Sanyo SAP-CM1621GA Technical & Service Manual Download Page 4 | Manualshive

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Unit Combination

Combine indoor and outdoor units only as listed below.

Indoor Unit

Outdoor Unit

A

B

Fi 1

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

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Summary of Contents for SAP-CM1621GA

Page 1: ...IT 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 ...

Page 2: ...g 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...

Page 3: ... 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 AR...

Page 4: ... outdoor units only as listed below Indoor Unit Outdoor Unit A B Fi 1 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 ...

Page 5: ...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 6: ...eless 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 connect...

Page 7: ... 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 ...

Page 8: ...peeds 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 Refr...

Page 9: ... 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 ar...

Page 10: ... 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 capa...

Page 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...

Page 12: ...1 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 µ...

Page 13: ...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 ...

Page 14: ...0 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 ...

Page 15: ...or 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 ...

Page 16: ... 27 2 16 2 03 1 87 TC 2 65 2 53 2 42 2 30 2 16 1 99 CM 0 51 0 55 0 59 0 63 0 70 0 77 21 SHC 1 16 1 11 1 06 1 02 0 96 0 89 19 23 SHC 1 37 1 32 1 27 1 23 1 17 1 10 25 SHC 1 58 1 53 1 48 1 43 1 38 1 31 27 SHC 1 79 1 74 1 69 1 64 1 59 1 52 29 SHC 2 00 1 95 1 90 1 85 1 80 1 73 31 SHC 2 21 2 16 2 11 2 06 2 01 1 94 TC 2 80 2 68 2 56 2 44 2 29 2 11 CM 0 52 0 56 0 60 0 65 0 72 0 79 23 SHC 1 14 1 10 1 05 1 ...

Page 17: ... 4 06 3 74 TC 5 29 5 06 4 83 4 60 4 32 3 98 CM 1 02 1 10 1 18 1 26 1 36 1 46 21 SHC 2 33 2 23 2 13 2 03 1 92 1 78 19 23 SHC 2 75 2 65 2 55 2 45 2 34 2 20 25 SHC 3 17 3 07 2 97 2 87 2 76 2 62 27 SHC 3 59 3 48 3 39 3 29 3 18 3 04 29 SHC 4 00 3 90 3 81 3 71 3 59 3 45 31 SHC 4 42 4 32 4 23 4 13 4 01 3 87 TC 5 61 5 36 5 12 4 88 4 58 4 22 CM 1 05 1 13 1 21 1 30 1 40 1 50 23 SHC 2 29 2 19 2 09 2 00 1 89 ...

Page 18: ...2 30 2 11 TC 2 99 2 86 2 73 2 60 2 44 2 25 CM 0 69 0 74 0 79 0 85 0 92 0 99 21 SHC 1 32 1 26 1 20 1 14 1 08 0 99 19 23 SHC 1 53 1 47 1 41 1 35 1 29 1 20 25 SHC 1 74 1 68 1 62 1 56 1 50 1 41 27 SHC 1 95 1 89 1 83 1 77 1 71 1 62 29 SHC 2 16 2 10 2 04 1 98 1 92 1 83 31 SHC 2 37 2 31 2 25 2 19 2 12 2 04 TC 3 17 3 03 2 89 2 76 2 59 2 38 CM 0 70 0 76 0 82 0 87 0 95 1 02 23 SHC 1 30 1 24 1 18 1 13 1 06 0...

Page 19: ... 4 59 4 23 TC 5 98 5 72 5 46 5 20 4 89 4 50 CM 1 36 1 47 1 58 1 69 1 90 2 10 21 SHC 2 64 2 52 2 40 2 29 2 15 1 99 19 23 SHC 3 06 2 94 2 82 2 71 2 57 2 41 25 SHC 3 48 3 36 3 24 3 13 2 99 2 83 27 SHC 3 90 3 78 3 66 3 55 3 41 3 25 29 SHC 4 31 4 20 4 08 3 97 3 83 3 67 31 SHC 4 73 4 62 4 50 4 38 4 25 4 09 TC 6 34 6 06 5 79 5 51 5 18 4 77 CM 1 40 1 52 1 62 1 74 1 95 2 15 23 SHC 2 60 2 48 2 36 2 25 2 12 ...

Page 20: ...2 2 30 2 11 TC 2 99 2 86 2 73 2 60 2 44 2 25 CM 0 66 0 71 0 76 0 82 0 89 0 97 21 SHC 1 32 1 26 1 20 1 15 1 08 1 00 19 23 SHC 1 53 1 47 1 41 1 36 1 29 1 21 25 SHC 1 74 1 68 1 62 1 57 1 50 1 42 27 SHC 1 95 1 89 1 83 1 78 1 71 1 63 29 SHC 2 16 2 10 2 04 1 99 1 92 1 84 31 SHC 2 37 2 31 2 25 2 20 2 13 2 05 TC 3 17 3 03 2 89 2 76 2 59 2 38 CM 0 67 0 73 0 78 0 84 0 92 1 00 23 SHC 1 30 1 24 1 19 1 13 1 06...

