Sanyo CH2442 Installation Instructions Manual Download

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S4359146

(1) Accessories

●

Check that the following parts are in the box when unpacking.

3-9. Duct for Fresh Air

●

There is a duct connection part on sideface of the

indoor unit. (Fig. 3-16)

●

Optional air-intake plenum (including duct connection

box and flange) can be attached to the indoor unit.

NAME

QT’Y

REMARKS

Cord with socket

Connecting line. Not necessary for

(9P)

intaking fresh air.

Screw

Air-intake filter

(M5

L5 in.)

(for fastening)

Screw

Duct connection flange/ box

(M4

L1/2 in.)

(for fastening)

Duct connection box

(for fresh air)

Duct connection flange

(for connecting fresh air duct)

(2) Installation

●

Installation steps (a) to (e) are the same for both the

CMB-GSJ80U and the GSJ140U. The drawing

illustrates installation of air-intake plenum to the

CMB-GSJ80U.

(a) Installing the air-intake plenum

●

Set the air-intake plenum to the indoor unit taking

care not to set the incorrect direction. (Fig. 3-17)

●

Fasten the air-intake plenum with the accessory

screws. (M5

L5 in., 4pcs) (Fig. 3-17)

(b) Installing the duct connection box

●

Fasten the duct connection flange to the duct

connection box with the accessory screws.

(M4

L1/2 in., 4pcs) (Fig. 3-18)

●

Put the duct connection box into the rectangular

hole of the air-intake plenum and fasten it to the

both sides of the indoor unit and plenum with the

accessory screws. (M4

L1/2 in., 3pcs) (Fig. 3-18)

(c) Installing the indoor unit

●

Install the indoor unit to the ceiling.

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

Fig. 3-17

When installing in a pre-

existing location, install the

indoor unit before installing

the duct connection box.

CAUTION

8P socket (red)
(ceiling panel side)

8P socket (red)

Clamper

Panel lead wire (8P)

Socket cover

Installation
screws

Air-intake
plenum

(electrical
component box)

Indoor unit

1975_X_S

Fig. 3-16

1974_X_S

For fresh air intake

2-5/32

2-3/8

4-ø1/8 hole

ø4-13/32

Detail of fresh air intake

Air-intake plenum

Type

CMB-GSJ80U

PNR-XH2442

(XH1242, XH1842, XH2442)

CMB-GSJ140U

PNR-XH3642

(XH3642, XH4242)

Summary of Contents for CH2442

Page 1: ... 1 1 1 1 X 2 2 2 2 2 K 3 3 3 3 3 T 4 4 4 4 4 U 5 5 5 5 5 C 6 6 6 6 6 7 7 7 7 7 8 8 8 8 8 9 9 9 9 9 OPERATING LIMITS Maximum Conditions Cooling Heating Outdoor temperature 115 F DB 65 F WB Room temperature 71 F WB 80 F DB Minimum Conditions Outdoor temperature 23 F 0 F DB 15 F WB Room temperature 57 F WB 59 F DB When air discharge chamber is installed Split System Heat Pump Air Conditioner 24 XH244...

Page 2: ...ce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers Important CAUTION When Installing In a Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors In Moist or Uneven Locations Use a raised concrete pad or concrete blocks to provide a solid level foundation for the outdoor u...

Page 3: ... Concealed Duct Type UH Type 35 3 22 Required Minimum Space for Installation and Service 3 23 Suspending the Indoor Unit 3 24 Installing the Drain Piping Page 3 25 Checking the Drainage 3 26 Increasing the Fan Speed 4 HOW TO INSTALL THE OUTDOOR UNIT 40 4 1 Removing the Protective Spacer for Transportation 4 2 Installing the Outdoor Unit 4 3 Tubing Direction 5 ELECTRICAL WIRING 41 5 1 General Preca...

Page 4: ... PROCESS TUBING 79 10 1 Use of the Flaring Method 10 2 Flaring Procedure with a Flare Tool 10 3 Precaution before Connecting Tubes Tightly 10 4 Precautions during Brazing 10 5 Connecting Tubing between Indoor and Outdoor Units 10 6 Insulating the Refrigerant Tubing 10 7 Taping the Tubes 10 8 Finishing the Installation 11 AIR PURGING 82 12 TEST RUN 85 12 1 Preparing for Test Run 12 2 PCB Setting 12...

Page 5: ...Copper Tube and Insulation Material Copper tubing for connecting the outdoor unit to the indoor unit is available in kits which contain the narrow and wide tubing fittings and insulation Consult your nearest sales outlet or A C workshop If you wish to purchase these materials separately from a local source you will need 1 Deoxidized annealed copper tube for refrigerant tubing 2 Foamed polyethylene...

