuit stops the outdoor fan motor till the

temp. drops to 131°F

❑ Fuzzy control controls the electronic refrigerant control valve.

Fig. 10

Section

1140_THS_I

– 33 –

SM830076

2. Processes and functions

2-8 Discharge Temperature Control (Cooling and Heating)

This function prevents the compressor motor from burnout by overheating.

239

221

203

Section

200

DISCHARGE GAS TEMP. (°F)

OUTDOOR

FAN SPEED

COMPRESSOR

ELECTRONIC REF.

CONTROL VALVE

(DISCHARGE TEMP.)

194

185

H OR M

OPENOPEN

TRIP IS OPERATED.

Chart Summary and Explanations

❑ Discharge temperature is sensed by TH8 (discharge gas sensor). ❑ When the temperature rises above 203°F the electronic refrigerant control valve opens at

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

❑ During HEATING operation, when the temperature rises above 221°F, the control circuit

stops the outdoor fan motor until the temperature falls below 194°F. Please note that this control does not function during COOLING operation.

❑ For both COOLING and HEATING modes, if the temperature reaches 239°F the operation

shuts down and alarm P3 appears on the remote controller.

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

1141_THS_I

Fig. 11

– 34 –

SM830076

2. Processes and functions

1. Specifications

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

❑ When the AUTO mode is selected, the microprocessor calculates the difference

between the set temperature and the room temperature, and automatically switches to the COOLING or HEATING mode to maintain the desired temperature.

Room temp. ] Set temp. ➔ COOLING Room temp. < Set temp. ➔ HEATING

This means that if the room temperature is higher or equal to the set temperature, COOLING operation starts. If the room temperature is lower than the set temperature, HEATING operation starts.

COOLING SELECTION TEMP.

SHIFT SET TEMP.

+5 deg

+4 deg

Section

REMOTE CONTROLLED

SET TEMP.

SHIFT SET TEMP.

–4 deg

HEATING SELECTION TEMP.

–6 deg

HEATING COOLING HEATING

1142_THS_I

Fig. 12

– 35 –

SM830076

Section

2. Processes and functions

Chart summary and Explanations

❑ This chart shows how the Operation Mode (COOLING or HEATING) is determined by the

microprocessor taking the room temperature into consideration. It also shows the temperature points at which the cooling or heating mode is switched, when the AUTO mode is selected.

❑ After operation starts, the set temperature shifts automatically by +4 deg. at cooling and

by -4 deg. at heating. For example, if cooling is selected, the set temperature changes from 68°F to 72°F. (The display of the remote controller remains 68°F.)

❑ The change of the operation mode (heating to cooling, cooling to heating) by the change of

the room temperature during the operation is as follows. Heating to Cooling; Room temp. ≥ Shifted temp +1.0 deg. Cooling to Heating; Room temp. ≤ Shifted temp -2.0deg. For example, if the room temperature rises above 73°F (=72+1) during the cooling

operation at the room temperature 68°F set by the remote controller, the operation changes to cooling. When the room temperature lowers below 63°F (=65-2) thereafter, the operation changes to heating again.

❑ In heating operation, using the body sensor, room temperature control is designed so that

room air temp. is sensed as 8 deg. lower than suctioned air at indoor unit taking into account of the temperature gap between upper part and lower part of the room.

❑ Within 10 minutes after the compressor turns OFF, the operation does not change to

cooling (heating), even when the room temperature changes from C to A (A to C).

❑ When switching from cooling (heating) to heating (cooling), the actuation of the 4 way valve

will delay about 30-50 seconds after the compressor turns ON.

– 36 –

SM830076

2. Processes and functions

1. Specifications

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

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

Flow of Defrosting

Heating operation

No counting time for detecting frost : 15 minutes

Detecting the frost

Stand by time for defros: 25 minutes

Defrosting

Release of defrosting

Time Chart for Defrosting

OUTDOOR COIL TEMP. C1 (°F)

“RELEASE OF DEFROSTING” RANGE

OUTDOOR AIR TEMP.

7.3 50 27 18

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

–4

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

Refer to time chart.

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

Occurs either when the temperature of C1 (the outdoor heat exchanger coil) has reached 50°F or above, or when the maximum defrosting time (9 minutes) has elapsed.

MAX. 9 MINUTES 1 MINUTE1 MINUTE

(°F)

Section

1143_THS_I

Fig. 13

COMPRESSOR

SOLENOID COIL (4 WAY VALVE)

OUTDOOR FAN (H OR L)

INDOOR FAN (SET SPEED)

“STANDBY” INDICATOR

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

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

“STANDBY” APPEARS

Defrosting Start

ON ON

OFF OR LL

Release of Defrosting

– 37 –

OFF OR LL

0442_M_S

Fig. 14

SM830076

Section

2. Processes and functions

2-11 4-Way Valve, Solenoid Control

The basic function of the 4-way valve is to direct the refrigerant in the correct direction according to the Operation Mode (COOLING or HEATING) selected. The following two charts show conditions of the controls and functions listed in the left hand column when the solenoid is ON or OFF. Chart (A) on this page shows the relationships when the temperature control is in NORMAL mode, and Chart (B) on the next page shows the relationships when the remote controller is set to AUTO mode.

(A) Normal Control Mode

POWER SOURCE

OPERATION BUTTON

MODE BUTTON

COMPRESSOR

SOLENOID COIL (4-WAY VALVE)

COOL

HEAT

OFF

HEAT

3 MINUTES

TURN OFF

ON ON ON

OFF

1. . . More than 5 minutes 2. . . More than 3 minutes

TURN ON

COOL

THERMO OFF

OFF

ONON

THERMO ON

1 111

HEAT

THERMO OFF

OFFOFFOFF

THERMO ON

0443_M_S

Fig. 15

Chart Summary and Explanations

❑ For the first 3 minutes after power is applied, the 4–way valve remains OFF and the

compressor will not operate, even if the ON button is pushed.

❑ If the 4–way valve is turned OFF with the compressor operating, the air conditioner

operates in COOLING mode. See Table below.

❑ If the 4–way valve is turned ON with the compressor operating, the air conditioner operates

in HEATING mode. See Table below.

Operation Mode

COOLING OFF

HEATING ON

4-way valve solenoid

Compressor

– 38 –

SM830076

(B) AUTO Control Mode

2. Processes and functions

1. Specifications

MORE THAN 10 MINUTES (THERMO. OFF)

COOL

OFFOFF

MORE THAN 30 – 50 SECONDS

OFF

HEAT

THERMO. OFF

THERMO. ON

MORE THAN 3 MINUTES

0445_M_S

OPERATION BUTTON

AUTO MODE CONTROL HEAT

COMPRESSOR

SOLENOID COIL (4-WAY VALVE)

COOL

OFFPOWER SOURCE

MORE THAN 10 MINUTES

3 MINUTES

OFF OFF

OFF

ON ON ON ON

30 – 50 SECONDS

(THERMO. OFF)

HEAT

MORE THAN

Fig. 16

When the Compressor has stopped while in AUTO mode, the 4-way valve switches on (heating) or off (cooling) within 1 minute according to the following conditions:

Section

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

2-12 Automatic Restart after Power Interruption

This air conditionner has a power failure recovery function.

Fig. 17

– 39 –

SM830076

2-13 Electronic Expansion Valve

❑ This valve allows very precise and smooth control of the amount of refrigerant flow in the

system. Since the valve is operated by a step motor, the control circuits can open or close it in very exact amounts, so the degree of heating or cooling can be changed by just a little, or changed very quickly or slowly.

(Completely close …… 0 step)

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

2. Processes and functions

Section

Model

24 type 100 step 120 step 480 step 36 type 90 step 90 step 480 step

Heating Cooling

Min. open

Max. open

❑ Fuzzy Control

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

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)

Indoor temp. (°F) 64 – 70 72 – 77 79 – 86 Outdoor temp. (°F) Compressor discharge

gas temp. (°F)

❑ Operate the unit at least 30 minutes to stabilize the discharge temperature. ❑ The above discharge temperature was measured with a 15m tubing length.

