05-423 KHS0971-1271 12/13/05 1:23 PM Page a
INSTALLATION INSTRUCTIONS
COOL/DRY/HEAT Model
– Inverter Split System Air Conditioner –
This air conditioner uses the new refrigerant R410A.
Contents
Model Combinations
Page
Combine indoor and outdoor units only as listed
below.
IMPORTANT!
Please Read Before Starting .................................. 2
Indoor Unit
KHS0971
KHS1271
Outdoor Unit
CH0971
1. GENERAL .......................................................... 3
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
CH1271
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Additional Materials Required for Installation
Power Source:
60 Hz, single-phase, 115 V
2. INSTALLATION SITE SELECTION ................... 4
2-1. Indoor Unit
Be sure to read the yellow instruction sheet
attached to the outdoor unit for models using the
new refrigerant R410A.
2-2. Outdoor Unit
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
7. REMOTE CONTROL UNIT INSTALLATION
POSITION ......................................................... 23
7-1. Mounting on a Wall
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
8. ADDRESS SWITCH.......................................... 24
8-1. Address Setting of the Remote
Control Unit
3-10. Drain Hose
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 16
4-1. Wiring Instructions for the Outdoor Unit
5. REFRIGERANT TUBING.................................. 17
5-1. Use of the Flaring Method
5-2. Flaring Procedure with a Flare Tool
5-3. Caution before Connecting Tubes Tightly
5-4. Connecting Tubing between Indoor and
Outdoor Units
5-5. Insulation of Refrigerant Tubing
5-6. Taping the Tubes
5-7. Finishing the Installation
NOTE
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.
6. AIR PURGING................................................... 19
I Air Purging with a Vacuum Pump (for Test Run)
I Basic Functions of the Service Valves
I Pump Down
In Canada
SANYO FISHER COMPANY
SANYO Canada Inc.
A DIVISION OF SANYO NORTH AMERICA CORPORATION
21605 Plummer Street
300 Applewood Crescent, Concord
Ontario, L4K 5C7, Canada
Chatsworth, CA 91311 U.S.A.
85264189990003 © SANYO 2006
W
05-423 KHS0971-1271 12/13/05 1:23 PM Page 3
1. General
6. Sabre saw or key hole saw
7. Hacksaw
8. Core bits
9. Hammer
10. Drill
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.
11. Tube cutter
1-1. Tools Required for Installation (not supplied)
1. Standard screwdriver
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
5. Carpenter’s level
1-2. Accessories Supplied with Unit
Table 1
Parts
Figure
Q’ty
Parts
Figure
Q’ty
Parts
Figure
Q’ty
Truss-head
Remote
control unit
Tapping screw
Phillips
Hex wrench*
1
10
1
5/32 ¥ 5/8" (4¥16 mm)
Remote control
unit holder
1
8
Clamp
1
Rawl plug
*Packed in the outdoor unit.
Drain hose
adapter
AAA alkaline
battery
2
2
1
4
Cushion
rubber*
Air clean filter
1-3. Optional Copper Tubing Kit
2. Foamed polyethylene insulation for the specified
copper tubes as required to precise length of tubing.
Wall thickness of the insulation should be not less
than 5/16" (8 mm).
Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or A/C workshop.
3. Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring. Refer to 3-6.
Wiring Instructions for details.
1-4. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately from
a local source, you will need:
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
CAUTION
1. Deoxidized annealed copper tube for refrigerant tub-
ing as detailed in Table 2.
Cut each tube to the appropriate lengths 1' to 1'4"
(30 cm to 40 cm) to dampen vibration between units.
Table 2
Narrow Tube
Model
Wide Tube
Outer Dia. Thickness
0.0314" (0.8 mm)
Outer Dia.
Thickness
KHS0971/1271
1/4" (6.35 mm)
0.0314" (0.8 mm)
3/8" (9.52 mm)
3
05-423 KHS0971-1271 12/13/05 1:23 PM Page 4
1-5. Additional Materials Required for Installation
Indoor unit
1. Refrigeration (armored) tape
2. Insulated staples or clamps for connecting wire
(See local codes)
3. Putty
4. Refrigeration lubricant
5. Clamps or saddles to secure refrigerant tubing
Drain hose
2. Installation Site Selection
Outside drainage
2-1. Indoor Unit
Fig. 1
To prevent abnormal heat genera-
tion and the possibility of fire, do
not place obstacles, enclosures
and grilles in front of or surround-
ing the air conditioner in a way
that may block air flow.
