Sanyo SAP–KR184GJH Technical & Service Manual
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Sanyo SAP–KR184GJH Technical & Service Manual

Split system air conditioner
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TECHNICAL & SERVICE MANUAL
SAP – KR184GJH + SAP – CR184GH
SAP – KR224GJH + SAP – CR224GH
SPLIT SYSTEM AIR CONDITIONER
Indoor Model No.
SAP – KR184GJH
SAP – KR224GJH
SAP – KR184GJH
SAP – KR224GJH
IMPORTANT
These air conditioners employ new
refrigerant R410A.
Pay special attention when
servicing the unit.
Product Code No.
1 852 094 03
1 852 094 02
Indoor Unit
FILE NO.
Destination: Australia (50Hz)
Outdoor Model No.
Product Code No.
SAP – CR184GH
SAP – CR224GH
Outdoor Unit
SAP – CR184GH
SAP – CR224GH
REFERENCE NO.
General area (50Hz)
1 852 094 07
1 852 094 06
SM
700629

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  • Page 1 TECHNICAL & SERVICE MANUAL SAP – KR184GJH + SAP – CR184GH FILE NO. SAP – KR224GJH + SAP – CR224GH Destination: Australia (50Hz) General area (50Hz) SPLIT SYSTEM AIR CONDITIONER Indoor Model No. Product Code No. Outdoor Model No. Product Code No. SAP –...

  • Page 2: Please Read Before Starting

    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 3: Table Of Contents

    Table of Contents Page 1. OPERATING RANGE ..........................5 2. SPECIFICATIONS 2-1. Unit Specifications .......................... 6 2-2. Major Component Specifications....................8 2-3. Other Component Specifications....................12 3. DIMENSIONAL DATA..........................13 4. REFRIGERANT FLOW DIAGRAM ......................15 5. PERFORMANCE DATA 5-1. Performance charts ........................16 5-2.
  • Page 4 11. CHECKING ELECTRICAL COMPONENTS 11-1. Measurement of Insulation Resistance ..................60 11-2. Checking Continuity of Fuse on PCB Ass'y..................61 11-3. Checking Motor Capacitor ......................61 12. MAINTENANCE 12-1. Address Setting of the Remote Control Unit .................. 62 APPENDIX ..............................63...

  • 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. Maximum 27°C D.B. 24°C D.B. / 18°C W.B. Heating Minimum 16°C D.B. –...

  • Page 6: Specifications

    2. SPECIFICATIONS 2-1. Unit Specifications Indoor Unit SAP – KR184GJH Outdoor Unit SAP – CR184GH Power Source 220–240V Single phase 50Hz Voltage rating 220 / 230 / 240 V Performance Cooling Heating Capacity 5.15 5.15 5.30 5.70 5.70 5.70 BTU/h 17,600 / 17,600 / 18,100 19,400 / 19,400 / 19,400 Air circulation (High)
  • Page 7 Indoor Unit SAP – KR224GJH Outdoor Unit SAP – CR224GH Power Source 220–240V Single phase 50Hz Voltage rating 220 / 230 / 240 V Performance Cooling Heating Capacity 6.40 6.40 6.40 7.20 7.20 7.20 BTU/h 21,800 / 21,800 / 21,800 24,600 / 24,600 / 24,600 Air circulation (High) Moisture removal (High)

  • Page 8: Major Component Specifications

    2-2. Major Component Specifications 2-2-1. Indoor Unit Indoor Unit SAP – KR184GJH Controller PCB Part No. CB-KR184EH (POW-KR184GJH) Controls Microprocessor Control circuit fuse 250 V 3.15 A Remote Control Unit RCS-4HPIS4E Fan & Fan Motor Type Cross-flow Q'ty ... Dia. and length 1 ...
  • Page 9 Indoor Unit SAP – KR224GJH Controller PCB Part No. CB-KR224EH (POW-KR184GJH) Controls Microprocessor Control circuit fuse 250 V 3.15 A Remote Control Unit RCS-4HPIS4E Fan & Fan Motor Type Cross-flow Q'ty ... Dia. and length 1 ... ø94 / L845 Fan motor model ...

