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Related Manuals for Sanyo W MULTI SGP-EW120M2G2W
Summary of Contents for Sanyo W MULTI SGP-EW120M2G2W
- Page 1 Gas Heat Pump Air Conditioner Periodic Inspections, Periodic Parts Replacement Manual March 2008 Applicable Models W MULTI SGP-EW120M2G2W SGP-EW150M2G2W SGP-EW190M2G2W SGP-EW240M2G2W 3WAY MULTI SGP-EZ150M2G2 SGP-EZ190M2G2 SGP-EZ240M2G2 SANYO Electric Co., Ltd. Reference No.SM7110012...
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Page 2: Table Of Contents
CONTENTS 1. Periodic Inspections, Periodic Parts Replacement Work (1) Gas Heat Pump Air Conditioner ................I-1 (2) Periodic Inspections and Their Scheduling j W arranty Period ...................... I-1 k I nspection Menu for Periodic Inspection Contract ..........I-1 l M iscellaneous ......................I-1 (3) Outdoor main board switch and LED arrangement diagram ........ -
Page 3: Periodic Inspections, Periodic Parts Replacement Work (1) Gas Heat Pump Air Conditioner
Note 1: “ Periodic inspection” refers to 1 entire inspection of the items marked with in the table, including replacement of periodically replaceable parts. This inspection will be performed at either 10,000 hours of operation or at 5 years, whichever comes first. Note 2: T he periodic inspection contract is renewable as long as the parts necessary to use the equipment are available. In this case, however, if parts that are not periodically replaceable parts must be replaced, the cost of those parts and the expense of replacement will be charged separately. Note 3: W hen the hours of operation reach 30,000 hours, Sanyo will arrange for “refresh maintenance.” This may be re- peated for up to 13 years (if 13 years are exceeded, the equipment is replaced). Furthermore, a periodic inspection is required either 10,000 hours of operation or 5 years after “refresh maintenance,” whichever comes first. For details, contact the person responsible for inspecting the equipment. l Miscellaneous Indoor and outdoor heat exchanger cleaning is generally required once every 3 - 4 years. However, this varies ac- cording to the level of contamination, type of industry, and installation conditions. If foreign matter or dust adheres to indoor or outdoor heat exchanger fins, it will degrade performance and cause malfunctions. Cleaning must be performed to ensure proper use of the air conditioner. Cleaning costs are estimated separately. -
Page 4: Outdoor Main Board Switch And Led Arrangement Diagram
(3) Outdoor main board switch and LED arrangement diagram Name Name Terminating resistance ON/OFF switch (S010) CN075 STOP SW (S001) EEPROM Indoor/outdoor communication monitor (D043) CN037 (white) Fuel gas solenoid valve force close switch (S002) CN049 (red) Compressor outlet/inlet pressure sensors PS1: Inlet, PS2: outlet SET key (S007) DOWN key (S006) CN029 (blue) UP key (S005) CN014 (blue) LEVEL LED (D053) CN016 (black) TEST/WARNING LED (D052) CN062 (green) Hot water outlet temperature HOME key (S004) CN060 (blue) Clutch coil temperature CN015 (white) CN058 (white) Coolant temperature CN063 (yellow) CN059 (black) Outdoor air temperature CN012 (red) CN055 (blue) Heat exchanger inlet temperature CN011 (black) CN064 (yellow) Clutch 2 coil temperature CN010 (white) CN053 (black) Compressor inlet temperature CN006 (black) CN054 (red) Compressor outlet temperature... -
Page 5: B Ackup Operation During Maintenance Work (For W Multi
(4) Basic Operations for Periodic Inspection Work All work other than when the STOP (all stop) switch (S001) is set to STOP and the VG (fuel solenoid valve forced off switch) switch (S002) is set to OFF should be performed with the HOME (S004), SET (S007), UP (S005), and DOWN (S006) keys. It is extremely dangerous if the customer performs an operation that runs the engine during a maintenance inspection or when not expected. Make sure you stop operation during work in the way described below. * Pressing the HOME (S004) key for 1 second or more forcefully returns the state to the initial state. The value of a partially set item will be discarded, and the item number will return to “ .” * If there is no operation for 10 minutes when other than the “... -
