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Sanyo XHS3632 Service Manual

Split system air conditioner
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SERVICE MANUAL

XHS2432 / CH2432
XHS3632 / CH3632
SPLIT SYSTEM AIR CONDITIONER
INDOOR MODEL No.
XHS2432
XHS3632
Indoor Unit
XHS2432
XHS3632
85464849176000
PRODUCT CODE No.
OUTDOOR MODEL No.
854 013 40
854 015 45
FILE NO.
PRODUCT CODE No.
CH2432
854 013 42
CH3632
854 014 57
Outdoor Unit
CH2432
CH3632
REFERENCE NO.
Section
1
2
3
4
SM
830076

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Summary of Contents for Sanyo XHS3632

  • Page 1: Service Manual

    SERVICE MANUAL FILE NO. XHS2432 / CH2432 XHS3632 / CH3632 Section SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No. PRODUCT CODE No. OUTDOOR MODEL No. PRODUCT CODE No. XHS2432 854 013 40 CH2432 854 013 42 XHS3632 854 015 45 CH3632...

  • Page 2: Please Read Before Starting

    Important Please Read Before Starting When Installing …………………………………………………………………… …In a Room This air conditioning system meets strict safety and operating Properly insulate any tubing run inside a room to prevent standards. As the installer or service person, it is an important “sweating”...

  • Page 3: Table Of Contents

    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.
  • Page 4 Auto. Mode for Automatic Heating/Cooling Switching ........35 2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating)......37 2-11 4-Way Valve, Solenoid Control ................38 (A) Normal Control Mode ..................38 (B) AUTO Control Mode ..................39 2-12 Automatic Restart after Power Interruption ............39 2-13 Electronic Expansion Valve ................40 2-14 Compressor Discharge Gas Temperature ............
  • Page 5 Introduction: Read Me First! WHAT IS IN THIS MANUAL This manual will help you understand and service the air conditioner. To help you find the information you need, we have divided it into 5 main sections. Each section is divided into chapters with charts, tables and explana- tions to help you find and repair problems.

  • Page 6: Specifications

    1. SPECIFICATIONS Unit Specifications ...................7 Major Component Specifications ..............11 (A) Indoor Unit ....................11 (B) Outdoor Unit .....................13 Other Component Specifications ..............15 (A) Indoor Unit ....................15 (B) Outdoor Unit .....................17 Dimensional Data ...................19 (A) Indoor Unit ....................19 (B) Outdoor Unit .....................21 Refrigerant Flow Diagram ................

  • Page 7: Unit Specifications

    1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit XHS2432 Outdoor Unit CH2432 POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz PERFORMANCE Cooling Heating Capacity* BTU / h 24,000 23,400 25,000 24,300 (17 F)** 16,400 15,800 Moisture removal (High) Pints / h —...
  • Page 8 1. Specifications 1-1 Unit Specifications DIMENSIONS & WEIGHT Indoor unit Outdoor unit Unit dimensions Height in. (mm) 9-27/32 (250) 28-30/32 (735) Width in. (mm) 29-29/32 (760) (940) Depth in. (mm) 29-29/32 (760) 13-12/32 (340) Net weight lbs. (kg) (22) (71) Indoor grille dimensions Height in.
  • Page 9 1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit XHS3632 Outdoor Unit CH3632 POWER SOURCE 230 - 208 VAC / 1 Phase / 60 Hz PERFORMANCE Cooling Heating Capacity* BTU / h 34,500 33,500 37,500 36,500 (17 F)** 25,000 23,500...
  • Page 10 29-29/32 (760) 13-12/32 (340) Net weight lbs. (kg) (27) (92) Indoor grille dimensions Height in. (mm) 3-1/6 (78) PNR-XHS3632 Width in. (mm) 33-27/32 (1,150) Depth in. (mm) 33-27/32 (860) Net weight lbs. (kg) Indoor / Outdoor unit Height in. (mm)

  • Page 11: Major Component Specifications

    1. Specifications 1-2 Major Component Specifications (A) Indoor Unit MODEL No. XHS2432 Source 230 - 208 VAC / 1 phase / 60 Hz Remote controller (Accessory) RCS - 5HPS4U Controller P. C. B Ass'y CR - THS2432 Control circuit fuse 250 VAC, 3 A Controller Ass'y CR - 3XHS...
  • Page 12 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 V, W,...

