Sanyo KS1872 User's Manual
Contents
1. N W YAN A Z My xy ANN iN AN N Wy AN NII N W AN AN MRD ANN XN l MLM Air intake Min 6 15 cm ANN Aiii ANN AN N ili AIi ez is i A NN Concrete or equal sl y Ais KAATI ANN N NO vr Hot air a 7 af 3 J Heat source a Outdoor unit Fig 4 C1872 CL1872 Air intake Min 4 10 cm Valve side Min 10 25 cm Min 1 4 40 cm Min i Airdi Fig 5a C2472 CL2472 Air intake Min 8 20 cm Valve side Min 10 25 cm Min 4 10 cm Air discharge Min 1 8 50 cm Fig 5b YIN v KAY ANI A NN ANN A AN AN iy A AN N ANS A A AWIN ANI ANN W LLL ANNY AN i AW Ss FA Ls y W f LLL Fig 5e Exhaust fan Obstacle above a A J Min _Min A VA a 1 5 ra 4 ad x P e5 J O A A Ground Min 4 10 cm Air intake Obstacle above 2 Min E 2 m E O T K g lt 1 8 O Ground Min 8 20 cm Air intake Q Cushion rubber 2 3 Baffle Plate for the Outdoor Unit CLxx models only2. insulate the hose with insulation so that chilled condensation will not damage furniture or floors Fig 44 Foamed polyethylene or its equivalent is recom mended unit or operate it until all tubing and wiring to the out side unit are completed uo Do not supply power to the Risk of Electric Shock 16 f Push Fig 42 Slant Ind E al Drain hose Fig 43 Condensation IE a d d t Insulation material gt Locally purchased must be used Fig 44 4 How to Install the Outdoor Unit First refer to Section 2 Installation Site Selection 4 1 Wiring Instructions for the Outdoor Unit Regulations on wire size differ from locality to locality For field wiring requirements please refer to your local elec trical codes Make sure that the installation fully complies with all local and national regulations 1 Remove access panel C Fig 46 2 Connect the inter unit and power supply line accord ing to the drawing on the panel side 3 Be sure to size each wire allowing approx 4 10 cm longer than the required length for wiring Store excess wiring inside the cabinet 4 When connections are completed check that all connections are correct as shown in the wiring sys tem diagram on panel side 5 Be sure to ground the unit according to your local codes Lock nut Cabinet Terminal block Conduit plate ee a i Acces
3. lt is recommended to use baffle plates for models CL1872 and CL2472 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 tempera ture in winter baffle plates must be installed in front of the outdoor unit Fig 5f 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 min Baffle plate t o C amp J Air discharge 6 min Baffle plate 4 Air discharge 3 How to Install the Indoor Unit 3 1 Remove the Rear Panel from the Unit 1 Remove and discard the set screw on the rear panel Fig 6 2 Press the 2 A marks on the frame cover and disen gage the stationary tabs from the frame Fig 7 3 Remove the rear panel Tubing can be extended in 5 directions as shown in Fig 8 Select the direction you need providing the shortest run to the outside unit When left tubing is to be done switch the drain hose and drain cap For details refer to Switching drain hose and drain cap on page 14 3 2 Make a Hole 1 Place the rear panel from the indoor unit on the wall at the location selected Make sure the panel is hori zontal using a carpenter s level or tape measure
4. THE OUTDOOR UNIT 17 Control Unit 4 1 Wiring Instructions for the Outdoor Unit 5 REFRIGERANT TUBING 0000000 18 5 1 Use of the Flaring Method 5 2 Flaring Procedure with a Flare Tool 5 3 Caution before Connecting Tubes Tightly 5 4 Connecting Tubing between Indoor and Outdoor Units 5 5 Insulation of Refrigerant Tubing 5 6 Taping the Tubes 5 7 Finishing the Installation The illustrations are based on the typical appearance of a standard model Consequently the shape may differ 6 AIR PURGING cc ceecccceeeeeeeeeeeeees 20 from that of the air conditioner that you are installing E Air Purging with a Vacuum Pump for Test Run WE Basic Functions of the Service Valves E Pump Down In Canada SANYO FISHER COMPANY SANYO Canada Inc A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent Concord 21605 Plummer Street Ontario L4K 5C7 Canada 85264189988000 SANYO 2006 Chatsworth CA 91311 U S A w IMPORTANT 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 or 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
5. booklet briefly outlines where and how to install the 6 Sabre saw or key hole saw air conditioning system Please read over the entire set 7 Hacksaw of instructions for the indoor and outdoor units and make 8 Core bits sure all accessory parts listed are with the system before 9 Hammer Genina 10 Drill 11 Tube cutter 1 1 Tools Required for Installation not supplied 12 Tube flaring tool 1 Standard screwdriver 13 Torque wrench 2 Phillips head screwdriver 14 Adjustable wrench 3 Knife or wire stripper 15 Reamer for deburring 4 Tape measure 5 Carpenter s level 1 2 Accessories Supplied with Unit Table 1 Parts Figure eee R t Sichuan Gg J GEIR Tapping screw Phillips Hex wrench ED 9 32 x 5 8 4x16 mm VA aoe a STe AAA alkaline Drain hose Packed in the outdoor unit battery adapter Cushion 1 3 Optional Copper Tubing Kit 2 Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing Wall thickness of the insulation should be not less than 5 16 8 mm 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 3 Use insulated copper wire for field wiring Wire size varies with the total length of wiring Refer to 3 6 1 4 Type of Copper Tube and Insulation Material E l Wiring Instruc
