SERVICE MANUAL FILE NO. XHS2432 / CH2432 XHS3632 / CH3632 Section SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No. PRODUCT CODE No. XHS2432 854 013 40 CH2432 854 013 42 XHS3632 854 015 45 CH3632 854 014 57 Indoor Unit OUTDOOR MODEL No. PRODUCT CODE No. 1 Outdoor Unit 2 3 85464849176000 XHS2432 CH2432 XHS3632 CH3632 REFERENCE NO.
Important Please Read Before Starting When Installing …………………………………………………………………… 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. …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.
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.
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 .......................................................................
Introduction: Read Me First! WHAT IS IN THIS MANUAL 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.
1. SPECIFICATIONS 1-1 1-2 1-3 1-4 1-5 1-6 Unit Specifications ...........................................................................................7 Major Component Specifications .................................................................. 11 (A) Indoor Unit ................................................................................................11 (B) Outdoor Unit .............................................................................................
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 Capacity* Heating BTU / h 24,000 23,400 Moisture removal (High) Pints / h 8.6 8.4 Air circulation (Hi) cu.ft. / min. S.E.E.R. (H.S.P.F.) BTU / Wh 10.0 Voltage rating VAC 230 Available voltage range VAC 25,000 16,400 (17°F)** 24,300 15,800 — 540 / 510 10.2 (7.0) 208 230 (7.
1. Specifications 1-1 Unit Specifications DIMENSIONS & WEIGHT Unit dimensions Indoor unit 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) lbs. (kg) 49 (22) in. (mm) 3-1/16 (78) Net weight Indoor grille dimensions PNR-XHS2432 Height 1 Package dimensions in. (mm) 33-27/32 (860) in. (mm) 33-27/32 (860) lbs. (kg) 11 Height in. (mm) 11-6/32 (284) 32-17/32 Width in.
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 Capacity* Heating BTU / h 34,500 33,500 Moisture removal (High) Pints / h 11.1 11.1 Air circulation (Hi) cu.ft. / min. S.E.E.R. (H.S.P.F.) BTU / Wh 10.7 Voltage rating VAC 230 Available voltage range VAC 37,500 25,000 (17°F)** 36,500 23,500 — 980 / 880 11.0 (7.0) 208 230 (7.
1. Specifications 1-1 Unit Specifications DIMENSIONS & WEIGHT Unit dimensions Indoor unit in. (mm) 11-1/32 Width in. (mm) 41-11/32 (1,050) Depth in. (mm) 29-29/32 (760) lbs. (kg) 60 (27) in. (mm) 3-1/6 (78) Net weight Indoor grille dimensions PNR-XHS3632 Height 1 Package dimensions Width in. (mm) 33-27/32 (1,150) in. (mm) 33-27/32 (860) lbs. (kg) 15 Height in. (mm) 12-14/32 (316) Width in. (mm) 43-27/32 (1,114) Depth in. (mm) 32-25/32 (833) lbs.
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 Fan (Number … diameter) CR - 3XHS 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.
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 Fan (Number … diameter) CR - 3XHS in. (mm) Turbo (1…19-9/32 (490)) Fan motor 1 Model SFG6X - 61A3P Source 230 - 208 V / 1 phase / 60 Hz No. of pole … r.p.m.
1. Specifications 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.
1. Specifications 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 1 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.
1. Specifications 1-3 Other Component Specifications (A) Indoor Unit MODEL No. XHS2432 Power Transformer Rated ATR – II174B 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) Ω Thermistor cut off temperature °F WHT - WHT , BRN - BRN : 0.42 PBC - 41E - S26 kΩ 14 °F : 23.7 23 °F : 18.8 32 °F : 15.
