Sanyo CHDZR09053 manual

a Outdoor Units 85464369098000 ©SANYO 2008 – W -3W A Y ECO-i System Air Conditioner – R410A Models Indoor Units Class 9 12 18 24 36 48 X 4-W ay Air Discharge Semi-Concealed T ype XHX1252 XHX1852 XHX2452 XHX3652 XM 4-W ay Air Discharge Semi-Concealed T ype XMHX1252 XMHX1852 A 1-W ay Air Discharge Semi-Concealed T ype AHX0752 AHX0952 AHX1252 U C[...]

2 IMPOR T ANT! Please Read Bef ore Star ting This air conditioning system meets strict safety and oper- ating standards. As the installer or ser vice person, it is an impor tant par t of your job to install or service the system so it operates saf ely and efficiently . For safe installation and tr ouble-free operation, you m ust: ● Carefully read[...]

3 2. The standards f or minimum room v olume are as follows . (1) No par tition (shaded por tion) (2) When there is an effectiv e opening with the adjacent room f or ventilation of leaking refrigerant gas (open- ing without a door , or an opening 0.15% or larger than the respective floor spaces at the top or bottom of the door). (3) If an indoor un[...]

4 New tool? 1-2. Pre vent impurities including water , dust and o xide from entering the tubing. Impur ities can cause R410A refriger- ant deterioration and compressor def ects. Due to the features of the refrigerant and refrigerating machine oil, the pre vention of w ater and other impur ities becomes more impor tant than ev er . 2. Be sure to rec[...]

5 V alve Liquid 3-2. Use R410A exclusiv e cylinder only . Single-outlet valve (with siphon tube) Liquid refrigerant should be recharged with the cylinder standing on end as shown. New refrigerant R410A cannot be used f or earlier models 1. Compressor specifications are different. If recharging a R22 or R407C compressor with R410A, durability will s[...]

6 CONTENTS P age P age IMPORT ANT! . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Please Read Before Starting Check of Density Limit Precautions for Installation Using New Refrigerant New refrigerant R410A cannot be used for earlier models 1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 1-1. T ools Required for Ins[...]

7 P age 6. HOW TO PROCESS TUBING . . . . . . . . . . . . 76 6-1. Connecting the Refrigerant T ubing 6-2. Connecting T ubing Between Indoor and Outdoor Units 6-3. Insulating the Refrigerant T ubing 6-4. T aping the T ubes 6-5. Finishing the Installation 7. AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . . 80 Air Purging with a V acuum Pu[...]

8 T able 1-1 Outdoor Unit 1-2. Accessories Supplied See T ab les 1-1 – 1-8. 1-1. T ools Required for Installation (not supplied) 1. Flathead screwdriver 2. Phillips head screwdriver 3. Knife or wire stripper 4. T ape measure 5. Car penter’ s lev el 6. Sabre saw or ke y hole saw 7. Hacksa w 8. Core bits 9. Hammer 10. Drill 11. T ube cutter 12. T[...]

9 T able 1-2 (4-W ay Air Dischar ge Semi-Concealed) (X-T ype) T able 1-3 (1-W ay Air Dischar ge Semi-Concealed) T able 1-4 (Concealed Duct) ● Use M10 or 3/8" f or suspending bolts. ● Field supply f or suspending bolts and nuts. Part Name Figure Q’ty Remarks Full-scale installation diagram 1 Drain hose 1 Hose band 1 Drain insulator 1 1 Fl[...]

10 T able 1-5 (Concealed Duct High-Static Pressure) T able 1-6 (Ceiling-Mounted) Part Name Figure Q’ty Remarks 8 For suspending indoor unit from ceiling W asher 8 For suspending indoor unit from ceiling Nut 1 For gas tube Flare insulator 1 For liquid tube 1 For drain pipe connection Drain sock et Part Name Figure Q’ty Remarks Full-scale install[...]

11 H3 LM LA LF LB LC L4 LG LH LD L2 H2 L1 H1 LE L3 C B 4 1 2 3 5 6 7 40 1. Main tubing length LM = LA + LB … b 262 ft. 2. Main distribution tubes LC – LH are selected according to the capacity after the distribution joint. 3. Sizes of indoor unit connection tubing 1 – 40 are determined by the connection tubing sizes on the indoor units. T-joi[...]

12 *1: If future extension is planned, select the tubing diameter based on the total horsepo wer after e xtension. Howe ver e xtension is not possible if the resulting tubing size is two r anks higher. *2: The balance tube (outdoor unit tube) diameter is ø3/8" (ø9.52). *3: T ype 1 tubing should be used f or the refr igerant tubes. *4: If the[...]

13 1-7. Straight Equivalent Length of Joints Design the tubing system by ref erring to the following tab le for the straight equiv alent length of joints. T able 1-14 Straight Equivalent Length of Joints T able 1-15 Refrigerant tubing (Existing tubing can be used.) T ubing size (in. (mm)) Material O Material 1/2H • H ø1/4" (ø6.35) t1/32 (t[...]

