Sanyo SPW-XR254EH56 User Manual

– DC INVERTER Air Conditioner –

INSTALLATION AND OPERATION MANUAL

■ R410A Models

Indoor Units

SPW-XR254EH56 SPW-XR364EH56 SPW-XR484EH56

Optional Controllers

Remote Controller RCS-SH80AG

Wireless Remote Controller RCS-TH80AG.WL

RC Wireless Remote Controller RCS-BH80AG.WL

Simplified Remote Controller RCS-KR1AG

for Refrigerant R410A

SANYO Airconditioners Europe S.r.l.

Via Bisceglie, No. 76

20152 Milano, Italy

37.4196.061.0 ©SANYO 2005

SPW-CR254GVH56-C, SPW-CR364GVH56-C, SPW-CR484GVH56-C

SPW-CR254GV56-C, SPW-CR364GV56-C, SPW-CR484GV56-C

Outdoor Units

* Refrigerant R410A is used in the outdoor units.

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.

●

This product is intended for professional use. Permission from the power supplier is required when installing an outdoor unit that is connected to a 16 A distribution network.

●

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 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

• Ventilate the room well, in the event that is refrigerant gas leaks during the installation. Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas.

• 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.

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” 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.

• 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 after installation that no refrigerant gas is leaking. If the gas comes in contact with a burning stove, gas water heater, electric room heater or other heat source, it can cause the generation of poisonous gas.

NOTE

WARNING

CAUTION

WARNING

CAUTION

2. The standards for minimum room volume are as follows.

(1) No partition (shaded portion)

(2) When there is an effective opening with the adja-

cent room for ventilation of leaking refrigerant gas (opening without a door, or an opening 0.15% or larger than the respective floor spaces at the top or bottom of the door).

(3) If an indoor unit is installed in each partitioned

room and the refrigerant tubing is interconnected, the smallest room of course becomes the object. But when mechanical ventilation is installed interlocked with a gas leakage detector in the smallest room where the density limit is exceeded, the volume of the next smallest room becomes the object.

3. The minimum indoor floor space compared with the amount of refrigerant is roughly as follows: (When the ceiling is 2.7 m high)

Check of Density Limit

The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its density will not exceed a set limit.

The refrigerant (R410A), which is used in the air conditioner, is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws imposed to protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its density should rise excessively. Suffocation from leakage of refrigerant is almost non-existent. With the recent increase in the number of high density buildings, however, the installation of multi air conditioner systems is on the increase because of the need for effective use of floor space, individual control, energy conservation by curtailing heat and carrying power, etc. Most importantly, the multi air conditioner system is able to replenish a large amount of refrigerant compared to conventional individual air conditioners. If a single unit of the multi air conditioner system is to be installed in a small room, select a suitable model and installation procedure so that if the refrigerant accidentally leaks out, its density does not reach the limit (and in the event of an emergency, measures can be made before injury can occur). In a room where the density may exceed the limit, create an opening with adjacent rooms, or install mechanical ventilation combined with a gas leak detection device. The density is as given below.

Total amount of refrigerant (kg)

Min. volume of the indoor unit installed room (m3)

≤ Density limit (kg/m

)

The density limit of refrigerant which is used in multi air conditioners is 0.3 kg/m

(ISO 5149).

1. If there are 2 or more refrigerating systems in a single refrigerating device, the amount of refrigerant should be as charged in each independent device.

For the amount of charge in this example:

The possible amount of leaked refrigerant gas in rooms A, B and C is 10 kg. The possible amount of leaked refrigerant gas in rooms D, E and F is 15 kg.