1. Specifications 1-3 Other Component Specifications (A) Indoor Unit MODEL No. XHS3632 Power Transformer Rated ATR – II174B Primary 220 VAC, 60 Hz Secondary 14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA Capacity 1 — Coil resistance (Ambient temprature 77 °F) Ω Thermistor cut off temperature °F WHT - WHT 2 , BRN - BRN : 0.42 PBC - 41E - S36 kΩ 14 °F : 23.7 23 °F : 18.8 32 °F : 15.
1. Specifications 1-3 Other Component Specifications (B) Outdoor Unit MODEL No. CH2432 Compressor Motor Magnetic Contactor FMCA - 1UL Coil rated Coil resistance (at 77 °F) 240 VAC, 60 Hz Ω 580 ± 15 % Contact rated (Main) 230 VAC, 20 A Contact rated (Auxiliary) 230 VAC, 3 A Power Relay HH62S Coil rated Coil resistance (at 77 °F) 240 VAC, 60 Hz kΩ 17.2 Contact rated 220 VAC, 5 A Power Transformer ATR - I65C 1 Rated Primary 220 VAC, 60 Hz Secondary 14 V, 0.4 A Capacity 5.
1. Specifications 1-3 Other Component Specifications (B) Outdoor Unit MODEL No. CH3632 Compressor Motor Magnetic Contactor FMCA - 1SUL Coil rated Coil resistance (at 68 °F) 240 VAC, 60 Hz Ω 588 ± 10 % Contact rated (Main) 240 VAC, 26 A Contact rated (Auxiliary) 240 VAC, 3 A Power Relay HH62S Coil rated 1 Coil resistance (at 77 °F) 240 VAC, 60 Hz 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 2 5.
1. Specifications 1-4 Dimensional Data (A) Indoor Unit: XHS2432 8-21/32 8-1/16 4-29/32 14 13-3/8 6-25/32 3-15/16 X-view • Remote controller (Accessory) 23/32 19/32 2-13/32 1 4-29/32 5-29/32 7-7/8 10-1/32 32-9/32 (Ceiling opening) 11-23/32 8-1/16 6-1/2 23-7/32 (Suspention bolt pitch) 1-3/16 2 33-27/32 19-11/16 1-3/8 14 3 33-27/32 19-11/16 29-29/32 3-15/16 4 1/2 Grille center X 12 13-2/4 28-3/4(Suspention bolt pitch) 32-9/32 (Ceiling opening) 1/2 1-7/8 1/2 4-29/32 Min.
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1. Specifications Dimensional Data (B) Outdoor Unit: CH2432 4-21/64 15-3/4 13-3/8 14-31/32 1-31/32 13/32 26 1-31/32 1-3/16 6-11/16 1 37 2 12-1/16 11 28-15/16 1-4 3 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.
1. Specifications 1-4 Dimensional Data (B) Outdoor Unit: CH3632 4-21/64 15-3/4 13-3/8 14-31/32 1-31/32 13/32 26 1-31/32 1-3/16 6-11/16 1 37 23-29/32 3 22-27/32 48-5/8 2 Dimension : inch 4 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.
1. Specifications 1-5 Refrigerant Flow Diagram Outdoor Unit: CH2432 Indoor Unit: XHS2432 Compressor Accumulator Accumulator Gas line service valve Gas line nipple O.D. 3/4" (19.05mm) HP High pressure switch 1 Muffler 4-way valve EC Heat exchanger EC P Heat exchanger Distributor P Strainer Electronic ref.control valve Distributor Liquid line service valve M O.D. 1/4" (6.
1. Specifications 1-5 Refrigerant Flow Diagram Outdoor Unit: CH3632 Indoor Unit: XHS3632 Compressor Accumulator Accumulator Gas line service valve 1 Gas line nipple O.D. 3/4" (19.05mm) HP High pressure switch Muffler 4-way valve EC Heat exchanger EC P Heat exchanger Distributor P 2 Strainer Electronic ref.control valve Distributor Liquid line service valve M O.D. 3/8" (9.
