Sanyo Cool-Dry User Manual

85264189991003 © SANYO 2006

In Canada

SANYO FISHER COMPANY SANYO Canada Inc.

A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent, Concord
21605 Plummer Street Ontario, L4K 5C7, Canada
Chatsworth, CA 91311 U.S.A.

W

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. Outdoor Unit
2-3. Baffle Plate for the Outdoor Unit

3. HOW TO INSTALL THE INDOOR UNIT ............. 6

3-1. Remove the Rear Panel from the Unit
3-2. Make a Hole
3-3. Install the Rear Panel on the Wall
3-4. Remove the Grille to Install the Indoor Unit
3-5. Shape the Indoor Side Tubing
3-6. Wiring Instructions
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
3-10. Drain Hose

4. HOW TO INSTALL THE OUTDOOR UNIT ....... 16

4-1. Wiring Instructions for the Outdoor Unit

5. REFRIGERANT TUBING.................................. 17

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................................................... 19

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

INSTALLATION INSTRUCTIONS

Model Combinations

Combine indoor and outdoor units only as listed
below.

Indoor Unit Outdoor Unit

KS0971 C0971

CL0971

KS1271 C1271

CL1271

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

– Inverter Split System Air Conditioner –

COOL/ DRY Model

This air conditioner uses the new refrigerant R410A.

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

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.

NOTE

7. REMOTE CONTROL UNIT INSTALLATION

POSITION ......................................................... 23

7-1. Mounting on a Wall

8. ADDRESS SWITCH.......................................... 24

8-1. Address Setting of the Remote

Control Unit

05-424 KS0971-1271 12/13/05 1:27 PM Page a

2

IMPORTANT!
Please Read Before Starting

This air conditioning system meets strict safety and operating
standards. As the installer or service person, it is an important
part of your job to install or service the system so it operates
safely and efficiently.

For safe installation and trouble-free operation, you
must:

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.

When Installing…

…In a Ceiling or Wall

Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.

…In a Room

Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to
walls and floors.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents
water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.

…In a Snowy Area (for Heat Pump-type Systems)

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

When Connecting Refrigerant Tubing

• Use the flare method for connecting tubing.

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

• Check carefully for leaks before starting the test run.

When Servicing

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

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

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

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.

05-424 KS0971-1271 12/13/05 1:27 PM Page 2

WARNING

CAUTION

WARNING

CAUTION

3

1. General

This booklet briefly outlines where and how to install the
air conditioning system. Please read over the entire set
of instructions for the indoor and outdoor units and make
sure all accessory parts listed are with the system before
beginning.

1-1. Tools Required for Installation (not supplied)

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. Carpenter’s level

6. Sabre saw or key hole saw

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

1-2. Accessories Supplied with Unit

Table 1

1-3. Optional Copper Tubing Kit

Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or A/C workshop.

1-4. Type of Copper Tube and Insulation Material

If you wish to purchase these materials separately from
a local source, you will need:

1. Deoxidized annealed copper tube for refrigerant tub­ing as detailed in Table 2.

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

Table 2

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. Refer to 3-6.
Wiring Instructions for details.

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

Model

Narrow Tube Wide Tube

Outer Dia. Thickness Outer Dia. Thickness

KS0971/1271 1/4" (6.35 mm) 0.0314" (0.8 mm) 3/8" (9.52 mm) 0.0314" (0.8 mm)

05-424 KS0971-1271 12/13/05 1:27 PM Page 3

Parts Figure Q’ty Parts Figure Q’ty

Remote
control unit

1

Tapping screw

Remote control
unit holder

1

Rawl plug

AAA alkaline
battery

Air clean filter

2

2

Drain hose

adapter

Cushion
rubber*

Tr uss-head
Phillips

5

/32 ¥5/8" (4¥16 mm)

10

Hex wrench*

8

1

4

Parts Figure Q’ty

Clamp

*Packed in the outdoor unit.

1

1

CAUTION

4

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

2. Installation Site Selection

2-1. Indoor Unit

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. (High on a wall is best.)

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 unre-

stricted air flow around the unit. (Fig. 2)

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. 3a.

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

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.

* If total tubing length becomes 25 ft. (max.), charge additional refrigerant (R410A) by 0.16 oz./ft.

No additional charge of compressor oil is necessary.

Fig. 3b

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

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

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

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

KS0971 25 50 23 0.16

KS1271 25 65 23 0.16

Table 3

05-424 KS0971-1271 12/13/05 1:27 PM Page 4

Indoor unit

WARNING

2" (5 cm)

min.

