Sanyo SPW-D253G56 Service Manual
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Sanyo SPW-D253G56 Service Manual

Sanyo SPW-D253G56 Service Manual

Split system air conditioner
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SERVICE MANUAL
SPW-D253G56 ⁄ SPW-C253G5 (/M), SPW-C253G8 (/M)
SPW-D273G56 ⁄ SPW-C253G5 (/M)
SPW-D363G56 ⁄ SPW-C363G5 (/M), SPW-C363G8 (/M)
SPW-D483G56 ⁄ SPW-C483G8 (/M)
SPLIT SYSTEM AIR CONDITIONER
INDOOR MODEL No.
SPW-D253G56
SPW-D273G56
SPW-D363G56
SPW-D483G56
NOTE) Models which does not have the alphabet " /M" behind outdoor Model No. comply
with the European regulations.
Indoor Unit
SPW-D253G56
SPW-D273G56
SPW-D363G56
SPW-D483G56
85464849144001
PRODUCT CODE No.
OUTDOOR MODEL No.
854 012 58
SPW-C253G5
SPW-C253G5/M
854 012 64
SPW-C253G8
SPW-C253G8/M
854 012 59
SPW-C363G5
SPW-C363G5/M
SPW-C363G8
SPW-C363G8/M
854 012 60
SPW-C483G8
SPW-C483G8/M
FILE NO.
PRODUCT CODE No.
854 012 22
854 012 65
854 012 23
854 012 68
854 012 25
854 012 66
854 012 26
854 012 70
854 012 27
854 012 67
Outdoor Unit
SPW-C253G5 SPW-C253G5/M
SPW-C253G8 SPW-C253G8/M
0409_C_S
SPW-C363G5 SPW-C363G5/M
SPW-C363G8 SPW-C363G8/M
SPW-C483G8 SPW-C483G8/M
REFERENCE NO.
Section
1
2
3
0408_C_S
4
5
SM
830044

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Summary of Contents for Sanyo SPW-D253G56

  • Page 1 SERVICE MANUAL FILE NO. SPW-D253G56 ⁄ SPW-C253G5 (/M), SPW-C253G8 (/M) SPW-D273G56 ⁄ SPW-C253G5 (/M) SPW-D363G56 ⁄ SPW-C363G5 (/M), SPW-C363G8 (/M) SPW-D483G56 ⁄ SPW-C483G8 (/M) SPLIT SYSTEM AIR CONDITIONER INDOOR MODEL No. PRODUCT CODE No. OUTDOOR MODEL No. PRODUCT CODE No.
  • Page 2 Important IMPORTANT! Please Read Before Starting When Transporting …………………………………………………………………… Be careful when picking up and moving the indoor and This air conditioning system meets strict safety and outdoor units. Get a partner to help, and bend your knees operating standards. As the installer or service person, it when lifting to reduce strain on your back.

  • Page 3: Table Of Contents

    WHO SHOULD USE THIS MANUAL This service manual is made to assist the service technician apply his knowledge and training to this model air conditioner. This manual is written both for experienced service persons and those who are new to air conditioning service. To help those with less experience or who are new to this kind of unit we have included more explanations of basic procedures in simple language than is usual in some service manuals.
  • Page 4 4. SERVICE PROCEDURES ................... 49 Troubleshooting ....................50 A Sensor is Defective ..................61 Operation of Major Electrical Parts ..............61 Checking the Electrical Components ..............62 5. INSTRUCTION MANUAL ................... 67 Wired Remote Controller / RCS-U251G ............68 SM830044 – 4 –...
  • Page 5 Introduction: Read Me First! WHAT IS IN THIS MANUAL This manual will help you understand and service the air conditioner. To help you find the information you need, we have divided it into 5 main sections. Each section is divided into chapters with charts, tables and explanations to help you find and repair problems.
  • Page 6 SM830044 – 6 –...

  • Page 7: Specifications

    1. SPECIFICATIONS Unit Specifications ..................8 Major Component Specifications ..............14 (A) Indoor Unit ....................14 (B) Outdoor Unit ................... 17 Other Component Specifications ..............20 (A) Indoor Unit ....................20 (B) Outdoor Unit ................... 21 Dimensional Data ...................22 (A) Indoor Unit ....................22 (B) Outdoor Unit .....................23 Refrigerant Flow Diagram ................

