Sanyo KH2442, XH4242, KH3642, CH4242, UH2442 User Manual

...

INSTALLATION INSTRUCTION

— Split System Heat Pump Air Conditioner —

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Units and Outdoor Units

Indoor Units Type

4-Way Air Discharge

Semi-Concealed

(Matching Ceiling Panel)

Wall-Mounted

Ceiling-Mounted

Concealed-Duct

Outdoor Units

Wired Remote Controller

Wireless Remote Controller

Weekly Timer

System Controller

XH2442

(PNR-XH2442)

KH2442

TH2442

UH2442

CH2442

Built-in type: RCS-SH80UA.WL (Optional part ) External type: RCS-BH80UA.WL (Optional part )

XH3642

(PNR-XH3642)

KH3642

TH3642

UH3642

CH3642

RCS-SH80UG (Optional part )

TM-SH80UG (Optional part )

SHA-KC64UG (Optional part )

XH4242

(PNR-XH3642)

TH4242

CH4242

(WD)

(WL)

85464359146001 © SANYO 2001

OPERATING LIMITS

■ Maximum Conditions Cooling / Heating Outdoor temperature : 115°F DB / 65°F WB Room temperature : 71°F WB / 80°F DB

■ Minimum Conditions Outdoor temperature : 23°F (0°F)* DB / 15°F WB Room temperature : 57°F WB / 59°F DB

* When air discharge chamber is installed.

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

SANYO FISHER COMPANY

A DIVISION OF SANYO NORTH AMERICA CORPORATION 21605 Plummer Street Chatsworth, CA91311

In Canada

SANYO Canada Inc.

300 Applewood Crescent Concord, Ontario L4K 5C7, Canada

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 :

ⓦ Carefully read this instruction booklet before beginning. ⓦ Follow each installation or repair step exactly as shown. ⓦ Observe all local, state, and national electrical codes. ⓦ Pay close attention to all warning and caution notices

given in this manual.

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

This symbol refers to a

CAUTION

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 accidentaly 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 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

……………………………………………………………………

• Ventilate the room well, in the event that refrigerant gas leaks during the installation. Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas.

• Keep all tubing runs as short as possible.

• 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.

NOTE

Depending on the system type, liquid and gas lines may be either narrow or wide. Therefore, to avoid confusion the refrigerant tubing for your particular model is specified as either “narrow” or “wide” rather than as “liquid” or “gas”.

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 when installation is finished. Check that no metal scraps or bits of wiring have been left inside the unit.

CAUTION

• Ventilate any enclosed areas when installing or testing the refrigeration system. Contact of refrigerant gas with fire or heat can produce poisonous gas.

• Confirm after installation that no refrigerant gas is leaking. If the gas comes in contact with a burning stove, gas water heater, electric room heater or other heat source, it can cause the generation of poisonous gas.

CONTENTS

Page

IMPORTANT Please Read Before Starting

1. GENERAL ................................................................... 4

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

2. SELECTING THE INSTALLATION SITE .................. 10

Indoor Unit Outdoor Unit

2-1. Air Discharge Chamber for Top Discharge 2-2. Installing the Outdoor Unit in Heavy Snow Areas 2-3. Precautions When Installing in Heavy Snow Areas 2-4. Dimensions of Snow / Wind-proof Ducting and

Refrigerant Tubing Space for Installation

3. HOW TO INSTALL THE INDOOR UNIT.................... 14

■ 4-Way Air Discharge Semi-Concealed Type

(XH Type)................................................................... 14

3-1. Suspending the Indoor Unit 3-2. Preparation for Suspending 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. Before Installing the Ceiling Panel 3-7. Installing the Ceiling Panel 3-8. When Removing the Ceiling Panel for Servicing 3-9. Duct for Fresh Air

■ Wall-Mounted Type (KH Type) ................................... 22

3-10. Removing the Wall Fixture from the Unit 3-11. Selecting and Making a Hole 3-12. Installing the Wall Fixture onto Wooden or

Gypsum Wall

3-13.

Removing the Casing to Install the Indoor Unit 3-14. Preparing the Indoor Side Tubing 3-15. Wiring Instructions 3-16.

Wiring Instructions for Inter-Unit Connections 3-17. Shaping the Tubing 3-18. Installing the Drain Hose

■ Ceiling-Mounted T ype (TH Type). .............................. 31

3-19. Suspending the Indoor Unit 3-20. Duct for Fresh Air 3-21. Installing the Drain Piping

■ Concealed-Duct T ype (UH Type) ............................... 35

3-22.

Required Minimum Space for Installation and Service 3-23. Suspending the Indoor Unit 3-24. Installing the Drain Piping

Page

3-25. Checking the Drainage 3-26. Increasing the Fan Speed

4. HOW TO INSTALL THE OUTDOOR UNIT ................ 40

4-1. Removing the Protective Spacer for Transportation 4-2. Installing the Outdoor Unit 4-3. Tubing Direction

5. ELECTRICAL WIRING ............................................. 41

5-1. General Precautions on Wiring 5-2. Recommended Wire Length and Wire Diameter

for Power Supply System 5-3. Wiring System Diagrams 5-4. How to Connect Wiring to the Terminal

HOW TO INSTALL THE WIRED REMOTE CONTROLLER

(OPTIONAL PART) .................................................... 45

6-1. Installation site selection 6-2. Wired Remote Controller Installation 6-3. Basic Wiring Diagram 6-4. Wiring System Diagram for Group Control 6-5. Wiring System Diagram for Multiple Remote

