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

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Unit	Outdoor Units
KS2462R	C2462R
	CL2462R

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
	11-4.	Charging Additional Refrigerant

		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!

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 WARNING 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

WARNING When Wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.

•Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.

•Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death.

•Ground the unit following local electrical codes.

•Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

When Transporting

Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers.

When Installing…

…In a Ceiling, 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

•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

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.

1

1. General

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

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

1.Standard screwdriver

2.Phillips head screwdriver

3.Knife or wire stripper

4.Tape measure

5.Carpenter’s level

6.Sabre saw or key hole saw

7.Hacksaw

8.Core bits

9.Hammer

10.Drill

11.Tube cutter

12.Tube flaring tool

13.Torque wrench

14.Adjustable wrench

15.Reamer (for deburring)

16.Pipe bending tool (spring bender)

1-2. Accessories Supplied with Indoor Unit Table 1

Parts	Figure	Q’ty	Parts	Figure	Q’ty	Parts			Figure	Q’ty
Rawl plug		12	AAA alkaline		2	Tapping	Truss-head			12
							Phillips
			battery			screw
							5/32	×	5/8" (4 ×	16 mm)
Remote		1	Remote control		1	Joint drain				1
control unit			holder

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.

NOTE For rear-left tubing, optional tube connection (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 tubing 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.

Table 2

	Model	Outer Diameter
		Narrow Tube	Wide Tube
	KS2462R	3/8"	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.

	CAUTION	Check local electrical codes
		and regulations before obtain-
		ing wire. Also, check any spec-
		ified instructions or limitations.

2

1-6. 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

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	Models

2. Installation Site Selection

2-1. Indoor Unit

To prevent abnormal heat genera- WARNING 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.

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.

Table 3

Indoor unit

Drain hose

Outside drainage

Fig. 1

6 in.	6 in. min.
	6 in.
min.	min.
	Front View
	Fig. 2
INDOOR	Tubing length (L)
UNIT

Elevation difference (H)

OUTDOOR

UNIT

Fig. 3a

CAUTION

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

Indoor unit

Wall

Minimum height from floor level

5 ft.

Floor level

Fig. 3b

	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.)*
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.

3

2-2. Outdoor Unit

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

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.

Exhaust fan

Hot air

Heat source

Outdoor unit

Fig. 4a

Min. 1 in.

Min. 1 in.

Min. 4 inches

Min. 2 ft.

Fig. 4b

Air in

Air discharge

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

Anchor bolts (4 pieces)

Fig. 4c

Obstacle above

Min. 7 ft.

Air discharge

Ground

Air in

Min. 6 in.

Air discharge

Fig. 5a

4

2-4. Wind Shield for “CL” Model

IMPORTANT

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.

Wind shield

(air discharge side)

Front

Fig. 5b

Recommended outer dimensions of wind shield (field supply)

	-9/16"		hole
1
φ
-
3
	9-27/32"
21-13/16"				hole
φ15/64"
-
6
	21-5/8"	22-7/16"		23-15/32"	5-3/16"

1-1/16"	9-27/32"	9-27/32"	15/16"	1/2"	5-5/32"
	21-13/16"

CL2462R

Fig. 5c

5

3. How to Install the Indoor Unit

3-1. Remove the Rear Panel from the Unit

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

NOTE

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.

	CAUTION	Also avoid areas where electri-
		cal 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)

PVC pipe (locally purchased)

Cut at slight angle

Fig. 9

Set screws for transportation only

	Fig. 6
Left-rear tubling	Right-rear
	tubing
	(recommended)

Right tubing

Fig. 7a

In case of left-rear or right-rear tubing

Center of	Center of
left-rear	right-rear
tubing hole	tubing hole

Fig. 7b

NOTE

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

Indoor Outdoor side side

		Fig. 8
	INSIDE	OUTSIDE
	Plastic cover	Wall
		PVC pipe
	(Field supply)
		Slight
		angle

Fig. 10

6

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 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.

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. 11

Fig. 12

1-3/16" or more

3/16" dia. hole

Rawl plug (Field supply)

Fig. 13

Grille

Air intake grille

Fig. 14a

Air intake grille

Fig. 14b

7

How to replace the grille

(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

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.

4)Each wiring connection must be done tightly and in accordance with the wiring system diagram. Wrong wiring may cause the unit to misoperate or become damaged.

5)Do not allow wiring to touch the refrigerant tubing, compressor, or any moving parts of the fan.

6)Unauthorized changes in the internal wiring can be very dangerous. The manufacturer will accept no responsibility for any damage or misoperation that occurs as a result of such unauthorized changes.

Fig. 15a

Fig. 15b

Frame

Right tubing outlet

Fig. 16

Mounting slot	Tab

Fig. 17

8

3-7. Recommended Wire Length and Diameter

Regulations on wiring diameter differ from locality to locality. For field wiring requirements, please refer to your local electrical codes. Carefully observe these regulations when carrying out the installation.

Table 5 lists recommended wire lengths and diameters for power supply systems.

Refer to the wiring system diagram (Fig. 18) for the meaning of “A” and “B” in Table 5.

Table 5

	AWG	(A) Power Supply	(B) Inter-Unit	Fuse or Circuit
		Wiring Length (ft.)	Power Line	Capacity
	Model	(#12)	(#14)
	C2462R, CL2462R	64 (Max.)	132 (Max.)	35A
			# … AWG (American Wire Gauge)

WARNING	● Be sure to comply with local		WIRING SYSTEM DIAGRAM
	codes on running the wire	INDOOR			OUTDOOR
	from the indoor unit to the		Disconnect
	outdoor unit (size of wire and	UNIT			UNIT
			switch	(Inter-unit)			60HZ
		Terminal			Terminal
	wiring method, etc.).		Field supply
				power line
	● No wire should be allowed to	1		230V/208V	1		230V/208V
	● Each wire must be firmly
				230V/208V
	connected.	2			2
		G	Grounding line
					G
		4		230V/208V	L1	(A)	supply phase
				(B)
	touch refrigerant tubing, the				4
	compressor, or any moving				L2		Power Single-
	part.
					G Grounding
	To avoid the risk of electric				line
WARNING shock, each air conditioner				Fig. 18
	unit must be grounded.

	CAUTION	Be sure to connect the power
		supply line to the outdoor unit
		as shown in the wiring dia-
		gram. The indoor unit draws its
		power from the outdoor unit.

9