INSTALLATION INSTRUCTIONS
– Split System Air Conditioner –
COOL/DRY Model
Contents
Model Combinations
Page
Combine indoor and outdoor units only as listed
below.
IMPORTANT!
Please Read Before Starting .................................. 2
Indoor Units
Outdoor Units
C0951
1. GENERAL .......................................................... 3
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
KS0951
CL0951
1-3. Optional Copper Tubing Kit
KS1251
C1251
1-4. Type of Copper Tube and Insulation Material
1-5. Field Wiring
CL1251
Power Source:
1-6. Additional Materials Required for Installation
60 Hz, single-phase, 115 V
2. INSTALLATION SITE SELECTION ................... 4
2-1. Indoor Unit
KS1852
C1852
2-2. Outdoor Unit
CL1852
2-3. Baffle Plate for the Outdoor Unit
Power Source:
60 Hz, single-phase, 230/208 V
3. HOW TO INSTALL THE INDOOR UNIT ............ 6
3-1. Remove the Rear Panel from the Unit
3-2. Make a Hole
3-3. Install the Rear Panel on the Wall
3-4. Remove the Grille to Install the Indoor Unit
3-5. Shape the Indoor Side Tubing
3-6. Wiring Instructions
5-7. Finishing the Installation
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
6. AIR PURGING................................................... 18
I Air Purging with a Vacuum Pump (for Test Run)
I Basic Function of the Service Valves
I Pump Down
3-10. Drain Hose
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 15
7. REMOTE CONTROL UNIT INSTALLATION
POSITION ......................................................... 22
7-1. Mounting on a Wall
4-1. Wiring Instructions for the Outdoor Unit
5. REFRIGERANT TUBING.................................. 16
5-1. Use of the Flaring Method
5-2. Flaring Procedure with a Flare Tool
5-3. Caution before Connecting Tubes Tightly
5-4. Connecting Tubing between Indoor and
Outdoor Units
5-5. Insulation of Refrigerant Tubing
5-6. Taping the Tubes
IMPORTANT
Power source for C0951, CL0951, C1251 and
CL1251 is 60 Hz, single-phase 115V.
In Canada
SANYO FISHER COMPANY
SANYO Canada Inc.
A DIVISION OF SANYO NORTH AMERICA CORPORATION 300 Applewood Crescent, Concord
21605 Plummer Street
Ontario, L4K 5C7, Canada
85264189593004 © SANYO 2002 Chatsworth, CA 91311 U.S.A.
W
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.
5. Carpenter’s level
6. Sabre saw or key hole saw
7. Hacksaw
8. Core bits
9. Hammer
10. Drill
1-1. Tools Required for Installation (not supplied)
1. Standard screwdriver
11. Tube cutter
12. Tube flaring tool
13. Torque wrench
14. Adjustable wrench
15. Reamer (for deburring)
2. Phillips head screwdriver
3. Knife or wire stripper
4. Tape measure
1-2. Accessories Supplied with Unit
Table 1
Parts
Figure
Q’ty
Parts
Figure
Truss-head
Phillips
5/32 × 5/8" (4 × 16 mm)
Q’ty
Parts
Remote
Figure
Q’ty
Tapping
screw
Rawl plug
12
12
1
control unit
Remote
control
holder
AAA alkaline
battery
Drain hose
adapter
1
2
1
1
Hex
wrench*
* Packed in the outdoor unit.
1-3. Optional Copper Tubing Kit
2. Foamed polyethylene insulation for the specified
O.D. copper tubes as required to precise length of
tubing. Wall thickness of the insulation should be
not less than 0.3 in. (8 mm).
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.
1-5. Field Wiring
1-4. Type of Copper Tube and Insulation Material
Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring. Refer to 3-6. Wiring
Instructions for details.
If you wish to purchase these materials separately from
a local source, you will need:
1. Deoxidized annealed copper tube for refrigerant
tubing as detailed in Table 2.
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
CAUTION
When cutting tubing, add approximately 12” to 16”
(30 cm to 40 cm) to each tube length to reduce
vibration between the air conditioning units.
Table 2
Narrow Tube
Wide Tube
Model
Outer Dia.
Thickness
Outer Dia.
Thickness
6.35 mm (1/4")
6.35 mm (1/4")
6.35 mm (1/4")
0.8 mm (0.0314")
0.8 mm (0.0314")
0.8 mm (0.0314")
9.52 mm (3/8")
12.7 mm (1/2")
0.8 mm (0.0314")
0.8 mm (0.0314")
C0951, CL0951
C1251, CL1251
C1852, CL1852
15.88 mm (5/8") 1.0 mm (0.0394")
3
1-6. Additional Materials Required for Installation
Indoor unit
1. Refrigeration (armored) tape
2. Insulated staples or clamps for connecting wire
(See local codes)
3. Putty
4. Refrigeration lubricant
5. Clamps or saddles to secure refrigerant tubing
Drain hose
2. Installation Site Selection
Outside drainage
2-1. Indoor Unit
Fig. 1
To prevent abnormal heat genera-
WARNING
tion and the possibility of fire, do
2" (5 cm) min.
