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Sinclair SDV5 Series Service Manual

Commercial air conditioners
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OUTDOOR UNITS SDV5-100-160EAS
C O M M E R C I A L A I R C O N D I T I O N E R S S D V 5

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Summary of Contents for Sinclair SDV5 Series

  • Page 1 OUTDOOR UNITS SDV5-100-160EAS C O M M E R C I A L A I R C O N D I T I O N E R S S D V 5...
  • Page 2 Original instructions IMPORTANT NOTE: Read this manual carefully before installing or operating your new air conditioning unit. Make sure to save this manual for future reference.

  • Page 3: Table Of Contents

    CONTENTS Part 1 General Information ................3 Part 2 Component Layout and Refrigerant Circuits ........7 Part 3 Control ....................18 Part 4 Field Settings ..................28 Part 5 Electrical Components and Wiring Diagrams ........33 Part 6 Diagnosis and Troubleshooting ............43...

  • Page 4: Part 1 General Information

    Part 1 General Information 1 Indoor and Outdoor Unit Capacities ............3 2 External Appearance ................4 3 Combination Ratio .................. 5...
  • Page 5 1 Indoor and Outdoor Unit Capacities 1.1 Indoor Units 1.1.1 VRF indoor units Table 1-1.1: Standard indoor unit abbreviation codes Abbreviation Abbreviation Type Type code code One-way Cassette High Static Pressure Duct Two-way Cassette Wall-mounted Compact Four-way Cassette Ceiling & Floor Four-way Cassette Floor Standing Medium Static Pressure Duct...
  • Page 6 2 External Appearance 2.1 Indoor Units Table 1-2.1: Indoor unit appearance One-way Cassette Two-way Cassette Compact Four-way Cassette Four-way Cassette Medium Static Pressure Duct High Static Pressure Duct Wall-mounted Ceiling & Floor Floor concealed Console 2.2 Outdoor Units Table 1-2.2: Outdoor unit appearance 10-12KW 14-16KW...
  • Page 7 3 Combination Ratio Sum of capacity indexes of the indoor units Combination ratio = Capacity index of the outdoor unit Table 1-4.1: Indoor and outdoor unit combination ratio limitations Type Minimum combination ratio Maximum combination ratio Mini C Series outdoor units 130% Table 1-4.2: Combinations of Indoor and outdoor units Outdoor unit capacity...

  • Page 8: Part 2 Component Layout And Refrigerant Circuits

    Part 2 Component Layout and Refrigerant Circuits 1 Piping Diagrams ..................7 2 Refrigerant Flow Diagrams ..............9...
  • Page 9 1 Piping Diagrams Figure 2-1.1: 80 model Piping diagram Figure 2-1.2: 100/120 model Piping diagram...
  • Page 10 Figure 2-1.3: 140/160 model Piping diagram Key components: 1. Oil separator: Separates oil from gas refrigerant pumped out of the compressor and quickly returns it to the compressor. Separation efficiency is up to 99%. 2. Gas-liquid separator: Stores liquid refrigerant and oil to protect compressor from liquid hammering. 3.
  • Page 11 2 Refrigerant Flow Diagrams Cooling operation Figure 2-3.1: 80 model refrigerant flow during cooling operation Figure 2-3.2: 100/120 model refrigerant flow during cooling operation...
  • Page 12 Figure 2-3.3: 140/160 model refrigerant flow during cooling operation Oil return operation in cooling mode Figure 2-3.4: 80 model refrigerant flow during oil return operation in cooling mode...
  • Page 13 Figure 2-3.5: 100/120 model refrigerant flow during oil return operation in cooling mode Figure 2-3.6: 140/160 model refrigerant flow during oil return operation in cooling mode...
  • Page 14 Heating operation Figure 2-3.7: 80 model refrigerant flow during heating operation Figure 2-3.8: 100/120 model refrigerant flow during heating operation...
  • Page 15 Figure 2-3.9: 140/160 model refrigerant flow during heating operation Oil return operation in heating mode Figure 2-3.10: 80 model refrigerant flow during oil return operation in heating mode...
  • Page 16 Figure 2-3.11: 100/120 model refrigerant flow during oil return operation in heating mode Figure 2-3.12: 140/160 model refrigerant flow during oil return operation in heating mode...
  • Page 17 Defrosting operation Figure 2-3.13: 80 model refrigerant flow during defrosting operation Figure 2-3.14: 100/120 model refrigerant flow during defrosting operation...
  • Page 18 Figure 2-3.15: 140/160 model refrigerant flow during defrosting operation...

