Sanyo SAP-K181A Technical & Service Manual

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TECHNICAL & SERVICE MANUAL

SAP – K181A + SAP – C181A

SAP – K241A + SAP – C241A

SPLIT SYSTEM AIR CONDITIONER

Indoor Model No.

SAP – K181A– S

SAP – K241A– S

SAP – K181A

SAP – K241A

Product Code No.

1 852 068 06

1 852 068 08

Indoor Unit

FILE NO.

Outdoor Model No.

Product Code No.

SAP – C181A– S

1 852 068 07

SAP – C241A– S

1 852 068 09

Outdoor Unit

SAP – C181A

SAP – C241A

REFERENCE NO.

Destination: Australia

700432

Table of Contents

Troubleshooting

Summary of Contents for Sanyo SAP-K181A

Page 1 TECHNICAL & SERVICE MANUAL SAP – K181A + SAP – C181A FILE NO. SAP – K241A + SAP – C241A Destination: Australia SPLIT SYSTEM AIR CONDITIONER Indoor Model No. Product Code No. Outdoor Model No. Product Code No. SAP – K181A– S 1 852 068 06 SAP –...
Page 3 Important! When Transporting Be careful when picking up and moving the indoor and Please Read Before Starting outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp This air conditioning system meets strict safety and edges or thin aluminum fins on the air conditioner can operating standards.
Page 4: Table Of Contents
Table of Contents Page 1. OPERATING RANGE ..........................1 2. SPECIFICATIONS 2-1. Unit Specifications .......................... 2 2-2. Major Component Specifications....................4 2-3. Other Component Specifications....................8 3. DIMENSIONAL DATA..........................9 4. REFRIGERANT FLOW DIAGRAM ......................12 5. PERFORMANCE DATA 5-1. Performance charts ........................13 5-2.
Page 5: Operating Range
1. OPERATING RANGE Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp. Maximum 32°C D.B. / 23°C W.B. 43°C D.B. Cooling Minimum 19°C D.B. / 14°C W.B. 19°C D.B.
Page 6: Specifications
2. SPECIFICATIONS 2-1. Unit Specifications Indoor Unit SAP – K181A Outdoor Unit SAP – C181A Power Source 240V Single phase 50Hz Voltage rating 240 V Performance Cooling Capacity BTU/h 17,100 Air circulation (High) Moisture removal (High) Liters/h Electrical Rating Cooling Available voltage range 216 ~ 264 Running amperes...
Page 7 Indoor Unit SAP – K241A Outdoor Unit SAP – C241A Power Source 240V Single phase 50Hz Voltage rating 240 V Performance Cooling Capacity BTU/h 21,500 Air circulation (High) Moisture removal (High) Liters/h Electrical Rating Cooling Available voltage range 216 ~ 264 Running amperes 13.2 Power input...
Page 8: Major Component Specifications
2-2. Major Component Specifications 2-2-1. Indoor Unit Indoor Unit SAP – K181A Controller PCB Part No. POW-K181GJ Controls Microprocessor Control circuit fuse 250 V 3.15 A Remote Control Unit RCS-7S3E Fan & Fan Motor Type Cross-flow Q'ty ... Dia. and length 1 ...
Page 9 Indoor Unit SAP – K241A Controller PCB Part No. POW-K241GJ Controls Microprocessor Control circuit fuse 250 V 3.15 A Remote Control Unit RCS-7S3E Fan & Fan Motor Type Cross-flow Q'ty ... Dia. and length 1 ... ø88 / L746 Fan motor model ... Q'ty UF2-31A5P-S ...
Page 10 2-2-2. Outdoor Unit Outdoor Unit SAP – C181A Compressor Type Rotary (Hermetic) Compressor model C-2R170H5T 80827445 Nominal output 1,700 Compressor oil ... Amount SUNISO 4GSD-T ... 750 Ω Coil resistance (Ambient temp. 25°C) C–R : 1.353 C–S : 3.422 Safety devices Type Internal protector Overload relay...
Page 11 Outdoor Unit SAP – C241A Compressor Type Rotary (Hermetic) Compressor model C-R221H5S 80687145 Nominal output 2,200 Compressor oil ... Amount SUNISO 4GSD-T ... 1,350 Ω Coil resistance (Ambient temp. 25°C) C–R : 0.777 C–S : 2.408 Safety devices Type Internal protector External(OLR T) Overload relay —...
Page 12: Other Component Specifications
2-3. Other Component Specifications Indoor Unit SAP – K181A SAP – K241A Transformer (TR) ATR-J105 Rating Primary AC 230V, 50 / 60 Hz Secondary 19V, 0.526A Capacity 10VA Ω (at 21°C) Coil resistance Primary (WHT – WHT): 205 ± 10% Secondary (BRN –...
Page 13: Dimensional Data