The temperature may vary with tubing length.

32 or below 104 – 176122 – 194122 – 194122 – 212140 – 221 122 – 194 140 – 212 158 – 221

34 – 50

32 or below

– 40 –

34 – 50 52 – 70

32 or below

34 – 50 52 – 70

SM830076

2. Processes and functions

1. Specifications

2-15 Compressor Current Detection Circuit

❑ The Compressor Current Detection Circuit detects the compressor current and,

depending on the current range, can stop the compressor motor so it will not be damaged by overcurrent.

❑ Overcurrent can be caused by several factors, particularly mechanical seizing of the

compressor or liquid backflow. Either of these conditions can hold the compressor to run, and thus drawing so much current that the motor can burn out.

Comp. Amps.(A)

Locked Comp. Cut-off Range

Is 1.4

Is 1.17

Rated Current value

Overload Protection Range

Normal Operation Range

0447_M_S

Section

Fig. 18

Outdoor Model

CH2432 17.1 20.0 23.9 CH3632 27.5 32.0 38.5

❑ Overload Protection

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

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

message H01, compressor overload.

❑ Locked Compressor Cut-off

• When the detected current is 1.4 times greater than the rated current value (ls) and continues for 2 seconds, both compressor and outdoor fan stop (Thermostat OFF).

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

❑ Failure of Compressor Current Detection

• When the Compressor Current Detection Circuit fails to detect the compressor current within 2 seconds after compressor starts, both compressor and outdoor fan stop (Thermostat OFF).

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

Failure of compressor Current Detection.

Rated Current Value Overload Protection Locked Compressor Cut-off

ls (A) ls x 1.17 (A) Is x 1.4 (A)

Chart Summary and Explanations

– 41 –

SM830076

2. Processes and functions

2-16 Electronic Expansion Valve Control

The circulation volume of the refrigerant is controlled by a pulse type electronic control valve. When the power is switched ON, the opening degree of the electronic control valve is controlled between 90 and 480 steps after setting the initial step at the time when the thermostat is ON.

Contents and Order of control

Section

Cooling

Start

Discharge gas temperature control

Outdoor unit coil temperature control

Freeze prevention control

Refrigerant flow distribution control

Discharge gas target temperature control (Fuzzy control)

Repeat control in accordance with the priority order.

Discharge gas temperature control

High load prevention control

Refrigerant flow distribution control

Discharge gas target temperature control (Fuzzy control)

Heating

Start

Heating start up control

0451_M_S

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

(1) Refrigerant flow distribution control

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

Cooling: indoor unit coil E2 temperature (located at the middle of coil) Heating: indoor unit coil E1 temperature (located at the outlet of coil)

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

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

– 42 –

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.

1. Specifications

Section

– 43 –

SM830076

Section

2. Processes and functions

– 44 –

SM830076

3. Electrical data

3. ELECTRICAL DATA

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

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

Section

– 45 –

SM830076

3-1 Indoor Unit

1 XHS2432, XHS3632

3. Electrical data

Section

ORG

Connector

GRN/YEL BLK

Earth

Terminal

49FI

GRN/YEL

FMI

RC1

Earth

• Electric Wiring Diagram

Control

Line

Terminal

GRY

IND

GRY GRY WHT VLT ORG YEL BLK BRN PNK

2 U1 U2

Power

Line

To Outdoor Unit

3P(WHT)

123

Connector

9P(WHT)

23456789

123456789

PNK BRN

BRN

6P(WHT)

CONT

GRN/YEL BLK GRY

RED

BRN

VLT ORG YEL BLK

BLU PNK

WHT RED

Earth

Terminal

BLK WHT RED YEL

PNL

(GRN)

212121

(BLK)

Coil E2

(GRN)

(RED)

Coil E1

GLM 12VSGCD

2143

31 31

49FI(GRY)

5713 231231

COM(YEL) HLLL

SG 12V G

SG1 SG2

N R

(YEL)

WL(BLU)

FMI(WHT)

RC(BLU)

SG1(BLU)

SUP(BLK)

Room Temp

SEC(WHT)

Controller (CR-THS2432)

PRY(WHT)

453

T6 (WHT)DP (BLU)FS (RED)E

BLK BLK

BRN BRN RED RED

WHT WHT

GRY BLK YEL RED ORG

BLK BLK

GRN/YEL

TR1

MOV

Earth

TH1 TH2 TH3

GRN/YEL

Terminal

Earth

Terminal

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

Terminal

Plate(4P)

– 46 –

SM830076

3-1 Indoor Unit

1 XHS2432, XHS3632

4P-1

4P-2

N COM

F1(3A)

3X 3X

LL L HHH COM

LL L HHHHT

FMI

RC1

F2(3A)

3. Electrical data

• Schematic Diagram

CR-THS2432

Controller

CONT

RY2

RY1

49FI

SG WL

12V

1 2

SEC

3 4

PRY

DC12V

SG1

12VRC

PNL

SG1 SG2

1 2 3

1 2 3 4 5

1 2 3

1 3

Room Thermistor

1 2

Indoor Coil

1 2

Indoor Coil

1 2

4P-U24P-

To Outdoor Unit

MOV

TH1 E1

TH2 E2

TH3

Section

49FI

RY2

11357

6 7543

49FI

RY1

333

IND

TR1

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 (Indoor Coil E2) Indoor Controller Controller Indicator Lamp Assy Terminal Plate Connector Terminal

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

– 47 –

SM830076

Section

3-2 Outdoor Unit

1 CH2432

TH6

BLK 1

BLK 2

(BLK)

TH7

BLK 1

BLK

(RED)

TH8

WHT

WHT 2

Discharge

Gas (GRN)

SEC

(WHT)

PRY

3P(WHT)

63PH

3P(RED)

20S

3P(YEL)

BRN BRN

WHT WHT

GRY RED

BLK BLK

AC 14V

AC 208V

AC 230V

RED

3. Electrical data

63PH

BLK

20S

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

SUP

BRN

3P (BLU)

GRN/YEL

9P(WHT)

3P(BLK)

3P(WHT)

RED

CN24

31 35791

52C

CT1

GRN/YEL

Earth Terminal

BLK

BRN

ORG

GRY

BRN

RED

WHT

Controller (CR-CH2432)

CN2

2P (BLU)

BLU

• Electric Wiring Diagram

PNK

1 2

U1 U2

To Indoor Unit

Terminal

Plate (2P)

RC2

Connector

2P (BLK)

P 87

VLT

WHT BLK

GRY BRN

PNK

Connector

Relay

Connector

BRN

YEL

S7 8

8P (WHT)

2P (WHT)

Earth

YEL VLT WHT GRY GRY BRN PNK

WHT WHT

Terminal

GRN/YEL

49FO

FMO

Earth

L2 GL1

To Indoor Unit Power Supply

Terminal

Terminal Plate (5P)

WHT

12G L1 L2

RED

WHT RED

BLK

PTC

RC1

WHT

WHT BLK RED

UVW

RST 31

52C

SM830076

– 48 –

3-2 Outdoor Unit

1 CH2432

3. Electrical data

Terminal Plate (5P)

-1

-2

-G

-L1

-L2

52C

RC1

PTC

63PH

F1(3A)

52C

F2(3A)

Symbols Description

CM FMO 52C 49FO 63PH CT RC1, RC2 TR CH 20S F1, F2

Compressor Motor Outdoor Fan Motor Compressor Motor Magnetic Contactor Outdoor Fan Motor Thermal Protector High Pressure Switch Current Transmitter Running Capacitor Power Transformer Crank Case Heater Four Way Valve Fuse

