Sanyo KH2442, XH4242, KH3642, CH4242, UH2442 User Manual

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INSTALLATION INSTRUCTION

— Split System Heat Pump Air Conditioner —

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Units and Outdoor Units

Indoor Units Type

4-Way Air Discharge

Semi-Concealed

(Matching Ceiling Panel)

Wall-Mounted

Ceiling-Mounted

Concealed-Duct

Outdoor Units

Wired Remote Controller

Wireless Remote Controller

Weekly Timer

System Controller

XH2442

(PNR-XH2442)

KH2442

TH2442

UH2442

CH2442

Built-in type: RCS-SH80UA.WL (Optional part ) External type: RCS-BH80UA.WL (Optional part )

XH3642

(PNR-XH3642)

KH3642

TH3642

UH3642

CH3642

RCS-SH80UG (Optional part )

TM-SH80UG (Optional part )

SHA-KC64UG (Optional part )

XH4242

(PNR-XH3642)

TH4242

CH4242

(WD)

(WL)

85464359146001 © SANYO 2001

OPERATING LIMITS

■ Maximum Conditions Cooling / Heating Outdoor temperature : 115°F DB / 65°F WB Room temperature : 71°F WB / 80°F DB

■ Minimum Conditions Outdoor temperature : 23°F (0°F)* DB / 15°F WB Room temperature : 57°F WB / 59°F DB

* When air discharge chamber is installed.

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

SANYO FISHER COMPANY

A DIVISION OF SANYO NORTH AMERICA CORPORATION 21605 Plummer Street Chatsworth, CA91311

In Canada

SANYO Canada Inc.

300 Applewood Crescent Concord, Ontario 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 unsafe practice which can result in severe personal injury or death.

This symbol refers to a

CAUTION

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 accidentaly 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 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.

NOTE

Depending on the system type, liquid and gas lines may be either narrow or wide. Therefore, to avoid confusion the refrigerant tubing for your particular model is specified as either “narrow” or “wide” rather than as “liquid” or “gas”.

When Servicing

……………………………………………………………………

• Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring.

• Keep your fingers and clothing away from any moving parts.

• Clean up the site when installation is finished. Check that no metal scraps or bits of wiring have been left inside the unit.

CAUTION

• Ventilate any enclosed areas when installing or testing the refrigeration system. Contact of refrigerant gas with fire or heat can produce poisonous 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.

CONTENTS

Page

IMPORTANT Please Read Before Starting

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

1-1. Tools Required for Installation (Not Supplied) 1-2. Accessories Supplied with Unit 1-3. Type of Copper Tube and Insulation Material 1-4. Additional Materials Required for Installation 1-5. Tubing Length

2. SELECTING THE INSTALLATION SITE .................. 10

Indoor Unit Outdoor Unit

2-1. Air Discharge Chamber for Top Discharge 2-2. Installing the Outdoor Unit in Heavy Snow Areas 2-3. Precautions When Installing in Heavy Snow Areas 2-4. Dimensions of Snow / Wind-proof Ducting and

Refrigerant Tubing Space for Installation

3. HOW TO INSTALL THE INDOOR UNIT.................... 14

■ 4-Way Air Discharge Semi-Concealed Type

(XH Type)................................................................... 14

3-1. Suspending the Indoor Unit 3-2. Preparation for Suspending 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. Before Installing the Ceiling Panel 3-7. Installing the Ceiling Panel 3-8. When Removing the Ceiling Panel for Servicing 3-9. Duct for Fresh Air

■ Wall-Mounted Type (KH Type) ................................... 22

3-10. Removing the Wall Fixture from the Unit 3-11. Selecting and Making a Hole 3-12. Installing the Wall Fixture onto Wooden or

Gypsum Wall

3-13.

Removing the Casing to Install the Indoor Unit 3-14. Preparing the Indoor Side Tubing 3-15. Wiring Instructions 3-16.

Wiring Instructions for Inter-Unit Connections 3-17. Shaping the Tubing 3-18. Installing the Drain Hose

■ Ceiling-Mounted T ype (TH Type). .............................. 31

3-19. Suspending the Indoor Unit 3-20. Duct for Fresh Air 3-21. Installing the Drain Piping

■ Concealed-Duct T ype (UH Type) ............................... 35

3-22.

Required Minimum Space for Installation and Service 3-23. Suspending the Indoor Unit 3-24. Installing the Drain Piping

Page

3-25. Checking the Drainage 3-26. Increasing the Fan Speed

4. HOW TO INSTALL THE OUTDOOR UNIT ................ 40

4-1. Removing the Protective Spacer for Transportation 4-2. Installing the Outdoor Unit 4-3. Tubing Direction

5. ELECTRICAL WIRING ............................................. 41

5-1. General Precautions on Wiring 5-2. Recommended Wire Length and Wire Diameter

for Power Supply System 5-3. Wiring System Diagrams 5-4. How to Connect Wiring to the Terminal

HOW TO INSTALL THE WIRED REMOTE CONTROLLER

(OPTIONAL PART) .................................................... 45

6-1. Installation site selection 6-2. Wired Remote Controller Installation 6-3. Basic Wiring Diagram 6-4. Wiring System Diagram for Group Control 6-5. Wiring System Diagram for Multiple Remote

Control 6-6. How to Switch the Indoor Temperature Sensor 6-7. Explanation of Alarm Messages

HOW TO INSTALL THE WIRELESS REMOTE CONTROLLER

(OPTIONAL PART) .................................................... 52

7-1. Wireless Remote Controller Installation 7-2. Room Temperature Sensor Setting 7-3. Address Switches 7-4. Setting the Model Code <RCS-SH80UA. WL>

■ 4-Way Air Discharge Semi-concealed Type

(XH Type)................................................................... 54

7-5. Indicator section Installation 7-6. Operating Controller Installation

■ Ceiling Mounted Type (TH Type)......................... 55

7-7. Indicator Section Installation 7-8. Operating Controller Installation 7-9. Electrical Wiring 7-10. Test Run Switch 7-11. Misoperation Alarm Indicators

<RCS-BH80UA.WA>

7-12.

Separate type Signal Receiving Unit Installation 7-13. Electrical Wiring 7-14. Test Run Switch 7-15. Misoperation Alarm Indicators 7-16. Basic Wiring Diagram 7-17. Wiring System Diagram for Group Control 7-18. Wiring System Diagram for Multiple

8. HOW TO INSTALL THE WEEKL Y TIMER

(OPTIONAL PART) ................................................... 65

8-1. Mounting Dimensions for Continuous Installation 8-2. When Using a Wall Box for Flush Mounting 8-3. Wiring Diagram 8-4. Test Run Setting 8-5. Memory Back Up Function for Power Failure

Compensation

9. HOW TO INSTALL THE SYSTEM CONTROLLER

(OPTIONAL PART) ................................................... 67

9-1. System Controller Installation 9-2. Electrical Wiring 9-3. Address Switch Setting 9-4. Mode Setting 9-5. How to Perform Zone Registration 9-6. Connection with Other Equipments 9-7. Memory Back Up Switch 9-8. Test Run

Page

10. HOW TO PROCESS TUBING .................................. 79

10-1. Use of the Flaring Method 10-2. Flaring Procedure with a Flare Tool 10-3. Precaution before Connecting Tubes Tightly 10-4. Precautions during Brazing 10-5. Connecting Tubing between Indoor and Outdoor

Units 10-6. Insulating the Refrigerant Tubing 10-7. Taping the Tubes 10-8. Finishing the Installation

11. AIR PURGING .......................................................... 82

12. TEST RUN ................................................................ 85

12-1. Preparing for Test Run 12-2. PCB Setting 12-3. R.C. Address Setting Method 12-4. Automatic Address Setting Method 12-5. Displaying Indoor / Outdoor Unit Combination

Numbers 12-6. Test Run Procedure 12-7. Items to Check Prior to Test Run 12-8. The Main Alarms of Mis-wiring & Mis-setting 12-9. The Main Alarms of Unit Troubles 12-10

. The Main Alarms of Power Supply Troubles

13. PUMP DOWN............................................................ 93

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.

Check local electrical codes

CAUTION

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

1-4. Additional Materials Required for Installation

1-1. Tools Required for Installation (Not Supplied)

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. Level

6. Sabre saw or key hole saw

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

1-2. Accessories Supplied with Unit

See Table 1-1 to 1-9.

Table Type

1-1 4-Way Air Discharge Semi-Concealed 1-2 Wall-Mounted 1-3 Ceiling-Mounted 1-4 Concealed-Duct 1-5 Outdoor Unit 1-6 Wired Remote Controller 1-7 Wireless Remote Controller 1-8 Weekly Timer 1-9 System Controller

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

1-3. Type of Copper Tube and Insulation Material

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.

If you wish to purchase these materials separately from a local source, you will need:

1. Deoxidized annealed copper tube for refrigerant tubing.

Foamed polyethylene insulation for copper tubes as required to precise length of tubing. Wall thickness of the insulation should be not less than 5/16 in..

3. Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to Section 5. “Electrical Wiring” for details.

S4359146

Table 1-1 XH (4-Way Air Discharge Semi-Concealed)

Part Name Figure

Full-scale installation diagram 1 Flare insulator 2 Washer 8 Insulating tape 1 Hose band 2 Packing 1 Drain insulator 1 Drain hose 1 Drain hose adaptor 1 Sealing putty 1

Tube connector 1

Table 1-2 KH (Wall-Mounted)

Part Name Figure Q’ty Remarks

(White)

Q’ty

For determining suspension bolt pitch For wide and narrow tubes For suspending indoor unit from ceiling

For wide tube flare nuts For securing drain hose For drain joint For drain joint

For drain outlet For sealing recessed portion of power supply For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Remarks

Wall fixture *1 1

Insulator *1 1

Mounting plate *1 1

Truss-head

Tapping screw *1 20

Full-scale diagram 1

Wall fixture *2 1

Rawl plug *2 10

Cover *2 1

Tapping screw *2 10

Insulator 1

Phillips 4 × 1 in.

Truss-head Phillips 4 × 5/8 in.

For supporting the indoor unit

For insulation of the tubing of the indoor unit

For securing the indoor unit

For fixing the wall fixture

For determining the place where the indoor unit is installed

For supporting the indoor unit

For fixing the wall fixture

For improved tubing appearance

For fixing the wall fixture

For insulation of the tubing of the indoor unit

(WD)

(WL)

Tube connector 1

* 1 KH3642 only * 2 KH2442 only

For sizing up of narrow tube from 1/4 in. to 3/8 in. (only for 24 type)

S4359146

Table 1-3 TH (Ceiling-Mounted)

Part Name Figure Q’ty Remarks

Special washer

For temporarily suspending

indoor unit from ceiling

Drain insulator 1 Flare insulator

1 Set

Drain hose adaptor 1 Drain hose clamp 4

Insulating tape

Black

White (heat-resisting)

Vinyl clamp 2 Full-scale installation

diagram Sealing putty 1

Drain hose 1 Tube connector 1

Table1-4 UH (Concealed-Duct)

Part Name Figure

Flare insulator 2

(Black)

Insulating tape

(White)

For drain hose joint For wide tube joints

For wide tube and drain hose joint

For wide flare joints For ends of flare insulator

For determining suspension

bolt pitch For sealing recessed portion of power supply

For sizing up of narrow tube from 1/4 in. to 3/8 in. (only for 24 type)

Q’ty

Remarks

For wide and narrow tubes 2 2

For wide and narrow tubes

For wide and narrow tube flare nuts

Tapping screw TOTA4-10

14 or 20 or 24 Jumper cable* 1 Hose band 1 Packing 1 Sealing putty 1 Drain insulator 1 Drain hose 1 Drain hose adaptor 1 Clamp 9

Tube connector 1

* Jumper cable is housed inside the electrical component box.

Table 1-5 (Outdoor Unit)

Part Name Figure

Hexagonal Wrench 1

Grommet 1

Bushing 1

Q’ty

To open and shut the Narrow Tube Service Valve For protecting refrigerant pipe by attaching to the

edge of Tubing Outlet For protecting inter-unit control line by attaching to the edge of wiring outlet

Installation Instruction 1

For air intake duct connection For increasing the fan speed For securing drain hose For drain joint For sealing recessed portion of power supply For drain joint

For securing drain hose & refrigerant tubing For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Remarks

Owner’s manual 1

S4359146

Table 1-6 (Accessories for the Wired Remote Controller)

Part Name Figure

Wired remote controller (comes with 7-7/8 in. wire)

Machine screws M4 × 1 in.

Wood screws 2

Table 1-7 (Accessories for the Wireless Remote Controller) <RCS-SH80UA.WL>

Part Name Figure

Operation controller 1 Spacers 2

Run Timer

Indicator section 1 4

Heating preparations

Q’ty

1 Spacers 2

2 Wire joints 4

Q’ty

Pan-head tapping screws 4 × 13/32 in.

Part Name Figure

Q’ty

Wireless remote controller 1 2

Wireless remote controller mounting cradle

Batteries 2 Wire joints 4

<RCS-BH80UA.WL>

Part Name Figure

Separate type signal receiving unit (comes with 7-7/8 in. wire)

Carrier for ceiling installation 1 Wood screws 2

Wireless remote controller 1 Spacers 4

Truss-head tapping screws 4 × 5/8 in.

Vinyl clampers

L 5-29/32

Q’ty

Small screws

M4 × 1-9/16 in.

Part Name Figure

Q’ty

(WD)

(WL)

Wireless remote controller mounting cradle

Batteries 2 Clamper 1

Machine screws M4 × 1 in.

1 Wire joints 4

Ceiling installation paper pattern

(

3-3/4 × 2-1/32 in.

S4359146

)

Table 1-8 (Accessories for the Weekly Timer)

Part Name Figure

Q’ty

Part Name Figure

Weekly timer 1 Wood screws 2

Connecting wiring length 4 ft.

Machine screws

1 Spacers 2

2 Clampers 2

M4 × 1 in.

Table 1-9 (Accessories for the System Controller)

Part Name Figure

System controller 1 1

Rubber bushing (7/8 in.)

Screws for fixture (1-3/16 in.)

Q’ty

Label (Identification label)

Label

(Terminal base label)

Part Name Figure

SYSTEM CONTROLLER IDENTIFICATION LABEL

ALL Central Control ALL RCU. ZONE1 Central Control

ZONE1 RCU.

ZONE2 Central Control

ZONE2 RCU.

ZONE3 Central Control

ZONE3 RCU.

ZONE4 Central Control

ZONE4 RCU.

*Please attach this label on surface of the lid after cleaning. *If need to write down some detail, use magic marker.

ALL ON

INPUT

Inter-

unit control wiring

ALL OFF

INPUT

COMMON

U2 Aux.

INPUT

OPERATION STATE

UNUSED

OUTPUT

ALARM OUTPUT

DC12V FROM INDOOR UNIT PCB.

COMMON OUTPUT

Q’ty

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1-5. T ubing Length

● Refrigerant tubing between the indoor and

outdoor units should be kept as short as possible.

● Select and decide the installation location so

that the length of the refrigerant tubing will be within the limits given in Table 1-10.

Table 1-10

Models

Tubing Data

Tubing size outer dia.

Limit of tubing length (ft.) 165 165

Limit of elevation difference between the 2 units

Max. allowable tubing length at shipment (ft.) 100 100 Required additional refrigerant (oz./ft.) 0.48

No additional charge of compressor oil is necessary.

*1If total tubing length becomes 100 to 165 ft., charge additional refrigerant (R22) by 0.48 oz./ft.. *2If total tubing length becomes 100 to 165 ft., charge additional refrigerant (R22) by 0.53 oz./ft..

Narrow tube in. (mm) 1/4 (6.35) 3/8 (9.52) Wide tube in. (mm) 3/4 (19.05) 3/4 (19.05)

Outdoor unit is higher than indoor unit (ft.)

Outdoor unit is lower than indoor unit (ft.)

CH2442

165 165

100 100

INDOOR UNIT

Elevation difference (H)

CH3642, CH4242

0.53

Tubing length (L)

OUTDOOR UNIT

Fig. 1-1

0711_M_I

(WD)

(WL)

S4359146

2. SELECTING THE INSTALLATION SITE

Indoor Unit

AVOID:

● areas where leakage of flammable gas may be expected.

● places where large amounts of oil mist exist.

● direct sunlight.

● locations near inverter lamps which may affect

performance of the unit.

● locations near heat sources which may affect performance of the unit.

● locations where external air may enter the room directly. This may cause “sweating” on the air discharge ports, causing them to spray or drip.

● locations where the remote control unit will be splashed with water or affected by dampness or humidity.

● installing the remote control unit behind curtains or furniture.

● locations where the receiver in the indoor unit is exposed to the inver ter lamp light. Faulty operation of the unit occurs.

DO:

Ceiling-Mounted Type

Ceiling

Wall

Min.10 inch

Front view

Min.10 inch

NOTE

The rear of the indoor unit can be installed flush against the wall.

Air discharge

Min.2 ft.

Side view

Ceiling

Air intake

1091_T_I

4-Way Air Discharge Type

Concealed-Duct Type

3 ft.