Control 6-6. How to Switch the Indoor Temperature Sensor 6-7. Explanation of Alarm Messages

HOW TO INSTALL THE WIRELESS REMOTE CONTROLLER

(OPTIONAL PART) .................................................... 52

7-1. Wireless Remote Controller Installation 7-2. Room Temperature Sensor Setting 7-3. Address Switches 7-4. Setting the Model Code <RCS-SH80UA. WL>

■ 4-Way Air Discharge Semi-concealed Type

(XH Type)................................................................... 54

7-5. Indicator section Installation 7-6. Operating Controller Installation

■ Ceiling Mounted Type (TH Type)......................... 55

7-7. Indicator Section Installation 7-8. Operating Controller Installation 7-9. Electrical Wiring 7-10. Test Run Switch 7-11. Misoperation Alarm Indicators

<RCS-BH80UA.WA>

7-12.

Separate type Signal Receiving Unit Installation 7-13. Electrical Wiring 7-14. Test Run Switch 7-15. Misoperation Alarm Indicators 7-16. Basic Wiring Diagram 7-17. Wiring System Diagram for Group Control 7-18. Wiring System Diagram for Multiple

8. HOW TO INSTALL THE WEEKL Y TIMER

(OPTIONAL PART) ................................................... 65

8-1. Mounting Dimensions for Continuous Installation 8-2. When Using a Wall Box for Flush Mounting 8-3. Wiring Diagram 8-4. Test Run Setting 8-5. Memory Back Up Function for Power Failure

Compensation

9. HOW TO INSTALL THE SYSTEM CONTROLLER

(OPTIONAL PART) ................................................... 67

9-1. System Controller Installation 9-2. Electrical Wiring 9-3. Address Switch Setting 9-4. Mode Setting 9-5. How to Perform Zone Registration 9-6. Connection with Other Equipments 9-7. Memory Back Up Switch 9-8. Test Run

Page

10. HOW TO PROCESS TUBING .................................. 79

10-1. Use of the Flaring Method 10-2. Flaring Procedure with a Flare Tool 10-3. Precaution before Connecting Tubes Tightly 10-4. Precautions during Brazing 10-5. Connecting Tubing between Indoor and Outdoor

Units 10-6. Insulating the Refrigerant Tubing 10-7. Taping the Tubes 10-8. Finishing the Installation

11. AIR PURGING .......................................................... 82

12. TEST RUN ................................................................ 85

12-1. Preparing for Test Run 12-2. PCB Setting 12-3. R.C. Address Setting Method 12-4. Automatic Address Setting Method 12-5. Displaying Indoor / Outdoor Unit Combination

Numbers 12-6. Test Run Procedure 12-7. Items to Check Prior to Test Run 12-8. The Main Alarms of Mis-wiring & Mis-setting 12-9. The Main Alarms of Unit Troubles 12-10

. The Main Alarms of Power Supply Troubles

13. PUMP DOWN............................................................ 93

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.

Check local electrical codes

CAUTION

and regulations before obtaining wire. Also, check any specified instructions or limitations.

1-4. Additional Materials Required for Installation

1-1. Tools Required for Installation (Not Supplied)

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. 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

See Table 1-1 to 1-9.

Table Type

1-1 4-Way Air Discharge Semi-Concealed 1-2 Wall-Mounted 1-3 Ceiling-Mounted 1-4 Concealed-Duct 1-5 Outdoor Unit 1-6 Wired Remote Controller 1-7 Wireless Remote Controller 1-8 Weekly Timer 1-9 System Controller

1. Refrigeration (armored) tape

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

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

1-3. Type of Copper Tube and Insulation Material

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.

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

1. Deoxidized annealed copper tube for refrigerant tubing.

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

3. Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to Section 5. “Electrical Wiring” for details.

S4359146

Table 1-1 XH (4-Way Air Discharge Semi-Concealed)

Part Name Figure

Full-scale installation diagram 1 Flare insulator 2 Washer 8 Insulating tape 1 Hose band 2 Packing 1 Drain insulator 1 Drain hose 1 Drain hose adaptor 1 Sealing putty 1

Tube connector 1

Table 1-2 KH (Wall-Mounted)

Part Name Figure Q’ty Remarks

(White)

Q’ty

For determining suspension bolt pitch For wide and narrow tubes For suspending indoor unit from ceiling

For wide tube flare nuts For securing drain hose For drain joint For drain joint

For drain outlet For sealing recessed portion of power supply For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Remarks

Wall fixture *1 1

Insulator *1 1

Mounting plate *1 1

Truss-head

Tapping screw *1 20

Full-scale diagram 1

Wall fixture *2 1

Rawl plug *2 10

Cover *2 1

Tapping screw *2 10

Insulator 1

Phillips 4 × 1 in.

Truss-head Phillips 4 × 5/8 in.

