Sanyo PNR-XS2432 User Manual

INSTALLATION INSTRUCTIONS

— Split System Air Conditioner —

CONTENTS

IMPORTANT Page Please Read Before Starting

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 1-6. Operating Range 1-7. Tubing Length

2. SELECTING THE INSTALLATION SITE ............ 5

Indoor Unit Outdoor Unit 2-1. Baffle Plates for the Outdoor Unit

3. HOW TO INSTALL THE INDOOR UNIT.............. 7

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

■ Ceiling Panel......................................................11

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

4. HOW TO INSTALL THE REMOTE

CONTROL UNIT .................................................15

■ Wireless Remote Control Unit

4-1. Mounting on a Wall

■ Wired Remote Control Unit (Option)

4-2. Installing the Wired Remote Control Unit

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor units Outdoor units

XS1852 (PNR-XS2432) C1852, CL1852

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

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

7. HOW TO PROCESS TUBING ........................... 21

7-1. Use of the Flaring Method 7-2. Flaring Procedure with a Flare Tool 7-3. Precaution before Connecting Tubes Tightly 7-4. Precautions during Brazing 7-5. Connecting Tubing between Indoor and

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

8. AIR PURGING ....................................................24

■ Air Purging with a Vacuum Pump

(for Test Run)

9. TEST RUN ..........................................................26

9-1. Performing Test Run 9-2. Performing Test Run with Optional Wired

Remote Control Unit 9-3. Basic Function of the Service Valves 9-4. Pump Down

5. ADDRESS SWITCHES.......................................17

5-1. Finding the Address Switches 5-2. Switch Positions for 2 Units or 2 Groups of

Units

6. ELECTRICAL WIRING .......................................18

6-1. General Precautions on Wiring 6-2. Recommended Wire Length and Wire

Diameter for Power Supply System 6-3. Wiring Instructions for the Outdoor Unit 6-4. Examples of Incorrect Wiring 6-5. How to Connect Wiring to the Terminal

85464359128000 SANYO 2000

SANYO FISHER COMPANY A DIVISION OF SANYO NORTH AMERICA CORPORATION 21605 Plummer Street

S4359128

Chatsworth, CA91311

Important

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 hazard

CAUTION

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 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

……………………………………………………………………

• Execute enough ventilation in case refrigerant gases leak during operations. Be careful that the contact of the refrigerant gases with the flare will cause the generation of poisonous gases.

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

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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. 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)

16. Service valve wrench

17. Wire cutter

1-2. Accessories Supplied with Unit

Table 1-1

Part Name Figure Q’ty Remarks

Full-scale installation diagram

Flare insulator

Installation gauge

For determining suspension bolt

pitch For wide tubes

For adjusting the

unit position

Part Name Figure Q’ty

Wireless remote control unit

AAA alkaline battery

Tapping screw Tapping screw

Special screw 4 ✕ 16 mm

TOTA 4 ✕ 16

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. Cut each tube 12 in. to 16 in. longer than the appropriate lengths to dampen vibration between units.

2. Foamed polyethylene insulation for 5/8" (15.88 mm) O.D. copper tubes as required to precise length of tubing. Wall thickness of the insulation should be not less than 0.3 inch (8 mm).

Check local electrical codes

CAUTION

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

Insulating tape

(White for insulating)

Hose band Packing

Drain insulator

Drain hose Drain hose

adapter Owner’s

manual Hexagonal

Wrench*

*Packed in the outdoor unit

For wide tube

flare nuts For securing drain

hose

For drain joint For drain joint

1 1 1

For drain outlet

To open and shut the Narrow Tube

Service Valve

1-5. Additional Materials Required for Installation

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

2. Putty

3. Refrigeration tubing lubricant

4. Clamps or saddles to secure refrigerant tubing

5. Scale for weighing

1-6. Operating Range

Temperature Indoor Air Intake Outdoor Air Intake

Maximum 95°F DB, 71°F WB 115°F DB

Minimum 67°F DB, 57°F WB 67°F DB (0°F DB)*

*CL&&&& Models

Cooling

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1-7. Tubing 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 1-2.

Elevation difference (H)

Table 1-2

Models C1852

Tubing Data

Tubing size outer dia.

Narrow tube in. (mm) 1/4 (6.35): Thickness 0.0314" (0.8 mm) Wide tube in. (mm) 5/8 (15.88): Thickness 0.0394" (1.0 mm)

CL1852

Limit of tubing length (ft.) 65

Limit of elevation difference between the 2 units

Outdoor unit is higher than indoor unit (ft.)

Outdoor unit is lower

than indoor unit (ft.) Max. allowable tubing length at shipment (ft.) 33 Required additional refrigerant *

(oz./ft.) 0.27

INDOOR UNIT

Tubing length (L)

OUTDOOR UNIT

0711_M_I

Fig. 1-1

No additional charge of compressor oil is necessary. *1If total tubing length becomes 33 to 65 ft., charge additional refrigerant (R22) by 0.27 oz./ft..

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2. Selecting the Installation Site

Indoor Unit

AVOID:

● areas where leakage of flammable gas may be expected.

● places where large amount of oil mist exist.

● direct sunlight.

● 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 inverter lamp light. Faulty operation of the unit occurs.

DO:

● 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. (Fig. 2-1)

● 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 1-2.

● 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.

3 ft.

1330_X_S

Fig. 2-1

NOTE

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

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Air intake

Concrete or equal

About 4" (10 cm)

Min. 4" (10 cm)

Anchor bolts (4 pcs)

About 16" (40 cm)

1820_M_I

Outdoor Unit

AVOID:

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

● damp, humid or uneven locations.

Hot air

Exhaust fan

Heat source

Outdoor unit

DO:

● choose a place as cool as possible.

● choose a place that is well ventilated.

● allow enough room around the unit for air intake/

exhaust and possible maintenance. (Fig. 2-3)

● Install the outdoor unit above

CAUTION

snowfall line.

● Do not place objects on or sit

on the outdoor unit. Also, never block the air intake/outlet or exhaust. Distortion of the outdoor unit or incomplete combustion may result.

● Do not introduce foreign matter

into the air intake/outlet or exhaust. Do not poke them with such objects as a stick.

● provide a solid base (level concrete pad, concrete block, 4 in. × 16 in. (10 × 40 cm) beams or equal), a minimum of 4 in. (10 cm) above ground level to reduce humidity and protect the unit against possible water damage and decreased service life (Fig. 2-4).

Air intake

Min. 6" (15 cm)

Air discharge

Fig. 2-2

Valve side Min. 10" (25 cm)

Min. 12" (30 cm)

Fig. 2-3

1818_M_I

1817_C_I

Obstacle above

Min.

7 ft.

(2 m)

Air discharge

Ground

Min. 6 in. (15 cm) Air intake

Min.

7 ft.

(2 m)

Obstacle

1819_M_I

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

2-1. Baffle Plates for the Outdoor Unit

(CL×× models only)

NOTE

It is recommended to use baffle plates for model CL1852. 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 on the outdoor unit. (Fig. 2-5)

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

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Baffle plate

Fig. 2-4

Fig. 2-5

Air discharge

6" min

Baffle plate

1821_M_I

3. How to Install the Indoor Unit

3-1. Suspending the Indoor Unit

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 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

XS1852 (PNR-XS2432) 32-9/32 (820) 28-3/4 (730)

(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.

Hole-in-anchor Hole-in-plug

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

Fig. 3-1

A (ceiling opening dimension)

1/2"

1/2"1/2"

590 (suspension bolt pitch)

820 (ceiling opening dimension)

B (suspension bolt pitch)

Fig. 3-2

Concrete Insert

0038_T_I

1/2"

Refrigerant tubing side

Drain hose side

Unit: inch

0962_S_I

Refrigerant tubing joint (narrow tube side) Refrigerant tubing joint (wide tube side)

Suspension lug

15/32" 15/32"

Power supply inlet

Table 3-2 Unit : inch

Type

Length

ABCDE

XS1852 (PNR-XS2432) 5-29/32 7-7/8 10-1/32 11-23/32 4-29/32

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Fig. 3-3

Drain inspection port

1019_X_I

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 more than 2-3/8 in. as shown in Fig. 3-4.

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

supply) 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.

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

More than 2-3/8 inch

Nuts and washers

(2 sets)

1-7/8 inch

Full-scale installation

diagram

0963_X_I

Fig. 3-4

Suspension bolt

Suspension lug

Upper

Lower

(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.) using the supplied installation gauge. (Fig. 3-4)

0041_X_

Fig. 3-5

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3-4. Installing the Drain Piping

(1) Prepare standard hard PVC pipe (O.D. 1-3/64 in.)

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 drainage. (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)

0964_X_I

0197_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 10 in. Do not raise it any higher than 10 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

5 in. or less (as short as possible)

10 in. or less

0965_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

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