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Sanyo SAP-CR184G, Technical & Service Manual

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Sanyo SAP-CR184G Technical & Service Manual Download Page 22

22

To avoid electrical shock hazard, be sure to

disconnect power before checking, servicing

and/or cleaning any electrical parts.

WARNING

Indoor Unit

SAP – KR224GJ

Outdoor Unit

SAP – CR224G

11

22

33

44

55

11

22

33

44

55

11

22

33

44

11

22

33

11

22

33

44

11

22

33

44

55

66

77

88

99

11

22

33

44

55

66

77

88

99

44

33

22

11

55

66

RED

WHT

WHT

WHT

WHT

WHT

WHT

WHT

WHT

BLK

BLK

BLK

BLK

IND  LAMP  ASSY

R

OOM  

THERMIST

OR

COIL  

THERMIST

OR

CONNECT

OR

RED

PNK

BLU

BRN

YEL

RED

BLK

WHT

YEL

BLU

FM

FLAP

EV

APORA

T

O

R

FLAP  MO

T

O

R

FLAP

5P

(WHT

)

DCM

6P

(BLU

)

GRN/YEL

GRN/YEL

E

F

AN  MO

T

O

R

CONTR

OLLER

BLK

WHT

RED

TERMINAL

BASE

IN1

IN2

PR

LAMP

9P

(WHT

)

R

OOM/COIL

4P

(BLK

)

ION

3P

(WHT

)

ION

ASSY

ION

TERMINAL

BLK

WHT

RED

BLK

BLK

1

7

6

5

4

3

2

1

N

L

6

5

4

3

2

TERMINAL

BASE

(8P

)

EAR

TH

POWER

SUPPL Y

BL

K

BL

K

A1

A2

L1

T1

L3

T3

MAGNETIC

CONT A

CT

OR

FM

GRN/YEL

CM

GRN/YEL

C

R

S

COMPRESSOR

M

OTO

R

FA

N

M

OTO

R

BLK

BLK

(BLU

)

WHT

CM

CAP

A

C

IT

OR

BLU

YEL

THERMOST AT

    CONNECTOR

CONNECTOR

FM

CAP A

CIT

OR

YE

L

BRN

RED

BLU

YE

L

BR

N

RED

(PNK

)

INDOOR  UNIT

OUTDOOR  UNIT

ORG

RED

1

1

2

2

3

3

P    S

WHT

WHT

BLK

RED

BLK

RED

WHT

GRY

6

6

5

5

4

4

3

3

2

2

1

1

P    S

8F

A-2-5257-312-XX-0

8F

A-2-5257-364-XX-0

Summary of Contents for SAP-CR184G

Page 1: ...IONER SAP KR184GJ SAP KR224GJ SAP CR184G SAP CR224G IMPORTANT These air conditioners employ new refrigerant R410A Pay special attention when servicing the unit Indoor Model No Product Code No SAP KR184GJ 1 852 094 05 SAP KR224GJ 1 852 094 04 Outdoor Model No Product Code No SAP CR184G 1 852 094 09 SAP CR224G 1 852 094 08 Destination Australia 50Hz General area 50Hz ...

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 units weight It may be necessary to construct a st...

Page 3: ...eze Prevention 30 8 4 Automatic fan speed 31 8 5 Outdoor Fan Speed Control 31 9 TROUBLESHOOTING 9 1 Check before and after troubleshooting 32 9 2 Air conditioner does not operate 33 9 3 Some part of air conditioner does not operate 37 9 4 Air conditioner operates but abnormalities are observed 39 10 REFRIGERANT R407C SPECIAL PRECAUTIONS WHEN SERVICING THE UNIT 10 1 Characteristics of new refrigera...

Page 4: ...4 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: ...direction Indoor Horizontal Manual Vertical Auto Air filter Washable Anti Mold Compressor Rotary Hermetic Refrigerant Amount charged at shipment g R410A 1 300 Refrigerant control Capillary tube Operation sound Indoor Hi Me Lo Qt dB A 42 39 35 32 Qt Quiet mode at Lo Outdoor Hi dB A 55 Refrigerant tubing connections Flare type Max allowable tubing length at shipment m 7 5 Refrigerant Narrow tube mm ...