Page 21: ... 4 59 4 23 TC 5 98 5 72 5 46 5 20 4 89 4 50 CM 1 34 1 45 1 55 1 66 1 81 1 96 21 SHC 2 64 2 52 2 41 2 29 2 16 2 00 19 23 SHC 3 06 2 94 2 83 2 71 2 58 2 42 25 SHC 3 48 3 36 3 25 3 13 3 00 2 83 27 SHC 3 90 3 78 3 67 3 55 3 42 3 25 29 SHC 4 32 4 20 4 09 3 97 3 84 3 67 31 SHC 4 74 4 62 4 51 4 39 4 26 4 09 TC 6 34 6 06 5 79 5 51 5 18 4 77 CM 1 38 1 49 1 59 1 71 1 86 2 01 23 SHC 2 60 2 49 2 37 2 26 2 13 ...

Page 22: ...ART Horizontal distance m Axis air verocity 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 18 Indoor Unit SAP K91GJA ...

Page 23: ...st be well insulated with a proper insula tion 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 Wide tube Thickness Min 8 mm Insulation Narrow tube Thickness Min 8 mm CAUTION Outdoor Unit Wide tube O D ø9 52mm 3 8 Narrow tube O D ø6 35 mm 1 4 Condenser Wid...

Page 24: ...ns Indoor Air Temperature 32 C D B 23 C W B Outdoor Air Temperature 43 C D B Indoor Unit SAP K91GA 2 Outdoor Unit SAP CM1621GA Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230V Single phase 50Hz Rating Conditions Running Amps A 0 18 0 49 2 83 3 5 Power Input kW 0 037 0 112 0 631 0 78 Full Load Conditions Running Amps A 0 18 0 49 3 63 4 3 Power Input kW 0 037...

Page 25: ...e 32 C D B 23 C W B Outdoor Air Temperature 43 C D B Indoor Unit SAP K91GA 2 Outdoor Unit SAP CM1821GA Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230V Single phase 50Hz Rating Conditions Running Amps A 0 18 0 49 4 13 4 8 Power Input kW 0 037 0 112 0 851 1 00 Full Load Conditions Running Amps A 0 18 0 49 5 03 5 7 Power Input kW 0 037 0 112 1 041 1 19 Rating...

Page 26: ...e 32 C D B 23 C W B Outdoor Air Temperature 43 C D B Indoor Unit SAP K91GA 2 Outdoor Unit SAP CM1821JA Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 220V Single phase 60Hz Rating Conditions Running Amps A 0 15 0 52 3 93 4 6 Power Input kW 0 031 0 114 0 815 0 96 Full Load Conditions Running Amps A 0 15 0 52 4 73 5 4 Power Input kW 0 031 0 114 1 025 1 17 Rating...

Page 27: ...23 7 2 Electric Wiring Diagram Indoor Unit SAP K91GJA To avoid electrical shock hazard be sure to disconnect power before checking servicing and or cleaning any electrical parts WARNING ...

Page 28: ...24 Outdoor Unit SAP CM1621GA SAP CM1821GA SAP CM1821JA To avoid electrical shock hazard be sure to disconnect power before checking servicing and or cleaning any electrical parts WARNING ...

Page 29: ...NIT Front View Wall mounted Type Wall Mounted Type Front View Fig 2a WARNING Minimum height from floor level 1 5m Indoor Unit Wall Floor level For stable operation of the air conditioner do not install wall mounted type indoor units less than 1 5m from floor level CAUTION Fig 2b 8 1 Installation Site Selection Maximum Allowable Tubing Length L and Elevation Difference H The Multi Split System outd...

Page 30: ... 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 vibra tion and noise Outdoor Unit Outdoor unit Hot air Heat source Exhaust fan Fig 3 Fig 3 Air intake Min 10 cm Air discharge Min 5 cm Min 40 cm Valve side Min 25 cm Top View Air intake Concrete or equal About 10 cm Min 10 cm Anchor bolts 4 pcs A...

Page 31: ...it pull it from the holder When using the remote control unit Point the transmission portion of the remote con trol unit at the receiver area of the indoor unit when operating the remote control unit and dur ing operation of the air conditioner Do not place objects which may block the transmit ted signals between the receiver and the remote control unit When mounting the remote control unit to pre...