  • Page 8: Unit Specifications

    1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit SPW-D253G56 Outdoor Unit SPW-C253G5, SPW-C253G5/M POWER SOURCE 220 - 230 - 240 V / 1 Phase / - 50 Hz PERFORMANCE Cooling Capacity BTU / h 25,000 Air circulation (Hi/Me/Lo) m3 / h...
  • Page 9 1. Specifications 1. Specifications 1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit SPW-D273G56 Outdoor Unit SPW-C253G5, SPW-C253G5/M POWER SOURCE 220 - 230 - 240 V / 1 Phase / 50 Hz PERFORMANCE Cooling Capacity 7.85 BTU / h 26,800 Air circulation (Hi/Me/Lo) m3 / h 1,380/1,320/1,260...
  • Page 10 1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit SPW-D363G56 Outdoor Unit SPW-C363G5, SPW-C363G5/M POWER SOURCE 220 - 230 - 240 V / 1 Phase / - 50 Hz PERFORMANCE Cooling Capacity 10.6 BTU / h 36,000 Air circulation (Hi/Me/Lo) m3 / h 1,800/1,680/1,500 Moisture removal(High)
  • Page 11 1. Specifications 1. Specifications 1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit SPW-D253G56 Outdoor Unit SPW-C253G8, SPW-C253G8/M POWER SOURCE 380 - 400 - 415 V / 3 N / 50 Hz PERFORMANCE Cooling Capacity BTU / h 25,000 Air circulation (Hi/Me/Lo)
  • Page 12 1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit SPW-D363G56 Outdoor Unit SPW-C363G8, SPW-C363G8/M POWER SOURCE 380 - 400 - 415 V / 3N / 50 Hz PERFORMANCE Cooling Capacity 10.6 BTU / h 36,000 Air circulation (Hi/Me/Lo) m3 / h 1,800/1,680/1,500 Moisture removal(High) Liters/h...
  • Page 13 1. Specifications 1. Specifications 1. Specifications 1-1 Unit Specifications MODEL No. Indoor Unit SPW-D483G56 Outdoor Unit SPW-C483G8, SPW-C483G8/M POWER SOURCE 380 - 400 - 415 V / 3N / 50 Hz PERFORMANCE Cooling Capacity BTU / h 47,800 Air circulation (Hi/Me/Lo) m3 / h 2,160/2,100/1,980 Moisture removal(High)

  • Page 14: Major Component Specifications

    1. Specifications 1-2 Major Component Specifications (A) Indoor Unit MODEL No. SPW-D253G56 SPW-D273G56 Source 220 - 230 - 240 V / 1 phase / 50 Hz Remote controller (Accessory) RCS - U251G (Microprocessor) Controller P.C.B. Ass’y CR - X363GS (Microprocessor) Fan (Number…diameter)
  • Page 15 1. Specifications 1. Specifications 1. Specifications 1-2 Major Component Specifications (A) Indoor Unit MODEL No. SPW-D363G56 Source 220 - 230 - 240 V / 1 phase / 50 Hz Remote controller (Accessory) RCS - U251G (Microprocessor) Controller P.C.B. Ass’y CR - X363GS (Microprocessor) Fan (Number…diameter) Centrifugal (1 ...
  • Page 16 1. Specifications 1-2 Major Component Specifications (A) Indoor Unit MODEL No. SPW-D483G56 Source 220 - 230 - 240 V / 1 phase / 50 Hz Remote controller (Accessry) RCS - U251G (Microprocessor) Controller P.C.B. Ass’y CR - X363GS (Microprocessor) Fan (Number…diameter) Centrifugal (1 ...

