Sanyo SAP-KRV91EH Operating manual

The reason for change
A : Correction B : Quality reliability C : Standardization
D : Design change E : Addition of parts F : New information
Notice
CORRECTION
SERVICE FLASH
Please add this notice to the TECHNICAL & SERVICE MANUAL listed below.
FILE NO.
REFERENCE NO. SM700386–01
PRODUCTION CHANGE
ADDED INFORMATION
●
Category : MULTI-SPLIT SYSTEM AIR CONDITIONER Date : Jun, 1999
Model : SAP–KRV91EH + SAP–CRV91EH
Destination : Europe
Serial No. :
Issue Number : 1
Outdoor Model No. Product Code No.
Reference No. Page Contents Remarks
Old SM700386 — Supplementary information for servicing
has been added. F
New SM700386-01 —
Destination
SAP–CRV91EH 1 852 065 79 Europe
Indoor Model No. Product Code No.
1 852 065 78SAP–KRV91EH

1
– Replacement Procedures for Outdoor Control PCB / Active Inverter PCB –
]These Installation Instructions provide the correct method for replacing the Control PCB and Active
Inverter PCB on the outdoor unit.
]Since how they are mounted differs from the conventional PCB, their wiring method may not be easily
apparent. Therefore, carefully observe the procedures outlined below.
]Leads of sensors and other connectors are secured with a locking mechanism. Therefore, never use
force to pull on the leads. Also, refer to “Disconnecting Positive Connector” on Page 4 to disengage this
type of connector.
]Be sure to disconnect the power to the indoor unit before starting any work.
nSUPPLEMENTARY INFORMATION
Use the following procedure to remove the tubing cover, exterior panels and lid of the electrical component box.
These steps are used when replacing the Control PCB or Active Inverter PCB.
1. Remove the screws used to attach the tubing cover and exterior panels of the outdoor unit, then remove the tub-
ing cover and panels (top and front sides). (Figs. 1, 2)
2. Disengage the tab on the lid of the electrical component box and remove the lid. (Fig. 3)
3. Confirm the red LED (discharge lamp) located on the side of the Control PCB is not illuminated. (Fig. 3)
Fig. 1
Fig. 2
Active inverter PCB
Lid
Control PCB
Tab
Red LED Connectors located on front of Control PCB
Fig. 3
To Remove Exterior Panels, Etc.
W

2
Leads from HIC
From 4-way valve
From FM
Step-up coil Yellow leads to PIC (POSISTOR)
Fig. 4
If the Control PCB is faulty, remove and replace it using the following procedure:
1. To Remove Faulty PCB
1. Using a pliers or similar tool, disconnect the positive connectors of the leads (red: 1, white: 2) connected to the 3P
terminal plate.
2. Disconnect all connectors at the front of the control PCB (front of unit).
3. Unhook the tabs used to secure the Control PCB, and slightly tilt up its right edge to allow access to the connec-
tors. Then disconnect all connectors including positive connectors. (Fig. 4)
➀Connectors (for FM valve, 4-way valve, etc.) located on right side of Control PCB
➁Connectors with yellow leads of PTC (POSISTOR)
➂Connectors with leads of HIC
➃5P connectors with locking mechanism connecting Control PCB and Active Inverter PCB
*When only the Active Inverter PCB is to be replaced, disconnect the connectors only for the Active Inverter
PCB while leaving the connectors on the Control Panel PCB still connected.
4. Remove the Control PCB from the electrical component box.
2. To Install New Control PCB
1. Place the new Control PCB upon the electrical component box, but don’t yet attempt to firmly secure it.
2. Raise the front of the Control PCB, and connect the following:
➀Connectors (2) with yellow leads from PTC (POSISTOR)
➁5P connectors with leads to connect the Active Inverter PCB and Control PCB
➂Connectors with leads from HIC
➃Connectors with leads from 4-way valve, FM, etc. to right side of Control PCB
3. Secure the Control Panel PCB by engaging its attachment tabs. Then connect the connectors at the front of the
Control Panel PCB. (Fig. 4)
4. Connect the red lead and two white leads to the 3P terminal plate.
*After completing the connection, confirm that the connectors are securely engaged by pulling lightly on their
leads.
Procedure for Replacing Control PCB

