MULTI-SPLIT SYSTEM AIR CONDITIONER

Transcription

1 TECHNICAL & SERVICE MANUAL SAP KM97AHA ( 2) + SAP CM1827AHA FILE NO. Destination: Australia MULTI-SPLIT SYSTEM AIR CDITIER Indoor Model No Product Code No. Outdoor Model No. Product Code No. SAP KM97AHA S SAP CM1821AHA S Indoor Unit Outdoor Unit SAP CM1821AHA SAP KM97AHA ( 2) REFERENCE NO. SM700505

2 IMPORTANT! Please Read Before Starting This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently. For safe installation and trouble-free operation, you must: Carefully read this instruction booklet before beginning. Follow each installation or repair step exactly as shown. Observe all local, state, and national electrical codes. Pay close attention to all warning and caution notices given in this manual. This symbol refers to a hazard WARNING or unsafe practice which can result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can CAUTI result in personal injury or product or property damage. If Necessary, Get Help These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions. In Case of Improper Installation The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to follow the instructions in this document. SPECIAL PRECAUTIS WARNING When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSAL INJURY OR DEATH. LY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM. Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked. Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death. Ground the unit following local electrical codes. Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard. When Transporting 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 In a Ceiling or Wall Make sure the ceiling/wall is strong enough to hold the unit s weight. It may be necessary to construct a strong wood or metal frame to provide added support. 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 blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration. In an Area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle. In a Snowy Area (for Heat Pump-type Systems) Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents. When Connecting Refrigerant Tubing Use the flare method for connecting tubing. Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leakfree connection. Check carefully for leaks before starting the test run. When Servicing Turn the power at the main power box (mains) before opening the unit to check or repair electrical parts and wiring. Keep your fingers and clothing away from any moving parts. Clean up the site after you finish, remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced. Others CAUTI Ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas. Confirm upon completing installation that no refrigerant gas is leaking. If escaped gas comes in contact with a stove, gas water heater, electric room heater or other heat source, it can produce dangerously toxic gas. i

3 Table of Contents Page Unit Combination... iii 1. OPERATING RANGE SPECIFICATIS 2-1. Unit Specifications Major Component Specifications Other Component Specifications DIMENSIAL DATA COOLING CAPACITY HEATING CAPACITY AIR THROW DISTANCE CHART REFRIGERANT FLOW DIAGRAM ELECTRICAL DATA 8-1. Electrical Characteristics Electric Wiring Diagrams INSTALLATI INSTRUCTIS 9-1. Installation Site Selection Remote Control Unit Installation Position Recommended Wire Length and Diameter FUNCTI Room Temperature Control Dry Operation Freeze Prevention Overload Prevention Cold draft Prevention Defrosting Operation TROUBLESHOOTING Check before and after troubleshooting Air conditioner does not operate Some part of air conditioner does not operate Air conditioner operates, but abnormalities are observed If a sensor is defective ARRANGEMENT OF ELECTRICAL COMPENT CHECKING ELECTRICAL COMPENTS Measurement of Insulation Resistance Checking Continuity of Fuse on PCB Ass'y Checking Motor Capacitor MAINTENANCE Changing Address of Remote Control Unit in Indoor Unit APPENDIX ii

4 Unit Combination Combine indoor and outdoor units only as listed below. Outdoor Unit Indoor Unit Symbol of Indoor Unit Refer to SAP CM1827AHA KM97 KM97 A B Fig.1 Indoor Unit Outdoor Unit A B Fig.1 iii

5 1. OPERATING RANGE Cooling Heating Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp. Maximum 32 C D.B. / 23 C W.B. 43 C D.B. Minimum 19 C D.B. / 14 C W.B. 19 C D.B. Maximum 27 C D.B. 24 C D.B. / 18 C W.B. Minimum 16 C D.B. 8 C D.B. / 9 C W.B. 1

6 2. SPECIFICATIS 2-1. Unit Specifications Indoor Unit Outdoor Unit SAP KM97AHA SAP CM1827AHA No. of indoor units. 1-unit 2-unit Power Source 240 V 1-phase 50 Hz 240 V 1-phase 50 Hz Cooling Heating Cooling Heating Capacity kw BTU/h 9,000 11,300 17,400 21,700 Air circulation (High) m 3 /h x 2 Moisture removal (High) Liters/h x 2 Voltage rating V Available voltage range V 216 to to 264 Running amperes A Power input W 1,040 1,090 2,120 2,000 Power factor % C.O.P. W/W Compressor locked rotor amperes A Controls / Temperature control Microprocessor / I.C. thermostat Control unit Wireless remote control unit Timer 1-hour / 12-hour or Fan speeds Indoor / Outdoor 3 and Auto / 1 Airflow direction (Indoor) Horizontal Manual Vertical Auto Air filter Washable, Anti Mold Compressor Rotary (Hermetic) Refrigerant / Amount charged at shipment g R22 / 1,200 Refrigerant control Capillary tube Dimensions & Weight Features Electrical Rating Performance Operation sound Indoor Hi / Me / Lo db-a 40 / 34 / 31 Outdoor Hi db-a 53 Refrigerant tubing connections Flare type Max. allowable tubing length at shipment m 7.5 Refrigerant tube Narrow tube mm (in.) 6.35 (1/4) diameter Wide tube mm (in.) 9.52 (3/8) Refrigerant tube kit / Accessories Optional / Hanging wall bracket Indoor Unit Outdoor Unit Unit dimensions Height mm Width mm Depth mm package dimensions Height mm Width mm Depth mm Weight Net kg Shipping kg Shipping volume m Remarks: Rating conditions are: Cooling: Indoor air temperature 27 C DB/19 C WB Outdoor air temperature 35 C DB/24 C WB Heating: Indoor air temperature 20 C DB Outdoor air temperature 7 C DB/6 C WB 2 DATA SUBJECT TO CHANGE WITHOUT NOTICE.

