Sanyo C0951 User's Manual
Contents
1. E Right side tubing 1 Shape the refrigerant tubing so that it can easily go into the wall hole Fig 35 2 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 3 Carefully bend the tubing if necessary to run along the wall in the direction of the outdoor unit and then tape as far as the fittings See Caution on page 17 The drain hose should come straight down the wall to a point where water runoff won t stain the wall 4 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 5 Assemble the refrigerant tubing drain hose and conduit including inter unit wiring as shown in Fig 37b Push Fig 33 Stand Fig 34 Rear panel Cover Refrigerant tubing 7 VASA a Inter unit wiring Drain hose Fig 37a Refrigerant tubing N eer Insulation O Conduit Drain hose Inter unit wiring Fig 37b 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 38 3 10 Drain Hose a The drain hose should be slanted downward to the outdoors Fig 39 b Nev2. KS0951 KS1251 Inter unit wiring Earth fi Inter unit n wiring Top of conduit Ve connector BN Fig 26c Lock 7 nut Top of conduit connector Fig 26d VANN Loose wiring may cause the termi nal to overheat or result in unit mal function A fire hazard may also exist Therefore be sure all wiring is tightly connected When connecting each power wire to the corresponding termi nal follow the instructions How to connect wiring to the termi nal 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 insu lation to expose the wire about 9 32 in 7 mm See the label Fig 28 near the terminal plate 2 Using a screwdriver loosen the terminal screw on the ter minal plate 3 Insert the wire and tighten the terminal screw completely 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 insu lation to expose the solid wire about 15 16 in 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 suit able for the terminal screw 4 Shape the loop wire properly place it on the terminal plate and fix it securely with the removed terminal screw using a screwdriver E
3. SANYO INSTALLATION INSTRUCTIONS Split System Air Conditioner COOL DRY Mode Contents Model Combinations Page IMPORTANT Combine indoor and outdoor units only as listed Please Read Before Starting 0 cce 2 below 1 GENERAL 3 Indoor Units Outdoor Units 1 1 Tools Required for Installation not supplied Roe possi 1 2 Accessories Supplied with Unit CL0951 1 3 Optional Copper Tubing Kit KS1251 C1251 1 4 Type of Copper Tube and Insulation Material CL1251 1 5 Field Wiring 1 6 Additional Materials Required for Installation Power Source 60 Hz single phase 115 V 2 INSTALLATION SITE SELECTION 4e WW a ia en RA tari ee ee eet net bi teat At 2 1 Indoor Unit 2 2 Outdoor Unit KS1852 C1852 2 3 Baffle Plate for the Outdoor Unit i CL1852 3 HOW TO INSTALL THE INDOOR UNIT 6 ere eee Sas 3 1 Remove the Rear Panel from the Unit 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 5 7 Finishing the Installation 3 6 Wiring Instructions 3 7 Recommended Wire Length and Diameter AIR PURGING se isasccivienehiatzrtelniaedunitenattss 18 3 8 Wiring Instructions for Inter unit Connections E Air Purging with a Vacuum Pump for Test Run 3 9 Mounting E Basic Function of the Service Valves 3 10 Drain Hose 4 HOW TO INSTALL THE OUTDOOR UNIT 15 4 1 Wir
4. CL1852 and CL0951 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 temper ature in winter baffle plates must be installed in front of the outdoor unit Fig 5c 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 Air intake Outdoor unit Fig 4 Min 6 15 cm Min 6 Air discharge Min 12 15 cm 30 cm Fig 5a s Air intake Concrete or equal N Ab 40 Cm Fig 5b Baffle plate 8 5 x 1 Z z lt x io j Air discharge Fig 5c Exhaust fan _ Heat source Obstacle above Min Min 4 2 7ft 7ft S 2m 2 ne 2 lt g Ry _ 8 Oo Ground Min 6 in 15 cm Air intake Anchor bolts 4 pes 6 min Baffle plate lt lt lt 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 disengage the sta tionary tabs from the frame Fig 7 3 Remove the rear panel NOTE Set screw only for tr
5. For stranded wiring 1 Cut the wire end with a cutting pliers then strip the insu lation to expose the stranded wiring about 3 8 in 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 and replace and tighten the removed terminal screw using a screwdriver Fig 32 Wire strip 9 32 7mm ACTUAL SIZE SIZE Fig 28 E Solid wire a Loop 3 Q 3 2 a Insulation Fig 29 Stranded wire Strip 3 8 10 mm Twist wire a Special washer A Screw Sy Ring connector we Terminal plate Ring N N Connector Fig 30 ends Fig 31 T D Screw and special washer Z Ring 4 lt connector ZZ 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 secure ly fasten to the 2 tabs on the lower part of the rear plate Fig 33 For tubing choose either the right or left tubing direc tion and follow the steps below Also extend the sup port on the back of the indoor unit as a stand to make your work easier Fig 34
