Sanyo SAP–K303A,SAP–C303A,SAP–K302A,SAP–C302A Technical & Service Manual
TECHNICAL & SERVICE MANUAL
SAP–K303A + SAP–C303A
FILE NO.
REFERENCE NO. SM700644
Indoor Unit Outdoor Unit
SPLIT SYSTEM AIR CONDITIONER
SAP–K303A SAP–C303A
Destination: Australia
Outdoor Model No. Product Code No.
SAP–C303A–A 1 852 098 62
Indoor Model No. Product Code No.
SAP–K303A–A 1 852 098 83
AIR CO
N
DITIONER
i
Important!
Please Read Before Starting
This air conditioning system meets strict safety and
operating standards. As the installer or service person,
it is an important part of your job to install or service the
system so it operates safely and efficiently.
For safe installation and trouble-free operation, you
must:
●Carefully read this instruction booklet before
beginning.
●Follow each installation or repair step exactly as
shown.
●Observe all local, state, and national electrical codes.
●Pay close attention to all warning and caution notices
given in this manual.
This symbol refers to a hazard or
unsafe practice which can result
in severe personal injury or
death.
This symbol refers to a hazard or
unsafe practice which can result
in personal injury or product or
property damage.
If Necessary, Get Help
These instructions are all you need for most installation
sites and maintenance conditions. If you require help
for a special problem, contact our sales/service outlet
or your certified dealer for additional instructions.
In Case of Improper Installation
The manufacturer shall in no way be responsible for
improper installation or maintenance service, including
failure to follow the instructions in this document.
Special Precautions
When Wiring
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR
DEATH. ONLY A QUALIFIED,
EXPERIENCED ELECTRICIAN SHOULD
ATTEMPT TO WIRE THIS SYSTEM.
• Do not supply power to the unit until all wiring and
tubing are completed or reconnected and checked.
• Highly dangerous electrical voltages are used in this
system. Carefully refer to the wiring diagram and
these instructions when wiring. Improper connections
and inadequate grounding can cause accidental
injury or death.
• Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause
overheating at connection points and a possible fire
hazard.
WARNING
CAUTION
WARNING
When Transporting
Be careful when picking up and moving the indoor and
outdoor units. Get a partner to help, and bend your
knees when lifting to reduce strain on your back. Sharp
edges or thin aluminum fins on the air conditioner can
cut your fingers.
When Installing…
…In a Ceiling or Wall
Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.
…In a Room
Properly insulate any tubing run inside a room to
prevent “sweating” that can cause dripping and water
damage to walls and floors.
…In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to
provide a solid, level foundation for the outdoor unit.
This prevents water damage and abnormal vibration.
…In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.
…In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is
higher than drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces
of the flare and union tubes before connecting them,
then tighten the nut with a torque wrench for a leakfree connection.
• Check carefully for leaks before starting the test run.
When Servicing
• Turn the power off at the main power box (mains)
before opening the unit to check or repair electrical
parts and wiring.
• Keep your fingers and clothing away from any
moving parts.
• Clean up the site after you finish, remembering to
check that no metal scraps or bits of wiring have
been left inside the unit being serviced.
Others
• Ventilate any enclosed areas when installing or
testing the refrigeration system. Escaped refrigerant
gas, on contact with fire or heat, can produce
dangerously toxic gas.
• Confirm upon completing installation that no
refrigerant gas is leaking. If escaped gas comes in
contact with a stove, gas water heater, electric room
heater or other heat source, it can produce
dangerously toxic gas.
CAUTION
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. Air Throw Distance Chart .............................................................................................................. 10
5-3. Cooling Capacity ........................................................................................................................... 11
6. ELECTRICAL DATA
6-1. Electrical Characteristics................................................................................................................ 12
6-2. Electric Wiring Diagram.................................................................................................................. 13
7. INSTALLATION INSTRUCTIONS
7-1. Installation Site Selection............................................................................................................... 15
7-2. Remote Control Unit Installation Position....................................................................................... 17
7-3. Wiring instructions.......................................................................................................................... 18
8. FUNCTION
8-1. Room Temperature Control ........................................................................................................... 19
8-2. Dry Operation ................................................................................................................................ 20
8-3. Freeze Prevention ......................................................................................................................... 20
8-4. Outdoor Fan Speed Control .......................................................................................................... 21
9. TROUBLESHOOTING
9-1. Check before and after troubleshooting ........................................................................................ 22
9-2. Air conditioner does not operate .................................................................................................... 23
9-3. Some part of air conditioner does not operate ..............................................................................27
9-4. Air conditioner operates, but abnormalities are observed ............................................................. 30
10.CHECKING ELECTRICAL COMPONENTS
10-1. Measurement of Insulation Resistance .......................................................................................... 30
10-2. Checking Continuity of Fuse on PCB Ass'y.................................................................................... 31
10-3. Checking Motor Capacitor ............................................................................................................. 31
11.MAINTENANCE
11-1. Changing Address of Remote Control in Indoor Unit ..................................................................... 32
INSTRUCTION MANUAL ........................................................................................................ 33
APPENDIX
ii
1
1. OPERATING RANGE
Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp.