7 2-2. Major Component Specifications Indoor Unit SAP KM97AHA Part No. POW KM97GHS Controls Microprocessor Control circuit fuse 250 V 3.15 A Remote Control Unit RCS 2MHS4E G Type Cross flow Number... Dia. and length mm 1... ø70 / L598 Fan motor model... Q ty KFV2Q 11B5P... 1 No. of poles... rpm (240 V, High) ,960 Nominal output W 10 Coil resistance (Ambient temp. 20 C) Ω WHT BRN : WHT VLT : VLT ORG : 37.4 ORG YEL : 87.8 YEL PNK : 95.8 Type Internal thermal fuse Safety Open C 145 ± 2 devices Operating temp. Close Run capacitor µf 1.0 VAC 440 Type Stepping motor Model MP24GA1 Rating DC 12 V Coil resistance (Ambient temp. 25 C) Ω WHT BLU (respectively 4 wires) : 380 ± 7% Coil Aluminum plate fin / Copper tube Rows 2 Fin pitch mm 1.4 Face area m Controller PCB Flap Motor Fan & Fan Motor Heat Exch. Coil DATA SUBJECT TO CHANGE WITHOUT NOTICE. 3

8 Outdoor Unit SAP CM1827AHA Controller PCB POW C186CMH Control circuit fuse 250 V 3 A Type Rotary (Hermetic) Compressor model... Q ty C R95H5K... 2 / S... 2 Nominal output W 950 x 2 Compressor oil... Amount cc SUNISO 4GSD T x 2 Coil resistance (Ambient temp. 25 C) Ω C R : 2.88 C S : 6.87 Type External (OLR 1, 3) External (OLR 2, 4) Overload relay... Number MRA CS 7C Safety Operating Open C 145 ± ± 3 devices temp. Close C 69 ± ± 5 Operating amp.(ambient temp. 25 C) Trip in 6 to 16 sec. at 16.5 A Run capacitor µf Q ty VAC Type Propeller Number... Dia. mm 1... ø400 Fan motor model... Q ty SG6 51B5P... 1 No. of poles... rpm (240 V,High) Nominal output W 50 Coil resistance (Ambient temp. 20 C) Ω WHT BRN : 92.1 WHT PNK: Safety Type Internal protector devices Operating Open C 130 ± 8 temp. Close Automatic reclosing Run capacitor µf 2.0 VAC 480 Coil Aluminum plate fin / Copper tube Rows 2 Fin pitch mm 1.6 Face area m External Finish Acrylic baked-on enamel finish Compressor Fan & Fan Motor Heat Exch. Coil DATA SUBJECT TO CHANGE WITHOUT NOTICE. 4

9 2-3. Other Component Specifications Indoor Unit SAP KM97AHA Transformer (TR) ATR-J125 Rating Primary AC 230V, 50Hz Secondary 19V, 0.631A Capacity 12VA Coil resistance Ω (at 21 C) Primary (WHT WHT): 205 ± 10% Secondary (BRN BRN): 1.5 ± 10% Thermal cut-off temp. 150 C Thermistor (Coil sensor TH1) PBC-41E-S4 Resistance kω 20 C 40.1 ± 5% 20 C 6.5 ± 5% 10 C 24.4 ± 5% 30 C 4.4 ± 5% 0 C 15.3 ± 5% 40 C 3.0 ± 5% 10 C 9.9 ± 5% 50 C 2.1 ± 5% Thermistor (Room sensor TH2) DTN-TKS106E Resistance kω 25 C 5.0 ± 3% Outdoor Unit SAP CM1827AHA Power Relay (PRA, PRB) DFU24D1-F (M) Coil rating DC 24V Coil resistance Ω (at 20 C) 650 ± 10% Contact rating AC 250V, 20A Termistor (Coil sensor) PBC-41E-S15 Resistance kω 10 C 23.7 ± 5% 25 C 5.3 ± 5% 0 C 15.0 ± 5% 30 C 4.4 ± 5% 10 C 9.7 ± 5% 40 C 3.1 ± 5% 20 C 6.5 ± 5% Solenoid Coil (4-way Valve SCA, SCB) CHV-01Ai038A1 (Coil), CHV-0101 (Valve) Coil rating AC 230V, 50Hz, 5W Coil resistance Ω (at 20 C) 1,408 ± 7% 5

10 3. DIMENSIAL DATA Indoor Unit SAP KM97AHA Rear panel (center point of gravity) Remote control unit Center of tubing hole (3 places) 124 Drain hose ø18 Narrow tube ø6.35 (1/4") Wide tube ø9.52 (3/8") Unit : mm 6

11 Outdoor Unit SAP CM1827AHA Air intake Air discharge 4 ø12 holes Magnified illustration 3 1 To Indoor Unit A To Indoor Unit B 1 2 Narrow tube service valve ø6.35(1/4") Wide tube service valve ø9.52(3/8") 3 Check Port Unit : mm 7

