Sanyo CL1872 User Manual

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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).

Panel top

Panel front

Panel side R

Panel side L

Panel side R

Panel top

Panel front

Panel side L

I CL1872

1. Air Intake Baffle

(1) Left side

1. Remove the top panel from the unit.

2. Remove the panel side L, and drill 3 holes of ø1/4 inch (6.5 mm) at the prescribed positions.

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 top 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, top, 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.

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

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

(4) Precautions for installation

1. Be sure not to damage painted surfaces.

2. Finish the edges of the windbaffle to avoid cuts or injury.

3. Drilling of holes must be carefully done so that no damage is caused to external or internal parts of the unit.

Fig. 5j

NOTE

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

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

Particular care must be taken that drill chips do not drop into the unit.

Fig. 5k

Hole-in-anchor

Concrete Insert

Suspension bolt (M10 or 3/8")

Hole-in-plug

(locally purchased)

1/2" — 23/32" (13~18

)

Over 19/32" (15

)

Supplied screw

Full-scale installation diagram (printed on top of container box)

3. How to Install the Indoor Unit

Nuts and washers (used for upper and lower)

Double nut

Notch

Suspension lug

Suspension bolt

1/2" — 23/32"

(13~18

)

3-1. Preparation for Suspending

This unit uses a drain pump. Use a carpenter’s level to check that the unit is level.

3-2. Suspending the Indoor Unit

(1) Fix the suspension bolts securely in the ceiling using

the method shown in the diagrams, by attaching them to the ceiling support structure, or by any other method that ensures that the unit will be securely and safely suspended. (Fig. 6-1)

(2) Follow the diagram to make the holes in the ceiling.

Fig. 6-1

23-5/8"(600mm)

Ceiling opening dimensions

21-1/32"(534

Suspension bolt pitch

)

(3) Determine the pitch of the suspension bolts using

the supplied full-scale installation diagram. The diagram shows the relationship between the positions of the suspension fitting, unit, and panel. (Fig. 6-2)

3-3. Placing the Unit Inside the Ceiling

(1) Be sure to remove the fan protection (4pcs) for

transportation before hanging up the indoor unit.

(2) When placing the unit inside the ceiling, determine

the pitch of the suspension bolts using the supplied full-scale installation diagram. (Fig. 6-3) Tubing and wiring must be laid inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing and wiring into position for connection to the unit before placing the unit inside the ceiling.

(3) The length of suspension bolts must be appropriate

for a distance between the bottom of the bolt and the bottom of the unit of more than 19/32" (15 mm) as shown in the diagram. (Fig. 6-3)

) mm

1-25/32"

(45

)

mm (45

1-25/32"

4-19/32"

(117

Power supply port

22-5/8"(575mm)

6-5/16"2-3/32"

6-11/16"

)(160mm)(53mm)

(170

Refrigerant tubing joint (narrow tube side) 1/4( 6.35mm) (flared)

Fig. 6-2

)

23-5/8"(600

21-1/32"(534

Suspension bolt pitch

Ceiling opening dimensions

Drain tube connection port (outer dia 1-1/32"( 26mm))

) mm

(215

8-15/32"

11-5/32"(283

) mm

1-3/16"

(30

(4) Thread the 3 hexagonal nuts (locally purchased) and

2 supplied washers onto each of the 4 suspension bolts as shown in the diagram. Use 1 nut and 1 washer for the upper side, and 2 nuts and 1 washer for the lower side, so that the unit will not fall off the suspension lugs. (Fig. 6-4)

(5) Adjust so that the distance between the unit and the

ceiling bottom is 1/2" (13 mm) to 23/32" (18 mm). Tighten the nuts on the upper side and lower side of the suspension lug. (Fig. 6-4)

Fig. 6-3

Fig. 6-4

Drain port

Twist tie (4 vinyl ties, supplied)

Hard PVC pipe

Position to

Drain hose (supplied)

Hose band (2 bands, supplied)

3/16" (5mm)

3/16"

(5mm)

15/16"

(25mm)

15/16"

(25mm)

5-1/2"(140

)

Drain hose

(locally purchased)

bands

(supplied)

O.D. 1-1/32" (26mm))

fasten hose

insulation

(equivalent to

Unit

Air bleeder prohibited

Support bracket

Uphill slope

3-4. Installing the Drain Piping

1 ft.(300mm) or less

0 - 45

2.78 ft.(850

) or less

* Length of supplied drain hose = 5-1/2"(140

)

CAUTION

(1) Prepare standard hard PVC pipe (locally purchased O.D.

1-1/32" (26 mm)) for the drain and use the supplied hose band to prevent water leaks. (Fig. 6-5)

(2) To install the drain hose, first place 1 of the 2 hose bands

over the unit drain port and the other hose band over the hard PVC pipe (not supplied). Then connect both ends of the supplied drain hose. (Fig. 6-5)

(3) On the unit drain side, grasp the hose band with pliers

and insert the drain hose all the way to the base.

G If other commercially available hose bands are used, the

drain hose may become pinched or wrinkled and there is danger of water leakage. Therefore be sure to use the supplied hose bands. When sliding the hose bands, be careful to avoid scratching the drain hose.

