Gas Heat Pump Air Conditioner SANYO Electric Co., Ltd. Applicable Models W MULTI SGP-EW120M2G2W SGP-EW150M2G2W SGP-EW190M2G2W SGP-EW240M2G2W 3WAY MULTI SGP-EZ150M2G2 SGP-EZ190M2G2 SGP-EZ240M2G2 Reference No.SM7110012 Periodic Inspections, Periodic Parts Replacement Manual March 2008
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Gas Heat Pump Air Conditioner - Panasonic PRO Club...(1) Gas Heat Pump Air Conditioner A gas-fueled engine drives the compressor that is the heart of the gas heat pump air conditioner
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Gas Heat Pump Air Conditioner
SANYO Electric Co., Ltd.
Applicable Models
W MULTISGP-EW120M2G2WSGP-EW150M2G2WSGP-EW190M2G2WSGP-EW240M2G2W
3WAY MULTISGP-EZ150M2G2SGP-EZ190M2G2SGP-EZ240M2G2
Reference No.SM7110012
Periodic Inspections, Periodic Parts Replacement ManualMarch 2008
CONTENTS
1. Periodic Inspections, Periodic Parts Replacement Work(1) Gas Heat Pump Air Conditioner .............................................................................. I-1(2) Periodic Inspections and Their SchedulingjWarranty Period ...................................................................................................... I-1kInspection Menu for Periodic Inspection Contract .................................................. I-1lMiscellaneous ......................................................................................................... I-1
(3) Outdoor main board switch and LED arrangement diagram .................................... I-2(4) Basic Operations for Periodic Inspection WorkjBackup operation during maintenance work (for W MULTI) ................................... I-3kEngine Stop ............................................................................................................ I-4lCanceling Engine Stop ........................................................................................... I-4mEngine Oil Use Time Reset Method ....................................................................... I-5nOperating the Fuel Gas Solenoid Valve Forced Off Switch .................................... I-5oCoolant Circulation Operation ................................................................................ I-6pForced Rotational Speed Setting Operation ........................................................... I-7qTest Run Procedure ................................................................................................ I-7
2. Periodic Inspection and Periodic Replacement Work Manual(1) Engine Oil Replenishment and Oil Filter Replacement ........................................... II-1(2) Engine oil Inspection, Replenishment, Replacement Work List .............................. II-4(3) Valve Clearance Adjustment .................................................................................. II-5(4) Sparkplug Replacement ......................................................................................... II-8(5) Air Cleaner Element Replacement ........................................................................II-10(6) Coolant Level Check, Replenishment ...................................................................II-12(7) Compressor Drive Belt Replacement ....................................................................II-13(8) Drain Filter Filling Stone Inspection, Replenishment .............................................II-17(9) Gas Leak Inspection ..............................................................................................II-19(10) Control program version check..............................................................................II-19
3. Periodic Replacement Parts List .............................................................. III-1
1. Periodic Inspections, Periodic Parts Replacement Work(1) Gas Heat Pump Air Conditioner
A gas-fueled engine drives the compressor that is the heart of the gas heat pump air conditioner (GHP) system. The use of a gas engine offers several advantages:● Becausethereisnodefrostoperation,stableheatingispossibleevenwhenexternaltemperaturesarelow.● Asshownbelow,electricpowerconsumptionisrelativelylow(whenheatingwith60Hzpowersource)andreduces
(2) Periodic Inspections and Their SchedulingjWarrantyPeriod
Theequipmentiscoveredbywarrantyfor1yearaftercompletionoftestrunanddelivery.Howevertheengineitselfandperiodicallyreplaceablepartsarecoveredbywarrantyforoneyearor2,000hoursofoperation(whicheveris shorter) after completion of test run and delivery.
kInspection Menu for Periodic Inspection ContractSinceperiodicinspectionsarenecessarytoensurelong-termtroublefreeuseofthegasheatpumpairconditioner(GHP)afterthewarrantytermends,Sanyohaspreparedthemenuofinspectionsshownbelow.Pleasenotethattheservicecontractforperiodicinspectionsonlyincludestheinspectionsshowninthetablebelow.Servicecallsformalfunctionswillbechargedseparately.