Elevation
difference (H)

Outside drainage

INDOOR
UNIT

6" (15 cm)
min.

Front View

Tubing length (L)

Drain hose

2" (5 cm)

min.

OUTDOOR
UNIT

CAUTION

Indoor unit

Minimum height
from floor level

5' (1.5 m)

Floor level

Wall

5

2-2. Outdoor Unit

AVOID:

G heat sources, exhaust fans, etc. (Fig. 4)
G damp, humid or uneven locations.

DO:

G choose a place as cool as possible.
G choose a place that is well ventilated.
G allow enough room around the unit for air intake/

exhaust and possible maintenance. (Fig. 5a)

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. 5b)

G Install cushion rubber under unit’s feet to reduce

vibration and noise. (Fig. 5c)

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).

2-3. Baffle Plate for the Outdoor Unit

(CLxx models only)

It is recommended to use baffle plates for models
CL0971 and CL1271. The baffle plates are not normally
required for the other models.

When the outdoor unit is installed in a position exposed
to strong wind (like seasonal winds with low air tempera­ture in winter), baffle plates must be installed in front of
the outdoor unit. (Fig. 5d)

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.

NOTE

Fig. 4

Fig. 5a

Fig. 5b

Fig. 5c

Fig. 5d

05-424 KS0971-1271 12/13/05 1:27 PM Page 5

NO

Hot air

Outdoor unit

Air intake Min. 2" (5 cm)

Min.

2" (5 cm)

Air intake

Concrete
or equal

Air discharge

Valve
side
Min. 10"
(25 cm)

Min.
8" (20 cm)

Exhaust fan

Heat source

Ground

Obstacle above

Min.

7' (2 m)

Air discharge

Min. 2" (5 cm)

Air intake

Anchor bolts
(4 pcs.)

Min. 4" (10 cm)

Min.

7' (2 m)

Obstacle

Baffle
plate

6" min

6" min

Air discharge

Air discharge

Baffle
plate

About 16" (40 cm)

4" (10 cm)

About

Cushion rubber

6

Fig. 6

Fig. 7

Fig. 8

3. How to Install the Indoor Unit

3-1. Remove the Rear Panel from the Unit

(1) Remove and discard the set screw on the rear

panel. (Fig. 6)

(2) Press the 2 LL marks on the frame cover and disen-

gage the stationary tabs from the frame. (Fig. 7)

(3) Remove the rear panel.

Tubing can be extended in 5 directions as shown in Fig.

8. Select the direction you need providing the shortest

run to the outside unit.

G When left tubing is to be done, switch the drain hose

and drain cap. (For details, refer to “Switching drain
hose and drain cap” on page 14.)

3-2. Make a Hole

(1) Place the rear panel from the indoor unit on the wall

at the location selected. Make sure the panel is hori­zontal, using a carpenter’s level or tape measure to
measure down from the ceiling. Wait until after cut­ting the hole before attaching the rear panel to the
wall.

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

the hole for tubing and wiring. (Fig. 9)

In the case of left-rear tubing, use the measurement
points 2-3/4" (70 mm) from the edge of the rear panel for
precise placement of the hose outlet. (Fig. 9)

(3) Before making the hole, check carefully that no

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

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

NOTE

NOTE

Fig. 9

Also avoid areas where elec­trical wiring or conduits are
located.

05-424 KS0971-1271 12/13/05 1:27 PM Page 6

Left
tubing

Set screw only for transportation

Rear panel

Left-rear
tubing

marks

Right-rear
tubing
(recommended)

Right tubing

Downward tubing

CAUTION

2-3/4" (70 mm)

7

Indoor
side

Outdoor
side

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

NOTE

Fig. 10

Fig. 12

g

Fig. 11

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

attachment, cut a hole in the wall. See Table 4 and
Fig. 10.

Table 4

(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" (6 mm) shorter than the thickness of
the wall. (Fig. 11)

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

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

12)

3-3. Install the Rear Panel on the Wall

Be sure to confirm that the wall is strong enough to sus­pend the unit.

See either Item a) or b) below depending on the wall type.

a) If Wooden Wall

(1) Attach the rear panel to the wall with the 8 screws

provided. (Fig. 13)

If you are not able to line up the holes in the rear
panel with the beam locations marked on the wall,
use rawl plugs or toggle bolts to go through the
holes on the panel or drill 3/16" (5 mm) dia. holes in
the panel over the stud locations and then mount the
rear panel.

