Sanyo 200 BTU User Manual Download

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IMPORTANT

These air conditioners employ new

refrigerant R410A.

Pay special attention when

servicing the unit.

TECHNICAL & SERVICE MANUAL

K CH1872

K CH2472

DC INVERTER SPLIT SYSTEM AIR CONDITIONER

Destination: North America

Outdoor Model No.

CH1872
CH2472

Product Code No.

1 852 330 38
1 852 330 39

Indoor Unit

Outdoor Unit

KHS1872

KHS2472

CH1872

CH2472

Indoor Model No.

KHS1872
KHS2472

Product Code No.

1 852 099 85
1 852 099 86

REFERENCE NO.

700656-05

FILE NO.

Summary of Contents for 200 BTU

Page 1: ...L KHS1872 CH1872 KHS2472 CH2472 DC INVERTER SPLIT SYSTEM AIR CONDITIONER Destination North America Outdoor Model No CH1872 CH2472 Product Code No 1 852 330 38 1 852 330 39 Indoor Unit Outdoor Unit KHS1872 KHS2472 CH1872 CH2472 Indoor Model No KHS1872 KHS2472 Product Code No 1 852 099 85 1 852 099 86 REFERENCE NO SM700656 05 FILE NO ...

Page 2: ...e 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 Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construc...

Page 3: ...ELECTRICAL DATA 6 1 Electrical Characteristics 6 2 Electric Wiring Diagrams 7 MAINTENANCE 7 1 Address Setting of the Remote Control Unit 7 2 Disconnecting and Connecting Positive Connector for Outdoor Unit 8 FUNCTIONS 8 1 Operation Functions 8 2 Protective Functions 9 TROUBLESHOOTING 9 1 Precautions before Performing Inspection or Repair 9 2 Method of Self Diagnostics 9 3 Checking the Indoor and O...

Page 4: ...teristics of New Refrigerant R410A 11 2 Checklist before Servicing 11 3 Tools Specifically for R410A 11 4 Tubing Installation Procedures 11 5 In Case of Compressor Malfunction 11 6 In Case Refrigerant is Leaking 11 7 Charging Additional Refrigerant 11 8 Retro Fitting Existing Systems APPENDIX A INSTRUCTION MANUAL APPENDIX B INSTALLAION INSTRUCTIONS 52 53 54 55 56 56 57 59 60 60 A 1 A 2 Page 4 ...

Page 5: ... 67 F D B 57 F W B 80 F D B 67 F W B _ D B _ W B 1 OPERATING RANGE Maximum Minimum Maximum Minimum 115 F D B 0 F D B 75 F D B 65 F W B 0 F D B Temperature Indoor Air Intake Temp Outdoor Air Intake Temp Cooling Heating 5 ...

Page 6: ... A Available Voltage Range Running Amperes Refrigerant Tube Kit Accessories Narrow tube Wide tube Refrigerant inch mm Tube Diameter inch mm 26 5 33 1 4 23 12 0 15 0 0 12 97 0 105 8 9 88 44 0 48 0 0 28 29 1 8 39 27 32 14 31 32 740 1 012 380 298 1 065 218 670 880 285 11 3 8 44 7 8 14 29 32 289 1 140 379 Outdoor Unit Indoor Unit 11 23 32 41 15 16 8 19 32 26 3 8 34 21 32 11 7 32 1 4 6 35 1 2 12 7 ft m...

Page 7: ... Range Running Amperes Refrigerant Tube Kit Accessories Narrow tube Wide tube Refrigerant inch mm Tube Diameter inch mm 26 5 33 1 4 23 12 0 15 0 0 12 97 0 105 8 9 88 44 0 48 0 0 28 29 1 8 39 27 32 14 31 32 740 1 012 380 298 1 065 218 670 880 285 11 3 8 44 7 8 14 29 32 289 1 140 379 Outdoor Unit Indoor Unit 11 23 32 41 15 16 8 19 32 26 3 8 34 21 32 11 7 32 1 4 6 35 1 2 12 7 ft m Max allowable tubin...

Page 8: ...ange Running Amperes Refrigerant Tube Kit Accessories Narrow tube Wide tube Refrigerant inch mm Tube Diameter inch mm 26 5 33 1 4 23 12 0 15 0 0 12 130 1 138 9 12 71 59 0 63 0 0 36 33 27 32 40 5 8 16 1 4 860 1 032 413 298 1 065 218 740 900 320 11 3 8 44 7 8 14 29 32 289 1 140 379 Outdoor Unit Indoor Unit 11 23 32 41 15 16 8 19 32 29 1 8 35 7 16 12 19 32 1 4 6 35 5 8 15 88 ft m Max allowable tubing...

Page 9: ...ange Running Amperes Refrigerant Tube Kit Accessories Narrow tube Wide tube Refrigerant inch mm Tube Diameter inch mm 26 5 33 1 4 23 12 0 15 0 0 12 130 1 138 9 12 71 59 0 63 0 0 36 33 27 32 40 5 8 16 1 4 860 1 032 413 298 1 065 218 740 900 320 11 3 8 44 7 8 14 29 32 289 1 140 379 Outdoor Unit Indoor Unit 11 23 32 41 15 16 8 19 32 29 1 8 35 7 16 12 19 32 1 4 6 35 5 8 15 88 ft m Max allowable tubing...

Page 10: ...trol Circuit Fuse Controls Part No Microprocessor 250V 3A CB KHS1872 1 D3 11 16 L33 9 32 D94 L845 RCS 4HVPIS4U Cross Flow DC Motor SIC 39CVL D847 2 A 1 8 30 1 250 1 300 Internal Controller Yes Fan Remote Control Unit Q ty Dia and Length Type inch mm Fan Motor Nominal Output Coil Resistance Rough Measure RPM Cool Heat Type Model Q ty No of Poles Safety Device Type Over Current Protection Over Heat ...

