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
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
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 15
4-1. Wiring Instructions for the Outdoor Unit
COOL/DRY/HEAT Model
Model Combinations
Combine indoor and outdoor units only as listed
below.
Indoor Units Outdoor Units
KHS0951 CH0951
KHS1251 CH1251
Power Source:
60 Hz, single-phase, 115 V
KHS1852 CH1852
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
7. REMOTE CONTROL UNIT INSTALLATION
POSITION......................................................... 22
7-1. Mounting on a Wall
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.
85264189615003 © SANYO 2002 Chatsworth, CA 91311 U.S.A.
A DIVISION OF SANYO NORTH AMERICA CORPORATION
21605 Plummer Street Ontario, L4K 5C7, Canada
Power source for CH0951 and CH1251 is 60 Hz,
single-phase 115 V.
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") CH0951
6.35 mm (1/4") 0.8 mm (0.0314") 12.7 mm (1/2") 0.8 mm (0.0314") CH1251
6.35 mm (1/4") 0.8 mm (0.0314") 15.88 mm (5/8") 1.0 mm (0.0394") CH1852
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
*KHS1852 only
Fig. 2
Fig. 3a
● 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 the outdoor unit and within a total tubing length (L)
from the outdoor unit as detailed in Table 3 and Fig. 3a.
Table 3
Max. Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of
Length at Shipment Length (L) Difference (H) Additional Refrigerant Model
* 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.
(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
For stable operation of
the air conditioner, do
not install wall-mounted
type indoor units under
5 ft. (1.5 m) from floor
level.
Fig. 3b
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
Air intake
Concrete
or equal
Min. 4"
(10 cm)
Anchor bolts
(4 pcs)
About 16" (40 cm)
CH09, 12: 2 to 2-1/2" (5 to 6.5 cm)
CH18: 2-1/2 to 3" (6.5 to 7.5 cm)
CAUTION
Drain holes
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, 2 to 2-1/2 (CH09, 12) / 2-1/2 to 3 (CH18) in. ×
16 in. (5 to 6.5 / 6.5 to 7.5 × 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 (Figs. 5b
and 5c).
● use lug bolts or equal to bolt down unit, reducing
vibration and noise.
A solid base must not cover
the hole of the bottom plate.
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 (KHS0951, KHS1251 and
KHS1852) 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
KHS0951, KHS1251
● 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
KHS1852
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
3-4. Remove the Grille to Install the Indoor Unit
Flap
(Up and down air direction louvre)
Screw cover
Air intake grille
Basically, these models can be installed and wired without removing the grille. If access to any internal part is
needed, follow the steps as given below:
How to remove the grille
(1) Set the flap in the horizontal position.
(2) Unscrew the screws. (Fig. 16a or 16b)
KHS0951, KHS1251
(3) Remove the grille. (Fig. 17)
(a) Hold both corners of the air intake grille, then
pull out and up to open.
(b) Pull the lower part of the grille toward you to
remove.
(c) Use a standard screwdriver to push up the 3
tabs to remove the grille.
How to replace the grille
(1) Close the flaps.
(2) Reinstall the grille into the lower part while aligning
its tabs on the upper part. (Fig. 18) Insert the tabs in
the slots and push the lower part of the grille back
into position.
(3) Press at each of the 4 tabs to completely close the
grille. Make sure that the grille and frame are firmly
fitted together. (Fig. 19)
Fig. 16a
KHS1852
Fig. 16b
Fig. 17
Fig. 18
Fig. 19
8
3-5. Shape the Indoor Side Tubing
Frame
Right tubing
outlet
Frame
Left tubing
outlet
1) Arrangement of tubing by directions
a) Right or left tubing
Cut out the corner of the right/left frame with a
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:
Hang the 2 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)
3-6. Wiring Instructions
General precautions on wiring
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 circuit breaker for overcurrent protection provided in
the exclusive line.
3) To prevent possible hazard due to insulation failure,
the unit must be grounded.
4) Each wiring connection must be done tightly and in
accordance with the wiring system diagram. Wrong
wiring may cause the unit to misoperate or become
damaged.
Fig. 20
Fig. 21
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.
