Sanyo KS1872 User Manual
W
INSTALLATION INSTRUCTIONS
NOTE
– Inverter Split System Air Conditioner –
This air conditioner uses the new refrigerant R410A.
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 ............. 7
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 ....... 17
4-1. Wiring Instructions for the Outdoor Unit
COOL/ DRY Model
Model Combinations
Combine indoor and outdoor units only as listed
below.
Indoor Unit Outdoor Unit
KS1872 C1872
CL1872
KS2472 C2472
CL2472
Power Source:
60 Hz, single-phase, 230/208 V
Be sure to read the yellow instruction sheet
attached to the outdoor unit for models using the
new refrigerant R410A.
7. REMOTE CONTROL UNIT INSTALLATION
POSITION ......................................................... 24
7-1. Mounting on a Wall
8. ADDRESS SWITCH.......................................... 25
8-1. Address Setting of the Remote
Control Unit
5. REFRIGERANT TUBING.................................. 18
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................................................... 20
I Air Purging with a Vacuum Pump (for Test Run)
I Basic Functions of the Service Valves
I Pump Down
SANYO FISHER COMPANY SANYO Canada Inc.
A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent, Concord
21605 Plummer Street Ontario, L4K 5C7, Canada
85264189988000 © SANYO 2006
Chatsworth, CA 91311 U.S.A.
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.
In 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:
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
WARNING
CAUTION
or unsafe practice which can
result in severe personal injury
or death.
This symbol refers to a hazard
or unsafe practice which can
result in personal injury or product or property damage.
If Necessary, Get Help
These instructions are all you need for most installation
sites and maintenance conditions. If you require help for a
special problem, contact our sales/service outlet or your
certified dealer for additional instructions.
In Case of Improper Installation
The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to
follow the instructions in this document.
When Installing…
…In a Ceiling 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.
SPECIAL PRECAUTIONS
WARNING
• 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 Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.
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
CAUTION
• 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.
2
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
1-2. Accessories Supplied with Unit
Table 1
Parts Figure Q’ty Parts Figure Q’ty
Remote
control unit
Remote control
unit holder
AAA alkaline
battery
1
1
2
Tapping screw
Rawl plug
Drain hose
adapter
Tr uss-head
Phillips
5
/32 ¥ 5/8" (4¥16 mm)
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)
Parts Figure Q’ty
8
1
Hex wrench*
Clamp
*Packed in the outdoor unit.
10
1
1
Air clean filter
2
1-3. Optional Copper Tubing Kit
Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or A/C workshop.
1-4. Type of Copper Tube and Insulation Material
Cushion
rubber*
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.
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
Model
KS1872 1/4" (6.35 mm) 0.0314" (0.8 mm) 1/2" (12.70 mm) 0.0314" (0.8 mm)
KS2472 1/4" (6.35 mm) 0.0314" (0.8 mm) 5/8" (15.88 mm) 0.0393" (1.0 mm)
Outer Dia. Thickness Outer Dia. Thickness
Narrow Tube Wide Tube
4
CAUTION
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
3
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
WARNING
AVOID:
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.
2" (5 cm)
min.
Indoor unit
Outside drainage
Fig. 1
6" (15 cm)
min.
Drain hose
2" (5 cm)
min.
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.
Front View
Fig. 2
INDOOR
UNIT
Elevation
difference (H)
Fig. 3a
CAUTION
For stable operation of the
air conditioner, do not
install wall-mounted type
indoor units less than 5'
(1.5 m) from floor level.
Tubing length (L)
OUTDOOR
UNIT
Indoor unit
Minimum height
from floor level
5' (1.5 m)
Floor level
Wall
Fig. 3b
Table 3
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.)*
KS1872 25 98 49 0.27
KS2472 33 131 49 0.27
* If total tubing length becomes 25 to 98 ft. (Max.) or 33 to 131 ft. (Max.), charge additional refrigerant (R410A) by 0.27 oz./ft.
