Sanyo ECO-i 3-WAY MULTI SYSTEM Service Manual

5 series

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SERVICE MANUAL

Outdoor Unit

Class

Model Name

SPW-C0705DZH8

Indoor Unit

Class

SPW-

4-Way Air Discharge

XDR74GXH56(A/B)

Semi-Concealed

X075XH

4-Way Air Discharge

SPW-

XM075XH

Semi-Concealed

2-Way Air Discharge

SPW-

SR74GXH56(A/B)

Semi-Concealed

1-Way Air Discharge

SPW-

ADR74GXH56B

Semi-Concealed

1-Way Air Discharge

Semi-Concealed Slim

SPW-

UR74GXH56(A/B)

U075XH

Concealed-Duct

U075XHN

UR74SXH56B

U075SXH

U075SXHT

SPW-

Concealed-Duct

US075XH

Ceiling-Mounted

SPW-

Wall-Mounted

KR74GXH56(A/B)

K075XH

Concealed Floor Standing SPW-

FMR74GXH56(A/B)

SPW-

Floor Standing

FR74GXH56(A/B)

Total Heat Exchanger

with DX coil

Class

SPW-

Concealed-Duct

DR254GXH56(A/B)

High-Static Pressure

85464849271000

115

SPW-C0905DZH8

SPW-C1155DZH8

SPW-

XDR94GXH56(A/B)

XDR124GXH56(A/B)

XDR164GXH56(A/B)

X095XH

X125XH

X165XH

SPW-

XM095XH

XM125XH

XM165XH

SPW-

SR94GXH56(A/B)

SR124GXH56(A/B)

SR164GXH56(A/B)

SPW-

ADR94GXH56B

ADR124GXH56B

SPW-

LDR94GXH56(A/B)

LDR124GXH56(A/B)

LDR164GXH56(A/B)

SPW-

UR94GXH56(A/B)

UR124GXH56(A/B) UR164GXH56(A/B) UR184GXH56(A/B) UR254GXH56(A/B) UR304SXH56B

U095XH

U125XH

U165XH

U095XHN

U125XHN

U165XHN

UR94SXH56B

UR124SXH56B

UR164SXH56B

U095SXH

U125SXH

U165SXH

U095SXHT

U125SXHT

U165SXHT

SPW-

US095XH

US125XH

US165XH

SPW-

TDR124GXH56(A/B) TDR164GXH56(A/B) TDR184GXH56(A/B) TDR254GXH56(A/B)

T125XH

T165XH

SPW-

KR94GXH56(A/B)

KR124GXH56(A/B)

KR164GXH56(A/B)

K095XH

K125XH

SPW-

FMR94GXH56(A/B)

FMR124GXH56(A/B)

FMR164GXH56(A/B)

SPW-

FR94GXH56(A/B)

FR124GXH56(A/B)

FR164GXH56(A/B)

SPW-

GU055XH

GU075XH

SPW-

DR364GXH56(A/B)

DR484GXH56(A/B)

DR764GXH56(A/B)

MULTI SYSTEM

130

SPW-C1305DZH8

SPW-C1405DZH8

SPW-

XDR184GXH56(A/B)

XDR254GXH56(A/B)

X185XH

X255XH

SPW-

XM185XH

SPW-

SR184GXH56(A/B)

SR254GXH56(A/B)

SPW-

LDR184GXH56(A/B)

LDR254GXH56(A/B)

SPW-

U185XH

U255XH

U185XHN

U255XHN

UR184SXH56B

UR254SXH56B

U185SXH

U255SXH

U185SXHT

U255SXHT

SPW-

US185XH

SPW-

T185XH

T255XH

SPW-

KR184GXH56(A/B)

KR254GXH56(A/B)

SPW-

FMR184GXH56(A/B)

FMR254GXH56(A/B)

SPW-

FR184GXH56(A/B)

FR254GXH56(A/B)

SPW-

GU105XH

SPW-

DR964GXH56(A/B)

3-WAY ECO-i

5 series

140

SPW-

XDR364GXH56(A/B)

XDR484GXH56(A/B)

X365XH

X485XH

SPW-

UR364GXH56(A/B) UR484GXH56(A/B) UR604GXH56B

U305SXH

U365XH

U485XH

U305SXHT

U365XHN

U485XHN

UR364SXH56B

UR484SXH56B

U365SXH

U485SXH

U365SXHT

U485SXHT

SPW-

TDR364GXH56(A/B) TDR484GXH56(A/B)

T365XH

T485XH

SM830171-00

REFERENCE NO.