G Do not use adhesive when connecting the supplied drain

hose to the drain port (either on the main unit or the PVC pipe).

Reasons: a) It may cause water to leak from the connec-

tion. Since the connection is slippery just after the adhesive has been applied, the pipe easily slips off.

b) The pipe cannot be removed when mainte-

nance is needed.

Fig. 6-5

G Attach so that the hose band

fastener is on the side of the drain port.

G Attach the hose bands so that

each is approximately 3/16" (5 mm) to 15/16" (25 mm) from the end of the supplied drain hose.

(4) Wrap the hose with the supplied drain hose insulation

and use the 4 twist ties so that the hose is insulated with no gaps.

G Do not bend the supplied drain hose 90° or more. The

hose may slip off.

NOTE

Make sure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.

G In cases where it is necessary to raise the height of the

drain piping, the drain piping can be raised to a maximum height of 2.78 ft. (850 mm) above the bottom surface of the ceiling. Under no conditions attempt to raise it higher than 2.78 ft. (850 mm) above the bottom surface of the ceiling. Doing so will result in water leakage. (Fig. 6-7)

G Do not use natural drainage. G Do not install the pipe with an upward gradient from the

connection port. This will cause the drain water to flow backward and leak when the unit is not operating.

G Do not apply force to the piping on the unit side when

(Fig. 6-8)

connecting the drain pipe. The pipe should not be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 6-9)

G Provide insulation for any pipes that are run indoors.

Fig. 6-6

G Do not install an air bleeder as

this may cause water to spray from the drain pipe outlet. (Fig. 6-6)

Fig. 6-7

Fig. 6-8

Fig. 6-9

must be within the range of 1/2"(13mm) to 23/32"(18mm). (Fig. 6-11) If not within this range, malfunction or other trouble may occur.

Ceiling opening dimension

Ceiling side

Indoor unit

3-5. Checking the Drainage

CAUTION

Water drain

Control box

Drain pan outlet

Water

Plastic container for water intake

Over 4" (100

)

(Approx. 16 ounces (500m ) )

Flap

Latch

Air-intake grille

Ceiling panel

Air-intake grille hinge

FLAP

Control box

RCIND

After wiring and drain piping are completed, use the following procedure to check that the water will drain smoothly. For this, prepare a bucket and wiping cloth to catch and wipe up spilled water.

G Be sure to do the wiring between the units before installing the

ceiling panel. (Refer to 3-9. Wiring Instructions for Inter-unit Connections)

(1) Turn on the power. (Here, “power” refers to the power supply

from the outdoor unit.)

(2) Slowly pour approx. 16 ounces (500 ml) of water into the drain

pan to check drainage. (Fig. 6-10a)

(3) Remove the 2 screws from the control box cover, then open

the cover. Be careful not to drop the cover at this time.

(4) Disconnect the FS 3P connector (red) on the control PCB and

operate the drain pump. (Fig. 6-10b) Check the water flow through the transparent drain pipe and see if there is any leakage.

(5) When the check of drainage is complete, reconnect the FS

3P connector and remount the control cover.

The drain pump will continue to operate for a minimum of 6 minutes after the FS 3P connector is reconnected.

Fig. 6-10a

Fig. 6-10b

3-6. How to Install the Ceiling Panel

Checking the unit position

(1) Check that the ceiling hole is 23-5/8" (600 mm) × 23-5/8"

(600 mm) (Fig. 6-11)

(2) Confirm that the position of the indoor unit and the ceiling

as shown in the diagram. If the positions of the ceiling surface and unit do not match, air leakage, water leakage, flap operation failure, or other problems may occur. (Fig. 6-11)

G Never place the panel face-down. Neither hang it ver-

tically nor place it on top of a projecting object. Placing it face-down will damage the surface.

G Do not touch the flap or apply force to it. (This may

cause flap malfunction.) (Fig. 6-12)

3-6-1. Before Installing the Ceiling Panel

(1) Remove the air-intake grille and air filter from the ceiling

panel.

a) Press on and slide the two latches of the air-intake grille

with your thumb in the direction shown by the arrow to open the grille. (Figs. 6-13 and 6-14)

b) With the air-intake grille opened, remove the grille hinge

from the ceiling panel by sliding it in the direction shown by the arrow . (Fig. 6-15)

Fig. 6-12

Fig. 6-14

Fig. 6-11

Fig. 6-13

Fig. 6-15

(2) Removing the corner cover and

CAUTION

latch

Temporary latches

Temporary

DRAIN mark

Ceiling panel

Special screws

Refrigerant tubing joint

Drainage check

REF.PIPE mark

Panel installation hole (4 locations)

Indoor unit

Ceiling panel

Ceiling surface

Do not allo

gaps

indicator cover

a) While lightly pressing the cen-

ter of the corner cover, pull up the tab for the screw hole. Use the same procedure to remove the indicator cover. (Fig. 6-16)

Corner cover

Press

Pull up

Indicator cover

3-6-2. Installing the Ceiling Panel

(1) Hang the temporary latches on the inside of the ceil-

ing panel to the receptacle on the unit to temporarily attach the ceiling panel in place. (Fig. 6-17)

G The ceiling panel must be installed in the correct

direction relative to the unit. Align the REF. PIPE and DRAIN marks on the ceiling panel corner with the correct positions on the unit.

