Sanyo SPW-UMR124EXH56 Technical Data & Service Manual

TECHNICAL DATA

& SERVICE MANUAL

SPLIT SYSTEM AIR CONDITIONER

Model No.

SPW-UMR74EXH56

SPW-UMR94EXH56

SPW-UMR124EXH56

SPW-UMR164EXH56

SPW-UMR184EXH56

SPW-UMR224EXH56

Product Code No.

854.0.2263

854.0.2264

854.0.2265

854.0.2301

854.0.2266

854.0.2267

0.8180.439.0 June 2005

SM940046

IMPORTANT!

Please read before installation

This air conditioning system meets strict safety and operating standards.

For the installer or service person, it is important to install or service the system so that 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.

•The unit must be supplied with a dedicated electrical line.

WARNING

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION

This symbol refers to a hazard or unsafe practice which can 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 sale/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 PRECAUTIONS

• During installation, connect before the refrigerant system and then the wiring one; proceed in the reverse orden when removing the units.

WARNING When wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH. ONLY QUALIFIED,

EXPERIENCED ELECTRICIANS SHOULD ATTEMPT

TO WIRE THIS SYSTEM.

• Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked, to ensure the grounding.

• 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 and death.

• Ground the unit following local electrical codes.

• The Yellow/Green wire cannot be used for any connection different from the ground connection.

• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

• Do not allow wiring to touch the refrigerant tubing, compressor, or any moving parts of the fan.

• Do not use multi-core cable when wiring the power supply and control lines. Use separate cables for each type of line.

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 aluminium fins on the air conditioner can cut your fingers.

When installing...

… In a ceiling

Make sure the ceiling is strong enough to hold the unit-weight.

It may be necessary to build a strong wooden or metal frame to provide added support.

… In a room

Properly insulate any tubing run inside a room to prevent

"sweating", which can cause dripping and water damage to walls and floors.

... In moist or uneven locations

Use a raised concrete base to provide a solid level foundation for the outdoor unit. This prevents damage and abnormal vibrations.

... In area with strong 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 then drifting snow. Provide snow vents.

When connecting refrigerant tubing

• Keep all tubing runs as short as possible.

• Use the flare method for connecting tubing.

• Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them; screw by hand and then tighten the nut with a torque wrench for a leak-free connection.

• Check carefully for leaks before starting the test run.

NOTE:

Depending on the system type, liquid and gas lines may be either narrow or wide. Therefore, to avoid confusion, the refrigerant tubing for your particular model is specified as narrow tube for liquid, wide tube for gas.

When servicing

• Turn the power OFF at the main power board 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 the work, remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced.

• Ventilate the room during the installation or test ing the refrigeration system; make sure that, after the installation, no gas leaks are present, because this could produce toxic gas and dangerous if in contact with flames or heat-sources.

2

Table of Contents

1. SPECIFICATIONS

1-1 Unit specifications

1-2 Major Component specifications

1-3 Other Component specifications

2. DIMENSIONAL DATA

3. ELECTRICAL DATA

3-1 Electric Wiring Diagram

3-2 Control PCB switches and functions

4. FUNCTION

4-1 Room Temperature Control

4-2 Automatic control for heating and cooling

5. REPLACING PCB

5-1 Replacing PCB

5-2 How to replace PCB

5-3 How to replace EEPROM with EEPROM included in PCB service pack

5-4 Table of setting

6. SERVICING AND MAINTENANCE FUNCTIONS

6-1 Indoor unit refrigerant noise countermeasures

6-2 Outdoor unit noise countermeasures: EEPROM 05

7. TROUBLE DIAGNOSIS

7-1 Contents of remote controller switch alarm display

7-2 Outdoor unit control panel led display

7-3 Trouble indications and inspection points

7-4 Remote controller servicing functions

7-5 Super W-Multi alarm codes

7-6 Inspection of parts

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28

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35

Page

13

13

14

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7

10

4

4

11

3

1. SPECIFICATIONS

1-1 Unit Specifications

SPW-UMR74/94/124EXH56

Power source

Voltage rating

Performance

Capacity

Air circulation (High/Med./Low)

220 - 240V ~ 50Hz

230V

Cooling Heating

See catalogue with the requested matching

600/510/440 m³/h

Features

Controls/Temperature controls

Remote Controller (Option)

Fan speed

Air Filter

Sound pressure level (*)

Refrigerant tubing connections

Refrigerant tube diameter

Refrigerant

Refrigerant control

Dimensions & Weight

Dimensions high/med/low

Narrow tube

Wide tube wired wireless dB(A) mm(in.) mm(in.)

