Sanyo PNR-XS2432 User's Manual
Contents
1. Remote Control Unit Remove the lid by sliding it off You can see the switches inside the battery compartment Fig 5 1 Indoor Unit 1 Turn off the Power Switch 2 Remove the Grille 3 Remove the cover of the Electrical Component Box 5 2 Switch Positions for 2 Units or 2 Groups of Units Table 5 1 shows the positions you can use for up to 2 units or 2 groups of indoor units installed in the same room Two remote control units are necessary to allow the respective units or group to be controlled indepen dently Table 5 1 Remote Control Indoor Unit Unit No Address switch Address switch 1 2 1 A OFF OFF 2 B ON ON The indoor unit address switch is set at 1 OFF amp 2 OFF position at shipment An indoor unit cannot be controlled if its remote control unit is too far away more than 26 ft If the remote control unit does not work correctly bring it closer to the unit being operated and try again There should be no obstacles between the remote control unit and the indoor unit For this reason if the remote control unit is to be used from a fixed position check the operation before mounting 4359128 A B Address Address switch is in A position at time of shipment Fig 5 1 WIRED LwireLess R C U Switch Fig 5 2 Address Switch DSW1 1321_M_I 10082. 5 8 15 88 Thickness 0 0394 1 0 mm Limit of tubing length ft 65 Limit of elevation ae ae 23 difference between the 2 units Outdoor unit is lower 23 than indoor unit ft Max allowable tubing length at shipment ft 33 Required additional refrigerant oz ft 0 27 No additional charge of compressor oil is necessary 1 If total tubing length becomes 33 to 65 ft charge additional refrigerant R22 by 0 27 oz ft 4 4359128 0711_M_1 2 Selecting the Installation Site Indoor Unit AVOID areas where leakage of flammable gas may be expected places where large amount of oil mist exist direct sunlight locations near heat sources which may affect performance of the unit locations where external air may enter the room directly This may cause sweating on the air discharge ports causing them to spray or drip locations where the remote control unit will be splashed with water or affected by dampness or humidity installing the remote control unit behind curtains or furniture locations where the receiver in the indoor unit is exposed to the inverter lamp light Faulty operation of the unit occurs DO select an appropriate position from which every corner of the room can be uniformly cooled select a location where the ceiling is strong enough to support the weight of the unit select a location where tubing and drain pipe have the shortes
3. IMPORTANT Page Please Read Before Starting V GENERA aoa cores crass eons eeraa aasa 3 85464359128000 CONTENTS 1 1 Tools Required for Installation not supplied Accessories Supplied with Unit Optional Copper Tubing Kit Type of Copper Tube and Insulation Material Additional Materials Required for Installation Operating Range Tubing Length NOOR WY 4 2 SELECTING THE INSTALLATION SITE 5 Indoor Unit Outdoor Unit 2 1 Baffle Plates for the Outdoor Unit HOW TO INSTALL THE INDOOR UNIT 7 3 1 Suspending the Indoor Unit 3 2 Preparation for Suspending 3 3 Placing the Unit Inside the Ceiling 3 4 Installing the Drain Piping 3 5 Checking the Drainage Ceiling Panel cscccsseeecsseceesseeeeeseeeeeseeeenseees 11 3 6 Before Installing the Ceiling Panel 3 7 Installing the Ceiling Panel 3 8 When Removing the Ceiling Panel for Servicing 3 9 Duct for Fresh Air HOW TO INSTALL THE REMOTE CONTROL UNIT 1 cccccsseeeeesseeeseeeeenseeeesseeeenseees 15 Wireless Remote Control Unit 4 1 Mounting on a Wall Wired Remote Control Unit Option 4 2 Installing the Wired Remote Control Unit ADDRESS SWITCHES c csscssseeeessseensseeens 17 5 1 Finding the Address Switches 5 2 Switch Positions for 2 Units or 2 Groups of Units ELECTRICAL WIRING ccsscsssesessseesseeeens 18 6 1 General Precautions on Wiring 6 2 Recommended Wire Length and Wir
4. d INSTALLING THE INDOOR UNIT Install the indoor unit to the ceiling Install the indoor unit according to items 3 1 to 3 6 e INSTALLING THE CEILING PANEL Attach the ceiling panel to the chamber Remove the socket cover of the air intake chamber and pass the 3P and 6P sockets through it Fig 3 17 Connect the 3P socket to the 3P plug of the indoor unit electrical component box Connect the 6P socket to the 6P plug from the operation selector Reattach the socket cover f INSTALLING THE HIGH PERFORMANCE FILTER OR SUPER LONG LIFE FILTER Fig 3 18 Turn the filter hooks of the air intake chamber Install high performance or super long life filter into the chamber Install in the correct direction Set the filter so that the arrow on the side as shown in the drawing on the right can be installed into the air intake chamber Turn the filter hook positioned so the filter frame is aligned and secure the air filter in place Take adequate precautions CAUTION when installing onto the ceiling The air intake cham ber is especially prone to rupture if struck on it s side Installation screws Socket cover Air intake chamber _ socket 3P socket from ceiling panel 3P plug electrical of component box selector Indoor unit 1115_X_S Installation screws Installation screws M4 x 12 M4 x 12 Duct Air filter connection box Arrow Duct connec
5. 7 9 3 Clamp the tubing bundle to the wall using 1 clamp about every 3 feet Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also ensure that the condensation drain hose splits away from the bundle and drips clear of the unit and the tubing 7 8 Finishing the Installation After finishing insulating and taping over the tubing use sealing putty to seal off the hole in the wall to prevent rain and draft from entering Fig 7 10 23 Thickness Min 5 16 in Wide tube Apply putty here 4359128 Insulation Narrow tube Thickness Min 5 16 in 0999_CI Fig 7 9 Tubing 0137_C1 Fig 7 10 Insulated tubes Drain hose 0136_M_1 8 Air Purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated below Therefore they must be purged completely pressure in the system rises operating current rises cooling or heating efficiency drops moisture in the air may freeze and block capillary tubing water may lead to corrosion of parts in the refrigerant system E Air Purging with a Vacuum Pump for Test Run 1 Check that each tube both narrow and wide tubes between the indoor and outdoor units have been properly connected and all wiring for the test run has been completed Note that both narrow and wide tube service valves on the outdoor unit are kept closed at this stage 2 Using an adjustable wrenc
