Sanyo C0971 Technical & Service Manual Download Page 1

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IMPORTANT

These air conditioners employ new

refrigerant R410A.

Pay special attention when

servicing the unit.

TECHNICAL & SERVICE MANUAL

C0971

+ CL0971

C1271

+ CL1271

DC INVERTER SPLIT SYSTEM AIR CONDITIONER

Indoor Unit

Destination: North America

Outdoor Model No.

C0971
C1271

CL0971
CL1271

Product Code No.

1 852 330 23
1 852 330 24
1 852 330 25
1 852 330 26

Outdoor Unit

KS0971

KS1271

C0971

C1271

CL0971

CL1271

REFERENCE NO.

700655-05

Indoor Model No.

KS0971
KS1271

Product Code No.

1 852 099 81
1 852 099 82

FILE NO.

Summary of Contents for C0971

Page 1: ... C1271 CL1271 DC INVERTER SPLIT SYSTEM AIR CONDITIONER Indoor Unit Destination North America Outdoor Model No C0971 C1271 CL0971 CL1271 Product Code No 1 852 330 23 1 852 330 24 1 852 330 25 1 852 330 26 Outdoor Unit KS0971 KS1271 C0971 C1271 CL0971 CL1271 REFERENCE NO SM700655 05 Indoor Model No KS0971 KS1271 Product Code No 1 852 099 81 1 852 099 82 FILE NO ...

Page 2: ...e fire hazard When Transporting Be careful when picking up and moving the indoor and outdoor units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers When Installing In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construc...

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

Page 4: ...teristics of New Refrigerant R410A 11 2 Checklist before Servicing 11 3 Tools Specifically for R410A 11 4 Tubing Installation Procedures 11 5 In Case of Compressor Malfunction 11 6 In Case Refrigerant is Leaking 11 7 Charging Additional Refrigerant 11 8 Retro Fitting Existing Systems APPENDIX A INSTRUCTION MANUAL APPENDIX B INSTALLATION INSTRUCTIONS 48 49 50 51 52 52 53 55 56 56 A 1 A 2 Page 4 ...

Page 5: ...67 F D B Temperature Indoor Air Intake Temp Outdoor Air Intake Temp Cooling 95 F D B 71 F W B 67 F D B 57 F W B Maximum Minimum 115 F D B 0 F D B Temperature Indoor Air Intake Temp Outdoor Air Intake Temp Cooling Models KS0971 C0971 KS1271 C1271 Models KS0971 CL0971 KS1271 CL1271 5 ...

Page 6: ...rant Tube Kit Accessories Narrow tube Wide tube Refrigerant inch mm Tube Diameter inch mm 19 8 24 3 2 82 9 0 11 0 0 08 72 8 79 4 6 35 33 0 36 0 0 18 23 5 8 33 11 16 14 1 4 600 856 362 285 825 189 548 720 265 10 1 32 35 7 16 13 25 32 255 900 350 Outdoor Unit Indoor Unit 11 7 32 32 15 32 7 7 16 21 9 16 28 11 32 10 7 16 1 4 6 35 3 8 9 52 ft m Max allowable tubing length at shipment Flare Type 25 7 5 ...

Page 7: ... 0 0 18 23 5 8 33 11 16 14 1 4 600 856 362 285 825 189 548 720 265 10 1 32 35 7 16 13 25 32 255 900 350 Outdoor Unit Indoor Unit 11 7 32 32 15 32 7 7 16 21 9 16 28 11 32 10 7 16 1 4 6 35 3 8 9 52 ft m Max allowable tubing length at shipment Flare Type 25 7 5 36 33 29 25 47 R410A 2 43 1 100 Electric Expansion Valve Washable Anti Mold DC Rotary Inverter Manual Auto Timer Indoor Outdoor Fan Speeds 24...

Page 8: ...ories Narrow tube Wide tube Refrigerant inch mm Tube Diameter inch mm 19 8 24 3 2 82 9 0 11 0 0 08 72 8 79 4 6 35 33 0 36 0 0 18 23 5 8 33 11 16 14 1 4 600 856 362 285 825 189 548 720 265 10 1 32 35 7 16 13 25 32 255 900 350 Outdoor Unit Indoor Unit 11 7 32 32 15 32 7 7 16 21 9 16 28 11 32 10 7 16 1 4 6 35 3 8 9 52 ft m Max allowable tubing length at shipment Flare Type 25 7 5 34 31 28 23 46 R410A...

Page 9: ... 0 0 18 23 5 8 33 11 16 14 1 4 600 856 362 285 825 189 548 720 265 10 1 32 35 7 16 13 25 32 255 900 350 Outdoor Unit Indoor Unit 11 7 32 32 15 32 7 7 16 21 9 16 28 11 32 10 7 16 1 4 6 35 3 8 9 52 ft m Max allowable tubing length at shipment Flare Type 25 7 5 36 33 29 25 47 R410A 2 43 1 100 Electric Expansion Valve Washable Anti Mold DC Rotary Inverter Manual Auto Timer Indoor Outdoor Fan Speeds 24...

Page 10: ...Circuit Fuse Controls Part No Microprocessor 250V 3A CB KS0971 1 D3 11 16 L24 31 32 D94 L634 RCS 4VPIS4U Cross Flow AC Motor IBH 884 076 1 4 BRN WHT 57 9 RED WHT 55 2 16 1 200 Thermal Fuse 266 130 4 5 250 Fan Remote Control Unit Q ty Dia and Length Type inch mm Fan Motor Nominal Output Coil Resistance Rough Measure RPM Cool Type Model Q ty No of Poles Safety Device Type Operating Temp Close F C Op...

