Sanyo COOL, DRY, CM1972A, CM2472A, CM3172A Installation Instructions Manual

APPENDIX A

INSTALLATION INSTRUCTIONS

CM1972A
CM2472A
CM3172A

(II-852-6-4190-509-00-0)

A-1

CAUTION

For Outdoor Unit

NOTE

INSTALLATION INSTRUCTIONS

– Inverter Multi Split System Air Conditioner –

This air conditioner uses the new refrigerant R410A.

Refrigerant service valve size = 5/16"

Contents

Page

IMPORTANT!

Please Read Before Starting .................................. 2

1. GENERAL .......................................................... 3

1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Additional Materials Required for Installation

2. INSTALLATION SITE SELECTION ................... 4

2-1. Indoor Unit
2-2. Connecting Indoor Units
2-3. Outdoor Unit
2-4 Baffle Plate for the Outdoor Unit
2-5. Outer Dimensions of Outdoor Unit
2-6. Diagram of Outdoor Unit Installation

3. INSTALLATION PROCESS .............................. 15

3-1. Embedding the Tubing and Wiring
3-2. Use of the Flaring Method
3-3. Flaring Procedure with a Flare Tool
3-4. Caution before Connecting Tubes Tightly
3-5. Tubing Connections
3-6. Insulation of Refrigerant Tubing
3-7. Taping the Tubes
3-8. Finishing the Installation

4. AIR PURGING................................................... 18

I Air Purging with a Vacuum Pump (for Test Run)
I Pump Down

COOL/ DRY Model

Model Combinations

Combine indoor and outdoor units only as listed
below.

Indoor Unit Outdoor Unit

KMS0772 CM1972A
KMS0972 CM2472A
KMS1272 CM3172A
KMS1872
KMS2472
XMS0972
XMS1272
XS1872

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

Be sure to connect indoor and outdoor units
only in combinations that are listed in the
combination table(s) included in the outdoor
unit package.
Connecting any other model may result in
operation failure and malfunction.

Combination example

Indoor unit B

Indoor unit A

Indoor unit C

5. WIRING INSTRUCTIONS ................................. 21

5-1. General Precautions on Wiring
5-2. Recommended Wire Length and Diameter
5-3. Wiring System Diagram
5-4. How to Connect Wiring to the Terminal
5-5. Wiring Instructions for the Outdoor Unit

6. TEST RUN......................................................... 25

7. CONNECTING A HOME AUTOMATION

DEVICE ............................................................. 26

8. INSTALLATION CHECK SHEET ...................... 26

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

85264190509000 © SANYO 2010

Outdoor unit

Indoor unit D

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.

SANYO North America Corporation In Canada
Commercial Solutions Division SANYO Canada Inc.
2055 Sanyo Ave., San Diego 201 Creditview Road, Woodbridge
CA 92154, U.S.A. Ontario, L4L 9T1, Canada

IMPORTANT!

CAUTION

WARNING

WARNING

CAUTION

Please Read Before Starting

When Installing…

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:

G

Carefully read this instruction booklet before beginning.

G

Follow each installation or repair step exactly as shown.

G

Observe all local, state, and national electrical codes.

G

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 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.

…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

Install the outdoor unit on a raised platform that is higher
than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

• Use the flare method for connecting tubing.

• Apply refrigerant lubricant to the matching surfaces of
the flare and union tubes before connecting them, then
tighten the nut with a torque wrench for a leak-free
connection.

• Check carefully for leaks before starting the test run.

When Servicing

• Turn the power OFF at the main power box (mains) before
opening the unit to check or repair electrical parts and
wiring.

• Keep your fingers and clothing away from any moving
parts.

• Clean up the site after you finish, remembering to check
that no metal scraps or bits of wiring have been left inside
the unit being serviced.

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.

• Do not install only a single indoor unit.

2

CAUTION

1. General

This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instruc­tions for the indoor and outdoor units and make sure all accessory parts listed are with the system before beginning.
If the electric wiring diagram does not appear in this manual, please check for the diagram on the indoor unit.

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

6. Sabre saw or key hole saw

1-2. Accessories Supplied with Unit

Table 1

Parts Figure Q’ty Parts Figure Q’ty Parts Figure Q’ty

Hex wrench Cushion rubber 4

Labels for inter-unit
cable and tube

ABCD

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

1

4 each

Reducer
(3/8" 1/2")

CM1972A

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

16. Vacuum pump (For R410A)

17. Manifold valve

Reducer
(1/2" 3/8")

1

CM2472A

CM3172A

Packed in the outdoor unit.

1

2

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.

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" (8 mm).

3. Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring.

1-4. Type of Copper Tube and Insulation Material

Refer to 5. Wiring Instructions for details.

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.

Cut each tube to the appropriate lengths 1' to 1'4"

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

(30 cm to 40 cm) to dampen vibration between units.

