Sanyo CL1872 User Manual

INSTALLATION INSTRUCTIONS

– Inverter Split System Air Conditioner –

This air conditioner uses the new refrigerant R410A.

NOTE

Contents

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 2-3. Baffle Plate for the Outdoor Unit

3. HOW TO INSTALL THE INDOOR UNIT ........... 11

3-1. Preparation for Suspending 3-2. Suspending the Indoor Unit 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. How to Install the Ceiling Panel 3-7. Wiring Instructions 3-8. Recommended Wire Length and Diameter 3-9. Wiring Instructions for Inter-unit Connections

4. HOW TO INSTALL THE OUTDOOR UNIT ....... 19

4-1. Wiring Instructions for the Outdoor Unit

5. REFRIGERANT TUBING .................................. 20

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................................................... 22

I Air Purging with a Vacuum Pump (for Test Run) I Basic Functions of the Service Valves I Pump Down I Service Valve Connections

85264190478000 © SANYO 2008

Refrigerant service valve size = 5/16"

Page

SANYO Commercial Solutions In Canada A Division of SANYO North America Corporation SANYO Canada Inc. 1300 Michael Drive, Suite A 1-300 Applewood Crescent, Concord Wood Dale, IL 60191, U.S.A. Ontario, L4K 5C7, Canada

COOL/ DRY Model

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Unit Outdoor Unit

XS1271 C1271

CL1271 Power Source: 60 Hz, single-phase, 115 V

XS1872 C1872

CL1872 Power Source: 60 Hz, single-phase, 230/208 V

Ceiling Panel

PNR-XS1872

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

7. REMOTE CONTROL UNIT INSTALLATION

POSITION ......................................................... 26

7-1. Mounting on a Wall

8. ADDRESS SWITCH .......................................... 27

8-1. Address Setting of the Remote

Control Unit

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.

IMPORTANT!

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.

SPECIAL PRECAUTIONS

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

• Do not supply power to the unit until all wiring and tubing

• Highly dangerous electrical voltages are used in this

• Ground the unit following local electrical codes.

• Connect all wiring tightly. Loose wiring may cause over-

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 Wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.

are completed or reconnected and checked.

system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or

death.

heating at connection points and a possible fire hazard.

• 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.

Printed on container box

For unit & PVC tube connection

For drain hose connection

RemarksQ’ty

For full-scale installation diagram

For temporarily suspending indoor unit from ceiling

Flare insulation

For wide / narrow tube connection

For wide / narrow tube / flare nut connection

For flare / drain insulating connection

For drain tube connection

Insulation tape

Vinyl tie

Drain hose insulation

Washer

AAA alkaline battery

Remote control unit

Remote control unit holder

Parts PartsFigure RemarksQ’ty Figure

Drain hose

Full-scale installation diagram

5-1/2"(L140)

Hose band

Truss head screw

Hex wrench

Special screw

Cushion rubber

Tapping screw

set

1/8"(T3) 3/16"(T5)

13/32"(T10)

3/32"(T2)

Truss-head Phillips 5/32 5/8" (4 16mm)

3/16 13/32" (5 10mm)

5/32 15/32" (4 12mm)

3/16 1-9/16" (5 40mm)

Packed in the outdoor unit

Packed in the ceiling panel

Use M10 or 3/8" for suspension bolts. Suspension bolts and nuts (locally purchased)

1. General

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

5. Carpenter’s level

1-2. Accessories Supplied with Unit

Table 1

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)

1-3. 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.

2. Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing. Wall thickness

3. Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to 3-7. Wiring

Table 2

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

of the insulation should be not less than 5/16" (8 mm).

Instructions for details.

Model

XS1271 1/4" (6.35 mm) 0.0314" (0.8 mm) 3/8" (9.52 mm) 0.0314" (0.8 mm)

XS1872 1/4" (6.35 mm) 0.0314" (0.8 mm) 1/2" (12.70 mm) 0.0314" (0.8 mm)

Outer Dia. Thickness Outer Dia. Thickness

Narrow Tube Wide Tube

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

1-5. Additional Materials Required for Installation

3.3 ft.

(1m)

3.3 ft.

(1m)

3.3 ft.

(1m)

Tubing length (L)

Elevation difference (H)

Outdoor unit

Indoor unit

WARNING

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

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:

G direct sunlight.

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.

