Sinclair SDV IV Series User manual

FULL DC INVERTER SYSTEMS
SERVICE MANUAL
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1
CONTENTS
Part 1 General Information............................................................................ 3
Part 2 Component Layout and Refrigerant Circuits ..................................... 9
Part 3 Control ............................................................................................... 17
Part 4 Field Settings..................................................................................... 29
Part 5 Electrical Components and Wiring Diagrams .................................. 35
Part 6 Diagnosis and Troubleshooting......................................................... 49

2

3
Part 1
General Information
1 Indoor and Outdoor Unit Capacities .................................................. 4
2 External Appearance ............................................................................ 6
3 Combination Ratio................................................................................ 8

4
1Indoor and Outdoor Unit Capacities
1.1 Indoor Units
Table 1-1.1: Indoor unit abbreviation codes
Abbreviation
code
Type
Abbreviation
code
Type
C1A
One-way Cassette
DHA
High Static Pressure Duct
Two-way Cassette
HA
Wall-mounted
CA
Compact Four-way Cassette
FA
Ceiling & Floor
CA
Four-way Cassette
Floor Standing
DA
Medium Static Pressure Duct
PA
Console
Table 1-1.2: Indoor unit capacity range
Capacity
Capacity
index
C1A CA CA DA DHA HA FA
F
PA
kW
kBtu/h
HP
1.8
5
0.6
18 18
—
—
—
—
—
—
—
——
2.2
7
0.8
22 22
22
22
—
22
—
22
—
22 22
2.8
9
1
28 28
28
28
28
28
—
28
—
28 28
3.6
12
1.25
36 36
36
36
36
36
—
36
36
36 36
4.5
15
1.6
45 45
45
45
45
45
—
45
45
45 45
5.6
19
2
56 56
56
—
56
56
—
56
56
56 —
7.1
24
2.5
71 71
71
—
71
71
71
71
71
71 —
8.0
27
3
80 —
—
—
80
80
80
80
80
80 —
9.0
30
3.2
90 —
—
—
90
90
90
90
90
——
10.0
34
3.6
100
—
—
—
100
—
—
—
—
—
—
11.2
38
4
112
—
—
—
112
112
112
—
112
—
—
14.0
48
5
140
—
—
—
140
140
140
—
140
—
—
16.0
55
6
160
—
—
—
—
—
160
—
160
—
—
20.0
68
7
200
—
—
—
—
—
200
—
—
—
—
25.0
85
9
250
—
—
—
—
—
250
—
—
—
—
28.0
96
10
280
—
—
—
—
—
280
—
—
—
—
40.0
136
14
400
—
—
—
—
—
400
—
—
—
—
45.0
154
16
450
—
—
—
—
—
450
—
—
—
—
56.0
191
20
560
—
—
—
—
—
560
—
—
—
—

5
1.3 Outdoor Units
Table 1-1.4: Outdoor unit capacity range
Capacity
Model Name
10HP
SDV4-280EAA
12HP
SDV4-335EAA
Notes:
1. SDV4 Series outdoor units could not be combined.

6
2 External Appearance
2.1 Indoor Units
Table 1-2.1: Indoor unit appearance
One-way Cassette Two-way Cassette
C1A
Compact Four-way Cassette
Four-way Cassette
CA CA
Medium Static Pressure Duct
High Static Pressure Duct
DA DHA
Wall-mounted
Ceiling & Floor
HA FA
Floor Standing
Console
PA

7
2.3 Outdoor Units
Table 1-2.4: Outdoor unit appearance
10/12HP

8
3Combination Ratio
Table 1-3.1: Indoor and outdoor unit combination ratio limitations
Type
Minimum combination ratio
Maximum combination ratio
SDV4 Series outdoor units
50%
130%
Table 1-3.2: Combinations of Indoor and outdoor units
Outdoor unit capacity
Sum of capacity indexes of
connected indoor units (standard
indoor units only)
Sum of capacity indexes of connected indoor
units (fresh air processing units and standard
indoor units together)
Maximum number of
connected indoor
units
kW
HP
Capacity
index
28.0
10
280
140 to 364
140 to 280
16
33.5
12
335
167.5 to 435.5
167.5 to 335
20
Combination ratio =
Sum of capacity indexes of the indoor units
Capacity index of the outdoor unit

