Sanyo SA-128S5-A Operating manual

TECHNICAL & SERVICE MANUAL
SA–128S5 FILE NO.
REFERENCE NO. SM700338
WINDOW TYPE AIR CONDITIONER
Model No. Product Code No.
SA–128S5
Destination
SA-128S5-A 1 851 004 09 General (50Hz) & Europe

IMPORTANT!
Please Read Before Starting
This air conditioner 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 the INSTRUCTION MANUAL and
INSTALLATION INSTRUCTIONS attached to each air
conditioner 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.
SPECIAL PRECAUTIONS
When Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.
• All wiring must conform to local electrical codes.
• Each unit must be properly grounded with a ground (or
earth) wire or through the supply wiring.
• DO NOT, under any circumstances, cut or remove the
third (ground) prong from the power cord plug.
• DO NOT use an adapter Plug or extension cord.
• DO NOT use a damaged power cord, plug, or wall outlet.
Replace them immediately.
• DO NOT change the internal wiring or any part of the
system.
• DO NOT turn the air conditioner on and off by plugging
and unplugging. Use the Operation switch.
When Transporting
Be careful when picking up and moving the air conditioner.
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.
WARNING
When Installing
Place of Installation
• If possible, install the unit in a shady location. If the site
is exposed to the sun, you should provide a sun screen
as shown in Fig. a.
• Install it at a spot where optimum cooling circulation can
be obtained. No chairs or other obstructions are allowed
in front of the air conditioner.
• The back of the air conditioner must extend outside.
(Be sure the right and left intake vents are not obstructed
by walls or windows.)
• Keep more than 50 cm from any outside obstruction
(wall, bush, etc.).
• To provide water drainage, the unit must be tilted at a
downward angle 0.5 to 1 cm to the outside.
• While installing the air conditioner, be sure to loosen the
compressor locking nuts to avoid abnormal noise and
vibration. (NOTE: Locking nuts are not provided on some
models.)
• As a safety measure, it is recommended that two people
install the unit: one to hold and balance the unit — the
other to lower the window frame to secure the unit.
• Hold the unit securely, and be careful to not drop the
cabinet or any parts if the air conditioner is being
installed on an upper floor of a multistory building.
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 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 tools 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.
CAUTION
Room
sideFront
grille
OutsideWall
Screen
Enough space
from obstacle
or wall.
Tilt 0.5 to 1 cm
downward to outside.
Support
i
WARNING
CAUTION
Fig. a

HOW TO USE THIS MANUAL
This manual is designed to help service personnel to understand basic functions, operation and possible troubles
and their remedies on SANYO window type air conditioners. You can use this manual both as a reference to find
specific information about the capacity, construction of the unit, and as a source of information to help you set up
and maintain the air conditioner. Please use this manual to make your work easier, keep the air conditioner
functioning well, and keep your customer satisfied.
Please read IMPORTANT ! precautional information on the previous page before you start actual work.
SANYO WINDOW TYPE A/C NOMENCLATURE
SANYO window type air conditioner is identified by a model number. Cooling or heating capacity, electrical
information and special features included on the air conditioner are indicated on the model number.
ii
Example
SA – 12 8 S 5
Type
SA : SANYO window type A/C
Capacity
12 : 12,000 BTU/h class
Design Number
Voltage / Frequency
5 : 220-240V, 50Hz, Single phase
Special Features
S : Mechanical Control, Side Air Discharge
NOTE
To identify the correct model number of your air conditioner, you must find the nameplate.