Page 11: ...NOTICE Control PCB Control Circuit Fuse Controls Part No Microprocessor 250V 3A CB KS1271 1 D3 11 16 L24 31 32 D94 L634 RCS 4VPIS4U Cross Flow AC Motor IBH 884 076 1 4 BRN WHT 57 9 RED WHT 55 2 16 1 250 Thermal Fuse 266 130 4 5 250 Fan Remote Control Unit Q ty Dia and Length Type inch mm Fan Motor Nominal Output Coil Resistance Rough Measure RPM Cool Type Model Q ty No of Poles Safety Device Type ...

Page 12: ...50 Ohm DC Motor Type Compressor Model Nominal Output Compressor Coil Resistance Ambient Temp 68 F 20 C Ohm DC Rotary Hermetic G4C090LU1ER 900W U V V W W U 0 81 0 81 0 81 CT Peak current cut off control Compressor Discharge Temp Control Operation cut off control in abnormal ambient Temp Safety Device Micro F VAC Run Capacitor Crankcase Heater Yes Yes Yes Overload Relay CS 7L115 Model Operation Temp...

Page 13: ...Motor Type Compressor Model Nominal Output Compressor Coil Resistance Ambient Temp 68 F 20 C Ohm DC Rotary Hermetic G4C090LU1ER 900W U V V W W U 0 81 0 81 0 81 CT Peak current cut off control Compressor Discharge Temp Control Operation cut off control in abnormal ambient Temp Safety Device Micro F VAC Run Capacitor Crankcase Heater Yes Yes Yes Overload Relay CS 7L115 Model Operation Temp Open 239 ...

Page 14: ...or Type Compressor Model Nominal Output Compressor Coil Resistance Ambient Temp 68 F 20 C Ohm DC Rotary Hermetic G4C090LU1ER 900W U V V W W U 0 81 0 81 0 81 CT Peak current cut off control Compressor Discharge Temp Control Operation cut off control in abnormal ambient Temp Safety Device Micro F VAC Run Capacitor Crankcase Heater Yes Yes Yes Overload Relay CS 7L115 Model Operation Temp Open 239 F 1...

Page 15: ...or Type Compressor Model Nominal Output Compressor Coil Resistance Ambient Temp 68 F 20 C Ohm DC Rotary Hermetic G4C090LU1ER 900W U V V W W U 0 81 0 81 0 81 CT Peak current cut off control Compressor Discharge Temp Control Operation cut off control in abnormal ambient Temp Safety Device Micro F VAC Run Capacitor Crankcase Heater Yes Yes Yes Overload Relay CS 7L115 Model Operation Temp Open 239 F 1...

Page 16: ...6 95 104 10 15 20 25 30 35 40 Indoor air temp sensor Model PTM D51H S3 TH2 Indoor heat exchanger sensor Model PTM D51H S3 TH1 Compressor temp sensor Model DTN TKS274Y TH2 Resistance k ohm Resistance k ohm Temperature F C Outdoor air temp sensor Model DTN TKS269B Outdoor heat exchanger sensor Model DTN TKS274Y TH1 40 35 30 25 20 15 10 5 0 4 5 14 23 32 41 50 59 68 20 15 10 5 0 5 10 15 20 Resistance ...

Page 17: ...3 DIMENSIONAL DATA Indoor Unit KS0971 KS1271 Unit inch mm 17 ...

Page 18: ...1 6 21 3 16 6 3 32 4 9 32 2 5 32 Narrow tube service valve dia 1 4 6 35 Wide tube service valve dia 3 8 9 52 3 19 32 15 32 10 7 16 265 11 13 32 12 7 16 Unit inch mm 28 11 32 720 2 1 8 21 9 16 548 5 8 Outdoor Unit C0971 C1271 CL0971 CL1271 18 ...

Page 19: ...1 C1271 CL0971 CL1271 Insulation of Refrigerant Tubing Because capillary tubing is used in the outdoor unit both the wide and narrow tubes of this air conditioner become cold To prevent heat loss and wet floors due to dripping of condensation both tubes must be well insulated with a proper insulation material The thickness of the insulation should be a min 5 16 8 mm After a tube has been insulated...

Page 20: ... air performance chart 68 20 77 25 86 30 95 35 104 40 60 8 16 64 4 18 57 2 14 53 6 12 50 0 10 46 4 8 Outdoor inlet air D B temp F C Outdoor inlet air D B temp F C Outdoor inlet air D B temp F C Operating current A Indoor discharge air temperature F C 8 9 6 5 7 4 145 1 0 159 1 1 173 1 2 131 0 9 117 0 8 Low pressure at wide tube service valve psig MPaG Hi Fan Lo fan 68 20 77 25 86 30 95 35 104 40 80...

Page 21: ...5 35 104 40 60 8 16 64 4 18 57 2 14 53 6 12 50 0 10 46 4 8 Outdoor inlet air D B temp F C Outdoor inlet air D B temp F C Outdoor inlet air D B temp F C Operating current A Indoor discharge air temperature F C 8 9 6 5 7 4 145 1 0 159 1 1 173 1 2 131 0 9 117 0 8 Low pressure at wide tube service valve psig MPaG Hi Fan Lo fan 4 20 5 15 14 10 23 5 32 0 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 8...

