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Sanyo SAP-KRV96EH Technical & Service Manual

Dc inverter split system air conditioner
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TECHNICAL & SERVICE MANUAL
SAP-KRV96EH + SAP-CRV96EH
SAP-KRV126EH + SAP-CRV126EH
DC INVERTER SPLIT SYSTEM AIR CONDITIONER
Indoor Model No.
SAP-KRV96EH
SAP-KRV126EH
Indoor Unit
SAP-KRV96EH
SAP-KRV126EH
RoHS
This product does not contain any hazardous substances prohibited by the RoHS Directive.
WARNING
• You are requested to use RoHS compliant parts for maintenance or repair.
• You are requested to use lead-free solder.
Product Code No.
1 852 346 74
1 852 346 75
Compliance with regulation 842/EC/2006, Article 7(1) requirements
Do not vent R410A into the atmosphere:
R410A is a fluorinated greenhouse gas, covered by the Kyoto Protocol,
with a global warming potential (GWP) = 1975.
FILE NO.
Outdoor Model No.
Product Code No.
SAP-CRV96EH
1 852 346 81
SAP-CRV126EH
1 852 346 82
Outdoor Unit
SAP-CRV96EH
SAP-CRV126EH
REFERENCE NO.
Destination: Europe
SM
700728

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  Summary of Contents for Sanyo SAP-KRV96EH

  • Page 1 TECHNICAL & SERVICE MANUAL FILE NO. SAP-KRV96EH + SAP-CRV96EH SAP-KRV126EH + SAP-CRV126EH Destination: Europe DC INVERTER SPLIT SYSTEM AIR CONDITIONER Indoor Model No. Product Code No. Outdoor Model No. Product Code No. SAP-KRV96EH 1 852 346 74 SAP-CRV96EH 1 852 346 81...
  • Page 2 When Transporting Important! Please Read Before Starting 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 This air conditioning system meets strict safety and thin aluminum fins on the air conditioner can cut your operating standards.
  • Page 3: Table Of Contents

    Table of Contents Page 1. OPERATING RANGE ........................2. SPECIFICATIONS 2-1. Unit Specifications ......................2-2. Major Component Specifications ..................2-3. Other Component Specifications ..................3. DIMENSIONAL DATA ........................4. REFRIGERANT FLOW DIAGRAM 4-1. Refrigerant Flow Diagram ....................5. PERFORMANCE DATA 5-1.
  • Page 4 Page 10. TROUBLESHOOTING 10-1. Precautions before Performing Inspection or Repair ............10-2. Method of Self-Diagnostics ....................10-3. Checking the Indoor and Outdoor Units ................10-4. Noise Malfunction and Electromagnetic Interference ............11. CHECKING ELECTRICAL COMPONENTS 11-1. Measurement of Insulation Resistance ................
  • Page 5: Operating Range

    1. OPERATING RANGE Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp. 32 °C D.B. / 23 °C W.B. 43 °C D.B. Maximum Cooling 19 °C D.B. / 14 °C W.B. 19 °C D.B. Minimum 27 °C D.B. 24 °C D.B. / 18 °C W.B. Maximum Heating 16 °C D.B.
  • Page 6: Specifications

    2. SPECIFICATIONS 2-1. Unit Specifications Indoor Unit SAP-KRV96EH Outdoor Unit SAP-CRV96EH Power Source 220 to 240V Single-Phase 50Hz Voltage Rating 230V Performance Cooling Heating Capacity ( 0.9 to 3.2 ) ( 0.9 to 4.3 ) BTU/h 8,500 ( 3,100 to 10,900 )
  • Page 7 Indoor Unit SAP-KRV126EH Outdoor Unit SAP-CRV126EH Power Source 220 to 240V Single-Phase 50Hz Voltage Rating 230V Performance Cooling Heating Capacity ( 0.9 to 3.8 ) ( 0.9 to 5.0 ) BTU/h 11,300 ( 3,100 to 13,000 ) 13,600 ( 3,100 to 17,100 ) Air Circulation (High) Moisture Removal (High) Liters/h...
  • Page 8: Major Component Specifications