6. Air filter SUITS LUT WUE LE LMT 0150_X_1 11 54359128 3 7 Installing the Ceiling Panel 1 Lift the ceiling panel and position it to align the panel hook with the panel catch of the indoor unit The ceiling panel must be mounted in the correct direction Note that the 2 catches of the panel differ in size Confirm that the catches are correctly matched be tween the ceiling panel and the indoor unit body 2 Next check to see that the ceiling panel is prop erly aligned with the seamline of the ceiling If it is not remove the ceiling panel and slightly readjust the indoor unit body to the proper suspension point When the ceiling panel has been properly aligned use the supplied 4 mounting screws M5 with washers to permanently fasten the ceiling panel Install the wiring connector from the ceiling panel to the connector in the electrical component box of the indoor unit After installing the connector use the clamp on the body of the indoor unit to secure the wiring Panel catch pull down Ceiling panel SS l Electrical component box Clamp Ceiling panel wiring connector Install the air filter and air intake grille by perform ing the steps in section 3 6 in reverse Rehook the safety string before closing the air intake grille 5 3 8 When Removing the Ceiling Panel for Servicing When removing the ceiling panel for servicing remove the air intake gr
7. instructions when wiring Improper connections and inadequate grounding can cause accidental injury or death e Ground the unit following local electrical codes Connect all wiring tightly Loose wiring may cause overheating at connection points and a possible fire hazard When Transporting Be careful when picking up and moving the indoor and outdoor units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers When Installing Ina Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors n Moist or Uneven Locations Use a raised concrete pad or concrete blocks to provide a solid level foundation for the outdoor unit This prevents water damage and abnormal vibration In an area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame Provide a suitable air baffle In a Snowy Area for Heat Pump type Systems Install the outdoor unit on a raised platform that is higher than drifting snow Provide snow vents When Connecting Refrigerant Tubing e Execute enough ventilation in case refrigerant gases leak during operations Be careful that the contact of the refrigerant gases with the flare will cause the generation of poisonous gases Keep all tubing runs as short as possible Use the
8. table Fig 3 3 and Table 3 2 show Fig 3 2 the relationship between the positions of the suspension fitting the unit and the panel Refrigerant tubing joint narrow tube side Refrigerant tubing joint wide tube side Suspension lug Fig 3 3 Table 3 2 Unit inch Type Length A B C D E XS1852 PNR XS2432 5 29 32 7 7 8 10 1 32 11 23 32 4 29 32 7 54359128 1019 X_I 3 3 Placing the Unit Inside the Ceiling 1 When placing the unit inside the ceiling deter mine the pitch of the suspension bolts using the supplied full scale installation diagram Fig 3 4 The size of the opening for the indoor unit can be confirmed by attaching the full scale installation diagram beneath the unit Fig 3 4 Tubing and wiring must be laid inside the ceiling when suspending the unit If the ceiling is already constructed lay the tubing and wiring into posi tion for connection to the unit before placing the unit inside the ceiling The length of suspension bolt must be appropri ate for a distance between the bottom of the bolt and the bottom of the ceiling of more than 2 3 8 in as shown in Fig 3 4 Thread the 2 hexagonal nuts and washers field supply onto the 4 suspension bolts as shown in Fig 3 5 Use 2 sets of nuts and washers upper and lower so that the unit will not fall off the suspen sion lugs Remove the protective cardboard used to protect the fan parts during transport Adjust the distance between the uni
9. 4 Pump Down Pump down means collecting all refrigerant gas in the system back into the outdoor unit without losing any of the gas Pump down is used when the unit is to be moved or before servicing the refrigerant circuit Pump Down Procedure Be sure to carry out pump down with the unit in cooling mode 1 Connect the Lo side charging hose of the manifold valve to the service port on the wide tube service valve 2 Using a hex wrench turn the narrow tube service Hose with push pin Service valve Quay UO 1834_M_I Fig 9 3 valve clockwise all the way to close the service valve Be sure to confirm that the wide tube service valve is fully open Press the operation button and start cooling operation When the low pressure gauge reading falls to 1 to 0 5 kg cm 14 2 to 7 1 PSI fully close the wide tube valve stem with a standard screwdriver Then quickly stop the unit Disconnect all gauges and hose and replace the bonnets and the valve caps as they were before 4359128
