Sanyo C3682, KS3682, C3082, KS3082 User Manual

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. Additional Materials Required for Installation

2. INSTALLATION SITE SELECTION ................... 4

2-1. Indoor Unit 2-2. Outdoor Unit

3. HOW TO INSTALL THE INDOOR UNIT ............ 12

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. Removing and Installing the Grille 3-5. Shape the Indoor Side Tubing 3-6. Wiring Instructions 3-7. Wire Size and Length 3-8. Wiring Instructions for Inter-unit Connections 3-9. Mounting 3-10. Frame Fastening Method 3-11. Drain Hose

4. HOW TO INSTALL THE OUTDOOR UNIT ........ 22

4-1. Wiring Instructions for the Outdoor Unit 4-2. Routing the Tubing and Wiring

5. REFRIGERANT TUBING .................................. 23

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

6. AIR PURGING................................................... 25

■ Air Purging with a Vacuum Pump (for Test Run)

■ Basic Functions of the Service Valves

■ Pump Down

■ Service Valve Connections

This air conditioner uses the new refrigerant R410A.

Refrigerant service valve size = 5/16"

85264190499000 © SANYO 2010

INSTALLATION INSTRUCTIONS

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Unit Outdoor Unit

KS3082 C3082

KS3682 C3682

Power Source: 60 Hz, single-phase, 230/208 V

– Inverter Split System Air Conditioner –

COOL/ DRY Model

Be sure to read the yellow instruction sheet attached to the outdoor unit for models using the new refrigerant R410A.

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.

7. REMOTE CONTROL UNIT INSTALLATION

POSITION ......................................................... 29

7-1. Mounting on a Wall

8. ADDRESS SWITCH .......................................... 30

8-1. Address Setting of the Remote

Control Unit

SANYO North America Corporation In Canada Commercial Solutions Division SANYO Canada Inc. 2055 Sanyo Ave., San Diego 201 Creditview Road, Woodbridge CA 92154, U.S.A. Ontario, L4L 9T1, Canada

10-018 C3082-3682 2/15/10 11:50 AM Page a

NOTE

IMPORTANT! Please Read Before Starting

This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently.

For safe 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.

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.

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

Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

• 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.

Others

• Ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas.

• Confirm upon completing installation that no refrigerant gas is leaking. If escaped gas comes in contact with a stove, gas water heater, electric room heater or other heat source, it can produce dangerously toxic gas.

WARNING

CAUTION

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1. General

This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions for the indoor and outdoor units and make sure all accessory parts listed are with the system before beginning.

1-1. Tools Required for Installation (not supplied)

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

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)

1-2. Accessories Supplied with Unit

Table 1

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 air conditioning 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.

Cut each tube to the appropriate lengths 1' to 1'4" (30 cm to 40 cm) to dampen vibration between units.

Table 2

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).

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.

CAUTION

Check local electrical codes and regulations before obtaining wire. Also, check any specified instructions or limitations.

Model

Narrow Tube Wide Tube

Outer Dia. Thickness Outer Dia. Thickness

KS3082 3/8" (9.52 mm) 0.0314" (0.8 mm) 5/8" (15.88 mm) 0.0393" (1.0 mm)

KS3682 3/8" (9.52 mm) 0.0314" (0.8 mm) 5/8" (15.88 mm) 0.0393" (1.0 mm)

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Parts Figure Q’ty Parts Figure Q’ty

Remote control unit

Air clean filter

Remote control unit holder

Tapping screw

AAA alkaline battery

Tapping screw

Truss-head Phillips

/32 × 5/8" (4×16 mm)

Truss-head Phillips

/32 × 13/32" (4×10 mm)

Parts Figure Q’ty

Rawl plug

Drain hose

adapter

Flare insulation

1-5. Additional Materials Required for Installation

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

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 amounts 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.

● select a location where tubing and drain hose have the

shortest run to the outside. (Fig. 1)

● allow room for operation and maintenance as well as unre-

stricted air flow around the unit. (Fig. 2)

● install the unit within the maximum elevation difference (H)

above or below the outdoor unit and within the maximum tubing length (L) from the outdoor unit as detailed in Table 3 and Fig. 3a.

● 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.

Drain hose

Indoor unit

Outside drainage

Fig. 1

Fig. 2

INDOOR UNIT

Tubing length (L)

OUTDOOR UNIT

Elevation difference (H)

Fig. 3a

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.

Fig. 3b

For stable operation of the air conditioner, do not install wall-mounted type indoor units less than 5' (1.5 m) from floor level.

CAUTION

Table 3

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2" (5 cm)

min.

3" (7.5 cm) min.

2" (5 cm)

min.

Front View

Indoor unit

Minimum height from floor level

5' (1.5 m)

Wall

Model

KS3082 KS3682

* If total tubing length becomes 100 to 165 ft. (Max.), charge additional refrigerant (R410A) by 0.43 oz./ft.

No additional charge of compressor oil is necessary. For more detailed charging information, refer to the Technical & Service Manual.

Charge-less Tubing

Length (Actual Length)

(ft.)

Maximum Tubing

Maximum Elevation Difference (H)

Length (L)

(ft.)

16510 to 100 0.43

If the outdoor unit is higher

If the outdoor unit is lower

(ft.)

100

Required Amount

of Additional Refrigerant

Floor level

(oz./ft.)*

● Concerning air-intake side distance “A” (Fig. 5a)

The minimum for distance “A” is 6" if there are no obstructions on the air-discharge side (wall *1 side) and *2 or *4 is not present. In all other cases, the minimum for distance “A” is 8".

● If wall *1 is on the air-discharge side (Fig. 5a), or if

obstructions are present on all 3 sides *2, *3, and *4 (Fig. 5a), then the minimum distance for “B” and “C” is 39-3/8". Even if there is no wall on the air-discharge side, a minimum of 39-3/8" is required.

Fig. 5c

Air intake

Concrete or equal

About 6" (15 cm)

Min. 6" (15 cm)

Anchor bolts (4 pcs.)

About 1'4" (40 cm)

2-2. Outdoor Unit

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.

● install in a location where at least two sides are unob-

structed, so that the flow of air at the intake port or exhaust port is not blocked, and so that sufficient space is ensured for maintenance to be carried out without trouble. In general the top also must be unobstructed. (Fig. 5a)

● provide a solid base (level concrete pad, concrete block,

6" x 1'4" (15 x 40 cm) beams or equal), a minimum of 6" (15 cm) above ground level to reduce humidity and protect the unit against possible water damage and decreased service life. (Figs. 5b and 5c)

● install cushion rubber under unit’s feet to reduce

vibration and noise. (Fig. 5d)

● use lug bolts or equal to bolt down unit, reducing

vibration and noise.

● install in a location where no antenna of a television

or radio exists within 10' (3 m).

Outdoor unit

Hot air

Heat source

Exhaust fan

Fig. 4

Fig. 5d

Fig. 5a

Fig. 5b

CAUTION CAUTION

A solid base must not cover the hole of the bottom plate.

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Obstacle above

Drain holes

Air intake

Min.

6" (15 cm)

Air discharge

Min. 10"

(25 cm)

Min. 3'3" (100 cm)

Ground

Air discharge

Min. 8" (20 cm)

Air intake

Obstacle

Cushion rubber

(Locally purchased)

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2-2-1. Installing the Unit in an Area with High Winds and in a Snowy Area

● In locations with high winds, a wind-proof duct

should be fitted and direct exposure to the wind should be avoided as much as possible. (Fig. 5e)

● In regions with significant snowfall, the outdoor unit

should be provided with a platform and snow-proof duct. (Fig. 5f)

■ Countermeasures against snow and wind

In regions with snow and strong wind, the following problems may occur when the outdoor unit is not provided with a platform and ducting:

a) The outdoor fan may not run and damage to the

unit may occur.

b) There may be no air flow.

c) The tubing may freeze and burst.

d) The condenser pressure may drop because of

strong wind, and the indoor unit may freeze.

Air discharge

Outdoor unit

Air discharge

Fig. 5e

Duct

2-2-2. Precautions for Installation in a Snowy Area

(1) The platform should be higher than the maximum

snow depth. (Fig. 5g)

(2) The 2 anchoring feet of the outdoor unit should

be used for the platform, and the platform should be installed beneath the air intake side of outdoor unit.

(3) The platform foundation must be firm and the unit

must be secured with anchor bolts.

(4) In case of installation on a roof subject to strong

wind, countermeasures must be taken to prevent the unit from being blown over.

