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Sanyo SAP241RC User's Manual

Contents

1. 9 2 Panel Removal 265 o a Dare ede Lode e iua a 9 3 Fan Fan Motor Removal 4 9 4 Control Switch Unit Removal 4 OUT DOOR UNIT 9 5 Cabinet e re EE 9 6 Fan Fan Motor Removal 1 4 semen 9 7 Electrical Component Box Removal 98 Compressor Cover qossesustastaanes 99 Compressor Removal nb 9 10 Compressor Replacement 9 10 1 Tool List for Compressor Replacement 9 10 2 Safety Precautions 9 10 3 Compressor Replacement Procedures A Separating the Outdoor Unit B Removing the Old Compressor C Installing a New Compressor 9 11 Leak Test Evacuation and Charging 9 11 1 Required Tools and System Set up 9 11 2 System Leak Test at the Service Site 9 11 3 Evacuation 9 11 4 Charging Refrigerant R22 47 A SANYO INDOOR UNIT 9 1 Electrical Component Box Access and Removal 1 Lift the air intake panel slightly upward and then slide it in the direction shown by arrow A 2 To remove the air filter grasp the filter tabs and pull them downwards arrow B Fig 1 3 The electrical component box becom
2. 4 2 CONSTRUCTION OF THE UNIT 5 DIMENSIONAL DATA ERE 6 4 PERFORMANCE CHARTS 8 5 OPERATING INSTRUCTIONS 10 6 INSTALLATION INSTRUCTIONS 12 TROUBLESHOOTING ee Ee 27 8 CHECKING AND REPLACING ELECTRICAL COMPONENTS 38 9 DISASSMBLY AND SERVICE PROCEDURES 47 10 PARTS WEE 63 11 REFRIGERANT FLOW DIAGRM Ee 67 12 ELECTRIC WIRING DIAGRAM 68 13 APPENDIX Conversion Tables 71 1 SPECIFICATIONS 1 1 Unit Specifications Outdoor unit SAP241C PERFORMANCES ELECTRICAL RATINGS Heating BTU hr Moisture Removal High Pints hr 8 4 Circulation SEER EER BTU Whr Frequency Hz 60 Rated Voltage V _ 230 208 Running Amps REENEN Power Input 3 030 2 960 2 30 FEATURES Controls Microcomputer Yes Timer Air Deflection V
3. RIGID or equivalent Reamer 119 Good flare should have following conditions e Inside surface is glossy smooth Fig 23 e Edge is smooth Tapered sides are in uniform length Flare nut Copper tube Flaring tool er 5 3 Caution before Connecting Tubes Tightly Ig a Be sure to apply blind cap or water proof tape to prevent dust or water from getting into the copper tube until it is used b Be sure to apply refrigeration oil to the matching surfaces of flare and union before connecting them together This is Be sure to apply effective for reducing gas leaks Fig 25 refrigeration oil Fig 25 c For proper connection hold the tube with union and the flared tube straight with each other screw in the flare nut lightly at first to obtain smooth match Fig 26 ae Ee Union Flare nut Fig 26 259 5 4 5 5 5 6 5 7 Connecting Tubes between Indoor and Outdoor Units 1 Connect the indoor side refrigerant tubing extended from the wall with the outdoor side tubing tightly 2 Flare nut on large dia tube should be torqued to 510 550 lbs in Flare nut small dia tube should be torqued to 130 170 Ibs in Fig 27 3 After performing a leak test on the connecting part insulate it with INSUL NIPPLE and finish with a vinyl masking tape over it Fig 28 CG Never connect up tubes by brazing them If It is inevitable be sure to blow nitrogen gas while braz
4. ER _ 85 Stz NI o292s3 O A i 1 93Q KO DEI 82 62 e H c9 9S6922 Hv c B 35134 FM SUP 69 SANYO ul ELECTRIC WIRING DIAGRAM POW 24R CONTROLLER P C B 49 q Ut C MOd 8H 9u v2 DH LLY 02 ri9r z le gt Hg EZH ELY 9 lun L d Hg vu S CH NODOWSH Htc SOH CH ML LH 1 i L w x emm s wem Z SNVu 1 E SNVHL Fr 7 77 B EF Lu mmm J r 3 I I S 2 dH Bde C zAy 4 V dE fe Ti L LI 1 LJ 4 SS 3 44 4 40 3 966252 Joysisues UATE Mv l 1039159 6281 1 4 Xzrtr sa apoig 151272 20989 Xcvt SQ apoig 93879 MEIL 3039523 6 H VZO ELZS 10198 05 Xzrt sa poiq OE v 1039595 8 H 03M d 121 29 UAOL 203989 1 3 2 6292 11 8 403128Uu07 90r v8a 4039525 9 H 518 dE 3 04v AOS JOlIoede WEE Mb L 203959 GH 2 6292 2 10290 05 47220 0 AOS UAOL 1 4039595 dz 312200 AOS Jouseded UALL
5. 5 With an Oxy Acetlyine torch apply heat uniformly and unbraze the joints of upper section of the Liquid Injec tion Capillary tube to the compressor the upper section of the accumulator and the upper section of the compressor discharge tube respectively and pull them free with pliers Fig 19 shows unbrazing points with arrows Be sure to save all mounting components with the replacement compressor for future use 6 To remove the compressor raise it straight and disengage from the base unit TUBE DISCH 3 8 TUBE SUCT 5 87 Mounting Component ge NUT SPECIAL BYPASS 5 16 Mors Cover TUBE LIQUID terminal INJECTION 1 GT wert terminal Weld Terminal Compressor top Discharge tube SCREW SPECIAL LIQUID INJECTION CAPILLARY Fig 20 Fig 21 IMPORTANT NOTICE Before installing the new compressor check for possible system contamination by the following procedure Place about 10 cc of the oil from the old compressor into a transparent container and visually check the degree of oil contamination If the oil has a slight burnt odor but no color change or residue and ordinary compressor replacement accoring to the instructions below may be carried out If the oil has a burnt pungent odor and shows contamination dark color with tiny particles of metal the system must be cleaned sufficiently with a suction filter or a drier strainer and then replace the oil dri
6. Joysisay 2 692 2 10138 05 4NZZ0 0 AOS Jouseded 2039523 518 dc 471055 AOL JO0jIoede UAOL Mt lL Jojssay LH Z 6Z9ZL1 Z 1032 Jv A91 BJE 103959 Oly OZtV HNS 103 2 317200 AOS 1 SHE MEI 10395 6H 3H 7 921 2 412200 AOS Joyoeded 5996 101959 8H 3HtZ D21 Z 412200 AOS 10312 4 1 25481 1039593 98 3H C 9Z1 Aejay 2 312200 AOS Joyoedeg DEE 1039594 H Q8St9Vv1 1o1099uuoO 1001 MZ t 103959 CH 40 G8SGPWrNn 21 ZE 1O1SIS H 5094 MI 101959 13 APPENDIX Conversion Tables Centigrade gf Fahrenheit Numbers in the center column between those marked C and F refer to temperature Centigrade or Fahrenheit which it is desired to convert into the other scale To convert from Fahrenheit to Centigrade find equivalent temperature in left hand column 40 0 40 42 0 6 7 68 0 15 6 140 0 37 8 100 212 0 82 2 130 356 0 137 8 280 536 0 389 38 35 4 6 1 69 8 16 1 ei 141 8 38 9 102 215 6 83 3 182 359 6 140 6 235 545 0 37 8 36 32 8 5 6 22 71 6 16 7 62 143 6 40 0 104 219 2 84 4 184 363 2 143 3 290 554 0 36 7 34 29 2 5 0 23 73 4 17 2 63 145 4 41 1 106 222 8 85 6 186 366 8 146 1 295 563 0 35 6 32 25 6 4 4 24 75 2 17 8 64 147 2 42 2 108 226 4 86 7 188 370 4 148 9 300 572 0 344
7. 031 Ab 4 internal Protector 17AM035 Ab 4 3 5 Run Capacitor Coil Resistance WHT BRN 55 2 WHT BRN 24 1 Ambient Temp 68 F WHT YEL 53 2 WHT PNK 53 8 YEL PNK 74 6 Room Temp Sensor OCS5K UL Incorporated in the remote control unit 69 F 6 6 5 Resistance 86 F 3 9 4 2 77 F 4 9 5 2 Note thermistor Power Transformer for Controller PCB ATR J122U Primary WHT NHT 143 5 Resistance Secondary BRN BRN 1 2 Unit Model No SAP241C Magnet Relay CLK 16E3 21 2 Unit Model No SAP241C Outdoor Coil Thermostat YTB 4U201 Operating Temperature ON 75 F OFF 78 F Solenoid Valve NEV603DXFU valve NEVAC208 coil been 230 V 208 V 9 W 5 W 4 SANYO 1 3 Compressor ldentification Printed marking 1 Marking Stamped LOCKED ROTAR AMP THERMALLY Terminal PROTECTED Com t SE 806 486 46 6 Warning label BEER Stamped Marking Model No R190H6N S Sanyo E Electric Heater gt eee 30 01 5 lt 30 Jan 1985 Ratings V V230 208 Frequency Hz 260 1 and Phase R otary Compressor Mounting Component 2 Compressor Code No 806 486 46 ee ET WARNING SERVICEMAN 1 FIELD SERVICE LEAK TEST PRESSURE MUST identification Voltage NOT EXCEED 150 P S I G 2 115V AC 60 Hz 2 THIS
8. if this operation is continued for a long time there would be a bad effect on the air conditioner because of over cooling Therefore use this switch only for checking and in any case DO NOT KEEP ON COOLING FOR MORE THAN 15 MIN UNDER TEST RUN MODE When the checking is over TURN THE SWITCH BACK TO ITS ORIGINAL POSITION RUN WITHOUT FAIL REFERENCE TEST RUN KH 52 is SANYO Multimeter 152 range NEZ Compressor terminal lt gt Fig E 7 1 REMOTE CONTROL UNIT INDICATOR LAMP loreen OPERATION FAN SPEED OFF ON S OPERATION SWITCH THERMOSTAT TEST RN 69 N 13 78 77 29 8 83 85 8 FAN THERMOSTAT FAN AND SLIDE SWITCH Q SANYO Fig E 7A Check that all tubing and wiring have been completed correctly Check again that wide and narrow tube service valves are fully opened Turn on power and run the unit Cun If the room temperature is too low cooling operation may not be possible even if the thermostat knob is set at the lowest position In this event perform test run as follows a Pull off the thermostat knob Fig E 8 b Set the thermostat lever to the lowest position The central position of the lever becomes the TEST RUN position Fig E 9 c Press OPERATION ON button to start the air conditioner d After completion of tes
9. 3 9030 00508 4 2379 561 75 852 2 2396 10103 3 9030 00512 854 2 5304 26100 854 2 1358 46700 Ara A FARA 854 2 5304 26000 851 2 5250 76800 4 2339 56195 4 2329 56284 4 2239 56224 4 2239 56339 852 2 5301 20600 854 0 5301 33001 852 6 4729 17300 854 0 2325 16900 854 2 2208 195 0 852 0 4516 15700 Strainer Ass y Capillary Tube Packina Mounting Plate 6 Packing Heater Ass y 5700 230V30W Mounting Plate Accumulator Gasket Terminal Cover Terminal Nut 5mm Electrical Component Box Clamper EG Terminal Base 6P 30A Screw Special Clamper F 10 Cover Plate Label Cover Piate Wiring Diagram Thermostat Y TB 4U201 Relay CLK 16E3 21 Fixed Capacitor QS SANYO SAP241C OUTDOOR UNIT sch ech cA sch c sch sch sch sch sch ech sch 440VAC 5MFD Fixed Capacitor 400VAC 35MFD Clip Capacitor Electrical Component Box Ass y Label Cover Ass y Mounting Plate Ass y Compressor Ass y C R190H6N gt ad esch 806 4 8646 NOTE Metal and plastic parts will be supplied basically with necessary heat insulating pads or packing Some key numbers are intentionally omitted or left blank for the editor s convenience 11 REFRIGERANT FLOW DIAGRAM Model SAP241RC Capillary 4 Solenoid valve S T HUHH 2 Service N u D J 6 Wide gt Evap
10. 78 18 64 4 144 58 136 4 36 7 98 208 4 78 9 174 345 2 129 4 265 509 0 276 7 530 986 0 72 19 66 2 150 59 138 2 372 99 2102 80 0 176 348 8 132 2 270 518 0 282 3 540 1004 0 81 1 178 352 4 135 0 275 527 0 287 8 550 1022 0 Kilocalorie mp British Thermal Units 1kcal 3 9683 B T U 4 SANYO Kilocalories KR Kilograms Pounds Kilograms 100 158 730 198 413 238 095 277 778 317 460 357 143 386 250 3 968 43 651 83 333 123 016 162 698 202 381 242 063 281 746 321 428 361 111 400 793 7 937 47 619 87 302 126 984 166 667 206 349 246 032 285 741 325 397 365 079 404 762 11 905 51 587 91 270 130 952 170 635 210 317 250 000 289 682 329 365 369 047 408 730 1kg 2 205 ibs 15 873 55 556 95 238 134 921 174 603 214 286 253 968 293 651 333 333 373 016 412 698 19 841 59 524 99 206 138 889 178 571 218 254 257 936 297 619 337 301 376 984 416 666 23 810 63 497 103 175 142 857 182 540 222 222 261 905 301 587 341 270 380 952 420 635 27 778 67 460 107 143 146 825 186 508 226 190 265 873 305 555 345 238 384 920 424 603 31 746 71 429 111 111 150 794 190 476 230 159 269 841 309 524 349 206 388 889 428 571 35 714 75 391 115 079 154 762 194 444 234 127 273 809 313 492 353 174 392 857 432 539 Liters mii U S Gallons Liters Kilograms per Sq Cm ANA sf Ms SE 26 455 48 502 70 548 92 594