• Schematic Diagram

63PH

RY2

7 49 FO

49 C

Symbols Description

TH6 TH7 TH8 PTC CR-CH2432 RY1~RY4 1Y

RY3

RY4

H LL 20S 52C

HLM

FMO

RC2

RY1

3 3

765

20S

52C

CR-CH2432

Controller

Discharge

CN2

PRY

SEC

Outdoor

Coil C1

Outdoor

Coil C2

Gas

CT1

49FO

RY1

RY2

RY3

RY4

20S

52C

FM1

FM2

DC12V

Thermistor (Outdoor Coil C1) Thermistor (Outdoor Coil C2) Thermistor (Discharge Gas) PTC Thermistor Outdoor Controller Auxiliary Relay Auxiliary Relay Terminal Plate Terminal Connector

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

1 2

1 3

2 1

1 2

1 3

(U1) (U2)

AC 208V

230V

AC 14V

2P-22P-1

Section

TH6

TH7

TH8

– 49 –

SM830076

Section

3-2 Outdoor Unit

2 CH3632

TH6

BLK 1

BLK 2

(BLK)

TH7

BLK 1

TH8

BLK 2

(RED)

WHT

WHT 2

Discharge

Gas (GRN)

SEC

(WHT)

PRY

3P(WHT)

63PH

3P(RED)

20S

3P(YEL)

BRN BRN

WHT WHT

GRY RED

BLK BLK

AC 14V

AC 208V

AC 230V

RED

3. Electrical data

WHT BLK

Connector

2P (WHT)

RED

P 21

WHT RED

BLK BLK

63PH

20S

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

VLT WHT

SUP 3

BRN

3P (BLU)

RED

CN24

35791

9P(WHT)

52C

3P(BLK)

CT1

3P (WHT)

BLK

GRN/YELGRN/YEL

Earth Terminal

BRN

ORG

BRN

BRN BRN

BRN

GRY

Controller (CR-CH2432)

CN2

2P (BLU)

BLU

• Electric Wiring Diagram

PNK

1 2

U1 U2

To Indoor Unit

Terminal

Plate (2P)

RC3

RC2

Connector

2P (BLK)

P 87

VLT

WHT GRY

BRN

PNK

Connector

P 87

VLT

WHT GRY

GRY BRN

PNK

Connector

BRN

YEL

S7 8

8P (WHT)

S7 8

8P (WHT)

2P (WHT) 21

YEL VLT WHT GRY GRY BRN PNK

Earth

YEL VLT WHT GRY GRY BRN PNK

WHT WHT

Terminal

FMO2

GRN/YEL GRN/YEL

49FO1 49FO2

FMO1

Earth

L2 GL1

To Indoor Unit Power Supply

Terminal

Terminal Plate (5P)

WHT

12G L1 L2

RED

WHT RED

BLK

PTC

RC1

WHT

WHT BLK RED

UVW

RST 31

RED

52C

SM830076

– 50 –

3-2 Outdoor Unit

2 CH3632

3. Electrical data

Terminal Plate (5P)

-1

-2

-G

-L1

-L2

52C

RC1

PTC

63PH

F1(3A)

52C

RC2

F2(3A)

Symbols Description

CM FMO1, 2 52C 49FO1, 2 63PH CT RC1, 2, 3 TR CH 20S F1, F2

• Schematic Diagram

63PH

RY1

3 3

RY2

49 FO

52C20S

49 C

Symbols Description

TH6 TH7 TH8 PTC CR-CH2432 RY1~RY4 1Y

HLM

FMO1

RY3

RY4

H LL 20S 52C

HLM

765

FMO2

RC3

CR-CH2432

20S

52C

FM1

FM2

DC12V

Controller

Discharge

CN2

PRY

SEC

Outdoor

Coil C1

Outdoor

Coil C2

Gas

CT1

3 7

49FO1

49FO2

RY1

RY2

RY3

RY4

Thermistor (Outdoor Coil C1)

1 3

2 1

1 2

1 3

(U1) (U2)

AC 208V

230V

AC 14V

2P-22P-1

Section

TH6

TH7

TH8

Thermistor (Outdoor Coil C2) Thermistor (Discharge Gas) PTC Thermistor Outdoor Controller Auxiliary Relay Auxiliary Relay Terminal Plate

Terminal Connector

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

– 51 –

SM830076

Section

3. Electrical data

– 52 –

SM830076

4. Service procedures

4. SERVICE PROCEDURES

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

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

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

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

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

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

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

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

Section

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

– 53 –

SM830076

Section

4. Service procedures

4-1 Troubleshooting

This section explains:

❑ What the LED codes mean ❑ What the remote control unit display screen messages mean ❑ How to use the flow charts to find and solve problems

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

❑

This unit is made to be trouble free, and not need much service. However, with time, moving parts wear out, electronic components break down, and sometimes misuse damages the unit. The purpose of this section is to help you when the unit is not working properly. Sometimes your experience will tell you right away where to look for a problem, and when you find it you will know how to fix it at once. Often, however, all you have is a symptom like “poor cooling” or “outside fan doesn’t come on.” Now you must find out the cause of the problem, and then how to fix it. This section provides several ways to help you go from the symptom to the cause and then the solution. The first chart, General Troubleshooting Flow Chart is divided into two sections: Poor heating and Poor Cooling. Under each heading you will find the main things that can go wrong and cause either of these problems. Sometimes you can start with this chart and find the problem right away, but often you will come here for more suggestions after you have looked at the error code on the remote control unit display. This chart gives you the "big picture" of problems and solutions. The other main tool we explain here is the use of the Alarm Messages. When a certain part fails or a safety device has shut the unit down, any alpha-numeric codes appears on the display to guide you to the problem. By understanding the code you can often go right to the problem area and then, with this manual and your knowledge of air conditioning, find the solution.

– 54 –

SM830076

4. Service procedures

(1) Check before and after Troubleshooting

Many problems may happen because of wiring or power supply problems, so you should check these areas first. Problems here can cause false results in some of the other tests, and so should be corrected first.

1. Check power supply wiring

❑ Check the power supply wires are correctly connected between terminal

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

2. Check inter-unit wiring

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

indoor unit and outdoor unit. Power Supply: 60 Hz, single-phase, 230/208 V

Section

3. Check power supply

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

Disconnect SW (Field supply)

1 2

Ground

Inter unit

Indoor

control line

Unit

DC 5 V

Inter unit power line 230/208 V

U1 U2

Outdoor

Unit

1 2

Power supply single phase

230/208 V

L1 L2

Ground

L1 L2

1103_M_I

Fig. 19

If the following troubleshooting must be done with power being supplied, be careful not to touch any uninsulated live part that can cause ELECTRIC SHOCK.

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

❑ Check that the sheath of lead wires is not damaged. ❑ Check that the lead wires are firmly connected at the terminal plate. ❑ Check that the wiring is correct.

– 55 –

SM830076

Section

4. Service procedures

(2) General Troubleshooting Flow Chart: Diagnosis and Remedy

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

(A) Cooling

a. Cooling Poor cooling

Is setting temp. suitable ?

Change the setting temp.

Refrigerant flow failure

Is cooling load too heavy ?

4-way valve is defective.

Refrigerant shortage

Electronic refrigerant control valve is defective.

Service valves are not fully open.

Review cooling load estimate.

Replace the 4-way valve.

Charge refrigerant gas.

Replace the valve.

Replace the compressor.Compressor is defective.

Open the valves fully.

Not enough air circulation

Air filter is clogged.

Is fan speed set to LOW ?

Refrigerant tubes between indoor and outdoor units are not insulated.

– 56 –

Clean the filter.

Set the fan speed to either MEDIUM or HIGH.

Insulate wide and narrow tubes separately.

0458_M_I

SM830076

(B) Heating

b. Heating

Poor heating

4. Service procedures

Refrigerant flow failure

Is setting temp. suitable ?

Is heating load too large ?

