Sanyo 3WAY MULTI SGP-EZ150M2G2 Manual Download Page 4

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(3) Outdoor main board switch and LED arrangement diagram

No.

Name

No.

Name

Terminating resistance ON/OFF switch (S010)

CN075

STOP SW (S001)

EEPROM

Indoor/outdoor communication monitor (D043)

19 CN037 (white)

Fuel gas solenoid valve force close switch (S002)

20 CN049 (red) Compressor outlet/inlet pressure sensors

PS1: Inlet, PS2: outlet

SET key (S007)

DOWN key (S006)

CN029 (blue)

UP key (S005)

CN014 (blue)

LEVEL LED (D053)

CN016 (black)

TEST/WARNING LED (D052)

CN062 (green) Hot water outlet temperature

10 HOME key (S004)

25 CN060 (blue) Clutch coil temperature

CN015 (white)

26 CN058 (white) Coolant temperature

CN063 (yellow)

CN059 (black) Outdoor air temperature

CN012 (red)

28 CN055 (blue) Heat exchanger inlet temperature

CN011 (black)

29 CN064 (yellow) Clutch 2 coil temperature

15 CN010 (white)

30 CN053 (black) Compressor inlet temperature

16 CN006 (black)

CN054 (red) Compressor outlet temperature

Summary of Contents for 3WAY MULTI SGP-EZ150M2G2

Page 1: ...ctric 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 ...

Page 2: ...ced Off Switch I 5 o Coolant Circulation Operation I 6 pForced Rotational Speed Setting Operation I 7 qTest 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 Replac...

Page 3: ...E G system inspection jValve clearance adjustment kStart up check lAbnormal noise vibration check mHarness check 3 Coolant jCheck condition amount replenish kLeak check 4 Drain filter j Replenish clean oil absorption sheets change 5 Inspect fuel system jCheck for gas leaks 6 Inspect refrig eration system jCheck for gas leaks 7 Control program version check Update as required 8 Collect and record o...

Page 4: ...05 22 CN014 blue 8 LEVEL LED D053 23 CN016 black 9 TEST WARNING LED D052 24 CN062 green Hot water outlet temperature 10 HOME key S004 25 CN060 blue Clutch coil temperature 11 CN015 white 26 CN058 white Coolant temperature 12 CN063 yellow 27 CN059 black Outdoor air temperature 13 CN012 red 28 CN055 blue Heat exchanger inlet temperature 14 CN011 black 29 CN064 yellow Clutch 2 coil temperature 15 CN0...

Page 5: ...peration during inspection of outdoor unit Important This is the basic operation performed during inspection work If this operation is not performed and the power of the outdoor unit is turned off this will cause system fault and prevent backup operation to be car ried out and serious malfunction will occur If this happens see System recovery procedure to recover the system and then once again use...

Page 6: ... STOP switch S001 on the outdoor main board is set to NORM 3 If the power of the outdoor unit has been turned off turn on the circuit breaker 4 If Test run No 4 is set cancel it When adjusting to No 4 if TEST WARNING LED D052 lights this means Test run is being set In this state press the SET S007 key for one second or more The setting will be canceled TEST WARNING LED D052 goes off k Engine Stop ...

Page 7: ...me display on the 7 segment LED display Display Function DOWN UP Oil use time display clear setting Forcible oil replenishment setting 5 Clearing the Oil Use Time Display When the SET S007 key is pressed for 1 second or more while the oil use time display is selected will appear on the 7 segment LED display Figure 4 6 Release the SET S007 key once is dis played then quickly hold it down again will...

Page 8: ...ting test run setting Forced valve opening setting Forced coolant circulation setting Forced bypass valve closing Coolant air bleed mode Forced engine distributor mode Forced engine feedback Forced engine adjustment valve closing Forced compressor oil replenish W MULTI Forced compressor oil supply W MULTI Forced outdoor defrosting Ignore pressure sensor Force fuel gas solenoid valve off 5 Setting ...

Page 9: ...0 revolutions With the speed selected press the SET S007 key for 1 second or more The selected speed will be fixed as the forced engine revolutions During this time the forced setting in progress display will appear the TEST WARNING LED D052 will light To cancel the forced engine revolution setting press the SET S007 key for 1 second or more The forced setting in progress display will be cleared t...