12 4. COOLING CAPACITY 1 - indoor unit in operation A(or B) Indoor Unit SAP K97AHA ( 1) Outdoor Unit SAP CM1827AHA 240 V Single phase 50 Hz NOTE A : SAP K97AHA B : SAP K97AHA RATING CAPACITY 2.65 kw EVAPORATOR CDENSER ENT. TEMP. C OUTDOOR AMBIENT TEMP. C W.B. D.B TC CM SHC SHC SHC SHC SHC SHC TC CM SHC SHC SHC SHC SHC SHC TC # CM SHC SHC SHC SHC SHC SHC TC CM SHC SHC SHC SHC SHC TC CM SHC SHC SHC SHC TC : Total Cooling Capacity (kw) SHC : Sensible Heat Capacity (kw) CM : Compressor Input (kw) Rating conditions (#Mark) are Outdoor Ambient Temp. 35 C D.B. Indoor Unit Entering Air Temp. 27 C D.B. / 19 C W.B. 8

13 2 - indoor units in operation Indoor Unit SAP K97AHA ( 2) Outdoor Unit SAP CM1827AHA 240 V Single phase 50 Hz A + B NOTE A : SAP K97AHA B : SAP K97AHA RATING CAPACITY 5.10 kw EVAPORATOR CDENSER ENT. TEMP. C OUTDOOR AMBIENT TEMP. C W.B. D.B TC CM SHC SHC SHC SHC SHC SHC TC CM SHC SHC SHC SHC SHC SHC TC # CM SHC SHC SHC SHC SHC SHC TC CM SHC SHC SHC SHC SHC TC CM SHC SHC SHC SHC TC : Total Cooling Capacity (kw) SHC : Sensible Heat Capacity (kw) CM : Compressor Input (kw) Rating conditions (#Mark) are Outdoor Ambient Temp. 35 C D.B. Indoor Unit Entering Air Temp. 27 C D.B. / 19 C W.B. 9

14 5. HEATING CAPACITY Indoor Unit Outdoor Unit SAP K97AHA SAP CM1827AHA Heating capacity ratio (%) Outdoor temperature ( C DB) NOTE 1) Point of Rating condition Black dot in the chart indicate the following rating condition. Indoor : 20 C DB Outdoor : 7 C DB / 6 C WB 2) Above characteristics indicate instantaneous operation, which does not take into consideration defrost operation. 3) Fan speed : High 10

15 6. AIR THROW DISTANCE CHART Indoor Unit SAP KM97AHA Cooling Room air temp. Fan speed : : 27 C High Horizontal distance (m) Axis air velocity (m/s) Vertical distance (m) Axis air velocity Flap angle 0 30 Heating Room air temp. Fan speed : : 20 C High Horizontal distance (m) Axis air velocity (m/s) Vertical distance (m) Axis air velocity Flap angle

16 7. REFRIGERANT FLOW DIAGRAM Indoor Unit SAP K97AHA ( 2) Outdoor Unit SAP CM1827AHA Heat exchanger Indoor Unit A Wide tube O.D. 9.52mm (3/8") Narrow tube O. D. 6.35mm (1/4") Check port Muffler Strainer Accumulator Compressor A Check valve Drier ( ) 4 Way valve Heat exchanger Indoor Unit B Wide tube O.D. 9.52mm (3/8") Narrow tube O.D. 6.35mm (1/4") Check port Muffler Strainer Accumulator Compressor B Check valve Drier ( ) 4 Way valve Heat exchanger Capillary tube Wide Tube Service valve Narrow Tube Service valve 12

17 Heat exchanger Indoor Unit A Wide tube O.D. 9.52mm (3/8") Narrow tube O.D. 6.35mm (1/4") Check port Muffler Strainer Accumulator Compressor A Check valve Drier ( ) 4 Way valve Heat exchanger Indoor Unit B Wide tube O.D. 9.52mm (3/8") Narrow tube O.D. 6.35mm (1/4") Check port Muffler Strainer Capillary tube Accumulator Compressor B Check valve Drier ( ) 4 Way valve Heat exchanger Capillary tube Wide Tube Service valve Narrow Tube Service valve Insulation of Refrigerant Tubing IMPORTANT Because capillary tubing is used in the outdoor unit, both the wide and narrow tubes of this air conditioner become cold. To prevent heat loss and wet floors due to dripping of condensation, both tubes must be well insulated with a proper insulation material. The thickness of the insulation should be a min. 8 mm. Thickness: Min. 8 mm Wide tube Insulation Narrow tube Thickness: Min. 8 mm CAUTI After a tube has been insulated, never try to bend it into a narrow curve because it can cause the tube to break or crack. 13

18 8. ELECTRICAL DATA 8-1. Electrical Characteristics 1 - indoor unit in operation A(or B) Indoor Unit SAP K97AHA ( 1) Outdoor Unit SAP CM1827AHA NOTE A : SAP K97AHA B : SAP K97AHA COOLING Performance at Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor 240V Single phase 50Hz Rating Conditions Running Amps. A Power Input kw Full Load Conditions Running Amps. A Power Input kw Rating Conditions : Indoor Air Temperature 27 C D.B. / 19 C W.B. Outdoor Air Temperature 35 C D.B. Full Load Conditions : Indoor Air Temperature 32 C D.B. / 23 C W.B. Outdoor Air Temperature 43 C D.B. HEATING Performance at Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor 240V Single phase 50Hz Rating Conditions Running Amps. A Power Input kw Full Load Conditions Running Amps. A Power Input kw Rating Conditions : Indoor Air Temperature 20 C D.B. Outdoor Air Temperature 7 C D.B. / 6 C W.B. Full Load Conditions : Indoor Air Temperature 27 C D.B. Outdoor Air Temperature 24 C D.B. / 18 C W.B. 14