4-way valve is defective.

Refrigerant shortage

Electronic refrigerant control valve is defective.

Service valves are not fully open.

Change the setting temp.

Review heating load estimate.

Replace the valve.

Charge with refrigerant.

Replace the valve.

Replace the compressor.Compressor is defective.

Open the valves fully.

Section

Not enough air circulation

Cold air is discharged.

Cold draft prevention is not working.

Air filter is clogged.

Is fan speed set to LOW ?

Refrigerant tubes between indoor and outdoor units are not insulated.

4-way valve is defective.

“ STANDBY ” is displayed.

Indoor coil sensor E2 is defective.

Clean the filter.

Set the fan speed to either MEDIUM or HIGH.

Insulate wide and narrow tubes separately.

Replace the valve.

Replace indoor P.C.B. Ass'y.

Replace the sensor.

0459_M_I

– 57 –

SM830076

Section

4. Service procedures

(3) Meanings of alarm messages

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

Possible causes of troubles

Remote controller is detecting unusual signal from indoor unit.

• Indoor unit is detecting unusual signal from the remote controller and group control. (No serial communications signal)

Improper setting of indoor unit or remote controller.

Indoor unit is detecting unusual signal from signal option.

Improper setting of indoor unit or remote controller.

Indoor unit is detecting signal from outdoor unit.

Outdoor unit is detecting unusual signal from indoor unit.

• Serial communication errors • Mis-setting• Mis-setting Auto. address setting is not

correct. Indoor unit is detecting unusual

signal from another indoor unit.

Improper setting of indoor unit or remote controller.

Improper wiring connections of ceiling panel.

Protective device in indoor unit is activated.

Protective device in outdoor unit is activated.

• Activation of protective device

unusual

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. (judged by outdoor unit.) Error receiving of serial communications signal. Error transmitting of serial communications signal Error receiving of serial communications signal. (Confirmation error of unit numbers included) Error transmitting of serial communications signal. No. of judged indoor units or total capacity of indoor units is small. No. of judged indoor units or total capacity of indoor units is large. Error transmitting of serial communications signal Error receiving of serial communications signal. Indoor unit group address is not correct. Model setting of indoor unit is not matching the outdoor unit. When using group control, main indoor unit address setting is duplicated.

(judged by indoor unit.) Outdoor unit address is duplicated. Improper wiring between indoor units.

(There is a group connection wiring in case of individual control.) Indoor unit address (or group address) is not set. Capacity code of indoor unit is not set. Improper wiring of group control wiring. Indoor unit model setting is improper (capacity)

Thermal protector in indoor fan motor is activated. Float switch is activated.

• Thermal protector in outdoor fan motor is activated.

• Compressor thermal protector is activated.

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

260 V or less than 160 V.) Discharge gas temperature of comp. is unusual. High pressure switch is activated. Voltage drops. Other indooor unit is warning.

Wired remote controller display

E01 E02 E03

E08 E09 E10 E11 E14

E04 E05 E06

E07 E15 E16 E17 E18 L01 L02 L03

L04 L07

L08 L09 L11 L13 P09 P01 P10 P02

P03 P04 P05 P31

Wireless remote controller display

Operation lamp flashes

O:Operation lamp

v: Timer lamp v:Heat stand-by

lamp

Heat stand-by lamp flashes

v:Operation lamp v: Timer lamp

O:Heat stand-by

lamp

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

O:Operation lamp v: Timer lamp O:Heat stand-by

lamp

v:Operation lamp

O: Timer lamp O: Heat stand-by

lamp

Operation lamp and heat stand-by lamp flash alternately.

O:Operation lamp v: Timer lamp O:Heat stand-by

lamp

– 58 –

SM830076

4. Service procedures

Possible causes of troubles

Indoor thermistor is either open or short.

Outdoor thermistor is either open or short.

• Thermistor failure

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

compressor is activated.

compressor

and its circuit

• Fault with

O:flashes v: OFF

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.

Compressor motor is overloaded. Compressor motor is locked. Compressor current detection circuit is defective. Power supply voltage between phases is unbalanced. Standard comp. contactor (Mg SW)is chattering.

Wired remote controller display

F01 F02 F10 F04 F06 F07 F29

H01 H02 H03 H17 H18

Wireless remote controller display

Operation lamp and heat stand-by lamp flash alternately.

O:Operation lamp O: Timer lamp

v:Heat stand-by

lamp

v:Operation lamp O: Timer lamp v:Heat stand-by

lamp

Section

– 59 –

SM830076

4. Service procedures

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

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

Section

LED 2 on

P.C. board

vvNo message

v * No message

VvP02

VVP04, P05

V * F04~F09

* v H01, H02 **E15, E16

Flash at the same time

Flash alternately

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

LED 1 on

P.C. board

Remote

controller

E06, E07, L04

“SETTING” flashes.

Possible cause of trouble

Normal Outdoor unit serial communication signal is abnormal. Outdoor unit address is duplicated. Other outdoor units are performing auto address and detecting refrigerant shortage. FMo • CM thermal protection is in operation. Power supply voltage is abnormal. High 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.

LED 2 (D12) LED 1 (D11)

1125_C_I

CAUTION

Fig. 20

* REFRIGERANT SHORTAGE

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

LEDs and the Alarm Message does not appear on the Indoor Remote Controller . The

compressor keeps running even when the refrigerant is less, so when you find the LED indication on the outdoor P.C.B. Ass’y, stop the air conditioner immediately to avoid the compressor damage.

– 60 –

SM830076

4. Service procedures

(5) Symptoms and parts to inspect

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

Start

Miswiring of power supply wires and indoor/outdoor control lines

Correct the wiring. Remove the socket connected to the OC plug on the PCB and connect to the EMG plug instead.

Yes

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

Check and repair the power breaker etc.

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 there 230-208 V AC between R and S of the indoor PCB?

Yes

Is there 12 V DC

Yes

between 2 and 3 of the remote controller?

Replace the remote controller.

Yes

Section

Repair the remote controller wiring.

Correct the connections

Replace the indoor unit power transformer.

Are the connections for the 4P connector for the indoor unit’s PCB power transformer good?

Is there 15 V AC

between 1 and 2 of the 4P connector for the indoor unit’s power transformer?

Replace the indoor unit PCB.

Yes

Has the indoor unit PCB fuse blown?

Yes

Is the primary side of the indoor power transformer shorted?

Yes

Replace the indoor unit’s power transformer.

– 61 –

Is the 230-208 V AC circuit shorted?

Yes

Replace or repair.

NoNo

Replace the indoor unit PCB.

1144_THS_I

SM830076

2) Symptom: LCD on the remote controller displays “CHECK E01”. (Unusual communication between remote controller and indoor unit.)

Start

4. Service procedures

Section

Remote controller judges itself with self-diagnostic functions

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

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

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

Is the indoor pin shorted?

unit PCB’s

inspection

Yes

Replace the remote controller.

Correct the wiring.

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

Correct the setting.

Open the inspection pin.

Yes

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

Replace the indoor

unit PCB

3) Symptom: LCD on the remote controller displays “CHECK E02”.

(Unusual communication between remote controller and indoor unit)

Start

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

Remote controller judges itself with self-diagnostic functions. (To avoid misjudgment, always remove the No. 1 line of the remote controller wiring from the indoor unit terminal plate.)

Replace the indoor unit PCB.

Yes

Repair the wiring.

Replace the remote controller.

0334_M_I

– 62 –

1145_THS_I

SM830076

4. Service procedures

4) Symptom: LCD on the remote controller is displaying “CHECK E04”. (Unusual communication between the indoor and outdoor units.)

Start

Cut the breaker and remove the indoor/outdoor unit control lines connected to U1 and U2 of the indoor unit 8P terminal plate. After shorting the test pin (CN2) on the indoor unit PCB, switch the breaker on. Does the LED (red) on the PCB light up?