Outdoor unit

Refrigerant tubing

Indoor unit

Refrigerant tubing

NOTE

e.g., charged amount (10 kg)

Indoor unit

Room A Room B Room C Room D Room E Room F

Outdoor unit

e.g., charged amount (15 kg)

Outdoor unit

Very small room

Small room

Mechanical ventilation device – Gas leak detector

Medium room

Large room

Indoor unit

Range below the

density limit of 0.3 kg/m

(countermeasures not needed)

Min. indoor floor space

10 20 30

Total amount of refrigerant

Range above the density limit of 0.3 kg/m (countermeasures needed)

1-2. Accessories supplied with the unit

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 unit and make sure all accessory parts listed are with the system before beginning.

1-3. 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.

2. Foamed polyethylene insulation for copper tubes as required to precise length of tubing. Wall thickness of the insulation should be not less than 8 mm.

3. Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to

3. Electrical Wiring for details.

1-4. Additional Materials Required for Installation

1. Refrigeration (armored) tape

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

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

Check local electrical codes and regulations before obtaining wire. Also, check any specified instructions or limitations.

IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Please Read Before Starting Check of Density Limit

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-1. Tools Required for Installation (not supplied) 1-2. Accessories supplied with the unit 1-3. Type of Copper Tube and Insulation Material 1-4. Additional Materials Required for Installation

2. HOW TO INSTALL THE UNIT . . . . . . . . . . . . . .5

2-1. Suspending the Indoor Unit 2-2. Preparation for suspending 2-3. Placing the Unit inside the Ceiling 2-4. Installing the Drain Piping 2-5. Checking the Drainage 2-6. Before installing the Ceiling Panel 2-7. Installing the Ceiling Panel 2-8. When removing the Ceiling Panel for Servicing

CONTENTS

Page

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)

2-9. Duct for Fresh Air

3. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . .13

3-1. General Precautions on Wiring 3-2. Recommended Wire Length and Wire Diame-

ter for Power Supply System

3-3. Wiring System Diagrams

4. HOW TO PROCESS TUBING . . . . . . . . . . . . . .17

4-1. Connecting the Refrigerant Tubing 4-2. Connecting Tubing between Indoor and Out-

door Units 4-3. Insulating the Refrigerant Tubing 4-4. Taping the Tubes 4-5. Finishing the Installation

5. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Part Name Figure Q’ty Remarks

Full-scale installation diagram 1 For determinig suspension bolt pitch

Flare insulator 2 For wide and narrow tubes

Washer 8 For suspending indoor unit from ceiling

Hose band 2 For Securing drain hose

Packing 1 For drain joint

Dran insulator 1 For drain joint

Drain hose 1

Sealing putty 1 For sealing recessed portion of power supply

CAUTION

2. HOW TO INSTALL THE INDOOR UNIT

2-1. Suspending the Indoor Unit

This unit uses a drain pump. Use a carpenter’s level to check that the unit is level.

2-2. Preparation for Suspending

(1) Fix the suspension bolts securely in the ceiling

using the method shown in the diagrams (Figs. 2-1 and 2-2), 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. 2-2 and Table 2-1 to make the holes

in the ceiling.

Table 2-1 Unit: mm

Type

36, 48

Length

820566

1,110 856

Hole-in-anchor Hole-in-plug

Concrete Insert

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

Fig. 2-1

A (Ceiling opening)

(Suspention bolt pitch)

Grille center

0038_T_I

Drain hose side

32-9/32 (Ceiling opening)

29-13/16 (Suspention bolt pitch)

(3) Determine the pitch of the suspension bolts using

the supplied full-scale installation diagram. The diagram and table (Fig. 2-3 and Table 2-2) show the relationship between the positions of the suspension fitting, the unit, and the panel.

Refrigerant tubing joint (wide tube side)

Suspension lug

Fig. 2-3

Table 2-2 Unit :mm

Type

Length

ABCDE

25 157182261308124

36, 48 157 182 291 338 124

Fig. 2-2

Refrigerant tubing side

1969_X_S

Drain connection (another side) (VP25)

Refrigerant tubing joint (narrow tube side)

2259_X_S

2-3. 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. 2-4) The size of the opening for the indoor unit can be confirmed by attaching the full-scale installation diagram beneath the unit. (Fig. 2-4) 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 15 mm or more as shown in Fig. 2-4.