  • Page 19: Part 3 Control

    Part 3 Control 1 General Control Scheme Flowchart ............18 2 Stop Operation ..................19 3 Standby Control ..................19 4 Startup Control ..................20 5 Normal Operation Control ..............21 6 Protection Control................. 22 7 Special Control ..................24...

  • Page 20: General Control Scheme Flowchart

    1 General Control Scheme Flowchart Sections 3-2 to 3-7 on the following pages detail when each of the controls in the flowchart below is activated. Stop operation  Abnormal shutdown  System stop Standby control  Crankcase heater control Thermo on Startup control ...

  • Page 21: Stop Operation

    2 Stop Operation The stop operation occurs for one of the two following reasons: 1. Abnormal shutdown: in order to protect the compressors, if an abnormal state occurs the system makes a 'stop with thermo off' operation and an error code is displayed on the outdoor unit digital displays. 2.

  • Page 22: Startup Control

    4 Startup Control 4.1 Compressor Startup Delay Control When the ODU is powered on again and the compressor delays about 7 minutes to start. After the compressor stops running, it takes about 4 minutes to restart, in order to prevent frequent compressor on/off and to equalize the pressure within the refrigerant system.

  • Page 23: Normal Operation Control

    5 Normal Operation Control 5.1 Component Control during Normal Operation Table 3-5.1: Component control during normal cooling operation Wiring diagram Component 8~16kW Control functions and states label Inverter compressor COMP Controlled according to load requirement ● Fan speed controlled according to heat exchanger temperature DC fan motor ●...

  • Page 24: Protection Control

    6 Protection Control 6.1 High Pressure Protection Control This control protects the system from abnormally high pressure and protects the compressors from transient spikes in pressure. Figure 3-6.1: High pressure protection control Normal operation > 4.4MPa < 3.2MPa High pressure protection, error code P1 is displayed Notes: 1.
  • Page 25 6.4 Compressor and Inverter Module Protection Control This control protects the compressors from abnormally high currents and protects the inverter modules from abnormally high temperatures. Figure 3-6.4: Compressor current protection control Normal operation Current ≥ Current Current < Current Compressor current protection, error code P3 is displayed 6.5 Disable Cooling Control When the outdoor ambient temperature drops below or equal to -5°C，...

  • Page 26: Special Control

    7 Special Control 7.1 Oil Return Operation In order to prevent compressors from running out of oil, the oil return operation is conducted to recover oil that has flowed out of the compressor(s) and into the piping system. This operation is performed for all units including units that are in standby.
  • Page 27 7.2 Defrosting Operation In order to recover heating capacity, the defrosting operation is conducted when the outdoor unit heat exchanger is performing as an evaporator. The defrosting operation is controlled according to outdoor ambient temperature, outdoor heat exchanger temperature, indoor heat exchanger temperature and outdoor unit running time. When the outdoor unit is running in defrosting, the digital display on outdoor main PCB will display “df”.