11. This is the entire Sanyo warranty and it may not be changed or amended by any person agen Cy distributor dealer or company without prior written authority from Sanyo Electric Inc and Sanyo does not authorize any party to assume for it any obligation or liability This warranty gives the consumer specific leyal rights but may have other legal rights which may vary from state to state In no event shall Sanyo be liable and specifically denies responsibility for any consequential damages arising from the use of this product beyond the repair or replacement of the Air Conditioner or for any delay in the performance or this war ranty due to causes beyond our control Some states do not allow limitations on how long an impjlied warranty last and or do not allow the exclusuion or limitation of consequential damages so the above limitations on im plied warranty and consequential damages may not apply to you Should the consumer need repairs or assistance in locating his nearest qualified HVAC con tractor contact dealer of purchase or call write to Sanyo Electric Inc as follows Sanyo Electric Inc 200 Riser Road Little Ferry 07643 201 641 2333 SANYO CONDITIONER SERVICE MANUAL MODEL SAP241RC Table of Contents Page 1 eee 1 Bai de 1 1 2 Major Component SPECHICATIONS uuu u u n aus s s anu 2 1 3
12. 114 64 136 69 158 73 180 78 202 83 224 87 1 lit 0 264 13 228 35 274 57 320 79 366 101 41 123 46 145 51 167 55 189 60 211 64 233 69 465 Ann 102 90 2 17 63 7703 Gallons Gallons Gallons Gallons mm M Gallons Gallons arm BN 2 642 5 283 7 925 10 567 13 209 15 850 18 492 21 134 23 775 26 417 0 528 3 170 5 812 8 453 11 095 13 737 16 379 19 020 21 662 24 304 0 739 3 434 6 076 8 718 11 359 14 001 16 643 19 284 21 926 24 568 26 945 27 210 1 057 3 698 6 340 8 982 11 623 14 265 16 907 19 549 22 190 24 832 1 321 3 963 6 604 9 246 11 888 14 529 17 171 19 813 22 454 25 096 1 585 4 277 6 868 9 510 12 152 14 794 17 435 20 077 22 719 25 360 27 474 27738 28 002 1 849 4 491 7 133 9 774 12 416 15 058 17 699 20 341 22 983 25 625 28 266 2 113 4 755 7 397 10 038 12 680 15 322 17 964 20 605 23 247 25 889 28 530 2 378 5 019 7 611 10 303 12 944 15 586 18 288 20 869 23 511 26 153 28 795 Square Centimeters gt Square Inches 1cm 0 155 in Square o 1 2 3 s e 7 8 9 Ar omes CA ra p nr mm Aa AR ra em aa 0 1 10 76 21 53 32 23 43 06 53 82 64 58 75 35 86 11 96 88 10 107 64 118 40 SES 129 17 139 93 2 150 69 161 46 172 22 182 99 193 75 E 204 51 E 20 215 28 226 04
13. 33 4 14 CT AVOID e heat sources exhaust fans etc Fig 3 e damp humid or uneven locations choose a place as cool as possible e choose a place that is well ventilated and outside air temperature does not exceed 115 constantly e allow enough room around unit for air intake exhaust and possible maintenance Fig 4 e provide a solid base about 4 above ground level to reduce humidity and possible water damage in unit and decrease service life Fig 5 e use lug bolts or equal to bolt down unit reducing vibration and noise Air discharge A 4 Min Fig 5 3 HOW TO INSTALL INDOOR UNIT 3 1 Mount the Unit a Make an opening on the ceiling and determine the positions of the suspension bolt holes according to Fig 6 b In the holes for the bolts insert securely bolt anchors bolt holding plugs Then securely screw the bolts into the anchors as shown in the illustration at right Fig 7A 15 Exhaust fan Fig 3 uc E cU a eet 4 Pd 6 1 2 Outdoor unit lt Valve Side Fig 4 48 7 8 Ceiling opening 4 15 16 4 E F 5 I Gu S Suspension bolts pou D Sg s E e 7 2 7 d P SS LO Fig 6 bolt anchor bolt holding plug insert field supply DEN R 1 suspencion bolt M10 field supply Fig 7A 673 the ceiling p
14. 35 40 9C Outdoor ambient temps di 4 SANYO 5 OPERATING INSTRUCTIONS 1 REMOTE CONTROL UNIT FAN SPEED OFF ON THERMOSTAT OPERATION LA TES RUN 69 71 73 75 77 79 8 83 B5 87 FAN SANYO Note If the lamp goes out and the air conditioner stops operating refer to the section entitled REMEDIES THERMOSTAT The thermostat maintains the room temperature automatically at the desired level and ensures economical air conditioner opera tion Just set the thermostat lever for the temperature level you want TEST RUN FAN This position is to be used for test operation only after installation or during service Normally it should be locked Set thermostat lever to this position when FAN only operation is needed The numbers on the graduated scale are meant to serve as a guideline only The actual room temperature may differ from the thermostat set ting depending on room size and the cooling load 10 A INDICATOR LAMP Green This lamp lights up during fan only and cooling operation B OPERATiON SWITCH Stops air conditioner Starts air conditioner bringing cooling room air circulation and filtering dusts C FAN SPEED SWITCH To operate the fan at high speed set lever to HIGH position To operate the fan at low speed set lever to LOW position D THERMOSTAT FAN AND TEST RUN SLIDE SWITCH TEST RUN 69 71 73 75 77
15. 7 When the four screws removed as shown in the figure the fan motor can be removed Fig 10 9 4 Control Switch Unit Removal 1 Remove the two knobs 1 2 When the screwdriver 2 is inserted for about 1 8 into the notch of the control name plate 3 and raised to the front the name plate can be removed 3 When the four screws 4 are removed the cover plate and the control switch PCB assebly 5 can be separated from the box The control switch unit can be checked in this condition 4 For removal of the control switch PCB assembly 5 remov ed the connection of the lead wires 6 and remove the four screws 7 Fig 12 SANYO OUTDOOR UNIT 9 5 Cabinet Removal 1 Remove the outer panels in the order of front panel A side panel B and side panel C 2 Remove the cover plates D and E 3 Remove the mounting plate F Fig 13 9 6 Fan and Fan Motor Removal 1 Remove the guard A first and then remove the bolts a of the propeller fan B to remove the propeller fan by lifting it up 2 Remove the fan motor wire from the electrical component box and remove the top cover C with the fan motor fixed to the top cover Fig 14 Fig 14 _52 9 7 Electrical Component Removal 1 Remove the following wires from the electrical component box 1 Compressor wire 2 Crankcase heater wire 3 Solenoid valve wire 1 Remove the cov
16. 236 81 247 57 258 33 269 10 279 86 290 62 301 39 312 15 30 322 92 333 68 344 44 355 21 365 97 376 74 387 50 398 26 409 03 419 79 40 430 55 441 32 452 08 462 85 473 61 484 37 495 14 505 90 516 67 527 43 50 538 19 548 96 559 72 570 48 581 25 592 01 602 78 613 54 624 30 635 07 60 645 83 656 60 667 36 678 12 688 89 699 65 710 42 721 18 731 94 742 71 70 753 47 764 23 775 00 785 76 796 53 807 29 818 05 828 82 839 58 850 35 80 861 11 871 87 882 64 893 40 904 16 914 93 925 69 936 46 947 22 957 98 90 968 75 979 51 990 28 1001 04 1011 80 1022 57 1033 33 1044 10 1054 86 1065 62 100 1076 39 1087 15 1097 92 1108 68 1119 44 1130 21 1140 97 1151 74 1162 50 1173 26 Cubic E Inches 1cm 0 061 3 _ 2 3 5 s 7 8 Cubic Cm bic Cubic Cubic Cubic Cubic Cubic Cubic Cubic Cubic Inches Inches Inches Inches Inches Inches Inches Inches Inches Inches mud 0 0610 0 1221 0 1831 0 2441 0 3051 0 3661 0 4272 0 4882 0 5492 i0 0 6102 0 6712 0 7323 0 7933 0 8543 0 9153 0 9763 1 0374 1 0984 1 1594 20 1 2205 1 2815 1 3426 1 4063 1 4646 1 5256 1 5866 1 6477 1 7087 1 7697 30 1 8308 1 8918 1 9529 2 0139 2 0749 2 1359 2 1969 2 2580 2 3190 2 3800 40 2 4410 2 5020 2 5631 2 6241 2 6851 2 7461 2 8071 2 8682 2 9292 2 9902 50 3 0513 3 1123 3 1734 3 2344 3 2954 3 3564 3 4174 3 4785 3 5395 3 6005 60 3 6615 3 7225 3 7836 3 8446 3 9056 3 9666 4 0276 4 0887 4 1497 4 2107 70 4 2718 4 3328 4 3939 4 4549 4 5159 4 5769 4 6379 4 6990 4 7600 4 8210
17. 30 22 0 3 9 25 77 0 18 3 65 149 0 43 3 110 230 0 87 8 190 374 0 151 7 305 581 0 33 3 28 18 4 3 3 26 78 8 18 9 66 150 8 44 4 112 233 6 88 9 192 377 6 154 4 310 590 0 32 2 26 14 8 2 8 21 80 6 19 4 67 152 6 45 6 114 237 2 90 0 194 381 2 157 2 315 599 0 31 1 24 11 2 2 2 28 82 4 20 0 68 154 4 46 7 116 240 8 91 1 196 384 8 160 0 320 608 0 30 0 22 1 5 1 7 29 84 2 29 6 69 156 2 47 6 116 244 4 9 198 388 4 162 8 325 617 0 289 20 4 0 1 1 30 86 0 21 1 70 158 0 48 9 120 248 0 93 3 200 392 0 165 6 330 626 0 278 18 0 4 0 6 31 87 8 21 7 11 159 8 50 0 122 251 6 94 4 202 395 6 168 3 335 635 0 26 7 16 3 2 0 0 32 89 6 22 2 72 161 6 51 1 124 255 2 95 6 204 399 2 171 1 340 644 0 25 6 14 6 8 0 6 33 91 4 22 8 73 163 4 52 2 125 258 8 96 7 206 402 8 173 9 345 653 0 24 4 12 10 4 1 1 34 93 2 23 3 74 165 2 53 3 128 262 4 97 8 208 406 4 176 7 350 662 0 233 40 14 0 1 7 35 95 0 23 9 75 167 0 54 4 130 266 0 98 9 210 410 0 170 4 355 671 0 222 8 17 6 2 2 36 96 8 24 4 76 168 8 55 6 132 269 6 100 0 212 413 6 182 2 360 680 0 21 1 6 21 2 2 8 37 98 6 25 0 77 170 6 56 7 134 273 2 101 1 214 417 2 185 0 365 689 9 20 0 4 24 8 3 3 38 100 4 25 6 78 172 4 57 8 136 276 8 102 2 216 420 8 188 2 370 698 0 18 9 2 28 4 3 9 39 102 2 26 1 79 174 2 58 9 138 280 4 103 3 218 424 4 190 6 375 707 0 17 8 0 32 0 4 4 40 104 0 26 7 80 176 0 60 0 140 284 0 104 4 220 428 0 193 3 38
18. 49375 13 890625 14 2875 14 684375 15 08125 15 478125 16 271875 16 66875 17 065625 17 4625 17 8593 75 18 25625 18 653125 Milti meters 0 025 0 051 Se 0 076 0 310 0 102 0 320 0 127 0 330 0 152 0 340 0 178 0 350 0 203 0 360 0 229 0 370 0 254 0 380 0 508 0 390 0 762 0 400 1 016 0 410 1 270 0 420 1 524 0 430 1 778 0 440 2 032 0 450 2 286 0 460 2 540 0470 2 794 0 490 3 048 0 490 3 302 0 500 3 56 0 510 3 81 0 520 4 06 0 530 4 32 0 540 4 57 0 550 4 83 0 560 5 08 0 570 5 33 0 580 5 59 0 590 5 84 0 600 6 10 0 610 6 35 0 620 6 60 0 630 6 86 0 640 7 11 0 650 49 54 25 32 51 64 13 16 53 64 27 32 55 64 Se 7 37 0 680 7 62 0 670 7 87 0 680 8 13 0 690 8 38 0 700 8 64 0 710 8 89 0 720 9 14 0 730 9 40 0 740 9 65 0 750 9 91 0 760 10 16 0 770 10 41 0 780 10 67 0 790 10 92 0 800 11 18 0 810 11 43 0 820 11 68 0 830 11 94 0 840 12 13 0 850 12 45 0 880 12 70 0 870 12 95 0 880 13 21 0 890 13 46 0 900 13 72 0 910 13 97 0 920 14 22 0 930 14 48 0 940 14 73 0 950 14 99 0 960 15 24 0 970 15 49 0 980 15 75 0 990 16 00 1 000 1626 1651 0 765625 0 78125 0 796875 0 8125 0 828125 0 84375 0 859375 0 890625 0 90625 0 921875 0 9375 0 953125 0 96875 0 9843 5 SANYO 16 76 17 02 17 27 17 53 17 78 18 03 18 29 18 54 Millimeter 19 446875 19 84375 20 240625 20 6375 21 034375 21 43125 21 928125 22 621875 23 01875 23 415625 23 8125 24 2093
19. 79 81 83 85 87 FAN THERMOSTAT 1 69 71 73 75 77 79 81 83 85 87 FAN THERMOSTAT 3 AIR FLOW DIRECTION ADJUSTMENT AIR DEFLECTOR VANE ESS CEILING PLATE SQ p Su gt a S hs Mm 4 CAUTION SAFETY INTERVAL RESTARTING After pressing the OFF button the air conditioner stops and It will not start three 3 minutes To start the unit again after three minutes press the ON button 2 HOW TO OPERATE Turn on the power supply disconnect at least five hours before starting the air conditioner 1 Set THERMOSTAT lever to the desired position 2 Set FAN SPEED selector lever to the desired position 3 Press the ON button to start the air conditioner HOW TO STOP Press the OFF button to stop the air conditioner EMERGENCY SHUTDOWN If the air conditioner does not stop even when the OFF button is pressed disconnect the power supply Air deflector vanes can be manually adjusted for the desired air distribution RE START stis INSTALLATION INSTRUCTIONS Table of Contents MEET 1 1 Tools Required for Installation not supplied 1 2 Accessories Supplied with Unit for Installation 1 3 Optional Copper Tubing Kit 1 4 Type of Copper Tubes and Insulation Material 1 5 Additional Materials Required to Give Installation a Professional Appearance INSTALLATION SITE SELECTION Indoor Unit Outdoor Unit HOW TO INST
