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| Sanyo SAP commercial and residential air conditioning systems.
Trouble shooting, installation, controller information and service data. |
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Features |
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This air conditioner is an inverter type unit that
automatically adjusts capacity as appropriate. Details on these |
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functions are provided below; refer to these descriptions
when using the air conditioner. |
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Microprocessor Controlled Operation |
Automatic Switching between Cooling and |
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The interior compartment of the remote control |
Heating |
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unit contains several features to facilitate |
This unit automatically switches between cooling
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automatic operation, easy logically displayed for
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operation and heating operation according to the
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easy use. |
difference between the room temperature and the
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temperature setting. |
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Simple One-touch Wireless Remote Control |
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The remote control unit has several features to |
Hot Start Heating System |
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facilitate automatic operation. |
Right from the start, the air is warm and |
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comfortable. This system prevents any cold blasts
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24-Hour ON or OFF Timer |
at the beginning while the heat pump is warming
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This timer can be set to automatically turn the |
up, or even defrosting. |
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unit on or off at any time within a 24 hour period.
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Automatic Restart Function for Power Failure
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1-Hour OFF Timer |
Even when power failure occurs, preset |
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This timer can be set to automatically turn off the
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programmed operation can be reactivated once |
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unit at any time after one hour. |
power resumes. |
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Night Setback |
High Power Operation |
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Pressing this button changes the setting of the |
If not in Auto Operation, the unit operates at |
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room temperature thermostat, allowing you to set
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maximum output for 30 minutes, regardless of the
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the temperature at whatever level |
that you find |
desired temperature. |
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comfortable. |
The fan speed is 1 step above "High". |
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Automatic and 3-step Fan Speed |
Quiet Operation |
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Auto/High/Medium/Low |
The fan rotates slower than the fan speed setting
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to provide a quieter operating sound. |
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Air Sweep Control |
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This function moves a flap up and down in the air
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Anti-Mold Filter |
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outlet, directing air in a sweeping motion around
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This unit is equipped with an anti-mold filter that
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the room and providing comfort in every corner. |
inhibits the growth of mold and bacteria. |
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Auto. Flap Control |
Air Clean Filter |
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This automatically sets the flap to the optimum |
An air filter that eliminates unpleasant odors and
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position during heating, cooling, and drying |
cleans the air is available. |
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operation. |
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Room Temperature Control of the air conditioning system
Cooling
Room temperature control is
obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the remote control unit.
l The room temperature (and
other information) is transmitted every 5 minutes by the remote control unit to
the controller in the indoor unit.
l Once the compressor starts,
it keeps running for 5 minutes.
l Once the compressor stops,
it will not start running again for 3 minutes.
l Thermo ON : When room
temperature rises 1°C above the set temperature T°C.
Compressor ή
ON
l Thermo. OFF : When the room
temperature decreases below the set temperature T°C.
Compressor ή
OFF
n Heating
Room temperature control is
obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the remote control unit.
The room temperature (and
other information) is transmitted every 5 minutes by the remote control unit to
the controller in the indoor unit.
Once the compressor starts,
it keeps running for 5 minutes.
Once the compressor stops,
it will not start running again for 5 minutes. Thermo ON : When room
temperature decreases below 1°C below the set temperature T°C.
Compressor ή
ON
Thermo. OFF : When the room
temperature rises 1°C above the set temperature T°C.
Compressor ή
OFF
The temperature described in this page and previous page gives
you an example with remote control operation. In case of a body sensor operation, operation
temperature differ somewhat.
Dry Operation (Dehumidification) of the air conditioning system
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.
Automatic Switching between Cooling and Heating of the air
conditioning system
When AUTO mode is selected,
the microprocessor calculates the difference between the set temperature and the room temperature, and automatically switches to COOLING or
HEATING mode to maintain the desired temperature.
Room temp. ³
Set temp.
ή COOL
Room temp. < Set temp.
ή HEAT
This means that if the room temperature is
higher than or
equal to the set temperature,
COOLING operation begins. If the room temperature is
lower than the set temperature,
HEATING operation begins. Example of operation in the AUTO mode with the set room
temperature at 23 °C. The air conditioner changes the operation mode (from cool to
heat or vice versa)
TROUBLESHOOTING
the air conditioning system
Check power supply wiring
Check that power supply
wires are correctly connected to terminals
L and N on the terminal plate
in the indoor unit.