3. DIMENSIONAL DATA Indoor Unit SAP – K181A SAP – K241A Remote control unit 18.5 147.5 147.5 Center of tubing hole (2 places) Drain hose ø18 Narrow tube ø6.35 (1/4") Wide tube ø12.7 (1/2") K181 Wide tube ø15.88 (5/8") K241 Unit : mm...
Page 14 Outdoor Unit SAP – C181A AIR INTAKE ø12 AIR DISCHARGE Wide tube service valve ø12.7 (1/2") Narrow tube service valve ø6.35 (1/4") Unit : mm...
Page 15 Outdoor Unit SAP – C241A Air intake Air discharge Wide tube service valve ø15.88 (5/8") Narrow tube service valve ø6.35 (1/4") Unit : mm...
Page 16: Refrigerant Flow Diagram
4. REFRIGERANT FLOW DIAGRAM Indoor Unit SAP – K181A Outdoor Unit SAP – C181A Indoor Unit Outdoor Unit Wide tube service Compressor Accumulator valve Wide tube O.D. Capillary for ø12.7 mm liquid injection (1/2 ") Narrow tube service Narrow tube valve Capillary tube O.D.
Page 17: Performance Data
5. PERFORMANCE DATA 5-1. Performance charts Indoor Unit SAP – K241A Indoor Unit SAP – K181A Outdoor Unit SAP – C241A Outdoor Unit SAP – C181A Cooling Characteristics Cooling Characteristics Indoor inlet air Indoor inlet air D.B. temp. (°C) D.B. temp. (°C) Outdoor Outdoor fan speed...
Page 18: Air Throw Distance Chart
5-2. Air Throw Distance Chart Indoor Unit SAP – K181A Room air temp. : 27°C Fan speed High Horizontal distance (m) : Flap angle 0° , : Axis air velocity 0° : Flap angle 30°, : Axis air velocity 30 Heating Indoor Unit SAP –...
Page 19: Cooling Capacity
5-3. Cooling Capacity Indoor Unit SAP – K181A Outdoor Unit SAP – C181A 240V Single phase 50Hz RATING CAPACITY 5.00 kW AIR FLOW RATE 760 m EVAPORATOR CONDENSER ENT. TEMP. °C OUTDOOR AMBIENT TEMP. °C W.B. D.B. 4.60 4.38 4.11 3.79 1.75 1.88...
Page 20 Indoor Unit SAP – K241A Outdoor Unit SAP – C241A 240V Single phase 50Hz RATING CAPACITY 6.30 kW AIR FLOW RATE 830 m EVAPORATOR CONDENSER ENT. TEMP. °C OUTDOOR AMBIENT TEMP. °C W.B. D.B. 5.80 5.52 5.18 4.77 2.31 2.48 2.69 2.94 3.76...
Page 21: Electrical Data
6. ELECTRICAL DATA 6-1. Electrical Characteristics Indoor Unit SAP – K181A Outdoor Unit SAP – C181A Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 240V Single phase 50Hz Rating Conditions Running Amps. 0.38 0.50 8.72 Power Input 0.073 0.119...
Page 22: Electric Wiring Diagrams
6-2. Electric Wiring Diagrams To avoid electrical shock hazard, be sure to Indoor Unit SAP – K181A SAP – K241A disconnect power before checking, servicing WARNING and/or cleaning any electrical parts.
Page 23 To avoid electrical shock hazard, be sure to Outdoor Unit SAP – C181A disconnect power before checking, servicing WARNING and/or cleaning any electrical parts.
Page 24 To avoid electrical shock hazard, be sure to Outdoor Unit SAP – C241A disconnect power before checking, servicing WARNING and/or cleaning any electrical parts.
Page 25: Installation Instructions
7. INSTALLATION INSTRUCTIONS 7-1. Installation Site Selection Indoor Unit 15 cm min. 15 cm 15 cm min. To prevent abnormal heat min. INDOOR UNIT generation and the possibility WARNING of fire, don’t place obstacles, enclosures and grills in front Front View of or surrounding the air...
Page 26 Outdoor Unit AVOID: heat sources, exhaust fans, etc. (Fig. 3) damp, humid or uneven locations. Exhaust fan Hot air Heat source choose a place as cool as possible. Outdoor unit choose a place that is well ventilated. allow enough room around the unit for air intake/exhaust and possible maintenance.
Page 27: Remote Control Unit Installation Position
7-2. Remote Control Unit Installation Removable mounting Position Wall The remote control unit can be operated from either a non-fixed position or a wall-mounted position. To ensure that the air conditioner operates correctly, do not install the remote control unit in the following places: Special In direct sunlight mounting...
Page 28 7-3. Recommended Wire Length and Size Regulations on wiring diameter differ from locality to NOTE locality. For field wiring requirements, please refer to Refer to the WIRING SYSTEM DIAGRAM for the your local electrical codes. Carefully observe these meaning of "A" and "B" in Table 3. regulations when carrying out the installation.
