Sanyo SAP-CMRV3143GJ Technical & Service Manual

TECHNICAL & SERVICE MANUAL

OUTDOOR UNIT: SAP-CMRV3143GJ

DC INVERTER MULTI-SYSTEM AIR CONDITIONER

SAP-CMRV3143GJ

Destination: General area (50Hz)

Europe (50Hz)
Australia (50Hz)
General area (60Hz)

Indoor Model No. Product Code No.

SAP-CMRV3143GJ-C 1 852 084 47

REVISION NO. SM700544-01

IMPORTANT

These air conditioners employ new
refrigerant R410A.

Pay special attention when
servicing the unit.

4-room multi Outdoor unit

< Combined Indoor Units >

1. How these units may be combined is given in
the Unit Combination Tables in the Appendix.

2. Be sure to operate the air conditioning
system only when 2 or more indoor units
have been installed. If operated with only a
single unit installed, the returning fluid to the
compressor may cause a malfunction.

NOTE

●Concealed duct type
SAP-DMRV93GJ
SAP-DMRV123GJ
SAP-DMRV183GJ
SAP-DMRV243GJ

●Wall mounted type
SAP-KMRV93GJ
SAP-KMRV123GJ
SAP-KMRV183GJ
SAP-KMRV243GJ

Capacity

9.0 kW

W

Revised Edition

NOV.2003

i

Important!
Please Read Before Starting

This air conditioning system meets strict safety and
operating standards. As the installer or service person,
it is an important part of your job to install or service the
system so it operates safely and efficiently.

For safe installation and trouble-free operation, you
must:

●Carefully read this instruction booklet before
beginning.

●Follow each installation or repair step exactly as
shown.

●Observe all local, state, and national electrical codes.

●Pay close attention to all warning and caution notices

given in this manual.

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

This symbol refers to a hazard or
unsafe practice which can result
in personal injury or product or
property damage.

If Necessary, Get Help

These instructions are all you need for most installation
sites and maintenance conditions. If you require help
for a special problem, contact our sales/service outlet
or your certified dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for
improper installation or maintenance service, including
failure to follow the instructions in this document.

Special Precautions

When Wiring

ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR
DEATH. ONLY A QUALIFIED,
EXPERIENCED ELECTRICIAN SHOULD
ATTEMPT TO WIRE THIS SYSTEM.

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

• Highly dangerous electrical voltages are used in this
system. Carefully refer to the wiring diagram and
these instructions when wiring. Improper connections
and inadequate grounding can cause accidental
injury or death.

• Ground the unit following local electrical codes.

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

WARNING

CAUTION

WARNING

When Transporting

Be careful when picking up and moving the indoor and
outdoor units. Get a partner to help, and bend your
knees when lifting to reduce strain on your back. Sharp
edges or thin aluminum fins on the air conditioner can
cut your fingers.

When Installing…

…In a Ceiling or Wall

Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.

…In a Room

Properly insulate any tubing run inside a room to
prevent “sweating” that can cause dripping and water
damage to walls and floors.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to
provide a solid, level foundation for the outdoor unit.
This prevents water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.

…In a Snowy Area (for Heat Pump-type Systems)

Install the outdoor unit on a raised platform that is
higher than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

• Use the flare method for connecting tubing.

• Apply refrigerant lubricant to the matching surfaces
of the flare and union tubes before connecting them,
then tighten the nut with a torque wrench for a leak­free connection.

• Check carefully for leaks before starting the test run.

When Servicing

• Turn the power off at the main power box (mains)
before opening the unit to check or repair electrical
parts and wiring.

• Keep your fingers and clothing away from any
moving parts.

• Clean up the site after you finish, remembering to
check that no metal scraps or bits of wiring have
been left inside the unit being serviced.

Others

• Ventilate any enclosed areas when installing or
testing the refrigeration system. Escaped refrigerant
gas, on contact with fire or heat, can produce
dangerously toxic gas.

• Confirm upon completing installation that no
refrigerant gas is leaking. If escaped gas comes in
contact with a stove, gas water heater, electric room
heater or other heat source, it can produce
dangerously toxic gas.

• Do not install only on a single indoor unit.

