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Sanyo CH2432 User's Manual

Contents

1. Description Symbols Description Compressor Motor TH6 Thermistor Outdoor Coil C1 Outdoor Fan Motor TH7 Thermistor Outdoor Coil C2 Compressor Motor Magnetic Contactor TH8 Thermistor Discharge Gas Outdoor Fan Motor Thermal Protector PTC PTC Thermistor High Pressure Switch CR CH2432 Outdoor Controller Current Transmitter RY1 RY4 Auxiliary Relay RC1 RC2 Running Capacitor 1Y Auxiliary Relay TR Power Transformer gt Terminal Plate Crank Case Heater Terminal GENEE 854 2 5268 582 00 2 CH2432 SM830076 49 3 Electrical data 3 2 Outdoor Uni CH3632 ZE9ESHO 0 00 129 892S 2 7S8 M 1 UHM d s z Le u A S Ong dz J0 98UUOD al z 1oj euuog L JUHM T3ANHO J3A NY9 20 67 or ON euw NA LA ANd o LHM 48 3 tr DA eolet AHE jini LHM AUD oo co o 40 98UU0D ke Nua a ut NHA AUD E AUD AND LA LHM 19 LHM ANd LHM zZ R zl Jaojpoeuuog 10J98UU09 LHM 48 LHM dz NYa N LHM 294 IAS de NH sed abieyosig a34 Es Ona 19 Add HdE9 UHM de aaH dE z vzH9 H9 sopronuog euwe yeg ANEN TIA NHO
2. Multimeter Compressor motor capacitor Fan motor capacitor Fig 26 Continuity of fuse on P C B Ass y e Check for continuity using a multimeter as shown in Fig 27 C Fuse NOTE Method Used to Replace Fuse on PCB Ass y 1 Remove the PCB Ass y from the electrical compo nent box CR Fig 27 2 Remove the fuse from PCB Ass y using pliers while Soldering iron 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 When replacing the fuse be Na sure not to break down the Pliers varistor 1043_X_S Fig 28 SM830076 90 4 Service procedures Solenoid coil of the electronic refrigerant Measure the coil resistance control valve ERCV Indoor unit e 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 Compressor motor CM Outdoor unit Measure the coil resistance e Incase of single phase compressor Remove the cover of compressor terminal and measure the resistance between terminals Refer to 1 2 Major component specifications Compressor
3. Is gt i Normal Operation Range Kos Geet value 0447_M_S Fig 18 o Model Rated Current Value Overload Protection Locked Compressor Cut off utdoor Mode Is A Is x 1 17 A Is x 1 4 A CH2432 17 1 20 0 23 9 CH3632 27 5 32 0 38 5 Chart Summary and Explanations Overload Protection e 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 HO1 compressor overload Locked Compressor Cut off e When the detected current is 1 4 times greater than the rated current value Is 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 e 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 e After 3 minute pause if the air conditioner is ready for Thermostat ON
4. LHM dE LLO na de dns de ald eue L en In Jun soopuy oL wejbeig BuniM 91119813 dg ald Ruuue Bula ME K pi ei ol AAA jddns Jamog vun 100pu OL SM830076 50 3 Electrical data 3 2 Outdoor Unit CH3632 U1 U2 Pin et Terminal CR CH2432 Plate 5P Controller 1 De 8 WD De Ge SEC Outd Bes Coil Ci CT Outdoor Coil C2 Discharge Gas O Symbols Description Symbols Description CM Compressor Motor TH6 Thermistor Outdoor Coil C1 FMO1 2 Outdoor Fan Motor TH7 Thermistor Outdoor Coil C2 52C Compressor Motor Magnetic Contactor TH8 Thermistor Discharge Gas 49FO1 2 Outdoor Fan Motor Thermal Protector PTC PTC Thermistor 63PH High Pressure Switch CR CH2432 Outdoor Controller CT Current Transmitter RY1 RY4 Auxiliary Relay RC1 2 3 Running Capacitor 1Y Auxiliary Relay TR Power Transformer E Terminal Plate CH Crank Case Heater Terminal OS 854 2 5268 621 00 0 CH3632 SM830076 _51 3 Electrical data SM830076 _52 4 SERVICE PROCEDURES 4 1 TSS SOO
5. OFF ON OFF ON OFF ON 3 SECONDS x2 4 INDOOR FAN OFF Mri SET SPEED LL SET SPEED LL SET SPEED 2 STANDBY OFF ON OFF OFF ON ON OFF 88 F INDOOR HEAT EXCH COIL TEMP E2 SOLENOID COIL 4 WAY TEMP OPERATION BUTTON 81 F 77 F ON REVERSING CYCLE OFF ON x1 Refer to 2 4 Outdoor Fan Speed Control 2 Refer to 2 2 Cold Draft Prevention Heating 1134 THS 1 Fig 2 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 heating 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 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 gt OFF When set on body sensor NOTE In case of Body sensor operating temperature is shifted to setting temperature 7 F SM830076 2 Processes and functions 2 2 Cold Draft Prevention Heating Cycle The cold draft prevention f
6. SM830076 85 4 Service procedures J Change the period of the filter timer LI 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 Press the TEST CHK button for more than 4 seconds UNIT FLAP SET TEMP TIMER SET TI FE v NIA FAN SPEED SERGE CE 0213_M_I 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 Select the CODE No 02 with a e SET TEMP button Change the No from 0 to 1 with a w button EX UNIT No 1 6 CE CODE No 02 K type 150hr 75hr CE 0214_M_I Press the SET button CODE No 06 SET DATA and change from flashing to ON state If you made a mistake press the CL button Finally press the TEST CHK button SM830076 _ 86 4 2 Checking the Electrical Components 1 Measurement of Insulation Resistance e The electrical insulation is acceptable when the resistance exceeds 1 MQ Power Supply Wires Clamp the earthed wire of the Power Supply wires with a lead clip of the insulation res
7. 440 V 4uF Electronic expansion valve Coil DKV MOZS582E0 Coil resistance at 20 C ORG GRY 46 YEL GRY RED GRY 46 BLK GRY Valve body IKV 24D12 Heat exchanger Coil Aluminum plate fin Copper tube Rows Fins per inch 2 14 9 Face area 3 18 0 295 Panel Model No PNR XHS2432 Indicator Lamp Ass y IND 3THS Auto louver motor MT8 3C Auto louver motor Rated 240 VAC 3 W 3 rpm Coil resistance Ambient temperature 77 F 16 430 Q 8 DATA SUBJECT TO CHANGE WITHOUT NOTICE _11 SM830076 1 2 Major Component Specifications A Indoor Unit MODEL No 1 Specifications 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 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 6 560 Nominal output 60 Coil resistance Ambient temperature 68 F BRW WHT 71 1 ORG YEL WHT VLT 8 7 VLT PNK VLT ORG 133 EL BLK Safety device Operating temperature 266 174 2 27 Run capacitor 440 V 6 u
8. SHIFT SET TEMP 4 deg HEATING SELECTION TEMP y 6deg HEATING COOLING HEATING 1142_THS_I Fig 12 SM830076 35 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 gt Shifted temp 1 0 deg Cooling to Heating Room temp lt 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 i
9. 1 3 Other component specifications Power transformer TR eessen Outdoor unit Measure the coil resistance e Primary 230 208V Measure the resistance between No 1 and No 3 WHT lead wires terminals of 3P WHT socket jointed to power transformer e 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 eessen Indoor unit Measure the coil resistance e 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 0 200 Outdoor unit Measure the coil resistance e Measure the resistance in the same manner as explained above 3 Refer to 1 2 B Major component specifications SM830076 89 4 Service procedures Motor capacitor Both in indoor and outdoor unit e 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 e 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
10. 1JA NHD Wi D EG duet wooy LHM 93S NY 134 LHM AYd Z tzSHL H9 49 104 U0D n18 1M 9 ACL OS Gd AY9D 1467 LHM 91 LHMWIWA HH H 1 11 1ZA WOO me da n1g Ou 9 Ack DS LHM d9 10J98UU09 LHM d6 10J98UU079 146 seule es DAME wesbeig DUU 21179944 seule yue3 seule yueg 5 TAA NYD day S4 aos 19 4ns z9S LDS onuoD 1emod Wun 100pINO OL SM830076 46 3 Electrical data 3 1 Indoor Unit XHS2432 XHS3632 e Schematic Diagram CR THS2432 Controller Er oJ EER EERLJ s PEH PH EeP REE Room Thermistor TH1 ndoor Coil E1 ndoor Coil 4P Ge Doe Bur To Outdoor Unit Description Description Indoor Fan Motor TH1 Room Thermistor Indoor Motor Thermal Protector TH2 Thermistor Indoor Coil E1 Running Capacitor TH3 Thermistor Indoor Coil E2 Fuse CR THS2432 Indoor Controller Drain Pump CONT Controller Auto Louver M
11. COIL E3 CN70 WHT T6 CN6 RED EXCT Forced thermostat OFF input terminal CN32 BLK CN31 RED CN33 YEL CN1 WHT CN2 WHT CHECK PIN CN3 WHT TEST PIN CN5 WHT FORCED OPR COIL E2 COIL E1 ROOM TEMP DISP PIN CN44 BRN SG2 CN40 BLU SG1 F3 Fuse 125V 0 5A CN41 BLU Wired remote controller CN42 BLU For wireless remote controller L CN35 GRN PNL 1128_THS_I SM830076 102 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 F2 Fuse 250V 3A CR CH2432 F1 Fuse 250V 3A CN19 BLU SUP CN3 BRN SG2 CN2 BLU SG1 F3 Fuse 125V 0 5A D11 D12 RED MESSAGE LAMP CN4 BLK LINK SYSTEM S2 BLK R C address S3 GRN or BLU R C address S4 GRN or BLU Capacity code CN12 WHT CT1 D14 RED POWER LAMP S1 A ADD AUTO ADDRESS BUTTON CN11 YEL TEST PIN CN1 WHT SEC O CN13 BLK C1 CN7 RED CHECK PIN CN14 RED C2 CN15 GRN DISCHARGE CN8 WHT CK L PIN CN9 WHT CK H PIN 1129 THS 1 SM830076 103 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 c
12. 1 Specifications Outdoor unit Unit dimensions 9 27 32 28 30 32 29 29 32 37 29 29 32 13 12 32 Net weight 49 157 Indoor grille dimensions 3 1 16 PNR XHS2432 33 27 32 33 27 32 Net weight 11 Indoor Outdoor unit 11 6 32 32 17 32 Package dimensions 32 14 32 40 32 25 32 16 12 32 Shipping weight 60 170 Shipping volume 6 9 12 3 Indoor grille 4 3 32 Package dimensions 38 2 32 PNR XHS2432 39 11 32 Shipping weight 18 Shipping volume Cooling 3 5 DATA SUBJECT TO CHANGE WITHOUT NOTICE 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 SM830076 1 Specifications 1 1 Unit Specifications MODEL No Indoor Unit Outdoor Unit XHS3632 230 208 VAC 1 Phase 60 Hz Cooling Heating POWER SOURCE PERFORMANCE Capacity BTU h 34 500 33 500 37 500 25 000 36 500 23 500 Pints h 11 1 Lt cu ft min Moisture removal High Air circulation Hi S E E R H S P F 980 880 BTU Wh 11 0 7 0 7 0 ELECTRICAL RATINGS Voltage rating
13. 40 5 32 Suspention bolt pitch 41 11 32 Panel center 43 11 16 Ceiling opening Le Le Dimension inch 3 15 16 Air intake grille Air outlet Refrigerant liquid line 53 8 Refrigerant gas line 93 4 Drain connection Power supply entry For discharge duct Humidifier option mounting hole Suspension bolt mounting ei 3 15 16 1346_X_S SM830076 20 1 Specifications 1 4 Dimensional Data B Outdoor Unit CH2432 6 11 16 26 L4 21 64 e Ge 13198 1 31 32 Vv Vv 13 3 8 28 15 16 Dimension inch Hole for anchor bolt 4 9 1 2 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 1 SM830076 _21 1 4 Dimensional Data B Outdoor Unit CH3632 6 11 16 26 13 3 8 1 31 32 1 31 32 48 5 8 14 31 32