6. to 16 30 cm to 40 cm to each tube length to reduce 2 Foamed polyethylene insulation for the specified O D copper tubes as required to precise length of tubing Wall thickness of the insulation should be not less than 0 3 in 8 mm 1 5 Field Wiring Use insulated copper wire for field wiring Wire size varies with the total length of wiring Refer to 3 6 Wiring Instructions for details CAUTION Check local electrical codes and regulations before obtaining wire Also check any specified instructions or vibration between the air conditioning units limitations Table 2 Narrow Tube Wide Tube Model Outer Dia Thickness Outer Dia Thickness 6 35 mm 1 4 0 8 mm 0 0314 9 52 mm 3 8 0 8 mm 0 0314 C0951 CL0951 6 35 mm 1 4 0 8 mm 0 0314 12 7 mm 1 2 0 8 mm 0 0314 01251 CL1251 6 35 mm 1 4 0 8 mm 0 0314 15 88 mm 5 8 1 0 mm 0 0394 C1852 CL1852 1 6 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 Drain hose 2 Installation Site Selection Outside drainage 2 1 Indoor Unit Fig 1 To prevent abnormal heat genera YY tion and the possibility of fire do 2 5 cm min not place obs
7. 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 Ae SS Frame lt Left tubing outlet ie Frame Right tubing outlet 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 reg ulations when carrying out the installation Refer to the wiring system diagram Fig 23 Refer to your local codes or in the absence of local codes with the National Electric Code ANSI NFPA70 WARNING e Be sure to comply with local codes on running the wire from the outdoor unit to the indoor unit size of wire and wiring method etc e Each wire must be firmly connected No wire should be allowed to touch refrigerant tubing the compressor or any moving part WIRING SYSTEM DIAGRAM C0951 CL0951 C1251 CL1251 Models WARNING e To avoid the risk of electric shock each air conditioner unit must be grounded A N e Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram The indoor unit dr
8. a vacuum pump and the air conditioner is ready for actual operation Narrow tube 90 1 4 turn Hex wrench NJ x Valve cap Vacuum hose to manifold valve Fig 53 How to Test Run the Air Conditioner 6 Switch on the power source Press the ON OFF button on the remote control unit once Set the operation selector switch of the indoor unit to the TEST position This starts the fan producing uncooled forced air Figs 54a and 54b After 3 minutes the system shifts into cooling operation and cool air will start to be felt Cooling operation during with the switch at the TEST posi tion is unaffected by the room temperature After stopping the test run turn the operation selector switch of indoor unit to the OFF position once then move to ON position Press the ON OFF button on the remote control unit to stop the air conditioner If the unit does not operate and the OPERATION lamp on the unit is blinking after going through the proce dure check the wiring between the units 20 KS0951 KS1251 I I I I I I I i I OPERATION TIMER Fig 54a KS1852 i y Operation Sy selector switch ON 5 O Sd SE 4 Fig 54b Basic Func
9. ansportation Fig 6 Tubing can be extended in 5 directions KS0951 KS1251 and g KS1852 as shown in Fig 8a or 8b Select the direction you need Rear panel providing the shortest run to the outside unit 3 2 Make a Hole 1 Place the rear panel from the indoor unit on the wall at the loca tion selected Make sure the panel is horizontal using a carpen ter s level or tape measure to measure down from the ceiling Wait until after cutting the hole before attaching the rear panel to the wall Fig 7 A marks 2 Determine which side of the unit you should make the hole for tubing and wiring Fig 9 KS0951 KS1251 Right rear 3 Before making the hole check carefully that no studs or pipes tubing Left recommended are directly run behind the spot to be cut tubing CAUTION Left rear tubing Right tubing Also avoid areas where electrical wiring or conduits are Fig 8a Downward tubing located KS1852 Switching drain hose and drain cap a Locate the drain hose and the drain cap Fig 8c i Right rear tubing b Remove the drain hose on the right side by pushing and recommended turning the hose connector counter clockwise to release it Fig 8c 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 pli Right tubing ers Fig 8b n D dt bi d Reattach the drain hose to the le