  • Page 28: Part 4 Field Settings

    Part 4 Field Settings 1 Outdoor Unit Field Settings ..............28...
  • Page 29 1 Outdoor Unit Field Settings Figure 4-1.1: 80 model outdoor unit main PCB switches Dial switches Check button Digital display Table 4-1.1: 80 model outdoor unit main PCB switch settings Switch Switch Setting Description positions Spot check button and force cooling button(long pressed over 5 seconds 1.Spot check would into forced cooling mode, long pressed over 5 seconds again would 2.Force cooling...
  • Page 30 Figure 4-1.2: 100/120 model outdoor unit main PCB switches and communication switchboard Communication switchboard Dial switch Digital display Check button Main board Power switch ENC3 switch Table 4-1.2: 100/120 model outdoor unit main PCB switch settings Switch Switch Setting Description positions Force Press SW1 to enter the forced cooling mode;...
  • Page 31 Figure 4-1.3: 140/160 model outdoor unit main PCB switches and communication switchboard Digital display Check button and force cooling button Dial switch ENC2/ENC3 Table 4-1.3: 140/160 model outdoor unit main PCB switch settings Switch Switch Setting Description positions Force Press SW1 to enter the forced cooling function; press it again to exit the forced cooling cooling function Spot...
  • Page 32 Table 4-1.4: Spot check display table (for all model) DSP1 content Parameters displayed on DSP2 Remarks 0.-- Actual value = value displayed Operating frequency 1.-- Operating mode Refer to Note 1 2.-- Operating fan speed level Refer to Note 2 3.-- Total capacity requirement of indoor units 4.--...
  • Page 33 Part 5 Electrical Components and Wiring Diagrams 1 Outdoor Unit Electric Control Box Layout ..........33 2 Outdoor Unit Main PCB ................34 3 Wiring Diagrams ..................39...
  • Page 34 1 Outdoor Unit Electric Control Box Layout Figure 5-1.1: the view of 80 model electric control box Power input and power filter Module board PFC module IPM module DC fan motor control module Output control assembly Main control board Figure 5-1.2: the view of 100/120 model electric control box Common mode inductor PFC module Electric capacitor...
  • Page 35 Figure 5-1.3: the view of 140/160 model electric control box DC fan control Switch power supply module IPM module Communication terminals PFC module Main control board Power input and Filter board filter assembly Power input terminals 2 Outdoor Unit Main PCB 2.1 Ports Figure 5-1.1: 80 model outdoor unit main PCB ports Notes:...
  • Page 36 Figure 5-1.2: 100/120 model outdoor unit main board ports Table 5-1.2: 100/120 model main board 1 ports Label in Code Content Port voltage Figure 5-1.2 AC power input L ,VLN=220-240VAC 50Hz AC power input N ,VLN=220-240VAC 50Hz CN13 Four way valve 0V or 220-240VAC,50Hz CN11 Electric heating belt of crankcase...
  • Page 37 Table 5-1.3: 100/120 model communication converter board PCB ports Label in Port code Content Port voltage Figure 5-1.3 R T communication port 2.5-2.7V DC P Q E X Y E communication port（with main board） 2.5-2.7V DC O A communication port（reserved） 2.5-2.7V DC P Q E X Y E communication port 2.5-2.7V DC...
  • Page 38 CN11 Load output port(crankcase heating) AC 220 CN50 Power input port AC 220V EEPROM Port DC 5V CN17 DC fan1 port DC 380 CN19 DC fan2 port(Reserved) DC 380 Compressor’s U phase voltage output port DC 380 Compressor’s V phase voltage output port DC 380 Compressor’s W phase voltage output port DC 380...
  • Page 39 2.2.2 Function of buttons SW1 to SW2 Table 5-2.2: Function of buttons SW1 to SW2 Model Button Function Picture Force cooling button Force cooling button 100-160 Check button 2.2.4 System check button On pressing Spot check button, the parameters listed in Table 5-2.3 will be displayed in sequence. Table 5-2.3: 80/100/120/140/160 model system check Parameters displayed on DSP Remarks...
  • Page 40 2.2.5 Digital display output Table 5-2.8: Digital display output in different operating states Outdoor unit state Parameters displayed on DSP Standby The number of indoor units in communication with the outdoor unit Normal operation Compressor frequency Error or protection Error or protection code System check Refer to Table 5-2.3 3 Wiring Diagrams...
  • Page 41 Figure 5-3.2: 100/120 model wiring diagram Component code Description Component code Description Rectifier bridge stacking Relay CH1-CH6 Magnetic ring STF1 Four-way valve COMP. Compressor Outdoor heat exchanger temperature sensor AC current transformer Outdoor ambient temperature sensor D502,D503 Fast-recover diode Discharge temperature sensor Electronic expansion valve T6 dedicated line group DC fan...
  • Page 42 Figure 5-3.3: 140/160 model wiring diagram Component code Description Component code Description 3-slot power supply terminal H-PRO High pressure switch Communication converter board L-PRO Low pressure switch CHI-CH4 Magnetic ring STF1 Four-way valve COMP. Compressor Outdoor heat exchanger temperature sensor AC current transformer Outdoor ambient temperature sensor EEV1...