  • Page 17: (B) Outdoor Unit

    1. Specifications 1. Specifications 1. Specifications 1-2 Major Component Specifications (B) Outdoor Unit MODEL No. SPW-C253G5 SPW-C363G5 SPW-C253G5/M SPW-C363G5/M Source 220 - 230 - 240 V / 1 phase / 50 Hz Compressor Rotary (Hermetic) Model ... Code No. C - R221H5V C - R240H5W Nominal output 2,200...
  • Page 18 1. Specifications 1-2 Major Component Specifications (B) Outdoor Unit MODEL No. SPW-C253G8, SPW-C253G8/M Source 380 - 400 - 415 V / 3 phase / 50 Hz Compressor Rotary (Hermetic) Model … Code No. C - R224H8S Nominal output 2,200 Compressor oil 1,350 Ω...
  • Page 19 1. Specifications 1. Specifications 1. Specifications 1-2 Major Component Specifications (B) Outdoor Unit MODEL No. SPW-C363G8 SPW-C483G8 SPW-C363G8/M SPW-C483G8/M Source 380 - 400 - 415 V / 3 phase / 50 Hz Compressor Rotary (Hermetic) Scroll (Hermetic) Model...Code No. C - R243H8T ZR61KC - TFD - 522 Nominal output 2,400...

  • Page 20: Other Component Specifications

    1. Specifications 1-3 Other Component Specifications (A) Indoor Unit MODEL No. SPW-D253G56 SPW-D273G56 SPW-D363G56 SPW-D483G56 Power Transformer ATR – I75B Rated Primary AC 230 V, 50 Hz Secondary 10.6 V, 0.93 A Capacity 9.85 VAC Ω 0.8 (at 20 °C)

  • Page 21: (B) Outdoor Unit

    1. Specifications 1. Specifications 1. Specifications 1-3 Other Component Specifications Outdoor Unit MODEL No. SPW-C253G5 SPW-C363G5 SPW-C253G5/M SPW-C363G5/M Compressor Motor Mgnetic Contactor FMCA - 1SZ607 Coil rated AC 220 - 240 V, 50 Hz Ω 828 ± 15 % Coil resistance (at 20°C) Contact rated V, A AC 440 V, 13 A...

  • Page 22: Dimensional Data

    1. Specifications Dimensional Data (A) Indoor Unit : 25, 27, 36, 48 Type 25, 27, 36 type 48 type 25, 27 type 36, 48 type Ref. gas line ø 15.88 ø 19.05 Ref. liquid line ø 6.35 ø 9.52 Refrigerant liquid line Refrigerant gas line Power supply entry Drain connection (20 A / VP20)

  • Page 23: (B) Outdoor Unit

    1. Specifications 1. Specifications 1. Specifications 1-4 Dimensional Data (B) Outdoor Unit : SPW-C253G5, SPW-C253G5/M SPW-C253G8, SPW-C253G8/M Dimension : mm Hole for anchor bolt (4-ø13) Refrigerant tube joint (narrow tube) Flare connection 1/4 in (6.35 mm) Refrigerant tube joint (wide tube) Flare connection 5/8 in (15.88 mm) Refrigerant tubing inlet Power supply inlet...
  • Page 24 1. Specifications 1-4 Dimensional Data (B) Outdoor Unit : SPW-C363G5, SPW-C363G5/M SPW-C363G8, SPW-C363G8/M SPW-C483G8, SPW-C483G8/M Dimension : mm Hole for anchor bolt (4-ø13) Refrigerant tube joint (narrow tube) Flare connection 3/8 in (9.52 mm) Refrigerant tube joint (wide tube) Flare connection 3/4 in (19.05 mm) Refrigerant tubing inlet Power supply inlet 0412_C_S...

  • Page 25: Refrigerant Flow Diagram

    1. Specifications 1. Specifications 1. Specifications 1-5 Refrigerant Flow Diagram Indoor Unit : SPW-D253G56 Outdoor Unit : SPW-C253G5, SPW-C253G5/M SPW-D273G56 SPW-C253G8, SPW-C253G8/M Wide tube service valve Strainer Capillary O. D. Accumulator 15.88 mm (5/8") High pressure switch Narrow tube service valve Strainer O.

  • Page 26: Operating Range

    1. Specifications 1-5 Refrigerant Flow Diagram Indoor Unit : SPW-D483G56 Outdoor Unit : SPW-C483G8, SPW-C483G8/M Wide tube service valve O. D. Accumulator 19.05 mm (3/4") Narrow tube service valve Strainer O. D. Sub-condenser 9.52 mm (3/8") Fig. 5-2 1-6 Operating Range Temperature Indoor air intake temp.