Page 6: ...rizontal Manual Vertical Auto Air filter Washable Anti Mold Compressor Rotary Hermetic Refrigerant Amount charged at shipment g R410A 1 500 Refrigerant control Capillary tube Operation sound Indoor Hi Me Lo Qt dB A 45 41 37 32 Qt Quiet mode at Lo Outdoor Hi dB A 57 Refrigerant tubing connections Flare type Max allowable tubing length at shipment m 10 Refrigerant Narrow tube mm in 6 35 1 4 tube dia...

Page 7: ... SIC 39CVL D847 2 1 No of poles Rough measure rpm Cool 8 1 250 Nominal output W 30 Coil resistance Ambient temp 20 C Ω Safety devices Type Internal controller Over current protection Yes Overheat protection Yes Run capacitor on controller PCB µF VAC Flap Motor Type Stepping motor Model MP24Z3 12V Rating DC 12 V Coil resistance Ambient temp 25 C Ω Each pair of terminals 400 7 Heat Exch Coil Coil Al...

Page 8: ...poles Rough measure rpm Cool 8 1 300 Nominal output W 30 Coil resistance Ambient temp 20 C Ω Safety devices Type Internal controller Over current protection Yes Overheat protection Yes Run capacitor on controller PCB µF VAC Flap Motor Type Stepping motor Model MP24Z3 12V Rating DC 12 V Coil resistance Ambient temp 25 C Ω Each pair of terminals 400 7 Heat Exch Coil Coil Aluminum plate fin Copper tu...

Page 9: ...bient temp 25 C Run capacitor µF 50 VAC 400 Crank case heater Fan Fan Motor Type Propeller Q ty Dia 1 ø420 Fan motor model Q ty AC motor KFG6S 51E5P 1 No of poles Rough measure rpm Cool 6 870 Nominal output W 50 Coil resistance Ambient temp 20 C Ω WHT BRN 63 60 WHT YEL 58 48 YEL PNK 23 36 Safety devices Type Thermal protector Operating temp Open C 130 8 Close Automatic reclosing Run capacitor µF 4...

Page 10: ...mp 25 C Run capacitor µF 60 VAC 400 Crank case heater Fan Fan Motor Type Propeller Q ty Dia 1 ø420 Fan motor model Q ty AC motor KFG6S 51E5P 1 No of poles Rough measure rpm Cool 6 870 Nominal output W 50 Coil resistance Ambient temp 20 C Ω WHT BRN 63 6 WHT YEL 58 48 YEL PNK 23 36 Safety devices Type Thermal protector Operating temp Open C 130 8 Close Automatic reclosing Run capacitor µF 4 VAC 440 ...

Page 11: ... for 224 class Magnetic Contactor CLK 25J2 Coil rating 50Hz 220 240V Coil resistance kΩ at 20 C 2 0 Only for 184 class Power Relay PR EL1U Coil rating AC 200 240V 50 60Hz Contact rating AC 277V 30A Outdoor Unit SAP CR184G SAP CR224G Thermistor Coil Room sensor PBM D41E S1 Coil Room Resistance kΩ Coil 0 C 15 0 5 Room 25 C 5 0 4 Indoor Unit SAP KR184GJ SAP KR224GJ ...

Page 12: ...5 298 1065 50 60 100 5 1055 50 7 60 3 218 475 403 60 49 24 5 402 5 95 450 95 212 5 117 5 117 5 1065 298 45 Drain hose ø18 Narrow tube ø6 35 1 4 90 5 90 5 307 5 450 307 5 95 45 95 202 4 202 4 ø 8 0 196 46 5 27 4 70 32 133 8 52 23 Wide tube ø12 70 1 2 184 ø15 88 5 8 224 Unit mm ...

Page 13: ...CR224G 293 608 880 80 136 12 36 334 310 285 I D ø 1 8 2 I D ø 2 3 6 670 18 55 111 166 2 145 AIR DISCHARGE AIR INTAKE AIR INTAKE Narrow tube service valve ø6 35 1 4 Wide tube service valve ø12 70 1 2 184 ø15 88 5 8 224 unit m Unit mm ...

Page 14: ...lation 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 Compressor Accumulator Wide tube service valve Wide tube Narrow tube service valve Narrow tube O D ø6 35 mm 1 4 Condenser Capillary tube Indoor Unit Outdoor Unit ...