Microprocessor/ I.C. thermostat

RCS-SH80AG / RCS-KR1AG

RCS-BH80AG.WL

3 and Auto

Washable

54/52/49

Flare type

6,35 (1/4)

12,7 (1/2)

R410A

Electronic expansion valve

Package dimensions

Weight

Height

Width

Depth

Height

Width

Depth

Volume

Net

Shipping mm mm mm mm mm mm m3 kg kg

266

571

852

365

745

1086

0,3

30,0

34

DATA SUBJECT TO CHANGE WITHOUT NOTICE

(*) Power noise level measured at operating conditions (5mmH20 external static pressure)

4

SPW-UMR164/184EXH56

Power source

Voltage rating

Performance

Capacity

Air circulation (High/Med./Low)

Features

Controls/Temperature controls

Remote Controller (Option)

Fan speed

Air Filter

Sound pressure level (*)

Refrigerant tubing connections

Refrigerant tube diameter

Refrigerant

Refrigerant control

Dimensions & Weight

Dimensions

Package dimensions

Weight high/med/low

Narrow tube

Wide tube m³/h

220 - 240V ~ 50Hz

230V

Cooling Heating

See catalogue with the requested matching

875/600/400 wired wireless dB(A) mm(in.) mm(in.)

Microprocessor/ I.C. thermostat

RCS-SH80AG / RCS-KR1AG

RCS-BH80AG.WL

3 and Auto

Washable

54/47/42

Flare type

6,35 (1/4)

12,7 (1/2)

R410A

Electronic expansion valve

Height

Width

Depth

Height

Width

Depth

Volume

Net

Shipping mm mm mm mm mm mm m3 kg kg

266

571

1058

365

745

1292

0,35

35

39

DATA SUBJECT TO CHANGE WITHOUT NOTICE

5

SPW-UMR224EXH56

Power source

Voltage rating

Performance

Capacity

Air circulation (High/Med./Low)

Features

Controls/Temperature controls

Remote Controller (Option)

Fan speed

Air Filter

Sound pressure level (*)

Refrigerant tubing connections

Refrigerant tube diameter

Refrigerant

Refrigerant control

Dimensions & Weight

Dimensions

Package dimensions

Weight high/med/low

Narrow tube

Wide tube m³/h

220 - 240V ~ 50Hz

230V

Cooling Heating

See catalogue with the requested matching

1000/700/600 wired wireless dB(A) mm(in.) mm(in.)

Microprocessor/ I.C. thermostat

RCS-SH80AG / RCS-KR1AG

RCS-BH80AG.WL

3 and Auto

Washable

57/49/46

Flare type

9,52 (3/8)

15,88 (5/8)

R410A

Electronic expansion valve

Height

Width

Depth

Height

Width

Depth

Volume

Net

Shipping mm mm mm mm mm mm m3 kg kg

266

571

1058

365

745

1292

0,35

35

39

DATA SUBJECT TO CHANGE WITHOUT NOTICE

6

1-2 Major Component Specifications

SPW-XMR74/94/124EXH56

Controller PCB

Part No.

Controls

Fan & Fan Motor

Type

Q'ty ……. Dia. and lenght

Fan motor model…Q'ty

No. Of poles…rpm (230 V, High)

Running Amps

Power input

Coil resistance (Ambient temp. 20 °C )

Safety devices

Run capacitor mm

Type

Operating temp. Open °C

µF

VAC

A

W

Ω

CR-CRP50A-B

Microprocessor

Centrifugal fan

2…. Ø 160 / L 240

3RGB-CO-45-30 5V/1….1

4 … 1060

0,45

110

BLU-BRN: 95

BRN-BLK: 37

BLK-GRY: 15

GRY-VLT: 15

WLT-RED: 30

RED-YEL: 101

Internal thermal protector - 7AM 037 A 5

150 ± 5K

1,8

450

Electronic expansion valve

Coil

Valve body

Heat Exch. Coil

Coil

Rows

Fin pitch face area

UKV-U030E

UKV-18D31

Aluminium plate fin / Copper tube

2 mm 1,6 m2 0,126

DATA SUBJECT TO CHANGE WITHOUT NOTICE

7

SPW-XMR164/184EXH56

Controller PCB

Part No.

Controls

Fan & Fan Motor

Type

Q'ty ……. Dia. and lenght

Fan motor model…Q'ty

No. Of poles…rpm (230 V, High)

Running Amps

Power input

Coil resistance (Ambient temp. 20 °C )

Safety devices

Run capacitor

CR-CRP50A-B

Microprocessor mm

Type

Operating temp. Open

Close

°C

°C

µF

VAC

A

W

Ω

Centrifugal fan

2…. Ø 160 / L 240

3FGB-CO-65-38 5V/1….1

4 … 1106

0,6

138

BLU-BRN: 68

BRN-BLK: 9

BLK-GRY: 36

GRY-VLT: 18

VLT-RED: 18

BRN-YEL: 105

Internal thermal protector - 7AM 037 A 5

150 ± 5K

2,0

450

Electronic expansion valve

Coil

Valve body

Heat Exch. Coil

Coil

Rows

Fin pitch face area

UKV-U030E

UKV-25D32

Aluminium plate fin / Copper tube

3 mm 1,6 m2 0,168

DATA SUBJECT TO CHANGE WITHOUT NOTICE

8

SPW-XMR224EXH56

Controller PCB

Part No.

