Sanyo C2462R Technical Data & Service Manual
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Sanyo C2462R Technical Data & Service Manual

Split system air conditioner
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TECHNICAL DATA

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SERVICE MANUAL

KS2462R / C2462R, CL2462R
SPLIT SYSTEM AIR CONDITIONER
INDOOR MODEL No.
KS2462R
854648419200
PRODUCT CODE No.
OUTDOOR MODEL No.
854 019 00
Indoor Unit
KS2462R
FILE NO.
PRODUCT CODE No.
C2462R
854 019 01
CL2462R
854 019 02
– 1 –
Outdoor Unit
C2462R
CL2462R
SM
SM830092
REFERENCE NO.
830092

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  • Page 1: Technical Data

    TECHNICAL DATA & SERVICE MANUAL KS2462R / C2462R, CL2462R SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No. PRODUCT CODE No. KS2462R 854 019 00 Indoor Unit KS2462R 854648419200 FILE NO. OUTDOOR MODEL No. PRODUCT CODE No. C2462R 854 019 01 CL2462R...

  • Page 2: Please Read Before Starting

    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 ……………………………………………………………………...

  • Page 3: Table Of Contents

    OPERATING RANGE ... 4 SPECIFICATIONS ... 5 (1) Unit Specifications ... 5 (2) Major Component Specifications ... 7 (A) Indoor Unit ... 7 (B) Outdoor Unit ... 8 (3) Other Component Specifications ... 10 (A) Indoor Unit ... 10 (B) Outdoor Unit ... 12 DIMENSIONAL DATA ...

  • Page 4: Operating Range

    1. OPERATING RANGE KS2462R / C2462R Temperature Indoor Air Intake Temp. Maximum 95 F DB / 71 F WB Minimum 67 F DB / 57 F WB KS2462R / CL2462R Temperature Indoor Air Intake Temp. Maximum 95 F DB / 71 F WB...

  • Page 5: Specifications

    (mm) 48-15/32 in. (mm) 15-31/32 lbs. (kg) lbs. (kg) cu. ft.(m ) (0.162) DATA SUBJECT TO CHANGE WITHOUT NOTICE. – 5 – KS2462R C2462R Cooling 26,000 7.619 187 – 253 10.9 13.5 2,200 97.0 13.0 Microprocessor – / Automatic...
  • Page 6 2. SPECIFICATIONS 1-1 Unit Specifications MODEL No. Indoor Unit Outdoor Unit POWER SOURCE PERFORMANCE Capacity Air circulation (Hi) Moisture removal (High) ELECTRICAL RATINGS Voltage rating Available voltage range Running amperes* Max. running amperes** Power input Power factor S.E.E.R Max. starting amperes FEATURES Controls Timer...

  • Page 7: Major Component Specifications

    2. SPECIFICATIONS (2) Major Component Specifications (A) Indoor Unit MODEL No. Source Remote controller (Accessory) Controller P. C. B Ass'y Control circuit fuse Type Number ... Dia. and length Fan motor Model Source No. of pole … r.p.m. (230 V, High) Nominal output Coil resistance (Ambient temperature 68 F)

  • Page 8: (B) Outdoor Unit

    Close VAC, 440 V, 4 F Aluminum plate fin / Copper tube 2 … 14.1 8.72 (0.81) DATA SUBJECT TO CHANGE WITHOUT NOTICE – 8 – C2462R 2,400 1,120 — — – 0.15 VLT – YEL 11.42 YEL – PNK 10.60...
  • Page 9 2. SPECIFICATIONS (2) Major Component Specifications (B) Outdoor Unit MODEL No. Source Controller P.C.B. Ass'y Control circuit fuse Compressor Model Source Nominal output Compressor oil Coil resistance (Ambient temperature 77 F) Safety device Overload relay models Operating temperature Operating ampere (at 77 F) Run capacitor Crank case heater Refrigerant amount charged at shipment...

  • Page 10: Other Component Specifications

    2. SPECIFICATIONS (3) Other Component Specifications (A) Indoor Unit MODEL No. Power Transformer Rated Primary Secondary Capacity Coil resistance (Ambient temprature 77 F) Thermistor cut off temperature Thermistor (Coil sensor) Coil resistance Thermistor (Room sensor) Coil resistance Lamp Ass'y Flap Motor KS2462R ATR –...
  • Page 11 AC 240 V, 60 Hz AC 240 V, 26 A AC 240 V, 60 Hz 200 to 240 V, 1 A – 11 – C2462R FC - 1SUL AC 240 V, 3 A HH62S 17.2 AC 220 V, 5 A...