14 Common solenoid valve kit ● Multiple indoor units under group control can utilize a solenoid v alve kit in common. ● Categories of connected indoor unit capacities are deter mined by the solenoid v alve kit. T able 1-17 Refrigerant Charge Amount at Shipment (for outdoor unit) DC CHDZ09053 CHDZ14053 CHDZR09053 CHDZR14053 (oz) 416 416 1-9. Sys[...]

15 W ARNING Always check the gas density limit for the room in which the unit is installed. 1-1 1. Check of Limit Density When installing an air conditioner in a room, it is necessar y to ensure that e ven if the refrigerant gas accidentally leaks out, its density does not e xceed the limit le vel f or that room. If the density could e xceed the li[...]

16 1-13. Optional Distribution Joint Kits See the installation instructions packaged with the distribution joint kit f or the installation procedure. T able 1-19 1. APR-CHRZP900BAB F or outdoor unit (Capacity after distribution joint is 307.100 BTU/h or less.) 11 - 1 3 / 1 6 11 - 1 3 / 1 6 13-25/64 D C B E DF 3/4 1-1/8 3/8 5/8 1/2 1 Size 7/8 1-1/4 [...]

17 2. APR-RZP224BAB Use: For indoor unit (Capacity after distrib ution joint is 76.400 BTU/h or less.) 3. APR-RZP680BAB Use: For indoor unit (Capacity after distrib ution joint is greater than 76.400 BTU/h and no more than 232.000 BTU/h.) 4. APR-RZP1350BAB Use: For indoor unit (Capacity after distrib ution joint is greater than 232.000 BTU/h and no[...]

18 Part Number Cover of relay kit 14 Relay kit 13 Cover of control box 12 Earth (M5 with washer) 11 Terminal for communication line 10 Terminal for power line 9 Base of control box 8 Service panel 7 Discharge tube: ID1/2" 6 Suction tube: ID5/8" 5 Liquid tube : ID3/8" 4 Suspension hook 3 Liquid tube : ID1/4" 2 Types and specifica[...]

19 Part Number Cover of relay kit 14 Relay kit 13 Cover of control box 12 Earth (M5 with washer) 11 Terminal for communication line 10 Terminal for power line 9 Base of control box 8 Service panel 7 Discharge tube: ID1/2" 6 Suction tube: ID5/8" 5 Liquid tube : ID3/8" 4 Suspension hook 3 Liquid tube : ID3/8" 2 Types and specifica[...]

20 Suspension bolt (3/8" or M10) (field supplied) Nut (field supplied) (3/8" or M10) W asher M4 screws (12 pcs.) Suspension hook Notes on Installation • Be sure to secure the v alve body b y using its str ucture with the suspension bolt, etc. • Install the v alve body within a distance of 98 ft. from the indoor unit. Some refrigerant [...]

21 1-15. Example of T ubing Size Selection and Refrigerant Charge Amount Additional refrigerant charging Based on the values in T ables 1-10, 11, 12, 15 and 16-2 use the liquid tubing siz e and length, and calculate the amount of additional refrigerant charge using the formula below . Required additional refrigerant charge (oz) = Necessar y Amount [...]

22 Checking of limit density Density limit is determined on the basis of the size of a room using an indoor unit of minimum capacity . F or instance, when an indoor unit is used in a room (floor area 161 ft. 2 × ceil- ing height 8.8 ft. = room volume 1417 ft. 3 ), the g raph at right shows that the minimum room v olume should be 2455 ft. 3 (floor [...]

23 2. SELECTING THE INST ALLA TION SITE 2-1. Indoor Unit A V OID: ● areas where leakage of flammable gas ma y be expected. ● places where large amounts of oil mist exist. ● direct sunlight. ● locations near heat sources which may aff ect the perf or mance of the unit. ● locations where external air ma y enter the room directly . This ma y[...]

24 Fig. 2-5 Fig. 2-6 Fig. 2-7 2-2. Outdoor Unit A V OID: ● heat sources, e xhaust fans, etc. ● damp , humid or unev en locations ● indoors (no-ventilation location) DO: ● choose a place as cool as possible . ● choose a place that is well v entilated. ● allow enough room around the unit f or air intake/ e xhaust and possible maintenance [...]

25 2-3. Precautions When Installing in Heavy Snow Areas a) The platf or m should be higher than the maximum snow depth. (Fig. 2-8) b) The 2 anchoring f eet of the outdoor unit should be used f or the platform, and the platf or m should be installed beneath the air-intake side of the outdoor unit. c) The platf or m f oundation must be solid and the [...]

26 33-3/16 2-11/64 15/16 97-29/32 65-53/64 (32-5/64) 35-15/64 (Maximum brac ket dimensions) 35-3/64 (Ceiling panel dimensions) 33-3/16 35-15/64 (Maximum brac ket dimensions) 35-3/64 (Ceiling panel dimensions) 35-3/64 (Ceiling panel dimensions) 2-11/64 15/16 97-29/32 65-53/64 (32-5/64) 35-3/64 (Ceiling panel dimensions) Air direction: Front directio[...]