Page 22: ... 10 11 13 7 5 9 4 145 1 0 159 1 1 173 1 2 131 0 9 117 0 8 Low pressure at wide tube service valve psig MPaG Hi Fan Lo fan 68 20 77 25 86 30 95 35 104 40 80 F 27 C 75 F 24 C Indoor Air Temp 86 F 30 C 68 20 77 25 86 30 95 35 104 40 80 F 27 C 75 F 24 C Indoor Air Temp 86 F 30 C Check each performance value in test run mode Electrical performance values represent a combined indoor outdoor value Points...

Page 23: ... 1 0 159 1 1 173 1 2 131 0 9 117 0 8 Low pressure at wide tube service valve psig MPaG Hi Fan Lo fan 4 20 5 15 14 10 23 5 32 0 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 80 F 27 C 75 F 24 C Indoor Air Temp 86 F 30 C 4 20 5 15 14 10 23 5 32 0 41 5 50 10 59 15 68 20 77 25 86 30 95 35 104 40 Hi Fan Lo fan Hi Fan Lo fan 80 F 27 C 75 F 24 C Indoor Air Temp 86 F 30 C 80 F 27 C 75 F 24 C Indoor Air ...

Page 24: ...6 400 88 31 1 SHC 9 080 8 800 8 500 8 260 7 890 6 400 TC 9 440 9 160 8 860 8 630 8 250 6 580 72 22 2 SHC 5 770 5 610 5 500 5 390 5 220 4 510 63 76 24 4 SHC 6 700 6 590 6 430 6 370 6 160 5 500 17 2 80 26 7 SHC 7 690 7 580 7 470 7 360 7 200 6 480 84 28 9 SHC 8 680 8 570 8 400 8 300 8 130 6 580 88 31 1 SHC 9 440 9 160 8 860 8 630 8 250 6 580 TC 9 790 9 520 9 220 9 000 8 620 6 740 72 22 2 SHC 4 620 4 ...

Page 25: ...11 970 11 660 11 310 11 050 10 620 8 860 TC 12 370 12 070 11 730 11 480 11 050 9 020 72 22 2 SHC 7 220 7 050 6 880 6 760 6 530 5 620 63 76 24 4 SHC 8 190 8 020 7 850 7 730 7 560 6 590 17 2 80 26 7 SHC 9 220 9 100 8 930 8 820 8 590 7 680 84 28 9 SHC 10 250 10 080 9 900 9 790 9 560 8 650 88 31 1 SHC 11 220 11 050 10 880 10 760 10 590 9 020 TC 12 740 12 450 12 120 11 900 11 470 9 160 72 22 2 SHC 5 90...

Page 26: ...22 2 SHC 5 880 5 880 5 880 5 940 5 990 5 990 5 990 63 76 24 4 SHC 6 810 6 810 6 870 6 920 6 980 6 980 6 980 17 2 80 26 7 SHC 7 800 7 860 7 860 7 910 7 970 7 970 7 970 84 28 9 SHC 8 790 8 790 8 840 8 900 8 900 8 950 8 950 88 31 1 SHC 9 670 9 700 9 760 9 830 9 890 9 890 9 890 TC 9 460 9 510 9 660 9 840 10 010 10 120 10 120 72 22 2 SHC 4 450 4 450 4 560 4 620 4 670 4 730 4 730 67 76 24 4 SHC 5 440 5 ...

Page 27: ... 5 900 5 900 5 960 5 960 6 020 5 960 63 76 24 4 SHC 6 880 6 880 6 930 6 930 6 990 6 990 6 990 17 2 80 26 7 SHC 7 900 7 900 7 960 8 020 8 020 8 020 8 020 84 28 9 SHC 8 930 8 930 8 930 8 990 8 990 9 050 8 990 88 31 1 SHC 9 610 9 620 9 700 9 780 9 840 9 870 9 840 TC 9 460 9 490 9 640 9 770 9 890 9 960 9 970 72 22 2 SHC 4 480 4 480 4 530 4 590 4 650 4 700 4 700 67 76 24 4 SHC 5 450 5 500 5 560 5 620 5...

Page 28: ...ft Room air temp 80 F 26 7 C Fan speed High Cooling Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 5 4 Air Throw Distance Charts Indoor Unit KS0971 0 5 10 15 0 5 10 15 20 25 30 Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 28 ...

Page 29: ...tical distance ft Room air temp 80 F 26 7 C Fan speed High Cooling Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 Indoor Unit KS1271 0 5 10 15 0 5 10 15 20 25 30 Flap angle 0 Axis air velocity 0 Flap angle 30 Axis air velocity 30 29 ...

Page 30: ... Rating conditions Indoor air temperature 80 F 26 7 C D B 67 F 19 4 C W B Outdoor air temperature 95 F 35 C D B Cooling 7 6 750 Indoor Unit KS0971 Outdoor Unit CL0971 Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 115V Single phase 60Hz Rating conditions Running amp 0 45 Power input 45 7 15 705 Cooling 7 6 750 Rating conditions Indoor air temperature 80 F 26 7...

Page 31: ...ature 80 F 26 7 C D B 67 F 19 4 C W B Outdoor air temperature 95 F 35 C D B Cooling 10 9 1 090 Indoor Unit KS1271 Outdoor Unit CL1271 Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 115V Single phase 60Hz Rating conditions Running amp 0 45 Power input 45 10 45 1 045 Cooling 10 9 1 090 Rating conditions Indoor air temperature 80 F 26 7 C D B 67 F 19 4 C W B Outd...