  • Page 27: Processes And Functions

    2. Processes and functions 2. Processes and functions 2. PROCESSES AND FUNCTIONS Room Temperature Control ................28 Freeze Prevention ..................29 Outdoor Fan Control ..................29 SM830044 – 27 –...

  • Page 28: Room Temperature Control

    2. Processes and functions 2-1 Room Temperature Control The Unit adjusts room temperature by turning the outdoor unit’s compressor ON and OFF. This process is controlled by the thermostat located in the remote control unit. The figures on this and the next pages show how each part of the system performs when the room temperature changes and the thermostat activates the compressor to start (thermo ON) or stop (thermo OFF).

  • Page 29: Freeze Prevention

    2. Processes and functions 2. Processes and functions 2-2 Freeze Prevention Freeze Prevention keeps the indoor heat exchange coil from freezing. Freezing reduces the efficiency of the unit, and frost buildup on the coil blocks cool air circulation from the indoor unit’s fan.
  • Page 30 2. Processes and functions SM830044 – 30 –...

  • Page 31: Electrical Data

    3. Electrical data 3. ELECTRICAL DATA Indoor Unit (Electric Wiring Diagram, Schematic Diagram) ....... 32 Outdoor Unit (Electric Wiring Diagram, Schematic Diagram)......38 SM830044 – 31 –...

  • Page 32: Indoor Unit

    3. Electrical data Indoor Unit 1 1 1 1 1 SPW-D253G56, SPW-D273G56 SM830044 – 32 –...
  • Page 33 3. Electrical data Indoor Unit 1 1 1 1 1 SPW-D253G56, SPW-D273G56 • Schematic Diagram CR-X363GS Controller F0(6.3A) F1(3.15A) 4P-1 49FMI 4P-4 49FI 2Z 3Z 49FMI COIL 4P-2 Symbols Description Indoor Fan Motor 49FI Indoor Motor Thermal Protector Running Capacitor...
  • Page 34 3. Electrical data Indoor Unit 2 2 2 2 2 SPW-D363G56 SM830044 – 34 –...
  • Page 35 3. Electrical data Indoor Unit 2 2 2 2 2 SPW-D363G56 • Schematic Diagram CR-X363GS Controller F0(6.3A) F1(3.15A) 4P-1 49FMI 4P-4 49FI 2Z 3Z 49FMI COIL 4P-2 Symbols Description Indoor Fan Motor 49FI Indoor Motor Thermal Protector Running Capacitor F0, F1 Fuse Float Switch Power Transformer...
  • Page 36 3. Electrical data Indoor Unit 3 3 3 3 3 SPW-D483G56 SM830044 – 36 –...
  • Page 37 3. Electrical data Indoor Unit 3 3 3 3 3 SPW-D483G56 • Schematic Diagram CR-X363GS Controller F0(6.3A) F1(3.15A) 4P-1 49FMI 4P-4 49FI 2Z 3Z 49FMI COIL RC0 RC1 4P-2 Symbols Description Indoor Fan Motor 49FI Indoor Motor Thermal Protector RC0, RC1 Running Capacitor F0, F1 Fuse...