(2) Align the panel installation holes and the unit screw

holes. (Fig. 6-18)

(3) Tighten the supplied special screws at the 4 panel

installation locations so that the panel is attached tightly to the unit.

G Check that the wiring connectors are not caught

between the unit and the ceiling panel.

(4) Check that the panel is attached tightly to the ceiling.

(Fig. 6-19)

G At this time, make sure that there are no gaps

between the unit and the ceiling panel, or between the ceiling panel and the ceiling surface.

G If there is a gap between the panel and the ceiling,

leave the ceiling panel attached and make fine adjustments to the installation height of the unit to eliminate the gap with the ceiling.

Fig. 6-16

Fig. 6-17

Fig. 6-18

If the screws are not sufficiently tightened, trouble such as that shown in the figure below may occur. Be sure to tighten the screws securely.

Air leakage

Air leakage from

ceiling surface

Staining

Condensation, water leakage

If a gap remains between the ceiling surface and the ceiling panel even after the screws are tightened, adjust the height of the unit again.

Adjust so that there are no gaps.

Fig. 6-20

Fig. 6-19

The height of the unit can be adjusted from the ceiling panel corner hole, with the ceiling panel attached, to an extent that does not affect the unit levelness, the drain hose, or other elements.

fit into the holes in the ceiling panel.

Place the corner cover so that the 3 tabs

Then fasten it in place with the supplied screws.

Hole for ceiling panel hook

the grille from dropping

Hook that prevents

Can be installed rotated 90

* The grille can be installed

with these hinges facing in any of 4 directions.

3-6-3. Wiring the Ceiling Panel and the Indicator

FLAP

RCIND

Indicator

7P IND and 4P RC wiring connector

7P IND and 4P RC

Ceiling panel

5P FLAP wiring connector

Clamps

Control box

Indoor unit

* Pass the wiring connectors through the clamps to fasten them in place,

as shown in the figure.

wiring connector

5P FLAP

wiring connector

Control box

As to how to attach the indicator cover, refer to Fig.6-23.

Drain pipe side

Refrigerant tube side

Indicator cover

Power box

(1) Remove the 2 screws from the control box cover, then open

the cover. Be careful that the cover does not fall.

(2) Connect the 5P FLAP wiring connector from the ceiling

panel to the connector on the control PCB in the control box. (Fig. 6-21)

(3) Connect the 7P IND and 4P RC wiring connector from the

indicator to the connectors on the control PCB in the control box. (Fig. 6-21)

(4) Be sure to use the clamps to fasten the connector wires in

place. (Fig. 6-21)

(5) Tighten the 2 cover screws to

close the cover.

G Check that the wiring

connectors are not caught between the electrical component box and the cover.

G If the indicator connector is

not securely connected, the remote controller signal will not be received.

G If the connectors are not

connected, the auto flap will not operate. Be sure to connect them securely.

Fig. 6-22

3-6-4. How to Attach the Corner Cover and Air-Intake Grille

A. Attaching the corner cover

(1) Check that the safety strap from the corner cover is fas-

(2) Use the supplied screws to attach the corner cover to the

B. Attaching the air-intake grille

G To install the air-intake grille, follow the steps for 3-6-1.

G When attaching the air-intake

G Be sure to attach the safety

tened to the ceiling panel pin, as shown in the figure. (Fig. 6-23)

ceiling panel.

Before Installing the Ceiling Panel in the reverse order. By rotating the air-intake grille, it is possible to attach the grille onto the ceiling panel from any of 4 directions. (Fig. 6-25)

grille, be careful that the flap and the indicator wiring do not become caught.

cord that prevents the air-intake grille from dropping off to the ceiling panel unit as shown in Fig. 6-24.

Fig. 6-24 Fig. 6-25

Fig. 6-21

Fig. 6-23

3-6-5. Checking After Installation

G Check that there are no gaps between the unit and the ceiling panel, or between the ceiling panel and the ceiling sur-

face. Gaps may cause water leakage and condensation.

G Check that the wiring is securely connected.

If it is not securely connected, the auto flap will not operate. In addition, water leakage and condensation may occur.

3-6-6. When Removing the Ceiling Panel for Servicing

When removing the ceiling panel for servicing, remove the air-intake grille and air filter, disconnect the flap and the indicator wiring connectors inside the control box, and then remove the 4 mounting screws.

3-6-7. Adjusting the Auto Flap

The air-direction flap on the ceiling panel outlet can be adjusted as follows.

G Adjust the flap to the desired angle using the remote controller. The flap also has an automatic air-sweeping mecha-

nism.

NOTE

G Never attempt to move the flap by hand.

G Proper air flow depends on the location of the air conditioner, the layout of the room and furniture, etc. If cooling or

heating seems inadequate, try changing the direction of the air flow.

3-7. 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 hazards 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.