20. COMPRESSOR MUST BE GROUNDED 6 208 230VAC 60Hz 3 DO NOT OPERATE WITHOUT PROTECTIVE m COVER OVER TERMINALS DISCONNECT ALL Phase amp Application POWER BEFORE REMOVING THE PROTECTIVE 4 1 PH amp High Back Pressure COVER Design Serial No CAUTION Figures to express COMPRESSOR HOUSING MAY REACH 302 F 150 C Nominal Output Approx Watts WITH TERMNAL PROTECTOR APPROVED BY Figures to express TOKYO SANYO AND TESTED IN ACCORDANCE WITH UL984 1981 Compressor Type TOKYO SANYO ELECTRIC CO LTD 806 means ROTARY 3 Compressor Wire Orientation Discharge Tube anng Piagam Compressor S CIT N N INTERNAL Ne PROTECTOR UR POWER gt SUPPLY RUNNING S N CAPACITOR COMPRESSOR COMPRESSOR 2 CONSTRUCTION OF THE UNIT Drain hose Refrigerant tubing Evaporator Indoor heat exchanger Blower casing Drain pan Fan motor Air discharge panel Air filter Blower OO OUTDOOOR UNIT 241 Propeller fan Fan motor Condenser Outdoor heat exchanger Service valve Wide tube Service valve Narrow tube Electrical component box Compressor NOOR WH SANYO DIMENSIONAL DATA 3 SAP241R Indoor Unit 91 6 91 6 yog uoisuadsns 10 c SC xt 91 15 1 lanO ZE 6 ZE HILFE K
21. disconnect power for this Remove foreign matter or repair Check fan casing for foreign matter on the inside Check the fan rotation Turn the fan gently once or twice by hand Fan motor burn out or foreign matter in bearing Repair or The fan cannot replace The fan be turned smoothly ___ LL Refer to EE e Check fan motor capacitor ELC 5 Replace if defect P 41 GOOD Check fan motor winding Refer to No continuity Replace for continuity ELC 4 P 41 fan motor There is continuity Rewire fan motor correctly and try operation NOTE The fan motor does not run until the winding temperature lowers and automatic resetting works if the internal thermostat operates 932 Q SANYO 2 4 Only compressor does not run Check compressor motor sure to disconnect circuit power for this Wait for 30 minutes and Check operation of check for continuity compressor overload relay VENE e Check compressor motor Defect P No continuity Replace Check for a wire break in compressor compressor motor winding There is continuity In case of wrong wiring Correct e Check wiring according to wiring wiring diagram 34 2 5 Compressor frequently repeats ON and OFF Only compressor repeats ON and OFF while indoor unit and outdoor fan run without fail Check compressor
22. enough Approx 55 deg F or more e Check for clogging of air filter Reevaluate cooling load Air filter is clogged Clean filter Reduce cooling load or replace the unit with higher cooling Capacity estimate if performance of air conditioner is normal A SANYO 3 2 Excessive cooling e 5 TEST RUN selector switch at left side of remote control unit set to RUN upper position YES NO e isset temperature suitable YES e 5 remote control unit installed at a place where it can detect room tem perature properly YES Does compressor motor stop when operation push button is depressed to OFF YES NO NO Set switch to RUN Set temperature to higher value or set selector lever to AUTO Change installation position of remote control unit Power relay defect 2297 4 SANYO 8 CHECKING AND REPLACING ELECTRICAL COMPONENTS Quick Access Index Page ELA Connector Identification on Controller 39 ELC 1 Measurement of Insulation Resistance of the Power Cord 40 ELC 2 Measurement of Insulation Resistance of the Compressor 40 ELC 3 Measurement of Insulation Resistance of the Fan Motor 40 ELC 4 Checking of the Outdoor Fan Motor 41 ELC 5 Checking of the Motor Capacitor 41 ELC 6 Checki
23. in bearing smoothly ee e Check fan motor capacitor Reter to 5 P 41 Refer to No output Refer to d ELC 7 contro 42 unit Check output of fan motor ELC 10 P 45 terminals on controller YES There is output Replace Control In case ler PCB of defect No conti Refer to Replace winding for continuity EE Check indoor fan motor fan motor There is continuity e Rewire fan motor correct ly and try operation nig 2 2 Neither outdoor fan compressor runs Note Check following points at first 1 Is thermostat setting suitable 2 Has 3 minute timer operated No operation for 3 minutes after power ON In case of zero 0 volt eCheck voltage between ter minals No 2 and No 3 at terminal base of outdoor unit e At this time set selector switch at left side of remote control unit to bottom posi tion TEST RUN 90 or more of rated voltage If voltage is Check voltage of magnet contactor coil of compressor motor Refer to ELC 6 42 eCheck compressor wire eCheck outdoor fan motor wire Ig Check transformer Refer to ELC 10 P 45 Check con troller PCB Refer to ELC 8 P 44 4 SANYO 2 3 Only outdoor fan does not run e Check fan motor circuit Be sure to
24. in the packing of the remote control unit d Align the prongs of the dressing cover with the mating holes on the remote control unit body and fasten them firmly e After mounting pushbuttons on corresponding switches hang the remote control unit onto the mounting plate and slide it until it is seated Thus installation completes Mount on the wall Remote control unit body M4 Small screw Dressing cover 4 Pcs ROM plate Remote control wiring EN Pushbutton EM 18 Fig 17 Recessed NOTE In case of use recessed outlet box outlet box install remote control unit body dressing cover and pushbutton directly to outlet box as same as Fig 17 Do not use plastic box and mounting plate Fig 18 Fig 18 3 5 Install Ceiling Panel Fig 19 a Screw the M5 x 35 small screws provided in the ceiling panel packing into four points on the flange face of the unit body which has been bolted to the back of ceiling Screw in the small screws to an extent such that the distance between the bottom of the screw head and the bottom face of the flange is at least 3 4 See figure below b Next lift the ceiling panel into position so that the small screws four pcs which were screwed onto the unit body pass through the keyhole shaped openings in the panel then shift the panel sideways until it is caught by the screws c Keeping the ceiling panel in this position check to see
25. inside and out 6 When tubing is disconnected provide dust covers for both valves and tubes until unit is reconnected 25 7 PRECAUTIONS BEFORE STARTING After insulation be sure to bind up insulation material and refrigerant tubings with a water proof tape so as rain should not creep into the insulation material and wiring Fig 36 Before attempting to start the air conditioner check the following a All loose matter is removed from the cabinet especially steel fillings and chips b Control wirings are correctly connected and all electrical connections tight c Ail temporary jumper wires removed Refer to unit wiring diagram d Check to see if compressor mounting bracket or board which secures compressor during transportation is removed If not remove them Fig 37 e Be sure to confirm that all shut off valves are open f Power connected to unit for at least five hours before starting the compressor The bottom of compressor should be warm to the touch and crankcase heater around the feet of the compressor should be hot to the touch 8 TRIAL RUN SANYO Wide tube Narrow tube Water proof armoring tape Insulation material Fig 36 Nut with washer Compressor Remove board Fig 37 Check that all tubing and wiring have been completed correctly Check again that wide and narrow tube service valves are fully opened Turn on power and run the unit If the room temperat
26. overload relay Has overload relay tripp ed Is outdoor heat exchanger coil dirty or are there obstacles near air suction iniet NO YES Clean heat exchanger or remove obstacles Consult power supply Low 103V or less company and restore voltage to normal value Remove cause for voltage drop Check power supply voltage Is voltage ab normally low Check voltage between terminal No 5 and No 6 at terminal base in the outdoor unit Voltage is in specified range 115V 10 Check compressor motor Replace compressor in case of winding defect 35 3 Air conditioner operates but abnormalities are observed 3 1 Poor cooling e Confirm installation posi tion of remote control unit Does cool air from air conditioner reach position directly Are wide and narrow tubes between indoor unit and outdoor unit insulated separately YES Measure temperatures of suction and discharge air of air conditioner and com pare with the characteristics curve Change installation position of remote control unit Insulate wide tube and narrow tube separately and then execute taping Note Throttling capillary tube of this model is located in outdoor unit Temperature difference is small Charge Possibility of gas refrigerant gas R22 shortage Temperature difference between suction and discharge air is large
27. 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 SAP241C ELECTRIC WIRING DIAGRAM 3015341033 GVOTH3AO OTO 8 SS SEA lt lt vox o6 5 cr HOLI2VdV2 SS HOLIOVdV2O 3 P 2 E 5 T dz 5 _ 5 o lt lt lt 909 2909 gt 5 8 Sek 26 be Oe 2 gt 9 gt 5 5 lt lt r LHM u L G TERMINAL PLATE POWER SUPPLY TO INDOOR UNIT Multimeter Capacitor 41 ELC 6 Checking of the Compressor Motor Winding Remove the terminal cover of the compressor motor set the resistance measuring range of the multimeter to XII and check the continuity between each pair out of the 3 terminals as indicated in Fig E 7 It is in good working condition if there is continuity among each pair of terminals SAP241C Leadwire color Coil resistance CS 1 970 1095 Table 2 Note When ambient temp is 77 F ELC 7 Checking of the Remote Control Proper Unit A Caution Use of the Test Switch TEST RUN The position of the switch which 15 used to operate the air conditioner for a room temperature below 69 F 21 C is the position of the switch for this TEST RUN FAN SPEED SWITCH
28. 0 716 0 17 2 1 33 8 5 0 41 105 8 27 2 81 177 8 61 1 142 287 6 105 6 222 431 6 196 1 385 725 0 16 7 2 35 6 5 6 42 107 6 27 8 82 179 6 62 2 144 291 2 106 7 224 435 2 198 9 390 734 0 16 1 3 37 4 6 1 43 109 4 28 3 83 181 4 63 3 146 294 8 107 8 226 438 8 201 7 395 743 0 15 6 4 39 2 6 7 44 111 2 28 9 84 183 2 64 4 148 298 4 108 9 228 442 4 204 4 400 752 0 15 0 5 41 0 7 2 45 113 0 29 4 85 185 0 65 6 150 302 0 110 0 230 446 0 210 0 410 770 0 14 4 6 42 8 7 8 46 114 8 30 0 86 186 8 66 7 452 305 6 111 1 232 449 6 215 6 420 788 0 13 9 1 44 6 8 3 47 116 6 30 6 87 188 6 67 8 154 309 2 112 2 234 453 2 221 1 430 806 0 13 3 8 46 4 8 9 48 118 4 31 1 58 190 4 68 9 156 312 8 113 3 236 456 8 226 7 440 824 0 12 8 9 48 2 9 4 49 120 2 31 7 89 192 2 70 0 158 316 4 114 4 238 460 4 232 2 450 842 0 12 2 10 50 0 10 0 50 122 0 32 2 90 194 0 71 1 460 320 0 115 6 240 464 0 237 8 460 860 0 11 7 11 51 8 10 6 51 123 0 32 0 91 195 0 72 2 162 323 6 116 7 242 467 6 243 3 470 878 8 11 1 12 53 6 11 1 52 125 6 33 3 92 197 6 73 3 164 327 2 117 8 244 471 2 248 9 480 896 0 10 6 13 55 4 11 7 53 127 4 33 9 9 199 4 74 4 166 330 8 118 3 245 473 0 254 4 490 914 0 10 0 14 57 2 12 2 54 129 2 34 4 94 201 2 75 6 168 334 4 121 1 250 482 6 260 0 500 932 0 9 4 15 59 0 12 8 55 131 0 35 0 95 203 89 16 60 8 133 56 132 8 356 96 76 7 170 338 0 123 9 255 491 0 265 6 510 950 0 _83 47 62 6 13 9 57 134 6 36 1 97 206 6 77 8 172 341 6 126 7 260 500 0 271 1 520 968 0