14. This function prevents the air conditioner from overloading 4 F 147 144 140 INDOOR UNIT COIL TEMP E2 138 131 127 OVERLOAD E PROTECTION OVERLOAD PROTECTION s gi na St FUZZY CONTROL FUZZY CONTROL ELECTRONIC REF CONTROL VALVE OPEN OPEN START UP OUTDOOR FM FOR COMPENSATION n OU PKS Fig 10 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 SM830076 33 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 4 200 DISCHARGE GAS TEMP F 194 185 OUTDOOR FAN SPEED HORM Ek HORM COMPRESSOR ON ELECTRONIC REF CONTROL VALVE DISCHARGE TEMP OPEN OPEN A TRIP IS
15. Unusual communication between the indoor and outdoor units Indoor unit PCB transmission reception circuit defect Replace the indoor unit PCB 0336 MI SM830076 63 4 Service procedures 6 Symptom LCD on the remote controller is displaying CHECK E06 Unusual communication between the indoor and outdoor units Correct the setting Is the setting for the indoor address on the indoor unit PCB inappropriate No Is there a cut line or contact defect between an indoor and outdoor unit s control line 0337 MI 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 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 No 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 Are there two remote controllers master slave installed with both remote controllers set as masters No Replace the remote controller See the section of INSTALLATION INSTRUCTION con
16. a Z Lu L SERVICE MANUAL XHS2432 CH2432 XHS3632 CH3632 SPLIT SYSTEM AIR CONDITIONER PRODUCT CODE No OUTDOOR MODEL No PRODUCT CODE No 854 013 40 CH2432 854 013 42 XHS2432 XHS3632 854 014 57 CH3632 854 015 45 REFERENCE NO SM830076 Outdoor Unit CH2432 CH3632 NN BAB EA SC EB BBE Indoor Unit XHS2432 XHS3632 EE GAG GAB S GAZ GA BZ B lt A i EEE BA ABE EAE 85464849176000 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 0 Observe all local state and national electrical codes 0 Pay close attention to all warning and caution notices given in this manual This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage If Necessary Get Help These instructions are all you need for most installation sites and maintenance conditions If you require help for
17. 12 14 32 52 7 32 43 27 32 40 32 25 32 16 12 32 71 227 10 3 19 8 Indoor grille Package dimensions PNR XHS3632 Shipping weight Shipping volume Cooling Rating conditions Heating Rating conditions 4 3 32 49 16 32 39 11 32 29 4 6 DATA SUBJECT TO CHANGE WITHOUT NOTICE Room temperature 80 F DB 67 F WB Ambient temperature 95 F DB 75 F WB 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 10 SM830076 1 2 Major Component Specifications A Indoor Unit MODEL No 1 Specifications 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 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 6 451 Nominal output 40 Coil resistance Ambient temperature 68 F BRW WHT 1140 ORG YEL WHT VLT 239 WHT PNK VLT ORG 124 YEL BLK Safety device Operating temperature 266 174 2 27 Run capacitor
18. 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 ROOM TEMP deg 3 2 1 SET TEMP D INDOOR FAN SPEED H H High L Low M Middle LL Very low mn Fig 4 Chart Explanations and notes Q When the fan speed changes it keeps the speed step for at least 3 minutes even if the temperature changes to another speed step during the time B Heating ROOM TEMP deg SET TEMP D 2 4 INDOOR FAN SPEED H M H H High L Low M Middle LL Very low 0434_M_S Fig 5 Chart Explanations and notes Q 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 SM830076 29 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 Q 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 sud
19. Indoor unit No 4 will be set CD use In this example indoor unit address y ee UNIT No will be set 2 4 Ca 0370_M_I h Press the SET button UNIT No CODE No 13 Gams and SET DATA 0004 change from flashing to ON state SM830076 _ 84 4 Service procedures Select the code No 14 to set group setting with the A e SET TEMP button D Set the No of group setting as shown below with the a w button 7 Nos of group setting mel 0 Standard system except group Ee Ie control Sal do GE 1 Main indoor unit in case of group I TI ET control DW 9 Aire ge 2 Sub indoor unit in case of group ol control SES 99 No setting at factory shipment 0371 MI amp Press the SET button UNIT No CODE No 14 Gin and SET DATA change from flashing to ON state lt 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 Confirm the indoor unit address UNIT No with the UNIT button after pressing the ON OFF button 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
20. e Clean up the site when installation is finished Check that no metal scraps or bits of wiring have been left inside the unit e 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 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 on sntersensssoeneensienenentoirestnnnnendignsienenesnandetsuninieeinengnstansentesenenber tands 6 1 1
21. it starts again However when the circuit fails to detect the current twice in a row the remote controller displays alarm message HO3 Failure of compressor Current Detection SM830076 _41 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 Cooling Heating Discharge gas temperature control Discharge gas temperature control Outdoor unit coil temperature control High load prevention control Freeze prevention control Heating start up control Refrigerant flow distribution control Refrigerant flow distribution control Discharge gas target temperature control Fuzzy control i i Discharge gas target temperature control Fuzzy control Repeat control in accordance with the priority order 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
22. le 3 MINUTES TURN ON THERMO OFF THERMO OFF TURN OFF THERMO THERMO ON ON COMPRESSOR ON OFF ON OFF ON OFF ON gt 2 2 Le El dg Le 1 sl Le El sl Le 1 el SOLENOID COIL 4 WAY VALVE OFF ON OFF ON 1 More than 5 minutes 2 More than 3 minutes 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 4 way valve solenoid COOLING OFF HEATING ON Operation Mode Compressor ON SM830076 38 2 Processes and functions B AUTO Control Mode POWER SOURCE OFF ON OPERATION BUTTON ON MORE THAN 10 MINUTES MORE THAN 10 MINUTES THERMO OFF THERMO OFF ef gt AUTO COOL ane Set CONTROL HEAT HEAT HEAT XTHERMO OFF THERMO ON lt 3 MINUTES MORE THAN 3 MINUTES COMPRESSOR OFF ON OF ON OF ON OFF ON MORE THAN MORE THAN 30 50 SECONDS 30 50 SECONDS SOLENOID COIL WAY VALVE OFF ON OFF ON 0445_M_S Fig 16 When the Compressor has stopped while in AUTO mode the 4 way valve
23. up or FLAP down buttons 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 E AIR FLOW ir MODE the R C No 3 td x CODE No SET TEMP AL Cy i Ca STEE se mm PUTZ 7v AEL SE DATA TIN CED o oto siens 0363 MI 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 SM830076 80 4 Service procedures Setthe required new indoor unit s No by pressing the A se button Ex UNIT No 3 6 currently registered indoor unit address IMER SE 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 MI Press the SET button UNIT No SET DATA 0008 and gam changes from flashing to ON state If you made a mistake press the CL button 5 Finally press the TEST CHK button If you want to change the indoor unit address of the other R C No follow the step to bh in the same way SM830076 81 4 Service procedures H Change the shift temperature in heat
24. Electronic expansion valve open 09 Outdoor Unit OA TH8 Discharge gas Temp 0B OC OD TH7 Outdoor coil liquid Temp C2 OE TH6 Outdoor coil liquid Temp C1 NOTE In case there are no sensor equipped with the unit is shown on the display Resetting the remote controller display to previous mode Q 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 LI This function is usable even if the unit is not working LI To display the past error codes follow the procedure below Procedure 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 Oe SERVICE CHECK DISPLAY Set temp gt Code No UNIT No gt UNIT No Indoor unit address Hours Minutes gt Alarm Message SM830076 76 4 Service procedures This picture shows the service check display Sell UNIT No UNIT No F l 1 tno 17 deu KT Refrig
25. Heating Poor heating Is setting temp suitable 4 Service procedures Change the setting temp Is heating load too large 4 way valve is defective Refrigerant flow failure Review heating load estimate Replace the valve Refrigerant shortage Electronic refrigerant control valve is defective Compressor is defective Service valves are not fully open Charge with refrigerant Replace the valve Replace the compressor 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 Clean the filter Set the fan speed to either MEDIUM or HIGH Insulate wide and narrow tubes separately Cold air is 4 way valve is discharged defective Cold draft prevention STANDBY is is not working displayed Indoor coil sensor E2 is defective _57 Replace the valve Replace indoor P C B Ass y Replace the sensor 0459 MI SM830076 3 4 Service procedures 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 Wired remote Wireless remo
26. OPERATED 1141_THS_I Fig 11 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 SM830076 _34 2 Processes and functions 2 9 Auto Mode for Automatic Heating Cooling Switching Q 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 Settemp gt COOLING Room temp lt Settemp gt 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 5 deg SHIFT SET TEMP 4 deg gt lt REMOTE CONTROLLED SET TEMP
27. OUTDOOR FAN ON OFF ON OFF ON H OR M INDOOR FAN SET SPEED 1 Refer to 2 4 Outdoor Fan Speed Control 1133_THS_1 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 below the set temperature T Compressor gt OFF SM830076 26 B Heating REMOTE CONTROL SENSOR Only for wireless THERMO ON THERMO OFF 2 Processes and functions THERMO ON THERMO OFF THERMO ON remote controller SET 2 F SETTING TEMP SET 2 F THERMO OFF THERMO OFF THERMO ON BODY SENSOR SB SEA THERMO ON THERMO ON 2 F SET TEMP 7 F SHIFT 2 F SET TEMP gt MORE THAN 3 MINUTES Le gt MORE THAN 5 MINUTES 3 MINUTES 5 MINUTES wa gt a COMPRESSOR OFF ON OFF ON OFF ON a OUTDOOR FAN H OR Mi