Page 10: ...150 190 240M2G2W 3WAY MULTI For details on how and when to perform engine oil inspection replenishment and replacement see attached table Chapter 2 2 j Use Sanyo genuine oil for the engine oil Idemitsu Kosan Co Ltd Sanyo Genuine AP GHP D 125 Nippon Oil Corporation Sanyo Genuine GHP Oil 10TH COSMO OIL LUBRICANTS Co Ltd Sanyo Genuine GHP Oil 10W30C2 k Engine oil and oil filter replacement period Rep...

Page 11: ...filter removal 2 Install the new oil filter a Apply fresh engine oil thinly and evenly to the O ring of the new filter Figure 3 b During oil filter installation turn the filter two three or more times after the packing is seated in the engine to tighten it See Figure 4 c Use a rag to wipe up spilled oil Tightening torque 14 7 20 6N m Figure 2 Detaching the oil filter For models with a K25 engine F...

Page 12: ...rge is complete use a waste cloth to wipe off the old oil from the outlet of the oil drain hose After this insert the caps that were removed during Step 5 Bring the oil drain hose back to its original position 7 Use the oil container to slowly fill 43 liters into the oil tank from the oil tank aperture and 3 liters into the engine via the engine head When doing so fill the oil from the wider side ...

Page 13: ... 1 2 3 4 5 6 7 8 9 10 11 12 13 2 4 6 8 10 12 14 16 18 20 22 24 Periodic inspection 5 years or 10 000 hours Replace 2 When delivered there is enough oil for 10 000 hours of operation 3 Oil replacement are performed every 10 000 operating hours 4 The amount of oil sufficient for 10 000 operating hours is as follows Tank location Engine Oil tank Total Oil Types 120 150 190 240 3 liters 43 liters 46 l...

Page 14: ...nt or other reason 3 Perform the valve clearance adjustment when the engine is warm 4 Stop the engine after warming it up for 10 to 15 minutes Refer to the safety precautions and Section 1 4 k Engine Stop Caution Perform the valve clearance adjustment within 10 minutes of stopping the engine The engine will be hot immediately after stopping Take appropriate precautions k The following tools and ga...

Page 15: ...mpression top dead center Perform the valve clearance adjustments that are marked in Table 1 below Figure 7 4 If the check above is not successful rotate the intake and discharge side pushrods for the fourth cylinder with your fingers checking that they move easily If these rods move easily it means that the fourth cylinder is at compression top dead center Perform the valve clearance adjustments ...

Page 16: ... clearance while the engine is warm Intake valves Discharge valves When warm 0 45 mm 3 When finished adjusting the valve clearance tighten the lock nut to the specified torque Lock nut Tightening torque 27 4 34 3 N m o After adjustment 1 Reinstall the engine rocker arm cover and sparkplugs and tighten to the specified torques First tighten the 2 nuts for the engine rocker arm cover evenly on the l...

Page 17: ...e sparkplug replacement must be performed every 10 000 hours or 5 years whichever comes first k Make sure to use genuine parts for the replacement sparkplugs Figure 1 l The following tools gauges and parts are required for doing this work Pre pare them before starting Preparation for work Name Specification Q ty Remarks Tools Sparkplug wrench 1 Torque wrench 9 8 29 4N m 1 Screwdriver No 3 Phillips...

Page 18: ... bolts o Installation Install new sparkplugs by following the reverse of the removal procedure from l to j Sparkplugs Sparkplug coils bracket 19 6 29 4 N m Sparkplug coils bracket Sparkplug coils bracket 15 7 17 7 N m Operation check j Move the STOP SW to NORMAL Refer to Section 1 4 lCanceling Engine Stop k Operate the unit and perform an engine startup check l Reinstall the removed unit panel in ...

Page 19: ... collect in a dust cup while finer particles are filtered out by folded paper filter elements 2 If the air cleaner element becomes clogged the quantity of air will be reduced causing the engine to stall Make sure to replace the element periodically Replace the element more frequently in dusty or oily environ ments k Replacement Period Replace the air cleaner element every 5 years or 10 000 operati...

Page 20: ...p Fastener attachment Move the fastener on the air cleaner from the left to the right and secure it in the center using a securing screw Figure 2 q Operation check 1 Move the STOP SW to NORMAL Refer to Section 1 4 l Canceling Engine Stop 2 Recheck the air cleaner installation 3 Operate the engine for 10 15 minutes and make sure there are no changes in the revolutions per minute no abnormal noises ...