Page 11: ... NOTICE Yes Control PCB Control Circuit Fuse Controls Part No Microprocessor 250V 3A CB KHS2472 1 D3 11 16 L33 9 32 D94 L845 RCS 4HVPIS4U Cross Flow DC Motor SIC 39CVL D847 2 A 1 8 30 1 500 1 550 Internal Controller Yes Fan Remote Control Unit Q ty Dia and Length Type inch mm Fan Motor Nominal Output Coil Resistance Rough Measure RPM Cool Heat Type Model Q ty No of Poles Safety Device Type Ambient...

Page 12: ...m DC Motor Type Compressor Model Nominal Output Compressor Coil Resistance Ambient Temp 68 F 20 C Ohm DC Twin Rotary Hermetic C 6RVN93H0M 1 050W R S S T T R 0 482 0 482 0 482 CT Peak current cut off control Compressor Discharge Temp Control Operation cut off control in abnormal ambient Temp Safety Device Micro F VAC Run Capacitor Crankcase Heater Yes Yes Yes Overload Relay CS 7L115 Model Operation...

Page 13: ...put Compressor Coil Resistance Ambient Temp 68 F 20 C Ohm DC Twin Rotary Hermetic G8T265FU1JW 2 410W U V V W W U 0 36 0 36 0 36 CT Peak current cut off control Compressor Discharge Temp Control Operation cut off control in abnormal ambient Temp Safety Device Micro F VAC Run Capacitor Crankcase Heater Yes Yes Yes Overload Relay CS 7L115 Model Operation Temp Open 239 F 115 C Close 203 F 95 C 230V 30...

Page 14: ...7 86 95 104 10 15 20 25 30 35 40 Indoor air temp sensor Model PTM D51H S3 2 TH2 Indoor heat exchanger sensor Model PTM D51H S3 2 TH1 Compressor temp sensor Model TKS293B Resistance k ohm Resistance k ohm Temperature F C Outdoor air temp sensor Model TKS295B Outdoor heat exchanger sensor Model TKS292B 40 35 30 25 20 15 10 5 0 4 5 14 23 32 41 50 59 68 20 15 10 5 0 5 10 15 20 Resistance k ohm Tempera...

Page 15: ...3 DIMENSIONAL DATA Indoor Unit KHS1872 KHS2472 Unit inch mm 15 ...

Page 16: ...ube service valve dia 1 2 12 70 4 3 8 2 5 32 6 17 32 5 23 32 3 32 26 3 8 670 23 32 1 13 16 34 21 32 880 23 15 16 5 11 32 15 32 11 7 32 285 12 7 32 13 5 32 11 17 32 I D 2 3 3 2 4 I D 1 5 1 6 1 3 8 2 17 32 2 13 32 Outdoor Unit CH1872 Unit inch mm 16 ...

Page 17: ...ow tube service valve dia 1 4 6 35 4 7 16 5 29 32 2 1 32 4 1 2 29 1 8 740 23 32 1 21 32 35 7 16 900 23 15 16 5 11 32 15 32 12 19 32 320 13 19 32 14 17 32 11 17 32 I D 2 3 3 2 5 I D 1 5 1 6 1 3 8 2 15 16 2 7 8 Outdoor Unit CH2472 Unit inch mm 17 ...

Page 18: ...iagram Indoor Unit KHS1872 KHS2472 Outdoor Unit CH1872 CH2472 Insulation of Refrigerant Tubing Because capillary tubing is used in the outdoor unit both the wide and narrow tubes of this air conditioner become cold To prevent heat loss and wet floors due to dripping of condensation both tubes must be well insulated with a proper insulation material The thickness of the insulation should be a min 5...

Page 19: ...oor inlet air D B temp F C Operating current A Indoor discharge air temperature F C Low pressure at wide tube service valve psig MPaG 4 20 5 15 14 10 23 5 32 0 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 4 20 5 15 14 10 23 5 32 0 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 60 8 16 64 4 18 57 2 14 53 6 12 50 0 10 46 4 8 2 3 4 5 6 7 8 104 0 7 117 0 8 131 0 9 145 1 0 159 1 1 174 1 2 90 0 6 76...

Page 20: ...air D B temp F C 70 F 21 C 63 F 17 C Indoor air temp 73 F 23 C Outdoor inlet air D B temp F C 23 5 32 0 41 5 11 10 9 8 7 6 5 50 10 59 15 68 20 77 25 Operating current A 63 F 17 C Indoor air temp 73 F 23 C 70 F 21 C 23 5 32 0 41 5 50 10 131 55 122 50 113 45 104 40 95 35 86 30 59 15 68 20 77 25 Outdoor inlet air D B temp F C 70 F 21 C 63 F 17 C Indoor air temp 73 F 23 C High pressure at wide tube se...

Page 21: ... 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 4 20 5 15 14 10 23 5 32 0 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 Check each performance value in test run mode Electrical performance values represent a combined indoor outdoor value NOTE 57 2 14 60 8 16 64 4 18 68 0 20 53 6 12 50 0 10 46 4 8 42 8 6 4 5 6 7 8 9 10 11 12 13 14 104 0 7 117 0 8 131 0 9 145 1 0 159 1 1 174 1 2 90 0 6 76 0 5 Hi ...