(2) Double check with a carpenter’s level or tape mea-

sure that the panel is level. This is important to
install the unit properly. (Fig. 14)

(3) Make sure the panel is flush against the wall. Any

space between the wall and unit will cause noise
and vibration.

b) If Block, Brick, Concrete or Similar Type Wall

Make 3/16" (4.8 mm) dia. holes in the wall. Insert rawl
plugs for appropriate mounting screws. (Fig. 15)

Hole Dia.

2-9/16" (65 mm)

Fig. 13

Fig. 14

Fig. 15

05-424 KS0971-1271 12/13/05 1:27 PM Page 7

PVC pipe (Locally purchased)

INSIDE OUTSIDE

Plastic cover

(Locally purchased)

Cut at sli

Wall

ht angle

PVC pipe

Slight
angle

3/16"
(4.8 mm) dia. hole

Rawl plug

8

3-4. Remove the Grille to Install the Indoor Unit

Basically, these models can be installed and wired without
removing the grille. If access to any internal part is need­ed, follow the steps as given below.

How to remove the grille

(1) Grasp both ends of the air intake grille, and remove it

by opening towards the front and pulling towards you.
(Fig. 16a)

(2) Remove the 2 screws. (Fig. 16b)
(3) Remove the screw on the right side cover plate and

open the cover. (Fig. 17a)

(4) Take out the thermistor from the grille. (Fig. 17b)
(5) Pull the lower part of the grille toward you to remove.

(Fig. 18a)

(6) Use a standard screwdriver to push on the tabs to

remove the grille.

How to replace the grille

(1) Reinstall the grille into the lower part while aligning

its tabs on the upper part. (Fig. 18b) Insert the
tabs in the slots and push the lower part of the
grille back into position.

(2) Make sure that the grille and frame are firmly fitted

together by engaging the tabs.
(3) Attach the thermistor on the grille. (Fig. 17a)
(4) Close the cover and replace the screw. (Fig. 17a)
(5) Affix the grille with the 2 previously removed

screws. (Fig. 16b)
(6) Install the air intake grille.
(a) Allow the edge of the air intake grille to slide into

the top of the indoor unit, and then insert it all the

way inside. (Fig. 19a)
(b) Press the bottom right and left corners of the air

intake grille to attach it to the indoor unit. (Fig. 19b)

Attach so that the round pins at the top right and left cor­ners of the air intake grille are inserted into the grooves at
the top right and left of the indoor unit.

NOTE

Fig. 16a

Fig. 16b

Fig. 17a

Fig. 17b

Fig. 18a

Fig. 18b

Fig. 19b

Fig. 19a

Pin

Groove

Be sure to wear work gloves
during installation to avoid being
cut by the sharp aluminum fins
of the heat exchanger.

05-424 KS0971-1271 12/13/05 1:27 PM Page 8

CAUTION

Screw cover

Thermistor

Air intake grille

Cover

Grille

Thermistor

Ta b

*

*

*

Grille

Frame

Ta b

*

9

3-5. Shape the Indoor Side Tubing

(1) Arrangement of tubing by direction

a) Right or left tubing

Cut out the corner of the right/left frame with a
hacksaw or the like. (Figs. 20 and 21)

b) Right-rear or left-rear tubing

In this case, the corner of the frame need not be
cut.

(2) To mount the indoor unit on the rear panel:

Hang the 2 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)

3-6. 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 manufacturer will accept no
responsibility for any damage or misoperation that
occurs as a result of such unauthorized changes.

Fig. 21

Fig. 22

Fig. 20

05-424 KS0971-1271 12/13/05 1:27 PM Page 9

Frame

Left tubing
outlet

Frame

Right tubing
outlet

10

3-7. 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 5 lists recommended wire lengths and diameters for power supply systems.

Refer to the wiring system diagram (Fig. 23) for the meaning of (A), (B), and (C) in
Table 5.

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

NOTE

Fig. 23

WIRING SYSTEM DIAGRAM

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 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.

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 elec-

tric appliances.