19 2 - indoor units in operation Indoor Unit SAP K97AHA ( 2) Outdoor Unit SAP CM1827AHA A + B NOTE A : SAP K97AHA B : SAP K97AHA COOLING Performance at Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor 240V Single phase 50Hz Rating Conditions Running Amps. A Power Input kw Full Load Conditions Running Amps. A Power Input kw Rating Conditions : Indoor Air Temperature 27 C D.B. / 19 C W.B. Outdoor Air Temperature 35 C D.B. Full Load Conditions : Indoor Air Temperature 32 C D.B. / 23 C W.B. Outdoor Air Temperature 43 C D.B. HEATING Performance at Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor 240V Single phase 50Hz Rating Conditions Running Amps. A Power Input kw Full Load Conditions Running Amps. A Power Input kw Rating Conditions : Indoor Air Temperature 20 C D.B. Outdoor Air Temperature 7 C D.B. / 6 C W.B. Full Load Conditions : Indoor Air Temperature 27 C D.B. Outdoor Air Temperature 24 C D.B. / 18 C W.B. 15

20 8-2. Electric Wiring Diagram Indoor Unit SAP KM97AHA WARNING To avoid electrical shock hazard, be sure to disconnect power before checking, servicing and/or cleaning any electrical parts. 16

21 Outdoor Unit SAP CM1827AHA WARNING To avoid electrical shock hazard, be sure to disconnect power before checking, servicing and/or cleaning any electrical parts. 17

22 9. INSTALLATI INSTRUCTIS 9-1. Installation Site Selection Maximum Allowable Tubing Length(L) and Elevation Difference(H). INDOOR UNIT Tubing length (L) The Multi-Split System outdoor unit should be installed as close to the indoor units as possible. Maximum allowable length of the refrigerant tubing and elevation difference between outdoor and indoor units are shown in Table 1. Table 1 Indoor Unit AVOID: direct sunlight., Combination Max allowable Limit of Limit of elevation Required amount tubing length tubing length(l). difference(h). of additional Outdoor unit Indoor unit at shipment.(m) (m) (m) refrigerant*(g/m) CM1827 WARNING KM97 KM97 To prevent abnormal heat generation and the possibility of fire, don t place obstacles, 5 cm min. enclosures and grills in front of or surrounding the air conditioner in a way that may block air flow. Less than elevation difference (H) between the 2 units * If total tubing length becomes 7.5 to 15 m (max.),charge additional refrigerant (R22) by 15 g/ m. No additional charge of compressor oil is necessary. Fig. 1 Wall-Mounted Wall-mounted Type Type 5 cm min. INDOOR UNIT Front View Fig.2a OUTDOOR UNIT 5 cm min. nearby heat sources that may affect performance of the unit. areas where leakage of flammable gas may be expected. places where large amounts of oil mist exist. DO: select an appropriate position from which every corner of the room can be uniformly air-conditioned. (High on a wall is best) select a location that will hold the weight of the unit. select a location where tubing and drain pipe have the shortest run to the outside. allow room for operation and maintenance as well as unrestricted air flow around the unit. (Fig. 2a) CAUTI For stable operation of the air conditioner, do not install wall-mounted type indoor units less than 1.5m from floor level. Indoor Unit Minimum height from floor level 1.5m Floor level Fig. 2b Wall 18

23 Outdoor Unit AVOID: heat sources, exhaust fans, etc. (Fig. 3) damp, humid or uneven locations. DO: choose a place as cool as possible. choose a place that is well ventilated. Outdoor unit Hot air Exhaust fan Heat source allow enough room around the unit for air intake/exhaust and possible maintenance. (Figs. 4a and 4b) provide a solid base (concrete block, cm beams or equal), a minimum of 10 cm above ground level to reduce humidity and protect the unit against possible water damage and decreased service life. (Fig. 5) use lug bolts or equal to bolt down unit, reducing vibration and noise. Fig. 3 Fig 3 Required space around the unit. Air intake Min. 5 cm Air discharge Min. 10 cm Top View Fig. 4a Top View Min. 40 cm Valve side Min. 25 cm Obstacle above Air discharge 2 m 2 m Ground Obstacle Side View Fig. 44b- C Anchor bolts (4 pcs.) Air intake Min. 10 cm Concrete or equal About 40 cm About 10 cm Fig. 5 Fig. 5 - A 19