1. Specifications 2. Processes and functions 2. PROCESSES AND FUNCTIONS 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 Room Temperature Control .......................................................................... 26 (A) Cooling .....................................................................................................26 (B) Heating .....................................................................................................
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.
1. Specifications 2. Processes and functions (B) Heating THERMO. ON REMOTE CONTROL SENSOR (Only for wireless remote controller) SET. +2°F SETTING TEMP. SET. –2°F THERMO. ON THERMO. OFF THERMO. OFF THERMO. ON THERMO. OFF BODY SENSOR THERMO. ON THERMO. OFF THERMO. ON THERMO. ON +2°F SET TEMP.+7°F SHIFT –2°F Section 1 SET TEMP.
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).
1. Specifications 2. Processes and functions 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 Section ROOM TEMP. (deg) +3 1 +2 +1 SET TEMP. INDOOR FAN SPEED H M L M H 2 H : High L : Low M : Middle LL: Very low 0433_M_S Fig.
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.
1. Specifications 2. Processes and functions 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 Section 1 INDOOR UNIT TEMP. 34 32 31 30 CONTINUOUS DETECTION FOR 2 MINUTES (°F) ELECTRONIC REF. CONTROL VALVE SIGNAL COMPRESSOR OPEN 2 OPEN ON MINIMUM 3 MINUTES ON 1138_THS_I 3 Fig.
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 Section OUTDOOR UNIT COIL TEMP. C2 (°F) 131 1 OUTDOOR FAN SPEED ELECTRONIC REF. CONTROL VALVE H, M FORCED H H, M OPEN 2 1139_THS_I Fig.
1. Specifications 2. Processes and functions 2-7 Overload Protection (Heating) This function prevents the air conditioner from overloading. (°F) 147 144 Section 140 INDOOR UNIT COIL TEMP. (E2) 138 1 131 127 OVERLOAD PROTECTION OVERLOAD PROTECTION FUZZY CONTROL ELECTRONIC REF. CONTROL VALVE OUTDOOR FM FUZZY CONTROL 2 OPEN OPEN START UP COMPENSATION OFF H OR M H M H OR M 1140_THS_I 3 Fig.
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) 1 2 194 185 OUTDOOR FAN SPEED H OR M COMPRESSOR ELECTRONIC REF. CONTROL VALVE (DISCHARGE TEMP.) H OR M M ON OPEN OPEN TRIP IS OPERATED. 1141_THS_I 3 Fig. 11 Chart Summary and Explanations 4 ❑ Discharge temperature is sensed by TH8 (discharge gas sensor).
1. Specifications 2. Processes and functions 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.
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.
1. Specifications 2. Processes and functions 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 OUTDOOR COIL TEMP.
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.
1. Specifications 2. Processes and functions (B) AUTO Control Mode ON POWER SOURCE OFF OPERATION BUTTON ON MORE THAN 10 MINUTES (THERMO. OFF) AUTO COOL MODE CONTROL HEAT MORE THAN 10 MINUTES (THERMO. OFF) COOL Section HEAT HEAT 1 THERMO. OFF THERMO. ON 3 MINUTES COMPRESSOR OFF MORE THAN 3 MINUTES ON OFF ON OFF MORE THAN 30 – 50 SECONDS SOLENOID COIL (4-WAY VALVE) OFF ON ON OFF MORE THAN 30 – 50 SECONDS ON OFF 2 ON 0445_M_S Fig.
2. Processes and functions 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) Section Model 1 2 3 Min. open Max.
1. Specifications 2. Processes and functions 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.
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.
1. Specifications 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.
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3. Electrical data 3. ELECTRICAL DATA 3-1 3-2 Indoor Unit (Electric Wiring Diagram, Schematic Diagram) ............................... 46 Outdoor Unit (Electric Wiring Diagram, Schematic Diagram).............................
