Sanyo DC Inverter Multi System Air conditioner - SAP-DMRV93 - SAP-DMRV123 - SAP-DMRV183 - SAP-DMRV243 – Self diagnosis – Error codes and causes

Method of self-diagnostics
If the indoor unit operation lamp is flashing every 0.5 seconds, follow the procedure below to perform detailed trouble diagnostics.
PROCEDURE

1 Turn the power switch ON.
2 Move the operation selector on the remote control receiver to OFF (self-diagnostics).
3 If there is a sensor failure or a protective function has activated, self-diagnostics lamps 1, 2, and 3 will illuminate in the following pattern: 5 seconds flashing (illuminated) + 2 seconds OFF. (Buzzer sounds once while lamps are OFF.)
Note: If there is no trouble, then self-diagnostics lamps 1, 2, and 3 do not illuminate, and the buzzer does not sound.
4 Diagnostics is completed when the buzzer sounds 3 beeps.
5 After inspection or repair is completed, be sure to move the operation switch on the indoor unit main body to the DEMO. position, turn the power ON, and erase the diagnostics contents. Then move the operation selector on the remote control. receiver to the OFF position and check that the diagnostics contents have been erased before using the unit.

Error codes and Causes

S01,S02,S03

# Room temperature sensor failure.

# Indoor heat exchanger sensor failure.

# Humidity sensor failure.

1. Sensor open circuit or short circuit.
2. Contact failure at connector or open circuit at terminal crimping location (short-circuit detection only for the humidity sensor)
3. Indoor/outdoor circuit board failure.

S04,S05,S06

# Outdoor heat exchanger sensor failure.
# Outdoor narrow tubing sensor failure.

# Outdoor air temperature sensor failure.
# Outdoor wide tubing sensor failure.

# Compressor temperature sensor failure.
# SH sensor failure.

1. Sensor open circuit or short circuit.
2. Contact failure at connector or open circuit at terminal crimping location.
3. Outdoor circuit board failure.

E02

# HIC circuit failure.
# Power Tr circuit failure.

1. HIC or power Tr failure.

2. Outdoor fan does not turn.

3. Instantaneous power outage.
4. Service valve not opened.

5. Outdoor fan blocked.

6. Continuous overload operation.
7. Compressor failure.

8. Outdoor circuit board failure.

E04

# Peak current cut-off.

1. Instantaneous power outage.

2. HIC or power Tr failure.
3. Outdoor circuit board failure.

E05

# PAM circuit failure.
# Active circuit failure.

1. Outdoor circuit board failure.

2. Outdoor power supply voltage failure.

E06

# Compressor discharge overheat prevention.

1. Electric expansion valve failure.

2. Capillaries blocked.

3. No gas.

4. Continuous overload operation.

5. Outdoor fan does not turn.

6. Outdoor circuit board failure.

E12

# Outdoor system communications failure.
# Outdoor Hi-pressure SW, OLR operation.
# Outdoor power supply open phase, outdoor coil freezing.

1. Miswiring.

2. Blown fuse.

3. Power relay failure.

4. Open phase.
5. Outdoor circuit board failure.

6. Compressor failure.

Test Run
(1) Switch on the power source.
(2) Set the remote control receiver of the indoor unit to the TEST position. This starts the fans, producing uncooled forced air with the OPR lamp lit.
(3) After 3 minutes, the system shifts into cooling operation, and cool air will start to be felt. Cooling operation with the switch at the TEST position is unaffected by the room temperature.
(4) After stopping the test run, turn the remote control receiver of the indoor unit to the OFF position once, then move it to the ON position.
(5) Press the ON/OFF button on the remote control unit to stop the air conditioner.