24 9-2. Remote Control Unit Installation Position The remote control unit can be operated from either a non-fixed position or a wall-mounted position. To ensure that the air conditioner operates correctly, do not install the remote control unit in the following places: In direct sunlight Behind a curtain or other place where it is covered More than 8 m away from the air conditioner In the path of the air conditioner's airstream Where it may become extremely hot or cold Where it may be subject to electrical or magnetic interference 6-1. When attaching to wall (Fig.6a) 1) Confirm the indoor unit beeps when the / button is pressed at the wall location where the remote control unit is to be attached, then attach the holder to the wall. 2) When taking out the remote control unit, pull it from the holder. When using the remote control unit Point the transmission portion of the remote control unit at the receiver area of the indoor unit when operating the remote control unit, and during operation of the air conditioner. Do not place objects which may block the transmitted signals between the receiver and the remote control unit. Truss-head tapping screw 4 16mm (supplied) Remote control unit holder Fig.6a When mounting the remote control unit to prevent theft (Fig.6b) 1) Attach the holder to the wall with one of the screws (using only the hole in the top of the holder). 2) Remove the cover of the remote control unit and take out the batteries. Next, place the remote control unit in the holder. 3) Fasten both the remote control unit and holder to the wall with the remaining screw (using the hole in the bottom of the holder). 4) Install the batteries in the remote control unit and close the cover. Truss-head tapping screw 4 16mm (supplied) Holder Fig.6b Holder 20

25 9-3. Recommended Wire Length and Diameter Regulations on wiring diameter differ from locality to locality. For field wiring requirements, please refer to your local electrical codes. Carefully observe these regulations when carrying out the installation. Table 2 lists recommended wire lengths and size for power supply systems. NOTE Refer to the WIRING SYSTEM DIAGRAM for the meaning of "A", "B" and "C" in Table 2. Table 2 Model Cross Sectional Area (mm 2 ) (A) Power Supply Wiring Length (m) (B) Power Line Length (m) (C) Cont rol Line 2 (#14) 3.5 (#12) 2 (#14) 0.75 (#18) Fuse or Circuit Capacity CM A # AWG (American Wire Gauge) WARNING WARNING CAUTI Be sure to comply with local codes on running the wire from the indoor unit to the outdoor unit (size of wire and wiring method, etc.). Each wire must be firmly connected. No wire should be allowed to touch refrigerant tubing, the compressor, or any moving part. To avoid the risk of electric shock, each air conditioner unit must be grounded. Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram. The indoor unit draws its power from the outdoor unit. Indoor unit A Terminal Indoor unit B Terminal WIRING SYSTEM DIAGRAM B C B C Grounding line 240 V 240 V Grounding line 240 V 240 V Power supply Single-phase, 50Hz, 240V Grounding line A Outdoor unit Terminal 8PA Power line Low voltage control line Terminal 8PB Power line Low voltage control line Terminal 3P 21

26 10. FUNCTI Room Temperature Control Cooling Room temperature control is obtained by cycling the compressor and under control of the room temperature sensor in the remote control unit. The room temperature (and other information) is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit. Signal from remote control unit 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes Thermo. Thermo. Thermo. Thermo. Thermo. Thermo. Thermo. set temp. T+1 C T C More than 5 minutes 5 minutes 3 minutes Room temp. Compressor Outdoor fan Indoor fan Set speed The control circuit will not attempt to turn the compressor until the compressor has been for at least 3 minutes. To protect the compressor from stalling out when trying to start against the high side refrigerant pressure, the control circuit has a built-in automatic time delay to allow the internal pressure to equalize. As a protective measure, the control circuit switches the compressor after 5 minutes or more of compressor operation. Thermo. : When the room temperature is above T + 1 C (T C is set temperature). Compressor Thermo. : When the room temperature is equal to or below set temperature T C. Compressor 22

27 Heating Room temperature control is obtained by cycling the compressor and under control of the room temperature sensor in the remote control unit. The room temperature (and other information) is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit. Signal from remote control unit More than 5 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes Thermo. Thermo. Thermo. Thermo. Set temp. T C T 1 C T 2 C 5 minutes 5 minutes Room temp. Compressor Outdoor fan 30 seconds 30 seconds Indoor fan LL Set speed LL LL Set speed LL Standby lamp * 1 * 1 Indoor heat exch. coil temp. 35 C * 1 25 C 20 C Solenoid coil (4-way valve) (Reversing cycle) Operation button The control circuit will not attempt to turn the compressor until the compressor has been for at least 5 minutes. To protect the compressor from stalling out when trying to start against the high side refrigerant pressure, the control circuit has a built-in automatic time delay to allow the internal pressure to equalize. As a protective measure, the control circuit switches the compressor after 5 minutes or more of compressor operation. Thermo. : When the room temperature is below T 1 C (T C is set temperature). Compressor Thermo. : When the room temperature is equal to or above set temperature T C. Compressor NOTE *1: Refer to "10-5 Cold Draft Prevention". 23

28 10-2. 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 and automatically as shown in the chart below according to the room temperature. Room temp. T+2 C Set temp. T C T 1 C Room temp. 15 C Cooling operation *Dry A1 zone Compressor : Continuous operation FMI (indoor fan) : L (low speed) / LL (very low speed) intermittent ventilation only while the compressor is. *Dry B zone Compressor : Intermittent operation ( for 3 minutes and for 9 minutes) FMI (indoor fan) : L (low speed) / LL (very low speed) intermittent ventilation only while the compressor is. Monitor zone Both the indoor and outdoor units stop. NOTE Intermittent ventilation occurs by switching the indoor fan speed between L LL. Dry operation does not occur when the room temperature is under 15 C, which is the monitor zone. When the compressor stops, the indoor fan stops as well. 24