Itemization and Schedule of Periodic Inspections and Periodic Parts ReplacementRemarksNumberofyearspassedortotalhoursofoperation 5yearsor
lMiscellaneousIndoorandoutdoorheatexchangercleaningisgenerallyrequiredonceevery3-4years.However,thisvariesac-cordingtothelevelofcontamination,typeofindustry,andinstallationconditions.Ifforeignmatterordustadherestoindoororoutdoorheatexchangerfins,itwilldegradeperformanceandcausemalfunctions.Cleaningmustbeperformed to ensure proper use of the air conditioner. Cleaning costs are estimated separately.
I - 2
(3) Outdoor main board switch and LED arrangement diagram
AllworkotherthanwhentheSTOP(allstop)switch(S001)issettoSTOPandtheVG(fuelsolenoidvalveforcedoffswitch)switch(S002)issettoOFFshouldbeperformedwiththeHOME(S004),SET(S007),UP(S005),andDOWN(S006)keys.Itisextremelydangerousifthecustomerperformsanoperationthatrunstheengineduringamaintenanceinspectionorwhennotexpected.Makesureyoustopoperationduringworkinthewaydescribedbelow.* 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 “” item number is displayed, the value of
a partially set item will be discarded, and the item number will return to “.”
• BackupoperationprocedureToperformbackupoperation,theoutdoorunitformaintenancework(hereafterreferredtoas"targetoutdoorunit")mustbecutofffromthesystemusingthefollowingprocedure.Reviewcontentofthemaintenanceworkandthenselectthemostsuitablemethod.Also,afterthemaintenanceworkisfinished,alwaysreferto[Systemrecovery procedure] and then return the system to its normal state.
[Backup operation procedure]To turn off power of target outdoor unit and then perform maintenance work (basic operation during inspection of outdoor unit)
« Important »Thisisthebasicoperationperformedduringinspectionwork.Ifthisoperationisnotperformedandthepoweroftheoutdoorunitisturnedoff,thiswillcausesystemfaultandpreventbackupoperationtobecar-riedout,andseriousmalfunctionwilloccur.Ifthishappens,see[Systemrecoveryprocedure]torecoverthesystem,andthenonceagainusethefollowingproceduretoperformsetup.Automaticbackupoperationwillkickin.
* �) Sometimes all outdoor units may stop. If there is operationinput,outdoorunitsotherthanthetargetonewillstartoperationagainafterapproximatelyfiveminutes.(Fordetailsonthesettings,seethenextitem.)
* 2) Alwayscarryoutthefollowingthreetasks.
jCheck to make sure « Step 2 » is finished. If the shut-offvalveisopened,refrigerantwillflowfromtheotheroutdoorunittothetargetoutdoorunit,causingseriousmalfunction.
kAfter 3 minutes has elapsed from completion of « Step 1 »,checktomakesuretheoutdoormainboarddisplays" "andthenperformthisoperation.Ifyouturnoffthepowerimmediatelyafterperforming"STOP"setting,theentiresystemwillstop.(Backupoperationcannotbeperformed.)Ifthishappens,see[Systemrecoveryprocedure],recoverthesystem,andthen start over again starting from « Step � ».
lTherewillnotbeanyproblemwhetherthecircuitbreak-er of the outdoor unit in « Step 3 »isONorOFF.Selectoneofthemaccordingtotheworkrequired.
On the outdoor main board of the target outdoor unit, set the STOP switch (S001) to "STOP". *1
(After confirming that the engine of the target outdoor unit is stopped) close the valves of re-frigerant gas tube, refrigerant gas liquid tube, and balance tube.
On the outdoor main board of the target outdoor unit, set the STOP switch (S001) to "STOP". Wait for three minutes or more and then turn off the circuit breaker of the target outdoor unit. *2
a) FortheWMULTIoutdoorunit2indicatedintheleftdiagram,perform«Step1»to«Step3»in[Backupoperationprocedure]inthatorder.Then,performmaintenanceworkonWMULTIoutdoorunit2.
b) When«Step3»isfinished,WMULTIoutdoorunit1isreset.(It'llstopeven if it is operating.)
c) Afterapproximatelyfiveminutes,ifthereisoperationinput(indoorremotecontrolleris"Run"ortestrunsettingonoutdoormainboard),WMULTIoutdoorunit1startsup.(Backupoperationstarts.)