  • Page 38: Outdoor Unit

    3. Electrical data Outdoor Unit 1 1 1 1 1 SPW-C253G5 SPW-C253G5/M • Electric Wiring Diagram Terminal Plate Connector 2P (WHT) 63PH Earth Terminal W 854-2-5268-461-00-1 (C253G5) SM830044 – 38 –...
  • Page 39 3. Electrical data Outdoor Unit 1 1 1 1 1 SPW-C253G5 SPW-C253G5/M • Schematic Diagram 63PH Symbols Description Compressor motor Fan Motor Compressor Motor Magnetic Contactor 63PH High Pressure Switch Fan Speedcontrol Thermostat C1, 2 Capacitor Overload relay Auxiliary Relay Connector Terminal Plate S 854-2-5268-461-00-1 (C253G5)
  • Page 40 3. Electrical data Outdoor Unit 3 3 3 3 3 SPW-C363G5 SPW-C363G5/M • Electric Wiring Diagram Terminal Plate Connector 2P (WHT) 63PH Earth Terminal W 854-2-5268-463-00-2 (C363G5) SM830044 – 40 –...
  • Page 41 3. Electrical data Outdoor Unit 3 3 3 3 3 SPW-C363G5 SPW-C363G5/M • Schematic Diagram 63PH Symbols Description Compressor motor FM1, 2 Fan Motor Compressor Motor Magnetic Contactor 63PH High Pressure Switch Fan Speedcontrol Thermostat C1, 2, 3 Capacitor Thermistor 1Y, 2Y Auxiliary Relay Connector...
  • Page 42 3. Electrical data Outdoor Unit 4 4 4 4 4 SPW-C253G8 SPW-C253G8/M • Electric Wiring Diagram Relay Terminal Plate Connector 2P (WHT) 63PH Earth Connector Terminal 6P (WHT) W 854-2-5268-458-00-0 (C253G8) SM830044 – 42 –...
  • Page 43 3. Electrical data Outdoor Unit 4 4 4 4 4 SPW-C253G8 SPW-C253G8/M • Schematic Diagram 63PH Symbols Description Compressor motor Fan Motor Compressor Motor Magnetic Contactor Compressor Motor Overcurrent Relay Compressor Motor Thermal Protector Negative Phase Relay 63PH High Pressure Switch Fan Speedcontrol Thermostat Capacitor Auxiliary Relay...
  • Page 44 3. Electrical data Outdoor Unit 5 5 5 5 5 SPW-C363G8 SPW-C363G8/M • Electric Wiring Diagram Relay Terminal Plate Connector 2P (WHT) 63PH Earth Terminal W 854-2-5268-459-00-1 (C363G8) SM830044 – 44 –...
  • Page 45 3. Electrical data Outdoor Unit 5 5 5 5 5 SPW-C363G8 SPW-C363G8/M • Schematic Diagram 63PH Symbols Description Compressor motor FM1, 2 Fan Motor Compressor Motor Magnetic Contactor Compressor Motor Overcurrent Relay Compressor Motor Thermal Protector Negative Phase Relay 63PH High Pressure Switch Fan Speedcontrol Thermostat C1, 2...
  • Page 46 3. Electrical data Outdoor Unit 6 6 6 6 6 SPW-C483G8 SPW-C483G8/M • Electric Wiring Diagram Relay Terminal Plate Connector 2P (WHT) 63PH Earth Terminal W 854-2-5268-460-00-1 (C483G8) SM830044 – 46 –...
  • Page 47 3. Electrical data Outdoor Unit 6 6 6 6 6 SPW-C483G8 SPW-C483G8/M • Schematic Diagram 63PH Symbols Description Compressor motor FM1, 2 Fan Motor Compressor Motor Magnetic Contactor Compressor Motor Overcurrent Relay Negative Phase Relay 63PH High Pressure Switch Fan Speedcontrol Thermostat C1, 2 Capacitor 1Y, 2Y...
  • Page 48 3. Electrical data SM830044 – 48 –...

  • Page 49: Service Procedures

    4. Service procedures 4. Service procedures 4. SERVICE PROCEDURES Troubleshooting .....................50 (1) Check before and after Troubleshooting ..........50 (2) Air conditioner does not operate ............51 (3) Outdoor unit does not run ..............55 (4) Indoor unit does not run ................. 57 (5) Some part does not operate ..............

  • Page 50: Troubleshooting

    4. Service procedures 4-1 Trobleshooting (1) Check before and after Troubleshooting Many problems may happen because of wiring or power supply problems, so you should check these areas first. Problems here can cause false results in some of the other tests, and so should be corrected first.

  • Page 51: Air Conditioner Does Not Operate

    4. Service procedures 4. Service procedures Air conditioner does not operate 1 1 1 1 1 Circuit breaker trips (or fuse blows). (a) When the circuit breaker is set to ON, it is tripped soon. • There is a possibility of ground fault. •...
  • Page 52 4. Service procedures (b) Circuit breaker trips in several minutes after turning the air conditioner on. • There is a possibility of short circuit. • Check capacity of circuit Replace it with a breaker. suitable one. Is capacity of circuit (= larger capacity) breaker sufficient ? •...
  • Page 53 4. Service procedures 4. Service procedures C. Check “Operation selector” switch in the indoor unit. : In case of wireless remote control unit (GS type) • Has “Operation selector” IND. LAMP Ass’y or P.C.B. switch been set to ON Ass’y in the indoor unit position ? is defective.
  • Page 54 4. Service procedures Check. auxiliary relay. (1Y or 2Y) • Check coil resistance of auxiliary relay. (1Y or 2Y) 0620_X_S Check indoor fan motor thermal protector (49FMI) • Disconnect the socket from 9P (WHT) connector. • Check the continuity between No. 8 and No.9 poles of the 9P socket.