10. _M_I 6 Electrical Wiring 6 1 General Precautions on Wiring 7 Regulations on wire diameters differ from locality 1 Before wiring confirm the rated voltage of the unit to locality For field wiring rules please refer to as shown on its nameplate then carry out the your LOCAL ELECTRICAL CODES ex National wiring closely following the wiring diagram Electric Code ANSI NFPA70 before beginning You must ensure that installation complies with all 2 Provide a power outlet to be used exclusively for relevant rules and regulations each unit and a power supply disconnect and circuit breaker for overcurrent protection should 8 To prevent malfunction of the air conditioner be provided in the exclusive line caused by electrical noise care must be taken 3 To prevent possible hazards from insulation when wiring as follows failure the unit must be grounded The inter unit control wiring and the remote control wiring option should be wired apart from the inter 4 Each wiring connection must be done in accor unit power wiring dance with the wiring system diagram Wrong wiring may cause the unit to misoperate or become damaged 5 Do not allow wiring to touch the refrigerant tubing compressor or any moving parts of the fan 6 Unauthorized changes in the internal wiring can be very dangerous The manufacturer will accept no responsibility for any damage or misoperation that occurs as a result of such unauthorize
11. am a Air discharge N 1821 M_I Fig 2 5 84359128 3 How to Install the Indoor Unit 3 1 Suspending the Indoor Unit This unit uses a drain pump Use a carpenter s level to check that the unit is level 3 2 Preparation for Suspending 1 Fix the suspension bolts securely in the ceiling using the method shown in the diagrams Figs 3 1 and 3 2 by attaching them to the ceiling support structure or by any other method that ensures that the unit will be securely and safely suspended 2 Follow Fig 3 2 and Table 3 1 to make the holes in the ceiling Table 3 1 Unit inch mm Type Length A B XS1852 PNR XS2432 32 9 32 820 28 3 4 730 820 ceiling opening dimension 590 suspension bolt pitch Hole in anchor Hole in plug Concrete Insert A ceiling opening dimension re ede adela p bas A A 5 5 Suspension bolt M10 or 3 8 field supply y 0038_T_I Fig 3 1 N 1 2 B suspension bolt pitch 1 2 Refrigerant tubing side Drain hose side 0962_S_I Drain inspection port a le ec ial E wecawscie 3 Determine the pitch of the suspension bolts using Y F the supplied full scale installation diagram The Unit inch diagram and
12. as been Sg i Disconnect oa incorrectly wired switch 52 Field supply 5 5 Ground the unit in accordance with local codes 6 Be sure to size each wire allowing several inches O Grounding longer than the required length for wiring line Baa 7 Use lock nuts to secure the conduit tubes Fig 6 2 Be sure to comply with To avoid the risk of local codes while running electric shock each air the wire from the indoor unit to the outdoor unit grounded size of wire and wiring method etc Be sure to connect the Every wire must be power supply line to the connected firmly er outdoor unit as shown in No wire should be the wiring diagram The conditioner unit must be allowed to touch indoor unit draws its refrigerant tubing the power from the outdoor compressor or any unit moving part 6 4 Examples of Incorrect Wiring The following are examples of improper wiring that result in system misoperation You should confirm that you have wired the units correctly before beginning the test run Problem 1 Problem 2 Short circuit will occur after approx Air conditioner will not operate 3 minutes and the power circuit fuse blows Disconnect Disconnect Disconnect A switch B switch C switch O ig Grounding line Indoor unit Outdoor unit Indoor unit Outdoor unit Indoor unit Outdoor unit 1301_C1 1302_C_I 1303_C_I Proble
13. d changes 6 2 Recommended Wire Length and Wire Diameter for Power Supply System A Power Supply B Inter unit Time Delay Power Supply Terminal Base i Fuse or Outdoor Unit Models Wiring aa Circuit Max Wi Capacity AKA NIIG AWG 12 AWG 12 Capacity Diameter C1852 CL1852 75 ft 65 ft 15A 20 A AWG 12 1 Refer to the Wiring System Diagrams See Fig 6 3 for the meaning of A B AWG American Wire Gauge i Terminal ock nut block 6 3 Wiring Instructions for the Outdoor Unit 1 To take off the access panel remove the 4 screws See Fig 6 1 2 Dismount plugs on the conduit plate 3 Temporarily mount the conduits on the conduit plate plate ae gt 4 Properly connect both the power supply and inter unit lines to the corresponding terminals on the terminal block Refer to the wiring diagram in Fig 6 2 which also appears on the access panel Plug Power supply Inter unit line Fig 6 1 1822_M_I 18 54359128 i mi INDOOR UNIT OUTDOOR UNIT Conduit s trade size for this unit is 1 2 The Inter unit conduit can be purchased at a hardware store Fower unes z gt T yri 230 208 V S The fuse located in the outdoor unit provides oto 1 230 208 v Fuse os N power supply protection and may blow when oo 230208 v gt g power is applied if the system h
14. djustable wrench 15 Reamer for deburring 16 Service valve wrench 17 Wire cutter ONAORWYD 1 2 Accessories Supplied with Unit Table 1 1 Part Name Figure Q ty Remarks Full scale For determining installation E 1 suspension bolt diagram pitch Flare ins lator E 1 For wide tubes Installation For adjusting the gauge er 1 unit position Insulating O 1 For wide tube tape White for insulating flare nuts For securing drain Hose band Gg 2 ia 3 Packing lt gt 1 For drain joint Drain ae ins lator amp D 1 For drain joint Drain hose CA D 1 Drain hose adapter qd 9 1 For drain outlet Owner s 1 manual Hexagonal To open and shut en 1 the Narrow Tube Service Valve Packed in the outdoor unit Part Name Figure Q ty Wireless A remote control unit C LI 1 AAA alkaline battery Q__ 2 Special Tapping screw screw 1 4xX16mm i A Tapping screw Oma i 1 1 3 Optional Copper Tubing Kit Copper tubing for connecting the outdoor unit to the indoor unit is available in kits which contain the narrow and wide tubing fittings and insulation Consult your nearest sales outlet or A C workshop 1 4 Type of Copper Tube and Insulation Material If you wish to purchase these materials separately from a local source you will need 1 Deoxidized annealed copper tube for refrigerant tubing Cut each tube 12 in to 16 in longer t
