TECHNICAL & SERVICE MANUAL KGS1411 / CG1411 FILE NO. Destination: U.S.A. GAS HEATER AIR CONDITIONER Indoor Model No. Product Code No. Outdoor Model No. Product Code No. KGS 1411 1 852 062 56 CG 1411 1 714 734 00 Indoor Unit Outdoor Unit KGS1411 CG1411 REFERENCE NO.
IMPORTANT! Please Read Before Starting When Installing… This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently. …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 metal frame to provide added support.
Table of Contents Page 1. OPERATING RANGE ................................................................................................................ 1 2. SPECIFICATIONS 2-1. Unit Specifications ............................................................................................................ 2-2. Major Component Specifications...................................................................................... 2-3. Other Component Specifications............................................
10. PROCEDURE FOR DISMANTLING THE UNIT 10-1. Procedure for Dismantling the Indoor Unit ....................................................................... 10-2. Procedure for Dismantling the Outdoor Unit..................................................................... 44 47 11. POINTS TO DIAGNOSE 11-1. Indoor Unit Alarm Signal .................................................................................................. 11-2. Manifold Pressure...................................................
1. OPERATING RANGE Cooling Heating Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp. Maximum 95°F (35°C) D.B. 71°F (21.7°C) W.B. 115°F (46.1°C) D.B. Minimum 67°F (19.4°C) D.B. 57°F (13.9°C) W.B. 67°F (19.4°C) D.B. Maximum 80°F (26.7°C) D.B. 67°F (19.4°C) W.B. 75°F (23.9°C) D.B. 65°F (18.3°C) W.B. Minimum — D.B. — W.B. 0°F (–17.8°C) D.B. –2°F (–19°C) W.B.
2. SPECIFICATIONS 2-1. Unit Specifications Indoor unit Outdoor unit KGS1411 CG1411 Power Source Electric power source Employed gas Cooling Heating 115V 60Hz — Natural gas (LP) Cooling Voltage Rating Performance Capacity Air circulation (High) Moisture removal (High) Electrical Rating Available voltage range Running amperes Power input Power factor SEER Compressor locked rotor amperes Heating 115V Cooling 2.58 8,800 282 (8.0) 2.2 kW ft3/min (m3/min) Pints/h Heating 4.1 / 2.9 / 1.
Indoor unit Outdoor unit KGS1411 CG1411 Dimensions & Weight Unit dimensions Package dimensions Weight Height Width Depth Height Width Depth Net Shipping Indoor Unit 10-5/8 (270) 31-11/16 (805) 6-31/32 (177) 9-13/16 (249) 33-21/32 (855) 13-5/16 (338) 17.6 (8.0) 22.0 (10.0) 2.51 (0.071) inch (mm) inch (mm) inch (mm) inch (mm) inch (mm) inch (mm) lb. (kg) lb. (kg) cu.ft (m3) Shipping volume Burner Outdoor Unit 23-7/32 (590) 28-1/2 (724) 11-15/32 (291) 31-1/16 (789) 25-1/32 (636) 14-29/32 (379) 85.
2-2. Major Component Specifications 2-2-1. Indoor Unit Indoor unit KGS1411 Control PCB Part No. Controls Control circuit fuse POW-KGS14A, B Microprocessor 115V Remote Control Unit RCS-IRS2U Fan & Fan Motor Type Q’ty … Dia. and length inch (mm) Fan motor model … Q’ty Nominal output W Coil resistance (ambient temp. 68°F (20°C)) Ω Safety devices Run capacitor Type Operating temp. Open °F (°C) Close µF VAC Flap Motor Type Model Rating Coil resistance (ambient temp.
2-2-2. Outdoor Unit (1) Outdoor unit CG1411 Control PCB Part No. Controls Control circuit fuse CG1411 Microprocessor 115V 5A Gas Connection Employed gas Gas connection Natural Gas (LP) 1/2 Female Compressor Type Compressor model Nominal output Compressor oil … Amount Coil resistance (ambient temp. 68°F (20°C)) Safety devices W cc Ω Type Overload relay Operating temp. Open °F (°C) Close °F (°C) Operating amp (ambient temp.
2-2-2. Outdoor Unit (2) Outdoor unit CG1411 Burner Type Q’ty … Material, thickness Ribbon burner 1 … Stainless steel, 0.0157 (0.4) inch (mm) Nozzle Q’ty … Material Diameter 1 … Brass 0.0807 (2.05 ± 0.05) ø inch (ø mm) Fan & Fan Motor Type Q’ty … Dia. and length inch (mm) Fan motor model … Q’ty No. of poles … rpm Nominal output W Coil resistance (ambient temp. 68°F (20°C)) Ω Safety devices Type Operating temp.
2-3. Other Component Specifications 2-3-1. Indoor Unit Indoor unit KGS1411 Transformer Rating Coil resistance ATR-1581T2-U AC 115V, 60Hz 13.7V, 0.5A 6.85VA Primary (WHT – WHT): 128 ± 20% Secondary (BRN – BRN): 2.28 ± 20% 277°F (136°C) Primary Secondary Capacity Ω (at 77°F (25°C)) Thermal cut-off temp. Thermistor (Coil sensor) Resistance kΩ DTN-TKS118B 32°F (0°C) 188 ± 4% Thermistor (Room sensor) Resistance kΩ DTN-TKS134B 77°F (25°C) 5.0 ± 3% DATA SUBJECT TO CHANGE WITHOUT NOTICE.
