Sanyo Ks1872 User Manual

INSTALLATION INSTRUCTIONS  
COOL/DRY 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  
Outdoor Unit  
C1872  
1. GENERAL .......................................................... 3  
1-1. Tools Required for Installation (not supplied)  
1-2. Accessories Supplied with Unit  
KS1872  
CL1872  
C2472  
1-3. Optional Copper Tubing Kit  
KS2472  
1-4. Type of Copper Tube and Insulation Material  
1-5. Additional Materials Required for Installation  
CL2472  
Power Source:  
60 Hz, single-phase, 230/208 V  
2. INSTALLATION SITE SELECTION ................... 4  
2-1. Indoor Unit  
2-2. Outdoor Unit  
2-3. Baffle Plate for the Outdoor Unit  
Be sure to read the yellow instruction sheet  
attached to the outdoor unit for models using the  
new refrigerant R410A.  
3. HOW TO INSTALL THE INDOOR UNIT ............. 7  
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  
3-7. Recommended Wire Length and Diameter  
3-8. Wiring Instructions for Inter-unit Connections  
3-9. Mounting  
7. REMOTE CONTROL UNIT INSTALLATION  
POSITION ......................................................... 24  
7-1. Mounting on a Wall  
8. ADDRESS SWITCH.......................................... 25  
8-1. Address Setting of the Remote  
Control Unit  
3-10. Drain Hose  
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 17  
4-1. Wiring Instructions for the Outdoor Unit  
5. REFRIGERANT TUBING.................................. 18  
5-1. Use of the Flaring Method  
5-2. Flaring Procedure with a Flare Tool  
5-3. Caution before Connecting Tubes Tightly  
5-4. Connecting Tubing between Indoor and  
Outdoor Units  
5-5. Insulation of Refrigerant Tubing  
5-6. Taping the Tubes  
5-7. Finishing the Installation  
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................................................... 20  
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.  
85264189988000 © SANYO 2006  
W
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  
Outer Dia.  
Thickness  
KS1872  
KS2472  
1/4" (6.35 mm)  
1/4" (6.35 mm)  
0.0314" (0.8 mm) 1/2" (12.70 mm) 0.0314" (0.8 mm)  
0.0314" (0.8 mm) 5/8" (15.88 mm) 0.0393" (1.0 mm)  
3
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  
KS1872  
KS2472  
25  
33  
98  
49  
49  
0.27  
0.27  
131  
* If total tubing length becomes 25 to 98 ft. (Max.) or 33 to 131 ft. (Max.), charge additional refrigerant (R410A) by 0.27 oz./ft.  
No additional charge of compressor oil is necessary.  
4
2-2. Outdoor Unit  
AVOID:  
Exhaust fan  
NO  
Hot air  
G heat sources, exhaust fans, etc. (Fig. 4)  
Heat source  
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.  
G allow enough room around the unit for air intake/  
exhaust and possible maintenance. (Fig. 5a or 5b)  
G provide a solid base (level concrete pad, concrete block,  
4" ¥ 1'4" (10 ¥ 40 cm) or 6" ¥ 1'4" (15 ¥ 40 cm) beams  
or equal), a minimum of 4" (10 cm) or 6" (15 cm) above  
ground level to reduce humidity and protect the unit  
against possible water damage and decreased service  
life. (Fig. 5c or 5d)  
G Install cushion rubber under unit’s feet to reduce  
vibration and noise. (Fig. 5e)  
G use lug bolts or equal to bolt down unit, reducing  
vibration and noise.  
Fig. 4  
Obstacle above  
(C1872, CL1872)  
Min.  
7' (2 m)  
Min.  
7' (2 m)  
Air intake  
Min. 4" (10 cm) Valve  
side  
Min. 10"  
(25 cm)  
Min.  
2" (5 cm)  
Air discharge  
Min.  
1'4" (40 cm)  
G Install in a location where no antenna of a television  
or radio exists within 10' (3 m).  
Ground  
Min. 4" (10 cm)  
Air intake  
Fig. 5a  
(C1872, CL1872)  
Anchor bolts  
Obstacle above  
(C2472, CL2472)  
(4 pcs.)  
Min.  
7' (2 m)  
Min.  
7' (2 m)  
Min. 4" (10 cm)  
Air intake  
Air intake  
Min. 8" (20 cm) Valve  
side  
Min. 10"  
(25 cm)  
Concrete  
or equal  
Min.  
4" (10 cm)  
Air discharge  
Min.  
1'8" (50 cm)  
Ground  
Min. 8" (20 cm)  
Air intake  
Fig. 5b  
Fig. 5c  
(C2472, CL2472)  
Anchor bolts  
(4 pcs.)  
Min. 6" (15 cm)  
Air intake  
Concrete  
or equal  
Cushion rubber  
Fig. 5e  
Fig. 5d  
5
2-3. Baffle Plate for the Outdoor Unit  
(CLxx models only)  
NOTE  
It is recommended to use baffle plates for models  
CL1872 and CL2472. 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 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.  
Air discharge  
Fig. 5f  
6
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 2-3/8" (60 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.  
2-3/8" (60 mm)  
Also avoid areas where elec-  
CAUTION  
trical wiring or conduits are  
located.  
Fig. 9  
The above precautions are also applicable if tubing  
goes through the wall in any other location.  
7
(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.  
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 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  
8
Grille  
Air intake grille  
3-4. Remove the Grille to Install the Indoor Unit  
Basically, these models can be installed and wired with-  
out removing the grille. If access to any internal part is  
needed, follow the steps as given below.  
How to remove the grille  
(1) Grasp both ends of the air intake grille, and remove  
it by opening towards the front and pulling towards  
you. (Fig. 16a)  
Fig. 16a  
(2) Remove the 3 screws. (Fig. 16b)  
(3) Remove the screw on the right side cover plate and  
open the cover. (Fig. 17a)  
(4) Take out the thermistor from the grille. (Fig. 17b)  
Fig. 16b  
(5) Press the 3 tabs at the top of the grille and the 3  
tabs on the front face to separate the grille from the  
frame. (Fig. 18a)  
Cover  
Thermistor  
Thermistor  
(6) Pull the grill toward you to remove it.  
How to replace the grille  
(1) When installing the grille, place the bottom of the  
grille into the frame first. (Fig. 18b)  
Fig. 17b  
Fig. 17a  
Tab  
Then insert the tabs on the top of the grille and on  
the front face into the frame.  
(2) Make sure that the grille and frame are firmly fitted  
together by engaging the tabs.  
(3) Attach the thermistor on the grille. (Fig. 17a)  
(4) Close the cover and replace the screw. (Fig. 17a)  
Tab  
(5) Affix the grille with the 3 previously removed screws.  
(Fig. 16b)  
Fig. 18a  
(6) Install the air intake grille.  
(a) Allow the edge of the air intake grille to slide into the  
top of the indoor unit, and then insert it all the way  
inside. (Fig. 19a)  
(b) Press the bottom right and left corners and center of  
the air intake grille to attach it to the indoor unit.  
(Fig. 19b)  
NOTE  
Fig. 18b  
Groove  
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  
9
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  
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 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.  
10  
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)  
C1872, C2472, CL1872, CL2472  
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)  
230/208V  
1
2
3
1
2
230/208V  
230/208V  
3
4
5
6
(C)  
(A)  
L1  
L2  
Grounding line  
WARNING  
(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.  
11  
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 the bottom right  
and left corners and center. (Fig. 27)  
Please refer to “How to replace the grille” on page 9 for  
installing the air intake grille.  
Terminal  
plate  
Fig. 27  
Inter-unit  
wiring  
Earth  
plate  
Lock nut  
Top of conduit  
connector  
Fig. 26b  
12  
Loose wiring may cause the  
terminal to overheat or result  
in unit malfunction. A fire  
hazard may also exist. There-  
fore, be sure all wiring is  
tightly connected.  
WARNING  
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  
13  
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  
14  
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  
15  
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  
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  
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.  
Cabinet  
(1) Remove access panel “C”. (Fig. 46)  
Terminal  
block  
(2) Connect the inter-unit and power supply line accord-  
ing to the drawing on the panel side.  
(3) Be sure to size each wire allowing approx. 4"  
(10 cm) longer than the required length for wiring.  
Store excess wiring inside the cabinet.  
Conduit  
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  
(5) Be sure to ground the unit according to your local  
codes.  
Inter unit  
(Conduit)  
Power supply  
(Conduit)  
Plug  
Fig. 46  
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  
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)  
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  
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.  
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  
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.  
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  
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  
Address 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  
25  

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