3
The Active Inverter PCB cannot be replaced unless the Control PCB is first removed. If the Active Inverter PCB is
faulty, remove the Control PCB as described on Page 2, and then remove
and replace the Active Inverter PCB using the following procedure:
1. To Remove the Faulty Active Inverter PCB
1. Disconnect the following leads connected to the Active Inverter PCB:
➀Leads connected to + and – terminals of HIC
➁All leads (Fig. 6) connected to terminals of bridged diodes
➂Wires connected to step-up coil (positive connectors)
2. Remove the two screws attaching the Active Inverter PCB. (Fig. 5)
3. Unhook the tabs used to secure the Active Inverter PCB and slightly tilt up its right edge to allow access to the
leads. (Fig. 7)
4. Disconnect the leads (5P connectors with locking mechanism) from the Control PCB.
5. Disconnect all leads connected to the Active Inverter PCB (positive terminal).
6. Cut the cable tie used to bind the leads and ground line (Fig. 8), and remove the leads and wires from the M-
shaped clamp underneath the electrical component box.
7. Release the ground line where it is attached by a screw on the left side of the terminal plate. (Fig. 7)
8. Take the Active Inverter PCB from the electrical component box.
9. Completely peel off the heat conductive sheet on the radiator, and attach the new heat conductive sheet included
with the product.
Procedure for Replacing Control PCB
Procedure for Replacing Active Inverter PCB
Bridged diodes Step-up coil Screw hole for attaching
ground lines
Fig. 7
Connector (5P) for the leads
from Control PCB Cable tie
Coil LO2
Fig. 8
White
Yellow
No polarity exists on these two white leads.
Gray White
Fig. 6
Fig. 5

4
Disconnecting Positive Connector
If the connector has a cover, pull the cover in the
direction shown by the arrow. The lock is released
permitting the connector to be disconnected.
If the connector does not have a cover, push down
on the projection to release the lock, then pull light-
ly on the connector to disconnect it.
Projection
2. To Install New PCB
1. Connect three leads (IN1 / IN2 / E) to the new Active Inverter PCB.
2. Bind together the leads coming from near the coil (LO2) on the Active Inverter PCB and three leads connected in
Step 1 above, using the new cable tie included with the product. (Fig. 8)
*Leave the cable tie loose to allow later adjustment.
*Adjust the leads so that they do not touch the coil (LO2) on the Active Inverter PCB.
3. Place the Active Inverter PCB upon the electrical component box but wait before securely attaching it. Put the
ground line (green) through the electrical component box and secure it with a screw on the left side of the termi-
nal plate. (Fig. 9)
4. Confirm the heat conductive sheet is in the appropriate position, and hook the Active Inverter PCB to its left tab
and secure it with two screws. (Figs. 9, 5)
*The leads in Step 2 above must be laid together under the electrolytic capacitor, while being careful not to put
them against the raised part at the bottom of the electrical component box.
*When securing it with screws, be careful not to put too much stress on the PCB.
5. Connect the leads to + and – terminals of the HIC and all terminals of the bridged diodes. (Fig. 6)
6. The ground line and black and white leads for the 3P terminal plate, etc., are to be positioned along the side wall
in front of the electrical component box and inserted into the M-shaped clamp under the electrical component box.
(Fig. 9)
7. Reinstall the Control PCB following the instructions
on Page 2,
8. Connect the leads from the Control PCB (5P) to the
Active Inverter PCB.
9. Connect the positive connectors of the yellow leads
(2) to the step-up coil. (Fig. 9)
Procedure for Replacing Control PCB
Close the lid of the electrical component box and reassemble the tubing cover and exterior panels. (Figs. 1, 2)
Electrolytic capacitor Be careful not to place or
touch leads at this location.
Step-up coil Hole for attachment
screw for ground lines
Fig. 9
Procedure for Replacing Active Inverter PCB

SANYO Electric Co.,Ltd.
Osaka, Japan
SM700386–01 06/99/200
Printed in Japan