15. e Diameter for Power Supply System 6 3 Wiring Instructions for the Outdoor Unit 6 4 Examples of Incorrect Wiring 6 5 How to Connect Wiring to the Terminal SANYO 2000 Model Combinations Combine indoor and outdoor units only as listed below Indoor units XS1852 PNR XS2432 Outdoor units C1852 CL1852 Power Supply 60Hz single phase 208 230 V Units should be installed by licensed contractor according to local code requirements HOW TO PROCESS TUBING ccseeeeetees 21 7 1 Use of the Flaring Method 7 2 Flaring Procedure with a Flare Tool 7 3 Precaution before Connecting Tubes Tightly 7 4 Precautions during Brazing 7 5 Connecting Tubing between Indoor and Outdoor Units 7 6 Insulating the Refrigerant Tubing 7 7 Taping the Tubes 7 8 Finishing the Installation AIR PURGING ccscccciccticcsiiecsuesscieseecuncccueecsnccnsses 24 E Air Purging with a Vacuum Pump for Test Run gt TEST RUN igina eaea aaea aaia 26 9 1 Performing Test Run 9 2 Performing Test Run with Optional Wired Remote Control Unit 9 3 Basic Function of the Service Valves 9 4 Pump Down SANYO FISHER COMPANY A DIVISION OF SANYO NORTH AMERICA CORPORATION 21605 Plummer Street Chatsworth CA91311 4359128 Please Read Before Starting This air conditioning system meets strict safety and operating standards As the installer or service person it is an important part of your job to install o
16. flare method for connecting tubing Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them then tighten the nut with a torque wrench for a leak free connection e Check carefully for leaks before starting the test run NOTE Depending on the system type liquid and gas lines may be either narrow or wide Therefore to avoid confusion the refrigerant tubing for your particular model is specified as either narrow or wide rather than as liquid or gas When Servicing e Turn the power OFF at the main power box mains before opening the unit to check or repair electrical parts and wiring Keep your fingers and clothing away from any moving parts Clean up the site after you finish remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced 2 4359128 1 General This booklet briefly outlines where and how to install the air conditioning system Please read over the entire set of instructions for the indoor and outdoor units and make sure all accessory parts listed are with the system before beginning 1 1 Tools Required for Installation not supplied 1 Standard screwdriver Phillips head screwdriver Knife or wire stripper Tape measure Level Sabre saw or key hole saw Hacksaw Core bits 9 Hammer 10 Drill 11 Tube cutter 12 Tube flaring tool 13 Torque wrench 14 A
17. h or box wrench remove the valve caps from the service valve on both narrow and wide tubes 3 Connect a vacuum pump and a manifold valve with pressure gauges to the service port on the wide tube service valve Fig 8 1 Be sure to use a manifold valve ee for air purging If it is not available use a stop valve for this purpose The Hi knob of the manifold valve must always be kept closed 4 With the Lo knob of the manifold valve open run the vacuum pump The operation time for the vacuum pump varies with tubing length and the capacity of the pump The following table shows the amount of time for evacuation Required time for evacuation when capacity of 100 liter h vacuum pump is used If tubing length is If tubing length is less than 33 ft 10 m more than 33 ft 10 m 10 min or more 15 min or more The required time in the above table is calculated based on the assumption that the ideal or target vacuum condition is around 10 mmHg abs 24 Indoor unit Pressure gauge 4359128 Manifold valve Hi Outdoor unit ZA exo Vacuum pump Fig 8 1 1824_M_I 5 With the vacuum pump still running close the Lo knob of the manifold valve Then stop the vacuum pump 6 With the accessory hex wrench turn the valve stem on the nar
18. han the appropriate lengths to dampen vibration between units 2 Foamed polyethylene insulation for 5 8 15 88 mm O D copper tubes as required to precise length of tubing Wall thickness of the insulation should be not less than 0 3 inch 8 mm Check local electrical codes ror and regulations before obtaining wire Also check any specified instructions or limitations 1 5 Additional Materials Required for Installation 1 Insulated staples or clamps for connecting wire See your local codes Putty Refrigeration tubing lubricant Clamps or saddles to secure refrigerant tubing Scale for weighing ap oN 1 6 Operating Range Temperature Indoor Air Intake Outdoor Air Intake Maximum 95 F DB 71 F WB 115 F DB Cooling Minimum 67 F DB 57 F WB 67 F DB 0 F DB CL o Models 4359128 1 7 Tubing Length Refrigerant tubing between the indoor and outdoor INDOOR units should be kept as short as possible Tubing length L UNIT Select and decide the installation location so that the length of the refrigerant tubing will be within the limits given in Table 1 2 Elevation difference H OUTDOOR UNIT SL ELALI EELS LE ESTS GL Fig 1 1 Table 1 2 Models C1852 Tubing Data CL1852 Tubing size Narrow tube in mm 1 4 6 35 Thickness 0 0314 0 8 mm outer dia Wide tube in mm
19. ille and air filter disconnect the wiring connector inside the electrical component box and then remove the 4 mounting screws Connector on unit inside electrical component box Electrical component box Connector of ceiling panel Unit body Panel catch pull down Ceiling panel Air filter Air intake grille 0967_X_I 12 54359128 3 9 Duct for Fresh Air Air intake chamber including Duct connection box and flange are attached to the indoor unit when used to take fresh outdoor air High performance filter or Super long life filter can be also installed in the air intake chamber 1 SETUP PRIOR TO INSTALLATION When installing the high performance filter or super long life filter the parts and parts numbers of filters to be assembled with the air intake chamber are listed below Please check that the correct part numbers are present Air intake High performance Super long life chamber filter filter CMB GSJ80T AFT MSJ80T AFT LSJ80T XS1852 AFT HSJ80T 2 ACCESSORIES Check that the following parts are in the box when unpacking NAME QTY REMARKS Cord with socket Connecting line Connect only when 1 9P ee high performance filter is used Screw Air intake filter M5 x L125 e 4 or fastening Screw Duct connection flange box M4 x L12 Q 44 or fastening Duct connection box 1 for fresh air Duct connection flange 1 for connecting fre