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

Fuse or Circuit AWG

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

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

Breaker Capacity

C0971, CL0971, C1271, CL1271

131 (Max.) 230 (Max.) 65 (Max.) 20A

# ... AWG (American Wire Gauge)

Table 5

05-424 KS0971-1271 12/13/05 1:27 PM Page 10

WARNING

WARNING

INDOOR

UNIT

Te r mi nal Terminal

1
2

3

Disconnect
switch

Field supply

115V

115V

115V

(C)

Grounding line

(B)

(B)

OUTDOOR

UNIT

1
2

3

4

5
6

Powe r supply

(A)

L

N

Grounding
line

Single phase 115V 60HZ

CAUTION

11

3-8. Wiring Instructions for Inter-unit Connections

(1) Insert the inter-unit wiring (according to local codes)

into the through-the-wall PVC pipe. Run the wiring
toward the indoor side allowing approx. 10" (25 cm)
to extend from the wall face. (Fig. 24)

(2) Grasp both ends of the air intake grille, and remove

it by opening towards the front and pulling towards
you.

(3) Remove the screw on the right side cover plate and

open the cover. (Fig. 25)

(4) Route the inter-unit wiring from the back of the

indoor unit and pull it toward the front for connec­tion. (Fig. 26a, 26b)

(5) Connect the inter-unit wiring to the corresponding

terminals on the terminal plate (Fig. 26a, 26b) while
referring to the wiring diagram.

(6) Be sure to secure the wiring with the provided

clamp.

When closing the air intake grille, press on both corners.
(Fig. 27)

Please refer to “How to replace the grille” on page 8 for
installing the air intake grille.

NOTE

Fig. 24

Fig. 25

Fig. 26a

Fig. 26b

Fig. 27

05-424 KS0971-1271 12/13/05 1:28 PM Page 11

Rear
panel

Wiring

Wall

Plastic
cover

10"
(25 cm)

Cover

Te r mi nal
plate

Inter-unit
wiring

Earth
plate

Lock nut

Top of conduit
connector

12

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. 28) 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 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. 29)

(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. 30
and 31)

(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. 30)

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

tighten the removed terminal screw using a screw­driver. (Fig. 32)

Fig. 29

Fig. 28

Fig. 30

Fig. 32

Screw and
special washer

Ring
connector

Wire

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. 31

05-424 KS0971-1271 12/13/05 1:28 PM Page 12

WARNING

STRIP
SIZE

Solid wire

9/32"

(7 mm)

(ACTUAL

SIZE)

Loop

Strip 15/16" (25 mm)

Insulation

Stranded wire

Strip 3/8" (10 mm)

Twist wire ends

Ring
connector

Wire

Special
washer

Screw

Ring connector

Terminal plate

13

3-9. Mounting

(1) To install the indoor unit, mount the indoor unit onto

the 2 tabs on the upper part of the rear plate.

(2) Hold down the air discharge outlet and press the

lower part of the indoor unit until it clicks to securely
fasten to the 2 tabs on the lower part of the rear
plate. (Fig. 33)

For tubing, choose either the right or left tubing direction
and follow the steps below. This work can be made easi­er by placing padding material (such as styrofoam) at the
rear right side of the indoor unit. (Fig. 34)

I Right-side tubing

(1) Shape the refrigerant tubing so that it can easily go

into the wall hole. (Fig. 35)

(2) Push the wiring, refrigerant tubing, and drain hose

through the hole in the wall. Adjust the indoor unit so
it is securely seated on the rear panel. (Fig. 36)

(3) Carefully bend the tubing (if necessary) to run along

the wall in the direction of the outdoor unit and then
tape as far as the fittings. (See Caution on page

18.) The drain hose should come straight down the
wall to a point where water runoff won’t stain the
wall.

(4) Connect the refrigerant tubing to the outdoor unit.

(After performing a leak test on the connecting part,
insulate it with the tubing insulation. (Fig. 37a)) Also,
refer to Section 5-4. Connecting Tubing between
Indoor and Outdoor Units.

(5) Assemble the refrigerant tubing, drain hose, and

conduit (including inter-unit wiring) as shown in
Fig. 37b.

NOTE

Fig. 35

Fig. 36

Fig. 33

Fig. 34

05-424 KS0971-1271 12/13/05 1:28 PM Page 13

Push

Padding material

Rear panel

Cover

Refrigerant
tubing

Refrigerant tubing

Fig. 37a

Insulation

Conduit

Fig. 37b

Drain hose

Inter-unit wiring

Inter-unit
wiring

Drain hose

14

Fig. 38

Fig. 39

I Left-side tubing

(1) Lead the tubing and drain hose through the wall,

allowing sufficient length for connection. Then bend
the tubing using a tube bender to make the attach­ment. (Fig. 38)

(2) Switch the drain hose and drain cap.