Page 32: ...T CONTROLLER FM GRN YEL FAN MOTOR CAPACITOR FAN MOTOR 1 3 5 1 2 3 1 3 5 1 2 3 ROOM THERMISTOR BLK BLK BLK WHT RED BLK BLK 1 2 3 4 1 2 3 4 COIL THERMISTOR ION 3P WHT HA JEM A 1 2 3 1 2 3 1 2 3 1 2 3 4P WHT 1 2 4 BLK 3 BLK BLK RED WHT 1 2 3 4 1 2 3 4 ION ASSY ION TERMINAL 1 3 5 1 3 5 1 2 3 WHT BLK RED 1 3 1 3 BRN PNK RED WHT BLK RED YEL BRN PNK CONNECTOR 8FA2 5257 71600 0 6 2 Electric Wiring Diagram...

Page 33: ...AL PLATE GND TO INDOOR UNIT POWER RELAY 6 1 4 5 BLK WHT RED BLK BLK BLK WHT 1 2 3 4 5 6 7 FM GRN YEL FAN MOTOR 1 2 3 4 5 6 7 1 2 3 4 5 6 7 BLK BLK YEL YEL YEL BLK BLK BLU RED BLK BLK BLK WHT YEL BLU RED BLK BLK YEL WHT GRY RED ORG WHT OUT DOOR THERMISTOR OVERLOAD RELAY OLR COIL THERMISTOR COMPRESSOR THERMISTOR 7P CONNECTOR WHT MV MAGNETIC COIL 2P CONNECTOR BLK 2P CONNECTOR WHT HIGH PRESSURE SWITCH...

Page 34: ...K WHT RED BLK BLK BLK WHT 1 2 3 4 5 6 7 FM GRN YEL FAN MOTOR 1 2 3 4 5 6 7 1 2 3 4 5 6 7 BLK BLK YEL YEL YEL BLK BLK BLU RED BLK BLK BLK WHT YEL BLU RED BLK BLK YEL WHT GRY RED ORG WHT OUT DOOR THERMISTOR OVERLOAD RELAY OLR COIL THERMISTOR COMPRESSOR THERMISTOR 7P CONNECTOR WHT MV MAGNETIC COIL 2P CONNECTOR BLK 2P CONNECTOR WHT HIGH PRESSURE SWITCH 1 1 2 2 WHT WHT WHT WHT 1 1 2 2 WHT W W C HEATER1...

Page 35: ...press and hold the ACL reset button with a pointed object such as the tip of a pen After 5 seconds release ACL button first then release ION and 1 HR TIMER buttons oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as shown below Press this button 2 times to change the display to oP 7 address setting Fig 15 5 ...

Page 36: ...lways hold the cover to disconnect See illustration at left For the connector without the resin cover push the lock in the direction of 2 while pulling it off How to Connect In order to connect hold the resin cover of the connector and push it in Confirm the click sound for the inside lock Pull the cover upward When the cover is pulled upward the lock is released with the sequence of 1 and 2 7 2 D...

Page 37: ...he monitoring range is entered the compressor stops and the indoor fan operates with 1 f fluctuation DRY A DRY B Monitor Conditions are monitored at all times when the room temperature is below 59 F 15 C Load COOL zone A zone B zone Emergency operation is available when the remote controller malfunctions has been lost or otherwise cannot be used The set temperature is 4 F 2 C below the detected ro...

Page 38: ...ON timer operation Frequency MAX 0 Start End Time 30 min 5 min Setting temperature Press the NIGHT SETBACK button When NIGHT SETBACK operation is set the temperature and fan speed settings will be adjusted automatically to allow comfortable sleep When NIGHT SETBACK operation is set mark appears on the remote controller The main unit display lamp also becomes dimmer COOL and DRY modes When the nigh...

Page 39: ...e temperature of the indoor heat exchanger reaches 46 F 8 C or above A B C a b c d Indoor heat exchanger temperature F C 36 2 43 6 46 8 This function controls the operation frequency to prevent the compressor discharge temperature from rising more than a specified temperature a Area Automatic capacity control b When the temperature rises above Point A the operation frequency is reduced at a specif...

Page 40: ...d trouble diagnostics PROCEDURE Step 1 Press and hold the remote controller ION button and 1 HR TIMER button Then press and hold the ACL reset button with a pointed object such as the tip of a pen After 5 seconds release ACL button first then release ION and 1 HR TIMER buttons oP 1 test run appears blinking in the remote controller clock display area Step 2 Next press the 1 HR TIMER button once to...

Page 41: ...detection only for the humidity sensor 3 Indoor outdoor PCboard failure 1 Sensor open circuit or short circuit 2 Contact failure at connector or open circuit at terminal crimping location 3 Outdoor PCboard failure Outdoor PCboard failure 1 Mis wiring 2 AC power failure 3 Blown fuse 4 Power Relay failure 5 Indoor or outdoor PCboard failure 6 Outdoor Fan Motor failure 7 Reactor failure 8 High Pressu...

Page 42: ...ng the current mode is TEST run If there are no problems with the above then check the outdoor unit 1 The rated voltage must be present between inter unit wirings 1 and 2 Connect a 5 k ohm resistor between inter unit wirings 2 and 3 When the voltage at both ends is measured approximately 12 to 15V DC must be output and the multimeter pointer must bounce once every 8 seconds Or instead of measuring...

Page 43: ...age B For terminal strip short circuit work or inter unit wiring removal turn off the power to avoid an electric shock Release the terminal strip short circuit after the completion of self diagnostics Do not perform the short circuit work between any other terminals except for specified ones on the specified terminal strip If such work is performed between the incorrect terminals the unit might be...