Yes

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?

Yes

Indoor/outdoor unit

control lines are cut off

No No

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

Yes

Replace the indoor unit PCB.

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

Replace the indoor unit PCB.

Correct the connections.

Section

Correct the connections.

Correct the wiring.

5) Symptom: LCD on the remote controller is displaying “CHECK E05”. (Unusual communication between the indoor and outdoor units)

Start

Indoor unit PCB transmission/ reception circuit defect

Replace the indoor unit PCB.

0336_M_I

0335_M_I

– 63 –

SM830076

4. Service procedures

6) Symptom: LCD on the remote controller is displaying “CHECK E06”. (Unusual communication between the indoor and outdoor units)

Start

Section

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?

Influenced by external noise

Yes

Correct the setting.

Correct wiring.

0337_M_I

* See the section of INSTALLATION INSTRUCTION concerning with flexible combination

system.

7) Symptom: LCD on the remote controller is displaying “CHECK E08”. (Duplicate indoor unit address setting)

Start

Is the setting for the non-volatile memory IC on the indoor unit PCB inappropriate? If the setting is appropriate, “F29” is displayed. (Are there two units with the same address?)

Yes

Correct the setting.

Influenced by external noise

0338_M_I

* See the section of INSTALLATION INSTRUCTION concerning with flexible combination

system.

8) Symptom: LCD on the remote controller is displaying “CHECK E09”. (Duplicate setting of RCU address switch of remote controllers)

Start

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

Replace the remote controller.

Yes

Correct the setting.

0339_M_I

* See the section of INSTALLATION INSTRUCTION concerning with controlling remote

controller switches when there are two remote controllers.

– 64 –

SM830076

4. Service procedures

9) Symptom: LCD on the remote controller displays “CHECK P01”. (Indoor fan protection thermostat operation warning)

Start

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

Yes

Is there

230-208 T20-3 and S4 after T20-1 and T20-3 on the indoor unit PCB shorted?

Replace the indoor unit PCB.

V AC between

Yes

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

Replace the indoor fan.

Section

Correct the connection

Yes

1146_THS_I

– 65 –

SM830076

10) Symptom: LCD on the remote controller displays “CHECK P02”. (Compressor / outdoor fan protection thermostat operation warning / power supply voltage abnormality)

Start

4. Service procedures

Section

Is the power supply to the outdoor unit normal? (Voltage / defective phase?)

Yes

Is the fuse on the outdoor unit PCB blown (F1 and F2)?

Is the high voltage switch (63 PH) off?

Is there 230-208 V AC between CN19-9 and CN19-1 on the outdoor unit PCB?

Yes

Check the power breaker etc. and repair.

Replace the fuse.

Replace the outdoor unit PCB.

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

Yes

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

Yes

• No refrigerant

• High load

• 4-way valve defect

• Clogged refrigerant circuit

• Electronic refrigerant control valve defect (indoor unit)

Is there connector contact defect?

Replace the outdoor unit PCB.

– 66 –

Replace the outdoor fan.

Yes

Correct the connection

1147_THS_I

SM830076

4. Service procedures

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

(Alarm for unusual discharge temp. of compressor)

Start

Unusual discharge gas temperature

• Refrigerant shortage

• Clogged refrigerant circuit

• Electronic refrigerant control valve defect (indoor unit)

0343_M_I

12) Symptom: LCD on the remote controller displays “CHECK P04”. (High-pressure switch activation warning)

Section

Start

The system does not operate again.

Yes

High-pressure switch activation

(Both cooling and heating)

• Electronic defect

•

Refrigerant

(Cooling)

• Outdoor unit, heat exchanger dirty, clogged

• Outdoor unit air short

• Outdoor fan stopped (Heating)

• Outdoor unit air short

• Indoor unit, heat exchanger dirty, clogged

• Large pipe side service valve closed

• Indoor fan stop

• Air filter clogged

refrigerant

over-charged

control valve

No Yes

Are there connection defects in the wiring?

High-pressure switch defect

Repair the wiring.

– 67 –

0344_M_I

SM830076

13) Symptom: LCD on the remote controller displays “CHECK P05”. (Negative phase detection operation warning)

Start

4. Service procedures

Section

Is the power supply to the outdoor unit normal? (Voltage defective phase?)

Yes

Does the outdoor unit operate when two of the three phases are changed? (Actuation of negative phase protector)

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

Is there a contact defect in the 3P connector?

Replace the outdoor PCB

Yes

Check the power breaker etc. and repair

No problem

Replace the fuse.

Correct the connection

0345_M_I

14) Symptom: LCD on the remote controller displays “CHECK E15”.

Start

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

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

Are there no contact failure between outdoor and indoor units?

Perform the same as “CHECK E04”.

Yes

Repair the wiring.

Select an indoor unit which matches with the outdoor capacity.

Check the contact.

0646_M_S

– 68 –

SM830076

4. Service procedures

15) Symptom: LCD on the remote controller displays “CHECK E16”.

Start

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

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

Confirm less than 5 indoor units are connected.

Yes

Repair the wiring.

Select indoor units which match with the outdoor capacity.

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

Start

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

Yes

Repair the wiring.

Section

0647_M_S

Check the capacity of the indoor unit by remote controller. See Test Run Manual.

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

Start

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

Yes

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

Yes

Connect firmly.

– 69 –

0648_M_S

0649_M_S

SM830076

4. Service procedures

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

* Please check the related part described in the following chart after confirming the code

setting (S4) of the outdoor unit’s capacity on the PCB in the outdoor unit.

Start

Section

“CHECK H01” display

Compressor overload detection

• Insufficient voltage

• Comp. motor magnetic contactor defect

• Refrigerant over-charged

“CHECK H02” display

Compressor lock detection

Compressor lock

“CHECK H03” display

Compressor current detection circuit defect

• L3 phase wire disconnected

• Comp. motor magnetic contactor defect

• Outdoor unit PCB defect

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

¶ If the electronic control valve failure occurred in Flexible Combination system

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

Operate the unit in cooling mode. (30 minutes after its operation)

0346_M_I

• 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 leakage from the pipe of the temperature detection section?)

Replace the sensor.

– 70 –

Yes

Normal

Failure in the electronic control valve activation.

0460_M_I

SM830076

(6) Procedures When a Specific Component Does Not Work

1) Indoor fan does not operate.

Is fan motor capacitor normal ?

Yes

Replace the capacitor.

4. Service procedures

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

Yes

• Check resistance of fan motor winding.

Out

Replace the fan motor.

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

0650_M_S

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

Check the louver motor resistance. Is auto louver motor normal?

Yes

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

Replace the motor.

Connect firmly.

Section

Yes

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

1200_M_S

SM830076

– 71 –

3) Compressor motor does not operate.

4. Service procedures

Section

Does compressor motor magnetic contactor (52C) actuate ?

Yes

Check resistance of compressor motor winding.

Replace the compressor.

4) Outdoor fan does not operate.

Are auxiliary relays (1Y) normal ?

Yes

Replace the compressor motor magnetic contactor.

0461_M_I

Replace the relays.

Is fan motor capacitor normal ?

Yes

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

Yes

Check resistance of fan motor winding.

Replace the fan motor.

Replace the capacitor.

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

1148_THS_I

– 72 –

SM830076

4. Service procedures

(7) Service Functions of Optional Wired Remote Controller

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

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

(A) Set service check switches. (B) Use the test run procedure. (C) Check the sensor temperature readings. (D) Find out about past service problems.

(E) Check the remote controller itself for correct operation. (F) Excute the auto. address operation. (G) Confirm and change the indoor unit address. (H) Change the shift temperature in heating mode ( I ) Set the indoor unit address. (J) Change the period of the filter timer

(A) Set service check switches

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

switch

RCU. ADR

ON OFF

Section

switch

RCU. CK

ON OFF

0354_M_I

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

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

operation”

(Remote Control Unit, Check)

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

controller (Remote Control Unit, Address)

– 73 –

SM830076

Section

4. Service procedures

(B) Use the test run procedure

❏ The purpose of the test run function is to let you control the operation of the unit

directly without turning the unit on or off by thermostat. As indicated in the following procedure, be sure to stop test run operation when you finish the procedure, or the air conditioner may be damaged.