  • Page 43: Part 6 Diagnosis And Troubleshooting

    Part 6 Diagnosis and Troubleshooting 1 Error Code Table ..................43 2 Troubleshooting ..................44...
  • Page 44 1 Error Code Table Table 6-1.1: Error code table Error code Content Note Communication fault between main control board and communicate converter board 100/120 model Abnormal shutdown of compressor inverter module board 80 model All models Communication fault between outdoor unit and indoor units All models T3 or T4 temperature sensor fault All models...
  • Page 45 2 Troubleshooting 2.1 Warning Warning  All electrical work must be carried out by competent and suitably qualified, certified and accredited professionals and in accordance with all applicable legislation (all national, local and other laws, standards, codes, rules, regulations and other legislation that apply in a given situation). ...
  • Page 46 2.3 E2: Communication error between indoor and outdoor unit (For all models) 2.3.1 Digital display output 2.3.2 Description  Communication error between indoor and outdoor unit.  The system stops running.  Error code is displayed on the outdoor unit PCB. 2.3.3 Trigger / recover condition ...
  • Page 47 Communication wires are close to a source Remove the source of interference, or of electromagnetic radiation such as add additional shielding to the transformer or strong fluorescent lamp communication wires The length of communication wire is over Reduce the wire length to less than 1200m 1200m or strengthen the signal Clear all indoor unit address by setting...
  • Page 48 capacitor between P and Q of outdoor unit. Installation refers to Figure 6-2.1: Figure 6-2.1: Indoor unit installation Notes: Communication wires should be shield wire and indoor units should be connected in series. 2.4 E4: Temperature sensor (T3/T4) fault (For all models) 2.4.1 Digital display output 2.4.2 Description ...
  • Page 49 Measure sensor resistance. If the resistance is too low, the sensor has short-circuited. If the resistance is not consistent with the sensor’s resistance characteristics table, the sensor has failed. 2.5 E5: Abnormal power supply voltage (For all models) 2.5.1 Digital display output 2.5.2 Description ...
  • Page 50 2.6 E6: DC fan motor error; Eb: E6 protection appears 6 times in one hour (For all models) 2.6.1 Digital display output E6 or Eb 2.6.2 Description  E6:DC fan motor error; Eb: E6 protection appears 6 times in one hour ...
  • Page 51 2.7 E7: Discharge temperature sensor (T5) error (only for 80 model) 2.7.1 Digital display output 2.7.2 Description  A compressor discharge pipe temperature sensor (T5) error.  The system stops running.  Error code is displayed on the outdoor unit PCB. 2.7.3 Trigger / recover condition ...
  • Page 52 2.8 E9: EEPROM error (For all models) 2.8.1 Digital display output 2.8.2 Description  EEPROM error  The system stops running.  Error code is displayed on the outdoor unit PCB. 2.8.3 Trigger / recover condition  Trigger condition: Unable to read the EEPROM when startup. ...
  • Page 53 2.9.5 Procedure E.9. Confirm whether the power setting number is Power off and reset the corresponding with the outdoor unit power number Replaced outdoor main control board Notes: Power setting switch is only for 100-160 model, 80 model don’t need to setting Power setting switch for 100/120 mode is S3, S3=100 is corresponding to 100 model and S3=010 is corresponding to 120 model.
  • Page 54 2.11 EH: Refrigerant radiator temperature sensor error (For all models) 2.11.1 Digital display output 2.11.2 Description  Refrigerant radiator temperature TL sensor error.  The system stops running.  Error code is displayed on outdoor unit PCB. 2.11.3 Trigger / recover condition ...
  • Page 55  TL temperature sensor damaged.  TL temperature sensor connect to the main control board is loose.  Main PCB damaged. 2.12.5 Procedure T4 sensor detected temperature is lower Temperature over operation range than -5℃ T4 temperature sensor has Replace the T4 sensor short-circuited or failed Replace outdoor main control board 2.13 F1: DC bus voltage protection (Only for 100~160 model)
  • Page 56 2.13.5 Procedure Check LED301 Is Replace outdoor main PCB flashing or not Check the wiring between main control Connect again board and filter board is correct or not. Voltage of power supply is 166-265V? Provide normal power supply 2.14 H0: Communicate malfunction between inverter module board and main control board (for all models) 2.14.1 Digital display output 2.14.2 Description...
  • Page 57 2.14.5 Procedure Power off for 3 minutes, and pull up the DC fan motor connection port, repower DC fan motor malfunction on to confirm whether the fault is cleared Confirm whether the connection is well External disturbance, maintain to use between CN52 and CN53 Confirm whether Power off for 3 minutes, then repower on...
  • Page 58 2.15.4 Possible causes  Communication wire or power supply wire connection problem.  Indoor unit main control board damaged.  Outdoor unit main control board damaged. 2.15.5 Procedure Waiting for 3 minutes to check whether There are some indoor units power off or the fault would resume power on in the operation period Inspect whether indoor unit address...