WARNING
6" (15 cm)
min.
2" (5 cm)
min.
2" (5 cm)
min.
AVOID:
G direct sunlight.
Front View
G nearby heat sources that may affect performance of the unit.
G areas where leakage of flammable gas may be expected.
G places where large amounts of oil mist exist.
Fig. 2
Tubing length (L)
INDOOR
UNIT
DO:
G select an appropriate position from which every corner of
Elevation
difference (H)
OUTDOOR
UNIT
the room can be uniformly cooled. (High on a wall is best.)
G select a location that will hold the weight of the unit.
G select a location where tubing and drain hose have the
Fig. 3a
shortest run to the outside. (Fig. 1)
G allow room for operation and maintenance as well as unre-
CAUTION
stricted air flow around the unit. (Fig. 2)
Indoor unit
Wall
G install the unit within the maximum elevation difference (H)
above or below the outdoor unit and within a total tubing length
(L) from the outdoor unit as detailed in Table 3 and Fig. 3a.
For stable operation of the
air conditioner, do not
install wall-mounted type
indoor units less than 5'
(1.5 m) from floor level.
Minimum height
from floor level
5' (1.5 m)
G Install the indoor unit more than 3.3' (1 m) away from any
antenna or power lines or connecting wires used for television,
radio, telephone, security system, or intercom. Electrical noise
from any of these sources may affect operation.
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
KHS0971
KHS1271
25
25
50
65
23
23
0.16
0.16
* If total tubing length becomes 25 ft. (max.), charge additional refrigerant (R410A) by 0.16 oz./ft.
No additional charge of compressor oil is necessary.
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 5
2-2. Outdoor Unit
Exhaust fan
NO
Hot air
AVOID:
Heat source
G heat sources, exhaust fans, etc. (Fig. 4)
G damp, humid or uneven locations.
Outdoor unit
DO:
G choose a place as cool as possible.
G choose a place that is well ventilated.
Fig. 4
G allow enough room around the unit for air intake/
exhaust and possible maintenance. (Fig. 5a)
Obstacle above
Min.
G provide a solid base (level concrete pad, concrete
block, 4" ¥ 1'4" (10 ¥ 40 cm) beams or equal), a mini-
mum of 4" (10 cm) above ground level to reduce
humidity and protect the unit against possible water
damage and decreased service life. (Figs. 5b and 5c)
Min.
7' (2 m)
7' (2 m)
Air intake
Min. 2" (5 cm)
Valve
side
Min. 10"
(25 cm)
Min.
2" (5 cm)
Air discharge
Min.
8" (20 cm)
A solid base must not cover
CAUTION
the hole of the bottom plate.
Ground
Min. 2" (5 cm)
Air intake
Fig. 5a
G Install cushion rubber under unit’s feet to reduce
vibration and noise. (Fig. 5d)
Drain holes
G use lug bolts or equal to bolt down unit, reducing
vibration and noise.
G Install in a location where no antenna of a television
or radio exists within 10' (3 m).
Fig. 5b
Anchor bolts
(4 pcs.)
Min. 4" (10 cm)
Air intake
Concrete
or equal
Fig. 5c
Cushion rubber
Fig. 5d
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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 L marks on the frame cover and disen-
gage the stationary tabs from the frame. (Fig. 7)
Set screw only for transportation
(3) Remove the rear panel.
Fig. 6
NOTE
Tubing can be extended in 5 directions as shown in Fig.
8. Select the direction you need providing the shortest
run to the outside unit.
Rear panel
G When left tubing is to be done, switch the drain hose
and drain cap. (For details, refer to “Switching drain
hose and drain cap” on page 14.)
3-2. Make a Hole
(1) Place the rear panel from the indoor unit on the wall
at the location selected. Make sure the panel is hori-
zontal, using a carpenter’s level or tape measure to
measure down from the ceiling. Wait until after cut-
ting the hole before attaching the rear panel to the
wall.
marks
Fig. 7
Right-rear
tubing
(recommended)
Left
tubing
(2) Determine which side of the unit you should make
the hole for tubing and wiring. (Fig. 9)
Left-rear
tubing
Right tubing
NOTE
In the case of left-rear tubing, use the measurement
points 2-3/4" (70 mm) from the edge of the rear panel for
precise placement of the hose outlet. (Fig. 9)
Downward tubing
Fig. 8
(3) Before making the hole, check carefully that no
studs or pipes are directly run behind the spot to be
cut.