● select an appropriate position from which every corner of the room can be uniformly cooled.

● select a location where the ceiling is strong enough to support the weight of the unit.

● select a location where tubing and drain pipe have the shortest run to the outdoor unit.

● allow room for operation and maintenance as well as unrestricted air flow around the unit.

● install the unit within the maximum elevation difference above or below the outdoor unit and within a total tubing length from the outdoor unit as detailed in Table 1-10.

● allow room for mounting the remote control unit about 3 ft. off the floor, in an area that is not in direct sunlight nor in the flow of cool air from the indoor unit.

NOTE

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

3 ft.

Min. 6 inch

3 ft.

1960_X_I

Wall-Mounted T ype

Min. 6 inch

Min. 12 inch

0930_K_I

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Outdoor Unit

AVOID:

● heat sources, exhaust fans, etc. (Fig. 2-1)

● damp, humid or uneven locations.

DO:

Hot air

Outdoor unit

Exhaust fan

Heat source

0591_C_I

● choose a place as cool as possible.

● choose a place that is well ventilated and outside

air temperature does not exceed maximum 115°F constantly.

● allow enough room around the unit for air intake/ exhaust and possible maintenance. (Fig. 2-2)

● provide a solid base; about 6 inch above ground level to reduce humidity and possib le water damage in the unit and decreased service life. (Fig. 2-3)

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

In case of multiple installations

Unit spacing if air discharge chamber is not used. Unit spacing when air discharge chamber is used.

Min. 4 ft. Min. 4 ft.Min. 5 ft.

Min. 1 ft.

Min. 12 ft.

Min. 8 inch

Min. 1 inch

Min. 4 ft.

Min. 1 ft. 2 inch

4 in.

Min. 2 ft.

Min. 8 inch

Fig. 2-1

Min. 1 inch

0931_C_I

Fig. 2-2

Min. 1 ft.

Obstacle above

Min. 7 ft.

Air discharge

Ground

Min. 4 ft.

Air discharge chamber

Min. 1 ft.

0932_C_I

(WD)

(WL)

If you would like to make the separation smaller on the air discharge side, use an air discharge chamber. You can install any number of units side-by -side.

Only up to 3 units can be installed side-by-side under the above conditions. The next group must be spaced at least 1 ft. away from the first group.

Air in

Air discharge

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

Anchor bolts (4 pieces)

Fig. 2-3

S4359146

Air in

Min. 6 inch

0934_C_I

0933_C_S

Air discharge

0426_C_I

2-1. 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 the obstacle.

● the air-discharge outlet is facing the sidewalk and discharge hot air can annoy the passers-by. Refer to Fig. 2-4.

8-ø1/4" hole

22-5/16"

23-5/16"

3-ø2-3/8" hole

11-13/16"

43-15/16"

9-7/8"9-7/8" 17-3/4" 3-15/16"

5-3/16"

5-5/32"

1352_C_

Recommended outer dimensions of wind shield (field supply)

21-13/16"

CH3642 CH2442

Fig. 2-4

3 - ø1-9/16" hole

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

6 - ø15/64" hole

22-7/16"1/2"

23-15/32"

5-3/16"

5-5/32"9-27/32"9-27/32"1-7/32"

0936_C_I

2-2.

Installing the Outdoor Unit in Heavy Snow Areas

In locations subject to strong winds, snow-proof ducting should be fitted and direct exposure to the wind should be avoided as much as possible.

The following problems may occur when the outdoor unit is not provided with a platform and snow-proof ducting.

a) The outdoor fan may not run and there may be

damage to the unit b) There may be no air flow. c) The tubing may freeze and burst. d) The condenser pressure may drop because of

strong wind, and the indoor unit may freeze.

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2-3. Precautions When Installing in Heavy Snow

Areas

(1) The platform should be higher than the maximum.

snow depth. (Fig. 2-5)

(2) The two anchoring feet of the outdoor unit should

be attached to the platform, and the platform should be installed beneath the air-intake side of the outdoor unit.

(3) The platform foundation must be solid and the

unit must be secured with anchor bolts.

(4) When installing on a roof subject to strong wind,

countermeasures must be taken to prevent the unit from being overturned.

2-4. Dimensions of Snow / Wind-proof Ducting

and Refrigerant Tubing Space for Installation

Min. 4"

Duct

Min. 4" 12" Unit: inch

Outdoor Unit

12"

1117_C_I

In regions with snow fall, the outdoor unit should be provided with a platform and snow-proof duct.

Without snowproof ducting (Low platform)

Fig. 2-5 Fig. 2-6

Outdoor Unit

Duct

Snow-proof ducting (High platform)

0937_C_I

Duct

(WD)

Air Intake

About 1/2 of the unit height

Platform (foundation)

Fig. 2-7

Example of Installation

Fig. 2-8

Higher than the maximum snow depth

Air Intake

0488_C_

0490_C_I

(WL)

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3. HOW TO INSTALL THE INDOOR UNIT

■

4-Way Air Discharge Semi-Concealed Type (XH Type)

3-1. Suspending the Indoor Unit

Hole-in-anchor Hole-in-plug

Concrete Insert

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

3-2. Preparation for Suspending

(1) Fix the suspension bolts securely in the ceiling

using the method shown in the diagrams (Figs.

3-1 and 3-2), by attaching them to the ceiling

support structure, or by any other method that

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

Fig. 3-1

0038_T_I

ensures that the unit will be securely and safely

suspended.

(2) Follow Fig. 3-2 and Table 3-1 to make the holes

in the ceiling.

Table 3-1 Unit: inch (mm)

Type

Length

XH1242, XH1842 , XH2442

(PNR-XH2442)

XH3642, XH4242

(PNR-XH3642)

32-9/32 (820) 22-9/32 (566)

43-11/16 (1,110) 33-11/16 (856)

A (Ceiling opening)

(Suspention bolt pitch)

Drain hose side

Grille center

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. 3-3 and Table 3-2) show

the relationship between the positions of the

suspension fitting, the unit, and the panel.

Refrigerant tubing joint (wide tube side)

Suspension lug

Fig. 3-3

Table 3-2 Unit : inch (mm)

Type

Length

ABCDE

XH1242, XH1842, XH2442 6-3/16 7-5/32 10-9/32 12-1/8 4-7/8

(PNR-XH2442) (157) (182) (261) (308) (124)

XH3642, XH4242 6-3/16 7-5/32 11-15/32 13-1/16 4-7/8

(PNR-XH3632) (157) (182) (291) (338) (124)

Fig. 3-2

Refrigerant tubing side

1969_X_S

Drain connection (another side) (VP25)

Refrigerant tubing joint (narrow tube side)

1-3/16

1970_X_S

S4359146

3-3. Placing the Unit Inside the Ceiling

(1) When placing the unit inside the ceiling, deter-

mine the pitch of the suspension bolts using the supplied full-scale installation diagram. (Fig. 3-4) The size of the opening for the indoor unit can be confirmed by attaching the full-scale installation diagram beneath the unit. (Fig. 3-4) Tubing and wiring must be laid inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing and wiring into position for connection to the unit before placing the unit inside the ceiling.

(2) The length of suspension bolt must be appropri-

ate for a distance between the bottom of the bolt and the bottom of the ceiling of 19/32 in. or more as shown in Fig. 3-4.

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

washers onto the 4 suspension bolts as shown in Fig. 3-5.

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

(4) Remove the protective cardboard used to protect

the fan parts during transport.

(5) Adjust the distance between the unit and surface

of the ceiling. (1-7/8 in.) (Fig. 3-4)

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

19/32 inch or more

Nuts and washers

(Use above and below)

Double nuts

Fig. 3-4

Suspension bolt

Upper

Lower

1-7/8 inch

Fig. 3-5

Full-scale installation

diagram

2040_X_I

Suspension lug

Notch

1-7/8 inch

1971_X_

S4359146

3-4. 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 drain-

age. (Fig. 3-6)

Tighten the hose clamps

CAUTION

so their locking nuts face upward. (Fig. 3-6)

(2) After checking the drainage, wrap the supplied

packing and drain pipe insulator around the pipe.

(Fig. 3-7)

NOTE

Ensure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.

Transparent part for checking drainage

Packing (supplied)

Drain hose (supplied)

Drain insulator (supplied)

Hose band (supplied)

Fig. 3-6

Fig. 3-7

Hard PVC pipe (not supplied)

Drain hose adapter (supplied)

0197_X_I

0964_X_I

● Do not install an air

CAUTION

bleeder tubes, as this may cause water to spray from the drain tube outlet. (Fig. 3-8)

● If it is necessary to increase the height

of the drain pipe, the section directly after the connection port can be raised a maximum of 19-11/16 in. Do not raise it any higher than 19-11/16 in., as this could result in water leaks. (Fig. 3-9)

● Do not install the pipe with an upward

gradient from the connection port. It will cause the drain water to flow backwards and leak when the unit is stopped. (Fig. 3-10)

● Do not apply force to the piping on the

unit side when connecting the drain pipe. The pipe should not be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 3-11)

Air bleeder

0047_X_I

Fig. 3-8

11-3/4 in. or less (as short as possible)

19-11/16 in. or less

1972_X_I

Fig. 3-9

Upward gradient

0049_X_

Fig. 3-10

● Provide insulation for any drain pipes

that are installed indoors.

Support pieces

0050_X_

Fig. 3-11

S4359146

3-5. 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 43 oz. 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. Refer to page 89.

CAUTION

(3) After drain checking is finished, return the

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

CAUTION

Be careful since the fan will start turning when checking the drainage.

To mount the tube cover, use 5/16" (4 screws. Do not use long screws as they may puncture the drain pan and cause water leakage.

××

× 8 mm) tapping

××

5/16"(4 × 8 mm) tapping screw

Tube cover

Siphon

0966_X_I

Fig. 3-12

S4359146

■ 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.

3-6. Before Installing the Ceiling Panel

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

ceiling panel. (Figs. 3-13 and 3-14)

(a) Remove the 2 screws on the latch of the air-

intake grille. (Fig. 3-13)

(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. 3-13)

remove the safety string (hook on the grille side). (Fig. 3-14)

(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. 3-15)

Ceiling panel

0149_X_I

Fig. 3-13

Air filter

45°

Safety string

0150_X_I

Fig. 3-14

S4359146

3-7. 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 3-6 in reverse.

NOTE

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

3-8. 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. 3-15

Air-intake grille

1973_X_I

S4359146

3-9. Duct for Fresh Air

● There is a duct connection part on sideface of the indoor unit. (Fig. 3-16)

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

Air-intake plenum Type

CMB-GSJ80U

CMB-GSJ140U

PNR-XH2442

(XH1242, XH1842, XH2442)

PNR-XH3642

(XH3642, XH4242)

For fresh air intake

2-3/8

2-5/32

4-ø1/8 hole

ø4-13/32

(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 × L5 in.) (for fastening)

Screw (M4 × L1/2 in.) (for fastening)

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

Connecting line. Not necessary for

Air-intake filter

Duct connection flange/ box

(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. 3-17)

● Fasten the air-intake plenum with the accessory screws. (M5 × L5 in., 4pcs) (Fig. 3-17)

Detail of fresh air intake

Fig. 3-16

)

Socket cover

1974_X_S

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 × L1/2 in., 4pcs) (Fig. 3-18)

● 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 × L1/2 in., 3pcs) (Fig. 3-18)

● Install the indoor unit to the ceiling. (Install the indoor unit according to items 3-1 to 3-6.)

When installing in a pre-

CAUTION

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

Air-intake plenum

Indoor unit

S4359146

Clamper

8P socket (red) (electrical component box)

8P socket (red) (ceiling panel side)

1975_X_S

Fig. 3-17

(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. 3-17)

● 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 × 1/2 in.)

Panel catch

Ceiling panel

Fig. 3-18

Duct connection box

1976_X_S

S4359146

■ Wall-Mounted Type (KH Type)

3-10. Removing the Wall Fixture from the Unit

KH2442

Remove and discard the set screws and take off the wall fixture. (Fig. 3-19)

3-11. Selecting and Making a Hole

KH2442

(1) Tape the full-scale installation diagram on the

wall at the location selected. Make sure the unit is horizontal, using a level or tape measure to measure down from the ceiling. (Fig. 3-20)

(2) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid area where electrical

CAUTION

(3) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the wall. The required minimum hole diameter for these models is 3-3/16 in. (Fig. 3-21)

(4) Measure the thickness of the wall from the inside

edge to the outside edge and cut PVC pipe at a slight angle 1/4 in. shorter than the thickness of the wall. (Fig. 3-22)

(5) Place the plastic cover over the end of the pipe,

(for indoor side only) and insert in the wall. (Fig. 3-23)

wiring or conduit is located. Also take this precaution if the tubing goes through a wall at any other location.

Wall fixture

Set screws only for transportation

1390_T_I

Fig. 3-19

Tape

Full-scale installation diagram

0940_T_I

Fig. 3-20

NOTE

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

Indoor side

Outdoor side

0066_T_

Fig. 3-21

PVC pipe (locally purchased)

Cut at slight angle

0941_T_I

Fig. 3-22

OUTSIDE

PVC pipe

Slight angle

0942_K_

Plastic cover

INSIDE

Wall

Fig. 3-23

S4359146

KH3642

One hole is required for the air conditioner tubing, and may be either on the left or right side. (Also see section 3-14. Preparing the Indoor Side Tubing.)

(1) Tape the full-scale installation diagram on the

wall at the location selected. Make sure the unit is horizontal, using a level or tape measure to measure down from the ceiling. (Fig. 3-24)

(2) Determine if the hole is to be drilled at the left or

right hole location.

(3) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid area where electrical

CAUTION

wiring or conduit is located. Also take this precaution if the tubing goes through a wall at any other location.

(4) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the wall. The required minimum hole diameter for these models is 3-3/16 in. (Fig. 3-25)

(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 in. shorter than the thickness of the wall. (Fig. 3-26)

Tape

Full scale installation diagram

1354_T_I

Fig. 3-24

NOTE

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

Indoor side

Outdoor side

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

(for indoor side only) and insert in the wall. (Fig. 3-27)

Fig. 3-25

PVC pipe (locally purchased)

Cut at slight angle

Fig. 3-26

INSIDE

Plastic cover

Wall

0066_T_

0941_T_I

OUTSIDE

PVC pipe

Slight angle

0942_K_

Fig. 3-27

S4359146

3-12. Installing the Wall Fixture onto Wooden or

Gypsum Wall

KH2442

Confirm that the wall is strong enough to support the unit.

a) If the Wall is Wooden

wall fixture

(1) Attach the wall fixture to the wall with the 9

screws provided. (Fig. 3-28) If you are not able to line up the holes in the wall fixture with the beam locations marked on the wall, use rawl plugs or toggle bolts to go through the holes on the panel or drill 13/64 in. dia. holes in the panel over the stud locations and then mount the wall fixture.

(2) Check with a tape measure or carpenter’s level.

This is important so that the unit is correctly installed.

(3) Make sure the wall fixture is flush against the

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

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-29)

KH3642

Confirm that the wall is strong enough to support the unit.

0943_T_I

Fig. 3-28

3/16 in. dia. hole

Rawl plug

0944_T_I

Fig. 3-29

a) If the Wall is Wooden

(1) Attach the wall fixture to the wall with the 12

screws provided. (Fig. 3-30) If you are not able to line up the holes in the wall fixture with the beam locations marked on the wall, use rawl plugs or toggle bolts to go through the holes on the panel or drill 3/16 in. dia. holes in the wall fixture over the stud locations.

(2) Check with a tape measure or carpenter’s level

that the wall fixture is level. This is important so that the unit is correctly installed.

(3) Make sure the wall fixture is flush against the

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

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-29)

Wall fixture

1355_M_I

Fig. 3-30

S4359146

3-13.

Removing the Casing to Install the Indoor Unit

KH2442

How to Remove the Casing

(1) Remove the plastic cover. (Fig. 3-31) (2) Remove the clamp for the wiring connector.

(Fig. 3-32) (3) Disconnect the wiring connector. (Fig. 3-33) (4) Set the flap in the horizontal position. (Fig. 3-34)

Plastic cover

Screw

(5) Remove the 3 screws. (Fig. 3-34) (6) Remove the casing. (Fig. 3-34)

NOTE

When replacing the casing, be careful not to crush the lead wires between the casing and the frame. (Fig. 3-34)

Casing

Frame

Flap

Clamp

Screw

0945_T_I

Fig. 3-31

Fig. 3-32

2023_T_I

Wiring connector

Screws

Fig. 3-34

0947_T_I

Fig. 3-33

2024_T_I

S4359146

1358_T_I

Hack saw

3-14. Preparing the Indoor Side Tubing

KH2442

Tubing can be extended in 4 directions as shown in Fig. 3-35.

Arrangement for Left Tubing

(a) Cut out the left tubing outlet. (Fig. 3-36)

Arrangement for Right Tubing

(a) Cut out the right tubing outlet using a hacksaw.