[System recovery procedure]Ifbackupoperationhasbeenperformed,byallmeanscheckthefollowingitemsafterthemaintenancework,andthenperform settings again to return the system to its normal state.1)Checktomakesureallshutoffvalvesofrefrigerantgastube,refrigerantliquidtube,andbalancetubeoftheoutdoor
unit are opened.2)ChecktomakesuretheSTOPswitch(S001)ontheoutdoormainboardissetto"NORM".3)Ifthepoweroftheoutdoorunithasbeenturnedoff,turnonthecircuitbreaker.4)If"Testrun"(No.4 - / )isset,cancelit.* WhenadjustingtoNo.4 - / ,ifTEST/WARNINGLED(D052)lights,thismeans
4)WhentheSET(S007)keyispressedwiththeoilusetimedisplayed(Figure3),thenextdisplayappears.BypressingtheUP(S005)keyorDOWN(S006)keyinthismode,theoilusetimedisplayclearsettingortheforcedoilreplenishmentsettingcanbeselected.Selectthesettingtoclearoilusetimedisplay(“ ” on the 7-segment LED display).
«This switch should normally be set to “NORMAL”. »
Figure 6
Figure 5
Figure 4
Figure 3
Oil use time (10,100 hours)
“o” is displayed, indicating oil use time
I-6
oCoolant Circulation OperationThisoperationforciblydrivesthecoolantpumpandthecoolantelectricthree-wayvalve.Itisusedforrefillingcool-ant and for removing air from the coolant circuit.Note:Checkthatthecoolantcircuitcontainssomecoolantbeforeperformingthisoperation.Thepumpmaybedam-
agedifforcedoperationisstartedwithoutanycoolant.1)PresstheHOME(S004)keyfor1secondormore.Themenuitemnumber“ ”willbedisplayed.2)NextpresstheUP(S005),DOWN(S006)keystodisplaymenuitemnumber“ ”3) After “ ” the test run/forced setting display
“ ”willappear(Figure7).PresstheSET(S007)keywhile“ ” is displayed.
qTest Run ProcedureThis setting is used to perform a test run from the outdoor unit.1)Setallremotecontrollerswitchesto“Stop”.2) Select ““ (forced cooling test run) or ““(forcedheatingtestrun).Fordetailsseesteps1)to4)
on page I-7.3)SettingandCancelingaForcedTestRunWhen“ “ (forced cooling test run) or “ “(forcedheatingtestrun)isselected,holdingdowntheSET(S007)key1secondorlongercausestheforcedsettingtoappear(TEST/WARNINGLED(D052)beforeatestrunstarts.Tocancelforcedtestrunoperation,holddowntheSET(S007)keyfor1secondorlonger.Thisclearstheforcedsetting(TEST/WARNINGLED(D052)goesoff)andtheforcedsettingselectionreappears.
Figure 9
II - �
2. Periodic Inspection and Periodic Replacement Work ManualPeriodic 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
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
● EngineandmodelnumberrelationshipEnginename Model No.
mReplaceoilfilterReplacetheoilfilterwhentheoilischanged.1)Removetheoilfiltera)Becauseoilremaininginthefilterwillspillwhenthefilterisremoved,positionatray(oildrainbasin)belowthefilterwhen removing it.
b)Useafilterwrenchtoremovetheoilfilter(Figure2).Takecarenottodamagethestudboltsthatholdthefilterin place when using a screwdriver or other tool to turn the oilfilterduringfilterremoval.
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
or other reason.3)Performthevalveclearanceadjustmentwhentheengineiswarm.4)Stoptheengineafterwarmingitupfor10to15minutes.(RefertothesafetyprecautionsandSection1.(4)“kEngineStop”.)
Caution● Perform the valve clearance adjustment within 10 minutes of stopping the engine.● The engine will be hot immediately after stopping. Take appropriate precautions.
ley is aligned with the timing pointer (Figure 5).Thecylindersarenumbered1,2,3,4insequencefromthecompressorside.
3)Rotatetheintakeanddischargesidepushrodsforthefirstcylinderwithyourfingers,checkingthattheymoveeas-ily(Figure6).Iftheymoveeasily,itmeansthatthefirstcylinder is at compression top dead center. Perform the valveclearanceadjustmentsthataremarked●inTable1below(Figure7).
