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Sanyo C4232 Technical Data & Service Manual

Split system air conditioner
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TECHNICAL DATA

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SERVICE MANUAL

XS4232 / C4232, CL4232
TS4232 / C4232, CL4232
SPLIT SYSTEM AIR CONDITIONER
INDOOR MODEL No.
XS4232
TS4232
Indoor Unit
85464869178000
PRODUCT CODE No.
OUTDOOR MODEL No.
854 016 10
854 016 09
XS4232
TS4232
FILE NO.
PRODUCT CODE No.
C4232
854 016 12
CL4232
854 016 11
C4232
854 016 12
CL4232
854 016 11
Outdoor Unit
C4232
CL4232
REFERENCE NO.
SM
830078

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Summary of Contents for Sanyo C4232

  • Page 1: Technical Data

    TECHNICAL DATA & SERVICE MANUAL XS4232 / C4232, CL4232 TS4232 / C4232, CL4232 SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No. PRODUCT CODE No. XS4232 854 016 10 TS4232 854 016 09 Indoor Unit XS4232 TS4232 85464869178000 FILE NO. OUTDOOR MODEL No.

  • 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 ... 5 SPECIFICATIONS ... 6 (1) Unit Specifications ... 6 (2) Major Component Specifications ... 10 (A) Indoor Unit ... 10 (B) Outdoor Unit ... 12 (3) Other Component Specifications ... 14 (A) Indoor Unit ... 14 (B) Outdoor Unit ... 16 DIMENSIONAL DATA ...
  • Page 4 Introduction: Read Me First! This manual will help you understand and service the air conditioner. To help you find the information you need, we have divided it into 5 main sections. Each section is divided into chapters with charts, tables and explana- tions to help you find and repair problems.

  • Page 5: Operating Range

    1. OPERATING RANGE XS4232, TS4232 / C4232 Temperature Indoor Air Intake Temp. Maximum 95 F DB / 71 F WB Minimum 67 F DB / 57 F WB XS4232, TS4232 / CL4232 Temperature Indoor Air Intake Temp. Maximum 95 F DB / 71 F WB...

  • Page 6: Specifications

    4-3/32 in. (mm) 49-1/2 (1,257) in. (mm) 39-11/32 lbs. (kg) cu. ft. (m (0.131) DATA SUBJECT TO CHANGE WITHOUT NOTICE – 6 – XS4232 C4232 Cooling 40,500 11.88 14.8 187 - 253 21.1 25.3 4,120 10.3 Microprocessor – / Automatic...
  • Page 7 2. SPECIFICATIONS (1) Unit Specifications MODEL No. 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 Maximum fuse size FEATURES Controls Low ambient control...
  • Page 8 (mm) 66-1/16 (1,678) in. (mm) 31-1/16 lbs. (kg) lbs. (kg) cu.ft. (m 14.8 DATA SUBJECT TO CHANGE WITHOUT NOTICE – 8 – TS4232 C4232 Cooling 40,500 11.88 14.6 187 - 253 21.0 22.7 4,100 10.3 Microprocessor Manual / Automatic...
  • Page 9 2. SPECIFICATIONS (1) Unit Specifications MODEL No. 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 Maximum fuse size FEATURES Controls Low ambient control...

  • Page 10: 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 Switch Ass'y Fan (Number … diameter) Fan motor Model Source No. of pole … r.p.m. (230 V, High) Nominal output Coil resistance (Ambient temperature 68 F)
  • Page 11 2. SPECIFICATIONS (2) Major Component Specifications (A) Indoor Unit MODEL No. Source Remote controller (Accessory) Controller P. C. B Ass'y Control circuit fuse Switch Ass'y Fan (Number … diameter) Fan motor Model Source No. of pole … r.p.m. (230 V, High) Nominal output Coil resistance (Ambient temperature 68 F)

  • Page 12: (B) Outdoor Unit

    Open Close VAC, 440 V, 4 F Aluminum plate fin / Copper tube 2 … 12.7 11.63 (1.08) DATA SUBJECT TO CHANGE WITHOUT NOTICE – 12 – C4232 4,270 1,240 — — + 2.0 + 0.5 VLT – YEL 11.42 YEL –...
  • Page 13 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 14: Other Component Specifications

    2. SPECIFICATIONS 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 or coil sensor) Coil resistance Drain pump Rated Float switch MAX Rated (Contact rated)
  • Page 15 2. SPECIFICATIONS 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 or coil sensor) Coil resistance Switch Ass'y Indicator Lamp Ass'y Synchronized Motor TS4232...

