Sanyo CM2472 Air Conditioner
Contents
1. A top of the outdoor unit 14 not provided LL Ke i Indoor unit B LEIT CEL CELI Label A A Im B is the indoor unit with refrigerant tubing that is Terminal board connected to service valve 3 B top of the outdoor unit Inter unit cables 14 not provided Indoor unit C C is the indoor unit with refrigerant tubing that is II Terminal board connected to service valve C top of the outdoor unit Inter unit cables 14 not provided Indoor unit D D is the indoor unit with refrigerant tubing that is Terminal board Power supply conduit Power Single phase 230 208VAC 60HZ Power switch not provided Ground Power cable not provided 12 Less than 85 ft Be sure to perform grounding e Attach a ground wire to either the outdoor unit or indoor unit e If there is a grounding terminal inside the room use the grounding screw inside the indoor unit connected to service valve D top of the outdoor unit i Inter unit cables Label 14 not provided e Be sure to apply the provided labels to both ends of the inter unit cables to prevent mis wiring The units will not function if the wiring connections are incorrect I2. 3 8 9 52mm D 4 i 1 4 6 35 6 35mm 3 8 9 52mm c 4 1 4 6 35 6 35mm eg Som B Li Ls F635 6 35mm 3 g 9 52mm GE A LA i a 1 4 6 35mm Flare 1 2 12 70mm Union 3 8 9 52mm L J 1 2 12 70mm 3 8 9 52mm Supplied Reducer Fig 4g Outdoor unit Indoor unit 3 8 9 52mm D J i 1 4 6 35 PD eg Szen Cl 4 Ce i d EM JA 6 3SMM eg 52mm B o S m 1 4 6 35mm 412 2gem Al 9 0 LC 1 4 6 35mm Flare 1 2 12 70mm Union 3 8 9 52mm L J 1 2 12 70mm 3 8 9 52mm Supplied Reducer Fig 4h Outdoor unit Indoor unit 3 8 9 52mm 3 8 9 52mm 1 2 12 70mm 1 2 12 70mm 3 8 9 52mm D mrem TT V4 6 35mm 3 8 9 52mm CO 1 4 6 35 635mm 4 2 12 70mm B 9 q D 1 4 6 35mm 1 2 12 70mm Al 9 q 1 4 6 35mm Fig 4i KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1 272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS1872 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS1872 KMS1872 Outdoor unit D 3 8 9 52mm c 3 8 9 52mm B 1 2 12 70mm A 1 2 12 70mm Flare 1 2 12 70mm Indoor unit 3 8 9
3. AN e To avoid the risk of electric shock each air conditioner unit must be grounded e 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 e Place a dedicated ground more than 7 2 m away from other grounds and do not have it shared with other electric appliances 20 4 indoor units with CM2472 CLM2472 CM3172 CLM3172 Disconnect switch Field supply 5 G o opu OUTDOOR UNIT Pls Lo 230 208V i DE E oe B Terminal 12P A OJ E 230 208V D S Grounding line i z Or DIe Disconnect 2 switch B G gt kK Field supply el E SSS weis 230 208v MEO oTo 4 B S E 5 1230 208V D ols Lo 9 Sy 230 208V Z B Poo N Grounding line 9 5 Disconnect switch inter unit re Q power line i E Z 230 208V ofo D 6 2 T S A C 230 208V C Lo oi E S Zz a Hi 230 208V B 15 Zo D wn zZ Grounding 96 S line 230 208V 40 iG 5 Disconnect switch a 2D Field suppl Oi es amp i i KE H B E F Z _ de 5 JE T E o
4. 1 4 6 35mm gs Ben KMSO0772 KMS0972 KMS1272 14 63Emm gr Wee KMS0772 KMS0972 KMS1272 mg 4 6 35mm E 8 15 88mm KMS2472 C Outdoor unit Di 0 3 8 9 52mm q c 4 3 8 9 52mm G B 9 3 8 9 52mm g Alg g 1 2 12 70mm GG Flare 1 2 12 70mm 1 4 6 35mm Union 5 8 15 88mm J 1 2 12 70mm 5 8 15 88mm Locally purchased Fig 4e 3 8 9 52mm Indoor unit KMS0772 KMS0972 KMS1272 1 4 6 35mm BEE D Outdoor unit D 4 3 8 9 52mm g c g KMS0772 KMS0972 KMS1272 3 8 9 52mm CH 1 4 6 35mm ao 1 2 12 70mm KMS1872 Re qa 3 8 9 52mm 1 4 6 35mm 5 8 15 88mm A a KMS2472 1 2 12 70mm q Flare 1 2 12 70mm l Union 5 8 15 88mm 1 4 6 35mm Flare 3 8 9 52mm 1 2 12 70mm gt 5 8 15 88mm Locally purchased Union 1 2 12 70mm L 3 8 9 52mm 1 2 12 70mm Locally purchased Fig 4f 3 Connecting indoor unit for CM3172 CLM31 72 A 3 8 9 52mm 3 8 9 52mm 1 2 12 70mm 1 2 12 70mm 3 8 9 52mm 3 8 9 52mm 1 2 12 70mm 1 2 12 70mm Outdoor unit Indoor unit