Cooling
Maximum 32°C D.B. / 23°C W.B. 43°C D.B.
Minimum 19°C D.B. / 14°C W.B. 19°C D.B.
2
2. SPECIFICATIONS
2-1. Unit Specifications
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks: Rating conditions are:
Cooling: Indoor air temperature 27°C D.B. / 19°C W.B.
Outdoor air temperature 35°C D.B. / 24°C W.B.
Heating: Indoor air temperature 20°C D.B.
Outdoor air temperature 7°C D.B. / 6°C W.B.
Power Source 240 V Single phase 50Hz
Voltage rating V 240
Cooling
Capacity
kW 8.50
BTU/h 29,000
Air circulation (High) m
3
/h 1,110
Moisture removal (High) Liters/h 3.4
Available voltage range V 216 to 264
Running amperes A 13.2
Power input W 3,150
Power factor % 99
C.O.P. W/W 2.70
Compressor locked rotor amperes A 63
Controls / Temperature control Microprocessor / I.C. thermostat
Control unit Wireless remote control unit
Timer 1-hour OFF / 12-hour ON or OFF
Fan speeds Indoor / Outdoor 3 and Auto / Auto(Hi, Lo)
Airflow direction (Indoor)
Horizontal Manual
Vertical Auto
Air filter Washable, Anti-Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 2,600
Refrigerant control Capillary tube
Operation sound
Indoor – Hi / Me / Lo dB-A 47 / 41 / 38
Outdoor – Hi dB-A 54
Refrigerant tubing connections Flare type
Max. allowable tubing length at shipment m 7.5
Refrigerant tube
Narrow tube mm (in.) 9.52 (3/8)
diameter
Wide tube mm (in.) 15.88 (5/8)
Refrigerant tube kit / Accessories Optional / Hanging wall bracket
Indoor Unit Outdoor Unit
Unit dimensions Height mm 330 735
Width mm 1,140 940
Depth mm 228 340
Package dimensions Height mm 325 826
Width mm 1,231 1,016
Depth mm 406 416
Weight Net
kg 18.0 71.0
Shipping
kg 20.0 77.0
Shipping volume m
3
0.16 0.35
Dimensions & Weight Features Electrical Rating Performance
Indoor Unit SAP–K303A
Outdoor Unit SAP–C303A
3
2-2. Major Component Specifications
2-2-1. Indoor Unit
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Part No. POW–K301A
Controls Microprocessor
Control circuit fuse 250 V – 3.15 A
Remote Control Unit RCS–4S4E–G
Type Cross-flow
Q´ty ... Dia. and length mm 1 ... ø100 / L847.4
Fan motor model ... Q´ty KFG4X–31B5P–C ... 1
No. of poles .... rpm (240V, High) 4 ... 1,270
Nominal output W 30
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN : 103.3 WHT – VLT : 32.5
VLT – ORG : 75.5 ORG – YEL : 28.6
YEL – BLK : 18.9 BLK – PNK : 48.0
– : –
– : –
Safety
Type Thermal protector
devices Operating temp. Open °C 130 ± 8
Close Automatic reclosing
Run capacitor µF 1.0
VAC 440
Type Stepping motor
Model ... Q´ty MP24GA2 ... 2
Rating DC 12 V
Coil resistance (Ambient temp. 20°C) kΩ Each terminals (1–2, 1–3, 1–4, 1–5) : 400 ± 7%
Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.3
Face area m2 0.214
Heat
Exch. Coil
Flap Motor Fan & Fan Motor
Circuit
Board
Ass´y
Indoor Unit SAP–K303A
4
2-2-2. Outdoor Unit
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Circuit Board Ass´y POW–C301A–A
Type Rotary (Hermetic)
Compressor model C–R240H5S 80669545
Nominal output W 2,400
Compressor oil ... Amount cc 4GSD–T or SAY–56T ... 1,350
Coil resistance (Ambient temp. 25°C) Ω C – R : 0.944
C – S : 1.732
Type Internal protector
Safety
Overload relay —
devices Operating temp. Open °C Automatic opening
Close °C Automatic reclosing
Operating amp.(Ambient temp. 25°C) —
Run capacitor ... Q´ty µF 35.0 ... 2
VAC 400 ... 2
Crank case heater —
Type Propeller
Q´ty ... Dia. mm 1 ... ø 460