9-1-2. Check inter-unit wiring.
Check that inter-unit
wiring is correctly connected between indoor unit and outdoor unit.
9-1-3. Check power supply.
Check that voltage is in
specified range (±10% of the rating).
Check that power is being
supplied.
9-1-4. Check lead wires and connectors in indoor and outdoor
units.
Check that coating of lead
wires is not damaged.
Check that lead wires and
connectors are firmly connected. Check that wiring is
correct.
2. Air conditioner does not operate.
9-2-1. Circuit breaker trips (or fuse blows).
A. When the circuit breaker is set to ON, it is tripped soon.
(Resetting is not possible.)
There is a possibility of
ground fault. Check insulation
resistance. If resistance value is 2M½
or less, insulation is defective
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9-2-2. Neither indoor nor outdoor unit
runs. A. Power is not supplied. B. Check
"LED lamps" on the front of indoor unit.
(Refer to item "8-9.Self
Diagnostic Function".) YES
OPERATION lamp, TIMER lamp or STANDBY lamp is blinking. Refer to "Self
diagnostic function" to find the error. Then, repair or replace the defective
parts. NO Check power supply. Power is being supplied to the indoor unit.
Circuit breaker is tripped. Power failure Reset breaker. Wait for recovery or
contact power company.
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Executing self-diagnostics |
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After turning on power to the air conditioner, use the
remote controller and |
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follow the steps below to execute self-diagnostics.
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Step 1:
Press and hold the remote controller QUIET button and 1 HR TIMER
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button. At the same time, press the ACL (reset) button. Use
a pointed |
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object such as the tip of a pen to press the ACL button.
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When this has been done, "oP-1" (test run) appears,
blinking, in the |
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remote controller clock display area.
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Step 2 :
Next, press the 1 HR TIMER button once to change the display from
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"oP-1" to "oP-3" (self-diagnostics). (The display continues
to blink.)
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Step 3:
Finally press the ON/OFF button to engage self-diagnostics mode.
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The self-diagnostics function utilizes the 3 indicator
lamps on the main unit, in |
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combinations of ON lamps, blinking lamps, and OFF lamps, to
report the |
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existence of sensor trouble or a protective operation. (The
lamps blink or |
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remain ON for 5 seconds, then turn OFF for 2 seconds.)
Self-diagnostics is |
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completed when the buzzer sounds 3 short beeps. |
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A maximum of 3 self-diagnostics reports are displayed, for
5 seconds each, |
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beginning with the most recent report. Following this
display the lamps turn |
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OFF. In order to view the self-diagnostics results again,
press the ON/OFF |
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button again. |
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The 3 lamps remain OFF if no trouble has occurred.
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<IMPORTANT>
After self-diagnostics
is completed, be sure to press the ACL |
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(reset) button to return to normal mode. The air
conditioner will |
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not operate if this is not done. |
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NOTE |
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1: If the operation lamp blinks every 0.5 seconds
immediately when the power |
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is turned ON, there is an external ROM (OTP data) failure on
the indoor |
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circuit board, or a ROM socket insertion problem, or the ROM
has not been |
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installed.
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2: The failure mode is stored in memory even when the power
is not ON. |
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Follow the procedure below to perform diagnostics
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Code |
Diagnostics item |
Diagnostics contents |
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S01 |
Room temperature sensor failure |
1 Sensor
open circuit or short circuit |
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S02 |
Indoor heat exchanger sensor failure |
2 Contact
failure at connector or open circuit at terminal crimping location
(short-circuit detection only for the humidity sensor) |
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3 Indoor/outdoor
circuit board failure |
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S03 |
Humidity sensor failure |
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S04 |
Compressor temperature sensor failure |
1 Sensor
open circuit or short circuit
2Contact
failure at connector or open circuit at terminal crimping location
3Outdoor
circuit board failure |
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S05 |
Outdoor heat exchanger sensor failure |
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S06 |
Outdoor air temperature sensor failure |
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S07 |
Outdoor electrical current detection failure |
Outdoor circuit board failure |
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E01 |
Indoor/outdoor communications failure (serial
communications) |
1 Mis-wiring
2
AC power
failure
3Blown
fuse 5Indoor
or outdoor circuit board failure |
4 Power
relay failure |
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E02 |
HIC circuit failure Power Tr (transistor) circuit
failure |
1 HIC
or power Tr failure
2Outdoor
fan does not turn.