  • Page 10: Outdoor Unit

    2-2-2. Outdoor Unit Outdoor Unit SAP – CR184GH Controller PCB — Compressor Type Rotary (Hermetic) Compressor model 5KS205DAJ21 85204526321 Nominal output 1,500 Compressor oil ... Amount FV50S ... 670 Ω Coil resistance (Ambient temp. 20°C) C–R : 1.780 C–S : 2.175 Safety devices Type Internal protector...
  • Page 11 Outdoor Unit SAP – CR224GH Controller PCB — Compressor Type Rotary (Hermetic) Compressor model 5JS270DAA21 85204526322 Nominal output 1,800 Compressor oil ... Amount FV50S ... 1,130 Ω Coil resistance (Ambient temp. 20°C) C–R : 1.166 C–S : 1.534 Safety devices Type Internal protector Overload relay...

  • Page 12: Other Component Specifications

    2-3. Other Component Specifications Indoor Unit SAP – KR184GJH SAP – KR224GJH Thermistor (Coil / Room sensor) PBM-D41E-S1 (Coil / Room) Resistance kΩ Coil 0°C 15.0 ± 5% / Room 25°C 5.0 ± 4% Outdoor Unit SAP – CR184GH SAP – CR224GH Power Relay (PR) EL1U Coil rating...

  • Page 13: Dimensional Data

    3. DIMENSIONAL DATA Indoor Unit SAP – KR184GJH SAP – KR224GJH...
  • Page 14 Outdoor Unit SAP – CR184GH SAP – CR224GH AIR INTAKE AIR DISCHARGE Wide tube service valve ø12.70(1/2") ø15.88(5/8") Narrow tube service valve ø6.35 ( 1/4" ) unit:m Unit : mm...

  • Page 15: Refrigerant Flow Diagram

    4. REFRIGERANT FLOW DIAGRAM Indoor Unit SAP – KR184GJH Outdoor Unit SAP – CR184GH SAP – KR224GJH SAP – CR224GH Indoor unit Outdoor unit Accumulator Wide tube service Wide tube valve 4-way Muffler valve O.D. ø12.7 mm (1/2 ") 18 class O.D.

  • Page 16: Performance Data

    5. PERFORMANCE DATA 5-1. Performance charts Indoor Unit SAP – KR184GJH Outdoor Unit SAP – CR184GH < Cooling Characteristics > < Heating Characteristics > Indoor inlet air Indoor inlet air D.B. temp. (°C) D.B. temp. (°C) Outdoor fan speed High –5 Outdoor inlet air D.B.
  • Page 17 Indoor Unit SAP – KR224GJH Outdoor Unit SAP – CR224GH < Cooling Characteristics > < Heating Characteristics > Indoor inlet air Indoor inlet air D.B. temp. (°C) D.B. temp. (°C) Outdoor fan speed High –5 Outdoor inlet air D.B. temp. (°C) Outdoor inlet air D.B.

  • Page 18: Air Throw Distance Chart

    5-2. Air Throw Distance Chart Indoor Unit SAP – KR184GJH Cooling 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 Room air temp.
  • Page 19 Indoor Unit SAP – KR224GJH Cooling 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 Room air temp. : 20°C Fan speed High...

  • Page 20: Cooling Capacity

    5-3. Cooling Capacity Indoor Unit SAP – KR184GJH Outdoor Unit SAP – CR184GH 240V Single Phase 50Hz RATING CAPACITY 5.30 kW AIR FLOW RATE 890 m EVAPORATOR CONDENSER ENT. TEMP. °C OUTDOOR AMBIENT TEMP. °C W.B. D.B. 4.88 4.64 4.36 4.02 1.32 1.41...
  • Page 21 Indoor Unit SAP – KR224GJH Outdoor Unit SAP – CR224GH 240V Single Phase 50Hz RATING CAPACITY 6.40 kW AIR FLOW RATE 980 m EVAPORATOR CONDENSER ENT. TEMP. °C OUTDOOR AMBIENT TEMP. °C W.B. D.B. 5.89 5.61 5.27 4.85 1.83 1.96 2.36 3.04 4.01...

  • Page 22: Heating Capacity

    5-4. Heating Capacity –8 –5 Outdoor temperature (°C D.B.) NOTE … Point of Rating condition Black dot in the chart indicate the following rating condition. Indoor : 20°C D.B. Outdoor : 7°C D.B. / 6°C W.B. 2) Above characteristics indicate instantaneous operation, which does not take into account defrost operation.

  • Page 23: Electrical Data

    6. ELECTRICAL DATA 6-1. Electrical Characteristics Indoor Unit SAP – KR184GJH Outdoor Unit SAP – CR184GH COOLING Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 240V Single phase 50Hz Rating Conditions Running Amps. 0.28 0.54 6.28 7.10 Power Input...
  • Page 24 Indoor Unit SAP – KR224GJH Outdoor Unit SAP – CR224GH COOLING Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 240V Single phase 50Hz Rating Conditions Running Amps. 0.37 0.71 8.53 Power Input 0.041 0.161 2.078 2.280 Full Load Conditions Running Amps.

  • Page 25: Electric Wiring Diagrams

    6-2. Electric Wiring Diagrams To avoid electrical shock hazard, be sure to Indoor Unit SAP – KR184GJH Outdoor Unit SAP – CR184GH disconnect power before checking, servicing WARNING and/or cleaning any electrical parts.
  • Page 26 To avoid electrical shock hazard, be sure to Indoor Unit SAP – KR224GJH Outdoor Unit SAP – CR224GH disconnect power before checking, servicing WARNING and/or cleaning any electrical parts.

  • Page 27: Installation Instructions

              7. INSTALLATION INSTRUCTIONS 7-1. Installation Site Selection Wall-mounted Type Indoor Unit 15 cm min. To prevent abnormal heat 5 cm 5 cm min. generation and the possibility min. WARNING INDOOR UNIT of fire, don’t place obstacles, enclosures and grilles in front Front View...
  • Page 28 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 29: Remote Control Unit Installation Position

    7-2. Remote Control Unit Installation Position 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: In direct sunlight Behind a curtain or other place where it is covered More than 8 m away from the air conditioner...

  • Page 30: Recommended Wire Length And Diameter

    7-3. Recommended Wire Length and Diameter 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" "B", and "C" in Table 2. regulations when carrying out the installation.

  • Page 31: How To Test Run The Air Conditioner

    7-4. How to Test Run the Air Conditioner (1) Switch on the power source. (2) When the air conditioner is not running, hold down the OPERATION button for at least 3 sec- onds. This starts the fan, producing uncooled forced air with the OPERATION lamp lit. (Fig. 6) (3) After 3 minutes, the system shifts into cooling operation, and cool air will start to be felt.

  • Page 32: Remove The Grille To Install The Indoor Unit

    7-5. Remove the Grille to Install the Indoor Unit Grille Air intake grille Basically , these models can be installed and wired without removing the grille. If access to any internal part is needed, follow the steps as given below How to remove the grille (1) Grasp both ends of the air intake grille, and Fig.

  • Page 33: Function

    8. FUNCTION 8-1. Room Temperature Control Cooling 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 5 minutes by the remote control unit to the controller in the indoor unit.
  • Page 34 Heating 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 5 minutes by the remote control unit to the controller in the indoor unit.

  • Page 35: 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 36: Automatic Switching Between Cooling And Heating

    8-3. Automatic Switching between Cooling and Heating When AUTO mode is selected, the microprocessor calculates the difference between the set temperature and the room temperature, and automatically switches to COOLING or HEATING mode to maintain the desired temperature. Room temp. ≥ Set temp. COOL Room temp.

  • Page 37: Freeze Prevention

    8-4. Freeze Prevention (Cooling and Dry) This function prevents freezing of the indoor heat 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.

  • Page 38: Cold Draft Prevention

    8-5. Cold Draft Prevention (Heating) This function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coil have sufficiently warmed up. Indoor fan speed varies according to the indoor heat exchange coil temperature as table shown below. Condition Indoor coil temperature (°C) Indoor fan speed...

  • Page 39: Overload Prevention

    8-6. Overload Prevention (Heating) This function prevents overheating of the indoor heat exchange coil. When the temperature of the indoor heat exchange coil rises above C°C outdoor fan speed changes from H (High speed) to L (low speed). When the temperature of the indoor heat exchange coil rises above B°C outdoor fan stops, if the indoor fan is L (low speed), then the fan speed changes from L (low speed) to M (medium speed).

  • Page 40: Automatic Fan Speed

    8-7. Automatic Fan Speed (Cooling, Dry and Heating) This automatically adjust the indoor fan speed for the room by the difference between the room temperature and set temperature. < Cooling> Room temp. T+2°c T+1°c Set temp. T°c Indoor fan H:High M:Medium L:Low <...

  • Page 41: Defrosting Operation

    8-8. Defrosting Operation (Heating) Reverse-cycle Defrosting Defrosting Sequence Heating operation Compressor ON 4-way valve ON Frost detection Frosting is assumed mostly under the following condition. Indoor heat exchanger coil temperature drops 0.8°C per 6 minutes and it repeats 3 times in succession. Indoor heat exchanger coil temperature drops below certain extent.

  • Page 42: Outdoor Fan Speed Control

    Defrosting Mode Timing Chart ∗1 Release of defrosting Start of defrosting Release of cold draft prevention 60 seconds 55 seconds Compressor ON 2 sec. Compressor 5 sec. 2 sec. Outdoor fan 55 sec. Solenoid coil (4–way valve) 60 seconds Indoor fan Standby lamp Auto air sweep (when selected)

  • Page 43: 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 L and N on the terminal plate in the outdoor unit.

  • Page 44: 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 45 B. Circuit breaker trips in several minutes after turning the air conditioner on. There is a possibility of short circuit. • Check capacity of circuit breaker. Replace with suitable one (larger capacity). Capacity of circuit breaker is suitable. In case of Heating operation : Measure resistance of outdoor fan •...
  • Page 46 C. Check remote control unit. • Try to run with another remote control unit. First remote control unit is defective. • Check for residue buildup on Clean transmitter. transmitter of remote control unit. • Check for residue buildup on remote Clean receiver.
  • Page 47 9-2-3. Only outdoor unit does not run. A. Check setting temperature. COOL HEAT Is room temperature too low ? Is room temperature too high ? Try to lower setting temperature by Try to raise setting temperature by temperature setting button ( button).

  • Page 48: 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 49 9-3-4. Only compressor does not run. • Check compressor motor Internal protetctor is working. capacitor. • Measure resistance of Temperature of compressor is abnormally high. compressor motor winding. Refrigerant gas shortage. Recover refrigerant. (R410A) • Measure Power supply Rotor may be locked up. Evacuate the air conditioner.

  • Page 50: Air Conditioner Operates, But Abnormalities Are Observed

    9-4. Air conditioner operates, but abnormalities are observed. 9-4-1. Operation does not switch from HEAT to COOL (or COOL to HEAT). • Remote control unit may be defective. Receiver in lamp Ass'y may be defective. • Measure resistance of 4–way valve's •...
  • Page 51 9-4-2. Poor cooling or heating. • Check position of remote control unit. Change position of remote • Cool or warm air from air conditioner control unit. reaches position directly. • Wide and narrow tubes between Insulate both wide and narrow indoor unit and outdoor unit are tubes separately and then insulated.
  • Page 52 9-4-3. Trouble Diagnosis of Indoor Fan Motor ..Applied for only indoor unit SAP-Kxxxx This indoor DC fan motor contains an internal control PCB. Therefore, it is not possible to measure the coil resistance, and the following procedure should be used to check the motor. To perform diagnosis, operate the unit in cooling mode with indoor fan speed "High".

  • Page 53: Refrigerant R410A: Special Precautions When Servicing The Unit

    10. REFRIGERANT R410A : SPECIAL PRECAUTIONS WHEN SERVICING UNIT 10-1. Characteristics of new refrigerant R410A 10-1-1. What is new refrigerant R410A R410A is a new refrigerant that contains three types of non-azeotropy-type mixed refrigerant. Its refrigeration capacity and energy efficiency are about the same level as the conventional refrigerant R22.
  • Page 54 Tubing precautions Refrigerant R410A is more easily affected by dust or moisture compared with R22, thus be sure to temporarily cover the ends of the tubing with caps or tape prior to installation. Never use 0.7mm-thick copper tubing or tubing which is less than 0.8mm in thickness, since air conditioners with R410A are subject to higher pressure than those using R22 and R407C.

  • Page 55: Tools Specifically For R410A

    10-3. Tools specifically for R410A For servicing, use the following tools for R410A Tool Distinction Tool Name • Gauge manifold • Charging hose • Gas leak detector • Refrigerant cylinder • Charging cylinder Tools specifically for R410A • Refrigerant recovery unit •...

  • Page 56: In Case Of Compressor Malfunction

    10-5. In case of compressor malfunction Should the compressor malfunction, be sure to replace compressor CAUTION as quickly as possible. Use only the tools indicated exclusively for R410A. See "10-3. Tools specifically for R410A". 10-5-1.Procedure for replacing compressor (1) Recovering refrigerant •...
  • Page 57 (5) Recharging Valve • Be sure to charge the specified amount of refrigerant in liquid state using the service port of the wide tube service valve. The proper amount is listed on the unit's nameplate. When the entire amount cannot be charged all at once, charge gradually while operating the unit in Cooling Operation.

  • Page 58: In Case Refrigerant Is Leaking

    10-6. In case refrigerant is leaking Never attempt to charge additional refrigerant when refrigerant has been leaking CAUTION from the unit. Follow the procedure described below to locate points of leaks and carry out repairs, then recharge the refrigerant. (1) Detecting Leaks •...

  • Page 59: Charging Additional Refrigerant

    10-7. Charging additional refrigerant 10-7-1.When tubes are extended • Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came with the indoor unit. Charge additional refrigerant in liquid state only. Never charge additional refrigerant if refrigerant is leaking from the unit. Follow CAUTION instructions given in "10-6.

  • Page 60: Checking Electrical Components

    11. CHECKING ELECTRICAL COMPONENTS Ground wire 11-1. Measurement of Insulation Resistance Clip The insulation is in good condition if the resistance exceeds 2MΩ. Probe 11-1-1. Power Supply Wires Insulation tester Clamp the ground wire of the power supply wires with Fig.

  • Page 61: Checking Continuity Of Fuse On Pcb Ass'y

    11-2. Checking Continuity of Fuse Fuse on PCB Ass'y 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 62: Maintenance

    12. MAINTENANCE 12-1. Address Setting of the Remote Control Unit The address can be set in order to prevent interference between remote controllers when two indoor units are installed near each other. The address is normally set to “A.” To set a different address, it is necessary to change the address on the second remote controller.

  • Page 63: Appendix

    APPENDIX Remote Control Unit Sensor Transmitter Display (Cover closed) ON/OFF operation button ION button 1 HR. TIMER button Temperature setting buttons (TEMP.) MODE Selector button QUIET button FAN SPEED selector button NIGHT SETBACK button FLAP button HIGH POWER button ON TIME Advance button OFF TIME Advance button...
  • Page 64 SANYO Electric Co.,Ltd. Osaka, Japan Jul/2005 Printed in Japan...

This manual is also suitable for:

Sap–kr224gjhSap–cr224ghSap–cr184gh

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