6. electrical codes Pay close attention to all warning and caution notices given in this manual This symbol refers to a hazard WARNING or unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can CAUTION result in personal injury or prod uct or property damage If 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 improp er installation or maintenance service including failure to follow the instructions in this document SPECIAL PRECAUTIONS SE when wiring POPP Ce eee eee EEE E EEE EOE EEE EEE EEE EEE EE EEE EEE ETEEEEE EOE ESE TEESE EE SEEE EEE SESE EEE ESEE EEE ESEE EEE SESE ESOS EEE SESE EEE EEE EE 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 Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequate grounding can cause accidental injury or death Ground the unit
7. 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 wrench or box wrench remove the valve caps from the service valve on both nar row 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 57 The service port on the wide tube service valve uses a Schrader core valve to access the refrigerant sys tem The valve core is similar to those used in automobile tires Therefore be sure to use a vacuum hose connector which has a push pin inside CAUTION Be sure to use a manifold valve for air purging If it is not avail able use a stop valve field sup ply 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 operat
8. to measure down from the ceiling Wait until after cut ting the hole before attaching the rear panel to the wall 2 Determine which side of the unit you should make the hole for tubing and wiring Fig 9 In the case of left rear tubing use the measurement points 2 3 8 60 mm from the edge of the rear panel for precise placement of the hose outlet Fig 9 3 Before making the hole check carefully that no studs or pipes are directly run behind the spot to be cut CAUTION ASD avoc areas where elec trical wiring or conduits are located The above precautions are also applicable if tubing goes through the wall in any other location Set screw only for transportation Fig 6 Rear panel Right rear tubing recommended J Left rear tubing Right tubing Downward tubing Fig 8 2 3 8 60 mm 4 Using a sabre saw key hole saw or hole cutting drill attachment cut a hole in the wall See Table 4 and Fig 10 Table 4 Hole Dia 3 5 32 80 mm 5 Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe ata slight angle 1 4 6 mm shorter than the thickness of the wall Fig 11 6 Place the plastic cover over the end of the pipe for indoor side only and insert the pipe in the wall Fig 12 3 3 Install the Rear Panel on the Wall Be sure to confirm that the wall is strong enough to s
9. 4 12 14 C1872 C2472 CL1872 CL2472 131 Max 230 Max 65 Max 20A AWG American Wire Gauge AN WIRING SYSTEM DIAGRAM Be sure to comply with local codes on running the wire INDOOR pcconnect OUTDOOR from the indoor unit to the outdoor unit size of wire and satu ee UNIT wiring method ete eses lt i s Each wire must be firmly connected No wire should be allowed to touch refrigerant tubing the compressor or any moving part WARNING a i f i To avoid the risk of electric shock each air conditioner unit must be grounded For the installation of a grounding device please observe local electrical codes e Grounding is necessary especially for units using inverter circuits in order to release charged electricity and electrical noise caused by high tension Otherwise electrical shock may occur Place a dedicated ground more than 7 2 m away from other grounds and do not have it shared with other elec tric appliances J N Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram The indoor unit draws its power from the outdoor unit Do not run wiring for antenna signal or power lines of television radio stereo telephone security system or intercom any closer than 3 4 1 m from the power cable and wires between the indoor and outdoor units Electrical noise may affect the operation Terminal Powe