*6" (15 cm) min.
not place obstacles, enclosures
and grilles in front of or surround-
ing the air conditioner in a way that
may block air flow.
2" (5 cm) min.
*6" (15 cm) min.
2" (5 cm) min.
*6" (15 cm) min.
Front View
*KS1852 only
AVOID:
Fig. 2
I direct sunlight.
Tubing length (L)
I nearby heat sources that may affect performance of the
INDOOR
UNIT
unit.
I areas where leakage of flammable gas may be expected.
Elevation
difference (H)
I places where large amount of oil mist exist.
OUTDOOR
UNIT
DO:
I select an appropriate position from which every corner of
Fig. 3a
the room can be uniformly cooled. (High on a wall is best.)
I select a location that will hold the weight of the unit.
CAUTION
Indoor unit
Wall
I select a location where tubing and drain hose have the
shortest run to the outside. (Fig. 1)
For stable operation of
the air conditioner, do
not install wall-mounted
type indoor units under
5 ft. (1.5 m) from floor
level.
I allow room for operation and maintenance as well as unre-
Minimum height
from floor level
5 ft. (1.5 m)
stricted air flow around the unit. (Fig. 2)
I install the unit within the maximum elevation difference (H)
above the outdoor unit and within a total tubing length (L)
from the outdoor unit as detailed in Table 3 and Fig. 3a.
Floor level
Fig. 3b
Table 3
Max. Allowable Tubing
Length at Shipment
(ft.)
Limit of Tubing
Length (L)
(ft.)
Limit of Elevation
Difference (H)
(ft.)
Required Amount of
Additional Refrigerant
(oz./ft.)*
Model
25
25
50
65
23
23
a) 0.16
b) 0.27
9,000 BTU
12,000/18,000 BTU
* If total tubing length becomes a) 25 to 50 ft. (max.), b) 25 to 65 ft. (max.) charge additional refrigerant (R22) by a) 0.16 oz./ft., b) 0.27 oz./ft.
No additional compressor oil is necessary.
4
2-2. Outdoor Unit
Exhaust fan
NO
AVOID:
Hot air
I heat sources, exhaust fans, etc. (Fig. 4)
I damp, humid or uneven locations.
DO:
Heat source
Outdoor unit
I choose a place as cool as possible.
I choose a place that is well ventilated.
I allow enough room around the unit for air intake/
Fig. 4
exhaust and possible maintenance. (Fig. 5a)
Obstacle above
CAUTION
Min.
Min.
7 ft.
(2 m)
7 ft.
Air intake
Min. 6" (15 cm)
Valve side
Min. 10"
(25 cm)
(2 m)
I Install the outdoor unit above snowfall line.
I Do not place objects on or sit on the out-
door unit. Also, never block the air
intake/outlet or exhaust. Distortion of the
outdoor unit or incomplete combustion
may result.
Min. 6"
(15 cm)
Air discharge
Min. 12"
(30 cm)
Ground
Min. 6 in.
(15 cm)
Air intake
I Do not introduce foreign matter into the air
intake/outlet or exhaust. Do not poke them
with such objects as a stick.
Fig. 5a
Anchor bolts
(4 pcs)
I provide a solid base (level concrete pad, concrete
block, 4 in. × 16 in. (10 × 40 cm) beams or equal), a
minimum of 4 in. (10 cm) above ground level to
reduce humidity and protect the unit against possible
water damage and decreased service life (Fig. 5b).
Min. 4"
(10 cm)
Air intake
Concrete
I use lug bolts or equal to bolt down unit, reducing
or equal
vibration and noise.
2-3. Baffle Plate for the Outdoor Unit
(CL×× models only)
NOTE
Fig. 5b
It is recommended to use baffle plates for models
CL1251, CL1852 and CL0951. The baffle plates are not
normally required for the other models.
6" min
Baffle
plate
Baffle
plate
When the outdoor unit is installed in a position exposed
to strong wind (like seasonal winds with low air temper-
ature in winter), baffle plates must be installed in front
of the outdoor unit. (Fig. 5c)
This unit is designed so that the fan of the outdoor unit
runs at low speed when the air conditioner is operated
at low outdoor air temperatures. When the outdoor unit
is exposed to strong wind, the system pressure drops
because of the freeze protector.
Air discharge
Fig. 5c
5
3. How to Install the Indoor Unit
3-1. Remove the Rear Panel from the Unit
(1) Remove and discard the set screw on the rear panel. (Fig. 6)
(2) Press the 2 I marks on the frame cover and disengage the sta-
tionary tabs from the frame. (Fig. 7)
(3) Remove the rear panel.
Set screw only for transportation
NOTE
Fig. 6
Tubing can be extended in 5 directions (KS0951, KS1251 and
KS1852) as shown in Fig. 8a or 8b. Select the direction you need
providing the shortest run to the outside unit.
Rear panel
3-2. Make a Hole
(1) Place the rear panel from the indoor unit on the wall at the loca-
tion selected. Make sure the panel is horizontal, using a carpen-
ter’s level or tape measure to measure down from the ceiling.
Wait until after cutting the hole before attaching the rear panel to
the wall.
Fig. 7
I marks
(2) Determine which side of the unit you should make the hole for
tubing and wiring. (Fig. 9)
KS0951, KS1251
Right-rear
tubing
(recommended)
(3) Before making the hole, check carefully that no studs or pipes
are directly run behind the spot to be cut.
Left
tubing
CAUTION
Left-rear
tubing
Right tubing
Fig. 8a
I Also avoid areas where electrical wiring or conduits are
Downward tubing
located.
KS1852
I Switching drain hose and drain cap
Left
tubing
(a) Locate the drain hose and the drain cap. (Fig. 8c)
Right-rear
tubing
(recommended)
(b) Remove the drain hose on the right side by pushing and
turning the hose connector counter-clockwise to release it.
(Fig. 8c)
(c) Apply moderate force to pull off the drain cap on the left
side. (If you cannot pull it off by hand, use a long-nose pli-
ers.)
Right tubing
Fig. 8b
Downward tubing
(d) Reattach the drain hose to the left side and the drain cap
to the right side. (Fig. 8c)
The above precautions are also applicable if tubing goes through the
wall in any other location.
Drain hose
In case of right-rear
Clamp
To slip on
Drain cap
60°
To remove
Fig. 9
Fig. 8c
6
(4) Using a sabre saw, key hole saw or hole-cutting drill
attachment, cut a hole in the wall. See Table 4 and
Fig. 10.
NOTE
Hole should be made at a slight downward slant to the
outdoor side.
Table 4
Indoor
side
Outdoor
side
Hole Dia.
2-9/16" (65 mm) / 3-5/32" (80 mm)
(5) Measure the thickness of the wall from the inside
edge to the outside edge and cut PVC pipe at a
slight angle 0.25 in. (6 mm) shorter than the thick-
ness of the wall. (Fig. 11)
Fig. 10
PVC pipe (locally purchased)
(6) Place the plastic cover (locally purchased) over the
end of the pipe (for indoor side only) and insert the
pipe in the wall. (Fig. 12)
3-3. Install the Rear Panel on the Wall
Cut at slight angle
Be sure to confirm that the wall is strong enough to sus-
pend the unit.
Fig. 11
INSIDE
OUTSIDE
See either Item a) or b) below depending on the wall type.
Wall
Plastic
cover
a) If Wooden Wall
PVC pipe
Slight
angle
(1) Attach the rear panel to the wall with the 10 screws
provided. (Fig. 13)
If you are not able to line up the holes in the rear
panel 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. (5 mm) dia. holes
in the panel over the stud locations and then mount
the rear panel.
Fig. 12
(2) Double check with a ruler or carpenter’s level that
the panel is level. This is important to install the unit
properly. (Fig. 14)
Fig. 13
Fig. 14
(3) Make sure the panel is flush against the wall. Any
space between the wall and unit will cause noise
and vibration.
b) If Block, Brick, Concrete or Similar Type Wall
Make 3/16 in. (4.8 mm) dia. holes in the wall. Insert
rawl plugs for appropriate mounting screws. (Fig. 15)
3/16" (4.8 mm)
dia. hole
Rawl plug
Fig. 15
7
3-4. Remove the Grille to Install the Indoor Unit
KS0951, KS1251
Basically, these models can be installed and wired with-
out removing the grille. If access to any internal part is
needed, follow the steps as given below:
How to remove the grille
(1) Set the flap in the horizontal position.
(2) Unscrew the screws. (Fig. 16a or 16b)
(3) Remove the grille. (Fig. 17)
Screw cover
Flap
(Up and down air direction louvre)
Fig. 16a
(a) Hold both corners of the air intake grille, then
pull out and up to open.
KS1852
(b) Pull the lower part of the grille toward you to
remove.
(c) Use a standard screwdriver to push up the 3
tabs to remove the grille.
How to replace the grille
(1) Close the flaps.
