Page 1: Table Of Contents
4-2. Mounting on a Wall (KS2432A only) I Pump Down I Wired Remote Control Unit (Option) (except 2432A) SANYO FISHER COMPANY A DIVISION OF SANYO NORTH 4-3. Installing the Wired Remote Control Unit AMERICA CORPORATION 21605 Plummer Street Chatsworth, CA91311...
Page 2: Important
Important IMPORTANT! Please Read Before Starting When Installing …………………………………………………………………… …In a Room This air conditioning system meets strict safety and Properly insulate any tubing run inside a room to prevent operating standards. As the installer or service person, it “sweating” that can cause dripping and water damage to is an important part of your job to install or service the walls and floors.
Page 3: General
1. General 1-4. Type of Copper Tube and Insulation Material This booklet briefly outlines where and how to install If you wish to purchase these materials separately the air conditioning system. Please read over the from a local source, you will need: entire set of instructions for the indoor and outdoor Deoxidized annealed copper tube for refrigerant units and make sure all accessory parts listed are with...
Page 4 Table 1-1 XS (Recessed) Part Name Figure Q’ty Remarks For determining suspension bolt pitch Full-scale installation diagram For wide tubes Flare insulator For adjusting the unit position Installation gauge (White For wide tube flare nuts Insulating tape -for insulating) For securing drain hose Hose band For drain joint Packing...
Page 5 Table 1-3-1 KS (Wall-Mounted except KS2432A) Part Name Figure Q’ty Remarks For supporting the indoor unit Wall fixture *1 Insulator *1 For insulation of the tubing of the indoor unit Mounting plate *1 For securing the indoor unit Truss-head For fixing the wall fixture Tapping screw *1 Phillips 4 ×...
Page 6: Tubing Length
If total tubing length becomes 50 to 165 ft., charge additional refrigerant (R22) by 0.86 oz./ft.. When either outdoor unit C2432A or CL2432A is combined with indoor unit KS2432A and total tubing length becomes 25 to 50 ft., charge additional refrigerant (R22) by 0.27 oz./ft..
Page 7: Selecting The Installation Site
2. Selecting the Installation Site Indoor Unit Ceiling-Mounted Type AVOID: Ceiling areas where leakage of flammable gas may be expected. places where large amounts of oil mist exist. Wall direct sunlight. Min.10 inch Min.10 inch locations near heat sources which may affect Front view performance of the unit.
Page 8: Outdoor Unit
Exhaust fan Outdoor Unit Hot air AVOID: Heat source Out- heat sources, exhaust fans, etc. (Fig. 2-1) door unit damp, humid or uneven locations. 0591_C_I Fig. 2-1 choose a place as cool as possible. choose a place that is well ventilated and outside air temperature does not exceed maximum 115°F Min.
Page 9: Air Discharge Chamber For Top Discharge
2-1. Air Discharge Chamber for Top Discharge Install the air-discharge chamber in the field when: Air discharge it is difficult to keep a space of minimum 2 ft. between the air-discharge outlet and the obstacle. the air-discharge outlet is facing the sidewalk and discharged hot air can annoy the passers-by.
Page 10: How To Install The Indoor Unit
3. How to Install the Indoor Unit Recessed Type (XS Type) 3-1. Suspending the Indoor Unit This unit uses a drain pump. Use a carpenter’s level to check that the unit is level. Hole-in-anchor 3-2. Preparation for Suspending Hole-in-plug Concrete Insert Fix the suspension bolts securely in the ceiling using the method shown in the diagrams (Figs.
Page 11: Placing The Unit Inside The Ceiling
3-3. Placing the Unit Inside the Ceiling When placing the unit inside the ceiling, deter- Full-scale installation diagram mine the pitch of the suspension bolts using the (printed on a cardboard packing) supplied full-scale installation diagram. (Fig. 3-4) The size of the opening for the indoor unit can be confirmed by attaching the full-scale installation diagram beneath the unit.
Page 12: Installing The Drain Piping
3-4. Installing the Drain Piping Transparent part for Hard PVC pipe Hose band checking drainage (not supplied) (supplied) (1) Prepare standard hard PVC pipe (O.D. 1-3/64 in.) for the drain and use the supplied drain hose and hose band to prevent water leaks. The PVC pipe must be purchased separately.