Fig. 22
9
3-7. Recommended Wire Length and Diameter
NOTE
INDOOR UNIT
Terminal
Disconnect
switch
(Field supply)
1
2
3
4
5
6
1
2
3
4
5
6
7
8
G
G
G
Grounding
line
(Inter-unit)
Power lines
(Inter-unit)
Control lines
Terminal
OUTDOOR UNIT
Power supply line
Single-phase, 115V
60Hz
L
N
INDOOR UNIT
Terminal
Disconnect
switch
(Field supply)
1
2
3
4
5
6
1
2
3
4
5
6
7
8
G
G
G
Grounding
line
(Inter-unit)
Power lines
(Inter-unit)
Control lines
Terminal
OUTDOOR UNIT
Power supply line
Single-phase, 230/208V
60Hz
L1
L2
CAUTION
WARNING
CAUTION
Rear
panel
Wiring
Wall
10 in.
(25 cm)
Plastic
cover
WIRING SYSTEM DIAGRAM
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.
Refer to the wiring system diagram (Fig. 23)
Refer to your local codes or in the absence of local
codes with the National Electric Code: ANSI/NFPA70.
● Be sure to comply with local codes on running
the wire from the outdoor unit to the indoor unit
(size of wire and wiring method, etc.).
● Each wire must be firmly connected.
● No wire should be allowed to touch refrigerant
tubing, the compressor, or any moving part.
CH0951, CH1251 Models
CH1852 Model
WARNING
● To avoid the risk of electric shock, each air
conditioner unit must be grounded.
● Be sure to connect the power supply line to the
outdoor unit as shown in the wiring diagram. The
indoor unit draws its power from the outdoor
unit.
3-8. Wiring Instructions for Inter-unit Connections
a) Remove the grille. (See 3-4. Remove the Grille to
Install the Indoor Unit on page 8.)
b) Insert the inter-unit wiring (according to local codes)
into the through-the-wall PVC pipe. Run the wiring
toward the indoor side allowing approx. 10 in. (25
cm) to extend from the wall face. (Fig. 24)
Fig. 23
Never fix the wiring by any
means before the indoor unit
is fully seated on the rear
panel.
Fig. 24
10
Cover
plate
Terminal
plate
Electrical
component
box
Earth plate
Cover
plate
Electrical
component box
Cover
plate
Terminal
plate
Electrical
Component
box
Earth plate
Cover
plate
Electrical
component box
Earth
Plate
c) Remove the screws to open the cover plate secur-
NOTE
WARNING
Inter-unit
(Power line)
wiring
Inter-unit
(Control line)
wiring
Earth
Plate
Lock nut
Lock
nut
Top of conduit
Inter-unit
Control line
Wiring
Earth
plate
Power line
Top of conduit
connector
Screw
Screw
hole
ing the electrical component box. (Figs. 25a, 25b,
25c and 25d)
d) Insert the wrapped tubing into the hole in the wall.
e) Hang the indoor unit on the rear panel.
f) Using a Phillips screwdriver, take out the screws on
the earth plate. (Fig. 26a KHS09, 12 models only)
Remove the earth plate.
g) Remove the lock nut from the conduit connector.
Insert the conduit connector through the opening
from the underside of the electrical component box.
After insertion, Fit the screw at the top of the conduit connector into the cut-out. (Fig. 26b). Position
the earth plate over the conduit connector, allowing
the connector and wires to extend through the hole
in the plate. Next, attach the conduit connector to
the earth plate by replacing and tightening the lock
nut (Figs. 26c and 26d). Then re-attach the earth
plate to the electrical component box with the 2
screws.
KHS0951, KHS1251
Fig. 25a
KHS1852
KHS0951, KHS1251
Fig. 25b
KHS1852
h) Give some play to the inter-unit wiring from the out-
door unit to the corresponding terminals on the terminal base. (See Wiring System Diagram on page 10.)
● Be sure to refer to the Wiring System Diagram
label inside the electrical component box and
carry out the correct field wiring. Wrong wiring
can cause the unit to misoperate or result in a fire
hazard.
● Check local electrical codes and any specified
wiring instructions or limitations.
i) Fix cover plate and cover plate and back into posi-
tion with their screws.
