Sanyo SAP-KRV91EH,SAP-CRV91EH Technical & Service Manual

TECHNICAL & SERVICE MANUAL

SAP-KRV91EH + SAP-CRV91EH

INVERTER SPLIT SYSTEM AIR CONDITIONER

SAP-CRV91EHSAP-KRV91EH

FILE NO.

REFERENCE NO. SM700386

W

Indoor Unit Outdoor Unit

IMPORTANT

These air conditioners employ new
refrigerant R410A.

Pay special attention when servicing
the unit.

➞ See “11. REFRIGERANT R410A

SPECIAL PRECAUTIONS WHEN
SERVICING THE UNIT”.

Indoor Model No. Product Code No. Outdoor Model No. Product Code No. Destination

SAP-KRV91EH 1 852 065 78 SAP-CRV91EH 1 852 065 79 Europe

i

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
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 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 leak­free 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.

WARNING

WARNING

CAUTION

CAUTION

ii

Table of Contents

Page

1. OPERATING RANGE................................................................................................................ 1

2. SPECIFICATIONS

2-1. Unit Specifications............................................................................................................ 2

2-2. Major Component Specifications...................................................................................... 3

2-3. Other Component Specifications...................................................................................... 5

3. DIMENSIONAL DATA................................................................................................................ 6

4. REFRIGERANT FLOW DIAGRAM

4-1. Refrigerant Flow Diagram................................................................................................. 8

5. PERFORMANCE DATA

5-1. Temperature Charts..........................................................................................................9

5-2. Air Throw Distance Charts................................................................................................ 10

5-3. Frequency Charts............................................................................................................. 11

6. ELECTRICAL DATA

6-1. Electrical Characteristics ..................................................................................................13

6-2. Electric Wiring Diagrams .................................................................................................. 14

7. INSTALLATION INSTRUCTIONS

7-1. Installation Site Selection .................................................................................................16

7-2. Refrigerant Tubing............................................................................................................ 19

7-3. Remote Control Unit Installation Position......................................................................... 20

8. MAINTENANCE

8-1. Changing Address of Indoor Unit and Remote Control Unit............................................. 21

8-2. Disconnecting and Connecting Positive Connector for Outdoor Unit............................... 21

9. FUNCTION

9-1. Functions for Operation.................................................................................................... 22

9-2. Protective Functions......................................................................................................... 25

10. TROUBLESHOOTING

10-1. Operating State................................................................................................................ 28

10-2. Troubleshooting Using the Self-Diagnostic Monitor......................................................... 29

10-3. Fault Assessment of Indoor/Outdoor Unit........................................................................ 31

10-4. Problems with Noise and Radio Interference................................................................... 32

11. REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN SERVICING UNIT

11-1. Characteristics of New Refrigerant R410A....................................................................... 33

11-2. Checklist Before Servicing ............................................................................................... 33

11-3. Tools Specifically for R410A............................................................................................. 35

11-4. Tubing Installation Procedures......................................................................................... 35

11-5. In Case of Compressor Malfunction................................................................................. 36

11-6. In Case Refrigerant is Leaking......................................................................................... 38

11-7. Charging Additional Refrigerant....................................................................................... 40

iii

11-8. Retro-Fitting Existing Systems......................................................................................... 40

12. CHECKING ELECTRICAL COMPONENTS

12-1. Measurement of Insulation Resistance............................................................................ 41

12-2. Checking Continuity of Fuse on PCB Ass’y ..................................................................... 42

12-3. Checking Motor Capacitor................................................................................................ 42

INSTRUCTION MANUAL

APPENDIX

1

1. OPERATING RANGE

Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp.

Cooling

Maximum 32°C D.B. / 23°C W.B. 43°C D.B.

Minimum 19°C D.B. / 14°C W.B. 19°C D.B.

Heating

Maximum 27°C D.B. 24°C D.B. / 18°C W.B.

Minimum 16°C D.B. –8°C D.B. / –9°C W.B.

2

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

Remarks: Rating conditions are:

Cooling: Indoor air temperature 27°C D.B. / 19°C W.B.

Outdoor air temperature 35°C D.B. / 24°C W.B.

Heating: Indoor air temperature 20°C D.B.

Outdoor air temperature 7°C D.B. / 6°C W.B.