2-3-2. Outdoor Unit Outdoor unit CG1411 Transformer (TR) Rating Coil resistance 4FF4L510034000 AC 115V, 60Hz DC 25.4V, 0.25A DC 12.6V, 0.1A AC 100V, 1Ma 5VA Primary (ORG – ORG): Secondary (RED – RED): Secondary (BLU – BLU): Secondary (YEL – YEL): 277°F (136°C) Primary Secondary S1 S2 S3 Capacity Ω (at 70°F (21°C)) Thermal cut-off temp. Power Relay (PR) Coil rating Coil resistance Contact rating 71.1 ± 10% 5.79 ± 10% 8.
3. DIMENSIONAL DATA 3-1. Unit 3-1-1. Indoor Unit Indoor unit KGS1411 31-11/16 (805) 10-5/8 (270) 6-31/32 (177) Drain hose ø23/32 (18) 6-7/32 (172.5) 1-5/8 (41.0) 1-5/8 (41.0) Remote control unit 2-2/5 (61) 25/32 (18.5) 2-5/16 3-29/32 (99.5) (58.5) Narrow tube ø1/4 (6.35) Center of tubing hole (2 places) Wide tube ø3/8 (9.
3-1-2. Outdoor Unit Outdoor unit CG1411 4-11/16 (119) 16-23/32 (425) 4-9/16 (116) 2-9/16 (65) 10-1/4 (260) 9-1/16 (230) Holes for anchor bolts (4-ø15/32) 2-13/32 (30) 25-31/32 (660) 9-1/16 (230) 2-21/32 (67.5) 3-5/16 (84) 2-5/32 (55) 24-23/32 (628) 5-5/32 (131) Wide tube service valve ø3/8 (9.52) 2-17/32 (64) 23-7/32 (590) 5-21/32 (144) Narrow tube service valve ø1/4 (6.35) Unit: inch (mm) 10-1/4 (260) NOTE Location of Service Valves Service valves are located behind the side panel.
3-2. Internal Components 3-2-1.
3-2-2.
3-3. Major Components Outdoor unit CG1411 (1) Combination Gas Valve (Proportional Control Valve) Type: Combination Gas Valve Model: UP13-27 Material: Aluminum Die-Cast Unit: inch (mm) Body Electromagnetic valve 1 0.590 (15) 0.906 0.708 (23) (18) 1.433 (36.4) 2.067 (52.5) 5 94 ) 4 (2 1.417 (36) 4.913 (124.8) MAX 0. Electromagnetic valve 2 1.948 (49.5) Proportional control valve 0.925 (23.5) Adjuster (2) Gas Nozzle Natural Gas Material Nozzle Dia.
(3) Main Burner Type: Ribbon Burner Material: Stainless Steel, Thickness: 0.0157 inch (0.4 mm) Unit: inch (mm) 0.433 (11) 2.165 (55) 2.756 (70) 6.457 (164) 0.984 (25) (4) Combustion Blower 5.185 (131.7) 1.597 (40.5) 1.578 (40) Combustion blower fan Outer diameter: 3-11/32 Combustion blower motor FU2-051F1MP 3.764 (95.
(5) Refrigerant Heater Unit: inch (mm) Aluminum Copper tube Outer dia. 5/16 Refrigerant outlet Refrigerant inlet 10.827 (275) 6.693 (170) 3.
4. REFRIGERANT FLOW DIAGRAM 4-1. Refrigerant Flow Diagram Indoor unit KGS1411 Outdoor unit CG1411 COOLING CYCLE Indoor unit Outdoor unit ON/OFF valve 2 Wide tube O.D. 3/8" (9.52 mm) Accumulator Compressor Wide tube service valve Muffler ( ) Reversing valve Check valve 2 Heat exchanger Capillary tube Refrigerant heater Heat exchanger ON/OFF valve 1 Narrow tube service valve ( Narrow tube O.D. 1/4" (6.
5. PERFORMANCE DATA 5-1. Performance Charts Indoor unit Outdoor unit KGS1411 CG1411 ● Cooling Characteristics ● Heating Characteristics 115 V Indoor inlet air D.B. temp. °F (°C) 12 11 90 (32.0) 80 (26.7) 70 (21.0) 10 9 8 7 6 11 10 9 8 7 80 (26.7) 70 (21.0) 59 (15.0) 6 5 60 70 80 90 5 10 100 110 120 20 30 40 50 60 70 (15.6)(21.1) (26.7) (32.2) (37.8) (43.3) (48.9) (–12.2)(–6.6) (–1.1) (4.4) (10.0) (15.6) (21.1) Outdoor inlet air D.B. temp. °F (°C) Outdoor inlet air D.B. temp.
5-2. Air Throw Distance Charts Indoor unit KGS1411 Cooling Room air temp.: 80°F (27°C) Fan speed: High Horizontal distance (ft.) Axis air velocity (ft./sec.) Vertical distance (ft.) 5 10 15 20 25 30 25 30 5 10 15 : Axis air velocity 0° : Axis air velocity 30° : Louver angle 0° : Louver angle 30° Heating Room air temp.: 70°F (20°C) Fan speed: High Horizontal distance (ft.) Axis air velocity (ft./sec.) Vertical distance (ft.