10. aws its power from the outdoor unit 3 8 Wiring Instructions for Inter unit Connections a Remove the grille See 3 4 Remove the Grille to Install the Indoor Unit on page 8 b 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 in 25 cm to extend from the wall face Fig 24 Never fix the wiring by any means before the indoor unit is fully seated on the rear panel INDOOR INDOOR UNIT Inter unit OUTDOOR UNIT Terminal ____ 4 Power lines Terminal g Q7 ai aN a Fuse gt g AE i 115V 2 OH ioo AE Disconnect 22 switch Oe 2G Field supply N Cee ar Mi Grounding O line C1852 CL1852 Models INDOOR INDOOR UNIT Inter unit OUTDOOR UNIT Terminal Power lines Terminal a Q aH fore ev fo 2R 3 oe Be Bes ve 28 Disconnect z2 switch Oel ze Field supply L2 an fe ea Grounding L O7 line Fig 23 Wall c Remove the screws to open the cover plate secur ing the electrical component box Figs 25a 25b 25c and 25d Insert the wrapped tubing into the hole in the wall Hang the indoor unit on the rear panel f Using a Phillips screwdriver take out the screws on the earth plate Fig 26a KS0951 1251 models only Remove the earth plate Remove the lock nut from the conduit connector Insert the conduit connector throu
11. check that no metal scraps or bits of wiring have been left inside the unit being serviced 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 2 Phillips head screwdriver 3 Knife or wire stripper 4 Tape measure 1 2 Accessories Supplied with Unit 5 Carpenter s level 6 Sabre saw or key hole saw 7 Hacksaw 8 Core bits 9 Hammer 10 Drill 11 Tube cutter 12 Tube flaring tool 13 Torque wrench 14 Adjustable wrench 15 Reamer for deburring Table 1 Parts Figure Q ty Parts Figure Q ty Parts Figure Q ty Ram plu 12 Toppa o ra Ramet wrench L Packed in the outdoor unit 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 as detailed in Table 2 When cutting tubing add approximately 12
12. death This symbol refers to a hazard or CAUTION akei practice which can result in personal injury or product 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 When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ONLY A QUALIFIED EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM e 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 instructions when wiring Improper connections and inadequate grounding can cause accidental injury or death Ground the unit following local electrical codes e Connect all wiring tightly Loose wiring may cause over heating at connection points and a possible fire hazard When Transporting 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 fi
13. ding to your local codes E Examples of Incorrect Wiring Lock nut Conduit Plug Inter unit line Terminal block Access panel h Power supply Fig 41 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 3 minutes and the power circuit fuse Sed j e Air conditioner will not operate Outdoor unit blows Disconnect A switch B OIE CH DHOO Lon ee GH Grounding line Grounding line Indoor unit Outdoor unit Indoor unit Problem 3 e Compressor will not start only indoor unit will operate Disconnect switch switch Disconnect E a o i Indoor unit Outdoor unit Indoor unit 15 Grounding line Outdoor unit Disconnect C switch Indoor unit Grounding line i Outdoor unit 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 a Cut the copper tube
14. e grille back into position 3 Press at each of the 4 tabs to completely close the grille Make sure that the grille and frame are firmly fitted together Fig 19 KS0951 KS1251 ae a N GEK Screw cover Flap Up and down air direction louvre Fig 16a KS1852 Fig 18 3 5 Shape the Indoor Side Tubing 1 Arrangement of tubing by directions 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 2 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 breaker for overcurrent protection provided in the exclusive line To prevent possible hazard 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