Page 22: ...5 104 40 95 35 86 30 59 15 68 20 77 25 Outdoor inlet air D B temp F C High pressure at wide tube service valve psig MPaG 494 3 4 421 2 9 348 2 4 275 1 9 Check each performance value in test run mode Electrical performance values represent a combined indoor outdoor value Overload prevention operates to protect the air conditioner when outdoor ambient temperature becomes extremely high in heating mo...

Page 23: ... 24 4 SHC 10 780 10 470 10 270 10 060 9 760 7 520 19 4 80 26 7 SHC 12 500 12 300 12 100 11 790 11 490 9 250 84 28 9 SHC 14 230 14 030 13 830 13 520 13 220 10 980 88 31 1 SHC 15 960 15 760 15 450 15 250 14 950 10 980 TC 19 880 19 350 18 760 18 220 17 460 11 160 72 22 2 SHC 6 810 6 600 6 400 6 200 5 890 3 650 71 76 24 4 SHC 8 540 8 330 8 130 7 930 7 620 5 380 21 7 80 26 7 SHC 10 270 10 060 9 860 9 6...

Page 24: ...170 TC 25 360 24 690 23 940 23 260 18 810 11 390 72 22 2 SHC 14 730 14 380 13 920 13 690 11 590 8 320 63 76 24 4 SHC 16 600 16 250 15 900 15 550 13 450 10 300 17 2 80 26 7 SHC 18 580 18 230 17 880 17 530 15 430 11 390 84 28 9 SHC 20 560 20 210 19 860 19 510 17 420 11 390 88 31 1 SHC 22 430 22 080 21 730 21 380 18 810 11 390 TC 26 250 25 590 24 850 24 200 19 150 11 590 72 22 2 SHC 12 170 11 820 11 ...

Page 25: ...9 550 9 550 9 660 9 760 9 860 9 860 63 76 24 4 SHC 11 280 11 280 11 280 11 390 11 490 11 490 11 590 17 2 80 26 7 SHC 13 110 13 110 13 110 13 220 13 220 13 320 13 320 84 28 9 SHC 14 740 14 740 14 840 14 950 14 950 15 050 15 050 88 31 1 SHC 15 050 15 050 15 090 15 350 15 480 15 620 15 640 TC 14 890 14 920 15 040 15 460 15 680 15 910 16 000 72 22 2 SHC 7 210 7 210 7 320 7 520 7 520 7 620 7 720 67 76 ...

Page 26: ...640 12 750 63 76 24 4 SHC 14 380 14 380 14 380 14 500 14 500 14 500 14 620 17 2 80 26 7 SHC 16 370 16 370 16 370 16 480 16 600 16 600 16 600 84 28 9 SHC 18 230 18 350 18 230 18 470 18 470 18 470 18 580 88 31 1 SHC 20 210 20 210 20 210 20 330 20 330 20 450 20 450 TC 20 300 20 400 20 560 21 150 21 250 21 360 21 620 72 22 2 SHC 9 610 9 610 9 610 9 950 9 950 9 950 10 070 67 76 24 4 SHC 11 470 11 470 1...

Page 27: ...BTU h AIR FLOW RATE 541 CFM OUTDOOR INDOOR ENT TEMP o F o C AMBIENT TEMP o F o C W B 60 65 70 75 80 15 6 18 3 21 1 23 9 26 7 0 17 8 TH 11 320 11 320 11 310 11 290 11 270 3 16 1 TH 11 700 11 700 11 690 11 680 11 650 8 13 3 TH 12 620 12 610 12 600 12 590 12 560 13 10 6 TH 13 570 13 560 13 550 13 530 13 510 18 7 8 TH 14 610 14 610 14 590 14 570 14 540 23 5 0 TH 15 710 15 700 15 690 15 660 15 630 28 2...

Page 28: ...FLOW RATE 653 CFM OUTDOOR INDOOR ENT TEMP o F o C AMBIENT TEMP o F o C W B 60 65 70 75 80 15 6 18 3 21 1 23 9 26 7 0 17 8 TH 16 210 16 210 16 200 16 180 16 150 3 16 1 TH 16 750 16 750 16 740 16 720 16 690 8 13 3 TH 18 050 18 050 18 040 18 010 17 980 13 10 6 TH 19 390 19 390 19 380 19 350 19 320 18 7 8 TH 20 870 20 860 20 850 20 820 20 780 23 5 0 TH 22 420 22 410 22 390 22 360 22 320 28 2 2 TH 24 0...

Page 29: ... C Fan speed High Cooling Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 Flap angle 45 Axis air velocity 45 Flap angle 60 Axis air velocity 60 5 5 Air Throw Distance Charts Indoor Unit KHS1872 0 5 10 15 0 5 10 15 20 25 30 Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 0 5 10 15 0 5 10 15 20 25 30 Flap angle 45 Axis air velocity 45 Flap angle 60 Axis air ve...

Page 30: ... temp 80 F 26 7 C Fan speed High Cooling Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 Flap angle 45 Axis air velocity 45 Flap angle 60 Axis air velocity 60 Indoor Unit KHS2472 0 5 10 15 0 5 10 15 20 25 30 Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 0 5 10 15 0 5 10 15 20 25 30 Flap angle 45 Axis air velocity 45 Flap angle 60 Axis air velocity 60 30 ...

Page 31: ...formance at 230V Single phase 60Hz Rating conditions Running amp 0 3 Power input 34 7 1 1 541 7 4 1 575 Indoor Unit Outdoor Unit Fan Motor Fan Motor Compressor Performance at 208V Single phase 60Hz Rating conditions Running amp 0 3 Power input 32 7 4 1 468 Heating Cooling 230V 208V 2 Voltage 208V 1 Voltage 230V 7 7 1 500 Indoor Unit Outdoor Unit Fan Motor Fan Motor Compressor Performance at 208V S...