Page 13: Checking The Drainage
3-5. Checking the Drainage After wiring and piping are completed, use the follow- ing procedure to check that the water will drain smoothly. For this, prepare a bucket and wiping cloth ready to catch and wipe up spilled water. Do not supply power to the unit until the tubing and wiring to the outdoor unit are completed.
Page 14: Before Installing The Ceiling Panel
Ceiling Panel Never touch or attempt to move the air direction louver CAUTION by hand or you may damage the unit. Instead, use the remote control unit if you want to change the direction or air flow. 3-6. Before Installing the Ceiling Panel (1) Remove the air-intake grille and air filter from the ceiling panel.
Page 15: Installing The Ceiling Panel
3-7. Installing the Ceiling Panel Lift the ceiling panel and position it to align the Install the air filter and air-intake grille by perform- panel hook with the panel catch of the indoor unit. ing the steps in section 3-6 in reverse. NOTE NOTE The ceiling panel must be mounted in the correct...
Page 16: Duct For Fresh Air
3-9. Duct for Fresh Air Air-intake chamber (including Duct connection box and flange) are attached to the indoor unit when used to take fresh outdoor air. High-performance filter or Super long-life filter can be also installed in the air-intake chamber. (1) SETUP PRIOR TO INSTALLATION When installing the high performance filter or super long-life filter, the parts and parts numbers of filters to be assembled with the air-intake chamber are listed below.
Page 17 (b) INSTALLING THE AIR-INTAKE CHAMBER Set the air-intake chamber to the indoor unit taking Installation screws care not to set to the incorrect direction. (Fig. 3-17) Socket cover Fasten the air-intake camber with the accessory screws. (M5 × L125, 4pcs) (Fig. 3-17) (c) INSTALLING THE DUCT CONNECTION BOX Fasten the duct connection flange to the duct connection box with the accessory screws (M4 ×...
Page 18: I Ceiling-Mounted Type (Ts Type)
Ceiling-Mounted Type (TS Type) Front face 3-10. Suspending the Indoor Unit Place the full-scale diagram (supplied) on the ceiling at the spot where you want to install the Rear indoor unit. Use a pencil to mark the drill holes. (Fig. 3-19) Full-scale diagram 0035_T_I NOTE...
Page 19 Pull out the Air-Intake grille pushing claws Hinge Before suspending the indoor unit, remove the 2 of the hinges Screw screws on the latch of the air-intake grilles, open Latch the grilles, and remove them by pushing the claws of the hinges as shown in Fig. 3-23. Then remove both side panels sliding them along the unit toward the front after removing the two screws which fix them.
Page 20 (b) Lift the indoor unit, and place it on the washers through the notches, so as to fix it in place. (Fig. 3-28) Tighten the two hexagonal nuts on each suspension bolt to suspend the indoor unit as shown in Fig. 3-29. NOTE A ceiling surface is not always level.
Page 21: Duct For Fresh Air
3-11. Duct for Fresh Air Duct connection port (Knock-out hole) There is a duct connection port (knock-out hole) at the right-rear on the Panel Top of the indoor unit for drawing in fresh air. If it is necessary to draw in fresh air, remove the cover by knocking out and connect the Panel Top duct to the indoor unit through the connection port.
Page 22: I Wall-Mounted Type (Ks Type)
Wall-Mounted Type (KS Type) 3-13. Removing the Wall Fixture from the Unit KS2432, KS2432A Wall fixture Remove and discard the set screws and take off the wall fixture. (Fig. 3-36) Set screws only for transportation 3-14. Selecting and Making a Hole 1390_T_I Fig.
Page 23 KS3032, KS3632 One hole is required for the air conditioner tubing, and Tape may be either on the left or right side. (Also see section 3-18. Preparing the Indoor Side Tubing.) Full scale installation diagram Tape the full-scale installation diagram on the wall at the location selected.
Page 24: Installing The Wall Fixture Onto Wooden Or Gypsum Wall
3-15. Installing the Wall Fixture onto Wooden or Gypsum Wall wall fixture KS2432, KS2432A Confirm that the wall is strong enough to suspend the unit. a) If the Wall is Wooden (1) Attach the wall fixture to the wall with the 9 screws 0943_T_I (10 screws for KS2432A) provided.
