Sanyo C3632 User's Manual
Contents
1. 16 A Indoor Uni au u un 16 B Outdoor endo ene Lt 17 1 9 Refrigerant Flow S m T 18 1 6 Operating Range dun sss 19 2 PROCESSES AND FUNCTIONS 21 2 1 Room Temperature Control aaaaaaalaaaaanaavananannnnnanananananuunnnouansunananunnnaanaaunia 22 2 2 Freeze Sst 23 2 3 Drain Pump Control Meer 23 2 4 Outdoor Fan Speed Control aaaaaaaaanasnan nnnanannanannnansanunnannanunaunsaaunnunnaaaannuaa 24 3 ELECTRICAL DATA 25 del Indoor nit es 26 9 2 OURO OOF nag eee ea 28 4 SERVICE PROCEDURES uns nsc ant te 33 431 uu Sian DL 34 4 2 ASensoris DefectiVe eee eee en 45 4 3 Operation of Major Electrical Parts 45 4 4 Checking the Electrical Components 46 5 830070 La 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 main2. Indoor unit Measure the coil resistance Primary 230 208 V Measure the resistance between two WHT lead wire terminals of socket connected to power transformer Secondary 10 6 V Measure the resistance between two BRN lead wires Refer to 1 3 Other component specifications Power transformer TR Outdoor unit Measure the coil resistance Primary 230 208 V Measure the resistance between two WHT lead wire terminals of socket jointed to power transformer Secondary 14V Measure the resistance between two BRN lead wires Refer to 1 3 Other component specifications Indoor fan motor FMI Indoor unit Measure the coil resistance Measure the resistance between each terminal of the socket connected to the indoor fan motor Refer to 1 2 A Major component specifications Outdoor fan motor FMO Outdoor unit Measure the coil resistance Measure the resistance in the same manner as explained above Refer to 1 2 Major component specifications Motor capacitor Both in indoor and outdoor unit Remove the lead wires from the capacitor terminals and then place a probe on the capacitor terminals as shown in Fig 11 Observe the deflection of the pointer setting the resistance measuring range of the multimeter to the maximum value Multimeter The capacitor is good if the pointer bounces to a gre
3. 26 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram 28 SM830070 2052 3 1 Indoor Unit D XS3632 TH1 Coil Earth Terminal e Electric Wiring Diagram TH2 Room Terminal Plate 4P To Outdoor Unit GRN YEL GRN YEL Earth Terminal W 854 2 5268 578 00 0 XS3632 SM830070 26 3 1 Indoor Unit D XS3632 Schematic Diagram SS ages E CR TS2432 APA s Pea PRY Fi 2 3A 1 TRI lt 3 9 5 me e pu m Avian Rely sw 854 2 5268 578 00 0 XS3632 SM830070 27 3 2 Outdoor Unit C3632 Electric Wiring Diagram Terminal Plate 6P p Connector P 8P WHT S End 5 i cn GRN YEL 854 2 5268 620 00 0 C3632 Earth Terminal GRN YEL 49FO1 Connector Connector 1 2 P 2P WHT Lilzis t PNK WHT k z EEE ENE O96 Earth Terminal HUN 200pUI oL A OEZ A BOT Hdl 2 09 Aiddng SM830070 28 Outdoor Unit C3632 Terminal Plate 6P Schematic Diagram D 854 2 5268 620 00 0 C3632 29 Outdoor Un 2 CL3632 3 2 269670 1 00 619 89 9 2 98 234N49 TANNED 2O36F uwa eg BS ra EEEF EEDE Te zr 5 oo edis LHM 204200009 20
4. UHM 48 20199000 Buui 21149913 A Xe N AA 49 ei amp ld puw uue3 Ajddns OL A DEC A 802 Hdi SM830070 30 Outdoor Unit CL3632 Schematic Diagram CR CL2432 FPT TT TT TT Controller F1 remnrae ron 2 outdoor Fan Motor hemasa D coma pre Jj TH Thermistor Outdoor Temperature m RY1 2 3 Auxiliary Relay 1Y 4Y Auxiliary Relay ETT 854 2 5268 619 00 1 CL3632 SM830070 31 4 SM830070 32 4 SERVICE PROCEDURES 4T TiOUDIESHOOUNG iae i rto eite tene ns lumu ss Soest es 34 1 Check before and after Troubleshooting 34 2 Air Conditioner does not Operate 35 3 Outdoor Unit does not 39 4 Indoor Unit does not Run 41 5 Some Part does not Operate 41 6 Outdoor Fan does not Run 42 7 Outdoor Fan Speed is Switched from High to Low even when the Outdoor Temperature Falls below 78 F C3632 42 8 Outdoor Fan Speed is not Switched from High to Med even when the