Page 32: ...ase 60Hz Rating conditions Running amp 0 5 Power input 58 11 5 2 432 12 0 2 490 Indoor Unit Outdoor Unit Fan Motor Fan Motor Compressor Performance at 208V Single phase 60Hz Rating conditions Running amp 0 5 Power input 55 11 6 2 300 Heating Cooling 230V 208V 2 Voltage 208V 1 Voltage 230V 12 1 2 355 Indoor Unit Outdoor Unit Fan Motor Fan Motor Compressor Performance at 208V Single phase 60Hz Ratin...

Page 33: ...AMP ASSY ROOM COIL 4P WHT DCM 6P BLU CONTROLLER FM FAN MOTOR 1 2 3 4 5 6 1 2 3 4 5 6 ROOM THERMISTOR BLK BLK BLK BLK 1 2 3 4 1 2 3 4 COIL THERMISTOR ION 3P WHT HA JEM A 1 2 3 1 2 3 4P WHT 1 2 4 BLK 3 BLK BLK RED WHT 1 2 3 4 1 2 3 4 ION ASSY ION TERMINAL 1 2 3 WHT BLK RED RED BLK YEL WHT BLU 8FA2 5257 70500 0 6 2 Electric Wiring Diagrams Indoor Unit KHS1872 KHS2472 WARNING To avoid electrical shock...

Page 34: ...HT GRY RED ORG WHT COMPRESSOR THERMISTOR OVERLOAD RELAY OLR OUT DOOR THERMISTOR 1 2 3 4 1 2 3 4 COIL OUTDOOR YEL YEL COIL THERMISTOR 7P CONNECTOR WHT 2P CONNECTOR WHT MVO MAGNETIC COIL 2P CONNECTOR RED WHT WHT WHT WHT 1 1 2 2 BRN W BD W BD WHT W HIC W HIC BLK W AC2 W AC2 BLU N L GND 1 2 3 4 5 6 POWER SUPPLY W E1 GRN YEL W E GRN YEL TERMINAL PLATE FERRITE CORE GND TO INDOOR UNIT POWER RELAY 6 1 4 5...

Page 35: ...LAY OLR OUT DOOR THERMISTOR 1 2 3 4 1 2 3 4 COIL OUTDOOR YEL YEL COIL THERMISTOR 7P CONNECTOR WHT 2P CONNECTOR WHT MVO MAGNETIC COIL 2P CONNECTOR RED WHT WHT WHT WHT 1 1 2 2 BRN W BD W BD WHT W HIC W HIC BLK W AC2 W AC2 BLU W W HEATER0 HEATER1 1P CONNECTOR WHT 1P CONNECTOR WHT WHT WHT WHT WHT 1 1 1 1 CRANKCASE HEATER N L GND 1 2 3 4 5 6 POWER SUPPLY W E1 GRN YEL W E GRN YEL TERMINAL PLATE FERRITE ...

Page 36: ...to B Fig 14 3 Press and hold the remote controller ION button and 1 HR TIMER button Then press and hold the ACL reset button with a pointed object such as the tip of a pen After 5 seconds release ACL button first then release ION and 1 HR TIMER buttons oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as show...

Page 37: ...lways hold the cover to disconnect See illustration at left For the connector without the resin cover push the lock in the direction of 2 while pulling it off How to Connect In order to connect hold the resin cover of the connector and push it in Confirm the click sound for the inside lock Pull the cover upward When the cover is pulled upward the lock is released with the sequence of 1 and 2 7 2 D...

Page 38: ... the remote controller malfunctions has been lost or otherwise cannot be used The set temperature is 4 F 2 C below the detected room temperature in the case of cooling operation and 4 F 2 C above the room temperature in the case of heating operation The flap and fan speed settings are AUTO GREEN RED Lamp Off COOL HEAT STOP When AUTO mode is selected the microprocessor calculates the difference bet...

Page 39: ...ears on the remote controller The main unit display lamp also becomes dimmer COOL and DRY modes When the night setback mode is selected the air conditioner automatically raises the temperature setting 2 F 1 C when 30 minutes have passed after the selection was made and then another 2 F 1 C after another 30 minutes have passed regardless of the indoor temperature when night setback was selected Thi...

Page 40: ... drops to below 36 F 2 C continuously for 2 minutes or longer the compressor stops Once the freeze condition is detected the air conditioner will work less than the maximum frequency until it is turned off Approx 127 53 At stability of operation At start of operation A High LL Stopped A B C B Indoor heat exchanger A Control start B Control end Set fan speed 77 25 86 30 Approx 104 40 a b c d a b c ...

Page 41: ...way valve ON Outdoor heating exchanger temp is over 57 2 F 14 C Defrosting operation lasts 12 minutes maximum 2 minutes after it is stopped compressor is ON 4 way valve is ON Outdoor fan is ON If the air conditioner is turned off during the defrosting cycle it will continue defrosting and turn itself off after defrosting is completed Compressor 1 minute after it is stopped compressor is ON Outdoor...

Page 42: ...d trouble diagnostics PROCEDURE Step 1 Press and hold the remote controller ION button and 1 HR TIMER button Then press and hold the ACL reset button with a pointed object such as the tip of a pen After 5 seconds release ACL button first then release ION and 1 HR TIMER buttons oP 1 test run appears blinking in the remote controller clock display area Step 2 Next press the 1 HR TIMER button once to...