9
Part 2
Component Layout and
Refrigerant Circuits
1 Layout of Functional Components ....................................................... 10
2 Piping Diagrams .................................................................................. 11
3 Refrigerant Flow Diagrams .................................................................. 13

10
1Layout of Functional Components
Figure 2-1.1: 10Hp/12Hp front view
Figure 2-1.2: 10Hp/12Hp side view
Figure 2-1.3: 10Hp/12Hp top view
Legend
No.
Parts name
No.
Parts name
1
Compressor
11
Stop valve (gas side)
2
High pressure switch
12
Stop valve (liquid side)
3
High pressure sensor
T3
Heat exchanger temperature outlet sensor
4
Oil separator
T4
Outdoor ambient temperature sensor
5
Four-way valve
T5
Discharge temperature sensor
6
Heat exchanger
Tf
Heat sink temperature sensor
7
Electronic expansion valve (EXV)
TL
Refrigerant cooling pipe temperature sensor
8
Fan
SV2
Liquid injection valve
9
Low pressure switch
SV4
Oil return valve
10
Accumulator
SV7
Refrigerant bypass valve
1
2
3
4
8
12
11
Tf
TL
SV7
5
6
7
9
10
T3
T5
SV4
SV2
T4

11
2Piping Diagrams
Figure 2-2.1: 10/12HP piping diagram
Legend
No.
Parts name
No.
Parts name
1
Compressor
11
Stop valve (gas side)
2
High pressure switch
12
Stop valve (liquid side)
3
High pressure sensor
T3
Heat exchanger temperature sensor
4
Oil separator
T4
Outdoor ambient temperature sensor
5
Four-way valve
T5
Discharge temperature sensor
6
Heat exchanger
Tf
Heat sink temperature sensor
7
Electronic expansion valve (EXV)
TL
Refrigerant cooling pipe temperature sensor
8
Fan
SV2
Liquid injection valve
9
Low pressure switch
SV4
Oil return valve
10
Accumulator
SV7
Refrigerant bypass valve
SV4
SV2
SV7
T4 Tf
1
2
3
4
5
67
9
8
10
11
12
T3
T5
TL

12
Key components:
1. Oil separator:
Separates oil from gas refrigerant pumped out of the compressor and quickly returns it to the compressor. Separation
efficiency is up to 99%.
2. Accumulator:
Stores liquid refrigerant and oil to protect compressor from liquid hammering.
3. Electronic expansion valve (EXV):
Controls refrigerant flow and reduces refrigerant pressure.
4. Four-way valve:
Controls refrigerant flow direction. Closed in cooling mode and open in heating mode. When closed, the heat
exchanger functions as a condenser; when open, the heat exchanger functions as an evaporator.
5. Solenoid valve SV2:
Protects the compressor. If compressor discharge temperature rises above 98°C, SV2 opens and sprays a small
amount of liquid refrigerant to cool the compressor. SV2 closes again once the discharge temperature has fallen
below 85°C.
6. Solenoid valve SV4:
Returns oil to the compressor. Opens once the compressor has run for 200 seconds and closes 600 seconds later and
then opens for 3 minutes every 20 minutes.
7. Solenoid valve SV7:
Allows refrigerant return to the compressor directly. Opens when indoor air temperature is close to the set
temperature to avoid frequent compressor on/off.
8. High and low pressure switches:
Regulate system pressure. When system pressure rises above the upper limit or falls below the lower limit, the high or
low pressure switches turn off, stopping the compressor. After 5 minutes, the compressor restarts.