29. 0354 0 58 0 0228 0 91 0 0358 0 59 0 0232 0 92 0 0362 0 60 0 0236 0 93 0 0366 0 61 0 0240 0 94 0 0370 0 62 0 0244 0 95 0 0374 0 63 0 0248 0 96 0 0378 0 64 0 0252 0 97 0 0382 0 65 0 0256 0 38 0 0386 0 66 0 0260 0 99 0 0390 0 67 0 0264 1 00 0 0394 Inches Millimeters inches 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 0 009 0 010 0 020 0 030 0 240 0 270 0 280 Fractional inches X3 Decimals and Millimeters Inch 0 125 3 175 0 375 9 525 0 625 15 875 0 875 22 225 9 64 5 32 11 64 3 16 13 64 7 32 15 64 Decimal Inch 0 015525 0 03125 0 046875 0 0625 0 078125 0 09375 439375 0 140625 0 15625 0 171875 0 1875 0 203125 0 21875 0 234375 Millimeter 0 396785 0 79375 1 190625 1 5875 1 984375 2 38125 2 778125 3 571875 3 96875 4 365625 4 7625 5 159375 5 55624 5 953125 27 64 Inch Decimal Inch 0 205823 0 28125 0 296875 0 3125 0 328125 0 34375 0 359375 0 390625 0 40625 0 421875 0 4375 0 453125 0 46875 0 984375 Millimeter 6 746375 7 14375 7 540625 7 9375 8 334375 8 73125 9 128125 9 921875 10 31875 10 715625 11 1125 11 509375 11 90625 12 303125 Decimal Inch 33 64 17 32 35 64 0 515625 0 53125 0 546875 0 5625 0 578125 0 59375 0 609375 0 640625 0 65625 0 671875 41 64 21 32 43 64 0 6875 0 703125 0 71875 0 734375 11 16 45 64 23 32 47 64 74 Millimeter 13 096875 13
30. 1 0 5290 687 1 Transformer Ass y ATR J122U 1 35 854 2 5304 26601 Cover Plate 1 36 854 2 5301 49401 Mounting Plate 1 37 854 2 5304 265H1 Cover Plate Ass y 1 38 854 2 1358 46700 Label 1 39 854 2 5301 49501 Mounting Plate 1 40 851 2 5250 83800 Wiring Diagram 1 41 859 4 7411 Controller POW 24R 1 42 4 2379 56168 Terminal Base 3P 20A 1 43 854 0 5301 33701 Electrical Component Box Ass y 1 44 851 0 5290 687T1 Thermistor Ass y OCSSK UL 1 45 854 0 1105 191H3 Top Panel Ass y 1 46 854 2 2314 184H2 Partition Plate Ass y 1 47 854 2 1130 12200 Mounting Plate 4 48 854 0 1102 196H2 Side Panel Ass y 2 49 854 2 1110 14001 Blade Louver 2 50 854 0 1306 177H2 Mounting Plate Ass y 1 51 854 2 1102 275 2 Side Panel Ass y 1 52 854 2 2314 183H2 Partition Plate Ass y 1 53 854 0 4118 35001 Evaporator Ass y 1 54 854 0 2301 300HO Drain Pan Ass y 1 55 854 0 2301 302H2 Drain Pan Ass y 1 56 854 2 4134 31601 Cover Plate Evaporator 1 57 854 0 2301 301 0 Drain Pan Ass y 1 58 854 2 4134 31501 Cover Plate Evaporator 1 59 854 0 2301 303 2 Drain Ass y 1 60 859 2 1463 Remote Control Switch Ass y 1 SAP241C OUTDOOR UNIT 10 PARTS LIST Compressor Ass y extracted 65 ATTENTION ensure correct parts supply please let us know followings when you make service parts order 5 PRODUCT MODEL NO K 2 1 Part No OI
31. 75 24 60625 25 0U3 125 Sanyo Electric Inc Appliance Division 200 Riser Road Little Ferry New Jersey 07643 Oct 85 1700 Printed in Japan
32. 80 4 8820 4 9430 5 0041 5 0651 5 1261 5 1871 5 2481 5 3092 5 3702 5 4312 90 5 4923 5 5533 5 6144 5 6754 5 7364 5 7974 5 8584 5 9195 5 9805 6 0415 100 6 1025 6 1635 6 2246 6 2856 6 3466 6 4076 6 4686 6 5297 6 5907 6 6517 Cubic Metres Feet m Cubic ll 3 Cubic erm Meters Feet Feet Feet Feet Feet Feet Feet Feet Feet Feet Millimeters Inches ler 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 09 0 10 0 11 0 12 9 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 9 25 0 26 0 27 0 28 0 29 0 30 031 0 32 0 33 0 34 2 0006 0 0012 0 0016 0 0020 0 0024 0 0028 0 0031 0 0035 0 0039 0 0043 0 0047 0 0051 0 0055 0 0063 0 0067 0 0071 0 0075 0 0079 0 0083 0 0087 0 0091 0 0094 0 0038 0 0102 0 0106 0 0110 0 0114 0 0118 0 0122 0 0126 0 0130 0 0134 0 35 0 0138 0 68 9 0268 0 36 0 0142 0 69 0 0272 0 37 0 0146 0 70 0 0276 0 38 0 0150 0 71 0 0280 0 39 0 0154 0 72 0 0283 0 40 0 0157 0 73 0 0287 0 41 0 0161 0 74 0 0291 0 42 0 0165 0 75 0 0295 0 43 0 0159 0 76 0 0299 0 44 0 0173 0 77 0 0303 0 45 0 0177 0 78 0 0307 0 46 0 0181 0 79 0 0311 0 47 0 0185 0 80 0 0315 0 48 0 0189 0 81 0 0319 0 49 0 0193 0 82 0 0323 0 50 0 0197 0 83 0 0327 0 51 0 0201 0 84 0 0331 0 52 0 0205 0 85 0 0335 0 53 0 0209 0 88 0 0339 0 54 0 0213 0 87 0 0343 0 55 0 0217 0 88 0 0346 0 58 0 0220 0 89 0 0350 0 57 0 0224 0 90 0
33. ALL INDOOR UNIT 3 1 Mount the unit 3 2 Wiring Instructions for Interunit Connections 3 3 Drain Piping 3 4 Install Remote Control Unit 3 5 Install Ceiling Panel HOW TO INSTALL OUTDOOR UNIT 4 1 Wiring Instruction on Outdoor Unit REFRIGERANT TUBING 5 1 Use of the Flaring Method 5 2 Flaring Procedure with a Flaring Tool 5 3 Caution before Connecting Tubes Tightly 5 4 Connecting Tubes between Indoor and Outdoor Units 5 5 Insulation of Refrigerant Tubing 5 6 Taping the Tubing 5 7 Finishing the Installation SALA PURGING uut i TUBING DIAGRAM FOR AIR PURGING 6 1 Quick Air Purge System 6 2 Air Purging Procedure SERVICE VALVE CONSTRUCTION PUMP DOWN PRECAUTIONS BEFORE STARTING TRIAL RUN 42 1 GENERAL Here is a brief outline of where and how to install the unit Please read over entire set of instructions for indoor and outdoor units and make sure all accessory parts listed are with the unit before beginning 1 1 Tools Required for Installation not supplied Drill 3 5 32 dia hole saw or key hole saw for normal walls However chisels or core bits will be required for brick concrete or similar walls Tube Cutter Flaring Tool Torque Wrench Adjustable Wrench Reamer or Small File e Regular Screwdriver Phillips Hea
34. ERVICE MANUAL j SANYO SPLIT TYPE AIR CONDITIONER SAP241RC U S A Indoor Unit SAP241R e vA Da Outdoor Unit SAP241C WM 14967 Q SANYO HVAC LIMITED WARRANTY OF ORIGINAL PURCHASER Sanyo Electric Inc takes pride in its products and believes they are manufactured to the highest possible standards Consequently Sanyo warrants to the oriainal consumer its Air Conditioner for one 1 year for parts only Sanyo will repair or replace at its option at no charge any part s found to be defective during the warranty period In addition Sanyo war rants the compressor for a total of five 5 years and will cover labor charges on compressor replacement only for a period of thirty 30 days OBLIGATIONS OF THE ORIGINAL OWNERS Warranty repair must be performed by a qualified HVAC contractor The dealer s original dated bill of sale must be retained as proof of purchase and must be presented to the qualified HVAC contractor EXCLUSIONS OF THE WARRANTY line voltage damage caused by improper installation labor cost of removing or reinstalling of product for repairs improper or unauthorized repair broken or marred cabinet accessories knobs filters custmer adjustments which are not covered in instruction book Warranty is void and of no effect if serial numbers on the Sanyo product are missing or altered This warranty is valid on products purchased and used in the United States of America only
35. N 11 12 13 14 15 16 17 18 i 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 56 57 57 58 58 854 0 1113 13801 854 0 1106 20201 854 2 2346 11400 854 0 2501 18100 854 2 2529 10101 852 2 2514 10700 851 0 5290 636M1 854 0 2511 14400 854 2 2360 18900 854 2 4134 32100 854 0 2206 18100 854 0 4106 18500 854 2 1113 12400 854 2 2360 19100 854 2 1353 11000 854 0 2204 35801 854 0 1102 234HO 854 2 1133 20101 DEA 9 1123 FENI gt 1 32 37 E AJ 854 2 4310 10100 3 9030 00506 854 2 2360 26801 854 0 1101 301 HO 852 2 1320 10500 854 2 1367 31500 854 6 4729 68600 854 6 4729 71600 854 2 1354 14300 854 0 1102 233 854 0 4514 10200 3 9030 00512 854 0 4521 11100 854 0 4506 16200 852 2 2356 13301 854 2 2336 48200 852 2 2356 13201 854 2 4315 13900 854 2 4316 12100 854 2 2336 49200 854 2 4316 12200 852 0 4505 13600 853 2 2340 21901 854 2 4134 16501 854 2 2360 28700 854 2 4315 13500 853 2 4319 11200 854 2 4549 10100 851 0 5290 636C1 854 2 2360 38000 854 2 4316 13101 854 0 4517 17800 851 2 2390 14000 851 2 2330 13201 854 2 2356 10500 854 2 23 56 1 0600 854 2 2349 12201 854 2 2356 10400 854 2 2356 10700 854 0 2321 10201 851 0 2395 10702 2 Description 3 Q ty Guard Ass y Top Cover Ass y Cap Propeller Fan Ass y Bolt Special Propeller Fan Cap Rubber Fan Mo
36. OULUUUI The refrigerant gas will seep out from the indoor unit as well as the tubing 6 Seal the ends of the tubing so that no moisture or dust to enter 7 Gradually open the narrow tube service valve and release the remaining refrigerant 8 Open the wide tube service valve and release the remaining refrigerant 9 Finally leave the wide tube service valve and narrow tube service valve fully open 10 Clean the oil that has spread around the periphery 11 Keep the separated outdoor unit in an upright position and carry it to the service station Removing the Old Compressor CAUTION Always wear welder s goggles when heating the tubing with a torch and make sure not to get too close to the opening of the tubing Furthermore pay special attention to the position of the torch flame so as not to burn the compressor terminals 1 The outdoor unit carried into the service shop may have some refrigerant gas remaining within it Therefore make sure that both wide tube service valve and narrow tube service valve are fully open 2 Remove the cabinet according to the disassembly procedure of the outdoor unit Refer to Page 52 Furthermore remove the terminal cover at the top of the compressor and remove the wiring of the overload relay and the compressor terminal Fig 20 3 Set aside an Oxy Acetylene torch which is needed for removing the tubing of the compressor 4 Confirm that system has reached atmospheric pressure
37. S e 2912 203 91 1 22 lt 1 edid esp 2 1 1 Outdoor Unit SAP 241C gt o 9 gt 3 8 z 2 a 2 5 8 Wide Tube Servise Valve lt Air Intake 4 x 15 32 Da Hole for fixing x Power Wiring Outlet 11 21 32 9 Discharge Interunit Wiring Knockout Air Intake 21 32 4 PERFORMANCE CHARTS Cooling characteristics Model SAP241RC Operating current characteristics versus outdoor ambient temperature and indoor temperature Indoor relative humidity 50 indoor air velocity High overall value for indoor and outdoor shown NOTE The solenoid valve opens to by pass refrigerant flow when the outdoor am bient temperature stays within the dotted line range Operating current A Cooling characteristics Model SAP241RC Operating current characteristics versus outdoor ambient temperature and indoor temperature Indoor relative humidity 50 indoor air velocity High overal value for indoor and outdoor shown NOTE The solenoid valbe opens to by pass refrigerant flow when the outdoor am bient temperature stays within the dotted line range Operating current A a SANYO 230 V 60 Hz 104 F 40 C wa GE 51 i Outdoor ambient tem