Page 15: ...ition 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 Indoor Unit SAP KR184GJ Outdoor Unit SAP CR184G Indoor inlet air D B temp C Outdoor inlet air D B temp C 25 30 35 40 45 50 Low pressure at wide tube serveice valve MPa 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0 0 9 0 8 0 7 1 8 Cooling Charac...

Page 16: ...art 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 16 Indoor Unit SAP KR184GJ ...

Page 17: ... 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 17 Indoor Unit SAP KR224GJ ...

Page 18: ... SHC 4 81 4 70 4 55 4 19 31 SHC 5 08 4 84 4 55 4 19 TC 5 41 5 15 4 84 4 45 CM 1 37 1 47 1 65 1 90 21 SHC 2 41 2 30 2 18 2 02 19 23 SHC 2 89 2 78 2 65 2 49 25 SHC 3 36 3 25 3 12 2 97 27 SHC 3 83 3 72 3 60 3 44 29 SHC 4 31 4 20 4 07 3 91 31 SHC 4 78 4 67 4 54 4 39 TC 5 73 5 46 5 13 4 72 CM 1 41 1 51 1 69 1 95 23 SHC 2 37 2 27 2 14 1 99 21 25 SHC 2 85 2 74 2 62 2 46 27 SHC 3 32 3 22 3 09 2 94 29 SHC ...

Page 19: ... 33 5 16 4 95 31 SHC 5 96 5 82 5 65 5 20 TC 6 72 6 40 6 02 5 54 CM 1 35 1 44 1 63 1 90 21 SHC 2 98 2 84 2 67 2 47 19 23 SHC 3 47 3 33 3 16 2 96 25 SHC 3 96 3 82 3 65 3 45 27 SHC 4 45 4 31 4 14 3 94 29 SHC 4 94 4 80 4 63 4 43 31 SHC 5 43 5 29 5 12 4 92 TC 7 12 6 78 6 38 5 87 CM 1 38 1 48 1 67 1 95 23 SHC 2 94 2 80 2 63 2 43 21 25 SHC 3 43 3 29 3 12 2 92 27 SHC 3 92 3 78 3 61 3 41 29 SHC 4 41 4 27 4...

Page 20: ...ions Indoor Air Temperature 32 C D B 23 C W B Outdoor Air Temperature 43 C D B Indoor Unit SAP KR224GJ Outdoor Unit SAP CR224G Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 240V Single phase 50Hz Rating Conditions Running Amps A 0 31 0 54 6 05 6 90 Power Input kW 0 035 0 122 1 473 1 630 Full Load Conditions Running Amps A 0 31 0 54 8 65 9 50 Power Input kW 0 ...

Page 21: ...BRN YEL RED B L K WHT Y E L B L U FM FLAP EVAPORATOR FLAP MOTOR FLAP 5P WHT DCM 6P BLU GRN YEL GRN YEL E FAN MOTOR CONTROLLER B L K W H T R E D TERMINAL BASE IN1 IN2 PR LAMP 9P WHT ROOM COIL 4P BLK ION 3P WHT ION ASSY ION TERMINAL BLK WHT RED BLK BLK 1 7 6 5 4 3 2 1 N L 6 5 4 3 2 TERMINAL BASE 8P EARTH POWER SUPPLY RED B L K B L K 6 5 4 1 POWER RELAY FM GRN YEL CM WHT GRN YEL C R S COMPRESSOR MOTO...

Page 22: ...N YEL RED B L K WHT Y E L B L U FM FLAP EVAPORATOR FLAP MOTOR FLAP 5P WHT DCM 6P BLU GRN YEL GRN YEL E FAN MOTOR CONTROLLER B L K W H T R E D TERMINAL BASE IN1 IN2 PR LAMP 9P WHT ROOM COIL 4P BLK ION 3P WHT ION ASSY ION TERMINAL BLK WHT RED BLK BLK 1 7 6 5 4 3 2 1 N L 6 5 4 3 2 TERMINAL BASE 8P EARTH POWER SUPPLY B L K B L K A1 A2 L1 T1 L3 T3 MAGNETIC CONTACTOR FM GRN YEL CM GRN YEL C R S COMPRESS...