5. Limit of elevation difference ft m Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52 outer diameter Wide tube in mm 3 4 19 05 Refrigerant amount at shipment Ibs kg R22 9 48 4 3 SM830070 DIMENSIONS amp WEIGHT Unit dimensions Outdoor unit Height in mm 11 1 32 280 48 5 8 1 235 Width in mm 41 11 32 1 050 37 940 EEN EEEN j TE Net weight Indoor grille dimensions Width in mm 45 9 32 1 50 Depth in mm 33 27 32 860 15 7 9 Net weight 0 12 7116 316 52 7 32 1 326 EEK 20 1018 Depth in mm 32 2532 833 16 12 32 416 Ibs kg 71 32 223 101 6 Indoor Unit Package dimensions Shipping weight cu ft m 19 8 0 56 Height mmf 4392 width 4912 Gs Shipping volume Indoor grille Package dimensions bs cg DATA SUBJECT TO CHANGE WITHOUT NOTICE Cooling Rating conditions 7 Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 95 F DB 75 F WB Full load conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 115 F DB Shipping weight Shipping volume SM830070 1 1 Unit Specifications Outd
6. Please use this manual to make your work easier keep the air conditioner functioning well and keep your customers satisfied SM830070 1 SPECIFICATIONS 1 1 1 2 1 4 1 5 1 6 Unit Specifications C 6 Major Component Specifications 10 A Indoor RFID S Q QE asd Une ss 10 B GTD Lo ole AOL LT E E 11 Other Component Specifications 13 A Indoor Unit SE 13 B Outdoor UN s esce ee 14 Dimensional Data Rt eT VR sd 16 dek dude uri vex DRE RARE 16 B Outdoor PERTINET 17 Refrigerant Flow Diagram 18 Operating na 19 SM830070 1 1 Unit Specifications POWER SOURCE 230 208 V 1 Phase 60 Hz Capacity BTU h 36 000 35 000 ELECTRICAL RATINGS Tv a a C amen w 3 440 3250 V V A A W Power 97 959 Z L toe Maximum fuse size Outdoor Hi dB A 56 RD Ec
7. 9 171 27 F E DATA SUBJECT TO CHANGE WITHOUT NOTICE Face area ft SM830070 1 2 Major Component Specifications B Outdoor Unit mme pese SH Compressor Mo Coil resistance Ambient temperature 77 F Safety device internal type Overload relay models pO operating ampere 77 AT W Ibs V 230 V 30 W kg R22 9 48 4 3 High pressure switch ACB 1UB11 Set pressure OFF kg cm 20 ON kg cm 24 2 0 Propeller 2 18 3 32 460 3 AUTO C Mes _ No of pole rpm 230 V High Nominal output Coil resistance Q BRN WHT 67 14 VLT YEL 11 42 Ambient temperature 68 F WHT VLT 64 85 YEL 10 60 Safety device Operating temperature Heat exchange Coil Aluminum plate fin Copper tube Rows Fins per inch 2 12 7 ft m 11 63 1 08 DATA SUBJECT TO CHANGE WITHOUT NOTICE Refrigerant amount charged at shipment Run capacitor SM830070 12 1 3 Other Component Specifications Indoor Unit MODEL No Power Transformer ATR evan 10 6 V 0 93 A 9 85 VAC Coil resistance 2 1 Ambient temprature 77 F WHT 101 BRN BRN 042 Thermistor cut off temperature Thermistor Coil sensor Drain pump WP20SL 21 Rated AC 200 V 14 7 W FS
8. 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 SM830070 WHO SHOULD USE THIS MANUAL This service manual is made to assist the service technician apply his knowledge and training to this model air conditioner This manual is written both for experienced service persons and those who are new to air conditioning service To help those with less experience or who are new to this kind of unit we have included more explanations of basic procedures in simple language than is usual in some service manuals The experienced technician will of course find he knows many of these things already and can go directly to the procedures and infor mation he needs the less experienced technician will better understand what to do even before he arrives on the job and therefore be better able to work by himself as well as assist the more experienced technician TABLE OF CONTENTS 1 SPECIFICATIONS SSL a ee 5 1 1 Unit SpecilicationS asm sd baka st 6 1 2 Major Component Specifications ss 10 A Indoor ntn n en nn ne RR 10 OUtdoOOF UM u n Rn MUR nr nes 11 1 3 Other Component Specifications esse 13 CALIDHOGE MIE clock eae al a EL 13 B O tdoop UDIDz uz unumanmi C 14 1 4 Dimensional a
9. Outdoor Temperature Falls below 77 F Outdoor Fan Speed is not Switched from Med to Low even when the Outdoor Temperature Falls below 59 F CL3632 42 9 Outdoor Fan does not Run for CL3632 43 10 Compressor does not Run 43 11 POOF ua UO aS Eat ee 44 12 EXCESSIVE GOOG o etc tempor IBI UR de 44 4 2 A Sens r iS a aS ua Tas 45 4 3 Operation of Major Electrical Parts 45 4 4 Checking the Electrical Components 46 1 Measurement of Insulation Resistance 46 2 Checking the Protective Devices 47 3 Checking the Electrical Parts 48 4 Thermistor Characteristic Curve 49 SM830070 33 4 1 Troubleshooting 1 Check before and after Troubleshooting Many problems may happen because of wiring or power supply problems so you should check these areas first Problems here can cause false results in some of the other tests and so should be corrected first Check power supply wiring a Single phase Check