(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 manu-

facturer will accept no responsibility for any damage or misoperation that occurs as a result of such unauthorized changes.

3-8. Recommended Wire Length and Diameter

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. Table 4 lists recommended wire lengths and diameters for power supply systems.

NOTE

Refer to the wiring system diagram (Fig. 7a or Fig. 7b) for the meaning of (A), (B) and (C) in Table 4.

Refer to your local codes or in the absence of local codes see the National Electric Code: ANSI/NFPA70.

Table 4

WARNING

CAUTION

Cross-Sectional (A)+(B) (A) Power Supply Wiring Length (ft) (C) Control

Area (AWG)

Model (#14) (#12) (#14)

C1271, CL1271 131 (Max.) 230 (Max.) 65 (Max.) 20A

C1872, CL1872 131 (Max.) 230 (Max.) 98 (Max.) 20A

(B) Power Line Length (ft) Line Length (ft)

# ... AWG (American Wire Gauge)

WIRING SYSTEM DIAGRAM

(C1271, CL1271)

G Be sure to comply with local codes on running the

wire from the indoor unit to the outdoor unit (size of wire and wiring method, etc.).

G Each wire must be firmly connected. G No wire should be allowed to touch refrigerant

tubing, the compressor, or any moving part.

G To avoid the risk of electric shock, each air con-

INDOOR

UNIT

Te r mi nal Terminal

Disconnect

switch Field supply

(C)

ditioner unit must be grounded.

G For the installation of a grounding device,

please observe local electrical codes.

G Grounding is necessary, especially for units

using inverter circuits, in order to release charged electricity and electrical noise caused by high tension. Otherwise, electrical shock may occur.

G Place a dedicated ground more than 7' (2 m)

away from other grounds and do not have it

INDOOR

UNIT

Te r mi nal Terminal

(C1872, CL1872)

Disconnect

switch Field supply

(C)

shared with other electric appliances.

Fuse or Circuit

Breaker Capacity

115V

Grounding line

Fig. 7a

230/208V

Grounding line

(B)

OUTDOOR

UNIT

OUTDOOR

UNIT

Powe r supply

(A)

Grounding line

Powe r supply

(A)

Single phase 115V 60HZ

Single phase 230/208V 60HZ

G 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.

G Do not run wiring for antenna, signal, or power

lines of television, radio, stereo, telephone, security system, or intercom any closer than 3'3" (1 m) from the power cable and wires between the indoor and outdoor units. Electrical noise may affect the operation.

Fig. 7b

NOTE

A disconnect switch may be required by national or local codes.

Always comply with national and local code requirements.

Grounding line

WARNING

Earth screw

Clamping strap

(Conduit)

Inter unit

Power wiring (Locally purchased)

3-9. Wiring Instructions for Inter-unit Connections

(1) Remove the 1 screw from the terminal cover, then open the

cover. Be careful that the cover does not fall.

(2) Remove the 3 screws from the power box cover, then open

the cover. Be careful that the cover does not fall.

(3) Use the screw to securely fasten the ground wire from the

outdoor unit in place.

(4) Remove the transparent plastic cover from the 3P terminal

plate.

(5) While viewing the wiring diagram, connect the inter-unit and

power supply line to terminals 1, 2 and 3 on the 3P terminal plate.

(6) Remount the transparent plastic cover onto the 3P terminal

plate.

(7) Be sure to use the clamping strap to fasten the wires in place.

(8) Tighten the screws to remount the terminal and the power

box cover.

Loose wiring may cause the terminal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, be sure all wiring is tightly connected.

Fig. 8

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 insulation to

expose the wire about 9/32" (7 mm). See the label (Fig. 9) near the terminal plate.

(2) Using a screwdriver, loosen the terminal screw on the terminal

plate.

(3) Insert the wire and tighten the terminal screw completely using a

screwdriver.

b) For Outdoor Unit

I For solid core wiring (or F-cable)

(1) Cut the wire end with a cutting pliers, then strip the insulation to

expose the solid wire about 15/16" (25 mm). (Fig. 10)

(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 suitable for the

terminal screw.

(4) Shape the loop wire properly, place it on the terminal plate and fix

it securely with the removed terminal screw using a screwdriver.

9/32"

STRIP SIZE

(7 mm)

Fig. 9

Solid wire

Strip 15/16" (25 mm)

Insulation

Fig. 10

(ACTUAL

SIZE)

Loop

I For stranded wiring

(1) Cut the wire end with a cutting pliers, then strip the insulation to expose the stranded wiring about 3/8" (10 mm) and

tightly twist the wire ends. (Figs. 11 and 12)

(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. 11)

(4) Place the ring connector wire, and replace and tighten the removed terminal screw using a screwdriver. (Fig. 13)

Stranded wire

Ring connector

Strip 3/8" (10 mm)

Fig. 11

Tw ist wire ends

Fig. 12

4. How to Install the Outdoor Unit

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.

Te r mi nal block

Special washer

Wire

Lock nut

Screw

Ring connector

Te r mi nal plate

Wire

Fig. 13

Cabinet

Screw and special washer

Ring connector

(1) Remove access panel “C”. (Fig. 14)

(2) Connect the inter-unit and power supply line

according to the drawing on the panel side.