2. SPECIFICATIONS

2-1. Unit Specifications

Indoor unit SAP-KRV91EH
Outdoor unit SAP-CRV91EH

Power Source 220 – 230V Single phase 50Hz

Performance Cooling Heating

Capacity kW 2.80 (0.5 – 4.0) 4.20 (0.5 – 6.0)

BTU/h 9,600 (1,700 – 13,600) 14,330 (1,700 – 20,500)
Air circulation (High) m3/h 550 680
Moisture removal (High) Liters/h 1.1 —

Electrical Rating Cooling Heating

Available voltage range V 198 – 253
Running amperes A 3.6 (0.7 – 6.2) 4.6 (0.6 – 7.8)
Power input W 700 (105 – 1,360) 990 (90 – 1,760)
Power factor % 85 94
C.O.P. W/W 4.0 4.2
Compressor locked rotor amperes A 15

Features

Controls / Temperature control Microprocessor / I.C. thermostat
Control unit Wireless remote control unit
Timer ON / OFF 24 hours & Daily program, 1-hour OFF
Fan speeds Indoor / Outdoor 3 and Auto / Auto (Variable)
Airflow direction (Indoor) Horizontal Auto

Vertical Auto
Air filter Washable, Anti-Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R410A / 1,290
Refrigerant control Electric Expansion Valve
Operation sound Indoor: Hi / Me / Lo dB-A 37 / 35 / 31 42 / 37 / 32

Outdoor: Hi dB-A 43 44
Refrigerant tubing connections Flare type
Max allowable tubing length at shipment m 7.5
Refrigerant Narrow tube mm (in.) 6.35 (1/4)
tube diameter Wide tube mm (in.) 9.52 (3/8)
Refrigerant tube kit / Accessories Optional / Air Clean Filter

Voltage Rating 230V

Dimensions & Weight Indoor Unit Outdoor Unit

Unit dimensions Height mm 285 620

Width mm 805 700

Depth mm 189 260
Package dimensions Height mm 264 681

Width mm 865 835

Depth mm 349 364
Weight Net kg 9.0 36.0

Shipping kg 12.0 38.0
Shipping volume m

3

0.08 0.207

3

2-2. Major Component Specifications

2-2-1. Indoor Unit

Indoor unit SAP-KRV91EH

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

Control PCB

Part No. CB-KRV91EH
Controls Microprocessor
Control circuit fuse 250V 3.15A

Flap Motor and Louver Motor

Type Stepping motor
Model MP24S1-5V MP24S2-5V
Rating DC5V
Coil resistance (Ambient temp. 25°C) Ω WHT – BLU (respectively 4 wires): 70 ± 7%

Heat Exchanger Coil

Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.3
Face area m

2

0.130

Fan & Fan Motor

Type Cross-flow
Q’ty … Dia. and length mm 1 … D88
Fan motor model … Q’ty DA4-23P36M … 1
No. of poles … rpm (230V, High) 4 … 1190
Nominal output W 10
Coil resistance (Ambient temp. 20°C) Ω BLU – RED: 5.67

RED – WHT: 5.67
WHT – BLU: 5.67

Safety devices Type —

Operating temp. Open °C —

Close —

Run capacitor µF —

VAC —

Remote Control Unit RCS-IHPS41E / RCS-IHCS4E

4

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

2-2-2. Outdoor Unit

Outdoor unit SAP-CRV91EH

Control PCB POW-CV121CH

Compressor

Type Rotary (Hermetic)
Compressor model C-6RVN73HOT 80879680
Compressor oil … Amount cc FV68S … 350
Coil resistance (Ambient temp. 25°C) Ω C – R: 0.781

C – S: 0.781

Safety devices

CT (Peak current cut-off control) YES
Compressor discharge temp. control YES
Operation cut-off control in abnormal ambient temp. YES

Run capacitor µF —

VAC —

Crankcase heater —

Fan & Fan Motor

Type Propeller
Q’ty … Dia. mm 1 … ø400
Fan motor model … Q’ty DB8-33B280H … 1
No. of poles … rpm (230V, High) 8 … 730
Nominal output W 30
Coil resistance (Ambient temp. 20°C) Ω RED – WHT: 150.3

