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Sanyo SAP–K301AH Technical & Service Manual

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TECHNICAL & SERVICE MANUAL
SAP – K301AH + SAP – C301AH
FILE NO.
Destination: Australia
SPLIT SYSTEM AIR CONDITIONER
Indoor Model No.
Product Code No.
Outdoor Model No.
Product Code No.
SAP – K301AH– S
1 852 071 34
SAP – C301AH– S
1 852 071 35
Indoor Unit
Outdoor Unit
SAP – K301AH
SAP – C301AH
SM
700459
REFERENCE NO.

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  • Page 1 TECHNICAL & SERVICE MANUAL SAP – K301AH + SAP – C301AH FILE NO. Destination: Australia SPLIT SYSTEM AIR CONDITIONER Indoor Model No. Product Code No. Outdoor Model No. Product Code No. SAP – K301AH– S 1 852 071 34 SAP – C301AH– S 1 852 071 35 Indoor Unit Outdoor Unit...

  • Page 3: Please Read Before Starting

    Important! When Transporting Be careful when picking up and moving the indoor and Please Read Before Starting outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp This air conditioning system meets strict safety and edges or thin aluminum fins on the air conditioner can operating standards.

  • Page 4: Table Of Contents

    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....................5 3. DIMENSIONAL DATA..........................6 4. REFRIGERANT FLOW DIAGRAM ......................8 5. PERFORMANCE DATA 5-1. Performance charts ........................9 5-2.

  • Page 5: Operating Range

    1. OPERATING RANGE Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp. Maximum 32°C D.B. / 23°C W.B. 43°C D.B. Cooling Minimum 19°C D.B. / 14°C W.B. 19°C D.B. Maximum 27°C D.B. 24°C D.B. / 18°C W.B. Heating Minimum 16°C D.B. –...

  • Page 6: Specifications

    2. SPECIFICATIONS 2-1. Unit Specifications Indoor Unit SAP – K301AH Outdoor Unit SAP – C301AH Power Source 240 V Single phase 50Hz Voltage rating Cooling Heating 8.00 9.00 Capacity BTU/h 27,300 30,700 Air circulation (High) 1,110 1,170 Moisture removal (High) Liters/h —...

  • Page 7: Major Component Specifications

    2-2. Major Component Specifications 2-2-1. Indoor Unit Indoor Unit SAP – K301AH Part No. POW – K301AH Controls Microprocessor Control circuit fuse 250 V – 3.15 A Remote Control Unit RCS – 2HS4E Type Cross-flow Q´ty ... Dia. and length 1 ...

  • Page 8: Outdoor Unit

    2-2-2. Outdoor Unit Outdoor Unit SAP – C301AH Circuit Board Ass´y POW – C301AH-A Type Rotary (Hermetic) Compressor model C – R240H5S 80669545 Nominal output 2,400 Compressor oil ... Amount 4GSD – T or SAY–56T ... 1,350 Ω Coil resistance (Ambient temp. 25°C) C –...

  • Page 9: Other Component Specifications

    2-3. Other Component Specifications Indoor Unit SAP – K301AH Transformer (TR) ATR-J105-I Rating Primary AC 230V, 50 / 60 Hz Secondary 19V, 0.526A Capacity 10VA Ω (at 21°C) Coil resistance Primary (WHT – WHT): 205 ± 10% Secondary (BRN – BRN): 2.0 ±...

  • Page 10: Dimensional Data

    3. DIMENSIONAL DATA Indoor Unit SAP – K301AH 1,140 Remote control unit Center of tubing hole (2 places) Narrow tube ø9.52(3/8") Wide tube ø15.88 (5/8") Drain hose ø18 Unit : mm...
  • Page 11 Outdoor Unit SAP – C301AH Hole for anchor bolt ø13 Narrow tube service valve ø9.52 (3/8 ") Wide tube service valve ø15.88 (5/8 ") Refrigerant tubing outlet Inter-unit wiring outlet Power supply wiring outlet Unit : mm Unit : mm...

  • Page 12: Refrigerant Flow Diagram

    4. REFRIGERANT FLOW DIAGRAM Indoor Unit SAP – K301AH Outdoor Unit SAP – C301AH Indoor unit Outdoor unit Accumulator Wide tube service Wide tube valve 4-way Muffler valve O.D. ø15.88 mm (5/8 ") Narrow tube service Narrow tube valve Cooling cycle O.D.