Table 2

Model

KMS0772 / 0972 / 1272 1/4" (6.35 mm) 0.0314" (0.8 mm) 3/8" (9.52 mm) 0.0314" (0.8 mm)

KMS1872 1/4" (6.35 mm) 0.0314" (0.8 mm) 1/2" (12.70 mm) 0.0314" (0.8 mm)

KMS2472 1/4" (6.35 mm) 0.0314" (0.8 mm) 5/8" (15.88 mm) 0.0393" (1.0 mm)

XMS0972 / 1272 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

1-5. Additional Materials Required for Installation

1. Refrigeration (armored) tape

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

3. Putty

4. Refrigeration lubricant

5. Clamps or saddles to secure refrigerant tubing

3

2. Installation Site Selection

Drain hose

Indoor unit

Outside drainage

INDOOR
UNIT (1)

INDOOR
UNIT (4)

INDOOR
UNIT (3)

INDOOR
UNIT (2)

Tubing length (L1)

L2

L3

L4

H2

H3

H4

OUTDOOR
UNIT

Elevation
difference (H1)

WARNING

CAUTION

3.3 ft.

(1m)

(1m)

(1m)

3.3 ft.

(1m)

3.3 ft.

3.3 ft.

3.3 ft.

(1m)

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.

Fig. 1

For wall-mounted units

G placing or allowing any obstructions near the air conditioner

inlet or outlet.

G installing in rooms that contain instant-on (rapid-start)

fluorescent lamps. (These may prevent the air conditioner
from receiving signals.)

G places where large amounts of oil mist exist.

G installing in locations where there are devices that

generate high-frequency emissions.

DO:

G select an appropriate position from which every corner of

the room can be uniformly cooled. (High on a wall is best
for wall-mounted types.)

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. (Fig. 1)

G allow room for operation and maintenance as well as

unrestricted air flow around the unit. (Fig. 2a or 2b)

G install the unit within the maximum elevation difference

(H1, H2, H3, H4) above or below the outdoor unit and
within a total tubing length (L1+L2+L3, L1+L2+L3+L4)
from the outdoor unit as detailed in Table 3 and Fig. 3a.

Fig. 3a

2" (5 cm)

min.

For ceiling-mounted cassette units

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

• For stable operation of the
air conditioner, do not install
wall-mounted units less
than 5' (1.5 m) from floor
level. (Fig. 3b)

4

6" (15 cm)
min.

Front View

Fig. 2a

Fig. 2b

Minimum height
from floor level

Fig. 3b

2" (5 cm)

Indoor unit

5' (1.5 m)

Floor level

min.

Wall

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.

G install in a sturdy manner to avoid increased operating

noise.

Table 3

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

Model Tubing Length at shipment (L1+L2+L3) or (H1, H2, H3, H4) Refrigerant

CM1972A 82 150 (L1+L2+L3) 150 (L1+L2+L3) 50 —

CM2472A 82 150 (L1+L2+L3+L4) 200 (L1+L2+L3+L4) 50 0.22

CM3172A 100 150 (L1+L2+L3+L4) 230 (L1+L2+L3+L4) 50 0.22

* If total tubing length becomes 150 to 200 ft. (Max.) or 150 to 230 ft. (Max.), charge additional refrigerant (R410A) by 0.22 oz./ft.

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

Allowable Tubing Length Total Tubing Length Difference of Additional

per unit (L1+L2+L3) or (L1+L2+L3+L4) (ft.) (oz./ft.)*

(ft.) (L1+L2+L3+L4) (ft.)

(ft.)

5

Union 1/2"(12.70mm)

1/2"(12.70

mm

)

Flare 3/8"(9.52

mm

)

A joint for connecting tubes of
different sizes
(3/8"(9.52mm) 1/2"(12.70mm)) Supplied Reducer

1/4"(6.35mm)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

C

B

A

Outdoor unit Indoor unit

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS1872)
(XS1872)

3/8"(9.52mm)

3/8"(9.52mm)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

C

B

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

D

Outdoor unit Indoor unit

3/8"(9.52

mm

)

3/8"(9.52mm)

3/8"(9.52

mm

)

3/8"(9.52mm)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

Union 3/8"(9.52mm)Flare 1/2"(12.70mm)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

1/2"(12.70mm)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

(1/2"(12.70

mm

) 3/8"(9.52mm)) Supplied Reducer

3/8"(9.52mm)

3/8"(9.52mm)

1/4"(6.35mm)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

C

B

A

Outdoor unit Indoor unit

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

2-2. Connecting Indoor Units

Figures (4a) – (4k) show the different types of indoor unit connections, including the use of a reducer.
To select the required indoor unit to be connected, refer to the Combination Table that was included in the
outdoor unit package.