Page 6: ...f power supply For sizing up of narrow tube from 1 4 in to 3 8 in only for 24 type Table 1 2 KH Wall Mounted Part Name Figure Q ty Remarks Wall fixture 1 1 Insulator 1 1 Mounting plate 1 1 Tapping screw 1 20 Full scale diagram 1 Wall fixture 2 1 Rawl plug 2 10 Cover 2 1 Tapping screw 2 10 Insulator 1 Tube connector 1 Truss head Phillips 4 5 8 in Truss head Phillips 4 1 in For supporting the indoor...

Page 7: ...nstallation Instruction 1 Owner s manual 1 To open and shut the Narrow Tube Service Valve For protecting refrigerant pipe by attaching to the edge of Tubing Outlet For protecting inter unit control line by attaching to the edge of wiring outlet Black White Table1 4 UH Concealed Duct Part Name Figure Q ty Remarks Flare insulator 2 Insulating tape 2 2 Tapping screw TOTA4 10 14 or 20 or 24 Jumper cab...

Page 8: ... 2 1 3 Batteries 2 Wire joints 4 Wired remote controller comes with 7 7 8 in wire Pan head tapping screws 4 13 32 in Truss head tapping screws 4 5 8 in Run Timer Heating preparations Machine screws M4 1 in Vinyl clampers L 5 29 32 Small screws M4 1 9 16 in Machine screws M4 1 in Ceiling installation paper pattern 3 3 4 2 1 32 in RCS BH80UA WL Part Name Figure Q ty Part Name Figure Q ty 1 2 Carrier...

Page 9: ...l Identification label 2 Screws for fixture 1 3 16 in Label Terminal base label SYSTEM CONTROLLER IDENTIFICATION LABEL ALL Central Control ALL RCU ZONE1 Central Control ZONE1 RCU ZONE2 Central Control ZONE2 RCU ZONE3 Central Control ZONE3 RCU ZONE4 Central Control Please attach this label on surface of the lid after cleaning If need to write down some detail use magic marker ZONE4 RCU ALL ON INPUT...

Page 10: ...0 Limit of elevation difference between the 2 units Models CH2442 CH3642 CH4242 Tubing Data Tubing size Narrow tube in mm 1 4 6 35 3 8 9 52 outer dia Wide tube in mm 3 4 19 05 3 4 19 05 Limit of tubing length ft 165 165 Outdoor unit is higher 165 165 than indoor unit ft Outdoor unit is lower 100 100 than indoor unit ft Max allowable tubing length at shipment ft 100 100 Required additional refriger...

Page 11: ...be uniformly cooled select a location where the ceiling is strong enough to support the weight of the unit select a location where tubing and drain pipe have the shortest run to the outdoor unit allow room for operation and maintenance as well as unrestricted air flow around the unit install the unit within the maximum elevation difference above or below the outdoor unit and within a total tubing ...

Page 12: ... bolt down unit reducing vibration and noise In case of multiple installations Fig 2 1 Fig 2 2 Min 1 inch Min 1 inch Min 2 ft 4 in 0931_C_I Min 7 ft Ground Air dis charge 0932_C_I Obstacle above Unit spacing if air discharge chamber is not used Unit spacing when air discharge chamber is used Min 4 ft Min 4 ft Min 5 ft Min 1 ft Min 12 ft Min 8 inch Min 4 ft Min 8 inch Min 4 ft Min 1 ft 2 inch Min 1...

Page 13: ...can annoy the passers by Refer to Fig 2 4 2 2 Installing the Outdoor Unit in Heavy Snow Areas In locations subject to strong winds snow proof ducting should be fitted and direct exposure to the wind should be avoided as much as possible The following problems may occur when the outdoor unit is not provided with a platform and snow proof ducting a The outdoor fan may not run and there may be damage...

Page 14: ...stallation 0490_C_I Fig 2 8 Fig 2 7 2 3 Precautions When Installing in Heavy Snow Areas 1 The platform should be higher than the maximum snow depth Fig 2 5 2 The two anchoring feet of the outdoor unit should be attached to the platform and the platform should be installed beneath the air intake side of the outdoor unit 3 The platform foundation must be solid and the unit must be secured with ancho...

Page 15: ...e pitch of the suspension bolts using the supplied full scale installation diagram The diagram and table Fig 3 3 and Table 3 2 show the relationship between the positions of the suspension fitting the unit and the panel 32 9 32 Ceiling opening Grille center 29 13 16 Suspention bolt pitch X 1969_X_S Refrigerant tubing side Drain hose side B Suspention bolt pitch A Ceiling opening Length Type Table ...

Page 16: ...uspension bolt must be appropri ate for a distance between the bottom of the bolt and the bottom of the ceiling of 19 32 in or more as shown in Fig 3 4 3 Thread the 2 hexagonal nuts field supply and washers onto the 4 suspension bolts as shown in Fig 3 5 Use 2 sets of nuts and washers upper and lower so that the unit will not fall off the suspen sion lugs 4 Remove the protective cardboard used to ...

