SAP–K91GJA (?2),SAP–CM1621GA,SAP–CM1821GA,SAP–CM1821JA,SAP-K92A,SAP-CM1822A,SAP–K91AA–S,SAP–CM1821AA–S
Sanyo SAP–K91GJA (?2),SAP–CM1621GA,SAP–CM1821GA,SAP–CM1821JA,SAP-K92A,SAP-CM1822A,SAP–K91AA–S,SAP–CM1821AA–S Technical & Service Manual
TECHNICAL & SERVICE MANUAL
SAP–K91GJA (✕2) + SAP–CM1621GA
SAP–K91GJA (✕2) + SAP–CM1821GA
SAP–K91GJA (✕2) + SAP–CM1821JA
FILE NO.
REFERENCE NO. SM700468
Indoor Unit
Outdoor Unit
MULTI-SPLIT SYSTEM AIR CONDITIONER
SAP–CM1621GA
SAP–CM1821GA
SAP–CM1821JA
SAP–K91GJA (✕2)
SAP–K91GJA (
✕2)
SAP–K91GJA (
✕2)
Destination: General (50Hz)
General (60Hz)
Indoor Model No Product Code No.
SAP–K91GJA–S 1 852 070 37
SAP–K91GJA–S 1 852 070 37
SAP–K91GJA–S 1 852 070 37
Outdoor Model No. Product Code No.
SAP–CM1621GA–S 1 852 071 48
SAP–CM1821GA–S 1 852 071 49
SAP–CM1821JA–S 1 852 071 50
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.
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.
WARNING
WARNING
CAUTION
CAUTION
Table of Contents
Page
■ Unit Combination.................................................................................................................................... iii
1. OPERATING RANGE .............................................................................................................................. 1
2. SPECIFICATIONS
2-1. Unit Specifications.......................................................................................................................... 2
2-2. Major Component Specifications.................................................................................................... 5
2-3. Other Component Specifications.................................................................................................... 9
3. DIMENSIONAL DATA.............................................................................................................................. 10
4. COOLING CAPACITY ............................................................................................................................. 12
5. AIR THROW DISTANCE CHART ........................................................................................................... 18
6. REFRIGERANT FLOW DIAGRAM ......................................................................................................... 19
7. ELECTRICAL DATA
7-1. Electrical Characteristics................................................................................................................ 20
7-2. Electric Wiring Diagrams................................................................................................................ 23
8. INSTALLATION INSTRUCTIONS
8-1. Installation Site Selection ............................................................................................................... 25
8-2. Remote Control Unit Installation Position....................................................................................... 27
8-3. Recommended Wire Length and Diameter ................................................................................... 28
9. FUNCTION
9-1. Room Temperature Control ........................................................................................................... 29
9-2. Dry Operation ................................................................................................................................ 30
9-3. Freeze Prevention ......................................................................................................................... 30
10. TROUBLESHOOTING
10-1. Check before and after troubleshooting ........................................................................................ 31
10-2. Air conditioner does not operate .................................................................................................... 32
10-3. Some part of air conditioner does not operate .............................................................................. 37
10-4. Air conditioner operates, but abnormalities are observed ............................................................. 39
10-5. If a sensor is defective ................................................................................................................... 40
11. ARRANGEMENT OF ELECTRICAL COMPONENT .............................................................................. 41
12. CHECKING ELECTRICAL COMPONENTS
12-1. Measurement of Insulation Resistance .......................................................................................... 42
12-2. Checking Continuity of Fuse on PCB Ass'y.................................................................................... 43
12-3. Checking Motor Capacitor ............................................................................................................. 43
13.MAINTENANCE
13-1. Changing Address of Remote Control Unit in Indoor Unit ............................................................. 44
ii
iii
■
Unit Combination
Combine indoor and outdoor units only as listed below.
Indoor Unit
Outdoor Unit
A
B
Fig.1
Outdoor Unit Indoor Unit
Symbol of
Indoor Unit
Refer to
SAP–CM1621GA
K91GJA A
K91GJA B
SAP–CM1821G
K91GJA A
Fig.1
K91GJA B
SAP–CM1821JA
K91GJA A
Fig.1
K91GJA B
Fig.1
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. SPECIFICATIONS
2-1. Unit Specifications
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks: Rating conditions are:
Indoor air temperature 27°C D.B. / 19°C W.B.