(1) Connecting indoor unit for CM1972A

(A)

Fig. 4a

(B)

(2) Connecting indoor unit for CM2472A

(A)

Fig. 4b

Fig. 4c

6

(B)

C

B

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

D

Outdoor unit Indoor unit

(KMS1872)
(XS1872)

1/2"(12.70

mm

)

1/2"(12.70

mm

)

3/8"(9.52mm)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

Locally purchased

C

B

(KMS1872)
(XS1872)

D

Outdoor unit Indoor unit

Union 1/2"(12.70

mm

)Flare 3/8"(9.52mm)

(3/8"(9.52

mm

) 1/2"(12.70mm))

1/2"(12.70mm)

3/8"(9.52

mm

)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35mm)

1/4"(6.35

mm

)

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52mm)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

(KMS1872)
(XS1872)

1/2"(12.70

mm

)

1/2"(12.70

mm

)

1/4"(6.35

mm

)

Union 5/8"(15.88mm)Flare 1/2"(12.70mm)

(1/2"(12.70

mm

) 5/8"(15.88mm)) Locally purchased

C

B

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

D

Outdoor unit Indoor unit

(KMS2472)

1/2"(12.70mm)

3/8"(9.52

mm

)

3/8"(9.52mm)

5/8"(15.88

mm

)

3/8"(9.52

mm

)

3/8"(9.52mm)

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

(C)

Fig. 4d

(D)

Fig. 4e

Fig. 4f

7

(3) Connecting indoor unit for CM3172A

Union 3/8"(9.52mm)Flare 1/2"(12.70mm)

(1/2"(12.70

mm

) 3/8"(9.52mm)) Supplied Reducer

D

C

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

Outdoor unit Indoor unit

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

1/2"(12.70mm)

1/2"(12.70

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

B

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52mm)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

1/4"(6.35mm)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

Union 3/8"(9.52mm)Flare 1/2"(12.70mm)

(1/2"(12.70

mm

3/8"(9.52mm)) Supplied Reducer

A

Outdoor unit Indoor unit

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52mm)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

B

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35mm)

C

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

1/2"(12.70

mm

)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

D

(KMS1872)
(XS1872)

1/2"(12.70

mm

)

1/2"(12.70

mm

)

1/4"(6.35

mm

)

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

B

Outdoor unit Indoor unit

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52mm)

1/4"(6.35

mm

)

1/4"(6.35mm)

D

C

(KMS1872)
(XS1872)

(KMS1872)
(XS1872)

1/2"(12.70

mm

)

1/2"(12.70

mm

)

1/2"(12.70

mm

)

1/2"(12.70mm)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

(A)

(B)

Fig. 4g

(C)

Fig. 4h

Fig. 4i

8

(D)

Union 5/8"(15.88mm)Flare 1/2"(12.70mm)

(1/2"(12.70

mm

) 5/8"(15.88mm))Locally purchased

C

D

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

Outdoor unit Indoor unit

(KMS2472)

Union 3/8"(9.52mm)Flare 1/2"(12.70mm)

(1/2"(12.70

mm

) 3/8"(9.52mm))Supplied Reducer

1/2"(12.70mm)

1/2"(12.70

mm

)

5/8"(15.88

mm

)

3/8"(9.52

mm

)

A

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

B

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35mm)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

Union 5/8"(15.88mm)Flare 1/2"(12.70mm)

(1/2"(12.70

mm

) 5/8"(15.88mm)) Locally purchased

B

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

A

Outdoor unit Indoor unit

(KMS0772,KMS0972,KMS1272)
(XMS0972,XMS1272)

3/8"(9.52mm)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

3/8"(9.52

mm

)

1/4"(6.35

mm

)

1/4"(6.35

mm

)

C

(KMS1872)
(XS1872)

1/2"(12.70

mm

)

1/2"(12.70

mm

)

1/4"(6.35mm)

D

(KMS2472)

1/2"(12.70

mm

)

5/8"(15.88

mm

)

1/4"(6.35

mm

)

(E)

Fig. 4j

Fig. 4k

9

2-3. Outdoor Unit

NOTE

Outdoor unit

Hot air

Heat source

Exhaust fan

NO

Min.

7' (2 m)

Min.

7' (2 m)

Ground

Obstacle

Obstacle above

Air discharge

Min. 8" (20 cm)

Air intake

CAUTION

AVOID:

G heat sources, exhaust fans, etc. (Fig. 5a)

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. (Fig. 5b)

G provide a solid base (level concrete pad, concrete block,

6" × 1'4" (15 × 40 cm) beams or equal), a minimum of 6"
(15 cm) above ground level to reduce humidity and
protect the unit against possible water damage and
decreased service life. (Figs. 5c and 5d)

Fig. 5a

Air intake Min. 8" (20 cm)

Min.

