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01-385 AirCon 12/11/01 4:41 PM Page 1
INSTALLATION INSTRUCTIONS
COOL/DRY/HEAT Model
– Split System Air Conditioner –
Contents
Model Combinations
Page
Combine indoor and outdoor units only as listed
IMPORTANT!
below.
Please Read Before Starting .................................. 2
Indoor Units Outdoor Units
1. GENERAL .......................................................... 3
1-1. Tools Required for Installation (not supplied) KHS0951 CH0951
1-2. Accessories Supplied with Unit
KHS1251 CH1251
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01-385 AirCon 12/11/01 4:41 PM Page 2 IMPORTANT! Please Read Before Starting This air conditioning system meets strict safety and operating When Transporting standards. As the installer or service person, it is an important Be careful when picking up and moving the indoor and out- part of your job to install or service the system so it operates door units. Get a partner to help, and bend your knees when safely and efficiently. lifting to reduce strain on your back. Sharp edges or thin alu- m
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01-385 AirCon 12/11/01 4:41 PM Page 3 1. General This booklet briefly outlines where and how to install the 5. Carpenter’s level air conditioning system. Please read over the entire set 6. Sabre saw or key hole saw of instructions for the indoor and outdoor units and 7. Hacksaw make sure all accessory parts listed are with the system 8. Core bits before beginning. 9. Hammer 10. Drill 1-1. Tools Required for Installation (not supplied) 11. Tube cutter 1. Standard screwdriver 12. Tube flaring
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01-385 AirCon 12/11/01 4:41 PM Page 4 1-6. Additional Materials Required for Installation Indoor unit 1. Refrigeration (armored) tape 2. Insulated staples or clamps for connecting wire (See local codes) 3. Putty 4. Refrigeration lubricant 5. Clamps or saddles to secure refrigerant tubing Drain hose 2. Installation Site Selection Outside drainage 2-1. Indoor Unit Fig. 1 To prevent abnormal heat genera- WARNING tion and the possibility of fire, do 2" (5 cm) min. not place obstacles, enclosure
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About 16" (40 cm) 01-385 AirCon 12/11/01 4:41 PM Page 5 2-2. Outdoor Unit Exhaust fan NO AVOID: Hot air Heat source heat sources, exhaust fans, etc. (Fig. 4) damp, humid or uneven locations. Outdoor unit DO: choose a place as cool as possible. choose a place that is well ventilated. allow enough room around the unit for air intake/ Fig. 4 exhaust and possible maintenance. (Fig. 5a) Obstacle above CAUTION Min. Min. 7 ft. 7 ft. (2 m) (2 m) Install the outdoor unit above snowfall lin
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01-385 AirCon 12/11/01 4:41 PM Page 6 3. How to Install the Indoor Unit 3-1. Remove the Rear Panel from the Unit (1) Remove and discard the set screw on the rear panel. (Fig. 6) (2) Press the 2 marks on the frame cover and disengage the sta- tionary tabs from the frame. (Fig. 7) (3) Remove the rear panel. NOTE Set screw only for transportation Fig. 6 Tubing can be extended in 5 directions (KHS0951, KHS1251 and Rear panel KHS1852) as shown in Fig. 8a or 8b. Select the direction you need pr
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01-385 AirCon 12/11/01 4:41 PM Page 7 (4) Using a sabre saw, key hole saw or hole-cutting drill NOTE attachment, cut a hole in the wall. See Table 4 and Hole should be made at a slight downward slant to the Fig. 10. outdoor side. Table 4 Indoor Outdoor Hole Dia. side side 2-9/16" (65 mm) / 3-5/32" (80 mm) (5) Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a Fig. 10 slight angle 0.25 in. (6 mm) shorter than the thick- ness of the wall. (Fig. 11) P
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01-385 AirCon 12/11/01 4:41 PM Page 8 3-4. Remove the Grille to Install the Indoor Unit KHS0951, KHS1251 Basically, these models can be installed and wired with- out removing the grille. If access to any internal part is needed, follow the steps as given below: How to remove the grille (1) Set the flap in the horizontal position. Screw cover Flap (2) Unscrew the screws. (Fig. 16a or 16b) (Up and down air direction louvre) (3) Remove the grille. (Fig. 17) Fig. 16a (a) Hold both corners of the
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01-385 AirCon 12/11/01 4:41 PM Page 9 3-5. Shape the Indoor Side Tubing 1) Arrangement of tubing by directions Frame a) Right or left tubing Cut out the corner of the right/left frame with a hacksaw or the like. (Figs. 20 and 21) Left tubing outlet b) Right-rear or left-rear tubing In this case, the corner of the frame need not be cut. 2) To mount the indoor unit on the rear panel: Fig. 20 Hang the 2 mounting slots of the unit on the upper tabs of the rear panel. (Fig. 22) Frame 3-6. Wiring
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01-385 AirCon 12/11/01 4:41 PM Page 10 3-7. Recommended Wire Length and Diameter WIRING SYSTEM DIAGRAM Regulations on wiring diameter differ from locality to CH0951, CH1251 Models locality. For field wiring requirements, please refer to Disconnect (Inter-unit) INDOOR UNIT OUTDOOR UNIT your local electrical codes. Carefully observe these reg- switch Power lines (Field supply) Terminal ulations when carrying out the installation. Terminal 1 1 NOTE 2 2 3 3 Refer to the wiring system diagram (Fig