28. Protective device in outdoor unit Thermal protector in outdoor fan motor is activated P02 Operation lamp and heat 8 is activated Compressor thermal protector is activated stand by lamp flash 5 Power supply voltage is unusual The voltage is more than alternately O 260 V or less than 160 V Operation lamp eg 5 Discharge gas temperature of comp is unusual P03 Timer lamp E High pressure switch is activated P04 KW ee stand by 2 Voltage drops POS i Other indooor unit is warning P31 58 SM830076 4 Service procedures Wired remote Wireless remote Possible causes of troubles controller controller display display ge Indoor thermistor is either Indoor coil temp E1 cannot be detected F01 Operation lamp and heat 5 open or short stand by lamp flash z Indoor coil temp E2 cannot be detected F02 alternately 5 Indoor room temperature cannot be detected F10 34 Operation lamp Outdoor thermistor is either Discharge gas temp cannot be detected F04 Timer lamp open or short Outdoor coil liguid temp C1 cannot be detected F06 r stand by amp Outdoor coil gas temp C2 cannot be detected F07 e Non volatile memory IC EEPROM is abnormal Indoor control panel F29 Protective device for Compressor motor is overloaded H01 Operation lamp Ko a EES Compressor motor is locked HO2 Timer lamp see Compressor current dete
29. VAC 230 Available voltage range VAC 187 Running amperes 18 2 Max running amperes Power input 3 850 3 150 Buck up heater Maximum fuse size 30 FEATURES Controls Microprocessor Fan speeds Indoor Outdoor 3 and Automatic control 2 Auto Timer ON OFF 24 hours amp Program Air deflection Horizontal Vertical Automatic Air filter Washable easy access long life fiter 2 500 hr Operation sound Hi Me Lo Indoor Outdoor Hi 43 40 36 56 Refrigerant control Electronic Refrigerant Control Valve REFRIGERANT PIPING Limit of piping length 165 50 Limit of piping length at shipment 100 30 Limit of elevation difference between the two units Outdoor unit is higher than indoor unit 165 50 Outdoor unit is lower than indoor unit 100 30 Refrigerant piping Flare type Narrow pipe Wide pipe 3 8 9 52 3 4 19 05 SM830076 1 1 Unit Specifications DIMENSIONS amp WEIGHT Indoor unit 1 Specifications Outdoor unit Unit dimensions Net weight 11 1 32 48 20 32 1 235 41 11 32 37 29 29 32 13 12 32 60 203 Indoor grille dimensions PNR XHS3632 Net weight 3 1 6 33 27 32 33 27 32 15 Indoor Outdoor unit Package dimensions Shipping weight Shipping volume
30. a auto address operation Press the TEST CHKand a buttons at the same time for more than 4 seconds Press the SET button after confirming the CODE No AA CODE No AA All Auto address operation 1 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 9 Individual auto address operation for each refrigerant circuit To select each refrigerant circuit individually and set addresses automatically press the TEST CHK and a buttons at the same time for more than 4 seconds then press the e SET TEMP button once to set CODE No A1 2 CODE No A1 Auto address operation 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 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 If the auto address operation finishes the display will disappear Execute the operation of the other R C line in the same way by following the above steps at to Complete the auto address operation by pressing the TEST CHK button _97 4 Service procedures Required time for auto addre
31. by the lower temperature sensed at either of the two sensors Chart Explanations and notes This chart shows when the electronic refrigerant control valve opens to regulate the temperature of the indoor unit coil to prevent freezing If the refrigerant control is not effective and the temperature continues to drop and stays below 30 F for 2 minutes continuously the control circuit stops the compressor The compressor does not start again until the temperature rises above 34 F The compressor stops for 3 minutes minimum SM830076 Be 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 CF ua OUTDOOR FAN FORCED SPEED H M SCH H M ELECTRONIC REF CONTROL VALVE OPEN 1139 THS 1 Fig 9 Chart Explanations and notes 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 SM830076 32 2 Processes and functions 2 7 Overload Protection Heating
32. connected 16 Symptom LCD on the remote controller displays CHECK L13 0647_M_S When the group of the units are installed is there any mis cross Spare wiring between inter unit control wiring and refrigerant tubing Check the capacity of the indoor unit by remote controller GE MS See Test Run Manual 17 Check P9 is displayed on the remote control unit Is 15P connector socket RED being attached to panel connected firmly with 15P plug Connect firmly Replace P C B Ass y in the indoor unit 0649_M_S SM830076 69 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 CHECK HO1 display Compressor overload detection CHECK H02 display CHECK H03 display Compressor lock detection Compressor current detection circuit defect e Insufficient voltage Compressor lock L3 phase wire disconnected e Comp motor magnetic contactor Comp motor magnetic contactor defect defect e Refrigerant over charged e Outdoor unit PCB defect 0346_M_I 19 Check the indoor unit When the alarm of communication failure is not activated f the electronic control valve failure occurred in Flexible Combinati
33. diagnosis and error codes which show on the display Look at the chapter about CHECKING ELECTRICAL COMPONENTS You already know about most of these procedures This chapter gives you the specific values and methods for these components If you don t know some of these procedures you can easily learn them here Read the Instruction Manual The Instruction Manual is included here because it helps you help the user to set the temperature controls properly and know how to take care of any simple problems that may happen as well as know when to call for service The Instruction Manual also has illustrations care and installation information not found in the rest of the service manual It is short and if you read it carefully you will be able to answer the customers questions easily and also know the most efficient ways for setting times and temperatures Please use this manual to make your work easier keep the air conditioner functioning well and keep your customers satisfied SM830076 1 SPECIFICATIONS TET Whit SS CIOS eer eege 7 1 2 Major Component Specifications aa 11 A Indoor E E 11 SHEI UIN seren eaten eel 13 1 3 Other Component Specifications AE 15 CA IGE WA E 15 CB OUI O OK UM cscs uns 17 1 4 Dimensional Data zimia www 19 ee 19 BONGO UIN sere eee eene 21 1 5 Refrigerant Flow Diagram is 23 126 Operating BANGS een ee eneen 29 SM830076 1 1 Unit Specifications MODEL No Indoor Unit 1 Specificatio
34. 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 C Central control when using the system controller In case of central control when using the system controller that is when linking outdoor units in a network a Before turning the power supply on set the R C address with S2 S3 on the outdoor control P C B b Remove the short plug CNA 2P Black from all outdoor units except one outdoor unit 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 0 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 L Indoor unit No Refrigerant Circuit No R C address Manual setting for indoor unit address can be performed also by remote controller SM830076 _95 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 c
35. gt 22 27 32 23 29 32 55 1 Specifications Dimension inch Hole for anchor bolt 4 013 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 Specifications 1 5 Refrigerant Flow Diagram Outdoor Unit CH2432 Indoor Unit XHS2432 Compressor Accumulator ES Accumulator Es Oe Gas line service i x valve OD Gas line 3 4 nipple lt 19 05mm High Le pressure E Switch 4 way valve Heat exchanger Heat exchanger Distributor Strainer Electronic Distributor ref control valve Liquid line service M valve Liquid line ve nipple lt 6 35mm Sub heat exchanger SE Cooling Cycle lt Heating Cycle 1 6 Operating Range Temperature Indoor Air Intake 1132_THS_I Outdoor Air Intake Maximum 95 F DB 71 F WB 115 F DB Cooling Minimum 67 F DB 57 F WB 23 F DB Maximum 80 F DB 67 F WB 75 F DB 65 F WB Heating Minimum DB WB 17 F DB 15 F WB SM830076 23 1 Specifications 1 5 Refrigerant Flow Diagram Outdoor Unit CH3632 Indoor Unit XHS3632 Compressor Accumulator Accumulator Ga
36. heater VAC 230 VAC 30 W Refrigerant amount charged at shipment Ibs kg R22 8 82 4 0 High pressure switch ACB 1UB11 Set pressure OFF bin kg cm 426 6 TEN 30 55 ON Ib in kg cm 341 3 28 44 24 2 0 Fan Propeller Number diameter 2 18 3 32 460 Fan speeds 2 AUTO Fan motor Model KFC6T 91D6P x 2 Source 230 208 V 1 phase 60 Hz No of pole rpm 230 V High 6 879 Nominal output 110x2 Coil resistance Ambient temperature 68 F BRN WHT 67 14 VLT YEL 11 42 WHT VLT 64 85 YEL PNK 10 60 Safety device Internal type Operating temperature 248 9 171 27 Run capacitor 440 VAC 4 uF x 2 Heat exchange Coil Aluminum plate fin Copper tube Rows Fins per inch 2 14 1 Face area 11 63 1 08 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830076 1 Specifications 1 3 Other Component Specifications A Indoor Unit Power Transformer XHS2432 ATR 11174B 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 BRN BRN Thermistor cut off temperature 277 Thermistor Coil sensor TH2 3 PBC 41E S26 Coil resistance H Thermistor Ro
37. motor magnetic contactor 520 Outdoor unit e 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 e Check the continuity between contactors MODEL FMCA 1UL Push button on Pair of terminals the magnetic contactor R U S V T W 31 32 no press YES press YES YES YES Solenoid coil of 4 way valve 20S Outdoor unit Measure the coil resistance e 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 SM830076 _91 4 Sensor and Solenoid Layout Diagram Indoor Unit e XHS2432 Outdoor Unit e CH2432 TH2 E1 RED OO TH6 7 8 TH8 GRN Discharge gas CM CH 1153_THS_I Electronic expansion valve TH3 E2 BLK 1582 KI 20S 63PH TH8 GRN TH6 C1 BLK 92 4 Service procedures CIO TH7 C2 RED 1154_THS_I SM830076 4 Service procedures 4 Sensor and Solenoid Layout Diagram Indoor Unit e XHS3632 Electronic expansion valve TH2 E1 RED TH3 E2 BLK U 1583_X_I Outdoor Unit e CH3632 G TH7 C2 RED Il TH8 GRN Discharge ga
