Sanyo Refrigerant Recovery Instructions
The Sanyo 3-WAY ECO-i SYSTEM Refrigerant Recovery instruction manual provides a step-by-step procedure for safely recovering refrigerant from the outdoor unit. It covers essential aspects like disconnecting power, closing service valves, connecting hoses and recovery units, and ensuring proper refrigerant recovery. The manual highlights the importance of following specific instructions that came with the refrigerant recovery unit to ensure a smooth and safe process.
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2 - 9
3-WAY ECO-i SYSTEM
Outdoor Unit Repair Procedures
2
5. Recovering Refrigerant
The following equipment and tools are required:
Jumper wire with clips, adjustable wrench, set of manifold gauge valves specially designed for refrigerant R410A
only, vacuum pump, refrigerant recovery unit, pre-purged refrigerant cylinder for recovery, flathead screwdriver, and
outdoor unit maintenance remote controller.
5-1. Refrigerant Recovery Procedures (from outdoor unit)
(1) Turn off the power of the outdoor unit beforehand (at power mains).
(2) Fully close each service valve on the suction tube, discharge tube, liquid tube, and the balance tube of the
outdoor unit.
(3) Connect the outdoor unit’s high-pressure and low-pressure outlet ports with the Hi and Lo sides of the manifold
gauge valves using hoses. (Fig. 7)
The remaining refrigerant in the faulty outdoor unit may create internal pressure.
Before connecting hoses, be sure to confirm that each of the manifold gauge
valves is tightly closed. Note that the connection ports employ Schrader-type
push-to-release valves.
(4) Connect the manifold gauge valves, refrigerant recovery unit, and recovery cylinder using hoses. To avoid the
entry of air into the refrigerant tubing, carry out this connection work carefully. (Fig. 7)
For detailed procedures such as connecting the refrigerant recovery unit with the
recovery cylinder and methods used for recovery, follow the specific instructions
that came with the refrigerant recovery unit.
(5) Locate the AP (Air Purge) pins on the control PCB in the faulty outdoor unit and short them using the clips of
the jumper wire. Then restore electrical power to the outdoor unit.
By short-circuiting the AP pins, each solenoid valve in the outdoor unit is forcibly
opened as soon as power comes on, which releases all remaining refrigerant into
the recovery cylinder. Since neglecting this procedure may leave some refrigerant
in the system, it is important that you carry out this step.
(6) Carry out refrigerant recovery.
To determine the completion of refrigerant recovery, follow the instructions that
came with the refrigerant recovery unit.
Fig. 7
CAUTION
CAUTION
CAUTION
CAUTION
Refrigerant recovery cylinder
Refrigerant
recovery unit
Manifold
gauge
High-pressure outlet port
(For 7.94mm-dia. connector)
Low-pressure outlet port
(For 7.94mm-dia. connector)
Lo Hi
3-WAY ECO-i SYSTEM
Outdoor Unit Repair Procedures
2
5. Recovering Refrigerant
The following equipment and tools are required:
Jumper wire with clips, adjustable wrench, set of manifold gauge valves specially designed for refrigerant R410A
only, vacuum pump, refrigerant recovery unit, pre-purged refrigerant cylinder for recovery, flathead screwdriver, and
outdoor unit maintenance remote controller.
5-1. Refrigerant Recovery Procedures (from outdoor unit)
(1) Turn off the power of the outdoor unit beforehand (at power mains).
(2) Fully close each service valve on the suction tube, discharge tube, liquid tube, and the balance tube of the
outdoor unit.
(3) Connect the outdoor unit’s high-pressure and low-pressure outlet ports with the Hi and Lo sides of the manifold
gauge valves using hoses. (Fig. 7)
The remaining refrigerant in the faulty outdoor unit may create internal pressure.
Before connecting hoses, be sure to confirm that each of the manifold gauge
valves is tightly closed. Note that the connection ports employ Schrader-type
push-to-release valves.
(4) Connect the manifold gauge valves, refrigerant recovery unit, and recovery cylinder using hoses. To avoid the
entry of air into the refrigerant tubing, carry out this connection work carefully. (Fig. 7)
For detailed procedures such as connecting the refrigerant recovery unit with the
recovery cylinder and methods used for recovery, follow the specific instructions
that came with the refrigerant recovery unit.
