Sanyo SAP-C303A Technical & Service Manual Download Page 1

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TECHNICAL & SERVICE MANUAL

SAP – K30

A + SAP – C30

FILE NO.

REFERENCE NO.

700

644

Indoor Unit

Outdoor Unit

SPLIT SYSTEM AIR CONDITIONER

SAP – K30

SAP – C30

Destination: Australia

Outdoor Model No.

Product Code No.

SAP – C30

–

1 852 0

Indoor Model No.

Product Code No.

SAP – K30

A–

1 852 0

AIR CONDITIONER

Summary of Contents for SAP-C303A

Page 1: ...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 CONDITIONER ...

Page 2: ...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 st...

Page 3: ...trol 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...

Page 4: ...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 ...

Page 5: ...FF 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 len...

Page 6: ...tput 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 ...

Page 7: ... 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...

Page 8: ...0 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 ...

Page 9: ...SIONAL 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 ...

Page 10: ...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 50 340 110 660 170 1 6 5 4 3 2 1 6 5 5 4 4 3 2 6 Unit mm ...

Page 11: ...terial 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 ...

Page 12: ...lve 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 High Low 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 1...

Page 13: ...hart Horizontal distance m Axis air velocity m s Vertical distance m Room air temp 27 C Fan speed High 0 1 2 3 4 0 1 2 3 4 5 6 7 8 9 Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 10 Indoor Unit SAP K303A ...

Page 14: ...HC 6 62 6 41 6 16 5 85 31 S HC 7 13 6 92 6 67 6 36 T C 8 93 8 50 7 99 7 35 C M 2 70 2 89 3 11 3 34 21 S HC 4 02 3 80 3 56 3 26 19 23 S HC 4 53 4 32 4 07 3 77 25 S HC 5 04 4 83 4 58 4 28 27 S HC 5 55 5 34 5 09 4 79 29 S HC 6 06 5 85 5 60 5 30 31 S HC 6 57 6 36 6 11 5 81 T C 9 46 9 01 8 47 7 79 C M 2 77 2 98 3 11 3 44 23 S HC 3 96 3 75 3 50 3 20 21 25 S HC 4 47 4 26 4 01 3 72 27 S HC 4 98 4 77 4 52 ...

Page 15: ...gle phase 50Hz Rating Conditions Running Amps A 0 330 0 660 12 21 13 2 Power Input kW 0 072 0 146 2 932 3 15 Full Load Conditions Running Amps A 0 330 0 660 14 51 15 5 Power Input kW 0 072 0 146 3 472 3 69 Rating Conditions Indoor Air Temperature 27 C D B 19 C W B Outdoor Air Temperature 35 C D B Full Load Conditions Indoor Air Temperature 32 C D B 23 C W B Outdoor Air Temperature 43 C D B ...

Page 16: ...ing any electrical parts WARNING Indoor Unit SAP K303A TRANS 1 2 4 5 6 7 8 C B P Controller PCB Ass y Power transformer Fan motor capacitor Terminal plate Room thermistor Coil thermistor Indicator lamp Ass y Upper flap motor Lower flap motor GREEN MAKE on lower flap motor Grille air outlet Side View Indoor Electrical Compornent Box ...

Page 17: ...arts WARNING Outdoor Unit SAP C303A Terminal plate 8P Terminal plate 3P Compressor motor capacitor C1 Compressor motor capacitor C2 Power relay Fan motor capacitor Controller PCB Ass y Clamp Fuse 250V 20A Outdoor Electrical Compornent Box Parts Layout in Outdoor Unit Compressor Fan motor Heat exchenger coil Air thermistor ...

Page 18: ...aintenance as well as unrestricted air flow around the unit Fig 1 install the unit within the maximum elevation difference H above or below the outdoor unit and within a total tubing length L from the outdoor unit as detailed Table 1 and Fig 2a Indoor Unit 15 cm min 15 cm min 15 cm min INDOOR UNIT Front View INDOOR UNIT Tubing length L OUTDOOR UNIT Elevation difference H Fig 2 Fig 2a Fig 1 WARNING...

Page 19: ... a minimum of 10 cm above ground level to reduce humidity and protect the unit against possible water damage and decreased service life Fig 5 use lug bolts or equal to bolt down unit reducing vibration and noise Outdoor Unit Outdoor unit Hot air Heat source Exhaust fan Fig 3 Fig 3 Min 1 cm Min 1 cm Min 50 cm Min 10 cm Air in Air in Air discharge Anchor bolts 4 pieces Min 10 cm Min 2 m Min 2 m Obst...

Page 20: ...obstacle between the remote control unit and air conditioner since a check signal is sent from the remote control unit every 5 minutes Attaching the remote control unit to wall Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location Fig 6 The indoor unit should make a beeping sound to indic...

Page 21: ...d to touch refrigerant tubing the compressor or any moving part To avoid the risk of electric shock each air conditioner unit must be grounded Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram The indoor unit draws its power from the outdoor unit WARNING WARNING CAUTION WIRING SYSTEM DIAGRAM 2 4 2 4 1 1 INDOOR UNIT 5 6 7 6 7 5 Terminal OUTDOOR UNIT B Power...