When closing the air intake grille, press on both corners
and the center. (Fig. 27)
Fig. 25c
KHS0951, KHS1251
Fig. 26a
KHS0951, KHS1251
Fig. 25d
KHS1852
Fig. 26b
KHS1852
Fig. 27
Fig. 26c
Fig. 26d
11
Solid wire
Loop
Insulation
Strip 15/16" (25 mm)
STRIP
SIZE
(ACTUAL
SIZE)
9/32" (7 mm)
Stranded wire
Ring
Connector
Strip 3/8" (10 mm)
Screw
Ring connector
Terminal plate
Wire
Special
washer
Screw and
special washer
Ring
connector
Wire
WARNING
Loose wiring may cause the termi-
Twist wire ends
nal to overheat or result in unit malfunction. A fire hazard may also
exist. Therefore, 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.
How to connect wiring to the terminal
a) For Indoor Unit
(1) Cut the wire end with a cutting pliers, then strip the insu-
lation to expose the wire about 9/32 in. (7 mm). See the
label (Fig. 28) near the terminal plate.
(2) Using a screwdriver, loosen the terminal screw on the ter-
minal plate.
(3) Insert the wire and tighten the terminal screw completely
using a screwdriver.
b) For Outdoor Unit
■ For solid core wiring (or F-cable)
(1) Cut the wire end with a cutting pliers, then strip the insu-
lation to expose the solid wire about 15/16 in. (25 mm).
(Fig. 29)
(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 suit-
able for the terminal screw.
Fig. 28
Fig. 29
Fig. 30
(4) Shape the loop wire properly, place it on the terminal
plate and fix it securely with the removed terminal screw
using a screwdriver.
■ For stranded wiring
(1) Cut the wire end with a cutting pliers, then strip the insu-
lation to expose the stranded wiring about 3/8 in. (10 mm)
and tightly twist the wire ends. (Figs. 30 and 31)
(2) Using a screwdriver, remove the terminal screw(s) on the
terminal plate.
(3) Using a ring connector fastener or pliers, securely clamp
each stripped wire end with a ring connector. (Fig. 30)
(4) Place the ring connector wire, and replace and tighten the
removed terminal screw using a screwdriver. (Fig. 32)
Fig. 31
Fig. 32
12
3-9. Mounting
NOTE
Cover
Refrigerant
tubing
Rear panel
Drain hose
Inter-unit
wiring
Insulation
Push
Stand
Refrigerant tubing
Drain hose
Conduit
Inter-unit wiring
(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)
For tubing, choose either the right or left tubing direction and follow the steps below. Also, extend the support on the back of the indoor unit as a stand to make
your work easier. (Fig. 34)
■ Right-side tubing
(1) Shape the refrigerant tubing so that it can easily go
into the wall hole. (Fig. 35)
Fig. 33
(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)
(3) Carefully bend the tubing (if necessary) to run
along the wall in the direction of the outdoor unit
and then tape as far as the fittings. (See Caution
on page 17.) The drain hose should come straight
down the wall to a point where water runoff won’t
stain the wall.
(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.
(5) Assemble the refrigerant tubing, drain hose, and
conduit (including inter-unit wiring) as shown in
Fig. 37b.
Fig. 34
Fig. 35
Fig. 36
Fig. 37a
Fig. 37b
13
To unmount indoor unit
WARNING
Risk of Electric Shock
Condensation
Insulation material
(locally purchased)
must be used.
Push
Slant
Drain
hose
Indoor
unit
Press the 2 ▲▲ marks on the lower part of the indoor
unit and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 38)
3-10. Drain Hose
a) The drain hose should be slanted downward to the
outdoors. (Fig. 39)
b) Never form a trap in the course of the hose.
c) If the drain hose will run in the room, insulate the
hose with insulation* so that chilled condensation
will not damage furniture or floors. (Fig. 40)
* Foamed polyethylene or its equivalent is recom-
mended.
Do not supply power to the
unit or operate it until all
tubing and wiring to the
outside unit are completed.