Page 29: Function
8. FUNCTION 8-1. Room Temperature Control Room temperature control is obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the remote control unit. The room temperature (and other information) is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit.
Page 30: Dry Operation
8-2. Dry Operation (Dehumidification) Dry operation uses the ability of the cooling cycle to remove moisture from the air, but by running at low level to dehumidify without greatly reducing the room temperature. The air conditioner repeats the cycle of turning ON and OFF automatically as shown in the chart below according to the room temperature.
Page 31: Outdoor Fan Speed Control
8-4. Outdoor Fan Speed Control To optimize performance of the air conditioner, 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. The operating temperature shown as 31.5 and 28.5 in the chart differ by models 31.5 Outdoor air...
Page 32: Troubleshooting
9. TROUBLESHOOTING 9-1. Check before and after troubleshooting WARNING Hazardous voltage can cause ELECTRIC SHOCK or DEATH. Disconnect power or turn off circuit breaker before you start checking or servicing. 9-1-1. Check power supply wiring. Check that power supply wires are correctly connected to terminals No.1 and No.2 on the terminal plate in the outdoor unit.
Page 33: Air Conditioner Does Not Operate
9-2. Air conditioner does not operate. 9-2-1. Circuit breaker trips (or fuse blows). A. When the circuit breaker is set to ON, it is tripped soon. (Resetting is not possible.) There is a possibility of ground fault. Check insulation resistance. If resistance value is 2MΩ...
Page 34 9-2-2. Neither indoor nor outdoor unit runs. A. Power is not supplied. Circuit breaker Reset breaker. is tripped. • Check power supply. Power is being supplied to the Wait for recovery outdoor unit. Power failure or contact power company. B. Check remote control unit. •...
Page 35 E. Check fuse on the indoor PCB Ass'y. • Measure resistance of indoor fan If fuse has been blown, • Check fuse on indoor PCB Ass'y motor winding. for continuity. (FM) • Check operation lamp to see • Measure resistance of flap motor if light is ON.
Page 36 9-2-3. Only outdoor unit does not run. A. Check setting temperature. Is room temperature too low ? Try to lower setting temperature by temperature setting button ( button). Outdoor unit still does not run. • Try to run using another remote control unit.
Page 37: Some Part Of Air Conditioner Does Not Operate
9-3. Some part of air conditioner does not operate. 9-3-1. Only indoor fan does not run. • Check fan casing Remove foreign foreign matter on matter or repair. Fan cannot inside. be turned. • Check fan rotation. Turn fan gently once or twice by hand.
Page 38 9-3-3. Only compressor does not run. • Either internal protector or • Check compressor moter overload relay is working. capacitor. • Measure resistance of • Temperature of compressor is abnormally high. compressor motor winding. Refrigerant gas shortage. Charge refrigerant gas (R22). •...
Page 39: Air Conditioner Operates, But Abnormalities Are Observed
9-4. Air conditioner operates, but abnormalities are observed. 9-4-1. Poor cooling. • Check position of remote control unit. Change position of remote Cool air from air conditioner reaches • control unit. position directly. • Wide and narrow tubes between Insulate both wide and narrow indoor unit and outdoor unit are tubes separately and then insulated.
Page 40: If A Sensor Is Defective
9-5. If a sensor is defective. 9-5-1. Indoor coil temp. thermistor (TH1) is defective. A. Open When thermistor opens, the air conditioner will be in the following conditions as the controller tries to detect extremely low indoor coil temperature. In Cooling mode: Function of freeze prevention continues to work. That is, the controller turns both compressor and outdoor fan motor periodically ON and OFF for several minutes.
Page 41: Checking Electrical Components