  • Page 12: (B) Outdoor Unit

    2. SPECIFICATIONS (3) Other Component Specifications (B) Outdoor Unit MODEL No. Compressor Motor Magnetic Contactor Coil rated Coil resistance (at 77 F) Contact rated (Main) Contact rated (Auxiliary) Power Relay Coil rated Coil resistance (at 77 F) Contact rated Power Transformer Rated Primary Secondary...

  • Page 13: Dimensional Data

    3. DIMENSIONAL DATA Indoor Unit: KS2462R 6-27/32 Center of tubing hole (2 places) 44-7/8 5-5/16 Wide tube 3/4"(ø19.05) Narrow tube 3/8"(ø9.52) Drain hose O.D. 23/32"(ø18) – 13 – 8-31/32 Remote control unit 2-13/32 25/32 Dimension : inch 2199_M_S SM830092...

  • Page 14: Outdoor Unit

    3. DIMENSIONAL DATA Outdoor Unit: C2462R, CL2462R 6-23/32 25-31/32 4-3/8 – 14 – Dimension : inch Hole for anchor bolt (4-R1/4) 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)

  • Page 15: Cooling Capacity

    : Compressor Input Rating conditions are : Outdoor Ambient Temp. 95 F DB : Indoor Unit Entering Air Temp. 80 F DB / 67 F WB Outdoor Unit: C2462R AIR FLOW RATE : CONDENSER AMBIENT TEMP. F ( C) (23.9) (29.4)
  • Page 16 : Compressor Input Rating conditions are : Outdoor Ambient Temp. 95 F DB : Indoor Unit Entering Air Temp. 80 F DB / 67 F WB Outdoor Unit: C2462R AIR FLOW RATE : CONDENSER AMBIENT TEMP. F ( C) (23.9) (29.4)

  • Page 17: Performance Charts

    (Indoor relative humidity: 50%, Indoor fan speed: High) 230V (15) (20) Outdoor ambient temp. F ( C) 208V (15) (20) Outdoor ambient temp. F ( C) Outdoor Unit: C2462R Outdoor fan speed High (25) (30) (35) (40) Outdoor fan speed High...
  • Page 18 5. PERFORMANCE CHARTS (1) Operating Current 2 Indoor Unit: KS2462R Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V (–5) 208V (–5) Outdoor Unit: CL2462R Outdoor fan speed (10) (15) (20) Outdoor ambient temp.

  • Page 19: High And Low Pressure

    Low pressure characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V / 208 V (15) (20) Outdoor ambient temp. F ( C) Outdoor Unit: C2462R Outdoor fan speed High Indoor temp. (25)
  • Page 20 5. PERFORMANCE CHARTS (2) High and Low Pressure 2 Indoor Unit: KS2462R • High Pressure High pressure characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230 / 208V (–5) • Low Pressure Low pressure characteristics versus outdoor ambient temperature and indoor temperature.

  • Page 21: Air Throw Distance Chart

    6. AIR THROW DISTANCE CHART Indoor Unit: KS2462R Room air temp. : 80 F (26.7 C) Fan speed High Horizontal distance (ft.) : Flap angle 0 , : Axis air velocity 0 : Flap angle 30 , : Axis air velocity 30 –...

  • Page 22: Refrigerant Flow Diagram

    O. D. 3/8" (9.52 mm) Indoor Unit: KS2462R Indoor Unit O. D. 3/4" (19.05mm) Narrow tube O. D. 3/8" (9.52 mm) Outdoor Unit: C2462R Wide tube O. D. 3/4" (19.05mm) Narrow tube Capillary service valve tube O. D. 3/8" (9.52 mm)