SPW-

XDR604GXH56(A/B)

X605XH

SPW-

U605XH

U605XHN

UR604SXH56B

U605SXH

U605SXHT

Table of Contents

Summary of Contents for Sanyo ECO-i 3-WAY MULTI SYSTEM

Page 1 SERVICE MANUAL 3-WAY ECO-i MULTI SYSTEM 5 series Outdoor Unit Class Model Name SPW-C0705DZH8 SPW-C0905DZH8 SPW-C1155DZH8 SPW-C1305DZH8 SPW-C1405DZH8 Indoor Unit Class SPW- SPW- SPW- SPW- SPW- SPW- SPW- SPW- SPW- 4-Way Air Discharge XDR74GXH56(A/B) XDR94GXH56(A/B) XDR124GXH56(A/B) XDR164GXH56(A/B) XDR184GXH56(A/B) XDR254GXH56(A/B) XDR364GXH56(A/B) XDR484GXH56(A/B) XDR604GXH56(A/B) Semi-Concealed...
Page 2 IMPORTANT! Please Read Before Starting When Installing… …In a Room This air conditioning system meets strict safety and operating standards. As the installer or service person, it is Properly insulate any tubing run inside a room to prevent “sweating” that can cause dripping and water damage to an important part of your job to install or service the system so it operates safely and efficiently.
Page 3 Check of Density Limit 2. The standards for minimum room volume are as follows. (1) No partition (shaded portion) The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its density will not exceed a set limit.
Page 4: Table Of Contents
— CONTENTS — Section 1: CONTROL FUNCTIONS ......... . 1-1 Introduction .
Page 5 Section 5. TROUBLE DIAGNOSIS ......... . 5-1 Contents of Remote Controller Switch Alarm Display .
Page 6: Control Functions
3-WAY ECO-i SYSTEM Control Functions 1. CONTROL FUNCTIONS 1. Introduction ............1-2 2.
Page 7: Introduction
3-WAY ECO-i SYSTEM 1. Introduction Control Functions The 3-WAY ECO-i is a system that allows multiple outdoor units to be connected. The outdoor units all contain inverter compressors, and the system does not utilize the sub units that were used in earlier systems. The outdoor unit where the unit No.
Page 8: Selecting Outdoor Unit For Operation
3-WAY ECO-i SYSTEM 2. Selecting Outdoor Unit for Operation Control Functions 2-1. Outdoor Unit Operating Rules Because in this system all outdoor units contain an inverter compressor, ordinarily there is no absolute order of priority for compressor operation. Therefore there is no order of priority for the outdoor units. However, it is possible to operate the outdoor units in sequence, beginning with unit No.
Page 9: Compressor Control
3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions 3-1. Compressors Mounted in the Outdoor Units [SPW-C0705DZH8, C0905DZH8, C1155DZH8, C1305DZH8, C1405DZH8] Capacity 0705 0905 1155 1305 1405 Compressor 1 Rotary DC Inverter DC Inverter DC Inverter DC Inverter DC Inverter Installed Compressor 2 Scroll 5 hp...
Page 10 3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions 3-3. Compressor Capacity Control The compressor operating conditions vary depending on the indoor unit operating conditions and on the effects of indoor heat load, outside temperature, and other factors. Unit No. 1 (CCU) calculates the required capacity according to these operating conditions, and allocates the capacity requirement among the outdoor units, according to the compressor start/stop rules.
Page 11 3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions 3-6-1. Evaporation Temperature (Te) Control: Control of Indoor Units Operating in Cooling Mode 16.0 Horsepower increase 12.0 11.1 Area A permitted 11.0 11.0 Horsepower increase permitted Area AB Horsepower increase Area B prohibited Horsepower decrease Area C...
Page 12 3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions 3-6-2. Condensation Temperature (Tc) Control: Control when there are indoor units operating in Heating mode PX=55.5°C Thermostat OFF Area D –0.1 Horsepower decrease Area C 51.1 51.0 51.0 Horsepower increase Area B prohibited 48.0 48.0...