Page 6: Engine Stop
[Work example] Perform maintenance on W MULTI outdoor unit 2 in refrigerant system 1. Refrigerant system 1 a) F or the W MULTI outdoor unit 2 indicated in the left diagram, perform « Step 1 » to « Step 3 » in [Backup operation procedure] in that order. Then, perform maintenance work on W MULTI outdoor unit 2. Refrigerant tube (outdoor branch tube) b) W hen « Step 3 » is finished, W MULTI outdoor unit 1 is reset. (It'll stop Balance tube even if it is operating.) c) A fter approximately five minutes, if there is operation input (indoor W MULTI W MULTI remote controller is "Run" or test run setting on outdoor main board), W outdoor outdoor unit 1 unit 2 MULTI outdoor unit 1 starts up. (Backup operation starts.) d) I f test run is set from outdoor main board, W MULTI outdoor unit 1 continues to run. However, if normal operation is started by the indoor... -
Page 7: Engine Oil Use Time Reset Method
m Engine Oil Use Time Reset Method Make sure to perform this procedure after checking (re- plenishing, changing) the engine oil. 1) P ress the HOME (S004) key for one second or more. The menu display will show item number “ ” 2) N ext, press the UP (S005) and DOWN (S006) key, Oil use time (10,100 hours) displaying the menu item numbers. Go to menu item “o” is displayed, indicating oil use time “ ” 3) A fter menu item number “ ” appears, the oil use time will be displayed. Press the SET (S007) key. Figure 3 4) W hen the SET (S007) key is pressed with the oil use time displayed (Figure 3), the next display appears. By... -
Page 8: C Oolant Circulation Operation
o C oolant Circulation Operation This operation forcibly drives the coolant pump and the coolant electric three-way valve. It is used for refilling cool- ant and for removing air from the coolant circuit. Note: C heck that the coolant circuit contains some coolant before performing this operation. The pump may be dam- aged if forced operation is started without any coolant. 1) Press the HOME (S004) key for 1 second or more. The menu item number “ ” will be displayed. 2) Next press the UP (S005), DOWN (S006) keys to display menu item number “ ” 3) After “ ” the test run/forced setting display “ ” will appear (Figure 7). Press the SET (S007) key while “ ” is displayed. 4) P ress the SET (S007) key in the forced cooling test Figure 7 run setting mode to select one of the displays shown in... -
Page 9: Forced Rotational Speed Setting Operation
p Forced Rotational Speed Setting Operation This setting is used to forcibly fix the revolution of en- gine when doing test runs. 1) P ress the HOME (S004) key for one second or more. The menu item number “ ” will be dis- played. 2) N ext press the UP (S005) and DOWN (S006) keys to display menu item number “ ” 3) P ress the SET (S007) key while “ ” is dis- played. The forced engine revolution setting display “ ” will appear (Figure 9). Figure 9 4) W hen the SET (S007) key is pressed in this mode, the following displays will cycle in sequence at 1-second intervals. -
Page 10: Periodic Inspection And Periodic Replacement Work Manual
2. Periodic Inspection and Periodic Replacement Work Manual Periodic inspections and replacements are very important for ensuring that users can enjoy long and trouble-free service from Sanyo gas heat pump air conditioners. (1) Engine Oil Replenishment and Oil Filter Replacement... - Page 11 Figure 2 Detaching the oil filter 2) Install the new oil filter a) Apply fresh engine oil thinly and evenly to the O-ring of the new filter (Figure 3). b) D uring oil filter installation, turn the filter two, three or more times after the packing is seated in the engine to tighten it. (See Figure 4.) c) Use a rag to wipe up spilled oil. Figure 3 Applying Sanyo genuine oil For models with a K25 engine Figure 4 oil filter install Caution Tightening torque : 14.7 – 20.6N•m Never use a filter wrench to install the oil filter.