38. ad is not strong enough to suspend the air conditioner or if it is difficult to use bolt anchors secure the suspension bolts with the construction member Refer to Fig 7B If tubing and wire are to go directly out back of unit make holes on the wall Fig 8 d Measure thickness of wall from inside edge to outside edge and cut PVC pipe at a slight angle Insert PVC pipe in wall Fig 9 PVC pipe INSIDE OUTSIDE Field Suppiy Cut Fig 9 Screw flanged nuts accessories into the four suspension bolts then lift the unit into position so that the suspension bolts pass through the holes in the suspension lugs on the unit Fig 10 f Put the special washers onto the suspension bolts upward which penetrate the suspension lugs and then fasten them with M10 nuts temporarily g Adjust the suspension height so that the distance between the bottom face of the flange of the indoor unit and the bottom face of the ceiling material is approx 3 4 Fig 11 Also suspend the unit horizontally to prevent leakage of drainage or other trouble Ensure that the clearance between the flange of the unit body and the ceiling opening is as shown in Fig 12 Adjust the position of the unit within the range of the diameter 020 of the suspension hole After adjustment fasten M10 nuts securely 16 A SANYO Gum Hole should be made at a slight downward slant to the outdoo
39. an body in direct line with the tubing opening 5 Before commensing the trial run be sure the unit is correctly wired and is grounded adequately when it is connected to the power a SANYO 9 10 3 Compressor Replacement Procedures A Separating the Outdoor Unit In case the compressor malfunctions with a split type air conditioner under normal conditions release the refrigerant gas at the location first and remove the tubing then separate the outdoor unit Pay special attention to ventilation if the place of installation is small 1 Make sure that the power 15 definitely turned OFF and remove the Access Panel of the outdoor unit with power line and inter unit line connectors Remove wires from terminals within the electrical component box and wrap the ends of the wires separately with the insulating tape 2 Place an oil pan at the under side of the service valves Then remove the caps of the wide tube service valve and narrow tube service valve with an adjustable wrench 3 Leave the wide tube service valve fully close by turning the spindle of the valve clockwise with valve key ratchet wrench Close the narrow tube service valve in the same manner 4 Apply two pairs of adjustable wrenches to the union of the wide tube service valve then disconnect tubing from the outdoor unit 5 Use adjustable wrench and a torque wrench 130 170 Ibs ml and disconnect narrow tube from the ee am sd zl OQ
40. connected to Terminal 6 of the electric magnetic contactor Clamp this lead wire with a lead clip of the insulation resistance tester and measure the resistance by placing a probe of the tester to the terminal GND The insulation is in good condition if the resistance exceeds 1 MQ Fig EA 3 3 Crankcase heater Disjoin and check both ends of the crankcase heater A SANYO tester Fig 1 D Insulation GRN fF nto jo Insulation tester Fig 2 terminal Insulation tester Fig E 3 Insulation tester Fig E 4 ELC 4 Checking of the Outdoor Fan Motor Remove the fan motor lead wires WHT BRN PNK and check as shown in the wiring diagram Fig E 5 Set the resistance measuring range of the multimeter to 10 and measure the resistance between the fan motor lead wires SAP241C Lead wire color Coil resistance WHT BRN 249 x 1096 WHT PNK 549 10 Table 1 Note When ambient temp is 70 F ELC 5 Checking of the Motor Capacitor Checking of any of the indoor fan motor capacitor outdoor fan motor capacitor and compressor motor capacitor can be done by the same method Remove both the lead wire terminals connected to the capacitor place the probe on the capacitor terminals as shown in the Fig E 6 and observe the deflection of the pointer setting the resistance measuring range of the multimeter to the maximum value For good condition of the capacitor the
41. connection outlets for the drain pipes are on the same side of the unit body as the refrigerant piping and electrical box Connecting up drain piping e There are two piping connection outlets as shown in the figure at right Connect up the PVC pipe connectors and straight pipe provided indicated Blind cover by solid lines to the connection outlets on the unit body Fig 16 Fig 16 For the piping past the above accesory pieces PVC piping connectors and straight pipe use PVC pipes and connect them up using adhesive Be sure to slope the drain piping downward ensuring that no traps are formed in it e Be sure to apply thermal insulation to drain piping in the room Upon completion of drain piping work remove the blind cover shown in the above figure then pour water into the drain pan and check to see whether or not it flows satisfactorily Install Remote Control Unit Fig 17 a Install the remote control mounting plate in a place which can be reached by the remote control cable b Connect up the remote control wiring according to the instructions on the label pasted on the back of the dressing cover of the remote control unit by matching up the colors of the remote control wiring with the numbers on the PCB in the remote control unit body c After wiring work as in the below figure fix the remote control unit body to the plastic box using the M4 small screws four provided The M4 small screws are contained
42. d Screwdriver Knife or Wire Stripper Level Tape Measure 1 2 Accessories Supplied with Unit for Installation Q ty Remarks Description PVC elbow 1 Flanged hex nut 2 For suspending unit For drain piping PVC pipe PVC socket Pan head screw 65 ceiling panel Countersunk For remote Drain Hose adaptor 1 3 Optional Copper Tubing Kit Remote control unit Install accessible position on the wall Length of lead wire 10m Lead wire for remote control unit Copper tubing for connecting outdoor unit to indoor unit is available in kits which contain the narrow and wide tubing fittings and insulation 1 4 Type of Copper Tubes and Insulation Material If you wish to purchase these materials separately from a local source you will need e Deoxidized annealed copper tube 1 4 outside dia with a 0 0314 wall thickness and an equal length of 5 8 outside dia with a 0 0394 wall thickness Cut to the appropriate lengths 12 to 20 on each to dampen vibration between units TEN jc SANYO e Foamed insulation 1 4 1 0 or 5 8 1 0 as required to precise length of copper tubing wall thickness of insulation should be 5 16 to 1 2 thick Refer to page 22 e Copper Wire Inter Unit Min AWG 14 in appropriate length Power Supply Min AWG 10 e 3 O D I D 2 13 16 wall thickness 3 16 PVC pipe length to match thickness of
43. e Valve Position a The valve stems of both wide amp narrow tubes are turned all the way in The unit is shipped from the factory in this position and it is also used for PUMP DOWN Fig 35 a Valve Position b The valve stems of both wide amp narrow tubes are turned all the way out BACK SEAT position This is the normal operating tion Fig 35 b e Valve Position c With the narrow tube valve kept at BACK SEAT only the wide tube valve stem is turn ed halfway down position This position 1 used for pressure measurement and gas charg ing Fig 35 e Valve Position d Like position a but with the flare nut of wide tube open This position is used for air purging Fig 35 d Be sure to use the valve tool or ratchet wrench when opening or closing the shut off valve spindle Close Open SS Fig 35 c c Condition at Gas Charging Cun d Condition at Air Purging PUMP DOWN Pump down means collecting all refrigerant in the system back into the outdoor unit without losing refrigerant gas Pump down is used when unit is moved or for servicing the refrigerant circuit 1 Close valve on wide tube halfway 2 turns 2 Close valve on narrow tube all the way 4 turns 3 Turn unit on cooling for approximately 3 minutes then shut off 4 Close valve on wide tube all the way 2 additional turns 5 Disconnect tubes slowly allowing pressure to equalize
44. er plate A and the fixed sensor B 2 Remove the insulation C loosen the fitting fixing the sensor D and remove it 3 When the above work has been completed the elctrical component box can be removed by removing the screw E 4 Loosen the screw H of the mounting plate F fixing the solenoid valve and remove the cover G Fig 15 9 8 Compressor Cover Removal 1 Remove the four screws 1 fixing the cover and lift the cover B to remove it Fig 16 Fig 16 4 SANYO 9 9 Compressor Removal 7 Use an oxyacetylene torch to cut the four places B C and D where the tubing is welded to the compressor 2 Remove the three nuts E fixing the compressor and raise the compressor to remove it Fig 17 CAUTION As there are many places where wires must be removed ex ecute removal after checking against the electric diagram at tached on the rear of the cover plate E Fig 13 and also refer to this electric diagram for reconnection after compressor exchange 3 For the new service compressor tubes are attached at the three points A B and C to prevent entry of dirt and moisture At the time of exchange connect the unit tubing after removing these tubes Fig 18 9 10 Compressor Replacement 9 10 1 Tool List for Compressor Replacement 1 Portable fire extinguisher 2 Oxy acetylene torch set 1 Prest O Lite Portable Outfit or equivalent 3 Torch lighter 1 4 O
45. er to page 25 Fig 35 b 11 Close and 12 hose connections and let refrigerant escape from hoses 5 a 8 e 9 13 Remove hoses charging cylinder and system analyzer set Now system charging has completed 61 SAP241R 10 PARTS LIST INDOOR UNIT Accessory Parts List LIST OF PACKAGED PARTS elbow 1 894 2 2 5 54 Flangea nut 654 0 1355 10201 trol emote contro 859 2 1463 unit PVC socket 854 2 2334 12100 4 3 9231 54003 Read wire Countersunk head for 1 1 0 2 RIESEN ie 3 9261 21301 remote control 851 0 5292 14600 unit Drain Hose NS adaptor 2 2334 13600 A SANYO SAP241R INDOOR UNIT ATTENTION To ensure correct parts supply please let us know followings when you make service parts order 1 Part No 2 Description 3 Q ty 4 Volts Hz Ph 5 PRODUCT MODEL NO Add RCS 24R Bottom Plate 859 3 4123 Panel Ass y 854 2 5301 44711 854 2 1114 10713 Cover Top Panel 851 0 5158 08000 Control Switch PCB Ass y 854 0 1105 224H2 Top Panel Ass y 1 854 0 5302 14201 Mounting Plate Ass y 854 0 1105 216H4 Top Panel Ass y 1 854 2 5304 28100 Cover Plate 854 6 4729 71600 Label 1 800 2 5367 11300 Filter 854 2 1521 11900 Mounting Rubber Blade 2 854 2 1359 21701 Indicator Plate 854 0 1505 178H2 Blade Louver Ass y 2 854 2 1311 12401 Knob 854 2 1521 11400 Mounting R
46. er with a new one However if just the compressor is replaced without sufficient system cleaning contaminated oil may cause the buring of the compressor again If the oil compressor is to be scrapped by pinching the terminal section with a pair of pliers there should not be any chance of it being mistakenly used SANYO Installing a New Compressor 1 Make sure that the defective old compressor has been removed and the new compressor to be installed is of the same specification by checking the 8 digit code number on stamped marking on the upper section of the compressor helmet case e g 80648646 For the detail of the compressor identification refer to page 4 2 Transfer the mounting parts to the new compressor 3 Nick the end of the pinched suction tube of the new compressor with a pincher and release the holding charge Nitrogen 29 psig 4 With an Oxy acetylene torch and pliers unbraze compressor seals at both discharge port and suction port upper part of the accumlator CAUTION Be careful of the position of the torch so as not to burn the terminals of the compressor when brazing or unbrazing 5 Install the new compressor in exactly the same manner as the original compressor See CAUTION bottom of this page 6 Shape both the suction and discharge lines to the approx area of the compressor fittings and engage each tube end to the mating compressor fitting 7 Hold tubing securely with plie
47. ertical Manual Air Filter Washable easy access Temperature Control Compressor Refrigerant R22 Ibs g 5 74 2 600 Refrigerant Tubing Connec Flare type tions Refrigerant Line Length Ft m Max Outdoor Unit Height Ft m Refrigerant Tube o d Narrow Tube In mm 1 4 6 35 Wide Tube In mm 5 8 15 88 Drain Tube v in mm DIMENSIONS amp WEIGHT Indoor Unit Dimensions Height In mm 19 1 4 490 30 1 8 765 Width In mm 51 3 16 1 300 26 6 16 670 Nei Waist bs Shipping Size Cu ft cum Without electric heater DATA SUBJECT TO CHANGE WITHOUT NOTICE a SANYO 1 2 Major Component Specifications Unit Model No SAP241C Compressor Hermetic Rotary Type Compressor Model No C R190H6N Source 230 208 V 60 Hz Single Phase Pole Nominal Output W Displacement cc rev Amps Full Load A 12 7 14 0 Locked Rotor A 84 240 V Type of Oil Special oil for Rotary Compressor Compressor Amount co Coil Resistance C R 0 66 Ambient Temp 77 F C S 1 968 Protectivo Device Internal Protector 15HM2505 370 or 400 Unit Model No SAP241R SAP241C Fan Motor Capacitor Run Induction Motor x Fan Motor Model No KFG4S 81B6P KFC8 101A6P Source 230 208 V 60 Hz Single Phase Pole oe C C Nominal Output W Load 0 83 0 77 Locked Rotor A Protective Device Internal Protector 17
48. es accessible when the cover A black color is removed Fig 2 4 Remove the cover plates 1 and 2 of the electrical compo nent box Fig 3 5 The electrical components be checked this condi tion 6 For removal of the electrical component box remove the four screws shown by the arrows A Fig 4 CAUTION Do not use excessive force for removal of connector sockets or lead wires 9 2 Ceiling Panel Removal 1 Loosen the four screws C black color The ceiling panel screw heads have a special shape as shown in the figure Slide the entire ceiling panel to the side The ceiling panel can be removed when the screw heads have moved from A to B Fig 5 CAUTION Support the ceiling panel at the time of removal so that it will not drop down 9 3 Fan and Fan Motor Removal 1 Remove the cover B and C Fig 6 Rell Ta 57 A SANYO 2 Remove the four screws A fixing the fan casing 3 When the four nuts fixing the fan motor installation base are removed removal is possible as shown in the figure Fig 7 CAUTION At the time of removal take care not to drop the fan motor etc Fig 7 4 Loosen the boit A fixing the fan boss on the motor shaft 5 Pull the motor shaft from the fan Fig 8 Fig 8 6 When the four screws A around the nozzel circumference are removed as shown in the figure the fan can be remov ed Fig 9
49. h local codes on running the wire from the indoor unit to outdoor unit size of wire and wiring method etc Every wire must be connected firmly No wire should touch refrigerant tubing compressor or any moving part Inter unit Power supply power line line Fig 20 WIRING SYSTEM DIAGRAM SAP241RC INDOOR UNIT Interunit OUTDOOR UNIT Power line 230 208 V 290200 v 230208v DISCONNECT SWITCH FIELD SUPPLY POWER SUPPLY LINE 1 Phase 230 208 V Grounding line Fig 21 20 5 REFRIGERANT TUBING 5 1 Use of the Flaring Method The refrigerant tubing for every split type air conditioner must be connected by flaring In this method the copper tubes are flared at each end and connected with flare nuts 5 2 Flaring Procedure with a Flaring Tool Deburring a Cut the copper tube to proper length with a tube cutter It is recommended to cut approx 12 20 in longer than the estimated tubing length b Remove burrs at the end of the copper tube with a reamer or a file This process is important and should be done carefully to make a good flare Fig 22 9 When reaming hold the copper tube end down Fig 22 ward and be sure that no copper scraps fall into the tube Fig 23 Remove the flare nut from the unit and be sure to mount Copper tube it on the copper tube x d Make a flare at the end of copper tube with a flaring tool Fig 24
50. if the joining patterns of the ceiling panes are in line with those of ceiling material If they are not in line remove the ceiling panel and finely adjust the suspension position of the unit body d Once the joining patterns are properly aligned with each other screw in the four small screws M5 x 35 small accessory screws four Ceiling face Toothed lock washer Screws on the unit body 4 pcs 1 Pass through screws the unit body into the keyhole shaped openings in the panel 2 Then shift the panel sideways until it is caught by the screws Fig 19 9 A SANYO 4 HOW TO INSTALL OUTDOOR UNIT e Place unit on level pad blocks or equal and anchor CONNECTOR SIZE Refer to INSTALLATION SITE LOCATION given in page 14 LINE CONNECTOR SIZE CONNECTOR SIZE SAP241C NETT 4 1 Wiring Instructions on Outdoor Unit and punch knockout holes on f a Remove access panel C the panel Fig 20 Outdoor unit b Connect interunit power line and power supply line per Access drawing on inside of the panel Fig 21 panel C Be sure to size each wire allowing several inches longer than the required length for wiring d When connections are completed secure both connectors on the panel with lock nuts and then close the panel e Ground unit in accordance with local codes CAUTION sure to comply wit
51. ing to avoid oxidation of inside copper tube Insulation of Refriqerant Tubinq Because the capillary tubing is installed in the outdoor unit both wide and narrow tubes of this air conditioner become armi tana RMeravaAnt haat ann iat flanra Aiia A LU VICVOTIL Moo MUC LU dripping of chilled sweat both tubes must be well insulated with proper insulation material Thickness of insulation material should be min 5 16 Fig 29 Insulation material The material must of course have good insulation character istics be easy to use age resistant and must not easily absorb moisture The following is recommended foamed polyure thane or polypropylene Taping the Tubing a At this time the two refrigerant tubes and electrical wire if code permits should be taped together with armoring tape The drain pipe may also be included and taped together as one bundle with the tubing b Wrap the armoring tape from the bottom of the outdoor unit to the top of the tubing where it enters the wall As you wrap the tubing cover half of each previous tape turn Fig 30 c Clamp tubing bundle to wall one clamp every 4 approx Do not wind the armoring tape around too tightly since this will impair the heat insulation effect Also be sure condensation drain hose splits away from bundle and empties clear of unit and tubing Finishing the Installati
52. ng of the Compressor Motor Winding 42 ELC 7 Checking of the Remote Control Unit Proper 42 ELC 8 Checking of the Continuity of Fuse on the Controller PCB 44 ELC 9 Method to Replace Fuse on the Controller PCB 44 ELC 10 Checking of the Power Transformer 45 ELC 11 Checking of the Indoor Fan 45 ELC 12 Checking of the Solenoid 46 ELC 13 Checking of the Coil 46 ELC 14 Checking of the Electric Magnetic 46 ELC 15 Checking of the Crankcase 46 ELA Connector Identification on Controller PCB POW 24R For SAP241RC TRANS 2 MADE JAPAN DEC I4V O 52620 FUSE 250V 5A N m o N N 24R Fig EA Connector Power Supply to Connector Transformer Primary Connector Fan Motor Connector Transformer Secondary 19V Connector Remote Control Unit 24V Connector Thermistor Sensor 24V OORUN Line Voltage 39 ELC 1 Measurement of Insulation Resistance of the Power Cord Clamp the ground GND line of the Power Cord with a lead clip of the insulation resistance tester and measure the re
53. nsult shop manual for specifications 5 While system is evacuating utilize this time to fill the charging cylinder if it is not ready 6 if vacuum gauge reading has reached 500 microns or less stop the vacuum pump and close 7 Keep this condition at least 5 minutes and observe the vacuum gauge for change Fig 25 If pointer on the gauge moves to larger numbers check system for leaks again according to the procedure in section 9 11 2 Page 59 If the indication of the vacuum gauge will not change system is now prepared for charging refrigerant Close M 8 9 Proceed to charging refrigerant in section 9 11 4 61 NOTE This model uses low pressure on the narrow tube side as well as on the wide tube side Accordingly the piping on both sides must be insulated at the time of installation A SANYO hy V6 Service cath valve Narrow tube C CN 2 Service x SHU valve Heat exchanqer Wide tube INDOOR UNIT OUTDOOR UNIT System analyzer valve set Compound Pressure Gauge Gauge KL9 c Hi Viv must be closed Tube cross fitting Vacuum pump Fig 24 If pointer moves this direction leackage Lo M be possible Target value Y liso MICRONS Ka A N 500 MICRONS x 300 MICRONS 100 MICRONS Fig 25 9 11 4 Charging refrigerant R22 e Preparation of Refrigeran
54. on After finishing insulation and taping over tubing fill the void space with putty to prevent rain and draft from entering Fig 31 A SANYO Torque wrench on flare nut Indoor unit Fig 27 INSUL NIPPLE Fig 28 Insulation CN Thickness d Min 5 16 Fig 29 Tubing Insulated tubes Wall Fig 30 Fig 31 6 AIR PURGING Air does not function as a refrigerant because it The pressure in the narrow tube rises cannot be liquefied in the condenser Air and e The operating current rises moisture remaining in the refrigerant system have fe Cooling efficiency drops undesirable cffects as indicated at right Therefore they must be purged completely Water contained in the air may freeze and block the capillary tubing e Water may lead to corrosion of parts in the refrigerant circuit TUBING DIAGRAM FOR AIR PURGING Model SAP241RC Service valve Drier Seen II tube Capillary Solenoid x Gi valve E Service valve Compr ge L Wide Evaporator tube Condenser INDOOR UNIT OUTDOOR UNIT The solenoid valve is provided to keep the unit running in cool atmosphere It opens to bypass refrigerant flow when the outdoor ambient tem prerature drops below 75 F and closes at 78 F 6 1 Quick Air Purge System New quick air purge system represents purg 9 Outdoor unit is pre charged a
55. orator tube INDOOR UNIT OUTDOOR UNIT NOTE The solenoid valve is provided to keep the unit running gt with sequential number shows flow atmosphere It opens to by pass refrigerant flow when the of regrigerant in COOLING CYCLE outdoor ambient temperature drops below 75 F and closes at 78 F 67 12 ELECTRIC WIRING DIAGRAM SAP241R ELECTRIC WIRING DIAGRAM TERMINAL PLATE TERMINAL TO OUTDOOR UNIT mem 5 11213 Za lt 7 lt lt GRY RP YEL 212152 WHT 33 N snp NOR 2 2 9 2 BRN 9 ORG 4 4 gt 1515 D ZRF 81616 G x x m THERMISTOR SAP 241C ELECTRIC WIRING DIAGRAM POWER SUPPLY I I ELECTRO MAGNETIC CONTACTOR d TERMINAL PLATE e Q 5 Q BLU SOLENOID COIL H COIL THERMO BRN PNK d BRN WHT INTERNAL OVERLOAD PROTECTOR CAPACITOR Indoor Unit THERMO FUSE TRANSFORMER H 2 EMOTE CONTROL R SWIT Outdoor Unit CRANK CASE HEATER CAPACITOR BLK INTERNAL OVERLOAD PROTECTOR COMPRESSOR MOTOR a SANYO PRINTED PATTERN CONTROLLER P C B POW 24R NO2ONWN3MS H L de los FN NA I2 22 015 m U qz 0 SIJ AA vid AA 8 AA zi 92 Re EIN EO At Old ch v2 21
56. ormal Replace YES Check indoor fan motor condenser Refer to ELC 5 P 41 Replace fan motor YES Check outdoor yo fan motor Is fan motor normal YES Check outdoor NO condenser YES Check NO compressor YES Check com pressor condenser ye Check solenoid coil Replace it with a suitable ong larger capacity Refer to ELC 5 P 41 Replace Refer to ELC 6 P 42 Replace Refer to ELC 5 P 41 Refer to ELC 12 P 46 Q SANYO 1 2 Neither indoor unit nor outdoor unit runs Circuit breaker is Reset breaker tripped eCheck power supply NO Is power being supplied to wall receptacle Wait for recovery or Power failure contact power YES Power failure Check transformer Refer to ELC 10 45 Check fuse the eCheck operation lamp Is the controller PCB for Refer to ELC 8 YES When fuse is blown Refer to ELC 9 P replace it 44 eController PCB is defective 30 2 Some part of air conditioner does not operate 2 1 Indoor fan does not run Remove Check fan casing foreign Fan cannot be for foreign matter turned d matter or on the inside repair Check fan rotation Turn the fan gently once or twice by hand Fan motor burn Repair or outor foreign matter See Fan turns
57. ps 208V 60 Hz OF C LUUT se S e 80 27 75 24 ERU uiii 68 95 104 20 TA 50 35 40 C Outdoor ambient temps NOTE The solenoid valbe Cooling characteristics Model High pressure characteristics versus outdoor ambient temperature and indoor temperature Indoor relative humidity 50 indoor air velocity High NOTE The solenoid valbe opens to by pass refrigerant flow when the outdoor am bient temperature stays within the dotted line range Cooling characteristics Model SAP241RC Low pressure characteristics ambient temperature and indoor temperature Indoor versus outdoor relative humidity 50 indoor air velocity High opens to by pass refrigerant flow when the outdoor am bient temperature stays within the dotted line range SAP241RC Suction pressure at wide tube service valve Discharge pressure at high pressure gage port oC 230 208 V 60 Hz 284 46 Spn HEHA eg on 75 24 LIL 256 02 ane 227 512 gt gt Be nm _ 170 67 psig E 6 Sg 12 68 77 86 95 104 20 25 30 35 40 Outdoor ambient temps 230 208 V 60 Hz 99 56 85 34 6 71 12 86 30 5 80 27 LH EE 75 24 lt SE 70 21 56 89 4 r 4 42 67 psig Ss 5 68 77 5 3 2 25 30
58. r side Indoor Outdoor Suspension bolts four Suspension lugs M10 nuts 8pcs Ceiling Unit flange 3 4 material 9 7 16 4 11 16 3 8 Piping side Air conditioner Fig 7B Flanged nuts accessories N Special accessory washers 4pcs Fig 12 3 2 Wiring Instructions for Interunit Connections a Insert the interunit wiring according to local codes into through the wall PVC pipe Run the wiring toward indoor unit Fig 13 Never fix the wiring by any means before the indoor unit is fully seated Fig 13 QJ d b Unscrew the cover plate of the electrical component box Fig 14 Re c Temporarily set the wiring connector in the hole at the Bi m electrical component box 4 gt d Secure the conduit connector to the electrical component SS box with a lock nut Fig 15 pd Cover e Give some play to the interunit wiring from the outdoor plate unit to the corresponding terminals on the terminal base Fig 14 Ceiling face Fig 15 CAUTION E e Be sure to refer the wiring system diagram labelled on the electrical component box and carry out correct field wiring Wrong wiring causes malfunction of the unit Check local electrical codes and also any specific wiring instructions or limitation dy s 3 3 Drain Piping 3 4 4 SANYO Drain piping accessory Drain pipe connecting parts The
59. ring bet Refer to wir ween indoor and outdoor Execute ing system units rewiring diagram in Is the wiring correct page 20 YES There is a possibility of ground fault eCheck insulation resistance of power cord eA defect of insulation of indoor unit is possible eCheck insulation resistance of outdoor unit Is the insula tion resistance low When resistance value is 1 MQ or less check insulation resistance of outdoor unit Separate interunit cables Check insulation resistance between terminal 2 and GND and between terminal 3 and GND in the elec trical component box of outdoor unit NO Check insula tion of indoor Refer to ELC 3 fan motor P AO Check insula tion of indoor transformer YES eA defect of insulation of NOTE outdoor unit is possible In case of insulation defect replace the respective part Refer to ELC 2 P AO Execute an insulation test for compressor motor Refer to ELC 3 P AO Execute an insulation test for outdoor fan motor Refer to ELC 15 46 Execute insulation test for crankcase heater Refer to ELC 12 46 Execute an insulation test for solenoid coil AQ SANYO 1 1 2 Circuit breaker trips when the operation switch is depressed Check capacity of circuit NO breaker Is capacity of circuit breaker suitable NO Check indoor fan motor Is fan motor n
60. rs and braze all connections carefully with the torch 8 Perform leak test evacuation and charging refrigerant according to procedures described in section 9 11 page 59 GIS If the old compressor was heavily contaminated be sure to replace strainer or drier when replac ing the new compressor 9 11 Leak Test Evacuation and Charging 9 11 1 Required tools and system set up Vacuum pump Vacuum gauge System analyzer valve set Charging hose With 1 4 connector 1 4 Flared tube cross fitting Charging Cylinder 1 4 Flared Packless valve To be used for V3 V4 and V5 9 11 2 System Leak Test at the Service Site After replacement of the new compressor the system must be checked for leaks according to the below mentioned proce dure f cylinder has not yet been filled move at least one pound of refrigerant R22 to the charging cylinder Fig 22 1 Prepare the system analyzer valve set and connect charging hoses as in Fig 23 Be sure to close all valves before connection Refer to page 25 Fig 35 C Confirm that both Narrow Tube and Wide Tube service valves on the outdoor unit and are fully opened and other valves are still closed Refer to Fig 24 Open valves and respectively to allow refrigerant gas entering into the system Charge about 1 2 pound of gas to the system and close OI and in sequence 2 3 Apply liquid soap at charge hose connectors discharge and s
61. sistance by placing a probe on either of the two power lines Then also meaure the resistance between the GND line and the other power line The insulation is in good condition if the resistance exceeds 1 MQ Then also measure the resistance between the ground and the other power line The insulation is in good condition if the resistance exceeds 1MQ Fig E 1 ELC 2 Measurement of Insulation Resistance of the compressor Remove the red lead wire connected to the compressor motor from 4 on the terminal base Clamp the removed black lead wire with a lead clip of the insulation resistance tester and measure the resistance by placing a probe of the tester to the terminal GND to which green lead wire is connected The insulation is in good condition if the resistance exceeds 1 MQ2 Fig E 2 ELC 3 Measurement of Insulation Resistance of the Fan Motor 3 1 In case of indoor fan motor Remove the fan motor connector from controller PCB P39 Fig E A Clamp the green lead wire at the bear section extended from the terminal GND in the electrical component box and measure insulation resistance by placing a probe of the insulation tester to either pole of this connector The insulation is in good condition if the resistance exceeds 1 Fig E 3 Note If the probe does not enter the pole because the hole is too narrow then use a probe with a thinner pin 3 2 In case of outdoor fan motor Disconnect the white lead wire
62. t Measure the net weight of the charging cylinder before charging refrigerant and memorize it Refill required amount of refrigerant from the container to the charging cylinder Be sure to measure the cylinder contents by weighing it Fig 26 MORI Do not confuse the refrigerant gas level graduations on the charging cylinder with the weight Vapor refrigerant on the upper cylinder part must be taken into considera tion b 0 516 plus specified amount given on the name plate of each unit See specifications on page 1 e Charging Procedure Evacuate system according to the procedure in section 9 11 3 Confirm that valves D D lt and are closed when evaculation is completed Open charging cylinder valve 672 slightly 1 Scale 2 Fig 26 3 4 Loosen hose connection at en a little to let air escape from the hose Then tighten connection again Measure and memories charging cylinder weight to charge ex act amount of refrigerant 6 Open CD fully to supply refrigerant gas to 6723 7 Close CR halfway 2 turns for charging refrigerant Refer to page 25 fig 35 b Open 672 gradually and let refrigerant gas entering into the system When full charge has entered system do not permit liquid level to drop blow 0 zero on the graduation of the charging cylinder close tightly 10 0pen fully until it reaches to the back seat position Ref
63. t run press OFF button to stop the unit e Reinstall the thermostat knob The stopper position facing down 42 Fig E 8 Checking of the Items of the Remote Control Unit At first pull out the connector 7P of the remote control unit from the controller PCB of the unit refer to Fig E 10 1 Fan Speed Selector Check the continuity of the connector No 3 against No 4 place the negative probe on No 4 and Fig E 10 positive probe on No 3 iti f th Checking points Position of the selector High Low 3 4 NO YES Table 3 NOTES YES 4 4 6 625 aud ew Continuity NO GA Discontinuity 2 Checking of the Operation Pushbutton The operating switch is in good working condition if there is continuity between No 2 placing the negative prove and No placing positive probe while the pushbutton is pressed CAUTION Do not disassemble the Remote Control Unit It is supplied as a complete assembly and is carefully adjusted in the factory by skillful workmanship Inexperienced disassembly will cause trouble and malfunction in the unit ELC 8 Checking of the Continuity of Fuse on the Controller PCB Check the continuity by the multimeter as shown in Fig E 11 If it is difficult to check in this way remove the lamp board ass y connector and then check it ELC 9 Method to Replace Fuse on the Controller PCB 1 Remove the controller PCB 2 Pull out
64. t the ing the air in the indoor unit and connection factory Don t open valves until tubing is tubes with the aid of refrigerant gas pre hooked up and you are ready to proceed charged in the outdoor unit with purging procedure By this system air purging has become much simpler and installation time has become shorter than conventional methods 29 6 2 Air Purging Procedure a Remove the valve caps from the service valves on the narrow tubes b Loosen the flare nut A of wide tube by 180 degrees 1 2 turn Fig 32 c Open the spindle of the narrow tube by 90 degrees 1 4 turn for 15 seconds and close it to the original position d After 45 seconds fasten the flare nut A of wide tube tightly as it was Fig 33 e Open the wide tube service valve by a quarter turn and close it as soon as hissing stops This indicates that tubings are filled with the refrigerant gas of the outdoor unit t Leak test the joints with liquid soap If no leakage wipe off the soap Fig 34 g Turn the valve stems all the way out to Back Seat on both service valves then tighten the valve seal caps with the copper gaskets h The all air purge procedure has been completed and the unit 15 ready for trial operation 4 SANYO Spindle PN Valve cap 3 P Open by 90 degrees and close in 15 sec Fi 32 Loosen Tighten Ose Fig 33 ane amp Wes Fig 34 SERVICE VALVE CONSTRUCTION
65. the fuse at the metal clasp by a pair of pliers while heating the soldered leads on the back side of the controller PCB with a soldering iron 3OW or 60W Fig E 12 3 Remove the fuse ends one by one For replacement insert a fuse of the same rating and solder it Allow time to radiate heat during soldering so that the fuse does not melt Be sure to replace the varistor adjacent to the fuse either when the fuse is blown 4 SANYO Fig E 11 Soldering iron CC E y C mi Fig E 12 ELC 10 Checking of the Power Transformer SAP241R ELECTRIC WIRING DIAGRAM 1 Remove connectors TRANS 1 and TRANS 2 from the ONERE controller PCB 2 Set the resistance measuring range of multimeter to 10 and measure the resistance of the lead wires between WHT WHT and BRN BRN as shown in Fig E 13 3 io zo 55 It will be completely satisfactory if all measured values agree with those indicated in Table 4 WHT WHT About 143 50 BRN BRN About 1 22 Table 4 NOTE Ambient room 70 F FAN MOTOR CONTROLLER REMOTE CONTROL x 2 m THERMISTOR LJ ELC 11 Checking of the Indoor Fan Motor Remove the fan motor connector FM from controller PCB and measure the resistance between each lead wires of the fan motor connector setting the resistance measuring range to XIQ The motor is in very good working condition if all
66. the values agree with those indicated in Table 5 WHT BRN About 56 Q WHT YEL About 54 WHT PNK About 75 Table 5 Note Ambient room temp 68 F 45 ELC 12 Checking of the Solenoid Coil 1 From the terminal plate No 2 terminal disconnect RED lead wire for the Solenoid Coil 2 From the Coil Thermo Terminal disconnect RED lead wire 3 Check Solenoid Coil for continuity between the moved RED lead wires with a multimeter No continuity means broken wire If so replace the wire ELC 13 Checking of the Coil Thermostat Disconnect the lead wire connected to the coil thermostat Check the coil thermostat itself Satisfactory if the value is as follows Table 6 OFF 79 F Table 6 ELC 14 Checking of the Electric Magnetic Contactor Disconnect BLU lead wire from terminal 21 and RED lead wire from terminal 22 on the contactor and check continuity using a multimeter Satisfactory if continuity is assured If continuity cannot be verified the coil must be broken Check and replace the coil ELC 15 Checking of the Crankcase Heater Disjoin both ends of the heater and check for continuity Satisfactory if continuity is assured If continuity cannot be verified the heater must have broken wire Check and replace broken wire SANYO 9 DISASSEMBLY AND SERVICE PROCEDURES Quick and Index INDOOR UNIT 9 1 Electrical Component Box Access and Removal
67. tor KFC8 101A6P Support Motor Ass y Mounting Plate Mounting Plate Frame Ass y Condenser Ass y Guard Mounting Plate Cushion Rubber Bottom Plate Ass y Side Panel Ass y Right Cover Plate Inta Cover Plate Mounting Rubber Capillary Clamper 4 Mounting Piate Front Panel Ass y Eyelet Rubber Name Plate Label Label Badge Side Panel Ass y Left Charge Port Ass y Clamper F 10 Valve Ass y 1 4 Valve Ass y 5 8 Mounting Plate Tube Packing Mounting Plate Tube Packing Mounting Plate Tube Packing Mounting Plate Tube Dehydrater Ass y Mounting Plate Tube Mounting Plate Tube Mounting Plate Packing Packing Solenoid Valve NEV603DXFU Solenoid Ass y NEVAC208V Mounting Plate Mounting Plate Tube Accumulator Ass y Cushion Rubber Spring Rubber Protection Rubber Protection Spacer Rubber Protection Rubber Protection Nut Special Ass y Nut Special Ass y CAP TUBE ASSY 854 0 205 30300 4 Volts is 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 B gt gt 71 78 79 80 81 82 83 84 85 86 87 88 N N GQ OO Q 0 GO 2 o K 2 2 Hz Ph 852 0 4506 14000 854 2 4219 58100 852 2 2353 19500 852 2 2309 34101 3 9030 00508 853 2 4310 10300 851 0 5290 636 1 851 2 2356 16901 801 2 5303 13100 801 2 6194 12100 801 2 8305 10100 854 2 5301 48401
68. ubber Blade 2 854 2 1311 10904 Knob 854 0 2308 23700 Air Filter Ass y 1 854 2 1311 12002 Knob 10 854 2 1133 193 2 Cover Plate Ass y 1 800 2 5367 11600 Filter 11 854 2 1133 194H2 Cover Plate Ass y 1 851 2 5261 24100 Label 12 854 0 1105 230H3 Top Panel Ass y 1 851 2 5261 26600 Label 13 854 2 1301 25001 Ornamental Sash 1 854 6 4119 38200 Opetation Manual 14 852 2 1504 16414 Badge 1 854 6 4139 34200 Installation Instructions 15 854 2 2307 11901 Cover Plate 1 16 851 0 5290 687 1 Fan Motor Ass y KFG4S 81B6P 1 NOTE Metal and plastic parts will be supplied basically 17 854 2 2534 13510 Cushion Rubber 2 with necessary heat insulating pads or packing 18 854 2 2519 11400 Air Guide 1 Some key numbers are intentionally omitted 19 854 2 1367 35300 Name Plate 1 ieft bank for the editor s convenience 20 854 0 2502 1 7801 Blower Casing Ass y 1 21 854 0 2501 14800 Blower Ass y 1 22 854 0 2511 15401 Support Motor Ass y 1 23 854 2 2360 41501 Mounting Plate 1 24 854 0 2516 12401 Partition Plate Ass y 1 25 854 2 2518 28700 Mounting Plate 1 26 854 2 2307 12401 Cover Plate 1 27 854 2 2352 12300 Guide 2 28 854 2 1133 181 3 Cover Plate Ass y 1 29 854 2 1101 450 2 Front Panel Ass y 1 30 852 2 2396 10103 Screw Special 1 31 854 0 5301 335H1 Electrical Component Box Ass y 1 32 852 6 4729 17300 Label 1 33 4 2239 56220 Fixed Capacitor 440V 3MFD 1 34 85
69. uction tubes and brazed liquid injection capillary section of the replaced compressor or other connection parts and check to see change of bubbles An electronic halogen gas leak detector of course may be used for this porpose 4 5 When leaks located depressurize system and repair leaks 6 If there are no leaks open QI purge the 1 2 pound of refrigerant from the system and proceed for evacuation in sec tion 9 11 3 Refer to page 60 Refer to page 25 in regard to the operation method for the serveice valve One of conventional system set up procedure for leak test evacuation and charging is described in section 9 11 for the reference Robinair or Imperial Portable Charging Station may be used as convenient packaged tool for the purpose of servising the refrigerant system x 27 Gas Charge fitting V1 must To be connected be closed to the V1 Wide Tube service valve Outdoor Unit Vacuum pump Fig 23 59 9 11 3 Evacuation 1 Connect instrument as in Fig 24 2 Confirm that all connections are made correctly and check all valves are closed and should be fully open ed Refer to page 25 Fig 35 3 Open only Open and CB Never fail to open the shut off valve on the vacuum pump if there is 4 Run the vacuum pump for evacuation Required time for complete evacuation differs with capacity of the pump Co
70. ure is too low cooling operation may not be possible even if the thermostat knob is set at the lowest position In this event perform test run as follows a Pull off the thermostat knob Fig 38 b Set the thermostat lever to the TEST RUN position Fig 39 Press OPERATION ON button to start the air conditioner d After completion of test run press OFF button to stop the unit e Reinstall the thermostat knob The stopper position facing down 26 Fig 39 7 TROUBLESHOOTING Quick Access Index Page Air conditioner does not operate 28 1 Circuit breaker trips or fuse blows 1 1 When circuit breaker is set to ON it trips soon resetting is not possible dod Circuit breaker trips when the operation switch is depressed 2 Neither indoor unit nor outdoor unit runs 2 Some part of air conditioner does not operate 31 2 1 Indoor fan does not run 2 2 Neither outdoor fan nor compressor runs 23 Only outdoor fan does not run 2 4 Only compressor does not run 2 5 Compressor frequently repeats ON and OFF 3 Air conditioner operates but abnormalities are observed 36 geck Poor cooling 3 2 Excessive cooling d 1 Air conditioner does not operate 1 1 Circuit breaker trips or fuse blows 1 1 1 When circuit breaker is set to ON it trips soon resetting is not possible eCheck interunit wi
71. wall 1 5 Additional Materials Required to Give Installation a Professional Appearance e Refrigeration armored tape e Refrigeration Oil e Insulated staples or clamps e 3 1 2 clamp use 1 every 4 ft for connecting wire To secure copper tubing Refer to local codes e Putty 1 2 1 5 2 INSTALLATION SITE SELECTION Indoor Unit 2 AVOID e areas where leakage of flammable gas may be expected e places where large amounts of oil mist exist Ceiling e direct sunlight bstacle e nearby heat sources that may affect performance of the unit e locations where remote control will be splashed with water or affected by dampness or humidity Air Intake installing remote control unit behind curtains or Air furniture that obstruct air circulation discharge DO select an appropriate position from which every corner of the room can be uniformly cooled Fig 1 e select a location that will hold the weight of the unit select a location where tubing and drain pipe have shortest run to the outside allow room for operation and maintenance as well as unrestricted air flow around the unit Fig 1 e allow room for mounting control unit about 4 off the floor in an area that is not in direct sunlight or in the flow of cool air from the unit Tubing install unit within 33 up or down of outdoor unit and length Elevation within a total of 50 from outdoor unit Fig 2 50 Max difference
72. xweld goggles 1 5 Brazing flux 1 6 Soldering rod 1 7 Vacuum pump Capacity 2 3 Cu ft min 1 Robinair or equivalent 8 Nitrogen gas in 10 Ibs container 1 9 Refrigerant R22 10 Ibs container 1 10 Refrigerant charging cylinder 5 lbs or more 1 11 System analyzer valve set 1 Robinair Imperial or equivalent Robbi thermistor vacuum gauge or equivalent i x wy Sv i x 12 Vacuum gauge Range 0 1000 microns 13 Charging hose W 1 4 fittings 14 Charge fitting 1 4 15 Tube adapter 1 4 16 Pinch off 100 17 Diagonal cutting plier 18 Long nose side cutting plier 19 Slip joint plier 20 Torque wrench 340 Ibs 21 Tube cutter 22 Flaring tool 23 Swaging tool 24 Combination file set 25 Regular screwdriver 8 26 Phillips screwdriver 6 27 Adjustable wrench 10 28 Adjustable wrench 12 29 Hex nut driver 6mm 30 Oil pan 31 Liquid soap with a brush 32 Clean moist cloth Imperial or Rigid Rigid or equivalent For compressor bolt sch sch sch sch o sech 4 9 10 2 Safety Precautions 1 Make sure unit is disconnected from the power source while it is being assembled or disassembled for servicing 2 Wear protective goggles at any time when brazing or unbrazing 3 Be sure to confirm system is at atmospheric pressure before using torch 4 When brazing or unbrazing tubes never locate face or any other parts of the hum

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