  • Page 23: Installation Instructions

    Max. Allowable Tubing Model Length at Shipment (ft.) C2462R, CL2462R * If total tubing length becomes 23 to 132 ft. (max.), additional refrigerant (R410A) charge of 0.43 oz./ft. is required. No additional charge of compressor oil is necessary. INDOOR UNIT Elevation difference (H) Fig.
  • Page 24 6 inches min. 6 inches min. INDOOR UNIT Front View Fig. 3a CAUTION For stable operation of the air conditioner, do not install wall-mounted type indoor units less than 5 ft. from floor level. Fig. 3b – 24 – Drain hose...
  • Page 25 8. INSTALLATION INSTRUCTIONS Outdoor Unit AVOID: heat sources, exhaust fans, etc. Fig. 4 damp, humid or uneven locations. choose a place as cool as possible. choose a place that is well ventilated and outside air temperature does not exceed maximum 115 F constantly. allow enough room around unit for air intake/ exhaust and possible maintenance.
  • Page 26 This unit is designed so that the fan of the outdoor unit runs at low speed when the air conditioner is operated at low outdoor air temperatures. When the outdoor unit is exposed to strong wind, the system pressure drops because of the freeze protector.
  • Page 27 8. INSTALLATION INSTRUCTIONS Electrical Wiring General Precautions on Wiring (1) Before wiring, confirm the rated voltage of the unit as shown on its nameplate, then carry out the wiring closely following the wiring diagram. (2) Provide a power outlet to be used exclusively for each unit, and a power supply disconnect and circuit breaker for overcurrent protection should be...
  • Page 28 7-2. Recommended Wire Length and Wire Diameter for Power Supply System Power Supply Models C2462R, CL2462R 64 ft. (AWG #12) *1 Refer to the Wiring System Diagrams (See below diagram) for the meaning of “A” and “B.” AWG = American Wire Gauge...

  • Page 29: Electrical Data

    9. ELECTRICAL DATA Electrical characteristics Indoor model: KS2462R / Outdoor model: C2462R, CL2462R Indoor Unit Fan Motor Performance at 0.38 - 0.37 Rating conditions 0.08 - 0.07 0.38 - 0.37 Full load conditions 0.08 - 0.07 Starting amperes Rating Conditions...

  • Page 30: Electrical Wiring Diagrams

    10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit KS2462R FAN MOTOR 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 CONNECTOR [WHT] [WHT] FLAP MOTOR [UPPER] CONNECTOR [WHT] [GRN] FLAP MOTOR [LOWER] • Electric Wiring Diagram GRN / YEL CONNECTOR 1 3 5...

  • Page 31: Outdoor Unit

    10. ELECTRICAL WIRING DIAGRAMS Outdoor Unit C2462R • Electric Wiring Diagram TERMINAL PLATE (6P) EARTH TERMINAL EARTH TERMINAL 2P (WHT) 2P (GRN) 49FO – 31 – 63PH 63PL (WHT) 854-2-5269-160-00-0 SM830092...

  • Page 32: Schematic Diagram

    10. ELECTRICAL WIRING DIAGRAMS Outdoor Unit C2462R TERMINAL PLATE (6P) – 1 – 2 – G – 4 – L1 – L2 49FO 63PH 63PL RC1, 2 1Y, 2Y • Schematic Diagram 63PH 63PL Symbols Description Compressor Motor Outdoor Fan Motor...

  • Page 33: Outdoor Unit

    10. ELECTRICAL WIRING DIAGRAMS Outdoor Unit CL2462R UNIT INDOOR 208V/230V 1ø 60Hz SUPPLY POWER – 33 – SM830092...

  • Page 34: Schematic Diagram

    10. ELECTRICAL WIRING DIAGRAMS Outdoor Unit CL2462R TERMINAL PLATE (6P) Symbols 49FO 63PH 63PL HGBV RC1, 2 RY1~3, 1Y CR-CL2432 F1, 2 • Schematic Diagram F1 (3A) 49FO 63PH 63PL HGBV F2 (3A) Description Compressor Motor Crankcase Heater Outdoor Fan Motor Compressor Motor Magnetic Contactor Outdoor Fan Motor Thermal Protector High Pressure Switch...

  • Page 35: Processes And Functions

    11. PROCESSES AND FUNCTIONS (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 indoor unit. The figures shows 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).

  • Page 36: Dry Operation

    11. PROCESSES AND FUNCTIONS (2) Dry Operation (Dehumidification) Dry operation uses the ability of the cooling cycle to remove moisture from the air, but by running at low level to dehumidify without greatly reducing the room temperature. The air conditioner repeats the cycle of turning ON and OFF automatically as shown in the chart below according to the room temperature.

  • Page 37: Freeze Prevention

    11. PROCESSES AND FUNCTIONS (3) 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. Room temp. T + 4 F Set temp.

  • Page 38: Outdoor Fan Speed Control

    11. PROCESSES AND FUNCTIONS (4) Outdoor Fan Speed Control (1) C2462R Type • In low outdoor temperature, the outdoor fan is set automatically from HIGH to LOW to prevent the indoor heat exchanger from freezing. • When the outdoor temperature falls below 78 F, the outdoor fan is set from HIGH to LOW automatically.