1 2 Earth Terminal 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 7 5 3 1 Connector 9P(WHT) 49FI 1 3 CONT 1 2 3 4 CD SG 12V G WL(BLU) FS Earth Terminal GRN/YEL DP MOV TR1 TH1 TH3 PNL (GRN) 1 2 3 ORG W 854-2-5268-772-00-0 (XHS) TH2 1 2 1 2 1 2 1 2 3 4 1 3 1 2 3 4 5 (BLK) Coil E2 1 3 (RED) Coil E1 1 3 (YEL) Room Temp 1 3 Earth Terminal Connector 3P(WHT) BLK BLK SEC(WHT) 1 2 3 1 2 3 LM (GRN) P S BLK BLK PRY(WHT) R N 6 6 Connector 6P(WHT) Controller (CR-THS2432) 49FI(GRY) P 1
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1 C B 52C CT A WHT RED RED U R R S 32 31 BLK WHT RC1 V W S T CM RED 2 WHT RED PTC Earth G L1 L2 Terminal Terminal Plate (5P) G CH P 1 2 Connector S 1 2 2P (WHT) ORG GRY 3 5 8 1Y 1 4 6 2 WHT BRN Earth Terminal BLK 7 BLU PNK GRN/YEL Relay BLK RED BRN GRN/YEL To Indoor Unit U1 U2 Terminal 1 2 Plate (2P) RED Power Supply RC2 3P(WHT) CT1 1 3 3P(BLK) 52C 1 3 FMO 49FO GRN/YEL Earth Terminal 3P(YEL) 20S 1 3 Controller (CR-CH2432) 9P(WHT) CN24 1 3 5 7 9 Conn
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1 A C B 52C RED CT RED WHT U R S CM R 32 31 BLK WHT RC1 V W S T BLK 2 WHT RED RED WHT PTC Earth G L1 L2 Terminal Terminal Plate (5P) ORG GRY CH P 1 2 Connector S 1 2 2P (WHT) FMO1 GRN/YEL 49FO1 BRN Earth Terminal Connector 1 2 3 4 5 6 7 8 P 8P (WHT) 1 2 3 4 5 6 7 8 S RC2 Earth Terminal 3 CT1 1 3P (WHT) BLK BLK 2 CN2 1 2P (BLU) 3 SUP 1 3P (BLU) GRN/YEL BLU PNK BRN RED GRN/YEL To Indoor Unit U1 U2 Terminal 1 2 Plate (2P) RC3 3P(BLK) 52C 1 3 9P(WHT) CN24 1 3 5
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4. Service procedures 4. SERVICE PROCEDURES 4-1 4-2 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 ..................
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 Section 1 2 3 4 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.
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 .
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 Section a.
4. Service procedures (B) Heating b. Heating Poor heating Is setting temp. suitable ? Change the setting temp. Is heating load too large ? Review heating load estimate. Section Refrigerant flow failure 1 4-way valve is defective. Replace the valve. Refrigerant shortage Charge with refrigerant. Electronic refrigerant control valve is defective. Replace the valve. Compressor is defective. Replace the compressor. Service valves are not fully open. Open the valves fully.
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).
4. Service procedures Wired remote Wireless remote controller controller display display Possible causes of troubles • Thermistor failure Indoor thermistor is either open or short. Outdoor thermistor is either open or short. Indoor coil temp. (E1) cannot be detected. F01 Indoor coil temp. (E2) cannot be detected. F02 Operation lamp and heat stand-by lamp flash alternately. Indoor room temperature cannot be detected. F10 O: Operation lamp Discharge gas temp. cannot be detected.
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. LED 2 on LED 1 on Remote P.C. board P.C. board controller Section 1 Possible cause of trouble v v No message v V E06, E07, L04 v * No message V v P02 V V P04, P05 V * F04~F09 Sensor is abnormal.
4. Service procedures (5) 1) Symptoms and parts to inspect Symptom: LCD on the remote controller does not display and remote controller does not operate.