Switching drain hose and drain cap

(a) Locate the drain hose and the drain cap. (Fig.

39)

(b) Remove the screws fastening the drain hose on

the right side, and pull out the drain hose to
remove it. (Fig. 39)

(c) Apply moderate force to pull off the drain cap

on the left side. (If you cannot pull it off by
hand, use a long-nose pliers.)

(d) Reattach the drain hose to the left side and the

drain cap to the right side. (Fig. 40a)

Drain hose

Slide the drain hose fully onto the drain pan outlet
until the drain hose edge is pushed into the insula­tion. Check that the screw holes in the drain bracket
and the drain pan outlet are aligned and securely in
contact, then fasten them with the screw. (After
attaching the drain hose, check that it is attached
securely.) (Fig. 40c)

Drain cap

Use a Phillips screwdriver to push the drain cap in
firmly. (If it is difficult to push in, wet the cap with
water first.)

(3) Install the indoor unit on the rear panel.

(4) Connect the tubing and wiring led inside from out-

doors.

(5) After completing a leak test, bundle the tubing

together with armoring tape and store it inside the
tubing storage area at the back of the indoor unit
and hold it with clamps. (Figs. 40a and 41)

Fig. 40a

Fig. 40b

Fig. 40c

Fig. 41

05-424 KS0971-1271 12/13/05 1:28 PM Page 14

Rear panel

Hole in wall

Drain hose

Bent part

Wide tube

Narrow tube

Drain cap

Drain hose

Clamp

Insulation

Drain bracket

Drain hose

Drain cap

Screw hole

Drain bracket

Screw

Conduit

Drain pan outlet

Drain hose

Refrigerant tubing

Inter-unit wiring

15

To unmount indoor unit

Press the 2 LL marks on the lower part of the indoor unit
and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 42)

3-10. Drain Hose

a) The drain hose should be slanted downward to the

outdoors. (Fig. 43)

b) Never form a trap in the course of the hose.

c) If the drain hose will run in the room, insulate the

hose with insulation* so that chilled condensation
will not damage furniture or floors. (Fig. 44)

* Foamed polyethylene or its equivalent is recom-

mended.

WARNING

Risk of Electric Shock

Do not supply power to the
unit or operate it until all
tubing and wiring to the out­side unit are completed.

Fig. 44

Fig. 42

Fig. 43

05-424 KS0971-1271 12/13/05 1:28 PM Page 15

Indoor
unit

Insulation material
(Locally purchased)
must be used.

Push

Slant

Drain
hose

Condensation

16

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.

(1) Remove access panel “C”. (Fig. 46)

(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

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.

Fig. 46

05-424 KS0971-1271 12/13/05 1:28 PM Page 16

Te r mi nal
block

Conduit
plate

Plug

Lock nut

Inter unit
(Conduit)

Cabinet

Access panel “C”

Power supply
(Conduit)

17

5. Refrigerant Tubing

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. 47)

When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 48)

(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. 49a and 49b)

(*Use “RIGID” or equivalent.)

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. 50)

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. 51)

NOTE

NOTE

Fig. 47

Fig. 48

Fig. 49b

Fig. 49a

Fig. 50

Flare nut

Union

Fig. 51

05-424 KS0971-1271 12/13/05 1:28 PM Page 17

Deburring

Before

If the special R410A
flare tool is used:

0 to 0.0196"
(0 to 0.5 mm)

After

Copper
tubing

Reamer

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.

Flare nut

Copper
tubing

Flare tool

Apply refrigerant
lubricant here and here

18

5-4. Connecting Tubing between Indoor and

Outdoor Units

a) Tightly connect the indoor side refrigerant tubing exten-

ded from the wall with the outdoor side tubing. (Fig. 52)

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

Table 6

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. (Fig. 53)
The thickness of the insulation should be a minimum 5/16"
(8 mm). (Fig. 54)

5-6. Taping the Tubes

(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. 55)

(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.

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. 56)

NOTE

IMPORTANT

Fig. 52

Fig. 54

Fig. 55

Clamp

Insulated tubes

Fig. 56

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.

Fig. 53

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)

05-424 KS0971-1271 12/13/05 1:28 PM Page 18

Torque wrench

CAUTION

Indoor unit

Min.
5/16"
(8 mm)

Spanner

Outdoor unit

Insulation

Insulation

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

Apply putty here

Tubing

19

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. 57)

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

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 7

Fig. 57

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.