(5) Locate the AP (Air Purge) pins on the control PCB in the faulty outdoor unit and short them using the clips of
the jumper wire. Then restore electrical power to the outdoor unit.
By short-circuiting the AP pins, each solenoid valve in the outdoor unit is forcibly
opened as soon as power comes on, which releases all remaining refrigerant into
the recovery cylinder. Since neglecting this procedure may leave some refrigerant
in the system, it is important that you carry out this step.
(6) Carry out refrigerant recovery.
To determine the completion of refrigerant recovery, follow the instructions that
came with the refrigerant recovery unit.
Fig. 7
CAUTION
CAUTION
CAUTION
CAUTION
Refrigerant recovery cylinder
Refrigerant
recovery unit
Manifold
gauge
High-pressure outlet port
(For 7.94mm-dia. connector)
Low-pressure outlet port
(For 7.94mm-dia. connector)
Lo Hi
3-WAY ECO-i SYSTEM
Outdoor Unit Repair Procedures
2 - 10
2
5. Recovering Refrigerant
5-2. Refrigerant Recovery Procedures (Indoor Unit)
The flowchart below shows the refrigerant recovery procedures you must follow when replacing or repairing the
indoor unit due to trouble in the refrigerant circuit.
★ Service work performed on indoor units is done simultaneously using the service ports at the liquid (narrow tube) side
and the gas (wide tube) side ball valves. Refer to each section in the “Installation Instructions” on refrigerant charging,
leak checking, and evacuation procedures.
5-2-1. Cooling operation (for all units)
(1) If the remote controller (RCS-TM80BG) is used for maintenance of the outdoor unit
➀ Connect the outdoor unit maintenance remote controller to the RC connector (CN006) (3P) (BLU) on any
one of the outdoor unit control PCBs. Then start a test run of all units. (Press and hold the (CHECK)
button for 4 seconds.)
➁ Press the (MODE) button and change to cooling operation.
Even if the mode that is originally displayed is “Cool,” be sure to press the
(MODE) button once or more to change to cooling operation. (Pressing the
(MODE) button ensures that heating/cooling operation is not mixed and that all
units are operating in either Heating or Cooling mode.)
➂ Use the remote controller (RCS-TM80BG) to check the operating status of the indoor units. Check that all
units are operating in Cooling mode.
With the 3-way valve, it is difficult to determine whether operation is heating or
cooling by touching the tubing.
START
5-2-1. Cooling operation (for all units)
Ball valve is provided in the indoor unit
5-2-2. Refrigerant recovery
procedures (1)
Turn off all equipment in system
When replacing or repairing a faulty
unit, let other normal indoor units run
(excluding indoor unit where refrigerant
is recovered)
Power can independently be turned
off for indoor unit where refrigerant is
recovered
Change controllable number of indoor
units (including changes in group
control and integrated-control settings)
Other indoor units can operate normally
Replace or repair faulty unit
Check for leakage in repaired unit ★
Evacuate air from repaired unit ★
Charge refrigerant in repaired unit ★
(Amount of charge should equal that
recovered by refrigerant recovery unit)
Change controllable number of indoor
units (including changes in group
control and integrated-control settings)
Open ball valve
Ready for normal operation
END
5-2-3. Refrigerant recovery
procedures (2)
Modify power to permit turning off
power to refrigerant-recovered
indoor units independently
Turn off all equipment in system
Replace or repair faulty unit
Check for leakage in repaired unit
Evacuate air from repaired unit
Charge refrigerant in repaired unit
(Amount of charge should equal that
recovered by refrigerant recovery unit)
Ready for operation
END
Replace or repair faulty unit
Check for leakage in repaired unit ★
Evacuate air in repaired unit ★
Charge refrigerant in repaired unit ★
(Amount of charge should equal that
recovered by refrigerant recovery unit)
Open the ball valve
Ready for normal operation
END
YES
YES
YES
NO
NO
NO
CAUTION
CAUTION
Outdoor Unit Repair Procedures
2 - 10
2
5. Recovering Refrigerant
5-2. Refrigerant Recovery Procedures (Indoor Unit)
The flowchart below shows the refrigerant recovery procedures you must follow when replacing or repairing the
indoor unit due to trouble in the refrigerant circuit.