4)Ifthecheckaboveisnotsuccessful,rotatetheintakeand discharge side pushrods for the fourth cylinder with yourfingers,checkingthattheymoveeasily.Iftheserods move easily, it means that the fourth cylinder is at compression top dead center. Perform the valve clearance adjustmentsthataremarked○inTable1below(Figure7).
5)Afteradjustment3)and4),turnthefly-wheel � revolution, and again align the topmark(orange)onthecamshaftpulleywith the timing pointer. If the valves were adjustedfirstatthefirstcylinderTDCposi-tion,adjusttheremainingvalveswiththe○markinTable1.IfthevalveswereadjustedfirstatthefourthcylinderTDCposition,adjust the clearance of the remaining valves withthe●markinTable1(Figures5,6,7).
nAdjustvalveclearances1)Rotatethepushrodwiththefingers,andcheckthattherodmoveseasily.Ifitdoes,loosenthevalvelocknut(14mm).Slightlyloosentheadjustingboltwithaflat(-)screwdriver,andinsertthethicknessgauge.Turntheadjustingbolttoadjustthevalveclearance.Whentheadjustmentisfinished,securetheadjustingboltwiththeflatscrew-driver so that it does not turn, then tighten thelocknut(Figure8).
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
jPreworkcheckitems1)Adry-typeaircleanerelementisused.Theintakeportcoverremovescoarseparticles.Astheintakeairisguidedintothebodyoftheairfilter,avortexiscreatedbyacyclonedevice.Thecurrents within the vortex cause particles in the air to collect in adustcup,whilefinerparticlesarefilteredoutbyfoldedpaperfilterelements.
2)Iftheaircleanerelementbecomesclogged,thequantityofairwill be reduced, causing the engine to stall.
abnormal noises, and no abnormal exhaust smell or color.
II - �2
(6) Coolant Level Check, Replenishment
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
Figure 3 Remove the rubber cap of the reserve tank
Coolant refill hole
Rubber cap
Coolant refillhole cover
Figure 2 Checking the coolant level
H level
L level
Maximum level during opera-
tion
II-13
(7) Compressor Drive Belt Replacement
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
nCompression drive belt tension adjustment1)Installthenewcompressordrivebeltwhenthebracketm has been raised. 2)Loosenthebelttensioningbolttoadjustbelttension.PressthebeltasshowninFigure5topreventitfromcom-ingoffthewheelswhilelooseningtheadjustingbolt.Maintainpressureonthebeltuntiltherequiredamountoftension 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.
Figure 5 Retensioning the belt(be sure to hold the belt steady while doing this)
Be sure to check that there is no slippage at these important places
4)Atensionmeasurementmadeafterabelttensionadjustmentbyrotatingtheenginepulleybyhandwillshowthattensionhasdropped.Thentightenthetensionadjustmentboltfurthertoadjusttension.Repeatthisproce-dure until desired tension is achieved.
CAUTIONIf 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. In particular, there is a high risk of the belt slipping off if the ribs are offset at the locations indicated by the circles in Figure 5 because of the ro-tation direction after operation starts. Be sure to support the belt with a hand while tightening the tension adjustment bolt. Furthermore, make sure you check that the belt has not come off before performing a test run.
II-17
(8) Drain Filter Filling Stone Inspection, Replenishment
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.
jInspection and replacementPerformdrainfilterfillingstoneinspectionandreplacementevery5yearsor10,000operatinghours,whichevercomesfirst.
oil absorbent mats and the oil absorbent mats.2)Replacetheoldoilabsorbentmatswithnewones(10pcs)
3)Removethefillingstonecaseandtakethestonesand oil absorbent tube out of the case.
4)Inserttheoilabsorbenttubeandaddthefillingstones. Addfillingstonesupto1/3ofthecaseandplacetheoilabsorbenttubeonthestones.Thenaddmore stones on top of the oil absorbent tube to fillthecasecompletely.
5)Replacethefillingstonecaseinthedrainfiltercase, place the new oil absorbent mats on top and use the securing screws to attach the fastener of the oil absorbent mats.
Safety PrecautionsStopping 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.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.