10. WHT WHT 4825 BRN 3 95 Thermistor Outdoor Temp sensor 41E 54 Power Transformer Coil resistance DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830070 15 1 4 Dimensional Data A Indoor Unit XS3632 40 5 32 Suspention bolt 16 33 27 32 19 11 16 Dimension inch Air intake grille Air outlet Refrigerant liquid line 03 8 Refrigerant gas line 23 4 Drain connection 8 Power supply entry For discharge duct Humidifier option mounting hole 9 Suspension bolt mounting 1346 X 5 SM830070 1 4 Dimensional Data B Outdoor Unit C3632 CL3632 1 31 32 1 31 32 13 3 8 48 5 8 N A A 11 WE Dimension inch D Hole for anchor bolt 4 213 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 8 Power supply inlet 1342 C S SM830070 ATS 1 5 Refrigerant Flow Diagram Indoor Unit XS3632 Outdoor Unit C3632 CL3632 Compressor Evaporator Capillary Condenser Narrow tube service valve S 2 1345 5 SM830070 18 1 6 Operating Range 53632 C3632 indoor Air Intake Temp Outdoor Air Intake Temp 95 F DB 71 F WB 115 F DB 67 F DB 57 F WB 67 F DB 83632
11. 0218 103 MAX Rated Contact rated AC 200 V 50 W Switch Ass y SW X363GS Indicator Lamp Ass y IND XS3632 Synchronized Motor MT8 3C DATA SUBJECT TO CHANGE WITHOUT NOTICE PBC 41E 536 14 F 23 7 41 F 12 1 23 F 18 8 50 F 97 32 F 15 0 59 F 8 0 Coil resistance KTEC 35 S6 32 F 16 5 104 F 27 Thermistor Room or coil sensor Coil resistance 41 F 12 8 113 F 22 50 F 10 0 5 122 F 1 8 68 F 63 j 131 F 15 86 F 4 0 i SM830070 13 1 3 Other Component Specifications B Outdoor Unit Compressor Motor Magnetic Contactor rated Goi resistance o 0 0 0 0 0 0 serie Contact rated Main Contact rated Auxiliary Power Relay rated resistance at 77 P Thermostat Coil sensor Operating Temperature F 79 3 OFF 75 3 ON Contact rated 200 to 240V 1A Thermistor PTC TDK 101YV Max voltage AC 400 V Resistance at 77 F 100 120 96 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830070 14 1 3 Other Component Specifications B Outdoor Unit MODEL No CL3632 Compressor Motor Magnetic Contactor FMCA 1SUL Coil resistance at 68 F 588 10 Contact rated Main AC 240 V 26 A Contact rated Auxiliary AC 240 V 3 A Power Relay HH62S AC 220 V 5 A ATR 135B Rated Ea a
12. CL3632 Indoor Air Intake Temp Outdoor Air Intake Temp 95 F 0 71 F WB 115 F DB 67 F DB 57 F WB 0 F DB 19 SM830070 SM830070 1 e Q 1 2 PROCESSES AND FUNCTIONS 2 1 Room Temperature Control 22 2 2 Freeze Prevention u u 23 2 3 Drain Pump Control 23 2 4 Outdoor Fan Speed Control 24 SM830070 21 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 ROOM TEMPERATURE MORE THAN 3 MINUTES WITHIN 3 MINUTE THERMO ON _ THERMO OFF THERMO OFF 2 MORE THAN 3 MINUTES 5 MINUTES COMPRESSOR INDOOR FAN OUTDOOR FAN Fi g 1 1028 X S Chart Summary and Explanations Once the compressor starts it keeps running for 5 minutes Once the compressor stops it will not start running again
13. SERVICE MANUAL SANYO XS3632 C3632 CL3632 SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No PRODUCT CODE No OUTDOOR MODEL No PRODUCT CODE No C3632 854 014 54 854 014 51 CL3632 854 014 52 Indoor Unit Outdoor Unit XS3632 C3632 CL3632 85464849170000 REFERENCE NO SM830070 Please Read Before Starting This air conditioning system meets strict safety and operating Standards As the installer or service person it is an important part of your job to install or service the system so it operates safely and efficiently For safe installation and trouble free operation you must Carefully read this instruction booklet before beginning Follow each installation or repair step exactly as shown Observe all local state and national electrical codes Pay close attention to all warning and caution notices given in this manual This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage If Necessary Get Help These instructions are all you need for most installation sites and maintenance conditions If you require help for a special problem contact our sales service outlet or your certified dealer for additional instructions In Case of Improper Installation The manufacturer shail in no way be responsible for improper instaltation or maintena