Page 43: ...detection only for the humidity sensor 3 Indoor outdoor PCboard failure 1 Sensor open circuit or short circuit 2 Contact failure at connector or open circuit at terminal crimping location 3 Outdoor PCboard failure Outdoor PCboard failure 1 Mis wiring 2 AC power failure 3 Blown fuse 4 Power Relay failure 5 Indoor or outdoor PCboard failure 6 Outdoor Fan Motor failure 7 Reactor failure 8 High Pressu...

Page 44: ... function fails to operate Check the indoor unit Is the fuse blown Replace the controller Replace the circuit board or the fuse No indicators illuminate and the indoor fan does not rotate Check the power voltage Normal Blown 44 ...

Page 45: ...ent between inter unit wirings 1 and 2 Connect a 5 k ohm resistor between inter unit wirings 2 and 3 When the voltage at both ends is measured approximately 12 to 15V DC must be output and the multimeter pointer must bounce once every 8 seconds Or instead of measuring the voltage you can insert an LED jig and check that the LED flickers once every 8 seconds Control No Check items unit operation Ap...

Page 46: ...age B For terminal strip short circuit work or inter unit wiring removal turn off the power to avoid an electric shock Release the terminal strip short circuit after the completion of self diagnostics Do not perform the short circuit work between any other terminals except for specified ones on the specified terminal strip If such work is performed between the incorrect terminals the unit might be...

Page 47: ...he operation button on the indoor unit 2 Perform the self diagnosis five seconds after the operation start 1 Turn off the power and wait until the power lamp LED of the outdoor unit controller is turned OFF 2 Remove the short circuit between the terminals 2 and 3 on the outdoor unit terminal strip 3 Disconnect the cable from the terminal 3 on the indoor unit terminal strip Fig 4 Short circuit betw...

Page 48: ...ter the operation start 1 Turn off the power and wait until the power lamp LED of the outdoor unit controller is turned OFF 2 Disconnect the cable from the terminal 3 on the Outdoor unit terminal strip Fig 6 Defect in the inter unit cable 1 Turn ON the power and operate the system using the remote controller or the operation button on the indoor unit 2 Perform the self diagnosis five seconds after...

Page 49: ...d Trouble symptom 1 The fan does not stop when the unit stops Indoor unit controller trouble Trouble symptom 2 The fan motor does not rotate when the unit is operating Diagnostic procedure Disconnect the motor connectors and measure the voltage at the DC motor connectors on the indoor unit controller 3 locations Diagnostic results All of the above measured values are normal Fan motor trouble Repla...

Page 50: ... 4 Fan motor rotation speed does not change during outdoor unit operation Trouble symptom 5 Fan motor rotation speed varies excessively during outdoor unit operation Remedy for symptom 3 to 5 It is not possible to identify whether the trouble is outdoor unit controller trouble or motor trouble Therefore first replace the outdoor unit controller then if necessary replace the DC motor Important A Tu...

Page 51: ...distance from the noise source 1 Use shielded wires 2 Move unit away from the noise source Trouble Either of the following trouble may occur 1 The unit may stop suddenly during operation 2 Indicator lamps may flicker 2 Electromagnetic interference This refers to noise generated by high speed switching of the microcomputer and compressor This noise radiates through space and returns to the electric...

Page 52: ...g 1 10 1 2 Indoor Unit Clamp an aluminum plate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw on the terminal plate Fig 2 Note that the ground line terminal should be skipped for the check 10 1 3 Outdoor Unit Clamp a metallic part of the unit with the lead clip of the insulation resistance tester and me...

Page 53: ... Fig 6 Fuse 10 2 Checking Continuity of Fuse on PCB Ass y Remove the PCB Ass y from the electrical component box Then pull out the fuse from the PCB Ass y Fig 5 Check for continuity using a multimeter as shown in Fig 6 53 ...

Page 54: ...use of a change in composition of the remaining refrigerant Therefore do not add new refrigerant Instead recover the remaining refrigerant with the refrigerant recovery unit Then after evacuation totally recharge the specified amount of refrigerant with the new refrigerant at its normal mixed composition state in liquid phase When refrigerant R410A is used the composition will differ depending on ...

Page 55: ...n R410A refrigerant is exposed to fire Therefore be sure to provide ample ventilation during installation work Caution in case of R410A leak Check for possible leak points with the special leak detector for R410A If a leak occurs inside the room immediately provide thorough ventilation A D Flare tool for R410A A D Conventional flare tool R22 Spacer 11 2 Checklist before Servicing Use a clutch type...

Page 56: ...s which can be com monly used for R22 R407C and R410A CAUTION The above tools specifically for R410A must not be used for R22 and R407C Doing so will cause malfunction of the unit For the above vacuum pump 1 2 and vacuum pump adapter 3 those for R22 type units can be used for R410A type However they must be used exclusively for R410A and never alternately with R22 and R407C For details on tubing i...

Page 57: ...it quickly 3 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 4 Evacuation Use a solenoid valve installed vacuum pump so that even if power is cut off in the middle of evacuation of air due to a power interruption the valve will prevent the pump oil from flowing back The equipment may be damaged i...

Page 58: ...use an electronic scale for charging refrigerant In this case if the volume of refrigerant in the cylinder becomes less than 20 of the fully charged amount the composition of the refrigerant starts to change Thus do not use the refrigerant if the amount in the charging cylinder is less than 20 Also charge the minimum necessary amount to the charging cylinder before using it to charge the air condi...

Page 59: ...lux and wax for R410A Prevent oxide film from forming inside the tubes utilizing substitution with nitrogen N2 in the refrigerant circuit of the unit Leave ends of tubes open during welding 4 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 5 Evacuation Use a solenoid valve installed vacuum pump s...