For supporting the indoor unit

For insulation of the tubing of the indoor unit

For securing the indoor unit

For fixing the wall fixture

For determining the place where the indoor unit is installed

For supporting the indoor unit

For fixing the wall fixture

For improved tubing appearance

For fixing the wall fixture

For insulation of the tubing of the indoor unit

(WD)

(WL)

Tube connector 1

* 1 KH3642 only * 2 KH2442 only

For sizing up of narrow tube from 1/4 in. to 3/8 in. (only for 24 type)

S4359146

Table 1-3 TH (Ceiling-Mounted)

Part Name Figure Q’ty Remarks

Special washer

For temporarily suspending

indoor unit from ceiling

Drain insulator 1 Flare insulator

1 Set

Drain hose adaptor 1 Drain hose clamp 4

Insulating tape

Black

White (heat-resisting)

Vinyl clamp 2 Full-scale installation

diagram Sealing putty 1

Drain hose 1 Tube connector 1

Table1-4 UH (Concealed-Duct)

Part Name Figure

Flare insulator 2

(Black)

Insulating tape

(White)

For drain hose joint For wide tube joints

For wide tube and drain hose joint

For wide flare joints For ends of flare insulator

For determining suspension

bolt pitch For sealing recessed portion of power supply

For sizing up of narrow tube from 1/4 in. to 3/8 in. (only for 24 type)

Q’ty

Remarks

For wide and narrow tubes 2 2

For wide and narrow tubes

For wide and narrow tube flare nuts

Tapping screw TOTA4-10

14 or 20 or 24 Jumper cable* 1 Hose band 1 Packing 1 Sealing putty 1 Drain insulator 1 Drain hose 1 Drain hose adaptor 1 Clamp 9

Tube connector 1

* Jumper cable is housed inside the electrical component box.

Table 1-5 (Outdoor Unit)

Part Name Figure

Hexagonal Wrench 1

Grommet 1

Bushing 1

Q’ty

To open and shut the Narrow Tube Service Valve For protecting refrigerant pipe by attaching to the

edge of Tubing Outlet For protecting inter-unit control line by attaching to the edge of wiring outlet

Installation Instruction 1

For air intake duct connection For increasing the fan speed For securing drain hose For drain joint For sealing recessed portion of power supply For drain joint

For securing drain hose & refrigerant tubing For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Remarks

Owner’s manual 1

S4359146

Table 1-6 (Accessories for the Wired Remote Controller)

Part Name Figure

Wired remote controller (comes with 7-7/8 in. wire)

Machine screws M4 × 1 in.

Wood screws 2

Table 1-7 (Accessories for the Wireless Remote Controller) <RCS-SH80UA.WL>

Part Name Figure

Operation controller 1 Spacers 2

Run Timer

Indicator section 1 4

Heating preparations

Q’ty

1 Spacers 2

2 Wire joints 4

Q’ty

Pan-head tapping screws 4 × 13/32 in.

Part Name Figure

Q’ty

Wireless remote controller 1 2

Wireless remote controller mounting cradle

Batteries 2 Wire joints 4

<RCS-BH80UA.WL>

Part Name Figure

Separate type signal receiving unit (comes with 7-7/8 in. wire)

Carrier for ceiling installation 1 Wood screws 2

Wireless remote controller 1 Spacers 4

Truss-head tapping screws 4 × 5/8 in.

Vinyl clampers

L 5-29/32

Q’ty

Small screws

M4 × 1-9/16 in.

Part Name Figure

Q’ty

(WD)

(WL)

Wireless remote controller mounting cradle

Batteries 2 Clamper 1

Machine screws M4 × 1 in.

1 Wire joints 4

Ceiling installation paper pattern

(

3-3/4 × 2-1/32 in.

S4359146

)

Table 1-8 (Accessories for the Weekly Timer)

Part Name Figure

Q’ty

Part Name Figure

Weekly timer 1 Wood screws 2

Connecting wiring length 4 ft.

Machine screws

1 Spacers 2

2 Clampers 2

M4 × 1 in.

Table 1-9 (Accessories for the System Controller)

Part Name Figure

System controller 1 1

Rubber bushing (7/8 in.)

Screws for fixture (1-3/16 in.)

Q’ty

Label (Identification label)

Label

(Terminal base label)

Part Name Figure

SYSTEM CONTROLLER IDENTIFICATION LABEL

ALL Central Control ALL RCU. ZONE1 Central Control

ZONE1 RCU.

ZONE2 Central Control

ZONE2 RCU.

ZONE3 Central Control

ZONE3 RCU.

ZONE4 Central Control

ZONE4 RCU.

*Please attach this label on surface of the lid after cleaning. *If need to write down some detail, use magic marker.

ALL ON

INPUT

Inter-

unit control wiring

ALL OFF

INPUT

COMMON

U2 Aux.

INPUT

OPERATION STATE

UNUSED

OUTPUT

ALARM OUTPUT

DC12V FROM INDOOR UNIT PCB.

COMMON OUTPUT

Q’ty

S4359146

1-5. T ubing Length

● Refrigerant tubing between the indoor and

outdoor units should be kept as short as possible.

● Select and decide the installation location so

that the length of the refrigerant tubing will be within the limits given in Table 1-10.

Table 1-10

Models

Tubing Data

Tubing size outer dia.

Limit of tubing length (ft.) 165 165

Limit of elevation difference between the 2 units

Max. allowable tubing length at shipment (ft.) 100 100 Required additional refrigerant (oz./ft.) 0.48

No additional charge of compressor oil is necessary.

*1If total tubing length becomes 100 to 165 ft., charge additional refrigerant (R22) by 0.48 oz./ft.. *2If total tubing length becomes 100 to 165 ft., charge additional refrigerant (R22) by 0.53 oz./ft..