Fig. 38
Fig. 39
Fig. 40
14
4. How to Install the Outdoor Unit
Lock nut
Terminal
block
Access panel
Control line
(Sheath cable)
Power line
(Conduit)
Plug
Conduit
plate
Power supply
(Conduit)
CAUTION
1
2
3
G
Disconnect
switch
Indoor unit
Grounding line
G
(D)
Outdoor unit
1
2
3
1
2
3
G
Disconnect
switch
Indoor unit
Grounding line
G
(E)
Outdoor unit
1
2
3
1
2
3
G
Disconnect
switch
Indoor unit
Grounding line
1
2
3
G
(A)
Outdoor unit
1
2
3
G
Disconnect
switch
Indoor unit
Grounding line
G
(B)
Outdoor unit
3
1
2
1
2
3
G
Disconnect
switch
Indoor unit
Grounding line
G
(C)
Outdoor unit
3
1
2
CAUTION
First refer to Section 2. Installation Site Selection.
4-1. Wiring Instructions for the Outdoor Unit
Regulations on wire size differ from locality to locality. For field
wiring requirements, please refer to your local electrical
codes. Make sure that the installation fully complies with all
local and national regulations.
(1) Remove access panel. (Fig. 41)
(2) Connect the power line according to the drawing on the
panel side.
(3) Be sure to size each wire allowing approx. 4 in. (10 cm)
Fig. 41
longer than the required length for wiring. Store excess
wiring inside the cabinet.
(4) When connections are completed, check that all connec-
tions are correct as shown in the wiring system diagram
on panel side.
(5) Be sure to ground the unit according to your local codes.
Apply sealer (putty, etc.) to
the gap between the sheath
cable and the hole of the
conduit plate to prevent
water from entering.
■ Examples of Incorrect Wiring
The following are examples of improper wiring that result in system misoperation. You should confirm that you have
wired the units correctly before beginning the test run.
Problem 1
Short circuit will occur after approx.
●
3 minutes and the power circuit fuse
blows.
Problem 2
Air conditioner will not operate.
●
Problem 3
●
Compressor will not start; only indoor unit will operate.
15
Deburring
Before
After
Reamer
Copper
tubing
Flare tool
Flare nut
Copper
tubing
Apply refrigerant
lubricant here and here
Flare nut
Union
5. Refrigerant Tubing
NOTE
NOTE
5-1. Use of the Flaring Method
Many of the conventional split system air conditioners
employ the flaring method to connect refrigerant tubes
which run between indoor and outdoor units. In this
method, the copper tubes are flared at each end and
connected with flare nuts.
5-2. Flaring Procedure with a Flare Tool
a) Cut the copper tube to the required length with a
tube cutter. It is recommended to cut approx. 12 to
20 in. (30 to 50 cm) longer than the tubing length
you estimate.
b) Remove burrs at the end of the copper tube with a
tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 42)
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 43)
c) Remove the flare nut from the unit and be sure to
mount it on the copper tube.
Fig. 42
Fig. 43
d) Make a flare at the end of copper tube with a flare
tool.* (Fig. 44)
(*Use “RIGID” or equivalent.)
A good flare should have the following characteristics:
● inside surface is glossy and smooth.
● edge is smooth.
● tapered sides are of uniform length.
5-3. Caution before Connecting Tubes Tightly
a) Be sure to apply a sealing cap or water-proof tape
to prevent dust or water from getting into the tubes
before they are used.
b) Be sure to apply refrigerant lubricant to the match-
ing surfaces of the flare and union before connecting them together. This is effective for reducing gas
leaks. (Fig. 45)
c) For proper connection, align the union tube and
flare tube straight with each other, then screw in
the flare nut lightly at first to obtain a smooth
match. (Fig. 46)
Fig. 44
Fig. 45
Fig. 46
16
5-4. Connecting Tubing between Indoor and
NOTE
IMPORTANT
Insulation
Insulation
Min.