BLU – WHT: 150.3
BLU – RED: 150.3

Safety devices Type —

Operating temp. Open °C —

Close °C —

Run capacitor µF —

VAC —

Heat Exchanger Coil

Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.4
Face area m

2

0.366

External Finish Acrylic baked-on enamel finish

5

2-3. Other Component Specifications

2-3-1. Indoor Unit

Indoor unit SAP-KRV91EH

Thermistor (Room sensor) DTN-TKS150Y

Resistance kΩ 25°C 5.0 ± 3%

Thermistor (Coil sensor) DTN-TKS150Y

Resistance kΩ 25°C 58.3

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

4-way Valve (SC) VPV-M0AJ503B (Coil), VHV-0202 (Valve)

Coil rating AC 220 /240V, 50Hz, 6W

Thermostat (Suction sensor) KTM-35D-S1

Resistance kΩ 0°C 15

Thermistor (Coil sensor) DTN-TKS163B

Resistance kΩ 0°C 15

Thermistor (Air sensor) KTEC-35D-S3

Resistance kΩ 0°C 15

Thermistor (Compressor sensor) DTN-TKS164B

Resistance kΩ 25°C 58.3

PTC Thermistor (TH) 912X24E400XR-A

Resistance Ω (at 25°C) 40

2-3-2. Outdoor Unit

Outdoor unit SAP-CRV91EH

DATA SUBJECT TO CHANGE WITHOUT NOTICE.

6

10 10785

805.0

285.0

126.0 40

193.0 (3)

10 56

61

182

23

Remote control unit

People sensor

130

22

Wide tube ø9.52 (3/8")

Narrow tube ø6.35 (1/4")

3. DIMENSIONAL DATA

Indoor unit SAP-KRV91EH

Unit: mm

7

Outdoor unit SAP-CRV91EH

289700

538

538

234

300

300

234

151.5 46

180

81

620

16

70

Narrow tube service valve ø6.35 (1/4")

Wide tube service valve ø9.52 (3/8")

Location of Service Valves

Service valves are located behind the side panel.
See the illustration below.

NOTE

Unit: mm

8

4. REFRIGERANT FLOW DIAGRAM

4-1. Refrigerant Flow Diagram

Indoor unit SAP-KRV91EH
Outdoor unit SAP-CRV91EH

ø9.52

ø6.35

Indoor heat
exchanger

Outdoor

heat exchanger

Outdoor unit Indoor unit

Wide tube
service valve

Narrow tube
service valve

Wide tube
nipple

Narrow tube
nipple

Accumulator

Muffler

Capillary
tube for distribution

EM valve

4-way valve

Cooling cycle
Heating cycle

Defrosting

Compressor

Strainer

Electronic expansion valve

Modulator

Insulation of Refrigerant Tubing

Because capillary tubing is used in the outdoor unit, both the
wide and narrow tubes of this air conditioner become cold. To
prevent heat loss and wet floors due to dripping of condensa­tion, both tubes must be well insulated with a proper insu­lation material. The thickness of the insulation should be a
minimum 8 mm.

IMPORTANT

CAUTION

After a tube has been insulated,
never try to bend it into a narrow
curve because it can cause the
tube to break or crack.

Wide tube

Thickness:
Min. 8 mm

Insulation

Narrow tube

Thickness:
Min. 8 mm

9

5. PERFORMANCE DATA

5-1. Temperature Charts

Indoor unit SAP-KRV91EH
Outdoor unit SAP-CRV91EH

■ Cooling Characteristics (50Hz, 230V) ■ Heating Characteristics (50Hz, 230V)

25 30 35 40

0.69
(6)

0.59
(5)

0.49
(4)

25 30 35 40

16

15

14

13

12

11

10

–5 0 5 10 15 20 25

2.45
(24)

2.06
(20)

1.67
(16)

1.28
(12)

–5 0 5 10 15 20 25

8

6

7

4

5

2

3

–5 0 5 10 15 20 25

60

55

50

45

40

35

30

25 30 35 40

Low pressure at wide tube service valve

MPa (kgf/cm

2

G)

High pressure at wide tube service valve

MPa (kgf/cm

2

G)

Outdoor inlet air D.B. temp.(˚C) Outdoor inlet air D.B. temp.(˚C)

Outdoor inlet air D.B. temp.(˚C) Outdoor inlet air D.B. temp.(˚C)

