Sanyo C1852, CL1251, C1251, C0951, KS1852 User Manual
...
INSTALLATION INSTRUCTIONS
W
IMPORTANT
– Split System Air Conditioner –
Contents
Page
IMPORTANT!
Please Read Before Starting .................................. 2
1. GENERAL.......................................................... 3
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Field Wiring
1-6. Additional Materials Required for Installation
2. INSTALLATION SITE SELECTION ................... 4
2-1. Indoor Unit
2-2. Outdoor Unit
2-3. Baffle Plate for the 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
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
3-10. Drain Hose
COOL/DRY Model
Model Combinations
Combine indoor and outdoor units only as listed
below.
Indoor Units Outdoor Units
KS0951 C0951
CL0951
KS1251 C1251
CL1251
Power Source:
60 Hz, single-phase, 115 V
KS1852 C1852
CL1852
Power Source:
60 Hz, single-phase, 230/208 V
5-7. Finishing the Installation
6. AIR PURGING................................................... 18
■ Air Purging with a Vacuum Pump (for Test Run)
■ Basic Function of the Service Valves
■ Pump Down
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 15
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
SANYO FISHER COMPANY SANYO Canada Inc.
85264189593004 © SANYO 2002 Chatsworth, CA 91311 U.S.A.
A DIVISION OF SANYO NORTH AMERICA CORPORATION
21605 Plummer Street Ontario, L4K 5C7, Canada
7. REMOTE CONTROL UNIT INSTALLATION
POSITION......................................................... 22
7-1. Mounting on a Wall
Power source for C0951, CL0951, C1251 and
CL1251 is 60 Hz, single-phase 115V.
In Canada
300 Applewood Crescent, Concord
IMPORTANT!
WARNING
WARNING
CAUTION
Please Read Before Starting
This air conditioning system meets strict safety and operating
standards. As the installer or service person, it is an important
part of your job to install or service the system so it operates
safely and efficiently.
For safe installation and trouble-free operation, you
must:
●
Carefully read this instruction booklet before beginning.
●
Follow each installation or repair step exactly as shown.
●
Observe all local, state, and national electrical codes.
●
Pay close attention to all warning and caution notices
given in this manual.
This symbol refers to a hazard or
unsafe practice which can result
in severe personal injury or
death.
This symbol refers to a hazard or
unsafe practice which can result
in personal injury or product or
property damage.
If Necessary, Get Help
These instructions are all you need for most installation
sites and maintenance conditions. If you require help for a
special problem, contact our sales/service outlet or your
certified dealer for additional instructions.
In Case of Improper Installation
The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to
follow the instructions in this document.
When Transporting
Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when
lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers.
When Installing…
…In a Ceiling or Wall
Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.
…In a Room
Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to
walls and floors.
…In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents
water damage and abnormal vibration.
…In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.
…In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is higher
than drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
SPECIAL PRECAUTIONS
When Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.
• Do not supply power to the unit until all wiring and tubing
are completed or reconnected and checked.
• Highly dangerous electrical voltages are used in this
system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and
inadequate grounding can cause accidental injury or
death.
• Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces of the
flare and union tubes before connecting them, then tighten
the nut with a torque wrench for a leak-free connection.
• Check carefully for leaks before starting the test run.
When Servicing
• Turn the power OFF at the main power box (mains)
before opening the unit to check or repair electrical parts
and wiring.
• Keep your fingers and clothing away from any moving
parts.
• Clean up the site after you finish, remembering to check
that no metal scraps or bits of wiring have been left inside
the unit being serviced.
2
1. General
Parts Figure Q’ty Parts Figure Q’ty
Rawl plug 12
12
Tapping
screw
Truss-head
Phillips
5/32 × 5/8" (4 × 16 mm)
2
1
1
AAA alkaline
battery
1
1
Parts Figure Q’ty
Remote
control unit
Drain hose
adapter
Hex
wrench*
Remote
control
holder
CAUTION
This booklet briefly outlines where and how to install the
air conditioning system. Please read over the entire set
of instructions for the indoor and outdoor units and
make sure all accessory parts listed are with the system
before beginning.