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. Cooling Capacity ........................................................................................................................... 7
6. ELECTRICAL DATA
6-1. Electrical Characteristics ............................................................................................................... 8
6-2. Electric Wiring Diagram.................................................................................................................. 9
7. TROUBLESHOOTING
7-1. Check before and after troubleshooting ........................................................................................ 10
7-2. Air conditioner does not operate .................................................................................................... 11
7-3. Some part of air conditioner does not operate ..............................................................................13
7-4. Air conditioner operates, but abnormalities are observed ............................................................. 15
8. CHECKING ELECTRICAL COMPONENTS
8-1. Measurement of Insulation Resistance .......................................................................................... 16
8-2. Checking Motor Capacitor.............................................................................................................. 17
8-3. Checking Fan Motor Winding......................................................................................................... 17
8-4. Checking Compressor Motor Winding............................................................................................ 17
9. DISASSEMBLY PROCEDURES
9-1. Removing Front Grille .................................................................................................................... 18
9-2. Removing Electrical Component Box ............................................................................................ 19
9-3. Removing Cabinet ......................................................................................................................... 19
9-4. Removing Evaporator .................................................................................................................... 20
9-5. Removing Blower Wheel ............................................................................................................... 20
9-6. Removing Condenser .................................................................................................................... 21
9-7. Removing Propeller Fan ................................................................................................................ 21
9-8. Removing Fan Motor ..................................................................................................................... 21
Unit Display and Control Panel ............................................................................................ 22
APPENDIX
iii

1
1. OPERATING RANGE
Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp.
Cooling Maximum 32°C D.B. / 23°C W.B. 43°C D.B.
Minimum 19°C D.B. / 14°C W.B. 19°C D.B.

2
2. SPECIFICATIONS
2-1. Unit Specifications
Model SA–128S5
Power Source 220–240V Single phase 50Hz
Voltage rating 220 / 230 / 240 V
Performance Cooling
Capacity kW 3.50
/
3.55
/
3.55
BTU/h 11,900
/
12,100
/
12,100
Air circulation (High)
m3/h 620
Moisture removal (High) Liters/h 2.0
Electrical Rating Cooling
Available voltage range V 198 ~ 264
Running amperes A 6.3
/
6.2
/
6.2
Power input W 1,300
/
1,340
/
1,360
Power factor % 94
/
94
/
91
C.O.P. W/W 2.69
/
2.65
/
2.61
Starting amperes A 34
Features
Controls / Temperature control Mechanical / Thermostat
Control unit —
Timer —
Fan speeds 2
Airflow direction (Indoor) Horizontal Auto
Vertical Manual
Air filter / Air exhaust Washable / Yes
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 780
Refrigerant control Capillary tube
Operation sound Indoor : Hi / Lo dB-A 52 / 50
Outdoor : Hi / Lo dB-A 56 / 52
Slide-out chassis Yes
Accessories —
Dimensions & Weight
Unit dimensions Height mm 375
Width mm 530
Depth mm 620
Package dimensions Height mm 435
Width mm 600
Depth mm 725
Weight Net kg 44.0
Shipping kg 47.0
Shipping volume
m30.19
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks:
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.

3
2-2. Major Component Specifications
Model SA–128S5
Controller PCB
Part No. —
Controls —
Control circuit fuse —
Remote Control Unit —
Compressor
Type Rotary (Hermetic)
Compressor model C-R110H5H 80619445
Source 220–240V Single phase 50Hz
Nominal output W 1,100
Compressor oil ... Amount cc SUNISO 4GSD-T ... 550
Coil resistance (Ambient temp. 25°C) ΩC–R: 1.962
C–S : 5.38
Safety devices Type External protector
Overload relay MRA98619-9200
Operating temp. Open °C 150±5
Close °C 69±11
Operating amp.(Ambient temp. 25°C) Trip in 6 to 16 sec. at 22.5A
Run capacitor µF 25.0
VAC 400
Fan & Fan Motor Indoor Outdoor
Type Centrifugal Propeller
Dia. / Depth mm ø210 / D96 ø320 / D —
Fan motor model ... Q'ty YSK70-4A-661 ... 1
Source 220–240V Single phase 50Hz
No. of poles ... rpm (230 V, High) 4 ... 1,010
Nominal output W 20
Coil resistance (Ambient temp. 20°C) ΩWHT-BRN: 60.0
WHT-YEL: 19.6
YEL-ORG(PNK) : 62.7
Safety devices Type Internal protector
Operating temp. Open °C 130±5
Close °C Automatic reclosing
Run capacitor µF 3.5
VAC 440
Heat Exch. Coil
Coil Evaporator Condenser
Rows 2 3
Fin pitch mm 1.4 1.6
Face area
m20.095 0.155
External Finish Acrylic baked-on enamel finish
DATA SUBJECT TO CHANGE WITHOUT NOTICE.

