Sanyo C2462R manual

– 1 – SM830092 854648419200 KS2462R C2462R CL2462R Indoor Unit Outdoor Unit SPLIT SYSTEM AIR CONDITIONER TECHNICAL D A T A & SER VICE MANU AL FILE NO. INDOOR MODEL No. PRODUCT CODE No. OUTDOOR MODEL No. PRODUCT CODE No. KS2462R 854 019 00 C2462R 854 019 01 CL2462R 854 019 02 KS2462R / C2462R, CL2462R REFERENCE NO. SM 830092[...]

– 2 – SM830092 Important CAUTION 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. …In Moist or Uneven Locations Use a raised concrete pad or concrete [...]

– 3 – SM830092 T able of Contents 1. OPERATING RANGE ....................................................................................... 4 2. SPECIFICATIONS ............................................................................................ 5 (1) Unit Specifications ..................................................................[...]

– 4 – SM830092 1. OPERA TING RANGE KS2462R / C2462R KS2462R / CL2462R T emperature Indoor Air Intake T emp. Outdoor Air Intake T emp. Maximum 95 ° F DB / 71 ° F WB 115 ° F DB Minimum 67 ° F DB / 57 ° F WB 67 ° F DB T emperature Indoor Air Intake T emp. Outdoor Air Intake T emp. Maximum 95 ° F DB / 71 ° F WB 115 ° F DB Minimum 67 ° F D[...]

– 5 – SM830092 2. SPECIFICA TIONS MODEL No. Indoor Unit KS2462R Outdoor Unit C2462R POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz PERFORMANCE Cooling Capacity kW 7.912 BTU / h BTU / Wh 27,000 Air circulation (Hi) Cu.ft. / min. 559 Moisture removal (High) Pints / h 6.5 7.619 26,000 519 6.4 ELECTRICAL RATINGS Voltage rating VAC VAC 230 Available vol[...]

– 6 – SM830092 2. SPECIFICA TIONS MODEL No. Indoor Unit KS2462R Outdoor Unit CL2462R POWER SOURCE 230 - 208 V / 1 Phase / 60 Hz PERFORMANCE Cooling Capacity kW 7.912 BTU / h BTU / Wh 27,000 Air circulation (Hi) Cu.ft. / min. 559 Moisture removal (High) Pints / h 6.5 7.619 26,000 519 6.4 ELECTRICAL RATINGS Voltage rating VAC VAC 230 Available vo[...]

– 7 – SM830092 2. SPECIFICA TIONS (2) Major Component Specifications (A) Indoor Unit MODEL No . KS2462R Source 230 - 208 V / 1 phase / 60 Hz Remote controller (Accessory) RCS - 1PS4U - G Controller P. C. B Ass'y CR - KS2462R Control circuit fuse 250 V, 3 A Fan Type Cross-flow Number ... Dia. and length in. (mm) 1 ... O.D. 4 (100), L33-3/8 [...]

– 8 – SM830092 2. SPECIFICA TIONS (2) Major Component Specifications (B) Outdoor Unit + 0 – 0.15 D A T A SUBJECT T O CHANGE WITHOUT NOTICE MODEL No . C2462R Source 230 - 208 V / 1 phase / 60 Hz Compressor Scroll (Hermetic) Model ZP23K3E Source 230 - 208 V / 1 phase / 60 Hz Nominal output W 2,400 Compressor oil cc 1,120 Coil resistance (Ambien[...]

– 9 – SM830092 2. SPECIFICA TIONS (2) Major Component Specifications (B) Outdoor Unit MODEL No. CL2462R Source 230 - 208 V / 1 phase / 60 Hz Controller P.C.B. Ass'y CR - CL2432 (Microprocessor) Control circuit fuse 250 V, 3 A Compressor Scroll (Hermetic) Model ZP23K3E Source 230 - 208 V / 1 phase / 60 Hz Nominal output W 2,400 Compressor o[...]

– 10 – SM830092 2. SPECIFICA TIONS (3) Other Component Specifications (A) Indoor Unit MODEL No . KS2462R Power Transformer ATR – T5 Rated Primary AC 230 V, 60 Hz Secondary AC19 V, 0.5 A Capacity 9.5 VA Coil resistance Ω Primary (WHT - WHT) : 457.5 (Ambient temprature 77 ° F) Secondary (BRN - BRN) : 3.9 Thermistor cut off temperature 277 °[...]