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

washers onto the 4 suspension bolts as shown in Fig. 2-5.

Use 2 sets of nuts and washers (upper and lower), so that the unit will not fall off the suspension lugs.

(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. (48 mm) (Fig. 2-4)

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

15 mm or more

Nuts and washers

(Use above and below)

Double nuts

48 mm

Full-scale installation

diagram

2260_X_I

Fig. 2-4

Suspension bolt

Suspension lug

Upper

Lower

Notch

48 mm

2261_X_

Fig. 2-5

2-4. Installing the Drain Piping

(1) Prepare standard hard PVC pipe 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. 2-6)

Tighten the hose clamps

CAUTION

so their locking nuts face upward. (Fig. 2-6)

(2) After checking the drainage, wrap the supplied

packing and drain pipe insulator around the pipe. (Fig. 2-7)

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. 2-6

Fig. 2-7

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. 2-8)

● 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 50 cm. Do not raise it any higher than 50 cm, as this could result in water leaks. (Fig. 2-9)

● 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. 2-10)

● 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. 2-11)

Air bleeder

0047_X_I

Fig. 2-8

30 cm or less (as short as possible)

50 cm or less

2262_X_I

Fig. 2-9

Upward gradient

0049_X_

Fig. 2-10

● Provide insulation for any drain pipes

that are installed indoors.

Support pieces

0050_X_

Fig. 2-11

2-5. Checking the Drainage

After wiring and piping are completed, use the following procedure to check that the water will drain smoothly. For this, prepare a bucket and wiping cloth ready to catch and wipe up spilled water.

Do not supply power to the unit until the tubing and wiring to the outdoor unit are completed.

(1) Take off the tube cover and through the opening,

slowly pour about 1,200 cc of water into the drain pan to check drainage.

(2) Do Test Run to check the drainage after complet-

ing installation. When performing Test Run, be sure to observe the Test Run procedure.

Be careful since the fan will

CAUTION

start turning when checking the drainage.

(3) After drain checking is finished, return the

Operation Selector switch to the RUN position (ON position ) and remount the tube cover.

4 × 8 tapping screw

CAUTION

To mount the tube cover,

××

use 4

× 8 tapping screws. Do

××

not use long screws as they may puncture the drain pan and cause water leakage.

Tube cover

Siphon

2263_X_I

Fig. 2-12

■ Ceiling Panel

Never touch or attempt to

CAUTION

move the air direction louver by hand or you may damage the unit. Instead, use the remote control unit if you want to change the direction or air flow.

2-6. Before Installing the Ceiling Panel

(1) Remove the air-intake grille and air filter from the

ceiling panel. (Figs. 2-13 and 2-14) (a) Remove the 2 screws on the latch of the air-

intake grille. (Fig. 2-13)

(b) Press on the 2 latches of the air-intake grille

with your thumb in the direction of the arrow to open the grille. (Fig. 2-13)

remove the safety string (hook on the grille side). (Fig. 2-14)

(d) Pull the air-intake grille towards you to

remove it from the ceiling panel.

Latch

Screw

Air intake grille

(2) Pull down the two panel catches on the body of

the indoor unit body. (Fig. 2-15)

Ceiling panel

0149_X_I

Fig. 2-13

Air filter

45°

Safety string

0150_X_I

Fig. 2-14

2-7. Installing the Ceiling Panel

(1) Lift the ceiling panel and position it to align the

panel hook with the panel catch of the indoor unit.

NOTE

The ceiling panel must be mounted in the correct direction. Note that the 2 catches of the panel differ in size. Confirm that the catches are correctly matched between the ceiling panel and the indoor unit body.