Page 44: ...he operation button on the indoor unit 2 Perform the self diagnosis five seconds after the operation start 1 Turn off the power and wait until the power lamp LED of the outdoor unit controller is turned OFF 2 Remove the short circuit between the terminals 2 and 3 on the outdoor unit terminal strip 3 Disconnect the cable from the terminal 3 on the indoor unit terminal strip Fig 4 Short circuit betw...

Page 45: ...ter the operation start 1 Turn off the power and wait until the power lamp LED of the outdoor unit controller is turned OFF 2 Disconnect the cable from the terminal 3 on the Outdoor unit terminal strip Fig 6 Defect in the inter unit cable 1 Turn ON the power and operate the system using the remote controller or the operation button on the indoor unit 2 Perform the self diagnosis five seconds after...

Page 46: ...seconds but then quickly stops when the outdoor unit operates There is trouble in the system that provides feedback of motor rotation speed from the motor to the outdoor unit controller Trouble symptom 4 Fan motor rotation speed does not change during outdoor unit operation Trouble symptom 5 Fan motor rotation speed varies excessively during outdoor unit operation Remedy for symptom 3 to 5 It is n...

Page 47: ...distance from the noise source 1 Use shielded wires 2 Move unit away from the noise source Trouble Either of the following trouble may occur 1 The unit may stop suddenly during operation 2 Indicator lamps may flicker 2 Electromagnetic interference This refers to noise generated by high speed switching of the microcomputer and compressor This noise radiates through space and returns to the electric...

Page 48: ...g 1 10 1 2 Indoor Unit Clamp an aluminum plate fin or copper tube with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw on the terminal plate Fig 2 Note that the ground line terminal should be skipped for the check 10 1 3 Outdoor Unit Clamp a metallic part of the unit with the lead clip of the insulation resistance tester and me...

Page 49: ... Fig 6 Fuse 10 2 Checking Continuity of Fuse on PCB Ass y Remove the PCB Ass y from the electrical component box Then pull out the fuse from the PCB Ass y Fig 5 Check for continuity using a multimeter as shown in Fig 6 49 ...

Page 50: ...use of a change in composition of the remaining refrigerant Therefore do not add new refrigerant Instead recover the remaining refrigerant with the refrigerant recovery unit Then after evacuation totally recharge the specified amount of refrigerant with the new refrigerant at its normal mixed composition state in liquid phase When refrigerant R410A is used the composition will differ depending on ...

Page 51: ...n R410A refrigerant is exposed to fire Therefore be sure to provide ample ventilation during installation work Caution in case of R410A leak Check for possible leak points with the special leak detector for R410A If a leak occurs inside the room immediately provide thorough ventilation A D Flare tool for R410A A D Conventional flare tool R22 Spacer 11 2 Checklist before Servicing Use a clutch type...

Page 52: ...s which can be com monly used for R22 R407C and R410A CAUTION The above tools specifically for R410A must not be used for R22 and R407C Doing so will cause malfunction of the unit For the above vacuum pump 1 2 and vacuum pump adapter 3 those for R22 type units can be used for R410A type However they must be used exclusively for R410A and never alternately with R22 and R407C For details on tubing i...

Page 53: ...it quickly 3 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 4 Evacuation Use a solenoid valve installed vacuum pump so that even if power is cut off in the middle of evacuation of air due to a power interruption the valve will prevent the pump oil from flowing back The equipment may be damaged i...

Page 54: ...use an electronic scale for charging refrigerant In this case if the volume of refrigerant in the cylinder becomes less than 20 of the fully charged amount the composition of the refrigerant starts to change Thus do not use the refrigerant if the amount in the charging cylinder is less than 20 Also charge the minimum necessary amount to the charging cylinder before using it to charge the air condi...

Page 55: ...lux and wax for R410A Prevent oxide film from forming inside the tubes utilizing substitution with nitrogen N2 in the refrigerant circuit of the unit Leave ends of tubes open during welding 4 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 5 Evacuation Use a solenoid valve installed vacuum pump s...

Page 56: ... R410A for existing units which use R22 This will cause the air conditioner to operate improperly and may result in a hazardous condition 11 8 2 Use of Existing Tubing If replacing an older unit that used refrigerant R22 with a R410A unit do not use its existing tubing Instead completely new tubing must be used CAUTION Never charge additional refrigerant if refrigerant is leaking from the unit Fol...

Page 57: ...INSTRUCTION MANUAL KS0971 C0971 CL0971 KS1271 C1271 CL1271 OI 852 6 4180 803 00 2 APPENDIX A A 1 ...

Page 58: ...able Automatic and 3 step Fan Speed Auto High Medium Low Air Sweep Control This function moves a flap up and down in the air outlet directing air in a sweeping motion around the room and providing comfort in every corner Auto Flap Control This automatically sets the flap to the optimum position during cooling and drying operation Automatic Restart Function for Power Failure Even when power failure...

Page 59: ...ct Information If you have problems or questions concerning your Air Conditioner you will need the following information Model and serial numbers are on the nameplate on the bottom of the cabinet Model No ______________________ Serial No ____________________ Date of purchase ________________________________________________ Dealer s address ________________________________________________ Phone num...

Page 60: ... not install this air conditioner where there are fumes or flammable gases or in an extremely humid space such as a greenhouse Do not install the air conditioner where excessively high heat generating objects are placed Avoid To protect the air conditioner from heavy corrosion avoid installing the outdoor unit where salty sea water can splash directly onto it or in sulphurous air near a spa Never ...

Page 61: ...lown out of the air conditioner through the air outlet Remote Control Unit The wireless remote control unit controls power ON OFF operation mode selection temperature fan speed timer setting and air sweeping Refrigerant Tubes The indoor and outdoor units are connected by copper tubes through which refrigerant gas flows Drain Hose Moisture in the room condenses and drains off through this hose Outd...