Page 13 3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions Compressor Control Table Condensation Temp. [Tc] High not_UP slow_UP Target STOP DOWN not_UP Evaporation temperature (Te) and condensation temperature (Tc) areas A, B, C, and D are the same as for evaporation temperature control and condensation temperature control. (2) Increasing/decreasing the heat exchanger capacity (when the outdoor unit heat exchanger is functioning as a condenser) •...
Page 14 3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions (3) Increasing/decreasing the heat exchanger capacity (when the outdoor unit heat exchanger is functioning as an evaporator) • Primarily when both the evaporation temperature (Te) and condensation temperature (Tc) are low This occurs when the cooling capacity (heat intake) is high and the heating capacity (heat discharge) is low. The outdoor heat exchanger capacity is increased, increasing the system evaporation capacity and raising the evaporation temperature (Te).
Page 15 3-WAY ECO-i SYSTEM 3. Compressor Control Control Functions (2) Current protection Inverter compressor current control is composed of primary current control and secondary current control. Current protection control for the inverter compressor is performed by self-protection in the inverter circuit, and does not increase or decrease the compressor capacity.
Page 16: Special Controls
3-WAY ECO-i SYSTEM 4. Special Controls Control Functions In addition to ordinary heating and cooling operation, this system also includes the following 3 types of special controls for control of the system as a whole. 1. Tube refrigerant recovery control 2.
Page 17 3-WAY ECO-i SYSTEM 4. Special Controls Control Functions 4-2-3. Flow of system refrigerant oil recovery control (1) Simplified flow of system refrigerant oil recovery control System refrigerant oil recovery control follows this flow: Normal operation 3-minute stop (May stop for 6 minutes.) System refrigerant oil recovery control (Max.
Page 18 3-WAY ECO-i SYSTEM 4. Special Controls Control Functions 4-3-4. Outdoor units where defrost occurs Even if the total time has not reached 35 minutes, if there is 1 or more outdoor units that fulfills the defrost detection conditions, all operating outdoor units perform defrost control at the same time. * Defrost control is also performed at outdoor units where the outdoor unit heat exchanger is not functioning as an evaporator (such as stopped outdoor units).
Page 19 3-WAY ECO-i SYSTEM 4. Special Controls Control Functions 4-3-6. Outdoor unit cycle defrost Outdoor unit cycle defrost is performed in systems where 2 or more outdoor units are connected to the refrigerant system. (1) Description of outdoor unit cycle defrost With this defrost method, when 1 outdoor unit operates in defrost mode (heat exchanger operating as a condenser), another outdoor unit operates as an evaporator in the same way as in ordinary heating mode.
Page 20 3-WAY ECO-i SYSTEM 4. Special Controls Control Functions 4-3-7. Defrost end judgment conditions Defrost ends when either of the below defrost end judgment conditions is met. Condition 1: The temperatures are 6°C or higher at all temperatures sensors installed on the outdoor unit heat exchangers.
Page 21: Other Controls
3-WAY ECO-i SYSTEM 5. Other Controls Control Functions 5-1. Oil Control 5-1-1. Oil level Oil level Meaning Oil state Assessment Sufﬁ cient There is more than an adequate amount of oil in This is the normal operating state of the compressor. the system and not a problem.
Page 22: Operation Of Solenoid Valves
3-WAY ECO-i SYSTEM 6. Operation of Solenoid Valves Control Functions 6-1. Refrigerant Control Valve [RCV] The main purpose of this valve is to detect the flow of refrigerant (refrigerant volume) on the indoor-unit side when the outdoor unit heat exchanger is functioning as a condenser. When the valve determines that there are signs of a low refrigerant level, refrigerant is supplied from the receiver tank to the system.