5/16" (8 mm)
Thickness:
min. 5/16" (8 mm)
Clamp
Insulated tubes
Apply putty here
Tubing
CAUTION
Outdoor Units
a) Tightly connect the indoor side refrigerant tubing extend-
ed from the wall with the outdoor side tubing. (Fig. 47)
b) To fasten the flare nuts, apply specified torque as:
Table 5
Tube Dia. Tightening Torque
1/4" (6.35 mm) Approx. 130 – 170 lbs.·in. (150 – 200 kg·cm)
3/8" (9.52 mm) Approx. 300 – 340 lbs.·in. (350 – 400 kg·cm)
1/2" (12.7 mm) Approx. 430 – 470 lbs.·in. (500 – 550 kg·cm)
5/8" (15.88 mm) Approx. 520 – 560 lbs.·in. (600 – 650 kg·cm)
5-5. Insulation of Refrigerant Tubing
To prevent heat loss and wet floors due to dripping of condensation, both tubes must be well insulated with a prop-
er insulation material. (Fig. 48) The thickness of the insulation should be a minimum 5/16" (8 mm). (Fig. 49)
Torque wrench
Spanner
Indoor unit
Outdoor unit
Fig. 47
Fig. 48
After a tube has been insulated,
never try to bend it into a narrow
curve, as this may cause the tube to
break or crack.
5-6. Taping the Tubes
a) At this time, the 2 refrigerant tubes (and electrical wire if
local codes permit) should be taped together with armoring tape. The drain hose may also be included and taped
together as 1 bundle with the tubing.
b) Wrap the armoring tape from the bottom of the outdoor
unit to the top of the tubing where it enters the wall. As
you wrap the tubing, overlap half of each previous tape
turn. (Fig. 50)
c) Clamp tubing bundle to wall, using 1 clamp approx. every
47 in. (120 cm).
Do not wind the armoring tape too tightly, since this will
decrease the heat insulation effect. Also, be sure the condensation drain hose splits away from the bundle and drips clear
of the unit and the tubing.
Fig. 49
Fig. 50
5-7. Finishing the Installation
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. 51)
Fig. 51
17
6. Air Purging
NOTE
HiLo
Indoor unit
Outdoor unit
Manifold valve
Pressure
gauge
Vacuum pump
Air and moisture remaining in the refrigerant system have
undesirable effects as indicated below. Therefore, they must
be purged completely.
● pressure in the system rises
● operating current rises
● cooling (or heating) efficiency drops
● moisture in the air may freeze and block capillary tubing
● water may lead to corrosion of parts in the refrigerant sys-
tem
■ 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 narrow and
wide tubes.
(3) Connect a vacuum pump and a manifold valve (with pres-
sure gauges) to the service port on the wide tube service
valve. (Fig. 52)
CAUTION
Be sure to use a manifold valve for
air purging. If it is not available, use
a stop valve for this purpose. The
“Hi” knob of the manifold valve
must always be kept closed.
(4) With the “Lo” knob of the manifold valve open, run the
vacuum pump. The operation time for the vacuum pump
varies with tubing length and the capacity of the pump.
The following table shows the amount of time for evacuation:
Table 6
Required time for evacuation when capacity
less than 33 ft. (10 m) more than 33 ft. (10 m)
of 100 liter/h vacuum pump is used
If tubing length is If tubing length is
10 min. or more 15 min. or more
Fig. 52
The required time in the above table is calculated based on
the assumption that the ideal (or target) vacuum condition is
around 10 mmHg abs.
18
(5) With the vacuum pump still running, close the “Lo”
CAUTION
90° (1/4 turn)
Narrow tube
Hex wrench
Wide tube
Valve cap
Vacuum hose to manifold valve
knob of the manifold valve. Then stop the vacuum
pump.
(6) With the accessory hex wrench, turn the valve
stem on the narrow tube service valve counterclockwise by 90 degrees (1/4 turn) for 10 seconds,
and then turn the stem clockwise to close it again.
(Fig. 53)
Be sure to completely insert
the hex wrench before
attempting to turn the valve.
(7) Leak test all joints at the tubing (both indoor and
outdoors) with liquid soap. Bubbles indicate a leak.
Be sure to wipe off the soap with a clean cloth.
(8) With the hex wrench, turn the wide tube service
valve stem counter-clockwise to fully open the
valve.
(9) Turn the narrow tube service valve stem counter-
clockwise to fully open the valve.
Fig. 53
(10) Loosen the vacuum hose connected to the wide
tube service port slightly to release the pressure.
Then, remove the hose.
(11) Replace the bonnet and flare nut on the wide tube
service port and fasten the flare nut securely with
an adjustable wrench or box wrench. Next, mount
the valve cap and tighten it with a torque wrench
(the cap needs to be tightened with the torque of
170 lbs.•in. (200 kg•cm)). This process is very
important to prevent gas from leaking from the
system.