4. Service procedures 2) Symptom: LCD on the remote controller displays “CHECK E01”. (Unusual communication between remote controller and indoor unit.) Start Remote controller judges itself with self-diagnostic functions NG Replace the remote controller. OK Section 1 Is there an open or a contact defect in the No. 1 line of the remote controller? Yes Correct the wiring.
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.
4. Service procedures 6) Symptom: LCD on the remote controller is displaying “CHECK E06”. (Unusual communication between the indoor and outdoor units) Start Is the setting for the indoor address on the indoor unit PCB inappropriate? Yes Correct the setting. No Is there a cut line or contact defect between an indoor and outdoor unit’s control line? Section Yes Correct wiring.
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 No Section Yes Is there 230-208 V AC between T20-3 and S4 after T20-1 and T20-3 on the indoor unit PCB shorted? No Is the indoor fan wire winding protection thermostat (49FI) off? Correct the connection 1 Yes No Replace the indoor fan. Replace the indoor unit PCB.
4. Service procedures 10) Symptom: LCD on the remote controller displays “CHECK P02”. (Compressor / outdoor fan protection thermostat operation warning / power supply voltage abnormality) Start Section Is the power supply to the outdoor No unit normal? (Voltage / defective phase?) Check the power breaker etc. and repair. Yes 1 Is the fuse on the outdoor unit PCB blown (F1 and F2)? Yes Replace the fuse. No 2 Is the high voltage switch (63 PH) off? Yes Replace the outdoor unit PCB.
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) Section 1 0343_M_I 12) Symptom: LCD on the remote controller displays “CHECK P04”. (High-pressure switch activation warning) 2 Start The system does not operate again.
4. Service procedures 13) Symptom: LCD on the remote controller displays “CHECK P05”. (Negative phase detection operation warning) Start Is the power supply to the outdoor unit normal? (Voltage defective phase?) No Check the power breaker etc. and repair Yes Section 1 Does the outdoor unit operate when two of the three phases are changed? (Actuation of negative phase protector) Yes No problem No Is the fuse (F1, F2) on the indoor unit PCB blown? Yes Replace the fuse.
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? Yes Repair the wiring. No Section Are the total capacities of indoor units to that of outdoor units more than 107%? Yes Select indoor units which match with the outdoor capacity. 1 No Confirm less than 5 indoor units are connected.
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.
4. Service procedures (6) Procedures When a Specific Component Does Not Work 1) Indoor fan does not operate. Is fan motor capacitor normal ? No Replace the capacitor. Yes Is there voltage output of P.C.B. Ass'y for fan motor ? No Replace the P.C.B. Ass'y in the indoor unit. Section Yes 1 • Check resistance of fan motor winding. Out 2 Replace the fan motor. 0650_M_S 2) Flaps in indoor unit’s air outlet does not operate, when you press SWEEP button. No Check the louver motor resistance.
4. Service procedures 3) Compressor motor does not operate. Does compressor motor magnetic No Replace the compressor contactor (52C) actuate ? motor magnetic contactor. Yes Check resistance of compressor motor winding. Section NG 1 Replace the compressor. 0461_M_I 4) 2 Outdoor fan does not operate. Are auxiliary relays (1Y) normal ? No Replace the relays. Yes 3 Is fan motor capacitor normal ? Replace the capacitor. Yes Is there voltage output of P.C.B.
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.
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.
4. Service procedures (C) Check the sensor temperature readings 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.
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 Sensor Address (CODE No.) Indoor Unit Section 1 01 02 03 04 05 06 07 08 09 Outdoor Unit 0A 0B 0C 0D 0E 0F 10 11 12 13 14 2 Location of Sensor (Themistor) TH1 TH2 TH3 TH8 TH7 TH6 — Indoor air suction Temp. Indoor coil Temp. (E1) Indoor coil Temp.