Outdoor air temperature 35°C D.B. / 24°C W.B.
2
No. of indoor units. 1-unit 2-units
Power Source 220 / 230 / 240 V Single phase 50 Hz
Cooling
Capacity kW 2.30 4.60
BTU/h 7,800 15,700
Air circulation (High) m3/h 430 430
✕
2
Moisture removal (High) Liters/h 0.8 0.8
✕
2
Voltage rating V 220 / 230 / 240
Available voltage range V 198 to 264
Running amperes A 3.5 / 3.5 / 3.5 6.5 / 6.5 / 6.5
Power input W 750 / 780 / 800 1,410 / 1,450 / 1,500
Power factor % 97 / 97 / 95 99 / 97 / 96
C.O.P. W/W 3.1 / 2.9 / 2.9 3.3 / 3.2 / 3.1
Compressor locked rotor amperes A 17 / 18 / 19 34 / 36 / 38
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 / 1(Hi)
Airflow direction (Indoor) Horizontal Manual
Vertical Auto
Air filter Washable, Anti–Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 1,320 (660
✕
2)
Refrigerant control Capillary tube
Operation sound Indoor – Hi / Me / Lo dB-A 39 / 37 / 33
Outdoor – Hi dB-A 53
Refrigerant tubing connections Flare type
Max. allowable tubing length at shipment m 7.5
Refrigerant tube
Narrow tube mm (in.) 6.35 (1/4)
diameter
Wide tube mm (in.) 9.52 (3/8)
Refrigerant tube kit / Accessories Optional / Hanging wall bracket
Indoor Unit Outdoor Unit
Unit dimensions Height mm 250 630
Width mm 790 810
Depth mm 174 275
Package dimensions Height mm 242 704
Width mm 850 953
Depth mm 312 369
Weight Net kg 7.0 48.0
Shipping kg 10.0 52.5
Shipping volume m
3
0.06 0.25
Dimensions & Weight Features Electrical Rating Performance
Indoor Unit SAP–K91GJA
Outdoor Unit SAP–CM1621GA
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks: Rating conditions are:
Indoor air temperature 27°C D.B. / 19°C W.B.
Outdoor air temperature 35°C D.B. / 24°C W.B.
No. of indoor units. 1-unit 2-units
Power Source 220 / 230 / 240 V Single phase 50 Hz
Cooling
Capacity kW 2.60 5.20
BTU/h 8,900 17,700
Air circulation (High) m3/h 430 430
✕
2
Moisture removal (High) Liters/h 0.80 0.80
✕
2
Voltage rating V 220 / 230 / 240
Available voltage range V 198 to 264
Running amperes A 4.6 / 4.8 / 5.0 8.5 / 8.5 / 9.0
Power input W 960 / 1,000 / 1,060 1,840 / 1,880 / 2,000
Power factor % 95 / 91 / 88 98 / 96 / 93
C.O.P. W/W 2.7 / 2.6 / 2.5 2.8 / 2.8 / 2.6
Compressor locked rotor amperes A 22 / 23 / 24 44 / 46 / 48
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 / 1(Hi)
Airflow direction (Indoor) Horizontal Manual
Vertical Auto
Air filter Washable, Anti–Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 1,260 (630
✕
2)
Refrigerant control Capillary tube
Operation sound Indoor – Hi / Me / Lo dB-A 39 / 37 / 33
Outdoor – Hi dB-A 53
Refrigerant tubing connections Flare type
Max. allowable tubing length at shipment m 7.5
Refrigerant tube
Narrow tube mm (in.) 6.35 (1/4)
diameter
Wide tube mm (in.) 9.52 (3/8)
Refrigerant tube kit / Accessories Optional / Hanging wall bracket
Indoor Unit Outdoor Unit
Unit dimensions Height mm 250 630
Width mm 790 810
Depth mm 174 275
Package dimensions Height mm 242 704
Width mm 850 953
Depth mm 312 369
Weight Net kg 7.0 48.0
Shipping kg 10.0 52.5
Shipping volume m
3
0.06 0.25
Dimensions & Weight Features Electrical Rating Performance
Indoor Unit SAP–K91GJA
Outdoor Unit SAP–CM1821GA
3
4
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks: Rating conditions are:
Indoor air temperature 27°C D.B. / 19°C W.B.