– 11 – SM830092 2. SPECIFICA TIONS (3) Other Component Specifications (A) Outdoor Unit MODEL No. C2462R Compressor Motor Magnetic Contactor FC - 1SUL Coil rated AC 240 V, 60 Hz Coil resistance (at 68 ° F) Ω 587 ± 5 % Contact rated (Main) AC 240 V, 26 A Contact rated (Auxiliary) AC 240 V, 3 A Power Relay HH62S Coil rated AC 240 V, 60 Hz Coil[...]

– 12 – SM830092 2. SPECIFICA TIONS (3) Other Component Specifications (B) Outdoor Unit MODEL No. CL2462R Compressor Motor Magnetic Contactor FC - 1SUL Coil rated AC 240 V, 60 Hz Coil resistance (at 77 ° F) Ω 587 ± 5 % Contact rated (Main) AC 240 V, 26 A Contact rated (Auxiliary) AC 240 V, 3 A Power Relay HH62S Coil rated AC 240 V, 60 Hz Coi[...]

– 13 – SM830092 3. DIMENSIONAL D A T A (1) Indoor Unit: KS2462R 6-27/32 Center of tubing hole (2 places) Narrow tube 3/8"(ø9.52) Wide tube 3/4"(ø19.05) 8-31/32 Remote control unit 1-7/8 5-5/16 13 44-7/8 1-7/8 Drain hose O.D. 23/32"(ø18) 2-13/32 25/32 6-7/32 Dimension : inch 2199_M_S[...]

– 14 – SM830092 3. DIMENSIONAL D A T A (2) Outdoor Unit: C2462R, CL2462R 13-3/8 36-5/8 6-23/32 25-31/32 37 4-3/8 14-31/32 16-7/8 18-1/16 25/32 3/4 15-15/16 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) Re[...]

– 15 – SM830092 4. COOLING CAPACITY TC : Total Cooling Capacity (BTU / h) SHC : Sensible Heat Capacity (BTU / h) CI : Compressor Input (kW) Rating conditions are : Outdoor Ambient Temp. 95 ° F DB : Indoor Unit Entering Air Temp. 80 ° F DB / 67 ° F WB RATING CAPACITY : 27,000 BTU / h AIR FLOW RATE : 559 Cu.ft / min EVAPORATOR CONDENSER ENT. T[...]

– 16 – SM830092 4. COOLING CAPACITY TC : Total Cooling Capacity (BTU / h) SHC : Sensible Heat Capacity (BTU / h) CI : Compressor Input (kW) Rating conditions are : Outdoor Ambient Temp. 95 ° F DB : Indoor Unit Entering Air Temp. 80 ° F DB / 67 ° F WB RATING CAPACITY : 26,000 BTU / h AIR FLOW RATE : 519 Cu.ft / min EVAPORATOR CONDENSER ENT. T[...]

– 17 – SM830092 5. PERFORMANCE CHAR TS (1) Operating Current 1 Indoor Unit: KS2462R Outdoor Unit: C2462R Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 208V 1061_X_S Operating current (A) 85 (30) 80 (27) 75 (24) 70 (21) 12 13 14 8 9 7 10 11 59 [...]

– 18 – SM830092 5. PERFORMANCE CHAR TS (1) Operating Current 2 Indoor Unit: KS2462R Outdoor Unit: CL2462R Operating current characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) 1063_X_S 70 (21) 85 (30) 80 (27) 75 (24) Operating current (A) 12 13 14 9 7 8 10 11 Indoor [...]

– 19 – SM830092 5. PERFORMANCE CHAR TS 230V / 208 V • Low Pressure Low pressure characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) (2) High and Low Pressure 1 Indoor Unit: KS2462R Outdoor Unit: C2462R • High Pressure High pressure characteristics versus outdoor [...]

– 20 – SM830092 5. PERFORMANCE CHAR TS 230 / 208V (2) High and Low Pressure 2 Indoor Unit: KS2462R Outdoor Unit: CL2462R • High Pressure High pressure characteristics versus outdoor ambient temperature and indoor temperature. (Indoor relative humidity: 50%, Indoor fan speed: High) • Low Pressure Low pressure characteristics versus outdoor a[...]