No additional charge of compressor oil is necessary.
4
2-2. Outdoor Unit
)
AVOID:
G heat sources, exhaust fans, etc. (Fig. 4)
G damp, humid or uneven locations.
NO
Hot air
Exhaust fan
Heat source
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 or 5b)
G provide a solid base (level concrete pad, concrete block,
4" ¥ 1'4" (10 ¥ 40 cm) or 6" ¥ 1'4" (15 ¥ 40 cm) beams
or equal), a minimum of 4" (10 cm) or 6" (15 cm) above
ground level to reduce humidity and protect the unit
against possible water damage and decreased service
life. (Fig. 5c or 5d)
G Install cushion rubber under unit’s feet to reduce
vibration and noise. (Fig. 5e)
G use lug bolts or equal to bolt down unit, reducing
vibration and noise.
G Install in a location where no antenna of a television
or radio exists within 10' (3 m).
(C1872, CL1872)
Anchor bolts
(4 pcs.)
Outdoor unit
(C1872, CL1872)
Air intake Min. 4" (10 cm)
Min.
2" (5 cm)
Air discharge
Min.
1'4" (40 cm)
(C2472, CL2472)
Fig. 4
Valve
side
Min. 10"
(25 cm)
Fig. 5a
Obstacle above
Min.
7' (2 m)
Air discharge
Ground
Obstacle above
Min. 4" (10 cm
Air intake
Min.
7' (2 m)
Obstacle
Air intake
Concrete
or equal
About 1'4" (40 cm)
(C2472, CL2472)
Air intake
Concrete
or equal
Fig. 5c
Min. 4" (10 cm)
About 4" (10 cm)
Anchor bolts
(4 pcs.)
Min. 6" (15 cm)
Air intake Min. 8" (20 cm)
Min.
4" (10 cm)
Air discharge
Valve
side
Min. 10"
(25 cm)
Min.
1'8" (50 cm)
Fig. 5b
Min.
7' (2 m)
Air discharge
Ground
Cushion rubber
Min. 8" (20 cm)
Air intake
Min.
7' (2 m)
Obstacle
About 1'4" (40 cm)
Fig. 5d
About 6" (15 cm)
Fig. 5e
5
2-3. Baffle Plate for the Outdoor Unit
NOTE
(CLxx models only)
It is recommended to use baffle plates for models
CL1872 and CL2472. 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. 5f)
This unit is designed so that the fan of the outdoor unit
runs at low speed when the air conditioner is operated at
low outdoor air temperatures. When the outdoor unit is
exposed to strong wind, the system pressure drops
because of the freeze protector.
6" min
Air discharge
Baffle
plate
Fig. 5f
6" min
Air discharge
Baffle
plate
6
3. How to Install the Indoor Unit
NOTE
NOTE
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.
Set screw only for transportation
Fig. 6
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 2-3/8" (60 mm) from the edge of the rear panel for
precise placement of the hose outlet. (Fig. 9)
Left
tubing
Left-rear
tubing
Rear panel
marks
Fig. 7
Right-rear
tubing
(recommended)
Right tubing
Downward tubing
Fig. 8
(3) Before making the hole, check carefully that no
studs or pipes are directly run behind the spot to be
cut.
CAUTION
Also avoid areas where electrical wiring or conduits are
located.
The above precautions are also applicable if tubing
goes through the wall in any other location.
2-3/8" (60 mm)
Fig. 9
7
Indoor
side
Outdoor
side
NOTE
g
(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
Hole Dia.
3-5/32" (80 mm)
(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)
Hole should be made at a slight downward slant to the
outdoor side.
Fig. 10
PVC pipe (Locally purchased)
Cut at sli
ht angle
Fig. 11
INSIDE OUTSIDE
Wall
Plastic cover
(Locally purchased)
PVC pipe
Slight
angle
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)
Fig. 12
Fig. 13
Fig. 14
3/16"
(4.8 mm) dia. hole
Rawl plug
Fig. 15
8
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