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01-385 AirCon 12/11/01 4:42 PM Page 11 c) Remove the screws to open the cover plate secur- KHS0951, KHS1251 KHS0951, KHS1251 ing the electrical component box. (Figs. 25a, 25b, Cover Electrical plate 25c and 25d) component box Cover plate d) Insert the wrapped tubing into the hole in the wall. e) Hang the indoor unit on the rear panel. Terminal f) Using a Phillips screwdriver, take out the screws on plate the earth plate. (Fig. 26a KHS09, 12 models only) Earth plate Remove the earth plate. E
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01-385 AirCon 12/11/01 4:42 PM Page 12 Loose wiring may cause the termi- WARNING nal to overheat or result in unit mal- function. A fire hazard may also exist. Therefore, be sure all wiring is tightly connected. When connecting each power wire to the corresponding termi- 9/32" (7 mm) (ACTUAL STRIP nal, follow the instructions “How to connect wiring to the termi- SIZE) SIZE nal” and fasten the wire securely tight with the fixing screw of the terminal plate. Fig. 28 How to connect wiring to th
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01-385 AirCon 12/11/01 4:42 PM Page 13 3-9. Mounting (1) To install the indoor unit, mount the indoor unit onto the 2 tabs on the upper part of the rear plate. (2) Hold down the air discharge outlet and press the lower part of the indoor unit until it clicks to secure- ly fasten to the 2 tabs on the lower part of the rear plate. (Fig. 33) Push NOTE Fig. 33 For tubing, choose either the right or left tubing direc- tion and follow the steps below. Also, extend the sup- port on the back of the i
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01-385 AirCon 12/11/01 4:42 PM Page 14 To unmount indoor unit Press the 2 marks on the lower part of the indoor unit and unlatch the tabs. Then lift the indoor unit and unmount. (Fig. 38) 3-10. Drain Hose a) The drain hose should be slanted downward to the outdoors. (Fig. 39) b) Never form a trap in the course of the hose. c) If the drain hose will run in the room, insulate the Push hose with insulation* so that chilled condensation Fig. 38 will not damage furniture or floors. (Fig. 40) *
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01-385 AirCon 12/11/01 4:42 PM Page 15 Terminal 4. How to Install the Outdoor Unit block Lock nut First refer to Section 2. Installation Site Selection. Access panel 4-1. Wiring Instructions for the Outdoor Unit Regulations on wire size differ from locality to locality. For field wiring requirements, please refer to your local electrical Conduit codes. Make sure that the installation fully complies with all plate local and national regulations. (1) Remove access panel. (Fig. 41) Plug Power s
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01-385 AirCon 12/11/01 4:42 PM Page 16 5. Refrigerant Tubing Deburring After Before 5-1. 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. In this method, the copper tubes are flared at each end and connected with flare nuts. 5-2. Flaring Procedure with a Flare Tool a) Cut the copper tube to the required length with a tube cutter. It is recommended to cut approx.
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01-385 AirCon 12/11/01 4:42 PM Page 17 5-4. Connecting Tubing between Indoor and Torque wrench Outdoor Units a) Tightly connect the indoor side refrigerant tubing extend- Spanner ed from the wall with the outdoor side tubing. (Fig. 47) Indoor unit b) To fasten the flare nuts, apply specified torque as: Table 5 Outdoor unit Tube Dia. Tightening Torque Fig. 47 1/4" (6.35 mm) Approx. 130 – 170 lbs. in. (150 – 200 kg cm) · · 3/8" (9.52 mm) Approx. 300 – 340 lbs.·in. (350 – 400 kg·cm) 1/2" (12.7 m
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01-385 AirCon 12/11/01 4:42 PM Page 18 6. Air Purging Indoor unit Air and moisture remaining in the refrigerant system have undesirable effects as indicated below. Therefore, they must be purged completely. pressure in the system rises operating current rises Outdoor unit cooling (or heating) efficiency drops moisture in the air may freeze and block capillary tubing water may lead to corrosion of parts in the refrigerant sys- tem Air Purging with a Vacuum Pump (for Test Run) (1) C
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01-385 AirCon 12/11/01 4:42 PM Page 19 (5) With the vacuum pump still running, close the “Lo” knob of the manifold valve. Then stop the vacuum 90° (1/4 turn) pump. Narrow tube (6) With the accessory hex wrench, turn the valve stem on the narrow tube service valve counter- Hex wrench clockwise by 90 degrees (1/4 turn) for 10 seconds, and then turn the stem clockwise to close it again. Wide tube (Fig. 53) Be sure to completely insert CAUTION Valve cap the hex wrench before Vacuum hose to manifol
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01-385 AirCon 12/11/01 4:42 PM Page 20 * How to Test Run the Air Conditioner. KHS0951, KHS1251 (1) Switch on the power source. (2) Press the ON/OFF button on the remote control unit once. ON OFF (3) Set the operation selector switch of the indoor unit TEST to the TEST position. This starts the fan, producing uncooled forced air. (Figs. 54a and 54b) (4) After 3 minutes, the system shifts into cooling operation, and cool air will start to be felt. Cooling operation during with the switch at the