4. Service procedures This picture shows the service check display. UNIT No. UNIT No. 1–1 R.C. No. Refrigerant Circuit No. No. CODE No. CODE No. CHECK Alarm message Section SERVICE 0358_M_I c. A maximum of 4 alarm messages can be accessed by pressing either SET TEMP button or as follows. MODE Past SET TEMP. Present NOTE Pressing CL (Clear) button will clear all the service history. 2 Present ... accessed in order of “Past È Present”. Past FAN SPEED ...
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 1 After checking the alarm messages, be sure to press the TEST / CHK button.
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 ( b Set CODE No. A1 with (SET TEMP) button. AIR FLOW UNIT FLAP , Section In this mode, the auto. address operation is executed at each R.C. (Refrigerant Circuit) line one by one. MODE R.C. CODE No.
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 Section AIR FLOW UNIT FLAP 1 ( ) buttons at the same time for more than 4 seconds. MODE R.C. CODE No. SET TEMP. TIMER SET FAN SPEED SETTING SET DATA SET CL ON • OFF • TEST / CHK 2 0362_M_I b Select the R.C. No.
4. Service procedures e Set the required new indoor unit’s No. by pressing the AIR FLOW UNIT FLAP , ( ) button. MODE R.C. Ex: UNIT No. 3-6: currently registered indoor unit address No. CODE No. SET TEMP. TIMER SET FAN SPEED SETTING SET DATA SET Required new indoor No.8: SET DATA Section CL * ON • OFF • TEST / CHK In this case, UNIT No. 3 – 6 (current) = 3 – 8 (NEW : after pressin the TEST / CHK button) 1 0364_M_I f Press the SET button.
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.
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.
4. Service procedures d Set the No. of R. C. which you want to set with AIR FLOW UNIT FLAP , ( ) button. Ex. No. of R. C. will be set 2. MODE UNIT No. R.C. No. SET TEMP. CODE No. TIMER SET FAN SPEED SETTING SET DATA Section SET CL ON • OFF • TEST / CHK 1 0369_M_I e Press the SET button. UNIT No., CODE No. 12, 2 3 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.
4. Service procedures i Select the code No. 14 to set group setting with the j Set the No. of group setting as shown below with the AIR FLOW UNIT FLAP No. CODE No. SET TEMP. TIMER SET FAN SPEED SETTING SET DATA SET (SET TEMP) button. , ( ) button. 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) MODE UNIT No. R.C.
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 MODE UNIT No. R.C. No. CODE No. Section SET TEMP.
4. Service procedures 4-2 Checking the Electrical Components (1) Earthed wire Clip Measurement of Insulation Resistance • 1 The electrical insulation is acceptable when the resistance exceeds 1 MΩ. Probe Insulation tester Power Supply Wires 0638_X_S 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.
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 Section 1 Multimeter Ω 2 Fig.
4. Service procedures (3) Checking the Electrical Parts 1 Power transformer (TR1) ..................... Indoor unit • Primary • Secondary *Measure the coil resistance. 230-208V ; Measure the resistance between No.1 and No.3 (WHT lead wires) terminals of 3P (WHT) socket connected to power transformer. 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). Section 1 Refer to “1-3 Other component specifications”.
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.
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.
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4. Service procedures (5) Thermistor Characteristic Curve (2) Indoor heat exch. coil sensor : TH2(E1), TH3(E2) Outdoor heat exch. coil sensor : TH6(C1), TH7(C2) (1) Room temp. sensor : TH1 (KTEC-35) ( PBC-41E) 40 Section 1 9 30 8 Resistance (kn ) Resistance (kn ) 2 35 10 7 6 5 4 3 25 20 15 10 2 5 1 0 –4 50 59 68 77 86 95 5 104 14 23 32 41 Temperature (°F) 50 59 68 1045_M_I Temperature (°F) 3 1044_M_I (3) Compressor discharge gas temp.
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.