29 10-3. Freeze Prevention (Cooling) This function prevents freezing of the indoor heat exchange coil. When the compressor has been running for 10 minutes or more and the temperature of the indoor heat exchange coil falls below 1 C, the control circuit stops the compressor for at least 6 minutes. The compressor does not start again until the temperature rises above 8 C or 6 minutes has elapsed. Room temp. Thermo. Thermo. T+1 C Set temp. T C Indoor heat exch. coil temp. 6 minutes More than 6 minutes 1 C More than 10 minutes More than 10 minutes Compressor Indoor fan Set speed Set speed Overload Prevention (Heating) This function prevents overheating of the indoor heat exchange coil. When the temperature of the indoor heat exchange coil rises above 54 C, and if the indoor fan is L (low speed), then the fan speed changes from L (low speed) to M (medium speed). When the temperature of the indoor heat exchange coil rises above 57 C, the outdoor fan stops. Indoor heat exch. coil temp. C Outdoor fan Indoor fan H or M or L H H, M M, L M Compressor 25

30 10-5. Cold Draft Prevention (Heating) This function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coil have sufficiently warmed up. STANDBY lamp on front of the indoor unit lights up when the indoor fan speed is either LL or. Indoor heat exch. coil temp. C 35 C 25 C 20 C Compressor Indoor fan LL Set speed LL Standby lamp Initial start LL = Very low speed 26

31 10-6. Defrosting Operation (Heating) Defrosting Flowchart * Split System A (or B) * Heating operation Split System B (or A) Heating operation * Split System A: Indoor unit A Compressor A Solenoid coil A * Split System B: Indoor unit B Compressor B Solenoid coil B 20 minutes masking Temperature in outdoor heat exchanger coil drops 1 deg/6 min. or more and repeats 3 times continuously. 6 minutes masking Temperature in outdoor heat exchanger coil falls to 14 C or lower. Preparation for defrosting Defrosting starts. Defrosting starts. Defrosting Defrosting (= Cooling cycle) Cold draft prevention Cold draft prevention Temperature in outdoor heat exchanger coil is 26 C or higher. Defrosting time is over 13.5 minutes. Defrosting stops. Defrosting stops. 27

32 Defrosting Mode Timing Chart Start of defrosting Defrosting 13.5 min. or outdoor coil temp. 26 C Release of defrosting 65 sec. 65 sec. Compressor A 5 sec. 5 sec. 5 sec. Compressor B 1 min. 4-way valve A and B Outdoor fan Indoor fan A Set speed 30 sec. * 1 Set speed Standby lamp A Light Indoor fan B Set speed * 1 Set speed Standby lamp B Light Indoor heat exch. coil temp. 35 C Unit A Unit B Release of cold draft prevention NOTE *1. No LL fan operation during this period. 28

33 11.TROUBLESHOOTING Check before and after troubleshooting WARNING Hazardous voltage can cause ELECTRIC SHOCK or DEATH. Disconnect power or turn off circuit breaker before you start checking or servicing Check power supply wiring. Check that power supply wires are correctly connected to terminals No.1 and No.2 on the 3p terminal plate in the outdoor unit Check inter-unit wiring. Check that inter-unit wiring is correctly connected to the indoor unit from the outdoor unit Check power supply. Check that voltage is in specified range (±10% of the rating). Check that power is being supplied. Outdoor unit 1 2 Terminal plate B Terminal plate A Power supply Single-phase, 50Hz, 240V Ground Inter-unit power wiring Inter-unit control wiring Inter-unit power wiring Inter-unit control wiring Indoor unit B Indoor unit A 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. 29

34 11-2. Air conditioner does not operate Circuit breaker trips (or fuse blows). A. When the circuit breaker is set to, it is tripped soon. (Resetting is not possible.) There is a possibility of ground fault. Check insulation resistance. If resistance value is 2MΩ or less, insulation is defective ( NO ). WARNING * Set circuit breaker to. 1 Remove both power supply wires and inter-unit wires from terminal plate in outdoor unit. Measure insulation resistance of outdoor unit. NO Insulation of outdoor unit is defective. Measure insulation resistance of electrical parts in outdoor unit. 2 Remove inter-unit wires from terminal plate in indoor unit. Measure insulation resistance of indoor unit. NO Insulation of indoor unit is defective. Measure insulation resistance of electrical parts in indoor unit. 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. Capacity of circuit breaker is suitable. NO Replace with suitable one (larger capacity). Measure resistance of compressor motor winding. (CMA and CMB) 30

35 Neither indoor nor outdoor unit runs. A. Power is not supplied. Check power supply. Power is being supplied to the outdoor unit. NO Circuit breaker is tripped. Power failure Reset breaker. Wait for recovery or contact power company. B. Check "OPERATI selector" switch in the indoor unit. OPERATI selector switch is set in position. YES Switch Ass'y or indoor PCB Ass'y is defective. NO Set OPERATI selector switch to. C. Check remote control unit. Try to run with another remote control unit. OK First remote control unit is defective. Check for residue buildup on transmitter of remote control unit. Clean transmitter. Check for residue buildup on remote control receiver on front of indoor unit. Clean receiver. 31

36 D. Check fuse on the indoor PCB Ass'y. Check fuse on indoor PCB Ass'y for continuity. (F) OK If fuse has been blown, Measure resistance of indoor fan motor winding. (FMI) OK Check operation lamp to see if light is. Light is Measure resistance of flap motor winding. (FLP) OK Measure resistance of primary and secondary winding of transformer. (TR) OK Replace the fuse. Indoor PCB Ass'y or switch Ass'y is defective. E. Check TIMER SELECT button on the remote control unit. Timer is turned. Check to see if is displayed on remote control. YES Cancel the timer mode. 32