★ Service work performed on indoor units is done simultaneously using the service ports at the liquid (narrow tube) side
and the gas (wide tube) side ball valves. Refer to each section in the “Installation Instructions” on refrigerant charging,
leak checking, and evacuation procedures.
5-2-1. Cooling operation (for all units)
(1) If the remote controller (RCS-TM80BG) is used for maintenance of the outdoor unit
➀ Connect the outdoor unit maintenance remote controller to the RC connector (CN006) (3P) (BLU) on any
one of the outdoor unit control PCBs. Then start a test run of all units. (Press and hold the (CHECK)
button for 4 seconds.)
➁ Press the (MODE) button and change to cooling operation.
Even if the mode that is originally displayed is “Cool,” be sure to press the
(MODE) button once or more to change to cooling operation. (Pressing the
(MODE) button ensures that heating/cooling operation is not mixed and that all
units are operating in either Heating or Cooling mode.)
➂ Use the remote controller (RCS-TM80BG) to check the operating status of the indoor units. Check that all
units are operating in Cooling mode.
With the 3-way valve, it is difficult to determine whether operation is heating or
cooling by touching the tubing.
START
5-2-1. Cooling operation (for all units)
Ball valve is provided in the indoor unit
5-2-2. Refrigerant recovery
procedures (1)
Turn off all equipment in system
When replacing or repairing a faulty
unit, let other normal indoor units run
(excluding indoor unit where refrigerant
is recovered)
Power can independently be turned
off for indoor unit where refrigerant is
recovered
Change controllable number of indoor
units (including changes in group
control and integrated-control settings)
Other indoor units can operate normally
Replace or repair faulty unit
Check for leakage in repaired unit ★
Evacuate air from repaired unit ★
Charge refrigerant in repaired unit ★
(Amount of charge should equal that
recovered by refrigerant recovery unit)
Change controllable number of indoor
units (including changes in group
control and integrated-control settings)
Open ball valve
Ready for normal operation
END
5-2-3. Refrigerant recovery
procedures (2)
Modify power to permit turning off
power to refrigerant-recovered
indoor units independently
Turn off all equipment in system
Replace or repair faulty unit
Check for leakage in repaired unit
Evacuate air from repaired unit
Charge refrigerant in repaired unit
(Amount of charge should equal that
recovered by refrigerant recovery unit)
Ready for operation
END
Replace or repair faulty unit
Check for leakage in repaired unit ★
Evacuate air in repaired unit ★
Charge refrigerant in repaired unit ★
(Amount of charge should equal that
recovered by refrigerant recovery unit)
Open the ball valve
Ready for normal operation
END
YES
YES
YES
NO
NO
NO
CAUTION
CAUTION
2 - 11
3-WAY ECO-i SYSTEM
Outdoor Unit Repair Procedures
2
5. Recovering Refrigerant
(2) If the remote controller (RCS-TM80BG) is not available for maintenance of the outdoor unit
➀ Determine the outdoor unit where the unit No. setting (S007) (3P DIP switch) (BLU) on the outdoor unit
control PCB is set to No. 1.
➁ Short-circuit the mode-change pin (CN101) on the outdoor unit control PCB of the No. 1 unit. Then
short-circuit the test-run pin (CN023) to start operation. (Short-circuiting the mode-change pin ensures that
heating/cooling operation is not mixed and that all units are operating in either Heating or Cooling mode.)
➂ Check the displays of the indoor unit remote controllers. Check that all units are operating in Cooling mode.
If all units are operating in Heating mode, perform the steps listed below.
With the 3-way valve, it is difficult to determine whether operation is heating or
cooling by touching the tubing.
➃ Release the short-circuit at the test-run pin (CN023) on the outdoor unit control PCB of the No. 1 unit. Then
short-circuit the stop pin (CN104) to stop operation.