38. of unit numbers included Timer lamp 9 Error transmitting of serial communications signal E07 Heat stand by Auto address setting is not No of judged indoor units or total capacity of indoor units is small E15 lamp correct No of judged indoor units or total capacity of indoor units is large E16 Indoor unit is detecting unusual Error transmitting of serial communications signal E17 he Mager Walt Error receiving of serial communications signal E18 Improper setting of indoor unit or Indoor unit group address is not correct LO1 Operation lamp and remote controller i WA heat stand by lamp Model setting of indoor unit is not matching the outdoor unit LO2 flash at the same time When using group control main indoor unit address setting is duplicated LO3 4 Operation lamp gt judged by indoor unit A Timer lamp b Outdoor unit address is duplicated LO4 p Heat stand by Improper wiring between indoor units LO7 lamp There is a group connection wiring in case of individual control Indoor unit address or group address is not set L08 Capacity code of indoor unit is not set LO9 Improper wiring of group control wiring L11 Indoor unit model setting is improper capacity L13 Improper wiring connections of ceiling panel P09 Operation lamp g Protective device in indoor unit Thermal protector in indoor fan motor is activated Pot i ey GE ZS lis activated fee taney 3 Float switch is activated P10 amp g
39. switches on heating or off cooling within 1 minute according to the following conditions 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 Fig 17 2 12 Automatic Restart after Power Interruption This air conditionner has a power failure recovery function SM830076 39 2 Processes and functions 2 13 Electronic Expansion Valve Q 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 Min open Model Max open Heating Cooling 24 type 100 step 120 step 480 step 36 type 90 step 90 step 480 step Q 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
40. 13 Electronic Expansion Valve AAR 40 2 14 Compressor Discharge Gas Temperature EEN 40 EE A0 B Heating Except During Defrosting nnen eenenenneneerennnnnnneeenenn 40 2 15 Compressor Current Detection Circuit 42e 41 2 16 Electronic Expansion Valve Control EE 42 2 17 Voltage Detection Control 43 3 ELECTRICAL DATA amande 45 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram nn 46 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram nn 48 4 SERVICE PROCEDURES nennen vennen 53 ei TEOUDISSNOGUND E 54 4 2 Checking the Electrical Components rset eenieder 87 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 explana tions 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 schem
41. 1_X_S Fig 24 SM830076 4 Service procedures 2 Checking the Protective Devices e Disconnect the connector which consists of P plug and S socket when you want to check the protective device e Then check continuity among plug s and or socket s terminal as in Fig 25 e 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 Fig 25 0642_X_S Indoor fan motor thermal protector 49FI Indoor unit e Disconnect the connector which leads to the indoor fan motor FMI e Check the socket s terminals Compressor motor thermal protector Outdoor unit e Disconnect the wires from terminals of compressor e Check the terminals of compressor Outdoor fan motor thermal protector 49FO Outdoor unit e Disconnect both the connector which leads to the outdoor fan motor FMO e Check socket s terminal SM830076 _ 88 4 Service procedures 3 Checking the Electrical Parts Power transformer TRI ees Indoor unit Measure the coil resistance e Primary 230 208V Measure the resistance between No 1 and No 3 WHT lead wires terminals of 3P WHT socket connected to power transformer e 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
42. 32 e Remote controller Accessory X view LI 6 25 32 14 2 13 32_ 23 32 4 29 32 32 9 32 Ceiling opening _ 23 7 32 Suspention bolt pitch 14 4316 Lu 33 27 32 19 11 16 gt 1 3 8 gt 13 2 4 28 3 4 Suspention bolt pitch 29 29 32 33 27 32 19 11 16 32 9 32 Ceiling opening Grille center Min 2 3 8 _ 3 1 32 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 29 29 32 1024_X_S SM830076 19 1 Specifications 1 4 Dimensional Data A Indoor Unit XHS3632 8 19 32 8 9 32 X view 5 23 32 29 29 32 1 3 8 2 13 32 6 1 2 oe 11 7 32 32 9 32 Ceiling opening 4 12 29 32 _1 3 16 33 27 32 23 7 32 Suspention bolt pitch SE p 19 11 16 13 15 32 Le
43. 341 3 28 44 24 2 0 Fan Propeller Number diameter in 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 110 Coil resistance 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 248 9 171 E27 Run capacitor 440 VAC 4 uF Heat exchange Coil Aluminum plate fin Copper tube Rows Fins per inch 2 14 1 Face area 6 78 0 63 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830076 BER 1 2 Major Component Specifications B Outdoor Unit MODEL No Source 1 Specifications CH3632 230 208 VAC 1 phase 60 Hz Controller P C B Ass y CR CH2432 Microprocessor Control circuit fuse 250 V 3A Compressor Rotary Hermetic Model C R221H6R Source 230 208 VAC 1 phase 60 Hz Nominal output 2 200 Compressor oil 1 500 Coil resistance Ambient temperature 77 F C R 0 549 C S 1 525 Safety device Internal type Overload relay models Operating temperature Open 320 9 Close 189 20 Operating ampere at 77 F Run capacitor VAC 400 VAC 40 uF Crank case
44. CB fuse blown Replace the indoor unit PCB transformer of the 4P connector power transformer for the indoor unit s shorted power transformer Replace or repair oe the Re the indoor units indoor unit oe Re transformer EI 1144 THS 1 SM830076 4 Service procedures 2 Symptom LCD on the remote controller displays CHECK E01 Unusual communication between remote controller and indoor unit Replace the remote controller Remote controller judges itself with self diagnostic functions OK Is there an open or a contact defect in the No 1 line of the Correct the wiring remote controller Is there 230 208 V AC between Mis wiring between the power Correct the wiring and pull out the U1 and U2 of 8 P terminal plate supply line and indoor outdoor socket connected to the OC plug unit operation lines to replace with the EMG plug Is the indoor unit PCB s non volatile Yes memory IC setting CHECK F29 displayed wrong Is the indoor unit PCB s inspection Yes pin shorted No Replace the indoor unit PCB 3 Symptom LCD on the remote controller displays CHECK E02 Unusual communication between remote controller and indoor unit Correct the setting Open the inspection pin 1145 THS 1 Is the No 1 line wire red for the Repair the wiring remote controller connected to another line 2 or 3 or are No 1 and No 3 black wi
45. 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 CD 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 32 or below 34 50 32 or below 34 50 52 70 32orbelow 34 50 52 70 Compressor discharge gas temp F 104 176 122 194122 194 122 212 140 2211122 1941140 212 158 221 Q Operate the unit at least 30 minutes to stabilize the discharge temperature Q The above discharge temperature was measured with a 15m tubing length The temperature may vary with tubing length SM830076 _ 40 2 Processes and functions 2 15 Compressor Current Detection Circuit Q 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 Q 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 x 1 4 Overload Protection Range Isx 1 17
46. F Electronic expansion valve Coil EKV MOZS584E0 Coil resistance at 20 C ORG GRY 46 YEL GRY RED GRY 46 BLK GRY Valve body HKV 30D16 Heat exchanger Coil Aluminum plate fin Copper tube Rows Fins per inch 2 14 9 Face area 5 17 0 48 Panel Model No PNR XHS3632 Indicator Lamp Ass y IND 3THS Auto louver motor MT8 3C Auto louver motor Rated 240 VAC 3 W 3 rpm Coil resistance Ambient temperature 77 F 16 430 Q 8 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830076 BER 1 Specifications 1 2 Major Component Specifications B Outdoor Unit 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 1 700 Compressor oil 800 Coil resistance Ambient temperature 77 F C R 0 885 C S 1 773 Safety device Internal type Overload relay models Operating temperature Open 297 9 Close 198 20 Operating ampere at 77 F Run capacitor VAC 400 VAC 40 uF Crank case heater VAC 230 VAC 30 W Refrigerant amount charged at shipment Ibs kg R22 6 17 2 8 High pressure switch ACB 1UB11 Set pressure OFF Ib in kg cm 426 6 1234 30158 ON Ib in kg cm
47. NG teres nente ende 54 1 Check before and after Troubleshooting annen 55 2 General Troubleshooting Flow Chart Diagnosis and Remedy 56 3 Meanings of alarm messages ss 58 4 LED Indication on the Outdoor Unit s P C B ASS y nn 60 5 Symptoms and parts to inspect ss 61 6 Procedures When a Specific Component Does Not Work 71 7 Service Functions of Optional Wired Remote Controller 13 4 2 Checking the Electrical Components Ann 87 1 Measurement of Insulation Resistance nanne vennen 87 2 Checking the Protective Devices wa 88 3 Checking the Electrical Parts sentent 89 4 Sensor and Solenoid Layout DIANA naer edet 92 5 Thermistor Characteristic Cume ennen 94 6 dee 95 7 R C Address Setting Method a den 96 8 Automatic Address Setting Method anne eneeeenennenn 97 9 Displaying Indoor Outdoor Unit Combination Numbers 97 10 Items to Check Prior to Test Run eternet 98 GE EE 99 12 PGB and Parts LOGOS de 102 13 Checking procedure tor each PC Board ww mmmmmemamammmmma 104 14 AA 105 SM830076 53 4 Service procedures 4 1 Troubleshooting This section explains Q What the LED codes mean Q What the remote control unit display screen messages mean Q How to use the flow charts to find and solve problems Q How to use the self diagnostic tests to find parts that aren t working right This unit is m
48. Unit ele E 7 1 2 Major Component Specifications zanden 11 A Indoor UMIE EE 11 B Outdoor UNIT RER 13 1 3 Other Component EE ne nement aie 15 A Indoor UMIT E 15 BI Out EE eegene 17 1 4 Dimensional DA een 19 A MOGI AN 19 B Outdoor UNIT Lesen 21 1 5 Refrigerant Flow Re EE 23 1 6 Operating Range seen 23 2 PROCESSES AND FUNCTIONS 2 une ue 25 2 1 Room Temperature Control un 26 KEE 26 B E er ae ie are ste er Reon a earner sO Ee nna oreo re er oy err ner cere er 27 2 2 Cold Draft Prevention Heating Cycle 28 2 3 Automatic Fan Speed Indoor Unit 29 AJ GOONG eegene 29 B Heating NE a aa a a Ea aa a a 29 2 4 Outdoor Fan Speed Control seren nnie 30 Eeer 30 EE 30 2 5 Freeze Prevention Cooling mwm miwani mwmwa miminika miwa 31 2 6 Condensing Temperature Control Cooling csecceeeeeeeeeeeeeeeeeeetneseeeeees 32 2 7 Overload Protection Heating wawaua 33 2 8 Discharge Temperature Control Cooling and Heating 34 SM830076 a 2 9 Auto Mode for Automatic Heating Cooling Switching nennen 35 2 10 Defrosting Control Outdoor Heat Exchanger Coil Heating 37 2 11 4 Way Valve Solenoid Control sis caccsisetidecnsvanscddusonnid lenensnuiuncategeddsseancneniaencenaaiaans 38 A Normal Control Mode si 38 CEP TO Control Mode ss de 39 2 12 Automatic Restart after Power Interruption 39 2