  • Page 13: (B) Outdoor Unit

    1. Specifications 1-2 Major Component Specifications (B) Outdoor Unit MODEL No. CH2432 Source 230 - 208 VAC / 1 phase / 60 Hz Controller P.C.B. Ass'y CR - CH2432 (Microprocessor) Control circuit fuse 250 VAC, 3 A Compressor Rotary (Hermetic) Model C - 2R160H6T Source...
  • Page 14 1. Specifications 1-2 Major Component Specifications (B) Outdoor Unit MODEL No. CH3632 Source 230 - 208 VAC / 1 phase / 60 Hz Controller P.C.B. Ass'y CR - CH2432 (Microprocessor) Control circuit fuse 250 V, 3 A Compressor Rotary (Hermetic) Model C - R221H6R Source...

  • Page 15: Other Component Specifications

    1. Specifications 1-3 Other Component Specifications (A) Indoor Unit MODEL No. XHS2432 Power Transformer ATR – II174B Rated Primary 220 VAC, 60 Hz Secondary 14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA Capacity — Coil resistance WHT - WHT BRN - BRN 0.42 (Ambient temprature 77 F) Thermistor cut off temperature...
  • Page 16 1. Specifications 1-3 Other Component Specifications (A) Indoor Unit MODEL No. XHS3632 Power Transformer ATR – II174B Rated Primary 220 VAC, 60 Hz Secondary 14.8 VAC 0.55 mA, 14.8 VAC 0.6 mA Capacity — Coil resistance WHT - WHT BRN - BRN 0.42...

  • Page 17: (B) Outdoor Unit

    1. Specifications 1-3 Other Component Specifications (B) Outdoor Unit MODEL No. CH2432 Compressor Motor Magnetic Contactor FMCA - 1UL Coil rated 240 VAC, 60 Hz Coil resistance (at 77 F) 15 % Contact rated (Main) 230 VAC, 20 A Contact rated (Auxiliary) 230 VAC, 3 A Power Relay HH62S...
  • Page 18 1. Specifications 1-3 Other Component Specifications (B) Outdoor Unit MODEL No. CH3632 Compressor Motor Magnetic Contactor FMCA - 1SUL Coil rated 240 VAC, 60 Hz Coil resistance (at 68 F) 10 % Contact rated (Main) 240 VAC, 26 A Contact rated (Auxiliary) 240 VAC, 3 A Power Relay HH62S...

  • Page 19: Dimensional Data

    1. Specifications 1-4 Dimensional Data (A) Indoor Unit: XHS2432 8-21/32 8-1/16 4-29/32 • Remote controller (Accessory) 2-13/32 23/32 4-29/32 5-29/32 7-7/8 10-1/32 32-9/32 (Ceiling opening) 11-23/32 1-3/16 33-27/32 19-11/16 8-1/16 23-7/32 (Suspention bolt pitch) 6-1/2 1-7/8 4-29/32 Min. 2-3/8 3-1/32 Dimension : inch Air intake Air outlet...
  • Page 20 1. Specifications 1-4 Dimensional Data (A) Indoor Unit: XHS3632 8-19/32 8-9/32 2-3/8 2-3/4 2-13/32 6-1/2 11-7/32 32-9/32 (Ceiling opening) 12-29/32 1-3/16 33-27/32 8-19/32 19-11/16 23-7/32 (Suspention bolt pitch) 4-29/32 13-15/32 19/32 1-7/8 8-9/32 Dimension : inch Air intake grille Air outlet Refrigerant liquid line (ø3/8")

  • Page 21: (B) Outdoor Unit

    1. Specifications 1-4 Dimensional Data (B) Outdoor Unit: CH2432 6-11/16 4-21/64 1-31/32 1-31/32 Dimension : inch Hole for anchor bolt (4-ø1/2) Refrigerant tube joint (narrow tube) Flare connection 1/4 in (6.35 mm) Refrigerant tube joint (wide tube) Flare connection 3/4 in (19.05 mm) Refrigerant tubing inlet Power supply inlet 1131_THS_I...
  • Page 22 1. Specifications 1-4 Dimensional Data (B) Outdoor Unit: CH3632 6-11/16 4-21/64 1-31/32 1-31/32 Dimension : inch Hole for anchor bolt (4-ø13) Refrigerant tube joint (narrow tube) Flare connection 3/8 in (9.52 mm) Refrigerant tube joint (wide tube) Flare connection 3/4 in (19.05 mm) Refrigerant tubing inlet Power supply inlet 1581_C_S...

  • Page 23: Refrigerant Flow Diagram

    1. Specifications 1-5 Refrigerant Flow Diagram Outdoor Unit: CH2432 Indoor Unit: XHS2432 Compressor Accumulator Accumulator Gas line service valve Gas line O.D. nipple 3/4" (19.05mm) High Muffler pressure switch 4-way valve Heat exchanger Heat exchanger Distributor Strainer Electronic ref.control Distributor valve Liquid line service...
  • Page 24 1. Specifications 1-5 Refrigerant Flow Diagram Outdoor Unit: CH3632 Indoor Unit: XHS3632 Compressor Accumulator Accumulator Gas line service valve Gas line O.D. nipple 3/4" (19.05mm) High pressure Muffler switch 4-way valve Heat exchanger Heat exchanger Distributor Strainer Electronic Distributor ref.control...

  • Page 25: Processes And Functions

    2. Processes and functions 1. Specifications 2. PROCESSES AND FUNCTIONS Room Temperature Control ................26 (A) Cooling .....................26 (B) Heating .....................27 Cold Draft Prevention (Heating Cycle) ............28 Automatic Fan Speed (Indoor Unit)............... 29 (A) Cooling .....................29 (B) Heating .....................29 Section Outdoor Fan Speed Control ................

  • Page 26: Room Temperature Control

    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).

  • Page 27: (B) Heating

    2. Processes and functions 1. Specifications (B) Heating THERMO. ON THERMO. ON REMOTE CONTROL THERMO. OFF THERMO. OFF SENSOR (Only for wireless THERMO. ON remote controller) SET. +2 F SETTING TEMP. SET. –2 F THERMO. OFF THERMO. OFF BODY SENSOR THERMO.

  • Page 28: Cold Draft Prevention (Heating Cycle)

    2. Processes and functions 2-2 Cold Draft Prevention (Heating Cycle) The cold draft prevention function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coils have warmed up. STANDBY shows on the remote controller when the indoor fan speed is LL (very low) or OFF.

  • Page 29: Automatic Fan Speed (Indoor Unit)

    2. Processes and functions 1. Specifications 2-3 Automatic Fan Speed (Indoor Unit) By pressing the FAN SPEED button on the remote controller, the fan speed can be set at one of four steps: AUTO., HI., MED., or LO. When set at AUTO. the indoor unit fan speed will be automatically adjusted to the room temperature as the two charts shown below.

  • Page 30: Outdoor Fan Speed Control

    2. Processes and functions 2-4 Outdoor Fan Speed Control To optimize the performance of air conditioner, the outdoor fan speed is selected automatically according to the outdoor temperature. Note that in both Cooling and Heating modes, the fan comes on at first at high speed (H mode) for 5 seconds.

  • Page 31: Freeze Prevention (Cooling)

    2. Processes and functions 1. Specifications 2-5 Freeze Prevention (Cooling) Freeze Prevention keeps the indoor heat exchange coil from freezing. Freezing reduces the efficiency of the unit, and frost buildup on the coil blocks cool air circulation from the indoor unit's fan.

  • Page 32: Condensing Temperature Control (Cooling)

    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. OUTDOOR UNIT COIL TEMP. C2 Section ( F) OUTDOOR FAN FORCED SPEED H, M H, M ELECTRONIC REF.

  • Page 33: Overload Protection (Heating)

    2. Processes and functions 1. Specifications 2-7 Overload Protection (Heating) This function prevents the air conditioner from overloading. ( F) Section INDOOR UNIT COIL TEMP. (E2) OVERLOAD PROTECTION OVERLOAD PROTECTION FUZZY CONTROL FUZZY CONTROL ELECTRONIC REF. CONTROL VALVE OPEN OPEN START UP OUTDOOR FM COMPENSATION...

  • Page 34: Discharge Temperature Control (Cooling And Heating)

    2. Processes and functions 2-8 Discharge Temperature Control (Cooling and Heating) This function prevents the compressor motor from burnout by overheating. Section DISCHARGE GAS TEMP. ( F) OUTDOOR FAN SPEED H OR M H OR M COMPRESSOR ELECTRONIC REF. CONTROL VALVE OPEN OPEN (DISCHARGE TEMP.)

  • Page 35: Auto. Mode For Automatic Heating/Cooling Switching

    2. Processes and functions 1. Specifications 2-9 Auto. Mode for Automatic Heating/Cooling Switching When the AUTO mode is selected, the microprocessor calculates the difference between the set temperature and the room temperature, and automatically switches to the COOLING or HEATING mode to maintain the desired temperature. Room temp.
  • Page 36 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.

  • Page 37: Defrosting Control, Outdoor Heat Exchanger Coil (Heating)

    2. Processes and functions 1. Specifications 2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating) When the outdoor temperature is low, frost may form on the outdoor heat exchanger coil. When this occurred, the defrosting system operates. The microprocessor in the outdoor unit monitors the relationship between the temperature of the outdoor heat exchanger coil and the outdoor temperature so it can defrost when necessary.

  • Page 38: 4-Way Valve, Solenoid Control

    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.

  • Page 39: (B) Auto Control Mode

    2. Processes and functions 1. Specifications (B) AUTO Control Mode POWER SOURCE OPERATION BUTTON MORE THAN 10 MINUTES MORE THAN 10 MINUTES (THERMO. OFF) (THERMO. OFF) AUTO COOL COOL Section MODE CONTROL HEAT HEAT HEAT THERMO. OFF THERMO. ON 3 MINUTES MORE THAN 3 MINUTES COMPRESSOR...

  • Page 40: Electronic Expansion Valve

    2. Processes and functions 2-13 Electronic Expansion Valve This valve allows very precise and smooth control of the amount of refrigerant flow in the system. Since the valve is operated by a step motor, the control circuits can open or close it in very exact amounts, so the degree of heating or cooling can be changed by just a little, or changed very quickly or slowly.

  • Page 41: Compressor Current Detection Circuit

    2. Processes and functions 1. Specifications 2-15 Compressor Current Detection Circuit The Compressor Current Detection Circuit detects the compressor current and, depending on the current range, can stop the compressor motor so it will not be damaged by overcurrent. Overcurrent can be caused by several factors, particularly mechanical seizing of the compressor or liquid backflow.

  • Page 42: Electronic Expansion Valve Control

    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.

  • Page 43: Voltage Detection Control

    2. Processes and functions 1. Specifications 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. Section SM830076 – 43 –...
  • Page 44 2. Processes and functions Section SM830076 – 44 –...

  • Page 45: Electrical Data

    3. Electrical data 3. ELECTRICAL DATA Indoor Unit (Electric Wiring Diagram, Schematic Diagram) ....... 46 Outdoor Unit (Electric Wiring Diagram, Schematic Diagram)......48 Section SM830076 – 45 –...

  • Page 46: Indoor Unit (Electric Wiring Diagram, Schematic Diagram)

    3. Electrical data Indoor Unit 1 1 1 1 1 XHS2432, XHS3632 Section GRN/YEL GRN/YEL GRN/YEL GRN/YEL SM830076 – 46 –...

  • Page 47: Schematic Diagram

    3. Electrical data 3-1 Indoor Unit 1 1 1 1 1 XHS2432, XHS3632 • Schematic Diagram CR-THS2432 Controller SG WL F1(3A) 49FI 4P-1 CONT Section 4P-2 49FI Room Thermistor Indoor Coil Indoor Coil 49FI DC12V F2(3A) To Outdoor Unit Symbols...

  • Page 48: Outdoor Unit (Electric Wiring Diagram, Schematic Diagram)

    3. Electrical data 3-2 Outdoor Unit 1 1 1 1 1 CH2432 Section Relay SM830076 – 48 –...
  • Page 49 3. Electrical data 3-2 Outdoor Unit 1 1 1 1 1 CH2432 • Schematic Diagram Terminal CR-CH2432 (U1) (U2) Plate (5P) Controller 63PH 2P-1 2P-2 F1(3A) 63PH AC 208V Section 230V AC 14V Outdoor 49FO Coil C1 Outdoor Coil C2 Discharge DC12V F2(3A)
  • Page 50 3. Electrical data 3-2 Outdoor Unit 2 2 2 2 2 CH3632 Section SM830076 – 50 –...
  • Page 51 3. Electrical data 3-2 Outdoor Unit 2 2 2 2 2 CH3632 • Schematic Diagram Terminal CR-CH2432 (U1) (U2) Plate (5P) Controller 63PH 2P-1 2P-2 F1(3A) 63PH AC 208V Section 230V AC 14V 49FO1 Outdoor Coil C1 Outdoor Coil C2 FMO1 FMO2 49FO2...
  • Page 52 3. Electrical data Section SM830076 – 52 –...

  • Page 53: Service Procedures

    4. Service procedures 4. SERVICE PROCEDURES Troubleshooting .....................54 (1) Check before and after Troubleshooting ..........55 (2) General Troubleshooting Flow Chart: Diagnosis and Remedy ....56 (3) Meanings of alarm messages ..............58 (4) LED Indication on the Outdoor Unit’s P.C.B. Ass’y ........ 60 (5) Symptoms and parts to inspect ..............

  • Page 54: Troubleshooting

    4. Service procedures 4-1 Troubleshooting This section explains: What the LED codes mean What the remote control unit display screen messages mean How to use the flow charts to find and solve problems How to use the self-diagnostic tests to find parts that aren’t working right Section This unit is made to be trouble free, and not need much service.

  • Page 55: Check Before And After Troubleshooting

    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.

  • Page 56: General Troubleshooting Flow Chart: Diagnosis And Remedy

    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.
  • Page 57 4. Service procedures (B) Heating b. Heating Poor heating Is setting temp. Change the setting temp. suitable ? Is heating load Review heating load too large ? estimate. Section Refrigerant flow 4-way valve is Replace the valve. failure defective. Refrigerant Charge with shortage refrigerant.

  • Page 58: Meanings Of Alarm Messages

    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 remote Possible causes of troubles...
  • Page 59 4. Service procedures Wired remote Wireless remote Possible causes of troubles controller controller display display Operation lamp and heat Indoor thermistor is either Indoor coil temp. (E1) cannot be detected. stand-by lamp flash open or short. Indoor coil temp. (E2) cannot be detected. alternately.

  • Page 60: Led Indication On The Outdoor Unit's P.c.b. Ass'y

    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.

  • Page 61: Symptoms And Parts To Inspect

    4. Service procedures Symptoms and parts to inspect Symptom: LCD on the remote controller does not display and remote controller does not operate. Start Is the LED (D80) on the indoor unit PCB lit? Section Is there 12 V DC Is there 12 V DC Repair the between R2 and R3...
  • Page 62 4. Service procedures 2) Symptom: LCD on the remote controller displays “CHECK E01”. (Unusual communication between remote controller and indoor unit.) Start Remote controller judges itself Replace the remote controller. with self-diagnostic functions Section Is there an open or a contact defect in the No.
  • Page 63 4. Service procedures Symptom: LCD on the remote controller is displaying “CHECK E04”. (Unusual communication between the indoor and outdoor units.) Start Cut the breaker and remove the Is the contact good at the 2P Correct the connections. indoor/outdoor unit control lines connector for indoor serial connected to U1 and U2 of the communications on the outdoor...
  • Page 64 4. Service procedures Symptom: LCD on the remote controller is displaying “CHECK E06”. (Unusual communication between the indoor and outdoor units) Start Correct the setting. Is the setting for the indoor address on the indoor unit PCB inappropriate? Is there a cut line or contact Correct wiring.
  • Page 65 4. Service procedures Symptom: LCD on the remote controller displays “CHECK P01”. (Indoor fan protection thermostat operation warning) Start Is there 230-208 V AC between S4 and T20-3 on the indoor unit PCB? Section Is there 230-208 V AC between Is the indoor fan wire winding Correct the connection T20-3 and S4 after T20-1 and T20-3...
  • Page 66 4. Service procedures 10) Symptom: LCD on the remote controller displays “CHECK P02”. (Compressor / outdoor fan protection thermostat operation warning / power supply voltage abnormality) Start Is the power supply to the outdoor Check the power breaker etc. unit normal? and repair.
  • Page 67 4. Service procedures 11) Symptoms: LCD on the remote controller displays “CHECK P03”. (Alarm for unusual discharge temp. of compressor) Start Unusual discharge gas temperature • Refrigerant shortage Section • Clogged refrigerant circuit • Electronic refrigerant control valve defect (indoor unit) 0343_M_I 12) Symptom: LCD on the remote controller displays “CHECK P04”.
  • Page 68 4. Service procedures 13) Symptom: LCD on the remote controller displays “CHECK P05”. (Negative phase detection operation warning) Start Is the power supply to the outdoor Check the power breaker etc. unit normal? and repair (Voltage defective phase?) Section Does the outdoor unit operate when No problem two of the three phases are changed? (Actuation of negative phase protector)
  • Page 69 4. Service procedures 15) Symptom: LCD on the remote controller displays “CHECK E16”. Start When the group of the units are Repair the wiring. installed, is there any mis-cross between inter unit control wiring and refrigerant tubing? Section Are the total capacities of indoor units Select indoor units which match with to that of outdoor units more than 107%? the outdoor capacity.
  • Page 70 4. Service procedures 18) Symptom: LCD on the remote controller displays “CHECK H01, H02, H03”. (compressor current detection) * Please check the related part described in the following chart after confirming the code setting (S4) of the outdoor unit’s capacity on the PCB in the outdoor unit. Start “CHECK H01”...

  • Page 71: Procedures When A Specific Component Does Not Work

    4. Service procedures Procedures When a Specific Component Does Not Work Indoor fan does not operate. Is fan motor capacitor Replace the capacitor. normal ? Is there voltage output Replace the P.C.B. Ass'y of P.C.B. Ass'y for fan in the indoor unit. motor ? Section •...
  • Page 72 4. Service procedures Compressor motor does not operate. Does compressor motor magnetic Replace the compressor contactor (52C) actuate ? motor magnetic contactor. Check resistance of compressor motor winding. Section Replace the compressor. 0461_M_I Outdoor fan does not operate. Are auxiliary relays (1Y) Replace the relays.

  • Page 73: Service Functions Of Optional Wired Remote Controller

    4. Service procedures 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).
  • Page 74 4. Service procedures (B) Use the test run procedure The purpose of the test run function is to let you control the operation of the unit directly without turning the unit on or off by thermostat. As indicated in the following procedure, be sure to stop test run operation when you finish the procedure, or the air conditioner may be damaged.
  • Page 75 4. Service procedures (C) Check the sensor temperature readings The air conditioner has thermo sensors which are used to control the unit. Each sensor has an address which is made up of the indoor unit address, and the sensor address. The indoor unit address is used only when several units are hooked up to one remote controller (group control).
  • Page 76 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 Location of Sensor (Themistor) (CODE No.) Indoor Unit —...
  • Page 77 4. Service procedures This picture shows the service check display. UNIT No. UNIT No. 1–1 R.C. CODE Refrigerant Circuit No. CODE No. CHECK Alarm message Section SERVICE 0358_M_I c. A maximum of 4 alarm messages can be accessed by pressing either SET TEMP button as follows.
  • Page 78 4. Service procedures Important Never press CL (clear) button unless you want to erase the accessed data in memory. Follow the procedure below only when erasing is necessary. To erase accessed data, press the CL button. When erasing is finished,“----” mark appears on the controller’s display. CAUTION Section After checking the alarm messages, be sure to press the TEST / CHK button.
  • Page 79 4. Service procedures (F) Execute the auto. address operation Auto. address operation is executed by pressing the A. ADD (S1) button of outdoor unit’s PCB usually. For your convenience it can be executed by remote controller also. a Press the TEST / CHK and ) buttons at the same time for more than 4 seconds.
  • Page 80 4. Service procedures (G) Confirm and change the indoor unit address The purpose of the above function is to let you confirm the indoor unit address after the auto. address operation, and change the indoor unit address if it is needed. a Press the TEST / CHK and ) buttons at the same time for more than 4 seconds.
  • Page 81 4. Service procedures e Set the required new indoor unit’s No. by pressing the ) button. AIR FLOW UNIT MODE Ex: UNIT No. 3-6: currently registered indoor unit address R.C. FLAP SET TEMP. CODE TIMER SET FAN SPEED SETTING DATA Required new indoor No.8: SET DATA Section In this case, UNIT No.
  • Page 82 4. Service procedures (H) Change the shift temperature in heating mode If the indoor unit is installed at high location (ex. ceiling level), the thermostat tends to turn off at heating mode because of the hot air temperature around ceiling level. In order to solve the problem, the shift temp.
  • Page 83 4. Service procedures ( I ) Set the indoor unit address This function is usable if the auto. address operation is not available. Indoor unit address can be set one by one by remote controller in such case. NOTE 1) In case of group control, branch wiring for group control should be removed temporarily.
  • Page 84 4. Service procedures d Set the No. of R. C. which you want to set with ) button. Ex. No. of R. C. will be set 2. AIR FLOW UNIT MODE UNIT No. R.C. FLAP SET TEMP. CODE TIMER SET FAN SPEED SETTING DATA...
  • Page 85 4. Service procedures i Select the code No. 14 to set group setting with the (SET TEMP) button. j Set the No. of group setting as shown below with the ) button. Nos. of group setting. 0 : Standard system (except group AIR FLOW UNIT MODE...
  • Page 86 4. Service procedures (J) Change the period of the filter timer If the period of filter timer is not suitable (for example in case of dirty environment), the period can be shortened to half as follows: a Press the TEST / CHK button for more than 4 seconds. AIR FLOW UNIT MODE...

  • Page 87: Checking The Electrical Components

    4. Service procedures 4-2 Checking the Electrical Components Earthed wire Clip Measurement of Insulation Resistance • The electrical insulation is acceptable when the resistance exceeds 1 M . Probe Insulation 1 1 1 1 1 Power Supply Wires Fig. 21 tester 0638_X_S Clamp the earthed wire of the Power...

  • Page 88: Checking The Protective Devices

    4. 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. 25. •...

  • Page 89: Checking The Electrical Parts

    4. Service procedures Checking the Electrical Parts Power transformer (TR1) ..... Indoor unit *Measure the coil resistance. • Primary 230-208V ; Measure the resistance between No.1 and No.3 (WHT lead wires) terminals of 3P (WHT) socket connected to power transformer. •...
  • Page 90 4. Service procedures 5 5 5 5 5 Motor capacitor .... Both in indoor and outdoor unit • Remove the lead wires from the capacitor terminals, and then place a probe on the capacitor terminals as shown in Fig. 26. Observe the deflection of the pointer, setting the resistanc measuring range of the multimeter to the maximum value.
  • Page 91 4. Service procedures Solenoid coil of the electronic refrigerant *Measure the coil resistance. control valve (ERCV) ………… Indoor unit • Measure the resistance between No. 5 (GRY lead wire) and other terminals (another color of lead wires) of 5P (WHT) plug connected to the solenoid coil. Refer to “1-2-(A) Major component specifications”.

  • Page 92: Sensor And Solenoid Layout Diagram

    4. Service procedures Sensor and Solenoid Layout Diagram Indoor Unit • XHS2432 Electronic expansion valve Section TH2 (E1), (RED) TH3 (E2), (BLK) 1582_X_I Outdoor Unit • CH2432 TH6, 7, 8 TH7 (C2), (RED) TH8 (GRN) ( Discharge gas) 63PH (GRN) TH6 (C1), (BLK) 1153_THS_I 1154_THS_I...
  • Page 93 4. Service procedures Sensor and Solenoid Layout Diagram Indoor Unit • XHS3632 Electronic expansion valve (E1), (RED) Section TH3 (E2), (BLK) 1583_X_I Outdoor Unit • CH3632 TH6, 7, 8 TH7 (C2), (RED) 63PH TH8 (GRN) ( Discharge gas) TH6 (C1), (BLK)

  • Page 94: Thermistor Characteristic Curve

    4. Service procedures 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) Section –4 Temperature ( F) 1045_M_I Temperature ( F) 1044_M_I (3) Compressor discharge gas temp.

  • Page 95: Setting

    4. Service procedures (6) P.C.B. Setting Setting of outdoor control P.C.B. (A) Standard control (single outdoor unit) In case of single outdoor unit installation, no indoor unit’s setting is necessary for twin, triple or quartet types (2, 3 or 4 indoor units). Leave R.C.

  • Page 96: Address Setting Method

    4. Service procedures (7) R.C. Address Setting Method Outdoor unit R.C. address setting method In case of group control or central control, set the R.C. address to 1, 2, 3, ... according to the No. of outdoor units. Outdoor control PCB CN4 (2P Black) Refrigerant circuit address (factory setting = 0)

  • Page 97: Automatic Address Setting Method

    4. Service procedures NOTE (8) Automatic Address Setting Method Required time for auto. address operation: — For group control and central control with In case of group control : a few minutes for multiple outdoor units — each R.C. In case of central control : max. about 20 min.

  • Page 98: Items To Check Prior To Test Run

    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 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.

  • Page 99: Test Run

    4. Service procedures (11) Test Run (11)-1. Preparing for Test Run Before starting the air conditioner, check the All OFF for initial settings. followings: Operation 1 2 3 4 selector ON • I ADDRESS SWEEP OFF•O 1. TEST RUN(ON) NORM. HOLD 2.
  • Page 100 4. Service procedures Important 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 only for servicing the air CAUTION conditioner. DO NOT use this switch for normal operation.
  • Page 101 4. Service procedures (11)-3. Test Run Procedure Start Turn on RCU address SW Multiple remote control? of sub remote control unit Recheck the test items before test operation. Check the indoor and outdoor unit combination (wiring). Section Single type? Multiple indoor (One indoor unit and one units for one outdoor remote controller for one...

  • Page 102: And Parts Location

    4. Service procedures (12) P.C.B. and Parts Location P.C.B. (CR-THS2432) FOR INDOOR UNITS CN80 (RED) : 26H CN77 (GRN) : LM CN78 (BLU) : DP F2 : Fuse 250V / 3A CN74 (WHT) : PRY CN85 (BLU) : DPH CN73 (BLK) : SUP CN81 (GRY) : 49FI Section F1 : Fuse 250V / 3A...
  • Page 103 4. Service procedures (12) P.C.B. and Parts Location P.C.B. (CR-CH2432) FOR OUTDOOR UNITS CN21 (YEL) : 20S CN23 (RED) : 63PH CN22 (BLK) : 52C CN20 (WHT) : PRY Section F2 : Fuse 250V / 3A CR-CH2432 F1 : Fuse 250V / 3A CN19 (BLU) : SUP CN3 (BRN) : SG2 CN2 (BLU) : SG1...

  • Page 104: Checking Procedure For Each Pc Board

    4. Service procedures (13) Checking procedure for each P.C.B. The indoor and outdoor P.C.B. have functions to check the signal transmission and reception of the serial circuit and to check the microcomputer operation. (Self-diagnosis function) Precautions required when checking 1. After turning off the power to the indoor (outdoor) unit, remove the inter-unit control wiring (U1-U2) and create a short-circuit between U1 and U2.

  • Page 105: Check Pins

    4. Service procedures (14) Check Pins When shorting check pins on the indoor and outdoor PCBs, operations shown on the above table will be performed on each indoor and outdoor unit. Use check pins to perform a quick check. NOTE •...
  • Page 106 • 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.

This manual is also suitable for:

Ch2432Xhs2432Ch3632

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