Outdoor inlet air D.B. temp.(˚C) Outdoor inlet air D.B. temp.(˚C)

Indoor inlet air
D.B. temp. (˚C)

Indoor inlet air
D.B. temp. (˚C)

20°C

24°C

27°C

30°C

Operating current (A)

Operating current (A)

Indoor inlet air
D.B. temp. (˚C)

Indoor inlet air
D.B. temp. (˚C)

24°C

27°C

30°C

Indoor discharge air temperature (˚C)

Indoor discharge air temperature (˚C)

Indoor inlet air
D.B. temp. (˚C)

Indoor inlet air
D.B. temp. (˚C)

24°C

27°C

30°C

23°C

17°C

20°C
17°C

23°C

5

4

3

2

20°C
17°C

23°C

Overload prevention operates to protect the air conditioner when outdoor ambient temperature becomes
extremely high in heating mode. (Refer to “9-2-3. Overload Prevention in Heating”.)

● … Points of rating condition
Black dots in above charts indicate the following rating conditions.

Cooling: Indoor air temperature 27°C D.B. / 19°C W.B. Heating: Indoor air temperature 20°C D.B.

Outdoor air temperature 35°C D.B. / 24°C W.B. Outdoor air temperature 7°C D.B. / 6°C W.B.

NOTE

10

5-2. Air Throw Distance Charts

Indoor unit SAP-KRV91EH

Horizontal distance (m)

Axis air velocity (m/s)

Vertical distance (m)

Room air temp. : 20°C
Fan speed : High

Heating

Horizontal distance (m)

Axis air velocity (m/s)

Vertical distance (m)

Room air temp. : 27°C
Fan speed : High

Cooling

0

1

2

3

4

0123456789

: Flap angle 0° , : Axis air velocity 0°
: Flap angle 30° , : Axis air velocity 30

0

1

2

3

4

0123456789

: Flap angle 45° , : Axis air velocity 45
: Flap angle 60° , : Axis air velocity 60

Flap angle 0°
Flap angle 30°

Axis air velocity 0°
Axis air velocity 30°

Flap angle 45°
Flap angle 60°

Axis air velocity 45°
Axis air velocity 60°

11

5-3. Frequency Charts

Indoor unit SAP-KRV91EH
Outdoor unit SAP-CRV91EH

1) Rating conditions in cooling mode are:
Indoor: 27°C D.B. / 19°C W.B.
Outdoor: 35°C D.B. / 24°C W.B.

2) Fan speed: High

NOTE

230V Single Phase 50Hz

0

200

400

600

800

1000

1200

1400

0102030405060708090

Operating Freqency (Hz)

Power Input (W)

54

700

■ Cooling

Power input (W)

Operating frequency (Hz)

0

1

2

3

4

5

0102030405060708090

Operating Freqency (Hz)

Cooling Capacity (kW)

54

2.8

Cooling capacity (kW)

Operating frequency (Hz)

12

1) Rating conditions in heating mode are:
Indoor: 20°C D.B.
Outdoor: 7°C D.B. / 6°C W.B.

2) Fan speed: High

NOTE

6

5

4

3

2

1

0

020406076 80 100 120 140 160

4.2

Cooling capacity (kW)

Operating frequency (Hz)

230V Single Phase 50Hz

1800

1600

1200
1000

800

990

600

200

400

0

020406076 80 100 120 140 160

1400

Cooling capacity (kW)

Operating frequency (Hz)

■ Heating

13

6. ELECTRICAL DATA

6-1. Electrical Characteristics

Indoor unit SAP-KRV91EH
Outdoor unit SAP-CRV91EH

Indoor Unit Outdoor Unit Complete Unit

Fan Motor Fan Motor Compressor
Performance at 230V Single phase 50Hz
Rating conditions Running amp. A 0.23 0.37 3.0 3.6

Power input kW 0.026 0.043 0.631 0.70

Full load Running amp. A 0.23 0.37 5.6 6.2

Power input kW 0.026 0.043 1.291 1.36

Rating conditions: Indoor air temperature 27°C D.B. / 19°C W.B.

Outdoor air temperature 35°C D.B.

Rating conditions: Indoor air temperature 20°C D.B.

Outdoor air temperature 7°C D.B. / 6°C W.B.