4
Model SA–128S5
Auto Deflector Motor M16B
Rating AC 220-240V, 50/60Hz, 3 W, 4.2/5.0 rpm
Coil resistance kΩ(at 25°C) 11.15 ± 5%
2-3. Other Component Specification

5
3. DIMENSIONAL DATA
Model SA–128S5
✽248 530
375
40 248 620
Slits for
ventilation
Side view (L) Front view Side view (R)
Power code
outlet Power code outlet
Unit : mm
Dimension with "✻" mark indicates the maximum allowable wall thickness required for ventilating the unit.
NOTE

4. REFRIGERANT FLOW DIAGRAM
6
Model SA–128S5
Compressor
Accumulator
Condenser
Evaporator
Capillary
tube Strainer

7
5. PERFORMANCE DATA
Model SA–128S5
RATINGCAPACITY 3.55 kW
AIRFLOWRATE 620
m3/h
EVAPORATOR CONDENSER
ENT.TEMP. °C OUTDOORAMBIENTTEMP. °C
W.B. D.B. 20 25 30 35 40 45
TC 3.58 3.42 3.27 3.11 2.92 2.69
CM 0.90 0.98 1.04 1.12 1.26 1.40
21 SHC 2.32 2.24 2.15 2.07 1.97 1.86
15 23 SHC 2.59 2.51 2.42 2.34 2.25 2.13
25 SHC 2.86 2.78 2.69 2.61 2.52 2.40
27 SHC 3.13 3.05 2.97 2.88 2.79 2.67
29 SHC 3.40 3.32 3.24 3.11 2.92 2.69
31 SHC 3.58 3.42 3.27 3.11 2.92 2.69
TC 3.84 3.67 3.50 3.34 3.14 2.89
CM 0.93 1.00 1.07 1.15 1.29 1.43
21 SHC 2.04 1.95 1.87 1.79 1.69 1.58
17 23 SHC 2.31 2.22 2.14 2.06 1.96 1.85
25 SHC 2.58 2.50 2.41 2.33 2.23 2.12
27 SHC 2.85 2.77 2.68 2.60 2.51 2.39
29 SHC 3.12 3.04 2.95 2.87 2.78 2.66
31 SHC 3.39 3.31 3.23 3.14 3.05 2.89
TC 4.08 3.91 3.73 #3.55 3.34 3.07
CM 0.96 1.03 1.11 1.19 1.33 1.47
21 SHC 1.74 1.66 1.57 1.49 1.40 1.28
19 23 SHC 2.01 1.93 1.84 1.76 1.67 1.55
25 SHC 2.28 2.20 2.12 2.03 1.94 1.82
27 SHC 2.55 2.47 2.39 2.31 2.21 2.09
29 SHC 2.82 2.74 2.66 2.58 2.48 2.37
31 SHC 3.10 3.01 2.93 2.85 2.75 2.64
TC 4.33 4.14 3.95 3.76 3.54 3.25
CM 0.98 1.06 1.14 1.22 1.37 1.51
23 SHC 1.71 1.62 1.54 1.46 1.37 1.26
21 25 SHC 1.98 1.90 1.81 1.73 1.64 1.53
27 SHC 2.25 2.17 2.09 2.01 1.91 1.80
29 SHC 2.52 2.44 2.36 2.28 2.18 2.07
31 SHC 2.79 2.71 2.63 2.55 2.45 2.34
TC 4.59 4.39 4.19 3.95 3.70 3.44
CM 1.00 1.09 1.17 1.25 1.40 1.55
23 25 SHC 1.66 1.58 1.49 1.40 1.31 1.21
27 SHC 1.93 1.85 1.76 1.67 1.58 1.48
29 SHC 2.20 2.12 2.04 1.94 1.85 1.75
31 SHC 2.47 2.39 2.31 2.22 2.12 2.02
TC:
Total Cooling Capacity (kW)
SHC: Sensible Heat Capacity (kW)
CM: Compressor Input (kW)
Rating conditions (#Mark) are
Outdoor Ambient Temp. 35°C D.B.
Indoor Unit Entering Air Temp. 27°C D.B. / 19°C W.B.
240V Single Phase 50Hz
5-1. Cooling Capacity