Toro Workman GTX Electric – Lawn mover – How to remove and replace battery – How to test the motor – LED blinking and cause – Troubleshooting – Home appliances repair and service

Contents of this article 

• How to test the motor 
• Led blinking and causes 
• How to remove the battery 

Toro Workman GTX Electric   

How to remove the battery

1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. Make sure that the vehicle battery charger is not connected to an electrical outlet.
2. Raise and support cargo bed to allow access to battery pack.
3. Remove hex nut from negative terminal on the left, rear battery that secures the negative cable from the vehicle controller, the wire harness ground conductor andthe negative (black and white) conductors from the battery charger. Remove all of the conductors from the negative battery terminal.
4. Remove hex nut from the positive terminal on the right, rear battery that secures the positive cable to the vehicle main contactor and the positive (red) conductor from the battery charger. Remove the conductors from the positive battery terminal.
5. Make sure that disconnected conductors are positioned away from the battery terminals.
6. Service electrical system on the vehicle as required. Take care during repairs, however, to not allow tools or vehicle components to complete the battery circuit that was opened with the cable removal.

1. Negative cable to controller

2. Negative conductors from charger and harness
3. Left, rear battery
4. Positive cable to main contactor
5. Positive conductor from charger
6. Right, rear battery

Main contactor clicks, but vehicle will not operate.

Battery charge is low (check battery discharge indicator on dash).
Battery cables are loose, corroded or damaged.
Cable connection at main contactor is/are loose or corroded.
Cable connection at controller is/are loose or corroded.
Cable connection at traction motor is/are loose or corroded.
Traction motor is faulty (check status indicator light on dash or LED on controller for possible fault).
Controller is faulty (check status indicator light on dash or LED on controller for possible fault).

Nothing happens when key switch is turned to ON.

Battery charge is extremely low (check battery discharge indicator on dash).
Battery cables are loose, corroded or damaged.
Cable connection(s) at main contactor is/are loose or corroded.

10 ampere fuse to the key switch is loose or faulty.
Cable connection(s) at controller is/are loose or corroded.
425 ampere fuse on controller is loose or faulty.
Main contactor or circuit wiring is faulty (check status indicator light on dash or LED on controller for possible fault).
The key switch or circuit wiring is faulty.
Controller is faulty (check status indicator light on dash or LED on controller for possible fault).

Traction motor stops during operation

Battery charge is extremely low (check battery discharge indicator on dash).
Wiring to the traction motor components (e.g. main contactor, controller, traction motor) is loose, corroded or damaged.
Battery cables are loose, corroded or damaged.
Traction motor is overheated (check status indicator light on dash or LED on controller for possible fault).
Controller is overheated (check status indicator light on dash or LED on controller for possible fault).
Traction motor is faulty (check status indicator light on dash or LED on controller for possible fault).
Brake problem exists.

Vehicle runs slowly

The supervision speed limit switch is in the slow position.
Tire pressure is low.
The parking brake is improperly adjusted.
Brakes are worn or faulty.
Battery charge is extremely low.
Controller is overheated (check status indicator light on dash or LED on controller for possible fault).
Traction motor is overheated (check status indicator light on dash or LED on controller for possible fault).

Vehicle movement is erratic or jerky.

Accelerator pedal movement is dirty preventing smooth pedal operation.
Accelerator pedal is worn or faulty (check status indicator light on dash or LED on controller for possible fault).
A brake system problem exists.
A transaxle problem exists .

How to test the Key Switch

1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch.
2. Make sure that vehicle battery charger IS NOT connected to electrical outlet. Open the battery circuit by disconnecting the conductors between the battery pack and vehicle components.
3. Raise hood to allow access to wire harness connections for switches mounted in dash.
4. Label and disconnect wire harness connectors from the key switch.
5. With the use of a multimeter (ohms setting), the key switch functions may be tested to determine whether continuity exists between the B1 and 3 terminals for each switch position. The key switch terminals are marked as shown in picture.

A. When the key switch is in the OFF position, no continuity (infinite ohms) should exist between switch terminals B1 and 3.