4" (10 cm)

Air discharge

Valve
side
Min. 10"
(25 cm)

Min.
1’8" (50 cm)

Fig. 5b

Drain holes

A solid base must not cover
the hole of the bottom plate.

G install cushion rubber under unit’s feet to reduce vibration

and noise. (Fig. 5e)

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).

2-4. Baffle Plate for the Outdoor Unit

It is recommended to use baffle plates.

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. 5f)

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. 5f, 5g, 5h, 5i, and 5j)

Air intake

Concrete
or equal

About 16" (40 c

Wind

Back

Fig. 5c

m)

Fig. 5d

Fig. 5e

Air intake baffle

Anchor bolts
(4 pcs.)

Min. 6" (15 cm)

About 6" (15 cm)

Cushion rubber

Front

Wind

10

Air discharge baffle

No air intake baffle required on this side.

Fig. 5f

(1) Recommended dimensions of the baffle plates

D

F

E

C

J

H

L

I

B

K

Q

R

A

G

O

(3- 6.5 mm)

3- 1/4"

(2- 6 mm)

2- 15/64"

A

B

H

C

E

F

K

I

J

G

G

D

(4- 6.5 mm)

4- 1/4"

Air Intake Baffle

Air Discharge Baffle

Fig. 5g

Fig. 5h

For Air Intake

Model

CM1972A
CM2472A

CM3172A

Dimensions

(inch)

(mm) 640 20 50 635 270 270 10 20 15 657 7.5 10 150 20 20

(inch)

(mm) 640 20 35 785 350 350 10 20 15 807 7.5 10 150 20 20

ABCDE FGH I JKLOQR

25-3/16 25/32 1-31/32 25 10-5/8 10-5/8 25/64 25/32 19/32 25-7/8 19/64 25/64 5-29/32 25/32 25/32

25-3/16 25/32 1-3/8

30-29/32 13-25/32 13-25/32

25/64 25/32 19/32

31-25/32

19/64 25/64 5-29/32 25/32 25/32

For Air Discharge

Dimensions

Model

CM1972A, 2472A,
3172A

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

(inch)

(mm) 560 585 350 150 490 35 55 465 60 85 25

(2) Parts required (field supply 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 JK

22-1/16 23-1/32 13-25/32 5-29/32 19-9/32 1-3/8 2-5/32 18-5/16 2-3/8 3-11/32 31/32

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

11

(3) Installation procedure

Panel top

Panel front

Panel side R

Panel side L

Panel side R

Panel top

Panel front

Panel side L

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 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 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.

Fig. 5i Fig. 5j

NOTE

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

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).

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

12

2-5. Outer Dimensions of Outdoor Unit

(1) CM1972A

(2) CM2472A

23-15/16

23-15/16

5-11/32

15/32

A

5-11/32

15/32

A

13-19/32

12-19/32

12-19/32

13-19/32

14-17/32

14-17/32

A

35-7/16 (900)

Fig. 6a

A

35-7/16 (900)

2-29/32

2-29/32

23/32

1-13/16

2-1/16

29-1/8 (740)

29-1/8 (740)

2-27/32

2-3/4

5-29/32

2-3/4

2-1/32

Service valve on narrow tube side
(Outer diameter 1/4"(

Service valve on wide tube side

(Outer diameter 3/8"(

2-3/4

2-15/16

4-1/2

4-7/16

Service valve on wide tube side
(Outer diameter 1/2"(12.70))

Service valve on narrow tube side
(Outer diameter 1/4"(6.35))

2-3/4

6.35

9.52

))

))

(3) CM3172A

23-15/16

5-11/32

15/32

A

12-19/32

13-19/32

14-17/32

Fig. 6b

A

35-7/16 (900)

2-29/32

23/32

1-13/16

2-1/16

2-13/32

23/32

1-13/16

2-1/16

2-13/32

2-27/32

5-29/32

2-3/4

35-1/32 (890)

2-27/32

5-29/32

2-1/32

2-1/32

4-1/2

4-1/2

2-15/16

4-7/16

Service valve on wide tube side
(Outer diameter 3/8"(9.52))

Service valve on narrow tube side
(Outer diameter 1/4"(6.35))

Service valve on wide tube side
(Outer diameter 1/2"(12.70))

2-3/4

2-15/16

4-7/16

Service valve on wide tube side
(Outer diameter 3/8"(9.52))

Fig. 6c

13

unit: inch (mm)

2-6. Diagram of Outdoor Unit Installation

(

Never install only a single indoor unit.

Over 4"(10cm)

Be sure to connect indoor and outdoor units only in
combinations that are listed in the catalog or in the
combination table that was provided with the outdoor unit.
(Use caution. Connecting any other model may result in
operation failure and malfunction.)

The dimensions indicated by in the figure below are
spaces that are required in order to maintain
performance. Install in a location where the dimensions
indicated by are ensured, and where 2 or more faces
of the unit are unobstructed. In principle, the top direction
should be unobstructed.