37 Only outdoor unit does not run. A. Check setting temperature. COOL Is room temperature too low? NO HEAT Is room temperature too high? NO Try to lower setting temperature by temperature setting button cooler. Outdoor unit still does not run. Try to raise setting temperature by temperature setting button warmer. Outdoor unit still does not run. Try to run using another remote control unit. OK Try to run using another remote control unit. OK Remote control unit is defective. Remote control unit is defective. B. Check PCB Ass'y in either indoor or outdoor unit. Check voltage between terminals No. 3(+) and No. 4 at terminal plate. (DC 24V) No voltage appears. OK Outdoor PCB Ass'y is defective. Indoor PCB Ass'y is defective Only indoor unit does not run. Indoor PCB Ass'y is defective. 33

38 11-3. Some part of air conditioner does not operate Only indoor fan does not run. Check fan rotation. Turn fan gently once or twice by hand. Fan cannot be turned. Check fan casing foreign matter on inside. Fan motor burnout or foreign matter in bearings. Remove foreign matter or repair. Repair or replace. Measure resistance of indoor fan motor winding. OK Check fan motor capacitor Only flap motor does not run. Measure resistance of flap motor winding Only outdoor fan does not run. Check fan rotation. Turn fan gently once or twice by hand. Fan cannot be turned. Check fan casing for foreign matter on inside. Fan motor burnout or foreign matter in bearings. Remove foreign matter or repair. Repair or replace. Measure resistance of outdoor fan motor winding. OK Check fan motor capacitor. (CF) 34

39 Only compressor does not run. Check compressor motor capacitor. (CA,CB) Overload relay is working. (OLR 1 to 4) YES Measure coil resistance of power relay. (PRA,PRB) Measure resistance of compressor motor winding. Temperature of compressor is abnormally high. YES Refrigerant gas shortage. NO YES Charge refrigerant gas (R22). Rotor may be locked up. 35

40 11-4. Air conditioner operates, but abnormalities are observed Operation does not switch from HEAT to COOL (or COOL to HEAT). Remote control unit may be defective. Receiver in switch Ass'y may be defective. Measure resistance of 4 way valve's winding. COOL HEAT Check voltage between terminals No. 3(+) and No. 5 at terminal plate. (DC 24V) No voltage appears. OK Outdoor PCB Ass'y is defective. Indoor PCB Ass'y is defective. HEAT COOL Check voltage between terminals No. 3(+) and No. 5 at terminal plate. (0V) CAUTI Units A and B cannot be operated in different modes simultaneously (for example, unit A operating in the heating mode while unit B is operating in the cooling or drying mode). When operating two units at the same time, set them both to the same mode. Note however that though technically different modes, unit A can operate in the cooling mode while B is operating in the drying mode. If the units are operated in different modes (for example, unit A in the heating mode and unit B in the cooling or drying mode), the results are as follows. (Example) Unit A in heating mode Unit B in cooling or drying mode Unit A in heating mode (Heating operation takes precedence.) Unit B fan operating If unit A is stopped, unit B will switch to cooling or drying operation. 36

41 Poor cooling or heating. Check position of remote control unit. Cool or warm air from air conditioner reaches position directly. YES Change position of remote control unit. Wide and narrow tubes between indoor unit and outdoor unit are insulated. YES NO Insulate both wide and narrow tubes separately and then tape together. Measure temperature of suction and discharge air of air conditioner. Temperature difference is small. Possibility of gas shortage. Charge refrigerant gas (R22). Temperature difference between suction and discharge air is large enough (approx. 10 deg. or more). Check for clogging of air filter. Air filter is clogged. Clean filter. Fan speed is set to LOW. YES Set fan speed to either HIGH or MEDIUM. Review cooling load estimate, if performance of air conditioner is normal. Reduce cooling or heating load or replace the air conditioner with larger capacity Excessive cooling or heating. Set temperature is suitable. NO Set temperature to higher or lower value using temperature setting buttons of the remote control unit. Remote control unit is placed where it can detect room temperature properly. NO Change position of remote control unit. 37

42 11-5. If a sensor is defective Indoor coil temp. thermistor (TH1) is defective. Operation lamp on front side of indoor unit is flashing on and off. (*) YES Thermistor (TH1 ) is defective. (That is, sensor is SHORT.) No Replace thermistor. Function of freeze prevention continues to work in cooling mode. Refer to 5-4 "Freeze Prevention" YES Thermistor (TH1 ) is not connected to indoor PCB Ass'y, or its temperature sensor is defective. (That is, sensor is OPEN.) Replace thermistor. No NOTE Alarm Signal (*) Operation lamp on the front side of the indoor unit will flash on and off when the indoor coil thermistor is defective. (That is, sensor is SHORT). At the same time the outdoor unit will stop. Indoor unit will operate only for ventilation Room temp. thermistor (TH2) is defective. A. Open When thermistor opens, the air conditioner will be in the following conditions as the controller tries to detect extremely low room temperature. a) In Cooling mode: The air conditioner soon stops and will not start again. (Thermo.) Neither outdoor fan nor compressor runs. b) In Heating mode: The air conditioner continues to operate. (Thermo.) Both the outdoor fan and compressor do not stop. As a result, the room becomes too warm. B. Short When thermistor is short, the air conditioner will be in the following conditions as the controller tries to detect extremely high room temperature. a) In Cooling mode: The air conditioner continues to operate. (Thermo.) Both the outdoor fan and compressor do not stop. As a result, the room becomes too cold. b) In Heating mode: The air conditioner soon stops and will not start again. (Thermo.) Neither outdoor fan nor compressor runs. Temperature sensor Lead wires Thermistor Structure NOTE Definition of Open or Short Circuit of Sensor (Thermistor) Open... A lead wire is broken or disconnected or the circuit inside the temperature sensor is open. Short... The protective cover of a lead wire has been damaged, and the exposed wire is touching another metal part, or both lead wires have become exposed and are touching each other. Alternatively, the circuit inside the temperature sensor is closed. 38