49. 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 e Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked e Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequate ground ing can cause accidental injury or death e Ground the unit following local electrical codes e Connect all wiring tightly Loose wiring may cause overheat ing at connection points and a possible fire hazard When Transporting Be careful when picking up and moving the indoor and outdoor units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers When Installing 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 pa
50. ade 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
51. atic and wiring diagrams so you can find the parts you need to check when something is wrong and see how they should be connected Section 4 Service Procedures has two main parts a diagnostic chapter to help you find the specific component to replace or adjust and a chapter with specific procedures and values to guide you in checking the electrical components in the unit HOW TO USE THIS MANUAL You can use this manual both as a reference to find specific information about the capacity functions and construction of this unit and as a source of information to help you set up and maintain the unit When this unit is not working properly and the cause is not known you can use the procedures in Section 3 Servicing Procedures to find the problem fix it and restore the unit to its proper functioning This air conditioner has many helpful self diagnostic features to help you identify problem areas quickly So you will be ready when a problem happens we suggest you look this manual over and become familiar with it by following these steps Look at the TABLE OF CONTENTS to get an idea of what is in this manual and where to find it Look at the chapter about TROUBLE SHOOTING so you are familiar with the way the flow charts work They are designed to guide you quickly through the possible causes for each kind of problem that is likely to happen to the Unit Particularly read the introduction to this section and the parts about the self
52. ation e Relays RY3 and RY4 are turned ON for 3 seconds gt The outdoor fan motor operates at the H fan speed e Relay RY3 is turned ON for 3 seconds The outdoor fan motor operates at the LL fan speed e Turn ON relay RY2 under the above conditions The magnet switch 52C turns ON If relay RY1 is turned ON the 4 way valve 20S turns ON X It will take about 18 seconds before heating operation begins e The outdoor unit operates independently regardless of the indoor units operation However the outdoor unit does not defrost e The indoor and outdoor units stop when the outdoor protection apparatus activates during the checking operation and automatically restarts unlike in normal operation SM830076 105 e 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
53. cerning with controlling remote controller switches when there are two remote controllers Correct the setting 0339_M_I SM830076 64 4 Service procedures 9 Symptom LCD on the remote controller displays CHECK P01 Indoor fan protection thermostat operation warning Is there 230 208 V AC between S4 and T20 3 on the indoor unit PCB Yes Correct the connection Is there 230 208 V AC between Is the indoor fan wire winding T20 3 and S4 after T20 1 and T20 3 protection thermostat 49FI off on the indoor unit PCB shorted Replace the indoor fan Replace the indoor unit PCB 1146_THS_I SM830076 65 4 Service procedures 10 Symptom LCD on the remote controller displays CHECK P02 Compressor outdoor fan protection thermostat operation warning power supply voltage abnormality Is the power supply to the outdoor Check the power breaker etc unit normal and repair Voltage defective phase Yes Is the fuse on the outdoor unit Replace the fuse PCB blown F1 and F2 No Replace the outdoor unit PCB Is the high voltage switch 63 PH off Is there 230 208 V AC between Replace the outdoor unit PCB CN19 9 and CN19 1 on the outdoor unit PCB Is the outdoor fan wire winding protection thermostat 49FO off No Replace the outdoor fan Is the compressor protection thermostat 49C off exce
54. 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 SM830076 _42 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 SM830076 43 2 Processes and functions SM830076 _ 44 3 ELECTRICAL DATA 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram en 46 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram en 48 SM830076 _45 3 Electrical data Indoor Uni 3 1 XHS2432 XHS3632 SHX 0 00 222 892S 2 7S8 MW 73 1109 wa La 1109 a34 NHD youl yeg TAaA NYD LHM d amp JOJ9eUUOD
55. 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 Outdoor control PCB S4 green or Blue capacity code 4P DIP switch 1127_C_I 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 SM830076 _ 98 4 Service procedures 11 Test Run 11 1 Preparing for Test Run Before starting the air conditioner check the followings 1234 Operation selector 1 TEST RUN 1 Remove all loose matter from the cabinet espe eS 2 OF cially metal filings bits of wire and clips SEN 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 Fig 11 1 Ceiling mounted and Recessed Type indoor units the flap s move s for one minute when the power is connec
56. ction circuit is defective HO3 Heat stand by Ses H17 lamp pes Power supply voltage between phases is unbalanced Standard comp contactor Mg SW is chattering H18 x flashes OFF 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 LED 2 on LED 1 on Remote P C board P C board controller E No message Normal Possible cause of trouble Outdoor unit serial communication signal is abnormal Outdoor unit address is duplicated O E06 E07 LO4 Other outdoor units are performing auto address and eo No message detecting refrigerant shortage O P02 FMo CM thermal protection is in operation Power supply voltage is abnormal O O P04 P05 High voltage SW activates Negative phase protector activates O F04 F09 Sensor is abnormal Open or short R HO1 HO2 Abnormal compressor current value is detected E15 E16 Auto address failure Flash at the same time SETTING Auto address is in operation Flash alternately flashes NOTE LED lamps OFF LED lamps ON lights up LED lamps ON flashes 1125 CI Fig 20 REFRIGERANT SHORTAGE Note particularly that a shortage of r
57. d 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 e 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 e 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 e 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
58. den surge of power may be necessary Q The outdoor fan operates in H mode for 3 minutes after the compressor stops excluding defrosting operation period Q Charts below show how the outdoor fan speed changes with the change in outdoor temperature A Cooling Outdoor unit coil Outdoor fan wA temperature C2 motor FMo 2 UI or more 77 F H 5 less than 77 F M 77 Z Lu ao 8 A M Fig 6 B Heating Outdoor coil Outdoor fan T temperature C2 motor FMo L M Lu or more 57 F M lt less than 57 F H i SS W jam 8 A H 2 Fig 7 SM830076 30 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 INDOOR UNIT TEMP 34 32 31 30 CONTINUOUS F i DETECTION i i FOR 2 MINUTES ELECTRONIC REF CONTROL VALVE SIGNAL OPEN OPEN COMPRESSOR MINIMUM 3 ON MINUTES ON 1138_THS_I Fig 8 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
59. efrigerant 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 SM830076 60 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 Is the LED D80 on the indoor unit PCB lit Is there 12 V DC Is there 12 VDC Repair the between R2 and R3 between 2 and 3 remote on the 8P terminal of the remote controller plate of the indoor unit controller wiring Miswiring of Yes Is there 230 208 V AC Is there 230 208 V AC power supply between U1 and U2 between R and S of wires and of the 8P terminal the indoor PCB indoor outdoor plate control lines Replace the remote controller Check and repair the power breaker etc Correct the wiring Remove the socket connected to the OC plug on the PCB and connect to the EMG plug instead No Are the connections for the 4P connector for the indoor unit s PCB power trans former good Replace the Is there 15 V AC Is the primary Is the 230 208 V AC No indoor unit power between 1 and 2 side of the indoor circuit shorted Yes Correct the connections Has the indoor unit P
60. erant Je HZ Circuit No EL I CODE No LANS lt N Lig me Alarm message gt E i SE 0358_M_I A maximum of 4 alarm messages can be accessed by pressing either SET TEMP button a or e as follows a so NOTE Pressing CL Clear button will clear SET TEMP all the service history Present FAN SPEED ra mom e accessed in order of Present gt 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 w button four times The 5th time you press w button you can repeat the display then the first message will be shown again a accessed in order of Past gt Present v lt Present FAN SPEED UNIT No UNIT No UNIT No UNIT No 7 D 7 D 7 D 7 D R C No gt R C No gt R C No gt R C No CODE No CODE No CODE No CODE No ef IZI IZI TI LI LA LI wie CT LU CHECK II II CHECK I NII CHECK I DT 1 CHECK woe TI LI IT LI TI LI SERVICE SERVICE SERVICE SERVICE UNIT No NN I RC No CODE No If there are no alarm messages the display shows i l Alarm message x CHECK SERVICE 0360 MI SM830076 77 4 Service procedures Never press CL clear button unless you want to erase the accessed da