B. In the ON position, continuity (zero ohms) should exist between switch terminals B1 and 3.
6. Replace key switch if testing determines that the switch is faulty.
7. If key switch tests correctly and circuit problem still exists, check wire harness for possible problems.
8. After key switch testing is complete, connect wire harness connectors to the switch.
9. Connect the conductors between the battery pack and vehicle components

Fuses Block
The fuse block is located under the seat assembly. All fuse block fuses are rated at 80
VDC.

1. Fuse block

2. Passenger hand hold
The fuse location in the fuse block is shown in picture.

1. 10 Amp (front fuse)
2. 15 Amp (bed lift kit)
3. 30 Amp (horn kit)
4. Optional kit

The front 10 amp (80 VDC) fuse protects the power supply to the key switch and all switched circuits. The battery charge indicator is also protected by the front fuse.
The second fuse position is used to protect the optional cargo bed lift circuit. When equipped with the bed lift kit, a 15 amp fuse (80 VDC) will be in the fuse block. The third fuse position is used to protect the optional horn circuit. When equipped with the horn kit, a 30 amp (80 VDC) fuse will be in the fuse block. The fourth fuse position is used for other optional kits, if equipped. An additional fuse is attached to the controller.

1. Controller

2. Fuse (425 A)
3. Screw (2 used)
4. Lock washer (2 used)
5. Flat washer (2 used)
This fuse is rated at 425 amperes continuous and protects the 48VDC vehicle power supply circuit. If this fuse has failed, vehicle operation will not occur.

Traction Motor Stator Winding Testing

Use a multimeter to measure resistance (ohms) between motor terminals (U, V and W). There should be very low (not zero) resistance between pairs of terminals (U and V, V and W and U and W). Also, measure resistance between each terminal and the motor drive end bracket. There should be infinite resistance between each terminal and the drive end bracket.
If resistance between terminals is either very high or zero, the stator is damaged. The stator is also faulty if resistance between any terminal and the drive end bracket is not infinite. If stator is damaged, replacement of the traction motor is necessary.

1. Thermistor connector

2. Terminal U
3. Terminal V
4. Terminal W
5. Drive end bracket
6. Encoder
7. Armature tone ring

Thermistor (Thermally Sensitive Resistor) Testing
Use a multimeter to measure resistance (ohms) between the pins in the thermistor connector. The measured resistance at 77F (25 Degree C) (motor temperature)
should be approximately 600 ohms. If resistance testing determines a short circuit (low resistance) or an open circuit (infinite resistance), the thermistor or thermistor wiring is damaged and the motor must be replaced. The thermistor is an integral component of the traction motor stator.

Encoder (Speed Sensor) Testing
If encoder problems exist, the vehicle controller should determine that a problem exists and a fault code should be displayed on the controller LED and the status indicator light.

Controller

The controller is secured to the rear frame beneath the cargo box. The controller uses inputs from several vehicle components to accurately control vehicle speed, direction (forward and reverse) and regenerative braking. Controller inputs include key switch, direction selector switch (forward/reverse), accelerator pedal, supervision speed limit switch, traction motor thermistor (temperature), traction motor encoder (speed sensor) and battery charger lockout. A single wire harness connection and five (5) cables are used to connect the controller to the vehicle electrical system.

1. Controller
2. Controller LED
3. Wire harness connector

A fuse that is rated at 425 amperes continuous is attached to the controller and protects the 48VDC vehicle power supply circuit. If this fuse has failed, vehicle operation will not occur.Cable connections for the controller are as follows:

Terminal B-: Negative (-) battery cable from the left, rear battery
Terminal B+: Positive (+) cable from the main contactor post
Terminal M1:Cable to traction motor terminal W
Terminal M2:Cable to traction motor terminal V
Terminal M3:Cable to traction motor terminal U

1. Controller
2. Controller LED
3. B+ terminal (+ cable from main contactor)
4. B- terminal (- cable from left, rear battery)
5. Fuse (425 A)
6. M1 terminal (cable to motor terminal W)
7. M2 terminal (cable to motor terminal V)
8. M3 terminal (cable to motor terminal U)

Because of the solid state circuitry built into the controller, there is no method to test it directly (e.g. using a multimeter). A LED exists on the controller to identify normal operation or faults that will prevent the vehicle from operating correctly. The status indicator light on the dash panel should display the same information as the LED on the controller. See chart below for light pattern fault codes identified by the controller LED and status indicator light.