  • Page 13: Performance Data

    5. PERFORMANCE DATA 5-1. Performance charts Indoor Unit SAP – K301AH Outdoor Unit SAP – C301AH Cooling Characteristics Heating Characteristics Indoor inlet air Indoor inlet air D.B. temp. (°C) D.B. temp. (°C) Outdoor Outdoor fan speed fan speed High High –5 Outdoor inlet air D.B.

  • Page 14: Air Throw Distance Chart

    5-2. Air Throw Distance Chart Indoor Unit SAP – K301AH Cooling Room air temp. : 27°C Fan speed High Horizontal distance (m) : Flap angle 0° , : Axis air velocity 0° : Flap angle 30°, : Axis air velocity 30° Heating Room air temp.

  • Page 15: Cooling Capacity

    5-3. Cooling Capacity Indoor Unit SAP – K301AH Outdoor Unit SAP – C301AH 240V Single Phase 50Hz RATING CAPACITY 8.00 kW AIR FLOW RATE 1110 m EVAPORATOR CONDENSER ENT. TEMP. °C OUTDOOR AMBIENT TEMP. °C W.B. D.B. 7.36 7.01 6.58 6.06 2.53 2.72...

  • Page 16: Heating Capacity

    5-4. Heating Capacity Indoor Unit SAP – K301AH Outdoor Unit SAP – C301AH –8 –5 Outdoor temperature (°C D.B.) NOTE … Point of Rating condition Black dot in the chart indicate the following rating condition. Indoor : 20°C D.B. Outdoor : 7°C D.B. / 6°C W.B. 2) Above characteristics indicate instantaneous operation, which does not take into account defrost operation.

  • Page 17: Electrical Data

    6. ELECTRICAL DATA 6-1. Electrical Characteristics Indoor Unit SAP – K301AH Outdoor Unit SAP – C301AH COOLING Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 240V Single phase 50Hz Rating Conditions Running Amps. 0.330 0.660 12.01 13.0 Power Input...

  • Page 18: Electric Wiring Diagram

    6-2. Electric Wiring Diagrams To avoid electrical shock hazard, be sure to Indoor Unit SAP – K301AH disconnect power before checking, servicing WARNING and/or cleaning any electrical parts. Indoor Electrical Compornent Box Controller ( PCB Ass'y ) Power transformer Fan motor capacitor TRANS Terminal plate Room thermistor...
  • Page 19 To avoid electrical shock hazard, be sure to Outdoor Unit SAP – C301AH disconnect power before checking, servicing WARNING and/or cleaning any electrical parts. Outdoor Electrical Compornent Box Fan motor capacitor Controller (PCB Ass´y) Fuse (250V, 20A) Compressor motor capacitor (C2) Compressor motor Terminal capacitor (C1)

  • Page 20: Installation Instructions

              7. INSTALLATION INSTRUCTIONS 7-1. Installation Site Selection Indoor Unit 15 cm min. 15 cm 15 cm min. To prevent abnormal heat min. INDOOR UNIT generation and the possibility WARNING of fire, don’t place obstacles, enclosures and grills in front Front View of or surrounding the air...
  • Page 21 Outdoor Unit AVOID: heat sources, exhaust fans, etc. (Fig. 3) Exhaust fan damp, humid or uneven locations. Hot air Heat source choose a place as cool as possible. Outdoor unit choose a place that is well ventilated. allow enough room around the unit for air intake/exhaust and possible maintenance.

  • Page 22: Remote Control Unit Installation Position

    7-2. Remote Control Unit Installation Position The remote control unit can be operated from either a non-fixed position or a wall-mounted position. To ensure that the air conditioner operates correctly, do not install the remote control unit in the following places: In direct sunlight Behind a curtain or other place where it is covered More than 8 m away from the air conditioner...
  • Page 23 7-3. Recommended Wire Length and Size Regulations on wiring diameter differ from locality to NOTE locality. For field wiring requirements, please refer to Refer to the WIRING SYSTEM DIAGRAM for the your local electrical codes. Carefully observe these meaning of "A", "B" and "C" in Table 2. regulations when carrying out the installation.

  • Page 24: Function

    8. FUNCTION 8-1. Room Temperature Control Cooling Room temperature control is obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the remote control unit. The room temperature (and other information) is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit.
  • Page 25 Heating Room temperature control is obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the remote control unit. The room temperature (and other information) is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit.

  • Page 26: Dry Operation

    8-2. Dry Operation (Dehumidification) Dry operation uses the ability of the cooling cycle to remove moisture from the air, but by running at low level to dehumidify without greatly reducing the room temperature. The air conditioner repeats the cycle of turning ON and OFF automatically as shown in the chart below according to the room temperature.