(12) Test run the air conditioner. (See next page.)
(13) While the air conditioner is running, apply liquid
soap to check for any gas leaks around the ser-
vice valves or caps.
(14) If there is no leakage, stop the air conditioner.
(15) Wipe off the soap on the tubing.
This completes air purging with a vacuum pump and
the air conditioner is ready for actual operation.
19
* How to Test Run the Air Conditioner.
NOTE
OFF
ON
TEST
OPERATION
TIMER
STANDBY
ON
OFF
TEST
Operation
selector
switch
(1) Switch on the power source.
(2) Press the ON/OFF button on the remote control
unit once.
(3) Set the operation selector switch of the indoor unit
to the TEST position. This starts the fan, producing
uncooled forced air. (Figs. 54a and 54b)
(4) After 3 minutes, the system shifts into cooling
operation, and cool air will start to be felt. Cooling
operation during with the switch at the TEST posi-
tion is unaffected by the room temperature.
(5) After stopping the test run, turn the operation
selector switch of indoor unit to the OFF position
once, then move to ON position.
(6) Press the ON/OFF button on the remote control
unit to stop the air conditioner.
If the unit does not operate and the OPERATION lamp
on the unit is blinking after going through the procedure, check the wiring between the units.
KHS0951, KHS1251
Fig. 54a
KHS1852
Fig. 54b
20
Action
Narrow Tube Service
Valve (2-Way)
Wide Tube Service
Valve (3-Way)
CLOSED
Fully OPEN
Fully OPEN
Shipping
Operating and
test running
the air conditioner
Measuring pressure
and gas charging
Air purging with
a vacuum pump
CLOSED
Valve cap
Stem
O-ring
*
*
PUSH
Hose with push-pin
Service valve
■
Basic Function of the Service Valves
The basic function of the service valves are given in Table 7 below.
Table 7
* The service port on the wide tube service
valve uses a Schrader core valve to access
the refrigerant system. Therefore, be sure to
use a hose connector which has a push-pin
inside. (Fig. 55)
■ Pump Down
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.
Pump Down Procedure
Be sure to carry out pump down with the unit in
cooling mode.
(1) Connect the Lo side charging hose of the manifold
valve to the service port on the wide tube service
valve.
(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.)
(3) Press the operation button and start cooling opera-
tion.
(4) When the low pressure gauge reading falls to 1 to
0.5 kg/cm2 (14.2 to 7.1 PSI), fully close the wide
tube valve stem with a standard screwdriver. Then
quickly stop the unit.
(5) Disconnect all gauges and hoses, and replace the
bonnets and the valve caps as they were before.
21
Fig. 55
7. Remote Control Unit Installation Position
Truss-head
tapping screw
5/32 × 5/8" (4 × 16mm supplied)
Remote
control
unit holder
Holder
Holder
Truss-head
tapping screw
5/32 × 5/8" (4 × 16mm supplied)
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:
● In direct sunlight
● Behind a curtain or other place where it is covered
● More than 26 ft. (8 m) away from the air conditioner
● In the path of the air conditioner’s airstream
● Where it may become extremely hot or cold
● Where it may be subject to electrical or magnetic
interference
7-1. Mounting on a Wall
1) Confirm the indoor unit beeps when the
ON/OFF button is pressed at the wall location
where the remote control unit is to be attached,
then attach the holder to the wall. (Fig. 56)
2) When taking out the remote control unit, pull it
from the holder.
When using the remote control unit
• Point the transmission portion of the remote
control unit at the receiver area of the indoor
unit when operating the remote control unit,
and during operation of the air conditioner.
• Do not place objects that may block the transmitted signals between the receiver and the
remote control unit.
When mounting the remote control unit to
prevent theft
1) Mount the holder to the wall with one of the
screws (using only the hole in the top of the
holder) (Fig. 57).
2) Remove the cover of the remote control unit
and take out the batteries. Next, place the
remote control unit in the holder.
Fig. 56
3) Fasten both the remote control unit and holder
to the wall with the remaining screw (using the
hole in the bottom of the holder).
4) Install the batteries in the remote control unit
and close the cover.
Fig. 57
22
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