Controls

Fan & Fan Motor

Type

Q'ty ……. Dia. and lenght

Fan motor model…Q'ty

No. Of poles…rpm (230 V, High)

Running Amps

Power input

Coil resistance (Ambient temp. 20 °C )

Safety devices

Run capacitor

CR-CRP50A-B

Microprocessor mm

Type

Operating temp. Open

Close

°C

°C

µF

VAC

A

W

Ω

Centrifugal fan

2…. Ø 160 / L 240

3FGB-CO-65-38 5V/1….1

4 … 1161

0,57

136

BLU-BRN: 68

BRN-BLK: 9

BLK-GRY: 36

GRY-VLT: 18

VLT-RED: 18

BRN-YEL: 105

Internal thermal protector - 7AM 037 A 5

150 ± 5K

3

450

Electronic expansion valve

Coil

Valve body

Heat Exch. Coil

Coil

Rows

Fin pitch face area

UKV-U030E

UKV-25D32

Aluminium plate fin / Copper tube

3 mm 1,6 m2 0,168

DATA SUBJECT TO CHANGE WITHOUT NOTICE

9

1-3 Other Component Specifications

Trasformer

Rating Primary

Secondary 1

Secondary 2

Secondary 3

Thermal cut-off temp.

Thermistor ( Coil sensor E1, E2)

Resistance

Thermistor ( Coil sensor E3)

Resistance

Thermistor ( Room sensor TA, TF/BL)

Resistance

Drain pump

Model

Rating Voltage

Input

Flow rate

Safety float switch

Model

Contact rating k Ω k Ω k Ω

ATR-IIJ225A

VAC 230V, 50Hz

AC 20V - 0.2A

AC 14V - 0.3A

AC 10,2V - 1.4A

136°C

PBC-41E-S26

0 °C 15,0 ± 5%

PBC-41E-S42-2

0 °C 15,0 ± 4,42%

DHKTEC-35-S85N

25 °C 5,0 ± 4%

PC 309564003

220/240V - 50Hz

14W

0,4 l/min

BI 1300 2725

230V AC/DC - 0,5A

10

2. DIMENSIONAL DATA

SPW-UMR74/94/124EXH56

11

SPW-UMR164/184/224EXH56

12

3. ELECTRICAL DATA

3-1 Electric Wiring Diagram

7P terminal board

1(L) 2(N) U1 power supply

U2 inter-unit control wiring

R1 R2 remote controller

13

3-2 Control PCB switches and functions

CR-TRP50A-B

EMG (CN044)

OC (CN040)

VARISTOR

(VA041)

T10:

(CN061)

EXCT:

(CN073)

DISP:

(CN072)

CHK:

(CN071)

JP1:

(JP001)

EXCT (CN073)

FAN DRIVE

(CN032)

FILTER

(CN070)

POWER LED

(D002)

JP1

(JP001)

GRL

(CN020)

DISP (CN072)

CHK (CN071)

T10 (CN061)

EEPROM

(IC010)

6 plug (yellow): used for remote control. (Refer to the remote control section)

1- start/stop input 2- COM

3- remote control prohibit/release input 4- start signal output

5- COM (+DC12v) 6- alarm signal output T10

2P plug (red): Can be used for demand control. When imput is present, forces the unit to operate with the termostat OFF.

2P plug (white): Short-circuiting this plug allows the unit to be operated by the remote controller, even if it is not connected to an outdoor unit. (In this case, alarm "E04", which indicates trouble in the serial communication between the indoor and outdoor unit, does not occur.)

2P plug (white): Test pin. Short-circuiting this pin allows the indoor FM (H fan speed), drain pump, flap motor (F1 position), and electronic expansion valve full-open position to checked. However this function turns OFF if the indoor unit protection mechanism is activated. The unit can be operated even if the remote controller and outdoor unit are not connected. However even if the remote controller cannot is connected, it cannot be used to operate the unit. This function can be used for short-term tests.

Jumper wire: Allows selection of the T10 terminal

14

4. FUNCTIONS

4-1 Room temperature control

15

4-2 Automatic control for heating and cooling

16

5. REPLACING PCB

5-1 Replacing PCB

About EEPROM

(Erasable Programmable Read-Only Memory)

EEPROM is a component in which the various information necessary for functionning can be electronically written or erased. This component holds informations that is essential for the running of the unit, and must be handled with care.

D002 led lamp (red)

17

5-2 How to replace PCB

18

5-3 How to replace EEPROM with EEPROM included in PCB service pack

19

20

5-4 Table of settings

21

6. SERVICING AND MAINTENANCE FUNCTIONS

22

7. TROUBLE DIAGNOSIS

7-1 Contents of remote controller switch alarm display

23

24

7-2 Outdoor unit control panel LED display

25

7-3 Trouble indications and inspection points

26

27

7-4 Remote controller servicing functions

28

7-5 Super W-Multi alarm codes

29

30

31

32

33

34

7-6 Inspection of parts

35

36

37

SANYO Airconditioners Europe S.r.l.

Via Bisceglie, No.76

20152 Milano, Italy