Over 8"(20cm)

Power breaker

Wall-mounted types

Indoor unit D

Indoor unit C

Indoor unit B

Indoor unit A

Service space

Ceiling-mounted

cassette types

Indoor unit D

Indoor unit C

Indoor unit B

Indoor unit A

Ensure 6"(15cm)
of space if a
drain hose is to
be used.

(50cm)

Over 1'8"

Base (not provided)
(concrete or similar material)

D
C
B
A

Fasten with anchor bolts
(not provided)

3/8" or M10, 4 locations)

Over 10

"(25cm)

Access panel C

Ground
wire
(not
provided)

Fig. 7

14

3. Installation Process

3-1. Embedding the Tubing and Wiring

G Do not connect tubes to locations that are embedded.

G Be sure to bind refrigerant tubing and inter-unit cables

together with vinyl tape.

G The power cable must be obtained on-site.

(#12: Less than 85 ft.)
# ... AWG (American Wire Gauge)

G Be sure to apply the provided labels to both ends of

the inter-unit cables to prevent miswiring.

G Securely seal the end of embedded tubing with vinyl

tape in order to prevent dirt or moisture entry.

G In order to prevent insulation breakdown and ground

faults, do not allow the wire ends to come in contact
with rainwater, or be subject to dew condensation.

3-2. 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.

Before

Deburring

After

3-3. 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. 8)

Fig. 8

15

NOTE

Flare nut

Union

Apply the provided labels
to the indoor and outdoor
unit tubing connectors to
prevent errors in
connections.

Service valve on
narrow tube side

Service valve on
wide tube side

A

B

C

D

When reaming, hold the tube end downward and be sure that
no copper scraps fall into the tube. (Fig. 9)

Copper
tubing

(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. 10 and 11)

(*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.

3-4. 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 matching

surfaces of the flare and union before connecting them
together. This is effective for reducing gas leaks.
(Fig. 12)

If the special R410A
flare tool is used:

0 to 0.0196"
(0 to 0.5 mm)

Reamer

Fig. 9

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. 10

Flare nut

Copper
tubing

Flare tool

Fig. 11

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. 13)

3-5. Tubing Connections

a) Temporary connection:

Screw in 3 – 5 turns by hand. (Fig.14)

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

Table 4

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)

16

Fig. 14

Apply refrigerant
lubricant here and here

Fig. 12

Fig. 13

IMPORTANT

Indoor unit

Outdoor unit

Spanner

Torque wrench

Insulation

CAUTION

Be sure to match refrigerant

Insulation tape (supplied)

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

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

Tube insulation

(not supplied)

Vinyl tie (supplied)

Flare nut

tubing and electric wiring
between indoor and outdoor
units.

Fig. 15

3-6. 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. 16)

I For wall-mounted units

After connecting the refrigerant tubing to the outdoor unit
and performing a leak test on the connecting part, insulate it
with the tubing insulation. (Fig 17a)

I For ceiling-mounted cassette units

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. 17b)

Min.
5/16"
(8 mm)

Insulation

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

Fig. 16

Fig. 17a

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.

Fig. 17b

Drain hose insulation
and vinyl tie
(supplied)

Drain hose
and hose band
(supplied)

Drain pipe and insulation
(not supplied)

Vinyl tie (supplied)

Flare
insulation

The procedure used for installing
the insulation for both wide and

narrow tubes are the same.

Refrigerant tubing
and insulation
(not supplied)

Insulation tape

Fig. 17c

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

17

CAUTION

3-7. Taping the Tubes

NOTE

Clamp

Insulated tubes

Apply putty here

Tubing

CAUTION

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

(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. 18)

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

every 47" (120 cm).

Do not wind the armoring tape too tightly, since this will
decrease the heat insulation effect. Also, be sure the con­densation drain hose splits away from the bundle and drips
clear of the unit and the tubing.

Fig. 18

Fig. 19

3-8. 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. 19)

4. 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 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

Air Purging with a Vacuum Pump

I

(for Test Run)

G In order to protect the earth’s environment, be sure to use

a vacuum pump to perform the air purge.
(Never perform an air purge by using the refrigerant gas
cylinder or other external gas, or by using the gas inside
the outdoor unit.)

Service
valve on
narrow
tube side

Service
valve on
wide tube
side

With push-pin

D
C

B
A

Hex wrench

Manifold gauge
(special for R410A)

Low-pressure
valve

Leave the
valve open.

Open

Charging hose
(special for R410A)

High-pressure valve

Vacuum pump
adapter

HiLo

(for preventing
reverse flow)
(special for
R410A)

Vacuum
pump

Fig. 20

In order to prevent charging errors
with the air conditioner that uses
R410A, the screw diameter at the
service valve charging port has
been changed. When recharging or
performing other servicing, use the
special charging hose and manifold
gauge.