20. ire end with a ring pressure terminal Fig 6 4 Place the ring pressure terminal and replace and tighten the removed terminal screw using a screwdriver Fig 6 5 20 Solid wire Loop Insulation 1004_M_I Fig 6 3 Stranded wire 2 On N Ring 2 ii IN pressure terminal E 1106_M_I Fig 6 4 Special washer Screw 4 Ring pressure D Screw and terminal Special washer Terminal plate 4359128 SHALE Ring connector 1308_M_I 7 How to Process Tubing ee Deburring The narrow tubing side is connected by flare nut and the wide tubing side is connected by brazing 7 1 Use of the Flaring Method Many of the conventional split system air conditioners employ the flaring method to connect refrigerant tubes which run between indoor and outdoor units In this method the copper tubes are flared at each end and connected with flare nuts 7 2 Flaring Procedure with a Flare Tool 1 Cut the copper tube to the required length with a tube cutter It is recommended to cut about Fig 7 1 0126 m1 12 20 in longer than the estimated tubing length 2 Remove burrs at the end of the copper tube with a tube reamer or file This process is important Copper and should be done carefully to make a good tubing flare Fig 7 1 NOTE m When reaming hold the tube end downward and be iak sure that no copper scraps fall into the tube Fig 7 2 3 Remove the flare nut fr
21. ll Fig 4 1 Remove the remote control cover by sliding it downward Remove the batteries of the remote control unit Hang the remote control unit from the mounting screw and use a screwdriver to screw the remote control unit securing screw into the wall through the hole in the battery compartment Fig 4 2 Replace the batteries Again confirm that the remote control unit operates correctly 54359128 Removable mounting Special screw Fig 4 1 Wall mounting Packed in indoor unit 0532_M_I Non removable mounting Screw Packed in indoor unit Fig 4 2 0533_M_I E Wired Remote Control Unit Option 1 To access the printed circuit board remove the cover plate of the electrical component box 2 Attach the remote control connectors securely to the mating connector pins on the printed circuit board 3 Turn the R C U switch from WIRELESS to WIRED 4 Replace the cover plate cu The mounting position for the remote control unit should be located in an accessible place for control and permit the average room temperature to be Do not supply power to the unit until the tubing and wiring to the outdoor unit is completed detected Never cover the unit or recess it into the wall 4 2 Installing the Wired Remote Control Unit 1 Use a ballpoint pen or similar pointed object to remove the plastic bushing which is inserted in the rear of the remote co
22. ll cause the drain water to flow backwards and leak when the unit is stopped Fig 3 10 Do not apply force to the piping on the unit side when connecting the drain pipe The pipe should not be allowed to hang unsupported from its connec tion to the unit Fasten the pipe to a wall frame or other support as close to the unit as possible Fig 3 11 Provide insulation for any drain pipes that are installed indoors Transparent part for checking drainage Hard PVC pipe not supplied Hose band supplied Drain hose Packing Drain hose adapter supplied supplied supplied 0964_X_I Fig 3 6 Drain insulator supplied Fig 3 7 0197 X1 Air bleeder ao 0047_X_I Fig 3 8 t lt 5 in or less as short as possible 10 in or less Fig 3 9 0965_X_1 Upward gradient 0049_X_1 Fig 3 10 0050_X_I Fig 3 11 54359128 3 5 Checking the Drainage After wiring and piping are completed use the follow ing procedure to check that the water will drain smoothly For this prepare a bucket and wiping cloth ready to catch and wipe up spilled water Do not supply power to the unit until the tubing and wiring to the outdoor unit are completed 1 Take off the tube cover and through the opening slowly pour about 43 oz of water into the drain pan to check drainage 2 Do Test Run to check the drainage after comple
23. m 3 Compressor will not start only indoor unit will operate Disconnect Disconnect D switch E switch Indoor unit Outdoor unit Indoor unit Outdoor unit 1304_C_I 1305_C_I 19 54359128 Loose wiring may cause the terminal to overheat or result in unit malfunction A fire hazard may also exist Therefore ensure that all wiring is tightly connected When connecting each power wire to the correspond ing terminal follow the instructions on How to connect wiring to the terminal and fasten the wire securely with the fixing screw of the terminal plate 6 5 How to Connect Wiring to the Terminal E For solid core wiring or F cable 1 Cut the wire end with a wire cutter or wire cutting pliers then strip the insulation to expose the solid wire about 1 in Fig 6 3 Using a screwdriver remove the terminal screw s on the terminal plate Using the pliers bend the solid wire to form a loop suitable for the terminal screw Shape the wire loop properly position it on the terminal plate and fix it securely with the terminal screw using a screwdriver E For stranded wiring 1 Cut the wire end with a wire cutter or wire cutting pliers then strip the insulation to expose the stranded wiring about 3 8 in Fig 6 4 Using a Pillips head screwdriver remove the terminal screw s on the terminal plate Using a ring connector fastener or pliers securely clamp each stripped w