CAUTION

Table of Contents

Page

1. OPERATING RANGE ............................................................................................................................... 1

2. SPECIFICATIONS

2-1. Unit Specifications.......................................................................................................................... 2

2-2. Major Component Specifications.................................................................................................... 3

2-3. Other Component Specifications.................................................................................................... 4

3. DIMENSIONAL DATA............................................................................................................................... 5

4. REFRIGERANT FLOW DIAGRAM .......................................................................................................... 6

5. PERFORMANCE DATA

5-1. Performance Charts ...................................................................................................................... 7

6. ELECTRICAL DATA

6-1. Electric Wiring Diagram.................................................................................................................. 9

7. INSTALLATION INSTRUCTIONS

7-1. Indoor Unit...................................................................................................................................... 10

7-2. Outdoor Unit................................................................................................................................... 12

7-3. Diagram of Outdoor Unit Installation .............................................................................................. 13

7-4. Recommended Wire Length and Diameter.................................................................................... 14

7-5. Wiring System Diagram.................................................................................................................. 14

8. FUNCTIONS

8-1. Current Control .............................................................................................................................. 15

8-2. Low Start Current .......................................................................................................................... 15

8-3. Compressor Temperature Control ................................................................................................. 15

8-4. Outdoor Fan Control ...................................................................................................................... 15

9. TROUBLESHOOTING

9-1. Outdoor Unit Trouble Diagnostics ................................................................................................. 17

9-2. Checking the Outdoor System ....................................................................................................... 18

9-3. Unit Problems and Inspection Points ............................................................................................. 19

9-4. Explanation of Functions ............................................................................................................... 22

10.REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN SERVICING UNIT

10-1. Characteristics of New Refrigerant R410A..................................................................................... 25

10-2. Checklist Before Servicing.............................................................................................................. 25

10-3. Tools Specifically for R410A .......................................................................................................... 27

10-4. Tubing Installation Procedures ...................................................................................................... 27

10-5. In Case of Compressor Malfunction .............................................................................................. 28

10-6. In Case Refrigerant is Leaking....................................................................................................... 30

10-7. Charging Additional Refrigerant .................................................................................................... 32

10-8. Retro-Fitting Existing Systems ....................................................................................................... 32

.................................................................................................................................................. 33

APPENDIX

ii

1

1. OPERATING RANGE

Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp.

Cooling

Maximum 32°C DB / 23°C W.B. 43°C D.B.

Minimum 19°C DB / 14°C W.B. 19°C D.B.

2

2. SPECIFICATIONS

2-1. Unit Specifications

Outdoor Unit SAP–CMRV3143GJ

Type 4-room multi outdoor unit
Number of connectable indoor units 4

Maximum capacity of connected indoor u

kW 15.4

Maximum capacity of operating indoor units kW 15.4
Power Source 220–240V ~ 50Hz 220V ~ 60Hz
Voltage rating 230 V 220 V
Performance Cooling Cooling

Capacity kW 9.0 (1.2 - 10.5) 9.0 (1.2 - 10.5)

BTU/h 30,700 30,700

Air circulation (High)

m3/h

2,800 2,800

Electrical Rating Cooling Cooling

Available voltage range V 198 ~ 264 198 ~ 242
Running amperes A 8.8 (Max.15.5) 8.8 (Max.15.5)
Power input W 1,940 1,940
Power factor % 96 96
C.O.P. W/W 4.64 4.64
Starting amperes A 12.7 12.7

Features

Controls Microprocessor
Fan speeds Auto (Hi, Lo)
Compressor Twin Rotary (DC inverter)
Refrigerant / Amount charged at shipment g R410A / 4,000
Refrigerant control Electric Expansion Valve
Operation sound Hi dB-A 53 53
Refrigerant tubing connections Flare type
Max. allowable tubing length per unit m 30
Refrigerant Narrow tube mm (in.)

6.35(1/4) × 4

tube diameter Wide tube mm (in.)

9.52(3/8) × 3

mm (in.)

12.7(1/2) × 1

Dimensions & Weight

Unit dimensions Height mm 880

Width mm 940
Depth mm 340

Package dimensions Height mm 981

Width mm 1,016
Depth mm 440

Weight Net kg 90

Shipping kg 92

Shipping volume

m

3

0.439

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

2. Rating conditions are:
Cooling : Indoor air temperature 27°C D.B. / 19° C W.B.
Outdoor air temperature 35°C D.B. / 24°C W.B.

Remarks:

1. The value shown in performance section and electrical rating section above are based on the following unit
combination. For other combination of indoor units, please refer to the "Unit Combination Table" in this manual.