Page 22: ...t pressure the control circuit has a built in automatic time delay to allow the internal pressure to equalize As a protective measure the control circuit switches the compressor OFF after 5 minutes or more of compressor operation Thermo ON When the room temperature is above T 1 C T C is set temperature Compressor ON Thermo OFF When the room temperature is equal to or below set temperature T C Comp...

Page 23: ...ng 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 ON ON ON ON OFF OFF Set speed More than 6 minutes 6 minutes T 1 C Indoor heat exch coil temp 1 C Compressor Indoor fan Room temp Thermo OFF Thermo ON Set temp T C More ...

Page 24: ... fan speed is switched automatically according to the outdoor temperature 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 H H L 31 29 Outdoor air temperature C Outdoor fan speed 21 ...

Page 25: ... in specified range 10 of the rating Check that power is being supplied 9 1 4 Check lead wires and connectors in indoor and outdoor units Check that coating of lead wires is not damaged Check that lead wires and connectors are firmly connected Check that wiring is correct 1 2 4 5 6 7 1 2 4 5 6 7 Indoor unit Outdoor unit Ground Inter unit power wiring Ground 1 2 4 5 6 7 8 8 Power supply Single phas...

Page 26: ...e Measure resistance of outdoor fan motor winding Measure resistance of compressor motor winding Measure insulation resistance of electrical parts in outdoor unit NO NO Measure insulation resistance of electrical parts in indoor unit 1 Remove both power supply wires and inter unit wires from terminal plate in outdoor unit Measure insulation resistance of outdoor unit 2 Remove inter unit wires from...

Page 27: ... Set OPERATION selector switch to ON Indoor PCB Ass y is defective OK Try to run with another remote control unit First remote control unit is defective Check for residue buildup on transmitter of remote control unit Check for residue buildup on remote control receiver on front of indoor unit Clean transmitter Clean receiver NO Check power supply Power is being supplied to the outdoor unit Circuit...

Page 28: ...indoor PCB Ass y for continuity F Check operation lamp to see if light is ON Light is OFF Measure resistance of primary and secondary winding of transformer TR Indoor PCB Ass y or switch Ass y is defective OK OK Measure resistance of indoor fan motor winding FM Measure resistance of flap motor winding FLP OK Measure coil resistance of power relay PR Replace the fuse If fuse has been blown 25 ...

Page 29: ...oor unit OK Measure coil resistance of power relay Check indoor PCB Ass y PR OK NO Is room temperature too low Try to lower setting temperature by temperature setting button button Outdoor unit still does not run Remote control unit is defective Try to run using another remote control unit 26 ...

Page 30: ...urnout or foreign matter in bearings Remove foreign matter or repair Repair or replace Measure resistance of outdoor fan motor winding Check fan motor capacitor Fan cannot be turned OK Check fan rotation Turn fan gently once or twice by hand Check fan casing foreign matter on inside Fan motor burnout or foreign matter in bearings Remove foreign matter or repair Repair or replace Measure resistance...

Page 31: ...in outdoor unit Measure resistance of flap motor winding FLP Check compressor motor capacitor Measure resistance of compressor motor winding Measure resistance of power relay PR NO NO YES YES Refrigerant gas shortage Charge refrigerant gas R22 Rotor may be locked up C1 or C2 Measure Power supply voltage The voltage is too low No Compressor internal protector is working Temperature of compressor is...

Page 32: ...h approx 10 deg or more Possibility of gas shortage YES Check position of remote control unit Cool air from air conditioner reaches position directly Change position of remote control unit Wide and narrow tubes between indoor unit and outdoor unit are insulated Insulate both wide and narrow tubes separately and then tape together Measure temperature of suction and discharge air of air conditioner ...

Page 33: ... metallic part of the unit with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw where power supply lines are connected on the terminal plate Fig 2 10 1 4 Measurement of Insulation Resistance for Electrical Parts Disconnect the lead wires of the desired electric part from terminal plate capacitor etc Similarly disconnect the con...

Page 34: ... and then place a probe on the capacitor terminals as shown in Fig 7 Observe the deflection of the pointer setting the resistance measuring range of the multimeter to the maximum value The capacitor is good if the pointer bounces to a great extent and then gradually returns to its original position The range of deflection and deflection time differ according to the capacity of the capacitor Fuse P...

Page 35: ...you cannot restore the original address setting of the remote control unit To Change Address on PCB 1 Cut jumper wire JP11 on the indoor unit PCB Use cutting pliers to cut and disconnect the Jumper wire To Change Address on Remote Control Unit NOTE NOTE 32 1 Remove the batteries before changing the address 2 Remove tab marked A to change the address of the remote control unit ACL button 3 When it ...

Page 36: ...peration Selector INDOOR UNIT NOTE The illustration above pictures the remote control unit after the cover has been opened and removed OPERATION TIMER ON OFF TEST OPERA TION lamp TIMER lamp Remote control receiver Operation selector ...

Page 37: ...SANYO Electric Co Ltd GSA SAMS SM700644 Aug 2005 Printed in Japan ...

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