Page 62: ...em is being controlled by the timer QUIET lamp This lamp lights during operation in the QUIET mode ION lamp This lamp lights during operation in the ION mode while the indoor unit is operating The unit s display lamps are dimmed during operation in the NIGHT SETBACK mode QUIET REMOTE CONTROL receiver Avoid using radio equipment such as mobile phone near within 4 ft the remote control receiver Some...

Page 63: ...OFF Timer 1 hour OFF Timer 5 NIGHT SETBACK 6 Confirmation of transmission 7 Auto fla dication Flap angle indication Sweep indication 8 High power operation 9 Quiet operation 10 ION operation Displayed when setting timer Displayed when transmitting data Displayed when indoor unit sensor is in use Displayed when setting temperature Displayed when temperature is shown Displayed when the time display ...

Page 64: ...negative ions generated during operation on and off ON OFF operation button This button is for turning the air conditioner on and off 1 HR TIMER button 1 HOUR OFF TIMER When you press this button regardless of whether the unit is operating or stopping the unit operates for one hour and then shuts down Transmitter Sensor Cover closed Display FAN SPEED selector button FLAP button ON TIME setting but...

Page 65: ...low direction to the auto flap in each mode or one of the six possible positions manually or to select the sweep function which moves the flap up and down automatically Auto flap setting If selected in a cooling or dry operation the flap is set at position 7 in the following chart The airflow direction can be set manually six positions The flap moves up and down automatically When you press the FL...

Page 66: ... not be bent The remote control unit sends the temperature signal to the air conditioner regularly at five minute intervals If the signal from the remote control unit stops for more than 15 minutes due to the loss of the remote control unit or other trouble the air conditioner will switch to the temperature sensor which is built into the indoor unit and control the room temperature In these cases ...

Page 67: ... remote control unit every 5 minutes Mounting the Remote Control Unit Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location The indoor unit should make a beeping sound to indicate that it has received the signal To take out the remote control unit pull it forward When Holding the Remote C...

Page 68: ...P 2 To start the air conditioner press the ON OFF operation button STEP 3 Press the TEMP setting buttons to change the temperature setting to the desired temperature Adjustable temperature range STEP 4 Set the FAN SPEED selector button to the setting you want STEP 5 Press the FLAP button and set the airflow direction as desired Refer to Adjusting the Airflow Direction on page 20 To stop the air co...

Page 69: ...the event of power failure the unit will stop 2 Adjusting the Fan Speed A Automatic fan speed Simply set the FAN SPEED selector button to the position This automatically sets the best fan speed for the room temperature B Manual fan speed If you want to adjust fan speed manually during operation just set the FAN SPEED selector button as desired or 3 Fan Only If you want to circulate air without any...

Page 70: ...When the night setback mode is selected the air conditioner automatically raises the temperature setting 2 F when 30 minutes have passed after the selection was made and then another 2 F after another 30 minutes 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...

Page 71: ...the display To cancel press HIGH POWER button again When the HIGH POWER button is pressed the unit operates at maximum output for 30 minutes regardless of the desired temperature The fan speed is 1 step above High QUIET Mode and HIGH POWER Mode cannot be used at the same time 7 ION Mode The ION mode is used during operation to generate negative ions that freshen up the air in the room Press the IO...

Page 72: ...cted from ice or frost when combined with the outdoor unit for Low Ambient Cooling models In the event of power failure the unit will stop When the power is resumed the unit will restart automatically within five minutes by the remote control unit Clicking sound is heard from the air conditioner In cooling operation any plastic parts may shrink due to a sudden temperature change In this event a cl...

Page 73: ...Return button until PM 10 30 is displayed The time can be set in 1 minute increments Holding down the button advances the time rapidly in 10 minute increments 3 Press the CLOCK button again This completes the setting of the current time 1 Press the OFF TIME setting button once The timer indication is displayed and the present OFF time is shown 2 Press the Advance Return button until AM 11 00 is di...

Page 74: ... operates as if it is turned off Operation Indication 1 Press the ON TIME setting button once The timer indication is displayed and the present ON time is shown 2 Press the Advance Return button until AM 7 10 is displayed The timer indication blinks The time can be set in 10 minute increments Holding down the button advances the time rapidly in 10 minute increments 3 Wait a few seconds and then th...

Page 75: ...to operate for one hour from that point in time and then stops It is not possible to use the OFF Timer and 1 Hour OFF Timer together Whichever function is set last takes precedence If the 1 HR TIMER button is pressed while the TIMER OFF function operates the OFF Timer is cancelled and the unit will stop operating one hour later 2 Operation together with the DAILY ON OFF REPEAT Timer The 1 Hour OFF...

Page 76: ...flap automatically closes when the unit is off Use the FLAP button on the remote control to adjust the position of the flap If you move the flap by hand the flap position according to the remote control and the actual flap position may no longer match If this should happen shut off the unit wait for the flap to close and then turn on the unit again the flap position will now be normal again Do not...

Page 77: ...components and cause an electric shock hazard Casing and Grille Indoor Unit Clean the casing and grille of the indoor unit with a vacuum cleaner brush or wipe them with a clean soft cloth If these parts are stained use a clean cloth moistened with a mild liquid detergent When cleaning the grille be careful not to force the vanes out of place 1 Never use solvents or harsh chemicals when cleaning th...