Page 60: ... R410A for existing units which use R22 This will cause the air conditioner to operate improperly and may result in a hazardous condition 11 8 2 Use of Existing Tubing If replacing an older unit that used refrigerant R22 with a R410A unit do not use its existing tubing Instead completely new tubing must be used CAUTION Never charge additional refrigerant if refrigerant is leaking from the unit Fol...

Page 61: ...INSTRUCTION MANUAL KHS1872 CH1872 KHS2472 CH2472 OI 852 6 4180 801 00 2 APPENDIX A A 1 ...

Page 62: ...rner Auto Flap Control This automatically sets the flap to the optimum position during heating cooling and drying operation Automatic Switching between Cooling and Heating This unit automatically switches between cooling operation and heating operation according to the difference between the room temperature and the temperature setting Hot Start Heating System Right from the start the air is warm ...

Page 63: ...e 25 Product Information If you have problems or questions concerning your Air Conditioner you will need the following information Model and serial numbers are on the nameplate on the bottom of the cabinet Model No ______________________ Serial No _______________________ Date of purchase ___________________________________________________ Dealer s address __________________________________________...

Page 64: ... install this air conditioner where there are fumes or flammable gases or in an extremely humid space such as a greenhouse Do not install the air conditioner where excessively high heat generating objects are placed Avoid To protect the air conditioner from heavy corrosion avoid installing the outdoor unit where salty sea water can splash directly onto it or in sulphurous air near a spa Never use ...

Page 65: ...lown out of the air conditioner through the air outlet Remote Control Unit The wireless remote control unit controls power ON OFF operation mode selection temperature fan speed timer setting and air sweeping Refrigerant Tubes The indoor and outdoor units are connected by copper tubes through which refrigerant gas flows Drain Hose Moisture in the room condenses and drains off through this hose Outd...

Page 66: ...mp lights up red and orange alternately when the system is defrosting TIMER lamp This lamp lights when the system is being controlled by the timer QUIET lamp This lamp lights during operation in the QUIET mode ION lamp This lamp lights during operation in the ION mode while the indoor unit is operating The unit s display lamps are dimmed during operation in the NIGHT SETBACK mode QUIET REMOTE CONT...

Page 67: ...mer OFF Timer 1 hour OFF Timer 5 NIGHT SETBACK 6 Confirmation of transmission 7 Auto flap indication Flap angle indication Sweep indication 8 High power operation 9 Quiet operation 10 ION operation Displayed when setting timer Displayed when transmitting data Displayed when indoor unit sensor is in use Displayed when setting temperature Displayed when temperature is shown Displayed when the time d...

Page 68: ...negative ions generated during operation on and off ON OFF operation button This button is for turning the air conditioner on and off 1 HR TIMER button 1 HOUR OFF TIMER When you press this button regardless of whether the unit is operating or stopping the unit operates for one hour and then shuts down Transmitter Sensor Cover closed Display FAN SPEED selector button FLAP button ON TIME setting but...

Page 69: ...e to save energy FLAP button Press this button either to select the setting of the airflow direction to the auto flap in each mode or one of the six possible positions manually or to select the sweep function which moves the flap up and down automatically Auto flap setting If selected in a heating operation the flap is set to position 3 in the following chart If selected in a cooling or dry operat...

Page 70: ... not be bent The remote control unit sends the temperature signal to the air conditioner regularly at five minute intervals If the signal from the remote control unit stops for more than 15 minutes due to the loss of the remote control unit or other trouble the air conditioner will switch to the temperature sensor which is built into the indoor unit and control the room temperature In these cases ...

Page 71: ...e remote control unit every 5 minutes Mounting the Remote Control Unit Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location The indoor unit should make a beeping sound to indicate that it has received the signal To take out the remote control unit pull it forward When Holding the Remote ...

Page 72: ... selected and the unit is preset by following the steps below you can have the air conditioner automatically bring the room to the desired temperature simply by pressing the ON OFF operation button STEP 1 Press the MODE selector button to STEP 2 Press the ON OFF operation button To stop the air conditioner press the ON OFF operation button again To change the temperature setting press the temperat...

Page 73: ...ration For cooling operation For fan only operation STEP 2 To start the air conditioner press the ON OFF operation button STEP 3 Press the TEMP setting buttons to change the temperature setting to the desired temperature Adjustable temperature range STEP 4 Set the FAN SPEED selector button to the setting you want STEP 5 Press the FLAP button and set the airflow direction as desired Refer to Adjust...

Page 74: ...the event of power failure the unit will stop 3 Adjusting the Fan Speed A Automatic fan speed Simply set the FAN SPEED selector button to the position This automatically sets the best fan speed for the room temperature B Manual fan speed If you want to adjust fan speed manually during operation just set the FAN SPEED selector button as desired or 4 Fan Only If you want to circulate air without any...

Page 75: ... of the indoor temperature when night setback was selected This enables you to save energy without sacrificing comfort This function is convenient when gentle cooling is needed Setting temperature Press the NIGHT SETBACK button 30 min 30 min Time 2 F 2 F When the night setback mode is selected the air conditioner automatically lowers the temperature setting 4 F when 30 minutes have passed after th...

Page 76: ...essed the unit operates at maximum output for 30 minutes regardless of the desired temperature The fan speed is 1 step above High HIGH POWER Mode cannot be used when the operation mode is Automatic Operation QUIET Mode and HIGH POWER Mode cannot be used at the same time 8 ION Mode The ION mode is used during operation to generate negative ions that freshen up the air in the room Press the ION butt...