14. at extent and then gradually returns to its original posi tion NOTE The range of deflection and the deflection time differ according to the capacity of the capacitor Compressor motor capacitor Fan motor capacitor Fig 11 0 5 5 830070 6 Continuity of fuse on P C B Ass y Check for continuity using a multimeter as shown in Fig 12 Method Used to Replace Fuse on PCB Ass y 1 Remove the Ass y from the electrical compo nent box 2 Remove the fuse from PCB Ass y using pliers while heating the soldered leads on the back side of the PCB Ass y with a soldering iron 30W 60W Fig 13 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 sure not to break down the varistor 4 Thermistor Characteristic Curve Room temp sensor KTEC 35 Resistance 50 50 68 77 86 95 104 Temperature F 1044 MI Resistance mA 1042 X 5 Soldering iron Fig 12 D Coil sensor PBC 41E 49 14 23 32 41 Temperature F 1043 X 5 13 1045 M SM830070 SANYO FISHER Service Company CENTRAL REGION 1165 Allgood Road Suite 22 Marietta GA 30062 Phone 770 509 5230 Fax 770 579 2860 Jan 99 Printed in U S A
15. ay 1Y or 2Y 0620 X 5 G Check indoor fan motor thermal protector 49FMI Disconnect the socket from 9P WHT connector Check the continuity between No 8 and No 9 poles of the 9P socket No continuity The thermal protector 49FMI is operated Check fan rotation Rotate the fan gently once or twice by hand Check fan casing for foreign matter on the inside Remove foreign matter or repair Repair or replace o0 XS Fan cannot be rotated Fan motor burnout or foreign matter in bearing Check fan motor capacitor H Check fuse on the P C B Ass y in the indoor unit Check fuse on the P C B Check resistance of drain Ass y in the indoor unit pump winding DP for continuity OK When the fuse blows Check transformer TR1 Check coil of compressor motor magnetic contactor OK 52C OK Check resistance of indoor fan motor winding r winding P C B Ass y is defective OK Check resistance of louver motor winding LM OK 1034 X 5 5 830070 38 3 Outdoor Unit does not Run A Check COOL FAN selector switch in the remote control unit 5 COOL FAN selector switch NO set to COOL Set to COOL 0623 X 5 Check set temperature Try to lower set temperature by Temperature setting button COOLER Set Operation selector switch to TEST in the i
16. e Outdoor unit Power supply cords ower line Ground P Set the circuit breaker to OFF D Remove power supply cords from the terminal plate in the outdoor unit Check insulation resistance of power supply cords Remove inter unit power line from the terminal plate in the outdoor unit Check insulation resistance of outdoor unit 8 Remove inter unit power line from the terminal plate in the indoor unit Check insulation resistance of indoor unit Inter unit power lines are defective 2 85 Execute rewiring Insulation of outdoor unit is defective Insulation of indoor unit is defective Execute rewiring Check insulation resistance of electrical parts in the outdoor unit Check insulation resistance of electrical parts in the indoor unit 1340 X SM830070 b Circuit breaker trips in several minutes after turning the air conditioner on There is a possibility of short circuit Check capacity of circuit breaker Replace it with a a suitable one capacity of circuit larger capacity breaker sufficient Check resistance of outdoor fan moior winding Check resistance of compressor motor winding 0614 X 5 Neither indoor unit nor outdoor unit runs A Power is not supplied Circuit breaker is tripped Reset the breaker Check power supply Is power being supp