Page 23: ...estricted 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 in Table 1 and Fig 2a Indoor Unit 5 cm min 5 cm min 15 cm min INDOOR UNIT Front View Wall mounted Type INDOOR UNIT Tubing length L OUTDOOR UNIT Elevation difference H Fig 2 Fig 2a Fig 1 WARNING Table...

Page 24: ...midity and protect the unit against possible water damage and decreased service life Fig 4c 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 NO Fig 3 Air intake Min 10 cm Air discharge Min 5 cm Min 40 cm Valve side Min 25 cm Top View Side air intake Rear air intake Concrete or equal About 10 cm Min 10 cm Anchor bo...

Page 25: ...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 5 The indoor unit should make a beeping sound to indic...

Page 26: ...cted No wire should be allowed 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 GROUNDING LINE 6 L N 5 4 3 2 1 TERMI...

Page 27: ...m shifts into cooling operation and cool air will start to be felt Cooling operation in the Test Run mode is unaffected by theroomtemperature 4 Press the OPERATION button again to stop the test run At this time you do not need to hold down the button for 3 seconds Used both as OPERATION button and RECEIVER Fig 6 CAUTION To protect the air conditioner from overloading do not leave the unit in Test ...

Page 28: ...he grille into the frame first Fig 9b Then insert the tabs on the top of the grille and on the front face into the frame 2 Make sure that the grille and frame are firmly fitted together by engaging the tabs 3 Attach the thermistor on the grille Fig 8a 4 Close the cover and replace the screw Fig 8a 5 Affix the grille with the 3 previously removed screws Fig 7b 6 Install the air intake grille a Allo...

Page 29: ...ops it will not start running again for 3 minutes Thermo ON When room temperature rises 1 C above the set temperature T C Compressor ON Thermo OFF When the room temperature decreases below the set temperature T C Compressor OFF Whenever the compressor is running the indoor unit always generates negative ions ION lamp lights up NOTE ON OFF ON OFF ON OFF Compressor ON OFF ON OFF ON OFF Outdoor fan T...

Page 30: ...eat exchange coil When the temperature of the indoor heat exchange coil falls below 2 C for 2 minutes the control circuit stops the outdoor fan and compressor The compressor stops after 3 seconds During this period Indoor fan operates in LL The outdoor fan then follows compressor does not start again until the temperature rises above 6 C Outdoor fan Compressor Indoor fan 6 c Indoor heat exch coil ...

Page 31: ...er the outdoor fan speed is switched automatically according to the outdoor temperature If the outdoor air temperature falls below 28 5 C the fan speed switches to LOW If the outdoor air temperature rises above 31 5 C the fan speed switches to HIGH This function does not become active in heating operation H H L 31 5 28 5 Outdoor air temperature C Outdoor fan speed Indoor fan H High M Medium L Low ...

Page 32: ... 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 GROUNDING LINE 6 L N 5 4 3 2 1 TERMINAL 7 6 5 4 3 2 1 TERMINAL INDOOR UNIT OUTDOOR UNIT GROUNDING LINE POWER SUPPLY 1PHASE 220 ...

Page 33: ... NO Set 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 u...

Page 34: ...r or indoor fan motor is defective NOTE Operation lamp on front side of indoor unit is flashing on and off YES Replace thermistor Indoor room thermistor is defective YES NO Check power supply Power is being supplied to the outdoor unit Circuit breaker is tripped Power failure Reset breaker Wait for recovery or contact power company Replace with suitable one larger capacity NO Check capacity of cir...

Page 35: ...see if light is ON Light is OFF Indoor PCB Ass y is defective Measure resistance of indoor and outdoor fan motor winding FM Measure resistance of compressor motor winding CM Replace the fuse If fuse has been blown 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 ...

Page 36: ...del Check coil resistance of magnetic contactor OK Replace the magnetic contactor Check indoor PCB Ass y Check coil terminal voltage between terminals No 5 and No 6 at power relay AC 220 240 V No voltage appears OK Check voltage between terminals No 2 and No 3 at terminal plate AC 220 240 V OK For 184 class model Replace the power relay NO Is room temperature too low Try to lower setting temperatu...

