Sanyo R410A User Manual

XAUDTKOutdoor Units85464359982001 ©SANYO 2006 SANYO Electric Co., Ltd.Gunma, Japan– W-2WAY System Air Conditioner – R410A ModelsIndoor Units Class 7

10Table 1-5 (Concealed Duct High-Static Pressure)Table 1-6 (Ceiling-Mounted)Part Name FigureQ’ty Remarks8For suspending indoor unit from ceilingWash

R410A distribution jointAPR-CHP680BA (for outdoor unit)APR-CHP1350BA (for outdoor unit)APR-P160BA (for indoor unit)APR-P680BA (for indoor unit)APR-P13

121-6. Tubing SizeTable 1-9 Main Tubing Size (LA)32249,100(73.0)26ø7/8"(ø22.22)1095,500(28.0)ø1/2"(ø12.7)153,600(45.0)16ø1-1/8"(ø28.5

13Table 1-16 Refrigerant Charge Amount at Shipment (for outdoor unit)DCCHDX09053 CHDX14053(oz)423 4581-9. System LimitationsTable 1-17 System Limit

WARNINGAlways check the gas densitylimit for the room in which theunit is installed.1-10. Check of Limit DensityWhen installing an air conditioner in

151-12. Optional Distribution Joint KitsSee the installation instructions packaged with the distribution joint kit for the installation procedure.Tab

163. APR-P160BAUse: For indoor unit (Capacity after distribution joint is 76,400 BTU/h (22.4 kW) or less.)Table 1-21 Size of connection point on each

171-13. Example of Tubing Size Selection and Refrigerant Charge AmountAdditional refrigerant chargingBased on the values in Tables 1-9, 10, 11, 12 an

18Checking of limit density Density limit is determined on the basis of the size of a roomusing an indoor unit of minimum capacity. For instance, when

2. SELECTING THE INSTALLATION SITE2-1. Indoor UnitAVOID: areas where leakage of flammable gas may be expected. places where large amounts of oil m

2IMPORTANT! Please Read Before StartingThis air conditioning system meets strict safety and operat-ing standards. As the installer or service person,

20Fig. 2-5Fig. 2-6Fig. 2-72-2. Outdoor UnitAVOID: heat sources, exhaust fans, etc. damp, humid or uneven locations indoors (no-ventilation locatio

2-3. Shield for Horizontal Exhaust DischargeIt is necessary to install an air-discharge chamber (fieldsupply) to direct exhaust from the fan horizont

33-3/162-11/64 15/1697-29/3265-53/64 (32-5/64)35-15/64(Maximum bracket dimensions)35-3/64(Ceiling panel dimensions)33-3/1635-15/64(Maximum bracket dim

97-29/3265-53/6436-7/6445-5/16(32-5/64)Air direction: Front directionAir direction: Right directionCeiling panelTop (Before installation of snowfall p

24X3. HOW TO INSTALL THE INDOOR UNIT 4-Way Air Discharge Semi-Concealed Type (X Type)3-1. Preparation for SuspendingThis unit uses a drain pump. Us

XFig. 3-5(2) The length of suspension bolts must be appropriate for a distance between the bottom of the bolt and the bottom of the unit of more than

26XFig. 3-911-3/16 in. or less (as short as possible)33-15/32 in. or less0 – 45°* Length of supplied drain hose = 9-27/32 in.Fig. 3-10Upward gradient

27XAir-intake grilleCeiling panelAir-intake grille hinge113-6. How to Install the Ceiling Panel3-6-1. Before Installing the Ceiling PanelChecking th

28X3-6-2. Installing the Ceiling PanelAfter completing the wiring process, install the supplied wiring cover before installing the panel.It is not po

29X3-6-3. Wiring the Ceiling Panel(1) Open the cover of the electrical component box. (2) Connect the 7P wiring connector (red) from the ceiling pane

2. The standards for minimum room volume are as fol-lows.(1) No partition (shaded portion)(2) When there is an effective opening with the adjacentroom

30X3-6-5. Checking After Installation Check that there are no gaps between the unit and the ceiling panel, or between the ceiling panel and the ceil

31A 1-Way Air Discharge Semi-Concealed Type (A Type)3-8. Suspending the Indoor Unit(1) Follow the diagrams to make the holes in the ceiling.(Figs. 3

32ACeiling tilesCeiling supportFig. 3-34Fig. 3-33Fig. 3-323-9. Placing the Unit Inside the Ceiling(1) Use the supplied M5 or 3/16" screws (4) to

33AFig. 3-37Fig. 3-382-1/8Suspension boltsTubing side19/3219/322-1/8Suspension bolts25/3225/3225/32Ceilingmaterial The indoor unit includes a drain p

34AFig. 3-41Air bleed valveFig. 3-43Fig. 3-420 – 45°11-13/16 in. or less33-15/32 in. or less* Length of supplied drain hose = 9-27/32 in.Uphill slopeF

Refrigerant tubing joint (gas tube)Refrigerant tubing joint (liquid tube)Drain pipe connection (Be sure to connect the supplied flexible hose.)Inter-u