Fig. 16b
(2) Reinstall the grille into the lower part while aligning
its tabs on the upper part. (Fig. 18) Insert the tabs in
the slots and push the lower part of the grille back
into position.
Air intake grille
(3) Press at each of the 4 tabs to completely close the
grille. Make sure that the grille and frame are firmly
fitted together. (Fig. 19)
Fig. 17
Fig. 18
Fig. 19
8
3-5. Shape the Indoor Side Tubing
1) Arrangement of tubing by directions
a) Right or left tubing
Frame
Cut out the corner of the right/left frame with a
hacksaw or the like. (Figs. 20 and 21)
Left tubing
outlet
b) Right-rear or left-rear tubing
In this case, the corner of the frame need not be
cut.
2) To mount the indoor unit on the rear panel:
Fig. 20
Hang the 2 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)
Frame
3-6. Wiring Instructions
General precautions on wiring
Right tubing
outlet
1) Before wiring, confirm the rated voltage of the unit
as shown on its nameplate, then carry out the
wiring closely following the wiring diagram.
2) Provide a power outlet to be used exclusively for
each unit, with a power supply disconnect and cir-
cuit breaker for overcurrent protection provided in
the exclusive line.
Fig. 21
3) To prevent possible hazard due to insulation failure,
the unit must be grounded.
4) Each wiring connection must be done tightly and in
accordance with the wiring system diagram. Wrong
wiring may cause the unit to misoperate or become
damaged.
Fig. 22
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.
9
3-7. Recommended Wire Length and Diameter
Regulations on wiring diameter differ from locality to
locality. For field wiring requirements, please refer to
your local electrical codes. Carefully observe these reg-
ulations when carrying out the installation.
WIRING SYSTEM DIAGRAM
C0951, CL0951, C1251, CL1251 Models
INDOOR
NOTE
OUTDOOR UNIT
Terminal
INDOOR UNIT
Terminal
(Inter-unit)
Power lines
Refer to the wiring system diagram (Fig. 23)
115V
115V
115V
Refer to your local codes or in the absence of local
codes with the National Electric Code: ANSI/NFPA70.
1
2
3
1
Fuse
2
3
4
Disconnect
switch
(Field supply)
L
N
5
6
WARNING
G
G
Grounding
line
I Be sure to comply with local codes on running
the wire from the outdoor unit to the indoor unit
(size of wire and wiring method, etc.).
C1852, CL1852 Models
I Each wire must be firmly connected.
INDOOR
I No wire should be allowed to touch refrigerant
tubing, the compressor, or any moving part.
OUTDOOR UNIT
INDOOR UNIT
Terminal
(Inter-unit)
Power lines
Terminal
1
230/208 V
230/208 V
230/208 V
1
2
3
Fuse
2
3
4
5
6
WARNING
Disconnect
switch
(Field supply)
L1
L2
I To avoid the risk of electric shock, each air
conditioner unit must be grounded.
G
G
Grounding
line
CAUTION
Fig. 23
I Be sure to connect the power supply line to the
outdoor unit as shown in the wiring diagram. The
indoor unit draws its power from the outdoor
unit.
3-8. Wiring Instructions for Inter-unit Connections
a) Remove the grille. (See 3-4. Remove the Grille to
Install the Indoor Unit on page 8.)
Rear
panel
Wall
Plastic
cover
b) 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. 10 in. (25
cm) to extend from the wall face. (Fig. 24)
Wiring
Never fix the wiring by any
10 in.
(25 cm)
CAUTION
means before the indoor unit
is fully seated on the rear
panel.
Fig. 24
10
c) Remove the screws to open the cover plate secur-
ing the electrical component box. (Figs. 25a, 25b,
25c and 25d)
KS0951, KS1251
KS0951, KS1251
Cover
plate
Electrical
component box
Cover
plate
d) Insert the wrapped tubing into the hole in the wall.
e) Hang the indoor unit on the rear panel.
f) Using a Phillips screwdriver, take out the screws on
the earth plate. (Fig. 26a KS0951, 1251 models
only) Remove the earth plate.
Terminal
plate
Earth plate
Electrical
component box
g) Remove the lock nut from the conduit connector.
Insert the conduit connector through the opening
from the underside of the electrical component box.
After insertion, Fit the screw at the top of the con-
duit connector into the cut-out. (Fig. 26b). Position
the earth plate over the conduit connector, allowing
the connector and wires to extend through the hole
in the plate. Next, attach the conduit connector to
the earth plate by replacing and tightening the lock
nut (Figs. 26c and 26d). Then re-attach the earth
plate to the electrical component box with the 2
screws.
Fig. 25b
Fig. 25a
KS1852
KS1852
Electrical
component box
Cover
plate
Cover
plate
Terminal
plate
Earth plate
h) Give some play to the inter-unit wiring from the out-
door unit to the corresponding terminals on the termi-
nal base. (See Wiring System Diagram on page 10.)
Electrical
component box
Fig. 25c
KS0951, KS1251
Fig. 25d
WARNING
Top of conduit
connector
KS1852
I Be sure to refer to the Wiring System Diagram
label inside the electrical component box and
carry out the correct field wiring. Wrong wiring
can cause the unit to misoperate or result in a fire
hazard.
Earth
plate
Screw
Screw
hole
I Check local electrical codes and any specified
wiring instructions or limitations.
Fig. 26a
KS0951, KS1251
i) Fix cover plate and cover plate and back into posi-
tion with their screws.
Fig. 26b
Inter-unit
wiring
NOTE
Earth
plate
KS1852
When closing the air intake grille, press on both corners
and the center. (Fig. 27)
Lock nut
Inter-unit
wiring
Top of conduit
connector
Earth
plate
Lock
nut
Fig. 26c
Top of conduit
connector
Fig. 27
Fig. 26d
11
Loose wiring may cause the termi-
nal to overheat or result in unit mal-
function. A fire hazard may also
exist. Therefore, be sure all wiring
is tightly connected.
WARNING
When connecting each power wire to the corresponding termi-
nal, follow the instructions “How to connect wiring to the termi-
nal” and fasten the wire securely tight with the fixing screw of
the terminal plate.
9/32" (7 mm)
(ACTUAL
SIZE)
STRIP
SIZE
Fig. 28
How to connect wiring to the terminal
a) For Indoor Unit
(1) Cut the wire end with a cutting pliers, then strip the insu-
lation to expose the wire about 9/32 in. (7 mm). See the
label (Fig. 28) near the terminal plate.
Solid wire
Loop
(2) Using a screwdriver, loosen the terminal screw on the ter-
minal plate.
Insulation
(3) Insert the wire and tighten the terminal screw completely
using a screwdriver.
Fig. 29
Stranded wire
b) For Outdoor Unit
Ring
Connector
I For solid core wiring (or F-cable)
(1) Cut the wire end with a cutting pliers, then strip the insu-
lation to expose the solid wire about 15/16 in. (25 mm).
(Fig. 29)
Fig. 30
(2) Using a screwdriver, remove the terminal screw(s) on the
terminal plate.
Twist wire ends
(3) Using the pliers, bend the solid wire to form a loop suit-
able for the terminal screw.
(4) Shape the loop wire properly, place it on the terminal
plate and fix it securely with the removed terminal screw
using a screwdriver.
I For stranded wiring
Fig. 31
(1) Cut the wire end with a cutting pliers, then strip the insu-
lation to expose the stranded wiring about 3/8 in. (10 mm)
and tightly twist the wire ends. (Figs. 30 and 31)
Special
washer
Screw
(2) Using a screwdriver, remove the terminal screw(s) on the
terminal plate.
Screw and
special washer
Ring connector
Terminal plate
(3) Using a ring connector fastener or pliers, securely clamp
each stripped wire end with a ring connector. (Fig. 30)
Ring
connector
Wire
(4) Place the ring connector wire, and replace and tighten the
removed terminal screw using a screwdriver. (Fig. 32)
Wire
Fig. 32
12
3-9. Mounting
(1) To install the indoor unit, mount the indoor unit onto
the 2 tabs on the upper part of the rear plate.
(2) Hold down the air discharge outlet and press the
lower part of the indoor unit until it clicks to secure-
ly fasten to the 2 tabs on the lower part of the rear
plate. (Fig. 33)
Push
NOTE
Fig. 33
For tubing, choose either the right or left tubing direc-
tion and follow the steps below. Also, extend the sup-
port on the back of the indoor unit as a stand to make
your work easier. (Fig. 34)
I Right-side tubing
(1) Shape the refrigerant tubing so that it can easily go
into the wall hole. (Fig. 35)
Stand
Fig. 34
(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 rear panel. (Fig. 36)
Rear panel
Cover
(3) Carefully bend the tubing (if necessary) to run
along the wall in the direction of the outdoor unit
and then tape as far as the fittings. (See Caution
on page 17.) The drain hose should come straight
down the wall to a point where water runoff won’t
stain the wall.
Refrigerant
tubing
Inter-unit
wiring
Drain hose
(4) Connect the refrigerant tubing to the outdoor unit.
(After performing a leak test on the connecting part,
insulate it with the tubing insulation (Fig. 37a)).
Also, refer to Section 5-4. Connecting Tubing
between Indoor and Outdoor Units.
Fig. 35
(5) Assemble the refrigerant tubing, drain hose, and
conduit (including inter-unit wiring) as shown in
Fig. 37b.
Fig. 36
Refrigerant tubing
Insulation
Fig. 37a
Conduit
Drain hose
Inter-unit wiring
Fig. 37b
13
To unmount indoor unit
Press the 2 I marks on the lower part of the indoor
unit and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 38)
3-10. Drain Hose
a) The drain hose should be slanted downward to the
outdoors. (Fig. 39)
b) Never form a trap in the course of the hose.
c) If the drain hose will run in the room, insulate the
hose with insulation* so that chilled condensation
will not damage furniture or floors. (Fig. 40)
Push
Fig. 38
* Foamed polyethylene or its equivalent is recom-
mended.
Slant
Do not supply power to the
unit or operate it until all
tubing and wiring to the
outside unit are completed.
WARNING
Indoor
unit
Drain
hose
Fig. 39
Risk of Electric Shock
Condensation
Insulation material
(locally purchased)
must be used.
Fig. 40
14
4. How to Install the Outdoor Unit
Terminal
block
Lock nut
First refer to Section 2. Installation Site Selection.
4-1. Wiring Instructions for the Outdoor Unit
Access panel
Regulations on wire size differ from locality to locality. For field
wiring requirements, please refer to your local electrical
codes. Make sure that the installation fully complies with all
local and national regulations.
Conduit
plate
(1) Remove access panel. (Fig. 41)
(2) Connect the power line according to the drawing on the
panel side.
(3) Be sure to size each wire allowing approx. 4 in. (10 cm)
longer than the required length for wiring. Store excess
wiring inside the cabinet.
Plug
Power supply
Inter-unit line
(4) When connections are completed, check that all connec-
tions are correct as shown in the wiring system diagram
on panel side.
Fig. 41
(5) Be sure to ground the unit according to your local codes.
CAUTION
I Examples of Incorrect Wiring
The following are examples of improper wiring that result in system misoperation. You should confirm that you have
wired the units correctly before beginning the test run.
Problem 1
Problem 2
Short circuit will occur after approx.
3 minutes and the power circuit fuse
blows.
I
Air conditioner will not operate.
I
Disconnect
(A)
Disconnect
(B)
Disconnect
switch
(C)
switch
switch
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
G
G
G
G
G
G
Grounding line
Grounding line
Grounding line
Outdoor unit
Outdoor unit
Outdoor unit
Indoor unit
Indoor unit
Indoor unit
Problem 3
Compressor will not start; only indoor unit will operate.
I
Disconnect
switch
Disconnect
switch
(D)
(E)
1
2
3
1
2
3
1
2
3
1
2
3
G
G
G
G
Grounding line
Grounding line
Outdoor unit
Outdoor unit
Indoor unit
Indoor unit
15
5. Refrigerant Tubing
Deburring
After
Before
5-1. 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.
5-2. Flaring Procedure with a Flare Tool
a) Cut the copper tube to the required length with a
tube cutter. It is recommended to cut approx. 12 to
20 in. (30 to 50 cm) longer than the tubing length
you estimate.
Fig. 42
Copper
tubing
b) Remove burrs at the end of the copper tube with a
tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 42)
Reamer
NOTE
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 43)
Fig. 43
c) Remove the flare nut from the unit and be sure to
mount it on the copper tube.
d) Make a flare at the end of copper tube with a flare
tool.* (Fig. 44)
Flare nut
Copper
tubing
(*Use “RIGID” or equivalent.)
NOTE
A good flare should have the following characteristics:
I inside surface is glossy and smooth.
I edge is smooth.
Flare tool
Fig. 44
I tapered sides are of uniform length.
5-3. Caution before Connecting Tubes Tightly
a) Be sure to apply a sealing cap or water-proof tape
to prevent dust or water from getting into the tubes
before they are used.
Apply refrigerant
lubricant here and here
Fig. 45
b) Be sure to apply refrigerant lubricant to the match-
ing surfaces of the flare and union before connect-
ing them together. This is effective for reducing gas
leaks. (Fig. 45)
c) For proper connection, align the union tube and
flare tube straight with each other, then screw in
the flare nut lightly at first to obtain a smooth
match. (Fig. 46)
Flare nut
Union
Fig. 46
16
5-4. Connecting Tubing between Indoor and
Outdoor Units
Torque wrench
a) Tightly connect the indoor side refrigerant tubing extend-
ed from the wall with the outdoor side tubing. (Fig. 47)
Spanner
Indoor unit
b) To fasten the flare nuts, apply specified torque as:
Table 5
Outdoor unit
Tube Dia.
Tightening Torque
Approx. 130 – 170 lbs. in. (150 – 200 kg cm)
Fig. 47
1/4" (6.35 mm)
3/8" (9.52 mm)
1/2" (12.7 mm)
5/8" (15.88 mm)
·
·
Approx. 300 – 340 lbs. in. (350 – 400 kg cm)
·
·
Approx. 430 – 470 lbs. in. (500 – 550 kg cm)
·
·
Approx. 520 – 560 lbs. in. (600 – 650 kg cm)
·
·
Insulation
5-5. Insulation of Refrigerant Tubing
IMPORTANT
Fig. 48
To prevent heat loss and wet floors due to dripping of con-
densation, both tubes must be well insulated with a prop-
er insulation material. (Fig. 48) The thickness of the insula-
tion should be a minimum 5/16" (8 mm). (Fig. 49)
Insulation
Thickness:
min. 5/16" (8 mm)
Min.
5/16" (8 mm)
After a tube has been insulated,
CAUTION
never try to bend it into a narrow
curve, as this may cause the tube to
break or crack.
Fig. 49
5-6. Taping the Tubes
a) At this time, the 2 refrigerant tubes (and electrical wire if
local codes permit) should be taped together with armor-
ing tape. The drain hose may also be included and taped
together as 1 bundle with the tubing.
Clamp
Insulated tubes
b) 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. 50)
Fig. 50
c) Clamp tubing bundle to wall, using 1 clamp approx. every
47 in. (120 cm).
Apply putty here
NOTE
Do not wind the armoring tape too tightly, since this will
decrease the heat insulation effect. Also, be sure the conden-
sation drain hose splits away from the bundle and drips clear
of the unit and the tubing.
Tubing
5-7. Finishing the Installation
Fig. 51
After finishing insulating and taping over the tubing, use seal-
ing putty to seal off the hole in the wall to prevent rain and
draft from entering. (Fig. 51)
17
6. Air Purging
Indoor unit
Air and moisture remaining in the refrigerant system have
undesirable effects as indicated below. Therefore, they must
be purged completely.
I pressure in the system rises
I operating current rises
Outdoor unit
I cooling (or heating) efficiency drops
I moisture in the air may freeze and block capillary tubing
I water may lead to corrosion of parts in the refrigerant sys-
tem
I Air Purging with a Vacuum Pump (for Test Run)
(1) Check that each tube (both narrow and wide tubes)
between the indoor and outdoor units have been properly
connected and all wiring for the test run has been com-
pleted. Note that both narrow and wide tube service
valves on the outdoor unit are kept closed at this stage.
Manifold valve
(2) Using an adjustable wrench or box wrench, remove the
valve caps from the service valve on both narrow and
wide tubes.
Pressure
gauge
Lo
Hi
(3) Connect a vacuum pump and a manifold valve (with pres-
sure gauges) to the service port on the wide tube service
valve. (Fig. 52)
Be sure to use a manifold valve for
CAUTION
air 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.
(4) With the “Lo” knob of the manifold valve open, run the
vacuum pump. The operation time for the vacuum pump
varies with tubing length and the capacity of the pump.
The following table shows the amount of time for evacua-
tion:
Vacuum pump
Fig. 52
Table 6
Required time for evacuation when capacity
of 100 liter/h vacuum pump is used
If tubing length is
If tubing length is
less than 33 ft. (10 m)
more than 33 ft. (10 m)
10 min. or more
15 min. or more
NOTE
The required time in the above table is calculated based on
the assumption that the ideal (or target) vacuum condition is
around 10 mmHg abs.
18
(5) With the vacuum pump still running, close the “Lo”
knob of the manifold valve. Then stop the vacuum
pump.
90° (1/4 turn)
Narrow tube
(6) With the accessory hex wrench, turn the valve
stem on the narrow tube service valve counter-
clockwise by 90 degrees (1/4 turn) for 10 seconds,
and then turn the stem clockwise to close it again.
(Fig. 53)
Hex wrench
Wide tube
Be sure to completely insert
CAUTION
Valve cap
the hex wrench before
Vacuum hose to manifold valve
attempting to turn the valve.
Fig. 53
(7) Leak test all joints at the tubing (both indoor and
outdoors) with liquid soap. Bubbles indicate a leak.
Be sure to wipe off the soap with a clean cloth.
(8) With the hex wrench, turn the wide tube service
valve stem counter-clockwise to fully open the
valve.
(9) Turn the narrow tube service valve stem counter-
clockwise to fully open the valve.
(10) Loosen the vacuum hose connected to the wide
tube service port slightly to release the pressure.
Then, remove the hose.
(11) Replace the bonnet and flare nut on the wide tube
service port and fasten the flare nut securely with
an adjustable wrench or box wrench. Next, mount
the valve cap and tighten it with a torque wrench
(the cap needs to be tightened with the torque of
170 lbs.•in. (200 kg•cm)). This process is very
important to prevent gas from leaking from the
system.
(12) Test run the air conditioner. (See next page.)
(13) While the air conditioner is running, apply liquid
soap to check for any gas leaks around the ser-
vice valves or caps.
(14) If there is no leakage, stop the air conditioner.
(15) Wipe off the soap on the tubing.
This completes air purging with a vacuum pump and
the air conditioner is ready for actual operation.
19
* How to Test Run the Air Conditioner.
KS0951, KS1251
(1) Switch on the power source.
(2) Press the ON/OFF button on the remote control
unit once.
ON
OFF
TEST
(3) Set the operation selector switch of the indoor unit
to the TEST position. This starts the fan, producing
uncooled forced air. (Figs. 54a and 54b)
(4) After 3 minutes, the system shifts into cooling
operation, and cool air will start to be felt. Cooling
operation during with the switch at the TEST posi-
tion is unaffected by the room temperature.
(5) After stopping the test run, turn the operation
selector switch of indoor unit to the OFF position
once, then move to ON position.
OPERATION
TIMER
(6) Press the ON/OFF button on the remote control
unit to stop the air conditioner.
NOTE
If the unit does not operate and the OPERATION lamp
on the unit is blinking after going through the proce-
dure, check the wiring between the units.
Fig. 54a
KS1852
Operation
selector
switch
ON
OFF
TEST
Fig. 54b
20
I Basic Function of the Service Valves
The basic function of the service valves are given in Table 7 below.
Table 7
Narrow Tube Service
Valve (2-Way)
Wide Tube Service
Valve (3-Way)
Action
O-ring
Valve cap
Stem
CLOSED
Shipping
Fully OPEN
Fully OPEN
CLOSED
Operating and
test running
the air conditioner
Measuring pressure
and gas charging
*
Air purging with
a vacuum pump
*
* The service port on the wide tube service
valve uses a Schrader core valve to access
the refrigerant system. Therefore, be sure to
use a hose connector which has a push-pin
inside. (Fig. 55)
Service valve
Hose with push-pin
PUSH
Fig. 55
I Pump Down
valve clockwise all the way to close the service
valve. (Be sure to confirm that the wide tube ser-
vice valve is fully open.)
Pump down means collecting all refrigerant gas in the
system back into the outdoor unit without losing any of
the gas. Pump down is used when the unit is to be
moved or before servicing the refrigerant circuit.
(3) Press the operation button and start cooling opera-
tion.
Pump Down Procedure
(4) When the low pressure gauge reading falls to 1 to
0.5 kg/cm2 (14.2 to 7.1 PSI), fully close the wide
tube valve stem with a standard screwdriver. Then
quickly stop the unit.
Be sure to carry out pump down with the unit in
cooling mode.
(1) Connect the Lo side charging hose of the manifold
valve to the service port on the wide tube service
valve.
(5) Disconnect all gauges and hoses, and replace the
bonnets and the valve caps as they were before.
(2) Using a hex wrench, turn the narrow tube service
21
7. Remote Control Unit Installation Position
The remote control unit can be operated from either a
non-fixed position or a wall-mounted position.
To ensure that the air conditioner operates correctly, do
not install the remote control unit in the following
places:
I In direct sunlight
I Behind a curtain or other place where it is covered
I More than 26 ft. (8 m) away from the air conditioner
I In the path of the air conditioner’s airstream
I Where it may become extremely hot or cold
I Where it may be subject to electrical or magnetic
interference
7-1. Mounting on a Wall
Truss-head
tapping screw
5/32 × 5/8" (4 × 16mm supplied)
1) Confirm the indoor unit beeps when the
ON/OFF button is pressed at the wall location
where the remote control unit is to be attached,
then attach the holder to the wall. (Fig. 56)
2) When taking out the remote control unit, pull it
from the holder.
Remote
control
unit holder
When using the remote control unit
•
Point the transmission portion of the remote
control unit at the receiver area of the indoor
unit when operating the remote control unit,
and during operation of the air conditioner.
Fig. 56
•
Do not place objects that may block the trans-
mitted signals between the receiver and the
remote control unit.
When mounting the remote control unit to
prevent theft
Truss-head
tapping screw
5/32 × 5/8" (4 × 16mm supplied)
1) Mount the holder to the wall with one of the
screws (using only the hole in the top of the
holder) (Fig. 57).
Holder
2) Remove the cover of the remote control unit
and take out the batteries. Next, place the
remote control unit in the holder.
3) Fasten both the remote control unit and holder
to the wall with the remaining screw (using the
hole in the bottom of the holder).
Holder
Fig. 57
4) Install the batteries in the remote control unit
and close the cover.
22
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