– 21 – SM830092 6. AIR THRO W DIST ANCE CHART Horizontal distance (ft.) Axis air velocity (ft./sec.) Vertical distance (ft.) Room air temp. : 80 ° F (26.7 ° C) Fan speed : High 0 5 10 15 5 1 01 52 02 53 0 : Flap angle 0 ° , : Axis air velocity 0 ° : Flap angle 30 ° , : Axis air velocity 30 ° 2200_M_S Indoor Unit: KS2462R[...]

– 22 – SM830092 7. REFRIGERANT FLO W DIA GRAM Indoor Unit: KS2462R Outdoor Unit: CL2462R Indoor Unit: KS2462R Outdoor Unit: C2462R Condenser Compressor Accumulator Sub-condenser HP High pressure switch O. D. 3/4" (19.05mm) O. D. 3/4" (19.05mm) Wide tube Narrow tube O. D. 3/8" (9.52 mm) O. D. 3/8" (9.52 mm) Evaporator Narrow [...]

– 23 – SM830092 8. INSTALLATION INSTRUCTIONS T able 3 Max. Allowable T ubing Limit of T ubing Limit of Elevation Required Amount of Model Length at Shipment Length (L) Difference (H) Additional Refrigerant (ft.) (ft.) (ft.) (oz./ft.) * C2462R, CL2462R 23 132 50 0.43 * If total tubing length becomes 23 to 132 ft. (max.), additional refrigerant ([...]

– 24 – SM830092 8. INST ALLA TION INSTR UCTIONS Minimum height from floor level 5 ft. Indoor Unit Wall Floor level 2205_M_S 2) Selecting the Installation Site AVOID: areas where leakage of flammable gas may be expected. places where large amounts of oil mist exist. (Fig. 2) direct sunlight. locations near heat sources which may affect performan[...]

– 25 – SM830092 8. INST ALLA TION INSTR UCTIONS Outdoor Unit AVOID: heat sources, exhaust fans, etc. Fig. 4 damp, humid or uneven locations. DO: 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[...]

– 26 – SM830092 8. INST ALLA TION INSTR UCTIONS Wind Shield for " CL" Model It is recommended to use wind shields for " CL" model (Fig. 5b). "CL" model is designed to use in low outdoor temperature conditions. General When the outdoor unit is installed in a position exposed to strong wind (like seasonal winds with [...]

– 27 – SM830092 8. INST ALLA TION INSTR UCTIONS 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 following the wiring diagram. (2) Provide a power outlet to be used exclusively for each unit, and a power supply disconnect and [...]

– 28 – SM830092 8. INST ALLA TION INSTR UCTIONS 7-2. Recommended Wire Length and Wire Diameter for Power Supply System 7-3. Wiring System Diagram Models Time Delay Fuse or Circuit Capacity (B) *1 Inter-unit Wiring (A) *1 Power Supply AGW #14 C2462R, CL2462R 64 ft. (AWG #12) 35 A 132 ft. *1 Refer to the Wiring System Diagrams (See below diagram)[...]

– 29 – SM830092 9. ELECTRICAL DATA Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230 - 208 V / 1 phase / 60 Hz Rating conditions A 0.38 - 0.37 0.90 - 0.90 8.8 - 9.6 10.1 - 10.9 kW 0.08 - 0.07 0.18 - 0.17 2.02 - 2.00 2.25 - 2.24 Full load conditions A 0.38 - 0.37 0.90 - 0.90 11.1 - 12.4 12.4 - 13.7 kW 0.08 [...]

– 30 – SM830092 10. ELECTRICAL WIRING DIA GRAMS (1) Indoor Unit 1 KS2462R 87654321 87654321 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 FLP CONNECT OR FLAP2 5P [BLK] FLAP1 5P [WHT] LAMP 4P [WHT] RECEIVER 3P [WHT] SEC 2P [WHT] PR Y 3P [RED] SUP 5P [WHT] ROOM/COIL 4P [WHT] [WHT] [GRN] [BLK] WHT BLU BLU BLU BLU 1 2 1 2 1 3 1 3 3 2 1 3 2 1 1 2 3 4 1 2 [...]