(3) Be sure to size each wire allowing approx. 4"

(10 cm) longer than the required length for wiring. Store excess wiring inside the cabinet.

(4) When connections are completed, check that all

connections are correct as shown in the wiring system diagram on panel side.

(5) Be sure to ground the unit according to your

local codes.

Conduit plate

Plug

Inter unit (Conduit)

Access panel “C”

Power supply (Conduit)

Fig. 14

5. Refrigerant Tubing

Flare nut

Union

Deburring

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

(1) Cut the copper tube to the required length with a

tube cutter. It is recommended to cut approx. 12" to 20" (30 to 50 cm) longer than the tubing length you estimate.

(2) 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. 15)

NOTE

When reaming, hold the tube end downward and be sure that no copper scraps fall into the tube. (Fig. 16)

Before

After

Fig. 15

Copper tubing

Reamer

Fig. 16

(3) Remove the flare nut from the unit and be sure to

mount it on the copper tube.

(4) Make a flare at the end of copper tube with a flare

tool.* (Figs. 17 and 18)

(*Use “RIDGID” or equivalent.)

NOTE

A good flare should have the following characteristics:

G inside surface is glossy and smooth.

G edge is smooth.

G 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. 19)

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. 20)

If the special R410A flare tool is used:

0 to 0.0196" (0 to 0.5 mm)

If the previous flare tool (clutch-type) is used:

0.0472" (1.2 mm)

Adjust so that the amount of tube protrusion is as shown in the figure.

Fig. 17

Flare nut

Copper tubing

Flare tool

Fig. 18

Apply refrigerant lubricant here and here

Fig. 19

Fig. 20

5-4. Connecting Tubing between Indoor and

IMPORTANT

CAUTION

Indoor unit

Outdoor unit

Spanner

Torque wrench

Insulation tape (supplied)

Flare insulation (3/16"(T5, supplied) )

Flare insulation (1/8"(T3, supplied) )

Tube insulation

(not supplied)

Vinyl tie (supplied)

Flare nut

The procedure used for installing the insulation for both wide and

narrow tubes are the same.

Flare insulation

Vinyl tie (supplied)

Insulation tape

Refrigerant tubing and insulation (not supplied)

Drain pipe and insulation (not supplied)

Drain hose insulation and vinyl tie (supplied)

Drain hose and hose band (supplied)

Outdoor Units

a) Tightly connect the indoor side refrigerant tubing exten-

ded from the wall with the outdoor side tubing. (Fig. 21)

b) To fasten the flare nuts, apply specified torque as:

Table 5

Tube Dia. Tightening Torque

1/4" (6.35 mm) Approx. 120 – 160 lbs·in (140 – 180 kgf· cm)

3/8" (9.52 mm) Approx. 300 – 360 lbs·in (340 – 420 kgf· cm)

1/2" (12.70 mm) Approx. 430 – 540 lbs·in (490 – 610 kgf·cm)

5/8" (15.88 mm) Approx. 590 – 710 lbs·in (680 – 820 kgf·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

proper insulation material.

The thickness of the insulation should be a minimum 5/16" (8 mm). (Fig. 22)

Min. 5/16" (8 mm)

Fig. 21

Insulation

Thickness: min. 5/16" (8 mm)

Fig. 22

Taping the flare nuts

Wind the insulation tape around the flare nuts at the tube connections. Secondly cover up the tubing connections with the flare insulation (1/8" (T3, supplied)). Then wind the other flare insulation (3/16" (T5, supplied)). Finally, fasten the insulation at both ends with the supplied vinyl ties. (Fig. 23)

Insulation material

The material used for insulation must have good insulation characteristics, be easy to use, be age resistant, and must not easily absorb moisture.

After a tube has been insulated, never try to bend it into a narrow curve because it can cause the tube to break or crack.

Fig. 23

Fig. 24

Never grasp the drain or refrigerant connecting outlets when moving the unit.

Insulated tubes

Drain hose

Clamp

5-6. Taping the Tubes

CAUTION

Apply putty here

Tubing

(1) 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.

(2) 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. 25)

(3) Clamp the tubing bundle to wall, using 1 clamp approx.

every 47" (120 cm).

NOTE

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. 25

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. 26)

6. Air Purging

Air and moisture remaining in the refrigerant system have undesirable effects as indicated below. Therefore, they must be purged completely.

G pressure in the system rises G operating current rises G cooling (or heating) efficiency drops G moisture in the air may freeze and block capillary tubing G water may lead to corrosion of parts in the refrigerant system

I 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

pressure gauges) to the service port on the wide tube service valve. (Fig. 27)

Manifold valve (Exclusively for R410A)

Pressure gauge

Fig. 26

Indoor unit

Outdoor unit

HiLo

The service port on the wide tube service valve uses a Schrader core valve to access the refrigerant system. The valve core is similar to those used in automobile tires. Therefore, be sure to use a vacuum hose connector which has a push-pin inside.