Air Intake



About 1/2 of the unit height

Fig. 5f



sno

igher than the

axi

Air Intake

Platform (foundation)

h

dept

Without snowproof ducting (Low platform)

Without snowproof ducting (High platform)

Fig. 5g

11-13/16" 13-3/8"

25-3/16"

22-7/8"

(6-21/32")

6-5/16"

21-25/32" (12-9/16")

2-11/16"

35-13/16"

37-1/32"

Air discharge

Hole for anchor bolt (4-R1/4") / Anchor bolt : 3/8" or M101

Air discharge

25-31/32"6-11/16"

13-3/8"

25/32"25/32"

14-31/32" 13/32"25/32"

Air Intake

Air discharge

Unit: inch

Air

Air Intake

(4-11/32")

discharge

Air discharge

2-2-3. Dimensions of Wind-proof Duct

Reference diagram for C3082/3682

(9/16")

21-9/16"

(1/4")

22-1/4"

23-7/16"

(4-31/32")

4-31/32"

21-25/32"

11-13/16"

1-5/16"

15/16"

18-15/16"

(1-31/32")

(1-31/32")8-21/32"1-3/16"

22-7/8"

Equivalent to the reverse side

Unit: inch

4- 1/4"

hole

Reference diagram for wind-proof duct (locally purchased): STK-DGV160E

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8" na

t ero

More than 9-27/32" More than 9-27/32"

More than 6"

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Required space around the outdoor unit

If the wind-proof duct is used, the space shown below must be secured around the outdoor unit. If the unit is used without the required space, a protective device may activate, preventing the unit from operating.

(1) Single-unit installation

or more

Min. 39-3/8"

" or more

Min. 8

Unit: inch

CAUTION

The top and both sides must remain open. If there are obstacles to the front and rear of the outdoor unit, the obstacle at either the front or rear must be no taller than the height of the outdoor unit.

(2) Multiple-unit installation

Installation in lateral rows

CAUTION

The front and top must remain open. The obstacles must be no taller than the height of the outdoor unit.

Installation in front-rear rows

intakes or outlets facing outlets

Unit: inch

Installation with intakes facing outletsInstallation with intakes facing

CAUTION

More than 11-13/16"

More than 47-1/4"

The front and both sides must remain open.

More than 78-3/4"

Unit: inch

25-13/32"

3/32"

13-3/8"

(11-15/16")

16-15/16"

Air Intake

Air discharge

39-1/4"

27-7/32"

7-1/32"

35-15/16"

28-15/16"

27-5/8" (11-5/8")

Air Intake

13/32"14-31/32"

25/32"

13-3/8"

4-11/32"

(8-15/16") 25-31/32"

Air discharge

Unit: inch

Hole for anchor bolt (4-R1/4") / Anchor bolt: 3/8" or M10

2-2-4. Dimensions of Snow-proof Duct

Reference diagram for C3082/3682

Unit: inch

Unit top, snow-proof duct

Unit right, snow-proof duct

Unit left, snow-proof duct

Unit front, snow-proof duct

Unit reverse side, snow-proof duct

Unit reverse side, reinforcement bracket for snow-proof duct

Unit left, reinforcement bracket for snowproof duct

Fastened by screws at 14 locations

Fastened by screws at 3 locations

Fixing with

front panel

2- 9/32"

hole

2- 9/32"

hole

2- 9/32"

hole

2- 9/32"

hole

9/32"

X13/32"hole

15-11/32"

Fastened by screws

(Same on the reverse side)

Fastened by screws at 2 locations

28-13/16"

16-15/16"

9-1/8"

31/32"

2-7/32"

24-3/16" 28-3/16"

Fixing with rear panel

5/8"

6-1/32"

28-3/16"

1-15/16"20-13/32"

5/16"

5-13/32"

34-23/32"

11-7/8"

28-/13/16"

16-15/16"

9-1/8"

4-1/32"

Fixing with rear panel

Unit anchor holes

(Unit fixed bottom plate)

9-7/32"

13-7/8"

5-1/8

4-11/32"

1-9/16"

5-7/8"

25/32"

4-27/32"

20-7/8"

3-27/32"

3-15/16"

4-23/32"

25-13/32"

17-9/16"

Fastened by screws

at 2 locations (Same on the reverse side)

Fixing with top panel

1/16" 27-9/16"

Reference diagram for snow-proof duct (locally purchased): STK-BDV80E

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