Page 37: ...r replace OK Check fan motor capacitor OK Check fan motor capacitor Check connectors to indoor PCB Ass y Measure resistance of outdoor fan motor winding Check connectors to outdoor fan motor lead wires Measure resistance of flap motor winding and connector Fan cannot be turned Check fan rotation Turn fan gently once or twice by hand Check fan casing foreign matter on inside Fan motor winding burno...

Page 38: ...ge Recover refrigerant R410A Rotor may be locked up Measure Power supply voltage The voltage is too low No Evacuate the air conditioner YES For compressor replacement refer to 10 5 In case of compressor malfunction CAUTION In case of leakage do not add refrigerant The unit must be vacuumed and recharged This is because composition of refrigerant in the unit has been changed due to leakage See 10 6...

Page 39: ... 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 Recover refrigeran...

Page 40: ...nect the motor connectors and measure the voltage at the DC motor connectors on the indoor unit controller 3 locations Measurement location Normal value 1 Vm Gnd Between pin 1 and pin 3 DC 230 V or more 2 Vcc Gnd Between pin 4 and pin 3 DC 14 V or more 3 Vs Gnd Between pin 5 and pin 3 Fluctuation between DC 1 0 4 3 V Diagnostic results All of the above measured values are normal Fan motor trouble ...

Page 41: ...ition state in liquid phase When refrigerant R410A is used the composition will differ depending on whether it is in gaseous or liquid phase and the basic performance of the air conditioner will be degraded if it is charged while the refrigerant is in gaseous state Thus always charge the refrigerant while it is in liquid phase Ether type oil is used for compressor oil for R410A type units which is...

Page 42: ...R22 and R407C No addition of compressor oil for R410A No additional charge of compressor oil is permitted No use of refrigerant other than R410A Never use a refrigerant other than R410A If refrigerant R410A is exposed to fire Through welding etc toxic gas may be released when R410A refrigerant is exposed to fire Therefore be sure to provide ample ventilation during installation work Caution in cas...

Page 43: ... improve the sealing of tubing The following is the HAB oil generally used Esso ZERICE S32 For details on tubing installation procedures refer to the installation manuals attached to the air conditioner 43 Tool Distinction Tool Name Gauge manifold Charging hose Gas leak detector Refrigerant cylinder Charging cylinder Tools specifically for R410A Refrigerant recovery unit Vacuum pump with anti reve...

Page 44: ...ly 3 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 4 Evacuation Use a solenoid valve installed vacuum pump so that even if power is cut off in the middle of evacuation of air due to a power interruption the valve will pre vent the pump oil from flowing back The equipment may be damaged if moist...

Page 45: ...cylinder becomes less than 20 of the fully charged amount the composition of the refrigerant starts to change Thus do not use the refrigerant if the amount in the refrigerant cylinder is less than 20 Also charge the minimum necessary amount to the charging cylinder before using it to charge the air conditioning unit Example In case of charging refrigerant to a unit requiring 0 76Kg using a capacit...

Page 46: ...in the refrigerant circuit of the unit Leave ends of tubes open during welding 4 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 5 Evacuation Use a solenoid valve installed vacuum pump so that even if power is cut off in the middle of evacuation of air due to a power interruption the valve will p...

Page 47: ...tions given in 10 6 In case refrigerant is leaking and completely carry out repairs Only then should you recharge the refrigerant 10 8 Retro fitting existing systems 10 8 1 Use of existing units Never use new refrigerant R410A for existing units which use R22 This will cause the air conditioner to operate improperly and may result in a hazardous condition 10 8 2 Use of existing tubing If replacing...

Page 48: ... 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 11 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 49: ...s 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 ...

Page 50: ...n When this has been done oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as shown below Press this button once to change the display to oP 7 address setting Fig 3 5 oP 7 has now been selected for address setting 6 Press the ON OFF operation button on the remote controller Fig 3 Check that the beep signal r...

Page 51: ... ON TIME setting button Return button Advance button CANCEL button SENSOR button CLOCK button Advance button NIGHT SETBACK button HIGH POWER button OFF TIME setting buttons Return button ION button QUIET button ADDRESS switch Temperature display selector button Time display selector button Display Sensor Transmitter ON OFF operation button ACL button MODE Selector button 1 HR TIMER button Cover cl...

Page 52: ...SANYO Electric Co Ltd Osaka Japan Jul 2005 Printed in Japan ...

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