Indoor unts: SAP-KMRV93GJ 4 units
(Outdoor unit: SAP-CMRV3143GJ 1 unit )

3

2-2. Major Component Specifications

2-2-1. Outdoor Unit

Outdoor Unit SAP–CMRV3143GJ

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

Control PCB / HIC PCB / Filter PCB POW-CM5A1-C-T / CR-HIC50A2-C-T / POW-CM5B1-C-T

Compressor

Type DC Twin Rotary (Hermetic)
Compressor model C-9RVN273H0W 80867080
Compressor oil … Amount cc FVC68S … 1900
Coil resistance (Ambient temp. 25°C) Ω R – S: 0.169

S – T: 0.169
T – R: 0.169

Safety devices

CT (Peak current cut-off control) YES
Compressor discharge temp. control YES
Operation cut-off control in abnormal ambient temp. —

Run capacitor µF —

VAC —

Crankcase heater —

Fan & Fan Motor

Type Propeller
Q’ty … Dia. mm 1 … ø460
Fan motor model … Q’ty KFC6S-61C3PA-C … 1
No. of poles … rpm (220V, High) 6 … 712
Nominal output W 60
Coil resistance (Ambient temp. 20°C) Ω BRN – WHT: 66.53

WHT – YEL: 33.95
YEL – PNK: 12.50

Safety devices Type Thermal protector

Operating temp. Open °C 130 ± 8

Close °C 79 ± 15

Run capacitor µF 5

VAC 440

Heat Exchanger Coil

Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.4
Face area m

2

0.630

External Finish Acrylic baked-on enamel finish

2-3. Other Component Specifications

4

Outdoor Unit SAP–CMRV3143GJ

0

0 102030405060708090

40

60

80

100

120

140

160

180

200

20

Temperature (°C)

• Compressor temp sensor

• Outdoor air temp sensor

• Narrow tube sensor

• Wide tube sensor

40
35
30
25
20
15
10

5
0

|20|15|10|

50 5 101520

Temperature (°C)

Resistance (Ω)

Resistance (Ω)

5

3. DIMENSIONAL DATA

Outdoor Unit SAP–CMRV3143GJ

18

880

940

33.7

Wide tube service
valve ø9.52 (3/8")

Wide tube service
valve ø12.7 (1/2")

Narrow tube service
valve ø6.35 (1/4")

336

256

416

176

25

13

380

AIR DISCHARGE

25

13

465 Unit: mm

25

25

10

405

1313

660

109

Drain hole

AIR INTAKE

296

340

AIR INTAKE

15

4. REFRIGERANT FLOW DIAGRAM

6

Outdoor Unit SAP–CMRV3143GJ

4-Room Multi-Refrigerant Tubing System Diagram

Unit: mm

Service valve on
wide tube side

Service valve on
narrow tube side

Strainer

Electric expansion
valve

Electric
expansion
valve

Receiver tank

Indoor unit

When cooling

Outdoor heat
exchanger

Main accumulator

Compressor

Muffler

Muffler

Sub-accumulator

Insulation of Refrigerant Tubing

Because capillary tubing is used in the outdoor unit, both the
wide and narrow tubes of this air conditioner become cold. To
prevent heat loss and wet floors due to dripping of
condensation, both tubes must be well insulated with a
proper insulation material. The thickness of the insulation
should be a min. 8 mm.

After a tube has been insulated,
never try to bend it into a narrow
curve because it can cause the tube
to break or crack.

IMPORTANT

CAUTION

Wide tube

Thickness:
Min. 8 mm

Insulation

Narrow tube

Thickness:
Min. 8 mm

7

5. PERFORMANCE DATA

5-1. Performance charts

25

8

7

6

5

30 35 40

25

20
18
16
14
12
10

30 35 40

25 30 35 40

1.3

1.2

1.1

1.0

27

°C

24°C

Indoor air temp.30°C

Indoor air temp.30°C

27

°C

24°C

Indoor air temp.30°C

27

°C

24°C

Lo fan Hi fan

Lo fan Hi fan

Lo fan Hi fan

• Cooling Characteristics

(1) Low pressure performance chart
(RH: 46%, Indoor fan speed: High fan)

(2) Operating current performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

(50/60Hz, 220V)

(3) Indoor discharge air performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

Operating current (A) Low pressure (MPa)

Indoor discharge air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

Outdoor Unit SAP–CMRV3143GJ
Indoor Unit SAP–KMRV93GJ ××1

25

8

7

6

5

30 35 40

25

20
18
16
14
12
10

30 35 40

25 30 35 40

1.2

1.1

1.0

0.9

27

°C

24°C

Indoor air temp.30°C

Indoor air temp.30°C

27

°C

24°C

Indoor air temp.30°C

27

°C

24°C

Lo fan Hi fan

Lo fan Hi fan

Lo fan Hi fan

• Cooling Characteristics

(1) Low pressure performance chart
(RH: 46%, Indoor fan speed: High fan)