61. es 1 Set the indoor unit address Q 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 bh Press the TEST CHK SET and CL buttons at the same time for more than 4 seconds UNIR Noe KS E I RE 7 No IMER SE 0367_M_I Set the CODE No 12 to set the No of R C with the a e SET TEMP button 0368_M_I SM830076 83 4 Service procedures Set the No of R C which you want to set with a w button Ex No of R C will be set 2 UNIT UNIR Roc Le AN 1 FLAP REZ Wo IMER SE 0369_M_I Press the SET button UNIT No CODE No 12 Gsm and SET DATA 0002 change from flashing to ON state Select the CODE No 13 to set the indoor unit No with the 2 e SET TEMP button Set the indoor unit No which you want to set with the A w button eaae Ex
62. es 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 NG Replace the compressor 0461 MI 4 Outdoor fan does not operate Are auxiliary relays 1Y Replace the relays normal Yes Replace the capacitor Is fan motor capacitor normal Yes Is there voltage output of No Replace P C B Ass y P C B Ass y for fan motor in the outdoor unit Yes Check resistance of fan motor winding NG Replace the fan motor 1148_THS_I SM830076 _72 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 E F Excute the auto address operation G Confirm and change the indoor unit address H Change the shift temperature in heating mode Set the indoor unit address J J Change the period of t
63. ess the MODE button to select either COOLING or HEATING mode d When the test run starts TEST shows on the remote controller s display During the test run the air conditioner runs continuously and the thermostat does not control the system After the test run be sure to press the TEST CHK button once again to finish this mode and make sure TEST is not shown on the display Na AIR FLOW UNIT FLAP IMER SE UE Z Ml LI Alarm message TEST RUN CHECK button ON OFF operation button 1152_THS_I 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 SM830076 _74 4 Service procedures C Check the sensor temperature readings The air conditioner has thermo sensors which are used to control the unit LI 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 On the remote controller press both TEST CHK and CL button
64. he 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 e switch RCU ADR C ON Si RCU CK switch 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 LI RCU CK switch Refer to section E Checking the remote controller for correct operation Remote Control Unit Check LI RCU ADR switch Keep the switch OFF all the time except in case of sub remote controller Remote Control Unit Address SM830076 73 B Use the test run procedure 4 Service procedures Q 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 Q 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 Press the ON OFF operation button to start the test run Pr
65. heck 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 Short the CHECK PIN on the PC board of the indoor outdoor unit and turn on the power 3 When checking the Outdoor controller remove the compressor wiring from the compressor electromagnetic contactor 4 1 Checking the serial circuit Indoor controller A lighted LED indicates normal A blinking LED indicates abnormal Outdoor controller Blinking LEDs D11 and D22 indicate normal If one of the LEDs D11 and D22 goes off it indicates abnormal 4 2 Checking microcomputer operation When the microcomputer works normally the relays are switched in sequence as below Indoor controller Output ON time Indoor fan Very high fan speed HH 0 5 seconds Indoor fan High fan speed H 0 5 seconds Indoor fan Low fan speed L 0 5 seconds Indoor fan Very low fan speed LL 0 5 seconds Flap motor 0 5 seconds Drain pump 0 5 seconds Operation order Electric heater 0 5 seconds Operation signal 0 5 seconds In a lump 0 5 seconds Electronic control valve A 0 5 seconds Electronic control valve B 0 5 seconds Electronic control valve A 0 5 seconds Electronic control valve B 0 5 seconds Qutdoor controller O
66. ing mode Q Ifthe 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 Q1 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 gt manually as follows a Press the TEST CHK button for more than 4 seconds SET TEMP C hd LA Iessen IMER SE RU DE T m Ae B g CE 0365_M_I Bb 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 Select the CODE No 06 with a w SET TEMP button d Choose the shift temp with A e button EX UNIT No 1 6 CODE No 06 Shift temp 5 deg C lt 10 deg F gt 0366_M_I Press the SET button CODE No 06 SET DATA and change from flashing to ON state If you made a mistake press the CL button Finally press the TEST CHK button SM830076 _ 82 4 Service procedur
67. istance tester and mea sure 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 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 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 e Disconnect the connector of the desired electric part from terminal plate P C B Ass y etc Fig 23 e Similarly disconnect the lead wires from compressor capacitor etc Fig 24 e 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 Clip Copper tube or metallic part Clip Copper tube or metallic part Metallic part Clip _87 4 Service procedures Earthed wire AEN SL Insulation ji tester Fig 21 0638 KE Terminal plate Insulation tester 0639 KS Fig 22 Insulation ji tester Fig 23 0640_X_S From fan motor compressor and other parts Insulation toster 064
68. mpressor Motor Magnetic Contactor FMCA 1UL Coil rated 240 VAC 60 Hz Coil resistance at 77 F Q 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 17 2 Contact rated 220 VAC 5 A Power Transformer ATR 165C Rated Primary 220 VAC 60 Hz Secondary 14 V 0 4 A Capacity 5 6 VA Coil resistance at 73 F WHT WHT 395 5 BRN BRN 2 19 Thermal cut off temperature 266 Thermistor Coil sensor TH6 7 PBC 41E S4 i PBC 41E S26 Coil resistance 14 F 23 7 23 F 18 8 32 F 15 0 41 F 12 1 5 50 F 9 7 68 F 6 5 86 F 44 104 F 3 1 113 F 2 6 Thermistor Comp discharge gas sen PTC 51H S1 Coil resistance 140 F 158 F 167 F 176 F M gel 194 F 5 1 212 F 3 8 230 F 2 8 248 F 2 2 266 F 1 7 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 10033 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830076 17 1 Specifications 1 3 Other Component Specifications B Outdoor Unit MODEL N
69. n operation warning Is the power supply to the outdoor Check the power breaker etc unit normal and repair Voltage defective phase Does the outdoor unit operate when No problem two of the three phases are changed Actuation of negative phase protector Replace the fuse Is the fuse F1 F2 on the indoor unit PCB blown Is there a contact defect in the 3P connector No Correct the connection Replace the outdoor PCB 14 Symptom LCD on the remote controller displays CHECK E15 0345 MI When the group of the units are installed is there any mis cross p ER between interunit control wiring and refrigerant tubing Are the total capacities of indoor units to that of outdoor units less than 93 No Are there no contact failure between outdoor and indoor units No Select an indoor unit which matches with the outdoor capacity Check the contact Perform the same as CHECK E04 0646_M_S SM830076 68 4 Service procedures 15 Symptom LCD on the remote controller displays CHECK E16 When the group of the units are installed is there any mis cross Spar me Wing between inter unit control wiring and refrigerant tubing Select indoor units which match with the outdoor capacity Are the total capacities of indoor units to that of outdoor units more than 107 Confirm less than 5 indoor units are
70. n power supply switch Go to next R C line Press A ADD S1 button Execute auto address operation with the remote controller Yes Finish all R C line Le Display the combination number gt Le Set the remote controller to test operation Check according the self diagnostics function table and if you find defective parts repair them according to Service Manual Does the unit work Note Check the indoor side drain water Return the remote controller to normal 1585 MI NOTE 1 One of CN4 of all linked outdoor units shold be short 2 In case of using system controller zone registration is required after finishing Test run Regarding the zone registration please refer to Installation Instructions attached with system controller SM830076 101 4 Service procedures 12 P C B and Parts Location P C B CR THS2432 FOR INDOOR UNITS CN80 RED 26H CN78 BLU DP CN77 GRN LM F2 Fuse 250V 3A CN85 BLU DPH CN74 WHT PRY CN73 BLK SUP CNS GRY 49FI F1 Fuse 250V 3A CN84 YEL COM CN75 WHT SEC CN83 WHT FMI JP1 Jumper wire O O For sellecting the signal of T10 CR THS2432 Shipment state Pulse signal Jumper cut Static signal CN71 YEL T10 External input and output terminal CN9 RED FS E P ROM CN30 BRN
71. n the system 0 During the test run all of the 3 indicator lamps on the indoor unit will flash 0 During the test run the air conditioner runs continu ously and the thermostat does not control the sys tem To protect the air conditioner from overloading the outdoor unit will not start running for 3 minutes after power is applied or the air conditioner is turned off and then back on When the air conditioner fails to start the test run 1 or more of the 3 alarm indicator lamps on the indoor unit will flash SM830076 100 4 Service procedures 11 3 Test Run Procedure remote Turn on RCU address SW rol of sub remote control unit No la Recheck the test items before test operation Check the indoor and outdoor unit combination wiring Single type One indoor unit and one remote controller for one Multiple indoor units for one outdoor units Yes Turn on power supply for indoor units side first Then turn on power supply for outdoor unit side Group control for multiple outdoor units Set the outdoor unit R C address Turn on power supply switch Go to next R C line Press A ADD S1 button Execute auto address operation with the remote controller Finish all R C line Central control for multiple outdoor units CN4 Open Set the outdoor unit R C address Turn o
72. ndoor 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 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 Ci F Y RELEASE OF DEFROSTING Heating operation RANGE OUTDOOR AIR TEMP F X No counting time for detecting 50 frost 15 minutes The area below the heavy line Detecting the frost is the frost detection area Stand by time for defros 25 minutes Either continuous 8 minutes or cumulative 60 minutes are required to detect frost in the Frosting range Defrosting Refer to time chart Minimum continuous operating time by defrosting is 48 minutes 15 8 25 Occurs either when the temperature of C1 the ou