NOTE: If the controller LED and status indicator light are flashing, attempt to reset the controller by turning the key switch to OFF, waiting several seconds and then turning the switch to ON. If the controller LED and status indicator light continue flashing after the reset attempt, proceed with fault code identification and necessary action.

CONTROLLER LED FLASHING CASUES AND SOLUTION

Light Pattern	Cause	Solutions
Always on (not flashing)	System functioning normally.	None required.
Always off	System inoperable. No electrical power to the controller. Status indicator light on dash is faulty. The controller has failed.	Check for low battery voltage, faulty fuse, loose battery cable connections, damaged battery cables and/or faulty main contactor. If batteries, cables and other electrical components are in good condition, controller replacement may be needed.
1 Flash	System inoperable. There is a controller configuration fault	Turn key switch OFF, wait several seconds and turn key switch ON. If controller does not reset correctly, controller replacement may be required.
2 Flashes	The parking brake is engaged while in the FORWARD or REVERSE position. This fault could also be caused by a problem with accelerator pedal operation.	Release the parking brake if it is applied. If controller does not reset correctly, parking brake switch or circuit wiring may be faulty. Turn key switch OFF, wait several seconds and turn key switch ON. If controller does not reset correctly, check accelerator pedal operation. Also, if necessary, inspect the circuit wires between the accelerator pedal and the controller
3 Flashes	System inoperable. The motor current exceeded the controller rated maximum. There is an internal controller power component fault.	Turn key switch OFF, wait several seconds and turn key switch ON. If controller does not reset correctly, check battery pack voltage and all battery cable connections. Check all batteries and high current controller connections. Controller replacement may be required.
4 Flashes	Main contactor malfunction.	Turn key switch OFF, wait several seconds and turn key switch ON. If controller does not reset correctly, inspect main contactor Check main contactor wire and cable connections.
5 Flashes	Exceeded the maximum motor speed.	Turn key switch OFF, wait several seconds and turn key switch ON. If controller does not reset correctly, inspect traction motor encoder (speed sensor) Inspect the circuit wires between the traction motor encoder and the controller

Light Pattern	Cause	Solutions
6 Flashes	The accelerator pedal is pressed while starting the machine. Accelerator pedal operation is abnormal.	Release the accelerator pedal, turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position and check for normal vehicle operation. If controller does not reset correctly, check accelerator pedal operation Also, if necessary, inspect the circuit wires between the accelerator pedal and the controller
7 Flashes	The remaining charge on the batteries is low (vehicle speed has been limited by controller). The batteries are fully discharged (vehicle does not operate). The internal capacitor has a pre-charge of less than 5V.	Charge the batteries fully and then check for normal operation. If this fault occurs regularly, consider that battery charging has not been regular or that batteries may need replacement.
8 Flashes	The controller or traction motor is overheated or too cold.	The vehicle may continue to operate but at reduced power until the component temperature reaches normal levels. Determine if the motor or controller is very hot or very cold, then allow the machine to return to normal temperatures before resuming operation. Make sure that motor and controller are cleaned of all dirt and debris that could lead to component overheating.
10 Flashes	A controller configuration fault occurred.	Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation.
11 Flashes	A motor encoder (speed sensor) fault occurred. Exceeded the maximum motor speed.	Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation. If this fault continues to occur, inspect traction motor encoder (speed sensor) Also, inspect the circuit wires between the traction motor encoder and the controller If a traction motor armature problem exists in the motor (e.g. worn bearing in rear end bracket, missing retaining ring on rear of armature shaft, loose or damaged tone ring on armature), an encoder fault could be generated due to the armature issue.

