Sanyo Cl1251 User Manual

INSTALLATION INSTRUCTIONS  
– Split System Air Conditioner –  
COOL/DRY Model  
Contents  
Model Combinations  
Page  
Combine indoor and outdoor units only as listed  
below.  
IMPORTANT!  
Please Read Before Starting .................................. 2  
Indoor Units  
Outdoor Units  
C0951  
1. GENERAL .......................................................... 3  
1-1. Tools Required for Installation (not supplied)  
1-2. Accessories Supplied with Unit  
KS0951  
CL0951  
1-3. Optional Copper Tubing Kit  
KS1251  
C1251  
1-4. Type of Copper Tube and Insulation Material  
1-5. Field Wiring  
CL1251  
Power Source:  
1-6. Additional Materials Required for Installation  
60 Hz, single-phase, 115 V  
2. INSTALLATION SITE SELECTION ................... 4  
2-1. Indoor Unit  
KS1852  
C1852  
2-2. Outdoor Unit  
CL1852  
2-3. Baffle Plate for the Outdoor Unit  
Power Source:  
60 Hz, single-phase, 230/208 V  
3. HOW TO INSTALL THE INDOOR UNIT ............ 6  
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  
3-6. Wiring Instructions  
5-7. Finishing the Installation  
3-7. Recommended Wire Length and Diameter  
3-8. Wiring Instructions for Inter-unit Connections  
3-9. Mounting  
6. AIR PURGING................................................... 18  
I Air Purging with a Vacuum Pump (for Test Run)  
I Basic Function of the Service Valves  
I Pump Down  
3-10. Drain Hose  
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 15  
7. REMOTE CONTROL UNIT INSTALLATION  
POSITION ......................................................... 22  
7-1. Mounting on a Wall  
4-1. Wiring Instructions for the Outdoor Unit  
5. REFRIGERANT TUBING.................................. 16  
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  
IMPORTANT  
Power source for C0951, CL0951, C1251 and  
CL1251 is 60 Hz, single-phase 115V.  
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  
85264189593004 © SANYO 2002 Chatsworth, CA 91311 U.S.A.  
W
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.  
5. Carpenter’s level  
6. Sabre saw or key hole saw  
7. Hacksaw  
8. Core bits  
9. Hammer  
10. Drill  
1-1. Tools Required for Installation (not supplied)  
1. Standard screwdriver  
11. Tube cutter  
12. Tube flaring tool  
13. Torque wrench  
14. Adjustable wrench  
15. Reamer (for deburring)  
2. Phillips head screwdriver  
3. Knife or wire stripper  
4. Tape measure  
1-2. Accessories Supplied with Unit  
Table 1  
Parts  
Figure  
Q’ty  
Parts  
Figure  
Truss-head  
Phillips  
5/32 × 5/8" (4 × 16 mm)  
Q’ty  
Parts  
Remote  
Figure  
Q’ty  
Tapping  
screw  
Rawl plug  
12  
12  
1
control unit  
Remote  
control  
holder  
AAA alkaline  
battery  
Drain hose  
adapter  
1
2
1
1
Hex  
wrench*  
* Packed in the outdoor unit.  
1-3. Optional Copper Tubing Kit  
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).  
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.  
1-5. Field Wiring  
1-4. Type of Copper Tube and Insulation Material  
Use insulated copper wire for field wiring. Wire size  
varies with the total length of wiring. Refer to 3-6. Wiring  
Instructions for details.  
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.  
Check local electrical codes  
and regulations before  
obtaining wire. Also, check  
any specified instructions or  
limitations.  
CAUTION  
When cutting tubing, add approximately 12” to 16”  
(30 cm to 40 cm) to each tube length to reduce  
vibration between the air conditioning units.  
Table 2  
Narrow Tube  
Wide Tube  
Model  
Outer Dia.  
Thickness  
Outer Dia.  
Thickness  
6.35 mm (1/4")  
6.35 mm (1/4")  
6.35 mm (1/4")  
0.8 mm (0.0314")  
0.8 mm (0.0314")  
0.8 mm (0.0314")  
9.52 mm (3/8")  
12.7 mm (1/2")  
0.8 mm (0.0314")  
0.8 mm (0.0314")  
C0951, CL0951  
C1251, CL1251  
C1852, CL1852  
15.88 mm (5/8") 1.0 mm (0.0394")  
3
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-  
WARNING  
tion and the possibility of fire, do  
2" (5 cm) min.  
*6" (15 cm) min.  
not place obstacles, enclosures  
and grilles in front of or surround-  
ing the air conditioner in a way that  
may block air flow.  
2" (5 cm) min.  
*6" (15 cm) min.  
2" (5 cm) min.  
*6" (15 cm) min.  
Front View  
*KS1852 only  
AVOID:  
Fig. 2  
I direct sunlight.  
Tubing length (L)  
I nearby heat sources that may affect performance of the  
INDOOR  
UNIT  
unit.  
I areas where leakage of flammable gas may be expected.  
Elevation  
difference (H)  
I places where large amount of oil mist exist.  
OUTDOOR  
UNIT  
DO:  
I select an appropriate position from which every corner of  
Fig. 3a  
the room can be uniformly cooled. (High on a wall is best.)  
I select a location that will hold the weight of the unit.  
CAUTION  
Indoor unit  
Wall  
I select a location where tubing and drain hose have the  
shortest run to the outside. (Fig. 1)  
For stable operation of  
the air conditioner, do  
not install wall-mounted  
type indoor units under  
5 ft. (1.5 m) from floor  
level.  
I allow room for operation and maintenance as well as unre-  
Minimum height  
from floor level  
5 ft. (1.5 m)  
stricted air flow around the unit. (Fig. 2)  
I install the unit within the maximum elevation difference (H)  
above the outdoor unit and within a total tubing length (L)  
from the outdoor unit as detailed in Table 3 and Fig. 3a.  
Floor level  
Fig. 3b  
Table 3  
Max. Allowable Tubing  
Length at Shipment  
(ft.)  
Limit of Tubing  
Length (L)  
(ft.)  
Limit of Elevation  
Difference (H)  
(ft.)  
Required Amount of  
Additional Refrigerant  
(oz./ft.)*  
Model  
25  
25  
50  
65  
23  
23  
a) 0.16  
b) 0.27  
9,000 BTU  
12,000/18,000 BTU  
* If 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.  
4
2-2. Outdoor Unit  
Exhaust fan  
NO  
AVOID:  
Hot air  
I heat sources, exhaust fans, etc. (Fig. 4)  
I damp, humid or uneven locations.  
DO:  
Heat source  
Outdoor unit  
I choose a place as cool as possible.  
I choose a place that is well ventilated.  
I allow enough room around the unit for air intake/  
Fig. 4  
exhaust and possible maintenance. (Fig. 5a)  
Obstacle above  
CAUTION  
Min.  
Min.  
7 ft.  
(2 m)  
7 ft.  
Air intake  
Min. 6" (15 cm)  
Valve side  
Min. 10"  
(25 cm)  
(2 m)  
I Install the outdoor unit above snowfall line.  
I 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.  
Min. 6"  
(15 cm)  
Air discharge  
Min. 12"  
(30 cm)  
Ground  
Min. 6 in.  
(15 cm)  
Air intake  
I Do not introduce foreign matter into the air  
intake/outlet or exhaust. Do not poke them  
with such objects as a stick.  
Fig. 5a  
Anchor bolts  
(4 pcs)  
I provide a solid base (level concrete pad, concrete  
block, 4 in. × 16 in. (10 × 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).  
Min. 4"  
(10 cm)  
Air intake  
Concrete  
I use lug bolts or equal to bolt down unit, reducing  
or equal  
vibration and noise.  
2-3. Baffle Plate for the Outdoor Unit  
(CL×× models only)  
NOTE  
Fig. 5b  
It is recommended to use baffle plates for models  
CL1251, CL1852 and CL0951. The baffle plates are not  
normally required for the other models.  
6" min  
Baffle  
plate  
Baffle  
plate  
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 discharge  
Fig. 5c  
5
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 I marks on the frame cover and disengage the sta-  
tionary tabs from the frame. (Fig. 7)  
(3) Remove the rear panel.  
Set screw only for transportation  
NOTE  
Fig. 6  
Tubing can be extended in 5 directions (KS0951, KS1251 and  
KS1852) as shown in Fig. 8a or 8b. Select the direction you need  
providing the shortest run to the outside unit.  
Rear panel  
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-  
ters 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  
I marks  
(2) Determine which side of the unit you should make the hole for  
tubing and wiring. (Fig. 9)  
KS0951, KS1251  
Right-rear  
tubing  
(recommended)  
(3) Before making the hole, check carefully that no studs or pipes  
are directly run behind the spot to be cut.  
Left  
tubing  
CAUTION  
Left-rear  
tubing  
Right tubing  
Fig. 8a  
I Also avoid areas where electrical wiring or conduits are  
Downward tubing  
located.  
KS1852  
I Switching drain hose and drain cap  
Left  
tubing  
(a) Locate the drain hose and the drain cap. (Fig. 8c)  
Right-rear  
tubing  
(recommended)  
(b) Remove the drain hose on the right side by pushing and  
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-  
ers.)  
Right tubing  
Fig. 8b  
Downward tubing  
(d) Reattach the drain hose to the left side and the drain cap  
to the right side. (Fig. 8c)  
The above precautions are also applicable if tubing goes through the  
wall in any other location.  
Drain hose  
In case of right-rear  
Clamp  
To slip on  
Drain cap  
60°  
To remove  
Fig. 9  
Fig. 8c  
6
(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.  
NOTE  
Hole should be made at a slight downward slant to the  
outdoor side.  
Table 4  
Indoor  
side  
Outdoor  
side  
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)  
Fig. 10  
PVC pipe (locally purchased)  
(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  
Cut at slight angle  
Be sure to confirm that the wall is strong enough to sus-  
pend the unit.  
Fig. 11  
INSIDE  
OUTSIDE  
See either Item a) or b) below depending on the wall type.  
Wall  
Plastic  
cover  
a) If Wooden Wall  
PVC pipe  
Slight  
angle  
(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.  
Fig. 12  
(2) Double check with a ruler or carpenters level that  
the panel is level. This is important to install the unit  
properly. (Fig. 14)  
Fig. 13  
Fig. 14  
(3) 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)  
3/16" (4.8 mm)  
dia. hole  
Rawl plug  
Fig. 15  
7
3-4. Remove the Grille to Install the Indoor Unit  
KS0951, KS1251  
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)  
Screw cover  
Flap  
(Up and down air direction louvre)  
Fig. 16a  
(a) Hold both corners of the air intake grille, then  
pull out and up to open.  
KS1852  
(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.  
Fig. 16b  
(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 the grille back  
into position.  
Air intake grille  
(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)  
Fig. 17  
Fig. 18  
Fig. 19  
8
3-5. Shape the Indoor Side Tubing  
1) Arrangement of tubing by directions  
a) Right or left tubing  
Frame  
Cut out the corner of the right/left frame with a  
hacksaw or the like. (Figs. 20 and 21)  
Left tubing  
outlet  
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:  
Fig. 20  
Hang the 2 mounting slots of the unit on the  
upper tabs of the rear panel. (Fig. 22)  
Frame  
3-6. Wiring Instructions  
General precautions on wiring  
Right tubing  
outlet  
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 cir-  
cuit breaker for overcurrent protection provided in  
the exclusive line.  
Fig. 21  
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.  
Fig. 22  
5) Do not allow wiring to touch the refrigerant tubing,  
compressor, or any moving parts of the fan.  
6) Unauthorized changes in the internal wiring can be  
very dangerous. The manufacturer will accept no  
responsibility for any damage or misoperation that  
occurs as a result of such unauthorized changes.  
9
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.  
WIRING SYSTEM DIAGRAM  
C0951, CL0951, C1251, CL1251 Models  
INDOOR  
NOTE  
OUTDOOR UNIT  
Terminal  
INDOOR UNIT  
Terminal  
(Inter-unit)  
Power lines  
Refer to the wiring system diagram (Fig. 23)  
115V  
115V  
115V  
Refer to your local codes or in the absence of local  
codes with the National Electric Code: ANSI/NFPA70.  
1
2
3
1
Fuse  
2
3
4
Disconnect  
switch  
(Field supply)  
L
N
5
6
WARNING  
G
G
Grounding  
line  
I 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.).  
C1852, CL1852 Models  
I Each wire must be firmly connected.  
INDOOR  
I No wire should be allowed to touch refrigerant  
tubing, the compressor, or any moving part.  
OUTDOOR UNIT  
INDOOR UNIT  
Terminal  
(Inter-unit)  
Power lines  
Terminal  
1
230/208 V  
230/208 V  
230/208 V  
1
2
3
Fuse  
2
3
4
5
6
WARNING  
Disconnect  
switch  
(Field supply)  
L1  
L2  
I To avoid the risk of electric shock, each air  
conditioner unit must be grounded.  
G
G
Grounding  
line  
CAUTION  
Fig. 23  
I 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.  
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.)  
Rear  
panel  
Wall  
Plastic  
cover  
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)  
Wiring  
Never fix the wiring by any  
10 in.  
(25 cm)  
CAUTION  
means before the indoor unit  
is fully seated on the rear  
panel.  
Fig. 24  
10  
c) Remove the screws to open the cover plate secur-  
ing the electrical component box. (Figs. 25a, 25b,  
25c and 25d)  
KS0951, KS1251  
KS0951, KS1251  
Cover  
plate  
Electrical  
component box  
Cover  
plate  
d) Insert the wrapped tubing into the hole in the wall.  
e) 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.  
Terminal  
plate  
Earth plate  
Electrical  
component box  
g) Remove the lock nut from the conduit connector.  
Insert the conduit connector through 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.  
Fig. 25b  
Fig. 25a  
KS1852  
KS1852  
Electrical  
component box  
Cover  
plate  
Cover  
plate  
Terminal  
plate  
Earth plate  
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.)  
Electrical  
component box  
Fig. 25c  
KS0951, KS1251  
Fig. 25d  
WARNING  
Top of conduit  
connector  
KS1852  
I 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.  
Earth  
plate  
Screw  
Screw  
hole  
I Check local electrical codes and any specified  
wiring instructions or limitations.  
Fig. 26a  
KS0951, KS1251  
i) Fix cover plate and cover plate and back into posi-  
tion with their screws.  
Fig. 26b  
Inter-unit  
wiring  
NOTE  
Earth  
plate  
KS1852  
When closing the air intake grille, press on both corners  
and the center. (Fig. 27)  
Lock nut  
Inter-unit  
wiring  
Top of conduit  
connector  
Earth  
plate  
Lock  
nut  
Fig. 26c  
Top of conduit  
connector  
Fig. 27  
Fig. 26d  
11  
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.  
WARNING  
When connecting each power wire to the corresponding termi-  
nal, follow the instructions How to connect wiring to the termi-  
naland fasten the wire securely tight with the fixing screw of  
the terminal plate.  
9/32" (7 mm)  
(ACTUAL  
SIZE)  
STRIP  
SIZE  
Fig. 28  
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.  
Solid wire  
Loop  
(2) Using a screwdriver, loosen the terminal screw on the ter-  
minal plate.  
Insulation  
(3) Insert the wire and tighten the terminal screw completely  
using a screwdriver.  
Fig. 29  
Stranded wire  
b) For Outdoor Unit  
Ring  
Connector  
I 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)  
Fig. 30  
(2) Using a screwdriver, remove the terminal screw(s) on the  
terminal plate.  
Twist wire ends  
(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.  
I For stranded wiring  
Fig. 31  
(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)  
Special  
washer  
Screw  
(2) Using a screwdriver, remove the terminal screw(s) on the  
terminal plate.  
Screw and  
special washer  
Ring connector  
Terminal plate  
(3) Using a ring connector fastener or pliers, securely clamp  
each stripped wire end with a ring connector. (Fig. 30)  
Ring  
connector  
Wire  
(4) Place the ring connector wire, and replace and tighten the  
removed terminal screw using a screwdriver. (Fig. 32)  
Wire  
Fig. 32  
12  
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)  
Push  
NOTE  
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)  
I Right-side tubing  
(1) Shape the refrigerant tubing so that it can easily go  
into the wall hole. (Fig. 35)  
Stand  
Fig. 34  
(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)  
Rear panel  
Cover  
(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 wont  
stain the wall.  
Refrigerant  
tubing  
Inter-unit  
wiring  
Drain hose  
(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.  
Fig. 35  
(5) Assemble the refrigerant tubing, drain hose, and  
conduit (including inter-unit wiring) as shown in  
Fig. 37b.  
Fig. 36  
Refrigerant tubing  
Insulation  
Fig. 37a  
Conduit  
Drain hose  
Inter-unit wiring  
Fig. 37b  
13  
To unmount indoor unit  
Press the 2 I 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) Never form a trap in the course of the hose.  
c) If the drain hose will run in the room, insulate the  
hose with insulation* so that chilled condensation  
will not damage furniture or floors. (Fig. 40)  
Push  
Fig. 38  
* Foamed polyethylene or its equivalent is recom-  
mended.  
Slant  
Do not supply power to the  
unit or operate it until all  
tubing and wiring to the  
outside unit are completed.  
WARNING  
Indoor  
unit  
Drain  
hose  
Fig. 39  
Risk of Electric Shock  
Condensation  
Insulation material  
(locally purchased)  
must be used.  
Fig. 40  
14  
4. How to Install the Outdoor Unit  
Terminal  
block  
Lock nut  
First refer to Section 2. Installation Site Selection.  
4-1. Wiring Instructions for the Outdoor Unit  
Access panel  
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.  
Conduit  
plate  
(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.  
Plug  
Power supply  
Inter-unit line  
(4) When connections are completed, check that all connec-  
tions are correct as shown in the wiring system diagram  
on panel side.  
Fig. 41  
(5) Be sure to ground the unit according to your local codes.  
CAUTION  
I Examples of Incorrect Wiring  
The following are examples of improper wiring that result in system misoperation. You should confirm that you have  
wired the units correctly before beginning the test run.  
Problem 1  
Problem 2  
Short circuit will occur after approx.  
3 minutes and the power circuit fuse  
blows.  
I
Air conditioner will not operate.  
I
Disconnect  
(A)  
Disconnect  
(B)  
Disconnect  
switch  
(C)  
switch  
switch  
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
G
G
G
G
G
G
Grounding line  
Grounding line  
Grounding line  
Outdoor unit  
Outdoor unit  
Outdoor unit  
Indoor unit  
Indoor unit  
Indoor unit  
Problem 3  
Compressor will not start; only indoor unit will operate.  
I
Disconnect  
switch  
Disconnect  
switch  
(D)  
(E)  
1
2
3
1
2
3
1
2
3
1
2
3
G
G
G
G
Grounding line  
Grounding line  
Outdoor unit  
Outdoor unit  
Indoor unit  
Indoor unit  
15  
5. Refrigerant Tubing  
Deburring  
After  
Before  
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 to the required length with a  
tube cutter. It is recommended to cut approx. 12 to  
20 in. (30 to 50 cm) longer than the tubing length  
you estimate.  
Fig. 42  
Copper  
tubing  
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)  
Reamer  
NOTE  
When reaming, hold the tube end downward and be  
sure that no copper scraps fall into the tube. (Fig. 43)  
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)  
Flare nut  
Copper  
tubing  
(*Use RIGIDor equivalent.)  
NOTE  
A good flare should have the following characteristics:  
I inside surface is glossy and smooth.  
I edge is smooth.  
Flare tool  
Fig. 44  
I 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.  
Apply refrigerant  
lubricant here and here  
Fig. 45  
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)  
Flare nut  
Union  
Fig. 46  
16  
5-4. Connecting Tubing between Indoor and  
Outdoor Units  
Torque wrench  
a) Tightly connect the indoor side refrigerant tubing extend-  
ed from the wall with the outdoor side tubing. (Fig. 47)  
Spanner  
Indoor unit  
b) To fasten the flare nuts, apply specified torque as:  
Table 5  
Outdoor unit  
Tube Dia.  
Tightening Torque  
Approx. 130 170 lbs. in. (150 200 kg cm)  
Fig. 47  
1/4" (6.35 mm)  
3/8" (9.52 mm)  
1/2" (12.7 mm)  
5/8" (15.88 mm)  
·
·
Approx. 300 340 lbs. in. (350 400 kg cm)  
·
·
Approx. 430 470 lbs. in. (500 550 kg cm)  
·
·
Approx. 520 560 lbs. in. (600 650 kg cm)  
·
·
Insulation  
5-5. Insulation of Refrigerant Tubing  
IMPORTANT  
Fig. 48  
To prevent heat loss and wet floors due to dripping of con-  
densation, both tubes must be well insulated with a prop-  
er insulation material. (Fig. 48) The thickness of the insula-  
tion should be a minimum 5/16" (8 mm). (Fig. 49)  
Insulation  
Thickness:  
min. 5/16" (8 mm)  
Min.  
5/16" (8 mm)  
After a tube has been insulated,  
CAUTION  
never try to bend it into a narrow  
curve, as this may cause the tube to  
break or crack.  
Fig. 49  
5-6. Taping the Tubes  
a) At this 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  
together as 1 bundle with the tubing.  
Clamp  
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)  
Fig. 50  
c) Clamp tubing bundle to wall, using 1 clamp approx. every  
47 in. (120 cm).  
Apply putty here  
NOTE  
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.  
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)  
17  
6. Air Purging  
Indoor unit  
Air and moisture remaining in the refrigerant system have  
undesirable effects as indicated below. Therefore, they must  
be purged completely.  
I pressure in the system rises  
I operating current rises  
Outdoor unit  
I cooling (or heating) efficiency drops  
I moisture in the air may freeze and block capillary tubing  
I water may lead to corrosion of parts in the refrigerant sys-  
tem  
I 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 unit are kept closed at this stage.  
Manifold valve  
(2) Using an adjustable wrench or box wrench, remove the  
valve caps from the service valve on both narrow and  
wide tubes.  
Pressure  
gauge  
Lo  
Hi  
(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)  
Be sure to use a manifold valve for  
CAUTION  
air purging. If it is not available, use  
a stop valve for this purpose. The  
Hiknob of the manifold valve  
must always be kept closed.  
(4) With the Loknob 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:  
Vacuum pump  
Fig. 52  
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  
NOTE  
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.  
18  
(5) With the vacuum pump still running, close the Lo”  
knob of the manifold valve. Then stop the vacuum  
pump.  
90° (1/4 turn)  
Narrow tube  
(6) With 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)  
Hex wrench  
Wide tube  
Be sure to completely insert  
CAUTION  
Valve cap  
the hex wrench before  
Vacuum hose to manifold valve  
attempting to turn the valve.  
Fig. 53  
(7) Leak test all joints at the tubing (both indoor and  
outdoors) with liquid soap. Bubbles indicate a leak.  
Be sure to wipe off the soap with a clean cloth.  
(8) With the hex wrench, turn the wide tube service  
valve stem counter-clockwise to fully open the  
valve.  
(9) Turn the narrow tube service valve stem counter-  
clockwise to fully open the valve.  
(10) Loosen the vacuum hose connected to the wide  
tube service port slightly to release the pressure.  
Then, remove the hose.  
(11) 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 lbs.in. (200 kgcm)). 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 a vacuum pump and  
the air conditioner is ready for actual operation.  
19  
* How to Test Run the Air Conditioner.  
KS0951, KS1251  
(1) Switch on the power source.  
(2) Press the ON/OFF button on the remote control  
unit once.  
ON  
OFF  
TEST  
(3) 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)  
(4) 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.  
(5) After stopping the test run, turn the operation  
selector switch of indoor unit to the OFF position  
once, then move to ON position.  
OPERATION  
TIMER  
(6) Press the ON/OFF button on the remote control  
unit to stop the air conditioner.  
NOTE  
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.  
Fig. 54a  
KS1852  
Operation  
selector  
switch  
ON  
OFF  
TEST  
Fig. 54b  
20  
I Basic Function of the Service Valves  
The basic function of the service valves are given in Table 7 below.  
Table 7  
Narrow Tube Service  
Valve (2-Way)  
Wide Tube Service  
Valve (3-Way)  
Action  
O-ring  
Valve cap  
Stem  
CLOSED  
Shipping  
Fully OPEN  
Fully OPEN  
CLOSED  
Operating and  
test running  
the air conditioner  
Measuring pressure  
and gas charging  
*
Air purging with  
a vacuum pump  
*
* 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)  
Service valve  
Hose with push-pin  
PUSH  
Fig. 55  
I Pump Down  
valve clockwise all the way to close the service  
valve. (Be sure to confirm that the wide tube ser-  
vice valve is fully open.)  
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.  
(3) Press the operation button and start cooling opera-  
tion.  
Pump Down Procedure  
(4) When the low pressure gauge reading falls to 1 to  
0.5 kg/cm2 (14.2 to 7.1 PSI), fully close the wide  
tube valve stem with a standard screwdriver. Then  
quickly stop the unit.  
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.  
(5) Disconnect all gauges and hoses, and replace the  
bonnets and the valve caps as they were before.  
(2) Using a hex wrench, turn the narrow tube service  
21  
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:  
I In direct sunlight  
I Behind a curtain or other place where it is covered  
I More than 26 ft. (8 m) away from the air conditioner  
I In the path of the air conditioners airstream  
I Where it may become extremely hot or cold  
I Where it may be subject to electrical or magnetic  
interference  
7-1. Mounting on a Wall  
Truss-head  
tapping screw  
5/32 × 5/8" (4 × 16mm supplied)  
1) Confirm the indoor unit beeps when the  
ON/OFF button is pressed at the wall location  
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  
control  
unit holder  
When using the remote control unit  
Point the transmission portion of the remote  
control unit at the receiver area of the indoor  
unit when operating the remote control unit,  
and during operation of the air conditioner.  
Fig. 56  
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  
prevent theft  
Truss-head  
tapping screw  
5/32 × 5/8" (4 × 16mm supplied)  
1) Mount the holder to the wall with one of the  
screws (using only the hole in the top of the  
holder) (Fig. 57).  
Holder  
2) Remove the cover of the remote control unit  
and take out the batteries. Next, place the  
remote control unit in the holder.  
3) Fasten both the remote control unit and holder  
to the wall with the remaining screw (using the  
hole in the bottom of the holder).  
Holder  
Fig. 57  
4) Install the batteries in the remote control unit  
and close the cover.  
22  

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