27 97-29/32 65-53/64 36-7/64 45-5/16 (32-5/64) Air direction: F ront direction Air direction: Right direction Ceiling panel T op (Bef ore installation of snowf all protection duct) Ceiling panel F ront view Right side view F ront view Right side vie w Ceiling panel F ront view Right side view unit: in. unit: in. Note: Can be installed so that the a[...]

28 X 3. HOW TO INST ALL THE INDOOR UNIT ■ 4-W ay Air Dischar ge Semi-Concealed T ype (X T ype) 3-1. Preparation for Suspending This unit uses a drain pump . Use a car penter’ s lev el to check that the unit is le vel. 3-2. Suspending the Indoor Unit (1) Fix the suspension bolts securely in the ceiling using the method shown in the diag rams (Fi[...]

29 X Fig. 3-5 (2) The length of suspension bolts m ust be appropriate f or a distance between the bottom of the bolt and the bottom of the unit of more than 19/32 in. as shown in Fig. 3-5. (3) Thread the 3 hexagonal n uts and 2 washers (field supply) onto each of the 4 suspension bolts as shown in Fig. 3-5. Use 1 nut and 1 w asher f or the upper si[...]

30 X Fig. 3-9 11-3/16 in. or less (as shor t as possible) 33-15/32 in. or less 0 – 45° * Length of supplied drain hose = 9-27/32 in. Fig. 3-10 Upward gradient prohibited Fig. 3-11 Fig. 3-12 Suppor t pieces W ater (Approx. 0.3 gal) Drain pan outlet Drainage check Plastic container for w ater intake Over 3-15/16 in. ● In cases where it is necess[...]

31 X Air-intake grille Ceiling panel Air-intake grille hinge 1 1 3-6. How to Install the Ceiling P anel 3-6-1. Before Installing the Ceiling P anel Checking the unit position (1) Check that the ceiling hole is within this range: 33-55/64 × 33-55/64 to 35-53/64 × 35-53/64 in. (2) Use the full-scale installation diagram (from the packaging) that w [...]

32 X 3-6-2. Installing the Ceiling Panel After completing the wiring process, install the supplied wiring cov er before installing the panel. It is not possible to install the wiring cov er after install- ing the panel. The power m ust be tur ned ON in order to change the flap angle. (Do not attempt to mov e the flap by hand. Doing so ma y damage t[...]

33 X 3-6-3. Wiring the Ceiling P anel (1) Open the cov er of the electr ical component box. (2) Connect the 7P wiring connector (red) from the ceiling panel to the connector in the unit electrical component bo x. (Fig. 3-24) ● If the connectors are not connected, the Auto flap will not operate. Be sure to connect them securely . ● Check that th[...]

34 X 3-6-5. Checking After Installation ● Check that there are no gaps between the unit and the ceiling panel, or between the ceiling panel and the ceiling surf ace. Gaps may cause w ater leakage and condensation. ● Check that the wiring is securely connected. If it is not securely connected, the auto flap will not operate. (“P09” is displa[...]

35 XM ■ 4-Wa y Air Discharge Semi-Concealed T ype (XM T ype) 3-8. Preparation for Suspending This unit uses a drain pump . Use a car penter’ s lev el to check that the unit is le vel. 3-9. Suspending the Indoor Unit (1) Fix the suspension bolts securely in the ceiling using the method shown in the diag rams, b y attaching them to the ceiling su[...]

36 XM 3-11. Installing the Drain Piping (1) Prepare standard hard PVC pipe (O .D . 1-1/32") for the drain and use the supplied hose band to pre vent water leaks . (Fig. 3-33) The PVC pipe must be purchased separately . The transparent drain part on the unit allows you to check dr ainage. (2) Installing the drain hose ● T o install the drain [...]

37 XM 3-12. Checking the Drainage After wiring and drain piping are completed, use the follo wing pro- cedure to check that the w ater will drain smoothly . F or this, pre- pare a bu ck et and wiping cloth to catch and wipe up spilled water . (1) Connect power to the po wer ter minal board (R, S terminals) inside the electr ical component box. (2) [...]

38 XM ● If the scre ws are not sufficiently tight- ened, trouble such as that sho wn in the figure below ma y occur. Be sure to tighten the screws securely . ● If a gap remains between the ceil- ing surface and the ceiling panel ev en after the screws are tightened, adjust the height of the unit again. 3-13-3. Wiring the Ceiling Panel (1) Open [...]

39 XM 3-13-5. Checking After Installation ● Check that there are no gaps between the unit and the ceiling panel, or betw een the ceiling panel and the ceiling surf ace. Gaps ma y cause water leakage and condensation. ● Check that the wiring is securely connected. If it is not securely connected, the auto flap will not operate. (“P09” is dis[...]