➄ Short-circuit the mode-change pin (CN101) on the outdoor unit control PCB of the No. 1 unit.
* Switching of the 4-way valve occurs immediately before operation starts. Therefore it does not change at
this time. (Mode change cannot be judged from the sound.)
➅ Short-circuit the test-run pin (CN023) on the outdoor unit control PCB of the No. 1 unit. Then check the
displays of the indoor unit remote controllers. Check that all units are operating in Cooling mode.
5-2-2. Refrigerant recovery procedures (1) (using indoor unit ball valve)
(1) If a ball valve with a service port has been provided in the indoor unit as shown in Fig. 8, follow the instructions
given in (2) through (6) below. If the service port is instead located in the outdoor side, follow the instructions in
“5-2-3. Refrigerant recovery procedures (2).”
(2) After running the unit in Cooling mode for about 5 minutes as described in “5-2-1. Cooling operation (for all
units),” fully close the discharge line, the liquid line ball valve, and indoor unit ball valve.
(3) Run the unit in Cooling mode for 10 to 20 minutes more.
(4) Fully close the suction line ball valve, and stop the operation of all units.
(5) Use hoses to connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder
with each other. (Fig. 8) Do each connection quickly to prevent air from entering the tubing.
Remaining refrigerant may create internal pressure, therefore care should be
taken when connecting the hoses.
(6) Recover the remaining refrigerant from the indoor unit using the refrigerant recovery unit.
NOTE
To determine completion of refrigerant
recovery, follow the instructions that
came with the refrigerant recovery unit.
Fig. 8
CAUTION
CAUTION
Ball valve (separately purchased)
Suction tube
Discharge tube
Liquid tube
Outdoor
unit
side
Service port
Manifold
gauge
Refrigerant
recovery
unit
Refrigerant recovery cylinder
Solenoid
valve kit
Solenoid
valve kit
Indoor unit
3-WAY ECO-i SYSTEM
Outdoor Unit Repair Procedures
2
5. Recovering Refrigerant
(2) If the remote controller (RCS-TM80BG) is not available for maintenance of the outdoor unit
➀ Determine the outdoor unit where the unit No. setting (S007) (3P DIP switch) (BLU) on the outdoor unit
control PCB is set to No. 1.
➁ Short-circuit the mode-change pin (CN101) on the outdoor unit control PCB of the No. 1 unit. Then
short-circuit the test-run pin (CN023) to start operation. (Short-circuiting the mode-change pin ensures that
heating/cooling operation is not mixed and that all units are operating in either Heating or Cooling mode.)
➂ Check the displays of the indoor unit remote controllers. Check that all units are operating in Cooling mode.
If all units are operating in Heating mode, perform the steps listed below.
With the 3-way valve, it is difficult to determine whether operation is heating or
cooling by touching the tubing.
➃ Release the short-circuit at the test-run pin (CN023) on the outdoor unit control PCB of the No. 1 unit. Then
short-circuit the stop pin (CN104) to stop operation.
➄ Short-circuit the mode-change pin (CN101) on the outdoor unit control PCB of the No. 1 unit.
* Switching of the 4-way valve occurs immediately before operation starts. Therefore it does not change at
this time. (Mode change cannot be judged from the sound.)
➅ Short-circuit the test-run pin (CN023) on the outdoor unit control PCB of the No. 1 unit. Then check the
displays of the indoor unit remote controllers. Check that all units are operating in Cooling mode.
5-2-2. Refrigerant recovery procedures (1) (using indoor unit ball valve)
(1) If a ball valve with a service port has been provided in the indoor unit as shown in Fig. 8, follow the instructions
given in (2) through (6) below. If the service port is instead located in the outdoor side, follow the instructions in
“5-2-3. Refrigerant recovery procedures (2).”
(2) After running the unit in Cooling mode for about 5 minutes as described in “5-2-1. Cooling operation (for all
units),” fully close the discharge line, the liquid line ball valve, and indoor unit ball valve.
(3) Run the unit in Cooling mode for 10 to 20 minutes more.
(4) Fully close the suction line ball valve, and stop the operation of all units.
(5) Use hoses to connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder
with each other. (Fig. 8) Do each connection quickly to prevent air from entering the tubing.