Light Pattern	Cause	Solution
12 Flashes	A controller configuration fault occurred.	Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation.
13 Flashes	An internal controller software fault occurred	Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation.
14 Flashes	A controller communication fault occurred	Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation.

How to install an air conditioner - Split Air Conditioner Installation procedure

Selection of installation positions for indoor unit
# To be installed at the position where the air delivered from the unit can reach every corner of the room;
# To avoid being affected by the outdoor air;
# To avoid blockage to the air inlet or outlet of the unit;
# To avoid too much oil smoke or steam;
# To avoid possible generation, inflow, lingering or leakage of flammable gases;
# To avoid high-frequency facilities (such as high frequency arc welders, etc.);
# To avoid the places where acid solutions are frequently used;
# To avoid the places where some special sprayers (sulfides) are frequently used.
# Not to install a fire alarming device near the air outlet of the unit (during operation, the fire alarm device might be erroneously triggered by the warm air from the unit);

Make sure of enough space for installation and maintenance.
To take into consideration the operational convenience and safety in installation, it is recommended to ensure enough space between the unit and the walls.

Height limits of indoor and outdoor units.

Either the indoor unit or the outdoor unit can be higher, but the height difference must comply the stated requirements.
Try to reduce the bending of the piping line as much as possible so as to avoid possible negative impacts upon the performances of the units.

Selection of installation positions for outdoor unit

# To install the outdoor unit at the places which can stand the load of the machine weight and will not cause big vibrations and noises;
# To install the unit at the places not to be exposed to rain or direct sunshine, and the places with good ventilation;
# The noises generated from the unit will not affect the neighboring places;
# Do not install the unit on non-metal frame;
# Not to install the unit at the places where there might occur the generation, inflow, stay or leakage of inflammable gases;
# Pay attention to the drainage of the condensed water from the base plate during operations;
# To avoid the air outlet being directly against the wind

Detailed space requirements around the outdoor unit

Installation fixture of indoor unit

Pipelines can be connected in the directions of********and* as indicated in picture. When the pipelines are connected to the directions of***and*, a groove for the pipes has to be opened at the proper place on the base stand.

1. Installation of wall-mounting plate

Fix the wall-mounting plate firmly on the wall with screws. Make sure of the leveling of the plate. Slanted wall-mounting plate might jeopardize the smooth discharge of the condensed water.

2. Drill holes on the wall
Drill holes at places slightly below the wall-mounting plate, with hole diameter of 65mm(2-3/5") and the outer edge of the hole 5-10mm(1/5-2/5") lower  so that the condensed water can smoothly flow out. Cut the wall penetrating pipe to proper length according to the thickness of the wall (3- 5mm(1/10-1/5") longer than the wall thickness) and insert the pipe as indicated in picture

3.Installation of drain pipe

Install the pipelines of the indoor unit in accordance with the direction of the wall holes. Wrap tightly the drain pipe and the pipelines with tape. Make sure that the drain pipe is underneath the pipelines. (When the drain pipe passes the room interior, some condensed water might occur to its surfaces if the humidity is very high).

4.Installation of indoor unit

Pass the connection wires, connecting pipelines and drain pipe through the wall hole. Hang the indoor unit on the hooks at the top of the wall-mounting plate so that the hooks at the bottom of the indoor unit match the hooks of the wall-mounting plate.

Inspections:

a. Check if the hooks at the top and bottom are firmly fixed.
b. Check if the position of the master unit is properly leveled.
c. The drain pipe should not curve upward.
d. The drain pipe should be at the lower part of the wall pipes .