1-1. Tools Required for Installation (not supplied)
1. Standard screwdriver
2. Phillips head screwdriver
3. Knife or wire stripper
4. Tape measure
1-2. Accessories Supplied with Unit
Table 1
5. Carpenter’s level
6. Sabre saw or key hole saw
7. Hacksaw
8. Core bits
9. Hammer
10. Drill
11. Tube cutter
12. Tube flaring tool
13. Torque wrench
14. Adjustable wrench
15. Reamer (for deburring)
* Packed in the outdoor unit.
1-3. Optional Copper Tubing Kit
Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or A/C workshop.
1-4. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately from
a local source, you will need:
1. Deoxidized annealed copper tube for refrigerant
tubing as detailed in Table 2.
When cutting tubing, add approximately 12” 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
Outer Dia. Thickness Outer Dia. Thickness
6.35 mm (1/4") 0.8 mm (0.0314") 9.52 mm (3/8") 0.8 mm (0.0314") C0951, CL0951
6.35 mm (1/4") 0.8 mm (0.0314") 12.7 mm (1/2") 0.8 mm (0.0314") C1251, CL1251
6.35 mm (1/4") 0.8 mm (0.0314") 15.88 mm (5/8") 1.0 mm (0.0394") C1852, CL1852
3
2. Foamed polyethylene insulation for the specified
O.D. copper tubes as required to precise length of
tubing. Wall thickness of the insulation should be
not less than 0.3 in. (8 mm).
1-5. Field Wiring
Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring. Refer to 3-6. Wiring
Instructions for details.
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
Model
1-6. Additional Materials Required for Installation
Drain hose
Indoor unit
Outside drainage
*6" (15 cm) min.
Front View
2" (5 cm) min.
*6" (15 cm) min.
*KS1852 only
2" (5 cm) min.
*6" (15 cm) min.
2" (5 cm) min.
INDOOR
UNIT
Tubing length (L)
OUTDOOR
UNIT
Elevation
difference (H)
Indoor unit
Floor level
Wall
Minimum height
from floor level
5 ft. (1.5 m)
CAUTION
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
2. Installation Site Selection
2-1. Indoor Unit
WARNING
To prevent abnormal heat generation and the possibility of fire, do
not place obstacles, enclosures
and grilles in front of or surrounding the air conditioner in a way that
may block air flow.
AVOID:
● direct sunlight.
● nearby heat sources that may affect performance of the
unit.
● areas where leakage of flammable gas may be expected.
● places where large amount of oil mist exist.
DO:
● select an appropriate position from which every corner of
the room can be uniformly cooled. (High on a wall is best.)
● select a location that will hold the weight of the unit.
Fig. 1
Fig. 2
Fig. 3a
● select a location where tubing and drain hose have the
● allow room for operation and maintenance as well as unre-
● install the unit within the maximum elevation difference (H)
Table 3
Max. Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of
* 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.
shortest run to the outside. (Fig. 1)
For stable operation of
the air conditioner, do
stricted air flow around the unit. (Fig. 2)
not install wall-mounted
type indoor units under
above the outdoor unit and within a total tubing length (L)
from the outdoor unit as detailed in Table 3 and Fig. 3a.
5 ft. (1.5 m) from floor
level.
Fig. 3b
Length at Shipment Length (L) Difference (H) Additional Refrigerant Model
(ft.) (ft.) (ft.) (oz./ft.)*
25 50 23 a) 0.16 9,000 BTU
25 65 23 b) 0.27 12,000/18,000 BTU
4
2-2. Outdoor Unit
Outdoor unit
Hot air
Heat source
Exhaust fan
NO
Air intake Min. 6" (15 cm)
Air discharge
Min. 6"
(15 cm)
Min. 12"
(30 cm)
Valve side
Min. 10"
(25 cm)
Min.
7 ft.
(2 m)
Min.
7 ft.
(2 m)
Min. 6 in.