5-3. Cooling Capacity Indoor unit Outdoor unit KGS1411 CG1411 115V single-phase 60Hz Rating Capacity: 9,000 BTU/h Evaporator Ent. Temp. °F (°C) WB DB 59 (15.0) 72 (22.2) 76 (24.4) 80 (26.7) 84 (28.9) 88 (31.1) 63 (17.2) 72 (22.2) 76 (24.4) 80 (26.7) 84 (28.9) 88 (31.1) 67 (19.4) 72 (22.2) 76 (24.4) 80 (26.7) 84 (28.9) 88 (31.1) 71 (21.7) 72 (22.2) 76 (24.4) 80 (26.7) 84 (28.9) 88 (31.1) 75 (23.9) 76 (24.4) 80 (26.7) 84 (28.9) 88 (31.
5-4. Heating Capacity Heating capacity ratio % Indoor unit Outdoor unit KGS1411 CG1411 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 47 50 60 (–17.8) (–12.2) (–9.4) (–1.1) (4.4) (8.3) (10.0) (15.5) Outdoor temperature °F (°C) D.B. NOTE 1) ● … Point of rating condition Black dot in the chart indicates the following rating condition. Indoor: 70°F (21.1°C) D.B. Outdoor: 47°F (8.3°C) D.B. / 43°F (6.1°C) W.B.
6. ELECTRICAL DATA 6-1. Electrical Characteristics Indoor unit Outdoor unit KGS1411 CG1411 Cooling Indoor Unit Fan Motor Performance at Rating conditions Full load conditions Running amp. Power input Running amp. Power input Rating conditions: Indoor air temperature Outdoor air temperature Full load conditions: Indoor air temperature Outdoor air temperature A kW A kW 0.35 0.033 0.35 0.033 Outdoor Unit Fan Motor Compressor 115V Single phase 60Hz 0.64 7.2 0.077 0.79 0.64 9.0 0.077 0.
6-2. Electric Wiring Diagrams KGS1411 WARNING To avoid electrical shock hazard, be sure to disconnect power before checking, servicing and/or cleaning any electrical parts.
FM BLU BRN WHT BRN Fan motor Terminal block 1 2 3 4 5 6 V (BLU) CN02 C LD1 LD2 LD3 LD4 LD5 BLK WHT SWI (YEL) CN03 BLK BLU WHT RED W PNK Start relay ICI CM S R R BLK F PNK Compressor C ORG ORG G VR1 I GV1 K Thermistor 2 VR2 (BLK) CN15 (RED) CN16 (WHT) CN08 BLU RED WHT P (WHT) CN14 Thermistor 1 M 0 N (WHT) CN11 Q2 (WHT) CN10B Q1 (WHT) CN10A (WHT) CN12 CN17 J Power relay (K07) GV2 Gas Gas valve 1 valve 2 H (GRY) (RED) (WHT) CN06 CN07 CN09 WHT BLK I
R01 LD2 LD3 LD4 LD5 K05 R37 R36 R35 R34 R33 LD1 D15 C101 J02 LO/HIGH J34 J35 J01 IC6 PC2 R03 C17 R39 R02 PC1 SW1 R106 R38 J03 R41 C18 R101 R100 R40 IC7 C105 R58 R84 R51 J31 J05 C104 ABS1 R30 IC1 IC5 J06 PC3 Z02 R22 C21 R46 XX TD-T13V R54 J32 OSC J33 R102 J04 GND CN19 Z01 4FF4B10002710-2 CN21 C103 R49 J36 R04 J30 CN01 J29 RA1 C15 R10 R07 R09 C10 C01 C14 J08 C29 D04 IC9 J09 J37 TR1 C09 IC8 C100 C20 R21 C13 D07 J20 R60 R79 + R15
# " ! , 7. INSTALLATION INSTRUCTIONS 7-1. Installation Site Selection 7-1-1. Indoor Unit WARNING To prevent abnormal heat generation and the possibility of fire, do not place obstacles, enclosures and grilles in front of or surrounding the air conditioner in a way that may block air flow. AVOID: 2" (5 cm) min. Front View ● direct sunlight. ● nearby heat sources that may affect performance of the unit. Fig.
7-1-2. Outdoor Unit NO AVOID: ● heat sources, exhaust fans, etc. (Fig. 4) ● damp, humid or uneven locations. Exhaust fan Hot air Heat source 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/ exhaust and possible maintenance. (Fig. 5a) Fig. 4 Air intake ● Install the outdoor unit above snowfall line. ● Do not place objects on or sit on the outdoor unit.
● provide a solid base (level concrete pad, concrete block, 4 in. × 16 in. (10 × 40 cm) beams or equal), a minimum of 4 in. (10 cm) above ground level to reduce humidity and protect unit against possible water damage and decreased service life (Fig. 5b). ● use lug bolts or equal to bolt down unit, reducing vibration and noise. ● use only the type of gas indicated on the nameplate. This plate is located on the right side of the outdoor unit, and should be checked before gas line connection.
7-3. Remote Control Unit Installation Position 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 ● More than 26 ft.