(Fig. 3-37)

Arrangement for Left-rear and Right-rear Tubing.

(a) It is not necessary to cut a hole.

KH3642

Tubing can be extended in 4 directions as shown in Fig. 3-35.

Left tubing

Left tubing outlet

Fig. 3-36

Left-rear tubing

0950_T_I

Fig. 3-35

Right-rear tubing (Recommended)

Right tubing

0949_T_I

Right tubing outlet

0951_T_I

Fig. 3-37

Arrangement for Right-rear Tubing

(a) Remove the 2 screws and slide out the side

cover. (Fig. 3-38)

(b) Extend the wide tube from the outdoor side and

connect it directly to the mating tube inside the indoor unit. Use a flare nut. (Fig. 3-39)

Arrangement for Right Tubing

(a) Remove the 2 screws and take off the side cover.

(Fig. 3-38)

(b) Cut out the L-shaped tubing outlet using a hacksaw.

(Fig. 3-40)

tubing between the indoor and outdoor units. (Fig. 3-42)

Arrangement for Left and Left-rear Tubing.

(a) Remove the 4 screws (2 on each side) and take

off both left and right side cover. (Fig. 3-41) (b) Remove 4 screws to remove the bottom cover. (c) Using the L-shaped tube (field supply), connect

tubing as in Fig. 3-43.

Fig. 3-38

1356_T_I

Tubing from the outdoor unit

1357_T_I

Fig. 3-39

Left side cover

Indoor unit

Bottom cover

Fig. 3-41

Right side cover

1361_T_I

L-shaped tube

Fig. 3-42

Fig. 3-40

L-shaped tube

1359_T_I

1360_T_I

Fig. 3-43

S4359146

3-15. Wiring Instructions General Precautions on Wiring

(1) Before wiring, confirm the rated voltage of the

unit as shown on its name plate, then carry out the wiring closely following the wiring diagram.

(2) Provide a power outlet to be used exclusively for

each unit a power supply disconnect and circuit breaker for overcurrent protection should be provided in the exclusive line.

(3) To prevent possible hazards from insulation

failure, the unit must be grounded. (4) All wiring must be connected tightly. (5) Do not allow wiring to touch refrigerant tubing,

compressor, or any moving parts of the fan.

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.

S4359146

3-16.

Wiring Instructions for Inter-Unit Connections

(a) Insert the inter-unit wiring (according to local

codes) into the through-the-wall PVC pipe. Run the wiring toward the indoor side allowing approx. 5". to extend from the wall face. (Fig. 3-44)

Never fix the wiring by any

CAUTION

means before the indoor unit is fully seated on the rear panel.

(b) Remove the side cover and the metallic cover.

(Fig. 3-45 or 3-46, depending on model.)

a lock nut. (Fig. 3-45 or 3-46)

(d) Give some play to the inter-unit wiring from the

outdoor unit to the corresponding terminals on the terminal plate.

● Be sure to refer to the

CAUTION

wiring system diagram label inside the metallic cover and carry out the correct field wiring. Wrong wiring can cause the unit to malfunction.

● Check local electrical

codes and any specified wiring instructions or limitations.

(e) Secure the metallic cover with its screw. Then

replace the side cover.

KH2442

Rear panel

Wiring

KH3642

Connector Wiring

Wall

Plastic cover

1362_T_I

Wall fixture

Wall

KH2442

Lock nut

Power line

Look nut

Elbow conduit

Grounding line

Fig. 3-45

Metallic cover

Plastic cover

Screw

0968_T_I

KH3642

Lock nut

Connector

Fig. 3-44

Metallic cover

Fig. 3-46

Side cover

1363_T_

1395_T_I

S4359146

3-17. Shaping the Tubing

KH2442

(1) Shape the refrigerant tubing so that it can easily

go into the hole. (Fig. 3-47)

(2) Push the wiring, refrigerant tubing and drain hose

through the hole in the wall. Adjust the indoor unit

so it is securely seated on the wall fixture.

(3) Carefully bend the tubing (if necessary) to run

along the wall in the direction of the outdoor unit

and then insulate to the end of the fittings. The

drain hose should come straight down the wall to

a point where water runoff will not stain the wall.

(4) Connect the refrigerant tubing to the outdoor unit.

(After performing a leak test on the connection,

insulate it with insulating tape. (Fig. 3-48)) Also,

refer to Section 10-5. “Connecting Tubing be-

tween Indoor and Outdoor Units”.

(5) Assemble the refrigerant tubing, drain hose and

inter-unit wiring as shown in Fig. 3-49.

Cover

Fig. 3-47

Fig. 3-48

Refrigerant tubing

Inter-unit wiring

Refrigerant tubing

Drain hose

Insulating tape

Inter-unit wiring

0954_T_I

0955_T_I

KH3642

(1) Shape the narrow refrigerant tube and the drain

hose in the desired direction so that they can

easily go into the wall hole. (Fig. 3-50)

(2) Push the wiring, narrow tube, and drain hose

through the hole in the wall.

(3) Bend the tubing (if necessary) to run along the

wall in the direction of the outdoor unit, then tape

as far as the fittings. The drain hose should come

straight down the wall to a point where runoff

won't stain the wall.

(4) Hang the indoor unit on the wall fixture. (Fig. 3-51) (5) Install the mounting plate to secure the indoor unit

solidly to the wall. The plate can be positioned in

either of the 2 ways shown. (Fig. 3-52)

Mounting plate

Drain hose

1098_T_I

Fig. 3-49

Narrow tube

Drain hose

1365_T_I

Fig. 3-50

Wall

Indoor unit

Screws

Fig. 3-52

1367_T_I

S4359146

Wall fixture

Fig. 3-51

1366_T_I

0957_T_I

Drain hose

Slant

Indoor unit

3-18. Installing the Drain Hose

(a) The drain hose should be slanted downward on

the outdoor side. (Fig. 3-53) (b) Never form a trap in the course of the hose. (c) If the drain hose will run in the room, insulate* the

hose so that chilled condensation will not damage

furniture or floors. (Fig. 3-54)

Fig. 3-53

* Foamed polyethylene or its equivalent is recom-

mended.

Condensation

Do not supply power to the unit or operate it until all tubing and wiring to the outdoor unit are completed.

Insulation material (field supply) must be used.

0958_T_I

Fig. 3-54

S4359146

■ Ceiling-Mounted Type (TH Type)

unit

Ceiling surface

Fixture

0971_T_I

Within 2 in.

3-19. Suspending the Indoor Unit

(1) Place the full-scale diagram (supplied) on the

ceiling at the spot where you want to install the indoor unit. Use a pencil to mark the drill holes. (Fig. 3-55).

NOTE

Since the diagram is made of paper, it may shrink or stretch slightly because of high temperature or humidity. For this reason, before drilling the holes maintain the correct dimensions between the markings.

(2) Drill holes at the 4 points indicated on the full-

scale diagram.

(3) Depending on the ceiling type:

a) Insert suspension bolts as shown in Fig. 3-56.

b) Use existing ceiling supports or construct a

suitable support as shown in Fig. 3-57.

It is important that you use extreme care in supporting the indoor unit from the ceiling. Ensure that the ceiling is sufficiently strong enough to support the weight of the unit. Before hanging the ceiling unit, test the strength of each attached suspension bolt.

Rear

Hole-in-anchor Hole-in-plug

Front face

Full-scale diagram

Fig. 3-55

Concrete Insert

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

Fig. 3-56

Ceiling tiles

Ceiling support

0035_T_I

0038_T_I

(4) Screw in the suspension bolts, allowing them to

protrude from the ceiling as shown in Fig. 3-57. The distance of each exposed bolt must be of equal length within 2 inches. (Fig. 3-58)

0084_T_I

Fig. 3-57

Fig. 3-58

S4359146

(5) Before suspending the indoor unit, remove the 2

screws on the latch of the air-intake grilles, open the grilles, and remove them by pushing the claws of the hinges as shown in Fig. 3-59. Then remove both side panels sliding them along the unit toward the front after removing the two screws which fix them. (Fig. 3-60)

Pull out the Air-Intake grille pushing claws of the hinges

Screw

Latch

Hinge

Slide

(6) Preparation for suspending the indoor unit. The

suspension method varies depending on whether the unit is next to the ceiling or not. (Fig. 3-61 and 3-62)

(7) Suspend the indoor unit as follows.

(a) Mount a washer and two hexagonal nuts on

each suspension bolt as shown in Fig. 3-63.

Air-intake grille

Slide toward front side

Side panel

unit

Fig. 3-59

Fig. 3-60

Fixture

0973_T_

0972_T_

Suspension bolt (field supply)

Ceiling surface Washer (supplied) Double nut

(field supply)

0974_T_I

unit

Washer

(supplied)

Fig. 3-61

Suspension bolt (field supply) Washer (field supply)

Washer (supplied) Double nut

(field supply)

Fig. 3-62

Suspension bolt

Fig. 3-63

Approx.

Ceiling surface

Nut (field supply)

0976_T_I

1 inch

1096_T_I

S4359146

(b) Lift the indoor unit, and place it on the

INSIDE

Wall

Slight angle

PVC pipe

OUTSIDE

0068_T_I

washers through the notches, so as to fix it in place. (Fig. 3-64)

suspension bolt to suspend the indoor unit as shown in Fig. 3-65.

NOTE

A ceiling surface is not always level. Please confirm that the indoor unit is evenly suspended. For the installation to be correct, leave a clearance of about 3/8 in. between the ceiling panel and the ceiling surface and fill the gap with an appropriate insulation or filler material.

(8) If the tubing and wiring are to go towards the rear

of the unit, make holes in the wall. (Fig. 3-66)

(9) Measure the thickness of the wall from the inside

to the outside and cut PVC pipe at a slight angle to fit. Insert the PVC pipe in the wall. (Fig. 3-67)

0978_T_I

Fig. 3-64

0979_T_I

Fig. 3-65

NOTE

The hole should be made at a slight downward slant to the outside.

Indoor side

Outdoor side

0066_T_

Fig. 3-66

PVC pipe (locally purchased)

Cut at slight angle

0069_T_I

Fig. 3-67

S4359146

3-20. Duct for Fresh Air

There is a duct connection port (knock-out hole) at the right-rear on the Panel Top of the indoor unit for drawing in fresh air. If it is necessary to draw in fresh air, remove the cover by knocking out and connect the duct to the indoor unit through the connection port. (Fig. 3-68) If connection at the right-rear on the Panel Top is not appropriate, another duct connection port can be made by cutting an opening on the left side of the Rear Panel of the indoor unit as shown in Fig. 3-69.

3-21. Installing the Drain Piping

● Prepare a standard PVC pipe for the drain and connect it to the indoor unit drain pipe with the supplied hose clamps to prevent water leaks.

● Connect the drain piping so that it slopes downward from the unit to the outside. (Fig. 3-70)

● Never allow traps to occur in the course of the piping.

● Insulate any piping inside the room to prevent dripping.

Right side

Panel Top

Fig. 3-68

Rear side

Fig. 3-69

Duct connection port (Knock-out hole)

1017_M_I

2442 3642, 4242 A 3-15/16" 7-3/32" B 1-3/8" 1-31/32"

Cut this portion

4-11/32"

3-15/16"

1353_M_

● Use the supplied drain pipe to connect the drain pipe with the drain outlet of the indoor unit.

● After connecting the drain pipe securely, wrap the supplied drain pipe insulator around the pipe, seal the gap at the drain socket with the supplied black insulation tape, then secure it with clamps. (Fig. 3-71)

● After the drain piping, pour water into the drain pan to check that the water drains smoothly.

Check local electrical codes and regulations before

CAUTION

obtaining wire. Also, check any specified instruction or limitations.

Packing (supplied)

Fig. 3-70

Drain hose (supplied)

Good

Not good

Drain pipe clamp (supplied)

Min. 1/100

0961_T_I

Hard PVC pipe (not supplied)

Drain hose adapter (supplied)

1119_X_I

Fig. 3-71

S4359146

■ Concealed-Duct Type ( UH Type) 3-22. Required Minimum Space for

Installation and Service

● This air conditioner is usually installed above the ceiling so that the indoor unit and ducts are not visible. Only the air intake and air outlet ports are

visible from below.

● The minimum space for installation and service is shown in Fig. 3-72 and Table 3-3.

● It is recommended that space is provided (17-23/32 × 17-23/32 in.) for checking and servicing the

electrical system.

● Fig. 3-73 and Table 3-4 show the detailed dimensions of the indoor unit.

Table 3-3

Type

12, 18

Unit: inch (mm)

A (Suspension bolt pitch)

min. 9-27/32

22-27/32

Air outlet duct flange

Indoor Unit

Fig. 3-72

min.

9-27/32

min.

15-3/4

Electrical component box

Inspection access

17-23/32

Refrigerant tubing

min. 25-19/32

Unit: inch

1977_U_I

A (Length) Number of

duct flanges

Table 3-4

Dimension

Type

UH1242, UH1842

UH2442

UH3642

30-23/32 (780)

42-17/32 (1,080)

61-13/32 (1,560)

ABCDEFG HIJK

26-1/16

37-7/8

56-25/32

(O.D.)

10-1/4

31/32

23-5/8

(7-7/8×3)

35-7/16

(7-3/32×5)

54-11/32 (9-1/16×6) (9-21/32×2)

2-5/322-5/32 7-7/8

13/32

3-15/32

27-9/16 30-23/32 11-13/32 10-5/16 26-25/32 28-5/32 7-3/32 – 13-3/8 8 12

39-3/8 42-17/32 11-13/32 10-23/32 38-19/32 39-31/32 5-1/8

58-9/32 61-13/32 13-3/16 12-7/32 57-15/32 58-27/32 5-1/8

Refrigerant tubing joint (narrow tube) Refrigerant tubing joint (wide tube) Upper drain port (O.D. 1-1/4 in.) Bottom drain port (O.D. 1-1/32 in.)

Suspension lug Power supply outlet (2-ø1-3/16 hole) Fresh air intake port (ø5-29/32 hole) Flange for the flexible air outlet duct (ø7-7/8 hole)

Tube cover

Electrical component box

Flange for the air intake duct (Option or field supply)

L-ø1/4 (Hole)

A (O.D.)

H (Duct suspension bolt pitch) G (Ceiling opening dimension)

13/32

IJJK

3/43/4

4-ø15/32

(Hole)

9-21/32

(9-21/32×1)

19-9/32

9-27/32 12 16

9-7/16 16 18

Unit: inch

No. of holes

(Ceiling opening dimension)

3-17/32

7-9/32

(Suspension bolt pitch)

10-13/16

3-15/16

22-27/3231/32

(Suspension bolt pitch)

E E E F 2-15/16

D (5-29/32)

1-7/321-7/32

1-9/16

2-9/16

M-ø1/8

(Hole)

Inspection access

Fig. 3-73

S4359146

(17-23/32

17-23/32)

(Field supply)

4-17/32

12-7/32

31/32 8-9/32

13/32

24-13/16 31/32

6-5/16

2-3/4 1-3/16

31/32

2-3/4

3-11/32

Inspection access panel

5-1/8

11-7/32

Ceiling

31/32

6-7/8

1-3/8

7-15/32

1978_U_I

3-23. Suspending the Indoor Unit

Depending on the ceiling type:

• Insert suspension bolts as shown in Fig. 3-74

• Use existing ceiling supports or construct a

suitable support as shown in Fig. 3-75.

It is important that you use extreme care in supporting the indoor unit inside the ceiling. Ensure that the ceiling is strong enough to support the weight of the unit. Before hanging the unit, test the strength of each attached suspension bolt.

(1) When placing the unit inside the ceiling, deter-

mine the pitch of the suspension bolts referring to the dimensional data on the previous page. (Fig. 3-73) Tubing must be laid and connected inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing into position for connection to the unit before placing the unit inside the ceiling.

Hole-in-anchor Hole-in-plug

Nuts and washers

(2 sets)

Concrete Insert

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

0038_T_I

Fig. 3-74

Ceiling tiles

Ceiling support

0039_S_I

Fig. 3-75

Suspension bolt

Suspension lug

(2) Screw in the suspension bolts allowing them to

protrude from the ceiling as shown in Fig. 3-74. (Cut the ceiling material, if necessary.)

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

supply) onto the 4 suspension bolts as shown in Figs. 3-76 and 3-77. Use 2 sets of nuts and washers (upper and lower), so that the unit will not fall off the suspension lugs.

Suspension bolt

Hexagonal nut

Upper

Lower

Fig. 3-76

Fig. 3-77

0041_X_I

0784_U_I

S4359146

●

Fig. 3-78 shows an example of installation.

Bolt anchor

Air outlet duct

Air-outlet grille

Ceiling material Indoor unit

3-24. Installing the Drain Piping

(1) Prepare a standard hard PVC pipe for the drain

and use the supplied hose band to prevent water leaks. The PVC pipe must be purchased separately.