Page 78: ...y it How to replace the anti mold filter 1 With the FRONT mark of the anti mold filter at the front align the two indentions near the mark with the hooks at the rear of the air intake grille and then mount the anti mold filter 2 Allow the edge of the air intake grille to slide into the top of the indoor unit and then insert it all the way inside 3 Press in the bottom right and left corners of the ...

Page 79: ...e stubborn dirt moisten a cloth in warm water no hotter than 104 F wring thoroughly and then wipe The air intake grille can be removed in order to wash it with water Removing and remounting the air intake grille Refer to How to remove the anti mold filter and How to replace the anti mold filter on page 22 When using a footstool or the like be careful not to let it tip over Washing the grille with ...

Page 80: ...irty or clogged air filter 1 Clean air filter to improve airflow 2 Heat source or many people in room 2 Eliminate heat source if possible 3 Doors and or windows are open 3 Shut them to keep the heat out 4 Obstacle near air intake or air discharge port 4 Remove it to ensure good airflow 5 Thermostat is set too high for cooling 5 Set the temperature lower Clicking sound is heard from the air conditi...

Page 81: ...INSTALLATION INSTRUCTIONS KS0971 C0971 CL0971 KS1271 C1271 CL1271 II 852 6 4189 991 00 6 APPENDIX B A 2 ...

Page 82: ...nd Outdoor Units 5 5 Insulation of Refrigerant Tubing 5 6 Taping the Tubes 5 7 Finishing the Installation 6 AIR PURGING 21 I Air Purging with a Vacuum Pump for Test Run I Basic Functions of the Service Valves I Pump Down INSTALLATION INSTRUCTIONS Model Combinations Combine indoor and outdoor units only as listed below Indoor Unit Outdoor Unit KS0971 C0971 CL0971 KS1271 C1271 CL1271 Power Source 60...

Page 83: ...orting Be careful when picking up and moving the indoor and out door units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin alu minum fins on the air conditioner can cut your fingers When Installing In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construct a strong wood or meta...

Page 84: ...chase these materials separately from a local source you will need 1 Deoxidized annealed copper tube for refrigerant tub ing as detailed in Table 2 Cut each tube to the appropriate lengths 1 to 1 4 30 cm to 40 cm to dampen vibration between units Table 2 2 Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing Wall thickness of the insulation should b...

Page 85: ...unit more than 3 3 1 m away from any antenna or power lines or connecting wires used for television radio telephone security system or intercom Electrical noise from any of these sources may affect operation Drain hose Indoor unit Outside drainage Fig 1 2 5 cm min 6 15 cm min Front View 2 5 cm min Fig 2 INDOOR UNIT Tubing length L OUTDOOR UNIT Elevation difference H Fig 3a WARNING To prevent abnor...

Page 86: ...y required for the other models When the outdoor unit is installed in a position exposed to strong wind such as seasonal winds with low air tem perature in winter baffle plates must be installed on the outdoor unit Fig 5d This unit is designed so that the fan of the outdoor unit runs at low speed when the air conditioner is operated at low outdoor air temperatures When the outdoor unit is exposed ...

Page 87: ...3 64 19 64 17 3 8 25 64 5 29 32 25 32 25 32 mm 550 20 55 440 330 10 15 9 7 5 441 10 150 20 20 Dimensions A B C D E F G H I J K L M Model CL0971 CL1271 inch 19 3 32 20 3 32 13 25 32 5 29 32 17 17 32 25 32 2 5 32 14 9 16 2 3 4 3 11 32 19 32 1 3 8 1 3 8 mm 485 510 350 150 445 20 55 370 70 85 15 35 35 Air Intake Baffle Air Discharge Baffle Fig 5e Item Q ty Remarks Baffle plate 1 Screw 5 32 15 32 4 12 ...

Page 88: ...not to damage painted surfaces 2 Finish the edges of the windbaffle to avoid cuts or injury 3 Drilling of holes must be carefully done so that no damage is caused to external or internal parts of the unit Particular care must be taken that drill chips do not drop into the unit Panel front Panel side R Panel side L 1 Air Intake Baffle 1 Left side 1 Remove the front panel from the unit 2 Remove the ...

Page 89: ...ose and drain cap on page 16 3 2 Make a Hole 1 Place the rear panel from the indoor unit on the wall at the location selected Make sure the panel is hori zontal using a carpenter s level or tape measure to measure down from the ceiling Wait until after cut ting the hole before attaching the rear panel to the wall 2 Determine which side of the unit you should make the hole for tubing and wiring Fig...

Page 90: ...is strong enough to sus pend the unit See either Item a or b below depending on the wall type a If Wooden Wall 1 Attach the rear panel to the wall with the 8 screws provided Fig 13 If you are not able to line up the holes in the rear panel with the beam locations marked on the wall use rawl plugs or toggle bolts to go through the holes on the panel or drill 3 16 5 mm dia holes in the panel over th...

Page 91: ... part of the grille back into position 2 Make sure that the grille and frame are firmly fitted together by engaging the tabs 3 Attach the thermistor on the grille Fig 17a 4 Close the cover and replace the screw Fig 17a 5 Affix the grille with the 2 previously removed screws Fig 16b 6 Install the air intake grille a Allow the edge of the air intake grille to slide into the top of the indoor unit an...

Page 92: ...agram 2 Provide a power outlet to be used exclusively for each unit with a power supply disconnect and cir cuit breaker for overcurrent protection provided in the exclusive line 3 To prevent possible hazards due to insulation failure the unit must be grounded 4 Each wiring connection must be done tightly and in accordance with the wiring system diagram Wrong wiring may cause the unit to misoperate...