Fan motor model ... Q´ty KFC6S–91D5P–C ... 1
No. of poles .... rpm (240V, High) 6 ... 780
Nominal output W 90
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN :129.0
WHT – YEL : 57.4
YEL – PNK : 22.1
Safety
Type Thermal protector
devices Operating temp. Open °C 130 ± 8
Close Automatic reclosing
Run capacitor µF 6.0
VAC 440
Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.8
Face area m
2
0.630
External Finish Acrylic baked-on enamel finish
Heat
Exch. Coil
CompressorFan & Fan Motor
Outdoor Unit SAP–C303A
2-3. Other Component Specifications
5
Fuse
Cartridge type
Rating / Size
250V, 20A / ø6.4 x 30mm
Power Relay (PR)
EL1U
Coil rating
AC 200–240V, 50/60Hz
Contact rating
AC 277V, 30A
Thermistor (Air sensor)
PBC–41E–S14
Resistance kΩ
–20°C 40.1± 5% 20°C 6.5 ± 5%
–10°C 24.4 ± 5% 30°C 4.4 ± 5%
0°C 15.3 ± 5% 40°C 3.0 ± 5%
10°C 9.9 ± 5% 50°C 2.1± 5%
Outdoor Unit SAP–C303A
Thermistor (Room sensor)
DTN-TKS128B
Resistance kΩ
25°C 5.0 ± 3%
Thermistor (Coil sensor)
DTN-TKS131B
Resistance kΩ
0°C 15.0 ± 2%
Transformer (TR)
ATR-J105
Rating Primary
AC 230V, 50/60Hz
Secondary
19V, 0.526A
Capacity
10VA
Coil resistance Ω (at 21°C)
Primary (WHT – WHT): 205 ± 10%
Secondary (BRN – BRN): 2.0 ± 10%
Thermal cut-off temp.
150°C
Indoor Unit SAP–K303A
6
3. DIMENSIONAL DATA
Indoor Unit SAP–K303A
174
Center of tubing
hole (2 places)
Narrow tube ø9.52(3/8")
Wide tube ø15.88 (5/8")
228
48
135
330
1,140
48
Drain hose ø18
Remote control unit
Unit : mm
196
46. 5
27. 4
7
0
32
133 .8
52 23
7
Outdoor Unit SAP–C303A
735
280
307
940
Unit : mm
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
400
380
20
50 50
340
110660170
1
6
5
4
3
2
1
6
5
5
4
4
3
2
6
Unit : mm
4. REFRIGERANT FLOW DIAGRAM
8
Insulation of Refrigerant Tubing
Because capillary tubing is used in the outdoor unit, both the
wide and narrow tubes of this air conditioner become cold. To
prevent heat loss and wet floors due to dripping of
condensation, both tubes must be well insulated with a
proper insulation material. The thickness of the insulation
should be a min. 8 mm.
After a tube has been insulated,
never try to bend it into a narrow
curve because it can cause the tube
to break or crack.
IMPORTANT
CAUTION
Wide tube
Thickness:
Min. 8 mm
Insulation
Narrow tube
Thickness:
Min. 8 mm
Indoor Unit SAP–K303A Outdoor Unit SAP–C303A
Compressor
Accumulator
Wide tube
service
valve
Indoor Unit Outdoor Unit
Muffler
Wide tube
O.D.
ø15.88 mm
(5/8 ")
Narrow
tube
service
valve
Narrow tube
O.D.
ø9.52 mm
(3/8")
Evaporator
Condenser
Capillary tube
5. PERFORMANCE DATA
5-1. Performance charts
Indoor Unit SAP–K303A
Outdoor Unit SAP–C303A
9
Outdoor
fan speed
HighLow
1.28 (12)
1.18 (11)
1.08 (10)
0.98 ( 9 )
0.89 ( 8 )
0.79 ( 7 )
0.69 ( 6 )
25 30 35 40 45 50
Outdoor inlet air D.B. temp. (°C)
Low pressure at wide tube serveice valve MPa (kgf/cm
2
G)
0.59 ( 5 )
0.49 ( 4 )
0.39 ( 3 )
■ Cooling Characteristics
18
17
16
15
14
13
12
11
10
25 30 35 40 45 50
Outdoor inlet air D.B. temp. (°C)
Operating current (A)
19
Outdoor
fan speed
HighLow
9
Indoor inlet air
D.B. temp. (°C)
Indoor inlet air
D.B. temp. (°C)
32
27
21
32
27
21
● ...... Points of Rating condition
Black dots in above charts indicate the following rating conditions.
Cooling: Indoor air temperature 27°C D.B./19°C W.B.
Outdoor air temperature 35°C D.B./24°C W.B.
NOTE
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