18

Cap tightening torque:
170 – 215 lbs·in
(200 – 250 kgf·cm)
(Tighten by hand, then
use a wrench to turn
approximately
45°.)

Stopper

Spindle

Service port
Screw diameter: 1/2
UNF 20 threads

Valve core

Cap nut tightening torque:
60 – 95 lbs·in
(70 – 110 kgf·cm)
(Tighten by hand, then use a
wrench to turn approximately 30 .)

<Structure of service valve on wide tube side>

NOTE

CAUTION

CAUTION

Perform the air purge for tubes A, B, C, and D. Use the same

CAUTION

CAUTION

procedures for all tubes.

(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. 20).

Before using the vacuum pump
adapter, read the vacuum pump
adapter manual, and use the
adapter correctly.

External diameter of service port
R410A: 5/16"

Fig. 21

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

G When using a hex wrench to open the spindle, an

extremely small amount of refrigerant may leak.
This does not indicate a problem.

G Use a hex wrench of a type to which force can be

easily applied.

(4) With the “Lo” knob of the manifold valve open and high-pressure valve (“Hi”) closed completely, run the vacuum pump.

Run the pump until the pressure is –101 kPa (–76 cmHg). 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 required for evacuation:

Table 5

Required time for evacuation when capacity

of 100 liter/h vacuum pump is used

20 min. or more

NOTE

The required time in Table 5 is calculated based on the
assumption that the ideal (or target) vacuum condition is
around 10 mmHg abs.

(5) With the vacuum pump still running, close the “Lo” knob of the manifold valve. Then stop the vacuum pump. Fully

close the low-pressure valve and stop the vacuum pump. (Wait 1 – 2 minutes and check that the manifold gauge
pointer does not return. If it does return, find and repair the leak, then apply the vacuum again.)

(6) With a 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.

Be sure to completely insert the hex
wrench before attempting to turn the
valve.

(7) With a standard screwdriver, turn the wide tube service valve stem counterclockwise to fully open the valve.
(8) Turn the narrow tube service valve stem counter-clockwise to fully open the valve.
(9) Loosen the vacuum hose connected to the wide tube service port slightly to release the pressure. Then, remove

(10) Leak test all joints at the tubing (both indoor and outdoors) with liquid soap. Bubbles indicate a leak. Be sure to wipe

the hose.

off the soap with a clean cloth.

If a CFC gas detector is used, use a

special detector for HFC refrigerant
(such as R410A and R134a).

19

(11) Replace the flare nut on the wide tube service port and fasten the flare nut securely with an adjustable wrench or

box wrench. Next, mount the valve cap and tighten it with a torque wrench (the cap needs to be tightened with the
torque of 180 lbs·in (200 kgf·cm)). This process is very important to prevent gas from leaking from the system.

(12) Test run the air conditioner. (See page 25.)

(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.

I Pump Down

In order to protect the earth’s environment, be sure to perform pump-down to recover refrigerant

gas without releasing it into the atmosphere.

G When relocating or disposing of the air conditioner, request this

service from the dealer where the unit was purchased, or from an
appropriate agent. Perform pump-down as described below.

What is pump-down?

G Pump-down refers to recovering the refrigerant gas from the refrig-

erant cycle at the outdoor unit. This work must be performed dur­ing cooling operation. The refrigerant gas cannot be recovered
during heating operation.

G During winter, or if the temperature sensor prevents cooling opera-

tion, perform “forced cooling operation.”

Pump-down procedure

(1) Fully close the spindles at the valves on the narrow tube side of

tubes A, B, C and D. (Refer to Fig. 22.)

(2) Connect the manifold gauge to the charging port at the valve on

the wide tube side of tube D. Purge the air from the charging hose.
(Refer to Fig. 23.)

(3) Perform cooling operation or forced cooling operation.

When the pressure at the low-pressure side is 0.05 – 0.1 MPaG
(0.5 – 1 kg/cm

2

G), fully close the spindles at the valves on the
wide tube side of tubes A, B, C, and D, and immediately stop
operation. (Refer to Fig. 23.)
In the winter, the outdoor unit may stop after 5 - 10 minutes of
operation. This is in order to protect the indoor unit heat
exchanger from freezing and does not indicate a problem.

Narrow tube side

Charging port

Wide tube side

Charging hose

Cap

Close

D

Close

C

Close

B

Close

A

Fig. 22

D

C

B

A

Manifold gauge

Fig. 23

(4) Disconnect the manifold gauge and the inter-unit tubes, and

attach the caps and flare nuts. At this point, pump-down is com­pleted. (If the caps and flare nuts are not reattached, there is the
danger of gas leakage.) (Refer to Fig. 24.)

If pump-down is not possible

If the air conditioner cannot be operated because of a malfunction or
other cause, use a refrigerant recovery device to recover the refrigerant.