36AHookScrewHingeIntake grilleSlidePress on the tabs with a flathead (minus) screwdriver while pulling out the intake grille.ScrewRemoving the intake

37A(5) Align the installation holes on the panel with thebolt holes on the unit.(6) Insert the supplied washer head bolts into the 4panel installation

A3-13-3. Wiring the ceiling panel(1) Loosen the 2 screws on the electrical componentbox lid, and remove the lid. (Fig. 3-57)(2) Fasten the wiring conn

39UFig. 3-61Fig. 3-62Indoor unitInspectionaccess17-23/3217-23/32Air outlet duct flangemin. 9-27/32min. 15-3/4min. 25-19/3222-27/32A (Suspension bolt p

Newtool?1-2. Prevent impurities including water, dust and oxide from entering the tubing. Impurities can cause R410A refriger-ant deterioration and co

UFig. 3-633-15. Suspending the Indoor UnitDepending on the ceiling type:• Insert suspension bolts as shown in Fig. 3-63or• Use existing ceiling suppo

UFig. 3-68Fig. 3-69Drain hose (supplied) (not supplied) (not supplied)Packing (supplied)VP-25Align the hose band with end of the hose, and tighten so

42UFig. 3-74Inter-unit control wiringPower supply outlet(4) When the check of drainage is complete, open the check pin (CHK)and remount the insulator

43D Concealed Duct High-Static Pressure Type (D Type)3-19. Required Minimum Space for Installation and Service This air conditioner is usually inst

44DFig. 3-79Hole-in-anchorHole-in-plugConcrete InsertSuspension bolt (M10 or 3/8")(field supply)3-20. Suspending the Indoor UnitDepending on the

DFig. 3-83Fig. 3-84Fig. 3-85Min. 1-31/32 in.Inspection plugMin. 3-15/16 in.GoodMin. 1/100Downward gradientNot good3-21. Installing the Drain Piping(1

46T Ceiling-Mounted Type (T Type)3-24. Required Minimum Space for Installation and Service(1) Dimensions of suspension bolt pitch and unitTable 3-6D

47TWARNINGIt is important that you useextreme care in supporting theindoor unit from the ceiling.Ensure that the ceiling isstrong enough to support th

48T(5) Before suspending the indoor unit, remove the 2 or 3 screws on thelatch of the air-intake grilles, open the grilles, and remove them bypushing

TCAUTION Attach so that the hose band fastener ison the side of the drain port. (Fig. 3-108) Attach the hose bands so that each isapproximately 13/6

5ValveLiquid3-2. Use R410A exclusive cylinder only.Single-outlet valve(with siphon tube)Liquid refrigerant should be rechargedwith the cylinder standi

50T5-33/6463/64 63/6413/6413/64Twist tie (4 ties, supplied)Unit drain port Drain hose insulation (supplied)Hard PVC pipe (equivalent to VP-20)(Field s

51K Wall-Mounted Type (K Type)3-29. Removing the Rear Panel from the Unit(1) Remove the set screws used to fasten the rear panel to theindoor unit d

52K(2) Check with a tape measure or carpenter’s level. This is important so that the unit is correctly installed. (Fig. 3-117)(3) Make sure the panel

InsulatingtapeRefrigeranttubingRear panel tabPlastic coverIndoor and outdoor unit connection wiring(3) To mount the indoor unit on the rear panel.1. W

54K3-36. When Using Wireless Remote Controller Instead Of Wired Remote ControllerWhen the wireless remote controller is to be used, slide the switch

(Positions 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 (In

56Fig. 4-6Remove 2 screwsTubing coverBottomFrontRemove 11 panel screws from front panelUse cutting pliers or similar tool to cut cover outFig. 4-5Inde

574-4. Prepare the Tubing Material: Use C1220 phosphorous deoxidized copper as described in JIS H3300, “Copper and Copper Alloy Seamless Pipesand Tu

58 Precautions for brazingBe sure to replace the air inside the tube with nitrogen to prevent oxide film from forming during the brazing process. Be

59Control wiring(C) Inter-unit (between outdoor and indoor units) control wiring(D) Remote control wiring (E) Control wiring for group control(F) In

6IMPORTANT! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Please Read Before StartingCheck of Density LimitPrecautions for Installation

605-3. Wiring System DiagramU2U1L2L1R2R121U2U14334521WHTRemote controllerBLK2121WHTRemote controllerGroup control:BLK2121WHTRemote controllerDAEIndoor

61Outdoor unit Outdoor unit Outdoor unitIndoor unit Indoor unit Indoor unit Indoor unitIndoor unitmore than 3.3 ft.more than 3.3 ft.Branchpoint16 or f

62Fig. 5-4Shielded wireGroundGroundFig. 5-5Stranded wireRingpressureterminal Strip 3/8 in.Fig. 5-6WireSpecialwasherScrewRing pressure terminalTerminal

636. HOW TO PROCESS TUBINGThe liquid tubing side is connected by a flare nut, and thegas tubing side is connected by brazing.6-1. Connecting the Ref

64Caution Before Connecting Tubes Tightly(1) Apply a sealing cap or water-proof tape to prevent dustor water from entering the tubes before they are u