  • Page 39: Service Procedures

    12. SERVICE PROCEDURES (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 that power supply wires are correctly connected to L1 and L2 on the...
  • Page 40 12. SERVICE PROCEDURES 2) Air Conditioner does not Operate Circuit breaker trips (or fuse blows). (a) When the circuit breaker is set to ON, it is tripped soon. • There is a possibility of ground fault. • Check insulation resistance.
  • Page 41 12. SERVICE PROCEDURES (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. Is capacity of circuit breaker sufficient ? • Check resistance of outdoor fan motor winding.
  • Page 42 12. SERVICE PROCEDURES C. Check “Operation selector” switch in the indoor unit. • Has “Operation selector” switch been set to ON position ? 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.
  • Page 43 12. SERVICE PROCEDURES Check. auxiliary relay. (1Y or 2Y) • Check coil resistance of auxiliary relay. (1Y or 2Y) G. Check fuse on the P.C.B. Ass’y in the indoor unit. • Check fuse on the P.C.B. Ass'y in the indoor unit for continuity.
  • Page 44 12. SERVICE PROCEDURES 3) Outdoor Unit does not Run. A. Check COOL / FAN selector switch in the remote control unit. • Is MODE selector button set to COOL ? B. Check set temperature. Try to lower set temperature by Temperature setting button “COOLER”.
  • Page 45 12. SERVICE PROCEDURES C. Check compressor motor magnetic contactor. • Check coil resistance of compressor motor magnetic contactor. 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.
  • Page 46 12. SERVICE PROCEDURES 4) Indoor Unit does not Run. (Indoor fan and flap motor do not run.) P.C.B. Ass’y is defective. 5) Some Part does not Operate. A. Indoor fan does not run. • Check fan rotation. Rotate the fan gently once or twice by hand.
  • Page 47 7) Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F. (C2462R Type) • Check the thermostat (23S). 8) Outdoor Fan Speed is not Switched from High to Med even when the Outdoor Temperature Falls below 77 F.
  • Page 48 12. SERVICE PROCEDURES 9) Outdoor Fan does not Run for CL2462R. • Check fuse on PCB Ass’y in outdoor unit for continuity. If fuse blows, • Check resistance of primary winding of transformer. 10) Compressor does not Run. • Check compressor motor capacitor (RC1).
  • Page 49 • Check clogging of air filter. • Is fan speed set to LOW ? • Review cooling load estimate, if performance of air conditioner is normal. 12) Excessive Cooling. • The set temperature is too low. • Is the remote control unit installed...

  • Page 50: A Sensor Is Defective

    12. SERVICE PROCEDURES A Sensor is Defective. 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”...

  • Page 51: Checking The Electrical Components

    12. SERVICE PROCEDURES Checking the Electrical Components Measurement of Insulation Resistance • The electrical insulation is acceptable when the resistance exceeds 2 M . Power Supply Wires Clamp the earthed wire of the Power Supply wires with a lead clip of the insulation resistance tester and mea- sure the resistance by placing a probe on either of the power wires.
  • Page 52 12. SERVICE PROCEDURES 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. 20. •...
  • Page 53 12. SERVICE PROCEDURES Checking the Electrical Parts Power transformer ...Indoor unit • Primary 230-208 V ; Measure the resistance between two WHT lead wire terminals • Secondary 19 V ; Measure the resistance between two BRN lead wires. Power transformer (TR) ... Outdoor unit •...
  • Page 54 12. SERVICE PROCEDURES Continuity of fuse on P.C.B. Ass’y • Check for continuity using a multim- eter as shown in Fig. 22. NOTE Method Used to Replace Fuse on PCB Ass’y 1. Remove the PCB Ass’y from the electrical component box. 2.
  • Page 55 The composition of refrigerant R410A changes whether it is in a gaseous phase or liquid phase. Thus, when there is a refrigerant leak the basic performance of the air conditioner may be degraded because of a change in composition of the remaining refrigerant. Therefore, do not add new refrigerant. Instead, recover the remaining refrigerant with the refrigerant recovery unit.
  • Page 56 12. SERVICE PROCEDURES Tubing precautions Refrigerant R410A is more easily affected by dust or moisture compared to R22, thus be sure to temporarily cover the ends of the tubing with caps or tape prior to installation. Never use 0.7mm-thick copper tubing or tubing which is less than 0.8mm in thickness, since air conditioners with R410A are subject to higher pressure than those using R22 and R407C.
  • Page 57 12. SERVICE PROCEDURES 11-3. Tools Specifically for R410A For servicing, use the following tools for R410A Tool Distinction Tools specifically for R410A Tools which can be com- monly used for R22, R407C, and R410A The above tools specifically for R410A must not be used for R22 and R407C. CAUTION Doing so will cause malfunction of the unit.
  • Page 58 SM830092 – 58 –...

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