Page 21: ...ials Sanyo genuine coolant 3 9509 1040 As needed SS Part code 1743020 826 2 4521 10100 SS Part code 1743030 Rags Small q ty Tools Dispensing container 2 liters 1 For coolant free from oil Gauges Brine tester For ethylene glycol n Check and replenish coolant 1 Check the coolant level inside the reserve tank from the cutout of the side panel on the filler neck side of the unit Figure 2 Suitable Leve...

Page 22: ...ion for the outdoor unit j Replacement Period Replace the compressor drive belt every 5 years or 10 000 operating hours whichever comes first k Preparations The following tools gauges and parts are required for doing this work Prepare them before starting Name Specification Q ty Remarks Parts Compressor drive belt 638 018 9625 1 Tools Gauges Open end or closed wrench 19mm 1 Socket wrench 10mm 19mm...

Page 23: ...get to remove that plate 3 Turn the tension adjustment bolt counterclockwise and raise the bracket Figure 4 19 mm bolt indicated by arrow 4 Rotate the tension adjustment bolt until the compressor drive belt can be removed then remove the belt Figure 4 Raising bracket Figure 2 Removing tube fastener rear side Bolts Bolts Figure 3 Removing tube fastener ...

Page 24: ...ension is at the specified deflection value Belt tension 1670 1720 N New Belt Doctor Tension setup procedure Span 290 mm tension measurement location Density 0 018 kg m rib Number of ribs 10 Doctor Tension A product manufactured by Mitsuboshi Belting Ltd that measures tension based on the vibrat ing sound produced when tension is measured Press a finger against the belt at the measure ment locatio...

Page 25: ...ion 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 ten...

Page 26: ...pecification Q ty Remarks Materials Tools Drain filter filling stones CHEMICAL 638 007 4860 As needed Calcite 5 kg inside plastic bag Gasket 638 012 6149 1 For repairing Rags Small q ty Nut driver Across flats 10mm 1 Oil absorbent mat 623 200 4601 10 Oil absorbent tube 623 300 8660 1 j Removing the drain filter A 1 Remove the drain hoses 2 hoses that are attached to the drain filter A Figure 1 Be ...

Page 27: ...illing stone case in the drain filter case place the new oil absorbent mats on top and use the securing screws to attach the fastener of the oil absorbent mats n Attach the drain filter A 1 Place the drain filter A on the stand and use the four bolts and two nuts to secure it to the stand 2 Attach the drain hoses 2 hoses o Attach the drain filter B 1 Place the drain filter B on the outdoor unit st...

Page 28: ...utdoor 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 j Check for leaks in the fuel line connections 1 Open the main valve for the gas line 2 Using a gas leak detector Figure 1 or soapy water make sure there are no leaks in the fuel line connections...

Page 29: ...III 3 Periodic Replacement Parts List ...

Page 30: ...t 1 623 194 7664 Spark plugs 4 938 018 9626 Compressor operation belt 1 923 200 4602 Oil absorbent mat 10 623 300 8660 Oil absorbent tube 1 C 10 20 000 hours or 10 years SGP MTK560M 638 012 7993 Oil filter 1 923 196 0565 Air cleaner element 1 623 194 7664 Spark plugs 4 938 018 9626 Compressor operation belt 1 923 200 4602 Oil absorbent mat 10 623 300 8660 Oil absorbent tube 1 ...

Page 31: ...perating hours Hours 2 No of times ON OFF Times 3 Check replace j Coolant level check replenishment k Drain filter filling stone check replenishment l Sparkplug replacement m Engine oil change n Oil filter replacement o Air cleaner element replacement p Compressor drive belt replacement q Valve clearance adjustment r Oil absorbent mat s Oil absorbent tube Intake valve Exhaust valve Before adjustme...

Page 32: ...easurement Conclusion 11 Engine revolution speed min 1 12 Compressor inlet pressure MPa 13 Compressor outlet pressure MPa 14 Compressor inlet temperature C 15 Compressor outlet temperature C 19 External air temperature C 31 Outdoor fan output 34 Outdoor unit electrical valve 1 output Step Compressor intake superheat 2 outputs Deg Indoor unit operating data Operation mode cool heat Type Electric va...

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