Narrow tube in. (mm) 1/4 (6.35) 3/8 (9.52) Wide tube in. (mm) 3/4 (19.05) 3/4 (19.05)

Outdoor unit is higher than indoor unit (ft.)

Outdoor unit is lower than indoor unit (ft.)

CH2442

165 165

100 100

INDOOR UNIT

Elevation difference (H)

CH3642, CH4242

0.53

Tubing length (L)

OUTDOOR UNIT

Fig. 1-1

0711_M_I

(WD)

(WL)

S4359146

2. SELECTING THE INSTALLATION SITE

Indoor Unit

AVOID:

● areas where leakage of flammable gas may be expected.

● places where large amounts of oil mist exist.

● direct sunlight.

● locations near inverter lamps which may affect

performance of the unit.

● locations near heat sources which may affect performance of the unit.

● locations where external air may enter the room directly. This may cause “sweating” on the air discharge ports, causing them to spray or drip.

● locations where the remote control unit will be splashed with water or affected by dampness or humidity.

● installing the remote control unit behind curtains or furniture.

● locations where the receiver in the indoor unit is exposed to the inver ter lamp light. Faulty operation of the unit occurs.

DO:

Ceiling-Mounted Type

Ceiling

Wall

Min.10 inch

Front view

Min.10 inch

NOTE

The rear of the indoor unit can be installed flush against the wall.

Air discharge

Min.2 ft.

Side view

Ceiling

Air intake

1091_T_I

4-Way Air Discharge Type

Concealed-Duct Type

3 ft.

● select an appropriate position from which every corner of the room can be uniformly cooled.

● select a location where the ceiling is strong enough to support the weight of the unit.

● select a location where tubing and drain pipe have the shortest run to the outdoor unit.

● allow room for operation and maintenance as well as unrestricted air flow around the unit.

● install the unit within the maximum elevation difference above or below the outdoor unit and within a total tubing length from the outdoor unit as detailed in Table 1-10.

● allow room for mounting the remote control unit about 3 ft. off the floor, in an area that is not in direct sunlight nor in the flow of cool air from the indoor unit.

NOTE

● Air delivery will be degraded if the distance from the floor to the ceiling is greater than 10 ft..

3 ft.

Min. 6 inch

3 ft.

1960_X_I

Wall-Mounted T ype

Min. 6 inch

Min. 12 inch

0930_K_I

S4359146

Outdoor Unit

AVOID:

● heat sources, exhaust fans, etc. (Fig. 2-1)

● damp, humid or uneven locations.

DO:

Hot air

Outdoor unit

Exhaust fan

Heat source

0591_C_I

● choose a place as cool as possible.

● choose a place that is well ventilated and outside

air temperature does not exceed maximum 115°F constantly.

● allow enough room around the unit for air intake/ exhaust and possible maintenance. (Fig. 2-2)

● provide a solid base; about 6 inch above ground level to reduce humidity and possib le water damage in the unit and decreased service life. (Fig. 2-3)

● use lug bolts or equivalent to bolt down unit, reducing vibration and noise.

In case of multiple installations

Unit spacing if air discharge chamber is not used. Unit spacing when air discharge chamber is used.

Min. 4 ft. Min. 4 ft.Min. 5 ft.

Min. 1 ft.

Min. 12 ft.

Min. 8 inch

Min. 1 inch

Min. 4 ft.

Min. 1 ft. 2 inch

4 in.

Min. 2 ft.

Min. 8 inch

Fig. 2-1

Min. 1 inch

0931_C_I

Fig. 2-2

Min. 1 ft.

Obstacle above

Min. 7 ft.

Air discharge

Ground

Min. 4 ft.

Air discharge chamber

Min. 1 ft.

0932_C_I

(WD)

(WL)

If you would like to make the separation smaller on the air discharge side, use an air discharge chamber. You can install any number of units side-by -side.

Only up to 3 units can be installed side-by-side under the above conditions. The next group must be spaced at least 1 ft. away from the first group.

Air in

Air discharge

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

Anchor bolts (4 pieces)

Fig. 2-3

S4359146

Air in

Min. 6 inch

0934_C_I

0933_C_S

Air discharge

0426_C_I

2-1. Air Discharge Chamber for Top Discharge

Install the air-discharge chamber in the field when:

● it is difficult to keep a space of minimum 2 ft. between the air-discharge outlet and the obstacle.

● the air-discharge outlet is facing the sidewalk and discharge hot air can annoy the passers-by. Refer to Fig. 2-4.

8-ø1/4" hole

22-5/16"

23-5/16"

3-ø2-3/8" hole

11-13/16"

43-15/16"

9-7/8"9-7/8" 17-3/4" 3-15/16"

5-3/16"

5-5/32"

1352_C_

Recommended outer dimensions of wind shield (field supply)

21-13/16"

CH3642 CH2442

Fig. 2-4

3 - ø1-9/16" hole

9-27/32"21-5/8"15/16"

6 - ø15/64" hole

22-7/16"1/2"

23-15/32"

5-3/16"

5-5/32"9-27/32"9-27/32"1-7/32"

0936_C_I

2-2.

Installing the Outdoor Unit in Heavy Snow Areas

In locations subject to strong winds, snow-proof ducting should be fitted and direct exposure to the wind should be avoided as much as possible.