– 31 – SM830092 10. ELECTRICAL WIRING DIA GRAMS CM RC1 2P (GRN) 8P (WHT) 2P (WHT) 63PL 31 32 13 14 T W S V R U A B PS EARTH TERMINAL C R S GRN/YEL 52C 5 7 8 13 1 2 1 2 6 24 2Y 49FO EARTH TERMINAL POWER SUPPLY 60Hz 1ø 208V/230V TO INDOOR UNIT TERMINAL PLATE (6P) 1 2 G 4 L1 L2 RED 63PH PS 1 2 1 2 WHT WHT RED BRN YEL BLK WHT BLK RED RED WHT • E[...]

– 32 – SM830092 10. ELECTRICAL WIRING DIA GRAMS 2Y 52C 1 2 2Y TERMINAL PLATE (6P) 2Y RC2 63PH C LH C R S RC1 52C – 1 – 2 1Y 1Y HM FMO CM 6 5 1 2 49FO 52C 23S • Schematic Diagram Symbols Description CM FMO 49FO 52C 63PH 23S RC1, 2 1Y, 2Y Compressor Motor Outdoor Fan Motor Outdoor Fan Motor Thermal Protector Compressor Motor Magnetic Contac[...]

– 33 – SM830092 10. ELECTRICAL WIRING DIA GRAMS • Electric Wiring Diagram 1 2 4 G L1 L2 RC2 FMO RC1 PNK BRN GRY GRY WHT VLT YEL PNK BRN GRY BLK WHT VLT YEL 2 1 2 1 4 3 4 3 6 5 6 5 8 7 8 P 8P (WHT) 49FO S 7 POWER SUPPLY 60Hz 1ø 208V/230V TO INDOOR UNIT TERMINAL PLATE (6P) EARTH TERMINAL EARTH TERMINAL CM HGBV UV W 3 2 R B A ST 3 1 C R S 14 13[...]

– 34 – SM830092 10. ELECTRICAL WIRING DIA GRAMS • Schematic Diagram 3 1 2 1 2 1 TR AC 208V 230V AC 14V TH OUTDOOR TEMPERATURE 1 RY1 7 5 9 6 5 7 FMO RC2 COM COM RC1 RY3 -1 RY1 RY2 HL M 3 1 1 2 1 3 49FO CM 52C C S R 52C 52C 1Y -2 -G -4 -L1 -L2 CR-CL2462R CONTROLLER TERMINAL PLATE (6P) 1Y F1 (3A) M HGBV L DC12V SEC PRY TEMP RY3 52C CH 2 63PH 63P[...]

– 35 – SM830092 11. PR OCESSES 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 ac[...]

– 36 – SM830092 11. PR OCESSES 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 [...]

– 37 – SM830092 (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. 11. PR OCESSES AND FUNCTIONS ON ON ON ON OFF OFF Set speed More than 10 minutes 6 minutes T + 4 ° F Indoo[...]

– 38 – SM830092 (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. When the outdoor temperature rises to[...]

– 39 – SM830092 (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. 1 Check power supply wiring (a) Single-phase Check that powe[...]

– 40 – SM830092 2) Air Conditioner does not Operate 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 2 M Ω or less, it is a defect of insulation. 1 2 3 (Example) *Set the circuit breaker to[...]

– 41 – SM830092 12. SER VICE PROCEDURES (b) Circuit breaker trips in several minutes after turning the air conditioner on. • There is a possibility of short circuit. 2 Neither indoor unit nor outdoor unit runs. A. Power is not supplied 0616_X_S • Try to run both indoor and outdoor units with another remote control unit. The other remote con[...]

– 42 – SM830092 12. SER VICE PROCEDURES C. Check “Operation selector” switch in the indoor unit. D. Check compressor motor protectors. (a) High pressure switch (63PH) 0618_X_S • Check high pressure switch. Does high pressure switch actuate ? (63PH) YES YES Clean heat exchanger coil or remove obstacles. • Is outdoor heat exchanger coil d[...]

– 43 – SM830092 12. SER VICE PROCEDURES F. Check. auxiliary relay. (1Y or 2Y) 0620_X_S • Check coil resistance of auxiliary relay. (1Y or 2Y) G. Check fuse on the P.C.B. Ass’y in the indoor unit. 2219_X_S • Check fuse on the P.C.B. Ass'y in the indoor unit for continuity. • Check resistance of primary and secondary winding of trans[...]