Page 77: ...vary slightly depending upon the outdoor temperature and the way in which frost forms Cold draft prevention For several minutes after the start of heating operation the indoor fan runs at lower speed until the indoor heat exchanger coil has warmed up sufficiently However the fan may remain stopped when the room temperature is low This is because the COLD DRAFT PREVENTION SYSTEM is operating Someti...

Page 78: ...Return button until PM 10 30 is displayed The time can be set in 1 minute increments Holding down the button advances the time rapidly in 10 minute increments 3 Press the CLOCK button again This completes the setting of the current time 1 Press the OFF TIME setting button once The timer indication is displayed and the present OFF time is shown 2 Press the Advance Return button until AM 11 00 is di...

Page 79: ...r operates as if it is turned off Operation Indication 1 Press the ON TIME setting button once The timer indication is displayed and the present ON time is shown 2 Press the Advance Return button until AM 7 10 is displayed The timer indication blinks The time can be set in 10 minute increments Holding down the button advances the time rapidly in 10 minute increments 3 Wait a few seconds and then t...

Page 80: ...to operate for one hour from that point in time and then stops It is not possible to use the OFF Timer and 1 Hour OFF Timer together Whichever function is set last takes precedence If the 1 HR TIMER button is pressed while the TIMER OFF function operates the OFF Timer is cancelled and the unit will stop operating one hour later 2 Operation together with the DAILY ON OFF REPEAT Timer The 1 Hour OFF...

Page 81: ...on position until the air being blown out of the unit begins to warm Once the air warms up the flap position and fan speed change to the settings specified with the remote control Use the FLAP button on the remote control to adjust the position of the flap If you move the flap by hand the flap position according to the remote control and the actual flap position may no longer match If this should ...

Page 82: ... 2 Do not pour water on the indoor unit to clean it This will damage the internal components and cause an electric shock hazard Casing and Grille Indoor Unit Clean the casing and grille of the indoor unit with a vacuum cleaner brush or wipe them with a clean soft cloth If these parts are stained use a clean cloth moistened with a mild liquid detergent When cleaning the grille be careful not to for...

Page 83: ...e the anti mold filter 1 With the FRONT mark of the anti mold filter at the front align the two indentions near the mark with the hooks at the rear of the air intake grille and then mount the anti mold filter 2 Allow the edge of the air intake grille to slide into the top of the indoor unit and then insert it all the way inside 3 To attach the air intake grille to the indoor unit press its bottom ...

Page 84: ...e stubborn dirt moisten a cloth in warm water no hotter than 104 F wring thoroughly and then wipe The air intake grille can be removed in order to wash it with water Removing and remounting the air intake grille Refer to How to remove the anti mold filter and How to replace the anti mold filter on page 23 When using a footstool or the like be careful not to let it tip over Washing the grille with ...

Page 85: ... people in room 2 Eliminate heat source if possible 3 Doors and or windows are open 3 Shut them to keep the heat or cold out 4 Obstacle near air intake or air discharge port 4 Remove it to ensure good airflow 5 Thermostat is set too high for cooling or too low for heating 5 Set the temperature lower or higher 6 Outdoor temperature is too low for heating 6 Consult your dealer or try to use another ...

Page 86: ...INSTALLATION INSTRUCTIONS KHS1872 CH1872 KHS2472 CH2472 II 852 6 4189 989 00 3 APPENDIX B A 2 ...

Page 87: ...ter unit Connections 3 9 Mounting 3 10 Drain Hose 4 HOW TO INSTALL THE OUTDOOR UNIT 16 4 1 Wiring Instructions for the Outdoor Unit 5 REFRIGERANT TUBING 17 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 5 7 Finishing the...

Page 88: ...orting Be careful when picking up and moving the indoor and out door units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin alu minum fins on the air conditioner can cut your fingers When Installing In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construct a strong wood or meta...

Page 89: ...ely from a local source you will need 1 Deoxidized annealed copper tube for refrigerant tub ing as detailed in Table 2 Cut each tube to the appropriate lengths 1 to 1 4 30 cm to 40 cm to dampen vibration between units Table 2 2 Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing Wall thickness of the insulation should be not less than 5 16 8 mm 3 U...

Page 90: ...nit more than 3 3 1 m away from any antenna or power lines or connecting wires used for television radio telephone security system or intercom Electrical noise from any of these sources may affect operation Drain hose Indoor unit Outside drainage Fig 1 2 5 cm min 6 15 cm min Front View 2 5 cm min Fig 2 INDOOR UNIT Tubing length L OUTDOOR UNIT Elevation difference H Fig 3a WARNING To prevent abnorm...

Page 91: ...ect the unit against possible water damage and decreased service life Figs 5c and 5d or 5e G Install cushion rubber under unit s feet to reduce vibration and noise Fig 5f G use lug bolts or equal to bolt down unit reducing vibration and noise G Install in a location where no antenna of a television or radio exists within 10 3 m Outdoor unit Hot air Heat source Exhaust fan NO Fig 4 Air intake Min 4...

Page 92: ...ose and drain cap on page 14 3 2 Make a Hole 1 Place the rear panel from the indoor unit on the wall at the location selected Make sure the panel is hori zontal using a carpenter s level or tape measure to measure down from the ceiling Wait until after cut ting the hole before attaching the rear panel to the wall 2 Determine which side of the unit you should make the hole for tubing and wiring Fig...

Page 93: ...is strong enough to sus pend the unit See either Item a or b below depending on the wall type a If Wooden Wall 1 Attach the rear panel to the wall with the 8 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 5 mm dia holes in the panel over th...