2-3/4" (70 mm)
Also avoid areas where elec-
CAUTION
trical wiring or conduits are
located.
The above precautions are also applicable if tubing
goes through the wall in any other location.
Fig. 9
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(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)
(5) Measure the thickness of the wall from the inside
edge to the outside edge and cut PVC pipe at a
slight angle 1/4" (6 mm) shorter than the thickness of
the wall. (Fig. 11)
Fig. 10
PVC pipe (Locally purchased)
(6) Place the plastic cover over the end of the pipe (for
indoor side only) and insert the pipe in the wall. (Fig.
12)
3-3. Install the Rear Panel on the Wall
Cut at slight angle
Be sure to confirm that the wall is strong enough to sus-
pend the unit.
Fig. 11
INSIDE
OUTSIDE
PVC pipe
See either Item a) or b) below depending on the wall type.
Wall
a) If Wooden Wall
Plastic cover
(Locally purchased)
Slight
angle
(1) Attach the rear panel to the wall with the 8 screws
provided. (Fig. 13)
If you are not able to line up the holes in the rear
panel with the beam locations marked on the wall,
use rawl plugs or toggle bolts to go through the
holes on the panel or drill 3/16" (5 mm) dia. holes in
the panel over the stud locations and then mount the
rear panel.
Fig. 12
(2) Double check with a carpenter’s level or tape mea-
sure that the panel is level. This is important to
install the unit properly. (Fig. 14)
Fig. 13
(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" (4.8 mm) dia. holes in the wall. Insert rawl
plugs for appropriate mounting screws. (Fig. 15)
Fig. 14
3/16"
(4.8 mm) dia. hole
Rawl plug
Fig. 15
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Grille
Air intake grille
3-4. Remove the Grille to Install the Indoor Unit
Basically, these models can be installed and wired without
removing the grille. If access to any internal part is need-
ed, follow the steps as given below.
Be sure to wear work gloves
CAUTION
during installation to avoid being
cut by the sharp aluminum fins
of the heat exchanger.
Fig. 16a
How to remove the grille
(1) Grasp both ends of the air intake grille, and remove it
by opening towards the front and pulling towards you.
(Fig. 16a)
Screw cover
(2) Remove the 2 screws. (Fig. 16b)
Fig. 16b
(3) Remove the screw on the right side cover plate and
open the cover. (Fig. 17a)
Cover
Thermistor
(4) Take out the thermistor from the grille. (Fig. 17b)
(5) Pull the lower part of the grille toward you to remove.
(Fig. 18a)
Thermistor
(6) Use a standard screwdriver to push on the tabs to
remove the grille.
Fig. 17b
Fig. 17a
How to replace the grille
Tab
*
(1) Reinstall the grille into the lower part while aligning
its tabs on the upper part. (Fig. 18b) Insert the
tabs in the slots and push the lower part of the
grille back into position.
Grille
Frame
*
(2) Make sure that the grille and frame are firmly fitted
together by engaging the tabs.
Tab
(3) Attach the thermistor on the grille. (Fig. 17a)
Fig. 18a
(4) Close the cover and replace the screw. (Fig. 17a)
(5) Affix the grille with the 2 previously removed
screws. (Fig. 16b)
*
*
(6) Install the air intake grille.
(a) Allow the edge of the air intake grille to slide into
the top of the indoor unit, and then insert it all the
way inside. (Fig. 19a)
(b) Press the bottom right and left corners of the air
intake grille to attach it to the indoor unit. (Fig. 19b)
Fig. 18b
Groove
NOTE
Attach so that the round pins at the top right and left cor-
ners of the air intake grille are inserted into the grooves at
the top right and left of the indoor unit.
Pin
Fig. 19b
Fig. 19a
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3-5. Shape the Indoor Side Tubing
(1) Arrangement of tubing by direction
a) Right or left tubing
Frame
Cut out the corner of the right/left frame with a
Left tubing
outlet
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:
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 hazards 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
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3-7. Recommended Wire Length and Diameter
Regulations on wiring diameter differ from locality to locality. For field wiring
requirements, please refer to your local electrical codes. Carefully observe these
regulations when carrying out the installation.
Table 5 lists recommended wire lengths and diameters for power supply systems.
NOTE
Refer to the wiring system diagram (Fig. 23) for the meaning of (A), (B), and (C) in
Table 5.
Refer to your local codes or in the absence of local codes see the National Elec-
tric Code: ANSI/NFPA70.
Table 5
(A)+(B)
(A) Power Supply Wiring Length (ft)
(B) Power Line Length (ft)
(C) Control
Line Length (ft)
AWG
Fuse or Circuit
Breaker Capacity
Model
(#14)
131 (Max.)
(#12)
(#14)
CH0971, CH1271
230 (Max.)
65 (Max.)
20A
# ... AWG (American Wire Gauge)
WARNING
WIRING SYSTEM DIAGRAM
G 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.).
G Each wire must be firmly connected.
G No wire should be allowed to touch refrigerant tubing, the
compressor, or any moving part.
INDOOR
OUTDOOR
UNIT
Disconnect
UNIT
switch
Field supply
Terminal
Terminal
(B)
115V
115V
115V
1
2
3
1
2
3
4
5
6
(C)
(A)
L
Grounding line
WARNING
N
(B)
Grounding
line
G To avoid the risk of electric shock, each air conditioner
unit must be grounded.
G For the installation of a grounding device, please
observe local electrical codes.
Fig. 23
G 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.
G Place a dedicated ground more than 7' (2 m) away from
other grounds and do not have it shared with other elec-
tric appliances.
CAUTION
G 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.
G Do not run wiring for antenna, signal, or power lines of television, radio, stereo, telephone,
security system, or intercom any closer than 3'4" (1 m) from the power cable and wires
between the indoor and outdoor units. Electrical noise may affect the operation.
10
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3-8. Wiring Instructions for Inter-unit Connections
Rear
panel
Wall
(1) Insert the inter-unit wiring (according to local codes)
into the through-the-wall PVC pipe. Run the wiring
toward the indoor side allowing approx. 10" (25 cm)
to extend from the wall face. (Fig. 24)
Plastic
cover
(2) Grasp both ends of the air intake grille, and remove
it by opening towards the front and pulling towards
you.
Wiring
10"
(25 cm)
(3) Remove the screw on the right side cover plate and
open the cover. (Fig. 25)
Fig. 24
Fig. 25
Fig. 26a
(4) Route the inter-unit wiring from the back of the
indoor unit and pull it toward the front for connec-
tion. (Fig. 26a, 26b)
Cover
(5) Connect the inter-unit wiring to the corresponding
terminals on the terminal plate (Fig. 26a, 26b) while
referring to the wiring diagram.
(6) Be sure to secure the wiring with the provided
clamp.
NOTE
When closing the air intake grille, press on both corners.
(Fig. 27)
Please refer to “How to replace the grille” on page 8 for
installing the air intake grille.
Terminal
plate
Fig. 27
Inter-unit
wiring
Earth
plate
Lock nut
Top of conduit
connector
Fig. 26b
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Loose wiring may cause the
WARNING
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.
9/32"
(7 mm)
(ACTUAL
STRIP
SIZE
SIZE)
How to connect wiring to the terminal
a) For Indoor Unit
Fig. 28
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the wire about 9/32" (7 mm).
See the label (Fig. 28) near the terminal plate.
Solid wire
Loop
(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.
Insulation
b) For Outdoor Unit
Fig. 29
I For solid core wiring (or F-cable)
Stranded wire
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the solid wire about 15/16" (25
mm). (Fig. 29)
Ring
connector
(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.
Fig. 30
Twist wire ends
(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.
I For stranded wiring
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the stranded wiring about 3/8"
(10 mm) and tightly twist the wire ends. (Figs. 30
and 31)
Fig. 31
(2) Using a screwdriver, remove the terminal screw(s)
on the terminal plate.
Special
washer
Screw
(3) Using a ring connector fastener or pliers, securely
clamp each stripped wire end with a ring connector.
(Fig. 30)
Screw and
special washer
Ring connector
Terminal plate
Ring
connector
Wire
(4) Place the ring connector wire, and replace and
tighten the removed terminal screw using a screw-
driver. (Fig. 32)
Wire
Fig. 32
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3-9. Mounting
(1) To install the indoor unit, mount the indoor unit onto
the 2 tabs on the upper part of the rear plate.
(2) Hold down the air discharge outlet and press the
lower part of the indoor unit until it clicks to securely
fasten to the 2 tabs on the lower part of the rear
plate. (Fig. 33)
Push
NOTE
For tubing, choose either the right or left tubing direction
and follow the steps below. This work can be made easi-
er by placing padding material (such as styrofoam) at the
rear right side of the indoor unit. (Fig. 34)
Fig. 33
I 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)
Padding material
(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
18.) The drain hose should come straight down the
wall to a point where water runoff won’t stain the
wall.
Fig. 34
Rear panel
Cover
Refrigerant
tubing
(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.
Inter-unit
wiring
Drain hose
(5) Assemble the refrigerant tubing, drain hose, and
conduit (including inter-unit wiring) as shown in
Fig. 37b.
Fig. 35
Refrigerant tubing
Insulation
Fig. 37a
Conduit
Drain hose
Fig. 36
Inter-unit wiring
Fig. 37b
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I Left-side tubing
Rear panel
(1) Lead the tubing and drain hose through the wall,
allowing sufficient length for connection. Then bend
the tubing using a tube bender to make the attach-
ment. (Fig. 38)
Hole in wall
Wide tube
Narrow tube
Bent part
(2) Switch the drain hose and drain cap.
Fig. 38
Switching drain hose and drain cap
(a) Locate the drain hose and the drain cap. (Fig.
39)
(b) Remove the screws fastening the drain hose on
the right side, and pull out the drain hose to
remove it. (Fig. 39)
Drain cap
(c) Apply moderate force to pull off the drain cap
on the left side. (If you cannot pull it off by
hand, use a long-nose pliers.)
Drain hose
Fig. 39
(d) Reattach the drain hose to the left side and the
drain cap to the right side. (Fig. 40a)
Drain hose
Drain hose
Slide the drain hose fully onto the drain pan outlet
until the drain hose edge is pushed into the insula-
tion. Check that the screw holes in the drain bracket
and the drain pan outlet are aligned and securely in
contact, then fasten them with the screw. (After
attaching the drain hose, check that it is attached
securely.) (Fig. 40c)
Clamp
Drain cap
Drain cap
Use a Phillips screwdriver to push the drain cap in
firmly. (If it is difficult to push in, wet the cap with
water first.)
Fig. 40a
Screw hole
(3) Install the indoor unit on the rear panel.
(4) Connect the tubing and wiring led inside from out-
doors.
Drain pan outlet
(5) After completing a leak test, bundle the tubing
together with armoring tape and store it inside the
tubing storage area at the back of the indoor unit
and hold it with clamps. (Figs. 40a and 41)
Insulation
Drain bracket
Drain bracket
Screw
Drain hose
Drain hose
Fig. 40c
Fig. 40b
Refrigerant tubing
Inter-unit wiring
Conduit
Fig. 41
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To unmount indoor unit
Press the 2 L marks on the lower part of the indoor unit
and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 42)
3-10. Drain Hose
a) The drain hose should be slanted downward to the
outdoors. (Fig. 43)
b) Never form a trap in the course of the hose.
c) 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. 44)
Push
* Foamed polyethylene or its equivalent is recom-
Fig. 42
mended.
Do not supply power to the
unit or operate it until all
tubing and wiring to the out-
side unit are completed.
WARNING
Slant
Indoor
unit
Drain
hose
Risk of Electric Shock
Fig. 43
Condensation
Insulation material
(Locally purchased)
must be used.
Fig. 44
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 16
4. How to Install the Outdoor Unit
First refer to Section 2. Installation Site Selection.
4-1. Wiring Instructions for the Outdoor Unit
Lock nut
Cabinet
Regulations on wire size differ from locality to locality. For
field wiring requirements, please refer to your local elec-
trical codes. Make sure that the installation fully complies
with all local and national regulations.
Terminal
block
(1) Remove access panel “C”. (Fig. 46)
(2) Connect the inter-unit and power supply line accord-
ing to the drawing on the panel side.
Conduit
(3) Be sure to size each wire allowing approx. 4"
(10 cm) longer than the required length for wiring.
Store excess wiring inside the cabinet.
plate
(4) When connections are completed, check that all
connections are correct as shown in the wiring sys-
tem diagram on panel side.
Access panel “C”
Plug
Inter unit
(Conduit)
Power supply
(Conduit)
(5) Be sure to ground the unit according to your local
codes.