Page 17: ...ure the drain pipe has a downward gradient 1 100 or more and that there are no water traps Do not install an air bleeder tubes as this may cause water to spray from the drain tube outlet Fig 3 8 If it is necessary to increase the height of the drain pipe the section directly after the connection port can be raised a maximum of 19 11 16 in Do not raise it any higher than 19 11 16 in as this could r...

Page 18: ...of water into the drain pan to check drainage 2 Do Test Run to check the drainage after complet ing installation When performing Test Run be sure to observe the Test Run procedure Refer to page 89 Be careful since the fan will start turning when checking the drainage 3 After drain checking is finished return the Operation Selector switch to the RUN position ON position and remount the tube cover T...

Page 19: ...ng Panel 1 Remove the air intake grille and air filter from the ceiling panel Figs 3 13 and 3 14 a Remove the 2 screws on the latch of the air intake grille Fig 3 13 b Press on the 2 latches of the air intake grille with your thumb in the direction of the arrow to open the grille Fig 3 13 c With the air intake grille open about 45 remove the safety string hook on the grille side Fig 3 14 d Pull th...

Page 20: ...n the ceiling panel 4 Install the wiring connector from the ceiling panel to the connector in the electrical component box of the indoor unit After installing the connector use the clamp on the body of the indoor unit to secure the wiring NOTE NOTE 5 Install the air filter and air intake grille by perform ing the steps in section 3 6 in reverse Rehook the safety string before closing the air intak...

Page 21: ...correct direction Fig 3 17 Fasten the air intake plenum with the accessory screws M5 L5 in 4pcs Fig 3 17 b Installing the duct connection box Fasten the duct connection flange to the duct connection box with the accessory screws M4 L1 2 in 4pcs Fig 3 18 Put the duct connection box into the rectangular hole of the air intake plenum and fasten it to the both sides of the indoor unit and plenum with ...

Page 22: ...he socket cover of the air intake plenum and pass the 8P sockets through it Fix the panel lead wire to chamber side clamper Fig 3 17 Connect the 8P socket electrical component box side to the 8P socket ceiling panel side of the indoor unit electrical component box Reattach the socket cover Fig 3 18 Ceiling panel Panel catch Installation screws M4 1 2 in Duct connection flange Duct connection box 1...

Page 23: ...elected Make sure the unit is horizontal using a level or tape measure to measure down from the ceiling Fig 3 20 2 Before drilling a hole check that there are no studs or pipes behind the determined location Avoid area where electrical wiring or conduit is located Also take this precaution if the tubing goes through a wall at any other location 3 Using a sabre saw key hole saw or 3 5 32 in hole cu...

Page 24: ...he tubing goes through a wall at any other location 4 Using a sabre saw key hole saw or 3 5 32 in hole cutting drill attachment make a hole in the wall The required minimum hole diameter for these models is 3 3 16 in Fig 3 25 5 Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a slight angle 1 4 in shorter than the thickness of the wall Fig 3 26 6 Place...

Page 25: ...ia holes in the wall Insert rawl plugs for appropriate mounting screws Fig 3 29 Confirm that the wall is strong enough to support the unit a If the Wall is Wooden 1 Attach the wall fixture to the wall with the 12 screws provided Fig 3 30 If you are not able to line up the holes in the wall fixture with the beam locations marked on the wall use rawl plugs or toggle bolts to go through the holes on ...

Page 26: ...the wiring connector Fig 3 33 4 Set the flap in the horizontal position Fig 3 34 5 Remove the 3 screws Fig 3 34 6 Remove the casing Fig 3 34 When replacing the casing be careful not to crush the lead wires between the casing and the frame Fig 3 34 KH2442 NOTE Fig 3 32 Fig 3 33 0947_T_I Frame Flap Casing Screws Fig 3 34 Fig 3 31 Plastic cover Screw 0945_T_I Clamp Screw 2023_T_I Wiring connector 202...

Page 27: ...ng tube inside the indoor unit Use a flare nut Fig 3 39 Arrangement for Right Tubing a Remove the 2 screws and take off the side cover Fig 3 38 b Cut out the L shaped tubing outlet using a hacksaw Fig 3 40 c Using the L shaped tube field supply connect tubing between the indoor and outdoor units Fig 3 42 Arrangement for Left and Left rear Tubing a Remove the 4 screws 2 on each side and take off bo...

Page 28: ...onnect and circuit breaker for overcurrent protection should be provided in the exclusive line 3 To prevent possible hazards from insulation failure the unit must be grounded 4 All wiring must be connected tightly 5 Do not allow wiring to touch refrigerant tubing compressor or any moving parts of the fan Unauthorized changes in the internal wiring can be very dangerous The manufac turer will accep...

Page 29: ... the inter unit wiring from the outdoor unit to the corresponding terminals on the terminal plate Be sure to refer to the wiring system diagram label inside the metallic cover and carry out the correct field wiring Wrong wiring can cause the unit to malfunction Check local electrical codes and any specified wiring instructions or limitations e Secure the metallic cover with its screw Then replace ...