    2-2. Major Component Specifications 2-2-1. Indoor Unit Indoor Unit SAP-KRV96EH Control PCB Part No. CB-KRV96EH Controls Microprocessor Control Circuit Fuse 250V 3.15A Remote Control Unit RCS-6HVPUS4E Type Cross-Flow Q'ty ... Dia. and Length 1 ... D94 / L634 Fan Motor...
  • Page 9 Indoor Unit SAP-KRV126EH Control PCB Part No. CB-KRV126EH Controls Microprocessor Control Circuit Fuse 250V 3.15A Remote Control Unit RCS-6HVPUS4E Type Cross-Flow Q'ty ... Dia. and Length 1 ... D94 / L634 Fan Motor Type AC Motor Model ... Q'ty IBH-884-066A ... 1 No.
  • Page 10: Outdoor Unit

    2-2-2. Outdoor Unit Outdoor Unit SAP-CRV96EH Control PCB Part No. CB-CRV96EH Controls Microprocessor Control Circuit Fuse 250V 20A Compressor Type DC Rotary (Hermetic) Compressor Model / Nominal Output C-1RVN68H0K / 650W Compressor Oil ... Amount FV50S ... 350 Coil Resistance (Ambient Temp. 20 °C) R - S : 0.632 S - T : 0.632 T - R : 0.632...
  • Page 11 Outdoor Unit SAP-CRV126EH Control PCB Part No. CB-CRV126EH Controls Microprocessor Control Circuit Fuse 250V 20A Compressor Type DC Rotary (Hermetic) Compressor Model / Nominal Output C-1RVN68H0K / 750W Compressor Oil ... Amount FV50S ... 350 Coil Resistance (Ambient Temp. 20 °C) R - S : 0.632 S - T : 0.632 T - R : 0.632...
  • Page 12: Other Component Specifications

    2-3. Other Component Specifications Indoor Unit SAP-KRV96EH SAP-KRV126EH Outdoor Unit SAP-CRV96EH SAP-CRV126EH • Indoor heat exchanger sensor (Model:DTN-TKS332Y TH1) • Indoor air temp sensor • Compressor temp sensor (Model:DTN-TKS332Y TH2) (Model:DTN-TKS335B) 10 20 30 40 50 60 70 80 90 Temperature (°C)
  • Page 13: Dimensional Data

    3. DIMENSIONAL DATA Indoor Unit SAP-KRV96EH SAP-KRV126EH Unit: mm...
  • Page 14 Outdoor Unit SAP-CRV96EH SAP-CRV126EH AIR INTAKE AIR DISCHARGE 2-ID:12 Wide tube service valve dia.9.52 (3/8") Narrow tube service valve dia.6.35 ( 1/4" ) Unit: mm...
  • Page 15: Refrigerant Flow Diagram

    4. REFRIGERANT FLOW DIAGRAM 4-1. Refrigerant Flow Diagram Indoor Unit SAP-KRV96EH Outdoor Unit SAP-CRV96EH SAP-KRV126EH SAP-CRV126EH Indoor unit Outdoor unit Accumulator Wide tube service Wide tube valve 4-way Muffler valve O.D. 9.52 mm (3/8 ") Capillary tubes (both for heating...
  • Page 16: Performance Data

    5. PERFORMANCE DATA 5-1. Temperature Charts Indoor Unit SAP-KRV96EH Outdoor Unit SAP-CRV96EH Cooling Characteristics Heating Characteristics (40.8) (12.2) (35.7) (10.2) (30.6) (8.2) (25.5) (6.2) (20.4) –5 Outdoor air temperature (°C) Outdoor air temperature (°C) –5 Outdoor air temperature (°C) Outdoor air temperature (°C) –5...
  • Page 17 Indoor Unit SAP-KRV126EH Outdoor Unit SAP-CRV126EH Cooling Characteristics Heating Characteristics (40.8) (14.2) (35.7) (12.2) (30.6) (10.2) (25.5) (20.4) (8.2) –5 Outdoor air temperature (°C) Outdoor air temperature (°C) –5 Outdoor air temperature (°C) Outdoor air temperature (°C) –5 Outdoor air temperature (°C) Outdoor air temperature (°C) NOTE Check each performance value in test-run mode.
  • Page 18: Air Throw Distance Charts

    5-2. Air Throw Distance Charts Indoor Unit SAP-KRV96EH Cooling 27 °C Room air temp. : Fan speed High Horizontal distance (m) : Flap angle 0°, : Axis air velocity 0° : Flap angle 30°, : Axis air velocity 30° Heating 20 °C...
  • Page 19 Indoor Unit SAP-KRV126EH Cooling 27 °C Room air temp. : Fan speed High Horizontal distance (m) : Flap angle 0°, : Axis air velocity 0° : Flap angle 30°, : Axis air velocity 30° Heating 20 °C Room air temp. : Fan speed High Horizontal distance (m)
  • Page 20: Electrical Data

    6. ELECTRICAL DATA 6-1. Electrical Characteristics Indoor Unit SAP-KRV96EH Outdoor Unit SAP-CRV96EH Cooling Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor + Compressor Performance at 230V Single-phase 50Hz Rating conditions Running amp. 0.13 3.79 3.92 Power input 27 °C D.B. / 19 °C W.B.
  • Page 21: Electric Wiring Diagrams

    6-2. Electric Wiring Diagrams Indoor Unit SAP-KRV96EH SAP-KRV126EH To avoid electrical shock hazard, be sure to WARNING disconnect power before checking, servicing and/or cleaning any electrical parts. EVAPORATOR TERMINAL BASE FLAP MOTOR AC IN AC IN-2 SI-2 SI FLAP FLAP...
  • Page 22 Outdoor Unit SAP-CRV96EH SAP-CRV126EH To avoid electrical shock hazard, be sure to WARNING disconnect power before checking, servicing and/or cleaning any electrical parts. NOISE FILTER ACIN1 OUT1 ACIN2 OUT2 SICOM AC250V CONTROLLER TERMINAL PLATE FERRITE CORE (WHT) (WHT) FMC FM0 FM1 T-RUN/TEST COIL/COMP 1 2 3...
  • Page 23: Installation Instructions

    7. INSTALLATION INSTRUCTIONS 7-1. Installation Site Selection 7-1-1. Indoor Unit To prevent abnormal heat WARNING generation and the possibility of fire, do not place obstacles, 15 cm min. 5 cm enclosures and grilles in front 5 cm min. min. of or surrounding the air conditioner in a way that may block air flow.
  • Page 24 7-1-2. Outdoor Unit Exhaust fan AVOID: Hot air Heat source heat sources, exhaust fans, etc. (Fig. 4) damp, humid or uneven locations. Outdoor unit position the outdoor unit in a protected location where snow will not blow into it. choose a place as cool as possible. Fig.
  • Page 25: Recommended Wire Length And Diameter

    7-2. 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 diameters for power supply systems. NOTE Refer to the wiring system diagram (Fig.
  • Page 26: Remote Control Unit Installation Position

    7-3. 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...
  • Page 27: How To Test Run The Air Conditioner

    7-4. How to Test Run the Air Conditioner After turning on power to the air conditioner, use the remote controller and follow the steps below to conduct the test run. (1) Set the remote controller in Test Run mode. (Fig. 8a) a) Press and hold the QUIET button.
  • Page 28: Removing And Installing The Grille

    Front panel 7-5. Removing and Installing the Grille Basically, these models can be installed and wired without removing the grille. If access to any internal part is needed, follow the steps as given below. How to remove the grille (1) Open the front panel until it is nearly horizontal, Fig.
  • Page 29: Maintenance

    8. MAINTENANCE 8-1. Address Setting of the Remote Control Unit The address can be set in order to prevent interference between remote controllers when two indoor units are installed near each other. The address is normally set to "A." To set a different address, it is necessary to change the address on the Fig.
  • Page 30: Disconnecting And Connecting Positive Connector For Outdoor Unit

    8-2. Disconnecting and Connecting Positive Connector for Outdoor Unit One of the two types of connectors illustrated at left is used. Their basic structure is the same for each. How to Disconnect Hold the resin connector cover, and pull the connector off. You cannot disconnect the connector by pulling the wire since it is locked inside.
  • Page 31: Functions