Fig. 46
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 17
Deburring
5. Refrigerant Tubing
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
(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.
Fig. 47
Copper
tubing
(2) Remove burrs at the end of the copper tube with a
tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 47)
Reamer
NOTE
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 48)
Fig. 48
If the previous flare tool
(clutch-type) is used:
If the special R410A
flare tool is used:
(3) Remove the flare nut from the unit and be sure to
mount it on the copper tube.
0.0472" (1.2 mm)
(4) Make a flare at the end of copper tube with a flare
0 to 0.0196"
(0 to 0.5 mm)
tool.* (Figs. 49a and 49b)
Adjust so that the amount of tube
protrusion is as shown in the figure.
(*Use “RIGID” or equivalent.)
Fig. 49a
NOTE
A good flare should have the following characteristics:
G inside surface is glossy and smooth.
G edge is smooth.
Flare nut
Copper
tubing
G tapered sides are of uniform length.
5-3. Caution before Connecting Tubes Tightly
Flare tool
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.
Fig. 49b
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. 50)
Apply refrigerant
lubricant here and here
Fig. 50
c) For proper connection, align the union tube and
flare tube straight with each other, then screw in the
flare nut lightly at first to obtain a smooth match.
(Fig. 51)
Flare nut
Union
Fig. 51
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 18
5-4. Connecting Tubing between Indoor and
Outdoor Units
Torque wrench
a) Tightly connect the indoor side refrigerant tubing exten-
ded from the wall with the outdoor side tubing. (Fig. 52)
Spanner
Indoor unit
b) To fasten the flare nuts, apply specified torque as:
Table 6
Outdoor unit
Tube Dia.
Tightening Torque
Fig. 52
1/4" (6.35 mm)
3/8" (9.52 mm)
1/2" (12.70 mm)
5/8" (15.88 mm)
Approx. 120 – 160 lbs·in (140 – 180 kgf·cm)
Approx. 300 – 360 lbs·in (340 – 420 kgf·cm)
Approx. 430 – 540 lbs·in (490 – 610 kgf·cm)
Approx. 590 – 710 lbs·in (680 – 820 kgf·cm)
Insulation
5-5. Insulation of Refrigerant Tubing
IMPORTANT
Fig. 53
To prevent heat loss and wet floors due to dripping of con-
densation, both tubes must be well insulated with a
proper insulation material. (Fig. 53)
The thickness of the insulation should be a minimum 5/16"
(8 mm). (Fig. 54)
Insulation
Thickness:
min. 5/16"
(8 mm)
Min.
5/16"
(8 mm)
5-6. Taping the Tubes
Fig. 54
After a tube has been insulat-
ed, never try to bend it into a
narrow curve, as this may
cause the tube to break or
crack.
CAUTION
Clamp
Insulated tubes
(1) At this time, the 2 refrigerant tubes (and electrical wire
if local codes permit) should be taped together with
armoring tape. The drain hose may also be included
and taped together as 1 bundle with the tubing.
(2) Wrap the armoring tape from the bottom of the outdoor
unit to the top of the tubing where it enters the wall. As
you wrap the tubing, overlap half of each previous tape
turn. (Fig. 55)
Fig. 55
(3) Clamp the tubing bundle to wall, using 1 clamp approx.
every 47" (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 con-
densation drain hose splits away from the bundle and drips
clear of the unit and the tubing.
Tubing
5-7. Finishing the Installation
Fig. 56
After finishing insulating and taping over the tubing, use
sealing putty to seal off the hole in the wall to prevent rain
and draft from entering. (Fig. 56)
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 19
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.
G pressure in the system rises
G operating current rises
G cooling (or heating) efficiency drops
G moisture in the air may freeze and block capillary tubing
Outdoor unit
G water may lead to corrosion of parts in the refrigerant
system
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 completed. Note that both narrow and
wide tube service valves on the outdoor unit are
kept closed at this stage.
(2) Using an adjustable wrench or box wrench, remove
the valve caps from the service valve on both nar-
row and wide tubes.
Manifold valve
(Exclusively for R410A)
(3) Connect a vacuum pump and a manifold valve (with
pressure gauges) to the service port on the wide
tube service valve. (Fig. 57)
Lo
Hi
Pressure
gauge
The service port on the wide tube
service valve uses a Schrader core
valve to access the refrigerant sys-
tem. The valve core is similar to
those used in automobile tires.