Page 30: ... hose and inter unit wiring as shown in Fig 3 49 0954_T_I Cover Refrigerant tubing Inter unit wiring Drain hose Fig 3 47 0955_T_I Insulating tape 1 Shape the narrow refrigerant tube and the drain hose in the desired direction so that they can easily go into the wall hole Fig 3 50 2 Push the wiring narrow tube and drain hose through the hole in the wall 3 Bend the tubing if necessary to run along t...

Page 31: ...ill run in the room insulate the hose so that chilled condensation will not damage furniture or floors Fig 3 54 Foamed polyethylene or its equivalent is recom mended Do not supply power to the unit or operate it until all tubing and wiring to the outdoor unit are completed Fig 3 53 Fig 3 54 0957_T_I Drain hose Slant Indoor unit 0958_T_I Condensation Insulation material field supply must be used ...

Page 32: ...b Use existing ceiling supports or construct a suitable support as shown in Fig 3 57 It is important that you use extreme care in supporting the indoor unit from the ceiling Ensure that the ceiling is sufficiently strong enough to support the weight of the unit Before hanging the ceiling unit test the strength of each at tached suspension bolt 4 Screw in the suspension bolts allowing them to protr...

Page 33: ... ceiling or not Fig 3 61 and 3 62 7 Suspend the indoor unit as follows a Mount a washer and two hexagonal nuts on each suspension bolt as shown in Fig 3 63 Fig 3 59 Slide toward front side Side panel 0972_T_I Fig 3 60 unit Suspension bolt field supply Ceiling surface Washer supplied Double nut field supply Fixture 0974_T_I Fig 3 61 unit Suspension bolt field supply Washer supplied Washer field sup...

Page 34: ...eiling panel and the ceiling surface and fill the gap with an appropriate insulation or filler material 8 If the tubing and wiring are to go towards the rear of the unit make holes in the wall Fig 3 66 9 Measure the thickness of the wall from the inside to the outside and cut PVC pipe at a slight angle to fit Insert the PVC pipe in the wall Fig 3 67 Fig 3 64 0979_T_I 0978_T_I Fig 3 65 NOTE The hol...

Page 35: ...ig 3 70 Never allow traps to occur in the course of the piping Insulate any piping inside the room to prevent dripping Use the supplied drain pipe to connect the drain pipe with the drain outlet of the indoor unit After connecting the drain pipe securely wrap the supplied drain pipe insulator around the pipe seal the gap at the drain socket with the supplied black insulation tape then secure it wi...

Page 36: ...ng joint wide tube Upper drain port O D 1 1 4 in Bottom drain port O D 1 1 32 in Suspension lug Power supply outlet 2 ø1 3 16 hole Fresh air intake port ø5 29 32 hole Flange for the flexible air outlet duct ø7 7 8 hole Tube cover Electrical component box Flange for the air intake duct Option or field supply 9 10 9 10 11 1978_U_I 11 Suspension bolt pitch Suspension bolt pitch M ø1 8 Hole 4 ø15 32 H...

Page 37: ...d and connected inside the ceiling when suspending the unit If the ceiling is already constructed lay the tubing into position for connection to the unit before placing the unit inside the ceiling 2 Screw in the suspension bolts allowing them to protrude from the ceiling as shown in Fig 3 74 Cut the ceiling material if necessary 3 Thread the 2 hexagonal nuts and washers field supply onto the 4 sus...

Page 38: ...g nuts face upward Fig 3 79 2 After connecting the drain piping securely wrap the supplied packing and drain pipe insulator around the pipe then secure it with the supplied clamps Fig 3 80 Make sure the drain pipe has a downward gradient 1 100 or more and that there are no water traps Fig 3 78 Fig 3 79 Fig 3 80 Drain insulator supplied Clamps supplied 0046_X_I CAUTION NOTE Air outlet duct Air outl...

Page 39: ...ompleted use the following procedure to check that the water will drain smoothly For this prepare a bucket and wiping cloth to catch and wipe up spilled water 1 Connect power to the power terminal board L1 L2 terminal inside the electrical component box 2 Remove the tube cover and through the opening slowly pour about 43 oz of water into the drain pan to check drainage 3 Short the check pin CN5 wh...

Page 40: ...l axis represents the AIR FLOW CFM The characteristic curves for HT H M and L fan speed control are shown The nameplate values are shown based on the H air flow For the 24 type the air flow is 636 CFM while the external static pressure is 49 Pa at H position If external static pressure is too great due to long extension of duct for example the air flow volume may drop too low at each air outlet Th...

Page 41: ...nside the unit To access them remove the access panel by removing the 3 attaching screws then slide the panel downward and pull it toward you If either rear right or front tubing is needed punch out the knockout holes with a hammer or similar tool After punching out the knockout holes mount plastic protectors on the tubing outlets These accessories are packed inside the unit and can be accessed th...