Be sure to use a manifold valve for air purging. If it is not available, use a stop valve (field supply) for this purpose. The “Hi” knob of the manifold valve must always be kept closed.

Charging hose (Exclusively for R410A)

Vac uum pump adapter (Exclusively for R410A) (with reverse flow prevention)

Vac uum pump

Fig. 27

(4) With the “Lo” knob of the manifold valve open, run

CAUTION

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

26.4 gal/h (100 liter/h) vacuum pump is used

If tubing length is If tubing length is

less than 33 ft. (10 m) more than 33 ft. (10 m)

10 min. or more 15 min. or more

(5) With the vacuum pump still running, close the “Lo”

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 counter-clockwise by 90 degrees (1/4 turn) for 10 seconds, and then turn the stem clockwise to close it again. (Fig. 28)

NOTE

To prevent other refrigerants from being mistakenly charged to units which use R410A, the size of the charge port on the service valve is different from the one for other refrigerant types. For servicing such as recharging, the specified charging hose, manifold and vacuum pump adapter (with reverse flow prevention) for R410A must be used.

NOTE

The required time in Table 6 is calculated based on the assumption that the ideal (or target) vacuum condition is around 0.193 psi (10 mmHg abs.).

90° (1/4 turn)

Narrow tube

Hex wrench

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

soapy water. Bubbles indicate a leak. Tighten the joint more when leaks, then check if there is no 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.

(10) Loosen the vacuum hose connected to the wide tube service

port slightly to release the pressure. Then, remove the hose.

This may cause the refrigerant gas to leak. In order to avoid this, take off the hose quickly.

(11) Fasten the valve cap on the wide tube service port securely

with an adjustable wrench or box wrench. Next, mount the valve cap on the service valve and tighten it to 170 lbs·in (200 kgf·cm) with a torque wrench. This process is very important to prevent gas from leaking from the system.

Wide tube

Valve cap

Vac uum hose to manifold valve

Fig. 28

(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 service 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.

How to Test Run the Air Conditioner

IMPORTANT

ACL (Reset)

button

1HR. TIMER button

ON/OFF

operation

button

HIGH POWER button

OPERATION lamp

TIMER lamp

HIGH POWER lamp

REMOTE CONTROL receiver

OPERATION button

After turning on the power of the air conditioner, use the remote controller and follow the steps below to conduct the test run.

(1) Set the remote controller in Test Run mode. (Fig. 29)

a)Press and hold the HIGH POWER button and the

1HR. TIMER button.

b)Then press and hold the ACL (Reset) button with

a pointed object such as the tip of a pen. After 5 seconds, release the ACL button first.

c) Then release the HIGH POWER and 1HR. TIMER

buttons.

d) appears and “oP-1” blinking in the remote con-

troller clock display area. (Fig. 30)

(2) Start Cooling mode test run by pressing the ON/OFF

operation button of the remote controller. (Fig. 29)

• This starts the fan producing uncooled forced air with the 3 indicator lamps (OPERATION lamp, TIMER lamp, and HIGH POWER lamp) on the main unit blinking. (Fig. 31)

• After 3 minutes, the system shifts into cooling operation, and cool air will start to be felt. Cooling mode test run is unaffected by the room temperature.

(3) Press the ON/OFF operation button of the remote

controller again to stop the test run. (Fig. 29)

(4) Finally press the ACL (Reset) button of the remote

controller to release it from Test Run mode to return to normal mode. (Fig. 29)

• “ ” and “oP-1” will disappear from the remote controller clock display area.

Fig. 29

NOTE

Troubleshooting: In the event that the green OPERATION lamp is blinking upon powering up the system, an error condition exists. In this case, refer to the self-diagnostics procedure which can be seen by opening the air-intake grille.

After the test run is completed, be sure to press the ACL (Reset) button to return to normal mode. The air conditioner will not operate correctly if this is not done.

Fig. 30

Fig. 31

I Basic Functions of the Service Valves

PUSH

Hose with push-pin

Service valve

Hex wrench

Open

CAUTION

The basic functions of the service valves are given in Table 7 below.

Table 7

Action

Shipping

Operating and

test running

the air conditioner

Measuring pressure

and gas charging

Air purging with

a vacuum pump

Narrow Tube Service

Valve (2-Way)

CLOSED

Fully OPEN

CLOSED

Wide Tube Service

Valve (3-Way)

O-ring

Valve cap

Stem

* The service port on the wide tube ser-

vice 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. 32)

I 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

When opening or closing the service valve stem, use the accessory hex wrench. Be sure to fully seat the wrench

Fig. 33

before turning the valve.

valve to the service port on the wide tube service valve.

NOTE

External diameter of service port R410A: 5/16"

Fig. 32

(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 oper-

ation.

(4) When the low pressure gauge reading falls to 14.2 to

7.1 psi (1 to 0.5 kg/cm

), fully close the wide tube

valve stem. Then quickly stop the unit.

(5) Disconnect all gauges and hoses, and replace the

valve caps as they were before.

I Service Valve Connections

CAUTION

a) Temporary connection:

Screw in 3 – 5 turns by hand. (Fig. 34)

b) To fasten the flare nuts, apply specified torque

as Table 8 and Fig. 35.