8
6. ELECTRICAL DATA
6-1. Electrical Characteristics
Model SA–128S5
Fan Motor Compressor Complete Unit
Performance at 220–240V Single phase 50Hz
Rating Conditions Running Amps. A0.69
/
0.73 5.6 /5.5 6.3 /6.2
Power Input kW 0.152
/
0.173 1.15 /1.19 1.30 /1.36
Full Load Conditions Running Amps. A 0.69
/
0.73 7.2 /7.0 7.9 /7.7
Power Input kW 0.152
/
0.173 1.52 /1.55 1.67 /1.72
Rating Conditions : Indoor Air Temperature 27°C D.B. / 19°C W.B.
Outdoor Air Temperature 35°C D.B.
Full Load Conditions : Indoor Air Temperature 32°C D.B. / 23°C W.B.
Outdoor Air Temperature 43°C D.B.

9
6-2. Electrical Wiring Diagrams
Model SA-128S5
CM
12
1b 1a
1a
LC
p
C
RS
p
N
DS
Terminal plate Operation switch Thermostat (Room)
Overload relay
Fan speed switch
Fan motor
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
Auto deflector motorAuto deflector swithc
BLU
BLU
BLU
BLU
RED
RED
RED
YELBRN
WHT
BLK
BLK
BLK
(1)
(2)
L
BRN BRN
BLU
ORG
(PNK)
FM
WHT
Compressor motor
REDRED
Capacitor
Capacitor
Power supply
To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.
WARNING
DATA SUBJECT TO CHANGE WITHOUT NOTICE.

7. TROUBLESHOOTING
7-1. Check before and after troubleshooting
7-1-1. Check power supply.
●Check that voltage is in specified range (±10% of the rating).
●Check that power is being supplied.
7-1-2. Check lead wires and connectors.
●Check that coating of lead wires is not damaged.
●Check that lead wires and connectors are firmly connected.
●Check that wiring is correct.
10
Hazardous voltage can cause ELECTRIC SHOCK or
DEATH. Disconnect power or turn off circuit breaker
before you start checking or servicing.
WARNING

7-2. Air conditioner does not operate.
7-2-1. Circuit breaker trips (or fuse blows).
A. When the circuit breaker is set to ON, it is tripped soon. (Resetting is not possible.)
●There is a possibility of ground fault.
●Check insulation resistance.
If resistance value is 2MΩor less, insulation is defective (“NO”).
1. If any poorly insulated part is found, exclude that part from circuit with other parts properly connected, and then
measure insulation resistance of entire air conditioner again to locate defective part.
2. Replace defective part with new one.
NOTE
Measure insulation
resistance of electrical
parts.
(Example)
Compressor, Fan motor,
Capacitor, Relay etc.
NO
Set circuit breaker to OFF.
*
1Pull the power plug out of the
wall outlet.
Measure insulation resistance
of unit.
•
•
Insulation of
unit is
defective.
WARNING
Window type air conditioner
Wall outlet
(Receptacle)
Power
supply
Circuit
breaker
Ground
1
Power plug
(Field supply)
11