8. FUNCTION 8-1. Motion Explanation 8-1-1. Heating Heating operation begins with the refrigerant pump down cycle to move refrigerant into the heating circuit of the system. Simultaneously, gas burner ignition is initiated for a period of about 1 minute. When the refrigerant transport period is completed, refrigerant is contained within the heating circuit tubing and retained there by the 2 check valves.
8-1-3. Combustion Control (1) Combustion Combustion air is supplied into the burner for 20 seconds prior to ignition. The variable speed combustion air blower motor speed is sensed and controlled. After this pre-purge is competed, spark ignition is provided at the burner. Burner condition is monitored continuously during the burning period.
8-2. Cooling 8-2-1. Room Temperature Control ● Room temperature control is obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the indoor unit. ● All information is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit. Thermo. ON Thermo. OFF Set temp. Thermo. OFF Thermo.
8-2-2. Freeze Prevention (Cooling) ● This function prevents freezing of the indoor heat exchange coil. ● When the compressor has been running for 6 minutes or more and the temperature of the indoor heat exchange coil falls below 36°F (2.4°C), the control circuit stops the compressor for at least 6 minutes. The compressor does not start again until the temperature rises above 46°F (8°C) or 6 minutes have elapsed. Indoor heat exch. coil temp. 46°F More than 10 minutes Set temp.
8-3. Heating 8-3-1. Room Temperature Control ● Room temperature control is obtained by cycling the compressor ON and OFF under control of the room temperature sensor in the indoor unit. ● All information is transmitted every 3 minutes by the remote control unit to the controller in the indoor unit. Thermo. ON Set temp. Thermo. OFF Thermo. OFF Thermo.
8-3-2. Refrigerant Control (1) Thermistor 1 1) Initial check: Must be able to confirm temperature increase of 2°F (1°C) within approximately 1 minute. Objectives: 1. To detect error in switching reversing valve 2. To detect disconnection of Thermistor 1 2) Limit on amount of combustion at low temperature: When starting up at low temperature, this function prevents rapid increase in temperature of refrigerant. 1. Minimum combustion at 50°F (10°C) or below 2.
8-3-3. Combustion Saving Function After Thermo. OFF occurs, shifts to Continuous Combustion Mode, Save Mode 1, or Save Mode 2, according to the load inside the room. Performs combustion which is proportionally controlled by setting the maximum amount of gas equivalent to the amount of rated combustion. Performs combustion which is proportionally controlled by setting the maximum amount of gas to about 70% of the rated amount of combustion.
8-3-4. Cold Draft Prevention Function (During Heating Operation) This function prevents a cold draft from being released at the beginning of Heating Operation or during operation of the room temperature thermo.
8-4. Fan Speed Control During Cooling Operation Automatic fan speed 3 minutes OFF TS + 4°F (2°C) 3 minutes ON TR: Room temp. TS + 2°F (1°C) Set Value (TS) H Fan Speed M L Compressor ON OFF * For 3 minutes after power ON, the compressor does not turn on. During Heating Operation Automatic fan speed TR: Room temp.
8-5. Dry Operation (Dehumidification) ● Dry operation uses the ability of the cooling cycle to remove moisture from the air, but by running at low level to dehumidify without greatly reducing the room temperature. The air conditioner repeats the cycle of turning ON and OFF automatically as shown in the chart below according to the room temperature. Room temp. Cooling operation T + 4°F (2°C) * Dry A Zone Set temp.
8-6. Automatic Operation (1) Normal Room temperature at start of operation TR °F (°C) Temperature set automatically °F (°C) Operation mode 88 (30) ≤ TR 82 (27) 84 (24) ≤ TR < 88 (30) 80 (26) 80 (26) ≤ TR < 84 (28) 78 (25) 72 (22) ≤ TR < 80 (26) 76 (24) Dry TR < 72 (22) 76 (24) Heating Cooling ● Set temperature can be shifted ± 4°F (2°C), in 2°F (1°C) steps. ● If operation commences again within 2 hours of the previous operation, the previous setting is applied.
8-7. Freeze Prevention When the evaporation temperature drops to less than the temperatures stated below during Cooling or Dry Operation, the operation of the outdoor unit is automatically stopped to prevent the heat exchanger from freezing up. (1) Cooling / Dry Cooling Zone: Dry A Zone < Conditions of freeze prevention operation > a. Temperature of heat exchanger is less than 36°F (2.4°C) b. During Cooling or Dry Operation When the conditions of a, b, and c are met c.
8-8. Overload Prevention (Heating) 8-8-1. Indoor Unit ● This function prevents overheating of the indoor heat exchange coil. ● When the temperature of the indoor heat exchange coil rises above 131°F (55°C), and if the indoor fan is L (low speed), then the fan speed changes from L (low speed) to M (medium speed). 131°F (55°C) Indoor heat exch.coil temp. 113°F (45°C) Indoor fan H or M or L H→H, M→M, L→M ON Compressor 8-8-2.
9. OPERATION FLOWCHARTS 9-1-2. Stopping Flowchart 9-1. Cooling, Dry 9-1-1. Starting Flowchart Operation starts Cool • Dry Operation lamp Operation starts 1 Troubleshoot Operation lamp light ON Flap motor ON Dry Indoor fan: Start speed ON Outdoor fan motor OFF Compressor OFF Room temp. ≥ Preset +2 Cooling YES Compressor YES Dry A Indoor fan Outdoor fan motor Room temp. ≥ 15°C YES YES Room temp. higher than preset temp. OFF Outdoor fan OFF 9-1-3.