Page 42: ...follows The remote control wiring and the inter unit control wiring should be wired apart from the inter unit power wiring Use shielded wires for inter unit control wiring between units and ground the shield on both sides 9 If the power supply cord of this appliance is damaged it must be replaced by a repair shop appointed by the manufacture because special purpose tools are required 10 All wiring...

Page 43: ...n the above diagrams 2 Inter Unit Control Wiring C and remote control ler wiring D E has no polarity But for other wiring respect polarity Be sure to connect as shown in the Wiring System Diagram 3 R C Address should be set before turning the power on 4 Regarding the R C Address setting refer to page 87 Auto address setting can be executed by a remote controller automatically G L2 L1 1 2 Power sup...

Page 44: ... Inter unit power wiring single phase 230 208V Inter unit control wiring Low voltage RED BLK Remote controller Outdoor Unit Ground Ground Option B D A A A E 2089_M_I Power supply single phase 230 208V 1 R C Address on the PCB 1 S2 BLK L1 L2 U1 U2 1 1 2 U1 U2 1 2 1 2 4 L1 L2 G Indoor Unit Inter unit power wiring single phase 230 208V Inter unit control wiring Low voltage Outdoor Unit Ground Ground ...

Page 45: ...wire end with a wire cutter or wire cutting pliers then strip the insulation to expose the stranded wiring about 3 8 in Fig 5 1 2 Using a Pillips head screwdriver remove the terminal screw s on the terminal plate 3 Using a ring connector fastener or pliers securely clamp each stripped wire end with a ring pressure terminal Fig 5 1 4 Place the ring pressure terminal and replace and tighten the remo...

Page 46: ...ontinuous installation JIS CB8340 Two switchbox no cover Fig 6 1 6 1 Installation site selection Install the remote controller at a height of between 3 5 ft above the floor Do not install the remote controller in a place where it will be exposed to direct sunlight or near a window or other place where it will be exposed to the outside air Be sure to install the remote controller vertically such as...

Page 47: ...n into these gaps and pry off the back case Fig 6 4 2 Attach the back case with the 2 small screws provided Using a screwdriver push open the cut outs on the back case These holes are for screws Use the spacers and take care not to tighten the screws excessively If the back case will not seat well cut the spacers to a suitable thickness Fig 6 3 3 Connect the remote controller wiring 2 wires correc...

Page 48: ... unit Operation takes place successively at intervals of 1 second by using combinations of the address setting of each unit Shielded wire 0797_M_I ground ground Fig 6 5 2031_M_I Inter unit wiring Group control wiring Main Sub Indoor unit 8 Indoor unit 7 Indoor unit 2 Indoor unit 1 6 6 6 6 6 RC WD 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Ground earth Outdoor unit Indoor unit No 8 Indoor unit No 3 Indoor uni...

Page 49: ...ollers you set as the main controller When using multiple remote controllers up to 2 of them can be used one is the main remote controller and the other is the sub remote controller To set up a sub remote controller change its remote control address connector RCU ADR located on its PCB from main to sub position main when shipped from factory 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Ground earth Outdoor...

Page 50: ... be used but normally only the sensor set on the indoor unit is used However use the following procedure if you must use the sensor on the remote controller 1 Hold down the buttons for at least 4 seconds Note The Unit No first displayed is the main indoor unit address for group control Note Do not press the button 2 Select CODE NO 32 with the Temp setting buttons 3 Change the set data from 0000 to...

Page 51: ...rial communications signal Error in receiving serial communications signal Error in transmitting serial communications signal Error in receiving serial communications signal Indoor unit is damaged Power is not supplied Error in transmitting serial communications signal Indoor unit address setting is duplicated Remote controller address RCU ADR switch is duplicated Do not press Auto address button ...

Page 52: ...troller connect wired remote controller with the indoor unit temporarily to check the alarm message in detail System controller is transmitting incorrect signal System controller is detecting incorrect signal Protective device of the sub indoor unit is activated in group contorl Serial commu nication errors Mis setting Activation of protective device Possible Cause of Malfunction The following mes...

Page 53: ...ot install the remote controller in the following places In direct sunlight Behind a curtain or other place where it is covered More than 26 ft away from the air conditioner In the path of the air conditioner s airstream Where it may become extremely hot or cold Where it may be subject to electrical or magnetic interference 1 If Wall mounted Fixed Position Install the remote controller at a conven...

Page 54: ...troller Up to 6 indoor units can be controlled separately through the address switches The operating control has the reception address switch and the remote controller has transmission address switch This function is utilized by matching the transmission and reception address switches 1996_M_I Sensor button SENSOR ADR ACL CL SET Fig 7 3 NOTE ADR ADR ADR ADR 7 4 Setting the Model Code 1 Flap displa...

Page 55: ...ing a noise filter Install the operating controller at the indoor unit intake port section 1 Fasten the operating controller to the indoor unit intake port section electrical component box opposite side with the 2 accessory screws 4 L13 32 in 2 Connect the operating controller 2 wires WHT BLK to the remote control wire WHT in the electrical component box For details on the wiring see 7 9 Electrica...