73. ns Outdoor Unit POWER SOURCE XHS2432 CH2432 230 208 V 1 Phase 60 Hz PERFORMANCE Cooling Heating Capacity BTU h 24 000 23 400 25 000 16 400 24 300 15 800 Moisture removal High Pints h 8 4 Air circulation Hi cu ft min 540 510 S E E R H S PF BTU Wh 7 0 7 0 ELECTRICAL RATINGS Voltage rating VAC 230 Available voltage range VAC Running amperes Max running amperes Power input Buck up heater Maximum fuse size FEATURES Controls Microprocessor Fan speeds Indoor Outdoor 3 and Automatic control 2 Auto Timer ON OFF 24 hours amp Program Air deflection Horizontal Vertical Automatic Air filter Washable easy access long life fiter 2 500 hr Operation sound Indoor Hi Me Lo Outdoor Hi 37 35 31 53 Refrigerant control Electronic Refrigerant Control Valve REFRIGERANT PIPING Limit of piping length 165 50 Limit of piping length at shipment 100 30 Limit of elevation difference between the two units Outdoor unit is higher than indoor unit 165 50 Outdoor unit is lower than indoor unit 100 30 Refrigerant piping Flare type Wide pipe Narrow pipe 1 4 6 35 3 4 19 05 SM830076 1 1 Unit Specifications DIMENSIONS amp WEIGHT Indoor unit
74. o CH3632 Compressor Motor Magnetic Contactor FMCA 1SUL Coil rated 240 VAC 60 Hz Coil resistance at 68 F Q 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 17 2 Contact rated 220 VAC 5 A Power Transformer ATR 165C Rated Primary 220 VAC 60 Hz Secondary 14 V 0 4 A Capacity 5 6 VA Coil resistance at 73 F WHT WHT 395 5 BRN BRN 2 19 Thermal cut off temperature 266 Thermistor Coil sensor TH6 7 PBC 41E S4 PBC 41E S36 Coil resistance 14 F 23 7 23 F 18 8 32 F 15 0 41 F 12 1 5 50 F 9 7 68 F 6 5 86 F 4 4 104 F 3 1 113 F 2 6 Thermistor Comp discharge gas sen PTC 51H S1 Coil resistance 140 F 158 F 167 F 176 F 185 F 194 F 5 1 212 F 38 230 F 2 8 248 F 2 2 266 F 1 7 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 5A Resistance at 77 F 100539 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830076 _18 1 Specifications 1 4 Dimensional Data A Indoor Unit XHS24
75. of air conditioning find the solution SM830076 _54 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 Check power supply wiring Q Check the power supply wires are correctly connected between terminal No 1 amp 2 on the 5P terminal plates in the indoor unit and the outdoor unit Check inter unit wiring Q 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 Disconnect SW Inter unit Field supply power line N _ 230 208 V rof LL B 1005 Power supply EENG single phase Ground 230 208 V 0 Cc V Indoor nit Check power supply EEn Inter unit control line aller sle Ce Q Check that voltage is within the specified range 10 of the rating Q Check that power is being supplied Outdoor Unit 1103 MI 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 Check the lead wires and connectors in indoor and outdoor units Q Check that the sheath of lead wire
76. oling Switching nnen 35 2 10 Defrosting Control Outdoor Heat Exchanger Coil eating 37 2 11 4 Way Valve Solenoid Control ss 38 A Normal Control Mode neren antennen 38 By AUTO Control Mod soeren eee en ane 39 2 12 Automatic Restart after Power Interruption annen eeeeeneeneeee nennen 39 2 13 Electronic Expansion Valve seen eee 40 2 14 Compressor Discharge Gas Temperature EEN 40 A COMMAS RP eden dede 40 B Heating Except During Defrosting AAA 40 2 15 Compressor Current Detection Circuit een 41 2 16 Electronic Expansion Valve Control 42 2 17 Voltage Detection Control seen 43 SM830076 25 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 OFF ROOM TEMP THERMO ON THERMO ON BODY SENSOR T 2 F SET TEMP T F T 2 F MORE THAN MORE THAN MORE THAN 5 MINUTES 3 MINUTES 5 MINUTES 3 MINUTES 5 MINUTES pt mt Aa et COMPRESSOR ON OFF ON OFF ON 1
77. om sensor TH1 KTEC 35 S6 Coil resistance Drain pump WP20SL 21 Rated 230 208 VAG 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 SM830076 15 1 Specifications 1 3 Other Component Specifications A Indoor Unit Power Transformer XHS3632 ATR 11174B 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 BRN BRN Thermistor cut off temperature 277 Thermistor Coil sensor TH2 3 PBC 41E S36 Coil resistance H Thermistor Room sensor TH1 KTEC 35 S6 Coil resistance 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 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830076 _16 1 Specifications 1 3 Other Component Specifications B Outdoor Unit MODEL No CH2432 Co
78. on 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 Cooled air comes out e 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 Failure in the electronic control valve activation Replace the sensor 0460_M_I SM830076 70 4 Service procedures 6 Procedures When a Specific Component Does Not Work Replace the capacitor 1 Indoor fan does not operate Is fan motor capacitor normal Yes Is there voltage output of P C B Ass y for fan motor Replace the P C B Ass y in the indoor unit e Check resistance of fan motor winding Out Replace the fan motor 2 Flaps in indoor unit s air outlet does not operate when you press SWEEP button No Check the louver motor resistance Is auto louver motor normal Replace the motor Is 2P connector socket WHT attached to panel Connect firmly connected firmly with 2P plug Replace P C B Ass y in the indoor unit 1200_M_S SM830076 my 4 Service procedur
79. ontrol PCB CN4 2P Black Refrigerant circuit address factory setting 0 AN wy Refrigerant circuit address 2P DIP switch green or Blue 10 20 position position ON S2 ON side A ADD S1 Automatic address setting start button Used for central control link system and group control Normally not used 1126_C_I R C address R C address R C address S3 2P dip switch green or Blue S2 Rotary switch Black ON _ ONside 00 auto address g g AU 0 when shipped from factory Both OFF EE 4 KR 7 Set to 0 OFF side ON ON side 02 In case of No 2 outdoor unit Both OFF J g Set to 2 1 2 OFF side ON ON side 03 In case of No 3 outdoor unit Both OFF J A B Set to 3 1 _2__loFF side ON _ ONside 11 In case of No 11 outdoor unit 10 s SW is ON 4 amp Set to 1 1 2 loer side ON ON side 21 In case of No 21 outdoor unit 20 s SW is ON g 4 Gi Set to 1 1 2 Jof side ON ON side Both 10 s and 20 s AN 30 In case of No 30 outdoor unit switches are ON VC Set to 0 1 2 OFF side SM830076 96 8 Automatic Address Setting Method For group control and central control with multiple outdoor units In case of central control Carry out automatic address setting with the remote controller 1
80. otor Indicator Lamp Assy Power Transformer Terminal Plate Auxiliary Relay Connector Auxiliary Relay Terminal Motor Operated Valve Float Switch 854 2 5268 772 00 0 XHS SM830076 _47 3 Electrical data 3 2 Outdoor Uni CH2432 ZEvZHO Z 00 28S 892S 2 7G8 W TAA NYD Os6y euwe yeg LHM d8 10 98UUOD lt m D A L HAHD AHO n AUD Aa NHA SI d 8 0118 de J0 98UUO0D ya Nga LH an EU LHM de 2 J0 98UU0D z NHg TAA Moez OV Av OW l A802 OV HL D D I ug LUE mia 935 de Hd 9 soe 925 TANI LH qzH de 13A dE Ona de mia NHD seo abieyosig aat DAME _ az z zH9 49 1811onu09 zo ona 19 LUED DUU 9141199 3 de alteid puwa en in Wun 100pu OL nga ag erelid eua uwa L BEN SSI ue BIG Di eum Ll jddng semog ito uur 100pU OL SM830076 Ag 3 Electrical data 3 2 Outdoor Unit D CH2432 e Schematic Diagram Terminal Plate 5P O WW le SEC Outdoor Coil C1 Outdoor Coil C2 Discharge Gas
81. pt 48 type No refrigerant High load e 4 way valve defect e Clogged refrigerant circuit e Electronic refrigerant control valve defect indoor unit Yes Is there connector contact defect Correct the connection Replace the outdoor unit PCB A 1147 THS 1 SM830076 66 4 Service procedures 11 Symptoms LCD on the remote controller displays CHECK P03 Alarm for unusual discharge temp of compressor Unusual discharge gas temperature e Refrigerant shortage Clogged refrigerant circuit e Electronic refrigerant control valve defect indoor unit 0343 MI 12 Symptom LCD on the remote controller displays CHECK P04 High pressure switch activation warning The system does not operate again Repair the wiring Yes Are there connection defects in the wiring No High pressure switch defect High pressure switch activation Both cooling and heating Electronic refrigerant control valve defect e Refrigerant over charged Cooling e Outdoor unit heat exchanger dirty clogged Outdoor unit air short Outdoor fan stopped Heating Outdoor unit air short e Indoor unit heat exchanger dirty clogged Large pipe side service valve closed e Indoor fan stop e Air filter clogged 0344 MI SM830076 _67 4 Service procedures 13 Symptom LCD on the remote controller displays CHECK P05 Negative phase detectio
82. red 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 remote controller Replace the indoor unit PCB 0334_M_I SM830076 62 4 Service procedures 4 Symptom LCD on the remote controller is displaying CHECK E04 Unusual communication between the indoor and outdoor units Cut the breaker and remove the indoor outdoor unit control lines connected to U1 and U2 of the indoor unit 8P terminal plate Is the contact good at the 2P connector for indoor serial Correct the connections communications on the outdoor unit PCB After shorting the test pin CN2 on the indoor unit PCB switch the breaker on Does the LED red on the PCB light up Replace the indoor unit PCB Yes Yes Cut the breaker remove the Is the contact good at the 2P Correct the connections indoor outdoor unit control connector for indoor serial lines connected to U1 and U2 of communications on the outdoor the outdoor unit 8P terminal plate unit PCB After shorting the test pin CN11 on the outdoor unit PCB switch the breaker on Do the LEDs red x 2 on the PCB flash Yes Indoor outdoor unit Replace the indoor unit PCB control lines are cut off Correct the wiring ji 0335 MI 5 Symptom LCD on the remote controller is displaying CHECK E05