Fig. 3-78

Transparent part for checking drainage

Suspension bolt

Air-intake duct

Air-intake grille

Hose band (supplied)

0785_U_I

Hard PVC pipe (not supplied)

When doing this, leave a gap between the drain socket of the unit and the PVC pipe to allow the drainage to be checked. The transparent drain pipe allows you to check drainage. (Fig. 3-79)

Tighten the hose clamps so

CAUTION

their locking nuts face upward. (Fig. 3-79)

(2) After connecting the drain piping securely, wrap

the supplied packing and drain pipe insulator around the pipe, then secure it with the supplied clamps. (Fig. 3-80)

NOTE

Make sure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.

Packing (supplied)

Drain hose (supplied)

Drain hose adapter (supplied)

Fig. 3-79

Clamps (supplied)

Drain insulator (supplied)

Fig. 3-80

0964_X_I

0046_X_I

S4359146

● Do not install an air

bleeder as this may

CAUTION

cause water to spray from the drain pipe outlet. (Fig. 3-81)

●

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 19-11/16 in. Do not raise it any higher than 19-11/16 in., as this could result in water leaks. (Fig. 3-82)

● Do not install the pipe with an upward gradient

from the connection port. This will cause the drain water to flow backward and leak when the unit is not operating. (Fig. 3-83)

● Do not apply force to the piping on the unit side

when connecting the drain pipe. The pipe should not be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 3-84)

Not good

Good

No good

Air bleeder

Fig. 3-81

11-13/16 in. or less

19-11/16 in. or less

Fig. 3-82

Upward gradient

Fig. 3-83

1593_U_I

1979_U_I

1595_U_I

3-25. Checking the Drainage

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

(1) Connect power to the power terminal board (L1,

L2 terminal) inside the electrical component box.

(2) Remove the tube cover and through the opening,

slowly pour about 43 oz. of water into the drain pan to check drainage.

(3) Short the check pin (CN5 white) on the indoor

control board and operate the drain pump. Check the water flow and see if there is any leakage.

Be careful since the fan will

CAUTION

start when you short the pin on the indoor control board.

(4) When the check of drainage is complete, open

the check pin (CN5 white) and remount the insulator and drain cap onto the drain inspection port.

Support pieces

Good

Fig. 3-84

1596_U_I

CAUTION

To mount the tube cover, use 5/16" (4

××

× 8 mm) tapping

××

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

S4359146

3-26. Increasing the Fan Speed

1981_U_I

400 500

Air Flow (CFM)

External Static Pressure

0.1

0.2

0.3

0.4

0.5

150

200 300

Limit line

100

(inAq)

(Pa)

Limit line

If external static pressure is too great (due to long extension of ducts, for example), the air flow volume may drop too low at each air outlet. This problem may be solved by increasing the fan speed using the following procedure:

(1) Remove 4 screws on the electrical component

box and remove the cover plate. (2) Disconnect the fan motor sockets in the box. (3) Take out the booster cable (sockets at both

ends) clamped in the box. (4) Securely connect the booster cable sockets

between the disconnected fan motor sockets in

step 2 as shown in the Fig. 3-85. (5) Place the cable neatly in the box and reinstall

the cover plate.

Indoor Fan Performance

Fan

motor

Booster cable

Fan motor socket

(At shipment) (Booster cable installed)

12 Type

150

(Pa)

100

Limit line

External Static Pressure

200 300

Air Flow (CFM)

Electrical component box

Fig. 3-85

(inAq)

0.5

0.4

0.3

0.2

0.1

400

1980_U_I

Booster cable

18 Type

0491_M_I

150

Limit line

(Pa)

100

Limit line

External Static Pressure

NOTE

24 Type

(inAq)

0.5

0.4

0.3

0.2

700500300

Air Flow (CFM)

HT : Using the booster cable

H : At shipment

0.1

900

1982_U_I

36 Type

200

(Pa)

150

100

External Static Pressure

Limit line

0 500 1000

Air Flow (CFM)

Fig. 3-86

0.8

(inAq)

0.6

0.5

0.4

0.3

0.2

0.1

1983_U_I

■ How to read the diagram

The vertical axis is the external static pressure (Pa) while the horizontal axis represents the AIR FLOW (CFM). The characteristic curves for “HT”, “H”, “M” and “L” fan speed control are shown. The nameplate values are shown based on the “H” air flow. For the 24 type, the air flow is 636 CFM, while the external static pressure is 49 Pa at “H” position. If external static pressure is too great (due to long extension of duct, for example), the air flow volume may drop too low at each air outlet. This problem may be solved by increasing the fan speed as explained above.

S4359146

4. HOW TO INSTALL THE OUTDOOR UNIT

4-1. Removing the Protective Spacer for

Transportation

Remove the packing skid from the bottom of unit and then remove the plastic spacer used to secure the compressor during transportation. (Fig. 4-1)

Place the unit on a level concrete pad, block or equal and anchor.

Compressor

Refer to Section 2. “Selecting the Installation Site”.

4-2. Installing the Outdoor Unit

(1) Install blocks or a solid platform under the out-

door unit which provides a minimum height of 6 in. from ground level. (Fig. 4-2)

(2) The outdoor unit must be bolted down tightly to

the blocks or platform with 4 anchor bolts.

4-3. Tubing Direction

● Tubing can be extended in 4 different directions as shown in Fig. 4-3.

● Service valves are housed inside the unit. To access them, remove the access panel by removing the 3 attaching screws, then slide the panel downward and pull it toward you.

If either rear, right or front tubing is needed, punch out the knockout holes with a hammer or similar tool.

● After punching out the knockout holes, mount plastic protectors on the tubing outlets. These accessories are packed inside the unit and can be accessed through the access panel.

● Use tube benders to extend refrigerant tubing to the outside.

skid

Plastic spacerPacking

Fig. 4-1

13-3/8

6-11/16 26 4-21/64

Anchor bolts (not supplied)

Height : Min: 6 in.

Fig. 4-2

0496_C_

14-31/32

1-3/16 1-3/16

Unit: inch

1168_C_I

15-3/4

Access panel

Front

Inter-unit wiring outlets

Tubing outlets

Fig. 4-3

Down

Rear

Right

Control wiring outlets

Power supply wiring outlets

Power supply line

Connector Size

Power Supply Inter-unit Power Line

Inter-unit control line

S4359146

1/2" 1/2"

Inter-unit power line

1102_C_I

5. ELECTRICAL WIRING

5-1. 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, and a power supply disconnect and circuit breaker for overcurrent protection should be provided in the exclusive line.

(3) To prevent possible hazards from insulation

failure, the unit must be grounded.

(4) Each wiring connection must be done in accor-

dance 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.

(7)

Regulations on wire diameters differ from locality to locality. For field wiring rules, must follow your LOCAL ELECTRICAL CODES before beginning.

You must ensure that installation complies with all relevant rules and regulations.

(8) To prevent malfunction of the air conditioner

caused by electrical noise, care must be taken when wiring as follows:

● The remote control wiring and the inter-unit control wiring should be wired apart from the inter-unit power wiring.

● Use shielded wires for inter-unit control wiring between units and ground the shield on both sides.

(9) If the power supply cord of this appliance is

damaged, it must be replaced by a repair shop appointed by the manufacture, because special purpose tools are required.

(10)All wiring must be used class 1.

5-2. Recommended Wire Length and Wire Diameter for Power Supply System

Must follow LOCAL ELECTRICAL CODES for wiring. Outdoor Unit * AWG = American Wire Gauge

Model Name

CH2442 3/4 in. 25 A 50 A CH3642 3/4 in. CH4242 3/4 in. 45 A 50 A

(A) Power Supply Power Supply Terminal Base

AWG #12

Max. length 69 ft.

AWG #12

Max. length 69 ft.

AWG #10

Max. length 67 ft.

Trade size of Conduit

35 A/40 A (230/208 V)

MOP

(Fuse or HACR

type circuit braker)

Capacity Max. Wire Diameter

50 A

AWG #6 1-1/4 in. AWG #6 1-1/4 in. AWG #6 1-1/4 in.

Trade size of Conduit

Indoor Unit

Type

(B) Power Supply Power Supply Terminal Base

Trade size of Conduit

MOP

(Fuse or HACR

type circuit braker)

Capacity Max. Wire Diameter

X, K, T, U Max. length 330 ft. 3/4 in. 15 A 25 A

AWG #10 3/4 in.

Trade size of Conduit

Control Wiring

AWG #18 (0.75 mm2) AWG #18* (0.75 mm2) AWG #18*2 (0.75 mm2)

Use high voltage wire (300 V)

Max. 3,300 ft. Max. 1,650 ft. Max. 1,650 ft. (Total)

NOTE

*1With ring type wire terminal. *2Wire joint connection.

S4359146

5-3. Wiring System Diagrams

Inter-unit

control wiring

4P terminal board

2088_M_I

Inter-unit

power wiring

U1 U2

KH Type

(1) Basic wiring diagram for standard control

Indoor Unit

Inter-unit power wiring Single phase 230/208V

Inter-unit control wiring (Low voltage)

Remote controller

(Option)

*Remote controller wirings are wire joint connection.

1 2 G G

U1 U2

1 2

Ground

NOTE

(1) Refer to Section 5-2. “Recommended Wire

Length and Wide Diameter for Power Supply System” for the explanation of “A”, “B”, “C”, “D”, and “E”, in the above diagrams.

(2) Inter-Unit Control Wiring (C) and remote control-

ler wiring (D), (E) has no polarity. But for other wiring, respect polarity. Be sure to connect as shown in the Wiring System Diagram.

(3) R.C. Address should be set before turning the

power on.

Outdoor Unit

1 2

XH, TH, UH Type

5P terminal board

R.C. Address on the PCB: 0 (S2, BLK) (0: Factory shipped state)

Power supply

Single phase

230/208V

Ground

CH Type

5P terminal board + 2P terminal board

Inter-unit

power wiring

L2L1

Power

supply

Inter-unit

control wiring

2086_M_I

2085_M_I

(4) Regarding the R.C. Address setting, refer to

page 87. Auto. address setting can be executed by a remote controller automatically.

Inter-unit

power wiring

Inter-unit

control wiring

2087_M_I

Remote

controller wiring

3003_M_I

Remote

controller wiring

3003_M_I

S4359146

(2) Basic wiring diagram for group control

This diagram shows when several units (max. 8) are controlled by a remote controller. In this case, a remote controller can be connected at any indoor unit.

RED BLK

Remote controller

(Option)

Inter-unit power wiring single phase 230/208V

Inter-unit control wiring (Low voltage)

Inter-unit power wiring single phase 230/208V

Inter-unit control wiring (Low voltage)

Indoor Unit

1 2

G G

U1 U2

11 2

Indoor Unit

1 2

U1 U2

1 2

Ground

Outdoor Unit

1 2

Outdoor Unit

1 2

*1 R.C. Address on the PCB: 1 (S2, BLK)

Power supply single phase

230/208V

Ground

R.C. Address on the PCB: 2 (S2, BLK)

Power supply single phase

230/208V

Ground

Inter-unit power wiring single phase 230/208V

Inter-unit control wiring (Low voltage)

*Remote controller wirings are wire joint connection.

Indoor Unit

1 2

U1 U2

1 2

Ground

Outdoor Unit

1 2

R.C. Address on the PCB: 8 (S2, BLK)

Power supply single phase

230/208V

Ground

2089_M_I

NOTE

● R.C. Address should be set before turning the power on.

● Auto. address setting can be executed by a remote controller automatically.

Please refer to 12-4 “Automatic Address Setting Method”.

● Each successive unit will respond at one-second intervals following the order of the R.C. address when the remote controller is operated.

S4359146

Loose wiring may cause the

terminal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, ensure that all wiring is tightly connected.

When connecting each power wire to the corresponding terminal, follow the instructions on “How to connect wiring to the terminal” and fasten the wire securely with the fixing screw of the terminal plate.

5-4. How to Connect Wiring to the Terminal

Stranded wire

Ring pressure terminal

Strip 3/8 in.

1106_M_I

Fig. 5-1

■ For stranded wiring

(1) Cut the wire end with a wire cutter or wire-cutting

pliers, then strip the insulation to expose the stranded wiring about 3/8 in.. (Fig. 5-1)

(2) Using a Pillips head screwdriver, remove the

terminal screw(s) on the terminal plate.

(3) Using a ring connector fastener or pliers, securely

clamp each stripped wire end with a ring pressure terminal. (Fig. 5-1)

(4) Place the ring pressure terminal, and replace and

tighten the removed terminal screw using a screwdriver. (Fig. 5-2)

Special washer

Wire

Screw

Ring pressure terminal

Terminal plate

Fig. 5-2

Screw and Special washer

Ring pressure terminal

Wire

1107_M_

S4359146

HOW TO INSTALL THE WIRED REMOTE CONTROLLER (

OPTIONAL PART

)

6-1. Installation site selection

● Install the remote controller at a height of between

3–5 ft. above the floor.

● Do not install the remote controller in a place where

it will be exposed to direct sunlight or near a window or other place where it will be exposed to the outside air.

● Be sure to install the remote controller vertically,

such as on a wall.

● The mounting position for the remote controller

should be located in an accessible place for control.

● Never cover the remote controller or recess it into

the wall.

Mounting dimensions for continuous installation

● When mounting the remote controller on a wall,

please see Fig. 6-1 and Fig.6-2.

Wall

Hole for routing remote control cable

JIS CB8340 One switchbox (no cover)

3-21/32 in. or more

(from wall) Spacer

3-17/32 in. or more

(from wall)

Fig. 6-1

Spacer

4-29/32 in. or more

(during continuous

installation)

4-29/32 in. or more

(during continuous

installation)

3/32 in.

(amount offset from JIS box)

1987_C_I

Wall

Hole for routing remote control cable

JIS CB8340 Two switchbox (no cover)

3-17/32 in. or more

(from wall)

Fig. 6-2

4-29/32 in. or more (during continuous

installation)

1988_C_I

(WD)

S4359146

6-2. Wired Remote Controller Installation

● Do not supply power to

the unit or try to operate it until the tubing and wiring to the outdoor unit is completed.

● Do not twist the control

CAUTION

wiring with the power wiring or run it in the same metal conduit, because this may cause malfunction.

● Install the remote control-

ler away from sources of electrical noise.

● Install a noise filter or

take other appropriate action if electrical noise affects the power supply circuit of the unit.

● If local codes allow, this remote controller can be

mounted using a conventional wall box for flush mounting.

(1) When you open the decorative cover, you will see

two gaps under the remote controller. Insert a coin into these gaps and pry off the back case. (Fig. 6-4)

(2) Attach the back case with the 2 small screws

provided. Using a screwdriver, push open the cutouts on the back case. These holes are for screws. Use the spacers and take care not to tighten the screws excessively. If the back case will not seat well, cut the spacers to a suitable thickness. (Fig. 6-3)

(3) Connect the remote controller wiring (2 wires)

correctly to the corresponding terminals in the electrical component box of the indoor unit.

Wired remote controller

Coin

M4 × 25 Screws (2)

Decorative cover

Control panel

Gap

Concealed box for 1

Spacer

Fig. 6-3

Gap

Fig. 6-4

Under case (Back case)

1989_C_I

1990_M_I

When wiring, do not connect

CAUTION

the remote controller wires to the adjacent terminal block for the power wiring. Otherwise, the unit will break down.

(4) To finish, fit the back tabs of the case into the

remote controller and mount it.

S4359146

6-3. Basic Wiring Diagram

Wire joint

Outdoor unit

CAUTION

Group control

Indoor unit

: Ground (earth)

Connection wiring for group control

No. 1

Install wiring correctly (incorrect wiring will damage the equipment).

Standard remote control

Indoor unit

No. 2

Inter-unit control wiring

Indoor unit

No. 3

Multiple remote control

Indoor unit

No. 8

● Use shielded wires for inter-unit control wiring and ground the shield on both sides. (Fig. 6-5) Otherwise misoperation because of noise may occur.

Shielded wire

ground

0797_M_I

Fig. 6-5

2030_M_I

Indoor unit 1

Group-control wiring

● Wiring procedure

Install the wiring according to the above wiring diagram.

● The address setting is automatically executed after turning on the system. An indoor unit address is assigned to each indoor unit.

● Operation takes place successively at intervals of 1 second, by using combinations of the address setting of each unit.

Indoor unit 2

Inter-unit wiring

Indoor unit 7

(Main) (Sub)

Indoor unit 8

2031_M_I

● Diagram of outer dimensions

5/32

3/32

4-23/32

(WD)

S4359146

4-23/32

5/8

1991_M_I

6-4. Wiring System Diagram for Group Control

This diagram shows when several units (maximum of

8) are controlled by a remote controller (master unit). In this case, a remote controller can be connected at any indoor unit.

Remote controller

Connection wiring for group control

Indoor unit

No. 2

Indoor unit

No. 3

Wire joint

Inter-unit control wiring

Indoor unit

No. 1

Outdoor unit

Indoor unit

No. 8

Wiring procedure

Wire according to the left diagram:

● Address setting is executed automatically when the outdoor unit is turned on.

● Each successive unit will respond at one-second intervals following the order of the group address when the remote controller is operated.

: Ground (earth)

● Group control using 2 remote controllers.