Outdoor air temperature 35°C D.B. / 24°C W.B.
No. of indoor units. 1-unit 2-units
Power Source 220V Single phase 60 Hz
Cooling
Capacity kW 2.60 5.20
BTU/h 8,900 17,700
Air circulation (High) m3/h 430 430
✕
2
Moisture removal (High) Liters/h 0.85 0.85
✕
2
Voltage rating V 220
Available voltage range V 198 to 242
Running amperes A 4.6 8.5
Power input W 960 1,840
Power factor % 95 98
C.O.P. W/W 2.7 2.8
Compressor locked rotor amperes A 24 48
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 / 1(Hi)
Airflow direction (Indoor) Horizontal Manual
Vertical Auto
Air filter Washable, Anti–Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 1,320 (660
✕
2)
Refrigerant control Capillary tube
Operation sound Indoor – Hi / Me / Lo dB-A 39 / 37 / 33
Outdoor – Hi dB-A 53
Refrigerant tubing connections Flare type
Max. allowable tubing length at shipment m 7.5
Refrigerant tube
Narrow tube mm (in.) 6.35 (1/4)
diameter
Wide tube mm (in.) 9.52 (3/8)
Refrigerant tube kit / Accessories Optional / Hanging wall bracket
Indoor Unit Outdoor Unit
Unit dimensions Height mm 250 630
Width mm 790 810
Depth mm 174 275
Package dimensions Height mm 242 704
Width mm 850 953
Depth mm 312 369
Weight Net kg 7.0 48.0
Shipping kg 10.0 52.5
Shipping volume m
3
0.06 0.25
Dimensions & Weight Features Electrical Rating Performance
Indoor Unit SAP–K91GJA
Outdoor Unit SAP–CM1821JA
5
2-2. Major Component Specifications
2-2-1. Indoor Unit
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Part No. POW–K91GJA
Controls Microprocessor
Control circuit fuse 250 V – 3.15 A
Remote Control Unit RCS–2S2E
Type Cross–flow
Number ... Dia. and length mm 1 ... ø95 / L578
Fan motor model ... Number IBH-884-020 ... 1
No. of poles ...50/60Hz rpm (High) 2 ... 1,280/1,280
Nominal output W 20
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN :201
WHT – VLT : 261
Safety Type Thermal fuse
devices Operating temp. Open °C 130
Close —
Run capacitor µF 1.5
VAC 440
Type Stepping motor
Model MP24GA3
Rating DC 12 V
Coil resistance (Ambient temp. 25°C) Ω A pair of each terminal: 380 ± 7%
Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.4
Face area m
2
0.110
Heat
Exch. Coil
Flap Motor Fan & Fan Motor
Controller
PCB
Indoor Unit SAP–K91GJA
2-2-2. Outdoor Unit
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Type Rotary (Hermetic)
Compressor model ... Number C–1R71H5U ... 2 / 80688745–S ... 2
Nominal output W 700
Compressor oil ... Amount cc 4GSD–T or SAY-56T ... 320
✕
2
Coil resistance (Ambient temp. 25°C) Ω C – R : 4.57
C – S : 6.90
Type External protector (OLR 1, 3) External protector (OLR 2, 4)
Safety
Overload relay ... Number MRA98782–9201 ... 2 CS–7C115 ... 2
devices Operating temp. Open °C 130 ± 5 115 ± 3
Close °C 69 ±11 95 ± 5
Operating amp.(Ambient temp. 25°C) Trip in 6 to 16 sec. at 13.5A —
Run capacitor ... Number µF 20.0 ... 2
VAC 400 ... 2
Type Propeller
Number ... Dia. mm 1 ... ø420
Fan motor model ... Number KFG6–51C5P–S ... 1
No. of poles ... rpm (230 V) 6 ... 870
Nominal output W 50
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN : 67.1
WHT – YEL : 83.8
Safety
Type Thermal protector
devices Operating temp. Open °C 130 ± 8
Close Automatic reclosing
Run capacitor µF 4.0
VAC 440
Coil Aluminum plate fin / Copper tube
Rows 1