Page 23 3-WAY ECO-i SYSTEM 6. Operation of Solenoid Valves Control Functions 6-3. Balance Valve (BALV) This valve moves some of the oil from the oil separator to the balance tube. (1) When unit is stopped This valve is always OFF. (2) When unit is operating (A) This valve is ON when separator oil self-recovery control is in progress.
Page 24: Outdoor Unit Electronic Control Valves [Mov1, Mov2, Mov3, Mov4]
3-WAY ECO-i SYSTEM 7. Outdoor Unit Electronic Control Valves Control Functions [MOV1, MOV2, MOV3, MOV4] 7-1. Types of Electronic Control Valves [SPW-C0705DZH8, C0905DZH8, C1155DZH8, C1305DZH8, C1405DZH8] Capacity 0705 0905 1155 1305 1405 Electronic Heat exchanger Heat exchanger Heat exchanger Heat exchanger Heat exchanger control valve 1 1 valve...
Page 25 3-WAY ECO-i SYSTEM 7. Outdoor Unit Electronic Control Valves Control Functions [MOV1, MOV2, MOV3, MOV4] 7-4. SC Circuit Electronic Control Valve [MOV4] (1) Operation to increase SC During cooling operation, or mixed heating/cooling operation when the outdoor unit heat exchanger is functioning as a condenser, the liquid refrigerant which condenses at the outdoor unit heat exchanger flows into the receiver tank, and SC (sub-cool = supercooling) approaches 0°C.
Page 26: Outdoor Fan Control
3-WAY ECO-i SYSTEM 8. Outdoor Fan Control Control Functions 8-1. Fan mode These outdoor units utilize a DC fan motor that can be controlled in a maximum of 16 steps (16 modes). However, fan modes 15 and 16 can only be used if high static-pressure mode has been set. * For information concerning EEPROM settings, refer to the field application functions.
Page 27: Demand Control
3-WAY ECO-i SYSTEM 9. Demand Control Control Functions Serial-parallel I/O must be connected in order to perform demand control. The below input is received by serial-parallel I/O, and demand control is performed. The demand values can be set as needed with this device. For more information, refer to the field application functions.
Page 28: Indoor Unit Control Of The Electronic Control Valve
3-WAY ECO-i SYSTEM 10. Indoor Unit Control of the Electronic Control Valve Control Functions 10-1. Normal Control (1) Except Types D and GU Position of electronic control valve Remote Outdoor unit Mode Outdoor unit operation Controller stopped Cooling Thermostat ON Performs SH control in the range of 55 - 480 pulses.
Page 29 3-WAY ECO-i SYSTEM 10. Indoor Unit Control of the Electronic Control Valve Control Functions 10-2. Special Control Outdoor Subject indoor units heat Control Position of electronic control valve exchanger Remote Mode mode Controller Condenser All indoor units Fixed pulse for cooling, according to indoor unit capacity Tube refrigerant oil recovery control Evaporator...
Page 30: Solenoid Valve Kit Control
3-WAY ECO-i SYSTEM 11. Solenoid Valve Kit Control Control Functions This device connects the solenoid valve kit which is used to switch between indoor unit cooling/heating for 3-WAY types. 1. Operation of the except types D and GU solenoid valve kit Remote Discharge Intake...
Page 31: Indoor Special Control
3-WAY ECO-i SYSTEM 12. Indoor Special Control Control Functions 12-1. Switching Control (EC control) If the settings indicate that an RAP valve kit is present (for types D and GU, the setting on initial shipment from the factory is “present”), then the thermostat does not turn ON for 3 minutes after the indoor unit operating mode is changed from any mode other than heating (including stopped) to heating with thermostat ON.
Page 32: Discharge Temperature
3-WAY ECO-i SYSTEM 13. Discharge Temperature Control Functions <Alarm Information> (1) Discharge temperature protection alarm This device sets an upper limit discharge temperature of 105°C for all compressors. When the discharge tem- perature reaches 105°C, that compressor is stopped and restarted. If the same high discharge condition occurs 4 times, then an alarm occurs.