43 ON ON LL YES ON OFF ON NO 17 Thermistor-1 (higher than 47°C) 8 OFF OFF Compressor Solenoid valve GV1 Solenoid valve GV2 OFF Proportional control valve OFF OFF OFF Indoor fan YES Room temp. (higher than set temp.) YES Safety device works Combustion lamp 4 3 a Ignitor (15 sec. after) NO NO NO First ON/OFF valve 2 LD 2 3 4 5 LD 2 3 4 5 LD 2 3 4 5 OFF First YES : light off : light on NO (60 sec.
10. PROCEDURE FOR DISMANTLING THE UNIT 10-1. Procedure for Dismantling the Indoor Unit (1) How to remove grille ➀ Close the flap (upper airflow adjustment plate) ➁ Remove the fixing tabs (3) at the bottom of and open the screw covers. Then remove the screws (2). decorative grille. ➂ Detach the attachment tabs (2) at the top of the grille by lifting the grille. (2) How to remove PCBs Detach all the wire connectors on PCB A and B in the electrical component box, and remove the tabs holding the PCBs.
(3) How to remove electrical component box ➀ Remove the screw for ground screw (green, 1). ➁ Remove the connectors for sensor, fan motor and flap motor, which are connected to the electrical component box. ➂ Remove the screws (3) attaching the electrical component box, and remove the box from the frame by pressing the tabs at the back of the box.
(5) How to detach heat exchanger ➀ Remove the screws (2) attaching the metal clip ➁ Remove the screws (3) attaching the heat of the tube. Extend the supplementary tubing at the back of the unit. exchanger. Remove the tabs holding the resin boss at the top right of the heat exchanger, and then pull the heat exchanger off from the frame. (6) How to detach fan and fan motor ➀ Loosen the hexagonal screw in the fan boss ➁ Remove the screw (1) for the fan bearing which attaches the fan. cover.
10-2. Procedure for Dismantling the Outdoor Unit (1) How to remove the external panels ➀ Remove the screws (2) of the top panel and ➁ Remove the screw (1) of the side cover, the the screws (5) of the front panel. screws (3) of the terminal block cover, and the screws (2) of the terminal block. (2) How to detach the rear panel ➀ Remove the front panel and unscrew the screws (9) attaching the rear panel, and detach the manual shut-off valve.
(4) How to detach combination valve and gas conduit ➀ Remove the screw (1) for the attachment plate of the combination valve in back of the main unit. ➁ Detach the 2 connectors (CN11 for proportional valve and CN08 for solenoid valve). ➂ Remove the screws (2) attaching the gas conduit in front of the combustion chamber, and take off the combination valve with gas conduit. ➂ (5) How to detach combination valve ➀ Remove the attachment screws, and dismantle as shown below.
(6) How to detach ignition probe and flame sensor electrode ➀ Detach the connector of the ignition probe. ➁ Remove connector CN17 from outdoor unit PCB. ➂ Remove the screw (1) for the attaching metal clip and remove the ignition probe and flame sensor electrode. (Flame sensor electrode is replaced together with the wires connected.) (7) How to detach burner unit ➀ Remove the attachment screws (6) and pull the burner unit to the front. (When reattaching the burner unit, replace the center screw first.
11. POINTS TO DIAGNOSE 11-1. Indoor Unit Alarm Signal Alarm Signal Error Meaning Misconnection of inter-unit wiring Room temp. thermistor is defective Power Lamp Heat exch. thermistor is defective Flashing Fan motor is defective Amp. current is high Amp. current is low Heat exch.
11-3. Checking Electrical Components 11-3-1. Components Flow No. Measurement Target CO. No.
11-3-2. Indoor Unit Indoor Unit Transformer Voltage • Coil Resistance Measurement Target (Normal) Upper: Voltage CN Wire Color (Normal) Lower: Resistance AC 100 – 130 V Y1 WHT – WHT 45 – 100 Ω AC 12 – 18 V Y2 BRN – BRN 0.5 – 4 Ω 11-3-3. Outdoor Unit Outdoor Unit Transformer Voltage • Coil Resistance Measurement Target (Normal) Upper: Voltage CN Wire Color (Normal) Lower: Resistance AC 100 – 130 V H ORG – ORG 50 – 100 Ω AC 100 – 130 V Q2 YEL – YEL 0.
12. TROUBLESHOOTING 12-1. Check Before and After Troubleshooting 12-1-1. Check Power Supply Wiring ● Check that power supply wires are correctly connected to Terminals L and N on the terminal plate in the outdoor unit. (Inter-unit) Power line 115V INDOOR UNIT Terminal (4P) OUTDOOR UNIT Terminal (6P) 1 1 2 2 3 3 4 4 Grounding line G G Disconnect switch (Field supply) 5 L1 L2 Power supply Single-phase 60 Hz 115 VAC Grounding line 6 G 12-1-2.
12-2. When the Air Conditioner Does Not Work at All (Both Indoor and Outdoor Units) — Operation Lamp Does Not Light 12-2-1. Malfunction in Power Supply ➀ Check if operation selector of the indoor unit is set to ON. If it is not, set the switch to ON. ➁ Check if the circuit breaker is disengaged or if electricity is not being supplied properly. Normal AC 104 – 126 V * Use a circuit tester (set to AC range). In case of abnormality ➞ Check power source No abnormalities, proceed to 12-2-2. 12-2-2.