17. ed to either HIGH or MEDIUM Is fan speed set to LOW Review cooling load estimate Reduce cooling load or if performance of air conditioner replace the unit with is normal higher cooling capacity 1040 X S Excessive Cooling Set the temperature to higher value using temperature setting button of the remote control unit The set temperature is too low s the remote control unit installed installation at a place where it can Change installatio position of the remote control unit detect the room temperature properly SM830070 4 2 A Sensor is Defective D Indoor heat exchanger coil temp Sensor is defective a Open No continuity in sensor Compressor and outdoor fan repeat ON for 10 minutes and OFF for 6 minutes when sensor opens b Short Freeze Prevention does not operate when dehumidified water is frozen on the indoor coil Room temp Sensor in the remote control unit is defective a Open No continuity in sensor Neither outdoor fan nor compressor runs b Short Outdoor fan and compressor do not stop Excessive cooling 4 3 Operation of Major Electrical Parts Operation Mode Operation Indoor unit and Remote Control unit Room Night setback Function Temp Cool Timer Energy saver Indicator lamps Compressor Thermo ON Thermo OFF KEREN ECHECS setback IThemoOFF O O 709 T
18. for 3 minutes If you change the operation mode during the cooling cycle the contro circuit stops the compressor for 3 minutes For 5 minutes after the compressor is first turned on and for 3 minutes after it is turned off the compressor is not controlled by the room sensor Thermo ON When room temperature rises 1 F above the set temperature T T 1 F Compressor ON Thermo OFF When the room temperature is equal to or below the set temperature T Compressor OFF SM830070 2 2 Freeze Prevention Freeze Prevention keeps the indoor heat exchange coil from freezing Freezing reduces the efficiency of the unit and frost buildup on the coil blocks cool air circulation from the indoor unit s fan FREEZE FREEZE PREVENTION PREVENTION MORE THAN 10 MINUTES 6 MINUTES 10 MINUTES 6 MINUTES INDOOR COIL TEMPERATURE SE THERMO ON COMPRESSOR OUTDOOR FAN INDOOR FAN 1029 X_ Fig 2 2 3 Drain Pump Control Drain pump operates when compressor starts to operate or when Float Switch turns off FLOAT SWITCH ON iow water level OFF high water level OFF 20 MINUTES COMPRESSOR OFF DRAIN PUMP OUTDOOR FAN INDOOR FAN 0609 X 5 Fig 3 SM830070 23 _ 2 4 Outdoor Fan Speed Control 1 2 C3632 Type In low outdoor temperature the outdoor fan is set automatically from HIGH to LOW to prevent the indoor heat exchanger from freezing Whe
19. imaer LON Timer set OFF Timer O O Freeze prevention O O Fa 10 Sweep Fa loj col Jojo Fa dol NOTE O Refer to Cooling Mode Flap oj EN en SBS es EE EE NS 5 830070 45 4 4 Checking the Electrical Components 1 Measurement of Insulation Resistance The electrical insulation is acceptable when the resistance exceeds 1 MQ D Power Supply Wires Clamp the earthed wire of the Power Supply wires with a lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the power wires Fig 6 Then measure the resistance between the earthed wire and the other power wires Fig 6 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 7 Outdoor Unit Measure the resistance by placing a probe on the terminal plate in the same manner as explained above Fig 7 Measurement of Insulation Resistance for Electrical parts Disconnect the connector of the desired electric part from terminal plate P C B Ass y etc Fig 8 Similarly disconnect the lead wires from compressor capacitor etc Fig 9 Measure the resistance in the same manner as illustrated on the right Refer to Electrical Wiring Diagram if the probe does no
20. lie to outdoor unit NO Wait for recovery or consult power supply company Power failure 0615 X 5 B Check remote control unit Try to run both indoor and NO outdoor units with another remote control unit Refer to item C The other remote control unit is defective 0616 X 5 SM830070 36 C Check Operation selector switch in the indoor unit Has Operation selector switch been set to ON position IND LAMP Ass y or P C B Ass y in the indoor unit is defective Set Operation selector Switch to ON But neither unit runs Switch Ass y or P C B Ass y in the indoor unit is defective 0617 X 5 D Check compressor motor protectors a High pressure switch 63PH Disconnect the socket from 2P WHT connector Check the continuity between No 1 and No 2 poles of the socket Check high pressure switch Does high pressure switch actuate 63PH Is outdoor heat exchanger coil dirty or are there obstacles near air suction inlet of outdoor unit Clean heat exchanger coil or remove obstacles Check if outdoor fan rotates Refer to Only outdoor fan does not run 0618 X 5 E Transformer in indoor unit Check resistance of transformer winding TR1 1033 X 5 SM830070 37 F Check auxiliary relay 1Y or 2Y Check coil resistance of auxiliary rel