40 A ■ 1-W ay Air Dischar ge Semi-Concealed T ype (A T ype) 3-14. Suspending the Indoor Unit (1) Follo w the diagrams to mak e the holes in the ceiling. (Figs. 3-52 and 3-53) (2) Depending on the ceiling type: ● Inser t suspension bolts as shown in Fig. 3-54 or ● Use existing ceiling suppor ts or construct a suitable suppor t as shown in Fig.[...]

41 A Fig. 3-57 Fig. 3-56 3-15. Placing the Unit Inside the Ceiling (1) Use the supplied M5 or 3/16" screws (4) to attach the full-size installation diag ram to the indoor unit suspension lugs, in order to obtain the ceiling opening dimensions f or suspending the unit. (Fig. 3-56) Caution: Piping and wiring work must be performed inside the cei[...]

42 A Fig. 3-60 Fig. 3-61 2-1/8 Suspension bolts T ubing side 19/32 19/32 2-1/8 Suspension bolts 25/32 25/32 25/32 Ceiling material ● The indoor unit includes a drain pump. Be sure to use a level gauge and verify that the unit is level. ● Before inserting the ceiling material, complete as muc h of the drain piping work and refrigerant tubing wor[...]

43 A Fig. 3-64 Air bleed v alve Fig. 3-66 Fig. 3-65 0 – 45° 11-13/16 in. or less 33-15/32 in. or less * Length of supplied drain hose = 9-27/32 in. Uphill slope Fig. 3-67 Suppor t brack et CA UTION 3-17. Checking the Drainage After wiring and drain piping are completed, use the f ollowing procedure to chec k that the water will drain smoothly . [...]

44 A Refrigerant tubing joint (gas tube) Refrigerant tubing joint (liquid tube) Drain pipe connection (Be sure to connect the supplied flexib le hose.) Inter-unit Control Wiring P ower supply outlet Fig. 3-69 ● Route the power wiring into the indoor unit thr ough the power inlet on the side of the unit. At this time, be sure that the wiring passe[...]

45 A Hook Screw Hinge Intake grille Slide Press on the tabs with a flathead (minus) screwdriver while pulling out the intak e grille. Screw Removing the intake grille Slide the intake g rille hooks (2 locations) in the direction of the arrow to open the intak e gr ille. (Fig. 3-72) When the intake g rille is open, press a flathead screwdriv er agai[...]

46 A (5) Align the installation holes on the panel with the bolt holes on the unit. (6) Inser t the supplied washer head bolts into the 4 panel installation holes, and tighten until the panel is securely f astened against the unit. (Fig. 3-77) (7) V er ify that the panel is securely f astened against the unit. ● At this time, mak e sure that ther[...]

47 A 3-19-3. Wiring the ceiling panel (1) Loosen the 2 screws on the electrical component bo x lid, and remov e the lid. (Fig. 3-80) (2) F asten the wir ing connector (7P , red) which comes out from the ceiling panel using the lead wire clamps (2 locations) on the unit. Then connect it to the connector (7P , red) inside the indoor unit electrical c[...]

48 U Fig. 3-84 Fig. 3-85 Indoor unit Inspection access 17-23/32 17-23/32 Air outlet duct flange Min. 9-27/32 Min. 15-3/4 Min. 25-19/32 22-27/32 A (Suspension bolt pitch) Electrical component box Refrigerant tubing Min. 9-27/32 ■ Concealed Duct T ype (U T ype) 3-20. Required Minimum Space for Installation and Service ● This air conditioner is us[...]

49 U Fig. 3-86 3-21. Suspending the Indoor Unit Depending on the ceiling type: • Inser t suspension bolts as shown in Fig. 3-86 or • Use e xisting ceiling suppor ts or constr uct a suitable support as shown in Fig. 3-87. Hole-in-anchor Hole-in-plug Concrete Inser t Suspension bolt (M10 or 3/8") (field supply) Fig. 3-87 Fig. 3-88 Ceiling ti[...]

50 U Fig. 3-91 Fig. 3-92 Drain hose (supplied) (not supplied) (not supplied) P acking (supplied) VP-25 Align the hose band with end of the hose, and tighten so that it does not contact the bead. Drainage check section on drain port (transparent) Hard PVC sock et VP-25 Hard PVC pipe PVC adhesive Bead Vinyl clamps Drain insulator (supplied) 3-22. Ins[...]

51 U Fig. 3-97 Inter-unit control wiring P ower supply outlet (4) When the check of drainage is complete , open the check pin (CHK) and remount the insulator and drain cap onto the drain inspection port. CA UTION Be careful since the fan will star t when you short the pin on the indoor control board. HT: Using the booster cable H: At shipment 177 A[...]

52 D ■ Concealed Duct High-Static Pressure T ype (D T ype) 3-25. Required Minimum Space for Installation and Service ● This air conditioner is usually installed abov e 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 f or installation and ser [...]

53 D Fig. 3-102 Hole-in-anchor Hole-in-plug Concrete Insert Suspension bolt (M10 or 3/8") (field supply) 3-26. Suspending the Indoor Unit Depending on the ceiling type: ● Inser t suspension bolts as shown in Fig. 3-102 or ● Use e xisting ceiling suppor ts or construct a suitable suppor t as shown in Fig. 3-103. Fig. 3-103 Fig. 3-104 Ceilin[...]

