Sanyo SAP91KC - Leak Test, Evacuation and Charging; Required Tools and System Set up; System Leak Test at the Service Site

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Table of Contents1
Performance & Electrical Ratings2
Features2
Dimensions & Weight2
Major Components Specifications5
External Line Break Overload Relay8
Compressor Identification11
Marking11
Compressor Code No.11
Compressor Wire Orientation11
Construction of the Unit12
Indoor Unit12
Outdoor Unit12
Dimensional Data15
Dimensions15
Performance Charts18
Heater18
High Load Prevention Mechanism18
Outdoor Fan Speed18
Cooling Characteristics19
Operating Instructions28
Control Unit28
Monitor Panel28
How to Start Air Conditioner29
How to Stop29
NIGHT SET BK Operation29
TIMER Operation30
Set off Mode30
Set on Mode30
FAN Speed Control30
Air Flow Direction Adjustment31
Adjustment in Vertical Direction31
Adjustment in Horizontal Direction31
Heating Performance36
Automatic Electric Heater Control36
Microcomputer Defrosting36
When Stand by Lamp Glows36
Installation Instructions37
General38
Tools Required for Installation38
Accessories Supplied with Unit for Installation38
Optional Copper Tubing Kit38
Installation Site Selection39
Additional Materials Required39
How to Install Indoor Unit40
Make a Hole40
Remove the Rear Panel from the Unit41
Install the Rear Panel41
Remove the Casing in Order to Install the Indoor Unit42
Shape the Indoor Side Piping42
Wiring Instruction for Interunit Connections42
Mounting43
How to Install Outdoor Unit44
Drain Piping44
Install the Control Unit44
Wiring Instructions on Outdoor Unit44
Refrigerant Piping45
Use of the Flaring Method45
Flaring Procedure with a Flare Tool45
Caution before Connecting Pipes Tightlyt45
Connecting Pipes between Indoor and Outdoor Units46
Insulation of Refrigerant Pipes46
Taping the Pipes46
Finishing the Installation46
Air Purging47
Piping Diagram for Air Purging47
Quick Air Purge System47
Air Purging Procedure47
Trial Run48
Service Valve Construction48
Valve Position48
Pump down48
Type of Copper Tubes and Insulation Material50
Refrigerant Tubing57
Connecting Tubes between Indoor and Outdoor Units58
Insulation of Refrigerant Tubes58
Taping the Tubes58
Tubing Diagram for Air Purging59
Troubleshooting61
Air Conditioner Does Not Operate62
Circuit Breaker Trips62
Neither Indoor Unit nor Outdoor Unit Runs64
Some Part of Air Conditioner Does Not Operate65
Indoor Fan Does Not Run65
Neither Outdoor Fan nor Compressor Runs66
Only Outdoor Fan Does Not Run67
Only Compressor Does Not Run68
Compressor Frequently Repeats on and off69
Poor Cooling70
Excessive Cooling71
Description of Functions72
Mode Selection72
Manual Mode72
Night Set BK Mode72
Checking and Replacing Electrical Components91
Connector Identification on Controller PCB92
Measurement of Insulation Resistance of the Power Cord93
Measurement of Insulation Resistance of the Fan Motor93
Checking of the Outdoor Fan Motor94
Checking of the Motor Capacitor95
Checking of the Compressor Motor Winding95
Checking of the Remote Control Unit Proper96
Use of the Test Switch96
Checking of the Items of the Remote Control Unit96
Checking of the Operation Pushbutton97
Checking of the Timer97
Checking of the Thermostat97
Checking of the Continuity of Fuse on the Controller PCB98
Method to Replace Fuse on Controller PCB98
Checking of the Output of the Controller PCB for Fan Motor Terminals98
Checking of the Power Transformer99
Checking of the Indoor Fan Motor99
Checking of the PTC Thermistor100
Checking of the Compressor Overload Relay100
Measurement of Insulation Resistance of the Compressor101
Position of the Selector104
Method to Replace Fuse on the Controller PCB105
Disassembly and Service Procedures108
Casing Removal109
Electrical Components Box109
Controller PCB109
Evaporator Removal110
Heater Thermal Protector110
Removal of the Electric Heater110
Fan and Fan Motor Removal111
Cabinet Removal112
Compressor Replacement113
Tool List for Compressor Replacement113
Safety Precautions113
Compressor Replacement Procedures114
Separating the Outdoor Unit114
Removing the Old Compressor115
Important Notice116
Installing a New Compressor117
Leak Test, Evacuation and Charging118
Required Tools and System Set up118
System Leak Test at the Service Site118
Evacuation119
Charging Refrigerant120
Preparation of Refrigerant120
Charging Procedure120
Parts List122
Refrigerant Schematic Diagram146
Cooling Cycle147
Heating Cycle147
Electric Wiring Diagram148

Sanyo SAP91KC - Leak Test, Evacuation and Charging; Required Tools and System Set up; System Leak Test at the Service Site

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