Installation fixture of outdoor unit

# Try to ship the product to the installation location in its original package;
# As the gravity center of the unit is not at the installation center, special caution should be taken when using hoisting cables to lift it up;
# During shipping, the outdoor unit must not be slanted to over 45 degrees (Do not store the unit in a horizontal way).
# Use expansion bolts to fix the mounting supports on the wall;
# Use bolts and nuts to fix the outdoor unit firmly on the supports and keep on the same level;
# If the unit is installed on the wall or at the rooftop, the supports have to be firmly fixed so as to resist earthquake or strong wind.
Dimensions for parallel units installations

Pipelines connection

Ordinary pipelines connection (it is suitable for non-quick coupler)
No dust ,foreign articles,air or moisture should be allowed to enter the air conditioning system.Careful attention should be paid when pipeline connection for outdoor unit is made.Try to avoid repeated curves as much as possible,otherwise hardening or cracks might be caused to the copper pipes.Suitable wrenches should be used when the pipeline connection is done so as to ensure appropriate torque.Excessive torque might damage the joints while too little torque might lead to leakage.

Special pipelines connection(it is suitable for quick coupler)

In case of the users purchasing the machine for quick coupler,there is no need to do the air purging procedures and the following pipeline connection procedures should be adopted:
1.Remove the dust caps from the indoor and outdoor units, and the connecting pipe.
2.Align the joint counter of connecting pipe with the proper indoor and outdoor joint conic surfaces,tighten the connecting nut manually.Then,make it secure with a wrench as shown in picture.

3.Remove the two valve core caps from the outdoor unit.

4.Turn on the high and low pressure valve cores with an socket wrench,then tighten the two valve core caps of the outdoor unit .

Notes on installation of quick coupler

1.Connecting pipe bending minimum radius parameters.
2.Quick coupler assembly and disassembly limit: the assembly and disassembly times are inadvisably more than 7.
Air purging

Air purging with vacuum pump
1.Check that pipelines connection have been properly connected,remove the charging port cap,and connect the manifold gauge and the vacuum pump to the charging valve trough a hoses as shown in picture .

2.Open the valve of the low pressure side of manifold gauge,then,run the vacuum pump.Vacuum the indoor unit and the connecting pipes until the pressure in them lowers to below 1.5mmHG (The operation time for vacuuming is about 10 minutes).When the desired vacuum is reached,close the valve of the low pressure of the manifold and stop the vacuum pump.

3.Disconnect the hoses and fit the cap to the charging valve.
4.Remove the blank caps,and fully open the spindles of the 2-way and 3-ways valves with a service valve wrench.

5.Tighten the blank caps of the 2-way and 3-ways valves.

Adding refrigerant
Refrigerant must be added if the piping measures more than 5 metres(16'5") in length.

Additional refrigerant amount
Liquid pipe diameter 6.35(1/4")	Liquid pipe diameter: 9.52(3/8")
(piping length-5)m x 30g or (piping length-16)ft x 0.3oz	(piping length-5)m x 65g or (piping length-16)ft x 0.7oz

Gas leakage inspection

After the pipeline connection is done,use a leakage inspection device or soap suds to carefully check if there is any leakage at the joints.This is an important step to ensure the quality of installation.Once a leakage is detected,proper treatment should be taken immediately.

Connection of power cable
1.Remove the drawer of the outdoor unit.
Non-quick coupler: Connect the indoor power and control wires with the matched
Quick coupler: Directly connect quick cable couplers with indoor and outdoor quick cable couplers after disassembly of the outdoor unit connecting box cover
3.Use a press plate to fix the wires firmly,and re-install the drawer.

Finishing touches

# Use thermal tube to wrap the joints and wrap the tube tightly with ethylene tapes.
# Fix the wrapped pipelines on the exterior wall with clamps.
# Fill in the gaps left over by the pipeline hole and wall hole to prevent rain-water from entering.

Test running

# Connect to the power source,check if the function selection keys on the remote controller are working properly.
# Check if the room temperature adjustments and timer settings are working properly.
# Check if the drain is smooth.
# Check if there is any abnormal noise or vibration during operation.
# Check if there is leakage of refrigerant.