Page 56: ... the remote control wires in the electrical component box 3 Connect the indicator section and the operating controller by 6P connector in the electrical component box CAUTION Fig 7 8 1537_T_I Operating controller Electrical component box Fig 7 9 3 3 3 3 3 T Ceiling Mounted Type TH Type 7 7 Indicator Section Installation Remove the side panel to install the indicator section Fig 7 8 1 Remove the si...

Page 57: ...ontinu ously and the thermostat does not control the system To protect the air conditioner from overloading the outdoor unit will not start running for 3 minutes after power is applied or the air conditioner is turned off and then back on When the air conditioner fails to start the test run 1 or more of the 3 alarm indicator lamps on the indoor unit will flash See next section Fig 7 10 WHT BLK 1 2...

Page 58: ...between the indoor unit s controller PCB and the remote controller O Compressor protector is working O S C errors between indoor and outdoor units O O Indoor or outdoor thermistor is malfunctioning O O Outdoor unit protector is working O O Indoor unit protector is working O O O TEST RUN switch on the operation controller is in ON state NOTE Stick the alarm message label accompanying with the wirel...

Page 59: ... noise filter If local codes allow this signal receving unit can be mounted using a conventional wall box for flush mounting 1 Insert a minus driver into the gap under the signal receving unit and pry off the cover Fig 7 14 2 Attach the signal receving unit with the 2 small screws provided Use the spacers and take care not to tighten the screws excessively If the signal receving unit will not seat...

Page 60: ...erting a flat tip minus screwdriver or similar tool into the notch in the lower section and prying it off 2 Cut out a section 3 3 4 2 1 32 in on the ceiling using the paper pattern supplied as a guide 3 Run the wire through the mounting carrier and insert into the installation hole as shown in Fig 7 19 4 Fit securely into the ceiling material at sections A and B as shown in Fig 7 20 5 Connect the ...

Page 61: ...lamps on the indoor unit will flash The TEST RUN switch is used only for servicing the air conditioner DO NOT use this switch for normal opera tion Otherwise it may put stress on the system 3 Make a test run using the air conditioner in COOL HEAT or FAN modes To protect the air conditioner from overloading the outdoor unit will not start running for 3 minutes after power is applied or the air cond...

Page 62: ...g unit refer to instruction manual that comes with the dedicated service check lines Fig 7 23 2013_M_I ALL RCU SUB RCU MAIN NORMAL PCB CHK TEST RUN Service connector Lamp OPERATION TIMER STANDBY Bright Cause of Trouble lamp lamp lamp No power supply or mis wiring of signal receiving unit O S C errors between the indoor unit s controller PCB and signal receiving unit O S C errors between indoor and...

Page 63: ... An indoor unit address is assigned to each indoor unit Operation takes place successively at intervals of 1 second by using combinations of the address setting of each unit Shielded wire 0797_M_I ground ground Fig 7 25 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Ground earth Outdoor unit Indoor unit No 8 Indoor unit No 3 Indoor unit No 2 Indoor unit No 1 1 2 Group control Connection wiring for group cont...

Page 64: ...iving unit you set as the main controller When using multiple signal receiving unit up to 2 of them can be used one is the main signal receiving unit and the other is the sub signal receiving unit To set up a sub signal receiving unit change its remote control address connector RCU ADR located on its PCB from main to sub position main when shipped from factory sub 1 2 Wire joint 2 wires Signal rec...

Page 65: ...al receiving unit make one the main signal receiving unit factory shipped state 2 On the other signal receiving unit change the address connector on the PCB from main to sub position In this state it functions as a sub signal receiving unit Basic wiring diagram Install wiring correctly incorrect wiring will damage the equipment To operate 1 indoor unit with 2 signal receiving unit set at different...

Page 66: ...or Flush Mounting If local codes allow this weekly timer can be mounted using a conventional wall box for flush mounting 1 Remove the flat top screw on the bottom of the back case When you open up the decorative cover you will see two gaps under the weekly timer Insert a coin into these gaps and remove the back case Figs 8 2 8 3 2 Attach the back case with the 2 small screws provided Using a screw...

Page 67: ...ew of the lead wire of the weekly timer remove the collar and connect the suppplied connection wiring to the timer terminal 4P connector of the weekly timer Place the supplied connection wiring into the groove neatly and then refasten the collar 2 Pass the supplied connection wiring through the lead wire drawing out port on the bottom case of the weekly timer then run it behind the wall and connec...

Page 68: ...om sources of electrical noise Install a noise filter or take other appropriate action if electrical noise affects the power supply circuit of the unit If local codes allow this system controller can be mounted using a conventional wall box for flush mounting 1 Remove the flat top screw on the bottom of the back case When you open up the decorative cover you will see two gaps under the system cont...