(2) Operating current performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

(50/60Hz, 220V)

(3) Indoor discharge air performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

Operating current (A) Low pressure (MPa)

Indoor discharge air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

Outdoor Unit SAP–CMRV3143GJ
Indoor Unit SAP–KMRV123GJ ××1

NOTE

• This performance chart shows operation of a single wall-mounted indoor unit. The performance chart will vary depending on the indoor unit type.

• Check each performance value in test-run mode. Electrical performance values represent a combined indoor/outdoor value.(In this case, be sure to
stop all the indoor units where performance is not being checked.)

• The performance is for a tubing length of 7.5 m. If the tubing length is different, the performance chart will vary.

8

25

10

9

8

7

30 35 40

25

10

12

14

16

18

20

30 35 40

25

1.2

1.1

1.0

0.9
30 35 40

27

°C

24°C

24°C

Indoor air temp.30°C

Indoor air temp.30°C

27

°C

27

°C

Indoor air temp.30°C

24°C

Lo fan Hi fan

Lo fan Hi fan

Lo fan Hi fan

• Cooling Characteristics

(1) Low pressure performance chart
(RH: 46%, Indoor fan speed: High fan)

(2) Operating current performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

(50/60Hz, 220V)

(3) Indoor discharge air performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

Operating current (A) Low pressure (MPa)

Indoor discharge air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

Outdoor Unit SAP–CMRV3143GJ
Indoor Unit SAP–KMRV183GJ ××1

25

10

12

14

16

18

20

30 35 40

25

1.2

1.1

1.0

0.9
30 35 40

27

°C

24°C

Indoor air temp.30°C

27

°C

Indoor air temp.30°C

24°C

Lo fan Hi fan

Lo fan Hi fan

• Cooling Characteristics

(1) Low pressure performance chart
(RH: 46%, Indoor fan speed: High fan)

(2) Operating current performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

(3) Indoor discharge air performance chart
(RH: 46%, Indoor fan speed: High fan)

(50/60Hz, 220V)

Low pressure (MPa)

Indoor discharge air temperature (°C)

Outdoor air temperature (°C)

Outdoor air temperature (°C)

25 30 35 40

11

10

9

8

24°C

Indoor air temp.30°C

27

°C

Lo fan Hi fan

(50/60Hz, 220V)

Operating current (A)

Outdoor air temperature (°C)

Outdoor Unit SAP–CMRV3143GJ
Indoor Unit SAP–KMRV243GJ ××1

NOTE

• This performance chart shows operation of a single wall-mounted indoor unit. The performance chart will vary depending on the indoor unit type.

• Check each performance value in test-run mode. Electrical performance values represent a combined indoor/outdoor value.(In this case, be sure to
stop all the indoor units where performance is not being checked.)

• The performance is for a tubing length of 7.5 m. If the tubing length is different, the performance chart will vary.

9

6. ELECTRICAL DATA

6-1. Electric Wiring Diagram

Outdoor Unit SAP–CMRV3143GJ

CAUTION

WHT

YEL

YEL

YEL

YEL

YEL
YEL

BLK

WHT

BLK
BLK
BLK

BLK

BLK
BLK

BLK

YEL
YEL

WHT

BLK
BLK
BLK
BLK
BLK

BLK

BLK
BLK

BLK

WHT

BLK
BLK
BLK
BLK
BLK

BLK

BLK
BLK

BLK

WHT

BLK

YEL

PNK

WHT

YEL
BLU

WHT

WHT

(WHT)

PRY

(WHT)

CT

L1 L2

(WHT)

PAM

WHT

WHT

BLK

BLK

BLK

BLK

BLK

BLK
BLK
BLK
BLK

RED

WHT

FERRITE CORE

WHT

WHT

THERMISTOR(ROOM D WIDE PIPE)

THERMISTOR(ROOM D NARROW PIPE)

THERMISTOR(ROOM C NARROW PIPE)

THERMISTOR(ROOM C WIDE PIPE)

WHT

RED

U V W

GRN/YEL

BLU

EARTH

UNIT D

INDOOR

UNIT C

INDOOR

UNIT B

INDOOR

WHT

GRN/YEL GRN/YEL GRN/YEL GRN/YEL

GRN/YEL

WHT

BLK

BLK

BLK

BLK

BLK

BASE(16P)