3Instantaneous
power outage
4Service
valve not opened.
5Outdoor
fan blocked.
6Continuous
overload operation
7Compressor
failure
8Outdoor
circuit board failure |
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E03 |
Outdoor unit external ROM (OTP data) failure |
1 External
ROM data failure |
2 Outdoor
circuit board failure |
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E04 |
Peak current cut-off |
1 Instantaneous
power outage
3Outdoor
circuit board failure |
2 HIC
or power transistor failure |
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E05 |
PAM circuit failure Active circuit failure |
1 Outdoor
circuit board failure |
2 Outdoor
power supply voltage failure |
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E06 |
Compressor discharge overheat prevention activated.
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1 Electric
expansion valve failure
2Capillaries
choked
3Shortage of
refrigerant
4Continuous
overload operation
5Outdoor
fan does not rotate
6Outdoor
circuit board failure |
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E07 |
Indoor fan operating failure |
1 Fan
motor failure |
2 Contact
failure at connector |
3 Indoor
circuit board failure |
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E08 |
4-way valve switching failure Indoor zero-cross failure
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1 4-way
valve failure (heat pump model only)
2Outdoor
circuit board failure |
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E09 |
No-refrigerant protection |
1 Service
valve not opened. |
2 Shortage
of refrigerant |
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E10 |
DC compressor drive circuit failure |
1 Open
phase |
2 Outdoor
circuit board failure |
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E11 |
Outdoor fan operating failure |
1 Fan
motor failure |
2 Contact
failure at connector |
3 Outdoor
circuit board failure |
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E12 |
Outdoor system communications failure Outdoor
high-pressure SW OLR operation Outdoor power supply open phase Outdoor
coil freezing |
1 Mis-wiring
2Blown
fuse 5Outdoor
circuit board failure |
3 Power
relay failure
6Compressor
failure |
4 Open
phase |
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E13 |
Freeze-prevention operation activated. |
1 Indoor
fan system failure |
2 Shortage
of refrigerant |
3 Low-temperature
operation |
11. CHECKING ELECTRICAL
Components
11-1. Measurement of Insulation
Resistance
The insulation is in good
condition if the resistance exceeds 1M½.
11-1-1. Power supply cord
Clamp the grounding wire of power cord with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the two power
wires. Then also measure the resistance between the grounding and other power terminals. (Fig. 1)
11-1-2. Indoor unit
Clamp an aluminum plate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw where power supply lines are connected on the terminal plate.
11-1-3. Outdoor unit
Clamp an aluminum plate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw on the
terminal plate. Note that the ground line terminal should be skipped for the check.
11-1-4. Measurement of insulation
resistance for electrical parts
Disconnect the lead wires of the desired electric part from terminal plate, capacitor, etc. Similarly disconnect the connector. Then measure the insulation resistance.
12. REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN SERVICING UNIT
12-1. Characteristics of New Refrigerant R410A
12-1-1. What is New Refrigerant R410A?
R410A is a new refrigerant that contains two types of
pseudo-non-azeotropic refrigerant mixture. Its
refrigeration capacity and energy efficiency are about the same
level as the conventional refrigerant, R22.
12-1-2. Components (mixing proportions)
HFC32 (50%) / HFC125 (50%)
12-1-3. Characteristics
Less toxic, more chemically
stable refrigerant 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. Then,
after evacuation, totally recharge the specified amount of refrigerant with the new refrigerant at its normal
mixed composition state (in liquid phase).
l When refrigerant R410A is
used, the composition will differ depending on whether it is in gaseous or
liquid phase, and the basic performance of the air conditioner will be
degraded if it is charged while the refrigerant is in gaseous state. Thus,
always charge the refrigerant while it is in liquid phase.