15. er as 1 bundle with the tubing Insulated tubes b Wrap the armoring tape from the bottom of the outdoor unit to the top of the tubing where it enters the wall As you wrap the tubing overlap half of each previous tape turn Fig 50 c Clamp tubing bundle to wall using 1 clamp approx every 47 in 120 cm Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also be sure the conden sation drain hose splits away from the bundle and drips clear of the unit and the tubing Fig 50 Apply putty here Tubing 5 7 Finishing the Installation Fig 51 After finishing insulating and taping over the tubing use seal ing putty to seal off the hole in the wall to prevent rain and draft from entering Fig 51 6 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 sys tem 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 com pleted Note that both narrow and wide tube service valves on the outdoor uni
16. er form a trap in the course of the hose c Ifthe drain hose will run in the room insulate the hose with insulation so that chilled condensation will not damage furniture or floors Fig 40 Foamed polyethylene or its equivalent is recom mended Do not supply power to the unit or operate it until all tubing and wiring to the outside unit are completed Risk of Electric Shock Fig 38 Slant ts B F Drain hose Fig 39 Indoor unit Condensation b oy 3 t Insulation material 9 lt locally purchased must be used Fig 40 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 electrical codes Make sure that the installation fully complies with all local and national regulations 1 Remove access panel Fig 41 2 Connect the power line according to the drawing on the panel side 3 Be sure to size each wire allowing approx 4 in 10 cm longer than the required length for wiring Store excess wiring inside the cabinet 4 When connections are completed check that all connec tions are correct as shown in the wiring system diagram on panel side 5 Be sure to ground the unit accor
17. ft side and the drain cap Pea ee to the right side Fig 8c The above precautions are also applicable if tubing goes through the wall in any other location In case of right rear To slip on ao Drain cap wa E G To remove SS Fig 9 Fig 8c 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 2 9 16 65 mm 3 5 32 80 mm 5 Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a slight angle 0 25 in 6 mm shorter than the thick ness of the wall Fig 11 6 Place the plastic cover locally purchased 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 sus 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 10 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 in 5 mm dia holes in the panel over the stud locations and then mount the rear panel S Double check with a ruler or carpenter s level that the panel is level This is important t
18. gh the opening from the underside of the electrical component box After insertion Fit the screw at the top of the con duit connector into the cut out Fig 26b Position the earth plate over the conduit connector allowing the connector and wires to extend through the hole in the plate Next attach the conduit connector to the earth plate by replacing and tightening the lock nut Figs 26c and 26d Then re attach the earth plate to the electrical component box with the 2 screws h Give some play to the inter unit wiring from the out door unit to the corresponding terminals on the termi nal base See Wiring System Diagram on page 10 ao Be sure to refer to the Wiring System Diagram label inside the electrical component box and carry out the correct field wiring Wrong wiring can cause the unit to misoperate or result in a fire hazard Check local electrical codes and any specified wiring instructions or limitations Fix cover plate and cover plate and back into posi tion with their screws When closing the air intake grille press on both corners and the center Fig 27 KS0951 KS1251 KS0951 KS1251 Electrical component box Earth plate Electrical component box Fig 25a Fig 25b KS1852 Electrical component box Cover SY Terminal on plate Earth plate Fig 25c Electrical component box KS0951 KS1251 Fig 25d KS1852 Top of conduit connector
19. h the accessory hex wrench turn the valve stem on the narrow tube service valve counter clockwise by 90 degrees 1 4 turn for 10 seconds and then turn the stem clockwise to close it again Fig 53 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 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 _ _ 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 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 ser vice 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