The following problems may occur when the outdoor unit is not provided with a platform and snow-proof ducting.

a) The outdoor fan may not run and there may be

damage to the unit b) There may be no air flow. c) The tubing may freeze and burst. d) The condenser pressure may drop because of

strong wind, and the indoor unit may freeze.

S4359146

2-3. Precautions When Installing in Heavy Snow

Areas

(1) The platform should be higher than the maximum.

snow depth. (Fig. 2-5)

(2) The two anchoring feet of the outdoor unit should

be attached to the platform, and the platform should be installed beneath the air-intake side of the outdoor unit.

(3) The platform foundation must be solid and the

unit must be secured with anchor bolts.

(4) When installing on a roof subject to strong wind,

countermeasures must be taken to prevent the unit from being overturned.

2-4. Dimensions of Snow / Wind-proof Ducting

and Refrigerant Tubing Space for Installation

Min. 4"

Duct

Min. 4" 12" Unit: inch

Outdoor Unit

12"

1117_C_I

In regions with snow fall, the outdoor unit should be provided with a platform and snow-proof duct.

Without snowproof ducting (Low platform)

Fig. 2-5 Fig. 2-6

Outdoor Unit

Duct

Snow-proof ducting (High platform)

0937_C_I

Duct

(WD)

Air Intake

About 1/2 of the unit height

Platform (foundation)

Fig. 2-7

Example of Installation

Fig. 2-8

Higher than the maximum snow depth

Air Intake

0488_C_

0490_C_I

(WL)

S4359146

3. HOW TO INSTALL THE INDOOR UNIT

■

4-Way Air Discharge Semi-Concealed Type (XH Type)

3-1. Suspending the Indoor Unit

Hole-in-anchor Hole-in-plug

Concrete Insert

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

3-2. Preparation for Suspending

(1) Fix the suspension bolts securely in the ceiling

using the method shown in the diagrams (Figs.

3-1 and 3-2), by attaching them to the ceiling

support structure, or by any other method that

Suspension bolt (M10 or 3/8") (field supply)

Fig. 3-1

0038_T_I

ensures that the unit will be securely and safely

suspended.

(2) Follow Fig. 3-2 and Table 3-1 to make the holes

in the ceiling.

Table 3-1 Unit: inch (mm)

Type

Length

XH1242, XH1842 , XH2442

(PNR-XH2442)

XH3642, XH4242

(PNR-XH3642)

32-9/32 (820) 22-9/32 (566)

43-11/16 (1,110) 33-11/16 (856)

A (Ceiling opening)

(Suspention bolt pitch)

Drain hose side

Grille center

32-9/32 (Ceiling opening)

29-13/16 (Suspention bolt pitch)

(3) Determine the pitch of the suspension bolts using

the supplied full-scale installation diagram. The

diagram and table (Fig. 3-3 and Table 3-2) show

the relationship between the positions of the

suspension fitting, the unit, and the panel.

Refrigerant tubing joint (wide tube side)

Suspension lug

Fig. 3-3

Table 3-2 Unit : inch (mm)

Type

Length

ABCDE

XH1242, XH1842, XH2442 6-3/16 7-5/32 10-9/32 12-1/8 4-7/8

(PNR-XH2442) (157) (182) (261) (308) (124)

XH3642, XH4242 6-3/16 7-5/32 11-15/32 13-1/16 4-7/8

(PNR-XH3632) (157) (182) (291) (338) (124)

Fig. 3-2

Refrigerant tubing side

1969_X_S

Drain connection (another side) (VP25)

Refrigerant tubing joint (narrow tube side)

1-3/16

1970_X_S

S4359146

3-3. Placing the Unit Inside the Ceiling

(1) When placing the unit inside the ceiling, deter-

mine the pitch of the suspension bolts using the supplied full-scale installation diagram. (Fig. 3-4) The size of the opening for the indoor unit can be confirmed by attaching the full-scale installation diagram beneath the unit. (Fig. 3-4) Tubing and wiring must be laid inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing and wiring into position for connection to the unit before placing the unit inside the ceiling.

(2) The length of suspension bolt must be appropri-

ate for a distance between the bottom of the bolt and the bottom of the ceiling of 19/32 in. or more as shown in Fig. 3-4.

(3) Thread the 2 hexagonal nuts (field supply) and

washers onto the 4 suspension bolts as shown in Fig. 3-5.

Use 2 sets of nuts and washers (upper and lower), so that the unit will not fall off the suspension lugs.

(4) Remove the protective cardboard used to protect

the fan parts during transport.

(5) Adjust the distance between the unit and surface

of the ceiling. (1-7/8 in.) (Fig. 3-4)

Full-scale installation diagram (printed on a cardboard packing)

19/32 inch or more

Nuts and washers

(Use above and below)

Double nuts

Fig. 3-4

Suspension bolt

Upper

Lower

1-7/8 inch

Fig. 3-5

Full-scale installation

diagram

2040_X_I

Suspension lug

Notch

1-7/8 inch

1971_X_

S4359146

3-4. Installing the Drain Piping

(1) Prepare standard hard PVC pipe for the drain and

use the supplied drain hose and hose band to

prevent water leaks.

The PVC pipe must be purchased separately.

The transparent part allows you to check drain-

age. (Fig. 3-6)

Tighten the hose clamps

CAUTION

so their locking nuts face upward. (Fig. 3-6)

(2) After checking the drainage, wrap the supplied

packing and drain pipe insulator around the pipe.