10. 98 ft Max or 33 to 131 ft Max charge additional refrigerant R410A by 0 27 oz ft No additional charge of compressor oil is necessary 2 2 Outdoor Unit AVOID heat sources exhaust fans etc Fig 4 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 5a or 5b provide a solid base level concrete pad concrete block 4 x 1 4 10 x 40 cm or 6 x 1 4 15 x 40 cm beams or equal a minimum of 4 10 cm or 6 15 cm above ground level to reduce humidity and protect the unit against possible water damage and decreased service life Fig 5c or 5d Install cushion rubber under unit s feet to reduce vibration and noise Fig 5e use lug bolts or equal to bolt down unit reducing vibration and noise Install in a location where no antenna of a television or radio exists within 10 3 m C1872 CL1872 Anchor bolts 4 pcs AN II AN A ZA N N AN xy Wy Aii NNN i N WW AA Ih AN A ANS oA Air intake Min 4 10 cm AN N W WW ATTIN AN z Concrete or equal s W k AN L C2472 CL2472 Anchor bolts 4 pcs
11. ION button ACL button Fig 63 OOOO OO00 AIR CONDITIONER OE saia SET TEMP ON OFF operation button 1HR TIMER button QUIET MODE FAN SPEED NIGHT SETBACK FLAP HIGH POWER CANCEL CLOCK D SENSOR C4 gt F 12H4 gt 24H ACL A_ LexydHe _ All Reset button Fig 64
12. SANYO INSTALLATION INSTRUCTIONS Inverter Split System Air Conditioner COOL DRY Model This air conditioner uses the new refrigerant R410A Contents Page Model Combinations IMPORTANT Combine indoor and outdoor units only as listed Please Read Before Starting 0 0 cc ee 2 below 1 GENERAL 3 Indoor Unit Outdoor Unit 1 1 Tools Required for Installation not supplied peels Go 1 2 Accessories Supplied with Unit CL1872 1 3 Optional Copper Tubing Kit KS2472 C2472 1 4 Type of Copper Tube and Insulation Material CL2472 1 5 Additional Materials Required for Installation Power Source 2 INSTALLATION SITE SELECTION 4 60 Hz single phase 230 208 V 2 1 Indoor Unit 2 2 Outdoor Unit 2 3 Baffle Plate for the Outdoor Unit Be sure to read the yellow instruction sheet 3 HOW TO INSTALL THE INDOOR UNIT 7 attached to the outdoor unit for models using the 3 1 Remove the Rear Panel from the Unit new refrigerant R410A 3 2 Make a Hole 3 3 Install the Rear Panel on the Wall 3 4 Remove the Grille to Install the Indoor Unit 3 5 Shape the Indoor Side Tubing 3 6 Wiring Instructions 3 7 Recommended Wire Length and Diameter 3 8 Wiring Instructions for Inter unit Connections 7 REMOTE CONTROL UNIT INSTALLATION POSITION veteran ees 24 7 1 Mounting on a Wall 3 9 Mountin E ce 8 ADDRESS SWITCH aan 25 8 1 Address Setting of the Remote 4 HOWTO INSTALL
13. aker for overcurrent protection provided in the exclusive line To prevent possible hazards due to insulation failure the unit must be grounded Each wiring connection must be done tightly and in accordance with the wiring system diagram Wrong wiring may cause the unit to misoperate or become damaged Do not allow wiring to touch the refrigerant tubing compressor or any moving parts of the fan 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 unauthorized changes 10 Frame te Left tubing outlet NA Fig 20 Frame l N Right tubing S outlet EN Fig 21 Fig 22 3 7 Recommended Wire Length and Diameter Regulations on wiring diameter differ from locality to locality For field wiring requirements please refer to your local electrical codes Carefully observe these regulations when carrying out the installation Table 5 lists recommended wire lengths and diameters for power supply systems Refer to the wiring system diagram Fig 23 for the meaning of A B and C in Table 5 Refer to your local codes or in the absence of local codes see the National Elec tric Code ANSI NFPA70 Table 5 A B A Power Supply Wiring Length ft C Control a AWG B Power Line Length ft Line Length ft Fuse or Circuit Breaker Capacity Model 1
14. ar as the fittings See Caution on page 18 The drain hose should come straight down the wall to a point where water runoff won t stain the wall Connect the refrigerant tubing to the outdoor unit After performing a leak test on the connecting part insulate it with the tubing insulation Fig 37a Also refer to Section 5 4 Connecting Tubing between Indoor and Outdoor Units Assemble the refrigerant tubing drain hose and conduit including inter unit wiring as shown in Fig 37b Refrigerant tubing A Insulation Fig 37a Drain hose Inter unit wiring Fig 37b 14 A Fig 33 Padding material Fig 34 Rear panel Refrigerant tubing Inter unit wiring Drain hose Fig 35 E Left side tubing 1 Lead the tubing and drain hose through the wall allowing sufficient length for connection Then bend the tubing using a tube bender to make the attach ment Fig 38 Switch the drain hose and drain cap Switching drain hose and drain cap a Locate the drain hose and the drain cap Fig 39 b Remove the screws fastening the drain hose on the right side and pull out the drain hose to remove it Fig 39 c Apply moderate force to pull off the drain cap on the left side If you cannot pull it off by hand use a long nose pliers d Reattach the drain hose to the left side and the drain cap to the right side Fig 40a Drain hose Slide the