13
3Refrigerant Flow Diagrams
Cooling operation
Figure 2-3.1: 10/12HP refrigerant flow during cooling operation
Oil return operation in cooling mode
Figure 2-3.2: 10/12HP refrigerant flow during oil return operation in cooling mode
SV4
SV2
SV7
T4 Tf
1
23
4
5
67
9
8
10
11
12
T3
Closed
Filter
Filter
Closed
Unit on
Thermostat off
Unit on
Thermostat on
Unit on
Thermostat on
Unit off
Filter
Indoor unit operation
Filter
Normal control
Filter
Filter
Normal control
Filter
Filter
Fan
on
Fan
off
Fan
on
Fan
on
High temperature, high pressure gas
High temperature, high pressure liquid
Low temperature, low pressure
TL
T5
SV4
SV2
SV7
T4 Tf
1
23
4
5
67
9
8
10
11
12
T3
300 steps
Filter
Filter
300 steps
Unit on
Thermostat off
Unit on
Thermostat on
Unit on
Thermostat on
Unit off
Filter
Indoor unit operation
Filter
Normal control
Filter
Filter
Normal control
Filter
Filter
Fan
on
Fan
off
Fan
on
Fan
on
High temperature, high pressure gas
High temperature, high pressure liquid
Low temperature, low pressure
T5

14
Heating operation
Figure 2-3.3: 10/12HP refrigerant flow during heating operation
Oil return operation in heating mode
Figure 2-3.4: 10/12HP refrigerant flow during oil return operation in heating mode
SV4
SV2
SV7
T4 Tf
1
23
4
5
67
9
8
10
11
12
T3
96 steps
Filter
Filter
96 steps
Unit on
Thermostat off
Unit on
Thermostat on
Unit on
Thermostat on
Unit off
Filter
Indoor unit operation
Filter
Normal control
Filter
Filter
Normal control
Filter
Filter
Fan
on
Fan
off
Fan
on
Fan
on
High temperature, high pressure gas
High temperature, high pressure liquid
Low temperature, low pressure
TL
T5
SV4
SV2
SV7
T4 Tf
1
23
4
5
67
9
8
10
11
12
T3
480 steps
Filter
Filter
480steps
Unit on
Thermostat off
Unit on
Thermostat on
Unit on
Thermostat on
Unit off
Filter
Indoor unit operation
Filter
Normal control
Filter
Filter
Normal control
Filter
Filter
Fan
on
Fan
off
Fan
on
Fan
on
High temperature, high pressure gas
High temperature, high pressure liquid
Low temperature, low pressure
T5
TL

15
Defrosting operation
Figure 2-3.5: 10/12HP refrigerant flow during defrosting operation
SV4
SV2
SV7
T4 Tf
1
23
4
5
67
9
8
10
11
12
T3
480 steps
Filter
Filter
480steps
Unit on
Thermostat off
Unit on
Thermostat on
Unit on
Thermostat on
Unit off
Filter
Indoor unit operation
Filter
Filter
Filter
Filter
Filter
Fan
on
Fan
off
Fan
on
Fan
on
High temperature, high pressure gas
High temperature, high pressure liquid
Low temperature, low pressure
T5
TL
480steps
480steps

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17
Part 3
Control
1 General Control Scheme Flowchart...................................................... 18
2 Stop Operation .................................................................................... 19
3 Standby Control................................................................................... 19
4 Startup Control.................................................................................... 20
5 Normal Operation Control ................................................................... 21
6 Protection Control ............................................................................... 24
7 Special Control..................................................................................... 26

18
1General Control Scheme Flowchart
Sections 3-2 to 3-7 on the following pages detail when each of the controls in the flowchart below is activated.
Legend
Numbers in the top right-hand
corners of boxes indicate the
relevant section of text on the
following pages.
Conditions met
for oil return
Conditions met
for defrosting
Special control
Oil return operation
Defrosting operation
7
Stop operation
Abnormal shutdown
System stop
2
Standby control
Crankcase heater control
3
Startup control
Compressor startup delay control
Startup control for cooling operation
Startup control for heating operation
4
Thermo on
Normal operation control
Component control during normal operation
Compressor output control
Compressor step control
Electronic expansion valve control
Outdoor fan control
5
Protection control
High pressure protection control
Low pressure protection control
Discharge temperature protection control

Compressor and inverter module protection
control
Disable heating control
6