Sanyo SAP commercial and residential air conditioning systems. Trouble shooting, installation, controller information and service data.

 

Features

This air conditioner is an inverter type unit that automatically adjusts capacity as appropriate. Details on these

functions are provided below; refer to these descriptions when using the air conditioner.

• Microprocessor Controlled Operation

• Automatic Switching between Cooling and

The interior compartment of the remote control

Heating

unit contains several features to facilitate

This unit automatically switches between cooling

automatic operation, easy logically displayed for

operation and heating operation according to the

easy use.

difference between the room temperature and the

temperature setting.

• Simple One-touch Wireless Remote Control

The remote control unit has several features to

• Hot Start Heating System

facilitate automatic operation.

Right from the start, the air is warm and

comfortable. This system prevents any cold blasts

• 24-Hour ON or OFF Timer

at the beginning while the heat pump is warming

This timer can be set to automatically turn the

up, or even defrosting.

unit on or off at any time within a 24 hour period.

• Automatic Restart Function for Power Failure

• 1-Hour OFF Timer

Even when power failure occurs, preset

This timer can be set to automatically turn off the

programmed operation can be reactivated once

unit at any time after one hour.

power resumes.

• Night Setback

• High Power Operation

Pressing this button changes the setting of the

If not in Auto Operation, the unit operates at

room temperature thermostat, allowing you to set

maximum output for 30 minutes, regardless of the

the temperature at whatever level

that you find

desired temperature.

comfortable.

The fan speed is 1 step above "High".

• Automatic and 3-step Fan Speed

• Quiet Operation

Auto/High/Medium/Low

The fan rotates slower than the fan speed setting

to provide a quieter operating sound.

• Air Sweep Control

This function moves a flap up and down in the air

• Anti-Mold Filter

outlet, directing air in a sweeping motion around

This unit is equipped with an anti-mold filter that

the room and providing comfort in every corner.

inhibits the growth of mold and bacteria.

• Auto. Flap Control

• Air Clean Filter

This automatically sets the flap to the optimum

An air filter that eliminates unpleasant odors and

position during heating, cooling, and drying

cleans the air is available.

operation.

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

 

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.

 

 

Executing self-diagnostics

After turning on power to the air conditioner, use the remote controller and

follow the steps below to execute self-diagnostics.

Step 1: Press and hold the remote controller QUIET button and 1 HR TIMER

button. At the same time, press the ACL (reset) button. Use a pointed

object such as the tip of a pen to press the ACL button.

When this has been done, "oP-1" (test run) appears, blinking, in the

remote controller clock display area.

Step 2: Next, press the 1 HR TIMER button once to change the display from

"oP-1" to "oP-3" (self-diagnostics). (The display continues to blink.)

Step 3: Finally press the ON/OFF button to engage self-diagnostics mode.

• The self-diagnostics function utilizes the 3 indicator lamps on the main unit, in

combinations of ON lamps, blinking lamps, and OFF lamps, to report the

existence of sensor trouble or a protective operation. (The lamps blink or

remain ON for 5 seconds, then turn OFF for 2 seconds.) Self-diagnostics is

completed when the buzzer sounds 3 short beeps.

• A maximum of 3 self-diagnostics reports are displayed, for 5 seconds each,

beginning with the most recent report. Following this display the lamps turn

OFF. In order to view the self-diagnostics results again, press the ON/OFF

button again.

• The 3 lamps remain OFF if no trouble has occurred.

<IMPORTANT> After self-diagnostics is completed, be sure to press the ACL

(reset) button to return to normal mode. The air conditioner will

not operate if this is not done.

NOTE

1: If the operation lamp blinks every 0.5 seconds immediately when the power

is turned ON, there is an external ROM (OTP data) failure on the indoor

circuit board, or a ROM socket insertion problem, or the ROM has not been

installed.

2: The failure mode is stored in memory even when the power is not ON.

Follow the procedure below to perform diagnostics

Code

Diagnostics item

Diagnostics contents

S01

Room temperature sensor failure

1Sensor open circuit or short circuit

S02

Indoor heat exchanger sensor failure

2Contact failure at connector or open circuit at terminal crimping location (short-circuit detection only for the humidity sensor)

3Indoor/outdoor circuit board failure

S03

Humidity sensor failure

S04

Compressor temperature sensor failure

1Sensor open circuit or short circuit 2Contact failure at connector or open circuit at terminal crimping location 3Outdoor circuit board failure

S05

Outdoor heat exchanger sensor failure

S06

Outdoor air temperature sensor failure

S07

Outdoor electrical current detection failure

Outdoor circuit board failure

E01

Indoor/outdoor communications failure (serial communications)

1Mis-wiring 2 AC power failure 3Blown fuse 5Indoor or outdoor circuit board failure

4Power relay failure

E02

• HIC circuit failure • Power Tr (transistor) circuit failure

1HIC 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

E03

Outdoor unit external ROM (OTP data) failure

1External ROM data failure

2Outdoor circuit board failure

E04

Peak current cut-off

1Instantaneous power outage 3Outdoor circuit board failure

2HIC or power transistor failure

E05

• PAM circuit failure • Active circuit failure

1Outdoor circuit board failure

2Outdoor power supply voltage failure

E06

Compressor discharge overheat prevention activated.

1Electric expansion valve failure 2Capillaries choked 3Shortage of refrigerant 4Continuous overload operation 5Outdoor fan does not rotate 6Outdoor circuit board failure

E07

Indoor fan operating failure

1Fan motor failure

2Contact failure at connector

3Indoor circuit board failure

E08

• 4-way valve switching failure • Indoor zero-cross failure

14-way valve failure (heat pump model only) 2Outdoor circuit board failure

E09

No-refrigerant protection

1Service valve not opened.

2Shortage of refrigerant

E10

DC compressor drive circuit failure

1Open phase

2Outdoor circuit board failure

E11

Outdoor fan operating failure

1Fan motor failure

2Contact failure at connector

3Outdoor circuit board failure

E12

• Outdoor system communications failure • Outdoor high-pressure SW • OLR operation • Outdoor power supply open phase • Outdoor coil freezing

1Mis-wiring 2Blown fuse 5Outdoor circuit board failure

3Power relay failure 6Compressor failure

4Open phase

E13

Freeze-prevention operation activated.

1Indoor fan system failure

2Shortage of refrigerant

3Low-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:

 

Length of tubing

Less than 10 meters

More than 10 meters

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.