15. as given below How to remove the grille 1 Grasp both ends of the air intake grille and remove it by opening towards the front and pulling towards you Fig 16a Y Remove the 3 screws Fig 16b Remove the screw on the right side cover plate and open the cover Fig 17a S Take out the thermistor from the grille Fig 17b G Press the 3 tabs at the top of the grille and the 3 tabs on the front face to separate the grille from the frame Fig 18a 6 N Pull the grill toward you to remove it How to replace the grille 1 When installing the grille place the bottom of the grille into the frame first Fig 18b Then insert the tabs on the top of the grille and on the front face into the frame 2 Make sure that the grille and frame are firmly fitted together by engaging the tabs 3 Attach the thermistor on the grille Fig 17a 4 Close the cover and replace the screw Fig 17a 5 Affix the grille with the 3 previously removed screws Fig 16b 6 Install the air intake grille a Allow the edge of the air intake grille to slide into the top of the indoor unit and then insert it all the way inside Fig 19a b Press the bottom right and left corners and center of the air intake grille to attach it to the indoor unit Fig 19b Attach so that the round pins at the top right and left cor ners of the air intake grille are inserted into the grooves at the top right and
16. drain hose fully onto the drain pan outlet until the drain hose edge is pushed into the insula tion Check that the screw holes in the drain bracket and the drain pan outlet are aligned and securely in contact then fasten them with the screw After attaching the drain hose check that it is attached securely Fig 40c Drain cap Use a Phillips screwdriver to push the drain cap in firmly If it is difficult to push in wet the cap with water first Install the indoor unit on the rear panel Connect the tubing and wiring led inside from out doors After completing a leak test bundle the tubing together with armoring tape and store it inside the tubing storage area at the back of the indoor unit and hold it with clamps Figs 40a and 41 A v a Rear panel e Hole in wall A Bent part Wide tube Narrow tube i Drain hose Drain hose Fig 40a Screw hole Drain pan outlet Insulation Drain bracket l L Drain bracket Drain hose Drain hose Screw Fig 40c Fig 40b Refrigerant tubing Inter unit wiring 15 To unmount indoor unit Press the 2 A marks on the lower part of the indoor unit and unlatch the tabs Then lift the indoor unit and unmount Fig 42 3 10 Drain Hose a The drain hose should be slanted downward to the outdoors Fig 43 b Never form a trap in the course of the hose c Ifthe drain hose will run in the room
17. following local electrical codes Connect all wiring tightly Loose wiring may cause over heating at connection points and a possible fire hazard When Transporting POPC meee eee EOE EEE EEE EEE EEE EEE ESET EEEOEE EEE EEEE EEE E EEE E EEE EEEEEEEEEEOEH EEE EESE ETE EEE EEE E EEE E EEE EL OEE ELE SESE E EOE EE EE Be careful when picking up and moving the indoor and out door units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin alu minum fins on the air conditioner can cut your fingers When Installing POPP Poe E EEE EEE EEE EEE E EE EEE EEE EEEE ETE EEE EEE EOE E EEE OEE EOEE EEE EEEE EEE EEEET EE EOES EEE SESE ESO ESET E SESE EEE EEE ELLE EE EE In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construct a strong wood or metal frame to provide added support 1n a Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors 1N 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 un
18. for 10 seconds and then turn the stem clockwise to close it again Fig 58 CAUTION Be Sure to completely insert the hex wrench before attempting to turn the valve 7 Leak test all joints at the tubing both indoor and out doors with soapy water Bubbles indicate a leak Tight en the joint more when leaks then check if there is no 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 This may cause the refriger ant gas to leak In order to avoid this take off the hose quickly 11 Fasten the valve cap on the wide tube service port securely with an adjustable wrench or box wrench Next mount the valve cap on the service valve and tighten it to 170 Ibs in 200 kgf cm with a torque wrench 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 conditio
19. ig 59a e ss and oP 1 will disappear from the remote con troller display area IMPORTANT After the test run is completed be sure to press the ACL reset button to return to normal mode The air conditioner will not operate correctly if this is not done EBB NA AY 22 OOOO OOO 0 AIR CONDITIONER ON OFF on Ti button 1HR TIMER button QUIET MODE FAN SPEED NIGHT SETBACK HIGH POWER TIMER D D SENSOR C4 gt F 12H424H ADR O ac ACL Reset button OPERATION p OPERATION lamp TIMER TIMER lamp QUIET QUIET lamp con ION lamp OPERATION J Fig 59c m Basic Functions of the Service Valves The basic functions of the service valves are given in Table 8 below Table 8 Action Shipping Narrow Tube Service Valve 2 Way oe VZATA ZA N ri ee jas Wide Tube Service Valve 3 Way KL LLA a Operating and test running the air conditioner eS AED 1 aand J jX l IS J qa E F gt RS a o Yi kansat Air purging with a vacuum pump yi VINITA yee ZZZ V Wi LA E Fully OPEN am rh Measuring pressure a and gas charging a ea eee i iA ee fn ee Nd a ILL CLOSED The service port on the wide tube ser vice valve uses a Schrader core valve to access the refr