20

Cap

Cap

Cap

After disconnecting
the inter-unit tubes,
attach the flare nuts
with flare bonnets.

Fig. 24

5. Wiring Instructions

5-1. General Precautions on Wiring

(1) Before wiring, confirm the rated voltage of the unit as

shown on its nameplate, then carry out the wiring
closely following the wiring diagram.

(2) Provide a power outlet to be used exclusively for each

unit, with a power supply disconnect and circuit break­er for overcurrent protection provided in the exclusive
line.

(3) To prevent possible hazard due to insulation failure,

the unit must be grounded.

(4) Each wiring connection must be done tightly and in

accordance with the wiring system diagram. Wrong
wiring may cause the unit to misoperate or become
damaged.

(5) Do not allow wiring to touch the refrigerant tubing,

compressor, or any moving parts of the fan.

(6) Unauthorized changes in the internal wiring can be

very dangerous. The manufacturer will accept no
responsibility for any damage or misoperation that
occurs as a result of such unauthorized changes.

5-2. 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 6 shows maximum wire lengths for control line and
power line and fuse or circuit capacity.

NOTE

Refer to the wiring system diagram (Fig. 25a or 25b) for the
meaning of (A), (B), and (C) in Table 6.

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

Table 6

AWG

Model

CM1972A 85 (Max.) 82 (Max.) 20 A

CM2472A 85 (Max.) 82 (Max.) 20 A

CM3172A 85 (Max.) 100 (Max.) 20 A

Max. Power Line Length (ft.)

(A)

(#12) (#14)

Max. Control Line Length (ft.)

(B) (C)

Fuse

or

Circuit Capacity

# ... AWG (American Wire Gauge)

21

WARNING

G Be sure to comply with local codes on running the

CAUTION

WARNING

CAUTION

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 Be sure to connect power wires correctly match-

ing up numbers on terminals of the outdoor unit
and respective indoor units A – D.

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 3'4" (1 m)
from the power cable and wires between the
indoor and outdoor units. Electrical noise may
affect the operation.

5-3. Wiring System Diagram

G To avoid the risk of electric shock, each air

conditioner 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 shared with
other electric appliances.

NOTE

*

Disconnect switch may be required by national
or local codes.

Always comply with national and local code
requirements.

(A)

INDOOR UNIT

*

(B)

INDOOR UNIT

*

(C)

INDOOR UNIT

3 indoor units with CM1972A

Disconnect

*

switch
Field supply

230/208V

(C)

Grounding
line

230/208V

230/208V

230/208V

(C)

Grounding
line

230/208V

230/208V

(C)

Grounding

(B)

230/208V

(B)

(B)

(B)

line

230/208V

230/208V

1

2

3

Terminal

Disconnect
switch

1

2

3

TerminalTerminal

Disconnect
switch

1

2

3

Field supply

Field supply

Fig. 25a

OUTDOOR UNIT

Te r mi n a l(9P

(B)

(B)

1

2

3

4

5

6

7

8

9

Terminal

(2P)

)

UNIT A

UNIT B

UNIT C

1

2

(A)

Power supply

Single-phase 230/208VAC 60HZ

L1

L2

Grounding line

(A)

INDOOR UNIT

(B)

INDOOR UNIT

(C)

INDOOR UNIT

(D)

INDOOR UNIT

4 indoor units with CM2472A, CM3172A

Disconnect

*

switch

Field supply

1

2

3

Terminal

1

2

3

Terminal

1

2

3

Terminal

Disconnect switch

*

Field supply

1

2

3

Terminal

(C)

Grounding line

Disconnect

*

switch
Field supply

(C)

Grounding line

Disconnect switch

*

(Inter-unit)
power line

230/208V

230/208V

(C)

230/208V

Grounding
line

230/208V

230/208V

(C)

Grounding
line

230/208V

230/208V

230/208V

230/208V

230/208V

230/208V

Field supply

230/208V

OUTDOOR UNIT

Terminal(12P

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

1

2

3

4

5

6

7

8

9

10

11

12

)

2P

(

Terminal

)

UNIT A

UNIT B

UNIT C

UNIT D

1

2

(A)

Power supply

Single-phase 230/208VAC 60HZ

L1

L2

Grounding line

Fig. 25b

22

Screw and
special washer

Ring
connector

Wire

WARNING

5-4. How to Connect Wiring to the Terminal

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.

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. 26) near the terminal plate.

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

the terminal plate.

STRIP
SIZE

9/32"

(7 mm)

Fig. 26

Solid wire

(ACTUAL

SIZE)

Loop

(3) Insert the wire and tighten the terminal screw com-

pletely 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. 27)

(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 termi-

nal plate and fix it securely with the removed termi­nal screw using a screwdriver.