  • Page 59 2.16.4 Possible causes  Pressure sensor/switch not connected properly or has malfunctioned.  Excess refrigerant.  System contains air or nitrogen.  High pressure side blockage.  Poor condenser heat exchange.  Main PCB damaged. 2.16.5 Procedure High pressure sensor connection on main Ensure the sensor is connected properly PCB is loose High pressure sensor has short-circuited or...
  • Page 60 2.17 P2: Suction pipe low pressure protection (For all models) 2.17.1 Digital display output 2.17.2 Description  Suction pipe low pressure protection.  The system stops running.  Error code is displayed on outdoor unit PCB. 2.17.3 Trigger / recover condition ...
  • Page 61 Notes: Measure the resistance among the three terminals of the pressure sensor. If the resistance is of the order of mega Ohms or infinite, the pressure sensor has failed. An insufficiency of refrigerant causes compressor discharge temperature to be higher than normal, discharge and suction pressures to be lower than normal and compressor current to be lower than normal, and may cause frosting to occur on the suction pipe.
  • Page 62 Flush all refrigerant then vacuum the System contains air or nitrogen system and recharge refrigerant. Add oil to the system if it leaks The condenser heat exchange is poor Inspect the system and fix the error The high pressure side is blocked, caused Inspect the system and fix the error by crushed or bent pipe or blocked EXV Inverter module has short-circuited...
  • Page 63 2.18.4 Possible causes  Temperature sensor/switch not  Indoor load too large.  System contains air or nitrogen. connected properly or has malfunctioned.  Insufficient refrigerant.  Poor condenser heat exchange.  System blockage.  Main PCB damaged. 2.18.5 Procedure Discharge pipe temperature...
  • Page 64 be higher than normal, abnormal compressor noise and an unsteady pressure meter reading. In cooling mode check outdoor heat exchangers, fans and air outlets for dirt/blockages. In heating mode check indoor heat exchangers, fans and air outlets for dirt/blockages. 2.19 P5: Outdoor heat exchanger temperature protection (For all models) 2.19.1 Digital display output 2.19.2 Description ...
  • Page 65 The high pressure side is blocked, caused Inspect the system and fix the error by crushed or bent pipe or blocked EXV Replace outdoor main PCB Notes: Measure sensor resistance. If the resistance is too low, the sensor has short-circuited. If the resistance is not consistent with the sensor’s resistance characteristics table, the sensor has failed.
  • Page 66 2.20.5 Procedure Trigger the protect Whether the fan blade was blow to high function, Wait unit the speed in standby strong wind stops Check history fault Power off for 3 minutes and then repower code to analyze on to confirm whether the fault is cleared Power off and pull up CN17(white) and CN19(black) of DC motor wire, repower ODU main control...
  • Page 67 2.21.5 Procedure Check whether average Check whether indoor side temperature T2 of evaporator is temperature is over the permit over 63 degrees operation range Test the temperature sensor Whether the heat exchanger temperature resistance to check whether it’s needs cleaning. sensor fault corresponding to the actual temperature.
  • Page 68 2.22.5 Procedure Power off for 3 minutes and then repower on to check whether PL fault is cleared Spot check the 8 TF temperature to confirm whether TF is over 90℃ in outdoor unit operation period Spot check the 9 TL temperature to confirm whether TL is too high ,and Inspect whether the refrigerant cooling tube and radiator is contacted well...
  • Page 69 Whether refrigerant cooling pipe Reinstallation to confirm refrigerant assemble properly cooling pipe contact with radiator tightly Replace the main control board to check whether the fault is occur again Exclude whether system is abnormal and compressor has any abnormal noise Replace the compressor 2.23.6 L5: Zero speed protection There is abnormal noise of...
  • Page 70 2.23.7 L8 / L9 troubleshooting L8/L9 Reconnect the cables based on Compressor wiring is not properly wiring diagram The resistance between 3 phases of compressor is over 5Ω Replace the compressor The insulation resistance of compressor is less than 100Ω The compressor has less than 12 hours preheating before initial Ensure enough preheating time...
  • Page 71 2.23.9 L2 : Procedure Voltage of power supply is 166-265V? Provide normal power supply Replace outdoor main PCB 2.23.10 Compressor replacement procedure Figure 6-2.5: Draining oil from a compressor Step 1: Remove faulty compressor and remove oil  Remove the faulty compressor from the outdoor unit. ...
  • Page 72 Figure 6-2.6: Compressor piping Step 6: Replace the faulty compressor and re-fit the other compressors  Replace the faulty compressor. Discharge pipe Suction pipe  If the oil had been spoiled and was drained from the non-faulty compressor in Step 3, use clean oil to clean them before re-fitting it into the unit. To clean, add oil into the compressor through the discharge pipe using a funnel, shake the compressor, and then drain the oil.
  • Page 73 SINCLAIR CORPORATION Ltd. 1-4 Argyll St. London W1F 7LD Great Britain www.sinclair-world.com This product was manufactured in China (Made in China). REPRESENTATIVE SINCLAIR Global Group s.r.o. Purkynova 45 612 00 Brno Czech Republic TECHNICAL SUPPORT SINCLAIR Global Group s.r.o. Purkynova 45...

This manual is also suitable for:

Sdv5-80easSdv5-100easSdv5-120easSdv5-140easSdv5-160eas

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