20. igerant system Therefore be sure to use a hose con nector which has a push pin inside Fig 60a CAUTION ing the service valve fully seat the wrench mE Pump Down stem use the accessory hex wrench Be sure to Close Hex wrench Fig 60b When opening or clos Open before turning the valve 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 Service valve Fig 60a Using a hex wrench turn the narrow tube service valve clockwise all the way to close the service valve Be sure to confirm that the wide tube service valve is fully open ation Press the operation button and start cooling oper When the low pressure gauge reading falls to 14 2 to 7 1 psi 1 to 0 5 kg cmz2 fully close the wide tube valve stem Then quickly stop the unit Disconnect all gauges and hoses and replace the valve caps as they were before 23 7 Remote Control Unit Installation Position The remote control unit can be operated from either a non fixed position or a wall mounted position To ensure that the air conditi
21. ion time for the vacu um pump varies with tubing length and the capacity of the pump The following table shows the amount of time for evacuation Table 7 Required time for evacuation when 100 liter h vacuum pump is used If tubing length is less than 33 ft 10 m If tubing length is more than 33 ft 10 m 15 min or more 10 min or more 20 Indoor unit oF Outdoor unit SS gt Manifold valve Exclusively for R410A Pressure o Co Hi auge coe gaug a _ 3 RZ SI R A BS Charging hose Exclusively for R410A ezeze eses Vacuum pump adapter Exclusively for R410A with reverse flow prevention ado Vacuum pump Fig 57 To prevent other refrigerants from being mistakenly charged to units which use R410A the size of the charge port on the service valve is different from the one for other refrigerant types For servicing such as recharging the specified charging hose manifold and vacuum pump adapter with reverse flow prevention for R410A must be used The required time in Table 7 is calculated based on the assumption that the ideal or target vacuum condition is around 10 mmHg abs 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 narrow tube service valve counter clockwise by 90 degrees 1 4 turn
22. it on a raised platform that is higher than drifting snow Provide snow vents When Connecting Refrigerant Tubing POPP OS eee EEE TEESE EEE EEE EEE EEE EEE EEEE EEE EEE OE EEES EEE OEEEEEEOEE EEO OESE TEESE EEESES EEE SESH EES EEE EES EDEL EDEL E ESE OS e Use the flare method for connecting tubing e 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 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 e 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 Others POPP Coe e ETE E EERE EEE HELE EEE EEE EEE EEEESO EEE EEE EEOC EEE EE EEE EE OEEE EEO SESEE TEESE EE EEES EEE EEEH EEE EES EEE SESE ELLE EEE EEE E EES Ventilate any enclosed areas when installing or testing the refrigeration system Escaped refrigerant gas on contact with fire or heat can produce dangerously toxic gas Confirm upon completing installation that no refrigerant gas is leaking If escaped gas comes in contact with a stove gas water heater electric room heater or other heat source it can produce dangerously toxic gas 1 General This
23. laces where large amounts of oil mist exist INDOOR Tubing length L UNIT DO select an appropriate position from which every corner of Elevation the room can be uniformly cooled High on a wall is best difference H 7 aia select a location that will hold the weight of the unit select a location where tubing and drain hose have the Fig 3a shortest run to the outside Fig 1 allow room for operation and maintenance as well as unre CAUTION CAUTION stricted air flow around the unit Fig 2 CAUTION ba aia Indoor unit install the unit within the maximum elevation difference H Wall For stable operation of the air conditioner do not install wall mounted type above or below the outdoor unit and within a total tubing length L from the outdoor unit as detailed in Table 3 and Fig 3a Minimum height Install the indoor unit more than 3 3 1 m away from any indoor units less than 5 from floor level antenna or power lines or connecting wires used for television 1 5 m from floor level 9 1 5 m radio telephone security system or intercom Electrical noise i f fth fact ii REEVES FO AAAA UE rom any of these sources may affect operation Floor level Fig 3b Table 3 Max Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of Model Length at Shipment Length L Difference H Additional Refrigerant ft ft ft oz ft If total tubing length becomes 25 to