Remaining refrigerant may create internal pressure, therefore care should be
taken when connecting the hoses.
(6) Recover the remaining refrigerant from the indoor unit using the refrigerant recovery unit.
NOTE
To determine completion of refrigerant
recovery, follow the instructions that
came with the refrigerant recovery unit.
Fig. 8
CAUTION
CAUTION
Ball valve (separately purchased)
Suction tube
Discharge tube
Liquid tube
Outdoor
unit
side
Service port
Manifold
gauge
Refrigerant
recovery
unit
Refrigerant recovery cylinder
Solenoid
valve kit
Solenoid
valve kit
Indoor unit
3-WAY ECO-i SYSTEM
Outdoor Unit Repair Procedures
2 - 12
2
5. Recovering Refrigerant
5-2-3. Refrigerant recovery procedures (2): for indoor unit with no ball valve
Refrigerant in all indoor units and the refrigerant tubing circuit must be pumped into the outdoor unit. The maximum
refrigerant storage capacity per a single outdoor unit is approx. 15kg. Thus, in order to collect all refrigerant from
the system, a separate refrigerant recovery unit is necessary. Follow these procedures to correctly perform pump
down.
Perform work correctly, according to the work procedures given below.
➀ Connect the manifold gauge to the high- and low-pressure outlet ports on the outdoor unit where pump down
will be performed. Be sure that no air enters the tubing at this time.
➁ Fully close the discharge tube valve on the outdoor unit where pump down will be performed.
➂ Follow the instructions in “5-2-1. Cooling operation (for all units)” and operate all units in Cooling mode for
approximately 5 minutes. Then fully close the liquid tube valve on the outdoor unit where pump down will be
performed.
➃ When the high-pressure gauge reaches 2.8 MPa or higher, or the low-pressure gauge reaches 0.5 MPa or
below, at the outdoor unit where pump down is being performed, press the ON/OFF button on the outdoor unit
maintenance remote controller to stop operation at all units. Then immediately fully close the suction tube valve
on the outdoor unit where pump down is being performed.
* If the outdoor unit maintenance remote controller is unavailable, follow the procedure below to stop all of the
units.
Pull out the SCT connector (2P) (YEL) (CN231) on the outdoor unit control PCB of the unit where pump
down is being performed. When the SCT connector is pulled out, immediately alarm F12 (sensor trouble)
occurs and all outdoor units stop operating. Be sure that you do NOT grasp the lead wire when pulling out the
connector. Removing any other connector may not cause the units to stop. Therefore be sure to pull out the
SCT connector only.
It is not necessary to recover the refrigerant from the balance tube. Therefore do
not operate the balance tube valve.
➄ Turn off power to all equipment in the system. Then pull out the RC1 connector (4P) (BLU) (CN106) on the
outdoor control PCB in the outdoor unit for which pump down has been completed.
* By pulling out the RC1 connector, communication between the main and the sub outdoor units will be isolated.
➅ Change the setting of controllable outdoor unit numbers (reduce by 1 unit).
* If the setting is incorrect, the E30 alarm (outdoor unit serial communication signal error) occurs and the unit
will not operate.
➆ Turn on power for all equipment in the system and let the remaining outdoor units run in Cooling mode.
➇ Repeat steps (1) through (7) and complete pump down for all outdoor units.
➈ Using hoses with Schrader-type push-to-release valves, connect the manifold gauge valves to the suction line
service port, the discharge line service port and the liquid line service port in the next outdoor unit to undergo
pump down. (Fig. 9)
Remaining refrigerant in the system may cause internal pressure. Check that each
valve on the manifold gauge is tightly closed. A Schrader-type
push-to-release valve is provided for each connection port.
➉ Use hoses to connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder.
Quickly connect each part to prevent air from entering the tubing.
11 Recover remaining refrigerant from the inter-unit tubing and indoor units using the refrigerant recovery unit.
NOTE
To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit.
CAUTION
CAUTION
Outdoor Unit Repair Procedures
2 - 12
2
5. Recovering Refrigerant
5-2-3. Refrigerant recovery procedures (2): for indoor unit with no ball valve
Refrigerant in all indoor units and the refrigerant tubing circuit must be pumped into the outdoor unit. The maximum
refrigerant storage capacity per a single outdoor unit is approx. 15kg. Thus, in order to collect all refrigerant from
the system, a separate refrigerant recovery unit is necessary. Follow these procedures to correctly perform pump
down.
Perform work correctly, according to the work procedures given below.
➀ Connect the manifold gauge to the high- and low-pressure outlet ports on the outdoor unit where pump down
will be performed. Be sure that no air enters the tubing at this time.
➁ Fully close the discharge tube valve on the outdoor unit where pump down will be performed.
➂ Follow the instructions in “5-2-1. Cooling operation (for all units)” and operate all units in Cooling mode for
approximately 5 minutes. Then fully close the liquid tube valve on the outdoor unit where pump down will be
performed.
➃ When the high-pressure gauge reaches 2.8 MPa or higher, or the low-pressure gauge reaches 0.5 MPa or
below, at the outdoor unit where pump down is being performed, press the ON/OFF button on the outdoor unit
maintenance remote controller to stop operation at all units. Then immediately fully close the suction tube valve
on the outdoor unit where pump down is being performed.
* If the outdoor unit maintenance remote controller is unavailable, follow the procedure below to stop all of the
units.
Pull out the SCT connector (2P) (YEL) (CN231) on the outdoor unit control PCB of the unit where pump
down is being performed. When the SCT connector is pulled out, immediately alarm F12 (sensor trouble)
occurs and all outdoor units stop operating. Be sure that you do NOT grasp the lead wire when pulling out the
connector. Removing any other connector may not cause the units to stop. Therefore be sure to pull out the
SCT connector only.
It is not necessary to recover the refrigerant from the balance tube. Therefore do
not operate the balance tube valve.
➄ Turn off power to all equipment in the system. Then pull out the RC1 connector (4P) (BLU) (CN106) on the
outdoor control PCB in the outdoor unit for which pump down has been completed.
* By pulling out the RC1 connector, communication between the main and the sub outdoor units will be isolated.
➅ Change the setting of controllable outdoor unit numbers (reduce by 1 unit).
* If the setting is incorrect, the E30 alarm (outdoor unit serial communication signal error) occurs and the unit
will not operate.
➆ Turn on power for all equipment in the system and let the remaining outdoor units run in Cooling mode.
➇ Repeat steps (1) through (7) and complete pump down for all outdoor units.
➈ Using hoses with Schrader-type push-to-release valves, connect the manifold gauge valves to the suction line
service port, the discharge line service port and the liquid line service port in the next outdoor unit to undergo
pump down. (Fig. 9)
Remaining refrigerant in the system may cause internal pressure. Check that each
valve on the manifold gauge is tightly closed. A Schrader-type
push-to-release valve is provided for each connection port.
➉ Use hoses to connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder.
Quickly connect each part to prevent air from entering the tubing.
11 Recover remaining refrigerant from the inter-unit tubing and indoor units using the refrigerant recovery unit.
NOTE
To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit.
CAUTION
CAUTION
5
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Key Features
- Safe refrigerant recovery
- Step-by-step procedures
- Importance of connection safety
- Detailed instructions for recovery units
- Clear and concise diagrams
- Emphasis on safety practices
Related manuals
Frequently Answers and Questions
How do I fully close each service valve on the suction tube, discharge tube, liquid tube, and the balance tube of the outdoor unit?
Turn off the power of the outdoor unit beforehand (at power mains). Then, fully close each service valve on the suction tube, discharge tube, liquid tube, and the balance tube of the outdoor unit.
What is the purpose of short-circuiting the AP (Air Purge) pins on the control PCB?
Short-circuiting the AP pins forces each solenoid valve in the outdoor unit to open as soon as power comes on, releasing all remaining refrigerant into the recovery cylinder. This step ensures that no refrigerant remains in the system.
Why is it important to connect the hoses quickly when recovering refrigerant?
Connecting hoses quickly prevents air from entering the refrigerant tubing, ensuring the purity of the recovered refrigerant.
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