It does not matter which of the 2 remote controllers you set as the main controller.

Remote controller (main)

Wire joint

Indoor unit

No. 1

: Ground (earth)

Connection wiring for group control

Indoor unit

No. 2

(sub)

Indoor unit

No. 3

Indoor unit

2032_M_

No. 8

2033_M_I

When using multiple remote controllers (up to 2 of them can be used), one is the main remote controller and the other is the sub-remote controller.

● To set up a sub-remote controller, change its remote control address connector (RCU. ADR) located on its PCB from main to sub position (main: when shipped from factory).

S4359146

6-5. Wiring System Diagram for Multiple Remote

Control

■ When Installing Multiple Remote Controllers

This multiple remote controller system is used for operating the unit(s) at different positions. (A maximum of 2 remote controllers can be installed.)

● Setting method

To execute this control, make the setting according to the following procedure.

(1) Of the two installed remote controllers, make one

the main remote controller (factory-shipped state).

(2) On the other remote controller, change the

address connector on the PCB from main to sub position. In this state, it functions as a sub-remote controller.

Remote controller Remote controller

address connector

Main

RCU check

Sub

RCU. ADR

1992_M_I

● Basic wiring diagram

Install wiring correctly

CAUTION

(incorrect wiring will damage the equipment).

● To operate 1 indoor unit with 2 remote controllers set at different places.

6-6. How to Switch the Indoor Temperature Sensor

The indoor unit and the remote controller both contain an indoor temperature sensor. The sensors on either unit can be used but normally only the sensor set on the indoor unit is used. However, use the following procedure if you must use the sensor on the remote controller.

(1)Hold down the + + buttons for at least

4 seconds. Note: The Unit No. first displayed is the main indoor unit address for group control.

Note: Do not press the button.

(2)Select CODE NO. 32 with the Temp.setting ( )

/ buttons.

(3)Change the set data from 0000 to 0001 with the

Timer ( ) / button.

(4)Press the button. (Setting is OK if the blinking

display changes to a lit up display.)

(5)Press the button.

This is the usual off condition. At this time, (remote controller) appears on the LCD display.

Remote control cable terminal board

Earth

(sub)(main)

(Option)

Indoor unit

Remote control cable

(wire it at local installation site)

1993_M_I

(WD)

NOTE

*1If using 2 remote controllers, either one (main or

sub-remote controller) can be used to make setting but only the main unit functions as the remote controller sensor.

*2The remote controller sensor will not function

during group control unless the group address is set in the main remote controller indoor unit.

*3Do not use remote controller switch for the remote

control sensor if the remote sensor is being used jointly with the remote controller switch.

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6-7. Explanation of Alarm Messages

Possible Cause of Malfunction

• Serial communication errors

• Mis-setting

Activation of protective device

Remote controller is detecting error signal from indoor unit.

• Indoor unit is detecting error signal from the remote controller. (No serial communications signal)

Indoor unit is detecting error signal from outdoor unit.

Outdoor unit is detecting error signal from indoor unit.

Indoor unit is not working correctly.

Outdoor unit is transmitting error signal.

Improper setting of indoor unit or remote controller.

When using group control, main indoor unit address setting is duplicated.

(For single heat pump type.)

Error in Auto. address setting.

(No. or capacity of judged indoor unit is small.)

Error in Auto. address setting.

(No. or capacity of judged indoor unit is large.)

Indoor unit is detecting error signal from another indoor unit.

Protective device in indoor unit is activated.

Protective device in outdoor unit is activated.

Error in receiving serial communications signal. Error in transmitting serial communications signal.

Error in receiving serial communications signal.

• Indoor unit is damaged.

• Power is not supplied.

Error in transmitting serial communications signal.

Indoor unit address setting is duplicated. Remote controller address (RCU.ADR) switch is duplicated.

Do not press Auto. address button S001: (A. ADD) of another R.C. line during Auto. address operation.

• Thermal protector in indoor fan motor is activated.

• Thermal protector in outdoor fan motor is activated.

• Comp. thermal protector is activated. Incorrect discharge gas temp. of comp.

High-pressure switch is activated. Incorrect power supply voltage . Negative phase, defective

phase or voltage drop.

Alarm message

E1 E2

E4 E5

E8 E9

E12

E14

E15

E16 E18

P2 P3

Incorrect discharge gas temp. of comp.

Protective device in indoor unit is activated.

Improper wiring connections of ceiling panel. Float switch is activated.

NOTE

● RCU : Remote Control Unit (remote controller)

● R.C. : Refrigerant Circuit

● comp. : Compressor

● temp. : Temperature

● PCB : Printed Circuit Board

P17

P10

S4359146

Possible Cause of Malfunction

Thermistor failure

EEPROM (ICB of PCB) failure Fault with

comp. and its circuit

Indoor thermistor is either open or damaged.

Outdoor thermistor is either open or damaged.

Protective device for comp. is activated.

Indoor coil temp. (E1 = TH1) cannot be detected. Indoor coil temp. (E2 = TH2) cannot be detected. Indoor coil temp. (E3 = TH3) cannot be detected. Indoor room (air-intake) temp. can not be detected. Discharge gas temp. (comp. = TH0A) cannot be detected. Outdoor coil gas temp. (C2 = TH0C) cannot be detected. Outdoor coil liquid temp. (C1 = TH0D) cannot be detected.

Comp. motor is overloaded. Comp. motor is locked.

Current of comp. cannot be detected when it is turned on. Current of comp. is detected when it is not operated. Comp. contactor (Mg SW) is chattering.

Alarm message

F1 F2 F3

F10

F25

F29

H1 H2

H3 F27 H18

Possible cause of Malfunction

Model setting of indoor unit is not matching the outdoor unit. When using group control, main indoor unit address setting is duplicated.

(Judging by indoor unit.) Outdoor unit address (R.C. No.) is duplicated. Priority setting of indoor unit is duplicated. — Improper wiring between indoor units.

(There is group connection wiring in case of individual control.) Capacity code of indoor unit is not set. Improper wiring of group control wiring.

Possible Cause of Malfunction (The following messages are displayed only for the system controller.)

• Serial communication errors

• Mis-setting

Activation of protective device

System controller is transmitting incorrect signal.

System controller is detecting incorrect signal.

Protective device of the subindoor unit is activated in group contorl.

• Indoor or outdoor unit is not working correctly.

• Control lines between indoor unit, outdoor unit, and system controller are not wired correctly.

• Same as for C05, above.

• Connector CN1 is not connected correctly. When using wireless remote controller or system controller,

connect wired remote controller with the indoor unit temporarily to check the alarm message in detail.

Alarm message

L2 L3 L4

L5 L6

L7 L9

L11

Alarm message

C05

C06

P30

(WD)

NOTE

● R.C. : Refrigerant Circuit

● comp. : Compressor

● temp. : Temperature

● PCB : Printed Circuit Board

S4359146

7. HOW TO INSTALL THE WIRELESS REMOTE CONTROLLER (OPTIONAL PART)

Important

When using this air conditioner (ECO multi system air conditioner) with the wireless remote controller it may sometimes be impossible to change the operation modes while other indoor unit is running.

●

When this happens, a double beep tone sounds, the (operation lamp) lights up, and the (Timer

lamp) and (Standby lamp) blink alternately. Operation is the same even during (AUTO mode) automatic cooling or heating.

● A beep tone sounds 5 times and no changes can be made when any of the ON/OFF, MODE, Temperature setting buttons were pressed while set under central control by the system controller.

7-1. Wireless Remote Controller Installation

The remote controller 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 controller in the following places:

● In direct sunlight.

● Behind a curtain or other place where it is covered.

● More than 26 ft. 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.

(1) If Wall-mounted Fixed Position

Install the remote controller at a convenient location on a nearby wall. However, before attaching the remote controller mounting cradle, check that the remote controller can operate from the desired wall position. (Fig. 7-1)

Screws for fixture Truss-head tapping screws (4 × L5/8")

Put on 1

Push

Mounting cradle

1994_M_I

■ How to Install Batteries

See Fig. 7-2. (1) Press and slide the lid on the back of the remote

controller in the direction of the arrow.

(2) Install two AAA alkaline batteries. Make sure the

batteries point in the direction marked in the battery compartment.

(3) Press the ACL button, then replace the lid. If you

press it, the current time, ON time, and OFF time are all reset to 0:00.

S4359146

Fig. 7-1

Cover

Fig. 7-2

ACL button

1995_M_I

7-2. Room Temperature Sensor Setting

The room temperature sensors are built into the indoor unit and the wireless remote controller. Either of these room temperature sensors can operate. The system is shipped from the factory set to the indoor unit sensor. To switch to the remote controller sensor, press the sensor switching button located inside the remote controller cover and check that A/C SENSOR on the LCD display panel goes out.

SET

ACL

ADR

SENSOR

NOTE

If the sensor switch is set to the remote controller side, but no room temperature data is sent to the main unit for 10 minutes, the sensor is automatically switched to the indoor unit side. As much as possible, install the remote controller facing the unit.

7-3. Address Switches

If you are installing more than 1 indoor unit (up to 6) in the same room, it is necessary for you to assign each unit its own address so they each can be operated by their remote controller.

Up to 6 indoor units can be controlled separately through the address switches. The operating control has the reception address switch and the remote controller has transmission address switch. This function is utilized by matching the transmission and reception address switches.

Remote controller address display

ADR

Sensor button

Fig. 7-3

ADR

1996_M_I

(WL)

Address switch positions

* Any address

switch position available

1 2 3 456

7-4. Setting the Model Code

1 Flap display selector switch

Make the slide switch settings in the battery compartment box of the remote controller depending on the type of indoor unit in which the wireless receiving unit is used.

2 Operation mode switch

In this Split System Air Conditioner set the switch to “A”. * The switch is factory set to “S” / “A”. * Always press the reset button after switching the setting.

SKN AHC

Fig. 7-4

Operation mode switch

Flap display selector switch

1997_M_I

SKN

XH, TH type UH typeKH type

AHC

Heat pump with

Auto mode (CH type)

Heat pump without

SKN SKN

AHC

Cooling only

Auto mode

AHC

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<RCS-SH80UA. WL>

■ 4-Way Air Discharge Semi-concealed Type

(XH Type)

7-5. Indicator section Installation

● Remove the ceiling panel and indicator cover

and install the indicator section.

Air intake grille

Mark section (indicator section)

(WL)

(1) Remove the ceiling panel. (2) Remove the corner cover behind the mark sec-

tion. (3 screws)

(3) Remove the mark section inside the ceiling panel.

(2 screws)

(4) Install the indicator section in the location where

the mark section was attached. (2 screws)

(5) Form the wire to match the panel ribs as in the

Fig. 7-6.

(6) Install the corner cover. (Restrain the wire with

the corner cover.)

7-6. Operating Controller Installation

● Do not twist the operating

CAUTION

controller wires together with the power supply wires. Doing so can result in malfunction.

● If noise is induced in the

unit power supply, take appropriate measures, for example installing a noise filter.

Install the operating controller at the indoor unit intake port section.

2 screws

3 screws

Fig. 7-5

Pass the wiring through under the shaft.

Indicator section

Fig. 7-6

Ceiling panel

0574_X_I

Corner cover

0517_X_I

Wiring

0518_X_I

(1) Fasten the operating controller to the indoor unit

intake port section (electrical component box

opposite side) with the 2 accessory screws

(4 × L13/32 in.).

(2) Connect the operating controller 2 wires (WHT,

BLK) to the remote control wire (WHT) in the

electrical component box. (For details on the

wiring, see “7-9. Electrical wiring” P56.)

(3) Install the ceiling panel. (4) Connect the indicator section and the operating

controller by 6P connector (white).

(5) Form the wires with vinyl clampers and fasten. (6) Connect the ceiling panel wiring connector (2P,

3P) to the body connector in the electrical compo-

nent box.

(7) For details on test operation, see “Test Run”.

Operating controller

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Screws

Electrical component box

1998_M_I

Fig. 7-7

■ Ceiling Mounted Type (TH Type)

7-7. Indicator Section Installation

Remove the side panel to install the indicator section. (Fig. 7-8)

(1) Remove the side panel.

Open the air intake grille, remove the screw at one place and then remove the side panel by sliding it toward the front (arrow direction).

(2) Remove cover A and cover B.

Put the minus-screwdriver into the recess of cover A to remove cover A and cover B. (When removing the cover, take care not to

scratch the panel.) (3) Remove cover B from cover A. (4) Install the indicator section at cover A. (5) After passing through the lead wires, install cover

A and the indicator section at the panel hole.

(The protrusion part of cover A is fixed with the

panel hole.) (6) Bundle the lead wires along with the wiring of the

louver motor. (7) Install the side panel.

Indicator section

Cover B

(Not used when the indicator section is installed.)

Recess

Cover A

Recess

Fig. 7-8

PanelIndicator section

Cover A

Side panel

Air intake grille

1536_T_I

7-8. Operating Controller Installation

● Do not twist the operating

controller wires together with the power supply wires. Doing so can result

CAUTION

in malfunction.

● If noise is induced in the

unit power supply, take appropriate measures, for example installing a noise filter.

Install the operating controller on the top face of the air intake section (space between the fan motor and the electrical component box). (Fig. 7-9)

(1) Fasten the operating controller to the ceiling

panel of the air intake section with the 2 accessory screws (4 × L13/32 in.).

(2) Draw the lead wires into the electrical component

box and connect the operating controller 2 wires (WHT, BLK) to the remote control wires in the electrical component box.

(3) Connect the indicator section and the operating

controller by 6P connector in the electrical component box.

Operating controller

(WL)

Fig. 7-9

Electrical component box

1537_T_I

S4359146

7-9. Electrical Wiring

Indoor PCB Operating controller

CN2

CN1

1 2

W1 (4.3 ft.)

WHT

BLK

Fig. 7-10

Connection method (1) Connect W1 to the indoor PCB WL connector. (2) Connect W3 from the indicator section with W2

from the operating controller using the relay connector.

7-10. Test Run Switch

Test run switch is located at operating control unit. Regarding the test run, please refer to section 12. Test Run.

NOTE

● In case of 4-way air discharge type, test run operation is not possible without the ceiling panel installation.

● During the test run, all of the 3 indicator lamps on the indoor unit will flash.

● During the test run, the air conditioner runs continuously and the thermostat does not control the system.

● To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes after power is applied or the air conditioner is turned off and then back on.

● When the air conditioner fails to start the test run, 1 or more of the 3 alarm indicator lamps on the indoor unit will flash (See next section).

Signal receving unit

(0.7 ft.)

BLU

YEL PNK RED GRY

BLK

Relay connector

(4.3 ft.)

BLU

YEL PNK RED

GRY

BLK

1.TEST RUN

2.PCB CHK.

3.RCU: MAIN RCU: SUB

4.NORMAL ALL •

Servicing switches

Indicator section

CN1

All OFF( ) for initial settings.

234

2035_M_I

ADR

2 3

456

Address switch

Fig. 7-11

Flap button

ON/OFF operation button

1999_M_I

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7-11. Misoperation Alarm Indicators

Alarm indicator lamps on the indoor unit indicate the error cause when the air conditioner fails to operate upon being switched on. The possible alarm indications are given in Table 7-1. Fig.7-12 shows the location of the alarm lamps on the indoor unit. (See Table 7-1, Fig. 7-12)

Table 7-1

Alarm

(OPERATION

lamp) lamp) lamp)

(TIMER

(STANDBY

Cause of Trouble

S.C. errors* between the indoor unit’s controller (PCB) and the remote

O ●●

controller.

● O ● Compressor protector is working.

●●O S.C. errors between indoor and outdoor units.

OO● Indoor or outdoor thermistor is malfunctioning. O ● O Outdoor unit protector is working.

● OOIndoor unit protector is working. OOOTEST RUN switch on the operation controller is in ON state.

* S.C. : Serial communications

OPERATION lamp

TIMER lamp

STANDBY lamp

Fig. 7-12

Remote control receiver

2000_M_I

(WL)

NOTE

Stick the alarm message label accompanying with the wireless remote controller on the electrical component box to find the cause of trouble in case of need.

S4359146

(WL)

<RCS-BH80UA.WA>

● If the signal receiving unit

CAUTION

is installed near rapidstart type or inverter type fluorescent lamp (neither one having glow lamps), it may be impossible to receive signals from the wireless remote controller. To avoid signal interference from fluorescent lamps, install the receiving unit at least 6.6 ft. away from the lamps and install at a location where wireless remote controller signals can be received when the fluorescent lamps are on.

7-12.

Separate type Signal Receiving Unit Installation

● Do not twist the operating

CAUTION

controller wires together with the power supply wires. Doing so can result in malfunction.

● If noise is induced in the

unit power supply, take appropriate measures, for example installing a noise filter.

● If local codes allow, this signal receving unit can be mounted using a conventional wall box for flush mounting.