54 D Fig. 3-105 Fig. 3-106 Fig. 3-107 Min. 1-31/32 in. Inspection plug Min. 3-15/16 in. Good Min. 1/100 Downward g radient Not good 3-27. Installing the Drain Piping (1) Prepare standard hard PVC pipe (O .D . 1-1/4") f or the drain and use the supplied drain soc ket to pre v ent water leaks. The PVC pipe must be purchased separately . When doi[...]

55 T ■ Ceiling-Mounted T ype (T T ype) 3-30. Required Minimum Space for Installation and Service (1) Dimensions of suspension bolt pitch and unit T able 3-6 Dimension T ype 12, 18 AB C 33-21/32 35-53/64 8-17/64 24 44-19/64 46-29/64 8-17/64 B C A 6-11/16 12-19/32 26-49/64 1-5/64 1-5/64 Ceiling side (Suspension bolt pitch) (Suspension bolt pitch) A[...]

56 T W ARNING It is important that you use extreme care in supporting the indoor unit from the ceil- ing. Ensure that the ceiling is strong enough to support the weight of the unit. Before hanging the ceiling unit, test the strength of each attached suspension bolt. Fig. 3-115 Fig. 3-116 Ceiling tiles Ceiling suppor t A A unit Ceiling surface Fixtu[...]

57 T (5) Before suspending the indoor unit, remo ve the 2 or 3 scre ws on the latch of the air-intake g rilles, open the grilles, and remov e them by pushing the claws of the hinges as sho wn in Fig. 3-117. Then remov e both side panels sliding them along the unit tow ard the front after removing the 2 attachment scre ws. (Fig. 3-118) (6) Carr y ou[...]

58 T CA UTION ● Attach so that the hose band fastener is on the side of the drain port. (Fig. 3-130) ● Attach the hose bands so that each is appro ximately 13/64 – 63/64 in. from the end of the supplied drain hose. Good Min. 1/100 Downward g radient Not good Fig. 3-129 P ower supply outlet (ø1-3/16 " , knock-out) Left-side drain hose ou[...]

59 T 5-33/64 63/64 63/64 13/64 13/64 T wist tie (4 ties) Unit drain port Drain hose insulation (supplied) Hard PVC pipe (equivalent to VP-20) (Field supply) P osition to fasten hose bands Drain hose (supplied) Hose band (2 bands, supplied) Unit drain pan Fig. 3-131 ● Nev er allow traps to occur in the course of the piping. ● Insulate any piping[...]

60 K ■ W all-Mounted T ype (K T ype) 3-35. Removing the Rear P anel from the Unit (1) Remov e the set screws used to f asten the rear panel to the indoor unit during transpor tation. (2) Press up on the frame at the 2 locations shown b y the arrows in the figure at right, and remove the rear panel. NO TE T ubing can be e xtended in 4 directions a[...]

61 K (2) Check with a tape measure or carpenter’ s lev el. This is impor tant so that the unit is correctly installed. (Fig. 3-140) (3) Make sure the panel is flush against the w all. Any space between the wall and unit will cause noise and vibr ation. b) If the W all is Brick, Concrete or Similar Drill 3/16" dia. holes in the wall. Inser t [...]

62 K Insulating tape Refrigerant tubing Rear panel tab Plastic cov er Indoor and outdoor unit connection wiring (3) T o mount the indoor unit on the rear panel. 1. When installing the indoor unit, position the indoor unit onto the installation tabs on the upper par t of the rear panel. (Fig. 3-146) 2. Press on the air outlet to hold it in place, an[...]

63 K 3-42. When Using Wireless Remote Controller Instead of Wired Remote Controller When the wireless remote controller is to be used, slide the s witch on the indoor unit control PCB. • If this setting is not made, an alarm will occur . (The operation lamp on the display b links.) • This setting is not necessar y if both the wired remote contr[...]

64 (P ositions where anchor bolts are fastened) 31-7/64 (Installation hole pitch) 37-13/32 (Maximum dimensions) 35-3/64 (Ceiling panel dimensions) 36-7/32 (Installation hole pitch) 35-3/64 (Ceiling panel dimensions) Installation anchor hole (4 – 19/32 s 25/32 oval holes) 4. HO W TO INST ALL THE OUTDOOR UNIT 4-1. T ransporting When transpor ting t[...]

65 Fig. 4-7 4-3. Remove the Brackets Used for T ransport ● After installing the unit, remov e the 2 transpor t brac kets from the front and rear (4 brac kets total). (Fig. 4-5) Remove the 2 screws (8 screws total) Remove the 2 transport brackets from the front and rear (4 brackets total) Remove 2 screws Tubing cover Bottom Front Remove 11 panel s[...]

66 4-5. Prepare the T ubing ● Material: Use C1220 phosphorous deo xidized copper as described in JIS H3300, “Copper and Copper Allo y Seamless Pipes and T ubes. ” (F or tubes that are ø1" (ø25.4 mm) or larger , use 1/2H material or H mater ial. For all others use O material.) ● T ubing size Use the tubing size indicated in the tab le[...]

67 ● Precautions for br azing Be sure to replace the air inside the tube with nitrogen to pre vent o xide film from forming during the brazing process. Be sure to use a damp cloth or other means to cool the valv e unit dur ing brazing. CA UTION 1. Be sure to use nitrogen. (Oxygen, CO 2 , and CFC must not be used.) 2. Use a pressure-reducing valve[...]

68 Control wiring (A) Inter-unit (between outdoor and indoor units) control wiring (B) Remote control wiring (C) Control wiring f or group contr ol (D) Inter-outdoor unit contr ol wiring A WG #18 (0.75 mm 2 ) Use shielded wiring* Use shielded wiring Use shielded wiring Use shielded wiring Max. 3,280 ft. Max. 1,640 ft. Max. 1,640 ft. (T otal) Max. 1[...]

69 * Disconnect switch ( Field Supply) * * * * * * U2 U1 L2 L1 R2 R1 2 1 U2 U1 4 3 3 4 5 2 1 WHT Remote controller BLK 2 1 2 1 WHT Remote controller Group control: BLK 2 1 2 1 WHT Remote controller B C Indoor unit (No . n) Indoor unit (No . 1) Indoor unit (No . 2) Indoor unit (No . 3) A Outdoor unit INV unit L1 L2 L3 Ground Ground L1 L2 L1 L2 L1 L2[...]

70 ● For XM T ype U2 U1 3 1 2 1 2 2 1 U2 U1 4 3 3 4 5 2 1 2 1 U2 U1 3 1 2 1 2 U2 U1 3 1 2 1 2 U2 U1 3 1 2 1 2 2 1 2 1 2 1 B C A L1 L2 L3 N L N L N L N L N 2 1 2 1 4 3 3 4 5 L1 L2 L3 N A D B B A A * * * * * * * Disconnect switch ( Field Supply) P ower supply 208/230V , 1ø , ~60Hz P ower supply 208/230V , 3ø , ~60Hz P ower supply 208/230V , 3ø ,[...]

71 Outdoor unit Outdoor unit Outdoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit more than 3.3 ft. more than 3.3 ft. Branch point 16 or fe wer Indoor unit Indoor unit Indoor unit Indoor unit less than 3.3 ft. Indoor unit Outdoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Outdoor unit Indoor uni[...]

72 Fig. 5-4 Stranded wire Ring pressure terminal Strip 3/8 in. Fig. 5-5 Wire Special washer Screw Ring pressure terminal T erminal plate Screw and Special washer Ring pressure terminal Wire W ARNING Loose wiring may cause the terminal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, ensure that all wir- ing is tig[...]

73 Earth screw Conduit Power wiring (field supplied) Optional remote control wire (field supplied) Earth screw Conduit Power wiring (field supplied) Clamping clip Optional remote control wire (field supplied) 3-way connection wiring with harness (supplied) Earth screw Conduit Clamping clip Power wiring (field supplied) Clamping clip 3-way connectio[...]

74 Optional remote control wire (field supplied) Earth screw Conduit Power wiring (field supplied) Clamping clip Earth screw Conduit Clamping clip Power wiring (field supplied) Optional remote control wire (field supplied) Model : KHX0752/0952/1252/1852 Conduit Clamping strap 3-way connection wiring with harness (supplied) Power wiring (field suppl[...]

75 Earth screw Clamping strap Conduit Power wiring (field supplied) Clasp Optional remote control wire (field supplied) 3-way connection wiring with harness (supplied) Entirely cover the remote wiring and the 3-way wiring harness with the clasp. Remote control wiring 5-5. Important Note When Wiring for XM T ype Connect the wires referring to the di[...]

76 6. HO W TO PR OCESS TUBING The liquid tubing side is connected by a flare n ut, and the gas tubing side is connected by br azing. 6-1. Connecting the Refrigerant T ubing Use of the Flaring Method Many of con ventional split system air conditioners emplo y the flaring method to connect refr igerant tubes which run between indoor and outdoor units[...]

77 Caution Before Connecting T ubes Tightly (1) Apply a sealing cap or water-proof tape to pre vent dust or water from entering the tubes bef ore they are used. (2) Be sure to apply refr igerant lubricant to the match- ing surf aces of the flare and union bef ore connecting them together . This is effectiv e for reducing gas leaks . (Fig. 6-4) (3) [...]

78 Unit side insulator Insulation tape (white) (supplied) Sealer (supplied) Flare insulator (supplied) T ube insulator (not supplied) Heat resistant 248°F or abov e Vinyl clamps (supplied) Flare nut Fig. 6-8 Fig. 6-7 6-3. Insulating the Refrigerant T ubing T ubing Insulation ● Ther mal insulation must be applied to all unit tubing, including the[...]

79 Fig. 6-10 Fig. 6-11 6-4. T aping the T ubes (1) At this time, the refrigerant tubes (and electrical wir- ing if local codes per mit) should be taped together with ar moring tape in 1 bundle . T o prev ent the con- densation from ov erflowing the drain pan, k eep the drain hose separate from the refrigerant tubing. (2) Wrap the armor ing tape fro[...]

80 Fig. 7-1a Fig. 7-2 Fig. 7-1b Fig. 7-3 7. AIR PURGING Air and moisture in the refrigerant system may ha ve undesirab le eff ects as indicated below . ● pressure in the system rises ● operating current rises ● cooling (or heating) efficiency drops ● moisture in the refrigerant circuit ma y freeze and bloc k capillar y tubing ● water ma y[...]

81 Fig. 7-4 (3) Do a leak test of all joints of the tubing (both indoor and outdoor) and all ser vice v alves . Bubbles indicate a leak. Wipe off the soap with a clean cloth after a leak test. (4) After the system is found to be free of leaks , reliev e the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder . When the[...]

82 Fig. 7-5 Fig. 7-6 NO TE The required time in the abov e table is calculated based on the assumption that the ideal (or target) vacuum condition is less than –14.7 psig (–755 mm Hg, 5 T orr). (2) When the desired vacuum is reached, close the “Lo” knob of the manif old valv e and tur n off the vacuum pump . Please confir m that the gauge p[...]

83 8. TEST RUN 8-1. Preparing for T est Run ● Before attempting to start the air conditioner , chec k the follo wing. (1) The control wiring is correctly connected and all electrical connections are tight. (2) The transpor tation pads f or the indoor fan ha ve been remov ed. If not, remove them no w . (3) The power has been connected to the unit [...]

84 YES Make necessary corrections. Check the alarm contents. Check the alarm contents. T ur n OFF the indoor and outdoor unit power . NO YES NO *1 *2 *3 *3 *2 CASE 1 CASE 2 CASE 3B CASE 3A YES YES NO YES NO NO NO YES YES NO Recheck the items to check bef ore the test r un. Hav e the outdoor sub units been connected? Are the inter-unit control wires[...]

85 2 3 2 1 ON 1 ON ON 3 12 3 2 1 ON 3 2 1 ON 3 1 1 1 1 1 1 1 ON 1 2 3 ON 1 2 3 ON 1 2 3 ON 1 2 3 2 1 ON 2 1 ON ON 1 2 2 1 ON ON 1 2 3 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 3 2 1 ON ON 12 3 2 1 ON 3 ON OFF ON OFF ON OFF L Examples of the No. of indoor units settings (S005, S004) L Examples [...]

86 S003 CN100 CN101 CN003 S002 S004 S005 S006 S007 Fig. 8-4 8-3. Main Outdoor Unit PCB Setting W-3WAY_ECO-i_US.indd 86 W-3WAY_ECO-i_US.indd 86 2008/02/07 10:56:12 2008/02/07 10:56:12[...]

87 8-4. Auto Address Setting Basic wiring diagram: Example (1) ON 1 2 3 1 ON 3 2 ON 1 2 2 ON 1 3 3 2 1 ON ON ON OFF ON OFF ON OFF ON OFF OFF (S006) (S007) (S005) (S004) (S003) (S002) 1 1-1 1-2 1-3 1-10 • If link wiring is not used (The inter-unit contr ol wires are not connected to multiple refrigerant systems.) Indoor unit addresses can be set w[...]

88 1-1 1-2 2-1 2-2 2-9 1-3 1-13 2 9 2 1 ON 3 ON 1 2 3 ON 1 2 3 ON 1 2 3 ON 1 2 2 ON 1 3 1 3 1 ON 3 2 ON 1 2 2 ON 1 3 3 2 1 ON ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF Automatic address setting in Heating mode Automatic address setting in Cooling mode * When multiple outdoor main units exist, remo ve the soc ket that is [...]

89 Case 1 Automatic Ad dress Setting (no compressor operation) ● Indoor and outdoor unit power can be turned ON f or each system separately . Indoor unit addresses can be set without operating the compressors . Automatic Address Setting from Outdoor Unit 1. On the outdoor main unit control PCB, chec k that the system address rotar y switch (S002)[...]

90 Case 2 Automatic Ad dress Setting in Heating Mode ● Indoor and outdoor unit power cannot be turned ON f or each system separately . In the f ollowing, automatic setting of indoor unit addresses is not possib le if the compressors are not operating. Theref ore perf or m this process only after completing all refrigerant tubing work. Automatic A[...]

91 Case 3 Automatic Ad dress Setting in Cooling Mode ● Indoor and outdoor unit power cannot be turned ON f or each system separately . In the f ollowing, automatic setting of indoor unit addresses is not possib le if the compressors are not operating. Theref ore perf or m this process only after completing all refrigerant tubing work. A utomatic [...]

92 is blinking LED 1 LED 2 ( : ON : Blinking : OFF) Display meaning After the power is turned ON (and automatic address setting is not in progress), no communication with the indoor units in that system is possible . After the power is turned ON (and automatic address setting is not in progress), 1 or more indoor units are confirmed in that system;[...]

93 Request concerning recording the indoor/outdoor unit combination Nos. After automatic address setting has been completed, be sure to record them f or future ref erence. List the outdoor main unit system address and the addresses of the indoor units in that system in an easily visible loca- tion (ne xt to the nameplate), using a per manent markin[...]

94 8-7. Meaning of Alarm Messages T able of Self-Diagnostics Functions and Description of Alarm Displays Alarm messages are indicated by the blinking of LED 1 and 2 (D72, D75) on the outdoor unit PCB . They are also displa yed on the wired remote controller . ● Viewing the LED 1 and 2 (D72 and D75) alarm displa ys P ossible cause of malfunction R[...]

95 P ossible cause of malfunction Thermistor fault Protective device f or compressor is activated Indoor thermistor is either open or damaged. Outdoor thermistor is either open or damaged. Oil sensor fault. Indoor coil temp . sensor (E1) Indoor coil temp . sensor (E2) Indoor coil temp . sensor (E3) Indoor suction air (room) temp . sensor (T A) Indo[...]

96 Alarm messages display ed on system controller Indoor or main outdoor unit is not operating correctly . Mis-wiring of control wiring between indoor unit, main outdoor unit and system controller . Indoor or main outdoor unit is not operating correctly . Mis-wiring of control wiring between indoor unit, main outdoor unit and system controller . CN[...]

97 X XM <How to remo ve the filter> 1. Use a screwdriv er to remov e the bolt screw on each side f or the two latches. (Be sure to reattach the two bolt scre ws after cleaning.) 2. Press on the two latches of the air intak e grille with your thumbs in the direction of the arrow to open the grille. 3. Open the air intake g rille downward. 9. A[...]

98 X XM 4. Remov e the air filter attached to the air intake grille. Care: After a prolonged idle period Care: Before a prolonged idle period Check the indoor and outdoor unit air intak es and outlets for bloc kage; if there is a bloc k- age, remo ve it. • Operate the f an for half a da y to dr y out the inside. • Disconnect the power supply an[...]

99 A Air filter finger-hold Air filter Air intake grill Latch Air filter finger-hold Hook Screw Slide Screw *T ake hold of the finger-hold on the air filter , pull it toward y ou. 9-2. 1-W ay Air Discharge Semi-Concealed T ype (A T ype) ■ NAME OF P ARTS ■ CARE AND CLEANING SEMI-CONCEALED A type (1-W A Y) Air intake Ceili ng p a nel (op t io na [...]

100 A Care: After a prolonged idle period Care: Before a prolonged idle period Check the indoor and outdoor unit air intak es and outlets for bloc kage; if there is a bloc kage, remov e it. • Operate the f an for half a da y to dr y out the inside. • Disconnect the power supply and also turn off the circuit breaker . • Clean the air filter an[...]

101 U D 9-3. Concealed Duct (High-Static Pressure) T ype (U, D T ypes) ■ NAME OF P ARTS ■ CARE AND CLEANING CONC EALED D UCT U ty p e (s ta n d a r d st at ic p r es s u re ) W a t e r d r a i n Fle x ib l e du ct (op t io nal) C a n v as duct (op t io nal) Air in take g rille (air intake) (op t io nal) Ai r ou tl et gr il l e (op t io na l) CA[...]

102 U D ■ TROUBLESHOOTING If your air conditioner does not w ork proper ly , first check the f ollowing points bef ore requesting ser vice. If it still does no t work properly , contact your dealer or a service center. Air conditioner does not r un at all 1. P ower f ailure. 1. After a po wer outage , pr ess O N/ OFF operation b ut ton o nt h e w[...]

103 T Air intake grill finger-hold Air filter Air intake grill Air filter finger-hold Latch Air filter finger-hold * Take hold of the finger-hold on the air filter, pull it toward you. Hook Screw Slide Screw <How to remo ve the filter> 1. T ake hold of the finger-hold on the air intake g rille and press it to the rear , and the grille will op[...]

104 T Care: After a prolonged idle period Care: Before a prolonged idle period Check the indoor and outdoor unit air intak es and outlets for bloc kage; if there is a bloc kage, remov e it. • Operate the f an for half a da y to dr y out the inside. • Disconnect the power supply and also turn off the circuit breaker . • Clean the air filter an[...]

105 K <How to remo ve the filter> 1. Mov e the flap on the air outlet gr ille to its low est position with the remote control unit. 2. The filter is disengaged by pushing the tab up gently . Hold the air filter by the tab at the bottom, and pull downw ard. When replacing the filter , make sure that the FRONT mark is f acing you. Push it up un[...]

106 K Care: After a prolonged idle period Care: Before a prolonged idle period Check the indoor and outdoor unit air intak es and outlets for bloc kage; if there is a bloc kage, remov e it. • Operate the f an for half a da y to dr y out the inside. • Disconnect the power supply and also turn off the circuit breaker . • Clean the air filter an[...]