The required time in Table 7 is calculated based on the
assumption that the ideal (or target) vacuum condition
is around 10 mmHg abs.

NOTE

Required time for evacuation when

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

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 push­pin inside.

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

05-424 KS0971-1271 12/13/05 1:28 PM Page 19

CAUTION

Manifold valve
(Exclusively for R410A)

Pressure
gauge

Indoor unit

Outdoor unit

HiLo

Charging hose
(Exclusively for R410A)

CAUTION

Vacuum pump adapter
(Exclusively for R410A)
(with reverse flow prevention)

Vacuum pump

20

(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. 58)

(7) Leak test all joints at the tubing (both indoor and out-

doors) 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.

(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.

(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.

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

Fig. 58

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

05-424 KS0971-1271 12/13/05 1:28 PM Page 20

CAUTION

90° (1/4 turn)

Valve cap

Vacuum hose to manifold valve

Narrow tube

Hex wrench

Wide tube

CAUTION

21

How to Test Run the Air Conditioner

After turning on power to 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. 59a)
a) Press and hold the ION button.
b) Then press and hold the 1HR TIMER button.

c) At the same time, press the ACL (reset) button once.

Use a pointed object such as the tip of a pen to press
the ACL button.

• After a few seconds, “ ” appears and “oP-1” blinks in
the remote controller display area.
(Fig. 59b)

d) Release the 1HR TIMER button.
e) Release the ION button.

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

operation button of the remote controller. (Fig. 59a)

• This starts the fan producing uncooled forced air with
the 4 indicator lamps (OPERATION lamp, TIMER
lamp, QUIET lamp, and ION lamp) on the main unit
blinking. (Fig. 59c)

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

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

troller again to stop the test run. (Fig. 59a)

(4) Finally press the ACL (reset) button of the remote con-

troller to release it from Test Run mode to return to nor­mal mode. (Fig. 59a)

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

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.

IMPORTANT

Fig. 59a

Fig. 59b

Fig. 59c

05-424 KS0971-1271 12/13/05 1:28 PM Page 21

ION

button

ON/OFF
operation

button

1HR.
TIMER

button

A

ACL
(Reset)

button

OPERATION lamp

TIMER lamp
QUIET lamp
ION lamp

22

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

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

(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

2

), 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 Basic Functions of the Service Valves

The basic functions of the service valves are given in Table 8 below.

Action

Narrow Tube Service

Valve (2-Way)

Wide Tube Service

Valve (3-Way)

CLOSED

Fully OPEN

Fully OPEN

Shipping

Operating and
test running
the air conditioner

Measuring pressure
and gas charging

Air purging with
a vacuum pump

CLOSED

Valve cap

Stem

O-ring

*

*

Table 8

* 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. 60a)

Fig. 60a

Close

Hex
wrench

Open

Fig. 60b

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

05-424 KS0971-1271 12/13/05 1:28 PM Page 22

CAUTION

Service valve

Hose with push-pin

PUSH

23

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)

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.

Fig. 61

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

05-424 KS0971-1271 12/13/05 1:28 PM Page 23

Remote control unit mount

Mounting screws

5/32 × 5/8" (4 × 16 mm)

(Included)

Press

Set in
place

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.

24

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 two Sanyo 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.

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. 62). When the tab is removed, the address is
automatically set to B (Fig. 63).

(3) Press and hold the remote controller ION button and

1 HR TIMER button. At the same time, press the
ACL(reset) button. Use a thin object such as the tip
of a pen to press the ACL button. When this has
been done, “oP-1” (test run) appears, blinking, in the
remote controller clock display area.

(4) Each time the 1 HR 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. 64)

(5) “oP-7” has now been selected for address setting.
(6) Press the ON/OFF operation button on the remote

controller. (Fig. 64) 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.

(7) Finally press the remote controller ACL (reset) but-

ton to cancel the blinking “oP-7” display.
(Fig. 64)

Changing of the second remote controller address is
now completed.

NOTE

Fig. 62

Fig. 63

Fig. 64

05-424 KS0971-1271 12/13/05 1:28 PM Page 24

Ta b

Te st run mode

Selfdiagnostic mode

Adress setting mode

ION

button

ACL button

ON/OFF
operation

button

1HR.
TIMER

button

A

ACL
(Reset)

button