12-3-2. Thermistor Abnormality (Indoor Unit Only) Check open / short circuit at the coil thermistor and room thermistor (between 1 and 2 of the lamp 8P) on the PCB of the indoor unit (but only when the room temperature is 14 to 113°F). 12-3-3. Protective Circuit of Outdoor (Burner) Unit Operated Check the following according to the failure display. Check items listed in 12-6. Heating Operation Not Possible. ● light off ● light on No.
12-3-5. Indoor Fan is Defective ➀ Check if the indoor fan is locked up. Turn fan gently by hand. When fan does not turn easily ➞ Replace fan motor No abnormalities, proceed to check ➁. ➁ Check if motor circuit is defective. Set temperature by remote controller so that air conditioner operates under Thermo. OFF in either cooling or heating operation, then start operation. Check if it operates without the operation lamp blinking for more than 3 minutes.
12-3-7. Outdoor Unit Power Supply Failure Measure voltage between Terminals 5 – 6 on terminal block of outdoor unit. Set temperature by remote controller so conditioner operates under Thermo. ON in either cooling or heating operation, then start operation. Then measure voltage between Terminals 1 – 2 on terminal block of outdoor unit. Caution: It is not possible to measure while 3-minute restart timer is in operation. Normal AC 104 – 126 V * Use a circuit tester (set to AC range).
12-3-10. Outdoor Unit Compressor Motor Defective ➀ Check if compressor motor is locked up. Set temperature by remote controller so air conditioner operates under Thermo. ON in cooling operation, then start operation. Check if compressor operates. In case of abnormality ➞ Stops in 2 to 5 seconds. Humming of compressor motor can be heard. After auto restart by 3-minute timer, same thing happens. If this condition continues, replace the compressor motor. No abnormalities, proceed to check ➁.
12-5. Flap Motor Does Not Work 12-5-1. Louver Motor Defective ➀ Set to cooling operation with flap to oscillate (movie) using remote controller and measure voltage applied to the louver motor at FLAP terminal of 5P connector. Normal Color Output Voltage WHT and each BLU wire DC 1 – 12 V (pulse) * Use a circuit tester (set to DC range). In case of abnormality ➞ Replace indoor unit PCB. No abnormalities, proceed to check ➁. ➁ Disconnect FLAP of 5P connector for louver motor and measure resistance.
12-6-3. Safety Device Operated Failure Display on Outdoor Unit PCB: ● ● ● ● Check safety device. ➀ Disconnect safety device connector (CN12, 2P, WHT) from outdoor unit PCB, and measure resistance on the safety device. Normal 1 Ω or less * Use a circuit tester (set to Ω range). In case of abnormality ➞ Replace temperature fuse or temperature limiting switch. 12-6-4. Erroneous Flame Detection Failure Display on Outdoor Unit PCB: ● ● ● ● Check flame sensor probe.
➁ Disconnect heating gas valve (GV1, CN08) connector, and measure resistance at connector. Normal WHT – WHT 1 – 2.5 kΩ * Use a circuit tester (set to Ω range). In case of abnormality ➞ Replace heating electromagnetic valve. 3) Check electromagnetic valve (GV2) of the combination gas valve. ➀ Measure DC voltage at electromagnetic valve connector (CN08) (under heating operation, during combustion). Normal ORG – ORG DC 90 – 120 V * Use a circuit tester (set to DC range).
12-6-7. Combustion Blower Motor Abnormal Revolution Failure Display on Outdoor Unit PCB: ● ● ● ● Check combustion blower motor. ➀ Measure AC voltage at blower motor connector (CN05) (under heating operation, during combustion). Normal PUR – PUR AC 30 – 115 V * Use a circuit tester (set to AC range). In case of abnormality ➞ Replace outdoor unit PCB. ➁ Disconnect combustion blower motor connector, and measure resistance at connector. Normal PUR – PUR 10 – 30 Ω * Use a circuit tester (set to Ω range).
12-7. Reset Method When Error Occurs During Heating Operation Wait for 4 minutes or more after the power is on, and then press the operation button on the remote control unit.
12-8. Failure Display on Outdoor Unit and Correction Method No.
13. SPECIAL PRECAUTIONS WHEN SERVICING THE UNIT Important! For your personal safety, be sure to read and understand the following precautions before servicing. WARNING ● Injuries can occur from burns or inhalation of toxic gas if servicing is performed while refrigerant remains in the refrigeration circuit. This servicing includes disassembling brazed tubing connections and removing any refrigeration parts or components.
13-2. Refrigerant Recovery 13-2-1. Open service valve to recover refrigerant into refrigerant recovery unit. Outdoor unit CAUTION Refrigerant released into the air contributes to destruction of our planet’s ozone layer. You should always use the refrigerant recovery unit to help protect the environment. 13-3. Service on Outdoor Unit 13-3-1.
13-4-2. Connect the vacuum pump and a manifold valve as shown Fig. 1. Confirm that all connections are correctly made. NOTE In order to withstand negative suction pressure during evacuation, the manifold valve should be equipped with a Hi/Lo compound gauge with a minimum scale reading of –76 cmHg. 13-4-3. Install (first by hand-tightening, then securely with a wrench) flare nuts and bonnets at service valves in the refrigeration circuit where evacuation will take place.