Page 33: Current Protection
3-WAY ECO-i SYSTEM 14. Current Protection Control Functions (1) Fan motor Alarm Description Occurs when the fan motor detects overcurrent, or when the motor is locked and does not turn. (2) Inverter compressor Alarm Description Occurs during ordinary operation when overcurrent (32.5 A) is detected. Occurs under the same conditions as P16 when the inverter compressor is operating at or above 80 Hz.
Page 34: Low Oil Alarm
3-WAY ECO-i SYSTEM 15. Low Oil Alarm Control Functions Ordinary operation is resumed after system oil recovery control is completed. If a stop occurs again as a result of a low oil level, this alarm occurs. This alarm will not occur if system oil recovery control has not already been performed.
Page 35: Pressure Sensor Failure
3-WAY ECO-i SYSTEM 16. Pressure Sensor Failure Control Functions This system contains 2 types of pressure sensors: a high-pressure sensor and a low-pressure sensor. (1) High-pressure sensor failure Identification of a failure caused by a loose or displaced connector is based on the relationship between the pres- sure detected by the high-pressure sensor and the operation of the high-pressure switch, and on the relationship between the temperature detected by the high-pressure sensor and the various temperature thermistors.
Page 36: Backup Operation
3-WAY ECO-i SYSTEM 17. Backup Operation Control Functions <Field Application Functions> 17-1. Automatic Backup Operation This system includes a function for automatic backup operation. An alarm is also displayed to inform the operator that a failure has occurred. (1) Alarms that result in automatic backup operation When compressor trouble or fan motor trouble makes emergency continued operation impossible, automatic backup operation mode is engaged.
Page 37 3-WAY ECO-i SYSTEM 17. Backup Operation Control Functions [2] Disabling operation of 1 compressor At the S010 switch on the PCB of the failed outdoor unit, turn ON the switch for the compressor to disable, and turn ON the “backup” switch. <S010 switch>...
Page 38: Service Maintenance Functions
3-WAY ECO-i SYSTEM 18. Service Maintenance Functions Control Functions The outdoor unit EEPROM settings can be used for the following functions. 18-1. Outdoor Unit Noise Countermeasure: EEPROM 05 (set at each outdoor unit) This unit includes 3 types of Quiet modes. (However, when they are engaged, operation is in Quiet mode 24 hours a day.) Selecting a Quiet mode results in operation that gives priority to reducing noise.
Page 39 3-WAY ECO-i SYSTEM 18. Service Maintenance Functions Control Functions 18-5. Automatic Backup Mode: Outdoor EEPROM 49 (set only on outdoor unit No. 1) Two types of automatic backup modes (when multiple outdoor units are installed) can be selected. Setting Operation Condition Backup outdoor units operate only during special control.
Page 40 3-WAY ECO-i SYSTEM 18. Service Maintenance Functions Control Functions 18-9. Compressor operating sequence: Outdoor EEPROM 49 (set at outdoor units which include CCU functions) When this setting is set to “1,” the compressors start in sequence beginning from the No. 1 outdoor unit. (The setting is “0”...
Page 41: Other Functions
3-WAY ECO-i SYSTEM 19. Other Functions Control Functions 19-1. Snowfall Sensor Functions: Outdoor EEPROM 04 A unit identified as having a snowfall sensor attached will periodically send a signal indicating the snowfall sensor input status to all outdoor units in the same system (or all wired outdoor units in the case of linked systems). It is therefore unnecessary to install and wire multiple snowfall sensors.
Page 42 3-WAY ECO-i SYSTEM 19. Other Functions Control Functions (3) Outdoor unit PCB LED indications in judgment mode LED1 LED2 Recommended response Judgment mode Blinking Blinking Normal Insufﬁ cient gas Blinking Charge with refrigerant a little at a time. Overcharge Blinking Recover refrigerant a little at a time.
