Sanyo C2432, CL2432 User Manual

INSTALLATION INSTRUCTIONS

– Split System Air Conditioner – COOL/DRY Model

ATTENTION

Use this manual when installing combined models of indoor unit KS2432A and outdoor unit C2432 or CL2432 only. On items not included in this manual, see the Installation Instructions (No. 85464179694003) packed in the outdoor unit model C2432 or CL2432.

Contents

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Unit Outdoor Units

KS2432A C2432

CL2432

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

Units should be installed by a licensed contractor according to local code requirements.

Page

IMPORTANT!

Please Read Before Starting.................................. 1

1. GENERAL.......................................................... 2

1-1. Tools Required for Installation (not supplied) 1-2. Accessories Supplied with Indoor 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................... 3

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

3. HOW TO INSTALL THE INDOOR UNIT ........... 5

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. REFRIGERANT TUBING .................................. 13

4-1. Indoor Unit Tubing 4-2. Outdoor Unit Tubing 4-3. Connecting Tubing between Indoor and

Outdoor Units 4-4. Insulation of Refrigerant Tubing 4-5. Taping the Tubes 4-6. Finishing the Installation

5. REMOTE CONTROL UNIT INSTALLATION

POSITION ......................................................... 16

5-1. Mounting on a Wall

In Canada

SANYO FISHER COMPANY SANYO Canada Inc.

A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent 21605 Plummer Street Concord, Ontario

85264189704003 © SANYO 2003 Chatsworth, CA 91311 U.S.A. L4K 5C7, Canada

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.

When Installing…

…In a Ceiling, Wall or Floor

Make sure the ceiling/wall/floor 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

SPECIAL PRECAUTIONS

When Wiring

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

• Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.

• Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or

death.

• Ground the unit following local electrical codes.

• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

When Transporting

Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers.

• 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.

1. General

CAUTION

Parts Figure Q’ty Parts Figure Q’ty

Remote control unit

Insulation

Parts Figure Q’ty

Tapping screw

Truss-head Phillips 5/32×5/8" (4

16 mm)

AAA alkaline battery

Joint drain

Tube Assy Packing A

Packing B

Clamp

Rawl plug

25/32"×1-3/8"×3/16"

1-3/16"

2-3/8"×3/16"

Remote control holder

NOTE

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 Indoor 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)

16. Pipe bending tool (spring bender)

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.

For rear-left tubing, optional tube connection (C) (APR- EN46U1B) is necessary. See page 13. Also 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 1' to 1'4" to each tube length to reduce vibration between the air conditioning units.

Table 2

Model

KS2432A

Narrow Tube

Outer Diameter

3/8"

Wide Tube

3/4"

2. Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing. Wall thickness of the insulation should be not less than 5/16".

1-5. Field Wiring

Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to 3-6. Wiring Instructions for details.

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

1-6. Additional Materials Required for Installation

6 inches

min.

6 inches

min.

6 inches min.

Front View

INDOOR UNIT

Tubing length (L)

OUTDOOR UNIT

Elevation difference (H)

Indoor unit

Floor level

Wall

Minimum height from floor level

5 ft.

CAUTION

Drain hose

Indoor unit

Outside drainage

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire (See local codes)

3. Putty

4. Refrigeration lubricant

5. Clamps or saddles to secure refrigerant tubing

2. Installation Site Selection

2-1. Indoor Unit

WARNING

AVOID:

● direct sunlight.

● nearby heat sources that may affect performance of

the unit.

● areas where leakage of flammable gas may be

expected.

● places where large amount of oil mist exist.

DO:

● select an appropriate position from which every corner

of the room can be uniformly cooled. (High on a wall is best.)

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

● 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 differ-

ence (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. 3a.

To prevent abnormal heat generation and the possibility of fire, do not place obstacles, enclosures and grilles in front of or surrounding the air conditioner in a way that may block air flow.

Fig. 1

Fig. 2

Fig. 3a

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

Fig. 3b

Table 3

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

C2432, CL2432 25 132 50 0.27

* If total tubing length becomes 25 to 132 ft. (max.), additional refrigerant (R22) charge of 0.27 oz./ft. is required.

No additional charge of compressor oil is necessary.

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

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

2-2. Outdoor Unit

Outdoor unit

Hot air

Heat source

Exhaust fan

Min. 1 inch

Min. 2 ft.

Min. 4 inches

Min. 7 ft.

Obstacle above

Ground

Air discharge

Air in

Air discharge

Concrete block 4 inch × 1 ft. 4 inch beams or equal

Anchor bolts (4 pieces)

Min. 6 inch

AVOID:

● heat sources, exhaust fans, etc. (Fig. 4a)

● 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. 4b)

● provide a solid base a minimum of 6 inches above

ground level to reduce humidity and protect the unit against possible water damage and decreased service life. (Fig. 5)

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

vibration and noise.

Fig. 4a

Fig. 4b

Fig. 5

Indoor side

Outdoor side

Set screws for transportation only

Right-rear tubing (recommended)

Right tubing

Left-rear tubling

Center of left-rear tubing hole

Center of right-rear tubing hole

NOTE

3. How to Install the Indoor Unit

NOTE

CAUTION

PVC pipe (locally purchased)

Cut at slight angle

3-1. Remove the Rear Panel from the Unit

Remove and discard the set screws and take off the rear panel. (Fig. 6)

Tubing can be extended in 3 directions as shown in Fig. 7a. Select the direction you need providing the shortest run to the outside unit.

3-2. Make a Hole

(1) Remove the rear panel from the indoor unit and

place it on the wall at the location selected. Make sure the unit is horizontal, using a carpenter’s level or tape measure to measure down from the ceiling.

(2) Determine which side of the unit you should make

the hole. (Fig. 7b)

(3) Before making a hole, check carefully that no studs

or pipes are directly run behind the spot to be cut.

Fig. 6

Fig. 7a

In case of left-rear or right-rear tubing

Also avoid areas where electrical wiring or conduits are located.

The above precautions are also applicable if tubing goes through the wall in any other location.

(4) Using a sabre saw, key hole saw or hole-cutting drill

attachment, cut a hole in the wall. See Table 4 and Fig. 8.

Table 4

Hole Dia. (inch)

3-3/16"

(5) Measure the thickness of the wall from the inside

edge to the outside edge and cut PVC pipe at a slight angle 1/4" shorter than the thickness of the wall. (Fig. 9)

(6) Place the plastic cover over the end of the pipe (for

indoor side only) and insert in the wall. (Fig. 10)

Fig. 7b

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

Fig. 8

Fig. 9

INSIDE

Wall

Plastic cover

(Field Supply)

OUTSIDE

PVC pipe

Slight angle

Fig. 10

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