- Page 12 n Change engine oil Replace all oil in the oil pan and the sub tank. ) Prepare the designated amount of oil. Amount of oil for 10,000 hours Oil tank: 43 liters Engine: 3 liters 2) S top the engine after warming up for between 10 and 15 minutes. (Refer to Section 1. (4) “k Stopping the Engine”.) 3) Open the cap of the oil tank (Figure 5). 4) Remove oil using the oil pump. First, insert the pump in the narrow side of the oil tank aper- ture to remove oil from the external tank. Next, insert the pump in the wider side of the oil tank to remove the oil from the internal tank (Figure 6). * Caution: F or the narrow side, a tube of ø16 mm or below is required. Figure 5 5) R emove the caps that are inserted at the ends of the discharge hose (2 in total) attached to the oil tank to remove the re- maining oil in the oil tank (Figure 7). 6) O nce the oil discharge is complete, use a waste cloth to wipe Oil tank Wider side off the old oil from the outlet of the oil drain hose. After this,...
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Page 13: Engine Oil Inspection, Replenishment, Replacement Work List
(2) Engine oil Inspection, Replenishment, Replacement Work List j Engine oil inspection, replenishment and replacement schedule 1) Engine oil replacement interval Year number Hours of operation × (1,000 hours) Maintenance item Periodic inspection (Replace) (Replace) (5 years or 10,000 hours) 2) When delivered there is enough oil for 10,000 hours of operation. 3) Oil replacement are performed every 10,000 operating hours. 4) The amount of oil sufficient for 10,000 operating hours is as follows: Tank location Engine: Oil tank Total Oil Types 120, 150, 190, 240 3 liters 43 liters 46 liters II - 4... -
Page 14: Valve Clearance Adjustment
(3) Valve Clearance Adjustment Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit. - Page 15 3) R emove the engine rocker arm cover from the cylinder head (Figure 3). Figure 3 m Position the first or fourth cylinder at compression top dead center. 1) Remove the ignition coil and sparkplugs for all cylinders. 2) R otate the crankshaft with a socket wrench (ratchet) (Figure 4) until the top mark (orange) on the camshaft pul- ley is aligned with the timing pointer (Figure 5). The cylinders are numbered 1, 2, 3, 4 in sequence from the compressor side. Timing pointer (white) (white) (white) (white) Top mark (orange) Timing indicator details Top mark (orange) Figure 5 Figure 4 Timing mark 3) R otate the intake and discharge side pushrods for the first cylinder with your fingers, checking that they move eas- ily (Figure 6). If they move easily, it means that the first...
- Page 16 5) A fter adjustment 3) and 4), turn the fly- wheel revolution, and again align the top mark (orange) on the camshaft pulley with the timing pointer. If the valves were adjusted first at the first cylinder TDC posi- tion, adjust the remaining valves with the ○ mark in Table 1. If the valves were adjusted discharge inlet inlet discharge discharge inlet inlet discharge first at the fourth cylinder TDC position, adjust the clearance of the remaining valves with the ● mark in Table 1 (Figures 5, 6, 7). Figure 7 Location of each valve n Adjust valve clearances 1) R otate the pushrod with the fingers, and check that the rod moves easily. If it does,...
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Page 17: Sparkplug Replacement
(4) Sparkplug Replacement Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit. - Page 18 m Sparkplug coil bracket Remove the 2 bolts shown in Figure 6, and remove the sparkplug coil bracket. Figure 5 Removing the wire harness plugs Figure 6 Removing the sparkplug coils n Sparkplugs Use a sparkplug wrench (16 mm) to remove the sparkplugs (Figure 7). Figure 7 Removing the sparkplug cover bolts o Installation Install new sparkplugs by following the reverse of the removal procedure (from l to j). Sparkplugs Sparkplug coils bracket : 19.6 - 29.4 N•m Sparkplug coils bracket Sparkplug coils bracket : 15.7 - 17.7 N•m ■ Operation check j Move the STOP SW to “NORMAL.” (Refer to Section 1. (4) “lCanceling Engine Stop.”) k Operate the unit, and perform an engine startup check. l Reinstall the removed unit panel in its original position.
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Page 19: Air Cleaner Element Replacement
(5) Air Cleaner Element Replacement Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit. - Page 20 o Replace Element Slide in the new element as far as it will go. Make sure the seal does not prevent insertion. (Figure 3.) Figure 3 Caution ● This is a dry element. Do not use oil. ● Replace the element earlier in dusty or oily environments. p Fastener attachment Move the fastener on the air cleaner from the left to the right and secure it in the center using a securing screw. (Figure 2.) q Operation check 1) Move the STOP SW to “NORMAL.” (Refer to Section 1. (4) “l Canceling Engine Stop.”)