24. left of the indoor unit Air intake grille Grille Fig 16a E ce E mann Cover Beier LAHKI iy v KI M5 ON V7 aa RAO My HH ft TARA MAW K UUW WWW Y NW MYMH MMH HAY SHE TULKVWWWWWWN f FAKKARNA POUTU KKHH ERAS ATS Fig 18b Groove 3 5 Shape the Indoor Side Tubing 1 2 Arrangement of tubing by direction a Right or left tubing Cut out the corner of the right left frame with a hacksaw or the like Figs 20 and 21 b Right rear or left rear tubing In this case the corner of the frame need not be cut To mount the indoor unit on the rear panel Hang the 2 mounting slots of the unit on the upper tabs of the rear panel Fig 22 3 6 Wiring Instructions General precautions on wiring 1 Before wiring confirm the rated voltage of the unit as shown on its nameplate then carry out the wiring closely following the wiring diagram Provide a power outlet to be used exclusively for each unit with a power supply disconnect and cir cuit bre
25. llow the instructions How to connect wiring to the terminal and fasten the wire securely tight with the fixing screw of the terminal plate How to connect wiring to the terminal a For Indoor Unit 1 Cut the wire end with a cutting pliers then strip the insulation to expose the wire about 9 32 7 mm See the label Fig 28 near the terminal plate 2 Using a screwdriver loosen the terminal screw on the terminal plate 3 Insert the wire and tighten the terminal screw com pletely using a screwdriver b For Outdoor Unit E For solid core wiring or F cable 1 Cut the wire end with a cutting pliers then strip the insulation to expose the solid wire about 15 16 25 mm Fig 29 2 Using a screwdriver remove the terminal screw s on the terminal plate 3 Using the pliers bend the solid wire to form a loop Suitable for the terminal screw 4 Shape the loop wire properly place it on the termi nal plate and fix it securely with the removed termi nal screw using a screwdriver For stranded wiring 1 Cut the wire end with a cutting pliers then strip the insulation to expose the stranded wiring about 3 8 10 mm and tightly twist the wire ends Figs 30 and 31 2 Using a screwdriver remove the terminal screw s on the terminal plate 3 Using a ring connector fastener or pliers securely clamp each stripped wire end with a ring connector Fig 30 4 Place the ring connector wire a
26. nd replace and tighten the removed terminal screw using a screw driver Fig 32 13 Special washer Ss Strip 15 16 25 mm Strip 3 8 10 mm SIZE 9 32 7 mm ACTUAL STRIP ee SIZE LZA Fig 28 Solid wire Insulation Fig 29 Stranded wire IN Ring S C connector Fig 30 Twist wire ends E gt a a lt Y Fig 31 Screw lt b Screw and Ring connector special washer Terminal plate y Ring 4 connector Z4 ee 3 9 Mounting 1 To install the indoor unit mount the indoor unit onto the 2 tabs on the upper part of the rear plate 2 Hold down the air discharge outlet and press the lower part of the indoor unit until it clicks to securely fasten to the 2 tabs on the lower part of the rear plate Fig 33 For tubing choose either the right or left tubing direction and follow the steps below This work can be made easi er by placing padding material such as styrofoam at the rear right side of the indoor unit Fig 34 E Right side tubing 1 2 Shape the refrigerant tubing so that it can easily go into the wall hole Fig 35 Push the wiring refrigerant tubing and drain hose through the hole in the wall Adjust the indoor unit so it is securely seated on the rear panel Fig 36 Carefully bend the tubing if necessary to run along the wall in the direction of the outdoor unit and then tape as f
27. ner is ready for actual operation 21 oP ea Narrow tube Hex wrench Rox S Wide tube ae SE Valve cap Vacuum hose to manifold valve Fig 58 How to Test Run the Air Conditioner After turning on power to the air conditioner use the remote controller and follow the steps below to conduct the test run 1 Set the remote controller in Test Run mode Fig 59a a Press and hold the ION button b Then press and hold the 1HR TIMER button c At the same time press the ACL reset button once Use a pointed object such as the tip of a pen to press the ACL button e After a few seconds amp appears and oP 1 blinks in the remote controller display area Fig 59b d Release the 1HR TIMER button e Release the ION button 2 Start Cooling mode test run by pressing the ON OFF operation button of the remote controller Fig 59a e This starts the fan producing uncooled forced air with the 4 indicator lamps OPERATION lamp TIMER lamp QUIET lamp and ION lamp on the main unit blinking Fig 59c e After 3 minutes the system shifts into cooling opera tion and cool air will start to be felt Cool mode test run is unaffected by the room temperature 3 Press the ON OFF operation button of the remote con troller again to stop the test run Fig 59a 4 Finally press the ACL reset button of the remote con troller to release it from Test Run mode to return to nor mal mode F