    9. FUNCTIONS 9-1. Operation Functions Emergency operation SENSOR DRY Emergency operation is available when the remote During DRY operation, the system adjusts the room temperature and fan speed according to the conditions in the controller malfunctions, has been lost, or otherwise room, in order to maintain a comfortable room environment.
  • Page 32: Night Setback

    HIGH POWER NIGHT SETBACK This function acts to raise the power but keeps the AC system in • When NIGHT SETBACK operation is set, the temperature and the same operating mode. fan speed settings will be adjusted automatically to allow This function is set with the HIGH POWER button on the remote comfortable sleep.
  • Page 33: Protective Functions

    9-2. Protective Functions Overload prevention during heating Cold-air prevention during heating During HEAT operation, the temperature of the indoor heat During heating, the fan speed is set to "LL" (very low) or stopped. exchanger is used to control the frequency and lessen the load As the temperature of the indoor heat exchanger rises, the fan on the compressor before the protective device is activated.
  • Page 34: Defrost Detection And Release

    Defrost detection and release CT (Peak current cut-off control) • This function prevents the circuit breaker or fuse from operating Reverse-Cycle Defrosting to open the circuit. This function works when electrical current has increased due to an increase in the cooling / heating load, or to a decrease in the power supply voltage.
  • Page 35: Troubleshooting

    10. TROUBLESHOOTING 10-1. Precautions before Performing Inspection or Repair After checking the self-diagnostics monitor, turn the power OFF before starting inspection or repair. High-capacity electrolytic capacitors are used inside the outdoor unit controller (inverter). They retain an electrical charge (charging voltage DC 310V) even after the power is turned OFF, and some time is required for the charge to dissipate. Be careful not to touch any electrified parts before the controller LED (red) turns OFF.
  • Page 36: Indoor Unit

    (1) Self-diagnostics Lamps INDOOR UNIT (3) LED CLEAN lamp (2) TIMER lamp (1) OPERATION lamp OPERATION button REMOTE (ON/OFF ) CONTROL receiver • Since the indications cover various units, the corresponding parts listed below may not be present in some models..
  • Page 37: Checking The Indoor And Outdoor Units

    (2) If the self-diagnostics function fails to operate • No indicators illuminate and the Check the indoor unit. indoor fan does not rotate. • Check the power voltage. Blown Is the fuse blown? Normal Replace the circuit board or the fuse. Replace the controller.
  • Page 38 (3) How to Identify a Serial Communication Error If the lamps on the main body show the following conditions after the completion of self-diagnosis, a communication error between the indoor unit and outdoor unit might be considered. In such a case, identify the breakdown section by using the following procedure. Refer to "Method of Self-Diagnosis"...
  • Page 39 (3-2) Condition: E12 1. Disconnect the inter-unit wiring on the indoor unit side. 2. Operate the system in TEST RUN mode. Then, five minutes later, perform the self-diagnosis. Condition: E01 What is the self-diagnosis result ? Condition: E12 1. Disconnect the inter-unit wiring on the outdoor An error in the P.
  • Page 40: Noise Malfunction And Electromagnetic Interference

    10-4. Noise Malfunction and Electromagnetic Interference An inverter A/C operates using pulse signal control and high frequencies. Therefore, it is susceptible to the effects of external noise, and is likely to cause electromagnetic interference with nearby wireless devices. A noise filter is installed for ordinary use, preventing these problems. However, depending on the installation conditions, these effects may still occur.
  • Page 41: Checking Electrical Components

    11. CHECKING ELECTRICAL COMPONENTS 11-1. Measurement of Insulation Ground wire Resistance Clip The insulation is in good condition if the resistance exceeds 1M ohm. Probe 11-1-1. Power Supply Cord Insulation Clamp the grounding wire of power cord with the lead tester clip of the insulation resistance tester and measure the Fig.
  • Page 42: Checking Continuity Of Fuse On Pcb Ass'y

    11-2. Checking Continuity of Fuse Fuse on PCB Ass'y Remove the PCB Ass'y from the electrical component box. Then pull out the fuse from the PCB Ass'y. (Fig. 5) Check for continuity using a multimeter as shown in PCB Ass'y Fig.
  • Page 43: Refrigerant R410A: Special Precautions When Servicing Unit

    12. REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN SERVICING UNIT 12-1. Characteristics of New Refrigerant R410A 12-1-1. What is New Refrigerant R410A? R410A is a new refrigerant that contains two types of pseudo-non-azeotropic refrigerant mixture. Its refrigeration capacity and energy efficiency are about the same level as the conventional refrigerant, R22. 12-1-2.
  • Page 44 Tubing precautions Refrigerant R410A is more easily affected by dust or moisture compared with R22, thus be sure to temporarily cover the ends of the tubing with caps or tape prior to installation. Never use 0.7mm-thick copper tubing or tubing which is less than 0.8mm in thickness, since air conditioners with R410A are subject to higher pressure than those using R22 and R407C.
  • Page 45: Tools Specifically For R410A

    12-3. Tools Specifically for R410A For servicing, use the following tools for R410A Tool Distinction Tool Name Gauge manifold Charging hose Gas leak detector Refrigerant cylinder Charging cylinder Refrigerant recovery unit Vacuum pump with anti-reverse flow (*1) Tools specifically for R410A (Solenoid valve-installed type, which prevents oil from flowing back into the unit when the power is off, is recommended.) Vacuum pump (*2)...can be used if the following adapter is attached.
  • Page 46: In Case Of Compressor Malfunction

    12-5. In Case of Compressor Malfunction Should the compressor malfunction, be sure to make the switch to a replacement CAUTION compressor as quickly as possible. Use only the tools indicated exclusively for R410A. See "12-3. Tools Specifically for R410A." 12-5-1. Procedure for Replacing Compressor (1) Recovering refrigerant Any remaining refrigerant inside the unit should not be released to the atmosphere, but recovered using the...
  • Page 47 (5) Recharging Configuration and characteristics of cylinders Be sure to charge the specified amount of Valve refrigerant in liquid state using the service port of the wide tube service valve. The proper amount is listed on the unit's nameplate. When the entire amount cannot be charged all at once, charge gradually while operating the unit in Cooling Operation.
  • Page 48: In Case Refrigerant Is Leaking

    12-6. In Case Refrigerant is Leaking Never attempt to charge additional refrigerant when refrigerant has been leaking CAUTION from the unit. Follow the procedure described below to locate points of leaks and carry out repairs, then recharge the refrigerant. (1) Detecting Leaks Use the detector for R410A to locate refrigerant leak points.
  • Page 49: Charging Additional Refrigerant

    12-7. Charging Additional Refrigerant 12-7-1. When Tubes are Extended Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came with the indoor unit. Charge additional refrigerant in liquid state only. Never charge additional refrigerant if refrigerant is leaking from the unit. Follow CAUTION instructions given in "12-6.
  • Page 50: Appendix

    APPENDIX INSTRUCTION MANUAL SAP-KRV96EH + SAP-CRV96EH SAP-KRV126EH + SAP-CRV126EH (OI-852-6-4181-002-00-0)
  • Page 51 FEATURES This air conditioner is an inverter type unit that automatically adjusts capability as appropriate. Details on these functions are provided below; refer to these descriptions when using the air conditioner. • Microprocessor Controlled Operation • Hot Start Heating System The interior compartment of the remote control unit Right from the start, the air is warm and comfortable.
  • Page 52: Product Information

    PRODUCT INFORMATION ELECTRICAL REQUIREMENTS If you have problems or questions concerning your Air Conditioner, you will need the following information. 1. All wiring must conform to the local electrical codes. Model and serial numbers are on the nameplate on the Consult your dealer or a qualified electrician for bottom of the cabinet.
  • Page 53: Names Of Parts