20. here and here Se ie Union Flare nut Fig 46 Copper tubing 5 4 Connecting Tubing between Indoor and Outdoor Units a Tightly connect the indoor side refrigerant tubing extend ed from the wall with the outdoor side tubing Fig 47 Torque wrench Spanner Indoor unit b To fasten the flare nuts apply specified torque as Table 5 Outdoor unit Tube Dia Tightening Torque Fig 47 1 4 6 35 mm Approx 130 170 Ibs in 150 200 kg cm 3 8 9 52 mm Approx 300 340 Ibs in 350 400 kg cm ala la e 5 8 15 88 mm Approx 520 560 Ibs in 600 650 kg cm 1 2 12 7 mm Approx 430 470 Ibs in 500 550 kg cm fan y I k Insulation 5 5 Insulation of Refrigerant Tubing Fig 48 IMPORTANT To prevent heat loss and wet floors due to dripping of con oN densation both tubes must be well insulated with a prop er insulation material Fig 48 The thickness of the insula n 7 in Thick tion should be a minimum 5 16 8 mm Fig 49 A n e aA A N CAUTION After a tube has been insulated never try to bend it into a narrow curve as this may cause the tube to Fig 49 break or crack 5 6 Taping the Tubes a Atthis time the 2 refrigerant tubes and electrical wire if local codes permit should be taped together with armor ing tape The drain hose may also be included and taped togeth
21. ing Instructions for the Outdoor Unit 5 REFRIGERANT TUBING 16 5 1 5 2 5 3 5 4 5 5 5 6 85264189593004 SANYO 2002 Chatsworth CA 91311 U S A Use of the Flaring Method Flaring Procedure with a Flare Tool Caution before Connecting Tubes Tightly Connecting Tubing between Indoor and Outdoor Units Insulation of Refrigerant Tubing Taping the Tubes SANYO FISHER COMPANY E Pump Down REMOTE CONTROL UNIT INSTALLATION POSITION jo ctl einen 22 7 1 Mounting on a Wall A N IMPORTANT Power source for C0951 CL0951 C1251 and CL1251 is 60 Hz single phase 115V In Canada SANYO Canada Inc A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent Concord 21605 Plummer Street Ontario L4K 5C7 Canada 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 electrical codes Pay close attention to all warning and caution notices given in this manual This symbol refers to a hazard or unsafe practice which can result in severe personal injury or
22. ll the way to close the service valve Be sure to confirm that the wide tube ser vice valve is fully open Press the operation button and start cooling opera tion 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 hoses and replace the bonnets and the valve caps as they were before 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 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 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 7 1 Mounting on a Wall Truss head 1 Confirm the indoor unit beeps when the tapping screw ON OFF button is pressed at the wall location SIS SNA x Temm SURP Iec where the remote control unit is to be attached then attach the holder to the wall Fig 56 2 When taking out the remote control unit pull it from the holder Remote M When using the remote control unit control N unit holder Ss e Point the transmission portion of the remote F c
23. ns on the air conditioner can cut your fingers When Installing 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 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 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 e Clean up the site after you finish remembering to
24. o install the unit properly Fig 14 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 in 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 Cut at slight angle Fig 11 INSIDE OUTSIDE Wall Plastic cover PVC pipe L Slight Say angle 3 16 4 8 mm dia hole 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 as given below How to remove the grille 1 Set the flap in the horizontal position 2 Unscrew the screws Fig 16a or 16b 3 Remove the grille Fig 17 a Hold both corners of the air intake grille then pull out and up to open b Pull the lower part of the grille toward you to remove c Use a standard screwdriver to push up the 3 tabs to remove the grille How to replace the grille 1 Close the flaps 2 Reinstall the grille into the lower part while aligning its tabs on the upper part Fig 18 Insert the tabs in the slots and push the lower part of th
25. ontrol unit at the receiver area of the indoor unit when operating the remote control unit and during operation of the air conditioner e Do not place objects that may block the trans mitted signals between the receiver and the remote control unit When mounting the remote control unit to Truss head prevent theft nae A A 1 Mount the holder to the wall with one of the SAX S B AEX LEMM SUPpIEC screws using only the hole in the top of the holder Fig 57 Remove the cover of the remote control unit and take out the batteries Next place the remote control unit in the holder D 3 Fasten both the remote control unit and holder Holder to the wall with the remaining screw using the hole in the bottom of the holder 4 Install the batteries in the remote control unit and close the cover 22