  • Page 16: (B) Outdoor Unit

    Power Relay Coil rated Coil resistance (at 77 F) Contact rated Thermostat (Coil sensor) Operating Temperature Contact rated C4232 FC - 2SUL AC 240 V, 60 Hz 10 % AC 240 V, 35 A AC 240 V, 3 A HH62S AC 240 V, 60 Hz 17.2...
  • Page 17 2. SPECIFICATIONS Other Component Specifications (B) Outdoor Unit MODEL No. Compressor Motor Magnetic Contactor Coil rated Coil resistance (at 68 F) Contact rated (Main) Contact rated (Auxiliary) Power Relay Coil rated Coil resistance (at 77 F) Contact rated Power Transformer Rated Primary Secondary...

  • Page 18: Dimensional Data

    3. DIMENSIONAL DATA Indoor Unit: XS4232 8-19/32 2-13/32 32-9/32 (Ceiling opening) 23-7/32 (Suspention bolt pitch) 13-15/32 • Remote controller (Accessory) 2-13/32 23/32 8-9/32 2-3/8 2-3/4 6-1/2 11-7/32 12-29/32 1-3/16 8-19/32 4-29/32 19/32 1-7/8 8-9/32 Dimension : inch Air intake grille Air outlet Refrigerant liquid line (ø3/8") Refrigerant gas line (ø3/4")
  • Page 19 3. DIMENSIONAL DATA Indoor Unit: TS4232 6-3/32 3-3/8 Air outlet or more 9-7/8 (Service space) Air intake 3-1/2 • Remote controller (Accessory) 2-13/32 23/32 7-31/32 12-7/32 11-1/32 11-1/32 4-3/4 Holes in the rear side (View from front) 5-3/16 59-1/4 (Suspension bolt hole pitch) 61-7/32 Front (Service space)

  • Page 20: Outdoor Unit

    3. DIMENSIONAL DATA Outdoor Unit: C4232, CL4232 6-11/16 1-31/32 4-21/64 1-31/32 – 20 – 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)

  • Page 21: 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: C4232, CL4232 42,000 BTU / h AIR FLOW RATE : CONDENSER AMBIENT TEMP. F ( C) (23.9)
  • Page 22 : Compressor Input Rating conditions are : Outdoor Ambient Temp. 95 F DB : Indoor Unit Entering Air Temp. 80 F DB / 67 F WB Outdoor Unit: C4232, CL4232 40,500 BTU / h AIR FLOW RATE : CONDENSER AMBIENT TEMP. F ( C) (23.9)
  • Page 23 4. COOLING CAPACITY 2 2 2 2 2 Indoor Unit: TS4232 Outdoor Unit: C4232, CL4232 • 230V / 1 phase / 60Hz RATING CAPACITY : EVAPORATOR ENT. TEMP. F ( C) 72(22.2) 76(24.4) (15.0) 80(26.7) 84(28.9) 88(31.1) 72(22.2) 76(24.4) (17.2) 80(26.7)
  • Page 24 : Compressor Input Rating conditions are : Outdoor Ambient Temp. 95 F DB : Indoor Unit Entering Air Temp. 80 F DB / 67 F WB Outdoor Unit: C4232, CL4232 40,500 BTU / h AIR FLOW RATE : CONDENSER AMBIENT TEMP. F ( C) (23.9)

  • Page 25: Performance Charts

    1 1 1 1 1 Indoor Unit: XS4232 Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V (15) 208V (15) Outdoor Unit: C4232 Outdoor fan speed High (20) (25) (30) (35) Outdoor ambient temp.
  • Page 26 2 2 2 2 2 Indoor Unit: TS4232 Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V (15) 208V (15) Outdoor Unit: C4232 Outdoor fan speed High (20) (25) (30) (35) Outdoor ambient temp.
  • Page 27 5. PERFORMANCE CHARTS (1) Operating Current 3 3 3 3 3 Indoor Unit: XS4232 Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V STOP / Med (-5) 208V STOP / Med (-5) Outdoor Unit: CL4232 Outdoor fan speed (Upper / Lower)
  • Page 28 5. PERFORMANCE CHARTS (1) Operating Current 4 4 4 4 4 Indoor Unit: TS4232 Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V STOP / Med (-5) 208V STOP / Med (-5) Outdoor Unit: CL4232 Outdoor fan speed (Upper / Lower)

  • Page 29: High And Low Pressure

    230V / 208V (15) • Low Pressure Low pressure characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V / 208V (15) Outdoor Unit: C4232 Outdoor fan speed High (20) (25) (30) (35) Outdoor ambient temp.
  • Page 30 5. PERFORMANCE CHARTS (2) High and Low Pressure 2 2 2 2 2 Indoor Unit: XS4232, TS4232 • High Pressure High pressure characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 230V / 208V STOP / Med (-5) •...

  • Page 31: Air Throw Distance Chart

    6. AIR THROW DISTANCE CHART MODEL: XS4232 MODEL: TS4232 HORIZONTAL DISTANCE (ft.) AXIS AIR VELOCITY COOLING FAN SPEED HIGH ROOM AIR TEMP. 80 F LOUVER ANGLE : COOLING Horizontal distance (ft.) COOLING FAN SPEED HIGH ROOM AIR TEMP. 80 F LOUVER ANGLE –...

  • Page 32: Refrigerant Flow Diagram

    After a tube has been insulated, CAUTION never try to bend it into a narrow curve because it can casue the tube to break or crack. Outdoor Unit: C4232, CL4232 Wide tube service valve Accumulator Narrow tube service valve...

  • Page 33: Installation Instructions

    If total tubing length becomes 50 to 165 ft., charge additional refrigerant (R22) by 0.86 oz./ft.. Tubing length (L) INDOOR UNIT Elevation difference (H) OUTDOOR UNIT Fig. 1 Model C4232 CL4232 in. (mm) 3/8 (9.52) in. (mm) 3/4 (19.05) (ft.) (ft.) (ft.) (ft.)
  • Page 34 8. INSTALLATION INSTRUCTIONS Selecting the Installation Site Indoor Unit AVOID: areas where leakage of flammable gas may be expected. places where large amounts of oil mist exist. direct sunlight. locations near heat sources which may affect performance of the unit. locations where external air may enter the room directly.
  • Page 35 8. INSTALLATION INSTRUCTIONS Outdoor Unit AVOID: heat sources, exhaust fans, etc. (Fig. 2) 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 the unit for air intake/ exhaust and possible mainte- nance.
  • Page 36 8. INSTALLATION INSTRUCTIONS Air Discharge Chamber for Top Discharge Install the air-discharge chamber in the field when: it is difficult to keep a space of minimum 2 ft. between the air-discharge outlet and the obstacle. the air-discharge outlet is facing the side- walk and discharged hot air can annoy the passers-by.
  • Page 37 Recommended Wire Length and Wire Diameter for Power Supply System Power Supply Models C4232, CL4232 65 ft. (AGW #10) *1 Refer to the Wiring System Diagrams (See below diagram) for the meaning of “A”, “B”. AWG = American Wire Gauge...

  • Page 38: Electrical Data

    9. ELECTRICAL DATA Electrical characteristics Indoor model: XS4232 / Outdoor model: C4232, CL4232 Indoor Unit Fan Motor Performance at 230 - 208 V / 1 phase / 60 Hz 0.9 - 0.8 Rating conditions 0.2 - 0.16 0.9 - 0.8 Full load conditions 0.2 - 0.16...

  • Page 39: Electrical Wiring Diagrams

    10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit 1 1 1 1 1 XS4232 • Electric Wiring Diagram 2P(RED) 2P(YEL) 5P(WHT) Earth 2 G 4 Terminal Terminal Plate(4P) To Outdoor Unit IND Lamp Assy Switch Assy 3P(WHT) 7P(WHT) SW ASSY W/LESS Controller (CR-TS2432) 2P(WHT) 2P(WHT)

  • Page 40: Schematic Diagram

    10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit 1 1 1 1 1 XS4232 4P-1 (3A) 4P-4 4P-2 Symbols Indoor Fan Motor 49FI Indoor Motor Thermal Protector Running Capacitor Fuse Drain Pump Auto Louver Motor Power Transformer RY1-RY5 Auxiliary Relay Float Switch •...

  • Page 41: Electric Wiring Diagram

    10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit 2 2 2 2 2 TS4232 • Electric Wiring Diagram 2P(RED) 2P(YEL) 5P(WHT) Earth 2 G 4 Terminal Terminal Plate(4P) To Outdoor Unit Switch IND Lamp Assy Assy 3P(WHT) 7P(WHT) SW ASSY W/LESS Controller (CR-TS2432) 2P(WHT) 2P(WHT)
  • Page 42 10. ELECTRICAL WIRING DIAGRAMS (1) Indoor Unit 2 2 2 2 2 TS4232 4P-1 (3A) 4P-4 4P-2 Symbols Indoor Fan Motor 49FI Indoor Motor Thermal Protector Running Capacitor Fuse Drain Pump Auto Louver Motor Power Transformer RY1~RY5 Auxiliary Relay Float Switch •...