    NAMES OF PARTS UNIT DISPLAY AND OPERATION BUTTON Air intakes INDOOR UNIT INDOOR UNIT LED CLEAN lamp TIMER lamp OPERATION lamp Air outlet Remote control unit OPERATION button REMOTE (ON/OFF ) CONTROL receiver Drain hose Refrigerant tubes IMPORTANT Avoid using radio equipment such as mobile phone near OUTDOOR UNIT (within 1 m) the remote control receiver.
  • Page 54: Remote Control Unit (Display)

    REMOTE CONTROL UNIT (DISPLAY) Displayed when transmitting data Displayed when indoor unit sensor is in use Displayed when setting temperature Displayed when temperature is shown Displayed when setting timer Displayed when the time display is set to 12-hour time. Symbols (1) Operation mode (4) Timer AUTO ........
  • Page 55: Remote Control Unit

    REMOTE CONTROL UNIT Transmitter When you press the buttons on the remote control unit, the mark appears in the display to transmit the setting changes to the receiver in the air conditioner. Display Information on the operating conditions is displayed while the remote control unit is switched on.
  • Page 56 Sensor A temperature sensor inside the remote control unit senses the room temperature. ON/OFF operation button This button is for turning the air conditioner on and off. 1 HR. TIMER button (1-HOUR OFF TIMER) : When you press this button, regardless of whether the unit is operating or stopping, the unit operates for one hour and then shuts down.
  • Page 57: Using The Remote Control Unit

    USING THE REMOTE CONTROL UNIT HOW TO INSTALL BATTERIES REMOTE CONTROL UNIT INSTALLATION POSITION The remote control unit may be operated either from a non-fixed position or from a wall-mounted position. To ensure that the air conditioner operates correctly, DO NOT install the remote control unit in the following places: DO NOT •...
  • Page 58: Operation With The Remote Control Unit

    OPERATION WITH THE REMOTE CONTROL UNIT 1. Automatic Operation 2. Manual Operation This unit automatically switches between cooling operation and heating operation according to the difference between the room temperature and the temperature setting. STEP 2 STEP 3 STEP 2 STEP 1 STEP 4 STEP 5...
  • Page 59: Adjusting The Fan Speed

    3. Adjusting the Fan Speed A. In Cooling and DRY Mode: ( A. Automatic fan speed When the night setback mode is selected, the air conditioner Simply set the FAN SPEED selector button to the automatically raises the temperature setting 1 °C when 30 minutes have passed after the selection was made, and then position.
  • Page 60: High Power Mode

    7. HIGH POWER Mode NOTE • Pressing the MODE selector button cancels LED CLEAN mode. • Do not open the front panel while the LED CLEAN lamp on the display is on. • Depending on the room brightness, light from the LED CLEAN lamp may reflect inside the air conditioner and be visible.
  • Page 61: Setting The Timer

    SETTING THE TIMER 3. How to set the ON time (Example) To start operation at 7:10 am. Operation Indication Press the ON TIME setting The timer indication is button once. displayed, and the present ON NOTE time is shown. In the descriptions below, the following settings are used for the Press the Advance, Return The timer indication...
  • Page 62: Using The 1-Hour Off Timer

    USING THE 1-HOUR OFF TIMER 1. 1-Hour OFF Timer CAUTION When the humidity is high, the vertical vanes should be in the front position during the cooling or dehumidifying operation. If the vertical vanes are positioned all of the way to the right or left, condensation may begin to form around the air vent and drip down.
  • Page 63: Operation Without The Remote Control Unit

    OPERATION WITHOUT THE Anti-Mold Filter The anti-mold filter behind the front panel should be checked and REMOTE CONTROL UNIT cleaned at least once every two weeks. How to remove the anti-mold filter INDOOR UNIT Open the front panel until it is nearly horizontal, grasp the sections near the front panel arms on both sides, and then pull forward to remove the front panel.
  • Page 64: Troubleshooting

    Air Clean Filter Trouble Possible Cause Remedy The air clean filter removes dust and dirt from the air, and reduces odors and smoke from tobacco. Air conditioner does 1. Power failure. 1. Restore power. not run at all. This air clean filter cannot remove 2.
  • Page 65 SANYO Electric co., Ltd. Osaka, Japan Sep. / 2007 Printed in Japan (T)

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Sap-crv96ehSap-krv126ehSap-crv126eh