Page 69: ...g on air conditioners concurrently A2 Input for turning off air conditioners concurrently A3 Common input for turning air conditioners on or off A4 On operation state indicator output A5 Alarm indicator output A6 Common indicator output Basic wiring diagram of control wiring Max 64 indoor units and 30 outdoor units can be connected in 1 system Up to 10 system controller can be connected in 1 syste...

Page 70: ...ch OFF Central control mode Individual setting by remote controller can be inhibited by system controller ON Remote control mode Setting by system controller is inhibited by other central control equipments Central control Main Sub selection switch OFF Main ON Sub 1 When AMY adaptor etc is used with system controller set the switch to ON position 2 When only one system controller is used set the s...

Page 71: ...All OFF and all indoor units to be 1 1 All indoor units to be 2 2 All OFF and all indoor units to be 2 2 All OFF No change Individual control of all indoor units to be permitted Ditto Ditto Ditto All ON Timer OFF ON Timer ON OFF System controller operation Switch No 2 3 4 5 6 1 ON OFF ON OFF ON OFF OFF OFF OFF ON ON OFF OFF ON ON OFF OFF OFF 1 3 2 Auxiliary switch Must be set to OFF position Beep ...

Page 72: ...ing as the table 9 1 4 Stick the system controller unit label in a con spicuous position Table 9 1 Central control Remote control ALL 1 ALL Central 6 ALL Remote ZONE1 2 ZONE1 Central 7 ZONE1 Remote ZONE2 3 ZONE2 Central 8 ZONE2 Remote ZONE3 4 ZONE3 Central 9 ZONE3 Remote ZONE4 5 ZONE4 Central 10 ZONE4 Remote 2048_M_I 2 ON OFF 3 4 5 6 ALL central control 2 ON OFF 3 4 5 6 ALL remote control Inter un...

Page 73: ...as shown on the next page For method c zone registration is executed automatically proceeding from small indoor unit address and small central addresses to larger numbers in numerical order For example NOTE 1 An indoor unit address is assigned to each indoor unit during automatic address operation Each indoor unit address combines an R C address and indoor unit number as follows This address is di...

Page 74: ...t press buttton 3 Once in this mode the UNIT No CODE No No of SET DATA and indications will flash on the display as shown Fig 9 6 NOTE NOTE In case of group control ALL instead of UNIT No will flash on the display Select the main indoor unit address by pressing the button once 4 Set CODE No to 03 using the and buttons The CODE No 03 must be selected to perform zone registration using the remote co...

Page 75: ...Indoor unit No button 5 Press the button GROUP No turns ON and UNIT No Indoor unit address changes from flashing to ON state UNIT No is registered to selected ZONE No and GROUP No If you make mistake then press the button and reselect the ZONE GROUP and UNIT No 6 Register the other UNIT No in the same way by following the steps 3 to 5 7 Finally complete the registration by pressing the button flas...

Page 76: ...ion will start 3 Registered GROUP No will be disappeared all 4 Central address will be assigned from small indoor unit address to large one in numerical order automatically Finishing automatic zone registration changes from flashing to OFF 5 If the error is happened the CHECK starts flashing and zone registration finishes at this time Press the button 6 Finally complete automatic zone registration...

Page 77: ...ashing and stops flashing and disappears there is no over lapping Then finally complete the auto overlap checking mode by pressing the button 4 If some of GROUP No ZONE No and UNIT No flash you should try again the zone registration 1 Select CODE No C1 by pressing button and press the button 2 Select the flashing GROUP No with ZONE and GROUP button Then press the button and reselect the ZONE GROUP...

Page 78: ... UNIT No Indoor unit address UNIT No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Unit location ZONE GROUP Central address 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56...

Page 79: ... Example All ON input All OFF input Pulse photo compler input Contact capacity DC 24V 10mA Pulse width more than 984 ft sec Wire length less than 330 ft Contact capacity DC 30V 0 5A 9 7 Memory Back Up Switch Check the back up switch is ON for back side of PCB by system controller 2056_M_I Back up switch ON OFF Back up battery 9 8 Test Run 1 Power on for all indoor units Next power on for system co...

Page 80: ... copper tube 4 Make a flare at the end of copper tube with a flare tool Fig 10 3 Use RIGID or equivalent A good flare should have the following characteristics inside surface is glossy and smooth edge is smooth tapered sides are of uniform length 10 3 Precaution before Connecting Tubes Tightly 1 Apply a sealing cap or water proof tape to pre vent dust or water from entering the tubes before they a...

Page 81: ...n 140 180 kg cm Approx 300 360 lbs in 340 420 kg cm Approx 870 1040 lbs in 1000 1200 kg cm Tube Dia 1 4 6 35 mm 3 8 9 52 mm 3 4 19 05 mm 10 6 Insulating the Refrigerant Tubing Always insulate tubes after draining water and complet ing leak tests on all connec tion points To avoid condensation and water leaks the wide tube gas line must be insulated with the supplied insula tion materials Taping th...

