Sanyo SAP commercial and residential air conditioning systems. Trouble shooting, installation, controller information and service data. |
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 |
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 |
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 |
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 |
Anti-Mold Filter |
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outlet, directing air in a sweeping motion around |
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. |
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.
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The room temperature (and other information) is transmitted every 5 minutes by the remote control unit to thecontroller in the indoor unit.
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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 ONl
Thermo. OFF : When the room temperature decreases below the set temperature T°C.Compressor
ή OFF
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HeatingRoom 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 ONThermo. OFF : When the room temperature rises 1°C above the set temperature T°C.
Compressor
ή OFFThe 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 COOLRoom temp. < Set temp.
ή HEATThis means that if the room temperature is
higher than or equal to the set temperature, COOLING operationbegins. 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.
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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.
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2: The failure mode is stored in memory even when the power is not ON. |
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. |
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 |
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).
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When refrigerant R410A is used, the composition will differ depending on whether it is in gaseous or liquidphase, 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
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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.
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If using a charging cylinder, transfer the specified amount of liquid refrigerant from the refrigerantcylinder 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 tothe unit. This may cause damage to the compressor.
CAUTION
To prevent the composition of R410A from changing, never bleed the refrigerantgas into the atmosphere while transferring the refrigerant.
12-7. Charging Additional Refrigerant
12-7-1. When Tubes are Extended
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Observe the proper amount of refrigerant as stated in this service manual or the installation manual that camewith the indoor unit.
Charge additional refrigerant in liquid state only.12-8. Retro-Fitting Existing Systems
12-8-1. Use of Existing Units
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Never use new refrigerant R410A for existing units which use R22.This will cause the air conditioner tooperate 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. Followinstructions given in 12-6. In Case Refrigerant is Leaking and completely carry
out repairs. Only then should you recharge the refrigerant.