  • Page 27: Freeze Prevention

    8-4. Freeze Prevention (Cooling) This function prevents freezing of the indoor heat exchange coil. When the compressor has been running for 6 minutes or more and the temperature of the indoor heat exchange coil falls below –1°C, the control circuit stops the compressor for at least 6 minutes. The compressor does not start again until the temperature rises above 8°C.

  • Page 28: Cold Draft Prevention

    8-6. Cold draft Prevention (Heating) This function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coil have sufficiently warmed up. As shown in the chart below, indoor fan speed automatically changes depending upon indoor coil temperature. STANDBY lamp on front of the indoor unit lights up when this function is working.

  • Page 29: Defrosting Operation

    8-7. Defrosting Operation (Heating) Reverse-cycle Defrosting Defrosting Sequence Heating operation Compressor ON 4-way valve ON Frost sensing Frosting is assumed under the following condition. Integrated operating time of compressor is longer than 20 minutes. Air conditioner operates with outdoor heat exchanger temperature lower than L1 for 3 minutes.
  • Page 30 Defrosting Mode Timing Chart Start of Release of defrosting defrosting 60 seconds Max. 12 minutes 60 seconds Compressor 2 seconds 2 seconds Solenoid coil (4-way valve) Outdoor fan Defrosting Zone Outdoor air temperature °C –13 –11 –9 –7 –5 –3 –1 –1 –2...

  • Page 31: Outdoor Fan Speed Control

    8-8. Outdoor Fan Speed Control To optimize performance of the air conditioner, the outdoor fan speed is switched automatically according to the outdoor temperature. Cooling and Dry If the outdoor air temperature falls below 29°C, the fan speed switches to LOW. If the outdoor air temperature rises above 31°C, the fan speed switches to HIGH.

  • Page 32: Troubleshooting

    9. TROUBLESHOOTING 9-1. Check before and after troubleshooting WARNING Hazardous voltage can cause ELECTRIC SHOCK or DEATH. Disconnect power or turn off circuit breaker before you start checking or servicing. 9-1-1. Check power supply wiring. Check that power supply wires are correctly connected to terminals No. 1 and No. 2 on the 3P-terminal plate in the outdoor unit.

  • Page 33: Air Conditioner Does Not Operate

    9-2. Air conditioner does not operate. 9-2-1. 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 2MΩ...
  • Page 34 B. Circuit breaker trips in several minutes after turning the air conditioner on. There is a possibility of short circuit. • Check capacity of circuit breaker. Replace with suitable one (larger capacity). Capacity of circuit breaker is suitable. In case of Heating operation : Measure resistance of outdoor fan •...
  • Page 35 C. Check remote control unit. • Try to run with another remote control unit. First remote control unit is defective. • Check for residue buildup on Clean transmitter. transmitter of remote control unit. • Check for residue buildup on remote control receiver on front of indoor Clean receiver.
  • Page 36 9-2-3. Only outdoor unit does not run. A. Check setting temperature. COOL HEAT Is room temperature too low ? Is room temperature too high ? Try to lower setting temperature by Try to raise setting temperature by temperature setting button ( button).

  • Page 37: Some Part Of Air Conditioner Does Not Operate

    9-3. Some part of air conditioner does not operate. 9-3-1. Only indoor fan does not run. • Check fan casing Remove foreign foreign matter on matter or repair. Fan cannot inside. be turned. • Check fan rotation. Turn fan gently once or twice by hand.
  • Page 38 9-3-4. Only outdoor fan does not run. • Check fan casing Remove foreign foreign matter on matter or repair. Fan cannot inside. be turned. • Check fan rotation. Turn fan gently once or twice by hand. Fan motor burnout or foreign matter in Repair or replace.

  • Page 39: Air Conditioner Operates, But Abnormalities Are Observed

    9-4. Air conditioner operates, but abnormalities are observed. 9-4-1. Operation does not switch from HEAT to COOL (or COOL to HEAT). • Remote control unit may be defective. Receiver in switch Ass'y may be defective. • Measure resistance of 4–way valve's winding.
  • Page 40 9-4-2. Poor cooling or heating. • Check position of remote control unit. Change position of remote Cool or warm air from air conditioner • control unit. reaches position directly. • Wide and narrow tubes between Insulate both wide and narrow indoor unit and outdoor unit are tubes separately and then insulated.