Therefore, be sure to use a vacuum
hose connector which has a push-
pin inside.
CAUTION
Charging hose
(Exclusively for R410A)
Vacuum pump adapter
(Exclusively for R410A)
(with reverse flow prevention)
Vacuum pump
Be sure to use a manifold valve
for air purging. If it is not avail-
able, use a stop valve (field sup-
ply) for this purpose. The “Hi”
knob of the manifold valve must
always be kept closed.
CAUTION
Fig. 57
NOTE
To prevent other refrigerants from being mistakenly
charged to units which use R410A, the size of the
charge port on the service valve is different from the
one for other refrigerant types. For servicing such as
recharging, the specified charging hose, manifold and
vacuum pump adapter (with reverse flow prevention)
for R410A must be used.
(4) With the “Lo” knob of the manifold valve open, run
the vacuum pump. The operation time for the vacu-
um pump varies with tubing length and the capacity
of the pump. The following table shows the amount
of time for evacuation:
Table 7
Required time for evacuation when
100 liter/h vacuum pump is used
NOTE
If tubing length is
less than 33 ft. (10 m)
If tubing length is
more than 33 ft. (10 m)
The required time in Table 7 is calculated based on the
assumption that the ideal (or target) vacuum condition
is around 10 mmHg abs.
10 min. or more
15 min. or more
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 20
(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. 58)
Hex wrench
Wide tube
Be sure to completely insert
CAUTION
the hex wrench before
attempting to turn the valve.
Valve cap
Vacuum hose to manifold valve
(7) Leak test all joints at the tubing (both indoor and out-
doors) with soapy water. Bubbles indicate a leak. Tight-
en the joint more when leaks, then check if there is no
leak. Be sure to wipe off the soap with a clean cloth.
Fig. 58
(8) With the hex wrench, turn the wide tube service
valve stem counter-clockwise to fully open the valve.
(9) Turn the narrow tube service valve stem counter-
clockwise to fully open the valve.
(10) Loosen the vacuum hose connected to the wide
tube service port slightly to release the pressure.
Then, remove the hose.
This may cause the refriger-
ant gas to leak. In order to
avoid this, take off the hose
quickly.
CAUTION
(11) Fasten the valve cap on the wide tube service port
securely with an adjustable wrench or box wrench.
Next, mount the valve cap on the service valve and
tighten it to 170 lbs·in (200 kgf·cm) with a torque
wrench. This process is very important to prevent
gas from leaking from the system.
(12) Test run the air conditioner. (See next page.)
(13) While the air conditioner is running, apply liquid
soap to check for any gas leaks around the service
valves or caps.
(14) If there is no leakage, stop the air conditioner.
(15) Wipe off the soap on the tubing.
This completes air purging with a vacuum pump and the
air conditioner is ready for actual operation.
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 21
How to Test Run the Air Conditioner
After turning on power to the air conditioner, use the remote
controller and follow the steps below to conduct the test run.
(1) Set the remote controller in Test Run mode.
(Fig. 59a)
a) Press and hold the ION button.
b) Then press and hold the 1HR TIMER button.
c) At the same time, press the ACL (reset) button once.
Use a pointed object such as the tip of a pen to press
the ACL button.
ON/OFF
operation
button
ION
button
• After a few seconds, “ ” appears and “oP-1” blinks in
the remote controller display area.
(Fig. 59b)
1HR.
TIMER
button
d) Release the 1HR TIMER button.
e) Release the ION button.
(2) Start Cooling mode test run by pressing the ON/OFF
operation button of the remote controller. (Fig. 59a)
• This starts the fan producing uncooled forced air with
the 4 indicator lamps (OPERATION lamp, TIMER
lamp, QUIET lamp, and ION lamp) on the main unit
blinking. (Fig. 59c)
• After 3 minutes, the system shifts into cooling opera-
tion, and cool air will start to be felt. Cool mode test
run is unaffected by the room temperature.
ACL
(Reset)
button
A
(3) Press the ON/OFF operation button of the remote con-
troller again to stop the test run. (Fig. 59a)
Fig. 59a
(4) Finally press the ACL (reset) button of the remote con-
troller to release it from Test Run mode to return to nor-
mal mode. (Fig. 59a)
• “ ” and “oP-1” will disappear from the remote con-
troller display area.
IMPORTANT
After the test run is completed, be sure to press the ACL
(reset) button to return to normal mode. The air conditioner
will not operate correctly if this is not done.
Fig. 59b
OPERATION lamp
TIMER lamp
QUIET lamp
ION lamp
Fig. 59c
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 22
I Basic Functions of the Service Valves
The basic functions of the service valves are given in Table 8 below.
Table 8
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
*
* The service port on the wide tube ser-
vice valve uses a Schrader core valve
to access the refrigerant system.
Therefore, be sure to use a hose con-
nector which has a push-pin inside.
(Fig. 60a)
Air purging with
a vacuum pump
*
Service valve
Hose with push-pin
CAUTION
Close
When opening or clos-
ing the service valve
PUSH
Open
stem, use the accessory
hex wrench. Be sure to
fully seat the wrench
Hex
wrench
Fig. 60a
Fig. 60b
before turning the valve.
I Pump Down
(2) Using a hex wrench, turn the narrow tube service
valve clockwise all the way to close the service
valve. (Be sure to confirm that the wide tube service
valve is fully open.)
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 oper-
ation.
Pump Down Procedure
Be sure to carry out pump down with the unit in
cooling mode.
(4) When the low pressure gauge reading falls to 14.2 to
7.1 psi (1 to 0.5 kg/cm2), fully close the wide tube
valve stem. Then quickly stop the unit.
(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
valve caps as they were before.
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 23
7. Remote Control Unit Installation Position
The remote control unit can be operated from either a
non-fixed position or a wall-mounted position.
To ensure that the air conditioner operates correctly, do
not install the remote control unit in the following places:
G In direct sunlight
G Behind a curtain or other place where it is covered
G More than 26' (8 m) away from the air conditioner
G In the path of the air conditioner’s airstream
G Where it may become extremely hot or cold
G Where it may be subject to electrical or magnetic
interference
G Where there is an obstacle between the remote con-
trol unit and the air conditioner (since a check signal
is sent from the remote control unit every 5 minutes)
7-1. Mounting on a Wall
Before mounting the remote control unit, press the
ON/OFF operation button at the mounting location to
make sure that the air conditioner operates from that
location. The indoor unit should make a beeping sound
to indicate that it has received the signal.
Rear side
Remote control unit mount
Press
Mounting screws
5/32 × 5/8" (4 × 16 mm)
(Included)
Hole
Set in
place
To prevent loss of the remote control
unit, you can connect the remote
control unit to the mount by passing
a string through the remote control
unit and attachment hole.
To take out the remote control unit, pull it forward.
Fig. 61
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05-423 KHS0971-1271 12/13/05 1:23 PM Page 24
8. Address Switch
Tab
8-1. Address Setting of the Remote Control Unit
The address can be set in order to prevent interference
between remote controllers when two Sanyo indoor units
are installed near each other. The address is normally
set to “A.” To set a different address, it is necessary to
change the address on the second remote controller.
Fig. 62
NOTE
Once changed, you cannot restore the original address
setting of the air conditioner.
(1) Switch on the power source.
(2) Break the address-setting tab marked “A” on the
second remote controller to change the address
(Fig. 62). When the tab is removed, the address is
automatically set to B (Fig. 63).
ACL button
(3) Press and hold the remote controller ION button and
1 HR TIMER button. At the same time, press the
ACL(reset) button. Use a thin object such as the tip
of a pen to press the ACL button. When this has
been done, “oP-1” (test run) appears, blinking, in the
remote controller clock display area.
Fig. 63
(4) Each time the 1 HR TIMER button is pressed, the
display changes as shown below. Press this button
2 times to change the display to “oP-7” (address
setting). (Fig. 64)
Test run mode
Selfdiagnostic mode
Adress setting mode
ON/OFF
operation
button
ION
button
(5) “oP-7” has now been selected for address setting.
1HR.
(6) Press the ON/OFF operation button on the remote
controller. (Fig. 64) Check that the “beep”signal-
received sound is heard from the second indoor unit
(approximately 5 times). The sound you hear is the
signal that the remote controller address has been
changed.
TIMER
button
(7) Finally press the remote controller ACL (reset) but-
ton to cancel the blinking “oP-7” display.
(Fig. 64)
Changing of the second remote controller address is
now completed.
ACL
(Reset)
button
A
Fig. 64
24
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