B. Circuit breaker trips in several minutes after turning the air conditioner on.
●There is a possibility of short circuit.
7-2-2. Neither fan motor nor compressor motor runs.
A. Power is not supplied.
B. Check OPERATION SELECTOR switch on the control panel.
If it is set at OFF.
•Check that OPERATION SELECTOR
switch is not set at "OFF". Set to "ON" .
NO
•Check power supply.
Power is being supplied to the unit.
Circuit breaker
is tripped.
Power failure.
Reset breaker.
Wait for recovery
or contact power
company.
Replace with suitable
one (larger capacity).
•
•
•
NO
Check capacity of circuit breaker.
Capacity of circuit breaker is
suitable.
Measure resistance of fan motor
winding.
Measure resistance of compressor
motor winding.
12

7-3. Some part of air conditioner does not operate.
7-3-1. Only fan does not run.
7-3-2. Auto deflector switch does not work.
Fan cannot
be turned.
OK
•Check fan rotation.
Turn fan gently once or twice by
hand.
•Check fan casing
foreign matter on
inside.
Fan motor burnout
or foreign matter in
bearings.
Remove foreign
matter or repair.
Repair or replace.
•Measure resistance of fan motor
winding.
•Check fan motor capacitor.
13
•Measure resistance of auto deflector
motor winding.
•

7-3-3. Only compressor does not run.
A. Check setting temperature.
B. Check compressor and electrical parts.
●If the unit is turned off during cooling, DO NOT restart it immediately, as this can damage it. Wait at least three
minutes before starting it again.
CAUTION
•Check compressor motor
capacitor.
•Measure resistance of
compressor motor winding.
NO
YES
YES
Overload relay is working.
YES
Temperature of compressor
is abnormally high.
Refrigerant gas shortage. Charge refrigerant gas (R22).
Rotor may be locked up.
•Measure power supply
voltage.
The voltage is too low.
No
NO
Is room temperature too low ?
Try to lower setting temperature by
thermostat knob COOLER.
14

7-4. Air conditioner operates, but abnormalities are observed.
7-4-1. Poor cooling
7-4-2. Excessive cooling
NO
•Set temperature is suitable. Set temperature to higher
value using thermostat on the
control panel.
Air filter is clogged.
Temperature
difference
is small.
YES
Temperature difference between
suction and discharge air is
large enough (approx. 10 deg. or more).
Possibility of
gas shortage.
•Measure temperature of suction and
discharge air of air conditioner. Charge refrigerant
gas (R22).
Check for clogging of air filter.
•Fan speed is set to LOW.
Clean filter.
Set fan speed to
HIGH.
•Review cooling load estimate,
if performance of air conditioner is
normal.
Reduce cooling load or
replace the air conditioner
with larger capacity.
15

16
8. CHECKING ELECTRICAL COMPONENTS
●The shape of the power plug may differ from that of
the air conditioner which you are servicing.
NOTE
Power plug
(Field supply)
Ground
Probe
Insulation tester
Fig. 1
8-1. Measurement of Insulation
Resistance
●The insulation is in good condition if the resistance
exceeds 2MΩ.
8-1-1. Power Cord and Unit
Clamp the grounding prong of the power plug with a lead
clip of the insulation resistance tester and measure the
resistance by placing a probe on either of the two power
blade. (Fig. 1)
Then, also measure the resistance between the grounding
prong and other power blade. (Fig. 1)
8-1-2. Measurement of Insulation Resistance
for Electrical Parts
Disconnect the lead wires of the desired electric part from
terminal plate, switch, capacitor, etc. Similarly disconnect
the connector. Then measure the insulation resistance.
(Figs. 2 to 3)
Refer to Electric Wiring Diagram.
If the probe cannot enter the poles because the hole is too
narrow then use a probe with a thinner pin.
NOTE
Copper
tube or
metallic part
Clip
Insulation
tester
Probe
Fig. 2
Clip
Insulation
tester
Probe
Metallic
part
From fan motor,
compressor and
other parts
Fig. 3