(Fig. 3-7)

NOTE

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

Transparent part for checking drainage

Packing (supplied)

Drain hose (supplied)

Drain insulator (supplied)

Hose band (supplied)

Fig. 3-6

Fig. 3-7

Hard PVC pipe (not supplied)

Drain hose adapter (supplied)

0197_X_I

0964_X_I

● Do not install an air

CAUTION

bleeder tubes, as this may cause water to spray from the drain tube outlet. (Fig. 3-8)

● If it is necessary to increase the height

of the drain pipe, the section directly after the connection port can be raised a maximum of 19-11/16 in. Do not raise it any higher than 19-11/16 in., as this could result in water leaks. (Fig. 3-9)

● Do not install the pipe with an upward

gradient from the connection port. It will cause the drain water to flow backwards and leak when the unit is stopped. (Fig. 3-10)

● Do not apply force to the piping on the

unit side when connecting the drain pipe. The pipe should not be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 3-11)

Air bleeder

0047_X_I

Fig. 3-8

11-3/4 in. or less (as short as possible)

19-11/16 in. or less

1972_X_I

Fig. 3-9

Upward gradient

0049_X_

Fig. 3-10

● Provide insulation for any drain pipes

that are installed indoors.

Support pieces

0050_X_

Fig. 3-11

S4359146

3-5. Checking the Drainage

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

Do not supply power to the unit until the tubing and wiring to the outdoor unit are completed.

(1) Take off the tube cover and through the opening,

slowly pour about 43 oz. of water into the drain pan to check drainage.

(2) Do Test Run to check the drainage after complet-

ing installation. When performing Test Run, be sure to observe the Test Run procedure. Refer to page 89.

CAUTION

(3) After drain checking is finished, return the

Operation Selector switch to the RUN position (ON position ) and remount the tube cover.

CAUTION

Be careful since the fan will start turning when checking the drainage.

To mount the tube cover, use 5/16" (4 screws. Do not use long screws as they may puncture the drain pan and cause water leakage.

××

× 8 mm) tapping

××

5/16"(4 × 8 mm) tapping screw

Tube cover

Siphon

0966_X_I

Fig. 3-12

S4359146

■ Ceiling Panel

Never touch or attempt to

CAUTION

move the air direction louver by hand or you may damage the unit. Instead, use the remote control unit if you want to change the direction or air flow.

3-6. Before Installing the Ceiling Panel

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

ceiling panel. (Figs. 3-13 and 3-14)

(a) Remove the 2 screws on the latch of the air-

intake grille. (Fig. 3-13)

(b) Press on the 2 latches of the air-intake grille

with your thumb in the direction of the arrow to open the grille. (Fig. 3-13)

remove the safety string (hook on the grille side). (Fig. 3-14)

(d) Pull the air-intake grille towards you to

remove it from the ceiling panel.

Latch

Screw

Air intake grille

(2) Pull down the two panel catches on the body of

the indoor unit body. (Fig. 3-15)

Ceiling panel

0149_X_I

Fig. 3-13

Air filter

45°

Safety string

0150_X_I

Fig. 3-14

S4359146

3-7. Installing the Ceiling Panel

(1) Lift the ceiling panel and position it to align the

panel hook with the panel catch of the indoor unit.

NOTE

The ceiling panel must be mounted in the correct direction. Note that the 2 catches of the panel differ in size. Confirm that the catches are correctly matched between the ceiling panel and the indoor unit body.

(2) Next, check to see that the ceiling panel is prop-

erly aligned with the seamline of the ceiling. If it is not, remove the ceiling panel and slightly readjust the indoor unit body to the proper suspension point.

(3) When the ceiling panel has been properly

aligned, use the supplied 4 mounting screws (M5) with washers to permanently fasten the ceiling panel.

(4) Install the wiring connector from the ceiling panel

to the connector in the electrical component box of the indoor unit. After installing the connector, use the clamp on the body of the indoor unit to secure the wiring.

(5) Install the air filter and air-intake grille by perform-

ing the steps in section 3-6 in reverse.

NOTE

Rehook the safety string before closing the air-intake grille.

3-8. When Removing the Ceiling Panel for

Servicing

When removing the ceiling panel for servicing, remove the air-intake grille and air filter, disconnect the wiring connector inside the electrical component box, and then remove the 4 mounting screws.

Ceiling panel

Clamp

Ceiling panel wiring connector

Electrical component box

Panel catch Electrical

component box

Unit body

Panel catch (arrange facing downwards)

(2 locations)

Screws M5 with washer

(supplied)

Air filter

Fig. 3-15

Air-intake grille

1973_X_I

S4359146

3-9. Duct for Fresh Air

● There is a duct connection part on sideface of the indoor unit. (Fig. 3-16)

● Optional air-intake plenum (including duct connection box and flange) can be attached to the indoor unit.

Air-intake plenum Type

CMB-GSJ80U

CMB-GSJ140U

PNR-XH2442

(XH1242, XH1842, XH2442)

PNR-XH3642

(XH3642, XH4242)

For fresh air intake

2-3/8

2-5/32

4-ø1/8 hole

ø4-13/32

(1) Accessories

● Check that the following parts are in the box when unpacking.

NAME QT’Y REMARKS

Cord with socket (9P) intaking fresh air.