26. t Length L Difference H Additional Refrigerant Model ft ft ft 0z ft 25 50 23 a 0 16 9 000 BTU 25 65 23 b 0 27 12 000 18 000 BTU f total tubing length becomes a 25 to 50 ft max b 25 to 65 ft max charge additional refrigerant R22 by a 0 16 oz ft b 0 27 oz ft No additional compressor oil is necessary 2 2 Outdoor Unit AVOID e 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 e Install the outdoor unit above snowfall line e Do not place objects on or sit on the out door unit Also never block the air intake outlet or exhaust Distortion of the outdoor unit or incomplete combustion may result e Do not introduce 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 protect the unit against possible water damage and decreased service life Fig 5b use lug bolts or equal to bolt down unit reducing vibration and noise 2 3 Baffle Plate for the Outdoor Unit CLxx models only It is recommended to use baffle plates for models CL1251
27. t are kept closed at this stage 2 Using an adjustable wrench 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 pres sure gauges to the service port on the wide tube service valve Fig 52 CAUTION Be sure to use a manifold valve 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 evacua tion Table 6 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 Indoor unit J Manifold valve Pressure gauge Outdoor unit acs Hi x ado Vacuum pump Fig 52 5 With the vacuum pump still running close the Lo knob of the manifold valve Then stop the vacuum pump 6 Wit
28. tacles enclosures 2 5 em min 6 15cm min 2 5 m min and grilles in front of or surround 6 15 cm min 6 15 cm min ing the air conditioner in a way that may block air flow f KS1852 only Front View AVOID Fig 2 direct sunlight nearby heat sources that may affect performance of the INDOOR Tubing length L unit UNIT areas where leakage of flammable gas may be expected places where large amount of oil mist exist suena OUTDOOR ifference H UNIT DO select an appropriate position from which every corner of Fig 3a the room can be uniformly cooled High on a wall is best select a location that will hold the weight of the unit 9 Mdai select a location where tubing and drain hose have the mean shortest run to the outside Fig 1 For stable operation of allow room for operation and maintenance as well as unre the air conditioner do Minimum height stricted air flow around the unit Fig 2 not install wall mounted from floor level 5 ft 1 5 m type indoor units under 5 ft 1 5 m from floor install the unit within the maximum elevation difference H above the outdoor unit and within a total tubing length L a level Floor level from the outdoor unit as detailed in Table 3 and Fig 3a ati Fig 3b Table 3 Max Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of Length at Shipmen
29. tion of the Service Valves The basic function of the service valves are given in Table 7 below Table 7 Action Narrow Tube Service Wide Tube Service Valve 2 Way Valve 3 Way CLOSED lt O ring er Valve cap Nf Np Stem Shipping r3 Fully OPEN lt gt Operating and test running the air conditioner Fully OPEN Measuring pressure and gas charging Air purging with a vacuum pump ae 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 55 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 21 Service valve Legg Fig 55 valve clockwise a
30. to the required length with a tube cutter It is recommended to cut approx 12 to 20 in 80 to 50 cm longer than the tubing length you estimate b 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 42 When reaming hold the tube end downward and be sure that no copper scraps fall into the tube Fig 43 c Remove the flare nut from the unit and be sure to mount it on the copper tube d Make a flare at the end of copper tube with a flare tool Fig 44 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 lubricant to the match ing surfaces of the flare and union before connect ing them together This is effective for reducing gas leaks Fig 45 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 46 Before Deburring After KASAI Fig 42 ee Copper tubing Flare tool Fig 44 Apply refrigerant lubricant
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