28. oner 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 8 m 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 Where there is an obstacle between the remote con trol unit and the air conditioner since a check signal is sent from the remote control unit every 5 minutes 7 1 Mounting on a Wall Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location The indoor unit should make a beeping sound to indicate that it has received the signal Rear side Remote control unit mount Mounting screws 5 32 x 5 8 4 x 16 mm Included w Hole To prevent loss of the remote control unit you can connect the remote control unit to the mount by passing a string through the remote control unit and attachment hole To take out the remote control unit pull it forward Fig 61 24 8 Address Switch 8 1 Address Setting of the Remote Control Unit The address can be set in order to prevent interference between remote controllers when two Sanyo indoor units are installed near each other The address is normally set to A To set a different address it is neces
29. r supply Single phase 230 208V 60HZ Grounding line Fig 23 11 3 8 Wiring Instructions for Inter unit Connections 1 6 Insert the inter unit wiring according to local codes into the through the wall PVC pipe Run the wiring toward the indoor side allowing approx 10 25 cm to extend from the wall face Fig 24 Grasp both ends of the air intake grille and remove it by opening towards the front and pulling towards you Remove the screw on the right side cover plate and open the cover Fig 25 Route the inter unit wiring from the back of the indoor unit and pull it toward the front for connec tion Fig 26a 26b Connect the inter unit wiring to the corresponding terminals on the terminal plate Fig 26a 26b while referring to the wiring diagram Be sure to secure the wiring with the provided clamp When closing the air intake grille press the bottom right and left corners and center Fig 27 Please refer to How to replace the grille on page 9 for installing the air intake grille Terminal plate Inter unit wiring Lock nut Top of conduit connector Fig 26b 12 Loose wiring may cause the terminal to overheat or result in unit malfunction A fire hazard may also exist There fore be sure all wiring is tightly connected When connecting each power wire to the corresponding terminal fo
30. ricant to the match ing surfaces of the flare and union before connect ing them together This is effective for reducing gas leaks Fig 50 c For proper connection align the union tube and flare tube straight with each other then screw in the flare nut lightly at first to obtain a smooth match Fig 51 18 Deburring Before Fig 47 Copper A T i n 4 Reamer Fig 48 If the previous flare tool clutch yanir is used TA 0 0472 1 2 mm Adjust so that the amount of tube protrusion is as shown in the figure Fig 49a If the special R410A flare tool is used 0 to 0 0196 0 to 0 5 mm Flare nut exe Copper tubing Fig 49b Apply refrigerant lubricant here and here Fig 50 Union Flare nut Fig 51 5 4 Connecting Tubing between Indoor and Outdoor Units a Tightly connect the indoor side refrigerant tubing exten ded from the wall with the outdoor side tubing Fig 52 b To fasten the flare nuts apply specified torque as Table 6 Tube Dia Tightening Torque 1 4 6 35 mm Approx 120 160 Ibs in 140 180 kgf cm 3 8 9 52 mm Approx 300 360 Ibs in 340 420 kgf cm 1 2 12 70 mm Approx 430 540 Ibs in 490 610 kgf cm 5 8 15 88 mm Approx 590 710 lbs in 680 820 kgf cm 5 5 Insulation of Refrigerant Tubing IMPORTANT To prevent heat loss and wet floors due to dripping of con densation bo
31. s panel C Plug Inter unit Conduit Power supply Conduit Fig 46 17 5 Refrigerant Tubing 5 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 5 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 approx 12 to 20 30 to 50 cm longer than the tubing length you estimate 2 Remove burrs at the end of the copper tube with a tube reamer or file This process is important and should be done carefully to make a good flare Fig 47 When reaming hold the tube end downward and be sure that no copper scraps fall into the tube Fig 48 3 Remove the flare nut from the unit and be sure to mount it on the copper tube 4 Make a flare at the end of copper tube with a flare tool Figs 49a and 49b Use RIGID or equivalent A good flare should have the following characteristics inside surface is glossy and smooth edge is smooth tapered sides are of uniform length 5 3 Caution before Connecting Tubes Tightly a Be sure to apply a sealing cap or water proof tape to prevent dust or water from getting into the tubes before they are used b Be sure to apply refrigerant lub