  • Page 41: If A Sensor Is Defective

    9-5. If a sensor is defective. 9-5-1. Indoor coil temp. thermistor (TH1) is defective. • Operation lamp on front side of • Thermistor (TH1 ) is defective. indoor unit is flashing on and off. (*) • Replace thermistor. Alarm Signal (*) NOTE Operation lamp on the front side of the indoor unit will flash on and off when the indoor coil thermistor is defective.

  • Page 42: Checking Electrical Components

    10. CHECKING ELECTRICAL COMPONENTS 10-1. Measurement of Insulation Ground wire Resistance Clip The insulation is in good condition if the resistance exceeds 2MΩ. Probe 10-1-1. Power Supply Wires Insulation tester Fig. 1 Clamp the ground wire of the power supply wires with the lead clip of the insulation resistance tester and Terminal plate measure the resistance by placing a probe on either of...

  • Page 43: Checking Continuity Of Fuse On Pcb Ass'y

    10-2. Checking Continuity of Fuse Fuse on PCB Ass'y Remove the PCB Ass’y from the electrical component box. Then pull out the fuse from the PCB Ass’y. (Fig. 5) PCB Ass’y Check for continuity using a multimeter as shown in Fig.

  • Page 44: Maintenance

    11. MAINTENANCE 11-1. Changing Address of Remote Control Unit in Indoor Unit If you are installing more than 1 indoor unit (up to 2) in the same room, it is necessary for you to assign each unit its own address, so each can be operated by its own separate remote control unit. You assign the addresses by matching the remocon address on the PCB of each indoor unit with the switch positions of its remote control unit.

  • Page 45: Appendix Instruction Manual

    APPENDIX INSTRUCTION MANUAL SAP – K301AH + SAP – C301AH (852-6-4180-400-00-0)
  • Page 46 Features This air conditioner is equipped with cooling, heating and drying functions. Details on these functions are provided below; refer to these descriptions when using the air conditioner. Compact Size Air Sweep Control • • This model is smaller than its predecessors This function moves a flap up and down in the and yet offers the same capabilities.
  • Page 47 Contents Page Features......................2 Product Information ..................3 Alert Symbols ....................3 Installation Location..................4 Electrical Requirements .................. 4 Safety Instructions ..................4 Names of Parts ....................5 Using the Remote Control Unit ..............10 Operation with the Remote Control Unit ........... 12 1.

  • Page 48: Installation Location

    Installation Location We recommend that this air conditioner be installed properly by • qualified installation technicians in accordance with the Installation Instructions provided with the unit. Before installation, check that the voltage of the electric supply in • your home or office is the same as the voltage shown on the nameplate.

  • Page 49: Names Of Parts

    Names of Parts Air intake INDOOR UNIT Air outlet Remote control unit Drain hose Refrigerant tubes OUTDOOR UNIT Air outlet This illustration is based on the external view of a standard model. NOTE Consequently, the shape may differ from that of the air conditioner which you have selected.
  • Page 50 Unit Display and Operation Selector INDOOR UNIT TEST Operation selector IMPORTANT OPERATION lamp TIMER lamp Remote control receiver Avoid using radio equipment such as mobile phone near OPERATION STANDBY TIMER (within 1 m of) the indoor unit. Some radio equipment may cause the unit to malfunction.
  • Page 51 Remote Control Unit (Display) Displayed when setting temperature Displayed when transmitting data Displayed when main unit sensor is in use Displayed when temperature is shown Displayed when the temperature setting is at the upper or lower allowable limit Displayed when setting timer Symbols (1) Operation mode (3) Set temperature...

  • Page 52: Remote Control Unit

    Remote Control Unit Sensor Transmitter Display (Cover closed) ON/OFF operation button 1 HR. TIMER button Temperature setting buttons (TEMP.) NIGHT SETBACK button MODE selector button FAN SPEED selector button FLAP button TIMER SET button (which advances the time displayed) TIMER ON button ADDRESS switch TIMER OFF button ACL button...
  • Page 53 Change the address switch to prevent mixing of signals from • remote control units when two Sanyo air conditioners are installed next to each other. Normally, the address switch is set to A. When switching the address, the remote control must be changed, and the jumper cables on the indoor unit board must be cut.

  • Page 54: Using The Remote Control Unit

    Using the Remote Control Unit How to Install Batteries 1. Slide the cover in the direction indicated by the arrow and remove it. 2. Install two AAA alkaline batteries. Make sure the batteries point in the direction marked in the battery compartment. 3.
  • Page 55 Using the Remote Control Unit (continued) Mounting the Remote Control Unit Truss-head tapping screws 4 x 16 mm (supplied) Press Remote control unit holder Hook When attaching to wall 1) Confirm the indoor unit beeps when the ON/OFF button is pressed at the wall location where the remote control unit is to be attached, then attach the holder to the wall.