13-5-5. If it is not possible to completely charge the unit with the proper amount of refrigerant, you can do an additional charging after installing the units. At that time, refrigerant should be recharged in the liquid state a little at a time using the wide tube service port, and the air conditioner should be operating in COOLING mode during the entire charging process. NOTE Charging the unit with a large amount of refrigerant at once may damage the compressor.
APPENDIX INSTRUCTION MANUAL KGS 1411 + CG1411 1
For Your Safety Read Before Operation WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is supplied natural gas for heat source into outdoor section. Read the following safety information before operation and/or maintenance is performed. B. This appliance dose not have a pilot light. It is equipped with an ignition device which automatically lights the burner.
Contents Page For Your Safety Read Before Operation ............................................................. 2 Product Information .............................................................................................. 3 Alert Symbols ........................................................................................................ 3 Features.................................................................................................................. 4 Installation Location............
Features This air conditioner is equipped with cooling, drying and heating functions. This air conditioner is a refrigerant heating type unit which uses combustion gas to heat the outdoor coil refrigerant during heating operation. Details on these functions are provided below; refer to these descriptions when using the air conditioner.
Installation Location We recommend that this air conditioner be installed properly by qualified installation technicians in accordance with the Installation Instructions provided with the unit. • • • • • • Avoid: The outdoor unit has been designed for outdoor use. It should never be used inside. This could result in incomplete combustion and is extremely dangerous. Use only the gas types indicated on the name plate.
Safety Instructions Read this Instruction Manual carefully before using this air conditioner. If you still have any difficulties or problems, consult your dealer for help. This air conditioner is designed to give you comfortable room conditions. Use this only for its intended purpose as described in this Instruction Manual. • • • • CAUTION • • • • • • 6 oi202000 Never use or store gasoline or other flammable vapor or liquid near the air conditioner — it is very dangerous.
Names of Parts Air intakes INDOOR UNIT Air outlet Remote control unit Drain hose Refrigerant tubes Combustion Lamp OUTDOOR UNIT Air outlet NOTE This illustration is based on the external appearance of a standard model. Consequently, the shape may differ from that of the air conditioner you have selected. This air conditioner consists of an indoor unit and an outdoor unit. You can control the air conditioner with the remote control unit.
Unit Display and Operation Selector Operation selector INDOOR UNIT ON OFF TEST Remote control receiver IMPORTANT Avoid using radio equipment such as mobile phones near (within 1 m of) the indoor unit. Some radio equipment may cause the unit to malfunction. OPERATION TIMER OPERATION lamp TIMER lamp If the trouble occurs, disconnect power and restart the air conditioner after a few minutes. REMOTE CONTROL receiver This section picks up infrared signals from the remote control unit (transmitter).
Remote Control Unit (Display) Displayed when setting temperature Displayed when transmitting data SET TEMP. Displayed when the comfortable temperature and operating mode for the customer is set automatically. NORMAL 1HR. ON H OFF Displayed when setting timer Symbols (1) Operation mode AUTO....................................... HEAT........................................ MILD DRY................................ COOL ....................................... FAN ......................................
Remote Control Unit Transmitter SET TEMP. NORMAL 1HR. ON H OFF Display (Cover closed) ON/OFF operation button 1HR. TIMER ON OFF TEMP. 1 HR. TIMER button TEMP. setting buttons FAN SPEED selector button FLAP button FLAP FAN SPEED MODE TIMER ON button ON TIMER OFF button SET button SET NIGHT CANCEL SETBACK BATTERIES CANCEL button MODE selector button OFF NIGHT SETBACK button ACL ACL button Battery compartment (Pull off the cover to expose the batteries.
Remote Control Unit (continued) MODE selector button Green or red (AUTO) Red (HEAT) Orange (DRY) Green (COOL) Green (FAN) FLAP button NOTE Use this button to select the AUTO, DRY, COOL or FAN mode. : When this setting is selected, the air conditioner calculates the difference between the thermostat setting and the room temperature and automatically switches to the ‘‘COOL’’ or ‘‘HEAT’’ mode as appropriate. : The air conditioner makes the room warmer. : The air conditioner reduces the humidity in the room.
Using the Remote Control Unit How to Install Batteries 1. Slide the cover in the direction indicated by the arrow and remove it. 2. Install two AAA alkaline batteries. Make sure the batteries point in the direction marked in the battery compartment. ACL button 3. Use a thin object such as the tip of a pen to press the ACL button. Cover NOTE • • • • How to Use the Remote Control Unit The batteries last about six months, depending on how much you use the remote control unit.
Using the Remote Control Unit (continued) Mounting the Remote Control Unit Removable mounting Non-removable mounting Wall Wall (Packed with the indoor unit) (Packed with the indoor unit) Mounting on a wall A. Removable mounting 1) Momentarily hold the remote control unit at the desired mounting position. 2) Confirm that the air conditioner responds correctly when you press keys on the remote control from that position.
Operation with the Remote Control Unit 1. Automatic Operation SET TEMP. NORMAL 1HR. TIMER ON OFF TEMP. STEP 2 FLAP FAN SPEED MODE ON SET NOTE STEP 1 OFF NIGHT CANCEL SETBACK Check that the circuit breaker on the power panel is turned on and that the operation selector of the indoor unit is in the ON position.