24. ntrol unit The bushing can be discarded Fig 4 4 2 Align the cord with the groove of the remote control unit 3 Attach the mounting plate to the wall with the 2 supplied screws Then align the rail on the rear of the control unit with the slot of the mounting plate and slide the unit down as far as it will go Fig 4 4 Fix the control unit cord to the wall 4 If local codes allow the remote control unit cord can be wired in the wall Fig 4 5 Electrical component box T Cover plate Connector for the wired remote control unit WIRED LwireLess R C U Switch 1006_M_I Fig 4 3 Flat head tapping screw 25 64 3 x 10 mm Groove SATA Om Plastic bushing Cord clip a Ballpoint pen Remote control unit Remote control Mounting a plate Truss head tapping screw O gt 5 8 4 x 16 mm TOTA 84359128 5 Address Switches If you are installing one indoor unit or one group of indoor units in the same room it is necessary for you to assign each unit its own address so that each can be operated by its own remote control unit You assign the addresses by matching the switch position of each indoor unit with the switch position of its remote control unit The switch of the remote control unit is shown in Fig 5 1 5 1 Finding the Address Switches
25. om the unit and mount it on the copper tube O17 MI 4 Make a flare at the end of copper tube with a flare Fig 7 2 tool Fig 7 3 Use RIGID or equivalent NOTE A good flare should have the following characteristics N Flare nut inside surface is glossy and smooth 45 ee edge is smooth tapered sides are of uniform length Flare tool 0128_M_I 7 3 Precaution before Connecting Tubes Tightly Fig 7 3 1 Apply a sealing cap or water proof tape to pre vent dust or water from entering the tubes before they are used 2 Apply refrigerant lubricant to the matching sur te refrigerant i e faces of the flare and union before connecting lubricant here and her them together This helps to reduce gas leaks 0129_M_1 Fig 7 4 Fig 7 4 3 For proper connection align the union tube and flare tube with each other then screw in the flare P nut lightly at first to obtain a smooth match Fig 7 5 Adjust the shape of the narrow and wide tubes using a tube bender at the installation site and connect them to the each tubing side valve using Union Flare nut oso a a flare nut a Fig 7 5 21 54359128 7 4 Precautions during Brazing Replace air inside the tube with nitrogen gas to prevent copper oxide film from forming during the brazing process Do not allow the tubing to get too hot during the brazing process The nitrogen gas inside the tubing may overheat causing refrige
26. oor unit MEF Refrigerant tubing li Seal suppligd Insulation tape white supplied Flare insulator supplied ae ae pope Tube insulator Unit side V TR Wry not supplied insulator Z a Flare nut Vinyl clamps supplied Fig 7 7 1015_X_I Refrigerant tubing and insulator not supplied Drain insulator and clamp Drain pipe and insulator Large not supplied supplied Packing _ clamp Insulation Small tape hose band Vinyl Flare clamp supplied insulator O558_X_I Never grasp the drain or refrigerant connecting outlets when moving the unit Fig 7 8 4359128 Because capillary tubing is installed in the outdoor unit both the wide and narrow tubes of this air conditioner become cold Therefore to prevent heat loss and wet floors due to dripping of condensation water both tubes must be well insulated with proper insulation material The thickness of the insulation material should be a min 8 mm 5 16 7 7 Taping the Tubes 1 At this time the refrigerant tubes and electrical wiring if local codes permit should be taped with armoring tape in 1 bundle To prevent the con densation from overflowing the drain pan keep the drain hose separate from the refrigerant tubing 2 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 overlap half of each previous tape turn Fig
27. or actual operation 25 ao entur Narrow tube A L a NJ Hex wrench wer Valve cap Vacuum hose to manifold valve 1825_M_I Fig 8 2 4359128 9 Test Run 9 1 Performing Test Run ren 1 The Operation Selector is located on the electrical component box inside the indoor unit To access the Operation Selector press the two latches of the air intake grille in the direction of the arrow to open the grille Open the air intake grille downward Fig 9 1 2 Set the Operation Selector to the Test position The air conditioner will start running Be careful since the fan will start when performing Test Run 3 Let the unit run for about 30 minutes and check that the unit operates normally 4 After the Test Run be sure to reset the Operation Selector to the ON position for normal operation The air conditioner continues to run 5 Referring to the Operating Instructions select the Cooling mode and press the ON OFF operation button on the remote control unit to confirm remote control unit operation Set the Operation Selector at the ON position Other wise the unit will stop or will not run correctly 9 2 Performing Test Run with Optional Wired Remote Control Unit 1 Service TEST RUN switch is located on the rear side of the remote control unit Set the switch to the TEST RUN position Fig 9 2 2 Referring to the Operating Instructions selec
28. r service the system so it operates safely and efficiently For safe installation and trouble free operation you must Carefully read this instruction booklet before beginning Follow each installation or repair step exactly as shown Observe all local state and national electrical codes Pay close attention to all warning and caution notices given in this manual WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage lf Necessary Get Help These instructions are all you need for most installation sites and maintenance conditions If you require help for a special problem contact our sales service outlet or your certified dealer for additional instructions In Case of Improper Installation The manufacturer shall in no way be responsible for improper installation or maintenance service including failure to follow the instructions in this document SPECIAL PRECAUTIONS When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ONLY A QUALIFIED EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked e Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these
29. rant system valves to become damaged Therefore allow the tubing to cool be tween brazings 7 5 Connecting Tubing between Indoor and Outdoor Units 1 Tightly connect the indoor side refrigerant tubing with the outdoor side tubing Fig 7 6 2 To fasten the flare nuts apply specified torque as Table 7 1 Tube Dia Tightening Torque Approx 140 180 kg cm 1 4 6 35 mm 120 160 Ibs in Approx 680 820 kg cm 590 710 lbs in 5 8 15 88 mm 7 6 Insulating the Refrigerant Tubing er To avoid condensation and water leaks the wide and narrow tubes must be insulated with the supplied insulation materials Always insulate tubes after completing leak tests on all connection points Taping the flare nuts Wind white insulation tape around the flare nuts at the wide and narrow tube connections Place the seal supplied on the unit Then cover up the tubing connections with the flare nut insulator and cover the gap at the union with the supplied black insulation tape Finally fix the insulator at both ends with vinyl clamps Fig 7 7 Insulation material The material used for insulation must have good insulation characteristics be easy to use be age resistant and must not easily absorb moisture After a tube has been insu CAUTION lated never try to bend it because it can cause the tube to break or crack Torque wrench Indoor unit Outd
30. row tube service valve counter clockwise by 90 degress 1 4 turn for 10 seconds and then turn the stem clockwise to close it again Fig 8 2 Be sure to completely insert N CAUTION the hex wrench before attempting to turn the valve 7 Leak test all joints at the tubing both indoor and outdoors with liquid soap Bubbles indicate a leak Be sure to wipe off the soap with a clean cloth 8 With the hex wrench turn the wide tube service valve stem counter clockwise to fully open the valve 9 Turn the narrow tube service valve stem counter clockwise to fully open the valve 10 Loosen the vacuum hose connected to the wide tube service port slightly to release the pressure Then remove the hose 11 lt Replace the bonnet and flare nut on the wide tube service port and fasten the flare nut securely with an adjustable wrench or box wrench or box wrench Next mount the valve cap and tighten it with a torque wrench the cap needs to be tightened with the torque of 170 ibs in 200 kg cm This process is very important to prevent gas from leaking from the system 12 Test run the air conditioner See next page 13 While the air conditioner is running apply liquid soap to check for any gas leaks around the service valves or caps 14 If there is no leakage stop the air conditioner 15 Wipe off the soap on the tubing This completes air purging with a vacuum pump and the air conditioner is ready f
31. sh air duct 3 INSTALLATION a Setup for the indoor unit When assembling the high performance filter open the lid of the electrical component box remove the socket 9P of the fan motor cable inside the electrical component box and connect the accessory cord with socket 9P Do not connect the acces er sory cord with socket to Cord with socket the electrical component box 9P when the unit is used to take fresh air Do not connect the acces sory cord with socket when assembling the super long life filter Always store the accessory cord with socket inside the electrical component box Installation steps a to b are the same for both er the CMB GSJ80T and the GSJ140T The drawing component box illustrates installation of air intake chamber to the CMB GSJ80T 1114_X_S Fig 3 16 13 54359128 b INSTALLING THE AIR INTAKE CHAMBER Set the air intake chamber to the indoor unit taking care not to set to the incorrect direction Fig 3 17 Fasten the air intake camber with the accessory screws M5 x L125 4pcs Fig 3 17 c INSTALLING THE DUCT CONNECTION BOX Fasten the duct connection flange to the duct connection box with the accessory screws M4 x L12 4 pcs Fig 3 18 Put the duct connction box into the rectangular hole of the air intake chamber and fasten it to the both sides of the indoor unit and chamber with the accessory screws M4 x L12 4 pcs Fig 3 18
32. t ing installation When performing Test Run be sure to observe the Test Run procedure Refer to page 37 rer 3 Be careful since the fan will start turning when checking the drainage After drain checking is finished return the Operation Selector switch to the RUN position ON position and remount the tube cover er To mount the tube cover use 5 16 4 x 8 mm tapping screws Do not use long screws as they may punc ture the drain pan and cause water leakage 10 5 16 4 x 8 mm tapping screw ane Tube cover 0966_X_I 4359128 E Ceiling Panel Never touch or attempt to ren move the air direction louver by hand or you may damage the unit Instead use the remote control unit if you want to change the direction or air flow 3 6 Before Installing the Ceiling Panel 1 Remove the air intake grille and air filter from the ceiling panel Figs 3 13 and 3 14 a Remove the 2 screws on the latch of the air intake grille Fig 3 13 b Press on the 2 latches of the air intake grille Latch go with your thumb in the direction of the arrow to open the grille Fig 3 13 c With the air intake grille open about 45 remove the safety string hook on the grille side Fig 3 14 d Pull the air intake grille towards you to remove it from the ceiling panel 2 Pull down the two panel catches on the body of the indoor unit body Fig 3 15 0149_X 1