5. 47 1 ed T Lea 2 15 16 2 1 32 4 1 2 Service valve on narrow tube side Outer diameter 1 4 6 35 Service valve on wide tube side Outer diameter 3 8 9 52 x isp a i etek 2 15 16 4 7 16 Fig 6b A 35 7 16 900 2 29 32 BOBOETOD 35 1 32 890 Fig 6c 11 _ les 32 w Ka D N D 2 13 32 29 3273 lt 23 4 4A 2 1 32 4 1 2 Service valve on wide tube side Outer diameter 1 2 12 70 5 Service valve on narrow tube side Outer diameter 1 4 6 35 Service valve on wide tube side Outer diameter 3 8 9 52 ee EE 2 3 4 2 15 16 LC 2 3 4 lt 2 1 32 4 1 2 5 29 32 2 27 32 4 7 16 Service valve on wide tube side Outer diameter 1 2 12 70 unit inch mm 2 6 Diagram of Outdoor Unit Installation Never install only a single indoor unit Be sure to connect indoor and outdoor units only in combinations that are listed in the catalog or in the combination table that was provided with the outdoor unit Use caution Connecting any other
6. Fig 5a Obstacle above J Min Zoch j t o 1 m Air intake f Min 8 20cm Valve SE side Min 10 25 cm T 2 em 8 K Air discharge Min lt _ e 4 10 cm 1 1 8 50 cm O Fig 5b l g Ground Min 8 20 cm Air intake CU CS Drain holes Fig 5c Anchor bolts 4 pcs ANN NIN OI NK NIK A MM Min 6 15 cm ANN A AN GM Air intake ANN AN ANN ANN Vi Concrete or equal A ANN A ANI A A AN ANN WA ANN ANI AN NK AN SS ANI ANN IN VW Cushion rubber Fig 5e 2 5 Outer Dimensions of Outdoor Unit 1 CM1972 CLM1972 23 15 16 5 11 32 Tas A 35 7 16 900 2 29 12 19 32 13 19 32 14 17 32 29 1 8 740 23 32 2 CM2472 CLM2472 23 15 16 5 11 32 WD 12 19 32 13 19 32 14 17 32 3 CM3172 CLM3172 23 15 16 5 11 32 WER 12 19 32 13 19 32 14 17 32 Fig 6a A 35 7 16 900 gE 2 1 16 29 1 8 740 2 27 32 5 29 32 2 3 4 An 2 27 32 Service valve on narrow tube side Outer diameter 1 4 6 35 Service valve on wide tube side Outer diameter 3 8 9 52
7. 7 CONNECTING A HOME AUTOMATION DEVICE tornen tementen 24 8 INSTALLATION CHECK SHEET 24 SANYO FISHER COMPANY A DIVISION OF SANYO NORTH AMERICA CORPORATION 21605 Plummer Street 85264190214000 SANYO 2006 Model Combinations Combine indoor and outdoor units only as listed below Indoor Unit Outdoor Unit KMS0772 CM1972 KMS0972 CM2472 KMS1272 CM3172 KMS1872 CLM1972 KMS2472 CLM2472 CLM3172 Combine indoor and outdoor units only as listed in the combination tables for 3 room or 4 room outdoor unit as shown in its respective manual Power Source 60 Hz single phase 230 208 VAC Be sure to read the yellow instruction sheet attached to the outdoor unit for models using the new refrigerant R410A Combination example Indoor unit B Indoor unit A Indoor unit C Outdoor unit Indoor unit D The illustrations are based on the typical appearance of a standard model Consequently the shape may differ from that of the air conditioner that you are installing In Canada SANYO Canada Inc 300 Applewood Crescent Concord Ontario L4K 5C7 Canada 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 install
8. the vacuum again 6 With a hex wrench turn the valve stem on the nar row tube service valve counter clockwise by 90 degrees 1 4 turn for 10 seconds and then turn the stem clockwise to close it again AN CAUTION Be sure to completely insert the hex wrench before attempting to turn the valve 7 With a standard screwdriver turn the wide tube service valve stem counterclockwise to fully open the valve 8 Turn the narrow tube service valve stem counter clockwise to fully open the valve 9 Loosen the vacuum hose connected to the wide tube service port slightly to release the pressure Then remove the hose 10 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 If a CFC gas detector is used use a special detector for HFC refrigerant such as R410 and R134a 17 11 Replace the 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 180 beim 200 kgf cm This process is very important to prevent gas from leaking from the system 12 Test run the air conditioner See page 23 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 a
9. is smooth tapered sides are of uniform length 3 4 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 matching surfaces of the flare and union before connecting them together This is effective for reducing gas leaks Fig 12 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 13 3 5 Tubing Connections a Temporary connection Screw in 3 5 rotations by hand Fig 14 b To fasten the flare nuts apply specified torque as ee If the special R410A flare tool is used A 1 0 to 0 0196 0 to 0 5 mm PN SE Copper a tubing 9 Reamer Pa dp SL Fig 9 If the previous flare tool clutch type is used TI AF 0 0472 1 2 mm Adjust so that the amount of tube protrusion is as shown in the figure Fig 10 1 Flare nut Sel Copper Flare tool Apply refrigerant lubricant here and here Fig 11 Table 4 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 mi 5 8 15 88 mm Approx 430 540 Ibs in 490 610 kgf c