Operation with the Remote Control Unit (continued) Press TEMP. to change the temperature setting. To raise the temperature setting TEMP.
Operation with the Remote Control Unit (continued) 2. Manual Operation SET TEMP. 1HR. TIMER ON OFF TEMP. STEP 2 STEP 3 STEP 4 STEP 5 FLAP FAN SPEED MODE STEP 1 ON SET NOTE OFF NIGHT CANCEL SETBACK Check that the circuit breaker on the power panel is turned on and that the operation selector of the indoor unit is in the ON position. If the automatic operation settings of the unit do not meet your needs, press the setting buttons as described below and change the settings as desired.
Operation with the Remote Control Unit (continued) NOTE • Choose the best position in the room for the remote control unit, which also acts as the sensor for room comfort and transmits the operating instructions. Once you’ve found this best position, always keep the remote control unit there. • This appliance has a built-in 3-minute time delay circuit to ensure reliable operation. When the operation button is pressed, the compressor will start running within three minutes.
Operation with the Remote Control Unit (continued) ON OFF 1HR. TIMER 4. Fan Only TEMP. STEP 2 STEP 3 FLAP FAN SPEED MODE ON STEP 1 OFF NIGHT CANCEL SETBACK SET BATTERIES ACL If you want to circulate air without any temperature control, follow these steps: STEP 1: Press the MODE selector button to switch to the fan mode ( ). STEP 2: Press the ON/OFF operation button. STEP 3: Press the FAN SPEED selector button to select the fan speed of your choice ( , , or ).
Operation with the Remote Control Unit (continued) A. In Cooling and DRY Mode: ( and ) When the night setback mode is selected, the air conditioner automatically raises the temperature setting 2 °F when 1 hour have passed after the selection was made, and then another 2 °F after another 1 hour have passed, regardless 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.
Special Remarks ‘‘DRY’’ ( ) Operation How it works? • • • Once the room temperature reaches the level that was set, the unit repeats the cycle of turning on and off automatically. During DRY operation, the fan speed is automatically set to LOW or VERY LOW; the fan speed then switches back and forth between LOW (for 20 seconds) and VERY LOW (for 10 seconds). ‘‘DRY’’ operation is not possible if the indoor temperature is 59 °F or less.
Using the 12-Hour ON and OFF Timer After the length of time set for TIMER ON elapses, the unit begins operating. 1. TIMER ON mode (Example) The display depicted at left indicates that the air conditioner will begin operating in three hours. ON Setting procedure: H 1HR. TIMER ON OFF STEP 1 Press the MODE selector button and select the desired operation mode. (See ‘‘Operation with the Remote Control Unit,’’ page 14.) STEP 2 Press the TIMER ON button.
Using the 1-Hour OFF Timer 1. 1-Hour OFF Timer This function causes the unit to operate for one hour and then stop, regardless of whether the unit is on or off when the button is pressed. The 1HR. indicator in the display indicates that this function is operating. 1HR. ON OFF 1HR. TIMER TEMP. Setting procedure: Regardless of whether the unit is operating or stopped, press the 1 HR. TIMER button. 1HR. appears in the display.
Adjusting the Airflow Direction 1. Horizontal CAUTION 2. Vertical 1HR. TIMER ON OFF The horizontal airflow can be adjusted by moving the vertical vanes with your hands to the left or right. When the humidity is high, the vertical vanes should be in the front position during the cooling or dehumidifying operation. If the vertical vanes are positioned all of the way to the right or left, condensation may begin to form around the air vent and drip down.
Operation without the Remote Control Unit INDOOR UNIT If you have lost the remote control unit or it has trouble, follow the steps below. ON OFF TEST Operation selector 1. When the air conditioner is not running If you want to turn on the air conditioner, switch the operation selector to the OFF position, and then to the ON position. NOTE The set temperature and fan speed are automatically set at the last selection before stopping. 2.
Care and Cleaning (continued) Anti-mold filter The anti-mold filter behind the air intake grille should be checked and cleaned at least once every two weeks. Air intake grille How to remove the anti-mold filter 1. Grasp both ends of the air intake grille and pull it out and up. 2. Push the anti-mold filter up slightly, and then pull it down. Anti-mold filter Cleaning How to replace the anti-mold filter Use a vacuum cleaner to remove light dust.
Care and Cleaning (continued) Air cleaning filter (not provided) NOTE The air cleaning filter removes dust and dirt from the air, and reduces odors and smoke from tobacco. The air cleaning filter is not provided with the air conditioner and must be purchased separately. The first time that you buy the air clean filter, it is necessary to get the STK-ARF4B-50 model with frame. When changing the filter subsequently, it is only necessary to replace the filter itself (model STK-F4B-50).
Troubleshooting If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or service center. Trouble Air conditioner does not run at all. OPERATION lamp flashes and air conditioner does not operate. Compressor runs but soon stops. Poor cooling (or heating) performance. Clicking sound is heard from the air conditioner. OPERATION lamp lights but outdoor unit will not run. Possible Cause 1.
For Parts or Service Contact SANYO FISHER SERVICE CORPORATION A DIVISION OF SANYO LOGISTICS CORPORATION 1411 West 190th Street, Suite 800, Gardena, CA 90248 U.S.A.