Fin pitch mm 1.3
Face area m
2
0.506
External Finish Acrylic baked-on enamel finish
Heat
Exch. Coil
Compressor
Fan & Fan Motor
Outdoor Unit SAP–CM1621GA
6
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Type Rotary (Hermetic)
Compressor model ... Number C–1R80H5K ... 2 / 80603345–S ... 2
Nominal output W 800
Compressor oil ... Amount cc 4GSD–T or SAY-56T ... 320
✕
2
Coil resistance (Ambient temp. 25°C) Ω C – R : 3.65
C – S : 5.38
Type External protector (OLR 1, 3) External protector (OLR 2, 4)
Safety
Overload relay ... Number MRA99109-9201 ... 2 CS-7C115 ... 2
devices Operating temp. Open °C 150 ± 5 115 ± 3
Close °C 69 ±11 95 ± 5
Operating amp.(Ambient temp. 25°C) Trip in 6 to 16 sec. at 16A —
Run capacitor ... Number µF 30.0 ... 2
VAC 400 ... 2
Type Propeller
Number ... Dia. mm 1 ... ø420
Fan motor model ... Number KFG6–51C5P–S ... 1
No. of poles ... rpm (230 V) 6 ... 870
Nominal output W 50
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN : 67.1
WHT – YEL : 83.8
Safety
Type Thermal protector
devices Operating temp. Open °C 130 ± 8
Close Automatic reclosing
Run capacitor µF 4.0
VAC 440
Coil Aluminum plate fin / Copper tube
Rows 1
Fin pitch mm 1.3
Face area m
2
0.506
External Finish Acrylic baked-on enamel finish
Heat
Exch. Coil
Compressor
Fan & Fan Motor
Outdoor Unit SAP–CM1821GA
7
8
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Type Rotary (Hermetic)
Compressor model ... Number C–1R71H6U ... 2 / 80688746–S ... 2
Nominal output W 700
Compressor oil ... Amount cc 4GSD–T or SAY-56T ... 320
✕
2
Coil resistance (Ambient temp. 25°C) Ω C – R : 2.87
C – S : 3.29
Type External protector (OLR 1, 3) External protector (OLR 2, 4)
Safety
Overload relay ... Number MRA99053-9201 ... 2 CS-7C115 ... 2
devices Operating temp. Open °C 145 ± 5 115 ± 3
Close °C 69 ±11 95 ± 5
Operating amp.(Ambient temp. 25°C) Trip in 6 to 16 sec. at 16.5A —
Run capacitor ... Number µF 25.0 ... 2
VAC 400 ... 2
Type Propeller
Number ... Dia. mm 1 ... ø420
Fan motor model ... Number KFG6–51C6P–S ... 1
No. of poles ... rpm (220 V) 6 ... 870
Nominal output W 50
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN : 81.3
WHT – PNK : 97.0
Safety
Type Thermal protector
devices Operating temp. Open °C 130 ± 5
Close Automatic reclosing
Run capacitor µF 3.0
VAC 440
Coil Aluminum plate fin / Copper tube
Rows 1
Fin pitch mm 1.3
Face area m
2
0.506
External Finish Acrylic baked-on enamel finish
Heat
Exch. Coil
Compressor
Fan & Fan Motor
Outdoor Unit SAP–CM1821JA
9
2-3. Other Component Specifications
Power Relay (PR) G7L-2A-TUB-55
Coil rating AC 200–240V, 50/60Hz
Coil resistance Ω (at 23°C) 21 ± 15%
Contact rating AC 220V, 25A
Outdoor Unit SAP–CM1621GA
SAP–CM1821GA
SAP–CM1821JA
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–K91GJA
10
3. DIMENSIONAL DATA
Indoor Unit SAP–K91GJA
790
250
174 (3)
Narrow tube ø6.35 (1/4")
Drain hose ø18
58.5
132
41.0
41.0
Center of tubing
hole (2 places)
Remote control unit
172
61 23
Wide tube ø9.52 (3/8")
Unit : mm
11
Outdoor Unit SAP–CM1621GA
SAP–CM1821GA
SAP–CM1821JA
810 15
538
AIR INTAKE
AIR DISCHARGE
136
140
302
630
22
5
275
98 45 45 45
325
Narrow tube service valve
ø6.35 (1/4")
Wide tube service valve
ø9.52 (3/8")
2
1
1
2
Unit : mm
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