10. model may result in operation failure and malfunction Indoor unit D The dimensions indicated by in the figure below are spaces that are required in order to maintain performance Install in a location where the dimensions indicated by gt are ensured and where 2 or more faces of the unit are unobstructed In principle the top direction should be unobstructed Indoor unit C Indoor unit B om os oS Power breaker SS SF Indoor unit A Service space SN IN Uf Nh SS Wf i Im My My a My D YM UM UM WI WU Uy UW I Uf Wn OMME ZL Lf Uf Ensure 6 15cm of space if a drain hose is to be used MM Wf Uf Uy jp yy 1 My II Ip WM Uff Uf Uf mm OM mmm UM Ai MW YW m jj Hf o f W UM WM Uf Uy M ZL Access panel C ae W D gt was Base not provided concrete or similar material Ground Fasten with anchor bolts wire not provided not 3 8 or M10 4 locations provided Fig 7 12 3 Installation Process 3 1 Embedding the Tubing and Wiring Do not connect tubes to locations that are embedded e Be sure to bind refrigerant tubing and inter unit cables together with vinyl tape e The power cable must be obtained on site 12 Less than 85 ft AWG American Wire Gauge e Be sure to apply the provided labels
11. the appropriate lengths 1 to 1 4 any specified instructions or 30 cm to 40 cm to dampen vibration between units limitations Table 2 Narrow Tube Wide Tube Model Outer Dia Thickness Outer Dia Thickness KMS0772 1 4 6 35 mm 0 0314 0 8 mm 3 8 9 52 mm 0 0314 0 8 mm KMS0972 1 4 6 35 mm 0 0314 0 8 mm 3 8 9 52 mm 0 0314 0 8 mm KMS1272 1 4 6 35 mm 0 0314 0 8 mm 3 8 9 52 mm 0 0314 0 8 mm KMS1872 1 4 6 35 mm 0 0314 0 8 mm 1 2 12 70 mm 0 0314 0 8 mm KMS2472 1 4 6 35 mm 0 0314 0 8 mm 5 8 15 88 mm 0 0393 1 0 mm 3 1 5 Additional Materials Required for Installation Refrigeration armored tape Insulated staples or clamps for connecting wire See local codes Putty Refrigeration lubricant Clamps or saddles to secure refrigerant tubing Indoor unit Installation Site Selection Indoor Unit To prevent abnormal heat generation WARNING and the possibility of fire do not place obstacles enclosures and P grilles in front of or surrounding the C ip fo Drain hose air conditioner in a way that may block air flow Outside drainage AVOID Fig 1 direct sunlight nearby heat sources that may affect performance of the 4 6 15 em Se unit 4 cm Gr 2 5 cm areas where leakage of flammable gas may be expected E 1 placing or allowing any obstructions near the A C inlet or YY outlet Front View install
12. 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 3 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 19 15 Torque wrench Spanner Indoor unit Outdoor unit Fig 15 J TT Insulation Fig 16 Insulation ae Thickness Min min 5 16 5 16 8 mm 8 mm Fig 17 Fe Apply putty here Tubing Fig 19 4 Air Purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated below Therefore they must be purged completely Service valve on narrow pressure in the system rises Manifold gauge e operating current rises ox special for R410A i He Service High pressure valve e cooling efficiency drops 5 Low pressure g y arop EE TIE valve Q Vacuum pump e moisture in the air may freeze and block capillary tubing We ng ee adapter side ANS Leave the AO for preventing reverse flow special for SA R410A water may lead to corrosion of parts in the refrigerant system valve open m Air Purging with a Vacuum Pump for Test Run In order to protect the earth s environment be sure to use a vacuum pump to perform the air purge Never perform an air p
13. to both ends of the inter unit cables to prevent miswiring e Securely seal the end of embedded tubing with vinyl tape in order to prevent dirt or moisture entry e In order to prevent insulation breakdown and ground faults do not allow the wire ends to contact rainwater or be subject to dew condensation 3 2 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 3 3 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 8 13 Before ISSS Deburring Fig 8 After WX When reaming hold the tube end downward and be sure that no copper scraps fall into the tube Fig 9 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 10 and 11 Use RIGID or equivalent A good flare should have the following characteristics inside surface is glossy and smooth edge