83. s TH6 C1 BLK 0585_C_S 0584_C_S SM830076 93 4 Service procedures 5 Thermistor Characteristic Curve 1 Room temp sensor TH1 KTEC 35 2 Indoor heat exch coil sensor TH2 E1 TH3 E2 Outdoor heat exch coil sensor TH6 C1 TH7 C2 PBC 41E 40 V 35 i CH 30 25 20 Resistance kQ Resistance KQ M wo A A OD N DO CO CH 4 5 14 23 32 41 50 59 68 50 59 68 77 86 95 104 e Temperature F 1044_M_I gt Temperature F 1045_M_I 3 Compressor discharge gas temp sensor TH8 PTC 51H Resistance ko 176 194 212 230 248 266 a Temperature F 1149 THS 1 SM830076 _ 94 4 Service procedures 6 P C B Setting 0 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 O 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
84. s at the same time for more than 4 seconds a ta z kui z p H JN f 5 5 a 0356_M_I The UNIT No the address and temperature of the sensors instead of its usual information will flash on the display check with UNIT button and the display shows the sensor address and temperature as shown below gt UNIT No Indoor unit address AIR FLOW UNIT No MODE LI ITLI i nsor ress GR Sensor addre CODE No SETTI A Le z _ Sensor temperature C Ca FAN SPEED seu mes CS Oo 25 em GEN Re CE oe TEST CHK 0357_M_I NOTE Do not press TIMER SET button during the procedure _75 LH Following example shows the UNIT No Indoor unit address is fixed at 01 01 Q Incase of group control select the UNIT NO Indoor unit address which you want to D Each time you press the a w SET TEMP button you can select a different sensor 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 Sensor Address l CODE No Location of Sensor Themistor 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
85. s executed at each R C Refrigerant Circuit line one by one 0361 MI 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 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 If the automatic address operation finishes the display will disappear Execute the operation of the other R C line in the same way by following the above steps to h Complete the automatic address operation by pressing the TEST CHK button SM830076 _79 4 Service procedures G Confirm and change the indoor unit address Q 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 Les CHE ES c Cay CODE No SET TEMP or Ce Ca Sant FAN SPEED g Steen Ca est oy 0362_M_I Select the R C No which you want to change with the UNIT
86. s is not damaged Q Check that the lead wires are firmly connected at the terminal plate Q Check that the wiring is correct SM830076 _55 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 aie Change the setting temp suitable 9 9 p Is cooling load too heavy Review cooling load estimate 4 way valve is defective Replace the 4 way valve Refrigerant flow failure Refrigerant shortage Electronic refrigerant Replace the valve control valve is defective Compressor is defective Charge refrigerant gas Replace the compressor Service valves are not fully open Open the valves fully de enough cl Ar filter Clean the filter circulation is clogged Is fan speed Set the fan speed to set to LOW either MEDIUM or HIGH Refrigerant tubes between Insulate wide and narrow indoor and outdoor units tubes separately are not insulated 0458 MI SM830076 _ 56 B Heating b
87. s line service i valve Gas line X Ge nipple lt 19 05mm High re lee el GR pressure Switch d 4 way valve Heat exchanger Heat exchanger Distributor Strainer LL Electronic N Distributor ref control A valve 1 Liquid line CH service M valve U ee sa Liquid line O D nipple lt 9 52mm gt PE J Sub heat exchanger Strainer Cooling Cycle Heating Cycle 1398 THS 1 1 6 Operating Range Temperature Indoor Air Intake Outdoor Air Intake 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 Cooling Heating SM830076 24 2 PROCESSES AND FUNCTIONS 2 1 Room Temperature Control ees eee 26 CAN SOMME ui aa auwawa 26 CSA on 27 2 2 Cold Draft Prevention Heating Cycle 28 2 3 Automatic Fan Speed Indoor Unit essesesseseeeeeeessennnnessrnennnseeerennnneeerren 29 A OND eenen E eee nnen 29 B Heating nen eeen eee eee eel eeb 29 2 4 Outdoor Fan Speed Control 30 A SOMME EE 30 BSN sassen te ante eee eee le ee 30 2 5 Freeze Prevention Cooling EE 31 2 6 Condensing Temperature Control Cooling nennen ereen 32 2 7 Overload Protection HAGAN eege geet 33 2 8 Discharge Temperature Control Cooling and Heating ennn 34 2 9 Auto Mode for Automatic Heating Co
88. ss operation In case of group control a few minutes for each R C max about 20 min for each Displaying Indoor Outdoor Unit Combination Numbers Display the indoor outdoor unit address after automatic address setting 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 2 3 Indoor Units 2 1 2 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 SM830076 4 Service procedures 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
89. ta in memory Follow the procedure below only when erasing is necessary 1 To erase accessed data press the CL button LI When erasing is finished mark appears on the controller s display AN 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 bi 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 LI Unusual condition All displays flash ON and OFF for 10 seconds then disappear Na After checking the panel be sure to set the RCU CK switch to this original OFF position SM830076 _78 4 Service procedures F Execute the auto address operation LI 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 a buttons at the same time for more than 4 seconds bi Set CODE No AT with a e SET TEMP button In this mode the auto address operation i
90. tdoor Release of defrosting heat exchanger coil has reached 50 F or above or when the maximum defrosting time 9 minutes has elapsed 1143_THS_I S e Fig 13 Time Chart for Defrosting 9 1 MINUTE MAX 9 MINUTES 1 MINUTE COMPRESSOR ON ON ON SOLENOID COIL 4 WAY VALVE ON ON OUTDOOR FAN H OR L ON ON INDOOR FAN WE ate theese el ___ OFF SET SPEED OFF OR LL OR LL STANDBY y INDICATOR STANDBY APPEARS Defrosting Release of Start Defrosting 0442_M_S Fig 14 Q During the defrost cycle STANDBY appears on the remote controller Cold Draft Prevention may operate occasionally SM830076 37 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 OFF ON OPERATION BUTTON ON OFF ON MODE COOL COOL BUTTON HEAT HEAT HEAT oe ee gt
91. te Possible causes of troubles controller controller display display Remote controller is detecting Error receiving of serial communications signal E01 Operation lamp unusual signaliromiindoor Unit Error transmitting of serial communications signal E02 flashes e Indoor unit is detecting unusual signal from the remote controller and group control E03 Operation lamp No serial communications signal Timer lamp Improper setting of indoor unit or Indoor unit address setting is duplicated E08 Heat stand by remote controller Remote controller address RCU ADR is duplicated E09 lamp Indoor unit is detecting unusual Error transmitting of serial communications signal E10 5 signal from signal option Error receiving of serial communications signal E11 S Improper setting of indoor unit or When using flexible combination control main indoor unit address E14 S remote controller setting is duplicated judged by outdoor unit bal SEH Ai 2 Indoor unit is detecting unusual Error receiving of serial communications signal E04 Heat stand by ignal f nit ai oat A E Signal from outdoor Unit Error transmitting of serial communications signal E05 lamp flashes 8 Outdoor unit is detecting Error receiving of serial communications signal E06 Operation lamp w unusual signal from indoor unit d 5 Confirmation error
92. ted 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 Air intake grille 1584_M_I 11 2 Performing Test Run Be careful since the fan will A 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 Setthe 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 SM830076 99 4 Service procedures Set the Operation Selector at the ON position Other wise the unit will stop or will not run correctly The TEST RUN switch is used AN only for servicing the air conditioner DO NOT use this switch for normal operation Otherwise it may put stress o
93. unction controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coils have warmed up LI 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 e During Thermo OFF refer to 2 1 B Room Temperature Control Heating e During the defrosting operation refer to 2 10 Defrosting Control Heating e Until either the coil temperature E2 reaches 81 F or when a maximum of 6 minutes has past Q The indoor fan motor operates in L instead of LL for 3 seconds as it starts to give the fan an initial boost 92 WA Lo MAX 6 MINUTES 88 INDOOR UNIT COIL TEMP E2 F 81 77 4 50 7 SET AUTO OR H LL LL OFF LL L M H FAN SPEED Mi LL LL OFF LL L M L LL LL OFF LL L L L STANDBY z INDICATOR STANDBY APPEARS LL Very low speed M Medium speed L Low speed H High speed 1135_THS_I Fig 3 Chart Summary and Explanations The main idea of this chart is to show that the indoor fan speed increases and gets closer to the set fan speed as the coil temperature E2 rises The indoor unit s coil temperature is taken from sensor E2 located in the middle of the indoor heat exchange coil The dotted line shows that the indoor fan motor is OFF When the temperature at sensor E2 falls below 50 F the indoor fan motor stops running SM830076 _ 28
94. utput ON time Outdoor fan High fan speed H 0 5 seconds Operation order Outdoor fan Low fan speed L 0 5 seconds 4 way valve 0 5 seconds Compressor 0 5 seconds SM830076 104 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 e When checking pin operation stop the indoor and outdoor units with the remote control unit 14 1 FORCED OPR pin of the indoor coniroller 0 Switch the pin from normal operation to check operation e Relay RY6 turns ON gt Indoor fan motor operates at the H fan speed e Relay RY2 turns ON gt Dew prevention heater DPH turns ON Indoor flap motor moves to the F1 position e Electronic control valve opens fully 480 steps e Even if the remote control unit is not connected the indoor unit operates independently 14 2 Shorting CK L or CK H pin of the outdoor PCB When shorting the cooling pin CN8 with normal operation e Relay RY3 is turned ON for 3 seconds The outdoor fan motor operates at the LL fan speed e Relay RY4 is turned ON for 3 seconds The outdoor fan motor oprates at the H fan speed e Turn ON relay RY2 under the above condition gt The magnet switch 52C turns ON X It will take about 18 seconds before cooling operation begins Shorting the heating pin CN9 with normal oper

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