Page 94: ...grille into the frame first Fig 18b Then insert the tabs on the top of the grille and on the front face into the frame 2 Make sure that the grille and frame are firmly fitted together by engaging the tabs 3 Attach the thermistor on the grille Fig 17a 4 Close the cover and replace the screw Fig 17a 5 Affix the grille with the 3 previously removed screws Fig 16b 6 Install the air intake grille a All...

Page 95: ...agram 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 3 To prevent possible hazards 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...

Page 96: ...nding line 230 208V 230 208V 230 208V INDOOR UNIT OUTDOOR UNIT Field supply Grounding line L1 L2 Power supply Single phase 230 208V 60HZ Terminal Terminal A B C B CAUTION G 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 G Do not run wiring for antenna signal or power lines of television radio stereo ...

Page 97: ... unit wiring from the back of the indoor unit and pull it toward the front for connec tion Fig 26a 26b 5 Connect the inter unit wiring to the corresponding terminals on the terminal plate Fig 26a 26b while referring to the wiring diagram 6 Be sure to secure the wiring with the provided clamp When closing the air intake grille press the bottom right and left corners and center Fig 27 Please refer t...

Page 98: ...the terminal screw 4 Shape the loop wire properly place it on the termi nal plate and fix it securely with the removed termi nal screw using a screwdriver I For stranded wiring 1 Cut the wire end with a cutting pliers then strip the insulation to expose the stranded wiring about 3 8 10 mm and tightly twist the wire ends Figs 30 and 31 2 Using a screwdriver remove the terminal screw s on the termin...

Page 99: ...the wall Adjust the indoor unit so it is securely seated on the rear panel Fig 36 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 18 The drain hose should come straight down the wall to a point where water runoff won t stain the wall 4 Connect the refrigerant tubing to the outdoor unit Afte...

Page 100: ...the drain hose fully onto the drain pan outlet until the drain hose edge is pushed into the insula tion Check that the screw holes in the drain bracket and the drain pan outlet are aligned and securely in contact then fasten them with the screw After attaching the drain hose check that it is attached securely Fig 40c Drain cap Use a Phillips screwdriver to push the drain cap in firmly If it is dif...

Page 101: ...f 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 44 Foamed polyethylene or its equivalent is recom mended WARNING Risk of Electric Shock Do not supply power to the unit or operate it until all tubing and wiring to the out side unit are completed Condensation Insulation material Locally purchas...

Page 102: ...s 1 Remove access panel C Fig 46 2 Connect the inter unit and power supply line accord ing to the drawing on the panel side 3 Be sure to size each wire allowing approx 4 10 cm longer than the required length for wiring Store excess wiring inside the cabinet 4 When connections are completed check that all connections are correct as shown in the wiring sys tem diagram on panel side 5 Be sure to grou...

Page 103: ...ool Figs 49a and 49b Use RIGID or equivalent A good flare should have the following characteristics G inside surface is glossy and smooth G edge is smooth G 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 b Be sure to apply refrigerant lubri...

Page 104: ...half of each previous tape turn Fig 55 3 Clamp the tubing bundle to wall using 1 clamp approx every 47 120 cm Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also be sure the con densation drain hose splits away from the bundle and drips clear of the unit and the tubing 5 7 Finishing the Installation After finishing insulating and taping over the tubin...

Page 105: ... time for evacuation Table 7 Hi Lo Indoor unit Outdoor unit Manifold valve Exclusively for R410A Pressure gauge Vacuum pump Charging hose Exclusively for R410A Vacuum pump adapter Exclusively for R410A with reverse flow prevention Fig 57 CAUTION Be sure to use a manifold valve for air purging If it is not avail able use a stop valve field sup ply for this purpose The Hi knob of the manifold valve ...

Page 106: ...rt slightly to release the pressure Then remove the hose 11 Fasten the valve cap on the wide tube service port securely with an adjustable wrench or box wrench Next mount the valve cap on the service valve and tighten it to 170 lbs in 200 kgf cm with a torque wrench 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...

Page 107: ...ain unit blinking Fig 59c After 3 minutes the system shifts into cooling opera tion and cool air will start to be felt Cool mode test run is unaffected by the room temperature 3 Press the ON OFF operation button of the remote con troller again to stop the test run Fig 59a 4 Finally press the ACL reset button of the remote con troller to release it from Test Run mode to return to nor mal mode Fig 5...

Page 108: ...ube valve stem Then quickly stop the unit 5 Disconnect all gauges and hoses and replace the valve caps as they were before I Basic Functions of the Service Valves The basic functions of the service valves are given in Table 8 below Action Narrow Tube Service Valve 2 Way Wide Tube Service Valve 3 Way CLOSED Fully OPEN Fully OPEN Shipping Operating and test running the air conditioner Measuring pres...

Page 109: ...there is an obstacle between the remote con trol unit and the air conditioner since a check signal is sent from the remote control unit every 5 minutes 7 1 Mounting on a Wall Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location The indoor unit should make a beeping sound to indicate that...

Page 110: ... object such as the tip of a pen to press the ACL button When this has been done oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as shown below Press this button 2 times to change the display to oP 7 address setting Fig 64 5 oP 7 has now been selected for address setting 6 Press the ON OFF operation button ...

Page 111: ...YO Commercial Solutions A Division of SANYO North America Corporation 1300 Michael Drive Suite A Wood Dale IL 60191 U S A Sanyo Canada Inc 1 300 Applewood Crescent Concord Ontario L4K 5C7 CANADA Jan 2009 T ...

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Sanyo 200 BTU, Technical & Service Manual

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