Sanyo C1852, CL1251, C1251, C0951, KS1852 User Manual

INSTALLATION INSTRUCTIONS

– Split System Air Conditioner –

COOL /DRY Model

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
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

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

7.REMOTE CONTROL UNIT INSTALLATION

POSITION .........................................................	22
7-1. Mounting on a Wall

IMPORTANT

Power source for C0951, CL0951, C1251 and CL1251 is 60 Hz, single-phase 115V.

	In Canada
SANYO FISHER COMPANY	SANYO Canada Inc.
A DIVISION OF SANYO NORTH AMERICA CORPORATION	300 Applewood Crescent, Concord
21605 Plummer Street	Ontario, L4K 5C7, Canada
85264189593004 © SANYO 2002 Chatsworth, CA 91311 U.S.A.
	W

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 WARNING unsafe practice which can result

in severe personal injury or death.

This symbol refers to a hazard or

CAUTION

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

WARNING

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 (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

•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

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)

Parts	Figure	Q’ty	Parts			Figure	Q’ty	Parts	Figure	Q’ty
			Tapping	Truss-head				Remote
Rawl plug		12		Phillips			12			1
			screw					control unit
				5/32	×	5/8" (4 ×	16 mm)
Drain hose			Remote				1	AAA alkaline
		1	control							2
adapter								battery
			holder

Hex

1

wrench*

* 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

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.

CAUTION Check local electrical codes and regulations before

obtaining wire. Also, check any specified instructions or limitations.

	Narrow Tube		Wide Tube		Model
	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

1-6. 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

Indoor unit

Drain hose

2. Installation Site Selection

2-1. Indoor Unit

To prevent abnormal heat genera-

WARNING

tion 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:

Outside drainage

Fig. 1

2" (5 cm) min. *6" (15 cm) min.

*KS1852 only

2" (5 cm) min.
*6" (15 cm) min.	2" (5 cm) min.
	*6" (15 cm) min.

Front View

Fig. 2

INDOOR	Tubing length (L)
UNIT

Elevation difference (H)

OUTDOOR

UNIT

●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 unrestricted 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

Fig. 3a

CAUTION

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

Indoor unit

Wall

Minimum height from floor level 5 ft. (1.5 m)

Floor level

Max. Allowable Tubing	Limit of Tubing	Limit of Elevation	Required Amount of
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

*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.

4

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.

●allow enough room around the unit for air intake/ exhaust and possible maintenance. (Fig. 5a)

CAUTION

●Install the outdoor unit above snowfall line.

●Do not place objects on or sit on the outdoor 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.

●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)

NOTE

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.

NO	Exhaust fan

Hot air

Heat source

Outdoor unit

Fig. 4

						Obstacle above
					(25 cm)	discharge		Min.	Min.
Air intake	Min. 6" (15 cm)							7 ft.	7 ft.
					Valve side
							(2 m)		(2 m)
					Min. 10"				Obstacle
Min. 6" Air discharge				Min. 12"		Air
(15 cm)				(30 cm)
						Ground
								Min. 6 in.
								(15 cm)
				Fig. 5a				Air intake
							Anchor bolts
							(4 pcs)
								Min. 4"
Air intake								(10 cm)
Concrete
or equal
								)
About							(10	cm
						About
	16"					4"
		(40	cm)

Fig. 5b

Baffle	6" min	Baffle
min	dischargeAir	plate
plate
6"
Air discharge

Fig. 5c

5

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 ▲ marks on the frame cover and disengage the stationary tabs from the frame. (Fig. 7)

(3)Remove the rear panel.

NOTE

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 location 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.

CAUTION

●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.

Set screw only for transportation

Fig. 6

Rear panel

Fig. 7 ▲ marks

KS0951, KS1251

Right-rear tubing

Left (recommended) tubing

Left-rear
tubing	Right tubing

Fig. 8a

Downward tubing

KS1852

Left

tubing Right-rear tubing (recommended)

Right tubing

Fig. 8b

Downward tubing

Drain hose

In case of right-rear

	Clamp
	To slip on
Drain cap	60° To remove

Fig. 9

Fig. 8c

6

(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.

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)

NOTE

Hole should be made at a slight downward slant to the outdoor side.

Indoor Outdoor side side

Fig. 10

PVC pipe (locally purchased)

		Cut at slight angle
		Fig. 11
	INSIDE	OUTSIDE
	Plastic	Wall
		PVC pipe
	cover
		Slight
		angle

Fig. 12

Fig. 13

Fig.

3/16" (4.8 mm) dia. hole

Rawl plug

Fig. 15

7