65Unit sideinsulatorInsulation tape (white)(supplied)Sealer (supplied)Flare insulator (supplied)Tube insulator(not supplied)Heat resistant248°F or abo

66Fig. 6-10Fig. 6-116-4. Taping the Tubes(1) At this time, the refrigerant tubes (and electrical wiringif local codes permit) should be taped togethe

67Fig. 7-1Fig. 7-2Fig. 7-37. AIR PURGINGAir and moisture in the refrigerant system may have undesirable effects as indicated below. pressure in the

68Fig. 7-4(4) Do a leak test of all joints of the tubing (both indoor andoutdoor) and both gas and liquid service valves. Bub-bles indicate a leak. Wi

69Fig. 7-5Fig. 7-6The required time in the above table is calculated based on theassumption that the ideal (or target) vacuum condition is lessthan –1

76. HOW TO PROCESS TUBING . . . . . . . . . . . . 636-1. Connecting the Refrigerant Tubing6-2. Connecting Tubing Between Indoor and Outdoor Units6-3

708. TEST RUN8-1. Preparing for Test Run Before attempting to start the air conditioner, checkthe following.(1) All loose matter is removed from th

YESMake necessary corrections.Check the alarm contents.Check the alarm contents.Turn OFF the indoor and outdoor unit power.NOYESNO*1*2*3 *3*2CASE 1CAS

728-3. Main Outdoor Unit PCB SettingS003CN100CN101CN003S002 S004 S005 S006 S007Fig. 8-407-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 72

732321ON1ONON312321ON321ON31111111ON123ON123ON123ON12321ON21ONON1221ONON123ONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFF321ON

(1) Automatic Address Setting from the Outdoor Unit1. To set the number of outdoor units, on the outdoor main unit control PCB set the No. of outdoor

751-1 1-22-1 2-2 2-91-3 1-132921ON3ON123ON123321ONON123ON122ON13131ON32ON122ON13321ONONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFONOFFOFFONAutomatic

76Automatic Address Setting (no compressor operation) Indoor and outdoor unit power can be turned ON for each system separately. Indoor unit addresse

77Automatic Address Setting in Heating Mode Indoor and outdoor unit power cannot be turned ON for each system separately. In the following, automati

78Automatic Address Setting in Cooling Mode Indoor and outdoor unit power cannot be turned ON for each system separately. In the following, automati

79is blinkingLED 1 LED 2( : ON : Blinking : OFF)Display meaningAfter the power is turned ON (and automatic address setting is not in progress), no

8Table 1-1 Outdoor Unit1-2. Accessories SuppliedSee Tables 1-1 – 1-7.1-1. Tools Required for Installation (not supplied)1. Standard screwdriver2. P

80Request concerning recording the indoor/outdoor unit combination Nos. After automatic address setting has been completed, be sure to record them for

81CAUTION This outdoor unit cannot collect more than the ratedrefrigerant amount as shownby the nameplate on the back. If the amount of refrigerant

8-7. Meaning of Alarm MessagesTable of Self-Diagnostics Functions and Description of Alarm DisplaysAlarm messages are indicated by the blinking of LE

Possible cause of malfunctionThermistorfaultProtectivedevice forcompressor isactivatedIndoor thermistor is either openor damaged.Outdoor thermistor is

Alarm messages displayed on system controllerIndoor or main outdoor unit is not operating correctly.Mis-wiring of control wiring between indoor unit,

85X<How to remove the filter>1. Use a screwdriver to remove the bolt screw on each side for the two latches. (Be sure toreattach the two bolt sc

86X4. Remove the air filter attached to the air intake grille.Air intake grilleBolt screwsLatchSafety chainAir filterCare: After a prolonged idle peri

Air filter finger-holdAir filterAir intake grillLatchAir filter finger-holdHookScrewSlideScrew*Take hold of the finger-hold on the air filter, pull it

88ACare: After a prolonged idle periodCare: Before a prolonged idle periodCheck the indoor and outdoor unit air intakes and outlets for blockage; if t

89UD9-3. Concealed Duct (High-Static Pressure) Type (U, D Type) NAME OF PARTS CARE AND CLEANINGCONCEALED DUCTU type (standard static pressure)Water

9Table 1-2 (4-Way Air Discharge Semi-Concealed)Table 1-3 (1-Way Air Discharge Semi-Concealed)Table 1-4 (Concealed Duct) Use 3/8" for suspendi

90UD TROUBLESHOOTINGIf your air conditioner does not work properly, first check the following points before requesting service. If it still does not

Air intake grillfinger-holdAir filterAir intake grillAir filter finger-holdLatchAir filter finger-hold* Take hold of the finger-hold on the air filter

92TCare: After a prolonged idle periodCare: Before a prolonged idle periodCheck the indoor and outdoor unit air intakes and outlets for blockage; if t

93K<How to remove the filter>1. Move the flap on the air outlet grille to its lowest position with the remote control unit.2. The filter is dise

94KCare: After a prolonged idle periodCare: Before a prolonged idle periodCheck the indoor and outdoor unit air intakes and outlets for blockage; if t