Indoor Unit Outdoor Unit Complete Unit

Fan Motor Fan Motor Compressor
Performance at 230V Single phase 50Hz
Rating conditions Running amp. A 0.35 0.34 3.91 4.6

Power input kW 0.041 0.037 0.912 0.99

Full load Running amp. A 0.35 0.34 7.11 7.8

Power input kW 0.041 0.037 1.682 1.76

Heating

Cooling

14

6-2. Electric Wiring Diagrams

Indoor unit SAP-KRV91EH

WARNING

To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.

8512-5253-520xx-2

1

3

5

2

4

6

Earth plate

Power cord

Terminal

plate

Power relay

4P

Room/coil

5P

Flap

(White)

5P

Louver

(Red)

Flap motor

Thermistor (coil)

Thermistor (room)

Louver motor

CONTROLLER

FM

Evaporator

To outdoor unit

L

N

1
2

4

GRN/YELGRN/YEL
BRN
BLU

GRN/YEL

1
2
3
4

5
4
3
2
1

1

321
321

101
101

321
321

2
3
4
5

1
2
3
4

5
4
3
2
1

1
2
3
4
5

1
2
3
4
5

1
2
3
4
5

1
2
3
4
5

1
2
3
4
5

BLK

BLK
ORG
ORG

WHT

GRY

GRY

GRY

GRY

WHT

GRY

GRY

GRY

GRY

WW

GRN/YEL

BRN

BLU

RED

WHT

BLK

3P

Power-SW

Power SW

10P

Lamp

3P

DCM

Fan

motor

IND lamp

assy

WHT

BLU

RED

WHT

WHT

Louver

Flap

15

Outdoor unit SAP-CRV91EH

WARNING

To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.

1
2

4

Terminal
plate

From indoor unit

W

W

W W

W W

+ +

W WW

IN1

E

OUT1

OUT2

DCIN+

DCIN–

DCOUT+

DCOUT–

IN2

BLK

WHT

RED

WHT

GRN/YEL

1 3

13

1 2123344556

11
22
33
44
55
66
77
88

99
10 10
11 11
12 12

6

12 12
11 11
10 10

99
88
77
66
55
44
33
22
11

1 2123344556

6

(BLK)

SI

1 3

13

(WHT)

SV

GRN/YEL

21
21

YEL

ORG

YEL

ORG

W

W W

W W

21
21

RED

BLK

RED

BLK

ACIN2

ACIN1

ACOUT2

(BLK)
A – B

HIC2

(RED)

HIC1

(RED)

(WHT)

A – B

Reactance

L1

W W

L2 DC 0V

–+

DC+DC–

ACOUT1

Ferrite

core

Diode

AC AC

–+

WHT

WHT

BLU

YEL

WHT

WHT

WHT

WHT

WHT

VLT

ORG

CONTROLLER B

+

+

W

DC 280V

+

BLK
WHT
WHT
WHT

WHT
WHT
WHT
WHT

11
22
33
44
55
66
77
88
99

9

22

8

21

7

20
619
518
417
316
215
114

BLK
WHT
WHT
WHT

WHT
WHT
WHT
WHT

WHT
WHT
WHT

HIC

U

+V+

W

11
22
33

CM

RED

RED

WHT

WHT

BLU

BLU

RED

BLU

Compressor

motor

R

S
T

GRN/YEL

GRN/YEL

CONTROLLER A

12123

3

13135

5

44556

6

(WHT)

SENSE

(WHT)

FM

(WHT)

MV-1

Fan motor

Magnetic
coil

FM

MV

WHT

PNK

BLK

BRN

YEL

VLT

121233445

5

ORG

RED

YEL

GRY

BLK

6 56522114

4

Solenoid valve

BLU

BLU

SV

1 3

13

(RED)

RV

4-way valve

BLU

BLU

RV

PTC

(YEL)

OUT

DOOR

Ooutdoor

thermistor

12

12

BLK

BLK

(WHT)

COMP

Compressor

thermistor

12

12

BLK

BLK

(BLK)

COIL

Coil thermistor

12

12

YEL

YEL

YEL

YEL

(RED)

SUC

SUC thermistor

12

12

W

PTC2

W

PTC1

YEL

YEL

BLK

RED

Ferrite

core

8512-5253-521xx-2

16

7. INSTALLATION INSTRUCTIONS

7-1. Installation Site Selection

7-1-1. Indoor Unit

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 1 and Fig. 3.

