Sanyo R410A User Manual

INSTALLATION INSTRUCTIONS

– Split System Air Conditioner –

COOL/DRY Model

In order to protect the environment, this air conditioner uses the new refrigerant R410A.

Contents

Page

IMPORTANT!

Please Read Before Starting.................................. 1

1. GENERAL.......................................................... 2

1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Indoor Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Field Wiring
1-6. Additional Materials Required for Installation
1-7. Operating Range

2. INSTALLATION SITE SELECTION................... 3

2-1. Indoor Unit
2-2. Outdoor Unit
2-3. Air Discharge Chamber for Top Discharge
2-4. Wind Shield for “CL” Model

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. REMOTE CONTROL UNIT INSTALLATION

POSITION ........................................................ 14

4-1. Mounting on a Wall

5. ADDRESS SWITCHES..................................... 15

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

6-1. Removing the Packaging Skid
6-2. Installing the Outdoor Unit
6-3. Tubing Direction

Combine indoor and outdoor units only as listed
below.

Indoor Unit Outdoor Units

KS2462R C2462R

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

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

7. ELECTRICAL WIRING ..................................... 17

7-1. General Precautions on Wiring
7-2. Recommended Wire Length and Wire

Diameter for Power Supply System
7-3. Wiring System Diagram
7-4. Examples of Incorrect Wiring

8. HOW TO PROCESS TUBING.......................... 19

8-1. Use of the Flaring Method
8-2. Flaring Procedure with a Flare Tool
8-3. Caution before Connecting Tubes Tightly
8-4. Precautions During Brazing
8-5. Indoor Unit Tubing
8-6. Connecting Tubing between Indoor and

Outdoor Units
8-7. Insulation of Refrigerant Tubing
8-8. Taping the Tubes
8-9. Finishing the Installation

9. AIR PURGING................................................... 22

10. TEST RUN......................................................... 25

10-1. Preparing for Test Run
10-2. Performing Test Run

11. REFRIGERANT R410A: SPECIAL PRECAUTIONS

WHEN INSTALLING UNIT ................................ 28

11-1. Characteristics of New Refrigerant R410A
11-2. Checklist Before Installation
11-3. Tools Specifically for R410A
1 1-4. Charging Additional Refrigerant

Model Combinations

CL2462R

In Canada

SANYO FISHER COMPANY SANYO Canada Inc.

A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent
21605 Plummer Street Concord, Ontario

85464359328000 © SANYO 2002 Chatsworth, CA 91311 U.S.A. L4K 5C7, Canada

IMPORTANT!

WARNING

WARNING

CAUTION

CAUTION

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
or unsafe practice which can
result in personal injury or prod­uct or property damage.

If Necessary, Get Help

When Installing…

…In a Ceiling, Wall or Floor

Make sure the ceiling/wall/floor 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

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.

• 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.

1

1. General

Parts Figure Q’ty Parts Figure Q’ty

12

1

1

Remote
control unit

Parts Figure Q’ty

12

Tapping
screw

Truss-head
Phillips
5/32 × 5/8" (

4 × 16 mm)

2

1

AAA alkaline
battery

Joint drain

Rawl plug

Remote control
holder

NOTE

CAUTION

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 Indoor Unit
Table 1

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. Pipe bending tool (spring bender)

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.

For rear-left tubing, optional tube connec-

tion (C) (APR-EN46U1B) is necessary. See
page 20.
Also 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 tub-

ing as detailed in Table 2.
When cutting tubing, add approximately 12 to 16 in.

to each tube length to reduce vibration between the
air conditioning units.

2

Table 2

Model

KS2462R

Narrow Tube

Outer Diameter

3/8"

Wide Tube

3/4"

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".

1-5. Field Wiring

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.

1-6. Additional Materials Required for Installation

6 in.
min.

6 in.
min.

6 in. min.

Front View

INDOOR
UNIT

Tubing length (L)

OUTDOOR
UNIT

Elevation
difference (H)

Indoor unit

Floor level

Wall

Minimum height
from floor level

5 ft.

CAUTION

Drain hose

Indoor unit

Outside drainage

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

1-7. Operating Range

Temperature Indoor Air Intake Outdoor Air Intake

Cooling

Maximum 95°F DB, 71°F WB 115°F DB

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

*CL



2. Installation Site Selection

2-1. Indoor Unit

To prevent abnormal heat genera-

WARNING

AVOID:

●

direct sunlight.

●

nearby heat sources that may affect performance of the
unit.

●

areas where leakage of flammable gas may be expected.

●

places where large amounts of oil mist exist.

DO:

●

select an appropriate position from which every corner of
the room can be uniformly cooled. (High on a wall is best.)

●

select a location that will hold the weight of the unit.

●

select a location where tubing and drain hose have the
shortest run to the outside. (Fig. 1)

●

allow room for operation and maintenance as well as
unrestricted air flow around the unit. (Fig. 2)

●

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.

tion 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.

Fig. 1

Models

Fig. 2

Fig. 3a

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

Fig. 3b

Table 3

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

C2462R, CL2462R 23 132 50 0.43

*

If total tubing length becomes 23 to 132 ft. (max.), additional refrigerant (R410A) charge of 0.43 oz./ft. is required.
No additional charge of compressor oil is necessary.

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

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

3

*

2-2. Outdoor Unit

Outdoor unit

Hot air

Heat source

Exhaust fan

Min.
1 in.

Min.
1 in.

Min. 2 ft.

Min. 4 inches

Min.
7 ft.

Obstacle above

Ground

Air
dis­charge

Air in

Air in

Air
discharge

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

Anchor bolts
(4 pieces)

Min. 6 in.

Air discharge

AVOID:

●

heat sources, exhaust fans, etc. (Fig. 4a)

●

damp, humid or uneven locations.

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. 4b)

●

provide a solid base a minimum of 6 inches above
ground level to reduce humidity and protect the unit
against possible water damage and decreased service
life. (Fig. 4c)

●

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

2-3. Air Discharge Chamber for Top Discharge

Fig. 4a

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 an obstacle.

●

the air-discharge outlet faces a sidewalk and dis­charged hot air may disturb people passing by.
Refer to Fig. 5a.

Fig. 4b

Fig. 4c

Fig. 5a

4

2-4. Wind Shield for “CL” Model

IMPORTANT

Wind shield
(air discharge side)

Front

3 - φ1-9/16" hole

6 - φ15/64" hole

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

5-3/16"

22-7/16"1/2"

23-15/32"

21-13/16"

5-5/32"9-27/32"9-27/32"1-1/16"

21-13/16"

It is recommended to use wind shields for “CL” model
(Fig. 5b). “CL” model is designed to use in low outdoor
temperature conditions.

General

When the outdoor unit is installed in a position exposed
to strong wind (like seasonal winds with low air tempera­ture in winter), a suitable wind shield must be installed
on the outdoor unit.

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.

For outer dimensions of the wind shield, see Fig. 5c.

Fig. 5b

Recommended outer dimensions of wind shield
(field supply)

CL2462R

Fig. 5c

5

Indoor
side

Outdoor
side

Set screws for transportation only

Right-rear
tubing
(recommended)

Right tubing

Left-rear tubling

Center of
left-rear
tubing hole

Center of
right-rear
tubing hole

NOTE

3. How to Install the Indoor Unit

NOTE

CAUTION

PVC pipe (locally purchased)

Cut at slight angle

3-1. Remove the Rear Panel from the Unit

Remove and discard the set screws and take off the rear
panel. (Fig. 6)

Tubing can be extended in 3 directions as shown in
Fig. 7a. Select the direction you need providing the
shortest run to the outside unit.

3-2. Make a Hole

(1) Remove the rear panel from the indoor unit and

place it on the wall at the location selected. Make
sure the unit is horizontal, using a carpenter’s level
or tape measure to measure down from the ceiling.

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

the hole. (Fig. 7b)

(3) Before making a hole, check carefully that no studs

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

Fig. 6

Fig. 7a

In case of left-rear or right-rear tubing

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.

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

attachment, cut a hole in the wall. See Table 4 and
Fig. 8.

Table 4

Hole Dia. (inch)

3-3/16"

(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" shorter than the thickness of the
wall. (Fig. 9)

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

indoor side only) and insert in the wall. (Fig. 10)

Fig. 7b

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

Fig. 8

Fig. 9

INSIDE

Wall

Plastic cover

(Field supply)

OUTSIDE

PVC pipe

Slight
angle

Fig. 10

6

3-3. Install the Rear Panel on the Wall

3/16

"

dia. hole

1-3/16

"

or more

Rawl plug
(Field supply)

Air intake grille

Grille

Air intake grille

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 10 screws

provided. (Fig. 11)
If you are not able to line up the holes in the rear
panel with the beam locations marked on the wall,
use toggle bolts to go through the holes on the panel

or drill 3/16"dia. holes in the panel over the stud
locations and then mount the rear panel.

(2) Double check with a ruler or carpenter’s level that

the panel is level. This is important to install the unit
properly. (Fig. 12)

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

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

Fig. 11

Fig. 12

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

Make 3/16" dia. holes in the wall. Insert rawl plugs for
appropriate mounting screws. (Fig. 13)

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) Set the 2 flaps in the horizontal position.
(2) Unscrew the 3 screws. (Fig. 14a)
(3) Remove the grille.

(a) Hold both corners of the air intake grille, then pull

out and up to open. (Fig. 14b)

(b) Use a standard screwdriver to push up the 3 tabs

to remove the grille. (Fig. 14b)

(c) Pull the lower part of the grille toward you to

remove. (Fig. 14a)

Fig. 13

Fig. 14a

Fig. 14b

7

How to replace the grille

Frame

Right tubing
outlet

Tab

Mounting slot

(1) Close the flaps.
(2) Reinstall the grille into the lower part while aligning

its tabs on the upper part. (Fig. 15a) Insert the tabs
in the slots and push the lower part of the grille back
into position.

(3) Press at each of the 5 tabs to completely close the

grille. Make sure that the grille and frame are firmly
fitted together. (Fig. 15b)

3-5. Shape the Indoor Side Tubing

1) Arrangement of tubing by directions

a) Right tubing

Fig. 15a

The corner of the right frame needs to be cut by a
hacksaw or the like. (Fig. 16)

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 3 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 17)

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 hazard due to insulation failure,
the unit must be grounded.

Fig. 15b

Fig. 16

Fig. 17

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.

8

3-7. Recommended Wire Length and Diameter

2

4

2

4

11

INDOOR

UNIT

Terminal

OUTDOOR

UNIT

(B)

Terminal

(A)

L2

L1

G

G

G

230V/208V

230V/208V

230V/208V

(Inter-unit)
power line

Grounding line

Grounding
line

Power supply

Single-phase 230V/208V 60HZ

Disconnect
switch

Field supply

WARNING

CAUTION

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. 18) for the
meaning of “A” and “B” in Table 5.

Table 5

AWG

Model

C2462R,CL2462R 64 (Max.) 132 (Max.) 35A

(A) Power Supply

Wiring Length (ft.)

(#12)

(B) Inter-Unit

Power Line

(#14)

# …AWG (American Wire Gauge)

Fuse or Circuit

Capacity

WARNING

●

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.).

●

Each wire must be firmly
connected.

●

No wire should be allowed to
touch refrigerant tubing, the
compressor, or any moving
part.

To avoid the risk of electric
shock, each air conditioner
unit must be grounded.

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.

WIRING SYSTEM DIAGRAM

Fig. 18

9