Page 93: ...the power supply line to the outdoor unit as shown in the wiring diagram The indoor unit draws its power from the outdoor unit G Do not run wiring for antenna signal or power lines of television radio stereo telephone security system or intercom any closer than 3 4 1 m from the power cable and wires between the indoor and outdoor units Electrical noise may affect the operation G To avoid the risk ...

Page 94: ...oute the inter unit wiring from the back of the indoor unit and pull it toward the front for connec tion Fig 26a 26b 5 Connect the inter unit wiring to the corresponding terminals on the terminal plate Fig 26a 26b while referring to the wiring diagram 6 Be sure to secure the wiring with the provided clamp When closing the air intake grille press on both corners Fig 27 Please refer to How to replac...

Page 95: ...the terminal screw 4 Shape the loop wire properly place it on the termi nal plate and fix it securely with the removed termi nal screw using a screwdriver I For stranded wiring 1 Cut the wire end with a cutting pliers then strip the insulation to expose the stranded wiring about 3 8 10 mm and tightly twist the wire ends Figs 30 and 31 2 Using a screwdriver remove the terminal screw s on the termin...

Page 96: ...the wall Adjust the indoor unit so it is securely seated on the rear panel Fig 36 3 Carefully bend the tubing if necessary to run along the wall in the direction of the outdoor unit and then tape as far as the fittings See Caution on page 20 The drain hose should come straight down the wall to a point where water runoff won t stain the wall 4 Connect the refrigerant tubing to the outdoor unit Afte...

Page 97: ...the drain hose fully onto the drain pan outlet until the drain hose edge is pushed into the insula tion Check that the screw holes in the drain bracket and the drain pan outlet are aligned and securely in contact then fasten them with the screw After attaching the drain hose check that it is attached securely Fig 40c Drain cap Use a Phillips screwdriver to push the drain cap in firmly If it is dif...

Page 98: ...f the hose c If the drain hose will run in the room insulate the hose with insulation so that chilled condensation will not damage furniture or floors Fig 44 Foamed polyethylene or its equivalent is recom mended WARNING Risk of Electric Shock Do not supply power to the unit or operate it until all tubing and wiring to the out side unit are completed Condensation Insulation material Locally purchas...

Page 99: ...s 1 Remove access panel C Fig 46 2 Connect the inter unit and power supply line accord ing to the drawing on the panel side 3 Be sure to size each wire allowing approx 4 10 cm longer than the required length for wiring Store excess wiring inside the cabinet 4 When connections are completed check that all connections are correct as shown in the wiring sys tem diagram on panel side 5 Be sure to grou...

Page 100: ...ool Figs 49a and 49b Use RIGID or equivalent A good flare should have the following characteristics G inside surface is glossy and smooth G edge is smooth G tapered sides are of uniform length 5 3 Caution before Connecting Tubes Tightly a Be sure to apply a sealing cap or water proof tape to prevent dust or water from getting into the tubes before they are used b Be sure to apply refrigerant lubri...

Page 101: ...half of each previous tape turn Fig 55 3 Clamp the tubing bundle to wall using 1 clamp approx every 47 120 cm Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also be sure the con densation drain hose splits away from the bundle and drips clear of the unit and the tubing 5 7 Finishing the Installation After finishing insulating and taping over the tubin...

Page 102: ... time for evacuation Table 7 Hi Lo Indoor unit Outdoor unit Manifold valve Exclusively for R410A Pressure gauge Vacuum pump Charging hose Exclusively for R410A Vacuum pump adapter Exclusively for R410A with reverse flow prevention Fig 57 CAUTION Be sure to use a manifold valve for air purging If it is not avail able use a stop valve field sup ply for this purpose The Hi knob of the manifold valve ...

Page 103: ...rt slightly to release the pressure Then remove the hose 11 Fasten the valve cap on the wide tube service port securely with an adjustable wrench or box wrench Next mount the valve cap on the service valve and tighten it to 170 lbs in 200 kgf cm with a torque wrench This process is very important to prevent gas from leaking from the system 12 Test run the air conditioner See next page 13 While the...

Page 104: ...ain unit blinking Fig 59c After 3 minutes the system shifts into cooling opera tion and cool air will start to be felt Cool mode test run is unaffected by the room temperature 3 Press the ON OFF operation button of the remote con troller again to stop the test run Fig 59a 4 Finally press the ACL reset button of the remote con troller to release it from Test Run mode to return to nor mal mode Fig 5...

Page 105: ...ube valve stem Then quickly stop the unit 5 Disconnect all gauges and hoses and replace the valve caps as they were before I Basic Functions of the Service Valves The basic functions of the service valves are given in Table 8 below Action Narrow Tube Service Valve 2 Way Wide Tube Service Valve 3 Way CLOSED Fully OPEN Fully OPEN Shipping Operating and test running the air conditioner Measuring pres...

Page 106: ...there is an obstacle between the remote con trol unit and the air conditioner since a check signal is sent from the remote control unit every 5 minutes 7 1 Mounting on a Wall Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location The indoor unit should make a beeping sound to indicate that...

Page 107: ... object such as the tip of a pen to press the ACL button When this has been done oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as shown below Press this button 2 times to change the display to oP 7 address setting Fig 64 5 oP 7 has now been selected for address setting 6 Press the ON OFF operation button ...

Page 108: ...YO Commercial Solutions A Division of SANYO North America Corporation 1300 Michael Drive Suite A Wood Dale IL 60191 U S A Sanyo Canada Inc 1 300 Applewood Crescent Concord Ontario L4K 5C7 CANADA Jan 2009 T ...

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