Page 82: ...verlap half of each previous tape turn Fig 10 10 3 Clamp the tubing bundle to the wall using 1 clamp about every 3 feet Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also ensure that the condensation drain hose splits away from the bundle and drips clear of the unit and the tubing 10 8 Finishing the Installation After finishing insulating and taping ...

Page 83: ...tube service valves on the outdoor unit are kept closed at this stage Leak test 1 With the service valves on the outdoor unit closed remove the 1 4 in flare nut and its bonnet on the wide tube service valve Save the flare nut and its bonnet for reuse 2 Attach the nitrogen gas cylinder to the service port of the wide tube via a manifold valve with pressure gauges See Fig 11 2 Use a manifold valve f...

Page 84: ... evacu ate the tubing and indoor unit Confirm that the Lo knob of the manifold valve is open Then run the vacuum pump The operation time for evacuation varies with the tubing length and capacity of the pump The following table shows the required time for evacuation The required time in the above table is calculated on the assumption that the ideal or target vacuum condition is around 10 mmHg abs 2...

Page 85: ...wide tube is turned all the way out BACK SEAT position 3 Loosen the charge hose connected to the wide tube service port 1 4 in slightly to release the pressure then remove the hose 4 Replace the 1 4 in flare nut and its bonnet on the wide tube service port and fasten the flare nut securely with an adjustable wrench or box wrench This process is very important to prevent gas from leaking from the s...

Page 86: ...dure switch out of TEST RUN when you are finished or the air conditioner can be damaged because it will not cycle on and off normally To protect the air conditioner from overloading the outdoor unit will not start running for 3 minutes after power is applied or the unit is turned OFF a Press the TEST RUN button on the remote controller Fig 12 3 b Press the ON OFF operation button to start the test...

Page 87: ...s Refrigerant circuit address 1 30 Regarding the example of R C address for group control please refer to page 43 and sec 12 3 page 87 C Central control when using the system controller In case of central control when using the system controller that is when linking outdoor units in a network a Before turning the power supply on set the R C address with S2 S3 on the outdoor control PCB b Remove th...

Page 88: ... address R C address S3 2P dip switch green or blue S2 Rotary switch Black 00 auto address Both OFF Set to 0 1 ON 10 position 20 position ON side S2 S3 OFF side Refrigerant circuit address 2P DIP switch green or Blue Refrigerant circuit address black Refrigerant circuit address factory setting 0 Outdoor control PCB 2093_C_I 2 0 A ADD S1 Automatic address setting start button Used for central contr...

Page 89: ...ration finishes the display will disappear 6 Execute the operation of the other R C line in the same way by following the above steps 2 to 3 7 Complete the auto address operation by pressing the button Required time for auto address operation In case of group control a few minutes for each R C In case of central control max about 20 min for each R C 12 5 Displaying Indoor Outdoor Unit Combina tion...

Page 90: ...is a location to correct correct it Sec 12 8 9 10 Note Check the indoor side drain water Recheck the test items before test operation Check the indoor and outdoor unit combination wiring Sec 5 3 Sec 12 2 B Sec 12 4 Sec 12 2 C Sec 12 4 Sec 12 7 Return the remote controller to normal Display the combination number Sec 12 5 Set the remote controller to test operation Sec 12 1 No No No Yes Yes Yes Yes...

Page 91: ...d tubing vacuuming and gas charging if necessary 3 Check the capacity code setting The factory setting is as shown in the table Double check it The capacity code is set by S4 green or blue 4P DIP switch on outdoor control PCB S4 Capacity code No Outdoor PCB Model No 1 2 3 4 24 type ON ON ON OFF 36 type OFF ON OFF ON 48 type ON ON OFF ON 1 ON ON side 2094_C_I OFF side S4 green or Blue capacity code...

Page 92: ...ssor Compressor motor is overloaded H1 protection Compressor motor is locked H2 Compressor current detection circuit is abnormal H3 Low pressure protector is activated H6 Ref Alarm P9 is not generated if the remote controller is set at test run 12 8 The Main Alarms of Mis wiring Mis setting Remote controller display Nothing displayed In case of individual remote control Remote controller not prope...

Page 93: ...Stem 0547_C_I Action Narrow Tube Service Wide Tube Service Valve 3 Way Valve Ball Valve CLOSED CLOSED Shipping and air purging Fully Fully OPEN OPEN Operating and test running the air conditioner Half Fully OPEN OPEN Measuring pressure and gas charging 0548_C_I O ring Valve cap 0989_C_I Stem Stem Valve cap O ring 1372_C_I 2 Way Valve CH2442 3 Way Valve CH3642 CH4242 ...

Page 94: ...the manifold valve to the service port B on the wide tube service valve 2 Using a hex wrench turn the narrow tube service valve clockwise all the way to close the service valve 3 Press the operation button and start cooling operation 4 When the low pressure gauge reading falls to 14 2 to 7 1 psi 1 to 0 5 kg cm2 fully close the wide tube valve stem with a standard screwdriver Then quickly stop the ...

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Sanyo CH2442, Installation Instructions Manual

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