43 12. ARRANGEMENT OF ELECTRICAL COMPENT Indoor Unit SAP KM97AHA Electric Parts Room temp. thermistor (TH2) Fan motor capacitor (C) Transformer (TR) Coil temp. thermistor (TH1) Terminal plate PCB Ass'y Switch Ass'y Flap motor (FLP) 39

44 ELEC BOX Outdoor Unit SAP CM1827AHA PCB Ass'y (Controller) Parts Layout in Unit Heat exchenger coil Thermistor Compressor A (CMA) Compressor B (CMB) PCB Ass'y Fan motor Solenoid coil B (SCB) Solenoid coil A (SCA) Electric Parts Compressor motor capacitor (CA) Compressor motor capacitor (CB) Varistor (SA1) Fan motor capacitor (CF) Varistor (SA2) Power relay B (PRB) Overload relay (OLR1) Overload relay (OLR3) Power relay A (PRA) Terminal Plate (To Indoor Unit A) Terminal Plate (To Indoor Unit B) Terminal Plate (To Power supply) 40

45 13. CHECKING ELECTRICAL COMPENTS Measurement of Insulation Resistance The insulation is in good condition if the resistance exceeds 2MΩ. Clip Ground wire Power Supply Wires Probe Clamp the ground wire of the power supply wires with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the power wires. (Fig. 1) Insulation tester Terminal plate Fig. 1 Then measure the resistance between the ground wire and the other power wire. (Fig. 1) Probe 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 on the terminal plate. (Fig. 2) Note that the ground line terminal should be skipped for the check. (Fig. 2) Outdoor Unit Copper tube or metallic part Clip Insulation tester Fig. 2 Clamp a metallic part of the unit 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. (Fig. 2) Probe Measurement of Insulation Resistance for Electrical Parts Clip Disconnect the lead wires of the desired electric part from terminal plate, capacitor, etc. Similarly disconnect the connector. Then measure the insulation resistance. (Figs. 3 and 4) Refer to Electric Wiring Diagram. Copper tube or metallic part Insulation tester Fig. 3 NOTE If the probe cannot enter the poles because the hole is too narrow then use a probe with a thinner pin. Metallic part Probe From fan motor, compressor and other parts Clip Insulation tester Fig. 4 41

46 13-2. Checking Continuity of Fuse on PCB Ass'y Fuse Remove the PCB Ass'y from the electrical component box. Then pull out the fuse from the PCB Ass'y. Check for continuity using a multimeter as shown in Fig. 6. PCB Ass y Checking Motor Capacitor Fig. 5 Remove the lead wires from the capacitor terminals, and then place a probe on the capacitor terminals as shown in Fig. 7. Observe the deflection of the pointer, setting the resistance measuring range of the multimeter to the maximum value. Fuse The capacitor is good if the pointer bounces to a great extent and then gradually returns to its original position. Fig. 6 The range of deflection and deflection time differ according to the capacity of the capacitor. Multimeter Compressor motor capacitor Fan motor capacitor Fig. 7 42

47 11. MAINTENANCE Changing Address of Remote Control Unit in Indoor Unit If you are installing more than 1 indoor unit (up to 2) in the same room, it is necessary for you to assign each unit its own address, so each can be operated by its own separate remote control unit. You assign the addresses by matching the switch positions of each indoor unit with the switch positions of its remote control unit. Following table shows the position you can use up to 2 indoor units installed in the same room. Unit No. Indoor Unit Address (Control PCB) Remote Control Address 1 A 2 B To Change Address on PCB Ass y (1) Locate the address switch S10 on the control PCB Ass y of indoor unit. (2) Change the switch to position. NOTE Address switche S10 on the control PCB Ass y is in the position at time of shipment. To Change Address on Remote Control Unit (1) Remove the batteries before changing the address. (2) Remove tab marked A to change the address of the remote control unit. (3) When it is removed, the address is automatically set to B. (4) After inserting the batteries, press ACL button. ACL button NOTE Address switch on the remote control unit is in A position at time of shipment. 43

48 APPENDIX Remote Control Unit Sensor Transmitter Display / operation button (Cover closed) 1 HR. TIMER button Temperature setting buttons (TEMP.) MODE selector button FLAP button TIMER button ADDRESS switch NIGHT SETBACK button FAN SPEED selector button TIMER SET button (which advances the time displayed) TIMER button ACL button A/C SENSOR button Battery compartment (Pull off the cover to expose the batteries.) NOTE The illustration above pictures the remote control unit after the coverhas been lowered and removed. Unit Display and Operation Selector INDOOR UNIT TIMER lamp STANDBY lamp OPERATI lamp OPERATI STANDBY TIMER TEST REMOTE CTROL receiver Operation selector 44

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50 SANYO Electric Co.,Ltd. Osaka, Japan SM /2002