DO:

G select an appropriate position from which every corner of

the room can be uniformly cooled.

G select a location that will hold the weight of the unit.

G select a location where tubing and drain hose have the

shortest run to the outside.

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

stricted air flow around the unit. (Fig. 1)

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. 2.

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.

Fig. 1

Fig. 2

Air delivery will be degraded if the distance from the floor to the ceiling is greater than 10 ft. (3 m).

Table 3

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

Model Length at Shipment Length (L) Difference (H) Additional Refrigerant

XS1271 25 65 23 0.16

XS1872 25 98 50 0.27

* If total tubing length becomes 25 to 65 ft. (Max.) or 25 to 98 ft. (Max.), charge additional refrigerant (R410A) by 0.16 or 0.27 oz./ft.

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

(ft.) (ft.) (ft.) (oz./ft.)*

2-2. Outdoor Unit

Outdoor unit

Hot air

Heat source

Exhaust fan

Min.

7' (2 m)

Min.

7' (2 m)

Ground

Obstacle

Obstacle above

Air discharge

Min. 4" (10 cm)

Air intake

AVOID:

G heat sources, exhaust fans, etc. (Fig. 3)

G damp, humid or uneven locations.

DO:

G choose a place as cool as possible.

G choose a place that is well ventilated.

G 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. (Figs. 4a and 4b)

G provide a solid base (level concrete pad, concrete

block, 4" × 1'4" (10 × 40 cm) beams or equal), a minimum of 4" (10 cm) above ground level to reduce humidity and protect the unit against possible water damage and decreased service life. (Fig. 5a)

G install cushion rubber under unit’s feet to reduce

vibration and noise. (Fig. 5b)

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

vibration and noise.

G install in a location where no antenna of a television

or radio exists within 10' (3 m).

(C1271, CL1271)

Air intake Min. 2" (5 cm)

Min.

2" (5 cm)

Air discharge

(C1872, CL1872)

Fig. 3

Valve side Min. 10" (25 cm)

Min. 8" (20 cm)

Fig. 4a

Obstacle above

Min.

7' (2 m)

Air discharge

Ground

Min. 2" (5 cm)

Air intake

Min.

7' (2 m)

Obstacle

Air intake

Concrete or equal

Abou

t 1'4" (40 cm)

Anchor bolts (4 pcs.)

Min. 4" (10 cm)

About 4" (10 cm)

Air intake Min. 4" (10 cm)

Min.

2" (5 cm)

Air discharge

Valve side Min. 10" (25 cm)

Min. 1'4" (40 cm)

Fig. 4b

Fig. 5a Fig. 5b

Cushion rubber

2-3. Baffle Plate for the Outdoor Unit

(CLxx models only)

Air intake baffle

NOTE

It is recommended to use baffle plates for models CL1271 and CL1872. The baffle plates are not normally required for the other models.

When the outdoor unit is installed in a position exposed to strong wind (such as seasonal winds with low air temperature in winter), baffle plates must be installed on 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.

Install a pair of windbaffle plates at the front and back of the outdoor unit if it will be subject to strong wind during the winter. (Figs. 5c to 5k)

Wind

Back

No air intake baffle required on this side.

Front

Wind

Air discharge baffle

Fig. 5c

(2- 6.5 mm)

2- 1/4"

(2- 6 mm)

2- 15/64"

(4- 6.5 mm)

4- 1/4"

I CL1271

(1) Recommended dimensions of the baffle plates

Air Intake Baffle

Air Discharge Baffle

Fig. 5d

Fig. 5e

For Air Intake

Model

CL1271

Dimensions

(inch)

(mm) 550 20 55 440 330 10 15 9 7.5 441 10 150 20 20

ABCDE FGH I JKNPQ

21-21/32

25/32 2-5/32 17-5/16 13 25/64 19/32 23/64 19/64 17-3/8 25/64 5-29/32 25/32 25/32

For Air Discharge

Dimensions

Model

CL1271

Material to be used: Metal plate with corrosion protection treatment

(inch)

(mm) 485 510 350 150 445 20 55 370 70 85 15 35 35

Plate thickness: 0.0394 to 0.0472" (1.0 to 1.2 mm)

Item Q’ty Remarks

(2) Parts required (locally purchased except for screws)