10. CHECKING ELECTRICAL COMPONENTS 10-1. Measurement of Insulation Ground wire Resistance Clip The insulation is in good condition if the resistance exceeds 2MΩ. Probe 10-1-1. Power Supply Wires Insulation Fig. 1 tester Clamp the ground wire of the power supply wires with the lead clip of the insulation resistance tester and Terminal plate measure the resistance by placing a probe on either of...
Page 42: Checking Continuity Of Fuse On Pcb Ass'y
10-2. Checking Continuity of Fuse on PCB Ass'y Fuse Remove the PCB Ass’y from the electrical component box. Then pull out the fuse from the PCB Ass’y. (Fig. 5) PCB Ass’y Check for continuity using a multimeter as shown in Fig.
Page 43: Appendix Instruction Manual
APPENDIX INSTRUCTION MANUAL SAP – K181A + SAP – C181A SAP – K241A + SAP – C241A...
Page 44 Features This air conditioner is equipped with cooling and drying functions. Details on these functions are provided below; refer to these descriptions when using the air conditioner. Compact Size Automatic and 3-step Fan Speed • • This model is smaller than its predecessors Auto/High/Medium/Low and yet offers the same capabilities.
Page 45 Contents Page Features......................2 Product Information ..................3 Alert Symbols ....................3 Installation Location..................4 Electrical Requirements .................. 4 Safety Instructions ..................4 Names of Parts ....................5 Using the Remote Control Unit ..............10 Operation with the Remote Control Unit ........... 12 1.
Page 46: Installation Location
Installation Location We recommend that this air conditioner be installed properly by • qualified installation technicians in accordance with the Installation Instructions provided with the unit. Before installation, check that the voltage of the electric supply in • your home or office is the same as the voltage shown on the nameplate.
Page 47: Names Of Parts
Names of Parts INDOOR UNIT Air intake Air outlet Remote control unit Drain hose Refrigerant tubes OUTDOOR UNIT Air outlet This illustration is based on the external view of a standard model. NOTE Consequently, the shape may differ from that of the air conditioner which you have selected.
Page 48 Unit Display and Operation Selector INDOOR UNIT TEST Operation selector IMPORTANT OPERATION lamp TIMER lamp REMOTE CONTROL receiver Avoid using radio equipment such as mobile phone near OPERATION TIMER (within 1 m) the indoor unit. Some radio equipment may cause malfunction of the unit. If the trouble happens, dis- connect power and restart the air conditioner after a few...
Page 49 Remote Control Unit (Display) Displayed when main unit sensor is in use Displayed when setting temperature SET TEMP. Displayed when transmitting data Displayed when temperature is shown Displayed when the temperature setting is at the upper or lower allowable limit Displayed when setting timer Symbols (1) Operation mode...
Page 50 Remote Control Unit AIR CONDITIONER Sensor Transmitter AIR CONDITIONER SET TEMP. Display (Cover closed) 1 HR. TIMER TEMP. TEMP. setting buttons 1 HR. TIMER button ON I /OFF ON/OFF operation button NIGHT MODE SETBACK NIGHT SETBACK button MODE selector button FLAP TIMER ON button FLAP button...
Page 51 Remote Control Unit (continued) TIMER ON button : The air conditioner starts at the set time. TIMER OFF button : The air conditioner stops at the set time. TIMER SET button This button is used to set the time at which you wish the air conditioner to go on or off.
Page 52: Using The Remote Control Unit
Using the Remote Control Unit How to Install Batteries ACL button 1. Slide the cover in the direction indicated by the arrow and remove it. 2. Install two AAA alkaline batteries. Make sure the batteries point in the direction marked in the battery compartment.
Page 53 Using the Remote Control Unit (continued) Mounting the Remote Control Unit Removable mounting Non-removable mounting Wall Wall (Packed in the indoor unit) (Packed in the indoor unit) Mounting on a wall A. Removable mounting 1) Momentarily hold the remote control unit at the desired mounting position.
Page 54: Operation With The Remote Control Unit