Page 25: Removing The Casing To Install The Indoor Unit
3-16. Removing the Casing to Install the Indoor Unit KS2432, KS3032, KS3632 How to Remove the Casing (1) Remove the plastic cover. (Fig. 3-48) (2) Remove the clamp for the wiring connector. Plastic cover (Fig. 3-49) (3) Disconnect the 2 wiring connectors. (Fig. 3-50) Screw (4) Set the flap in the horizontal position.
Page 26: Preparing The Indoor Side Tubing
Hou to replace the grille Close the flaps. Reinstall the grille into the lower part while aligning its tabs on the upper part. (Fig. 3-54) Insert the tabs in the slots and push the lower part of the grille back into position. 2244_T_I Fig.
Page 27: Wiring Instructions
Arrangement for Right Tubing (a) Remove the 2 screws and take off the side cover. (Fig. 3-59) Tubing (b) Cut out the L-shaped tubing outlet using a hacksaw. from the (Fig. 3-61) outdoor Using the L-shaped tube (field supply), connect unit tubing between the indoor and outdoor units.
Page 28: Wiring Instructions For Inter-Unit Connections
3-20. Wiring Instructions for Inter-Unit Connections KS2432A Insert the inter-unit wiring (according to local codes)into the through-the-wall PVC pipe. Run Rear Wall the wiring toward the indoor side allowing approx. panel 10 inch toextend from the wall face. (Fig. 65) Plastic Route the inter-unit wiring from the back of the cover...
Page 29 Wiring Instructions for Inter-Unit Connections KS2432 Insert the inter-unit wiring (according to local codes) into the through-the-wall PVC pipe. Run Rear Wall the wiring toward the indoor side allowing approx. panel 5". to extend from the wall face. (Fig. 3-68) Plastic Never fix the wiring by any cover...
Page 30: Shaping The Tubing
Cover 3-21. Shaping the Tubing Refrigerant KS2432, KS2432A (Right-side tubing) tubing Shape the refrigerant tubing so that it can easily go into the hole. (Fig. 3-71) Inter-unit Push the wiring, refrigerant tubing and drain hose wiring Drain hose through the hole in the wall. Adjust the indoor unit so it is securely seated on the wall fixture.
Page 31 Remove the 1/2" flare nut from the optional tube connection (C), place it on the cut wide tube, and 3. Cut wide tube 4. Flare wide tube then flare the wide tube. (Fig. 3-76) Connect the optional tube connection (C) to the wide tube.
Page 32: Installing The Drain Hose
KS3032, KS3632 Narrow (1) Shape the narrow refrigerant tube and the drain tube hose in the desired direction so that they can easily go into the wall hole. (Fig. 3-81) (2) Push the wiring, narrow tube, and drain hose through the hole in the wall. (3) Bend the tubing (if necessary) to run along the wall in the direction of the outdoor unit, then tape Drain hose...
Page 33: How To Install The Remote Control Unit
4. How to Install the Remote Control Unit Wireless Remote Control Unit The remote control unit can be operated from either a non-fixed position or a wall-mounted position. To ensure that the air conditioner operates correctly, do not install the remote control unit in the following places: In direct sunlight Behind a curtain or other place where it is covered...
Page 34: Mounting On A Wall (Ks2432A Only)
4-2. Mounting on a Wall (KS2432A only) Removable mounting Truss-head (1) Confirm the indoor unit beeps when the ON/ tapping screw OFF button is pressed at the wall location × × 5/32 5/8" (4 16mm supplied) where the remote control unit is to be attached, then attach the holder to the wall.
Page 35: Installing The Wired Remote Control Unit
Wired Remote Control Unit (Option) Electrical (except KS2432A) Cover plate component box To access the printed circuit board, remove the cover plate of the electrical component box. Attach the remote control connectors securely to the mating connector pins on the printed circuit board.
Page 36: Address Switches (Except Ks2432A)
5. Address Switches (except KS2432A) On address switches for KS2432A, please refer to page 9 in the instruction manual. If you are installing one indoor unit or one group of indoor units in the same room, it is necessary for you to assign each unit its own address so that each can be operated by its own remote control unit.
Page 37: How To Install The Outdoor Unit
6. How to Install the Outdoor Unit 6-1. Removing the Protective Spacer for Transportation Compressor Remove the packing skid from the bottom of unit and then remove the plastic spacer used to secure the compressor during transportation. (Fig. 6-1) Place the unit on a level concrete pad, block or equal and anchor.