Air Intake Baffle

Baffle plate 1

Screw 5/32 × 15/32" (4 × 12 mm) tapping 2 Attached to outdoor unit

Bolt 15/64 × 19/32 – 25/32" (M6 × 15 – 20 mm) 2

Nut 15/64" (M6) 2

Washer 2

Spring washer 2

ABCDE FGH I JKLM

19-3/32 20-3/32

13-25/32

5-29/32

17-17/32

25/32 2-5/32 14-9/16 2-3/4 3-11/32 19/32 1-3/8 1-3/8

Air Discharge Baffle

Baffle plate 1

Bolt 15/64 × 13/32 – 19/32" (M6 × 10 – 15 mm) 4

Nut 15/64" (M6) 4

Washer 4

Spring washer 4

Item Q’ty Remarks

(3- 6.5 mm)

3- 1/4"

(2- 6 mm)

2- 15/64"

(4- 6.5 mm)

4- 1/4"

I CL1872

(1) Recommended dimensions of the baffle plates

Air Intake Baffle

Air Discharge Baffle

Fig. 5f Fig. 5g

For Air Intake

Dimensions

Model

CL1872

(inch)

(mm) 620 20 45 565 235 235 10 20 15 587 7.5 10 150 20 20

For Air Discharge

Dimensions

Model

CL1872

(inch)

(mm) 530 560 350 150 460 35 55 440 60 85 25

Material to be used: Metal plate with corrosion protection treatment Plate thickness: 0.0394 to 0.0472" (1.0 to 1.2 mm)

(2) Parts required (locally purchased except for screws)

Air Intake Baffle

Baffle plate 1

Screw 5/32 × 15/32" (4 × 12 mm) tapping 2 Attached to outdoor unit

Bolt 15/64 × 19/32 – 25/32" (M6 × 15 – 20 mm) 3

Nut 15/64" (M6) 3

Washer 3

Spring washer 3

Item Q’ty Remarks

ABCDE FGH I JKLOQR

24-13/32

25/32 1-25/32 22-1/4 9-1/4 9-1/4 25/64 25/32 19/32 23-1/8 19/64 25/64 5-29/32 25/32 25/32

ABCDE FGH I JK

13-25/32

5-29/32 18-1/8 1-3/8 2-5/32 17-5/16 2-3/8 3-11/32 31/32

20-7/8 22-1/16

Air Discharge Baffle

Baffle plate 1

Bolt 15/64 × 13/32 – 19/32" (M6 × 10 – 15 mm) 4

Nut 15/64" (M6) 4

Washer 4

Spring washer 4

Item Q’ty Remarks

(3) Installation procedure

Panel front

Panel side R

Panel side L

I CL1271

1. Air Intake Baffle

(1) Left side

1. Remove the front panel from the unit.

2. Remove the panel side L, and drill 2 holes of ø1/4 inch (6.5 mm) at the prescribed position.

3. Install the windbaffle on the unit using field supply bolts and nuts.

4. Recommended bolts to be used are 15/64" (M6 ISO standard), and the recommended length of the bolts is between 19/32 – 25/32 inch (15 – 20 mm).

5. Use washers and spring washers to tightly fasten the windbaffle to the unit.

(2) Right side

1. Remove the front panel from the unit.

2. Use 2 preholes on the panel side R to install the baffle plate.

3. Remove the panel side R from the unit by removing the screws. These screws are used in step 4 below.

4. Put (sandwich) the windbaffle between the unit and the panel side R, then install the windbaffle on the unit using the above screws. Be careful not to damage the screw holes.

2. Air Discharge Baffle

1. Remove the panels front, side L and R from the unit and drill 4 holes of ø1/4 inch (6.5 mm) at the prescribed positions.

2. Install the windbaffle on the unit using field supply bolts and nuts.

3. Recommended bolts to be used are 15/64" (M6 ISO standard), and the recommended length of the bolts is between 13/32 – 19/32 inch (10 – 15 mm).

4. Use washers and spring washers to tightly fasten the windbaffle to the unit.

Panel side R

Panel front

Panel side L

Fig. 5h

NOTE

G In order to prevent contact of the bolts and heat exchanger and other parts inside the unit, install the windbaffle using

Fig. 5i

bolts from inside the unit and fasten the bolts with nuts from outside the unit.

G When the windbaffle is installed on the unit, the unit has higher wind resistance. In order to prevent the unit from

falling over, anchor the legs of the unit using anchor bolts (or similar method).

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