  • Page 55: Outdoor Unit Does Not Run

    4. Service procedures 4. Service procedures Outdoor unit does not run. Check COOL/FAN selector switch in the remote control unit. • Is COOL/FAN selector switch Set to COOL. set to COOL ? 0623_X_S Check set temperature. Try to lower set temperature by Temperature setting button “COOLER”.
  • Page 56 4. Service procedures Check compressor motor thermal protector (49C) • Check compressor motor Is temperature of compressor thermal protector. (49C) abnormally high ? Refrigerant gas shortage. Charge refrigerant gas. Compressor is defective. 0626_X_S • Check compressor motor magnetic contactor. (52C) 0627_X_S (Only outdoor fan does not run.) D.

  • Page 57: Indoor Unit Does Not Run

    4. Service procedures 4. Service procedures Indoor unit does not run. (Indoor fan and louver motor do not run. P.C.B. Ass’y is defective. 0630_X_S Some part does not operate. (1) Indoor fan does not run. Check fan casing Remove foreign for foreign matter matter or repair.

  • Page 58: Outdoor Fan Does Not Run

    4. Service procedures Outdoor fan does not run. • Check fan casing Remove foreign for foreign matter matter or repair. Fan cannot on the inside. be rotated. • Check fan rotation. Rotate the fan gently once or twice by hand. •...

  • Page 59: Poor Cooling

    4. Service procedures 4. Service procedures Poor cooling Check installation position Change installation of remote control unit. position of remote • Does cool air from air condi- control unit. tioner reach remote control unit directly ? Insulate wide tube and •...

  • Page 60: Excessive Cooling

    4. Service procedures (10) Excessive cooling. Set the temperature to higher value using • The set temperature is too low. temperature setting button of the remote control unit. • Is the remote control unit installed Change installation at a place where it can position of the remote detect the room temperature control unit.

  • Page 61: A Sensor Is Defective

    4. Service procedures 4. Service procedures 4-2 A Sensor is Defective. 1 1 1 1 1 Indoor (heat exchanger) coil temp. Sensor is defective. (a) Open (=No continuity in sensor) Compressor and outdoor fan repeat ON for 10 minutes and OFF for 6 minutes when sensor opens.

  • Page 62: Checking The Electrical Components

    4. Service procedures 4-4 Checking the Electrical Components Earthed wire Measurement of Insulation Clip Resistance • The electrical insulation is acceptable when the Probe resistance exceeds 1 MΩ. Insulation tester 0638_X_S Power Supply Wires Clamp the earthed wire of the Power Supply wires Fig.

  • Page 63: Checking The Protective Devices

    4. Service procedures 4. Service procedures Checking the Protective Devices • Disconnect the connector, which consists of P (plug) and S (socket) when you want to check the protective device. • Then check continuity among plug’s (and/or socket’s) terminal as in Fig. 46. •...

  • Page 64: Checking The Electrical Parts

    4. Service procedures Checking the Electrical Parts Power transformer (TR1) ....Indoor unit *Measure the coil resistance. • Primary 220-240 V ; Measure the resistance between two WHT lead wire terminals of socket connected to power transformer. • Secondary 10.6V ; Measure the resistance between two BRN lead wires. Refer to “1–3–(A) Other component specifications”.

  • Page 65: Thermistor Characteristic Curve

    4. Service procedures 4. Service procedures Fuse on indoor P.C.B. Ass’y • Remove the P.C.B. Ass’y from the electrical component box. Then pull out the fuse from the P.C.B. Ass’y. (Fig. 48) Fuses Indoor P.C.B. Ass’y 0644_X_S Fig. 48 • The check for continuity of the fuse by using the multimeter.
  • Page 66 4. Service procedures SM830044 – 66 –...

This manual is also suitable for:

Spw-d273g56Spw-d363g56Spw-d483g56Spw-c253g5Spw-c253g5mSpw-c363g5 ... Show all

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