Notch

M4 × L1 in Screws (2)

Cover plate

Signal receiving unit

Spacer

ALL• RCU : SUB PCB CHK. TEST RUN

RCU : MAIN NORMAL

ADR

Fig. 7-13

Switch box (no cover)

2001_M_I

(1) Insert a minus driver into the gap under the signal

receving unit and pry off the cover (Fig. 7-14)

(2) Attach the signal receving unit with the 2 small

screws provided. Use the spacers and take care not to tighten the screws excessively. If the signal receving unit will not seat well, cut the spacers to a suitable thickness. (Fig. 7-13)

(3) Connect the signal receving unit wiring (2 wires)

correctly to the corresponding terminals in the electrical component box of the indoor unit.

When wiring, do not connect

CAUTION

the signal receving unit wires to the adjacent terminal block for the power wiring. Otherwise, the unit will break down.

2002_M_I

Fig. 7-14

S4359146

● When using the signal receiving unit on a wall with

2004_M_I

Clamper (supplied)

About 3/32-1/8 in.

Connector

Remote control cord (Option)

the front exposed, choose a wall surface that the signal receiving unit can be mounted on.

(1) Insert a flat tip (minus) screwdriver into the slot on

the lower side of the signal receiving unit and pry off the back case as shown in Fig. 7-14.

(2) The wire rooting at the signal receiving unit

comes out of the upper case (thin portion at upper center) so use nippers or a similar tool to cut out a notch beforehand large enough for the remote control cable (option) to pass through as shown in Fig. 7-15.

(3) Remove the wire which is connected prior ship-

ping from the connector.

(4)

Connect the remote control cable (option) to the signal receiving unit connector shown in Fig. 7-16 after the clamper (supplied) with the unit is installed.

(5) After arranging the wiring on the printed circuit

board as shown in Fig. 7-17 so that it is contained within the signal receiving unit, attach the back case. At this time, arrange so that the head of the clamper faces the side.

(6) Remove the cover plate and install the signal

receiving unit using the 2 wood screws. (7) Fasten to the wall using the cord clip (supplied). (8) Reinstall the cover plate.

Run the remote control cable through a notch on the upper case.

2003_M_I

Fig. 7-16Fig. 7-15

Remote control cord (Option)

Clamper

2005_M_I

Fig. 7-17

Signal receiving unit

Wood screws (2)

● To use the signal receiving unit while mounted on a

ceiling, install by using the carrier for ceiling installation supplied with the unit.

(1) Remove the cover plate by inserting a flat tip

(2) Cut out a section (3-3/4 × 2-1/32 in.) on the

(3) (4) Fit securely into the ceiling material at sections (5) Connect the wire (2-wire core) from the signal

(6) Use the supplied spacers to adjust for a thickness

(7) Tighten the machine screws after fitting sections

(8) Reinstall the cover plate.

(minus) screwdriver or similar tool into the notch

in the lower section and prying it off.

ceiling using the paper pattern (supplied) as a

guide.

Run the wire through the mounting carrier and insert

into the installation hole as shown in Fig. 7-19.

(A) and (B) as shown in Fig. 7-20.

receiving unit with the wire from the indoor unit.

(See section on how to wire the receiving unit.) as

shown in Fig. 7-20.

several inches more than the ceiling material and

lightly fasten the receiving unit in place with the

small screws (M4 × 1-9/16 in., 2 pcs.) supplied

with the unit.

(A) and (B) into the openings, in the gap between

the signal receiving unit and ceiling surface as in

Fig. 7-21. Do not apply strong force when tighten-

ing the screws. Excessive force might warp or

damage the cover. When finished the signal

receiving unit should still be able to move slightly

when pressed as shown in Fig. 7-21.

Fig. 7-19

2007_M_I

ALL• RCU : SUB PCB CHK. TEST RUN

RCU : MAIN NORMAL

ADR

Fig. 7-18

Fig. 7-20

2006_M_I

2009_M_

(WL)

2008_M_I

Fig. 7-21

S4359146

7-13. Electrical Wiring

Make correct wiring without

CAUTION

any mistakes (incorrect wiring will damage the equipment).

● Recommended wire diameter and allowable length for signal receiving unit wiring and its branch wiring: AWG #18, MAX 1,300 ft.

Terminal board for indoor unit remote controller wiring

Wire joint (2 pcs. white, supplied)

1 2

Signal receiving unit wiring (field supply)

Signal receiving unit wiring

WHT

BLK 2

Wire from signal receiving unit

Connection

Signal receiving unit

1. Peel away 9/16 in. of shield from the wire for the connection.

Join the 2 wires as shown and crimp-connect

them with the wire joint (supplied).

Signal receiving unit wiring

Wire joint CE-1 (supplied)

3004_M_I

3. When no crimp tool is available or if a

solder connection was made then cover with insulating tape.

7-14. Test Run Switch

(1)

Remove the cover plate of the signal receiving unit. Set the "TEST RUN" switch of the dipswitches to the ON position.

(2) Press the ON/OFF operation button on the

wireless remote controller.

● During the test run, all of the 3 indicator lamps on the indoor unit will flash.

2010_M_I

ALL• RCU : SUB PCB CHK. TEST RUN

RCU : MAIN NORMAL

123

ADR

The TEST RUN switch is

CAUTION

used only for servicing the air conditioner. DO NOT use this switch for normal operation. Otherwise, it may put stress on the system.

(3) Make a test run using the air conditioner in

COOL, HEAT or FAN modes.

● To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes after power is applied or the air conditioner is turned off and then back on.

(4) After the test run, press the ON/OFF operation

button on the wireless remote controller. Then, set the TEST RUN switch back to the OFF position to cancel the test run mode.

2012_M_I

Fig. 7-22

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7-15. Misoperation Alarm Indicators

A blinking lamp for other than the signal receiving unit filter shows that a problem has occurred in the unit so make an inspection. (Refer to servicing information in the service manual, etc.) Also, if wired remote controller and dedicated service check lines (854-9-9536044-97: service use) are available, then detailed error information can be obtained by connecting to the service connector as shown in the drawing. For information on how to connect to the signal receiving unit, refer to instruction manual that comes with the

Service connector

ALL• RCU : SUB PCB CHK. TEST RUN

RCU : MAIN NORMAL

Fig. 7-23

2013_M_I

dedicated service check lines.

Table 7-2

Lamp

OPERATION

TIMER STANDBY

Bright Cause of Trouble

lamp lamp lamp

●●● No power supply or mis-wiring of signal receiving unit. S.C.* errors between the indoor unit’s controller (PCB) and

O ●●

signal receiving unit.

●●O S.C. errors between indoor and outdoor units.

● OOAlternately Indoor unit protector is activated.

O ● O Alternately Outdoor unit protector is activated.

● O ● Compressor protector is activated.

O ● O Concurrent Mis-setting of indoor unit. O V O Concurrent Mis-setting of outdoor unit.

* S.C. : Serial communications

(WL)

OPERATION lamp

STANDBY lamp

S4359146

TIMER lamp

FILTER lamp

2014_M_I

Fig. 7-24

7-16. Basic Wiring Diagram

Terminal 3P

Indoor unit

Outdoor unit

CAUTION

Group control

: Ground (earth)

Connection wiring for group control

No. 1

Install wiring correctly (incorrect wiring will damage the equipment).

Standard remote control

Indoor unit

No. 2

Inter-unit control wiring

Indoor unit

No. 3

● Use shielded wires for inter-unit control wiring and

ground the shield on both sides. (Fig. 7-25) Otherwise misoperation because of noise may occur.

Shielded wire

ground

Multiple remote control

Indoor unit

No. 8

2036_M_I

Fig. 7-25

ground

0797_M_I

Indoor unit 1

Group-control wiring

● Wiring procedure

Install the wiring according to the above wiring diagram.

● The address setting is automatically executed after turning on the system. An indoor unit address is assigned to each indoor unit.

● Operation takes place successively at intervals of 1 second, by using combinations of the address setting of each unit.

Indoor unit 2

Indoor unit 7

Inter-unit wiring

Indoor unit 8

(Main) (Sub)

2031_M_I

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7-17. Wiring System Diagram for Group Control

This diagram shows when several units (maximum of

8) are controlled by a signal receiving unit (master

unit). In this case, a signal receiving unit can be connected at any indoor unit.

Signal receiving unit

Connection wiring for group control

Indoor unit

No. 2

Indoor unit

No. 3

Wire joint (2 wires)

Inter-unit control wiring

Indoor unit

No. 1

Outdoor unit

Indoor unit

No. 8

Wiring procedure

Wire according to the left diagram:

● Address setting is executed automatically when the outdoor unit is turned on.

● Each successive unit will respond at one-second intervals following the order of the group address when the remote controller is operated.

: Ground (earth)

2037_M_I

● Group control using 2 signal receiving unit.

It does not matter which of the 2 signal receiving unit you set as the main controller.

Signal receiving unit (main)

Wire joint (2 wires)

Indoor unit

No. 1

: Ground (earth)

Connection wiring for group control

Indoor unit

No. 2

(sub)

Indoor unit

No. 3

Indoor unit

No. 8

When using multiple signal receiving unit (up to 2 of them can be used), one is the main signal receiving unit and the other is the sub-signal receiving unit.

● To set up a sub-signal receiving unit, change its remote control address connector (RCU. ADR) located on its PCB from main to sub position (main: when shipped from factory).

2038_M_I

(WL)

S4359146

7-18. Wiring System Diagram for Multiple

■ When Installing Multiple

This multiple system is used for operating the unit(s) at different positions. (A maximum of 2 signal receiving unit can be installed.)

● Setting method

To execute this control, make the setting according to the following procedure.

(1) Of the two installed signal receiving unit, make

one the main signal receiving unit (factoryshipped state).

(2) On the other signal receiving unit, change the

address connector on the PCB from main to sub position. In this state, it functions as a sub-signal receiving unit.

● Basic wiring diagram

Install wiring correctly

CAUTION

(incorrect wiring will damage the equipment).

● To operate 1 indoor unit with 2 signal receiving unit set at different places.

Signal receiving unit

Remote control cable terminal board

Earth

(sub)(main)

(Option)

Indoor unit

Connection wiring

2015_M_I

S4359146

2016_C_I

Spacer

3-17/32 in. or more

4-29/32 in. or more

Wall

Wiring outlet

Switch box

HOW TO INSTALL THE WEEKLY TIMER (

OPTIONAL PART

8-1.

Mounting Dimensions for Continuous Installation

● For vertical continuous installation, the space between the weekly timer and the remote controller must be 1 in. or more.

CAUTION

)

Do not supply power to the unit or try to operate it until the tubing and wiring to the outdoor unit is completed.

● Do not twist the control

wiring with the power wiring or run it in the same metal conduit, because this may cause malfunction.

● Install the weekly timer

away from sources of electrical noise.

Fig. 8-1

● Install a noise filter or

take other appropriate action if electrical noise affects the power supply circuit of the unit.

The mounting position for the weekly timer should be located in an accessible place for control. Never cover the weekly timer or recess it into the wall.

8-2. When Using a Wall Box for Flush Mounting

● If local codes allow, this weekly timer can be mounted using a conventional wall box for flush mounting.

(1) Remove the flat-top screw on the bottom of the

back case. When you open up the decorative cover, you will see two gaps under the weekly timer. Insert a coin into these gaps and remove

the back case. (Figs. 8-2, 8-3)

(2) Attach the back case with the 2 small screws

provided. Using a screwdriver, push open the cut-outs on the back case. These holes are for screws. Use the spacers and take care not to tighten the screws excessively. If the back case does not sit well, cut the spacers to a suitable

thickness. (Fig. 8-2)

(3) Connect the 4 wires to the weekly timer 4P

terminal base (see next page).

(4) To finish, fit the back tabs of the back case into

the weekly timer and mount it using the flat-top screw.

Weekly timer

M4 × 31/32 in. Screws (2)

Decorative cover

Control panel

Gap

Coin

Concealed box

Spacer

Fig. 8-2

Gap

2017_C_I

(WL)

2018_M_I

Fig. 8-3

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8-3. Wiring Diagram

(For wiring, always use the supplied wires)

Timer terminal

Weekly timer

Connection wiring (supplied)

Timer terminal

Remote

controller

System

controller

0806_M_I

● Layout

The weekly timer and remote controller may be located, either one on the left or right sides.

● Wiring procedure

Do the wiring according to the following procedure.

8-4. Test Run Setting

● After installation, check the output state of the weekly timer with the “FORCED OPR.” switch (OFF to ON) located on the rear side of its PCB. After confirming normal operation, turn the “FORCED OPR.” switch back to OFF without fail.

FORCED OPR. switch

STA

PUL

ON OFF ON OFF

2021_M_I

Fig. 8-5

1 Loosen the retaining screw of the lead wire of the

weekly timer, remove the collar, and connect the suppplied connection wiring to the timer terminal (4P connector) of the weekly timer. Place the supplied connection wiring into the groove neatly, and then refasten the collar.

To indoor unit Remote control cable terminal board

To weekly timer

Connection wiring (supplied)

To remote controller

Connector

2019_M_I

2 Pass the supplied connection wiring through the

lead-wire drawing-out port on the bottom case of the weekly timer, then run it behind the wall and connect it to the timer terminal (4P terminal) of the remote controller. (Fig. 8-4)

(Use the supplied collar for fastening the wire of the remote controller.)

Connection wiring (supplied)

8-5. Memory Back Up Function for Power Failure

Compensation

● This weekly timer keeps the settings of operating buttons memorized; so that after a power failure the operation can be restarted in the same set state by pressing the PROGRAM button.

● Using the “Back Up” After installation, confirm that the BAT.BKUP switch on the rear side of the weekly timer’s PCB is ON.

STA

PUL

Back-up switch

ON OFF ON OFF

2022_M_

Fig. 8-6

Lead wire drawing out port

2020_C_I

Fig. 8-4

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HOW TO INSTALL THE SYSTEM CONTROLLER (OPTIONAL PART)

Do not supply power to the unit or try to operate it until the tubing and wiring to the outdoor unit is completed.

9-1. System Controller Installation

● Do not twist the control

CAUTION

wiring with the power wiring or run it in the same metal conduit, because this may cause malfunction.

● Install the system con-

troller away from sources of electrical noise.

● Install a noise filter or

take other appropriate action if electrical noise affects the power supply circuit of the unit.

● If local codes allow, this system controller can be mounted using a conventional wall box for flush mounting.

(1) Remove the flat-top screw on the bottom of the

back case. When you open up the decorative cover, you will see two gaps under the system controller. Insert a coin into these gaps and remove the back case. (Figs. 9-1, 9-2)

System controller

Coin

M4 × 1-3/16 in. Screws (2)

Gap

Switch box (no cover)

Back case

Flat-top Screw

2041_C_I

Fig. 9-1

Gap

2042_M_I

(2) Connect the wires to terminal base of the system

controller (see next page).

(3) Attach the back case with the 2 M4 screws

provided.

(4) To finish, fit the back tabs of the back case into

the system controller and mount it using the flattop screw.

Fig. 9-2

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9-2. Electrical Wiring

How to connect electrical wiring

(1) Connect B1, B2 to indoor PCB CRV connector

using accessary 2P connector. (*No polarity) Total wire legth is less than 985 ft. and size is

AWG#18.

(2) Connect B5, B6 to indoor unit 2P terminal base.

(*No polarity). Wire size is AWG#18.

● Basic wiring

B1: B2: B3: Not be used B4: Auxiliary of inter-unit control wiring B5: B6:

Power supply: DC12V *No polarity To CRV connector (CN91) on indoor PCB

Inter-unit control wiring. (Low voltage) To indoor unit 2P terminal base (U1, U2) *No polarity

● Terminals for remote monitoring

A1: Input for turning on air conditioners concurrently. A2: Input for turning off air conditioners concurrently.

Common input for turning air conditioners on or off.

A3:

B1 B2 B3 B4 B5 B6

System controller

A1 A2 A3 A4 A5 A6

Accessary connector

Wire joint connection

U1 U2

2P terminal base

Fig. 9-3

Indoor unit PCB

CRV (CN91: WHT)

Indoor unit

2044_M_I

B6 B5 B4 B3 B2 B1

A4: On operation state indicator output. A5: Alarm indicator output. A6: Common indicator output.

Basic wiring diagram of control wiring

● Max. 64 indoor units and 30 outdoor units can be connected in 1 system.

● Up to 10 system controller can be connected in 1 system.

Fig. 9-4

RC1

Inter-unit control wiring

1-1

1-2 1-3 2-1 2-2 2-3 3-1

RC2 RC3

Connector for weekly timer (Under the terminal)

3005_M_I

System controller

2045_M_I

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9-3. Address Switch Setting

SW1

Main/sub selection switch

OFF: System controller operates as main controller. ON: System controller operates as sub-controller.

ALL/ZONE mode selection switch

ALL mode: All indoor units can be controlled by system controller ZONE 1, 2, 3, 4 mode: Indoor units in one of zone 1, 2, 3, or 4 can be controlled by system controller. All indoor units cannot be set.

OFF

ON ON ON ON

OFF

ALL mode ZONE 1 mode ZONE 2 mode ZONE 3 mode ZONE 4 mode

Central control/Remote control mode selection switch.