Screw (M5 × L5 in.) (for fastening)

Screw (M4 × L1/2 in.) (for fastening)

Duct connection box 1 (for fresh air) Duct connection flange 1

Connecting line. Not necessary for

Air-intake filter

Duct connection flange/ box

(for connecting fresh air duct

(2) Installation

●

Installation steps (a) to (e) are the same for both the CMB-GSJ80U and the GSJ140U. The drawing illustrates installation of air-intake plenum to the CMB-GSJ80U.

Installation screws

(a) Installing the air-intake plenum

● Set the air-intake plenum to the indoor unit taking care not to set the incorrect direction. (Fig. 3-17)

● Fasten the air-intake plenum with the accessory screws. (M5 × L5 in., 4pcs) (Fig. 3-17)

Detail of fresh air intake

Fig. 3-16

)

Socket cover

1974_X_S

Panel lead wire (8P)

(b) Installing the duct connection box

● Fasten the duct connection flange to the duct connection box with the accessory screws. (M4 × L1/2 in., 4pcs) (Fig. 3-18)

● Put the duct connection box into the rectangular hole of the air-intake plenum and fasten it to the both sides of the indoor unit and plenum with the accessory screws. (M4 × L1/2 in., 3pcs) (Fig. 3-18)

● Install the indoor unit to the ceiling. (Install the indoor unit according to items 3-1 to 3-6.)

When installing in a pre-

CAUTION

existing location, install the indoor unit before installing the duct connection box.

Air-intake plenum

Indoor unit

S4359146

Clamper

8P socket (red) (electrical component box)

8P socket (red) (ceiling panel side)

1975_X_S

Fig. 3-17

(e) Installing the ceiling panel

● Attach the ceiling panel to the chamber. Drawing the panel downwards sets the panel in position temporarily with the panel catch (at 2 locations).

● Remove the socket cover of the air-intake plenum and pass the 8P sockets through it. (Fix the panel lead wire to chamber side clamper.) (Fig. 3-17)

● Connect the 8P socket (electrical component box side) to the 8P socket (ceiling panel side) of the indoor unit electrical component box.

● Reattach the socket cover.

Duct connection flange

Installation screws

(M4 × 1/2 in.)

Panel catch

Ceiling panel

Fig. 3-18

Duct connection box

1976_X_S

S4359146

■ Wall-Mounted Type (KH Type)

3-10. Removing the Wall Fixture from the Unit

KH2442

Remove and discard the set screws and take off the wall fixture. (Fig. 3-19)

3-11. Selecting and Making a Hole

KH2442

(1) Tape the full-scale installation diagram on the

wall at the location selected. Make sure the unit is horizontal, using a level or tape measure to measure down from the ceiling. (Fig. 3-20)

(2) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid area where electrical

CAUTION

(3) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the wall. The required minimum hole diameter for these models is 3-3/16 in. (Fig. 3-21)

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

edge to the outside edge and cut PVC pipe at a slight angle 1/4 in. shorter than the thickness of the wall. (Fig. 3-22)

(5) Place the plastic cover over the end of the pipe,

(for indoor side only) and insert in the wall. (Fig. 3-23)

wiring or conduit is located. Also take this precaution if the tubing goes through a wall at any other location.

Wall fixture

Set screws only for transportation

1390_T_I

Fig. 3-19

Tape

Full-scale installation diagram

0940_T_I

Fig. 3-20

NOTE

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

Indoor side

Outdoor side

0066_T_

Fig. 3-21

PVC pipe (locally purchased)

Cut at slight angle

0941_T_I

Fig. 3-22

OUTSIDE

PVC pipe

Slight angle

0942_K_

Plastic cover

INSIDE

Wall

Fig. 3-23

S4359146

KH3642

One hole is required for the air conditioner tubing, and may be either on the left or right side. (Also see section 3-14. Preparing the Indoor Side Tubing.)

(1) Tape the full-scale installation diagram on the

wall at the location selected. Make sure the unit is horizontal, using a level or tape measure to measure down from the ceiling. (Fig. 3-24)

(2) Determine if the hole is to be drilled at the left or

right hole location.

(3) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid area where electrical

CAUTION

wiring or conduit is located. Also take this precaution if the tubing goes through a wall at any other location.

(4) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the wall. The required minimum hole diameter for these models is 3-3/16 in. (Fig. 3-25)

(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 in. shorter than the thickness of the wall. (Fig. 3-26)

Tape

Full scale installation diagram

1354_T_I

Fig. 3-24

NOTE

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

Indoor side

Outdoor side

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

(for indoor side only) and insert in the wall. (Fig. 3-27)

Fig. 3-25

PVC pipe (locally purchased)

Cut at slight angle

Fig. 3-26

INSIDE

Plastic cover

Wall

0066_T_

0941_T_I

OUTSIDE

PVC pipe

Slight angle

0942_K_

Fig. 3-27

S4359146

3-12. Installing the Wall Fixture onto Wooden or

Gypsum Wall

KH2442

Confirm that the wall is strong enough to support the unit.

a) If the Wall is Wooden

wall fixture

(1) Attach the wall fixture to the wall with the 9

screws provided. (Fig. 3-28) If you are not able to line up the holes in the wall fixture with the beam locations marked on the wall, use rawl plugs or toggle bolts to go through the holes on the panel or drill 13/64 in. dia. holes in the panel over the stud locations and then mount the wall fixture.

(2) Check with a tape measure or carpenter’s level.

This is important so that the unit is correctly installed.

(3) Make sure the wall fixture is flush against the

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

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-29)

KH3642

Confirm that the wall is strong enough to support the unit.

0943_T_I

Fig. 3-28

3/16 in. dia. hole

Rawl plug

0944_T_I

Fig. 3-29

a) If the Wall is Wooden

(1) Attach the wall fixture to the wall with the 12

screws provided. (Fig. 3-30) If you are not able to line up the holes in the wall fixture 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 in. dia. holes in the wall fixture over the stud locations.

(2) Check with a tape measure or carpenter’s level

that the wall fixture is level. This is important so that the unit is correctly installed.

(3) Make sure the wall fixture is flush against the

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

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-29)

Wall fixture

1355_M_I

Fig. 3-30

S4359146

3-13.

Removing the Casing to Install the Indoor Unit

KH2442

How to Remove the Casing

(1) Remove the plastic cover. (Fig. 3-31) (2) Remove the clamp for the wiring connector.

(Fig. 3-32) (3) Disconnect the wiring connector. (Fig. 3-33) (4) Set the flap in the horizontal position. (Fig. 3-34)

Plastic cover

Screw

(5) Remove the 3 screws. (Fig. 3-34) (6) Remove the casing. (Fig. 3-34)

NOTE

When replacing the casing, be careful not to crush the lead wires between the casing and the frame. (Fig. 3-34)

Casing

Frame

Flap

Clamp

Screw

0945_T_I

Fig. 3-31

Fig. 3-32

2023_T_I

Wiring connector

Screws

Fig. 3-34

0947_T_I

Fig. 3-33

2024_T_I

S4359146

1358_T_I

Hack saw

3-14. Preparing the Indoor Side Tubing

KH2442

Tubing can be extended in 4 directions as shown in Fig. 3-35.

Arrangement for Left Tubing

(a) Cut out the left tubing outlet. (Fig. 3-36)

Arrangement for Right Tubing

(a) Cut out the right tubing outlet using a hacksaw.

(Fig. 3-37)

Arrangement for Left-rear and Right-rear Tubing.

(a) It is not necessary to cut a hole.

KH3642

Tubing can be extended in 4 directions as shown in Fig. 3-35.

Left tubing

Left tubing outlet

Fig. 3-36

Left-rear tubing

0950_T_I

Fig. 3-35

Right-rear tubing (Recommended)

Right tubing

0949_T_I

Right tubing outlet

0951_T_I

Fig. 3-37

Arrangement for Right-rear Tubing

(a) Remove the 2 screws and slide out the side

cover. (Fig. 3-38)

(b) Extend the wide tube from the outdoor side and

connect it directly to the mating tube inside the indoor unit. Use a flare nut. (Fig. 3-39)

Arrangement for Right Tubing

(a) Remove the 2 screws and take off the side cover.

(Fig. 3-38)

(b) Cut out the L-shaped tubing outlet using a hacksaw.

(Fig. 3-40)

tubing between the indoor and outdoor units. (Fig. 3-42)

Arrangement for Left and Left-rear Tubing.

(a) Remove the 4 screws (2 on each side) and take

off both left and right side cover. (Fig. 3-41) (b) Remove 4 screws to remove the bottom cover. (c) Using the L-shaped tube (field supply), connect

tubing as in Fig. 3-43.

Fig. 3-38

1356_T_I

Tubing from the outdoor unit

1357_T_I

Fig. 3-39

Left side cover

Indoor unit

Bottom cover

Fig. 3-41

Right side cover

1361_T_I

L-shaped tube

Fig. 3-42

Fig. 3-40

L-shaped tube

1359_T_I

1360_T_I

Fig. 3-43

S4359146

3-15. Wiring Instructions General Precautions on Wiring

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

unit as shown on its name plate, then carry out the wiring closely following the wiring diagram.

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

each unit a power supply disconnect and circuit breaker for overcurrent protection should be provided in the exclusive line.

(3) To prevent possible hazards from insulation

failure, the unit must be grounded. (4) All wiring must be connected tightly. (5) Do not allow wiring to touch refrigerant tubing,

compressor, or any moving parts of the fan.

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.

S4359146

3-16.

Wiring Instructions for Inter-Unit Connections

(a) 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. 5". to extend from the wall face. (Fig. 3-44)

Never fix the wiring by any

CAUTION

means before the indoor unit is fully seated on the rear panel.

(b) Remove the side cover and the metallic cover.

(Fig. 3-45 or 3-46, depending on model.)

a lock nut. (Fig. 3-45 or 3-46)

(d) Give some play to the inter-unit wiring from the

outdoor unit to the corresponding terminals on the terminal plate.

● Be sure to refer to the

CAUTION

wiring system diagram label inside the metallic cover and carry out the correct field wiring. Wrong wiring can cause the unit to malfunction.

● Check local electrical

codes and any specified wiring instructions or limitations.

(e) Secure the metallic cover with its screw. Then

replace the side cover.

KH2442

Rear panel

Wiring

KH3642

Connector Wiring

Wall

Plastic cover

1362_T_I

Wall fixture

Wall

KH2442

Lock nut

Power line

Look nut

Elbow conduit

Grounding line

Fig. 3-45

Metallic cover

Plastic cover

Screw

0968_T_I

KH3642

Lock nut

Connector

Fig. 3-44

Metallic cover

Fig. 3-46

Side cover

1363_T_

1395_T_I

S4359146

+ 65 hidden pages