  • Page 43: Outdoor Unit

    10. ELECTRICAL WIRING DIAGRAMS (2) Outdoor Unit 1 1 1 1 1 C4232 GRN/YEL Unit Indoor 60Hz Supply Power – 43 – SM830078...
  • Page 44 10. ELECTRICAL WIRING DIAGRAMS (2) Outdoor Unit 1 1 1 1 1 C4232 Terminal Plate (6P) 63PH Symbols FMO1, 2 49FO1, 2 63PH RC1, 2, 3 1Y, 2Y • Schematic Diagram 49FO1 49FO2 Description Compressor Motor Outdoor Fan Motor Outdoor Fan Motor Thermal Protector...
  • Page 45 10. ELECTRICAL WIRING DIAGRAMS (2) Outdoor Unit 2 2 2 2 2 CL4232 Unit Indoor 60Hz Supply Power – 45 – SM830078...
  • Page 46 10. ELECTRICAL WIRING DIAGRAMS (2) Outdoor Unit 2 2 2 2 2 CL4232 Terminal Plate (6P) Symbols Compressor Motor Crankcase Heater FMO1, 2 Outdoor Fan Motor 49FO1, 2 Outdoor Fan Motor Thermal Protector Compressor Motor Magnetic Contactor Power Transformer Thermistor (Outdoor Temperature) RC1, 2, 3 Running Capacitor RY1, 2, 3...

  • Page 47: Processes And Functions

    11. PROCESSES AND FUNCTIONS 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 48: Freeze Prevention

    11. PROCESSES AND FUNCTIONS 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. MORE THAN 10 MINUTES INDOOR COIL TEMPERATURE 30 F...

  • Page 49: Outdoor Fan Speed Control

    11. PROCESSES AND FUNCTIONS Outdoor Fan Speed Control 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 from HIGH to LOW automatically.

  • Page 50: Service Procedures

    12. SERVICE PROCEDURES (1) Troubleshooting 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. 1 1 1 1 1 Check power supply wiring (a) Single-phase...
  • Page 51 12. SERVICE PROCEDURES 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.
  • Page 52 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 53 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 54 12. SERVICE PROCEDURES F. Check. auxiliary relay. (1Y or 2Y) • Check coil resistance of auxiliary relay. (1Y or 2Y) G. Check indoor fan motor thermal protector (49FMI) • Disconnect the socket from 9P (WHT) connector. • Check the continuity between No.
  • Page 55 12. SERVICE PROCEDURES Outdoor Unit does not Run. A. Check COOL / FAN selector switch in the remote control unit. • Is COOL/FAN selector switch set to COOL ? B. Check set temperature. Try to lower set temperature by Temperature setting button “COOLER”.
  • Page 56 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 57 12. SERVICE PROCEDURES Indoor Unit does not Run. (Indoor fan and louver motor do not run.) P.C.B. Ass’y is defective. Some Part does not Operate. A. Indoor fan does not run. • Check fan rotation. Rotate the fan gently once or twice by hand.
  • Page 58 Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 F. (C4232 Type) • Check the thermostat (23S). Outdoor Fan Speed is not Switched from High to Med even when the Outdoor Temperature Falls below 77 F.
  • Page 59 12. SERVICE PROCEDURES Outdoor Fan does not Run for CL4232. • 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 60 • 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 61: A Sensor Is Defective

    12. SERVICE PROCEDURES 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 6 minutes when sensor opens. (b) Short “Freeze Prevention”...

  • Page 62: Checking The Electrical Components

    12. SERVICE PROCEDURES Checking the Electrical Components Measurement of Insulation Resistance • The electrical insulation is acceptable when the resistance exceeds 1 M . 1 1 1 1 1 Power Supply Wires Clamp the earthed wire of the Power Supply wires with a lead clip of the insu- lation resistance tester and measure the resistance by placing a probe on either of the power wires.
  • Page 63 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. 17. •...
  • Page 64 12. SERVICE PROCEDURES 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. •...
  • Page 65 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. NOTE Method Used to Replace Fuse on PCB Ass’y 1. Remove the PCB Ass’y from the electri- cal component box.
  • Page 66 • 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 Jun. / ’2000 Printed in U.S.A.

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