❏ To protect the air conditioner from overloading, the outdoor unit will not start running

for 3 minutes after power is applied or the unit is turned OFF.

a Press the TEST / CHK button at

the bottom right on the remote controller.

AIR FLOW

b Press the ON / OFF operation

button to start the test run.

c Press the MODE button to select

UNIT

FLAP

°C

TIMER SET

MODE

SET TEMP.

either COOLING or HEATING mode.

FAN SPEED

d When the test run starts, “TEST”

shows on the remote controller’s display.

e During the test run, the air

SET CL

ON OFF••

TEST

TEST / CHK

conditioner runs continuously and the thermostat does not control the system.

Alarm message

f After the test run, be sure to

TEST RUN / CHECK button

press the TEST / CHK button once again

ON / OFF operation button

to finish this mode and make sure “TEST” is not shown on the display.

CAUTION

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

1152_THS_I

– 74 –

SM830076

4. Service procedures

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

❏ Each sensor has an address which is made up of the indoor unit address, and the

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

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

more than 4 seconds.

Section

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

AIM

SWEEP

No.CODE

SET TEMP.

SETTING

ON OFF••

MODE

°C

SET TEMP.

FAN SPEED

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. (Indoor unit address) which you want to

check with UNIT button.

❏ Each time you press the , (SET TEMP.) button you can select a different sensor,

and the display shows the sensor address and temperature as shown below.

UNIT No. (Indoor unit address)

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

MONITOR

SETTING

ON OFF••

MODE

Sensor address

SET TEMP .

No.CODE

Sensor temperature °C

FAN SPEED

DATA

TEST / CHK

NOTE

Do not press TIMER SET button during the procedure.

– 75 –

0357_M_I

SM830076

4. Service procedures

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

Relationship between the sensor address and the location of sensor

Section

Sensor Address (CODE No.)

Indoor Unit 01 —

02 TH1 Indoor air suction Temp. 03 TH2 Indoor coil Temp. (E1) 04 TH3 Indoor coil Temp. (E2) 05 — 06 — 07 — 08 Electronic expansion valve open 09 —

Outdoor Unit 0A TH8 Discharge gas Temp.

0B — 0C — 0D TH7 Outdoor coil liquid Temp. (C2) 0E TH6 Outdoor coil liquid Temp. (C1) 0F — 10 — 11 — 12 — 13 — 14 —

NOTE

Location of Sensor (Themistor)

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 problems the unit has had, if any. Knowing what has already occurred and been fixed helps you to know what to check at present.

❏ This function is usable even if the unit is not working. ❏ To display the past error codes, follow the procedure below.

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

more than 4 seconds.

b Once in this mode, display changes from the normal display to service check display as

shown in the table below:

NORMAL DISPLAY

Display Change

(È)

SERVICE CHECK DISPLAY

Set temp. È Code No. UNIT No. È UNIT No. ( Hours, Minutes È Alarm Message

Indoor unit address

– 76 –

)

SM830076

This picture shows the service check display.

4. Service procedures

UNIT No.

1–1

No.

Refrigerant Circuit No.

Alarm message

UNIT No.

R.C. No.

No.CODE

CODE No.

CHECK

SERVICE

0358_M_I

c. A maximum of 4 alarm messages can be accessed by pressing either SET TEMP button

or as follows.

MODE

SET TEMP.

FAN SPEED

Past

Present

Past

0359_M_I

NOTE Pressing CL (Clear) button will clear

all the service history.

... accessed in 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.

1234

Section

UNIT No.

R.C. No.

No.CODE

CHECK

SERVICE

If there are no alarm messages, the display shows:

UNIT No.

R.C. No.

No.CODE

CHECK

SERVICE

Alarm message

UNIT No.

R.C. No.

UNIT No.

R.C. No.

– 77 –

No.CODE

CHECK

SERVICE

No.CODE

CHECK

SERVICE

UNIT No.

R.C. No.

No.CODE

CHECK

SERVICE

0360_M_I

SM830076

4. Service procedures

Important

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

❏ To erase accessed data, press the CL button. ❏ When erasing is finished,“----” mark appears on the controller’s display.

CAUTION

Section

After checking the alarm messages, be sure to press the TEST / CHK button. (E) Check the remote controller itself for correct operation

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

a Turn ON the RCU.CK switch on the back of the P.C.B. Ass’y in the remote controller. See

section (A) for exact location.

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

correctly or not.

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

CAUTION

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

– 78 –

SM830076

4. Service procedures

(F) Execute the auto. address operation

❏ Auto. address operation is executed by pressing the A. ADD (S1) button of outdoor

unit’s PCB usually.

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

a Press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds. b Set CODE No. A1 with , (SET TEMP) button.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

MODE

R.C.

SET TEMP.

No.CODE

FAN SPEED

SETTING

ON OFF••

TEST / CHK

0361_M_I

operation is executed at each R.C. (Refrigerant Circuit) line one by one.

c Select R.C. No. which you want to execute the auto. address operation with UNIT button. d Press the SET button. The auto. address operation will start. CODE No. changes from

flashing to ON state.

e If an error occurs during operation, the alarm message will be displayed. Check and

remove the cause. If you want to stop the operation, press the CL button then the unit stands in waiting mode (Press the SET button again.)

In this mode, the auto. address

Section

f If the automatic address operation finishes, the display will disappear. g Execute the operation of the other R.C. line in the same way by following the above steps

c to d .

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

SM830076

– 79 –

Section

4. Service procedures

(G) Confirm and change the indoor unit address

❏ The purpose of the above function is to let you confirm the indoor unit address after

the auto. address operation, and change the indoor unit address if it is needed. a Press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

R.C.

SETTING

No.CODE

SET DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0362_M_

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

buttons.

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

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

Ex:

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

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0363_M_I

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.

– 80 –

SM830076

4. Service procedures

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

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

R.C. No.

SETTING

MODE

SET TEMP.

No.CODE

FAN SPEED

SET

DATA

ON OFF••

TEST / CHK

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

Required new indoor No.8: SET DATA

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

3 – 8 (NEW : after pressin the

TEST / CHK button)

0364_M_I

f Press the SET button.

UNIT No, SET DATA (0008) and

SETTING

changes from flashing to ON state.

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

Section

h Finally, press the TEST / CHK button. i If you want to change the indoor unit address of the other R.C. No., follow the step a to h

in the same way.

– 81 –

SM830076

Section

4. Service procedures

(H) Change the shift temperature in heating mode

❏ If the indoor unit is installed at high location (ex. ceiling level), the thermostat tends to turn off at

heating mode because of the hot air temperature around ceiling level. In order to solve the

problem, the shift temp. (valid while heating only) is set when shipped from factory.

❏ If the shift temp. is not enough (ex. the indoor unit is installed at position higher than 3 m), the

shift temp. can be set with remote controller from +1 to +10 deg (°C) <from +2 to 20 deg (°F)>.

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

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

SETTING

MODE

SET TEMP.

No.CODE

FAN SPEED

SET

DATA

ON OFF••

TEST / CHK

0365_M_

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.

EX:

UNIT No. 1–6

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SET TEMP.

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0366_M_

CODE No. 06 Shift temp. +5 deg (°C)

<+10 deg (°F)>

e Press the SET button.

CODE No. 06, SET DATA and

SETTING

change from flashing to ON state.

f If you made a mistake, press the CL button. g Finally, press the TEST / CHK button.