Page 43 – MEMO – 1 - 38...
Page 44: Outdoor Unit Repair Procedures
3-WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 2. OUTDOOR UNIT REPAIR PROCEDURES 1. Removing Panels ............2-2 2.
Page 45: Removing Panels
3-WAY ECO-i SYSTEM 1. Removing Panels Outdoor Unit Repair Procedures Procedures: 1. Removing Panels 2. Removing Electrical Component Box and Duct 3. Discharging Compressor Oil 4. Backup Operation 5. Recovering Refrigerant 6. Checking for Leakage After Repair 7. Evacuating System 8.
Page 46: Removing Electrical Component Box And Duct
3-WAY ECO-i SYSTEM 2. Removing Electrical Component Box and Duct Outdoor Unit Repair Procedures Be sure to turn off the power before removing the electrical component box. Then check that the power LED (D53) on the control PCB of the outdoor unit is not lit. (1) Remove the electrical component box cover (remove 6 screws).
Page 47 3-WAY ECO-i SYSTEM 2. Removing Electrical Component Box and Duct Outdoor Unit Repair Procedures (7) Remove the lower duct. (2 screws, 1 tab) (Fig. 5-1) Lower duct Fig. 5-1 (8) Remove the upper duct. (3 screws) (Fig. 5-2) Upper duct Fig.
Page 48: Discharging Compressor Oil
3-WAY ECO-i SYSTEM 3. Discharging Compressor Oil Outdoor Unit Repair Procedures Discharged oil can be used for checking the condition of the system. Based on the appearance and color of the discharged oil, a judgment can be made on whether the system is operating normally or not. 3-1.
Page 49: Backup Operation
3-WAY ECO-i SYSTEM 4. Backup Operation Outdoor Unit Repair Procedures This system includes an emergency automatic backup function that allows the A/C to operate during the period after trouble occurs until repairs are made. However, during repair and at other times, use manual backup operation.
Page 50 3-WAY ECO-i SYSTEM 4. Backup Operation Outdoor Unit Repair Procedures <If the failed unit is the No. 1 outdoor unit (main unit)> If the No. 1 unit (main unit) has failed, a different outdoor unit must be set as the No. 1 unit (main unit). •...
Page 51 3-WAY ECO-i SYSTEM 4. Backup Operation Outdoor Unit Repair Procedures • After adjusting the amount of refrigerant, turn OFF the power at the failed outdoor unit, release the short-circuit at the vacuum application pin, and close the liquid tube valve at the failed outdoor unit. * Refrigerant recovery is not affected by the power status of the failed outdoor unit.
Page 52: Recovering Refrigerant
3-WAY ECO-i SYSTEM 5. Recovering Refrigerant Outdoor Unit Repair Procedures 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.
Page 53 3-WAY ECO-i SYSTEM 5. Recovering Refrigerant Outdoor Unit Repair Procedures 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. START 5-2-1.
Page 54 3-WAY ECO-i SYSTEM 5. Recovering Refrigerant Outdoor Unit Repair Procedures (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.
Page 55 3-WAY ECO-i SYSTEM 5. Recovering Refrigerant Outdoor Unit Repair Procedures 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.
Page 56 3-WAY ECO-i SYSTEM 5. Recovering Refrigerant Outdoor Unit Repair Procedures Discharge tube service port (For 7.94mm-dia. connector) Liquid tube service port (For 7.94mm-dia. connector) Manifold gauge Refrigerant recover unit Refrigerant Suction tube service port recovery cylinder (For 7.94mm-dia. connector) Fig. 9 5-3.
Page 57: Checking For Leakage After Repair
3-WAY ECO-i SYSTEM 6. Checking for Leakage After Repair Outdoor Unit Repair Procedures 6-1. Pressure Check for Leakage of Outdoor Unit After completing repair of the outdoor unit, carry out the following leakage check. (1) Check that all service valves for suction tube, discharge tube, liquid tube, and balance tube in the repaired outdoor unit are fully closed.

Sanyo ECO-i 3-WAY MULTI SYSTEM Service Manual

Control Functions

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