– 44 – SM830092 12. SER VICE PROCEDURES 3) Outdoor Unit does not Run. A. Check COOL / FAN selector switch in the remote control unit. B. Check set temperature. 2220_X_S • Is MODE selector button set to COOL ? NO Set to COOL. 2221_X_S Try to lower set temperature by Temperature setting button “COOLER”. • Set “Operation selector” swit[...]

– 45 – SM830092 12. SER VICE PROCEDURES C. Check compressor motor magnetic contactor. D. Check indoor unit P.C.B. 0628_X_S • Check voltage between terminals No.2 and No.4 at terminal plate. • Check P.C.B. Ass’y. No voltage appears. P.C.B. Ass’y is defective. E. Check outdoor unit P.C.B. (CL2462R Type) 1036_X_S • Check voltage between [...]

– 46 – SM830092 12. SER VICE PROCEDURES 5) Some Part does not Operate. A. Indoor fan does not run. 4) Indoor Unit does not Run. (Indoor fan and flap motor do not run.) B. Flap motor does not run. • Check resistance of fan motor winding. • Check fan motor capacitor. OK Relay RY1 or RY2 on the P.C.B. Ass’y is defective. • Check fan rotati[...]

– 47 – SM830092 12. SER VICE PROCEDURES 7) Outdoor Fan Speed is not Switched from High to Low even when the Outdoor Temperature Falls below 78 ° F. (C2462R Type) 6) Outdoor Fan does not Run. • Check resistance of fan motor winding. • Check fan motor capacitor OK • Check continuity between terminals on the compressor motor magnetic contac[...]

– 48 – SM830092 12. SER VICE PROCEDURES 9) Outdoor Fan does not Run for CL2462R. 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 (RC1). Wait for 30 minutes until com-[...]

– 49 – SM830092 12. SER VICE PROCEDURES 11) Poor Cooling. 12) Excessive Cooling. • The set temperature is too low. • Is the remote control unit installed at a place where it can detect the room temperature properly ? 0637_X_S Set the temperature to higher value using temperature setting button of the remote control unit. Change installation[...]

– 50 – SM830092 12. SER VICE PROCEDURES (2) A Sensor is Defective. 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” does not operate when dehumidified water is frozen on the [...]

– 51 – SM830092 12. SER VICE PROCEDURES (3) Checking the Electrical Components 1) Measurement of Insulation Resistance • The electrical insulation is acceptable when the resistance exceeds 2 M Ω . 1 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 resi[...]

– 52 – SM830092 12. SER VICE 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. 20 . • The Protective Device is proved normal if there is a continuity[...]

– 53 – SM830092 Fan motor capacitor Compressor motor capacitor 1041_X_S Multimeter Ω Fig. 21 3) Checking the Electrical Parts 1 Power transformer ........................... 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. •[...]

– 54 – SM830092 12. SER VICE PROCEDURES 6 Continuity of fuse on P.C.B. Ass’y • Check for continuity using a multim- eter as shown in Fig. 22. Method Used to Replace Fuse on PCB Ass’y 1. Remove the PCB Ass’y from the electrical component box. 2. Remove the fuse from PCB Ass’y using pliers while heating the sol- dered leads on the back [...]

– 55 – SM830092 12. SER VICE PROCEDURES 1 1. REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN INSTALLING UNIT 1 1-1. Characteristics of New Refrigerant R410A 1 1-1-1. What is New Refrigerant R410A? R410A is a new refrigerant that contains two types of pseudo-non-azeotropic refrigerant mixture which do not adversely affect the earth ’ s ozone layer[...]

– 56 – SM830092 12. SER VICE PROCEDURES T ubing precautions Refrigerant R410A is more easily af fected 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 [...]

– 57 – SM830092 12. SER VICE PROCEDURES 1 1-3. T ools Specifically for R410A For servicing, use the following tools for R410A T o prevent other refrigerants (R22, R407C) from being mistakenly charged to this unit, sizes of the service ports and flare nuts of the narrow tube service valve and wide tube service valve have been altered. T ool Dist[...]

– 58 – SM830092[...]