– 82 –

SM830076

4. Service procedures

( I ) Set the indoor unit address

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

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

NOTE

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

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

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

(DISP PIN : Refer to P. VI–2)

b Press the TEST / CHK , SET and CL buttons at the same time for more than 4

seconds.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

SETTING

MODE

SET TEMP.

No.CODE

FAN SPEED

SET

DATA

ON OFF••

TEST / CHK

0367_M_I

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

Section

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0368_M_I

SM830076

– 83 –

4. Service procedures

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

Section

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0369_M_I

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

e Press the SET button.

UNIT No., CODE No. 12,

SETTING

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

f Select the CODE No. 13 to set the indoor unit No. with the , (SET TEMP) button. g Set the indoor unit No. which you want to set with the , ( ) button.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

Ex.Indoor unit No. 4 will be set.

In this example, indoor unit address (UNIT No.) will be set 2–4.

h Press the SET button.

UNIT No., CODE No. 13, state.

SETTING

0370_M_I

and SET DATA (0004) change from flashing to ON

SM830076

– 84 –

4. Service procedures

i Select the code No. 14 to set group setting with the , (SET TEMP) button. j Set the No. of group setting as shown below with the , ( ) button.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

0371_M_I

Nos. of group setting.

0 : Standard system (except group

control)

1 : Main indoor unit in case of group

control

2 : Sub indoor unit in case of group

control

99: No setting (at factory shipment)

k Press the SET button.

UNIT No., CODE No. 14,

SETTING

and SET DATA change from flashing to ON state.

l If you made a mistake, press the CL button so that setting returns to the initial state. m Press the TEST / CHK button to finish this mode.

The display is disappeared.

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

OFF button.

Section

o Finally, remove the short circuit of DISP PIN.

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

– 85 –

SM830076

Section

4. Service procedures

(J) Change the period of the filter timer

❏ If the period of filter timer is not suitable (for example in case of dirty environment), the

period can be shortened to half as follows:

a Press the TEST / CHK button for more than 4 seconds.

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

SETTING

SET

OFF••

MODE

SET TEMP.

No.CODE

FAN SPEED

DATA

TEST / CHK

0213_M_I

b In case of group control, if you want to change all units in group control collectively,

proceed next step remaining “ALL” displayed. If you want to change a unit individually, select the indoor unit address (UNIT No.) with UNIT button.

c Select the CODE No. 02 with , (SET TEMP) button. d Change the No. from 0 to 1 with , ( ) button.

EX:

AIR FLOW

UNIT

FLAP

TIMER SET

SET CL

UNIT No.

R.C. No.

No.CODE

SET TEMP.

SETTING

SET

DATA

ON OFF••

MODE

SET TEMP.

FAN SPEED

TEST / CHK

UNIT No. 1–6 CODE No. 02 K type 150 hr

→

75 hr

0214_M_

e Press the SET button.

CODE No. 06, SET DATA and

SETTING

change from flashing to ON state.

f If you made a mistake, press the CL button. g Finally, press the TEST / CHK button.

– 86 –

SM830076

4. Service procedures

Copper tube or metallic part

Clip

Insulation tester

Probe

Terminal plate

0639_X_S

4-2 Checking the Electrical Components

(1) Measurement of Insulation

Resistance

•

The electrical insulation is acceptable when the resistance exceeds 1 MΩ.

1 Power Supply Wires

Clamp the earthed wire of the Power Supply wires with a lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the power wires. (Fig. 21)

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

2 Indoor Unit

Clamp an aluminum plate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on the terminal plate (Fig. 22)

Probe

Clip

Earthed wire

Insulation tester

0638_X_S

Fig. 21

Section

3 Outdoor Unit

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

Measurement of Insulation Resistance

for Electrical parts

• Disconnect the connector of the

desired electric part from terminal plate, P.C.B. Ass’y, etc. (Fig. 23)

• Similarly, disconnect the lead wires

from compressor, capacitor, etc. (Fig. 24)

• Measure the resistance in the same

manner as illustrated on the right. Refer to Electrical Wiring Diagram.

NOTE

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

Copper tube or metallic part

Metallic part

Clip

Insulation tester

From fan motor, compressor and other parts.

Probe

0640_X_S

Fig. 22

Fig. 23

– 87 –

Insulation tester

0641_X_S

Fig. 24

SM830076

Section

4. Service procedures

(2) Checking the Protective Devices

• Disconnect the connector, which consists of P (plug) and S (socket) when you want to

check the protective device.

• Then check continuity among plug’s (and/or socket’s) terminal as in Fig. 25.

• Normality of the protective device can be judged by the following table.

The Protective Device is proved normal if there is a continuity between terminals.

socket

Multimeter

Ω

0642_X_S

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

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

• Check the socket’s terminals.

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

• Disconnect the wires from terminals of compressor.

• Check the terminals of compressor.

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

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

Fig. 25

• Check socket’s terminal.

– 88 –

SM830076

4. Service procedures

(3) Checking the Electrical Parts

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

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

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

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

(RED lead wires).

14.8V ; Measure the resistance between No.3 and No.4 (BRN lead wires).

Refer to “1-3 Other component specifications”.

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

• Primary 230-208V ; Measure the resistance between No.1 and No.3 (WHT lead wires) terminals of 3P(WHT) socket jointed to power transformer.

• Secondary 14 V ; Measure the resistance between No.1 and No.2 (BRN lead wires).

Refer to “1-3 Other component specifications”.

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

• Measure the resistance between each terminal of 7P (WHT) socket and 3P (YEL)

socket connected to the indoor fan motor.

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

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

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

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

Section

– 89 –

SM830076

Section

1042_X_S

Fuse

4. Service procedures

5 Motor capacitor ............ Both in indoor and outdoor unit

• Remove the lead wires from the capacitor terminals, and then place a probe on the capacitor terminals as shown in Fig. 26. Observe the deflection of the pointer, setting the resistanc measuring range of the multimeter to the maximum value.

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

NOTE

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

Multimeter

Ω

6 Continuity of fuse on P.C.B. Ass’y

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

NOTE

Method Used to Replace Fuse on PCB Ass’y

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

2. Remove the fuse from PCB Ass’y using pliers while heating the soldered leads on the back side of the PCB Ass’y with a soldering iron (30W or 60W). (Fig. 28)

3. For replacement, insert a fuse of the same rating to the intended position and solder it. (Allow time to radiate heat during soldering so that the fuse does not melt.)

Compressor motor capacitor

Fan motor capacitor

Soldering iron

PCB Ass’y

Fuse Varistor

1041_X_S

Fig. 26

Fig. 27

CAUTION

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

Pliers

1043_X_S

Fig. 28

SM830076

– 90 –

4. Service procedures

7 Solenoid coil of the electronic refrigerant *Measure the coil resistance.

control valve (ERCV) ………… Indoor unit

Measure the resistance between No. 5 (GRY lead wire) and other terminals (another color of

• lead wires) of 5P (WHT) plug connected to the solenoid coil.

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

8 Compressor motor (CM) ……… Outdoor unit *Measure the coil resistance.

• In case of single -phase compressor Remove the cover of compressor terminal and measure the resistance

between terminals.

Refer to “1-2 Major component specifications”.

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

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

Refer to “1-3 Other component specifications”.

• Check the continuity between contactors.

MODEL Push button on

the magnetic contactor

no press press

R – U S – V T – W 31 – 32

–––– –––– –––– YES

YES YES YES ––––

FMCA–1UL

Pair of terminals

Section

0 Solenoid coil of 4-way valve (20S) … Outdoor unit

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

Refer “1-3 Other component specifications”.

– 91 –

*Measure the coil resistance.