Operation with the Remote Control Unit 1. Operation AIR CONDITIONER SET TEMP. 1 HR. TIMER TEMP. STEP 3 ON I /OFF STEP 2 NIGHT MODE SETBACK STEP 1 FLAP STEP 5 FAN SPEED SENSOR STEP 4 SELECT TIMER BATTERIES Check that the circuit breaker on the power panel is turned on and that NOTE the operation selector of the indoor unit is in the ON position.
Page 55: Adjusting The Fan Speed
Operation with the Remote Control Unit (continued) Choose the best position in the room for the remote control unit, • NOTE which also acts as the sensor for room comfort and transmits the operating instructions. Once you’ve found this best position, always keep the remote control unit there.
Page 56: Night Setback Mode
Operation with the Remote Control Unit (continued) 3. Night Setback Mode SET TEMP. 1 HR. TIMER TEMP. ON I /OFF NIGHT MODE SETBACK FLAP FAN SPEED Night Setback Mode is used for saving energy. Press the NIGHT SETBACK button while operation. mark appears in the display.
Page 57: Special Remarks
Special Remarks ‘‘DRY’’ ( ) Operation How it works? Once the room temperature reaches the level that was set, the unit • repeats the cycle of turning on and off automatically. During DRY operation, the fan speed is automatically set to LOW or •...
Page 58: Using The 12-Hour On And Off Timer
Using the 12-Hour ON and OFF Timer 1. TIMER ON mode After the length of time set for TIMER ON elapses, the unit begins operating. (Example) The display depicted at left indicates that the air conditioner will begin operating in three hours. Setting procedure: STEP 1 Press the MODE button and set the desired operation...
Page 59 Using the 12-Hour ON and OFF Timer (continued) 3. ON/OFF Program Timer A combination of the TIMER ON and TIMER OFF modes, this function allows you to specify the time that the unit turns on and the time when it turns off. (Example) The unit will turn on three hours from now, and turn off five hours from now.
Page 60: Using The 1-Hour Off Timer
Using the 1-Hour OFF Timer 1. 1-Hour OFF Timer This function causes the unit to operate for one hour and then stop, regardless of whether the unit is on or off when this button is pressed. indicator in the display indicates that this function is operating. Setting procedure: Regardless of whether the unit is operating or stopped, press the 1 HR.
Page 61: Adjusting The Airflow Direction
Adjusting the Airflow Direction 1. Horizontal The horizontal airflow can be adjusted by moving the vertical vanes with your hands to the left or right. When the humidity is high, the vertical vanes should be in the front CAUTION position during the cooling or dehumidifying operation. If the vertical vanes are positioned all of the way to the right or left, condensation may begin to form around the air vent and drip down.
Page 62: Operation Without The Remote Control Unit
Operation without the Remote Control Unit If you have lost the remote control unit or it has trouble, follow the INDOOR UNIT steps below. 1. When the air conditioner is not running If you want to turn on the air conditioner, switch the operation selector to the OFF position, and then to the ON position.
Page 63 Care and Cleaning (continued) Anti-Mold Filter The anti-mold filter behind the air intake grille should be checked and cleaned at least once every two weeks. How to remove the 1. Grasp both ends of anti-mold filter the air intake grille Air intake grille and pull it out and 2.
Page 64 Care and Cleaning (continued) Air cleaning filter The air cleaning filter removes dust and dirt from the air, and reduces (not provided) odors and smoke from tobacco. The air clean filter is not provided with the air conditioner and must be NOTE purchased separately.
Page 65: Troubleshooting
Troubleshooting If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or service center. Trouble Possible Cause Remedy Air conditioner does not 1. Power failure. 1.
Page 66 SANYO Electric Co.,Ltd. Osaka, Japan 700432 12/99/200 Printed in Japan...

This manual is also suitable for:

Sap-k241a Sap-c181a Sap-c241a