(2) Next, check to see that the ceiling panel is prop-

erly aligned with the seamline of the ceiling. If it is not, remove the ceiling panel and slightly readjust the indoor unit body to the proper suspension point.

(3) When the ceiling panel has been properly

aligned, use the supplied 4 mounting screws (M5) with washers to permanently fasten the ceiling panel.

(4) Install the wiring connector from the ceiling panel

to the connector in the electrical component box of the indoor unit. After installing the connector, use the clamp on the body of the indoor unit to secure the wiring.

(5) Install the air filter and air-intake grille by perform-

ing the steps in section 2-6 in reverse.

NOTE

Rehook the safety string before closing the air-intake grille.

2-8. When Removing the Ceiling Panel for

Servicing

When removing the ceiling panel for servicing, remove the air-intake grille and air filter, disconnect the wiring connector inside the electrical component box, and then remove the 4 mounting screws.

Ceiling panel

Clamp

Ceiling panel wiring connector

Electrical component box

Panel catch Electrical

component box

Unit body

Panel catch (arrange facing downwards)

(2 locations)

Screws M5 with washer

(supplied)

Air filter

Fig. 2-15

Air-intake grille

1973_X_I

2-9. Duct for Fresh Air

● There is a duct connection part on sideface of the indoor unit. (Fig. 2-16)

● Optional air-intake plenum (including duct connection box and flange) can be attached to the indoor unit.

For fresh air intake

Air-intake plenum Type

CMB-GSJ80U 25

CMB-GSJ140U 36, 48

(1) Accessories

● Check that the following parts are in the box when unpacking.

NAME QT’Y REMARKS

Cord with socket (9P) intaking fresh air.

Screw (M5 × L125) (for fastening)

Screw (M4 × L12) (for fastening)

Connecting line. Not necessary for

Air-intake filter

Duct connection flange/ box

Duct connection box 1 (for fresh air) Duct connection flange 1

(for connecting fresh air duct

(2) Installation

●

Installation steps (a) to (e) are the same for both the CMB-GSJ80U and the GSJ140U. The drawing illustrates installation of air-intake plenum to the CMB-GSJ80U.

Installation screws

(a) Installing the air-intake plenum

● Set the air-intake plenum to the indoor unit taking care not to set the incorrect direction. (Fig. 2-17)

● Fasten the air-intake plenum with the accessory screws. (M5 × L125, 4pcs) (Fig. 2-17)

4-ø3.1 hole

Detail of fresh air intake

Fig. 2-16

ø112

2264_X_S

)

Socket cover

Panel lead wire (8P)

(b) Installing the duct connection box

● Fasten the duct connection flange to the duct connection box with the accessory screws. (M4 × L12, 4pcs) (Fig. 2-18)

● Put the duct connection box into the rectangular hole of the air-intake plenum and fasten it to the both sides of the indoor unit and plenum with the accessory screws. (M4 × L12, 3pcs) (Fig. 2-18)

● Install the indoor unit to the ceiling. (Install the indoor unit according to items 2-1 to 2-6.)

When installing in a pre-

CAUTION

existing location, install the indoor unit before installing the duct connection box.

Air-intake plenum

Indoor unit

Clamper

8P socket (red) (electrical component box)

8P socket (red) (ceiling panel side)

1975_X_S

Fig. 2-17

(e) Installing the ceiling panel

● Attach the ceiling panel to the chamber.

Drawing the panel downwards sets the panel in position temporarily with the panel catch (at 2 locations).

● Remove the socket cover of the air-intake plenum

and pass the 8P sockets through it. (Fix the panel lead wire to chamber side clamper.) (Fig. 2-17)

● Connect the 8P socket (electrical component box

side) to the 8P socket (ceiling panel side) of the indoor unit electrical component box.

● Reattach the socket cover.

Duct connection flange

Installation screws

(M4 × 12)

Panel catch

Ceiling panel

Duct connection box

2265_X_S

Fig. 2-18

+ 28 hidden pages