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. 28
and 29)

(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. 28)

Wire

Special
washer

Strip 15/16" (25 mm)

Insulation

Fig. 27

Stranded wire

Strip 3/8" (10 mm)

Fig. 28

Twist wire ends

Fig. 29

Screw

Ring connector

Te r mi nal plate

Ring
connector

(4) Place the ring connector wire, and replace and

tighten the removed terminal screw using a screw­driver. (Fig. 30)

Fig. 30

23

5-5. Wiring Instructions for the Outdoor Unit

CAUTION

G Be sure to correctly align inter-unit cables A, B, C and D.

Outdoor unit

Terminal board

1 2

Indoor unit A

A is the indoor unit with
refrigerant tubing that is
connected to service valve
A (bottom) of the outdoor unit.

Terminal board

Indoor unit B

B is the indoor unit with
refrigerant tubing that is
connected to service valve B
(second from the bottom) of
the outdoor unit.

Terminal board

1 2 3 4 5 6 7 8 9 10 11 12

Power supply
(conduit)

Power:
Single-phase,
230/208VAC 60HZ

Power breaker
(not provided)

Ground

Power cable (not provided)
Inter Unit
(conduit)

3

2

1

Label A

A

Inter-unit cables
#14 (not provided)

3

2

1

Label B

B

Inter-unit cables
#14 (not provided)

Inter-unit cables
#14 (not provided)

Inter Unit
(conduit)

Label D

D

Inter-unit cables
#14 (not provided)

Label C

C

(#12: Less than 85 ft.)

Indoor unit D

D is the indoor unit with
refrigerant tubing that is
connected to service valve

3

2

1

D (top) of the outdoor unit.

Indoor unit C

C is the indoor unit with
refrigerant tubing that is
connected to service valve

3

2

1

C (third from the bottom)
of the outdoor unit.

Terminal board

Terminal board

Be sure to perform grounding.

Attach a ground wire to either the
outdoor unit or indoor unit.
If there is a grounding terminal
inside the room, use the grounding
screw inside the indoor unit.

G Use a dedicated air conditioner circuit for power.
G To make connections to the outdoor unit, remove the inspection panel and tubing panel.
G Do not bring the inter-unit cables or power cable into contact with tubing or service valves.
G Use outdoor unit cable fasteners and fasten the inter-unit cables at the location where the cables are double-

sheathed.

G Arrange the wiring so that the inter-unit cables are contained in the inspection panel and tubing panel, as shown in

Fig. 31.

Be sure to apply the provided labels to both
ends of the inter-unit cables to prevent mis­wiring. The units will not function if the wiring
connections are incorrect.

# ... AWG (American Wire Gauge)

Fig. 31

24

Regulations on wire size differ from locality to locality. For

CAUTION

Conduit plate

Make sure there is no gap between
access panel “C” and the conduit plate.

Access panel C

CAUTION

field wiring requirements, please refer to your local electri­cal codes. Make sure that the installation fully complies
with all local and national regulations.

(1) Remove access panel “C”. (Fig. 32)

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

ing 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 con-

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

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

codes.

6. Test Run

Performing a test run

G Refer to the test run procedures in the indoor unit

installation manual.

G Perform the test run separately for each connected

indoor unit. If 2 units are operated simultaneously, it is
not possible to correctly check for errors in tubing and
wiring.

Terminal
block

Conduit
plate

Plug

Lock nut

Inter unit
(Conduit)

Cabinet

Access panel “C”

Power supply
(Conduit)

Fig. 32

Checking tubing and wiring

Perform the test run and check that operation is normal.
If there is an error in tubing or wiring, the refrigerant may
flow to indoor unit B when indoor unit A is operated (for
example).

G Stop operation immediately if there is an error in tubing

or wiring. Turn the power (breaker) to OFF, and check
whether the inter-unit cables are connected incorrectly,
or whether the narrow tubes A and B are connected in
reverse. Correct the connections.

G If there is an error in tubing, pump-down must be per-

formed. Be sure to perform pump-down. After making
corrections, again purge the air from the tubes.

Fig. 33

25

7. Connecting a Home Automation device

The HA (white) 4P terminal is located on the indoor unit PCB. If a HA device will be used,
connect it to this terminal.

8. Installation Check Sheet

The strength of the installation location is sufficient to support the air conditioner weight.

The indoor and outdoor units are installed level and vertically.

The power and voltage are as specified.

Inter-unit cables are securely fastened to the terminal board.

Inter-unit cables are securely fixed.

The power cable and inter-unit cables are not connected anywhere along their paths.

The ground wire is securely connected.

An air purge of the refrigerant circuit has been conducted.

A leak test of the tubing connections has been performed.

Thermal insulation has been applied to the tubing connections.

Drain connections are secure and water drains properly.

Putty has been used to close the hole in the wall.

All service valves are fully open.

Remote controller signals are being positively received.

26