(15 cm)
Air intake
Ground
Obstacle
Obstacle above
Air discharge
CAUTION
NOTE
Air intake
Concrete
or equal
About
4" (10 cm
)
Min. 4"
(10 cm)
Anchor bolts
(4 pcs)
About 16" (40 cm)
Air discharge
6" min
Air discharge
6" min
Baffle
plate
Baffle
plate
AVOID:
● heat sources, exhaust fans, etc. (Fig. 4)
● damp, humid or uneven locations.
DO:
● choose a place as cool as possible.
● choose a place that is well ventilated.
● allow enough room around the unit for air intake/
exhaust and possible maintenance. (Fig. 5a)
● Install the outdoor unit above snowfall line.
● 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.
● Do not introduce foreign matter into the air
intake/outlet or exhaust. Do not poke them
with such objects as a stick.
Fig. 4
Fig. 5a
● 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).
● use lug bolts or equal to bolt down unit, reducing
vibration and noise.
2-3. Baffle Plate for the Outdoor Unit
(CL×× models only)
It is recommended to use baffle plates for models
CL1251, CL1852 and CL0951. The baffle plates are not
normally required for the other models.
When the outdoor unit is installed in a position exposed
to strong wind (like seasonal winds with low air temperature 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.
Fig. 5b
Fig. 5c
5
Set screw only for transportation
Rear panel
▲ marks
Left
tubing
Right tubing
Downward tubing
Right-rear
tubing
(recommended)
Left-rear
tubing
3. How to Install the Indoor Unit
NOTE
CAUTION
Left
tubing Right-rear
tubing
(recommended)
Right tubing
Downward tubing
60°
Drain hose
Clamp
Drain cap
To slip on
To remove
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
▲▲ marks on the frame cover and disengage the sta-
tionary tabs from the frame. (Fig. 7)
(3) Remove the rear panel.
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.
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 carpenter’s level or tape measure to measure down from the ceiling.
Wait until after cutting the hole before attaching the rear panel to
the wall.
(2) Determine which side of the unit you should make the hole for
tubing and wiring. (Fig. 9)
(3) Before making the hole, check carefully that no studs or pipes
are directly run behind the spot to be cut.
Fig. 6
Fig. 7
KS0951, KS1251
● Also avoid areas where electrical wiring or conduits are
located.
● Switching drain hose and drain cap
(a) Locate the drain hose and the drain cap. (Fig. 8c)
(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 pliers.)
(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.
In case of right-rear
Fig. 9
Fig. 8a
KS1852
Fig. 8b
Fig. 8c
6
Indoor
side
Outdoor
side
NOTE
Plastic
cover
INSIDE OUTSIDE
Wall
Slight
angle
PVC pipe
PVC pipe (locally purchased)
Cut at slight angle
3/16" (4.8 mm)
dia. hole
Rawl plug
(4) Using a sabre saw, key hole saw or hole-cutting drill
attachment, cut a hole in the wall. See Table 4 and
Fig. 10.
Table 4
Hole Dia.
2-9/16" (65 mm) / 3-5/32" (80 mm)
(5) Measure the thickness of the wall from the inside
edge to the outside edge and cut PVC pipe at a
slight angle 0.25 in. (6 mm) shorter than the thickness of the wall. (Fig. 11)
(6) Place the plastic cover (locally purchased) over the
end of the pipe (for indoor side only) and insert the
pipe in the wall. (Fig. 12)
3-3. Install the Rear Panel on the Wall
Be sure to confirm that the wall is strong enough to suspend the unit.
See either Item a) or b) below depending on the wall type.
Hole should be made at a slight downward slant to the
outdoor side.
Fig. 10
Fig. 11
a) If Wooden Wall
(1) Attach the rear panel to the wall with the 10 screws
provided. (Fig. 13)
If you are not able to line up the holes in the rear
panel with the beam locations marked on the wall,
use rawl plugs or toggle bolts to go through the
holes on the panel or drill 3/16 in. (5 mm) dia. holes
in the panel over the stud locations and then mount
the rear panel.
(2) Double check with a ruler or carpenter’s level that
the panel is level. This is important to install the unit
properly. (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)
Fig. 12
Fig. 13
Fig. 14
Fig. 15
7
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