  • Page 56: Operation With The Remote Control Unit

    Operation with the Remote Control Unit 1. Automatic Operation STEP 2 STEP 1 Check that the circuit breaker on the power panel is turned on and that NOTE the operation selector of the indoor unit is in the ON position. Once mode is selected and the unit is preset by following the steps below, you can have the air conditioner automatically bring the room to...

  • Page 57: Manual Operation

    Operation with the Remote Control Unit (continued) 2. Manual Operation STEP 2 STEP 3 STEP 1 STEP 4 STEP 5 Check that the circuit breaker on the power panel is turned on and that NOTE the operation selector of the indoor unit is in the ON position. If the automatic operation settings of the unit do not meet your needs, press the setting buttons as described below and change the settings as desired.

  • Page 58: Adjusting The Fan Speed

    Operation with the Remote Control Unit (continued) This appliance has a built-in 3-minute time delay circuit to ensure • NOTE reliable operation. When the operation button is pressed, the compressor will start running within three minutes. In the event of power failure, the unit will stop.

  • Page 59: Night Setback Mode

    Operation with the Remote Control Unit (continued) 4. Night Setback Mode Night Setback Mode is used for saving energy. Press the NIGHT SETBACK button while operation. mark appears in the display. To release the night setback function, press the NIGHT SETBACK button again.
  • Page 60 Operation with the Remote Control Unit (continued) B. In Heating Mode: When the night setback mode is selected, the air conditioner automatically lowers the temperature setting 2°C when 30 minutes have passed after the selection was made, and then another 2°C after another 30 minutes have passed, regardless of the indoor temperature when night setback was selected.

  • Page 61: Special Remarks

    Special Remarks ‘‘DRY’’ ( ) Operation How it works? Once the room temperature reaches the level that was set, the unit • repeats the cycle of turning on and off automatically. During DRY operation, the fan speed is automatically set to LOW or •...

  • Page 62: Using The 12-Hour On And Off Timer

    Using the 12-Hour ON and OFF Timer 1. TIMER ON mode After the length of time set for TIMER ON elapses, the unit begins operating. (Example) The display depicted at left indicates that the air conditioner will begin operating in three hours. Setting procedure: STEP 1 Press the MODE button and set the desired operation...
  • Page 63 Using the 12-Hour ON and OFF Timer (continued) 3. ON/OFF Program Timer A combination of the TIMER ON and TIMER OFF modes, this function allows you to specify the time that the unit turns on and the time when it turns off. (Example) The unit will turn on three hours from now, and turn off five hours from now.

  • Page 64: Using The 1-Hour Off Timer

    Using the 1-Hour OFF Timer 1. 1-Hour OFF Timer This function causes the unit to operate for one hour and then stop, regardless of whether the unit is on or off when this button is pressed. indicator in the display indicates that this function is operating. Setting procedure: Regardless of whether the unit is operating or stopped, press the 1 HR.

  • Page 65: Adjusting The Airflow Direction

    Adjusting the Airflow Direction 1. Horizontal The horizontal airflow can be adjusted by moving the vertical vanes with your hands to the left or right. When the humidity is high, the vertical vanes should be in the front CAUTION position during the cooling or dehumidifying operation. If the vertical vanes are positioned all of the way to the right or left, condensation may begin to form around the air vent and drip down.

  • Page 66: Operation Without The Remote Control Unit

    Operation without the Remote Control Unit INDOOR UNIT If you have lost the remote control unit or it has trouble, follow the steps below. Operation 1. When the air conditioner is not running selector If you want to turn on the air conditioner, switch the operation selector TEST to the OFF position, and then to the ON position.
  • Page 67 Care and Cleaning (continued) Anti-Mold Filter The anti-mold filter behind the air intake grille should be checked and cleaned at least once every two weeks. How to remove the 1. Grasp both ends of anti-mold filter the air intake grille Air intake grille and pull it out and 2.
  • Page 68 Care and Cleaning (continued) Air cleaning filter The air cleaning filter removes dust and dirt from the air, and reduces (not provided) odors and smoke from tobacco. The air cleaning filter is not provided with the air conditioner and must NOTE be purchased separately.

  • Page 69: Troubleshooting

    Troubleshooting If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or service center. Trouble Possible Cause Remedy Air conditioner does not 1. Power failure. 1.
  • Page 70 SANYO Electric Co.,Ltd Osaka, Japan 700459 10/00/200 Printed in Japan...

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