4. Service procedures (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 CN4 (2P Black) Refrigerant circuit address (factory setting = 0) Section Refrigerant circuit address (black) 0 1 : S2 Refrigerant circuit address (2P DIP switch, green or Blue) 10 20 position position ON ON side A.
4. Service procedures NOTE (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.
4. Service procedures (10) Items to Check Prior to Test Run Section 1 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. 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..
4. Service procedures (11) Test Run (11)-1. Preparing for Test Run Before starting the air conditioner, check the followings: (1) (2) (3) (4) (5) (6) All OFF for initial settings. ON OFF Remove all loose matter from the cabinet especially metal filings, bits of wire, and clips. Connect the control wiring correctly and tighten all electrical connections. Remove the protective spacer for the compressor used for transportation.
4. Service procedures Important Set the Operation Selector at the “ON” position. Otherwise the unit will stop or will not run correctly. CAUTION The TEST RUN switch is used only for servicing the air conditioner. DO NOT use this switch for normal operation. Otherwise, it may put stress on the system. Section 1 NOTE ● During the test run, all of the 3 indicator lamps on the indoor unit will flash.
4. Service procedures (11)-3. Test Run Procedure Start Multiple remote control? Yes Turn on RCU address SW of sub remote control unit No Recheck the test items before test operation. Check the indoor and outdoor unit combination (wiring). Section Yes Single type? (One indoor unit and one remote controller for one outdoor unit) Multiple indoor units for one outdoor units? No No Group control for multiple outdoor units? No Go to next R.C.
4. Service procedures (12) P.C.B. and Parts Location ● P.C.B. (CR-THS2432) FOR INDOOR UNITS CN80 (RED) : 26H CN77 (GRN) : LM CN78 (BLU) : DP F2 : Fuse 250V / 3A CN74 (WHT) : PRY CN85 (BLU) : DPH CN73 (BLK) : SUP CN81 (GRY) : 49FI Section 1 F1 : Fuse 250V / 3A CN84 (YEL) : COM CN75 (WHT) : SEC 2 3 CN83 (WHT) : FMI JP1 (Jumper wire) : For sellecting the signal of T10.
4. Service procedures (12) P.C.B. and Parts Location ● P.C.B. (CR-CH2432) FOR OUTDOOR UNITS CN21 (YEL) : 20S CN23 (RED) : 63PH CN22 (BLK) : 52C CN20 (WHT) : PRY Section 1 F2 : Fuse 250V / 3A CR-CH2432 F1 : Fuse 250V / 3A CN19 (BLU) : SUP 2 CN3 (BRN) : SG2 CN2 (BLU) : SG1 S2 (BLK) : R.C. address F3 : Fuse 125V / 0.5A 0 2 ON CN12 (WHT) : CT1 3 2 1 S4 (GRN or BLU) : Capacity code ON S3 (GRN or BLU) : R.C.
4. Service procedures (13) Checking procedure for each P.C.B. The indoor and outdoor P.C.B. have functions to check the signal transmission and reception of the serial circuit and to check the microcomputer operation. (Self-diagnosis function) ● Precautions required when checking 1. After turning off the power to the indoor (outdoor) unit, remove the inter-unit control wiring (U1-U2) and create a short-circuit between U1 and U2. 2.
4. Service procedures (14) Check Pins When shorting check pins on the indoor and outdoor PCBs, operations shown on the above table will be performed on each indoor and outdoor unit. Use check pins to perform a quick check. NOTE • When checking pin operation, stop the indoor and outdoor units with the remote control unit. (14)-1. FORCED OPR pin of the indoor controller ● Switch the pin from normal operation to check operation • Relay RY6 turns ON ➞ Indoor fan motor operates at the “H” fan speed.
• The specifications, designs, and information in this brochure are subject to change without notice. SANYO FISHER Service Company CENTRAL REGION 1739 Sands Place, Suite G Marietta, GA 30067 Phone: (770) 951-8284 Fax: (770) 951-2077 Jan. / 2000 Printed in U.S.A.