21. n the outdoor temperature falls below 78 F the outdoor fan is set from HIGH to LOW automatically When the outdoor temperature rises to 82 F the outdoor fan is set from LOW to HIGH automatically CL3632 Type In low outdoor temperature the outdoor fan is set automatically from HIGH to MED LOW to prevent the indoor heat exchanger from freezing When the outdoor temperature falls below 77 F the outdoor fan is set from HIGH to MED automatically When the outdoor temperature rises to 81 F the outdoor fan is set from MED to HIGH automatically When the outdoor temperature falls below 59 F the outdoor fan is set from MED to LOW automatically When the outdoor temperature rises to 63 F the outdoor fan is set from LOW to MED automatically When the outdoor temperature falls below 47 F the outdoor upper fan is set from LOW to OFF and Lower fan is set from LOW to MED antomatically When the outdoor temperature rises to 50 F the outdoor upper fan is set from OFF to LOW and Lower fan is set from MED to LOW antomatically 80 Upper fan H Lower fan H 30 Upper fan OFF Lower fan M Upper fan M Lower fan M FAN ROTATION RPM 230 Upper fan L Lower fan L 47 50 59 63 77 81 OUTDOOR AIR TEMPERATURE F DB 1344 5 Fig 4 5 830070 24 3 ELECTRICAL DATA 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram
22. nce service including failure to follow the instructions in this document SPECIAL PRECAUTIONS When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ONLY A QUALIFIED EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequate ground ing can cause accidental injury or death Ground the unit following local electrical codes Connect all wiring tightly Loose wiring may cause overheat ing at connection points and a possible fire hazard When Transporting Be careful when picking up and moving the indoor and outdoor units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers When Installing 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 Moist or Uneven Locations Use a raised concrete pad or concrete blocks to provide a solid level foundation for the outdoor unit This prevents water damage and abnormal vibration in an area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame Provide a
23. ndoor unit Outdoor unit runs Is room temperature too low Try to run both indoor and outdoor units with another remote control unit The other remote control unit is defective Room sensor in the remote control unit is defective 0624 X 5 SM830070 362 C Check compressor motor magnetic contactor Check coil resistance of compressor motor magnetic contactor 52C 1035 X D Check indoor unit P C B Check P C B Ass y Check voltage between terminals No 2 and No 4 at terminal plate No voltage appears P C B Ass y is defective 0628 X 5 F Check float switch Is drainage prevented from flowing YES Check drain hose e Check float switch FS E Check outdoor unit P C B CL3632 Type Check P C B Ass y Check voltage between terminals L1 and L2 at terminal plate No voltage appears P C B Ass y is defective 1036 X S Refer to 2 3 Drain Pump Control NO Wait for 20 minutes 0629 X S SM830070 40 4 Indoor Unit does not Run Indoor fan and louver motor do not run P C B Ass y is defective 0630 X 5 5 Some Part does not Operate A Indoor fan does not run Check fan casing for foreign matter on the inside Remove foreign matter or repair Fan cannot be rotated Check fan rotation Rotate the fan gently once or t
24. not Run for CL3632 Check fuse on PCB Ass y in outdoor unit for continuity If fuse blows e Check resistance of primary _ winding of transformer TR 1038 X 5 10 Compressor does not Check compressor motor capacitor RC1 Check PTC Check resistance of compressor motor winding 43 Wait for 30 minutes until com pressor has cooled Compressor runs Compressor internal thermal protector is operated Check power supply voltage Is voltage abnormally low Is outdoor heat exchanger coil dirty or are there obstacles near air suction inlet 1039 X 5 SM830070 11 12 Poor Cooling Check installation position of remote control unit Does cool air from air condi tioner reach remote control unit directly Change installation position of remote control unit Insulate wide tube and then execute taping with narrow tube Is wide tube between indoor unit and outdoor unit insulated Temperature difference is small Possibility of refrigerant shortage Charge refrigerant R22 Measure temperatures of suction and discharge air of indoor unit Temperature difference between suction and discharge air is large enough Approx 10 deg or more Check clogging of air filter Clean filter Air filter is clogged YES Set fan spe
25. omponent Specifications A Indoor Unit MODEL No 230 208 V 1 phase 60 Hz Remote controller Accessory Controller P C B Ass y Control circuit fuse Switch Ass y Fan Number diameter mm Source ORG YEL 227 Coil resistance BRW 71 1 Ambient temperature 68 F WHT VT 87 VLT 43 2 VLT ORG 133 5432 Operating temperature 266 144 Close F 174 2 27 F Face area TNNT Model No PNR XS3632 DATA SUBJECT TO CHANGE WITHOUT NOTICE SM830070 10 1 2 Major Component Specifications B Outdoor Unit seme Compressor ki Compressor 3180 Coil resistance Ambient temperature 77 F Safety device Internal type VAC 400 V 40 pF Refrigerant amount charged at shipment Ibs kg R22 9 48 4 3 High pressure switch ACB 1UB11 Set pressure OFF kg m ON Propeller 2 18 3 32 460 9 189 20 2 2 AUTO Mode KFOBT 9106 x2 230 208 V 1 phase 60 Hz No of pole rpm 230 V High 6 879 Nominal output 110 2 Coil resistance BRW WHT 67 14 VLT YEL 11 42 Ambient temperature 68 F VLT 6485 YEL 10 60 Operating temperature 248
26. oor Unit nn nn ELECTRICAL RATINGS start Power factor 96 Maximum fuse size Drain pump Drain pipe trade size Compressor Outdoor Hi dB A REFRIGERANT TUBING d tom Limit of elevation difference ft Outdoor unit is higher than indoor unit 165 50 between the two units Outdoor unit is lower than indoor unit 100 30 Refrigerant tube Narrow tube in mm 3 8 9 52 outer diameter Wide tube in mm 3 4 19 05 Refrigerant amount at shipment Ibs kg R22 9 48 4 3 3 z o e qi e 2 SM830070 DIMENSIONS amp WEIGHT Unit dimensions 11 1 32 280 AZ 1 050 en e Net weight Indoor grille dimensions Heg incom o 1 0 Wit mm it 9 6 Net weight Indoor Unit Package dimensions Shipping weight Shipping volume Indoor grille oan Dep mim Package dimensions DATA SUBJECT TO CHANGE WITHOUT NOTICE Shipping weight Shipping volume Cooling Rating conditions Indoor air temperature 80 F DB 67 F WB Outdoor air temperature 95 F DB 75 F WB Full load conditions Indoor air temperature 80 F 67 F WB Outdoor air temperature 115 F DB SM830070 1 2 Major C
27. 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 schematic and wiring diagrams so you can find the parts you need to check when something is wrong and see how they should be connected Section 4 Service Procedures has two main parts a diagnostic chapter to help you find the specific component to replace or adjust and a chapter with specific procedures and values to guide you in checking the electrical components in the unit HOW TO USE THIS MANUAL You can use this manual both as a reference to find specific information about the capacity functions and construction of this unit and as a source of information to help you set up and maintain the unit When this unit is not working properly and the cause is not known you can use the procedures in Section 3 Servicing Procedures to find the problem fix it and restore the unit to its proper functioning This air conditioner has many helpful self diagnos
28. suitable air baffle In a Snowy Area for Heat Pump type Sys tems Install the outdoor unit on a raised platform that is higher than drifting snow Provide snow vents When Connecting Refrigerant Tubing Ventilate the room well in the event that refrigerant gas leaks during the installation Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas Keep all tubing runs as short as possible Use the flare method for connecting tubing Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them then tighten the nut with a torque wrench for a leak free connection Check carefully for leaks before starting the test run Depending on the system type liquid and gas lines may be either narrow or wide Therefore to avoid confusion the refrigerant tubing for your particular model is specified as either narrow or wide rather than as liquid or gas When Servicing Turn the power OFF at the main power box mains before opening the unit to check or repair electrical parts and wiring Keep your fingers and clothing away from any moving parts Clean up the site when installation is finished Check that no metal scraps or bits of wiring have been left inside the unit Ventilate any enclosed areas when installing or testing the refrigeration system Contact of refrigerant gas with fire or heat can produce poisonous gas
29. t enter the hole because the hole is too narrow use a probe with a thinner pin Insulation tester Terminal plate Insulation tester Copper tube or metallic part 0639 X S Copper tube or metallic part Insulation tester 0640 X S From fan motor compressor and other parts lt R erm Metallic Clip Insulation tester 0641_X_S 46 Fig 6 Fig 7 Fig 8 Fig 9 SM830070 2 Checking the Protective Devices Disconnect the connector which consists of P plug and S socket when you want to check the protective device Then check continuity among plug s and or socket s terminal as in Fig 10 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 Indoor fan motor thermal protector 49 Indoor unit Disconnect the connector which leads to the indoor fan motor Check the socket s terminals Compressor motor thermal protector Outdoor unit Disconnect the wires from terminals of compressor Check the terminals of compressor D Outdoor fan motor thermal protector 49FO Outdoor unit Disconnect both the connector which leads to the outdoor fan motor Check socket s terminal 47 5 830070 3 Checking the Electrical Parts Power transformer TR1
30. that power supply wires are correctly connected to terminal No 1 through No 4 on the 4P terminal plate in the indoor unit and L1 and L2 on the 6P terminal in the outdoor unit Check inter unit wiring Check that inter unit control wiring AC 230 208 V Line voltage is correctly connected between the indoor unit and outdoor unit Single phase outdoor unit Disconnect SW Field supply Indoor Unit Outdoor Unit B Inter Unit Wiring Line voltage Fig 5 Check power supply Check that voltage is within the specified range 10 of the rating Q Check that power is being supplied AN 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 wires is not damaged Q Check that the lead wires are firmly connected at the terminal plate Q Check that the wiring is correct 5 Reference Condition of general cooling operation Thermo ON SWEEP ON Indoor fan speed HIGH SM830070 es 2 Air Conditioner does not Operate D Circuit breaker trips or fuse blows a When the circuit breaker is set to ON it is tripped soon There is a possibility of ground fault Check insulation resistance If resistance value is 1 MQ or less itis a defect of insulation Exampl
31. tic 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 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
32. wice by hand Fan motor burnout or foreign matter in bearing Repair or replace Check resistance of fan motor winding Check fan motor capacitor Relay RY1 or RY2 on the P C B Ass y is defective 0631 5 B Louver motor does not run Check resistance of louver motor winding P C B Ass y or remote control unit is defective SM830070 41 6 Outdoor Fan does not Run Check fan casing for foreign matter on the inside Remove foreign matter or repair Fan cannot be rotated Check fan rotation Rotate the fan gently once or twice by hand Fan motor burnout or foreign matter in bearing Repair or replace Check resistance of fan motor winding Check fan motor capacitor Check continuity between terminals on the compressor motor magnetic contactor 0633 X 7 Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F C3632 Type Check the thermostat 23S 1037 X 5 8 Outdoor Fan Speed is not Switched from High to Med even when the Outdoor Temperature Falls below 77 F Outdoor Fan Speed is not Switched from Med to Low even when the Outdoor Temperature Falls below 59 F CL3632 Type Check outdoor unit P C B Ass y Check resistance of outdoor temp sensor 0722 XS 5 830070 42 9 Outdoor Fan does
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