33. t and surface of the ceiling 1 7 8 in using the supplied instal lation gauge Fig 3 4 8 x 2 Full scale installation diagram ie printed on a cardboard packing 0 a l I 5 S 5 So N 2 4 S A Full scale installation diagram Nuts and washers 2 sets 84359128 0963_X_I Fig 3 4 Suspension bolt Suspension lug 0041_X_1 Fig 3 5 3 4 Installing the Drain Piping 1 Prepare standard hard PVC pipe O D 1 3 64 in for the drain and use the supplied drain hose and hose band to prevent water leaks The PVC pipe must be purchased separately The transparent part allows you to check drain age Fig 3 6 Tighten the hose clamps N CAUTION so their locking nuts face upward Fig 3 6 2 After checking the drainage wrap the supplied packing and drain pipe insulator around the pipe Fig 3 7 Ensure the drain pipe has a downward gradient 1 100 or more and that there are no water traps rem Do not install an air bleeder tubes as this may cause waiter to spray from the drain tube outlet Fig 3 8 If it is necessary to increase the height of the drain pipe the section directly after the connection port can be raised a maximum of 10 in Do not raise it any higher than 10 in as this could result in water leaks Fig 3 9 Do not install the pipe with an upward gradient from the connection port It wi
34. t run to the outdoor unit allow room for operation and maintenance as well as unrestricted air flow around the unit Fig 2 1 install the unit within the maximum elevation difference above or below the outdoor unit and within a total tubing length from the outdoor unit as detailed in Table 1 2 allow room for mounting the remote control unit about 3 ft off the floor in an area that is not in direct sunlight nor in the flow of cool air from the indoor unit Air delivery will be degraded if the distance from the floor to the ceiling is greater than 10 ft 1330_X_S Fig 2 1 5 4359128 Outdoor Unit AVOID heat sources exhaust fans etc Fig 2 2 damp humid or uneven locations DO choose a place as cool as possible choose a place that is well ventilated allow enough room around the unit for air intake exhaust and possible maintenance Fig 2 3 ren Install the outdoor unit above snowfall line Do not place objects on or sit onthe outdoor unit Also never block the air intake outlet or exhaust Distortion of the outdoor unit or incomplete combustion may result Donotintroduce foreign matter into the air intake outlet or exhaust Do not poke them with such objects as a stick provide a solid base level concrete pad concrete block 4 in x 16 in 10 x 40 cm beams or equal a minimum of 4 in 10 cm above ground level to reduce humidity and protec
35. t the cooling mode and press the ON OFF operation button on the remote control unit 3 The air conditioner will start running 3 minutes after the ON OFF operation button is pressed 4 Let the unit run for about 30 minutes and check that it operates normally 5 Press the ON OFF operation button again to stop the unit Set the Service Test RUN switch at RUN position otherwise the unit will not run correctly 26 TEST OFF ON pled Operation Air intake grille 1323_M_I Fig 9 1 Service TEST RUN switch Bottom Remote control unit viewed from rear Fig 9 2 0543_M_1I 4359128 9 3 Basic Function of the Service Valves The basic function of the service valves are given in Table 7 below Narrow Tube Service Wide Tube Service Action Valve 2 Way Valve 3 Way Em O ring _ Valve cap Ph y Stem Shipping K ES 1827_M_I Operating and test running the air conditioner Measuring pressure and gas charging 1830_M_I 1831_M_I Air purging with a vacuum pump 1832_M_I 1833_M_1 The service port on the wide tube service valve uses a Schrader core valve to access the refrigerant system Therefore be sure to use a hose connector which has a push pin inside Fig 9 3 9
36. t the unit against possible water damage and decreased service life Fig 2 4 use lug bolts or equal to bolt down unit reducing vibration and noise 2 1 Baffle Plates for the Outdoor Unit CLxx models only It is recommended to use baffle plates for model CL1852 The baffle plates are not normally required for the other models When the outdoor unit is installed in a position exposed to strong wind like seasonal winds with low air temperature in winter baffle plates must be installed on the outdoor unit Fig 2 5 This unit is designed so that the fan of the outdoor unit runs at low speed when the air conditioner is operated at low outdoor air temperatures When the outdoor unit is exposed to strong wind the system pressure drops because of the freeze protector 6 NO Exhaust fan 4 E a 7 Hot air Heat source 1817_C1 Fig 2 2 Obstacle above Min Min L4 D 7t 7ft Air intake f Min 6 15 cm E 2m 2m QO D t kej z 3 Min 6 Air discharge Min 12 a PER s 15 cm q 30 cm 5 1818_M_I Ground Min 6 in 15 cm Air intake 1819 M_I Fig 2 3 Anchor bolts 4 pcs Q x Q Min 4 10 cm Air intake S S S WS NN Concrete NN or equal S 5 N om Ab 40 Sm 1820_M_I Fig 2 4 Baffle 6 min Baffle plate D plate t 7 O N 2 ZZZZZ7 ZZZZ R N 5 7 N o N
37. tion Rectangular hole Filter hook 1113_X_S Fig 3 18 4359128 4 How to Install the Remote Control Unit E Wireless Remote Control Unit The remote control unit can be operated from either a non fixed position or a wall mounted position To ensure that the air conditioner operates correctly do not install the remote control unit in the following places In direct sunlight Behind a curtain or other place where it is covered More than 26 ft away from the air conditioner In the path of the air conditioner s airstream Where it may become extremely hot or cold Where it may be subject to electrical or magnetic interference 4 1 Mounting on a Wall 1 Removable mounting a b c d Momentarily hold the remote control unit in the desired mounting position Confirm that the air conditioner responds correctly when you press keys on the remote control from that position After confirming correct operation use a screwdriver to screw the supplied special mounting screw into the wall Fig 4 1 Hang the remote control unit from the mounting screw 2 Non removable mounting a b n 3 Momentarily hold the remote control unit in the desired mounting position Confirm that the air conditioner responds correctly when you press keys on the remote control from that position After confirming correct operation use a screwdriver to screw the mounting screw into the wa
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