SM830076

Section

4. Service procedures

(4) Sensor and Solenoid Layout Diagram

Indoor Unit

• XHS2432

Electronic expansion valve

TH2 (E1), (RED)

TH3 (E2), (BLK)

1582_X_I

Outdoor Unit

• CH2432

TH6, 7, 8

TH8 (GRN) ( Discharge gas)

1153_THS_I

63PH

20S

TH8 (GRN)

TH6 (C1), (BLK)

TH7 (C2), (RED)

– 92 –

1154_THS_I

SM830076

(4) Sensor and Solenoid Layout Diagram

Indoor Unit

• XHS3632

TH2 (E1), (RED)

4. Service procedures

Electronic expansion valve

Outdoor Unit

• CH3632

20S

TH6, 7, 8

TH3 (E2), (BLK)

Section

1583_X_I

TH7 (C2), (RED)

63PH

TH8 (GRN) ( Discharge gas)

0584_C_S

TH6 (C1), (BLK)

0585_C_S

SM830076

– 93 –

(5) Thermistor Characteristic Curve

4. Service procedures

Section

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

9 8 7 6 5

Resistance (kn )

4 3 2 1

50 59 68 77 86 95 104

Temperature (°F)

1044_M_I

(2) Indoor heat exch.

coil sensor : TH2(E1), TH3(E2) Outdoor heat exch. coil sensor : TH6(C1), TH7(C2)

( PBC-41E)

Resistance (kn )

–4 5 14233241505968

Temperature (°F)

1045_M_I

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

Resistance (kn )

176 194 212 230 248 266

Temperature (°F)

– 94 –

1149_THS_I

SM830076

4. Service procedures

(6) P.C.B. Setting

● Setting of outdoor control P.C.B.

(A) Standard control (single outdoor unit)

In case of single outdoor unit installation, no indoor unit’s setting is necessary for twin, triple or quartet types (2, 3 or 4 indoor units). Leave R.C. address setting at “0” as factory shipment state.

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

(B) Group control (Multiple outdoor units)

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

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

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

In case of central control (when using the system controller,that is, when linking outdoor units in a network), (a) Before turning the power supply on, set the R.C. address with S2, S3 on the outdoor

control P.C.B..

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

unit.

Section

Regarding the example of R.C. address for central control and the position of CN4, please refer to R.C. Address Setting Method. * Temperature displaed on both controllers are not °F but °C.

● Setting of indoor control P.C.B.

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

Indoor unit No. Refrigerant Circuit No. (R.C. address)

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

– 95 –

SM830076

4. Service procedures

ON side

OFF side

ON side

OFF side

ON side

OFF side

ON side

OFF side

ON side

OFF side

ON side

OFF side

(7) R.C. Address Setting Method

Outdoor unit R.C. address setting method

In case of group control or central control, set the R.C. address to 1, 2, 3, ... according to the No. of outdoor units.

Outdoor control PCB

Section

Refrigerant circuit address

CN4 (2P Black)

(factory setting = 0) Refrigerant circuit address (black)

: S2

Refrigerant circuit address (2P DIP switch, green or Blue)

position

ON side

OFF side

: S3

A. ADD (S1): Automatic address setting start button Used for central control (link system) and group control (Normally, not used)

1126_C_I

position

R.C. address R.C. address

R.C. address

00 auto address

(“0” when shipped from factory)

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

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

– 96 –

Both 10’s and 20’s

Set to 0

SM830076

4. Service procedures

(8) Automatic Address Setting Method

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

Carry out automatic address setting with the remote controller.

1) All auto. address operation 1 Press the TEST / CHK and ( )

buttons at the same time for more than 4 seconds.

2 Press the SET button after

confirming the CODE No. AA (CODE No. AA: All Auto. address operation).

After addresses are automatically set in order for the outdoor units from No. 1 to No. 30, the system returns

to the normal stopped state.

2) Individual auto. address operation for each refrigerant circuit 1 To select each refrigerant circuit

individually and set addresses automatically, press the TEST / CHK and ( ) buttons at the same time for more than 4 seconds, then press the , (SET TEMP) button once to set CODE No. A1. (CODE No. A1: Auto. address operation)

2 Select R.C. No. which you want to

execute the auto. address operation with UNIT button.

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

4 If the error occurred during the

operation, the alarm message will be displayed. Check and remove the cause. If you want to interrupt the operation, press the CL button then the unit stands in waiting mode (Press the SET button).

5 If the auto. address operation

finishes, the display will disappear.

NOTE

Required time for auto. address operation:

In case of group control : a few minutes for

each R.C.

In case of central control

(9) Displaying Indoor / Outdoor Unit

Combination Numbers

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

1) When installing multiple units, match the indoor unit address numbers and the outdoor R.C. address numbers and display them at an easy-to-check location (near the nameplate) with an oil-based magic marker or other indelible marker so that the individual indoor and outdoor unit combinations can be checked.

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

1-3, ....

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

2-3, ....

2) Displaying indoor / outdoor unit address is necessary for maintenance. Always label numbers. *Check indoor unit address with the remote controller. Press the TEST / CHK button for at least 4 seconds and check the indoor unit address with the UNIT button. (Each time you press the UNIT button, the address changes 1-1, 1-2, ... 2-1, 2-2, ...) The fan for only the selected indoor unit turns on at high speed, so check which indoor unit runs and label the indoor unit address. (If there is 1 outdoor unit, the addresses are 1-1, 1-2, ...)

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

: max. about 20

min. for each R.C.

Section

6 Execute the operation of the other

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

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

– 97 –

SM830076

(10) Items to Check Prior to Test Run

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

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

4. Service procedures

Section

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..

S4 (green or Blue) capacity code (4P DIP switch)

ON side

Outdoor control PCB

2 3 4

S4. Capacity code

No. Outdoor PCB Model No. 1 2 3 4 24 type (1 phase) ON ON ON OFF 36 type (1 phase) OFF ON OFF ON

OFF side

1127_C_I

SM830076

– 98 –

(11) Test Run

(11)-1. Preparing for Test Run

4. Service procedures

Before starting the air conditioner, check the followings:

(1) Remove all loose matter from the cabinet espe-

cially metal filings, bits of wire, and clips.

(2) Connect the control wiring correctly and tighten

all electrical connections.

(3) Remove the protective spacer for the compressor

used for transportation.

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

hours before starting the compressor. The bottom of the compressor should be warm to the touch and the crankcase heater around the feet of the compressor should be hot to the touch. For Ceiling mounted and Recessed Type indoor units, the flap(s) move(s) for one minute when the power is connected to the unit. This is not the malfunction.

(5) Open both the wide and narrow tube service

valves after air purge.

(6) Remove the transportation cardboard protection

for the indoor fan.

All OFF for initial settings.

ON OFF

ADDRESS SWEEP

1. TEST RUN(ON)

2. PCB CHK.(ON)

3. RCU MAIN(OFF) / SUB(ON)

4. OFF

NORM. HOLD

Air filter

ON • I OFF•O

Fig. 11-1

Operation selector

1 2 3 4

1. TEST RUN

2. (OFF)

3. (OFF)

4. (ON)

Air intake grille

1584_M_I

Section

(11)-2. Performing Test Run

Be careful since the fan will

CAUTION

start when performing Test Run.

For XHS models

(1) For XHS models, the Operation Selector is located

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

(2) Set the TEST RUN switch of the SERVICING

switches on the Operation Selector (housed

inside

the indoor unit) to the ON position. (Fig. 11-1)

(3) Press the ON/OFF operation button on the

remote control unit and start the air conditioner in Cooling or Heating mode.

(4) Let the unit run for about 30 minutes and check

that the unit operates normally.

(5) After the test run, be sure to set the TEST RUN

switch back to the OFF position to cancel the test run mode. Then stop the air conditioner.

– 99 –

SM830076

Section

Important

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

The TEST RUN switch is used

CAUTION

NOTE

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

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

only for servicing the air conditioner. DO NOT use this switch for normal operation. Otherwise, it may put stress on the system.

4. Service procedures

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

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

– 100 –

SM830076

Sanyo CH2432, XHS3632, CH3632, XHS2432 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual