Page 2 - Important; CAUTION
– 2 – SM830078 Please Read Before Starting This air conditioning system meets strict safety and operatingstandards. As the installer or service person, it is an importantpart of your job to install or service the system so it operatessafely and efficiently. For safe installation and trouble-free ope...
Page 3 - Table of Contents
– 3 – SM830078 Table of Contents 1. OPERATING RANGE ....................................................................................... 5 2. SPECIFICATIONS ............................................................................................ 6 (1) Unit Specifications ........................
Page 4 - diagnostic chapter to help you find the; HOW TO USE THIS MANUAL; You can use this manual both as a
– 4 – SM830078 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...
Page 6 - Unit Specifications
– 6 – SM830078 (1) Unit Specifications 2. SPECIFICATIONS MODEL No. Indoor Unit XS4232 Outdoor Unit C4232 POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz PERFORMANCE Cooling Capacity BTU / h 42,000 40,500 kW 12.32 11.88 Air circulation (Hi) cu.ft. / min. 980 880 Moisture removal (High) Pints / h 14.6 14.8...
Page 25 - PERFORMANCE CHARTS; Operating Current
– 25 – SM830078 5. PERFORMANCE CHARTS (1) Operating Current 1 1 1 1 1 Indoor Unit: XS4232 Outdoor Unit: C4232 Operating current characteristics versus outdoor ambient temperature and indoor temperature.(Indoor relative humidity: 50%, Indoor fan speed: High) 230V 208V 1792_X_S Oper ating current (A) ...
Page 29 - High and Low Pressure
– 29 – SM830078 5. PERFORMANCE CHARTS (2) High and Low Pressure 1 1 1 1 1 Indoor Unit: XS4232, TS4232 Outdoor Unit: C4232 • High Pressure High pressure characteristics versus outdoor ambient temperature and indoor temperature.(Indoor relative humidity: 50%, Indoor fan speed: High) 230V / 208V • Low ...
Page 31 - AIR THROW DISTANCE CHART; COOLING
– 31 – SM830078 6. AIR THROW DISTANCE CHART MODEL: XS4232 0 3 7 10 13 17 20 0 3 7 10 13 HORIZONTAL DISTANCE (ft.) AXIS AIR VELOCITY (ft./sec) VER TICAL DIST ANCE (ft.) AXIS AIR VELOCITY FAN SPEED COOLING ROOM AIR TEMP. LOUVER ANGLE HIGH 80 ° F 30 ° : COOLING 1428_X_S MODEL: TS4232 COOLING FAN SPEED ...
Page 32 - REFRIGERANT FLOW DIAGRAM; Insulation of Refrigerant Tubing; C type
– 32 – SM830078 7. REFRIGERANT FLOW DIAGRAM Indoor Unit: 4232 Type Outdoor Unit: C4232, CL4232 O. D.3/4"(19.05 mm) Evaporator Capillary O. D.3/8"(9.52 mm) Condenser HP High pressure switch Compressor Accumulator Sub-condenser Wide tubeservice valve 1802_X_S Narrow tubeservice valve Strainer ...
Page 33 - INSTALLATION INSTRUCTIONS; Tubing Length; • Refrigerant tubing between the indoor and; Model; Table 1
– 33 – SM830078 8. INSTALLATION INSTRUCTIONS 1) Tubing Length • Refrigerant tubing between the indoor and outdoor units should be kept as short aspossible. • Select and decide the installation location so that the length of the refrigerant tubingwill be within the limits given in Table 1. Fig. 1 Tub...
Page 34 - Selecting the Installation Site; places where large amounts of oil mist exist.; Indoor Unit; Recessed Type; NOTE
– 34 – SM830078 8. INSTALLATION INSTRUCTIONS 2) Selecting the Installation Site AVOID: ã areas where leakage of flammable gas maybe expected. ã places where large amounts of oil mist exist. ã direct sunlight. ã locations near heat sources which mayaffect performance of the unit. ã locations where ex...
Page 35 - Outdoor Unit; choose a place as cool as possible.; In case of multiple installations
– 35 – SM830078 8. INSTALLATION INSTRUCTIONS Out-doorunit Heat source Hot air Exhaust fan 0591_C_I Fig. 2 Fig. 3 Min.1 inch Min.1 inch Min. 2 ft. 4 in. 0931_C_I Min.7 ft. Ground Airdis-charge 0932_C_I Obstacle above Outdoor Unit AVOID: ã heat sources, exhaust fans, etc. (Fig. 2) ã damp, humid or une...
Page 36 - Air Discharge Chamber for Top Discharge; Install the air-discharge chamber in the field when:; Wind Shield for “CL” Model; IMPORTANT
– 36 – SM830078 8. INSTALLATION INSTRUCTIONS Air Discharge Chamber for Top Discharge Install the air-discharge chamber in the field when: ã it is difficult to keep a space of minimum 2ft. between the air-discharge outlet andthe obstacle. ã the air-discharge outlet is facing the side-walk and dischar...
Page 37 - Electrical Wiring; (4) Each wiring connection must be done in; Models; Wiring
– 37 – SM830078 8. INSTALLATION INSTRUCTIONS 3) 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 followingthe wiring diagram. (2) Provide a power outlet to be used exclu- sively for eac...
Page 38 - Electrical characteristics
– 38 – SM830078 9. ELECTRICAL DATA Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230 - 208 V / 1 phase / 60 Hz 230 - 208 V / 1 phase / 60 Hz Rating conditions A 0.9 - 0.8 1.8 - 1.8 18.1 - 18.5 20.8 - 21.1 kW 0.2 - 0.16 0.36 - 0.34 3.67 - 3.62 4.23 - 4.12 Full l...
Page 39 - ELECTRICAL WIRING DIAGRAMS; • Electric Wiring Diagram; FMI
– 39 – SM830078 10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit 1 1 1 1 1 XS4232 TH1 (Coil) 3 1 DP Connector 9P(WHT) Connector 2P(YEL) 3 1 FS 2 1 3 1 3 1 3 1 7 5 3 1 5 2 1 3 2 1 3 S P 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 1 P S P S 2 2 2 1 1 3 4 5 6 7 8 9 Connector 3P(WHT) • Electric Wiring Diagram W 854-2-5...
Page 40 - • Schematic Diagram
– 40 – SM830078 10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit 1 1 1 1 1 XS4232 • Schematic Diagram S 854-2-5268-578-00-0 (XS3632) 2 1 3 1 3 1 2 IND 3 1 2 7 1 7 1 SW TR1 PRY Coil TH1 2 1 Room TH2 FS CR-TS2432 Controller 1 3 5 F1 (3A) 1 2 1 3 DP RY2 RY1 RY3 RY4 RY5 3 2 LM 1 1 RY5 4P-4 4P-2 4P-1 1 FMI...
Page 41 - ELECTRICAL WIRING DIAGRAMS
– 41 – SM830078 (1) Indoor Unit 2 2 2 2 2 TS4232 10. ELECTRICAL WIRING DIAGRAMS TH1 (Coil) 3 1 Connector 9P(WHT) Connector 2P(YEL) 3 1 2 1 3 1 3 1 3 1 7 5 3 1 5 2 1 3 2 1 3 Connector 2P(BLK) Connector2P(WHT) 1 2 3 4 5 6 7 8 9 1 P S P S P S 2 2 2 1 1 3 4 5 6 7 8 9 • Electric Wiring Diagram W 854-2-52...
Page 43 - CM
– 43 – SM830078 10. ELECTRICAL WIRING DIAGRAMS (2) Outdoor Unit 1 1 1 1 1 C4232 • Electric Wiring Diagram W 854-2-5268-896-00-0 (C4232) P S FMO2 RC3 49FO2 RC1 BLU BLK P S BRN PNK GRY GRY WHT VLT YEL 5 4 5 4 7 6 7 6 2 1 2 1 3 3 8 8 BRN PNK P S FMO1 RC2 49FO1 BRN PNK GRY GRY WHT VLT YEL 5 4 5 4 7 6 7 ...
Page 47 - PROCESSES AND FUNCTIONS; Room Temperature Control; Chart Summary and Explanations; Once the compressor starts, it keeps running for 5 minutes.; ON; OFF
– 47 – SM830078 11. PROCESSES AND FUNCTIONS Fig. 8 (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 p...
Page 48 - Freeze Prevention
– 48 – SM830078 11. PROCESSES AND FUNCTIONS (2) Freeze Prevention Freeze Prevention keeps the indoor heat exchange coil from freezing. Freezing reduces theefficiency of the unit, and frost buildup on the coil blocks cool air circulation from the indoorunit’s fan. Fig. 9 COMPRESSOR OUTDOOR FAN INDOOR...
Page 49 - Outdoor Fan Speed Control
– 49 – SM830078 11. PROCESSES AND FUNCTIONS (4) Outdoor Fan Speed Control 1) C4232 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 fr...
Page 50 - SERVICE PROCEDURES; Single-phase outdoor unit; Check that voltage is within the specified range (
– 50 – SM830078 12. SERVICE PROCEDURES Single-phase outdoor unit 1 2 G 4 1 2 4 G L1 L2 G Indoor Unit Outdoor Unit Power supply Ground B A 1089_M_I Ground Inter-UnitWiring(Line voltage) Disconnect SW(Field supply) Fig. 12 (1) Troubleshooting 1) Check before and after Troubleshooting Many problems may...
Page 51 - Air Conditioner does not Operate; If resistance value is 1 M
– 51 – SM830078 12. SERVICE PROCEDURES 2) Air Conditioner does not Operate 1 1 1 1 1 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 M Ω or less, it ...
Page 52 - • There is a possibility of short circuit.; Neither indoor unit nor outdoor unit runs.; A. Power is not supplied; OK
– 52 – SM830078 12. SERVICE PROCEDURES (b) Circuit breaker trips in several minutes after turning the air conditioner on. • There is a possibility of short circuit. 2 2 2 2 2 Neither indoor unit nor outdoor unit runs. A. Power is not supplied B. Check remote control unit. 0615_X_S • Check power supp...
Page 53 - C. Check “Operation selector” switch in the indoor unit.; YES
– 53 – SM830078 12. SERVICE PROCEDURES C. Check “Operation selector” switch in the indoor unit. D. Check compressor motor protectors.(a) High pressure switch (63PH) E. Transformer in indoor unit. 0617_X_S • Has “Operation selector” switch been set to ON position ? YES Set “Operation selector”switch ...
Page 55 - Outdoor Unit does not Run.; A. Check COOL / FAN selector switch in the remote control unit.
– 55 – SM830078 12. SERVICE PROCEDURES 3) Outdoor Unit does not Run. A. Check COOL / FAN selector switch in the remote control unit. B. Check set temperature. 0624_X_S Try to lower settemperature by Temperaturesetting button “COOLER”. • Set “Operation selector” switch to TEST in the indoor unit. YES...
Page 56 - C. Check compressor motor magnetic contactor.
– 56 – SM830078 12. SERVICE PROCEDURES C. Check compressor motor magnetic contactor. F. Check float switch. (XS Type only) • Refer to “2-3 Drain Pump Control” D. Check indoor unit P.C.B. 1036_X_S • Check voltage between terminals L1 and L2 at terminal plate. • Check P.C.B. Ass’y. No voltage appears....
Page 57 - Some Part does not Operate.; • Check fan motor capacitor.
– 57 – SM830078 12. SERVICE PROCEDURES 5) Some Part does not Operate. A. Indoor fan does not run. 4) Indoor Unit does not Run. (Indoor fan and louver motor do not run.) B. Louver motor does not run. • Check resistance of fan motor winding. • Check fan motor capacitor. OK Relay RY1 or RY2 on the P.C....
Page 58 - Outdoor Fan does not Run.; • Check fan motor capacitor
– 58 – SM830078 12. SERVICE PROCEDURES 7) Outdoor Fan Speed is not Switched from High to Low even when the OutdoorTemperature Falls below 78 ° F. (C4232 Type) 6) Outdoor Fan does not Run. 8) Outdoor Fan Speed is not Switched from High to Med even when the OutdoorTemperature Falls below 77 ° F. Outdo...
Page 59 - Outdoor Fan does not Run for CL4232.
– 59 – SM830078 12. SERVICE PROCEDURES 9) Outdoor Fan does not Run for CL4232. 10) Compressor does not Run. • Check fuse on PCB Ass’y in outdoor unit for continuity. • Check resistance of primary winding of transformer. (TR) 1038_X_S If fuse blows, • Check PTC. • Check compressor motor capacitor (RC...
Page 61 - A Sensor is Defective
– 61 – SM830078 12. SERVICE PROCEDURES (2) A Sensor is Defective 1 1 1 1 1 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 6minutes when sensor opens. (b) Short “Freeze Prevention” does not op...
Page 62 - Checking the Electrical Components
– 62 – SM830078 12. SERVICE PROCEDURES (4) Checking the Electrical Components 1) Measurement of InsulationResistance • The electrical insulation is acceptable when the resistance exceeds 1 M Ω . 1 1 1 1 1 Power Supply Wires Clamp the earthed wire of the PowerSupply wires with a lead clip of the insu...
Page 63 - Checking the Protective Devices
– 63 – SM830078 12. SERVICE PROCEDURES 2) Checking the Protective Devices • Disconnect the connector, which consists of P (plug) and S (socket) when you want to check the protective device. • Then check continuity among plug’s (and/or socket’s) terminal as in Fig. 17. • Normality of the protective d...
Page 64 - Checking the Electrical Parts
– 64 – SM830078 12. SERVICE PROCEDURES 3) Checking the Electrical Parts 1 1 1 1 1 Power transformer (TR1) ................. 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...
Page 65 - • Check for continuity using a multimeter; Thermistor Characteristic Curve; Coil sensor
– 65 – SM830078 12. SERVICE PROCEDURES 6 6 6 6 6 Continuity of fuse on P.C.B. Ass’y • Check for continuity using a multimeter as shown in Fig. 19. Method Used to Replace Fuse on PCBAss’y 1. Remove the PCB Ass’y from the electri- cal component box. 2. Remove the fuse from PCB Ass’y using pliers while...