14. units are operated simultaneously it is not possible to correctly check for errors in tubing and wiring Checking tubing and wiring Perform the test run and check that operation is normal If there is an error in tubing or wiring the refrigerant may flow to indoor unit B when indoor unit A is operated for example e Stop operation immediately if there is an error in tubing or wiring Turn the power breaker to OFF and check whether the inter unit cables are connected incorrectly or whether the narrow tubes A and B are connected in reverse Correct the connections e f there is an error in tubing pump down must be per formed Be sure to perform pump down After making corrections again purge the air from the tubes 23 Lock nut Cabinet Terminal block Tl S Conduit plate o 9 A I Inter unit Power supply Conduit Conduit Access panel C Fig 32 Access panel C Conduit plate Make sure there is no gap between access panel C and the conduit plate Fig 33 7 Connecting a Home Automation device The HA white 4P terminal is located on the indoor unit PCB If a HA device will be used connect it to this terminal 8 Installation Check Sheet The strength of the installation location is sufficient to support the A C weight The indoor and outdoor units are installed level and vertically The p
15. 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 28 and 29 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 28 4 Place the ring connector wire and replace and tighten the removed terminal screw using a screw driver Fig 30 21 9 32 7 mm ACTUAL STRIP SIZE SIZE Fig 26 E Solid wire e O Loop NL d ws y 2 Re Insulation Fig 27 Stranded wire E 5 O e I S Ring a Ch connector oi Ren Ro Fig 28 Twist wire ends gt Fig 29 Special washer S Screw L D Screw and Ring connector special washer 4 Z Ring ES connector ZZ 5 5 Wiring Instructions for the Outdoor Unit e Be sure to correctly align inter unit cables A B C and D Outdoor unit A Terminal board A Lee leie eieiei Indoor unit A SI 2345 6 TO TI 12 z 5 d G lle E Jol dl A is the indoor unit with refrigerant tubing that is Terminal board connected to service valve Inter unit cables
16. 52mm g KMS0772 KMS0972 KMS1272 1 4 6 35mm 3 8 9 52mm KMS0772 KMS0972 KMS1272 1 4 6 35mm 3 8 9 52mm J3 HA KMS0772 KMS0972 KMS1272 1 4 6 35mm 5 8 15 88mm KMS2472 1 4 6 35mm Union 5 8 15 88mm Flare 1 2 12 70mm Union 3 8 9 52mm l J 1 2 12 70mm 5 8 15 88mm Locally purchased Outdoor unit D 3 8 9 52mm c 3 8 9 52mm B 1 2 12 70mm A 1 2 12 70mm 1 2 12 70mm 3 8 9 52mm Supplied Reducer Fig 4j Indoor unit 3 8 9 52mm A KMS0772 KMS0972 KMS1272 L E 1 4 6 35mm 3 8 9 52mm KMS0772 KMS0972 KMS1272 1 4 6 35mm 1 2 12 70mm KMS1872 0 1 4 6 35mm 5 8 15 88mm ote KMS2472 0 N 1 4 6 35mm Flare 1 2 12 70mm Union 5 8 15 88mm L f 1 2 12 70mm 5 8 15 88mm Locally purchased Fig 4k 2 3 Outdoor Unit AVOID e heat sources exhaust fans etc Fig 5a damp humid or uneven locations DO e choose a place as cool as possible e choose a place that is well ventilated allow enough room around the unit for air intake exhaust and possible maintenance Fig 5b provide a solid base level concrete pad concrete block 6 x 1 4 15 x 40 cm beams or equal a min
17. 52mm J L 1 2 12 70mm 3 8 9 52mm Supplied Reducer Fig 4c B Outdoor unit 3 8 9 52mm Indoor unit 9 52mm Ge a 3 8 9 52mm 7 1 4 6 35mm 3 8 9 52mm B a 3 8 9 52mm 1 4 6 35mm eenden A H l 3 8 9 52mm 1 4 6 35mm Flare 3 8 9 52mm Union 1 2 12 70mm L J A joint for connecting tubes of different sizes 3 8 9 52mm 1 2 12 70mm Supplied Reducer Fig 4b 2 Connecting indoor unit for CM2472 CLM2472 A Outdoor unit 3 8 9 52mm Indoor unit 9 52mm Ge 3 8 9 52mm 1 4 6 35mm 3 8 9 52mm Se a 3 8 9 52mm 1 4 6 35mm 3 8 9 52mm Se 3 8 9 52mm a Ta 635mm 3 8 9 52mm Alg B A 1 2 12 70mm 1 4 6 35mm KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS1872 KMSO0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 KMS0772 KMS0972 KMS1272 Outdoor unit 3 8 9 52mm Indoor unit KMS0772 KMS0972 KMS1272 1 4 6 35mm ggr en KMS0772 KMS0972 KMS1272 1 4 6 35mm ggr ee KMS0772 KMS0972 KMS1272 146 4 6 35mm 4 0 42 70mm KMS1872 D 3 8 9 52mm g Cl 0 3 8 9 52mm S B 3 8 9 52mm g A 4 1 2 12 70mm q 1 4 6 35mm Fig 4d 3 8 9 52mm Indoor unit KMS0772 KMS0972 KMS1272
18. SANYO For Outdoor Unit INSTALLATION INSTRUCTIONS Inverter Multi Split System Air Conditioner COOL DRY Model E This air conditioner uses the new refrigerant R410A Contents Page IMPORTANT Please Read Before Starting 2 1 GENERAL oasrsnnersertenersenmernennintdansendeatnseind 3 1 1 Tools Required for Installation not supplied 1 2 Accessories Supplied with Unit 1 3 Optional Copper Tubing Kit 1 4 Type of Copper Tube and Insulation Material 1 5 Additional Materials Required for Installation 2 INSTALLATION SITE SELECTION 4 2 1 Indoor Unit 2 2 Connecting Indoor Units 2 3 Outdoor Unit 2 4 Baffle Plate for the Outdoor Unit CLM models only 2 5 Outer Dimensions of Outdoor Unit 2 6 Diagram of Outdoor Unit Installation 3 INSTALLATION PROCESS 13 3 1 Embedding the Tubing and Wiring 3 2 Use of the Flaring Method 3 3 Flaring Procedure with a Flare Tool 3 4 Caution before Connecting Tubes Tightly 3 5 Tubing Connections 3 6 Insulation of Refrigerant Tubing 3 7 Taping the Tubes 3 8 Finishing the Installation 4 AIR PURGING eenen 16 B Air Purging with a Vacuum Pump for Test Run E Pump Down 5 WIRING INSTRUCTIONS 19 5 1 General Precautions on Wiring 5 2 Recommended Wire Length and Diameter 5 3 Wiring System Diagram 5 4 How to Connect Wiring to the Terminal 5 5 Wiring Instructions for the Outdoor Unit 6 TEST RUN uerge eddie eens 23
19. a 230 208V REN TN 5 co la 230 208V gaya SI Ki E Ee Or E i Grounding B 2 i line E D EE 5 4 How to Connect Wiring to the Terminal JIP 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 follow 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 Cutthe wire end with a cutting pliers then strip the insulation to expose the wire about 9 32 7 mm See the label Fig 26 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 27 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 E For stranded
20. ation 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 WARNING result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can CAUTION resultin 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 WARNING 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 Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequat
21. e grounding can cause accidental injury or death Ground the unit following local electrical codes 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 fins 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 In 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 f
22. e sure to connect power wires correctly match ing up numbers on terminals of the outdoor unit and respective indoor units A D e 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 e Do not run wiring for antenna signal or power lines of television radio stereo telephone secu rity 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 5 3 Wiring System Diagram 3 indoor units with CM1972 CLM1972 Disconnect switch Field supply _ 1 i 5 Loo 230208V__ OUTDOOR UNIT 5 2 230 208V i oe KIO Loo weil Terminal 9P Q E 230 208V Oh S DD Z Grounding 5 Disconnect line B 3 gt switch Field SEN Bens SHE N m7 B 3 E 230 208V a 1 i ATO 4 Sis Q 230 208V es a Q AEO oo Ole 3 QE 230 208V E a II 6 g BOT oro amp E Grounding gt X Disconnect ine a switch Field supply 230 208V D o S E O Ai 230 208V 8 FE 5 A Sl Sa Z 3 2 r oo Ree ne GIELAL LET 230 208V je 2 Q C Ag aiia De eee A A SI z Grounding S ine Terminal PO VW Fig 25a
23. i mum of 6 15 cm above ground level to reduce humidity and protect the unit against possible water damage and decreased service life Figs 5c and 5d e Install cushion rubber under unit s feet to reduce vibration and noise Fig 5e A solid base must not cover the hole of the bottom plate use lug bolts or equal to bolt down unit reducing vibration and noise e Install in a location where no antenna of a television or radio exists within 10 3 m 2 4 Baffle Plate for the Outdoor Unit CLM models only It is recommended to use baffle plates for models CLM1972 CLM2472 and CLM3172 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 Baffle 12 min Baffle plate D plate t 1 he O EI Ge EE E lt N w E lt qm CJ N _ SN Air discharge Fig 5f 10 Z O Exhaust fan Heat source Outdoor unit
24. ing in rooms that contain instant on rapid start Fig 2 fluorescent lamps These may prevent the A C from receiving signals INDOOR Tubing length L1 e places where large amounts of oil mist exist UNIT 1 INDOOR installing in locations where there are devices that Soe UNIT generate high frequency emissions nend H1 OUTDOOR L2 us UNIT EEN DO D E D i H4 INDOOR INDOOR H3 e select an appropriate position from which every corner of UNIT 4 L4 UNIT 3 the room can be uniformly cooled High on a wall is best e select a location that will hold the weight of the unit Fig 3a e select a location where tubing and drain hose have the shortest run to the outside Fig 1 allow room for operation and maintenance as well as Indoor unit unrestricted air flow around the unit Fig 2 For stable operation of the NN Wall e install the unit within the maximum elevation difference air conditioner do not H1 H2 H3 H4 above or below the outdoor unit and install wall mounted type hitimu height within a total tubing length L1 L2 L3 L1 L2 L3 L4 indoor units less than 5 from floor level from the outdoor unit as detailed in Table 3 and Fig 3a 1 5 m from floor level 5 1 5 m Floor level Fig 3b e Install the indoor unit more than 3 3 1 m away from any antenna or power lines or connecting wires used for tele vision rad
25. ing 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 unauthorized changes 5 2 Recommended Wire Length and Diameter Regulations on wiring diameter differ from locality to locality For field wiring requirements please refer to your local elec trical codes Carefully observe these regulations when car rying out the installation Table 6 shows maximum wire lengths for control line and power line and fuse or circuit capacity Refer to the wiring system diagram Fig 25a or 25b for the meaning of A B and C in Table 6 Refer to your local codes or in the absence of local codes see the National Electric Code ANSI NFPA70 Table 6 AWG Max Power Line Length ft Max Control Line Length ft Fuse A B C or Model 12 14 Circuit Capasity CM1972 CLM1972 85 Max 82 Max 20 A CM2472 CLM2472 85 Max 82 Max 20 A CM3172 CLM3172 85 Max 100 Max 20 A 19 AWG American Wire Gauge e Be sure to comply with local codes on running the wire from the indoor unit to the outdoor unit size of wire and wiring method etc e Each wire must be firmly connected e No wire should be allowed to touch refrigerant tubing the compressor or any moving part B
26. io telephone security system or intercom Electrical noise from any of these sources may affect operation e install in a sturdy manner to avoid increased operating noise Table 3 Max Max Allowable Total Limit of Limit of Elevation Required Amount Allowable Tubing Length Total Tubing Length Difference of Additional Model Tubing Length at shipment L1 L2 L3 or H1 H2 H3 H4 Refrigerant per unit L1 L2 L3 or L1 L2 L3 L4 ft oz ft ft L1 L2 L3 L4 ft ft CM1972 CLM1972 82 150 L1 L2 L3 150 L1 L2 L3 50 CM2472 CLM2472 82 150 L1 L2 L3 L4 200 L1 L2 L3 L4 50 0 22 CM3172 CLM3172 100 150 L1 L2 L3 L4 230 L1 L2 L3 L4 50 0 22 If total tubing length becomes 150 to 200 ft Max or 150 to 230 ft Max charge additional refrigerant R410A by 0 22 oz ft No additional charge of compressor oil is necessary 2 2 Connecting Indoor Units 1 Connecting indoor unit for CM1972 CLM1972 3 8 9 52mm Indoor unit 1 4 6 35mm 3 8 9 52mm 1 4 6 35mm 3 8 9 52mm EE A Outdoor unit Sc 3 8 9 52mm q Ge 3 8 9 52mm S A Cf q 3 8 9 52mm 1 4 6 35mm Fig 4a Flare 1 2 12 70mm Union 3 8 9
27. ion Refer to Fig 23 In the winter the outdoor unit may stop after 5 10 minutes of en CH operation This is in order to protect the indoor unit heat Ce exchanger from freezing and does not indicate a problem A Ge vierun per Disconnect the manifold gauge andine ma unit tubes ang Op After discorinecting attach the caps and flare nuts At this point pump down is com B Ce the inter unit tubes pleted If the caps and flare nuts are not reattached there is the Ls alanine fare nuts Cap Ce with flare bonnets S Fig 23 E danger of gas leakage Refer to Fig 24 Sh e If pump down is not possible Cap SE w If the A C cannot be operated because of a malfunction or other cause use a refrigerant recovery device to recover the refrigerant Fig 24 18 a 5 Wiring Instructions 5 1 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 2 Provide a power outlet to be used exclusively for each unit with a power supply disconnect and circuit break er for overcurrent protection provided in the exclusive line 3 To prevent possible hazard due to insulation failure the unit must be grounded 4 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 5 Do not allow wir
28. ir conditioner 15 Wipe off the soap on the tubing This completes air purging with a vacuum pump and the air conditioner is ready for actual operation Pump Down In order to protect the earth s environment be sure to perform pump down to recover refrigerant gas without releasing it into the atmosphere e When relocating or disposing of the A C request this service from the dealer where the unit was purchased or from an appropriate agent Perform pump down as described below EA What is pump down e Pump down refers to recovering the refrigerant gas from the refrig erant cycle at the outdoor unit This work must be performed dur ing cooling operation The refrigerant gas cannot be recovered during heating operation e During winter or if the temperature sensor prevents cooling opera tion perform forced cooling operation Charging port Pump down procedure 1 Fully close the spindles at the valves on the narrow tube side of tubes A B C and D Refer to Fig 22 2 Connect the manifold gauge to the charging port at the valve on the wide tube side of tube D Purge the air from the charging hose Refer to Fig 23 Wide tube side 3 Perform cooling operation or forced cooling operation When the pressure at the low pressure side is 0 15 0 2 MPa 0 5 1 kg cm G fully close the spindles at the valves on the wide tube side of tubes A B C and D and immediately stop operat
29. lare 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 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 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 Do not install only a single indoor unit 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 If the electric wiring diagram does not appear in this manual please check for the diagram on the indoor unit 1 1 Tools Required for Installation not supplied 1 Standard screwdriver 5 Carpenter s level 6 Sabre saw o
30. m Approx 590 710 Ibs in 680 820 kgf cm Service valve on narrow tube side e Gr Service valve on E aie wide tube side 14 Union Flare nut Fig 13 D C B A Apply the provided labels to the indoor and outdoor unit tubing connectors to prevent errors in connections Ne Be sure to match refrigerant tubing and electric wiring between indoor and outdoor units For more details refer to Tubing Check Control in the Technical amp Service Manual 3 6 Insulation of Refrigerant Tubing IMPORTANT To prevent heat loss and wet floors due to dripping of con densation both tubes must be well insulated with a proper insulation material The thickness of the insulation should be a minimum 5 16 8 mm Fig 17 3 7 Taping the Tubes After a tube has been insulated 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 18 3 Clamp the tubing bundle to wall using 1 clamp approx every 47 120 cm Do not wind the armoring tape too
31. nter Unit conduit Fig 31 e Use a dedicated A C circuit for power To make connections to the outdoor unit remove the inspection panel and tubing panel e Do not bring the inter unit cables or power cable into contact with tubing or service valves e Use outdoor unit cable fasteners and fasten the inter unit cables at the location where the cables are double sheathed e Arrange the wiring so that the inter unit cables are con tained in the inspection panel and tubing panel as shown in Fig 31 22 AWG American Wire Gauge Regulations on wire size differ from locality to locality For field wiring requirements please refer to your local electri cal codes Make sure that the installation fully complies with all local and national regulations 1 Remove access panel C Fig 32 2 Connect the inter unit and power supply line accord ing to the drawing on the panel side Be sure to size each wire allowing approx 4 10 cm longer than the required length for wiring Store excess wiring inside the cabinet 3 4 When connections are completed check that all con nections are correct as shown in the wiring system diagram on panel side 5 Be sure to ground the unit according to your local codes 6 Test Run Performing a test run e Refer to the test run procedures in the indoor unit installation manual e Perform the test run separately for each connected indoor unit If 2
32. ower and voltage are as specified Inter unit cables are securely fastened to the terminal board Inter unit cables are securely fixed The power cord and inter unit cables are not connected anywhere along their paths The ground wire is securely connected An air purge of the refrigerant circuit has been conducted A leak test of the tubing connections has been performed Thermal insulation has been applied to the tubing connections Drain connections are secure and water drains properly Putty has been used to close the hole in the wall All service valves are fully open Remote controller signals are being positively received 24
33. pindle Screw diameter 1 2 UNF 20 threads CH Ch Valve cor gt D b SS Na Gr Cap nut tightening torque 60 95 Ibs in 70 110 kgf cm Tighten by hand then use a wrench to turn approximately 30 lt Structure of service valve on wide tube side gt Fig 21 e When using a hex wrench to open the spindle an extremely small amount of refrigerant may leak This does not indicate a problem e Use a hex wrench of a type to which force can be easily applied 4 With the Lo knob of the manifold valve open and high pressure valve Hi closed completely run the vacuum pump Run the pump until the pres sure is 101 kPa 76 cmHg 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 required for evacuation Table 5 Required time for evacuation when capacity of 100 liter h vacuum pump is used 20 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 5 With the vacuum pump still running close the Lo knob of the manifold valve Then stop the vacuum pump Fully close the low pressure valve and stop the vacuum pump Wait 1 2 minutes and check that the manifold gauge pointer does not return If it does return find and repair the leak then apply
34. r key hole saw 7 Hacksaw 8 Core bits 9 Hammer 10 Drill 11 Tube cutter 12 13 Tube flaring tool Torque wrench o Phillips head dri 14 Adjustable wrench a K Oe ea See TVG 15 Reamer for deburring S Se SE ER 16 Vacuum pump For R410A SES 17 Manifold valve 1 2 Accessories Supplied with Unit Table 1 Parts Figure Q ty Parts Figure Q ty Parts Figure Q ty 2472 1 Reducer Hex wrench pf 1 Cushion rubber 4 E Q gt 1 2 x 3 8 hat SSC gt Labels for inter unit Reducer Packed in the outdoor unit SE and iibe AIBIGIID 4 each 3 g x 1 2 A 1972 1 1 3 Optional Copper Tubing Kit 2 Foamed polyethylene insulation for the specified Copper tubing for connecting the outdoor unit to the CORSE as Ane fo prees longt of tubing indoor unit is available in kits which contain the narrow EE and wide tubing fittings and insulation Consult your EE HE nearest sales outlet or A C workshop 3 Use insulated copper wire for field wiring Wire size varies with the total length of wiring 1 4 Type of Copper Tube and Insulation Material Refer to 5 Wiring Instructions for details If you wish to purchase these materials separately from alapa Goure yor Wil nagd 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
35. urge by using the refrigerant gas cylinder or other external gas or by using the gas inside the outdoor unit Hex wrench Charging hose With push pin special for R410A Fig 20 In order to prevent charging errors with A C that uses R410A the screw diameter at the service valve charging port has been changed When recharging or per forming other servicing use the special charging hose and manifold gauge Perform the air purge for tubes A B C and D Use the same procedures for all tubes 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 Using an adjustable wrench or box wrench remove the valve caps from the service valve on both narrow and wide tubes Connect a vacuum pump and a manifold valve with pressure gauges to the service port on the wide tube service valve Fig 20 Before using the vacuum pump adapter read the vacuum pump adapter manual and use the adapter correctly 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 16 Stopper Cap tightening torque 170 215 Ibs in 200 250 kgf cm Tighten by hand then use a wrench to turn S
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