Table 8

Tube Dia. Tightening Torque

1/4" (6.35 mm) Approx. 120 – 160 lbs·in (140 – 180 kgf·cm)

3/8" (9.52 mm) Approx. 300 – 360 lbs·in (340 – 420 kgf·cm)

1/2" (12.70 mm) Approx. 430 – 540 lbs·in (490 – 610 kgf·cm)

5/8" (15.88 mm) Approx. 590 – 710 lbs·in (680 – 820 kgf·cm)

7. Remote Control Unit Installation Position

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:

G In direct sunlight

G Behind a curtain or other place where it is covered

G More than 26' (8 m) away from the air conditioner

G In the path of the air conditioner’s airstream

G Where it may become extremely hot or cold

G Where it may be subject to electrical or magnetic

interference

G Where there is an obstacle between the remote con-

trol unit and the air conditioner (since a check signal is sent from the remote control unit every 5 minutes)

Fig. 34

Torque wrench

Fig. 35

Be sure to tighten the flare nut using the prescribed torque. If the nut is over-tightened, refrigerant leakage may occur.

7-1. Mounting on a Wall

Before mounting the remote control unit, press the ON/OFF operation button at the mounting location to make sure that the air conditioner operates from that location. The indoor unit should make a beeping sound to indicate that it has received the signal.

Remote control

unit mount

Mounting screws 5/32 5/8" (4 16 mm)

(included)

To take out the remote control unit, pull it forward.

Press

Set in place

Fig. 36

Rear side

Hole

To prevent loss of the remote control unit, you can connect the remote

control unit to the mount by passing a string through the remote control unit and attachment hole.

ACL (Reset)

button

1HR. TIMER button

ON/OFF

operation

button

HIGH POWER button

8. Address Switch

8-1. Address Setting of the Remote Control Unit

The address can be set in order to prevent interference between remote controllers when 2 indoor units are installed near each other. The address is normally set to “A.” To set a different address, it is necessary to change the address on the second remote controller.

Ta b

NOTE

Once changed, you cannot restore the original address setting of the air conditioner.

(1) Switch on the power source.

(2) Break the address-setting tab marked “A” on the

second remote controller to change the address (Fig. 37). When the tab is removed, the address is automatically set to B (Fig. 38).

(3) Press and hold the remote controller HIGH

POWER button and 1HR. TIMER button. Then, press and hold the ACL (Reset) button with a pointed object such as the tip of a pen. After 5 seconds, release the ACL button first, then release the HIGH POWER and 1HR. TIMER buttons. “oP-1” (Test Run) appears, blinking in the remote controller clock display area.

(4) Each time the 1HR. TIMER button is pressed, the

display changes as shown below. Press this button 2 times to change the display to “oP-7” (Address setting). (Fig. 39)

Fig. 37

ACL button

Fig. 38

(5) “oP-7” has now been selected for address setting.

(6) Press the ON/OFF operation button on the remote

(7) Finally press the remote controller ACL (Reset)

Changing of the second remote controller address is now completed.

Te st run mode

Self-diagnostic mode

Address setting mode

controller. (Fig. 39) Check that the “beep” signalreceived sound is heard from the second indoor unit (approximately 5 times). The sound you hear is the signal that the remote controller address has been changed.

button to cancel the blinking “oP-7” display. (Fig. 39)

Fig. 39

SETTING THE TIMER

1. How to set the present time

(Example) To set to 9:10 pm.

3. How to set the ON time

(Example) To start operation at 7:10 am.

ON TIME Present time

Operation Indication

1. Press the SET button once. The timer indication alone

2. • Press the HH button until

AM 7 is displayed.

• Press the MM button until 10 is displayed.

3. Press the ON/OFF button to

start the air conditioner.

4. Press the TIMER SELECT

button once to set ON time.

flashes and the previous settime is only displayed.

The display will change automatically back to show the present time after about 10 sec.

The present time is displayed.

The present time and are displayed.

Operation Indication

1. Press the SET button three

times.

2. • Press the HH button until

PM 9 is displayed.

• Press the MM button until 10 is displayed.

The time indication alone flashes.

The display will flash for 10 sec. and automatically stop flashing except for the “:” symbol.

2. How to set the OFF time

(Example) To stop the air conditioner at 11:30 pm.

OFF TIME Present time

Operation Indication

1. Press the SET button twice. The timer indication alone

2. • Press the HH button until

PM 11 is displayed.

• Press the MM button until 30 is displayed.

3. Press the ON/OFF button to

start the air conditioner.

4. Press the TIMER SELECT

button twice to set OFF time.

flashes and the previous settime is only displayed.

The display will change automatically back to show the present time after about 10 sec.

The present time is displayed.

The present time and are displayed.

4. How to set daily ON/OFF repeat timer

(Example) To start operation at 7:10 am. and stop the air conditioner at 11:30 pm.

Present time OFF TIME

ON TIME

9:10 pm. Present time

7:10 am. ON

Operation Indication

1. Set the timer ON/OFF times

as shown in 2 and 3.