12-2. Checklist Before Servicing
Use a clutch-type flare tool for R410A or the conventional flare
tool. Note that sizes of the resultant flares differ between these two tools. Where a conventional flare tool is
used, make sure to observe A Specification (amount of extrusion) by using the flare spacer.
Tubing precautions
Refrigerant R410A is more easily affected by dust or moisture
compared with 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.
No addition of
compressor oil for R410A
No additional charge of compressor oil is permitted.
No use of refrigerant
other than R410A
Never use a refrigerant other than R410A.
If refrigerant R410A is
exposed to fire
Through welding, etc., toxic gas may be released when R410A
refrigerant is exposed to fire. Therefore, be sure to provide ample ventilation during installation work.
Caution in case of R410A
leak
Check for possible leak points with the special leak detector
for R410A. If a leak occurs inside the room, immediately provide thorough ventilation.
12-5-1. Procedure for replacing compressor
(1) Recovering refrigerant
Any remaining refrigerant
inside the unit should not be released to the atmosphere, but recovered using the refrigerant recovery unit for R410A.
Do not reuse the recovered
refrigerant, since it will contain impurities.
(2) Replacing Compressor
l Soon after removing seals
of both discharge and suction tubes of the new compressor, replace it quickly.
(3) Checking for sealing
Use nitrogen gas for the
pressurized gas, and never use a refrigerant other than R410A. Also do not use oxygen or any flammable gas.
(4) Evacuation
Use a solenoid
valve-installed vacuum pump
so that even if power is cut off in the middle of evacuation of air due to a power interruption, the valve will prevent the pump oil from flowing back.
The equipment may be
damaged if moisture remains in the tubing, thus carry out the evacuation thoroughly.
When using a vacuum pump
with exhaust air volume more than 25L/min. and ultimate vacuum pressure rate of 0.05Torr:
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Length of tubing |
Less than 10 meters |
More than 10 meters |
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Time |
More than 10 minutes |
More than 15 minutes |
(5) Recharging
Be sure to charge the
specified amount of refrigerant in liquid state using the service port of the wide tube service valve. The proper amount is listed on the unit's nameplate. When the entire amount cannot be charged all at once, charge gradually while operating the unit in Cooling Operation. When charging with a
refrigerant cylinder, use an electronic scale for charging refrigerant. In this case, if the volume of refrigerant in the cylinder becomes less than 20% of the fully-charged amount, the composition of the refrigerant starts to change. Thus,
do not
use the refrigerant if the amount in the charging cylinder is less than 20%.
Also, charge the minimum necessary amount to the charging cylinder before using it to charge the air conditioning unit.
Example:
In case of charging refrigerant to a unit requiring 0.76Kg using a capacity of a 10Kg cylinder, the minimum necessary amount for the cylinder is: 0.76 + 10 ΄ 0.20 = 2.76Kg
For the remaining refrigerant, refer to the instructions of the refrigerant manufacturer.
l If using a charging
cylinder, transfer the specified amount of liquid refrigerant from the refrigerant cylinder to the charging cylinder. Prepare an evacuated charging cylinder beforehand.
Do not use the refrigerant if the amount in the charging cylinder is less than 20%.
CAUTION Never charge a large
amount of liquid refrigerant at once to the unit. This may cause damage to the compressor.
CAUTION
To prevent the composition of R410A from changing, never bleed the refrigerant gas into the atmosphere while transferring the refrigerant.
12-7. Charging Additional Refrigerant
12-7-1. When Tubes are Extended
l Observe the proper amount
of refrigerant as stated in this service manual or the installation manual that
came with the indoor unit.
Charge additional refrigerant in liquid state only.
12-8. Retro-Fitting Existing Systems
12-8-1. Use of Existing Units
l Never use new
refrigerant R410A for existing units which use R22.This will cause the air
conditioner to operate improperly and may result in a hazardous condition.
12-8-2. Use of Existing Tubing
If replacing an older unit
that used refrigerant R22 with a R410A unit,
do not use its existing tubing.
Instead, completely new tubing must be used.
CAUTION Never charge
additional refrigerant if refrigerant is leaking from the unit. Follow instructions given in 12-6. In Case Refrigerant is Leaking and
completely carry out repairs. Only then should you recharge the refrigerant.
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Sanyo SAP air conditioning error codes