Table 1



5 cm

min.

5 cm
min.

5 cm min.

Front View

Fig. 1

INDOOR
UNIT

Tubing length (L)

OUTDOOR
UNIT

Elevation
difference (H)

Fig. 2

WARNING

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.

Indoor unit

Floor level

Wall

Minimum height
from floor level

1.5 m

Fig. 3

For stable operation of
the air conditioner, do not
install wall-mounted type
indoor units under 1.5 m
from floor level.

CAUTION

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

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

(m) (m) (m) (g/m)

*

KRV91 7.5 15 7 15

*

If total tubing length becomes 7.5 to 15 m (max.), charge additional refrigerant (R410A) by 15 g/m.
No additional compressor oil is necessary.

17

7-1-2. Outdoor Unit

AVOID:

●

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

●

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. 5a)

●

provide a solid base (level concrete pad, concrete
block, 10 ×40 cm beams or equal), a minimum of

10 cm above ground level to reduce humidity and
protect the unit against possible water damage
and decreased service life. (Fig. 5a)

●

Install cushion rubber under unit’s feet to reduce
vibration and noise. (Fig. 5b)

●

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

Outdoor unit

Hot air

Heat source

Exhaust fan

NO

Fig. 4

Air intake

Concrete
or equal

About 10 cm

Min. 10 cm

Anchor bolts
(4 pcs.)

About 40 cm

Fig. 5a

Cushion rubber

Fig. 5b

Air intake Min. 10 cm

Air discharge

Min.

5 cm

Min.
40 cm

Valve
side
Min.
25 cm

Min.
2 m

Min.
2 m

Min. 10 cm
Air intake

Ground

Obstacle

Obstacle above

Air discharge

18

7-1-3. 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 2 lists recommended wire lengths and diameters for power supply systems.

Refer to the wiring system diagram (Fig. 6) for the meaning of “A” and “B” in Table 2.

Table 2

NOTE

Cross-Sectional (A)+(B) (A) Power Supply Wiring Length (m)

Fuse or Circuit

Area (mm2) (B) Power Line Length (m)

Model 2 3.5

Capacity

CRV91 33 51 10A

INDOOR UNIT OUTDOOR UNIT

TerminalTerminal

Power

line

Control

line

Ground line

Power supply:
1ø 50 Hz,
220 V – 230 VAC

1

4

2

1

4

2

L

N

(B)

(A)

Fig. 6

CAUTION

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

WIRING SYSTEM DIAGRAM

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 electrical shock, each air
conditioner unit must be grounded.

●

For the installation of a grounding device,
please observe local electrical codes.

●

Grounding is necessary, especially for units
using inverter circuits, in order to release
charged electricity and electrical noise caused
by high tension. Otherwise, electrical shock
may occur.

●

Place a dedicated ground more than 2 meters
away from other grounds and do not have it
shared with other electric appliances.

WARNING

19

Deburring

Before

After

Fig. 7

Reamer

Copper
tubing

Fig. 8

Flare tool

Flare nut

Copper
tubing

Fig. 9

Apply refrigerant
lubricant here and here

0 to

0.5 mm

Fig. 11

Fig. 10

7-2. Refrigerant Tubing

7-2-1. Use of the Flaring Method

Many of the conventional split system air conditioners
employ the flaring method to connect refrigerant tubes
which run between indoor and outdoor units. In this
method, the copper tubes are flared at each end and
connected with flare nuts.

7-2-3. Flaring Procedure with a Flare Tool

a) Cut the copper tube to the required length with a

tube cutter. It is recommended to cut approx. 30 –
50 cm longer than the tubing length you estimate.

b) Remove burrs at the end of the copper tube with a

tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 7)

When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 8)

c) Remove the flare nut from the unit and be sure to

mount it on the copper tube.

d) Make a flare at the end of copper tube with a flare

tool.*(Fig. 9)
(*Use “RIGID” or equivalent.)

e) Use the special flare tool for R410A for making a

flare. If the conventional flare tool for R22 is uti­lized, use the spacer provided. (Fig. 10)

A good flare should have the following characteristics:

●

inside surface is glossy and smooth.

●

edge is smooth.