OFF: Central control mode. Individual setting by remote controller can be inhibited by system controller.

ON: Remote control mode. Setting by system controller is inhibited by other central control equipments.

OFF OFF

OFF

OFF OFF

ON ON

OFF

2 3 4

SW1

5 6 7 8

Central control Main/Sub selection switch (OFF: Main, ON: Sub)

1 When AMY adaptor etc. is used with system controller,

set the switch to ON position.

2 When only one system controller is used, set the switch to

OFF position.

3 Except 1, when multiple system controllers are used,

set only one system controller to OFF position others to ON position. ALL mode system controller to be OFF position. (recommended)

(Central control) button operation switch

OFF: (Central control) button operation is permitted. ON : button operation is inhibitted.

*All switches are OFF position at shipment.

2046_M_I

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SW2

Weekly timer input switches.

System controller operation can be set when weekly timer activates (ON/OFF).

Switch No.

System controller operation

132

Timer OFF→ON Timer ON→OFF

1 2

All ON

No change Individual control of all indoor units

All OFF

All OFF All indoor units to be 1*

OFF

OFF OFF

OFF

to be permitted

All OFF and all

Ditto

indoor units to be

OFF

All indoor units to

Ditto

be 2*

OFF

All OFF and all

Ditto

indoor units to be

OFF

Incase of Remote control mode, use 1 or 2. In case of ZONE 1, 2, 3, 4 mode, ALL, all indoor units means one of ZONE 1, 2, 3, 4.

: 1 (Central control 1) means ON/OFF operation cannot

excecute by remote controller.

: 2 (Central control 2) means ON/OFF, MODE change.

Temp. setting cannot be excecuted by remote controller.

OFF

2 3 4

SW2

5 6 7 8

Auxiliary switch

Must be set to OFF position.

Beep tone switch

OFF: Beep tone when each button is pushed. ON: No tone when each button is pushed.

Indication switch

Normally set to OFF position. When set to ON position, indication is not displayed on LCD of system controller.

*All switches are OFF position at shipment.

2047_M_I

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9-4. Mode Setting

According to function of each system controller, set SW1 as Fig. 9-5.

(1) Central control/Remote control mode

● Central control mode

System controller is used as central control equipment. Individual setting by remote controller can be inhibitted by system controller

● Remote control mode

System controller is used as remote controller. Setting by system controller is inhibitted by other central control equipments.

(2) ALL/ZONE mode

● ALL mode

All indoor units can be controlled by system controller.

● ZONE mode

Indoor units in one of ZONE 1, 2, 3 or 4 can be controlled by system controller

(3) Function of system controller is 10 types accord-

ing to combination of central control/remote control mode and ALL/ZONE mode setting as the table 9-1.

Central control

mode

3 4 5 6

ON OFF

ALL

central control

3 4 5 6

ON OFF

ZONE1

central control

3 4 5 6

ON OFF

ZONE2

central control

3 4 5 6

ON OFF

ZONE3

central control

3 4 5 6

ON OFF

ZONE4

central control

Remote control

mode

3 4 5 6

ON OFF

ALL

remote control

3 4 5 6

ON OFF

ZONE1

remote control

3 4 5 6

ON OFF

ZONE2

remote control

3 4 5 6

ON OFF

ZONE3

remote control

3 4 5 6

ON OFF

ZONE4

remote control

Fig. 9-5

Inter-unit control wiring

2 16

18 32

34 48

50 64

ZONE1

central control

address 1-16

ZONE2

central control

address 17-32

ZONE3 central control address 33-48

ZONE4 central control address 49-64

2048_M_I

(4) Stick the system controller unit label in a con-

spicuous position.

Table 9-1

Central control Remote control ALL 1. ALL/Central 6. ALL/Remote ZONE1 2. ZONE1/Central 7. ZONE1/Remote ZONE2 3. ZONE2/Central 8. ZONE2/Remote ZONE3 4. ZONE3/Central 9. ZONE3/Remote ZONE4 5. ZONE4/Central 10. ZONE4/Remote

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9-5. How to Perform Zone Registration

To operate the system controller properly, zone registration is required after finishing the test run (and after setting all indoor unit addresses) using one of the following methods.

(a) Zone registration using the remote controller (RCS-SH80UG)

Refer to page 73

(b) Zone registration using the system controller (SHA-KC64UG)

Refer to page 74

Refer to page 75

For methods (a) and (b), you should make a zone registration table manually before performing the registration as shown on the next page.

For method (c), zone registration is executed automatically, proceeding from small indoor unit address and small central addresses to larger numbers in numerical order. For example:

Central address 123456 ZONE–group 1-1 1-2 1-3 1-4 1-5 1-6 Indoor unit address 1-1 1-2 2-1 2-2 2-3 3-1

NOTE 1. An indoor unit address is assigned to each indoor unit during automatic address

operation. Each indoor unit address combines an R.C. address and indoor unit number as follows:

: Indoor unit address (UNIT No.)1 – 1 Indoor unit No. Refrigerant circuit No. (R.C. address)

2084_M_I

This address is displayed on remote controller for UNIT No. when the UNIT button is pressed.

2. The central address represents the zone and group number. These addressed are assigned in ascending numerical order.

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(a) Zone registration using the remote controller

(RCS-SH80UG)

(Determination of central address)

● In this case, after confirming which indoor unit is connected to the remote controller and that the air conditioner in the OFF state, you set the central addresses one at a time.

● If the system has no remote controller, connect a remote controller to the system temporarily. Then follow this procedure.

NOTE

The indoor unit address must already have been set before performing zone registration. If necessary, refer to the Installation Manual supplied with the outdoor unit.

(1) Press the and buttons at the same time

of the remote controller for more than 4 seconds. (2) Do not press buttton. (3) Once in this mode, the UNIT No., CODE No., No.

of SET DATA and indications will flash on

the display as shown Fig. 9-6.

NOTE

In case of group control “ALL” instead of “UNIT No.” will flash on the display. Select the main indoor unit address by pressing the button once.

(4) Set CODE No. to 03 using the and

( ) buttons.

NOTE

The CODE No. 03 must be selected to perform zone registration using the remote controller.

(5) Set the Central address which you want to assign

to the indoor unit address using the and

( ) buttons according to the zone

registration table.

(6) Press the button. The CODE No. and Central

address changes from flashing to ON state. If you make mistake, then press the button and reset the central address.

Fig. 9-6

2049_M_I

(7) Press the button to finish zone registration.

For example, in this case

Indoor unit address: 1–8 Central address : 17 (ZONE 2, GROUP 1)

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2050_M_I

Fig. 9-7

(b) Zone registration using the system controller

(SHA-KC640G)

● In this case, you set all central addresses by system controller at once manually.

(1) Press the and

buttons at the same

ZONE

time for more than 4 seconds.

and CODE No. C1 will flash.

(2) After confirming that CODE No. C1 is displayed,

press the button. Once in this mode, a change takes place as Fig. 9-8.

(3) Select the zone and group No. which you want to

set with

and (GROUP)

ZONE

buttons. If already set, press the buttons.

(4) Set the unit No. (Indoor unit address) with

and buttons, according to the zone registration table.

R.C. No. ................... button

Indoor unit No........... button

If data is registered the unit No. is displayed.

ZONE

SELECT

ZONE

Fig. 9-8

3 4

3 4 7

GROUP

If no data is registered no number is displayed.

Selected group No. if no data is registered.

2051_M_I

(5) Press the button.

GROUP No. turns ON and UNIT No. (Indoor unit address) changes from flashing to ON state. UNIT No. is registered to selected ZONE No. and GROUP No.. If you make mistake, then press the button

and reselect the ZONE, GROUP and UNIT No.

(6) Register the other UNIT No. in the same way by

following the steps (3) to (5).

(7) Finally, complete the registration by pressing the

button.

flashes for a few minutes, then OFF.

SELECT

ZONE

GROUP

2052_M_I

For example, in this case

Zone 3, group No. 7 Unit No. (indoor unit address) 2-8

Unit No. 2-8 is registered to zone 3-group 7.

Fig. 9-9

S4359146

controller (SHA-KC64UG)

(1) Press the and

buttons at the same

ZONE

time for more than 4 seconds.

and CODE No. C1 will flash.

(2) Select CODE. No. C2 by pressing and

( ) button and press the button.

C2 changes from flashing to ON state and

automatic zone registration will start. (3) Registered GROUP No. will be disappeared all. (4) Central address will be assigned from small

indoor unit address to large one in numerical

order automatically.

Finishing automatic zone registration,

changes from flashing to OFF. (5) If the error is happened, the “CHECK” starts

flashing and zone registration finishes at this

time. Press the button. (6) Finally, complete automatic zone registration

mode by pressing the button.

flashes for a few minutes, then OFF.

ZONE

SELECT

ZONE

3 4

ZONE

Fig. 9-10

GROUP

2053_M_I

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■

How to check overlapping of central address No.

(1) Press the and

ZONE

buttons at the same

time for more than 4 seconds.

and CODE No. C1 will flash.

(2) Select CODE. No. C3 by pressing ,

( ) button and press the button.

C3 changes from flashing to ON state and will flash. Then auto. overlap checking will start .

(3) If C3 changes from ON to flashing and

stops flashing and disappears, there is no overlapping. Then finally, complete the auto overlap checking mode by pressing the button.

(4) If some of GROUP No., ZONE No. and UNIT No.

flash, you should try again the zone registration.

1 Select CODE No. C1 by pressing ,

( ) button and press the button.

2 Select the flashing GROUP No. with ZONE

and GROUP button. Then press the button and reselect the ZONE, GROUP and UNIT No.

3 Then finally, complete the auto. overlap

checking mode by pressing the button.

ZONE

SELECT

ZONE

3 4

ZONE

Fig. 9-11

GROUP

2054_M_I

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■ ZONE registration table

ZONE GROUP

1 2 3 4 5 6 7

9 10 11 12 13 14

Central

address

1 2 3 4 5 6 7 8

9 10 11 12 13 14

Indoor unit

address

(UNIT No.)

Unit location ZONE GROUP

1 2 3 4 5 6 7

9 10 11 12 13 14

Central

address

33 34 35 36 37 38 39 40 41 42 43 44 45 46

Indoor unit

address

(UNIT No.)

Unit location

15 16

1 2 3 4 5 6 7

9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

15 16

1 2 3 4 5 6 7 8

9 10 11 12 13 14

47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

15 16

31 32

15 16

63 64

NOTE 1. Assign indoor unit addresses to the desired positions (central addresses)

manually.

2. For group control, only the main indoor unit should be assigned. Sub indoor units cannot be assigned.

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9-6. Connection with Other Equipments

System controller Equipment

NameDigital input/output terminals

Input/output

Input/output item

ON/OFF output Alarm output Potential tree A contact, static (relay output)

ON/OFF

Alarm

CPEV

AWG#16

Input/outputTerminal Terminal Example

Wire length: less than 330 ft.

Contact capacity DC 30V, 0.5A

All ON input All OFF input Pulse (photo compler input)

Control input Status output

Contact capacity DC 24V, 10mA

Output common

ALL ON (+)

ALL OFF (+)

Input common

CPEV

AWG#16

9-7. Memory Back Up Switch

Check the back up switch is ON for back side of PCB by system controller.

9-8. Test Run

(1) Power on for all indoor units. Next, power on for

system controller.

will flash, checking the indoor unit address

automatically.

(2) If group No. displayed on system controller is not

same as indoor unit No.* which is connected, see Fig. 9-5 and setting again.

*In case of group control, main unit No. only.

Digital input

+24

COM

Pulse width: more than 984 ft./sec. Wire length: less than 330 ft.

2055_M_I

ON OFF

Back up switch

Back up battery

2056_M_I

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10. HOW TO PROCESS TUBING

The narrow tubing side is connected by flare nut, and the wide tubing side is connected by brazing.

10-1. 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.

10-2. Flaring Procedure with a Flare Tool

(1)

Cut the copper tube to the required length with a tube cutter. It is recommended to cut about 12 – 20 in. longer than the estimated tubing length.

(2) 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. 10-1)

NOTE

When reaming, hold the tube end downward and be sure that no copper scraps fall into the tube. (Fig. 10-2)

Deburring

Before After

Fig. 10-1

Copper tubing

Reamer

0126_M_

(3) Remove the flare nut from the unit and mount it

on the copper tube.

(4) Make a flare at the end of copper tube with a flare

tool.* (Fig. 10-3) *Use “RIGID®” or equivalent.

NOTE

A good flare should have the following characteristics:

● inside surface is glossy and smooth.

● edge is smooth.

● tapered sides are of uniform length.

10-3. Precaution before Connecting Tubes Tightly

(1) Apply a sealing cap or water-proof tape to pre-

vent dust or water from entering the tubes before they are used.

(2) Apply refrigerant lubricant to the matching sur-

faces of the flare and union before connecting them together. This helps to reduce gas leaks. (Fig. 10-4)

(3) For proper connection, align the union tube and

flare tube with each other, then screw in the flare nut lightly at first to obtain a smooth match. (Fig. 10-5)

0127_M_I

Fig. 10-2

Flare tool

Fig. 10-3

Apply refrigerant lubricant here and here

0129_M_

Fig. 10-4

Flare nut

Copper tubing

0128_M_I

● Adjust the shape of the narrow and wide tubes using a tube bender at the installation site and connect them to the each tubing side valve using a flare nut.

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Union Flare nut

Fig. 10-5

0130_M_I

10-4. Precautions during Brazing

● Replace air inside the tube with nitrogen gas to prevent copper oxide film from forming during the brazing process.

● Do not allow the tubing to get too hot during the brazing process. The nitrogen gas inside the tubing may overheat, causing refrigerant system valves to become damaged. Therefore allow the tubing to cool between brazings.

Indoor unit

Torque wrench

Fig. 10-6

Insulation

Spanner

Outdoor unit

0131_C_I

10-5. Connecting Tubing between Indoor and

Outdoor Units

(1) Tightly connect the indoor side refrigerant tubing

with the outdoor side tubing. (Fig. 10-6)

(2)

To fasten the flare nuts, apply specified torque as:

Table 10-1

Tube Dia.

1/4" (6.35 mm)

3/8" (9.52 mm)

3/4" (19.05 mm)

Tightening Torque

Approx. 120 — 160 Ibs-in.

(140 — 180 kg-cm)

Approx. 300 — 360 lbs-in.

(340 — 420 kg-cm)

Approx. 870 — 1040 lbs-in.

(1000 — 1200 kg-cm)

10-6. Insulating the Refrigerant Tubing

Always insulate tubes after

CAUTION

draining water and completing leak tests on all connection points.

Important

To avoid condensation and water leaks, the wide tube (gas line) must be insulated with the supplied insulation materials.

Thickness: Min. 5/16 in.

Wide tube

Seal (supplied)

Unit side insulator

Flare nut

Drain insulator and clamp. Large (supplied)

Narrow tube

Fig. 10-7

Refrigerant tubing

Insulation tape (white)

(supplied)

Flare insulator (supplied)

Vinyl clamps (supplied)

Fig. 10-8

Refrigerant tubing and insulator (not supplied)

Drain pipe and insulator (not supplied)

Thickness: Min. 5/16 in.

0999_C_I

Tube insulator (not supplied)

1015_X_I

Taping the flare nuts

Wind white insulation tape around the flare nuts at the wide tube connections. Place the seal (supplied) on the unit. Then cover up the tubing connections with the flare nut insulator, and cover the gap at the union with the supplied black insulation tape. Finally, fix the insulator at both ends with vinyl clamps. (Fig. 10-8)

Insulation material

The material used for insulation must have good insuIation characteristics, be easy to use, be age resistant, and must not easily absorb moisture.

After a tube has been insu-

CAUTION

lated, never try to bend it into a narrow curve because it can cause the tube to break or crack.

Packing clamp. Small hose band (supplied)

Seal

Flare insulator

Insulation tape

Vinyl clamp

Never grasp the drain or refrigerant connecting outlets when moving the unit.

Fig. 10-9

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1373_X_I

10-7. Taping the Tubes

Tubing

Apply putty here

0137_C_I

(1) At this time, the refrigerant tubes (and electrical

wiring if local codes permit) should be taped with armoring tape in 1 bundle. To prevent the condensation from overflowing the drain pan, keep the drain hose separate from the refrigerant tubing.

(2) Wrap the armoring tape from the bottom of the

outdoor unit to the top of the tubing where it enters the wall. As you wrap the tubing, overlap half of each previous tape turn. (Fig. 10-10)

(3) Clamp the tubing bundle to the wall, using 1

clamp about every 3 feet.

Insulated tubes

Clamp

Drain hose

NOTE

Do not wind the armoring tape too tightly since this will decrease the heat insulation effect. Also ensure that the condensation drain hose splits away from the bundle and drips clear of the unit and the tubing.

10-8. Finishing the Installation

After finishing insulating and taping over the tubing, use sealing putty to seal off the hole in the wall to prevent rain and draft from entering. (Fig. 10-11)

Fig. 10-10

Fig. 10-11

1124_M_I

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11. AIR PURGING

Air and moisture in the refrigerant system may have undesirable effects as indicated below.