Page 38: Electrical Wiring
(Outdoor Unit) Fuse or Wiring Models Circuit Max. Wire Capacity Capacity AGW #14 Diameter C2432A, CL2432A 69 ft. (AWG #12) 25 A C3032A, CL3032A 101 ft. (AWG #10) 30 A 164 ft. 50 A AWG #6 C3632A, CL3632A 86 ft. (AWG #10)
Page 39: Examples Of Incorrect Wiring
Problem 1 CAUTION Short circuit will occur after approx. 3 minutes. 7-4. Examples of Incorrect Wiring The following are examples of improper wiring that result in system misoperation. You should confirm that you have wired the units correctly before beginning the Indoor unit Outdoor unit 1009_M_I Test Run described on page 47 and 48.
Page 40: How To Connect Wiring To The Terminal
Loose wiring may cause the terminal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, ensure that all wiring is tightly connected. When connecting each power wire to the correspond- ing terminal, follow the instructions on “How to connect wiring to the terminal”...
Page 41: How To Process Tubing
8. How to Process Tubing Deburring The narrow tubing side is connected by flare nut, and Before After the wide tubing side is connected by brazing. 8-1. Use of the Flaring Method Many of the conventional split system air conditioners employ the flaring method to connect refrigerant tubes which run between indoor and outdoor units.
Page 42: Precautions During Brazing
8-4. Precautions during Brazing Torque wrench Replace air inside the tube with nitrogen gas to prevent copper oxide film from forming during the Spanner brazing process. Indoor unit Do not allow the tubing to get too hot during the brazing process. Outdoor unit The nitrogen gas inside the tubing may overheat, 0131_C_I...
Page 43: Taping The Tubes
When installing “CL” mod- Insulation CAUTION els, insulate both wide and narrow tubes. Thickness: Thickness: Min. 5/16 in. Min. 5/16 in. When outdoor temperature is low, condensation can also form on a narrow tube. So always insulate both Narrow tube wide and narrow tubes.
Page 44: Air Purging
Air Purging Manifold valve Air and moisture in the refrigerant system may have undesirable effects as indicated below. Pressure gauge pressure in the system rises Charge hose operating current rises cooling (or heating) efficiency drops moisture in the refrigerant circuit may freeze and block capillary tubing Nitrogen gas cylinder (In vertical standing...
Page 45 To avoid nitrogen entering Manifold valve CAUTION the refrigerant system in a liquid state, the top of the cylinder must be higher than Pressure gauge the bottom when you pres- surize the system. Usually, the cylinder is used in a vertical standing position.
Page 46 Charging additional refrigerant Wide tube Charge additional refrigerant (calculated from the Outdoor Indoor narrow tube length as shown in Sec. 1-7) using the unit unit Narrow tube Max. allowable Required wide tube service valve with the system in cooling tubing length additional operating mode.
Page 47: Test Run
10. Test Run 10-1. Preparing for Test Run Before starting the air conditioner, check the following: Remove all loose matter from the cabinet espe- cially metal filings, bits of wire, and clips. Connect the control wiring correctly and tighten Air intake grille all electrical connections.
Page 48: Performing Test Run With Optional Wired
10-3. Performing Test Run with Optional Wired Remote Control Unit Service TEST RUN switch is located on the rear side of the remote control unit. Set the switch to Connected (ON) the TEST RUN position. (Fig. 10-5) Referring to the Operating Instructions, select the cooling mode and press the ON / OFF operation button on the remote control unit.
Page 49: I Basic Functions Of The Service Valves
0550_C_I 0548_C_I Narrow tube service valve Wide tube service valve Valve cap O-ring O-ring Valve cap Stem Stem Service port (B) 0554_C_I 0989_C_I 1372_C_I 2-Way Valve 3-Way Valve C2432A C3032A CL3032A CL2432A C3632A CL3632A C4232A CL4232A S4179694...
Page 50: I Pump Down
Pump Down Pump down means collecting all refrigerant gas in the system back into the outdoor unit without losing ant of the gas. Pump down is used when the unit is to be moved or before servicing the refrigerant circuit. Pump down procedure Be sure to carry out pump CAUTION...

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