32. sary to change the address on the second remote controller Once changed you cannot restore the original address setting of the air conditioner 1 Switch on the power source 2 Break the address setting tab marked A on the second remote controller to change the address Fig 62 When the tab is removed the address is automatically set to B Fig 63 3 Press and hold the remote controller ION button and 1 HR TIMER button At the same time press the ACL reset button Use a thin object such as the tip of a pen to press the ACL button When this has been done oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as shown below Press this button 2 times to change the display to oP 7 address setting Fig 64 Test run mode me 7a Selfdiagnostic mode Px 1 Address setting mode 5 oP 7 has now been selected for address setting Press the ON OFF operation button on the remote controller Fig 64 Check that the beep signal received sound is heard from the second indoor unit approximately 5 times The sound you hear is the signal that the remote controller address has been changed 7 Finally press the remote controller ACL reset but ton to cancel the blinking oP 7 display Fig 64 Changing of the second remote controller address is now completed 25
33. th tubes must be well insulated with a proper insulation material Fig 53 The thickness of the insulation should be a minimum 5 16 8 mm Fig 54 5 6 Taping the Tubes J N After a tube has been insulat ed never try to bend it into a narrow curve as this may cause the tube to break or crack 1 Atthis time the 2 refrigerant tubes and electrical wire if local codes permit should be taped together with armoring tape The drain hose may also be included and taped together as 1 bundle with the 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 55 3 Clamp the tubing bundle to wall using 1 clamp approx every 47 120 cm Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also be sure the con densation drain hose splits away from the bundle and drips clear of the unit and the tubing 5 7 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 56 19 Torque wrench Indoor unit J Insulation Fig 53 Insulation A Thickness Min min 5 16 5 16 8 mm 8 mm Fig 55 Apply putty here Tubing Fig 56 6 Air Purging Air and moisture remaining in the refrigerant
34. tions for details If you wish to purchase these materials separately from a local source you will need CAUTION Check local electrical codes 1 Deoxidized annealed copper tube for refrigerant tub and regulations before ing as detailed in Table 2 obtaining wire Also check Cut each tube to the appropriate lengths 1 to 1 4 ANY SPECIES MUCHONS GN limitations 30 cm to 40 cm to dampen vibration between units Table 2 Narrow Tube Wide Tube Model Outer Dia Thickness Outer Dia Thickness KS1872 1 4 6 35 mm 0 0314 0 8 mm 1 2 12 70 mm 0 0314 0 8 mm KS2472 1 4 6 35 mm 0 0314 0 8 mm 5 8 15 88 mm 0 0393 1 0 mm 1 5 Additional Materials Required for Installation Indoor unit 1 Refrigeration armored tape 2 Insulated staples or clamps for connecting wire See local codes 3 Putty 4 Refrigeration lubricant 5 Clamps or saddles to secure refrigerant tubing Z y Drain hose Outside drainage 2 Installation Site Selection Indoor Unit Fig 1 ANa To prevent abnormal heat genera tion and the possibility of fire do not place obstacles enclosures and grilles in front of or surround ing the air conditioner in a way that may block air flow AVOID direct sunlight Front View nearby heat sources that may affect performance of the unit Fig 2 areas where leakage of flammable gas may be expected p
35. us pend the unit See either Item a or b below depending on the wall type a If Wooden Wall 1 Attach the rear panel to the wall with the 8 screws provided Fig 13 If you are not able to line up the holes in the rear panel with the beam locations marked on the wall use rawl plugs or toggle bolts to go through the holes on the panel or drill 3 16 5 mm dia holes in the panel over the stud locations and then mount the rear panel Double check with a carpenter s level or tape mea sure that the panel is level This is important to install the unit properly Fig 14 Y Make sure the panel is flush against the wall Any space between the wall and unit will cause noise and vibration b If Block Brick Concrete or Similar Type Wall Make 3 16 4 8 mm dia holes in the wall Insert rawl plugs for appropriate mounting screws Fig 15 Hole should be made at a slight downward slant to the outdoor side Indoor Outdoor side ee Cut at slight angle Fig 11 INSIDE OUTSIDE Wall Plastic cover PVC pipe Locally purchased yp LLL a Slight ce ee angle Fig 12 Fig 14 3 16 4 8 mm dia hole Sp el Rawl plug Fig 15 3 4 Remove the Grille to Install the Indoor Unit Basically these models can be installed and wired with out removing the grille If access to any internal part is needed follow the steps
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