●

tapered sides are of uniform length.

7-2-4. Caution before Connecting Tubes

Tightly

a) Be sure to apply a sealing cap or water-proof tape

to prevent dust or water from getting into the tubes
before they are used.

b) Be sure to apply refrigerant lubricant to the match-

ing surfaces of the flare and union before connect­ing them together. This is effective for reducing gas
leaks. (Fig. 11)

c) For proper connection, align the union tube and

flare tube straight with each other, then screw on
the flare nut lightly at first to obtain a smooth
match. (Fig. 12)

NOTE

NOTE

Where the R410A
flare tool is used

1.2 mm

Spacer

Where the conventional flare tool
is utilized (clutching method)

Flare nut

Union

Fig. 12

By using the spacer, the pipe must be adjust­ed so that 1.2 mm of the pipe protrudes.

20

7-3-1. Mounting on a Wall

a) Remote Control Unit

When attaching to wall
(1) Confirm the indoor unit beeps when the ON/OFF

button is pressed at the wall location where the
remote control unit is to be attached, then attach
the holder to the wall. (Fig. 13)

(2) When taking out the remote control unit, pull it

from the holder. (Fig. 14)

When using the remote control unit

●

Point the transmission portion of the remote control
unit at the receiver area of the indoor unit when
operating the remote control unit, and during opera­tion of the air conditioner.

●

Do not place objects which may block the transmit­ted signals between the receiver and the remote
control unit.

b) People Sensor

How to use the remote control unit holder

Turn the power source switch ON at the spot where
you intend to install the holder, and confirm the
indoor unit beeps. (Figs. 14 and 15)

Truss-head tapping screws
4 × 16 mm (supplied)

Holder for People Sensor-type
remote control unit

Insert

Fig. 14

When attaching to wall

Insert

Fig. 15

When placed on table, etc.

7-3. Remote Control Unit Installation Position

The remote control unit can be operated from either a non-fixed position or a wall-mounted position.
To ensure that the air conditioner operates correctly, do not install the remote control unit in the following places:

●

In direct sunlight

●

Behind a curtain or other place where it is covered

●

More than 8 m away from the air conditioner

●

In the path of the air conditioner’s airstream

●

Where it may become extremely hot or cold

●

Where it may be subject to electrical or magnetic interference

●

Where the temperature changes rapidly (near heater, etc.)

●

Where strong vibration or shock occurs

●

Where there are obstacles which may block or inter­fere with the infrared signal, such as glass

●

Near telephone, computer or radio

●

Outside the detectable range, such as on top of
refrigerator

1

2

Truss-head
tapping screws
4 × 16 mm (supplied)

Remote
control
unit holder

Press

Hook

Fig. 13

21

8. MAINTENANCE

8-1. Changing Address of Indoor Unit and Remote Control Unit

If the operation is disturbed by radio interference of the remote control signals, change the address of the remote
control unit by cutting the jumper wire on the PCB A of the indoor unit.

To Change Address on PCB

(1) Cut jumper wire (JP02) on the indoor unit PCB.
(2) Switch the address switch on the remote control unit to “B” position.
(3) After inserting the batteries, press reset (

リセット

) button.

Once changed, you cannot restore the original address setting of the remote control unit.

NOTE

Pull the cover upward

When the cover is pulled upward, the lock is
released with the sequence of 1 and 2.

Address switch

Control PCB (POW-KV121CH) on Indoor Unit

JP02

(1) Remove tab for changing

the address (

アドレス

) of

the remote control unit.

(2) When it is removed, the

address (

アドレス

) is set

to B.

To Change Address on Remote Control

People Sensor-type remote control unit

(RCS-IHCS4E)

8-2. Disconnecting and Connecting Positive Connector for Outdoor Unit

One of the two types of connectors illustrated at left is used. Their
basic structure is the same for each.

How to Disconnect

Hold the resin connector cover, and pull the connector off.
You cannot disconnect the connector by pulling the wire since
it is locked inside. Always hold the cover to disconnect. (See
illustration at left.) For the connector without the resin cover,
push the lock in the direction of “2” while pulling it off.

How to Connect

In order to connect, hold the resin cover of the connector and
push it in. Confirm the click sound for the inside lock.

Remove the batteries before switching
the address switch.

NOTE