2. Press the ON/OFF button to

start the air conditioner.

3. Press the TIMER SELECT

button three times to set the ON/OFF combination timer.

The present time PM 9:10 and

are displayed.

Programmed daily ON / OFF

11:30 pm. OFF

NOTE

You can check the timer ON/OFF times after you have set them by pressing the SET button.

OI-119-8-EG

5. Cancellation of the time setting

You can cancel the time settings by pressing the TIMER SELECT button. The time settings cannot be canceled by pressing the ON/OFF operation button or MODE selector button.

6. Backup function

Even if the main power supply (circuit breaker) is cut off, the capacitor inside the remote control store the mode settings in the memory for 3 hours after the power is off. The mode settings are reset if the main power supply is off for 3 hours or more.

USING THE 1-HOUR OFF TIMER

1. 1-Hour OFF Timer

ADJUSTING THE AIRFLOW DIRECTION

The vertical airflow can be adjusted by moving the flap with the remote control unit. Do not move the flap with your hands. Confirm that the remote control unit has been turned on. Use the FLAP button to set either the sweep function or one of the six airflow direction settings.

A. Sweep function

The flap starts moving up and down to deliver air over the sweep range.

This function causes the unit to operate for one hour and then stop, regardless of whether the unit is on or off when this button is pressed.

The indicator in the display indicates that this function is operating.

Setting procedure:

Regardless of whether the unit is operating or stopped, press the 1 HR. TIMER button.

appears in the display.

Cancellation procedure:

Press the ON/OFF operation button to turn the unit off, wait for the unit to stop operating, and then press the ON/OFF operation button again. The 1-Hour Timer function is now cancelled and the unit operates normally.

NOTE

• If, while the 1-Hour Timer function is operating, the 1HR. TIMER button is pressed once to cancel the function and then again, the unit continues to operate for one hour from that point in time and then stops.

• It is not possible to use the OFF Timer and 1-Hour OFF Timer together. Whichever function is set last takes precedence. If the 1 HR. TIMER button is pressed while the TIMER OFF function operates, the OFF Timer is cancelled and the unit will stop operating one hour later.

B. Setting the airflow manually

Referring to the above illustration, use the FLAP button to set the airflow direction within the range used during the heating, cooling, or dehumidifying operation.

COOL

DRY

SWEEP

HEAT FAN

NOTE

• The flap automatically closes when the unit is off.

• During the heating operation, the fan speed will be very low and the flap will be in the horizontal position (position ) until the air being blown out of the unit begins to warm. Once the air warms up, the flap position and fan speed change to the settings specified with the remote control.

CAUTION

• Use the FLAP button on the remote control to adjust the

position of the flap. If you move the flap by hand, the flap position according to the remote control and the actual flap position may no longer match. If this should happen, shut off the unit, wait for the flap to close, and then turn on the unit again; the flap position will now be normal again.

• Do not have the flap pointed down during cooling operation.

Condensation may begin to form around the air vent and drip down.

2. Operation together with the daily ON/OFF repeat timer

The 1-Hour OFF Timer setting is given priority over the DAILY ON/ OFF REPEAT setting.

OI-119-9-EG

IMPORTANT

Q'ty Q'ty

Parts

Wired remote controller

Machine screws

Tapping screws

Spacers

Parts

Instruction manual

Figure Figure

Installation Instructions

Wire harness

5/32

15/16"

5/32

15/16"

25mm)

26.2 ft. (8m)

INSTALLATION INSTRUCTIONS

STK-RCS-7TWSU (Wired Remote Controller)

I Parts supplied with the remote controller

Table 1

See Table 1.

I Remote controller installation guidelines

Installation location

• Mount the remote controller 3.3 to 4.9 ft. (1 to 1.5 meters) off the floor where it can sense the average temperature of the room.

• Do not mount the remote controller in a place exposed to direct sunlight or where it is exposed to outside air such as near a window.

• Do not mount the remote controller behind a curtain or other object so that it is separated from the air circulation of the room.

• Mount the remote controller inside the room being air conditioned.

Switching the room temperature sensor

Room temperature sensors are separately incorporated in both the indoor unit and the remote controller. Either sensor can be used to sense the room temperature. The indoor unit sensor is usually used.

If you wish the remote controller to sense the room temperature, press the SENSOR button with a ballpoint pen or tool with a small tip. (Refer to Fig. 9 on page 4 to locate the SENSOR button.)

I How to install the remote controller

• The remote controller is set to “Cool/Dry/Heat model” at the time of shipment from the factory. If the purchased air conditioner is a COOL/DRY model, follow the instructions on the label and change the switch on the reverse side of the remote controller unit to “Cool/Dry model”. (Fig. 1)

• The remote controller is also set to “Single” at the time of shipment from the factory. For multiple use, set the switch on the reverse side of the remote controller unit to “Multi”. (Fig. 1)

• After all work is completed, if any switches have been changed, then be sure to press the ACL (Reset) button. (Refer to Fig. 9 on page 4 to locate the ACL (Reset) button.)

Fig. 1

Sanyo CL1872 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual