This document is a technical and service manual for the Sanyo SAP-K302AH and SAP-C302AH split system air conditioner. It provides detailed information on the unit's specifications, performance, installation, function, troubleshooting, and maintenance.
Function Description
The Sanyo SAP-K302AH + SAP-C302AH is a split system air conditioner designed for both cooling and heating. It utilizes a microprocessor/I.C. thermostat for control and comes with a wireless remote control unit. The system incorporates various automatic functions to optimize performance and protect the unit.
Cooling Operation:
Room temperature control in cooling mode is achieved by cycling the compressor ON and OFF based on the room temperature sensor in the remote control unit. The remote control unit transmits temperature and other information every 3 minutes to the indoor unit's controller. To protect the compressor, there's a 3-minute delay before the compressor turns ON after being OFF, allowing internal pressure to equalize. Additionally, the compressor switches OFF after 5 minutes or more of continuous operation as a protective measure. The "Thermo. ON" condition is when the room temperature is above the set temperature + 1°C, turning the compressor ON. "Thermo. OFF" occurs when the room temperature is at or below the set temperature, turning the compressor OFF.
Dry Operation (Dehumidification):
This mode leverages the cooling cycle to remove moisture from the air without significantly lowering the room temperature. It operates at a low level, with the air conditioner automatically cycling ON and OFF based on room temperature.
- Dry A zone (T+2°C to Set Temp.): Continuous compressor operation. Indoor fan (FMI) runs at low (L) or very low (LL) speed intermittently only when the compressor is ON.
- Dry B zone (Set Temp. to T-1°C): Intermittent compressor operation (ON for 3 minutes, OFF for 9 minutes). Indoor fan (FMI) runs at L or LL speed intermittently only when the compressor is ON.
- Monitor zone (Room Temp. under 15°C): Both indoor and outdoor units stop.
Intermittent ventilation in dry mode switches the indoor fan speed between L and LL. Dry operation does not occur below 15°C. When the compressor stops, the indoor fan also stops.
Automatic Switching between Cooling and Heating:
In AUTO mode, the microprocessor calculates the difference between the set temperature and the room temperature to automatically switch between COOLING and HEATING. If the room temperature is at or above the set temperature, COOLING begins. If it's below the set temperature, HEATING begins.
Freeze Prevention (Cooling):
This function prevents the indoor heat exchange coil from freezing. If the compressor runs for 6 minutes or more and the indoor coil temperature drops below -1°C, the control circuit stops the compressor for at least 6 minutes. The compressor will not restart until the temperature rises above 8°C.
Overload Prevention (Heating):
This function prevents overheating of the indoor heat exchange coil. If the indoor coil temperature rises above 55°C and the indoor fan is at low (L) speed, the fan speed changes to medium (M). If the indoor coil temperature rises above 57°C, the outdoor fan stops.
Cold Draft Prevention (Heating):
This function controls the indoor fan speed to prevent strong drafts of cold air before the indoor heat exchange coil has sufficiently warmed up. The indoor fan speed automatically adjusts based on the indoor coil temperature. The STANDBY lamp on the indoor unit illuminates when this function is active.
Defrosting Operation (Heating):
The system employs a reverse-cycle defrosting sequence. Frosting is detected if the compressor operates for more than 20 minutes, and the outdoor heat exchanger temperature is below L1 for 3 minutes, or below L2 for 120 minutes. During defrosting, the compressor and 4-way valve are ON, while the outdoor fan is OFF. The indoor fan operates in cold draft prevention mode. Defrosting lasts a maximum of 12 minutes, or until the outdoor heating exchanger temperature exceeds 12°C, or 150 seconds have passed since defrosting started.
Outdoor Fan Speed Control:
To optimize performance, the outdoor fan speed automatically adjusts based on the outdoor temperature.
- Cooling and Dry: Fan speed switches to LOW if outdoor temperature falls below 29°C, and to HIGH if it rises above 31°C.
- Heating: Fan speed switches to LOW if outdoor temperature rises above 20°C, and to HIGH if it falls below 16°C.
Important Technical Specifications
Indoor Unit (SAP-K302AH):
- Power Source: 240V Single phase 50Hz
- Cooling Capacity: 8.00 kW (27,300 BTU/h)
- Heating Capacity: 9.00 kW (30,700 BTU/h)
- Air Circulation (High): 1,110 m³/h (Cooling), 1,170 m³/h (Heating)
- Moisture Removal (High): 3.4 Liters/h
- Running Amperes: 13.0 A (Cooling), 12.0 A (Heating)
- Power Input: 3,100 W (Cooling), 2,850 W (Heating)
- C.O.P.: 2.58 W/W (Cooling), 3.16 W/W (Heating)
- Refrigerant: R22 / 2,800 g
- Operation Sound (Indoor - Hi/Me/Lo): 47/42/38 dB-A
- Dimensions (H x W x D): 330 x 1,140 x 228 mm
- Net Weight: 18.0 kg
- Fan Motor: Cross-flow type, 1 unit, 4 poles, 1,270/1,280 rpm (Cool/Heat High)
- Flap Motor: Stepping motor, DC 12V
- Coil: Aluminum plate fin / Copper tube, 2 rows
- Thermistor (Coil sensor): DTN-TKS131B (15.0 ± 2% at 0°C)
- Thermistor (Room sensor): DTN-TKS128B (5.0 ± 3% at 25°C)
Outdoor Unit (SAP-C302AH):
- Power Source: 240V Single phase 50Hz
- Compressor: Rotary (Hermetic), C-R240H5S 80669545
- Nominal Output (Compressor): 2,400 W
- Compressor Oil: 4GSD-T or SAY-56T, 1,350 cc
- Operation Sound (Outdoor - Hi): 54 dB-A
- Dimensions (H x W x D): 735 x 940 x 340 mm
- Net Weight: 71.0 kg
- Fan Motor: Propeller type, 1 unit, 6 poles, 780/760 rpm (Cool/Heat High)
- Coil: Aluminum plate fin / Copper tube, 2 rows
- Thermistor (Coil sensor): PBC-41E-S14 (e.g., 9.9 ± 5% at 10°C)
- Thermistor (Air sensor): PBC-41E-S14 (e.g., 9.9 ± 5% at 10°C)
- 4-way Valve: CHV-01AJ504D1 (Coil), STF-03U1 (Valve), AC 220-240V, 50Hz, 6W
- Power Relay: EL1U, AC 200-240V, 50/60Hz, AC 277V, 30A
- Fuse: Cartridge type, 250V, 20A / ø6.4 x 30mm
Refrigerant Tubing:
- Max. Allowable Tubing Length at Shipment: 7.5 m
- Max. Limit of Tubing Length (L): 30 m
- Max. Limit of Elevation Difference (H): 15 m
- Narrow Tube Diameter: 9.52 mm (3/8")
- Wide Tube Diameter: 15.88 mm (5/8")
- Additional Refrigerant (R22) Charge: 60 g/m for lengths between 7.5 m and 30 m.
Usage Features
- Wireless Remote Control: The unit is controlled via a wireless remote control unit, offering convenience. It can be used from a non-fixed position or wall-mounted.
- Timer Function: Includes a 1-hour OFF / 12-hour ON or OFF timer.
- Fan Speed Control: Offers 3 fan speeds (High, Medium, Low) and an Auto mode.
- Airflow Direction: Manual horizontal adjustment, automatic vertical adjustment.
- Washable, Anti-Mold Air Filter: Easy to maintain for cleaner air.
- Address Setting for Multiple Units: If installing more than one indoor unit in the same room, each unit can be assigned a unique address to be operated by its own remote control unit. This involves cutting a jumper wire (JP11) on the indoor unit PCB and switching an address switch on the remote control unit.
Maintenance Features
- Troubleshooting Guide: The manual provides comprehensive troubleshooting steps for various issues, including:
- Circuit breaker trips (ground fault, short circuit).
- Unit not operating (power supply, remote control unit, fuse, timer).
- Only indoor/outdoor fan not running (fan rotation, foreign matter, motor capacitor, motor winding).
- Only compressor not running (compressor motor capacitor, internal protector, refrigerant gas shortage, power relay, power supply voltage).
- Abnormal operation (operation not switching between heat/cool, poor cooling/heating, excessive cooling/heating).
- Defective sensors (indoor coil temp. thermistor, room temp. thermistor).
- Electrical Component Checks: Instructions for measuring insulation resistance for power supply wires, indoor unit, outdoor unit, and electrical parts. Also includes checking fuse continuity and motor capacitor functionality.
- Wiring Diagrams: Detailed electric wiring diagrams for both indoor and outdoor units to aid in diagnosis and repair.
- Installation Site Selection Guidelines: Provides recommendations for optimal placement of both indoor and outdoor units, considering factors like air flow, heat sources, humidity, and maintenance access.
- Recommended Wire Length and Size: Tables and diagrams for appropriate wiring based on cross-sectional area and length, adhering to local electrical codes.
- Safety Precautions: Emphasizes the importance of reading the manual, following installation/repair steps, observing electrical codes, and paying attention to warning and caution notices to prevent personal injury, death, or product damage. Specific warnings are given for wiring, transporting units, installation locations (ceiling/wall, moist/uneven, high winds, snowy areas), connecting refrigerant tubing, and servicing.
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