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Page 21: Coolant Level Check, Replenishment
● Take care that the coolant solution does not enter the eyes or mouth during work. Figure 1 m Preparations The following tools, gauges, and materials are required for doing this work. Prepare them before starting. Name Specification Q’ty Remarks 3-9509-1040 SS Part code: 1743020 Sanyo genuine coolant As needed 826-2-4521-10100 SS Part code: 1743030 Parts, Materials Rags Small q’ty Tools Dispensing container 2 liters... -
Page 22: Compressor Drive Belt Replacement
(7) Compressor Drive Belt Replacement Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit. - Page 23 2) Remove the tube securing bracket (Figures 2 and 3). CAUTION There is also tube-fixing plate on the rear panel side of the unit (Figure 2). Do not forget to remove that plate. Bolts Figure 3 Removing tube fastener Bolts Figure 2 Removing tube fastener (rear side) 3) Turn the tension adjustment bolt (counterclockwise), and raise the bracket. (Figure 4, 19 mm bolt indicated by arrow) Figure 4 Raising bracket 4) Rotate the tension adjustment bolt until the compressor drive belt can be removed, then remove the belt.
- Page 24 n Compression drive belt tension adjustment 1) Install the new compressor drive belt when the bracket m has been raised. 2) L oosen the belt tensioning bolt to adjust belt tension. Press the belt as shown in Figure 5 to prevent it from com- ing off the wheels while loosening the adjusting bolt. Maintain pressure on the belt until the required amount of tension has been obtained. CAUTION Do not grasp the belt as your fingers may then be caught in it. Adjust belt tension by applying pressure to it without grasping it. Be sure to check that there is no slippage at these important...
- Page 25 o Operation check 1) Move the STOP SW to “NORMAL.” (Refer to Section 1. (4) “l Canceling Engine Stop.”) 2) A fter starting the engine, make sure the belt does not slip or make abnormal noises. If the belt does slip or make abnormal noises, readjust the tension. CAUTION If there is belt deflection when you tighten the tension adjustment bolt to adjust the belt tension, the ribs of the belt will be offset from the pulley, which may result in the belt slipping off.
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Page 26: Drain Filter Filling Stone Inspection, Replenishment
(8) Drain Filter Filling Stone Inspection, Replenishment Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit. - Page 27 l Removing the drain filter B 1) R emove the connector of the drain filter heater Securing screw B that is attached to the drain filter. 2) L oosen the securing screw A (4 screws) of the stand upon which the drain filter B is placed. 3) R emove the fastening brackets (in three places) that hold the muffler and the drain filter B to- gether. 4) S lide the drain filter B and the stand downward. Sastening brackets (in three places) 5) T ighten the two foremost securing screws A to secure the stand. Srain filter B 6) R emove the drain filter B from the outdoor unit. Securing screw A Figure 3 Removing the drain filter B m Replenish the drain filter B filling stones Fastener of the oil absorbent mats...
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Page 28: Gas Leak Inspection
(9) Gas Leak Inspection Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit. -
Page 29: Periodic Replacement Parts List
3. Periodic Replacement Parts List III - ... - Page 30 Replacement rank Maintenance kit Part code Part name Q'ty (Replacement time) 638-0-7993 Oil filter 93-96-0565 Air cleaner element 63-94-7664 Spark plugs SGP-MTK560M (0,000 hours or 5 years) 938-08-966 Compressor operation belt 93-00-460 Oil absorbent mat 63-300-8660 Oil absorbent tube 638-0-7993 Oil filter 93-96-0565 Air cleaner element 63-94-7664...
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Page 31: Ghp Periodic Inspection, Periodic Replacement Checklist (Type M2
GHP Periodic Inspection, Periodic Replacement Checklist (Type M2) Delivery Company Destination · ( name · ( Inspection, Replacement Delivery Address Address SGP- M2 (No. Outdoor SGP- SGP- SGP- SGP- · SGP- SGP- SGP- SGP- ... - Page 32 Check items Measurement Conclusion 5. Engine system checks Version update available? □ Yes Version 6. Control program version □ No 7. Operation data collection j Data collection time (Time after starting operation) Min. Note: Operate all indoor units and measure. k Abnormal vibration, noise checks OK/ not Ok Data...