Page 32: ... to your local electrical codes Carefully observe these regula tions when carrying out the installation Table 2 lists recommended wire lengths and size for power supply systems Refer to the WIRING SYSTEM DIAGRAM for the meaning of A and B in Table 2 NOTE 28 WARNING 8 3 Recommended Wire Length and Diameter WARNING AWG American Wire Gauge Table 2 A Power Supply Wiring Length m B Power Line Length m ...

Page 33: ...t pres sure 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 Com...

Page 34: ...tes L low speed LL very low speed intermittent ventilation only while the compressor is ON Intermittent ventilation occurs by switching the indoor fan speed between L LL Dry operation does not occur when the room temperature is under 15 C which is the monitor zone When the compressor stops the indoor fan stops as well 9 3 Freeze Prevention This function prevents freezing of the indoor heat exchang...

Page 35: ...ating Check that power is being supplied 10 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 con nected Check that wiring is correct 31 WARNING Hazardous voltage can cause ELECTRIC SHOCK or DEATH Disconnect power or turn off circuit breaker before you start checking or servicing Ground Gr...

Page 36: ... circuit breaker to OFF 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 terminal plate in indoor unit Measure insulation resistance of indoor unit Insulation of outdoor unit is defective Insulation of indoor unit is ...

Page 37: ... conditioner on There is a possibility of short circuit Replace with suitable one larger capacity NO Check capacity of circuit breaker Capacity of circuit breaker is suitable Measure resistance of outdoor fan motor winding Measure resistance of compressor motor winding ...

Page 38: ...ecovery or contact power company YES NO OPERATION selector switch is set in ON position Set OPERATION selector switch to ON Switch Ass y or indoor PCB Ass y is defective Refer to Step C below Clean transmitter 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 cont...

Page 39: ...tance 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 FMI Measure resistance of flap motor winding FLP OK Measure coil resistance of power relay in outdoor unit PRA PRB Replace the fuse If fuse has been blown Timer is turned ON Check to see if is displayed on remote control YES Cancel the timer mo...

Page 40: ...door unit OK NO Is room temperature too low Try to lower setting temperature by temperature setting button cooler Outdoor unit still does not run Remote control unit is defective Try to run using another remote control unit OK Measure coil resistance of power relay Check indoor PCB Ass y PRA PRB ...

Page 41: ...e resistance of indoor fan motor winding Check fan motor capacitor OK Measure resistance of indoor fan motor winding Check fan motor capacitor NO When fan speed is changed does applied voltage between lead wires BRN and WHT change as well PCB Ass y is defective 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 burno...

Page 42: ...re resistance of compressor motor winding NO YES YES overload relay is working OLR 1 to 4 YES Temperature of compressor is abnormally high Refrigerant gas shortage Charge refrigerant gas R22 Rotor may be locked up C2 C3 Measure Power supply voltage The voltage is too low No Measure resistance of flap motor winding ...

Page 43: ...tdoor unit are insulated Insulate both wide and narrow tubes separately and then tape together Measure temperature of suction and discharge air of air conditioner Charge refrigerant gas R22 Check for clogging of air filter Fan speed is set to LOW Clean filter Set fan speed to either HIGH or MEDIUM Review cooling load estimate if performance of air conditioner is normal Reduce cooling load or repla...

Page 44: ...nditioner will be in the following conditions as the controller tries to detect extremely high room temperature In Cooling mode The air conditioner continues to operate Thermo ON Both the outdoor fan and com pressor do not stop As a result the room becomes too cold Definition of Open or Short Circuit of Sensor Thermistor Open A lead wire is broken or disconnected or the circuit inside the temperat...

Page 45: ...Compressor B CMB Fan motor Heat exchenger coil Electric Parts Parts Layout in Unit Power relay A PRA Overload relay 3 B Terminal plate To indoor unit B To indoor unit A From power supply 1 2 4 5 6 7 8 9101112 Compressor motor capacitor C2 Compressor motor capacitor C3 Outdoor Unit SAP CM1621GA SAP CM1821GA SAP CM1821JA ...

Page 46: ...p a 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 12 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 ...

Page 47: ...nd 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 accord ing to the capacity of the capacitor Compres...

Page 48: ...s remote control unit Once changed you cannot restore the original address setting of the remote control unit To Change Address on PCB 1 Cut jumper wire JP02 on the indoor unit PCB Use cutting pliers to cut and disconnect the Jumper wire 2 Switch the address switch on the remote control unit to B position 3 After inserting the batteries press reset button To Change Address on Remote Control Unit R...

Page 49: ......

Page 50: ...SANYO Electric Co Ltd Osaka Japan SM700468 11 00 200 Printed in Japan ...

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