TERMINAL

TRANSISTOR

DIODE

BRIDGE DIODE

MECHANICAL VALVE

THERMISTOR(ROOM B NARROW PIPE)

THERMISTOR(ROOM B WIDE PIPE)

CONTROL PCB

UNIT A

INDOOR

YEL

GRY

WHT

BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK

BLK
BLK

FILTER PCB

HS

CM

ORG

31 5 7 9

BRN

TERMINAL BASE(3P)

1

AC220V

240V

AC200-L2

TH11
TH10

BLK

YEL
YEL

BLK

4321

TH9
TH8

YEL
YEL

YEL

4321

TH7
TH6

YEL
YEL

YEL

4321

TH5
TH4

TH2
TH1

WHT

6

ORG

BLU

BRN

YEL

RED

1 54326

1 2 3 4 1 2 1 2 1 33 45 6 7 8 9

10

7 8

1110

RED

BLU

ORG

WHT

YEL

BRN

1

C0

3

GRY

+

MC01

MC02

ORG

GRY

6

TH3

1

31 21 54 7621

31 21 54 7621

WHT

HIC PCB

YEL

BLU

BRN

YEL

YEL

RED

WHT

YEL

YEL

+

54321

CN37

MVA

MVAMMV MVB MVC MVD

BRN

RED

YEL

ORG

BLU

6

WHT

(BLK)

BRN

WHT

RE1 RE2

RE1 RE2

D

TR

BD

6

ORG

RED

4

FMO

321

YEL

BLU

WHT

BRN

GRY

GRN/YEL

BLK

1 3 1 5 73 1 2 3 4 5 1 2 3 4 1 2

GRY

WHT

31 5

AC200-L1G1 G2

DC280-

DC280+

1 2 3 4 55432

SOLDERED TERMINAL

TERMINAL

TERMINAL BASE

CONNECTOR

THERMISTOR(ROOM A WIDE PIPE)

THERMISTOR(ROOM A NARROW PIPE)

THERMISTOR(COMPRESSOR TEMP)

THERMISTOR(OUTDOOR TEMP)

THERMISTOR(HEAT EXCHANGER)

BOARD-IN-WIRE

HEAT SINK

REACTOR

MAIN MOTOR OPERATED VALVE

FAN MOTOR

COMPRESSOR MOTOR

OPERATION CONDENSER

TH3

TH4

TH5

TH6

TH7

TH8

TH9

TH10

TH11

TH2

TH1

BDCMC0DFC1

,

2

FM0HSMMV

MVA MVD

RE1

,

2

TR

DESCRIPTION

SYMBOLS

ELECTRIC WIRING DIAGRAM

1 2 3 4 1 2 1 23 45 6 7 8 9

10

7 8

1110

49C

CN31

(BLU)

HIC3

CN18

(WHT)

HIC2

CN30

(WHT)

(WHT)

CN02

HIC2

(WHT)

CN03

HIC3

(WHT)

CN01

HIC1

HIC

+

HIC

-

FC2

HIC

+

HIC

-

HIC1

CN34

(WHT)

PAM

CN23

(WHT)

CT

CN08

(WHT)

PRY

CN21

(RED)

DC280

CN01

(WHT)

AC200

CN29

(RED)

SI

CN35

(WHT)

(RED)

CN38

MNB

(WHT)

CN36

MMV

(WHT)

CN09

FM0

(WHT)

CN16

FM0TH

(BLU)

CN39

MVC

(YEL)

CN40

MVD

(EHT)

CN13

COIL/GAIKI

(BLK)

CN19

COMP

(BLK)

CN24

ATH

(RED)

CN22

BTH

(BLU)

CN20

CTH

(YEL)

CN25

DTH

+

+

W

W

W

1 2 4 1 2 4 1 2 4 1 2

1 2

4

1 2 31 2 31 2 31 2 3

++

GRN/YEL

GRN/YEL

WWWWW

WW

W

854-2-5269-182-00-2

MULTIPLE INDOOR UNITS

COOLING ONLY OUTDOOR UNIT FOR FOUR-ROOM

Electric Wiring Diagram for 4-room multi outdoor unit (CMRV3143GJ)

Before replacing PCBs, turn off the power and check that all
lamps on the PCB are off before starting work. Electric shock
will occur if work is performed while the lamps are lit.

Electric Shock