● pressure in the system rises

● operating current rises

● cooling (or heating) efficiency drops

● moisture in the refrigerant circuit may freeze and

block capillary tubing

● water may lead to corrosion of parts in the refrigerant system

Therefore, the indoor unit and the tubing between the indoor and outdoor units evacuated to remove

must be checked for leaks

air and moisture.

and

Pressure gauge

Manifold valve

Lo Hi

Charge hose

Nitrogen gas cylinder (In vertical standing position)

■ Air Purging with a Vacuum Pump (for Test Run)

Preparation

Check that each tube (both narrow and wide) between the indoor and outdoor units has been properly connected and all wiring for the test run has been completed. Remove the valve caps from both the wide and narrow service valves on the outdoor unit. Note that both narrow and wide tube service valves on the outdoor unit are kept closed at this stage.

Leak test

(1) With the service valves on the outdoor unit

closed, remove the 1/4 in. flare nut and its bonnet on the wide tube service valve. (Save the flare nut and its bonnet for reuse.)

(2) Attach the nitrogen gas cylinder to the service

port of the wide tube via a manifold valve with pressure gauges. (See Fig. 11-2)

Use a manifold valve for air

CAUTION

purging. If It is not available, use a stop valve for this purpose. The “Hi” knob of the manifold valve must always be kept closed.

Outdoor unit

Service valve

tube

Indoor unit

3-way valve is used for 3642 type.

Fig. 11-1

Manifold valve

Pressure gauge

Cap

Lo Hi

Wide tubeNarrow

2090_C_I

(3)

Pressurize the system to about 150 P.S.I.G. with dry nitrogen gas and close the cylinder valve when the gauge reading reaches about 150 P.S.I.G. Then, test for leaks with liquid soap.

Narrow tube

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Wide tube

Nitrogen gas cylinder

1370_C_I

Fig. 11-2

To avoid nitrogen entering

CAUTION

the refrigerant system in a liquid state, do not use the nitrogen cylinder up side down. Use the cylinder in a vertical standing position. (Refer to the previous page.)

(4) Do a leak test of all joints of the tubing (both

indoor and outdoor) and both wide and narrow service valves. Bubbles indicate a leak. Wipe off the soap with a clean cloth after the leak tests.

(5) After the system is found to be free of leaks,

relieve the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder. When the system pressure is reduced to normal, disconnect the hose from the cylinder.

Pressure gauge

Manifold valve

Lo Hi

Vacuum pump

Evacuation

(1) Attach the charge hose end (described in the

preceding steps) to the vacuum pump to evacuate the tubing and indoor unit. Confirm that the “Lo” knob of the manifold valve is open. Then, run the vacuum pump. The operation time for evacuation varies with the tubing length and capacity of the pump. The following table shows the required time for evacuation:

Required time for evacuation

when 30 gal/h vacuum pump is used

If tubing length is

less than 50 ft.

45 minutes or more

If tubing length is longer than 50 ft.

90 minutes or more

NOTE

The required time in the above table is calculated on the assumption that the ideal (or target) vacuum condition is around 10 mmHg abs.

(2) When the desired vacuum is reached, close the

“Lo” knob of the manifold valve and turn off the vacuum pump.

Outdoor unit

Service valve

tube

Indoor unit

3-way valve is used for 3642 type.

Wide tubeNarrow

Fig. 11-3

Manifold valve

Vacuum gauge

Cap

Lo Hi

2091_C_

Narrow tube

Wide tube

Vacuum pump

0540_C_I

Fig. 11-4

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Charging additional refrigerant

● Charge additional refrigerant (calculated from the narrow tube length as shown in Sec. 1-5) using the wide tube service valve with the system in cooling operating mode. (Fig. 11-5)

● Use a balance to measure the refrigerant accurately.

Finishing the job

(1) With a hex wrench, turn the narrow tube service

valve stem counterclockwise to fully open the valve. (Fig. 11-6)

(2) With a screwdriver, turn the wide tube service

valve stem counterclockwise to fully open the valve. (Fig. 11-6)

To avoid gas from leaking

CAUTION

when removing the charge hose, make sure the stem of the wide tube is turned all the way out (“BACK SEAT” position).

(3) Loosen the charge hose connected to the wide

tube service port (1/4 in.) slightly to release the pressure, then remove the hose.

Outdoor unit

Hex wrench

Max. allowable tubing length at shipment

Narrow tube

Wide tube

Narrow tube

165 ft.

Fig. 11-5

Wide tube

Fig. 11-6

Indoor unit

Required additional charge

1396_M_I

CLOSE OPEN

1002_C_I

(4) Replace the 1/4 in. flare nut and its bonnet on the

wide tube service port and fasten the flare nut securely with an adjustable wrench or box wrench. This process is very important to prevent gas from leaking from the system.

(5) Replace the valve caps on both the wide and

narrow service valves and fasten them securely.

This completes air purging with the vacuum pump. The air conditioner is now ready for a test run.

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12. TEST RUN

12-1. Preparing for Test Run

● Before attempting to start the air conditioner,

check the following:

(1) All loose matter is removed from the cabinet

especially steel filings, bits of wire, and clips.

(2) The control wiring is correctly connected and all

electrical connections are tight.

(3) The protective spacers for the compressor used

for transportation have been removed. If not, remove them now.

(4) The transportation pads for the indoor fan have

been removed. If not, remove them now.

(5) The power has been connected to the unit for at

least 5 hours before starting the compressor. The bottom of the compressor should be warm to the touch and the crankcase heater around the feet of the compressor should be hot to the touch. (Fig. 12-1)

(6) Both the wide and narrow tube service valves are

open. If not, open them now. (Fig. 12-2)

(Power must be turned ON at least 5 hours before attempting test run)

Power mains switch

Fig. 12-1

Narrow tube service valve (3-way valve)

Wide tube service valve (ball valve)

Fully OPEN Fully OPEN

Fig. 12-2

0765_C_I

1371_C_I

● Test run procedure ❏ The purpose of the test run function is to let you control the operation of the unit directly without the

thermostat turning the unit on or off. As indicated in the following procedure, switch out of TEST RUN when you are finished, or the air conditioner can be damaged because it will not cycle on and off normally.

❏ To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes

after power is applied or the unit is turned OFF.

a Press the (TEST RUN) button on the remote

Alarm message

controller. (Fig. 12-3)

b Press the (ON / OFF operation) button

to start the test run.

c Press the (MODE) button to select either

COOL or HEAT mode.

d When the test run has started, “TEST” shows on

display of the remote controller.

e During the test run, the air conditioner runs

continuously and the thermostat does not control the system.

f After the test run, press the button once

again to cancel this mode and check that “TEST” is not shown on the display.

The TEST RUN button is

CAUTION

used only for servicing the air conditioner. Do not press this button for normal operation, or the system may be damaged.

TEST RUN/CHECK button

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ON/OFF operation button

Fig. 12-3

MODE button

2057_C_I

12-2. PCB Setting

● Setting of outdoor control PCB

(A) Standard control (single outdoor unit)

In case of single outdoor unit installation, even if in case of twin, triple or quartet type (2, 3 or 4 indoor units), no setting necessary. Keep factory shipment state (R.C. address is set in “0”).

In this case, auto. address operation takes place automatically for the first time when the power is switched on. This takes about a few minutes.

(B) Group control (Multiple outdoor units)

In case of group control (up to 8 indoor units can be connected with one remote controller), before turning the power supply on set the R.C. address with S2, S3 on the outdoor control PCB.

R.C. address: Refrigerant circuit address 1 ~ 30.

Regarding the example of R.C. address for group control, please refer to page 43 and sec. 12-3 (page 87).

controller)

In case of central control (when using the system controller,that is, when linking outdoor units in a network), (a) Before turning the power supply on, set the

R.C. address with S2, S3 on the outdoor control PCB.

(b) Remove the short plug (CN006, 2P Black)

from all outdoor units except any one of outdoor unit.

Regarding the example of R.C. address for central control and the position of CN006, please refer to sec. 12-3. (page 87).

● Setting of indoor control PCB

No setting necessary. Each indoor unit address (UNIT No.: R.C. – No.) is decided after auto. address operation.

Indoor unit No. Refrigerant Circuit No. (R.C. address)

Manual setting for indoor unit address can be performed also by remote controller.

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12-3. R.C. Address Setting Method

Outdoor unit R.C. address setting method

In case of group control or central control, set the R.C. address to 1, 2, 3, ... according to the No. of outdoor units.

Outdoor control PCB

CN006 (2P Black)

Refrigerant circuit address (factory setting = 0)

Refrigerant circuit address (black)

: S2

Refrigerant circuit address (2P DIP switch, green or Blue)

position

ON side

OFF side

: S3

A. ADD (S1): Automatic address setting start button Used for central control (link system) and group control (Normally, not used)

2093_C_I

position

R.C. address

00 auto address

(“0” when shipped from factory)

R.C. address R.C. address

(S3 2P dip switch, green or blue) (S2 Rotary switch, Black)

ON side

Both OFF Set to 0

OFF side

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12-4. Automatic Address Setting Method

— For group control and central control with multiple outdoor units —

Carry out automatic address setting with the remote controller.

(1) All auto. address operation

1 Press the and ( ) buttons at

the same time for more than 4 seconds.

2 Press the button after confirming the

CODE No. AA (CODE No. AA: All Auto. address operation).

After addresses are automatically set in order for the outdoor units from No. 1 to No. 30, the system returns to the normal stopped state.

(2) Individual auto. address operation for each

refrigerant circuit 1 To select each refrigerant circuit individually

and set addresses automatically, press the

and ( ) buttons at the same time for more than 4 seconds, then press the , ( ) button once to set CODE No. A1. (CODE No. A1: Auto. address operation)

2 Select R.C. No. which you want to execute

the auto. address operation with button.

12-5. Displaying Indoor / Outdoor Unit Combina-

tion Numbers

Display the indoor / outdoor unit address after automatic address setting. (1) When installing multiple units, match the indoor

unit address numbers and the outdoor R.C. address numbers and display them at an easy-tocheck location (near the nameplate) with an oilbased magic marker or other indelible marker so that the individual indoor and outdoor unit combinations can be checked.

Example:

Outdoor Unit 1 – Indoor Units 1-1, 1-2, 1-3, ....

Outdoor Unit 2 – Indoor Units 2-1, 2-2, 2-3, ....

(2) This is necessary for maintenance. Always label

these. *Check indoor unit address with the remote controller. Press the button for at least 4 seconds and check the indoor unit address with the button. (Each time you press the

button, the address changes 1-1, 1-2, ...

2-1, 2-2, ...) The fan for only the selected indoor unit turns on at high speed, so check which indoor unit runs and label the indoor unit address. (If there is 1 outdoor unit, the addresses are 1-1, 1-2, ...)

When you press the button again, the system returns to normal remote control mode.

3 Press the button. The auto. address

operation will start. CODE No. changes from flashing to ON state.

4 If the error is happened during the operation,

the alarm message will display. Check and remove the cause. If you want to interrupt the operation, press the button then the

unit stands in waiting mode (Press the button).

5 If the auto. address operation finishes, the

display will disappear.

6 Execute the operation of the other R.C. line

in the same way by following the above steps 2 to 3.

7 Complete the auto. address operation by

pressing the button.

NOTE

Required time for auto. address operation:

In case of group control : In case of central control

a few minutes for each R.C.

: max. about 20 min. for

each R.C.

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12-6. Test Run Procedure

Multiple remote

Start

control?

Yes

Turn on RCU address SW of sub remote control unit

Recheck the test items before test operation.

Check the indoor and outdoor unit combination (wiring). (Sec. 5-3)

Yes Yes

Single type?

(One indoor unit and one

remote controller for one

outdoor unit)

Group control

for multiple outdoor

units?

Yes

Central control

for multiple outdoor

units?

Yes

Go next R.C. line

Finish all

R.C. line?

Yes

Go next R.C. line

Finish all

R.C. line?

(Sec. 12-7)

units for one outdoor

Multiple indoor

units?

Set the outdoor unit R.C. address. Turn on power supply switch.

Press A. ADD (S1) button (See P87).

Execute auto. address operation with the remote controller.

CN4: Open (*) Set the outdoor unit R.C. address. Turn on power supply switch.

Press A. ADD (S1) button (See P87).

Execute auto. address operation with the remote controller.

Turn on power supply for indoor units side first Then turn on power supply for outdoor unit side.

(Sec. 12-2 (B))

(Sec. 12-4)

(Sec. 12-2 (C))

(Sec. 12-4)

Display the combination number. (Sec. 12-5)

Set the remote controller to test operation. (Sec. 12-1)

(Sec. 12-8, 9, 10)

NOTE

Is operation possible?

Yes

Return the remote controller to normal.

End

Check according the self-diagnostics function table, see Sec. 12-8, 9, 10, and if there is a location to correct, correct it.

Note: Check the indoor side drain water.

1) One of CN006 of all linked outdoor units shold be short.

2) In case of using system controller, zone registration is required after finishing Test run. Regarding the zone registration, please refer to page 74 and 75.

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0509_M_I

12-7. Items to Check Prior to Test Run

(1) Turn on the power supply switch more than 5 hours before in order to charge the crank case heater. (2) Fully open the outdoor service valve after making the leak inspection of field connected tubing, vacuuming,

and gas charging if necessary.

(3) Check the capacity code setting.

* The factory setting is as shown in the table. Double check it. * The capacity code is set by S4 (green or blue, 4P DIP switch) on outdoor control PCB.

Outdoor control PCB

S4 (green or Blue) capacity code (4P DIP switch)

2 3 4

ON side

OFF side

S4. Capacity code

No. Outdoor PCB

Model No. 1 2 3 4

24 type ON ON ON OFF 36 type OFF ON OFF ON 48 type ON ON OFF ON

2094_C_I

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12-8. The Main Alarms of Mis-wiring & Mis-setting

Remote controller

display Nothing

displayed

* Ref: Alarm “P9” is not generated if the remote controller is set at test run.

12-9. The Main Alarms of Unit Troubles

• In case of individual remote control

• Remote controller not properly connected.

• Power supply not ON.

• Remote controller not properly connected.

• Wiring connection fault of indoor/outdoor units

• Power supply of outdoor unit not ON.

• Combination of indoor/outdoor units is wrong. *Power supply of some indoor unit is not ON.

——

(*)

•Improper wiring connections of ceiling panel

Trouble detected Remote controller display

In case of group control

• Wiring connection fault of some indoor/outdoor units

Cause

inside the group

In case of multiple remote control

• 2 main remote controllers set.

Indoor protection Fan motor protection thermostat P1

Outdoor protection Fan motor protection thermostat P2

Compressor protection thermostat Abnormal discharge temp. P3 High pressure switch P4

Indoor protection Float switch P10

Indoor sensor Open/or damaged F1-F3 Outdoor sensor Open/or damaged F4-F9 Compressor Compressor motor is overloaded. H1

protection

12-10. The Main Alarms of Power Supply Troubles

Compressor motor is locked. H2 Compressor current detection circuit is abnormal. H3

Low pressure protector is activated. H6

Cause Remote controller display

Outdoor protection Power supply voltage is abnormal. P2

(More than 260 V or less than 160 V between L and N phase) Negative phase or defective phase P5 Compressor contactor (Mg SW) is chattering. H18

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■ Basic Functions of the Service Valves

0549_C_I

0550_C_I

Action

Shipping and air purging

Operating and test running the air conditioner

Narrow Tube Service Wide Tube Service

Valve (3-Way) Valve (Ball Valve)

CLOSED CLOSED

O-ring

Stem

0546_C_I

Fully Fully OPEN OPEN

0547_C_I

Half Fully OPEN OPEN

Measuring pressure and gas charging

Narrow tube service valve Wide tube service valve

O-ring Valve cap

Stem

0989_C_I

2-Way Valve

CH2442

O-ring

3-Way Valve

CH3642, CH4242

Valve cap

Stem

1372_C_I

0548_C_I

Service port (B)

0554_C_I

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13. PUMP DOWN

Pump down means collecting all refrigerant gas in the system back into the outdoor unit without losing ant of the gas. Pump down is used when the unit is to be moved or before servicing the refrigerant circuit.

Pump down procedure

Be sure to carry out pump

CAUTION

(1) Connect the low pressure side (wide tube valve

service port) charging hose of the manifold valve to the service port (B) on the wide tube service valve.

(2) Using a hex wrench, turn the narrow tube service

valve clockwise all the way to close the service valve.

(3) Press the operation button and start cooling

operation.

down with the unit in cooling mode.

(4) When the low pressure gauge reading falls to

14.2 to 7.1 psi (1 to 0.5 kg/cm2), fully close the wide tube valve stem with a standard screwdriver. Then quickly stop the unit.

(5) Disconnect all gauges and hoses, and replace

the bonnets and the valve caps as they were previously.

(6) Purge all air remaining inside the tubing before

operating the air conditioner.

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Sanyo KH2442, XH4242, KH3642, CH4242, UH2442 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual