Sanyo CG1411 Service Manual Download Page 48

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10. PROCEDURE FOR DISMANTLING THE UNIT

10-1. Procedure for Dismantling the Indoor Unit

(1) How to remove grille

(2) How to remove PCBs

➀

Close the flap (upper airflow adjustment plate)

and open the screw covers. Then remove the

screws (2).

➂

Detach the attachment tabs (2) at the top of the

grille by lifting the grille.

➁

Remove the fixing tabs (3) at the bottom of

decorative grille.

Detach all the wire connectors on PCB A and B in the electrical component box, and remove the tabs

holding the PCBs. Detach the PCBs A and B from the top.

Summary of Contents for CG1411

Page 1: ...AL SERVICE MANUAL KGS1411 CG1411 GAS HEATER AIR CONDITIONER FILE NO Indoor Model No Product Code No KGS 1411 1 852 062 56 Outdoor Model No Product Code No CG 1411 1 714 734 00 Indoor Unit Outdoor Unit Destination U S A KGS1411 CG1411 ...

Page 2: ...g 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 metal fra...

Page 3: ... Charts 18 5 3 Cooling Capacity 19 5 4 Heating Capacity 20 6 ELECTRICAL DATA 6 1 Electrical Characteristics 21 6 2 Electric Wiring Diagrams 22 7 INSTALLATION INSTRUCTIONS 7 1 Installation Site Selection 25 7 2 Recommended Wire Length and Diameter 27 7 3 Remote Control Unit Installation Position 28 8 FUNCTION 8 1 Motion Explanation 29 8 2 Cooling 31 8 3 Heating 33 8 4 Fan Speed Control 37 8 5 Dry O...

Page 4: ...t 54 12 3 Operation Lamp Blinks It Keeps Blinking after 3 Minutes Following Start of Operation 54 12 4 Outdoor Unit Fan Does Not Work 58 12 5 Flap Motor Does Not Work 59 12 6 Heating Operation Not Possible 59 12 7 Reset Method When Error Occurs During Heating Operation 63 12 8 Failure Display on Outdoor Unit and Correction Method 64 13 SPECIAL PRECAUTIONS WHEN SERVICING THE UNIT 13 1 BLK WHT Conne...

Page 5: ...or Air Intake Temp Cooling Maximum 95 F 35 C D B 115 F 46 1 C D B 71 F 21 7 C W B Minimum 67 F 19 4 C D B 67 F 19 4 C D B 57 F 13 9 C W B Heating Maximum 80 F 26 7 C D B 75 F 23 9 C D B 67 F 19 4 C W B 65 F 18 3 C W B Minimum D B 0 F 17 8 C D B W B 2 F 19 C W B ...

Page 6: ...vailable voltage range V 104 126 Running amperes A 8 2 5 9 Power input W 900 620 Power factor 95 91 SEER BTU W 10 0 Compressor locked rotor amperes A 49 Features Controls Temperature control Microprocessor I C thermostat Control unit Wireless remote control unit Timer ON OFF 12 hours 1 hour OFF Fan speeds Indoor Outdoor 3 and Auto 1 Hi Airflow direction Indoor Horizontal Manual Vertical Auto Air f...

Page 7: ...er diameter ø inch ø mm 0 0807 2 05 0 0630 1 60 Q ty 1 1 Safety Devices Cooling Heating Re start timer 3 minute Compressor over load limiting Circuit fuse Current limit function out of range between 0 8 17A Thermal fuse Auto reset temperature limiting 221 F 105 C Flame rod Governor Setting Pressure Natural gas LP P2 P1 P2 P1 P2 P1 Inches water column kPa High 3 43 0 853 7 0 1 74 3 54 0 883 11 0 2 ...

Page 8: ...C Ω WHT BLU respectively 4 wires 380 7 Heat Exchanger Coil Coil Aluminum plate fin Copper tube Rows 2 Fin pitch inch mm 1 16 1 4 Face area ft2 m2 1 40 0 130 Fan Fan Motor Type Cross flow Q ty Dia and length inch mm 1 ø 95 L617 ø 3 3 4 L24 9 32 Fan motor model Q ty KFV4 21HIP 1P Nominal output W 15 Coil resistance ambient temp 68 F 20 C Ω BLU BRN 104 9 BLU PNK 128 0 Safety devices Type X23 Operatin...

Page 9: ... 69 11 Operating amp ambient temp 77 F 25 C Trip in 6 to 16 sec at 34A Run capacitor µF 35 VAC 330 PTC starter Part number 912X24E400XR20 PS2A Resistance Ω 47 Max voltage 300 Crank case heater Fan Fan Motor Type Propeller Q ty Dia and length inch mm 1 13 25 32 ø 350 Fan motor model Q ty SB6 11H1P 1 No of poles rpm 115V High 6 600 Nominal output W 10 Coil resistance ambient temp 77 F 25 C Ω BLU BRN...

Page 10: ...rpm 2 1 300 2 900 Nominal output W 6 Coil resistance ambient temp 68 F 20 C Ω 21 3 Safety devices Type Thermal fuse Operating temp Open F C 293 145 Close Refrigerant Heater Case Coil Aluminum collapsible forming Copper tube Heat conduction face area ft2 m2 1 83 0 17 Heat load 10 3 BTU h ft2 m2 7 65 1 3 Combination Gas Valve Type Combination control Model UP13 27 Coil resistance Valve SV1 SV2 for s...

Page 11: ...V 60Hz Secondary 13 7V 0 5A Capacity 6 85VA Coil resistance Ω at 77 F 25 C Primary WHT WHT 128 20 Secondary BRN BRN 2 28 20 Thermal cut off temp 277 F 136 C Thermistor Coil sensor DTN TKS118B Resistance kΩ 32 F 0 C 188 4 Thermistor Room sensor DTN TKS134B Resistance kΩ 77 F 25 C 5 0 3 DATA SUBJECT TO CHANGE WITHOUT NOTICE ...

Page 12: ...ischarge pressure PB3M 41E Resistance kΩ 122 F 50 C 2 2 5 Thermistor 2 Outlet refrigerant temp PB3M 41E Resistance kΩ 131 F 55 C 2 2 5 Reversing Valve CHV 01AE Coil CHV 0101 Valve Coil rating AC115 120V 50 60Hz 6 5W Coil resistance Ω 370 ON OFF Valve Q ty 2 NEV MOAE Coil NEV 603DXF Valve Coil rating AC115 120V 50 60Hz 7W Coil resistance Ω 370 2 3 2 Outdoor Unit Outdoor unit CG1411 Power Relay PR D...

Page 13: ... 16 58 5 1 5 8 41 0 1 5 8 41 0 Drain hose ø23 32 18 Narrow tube ø1 4 6 35 Wide tube ø3 8 9 52 Center of tubing hole 2 places Unit inch mm 6 7 32 172 5 Remote control unit 2 2 5 61 25 32 18 5 3 DIMENSIONAL DATA 3 1 Unit 3 1 1 Indoor Unit Indoor unit KGS1411 ...

Page 14: ...60 5 5 32 131 2 1 4 57 84 3 5 16 Holes for anchor bolts 4 ø15 32 Narrow tube service valve Wide tube service valve ø3 8 9 52 ø1 4 6 35 Wide tube service valve ø3 8 9 52 Narrow tube service valve ø1 4 6 35 2 13 32 30 230 Unit inch mm 3 1 2 Outdoor Unit Outdoor unit CG1411 Location of Service Valves Service valves are located behind the side panel See the illustration at right NOTE ...

Page 15: ...n selector PCB A PCB B Transformer Terminal block Fan motor Ground screw Attachment plate of the conduit Louver motor Wireless remote control unit Indicator Cross flow fan Drain pan Room temperature sensor Flap Heat exchanger Vertical flap Refrigerant tubing Drain hose Heat exchanger sensor Anti vibration rubber for motor ...

Page 16: ... capacitor Reversing valve On Off valve Propeller fan Thermal fuse Bimetal thermostat Exhaust chimney Refrigerant heater Terminal block Thermistor 2 Thermistor 1 Flame sensor probe Ignition electrode Gas conduit Combustion blower Ignition transformer Burner Heat exchanger Compressor Accumulator Reversing valve Combination gas valve Manual shut off valve ...

Page 17: ...zzle 0 945 24 0 906 23 0 708 18 0 590 15 1 417 36 1 948 49 5 0 925 23 5 1 433 36 4 2 067 52 5 4 913 124 8 MAX Proportional control valve Electro magnetic valve 2 Adjuster Body Electro magnetic valve 1 Unit inch mm Natural Gas LPG Material Body Aluminum Die Cast Nozzle Brass Nozzle Dia 0 0807 inch 2 05 mm 0 0630 inch 1 60 mm Figure Unit inch mm 1 15 29 2 NAT 1 15 29 2 LPG ...

Page 18: ...ess Steel Thickness 0 0157 inch 0 4 mm 4 Combustion Blower 6 457 164 0 984 25 0 433 11 2 165 55 2 756 70 Unit inch mm 5 185 131 7 1 578 40 3 764 95 6 1 597 40 5 Combustion blower fan Outer diameter 3 11 32 Combustion blower motor FU2 051F1MP Fan casing ...

Page 19: ...gerant Heater 6 693 170 10 827 275 3 150 80 Aluminum Copper tube Outer dia 5 16 Packing both sides Ceramic fiber Side wall both sides Aluminum coated steel sheet Refrigerant outlet Refrigerant inlet Unit inch mm ...

Page 20: ...tube Capillary tube Strainer O D 3 8 9 52 mm O D 1 4 6 35 mm Heat exchanger Heat exchanger Refrigerant heater HEATING CYCLE Heating cycle Outdoor unit Indoor unit Wide tube Muffler Wide tube service valve Reversing valve Check valve 2 Check valve 1 ON OFF valve 2 ON OFF valve 1 Accumulator Compressor Narrow tube Narrow tube service valve Capillary tube Capillary tube Strainer O D 3 8 9 52 mm O D 1...

Page 21: ...B temp F C 115 V 150 140 130 120 110 100 90 80 70 60 50 Low pressure psig kg cm 2 G at wide tube service valve 115 V Outdoor inlet air D B temp F C 25 4 23 9 22 5 21 1 19 7 18 3 16 9 15 5 14 1 12 7 11 2 360 340 320 300 280 260 240 220 200 180 160 Indoor inlet air D B temp F C High pressure psig kg cm 2 G at wide tube service valve 10 12 2 60 15 6 20 6 6 30 1 1 40 4 4 50 10 0 60 15 6 70 21 1 10 12 ...

Page 22: ...h Heating 5 5 10 15 10 15 Horizontal distance ft Louver angle 0 Louver angle 30 Axis air velocity ft sec Vertical distance ft 20 25 30 Axis air velocity 0 Axis air velocity 30 5 5 10 15 10 15 Horizontal distance ft Flap angle 45 Flap angle 60 Axis air velocity ft sec Vertical distance ft 20 25 30 Axis air velocity 45 Axis air velocity 60 ...

Page 23: ...72 22 2 SHC 5 670 5 480 5 270 5 040 4 800 17 2 76 24 4 SHC 6 560 6 360 6 160 5 930 5 690 80 26 7 SHC 7 490 7 290 7 090 6 860 6 620 84 28 9 SHC 8 370 8 180 7 980 7 750 7 510 88 31 1 SHC 9 260 9 040 8 590 8 070 7 520 TC 9 820 9 430 9 000 8 520 8 000 CI 0 66 0 72 0 79 0 86 0 96 67 72 22 2 SHC 4 580 4 420 4 240 4 050 3 840 19 4 76 24 4 SHC 5 470 5 310 5 130 4 930 4 720 80 26 7 SHC 6 400 6 240 6 060 5 ...

Page 24: ...ating condition Indoor 70 F 21 1 C D B Outdoor 47 F 8 3 C D B 43 F 6 1 C W B 2 Above characteristics indicate instantaneous operation which does not take into account defrost operation 3 Fan speed High 4 Conventional heat pump type air conditioner may not generate enough heating capacity especially when the outdoor temperature falls to extremely low level Gas heater air conditioner can operate pow...

Page 25: ...mperature 95 F 35 C D B Full load conditions Indoor air temperature 95 F 35 C D B 70 F 21 2 C W B Outdoor air temperature 115 F 46 1 C D B Rating conditions Indoor air temperature 70 F 21 1 C D B Outdoor air temperature 47 F 8 3 C D B 43 F 6 1 C W B Full load conditions Indoor air temperature 80 F 26 7 C D B Outdoor air temperature 75 F 23 9 C D B 65 F 18 3 C W B Indoor Unit Outdoor Unit Complete ...

Page 26: ...11 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 G Fan motor G P S FM Connector Flap motor Flap 5P GRN Hole IC 3P WHT DC CONT 11P WHT DC CONT 11P WHT Power relay AC out Coil 2P WHT Lamp 8P WHT Fan 5P WHT Trans 2 2P RED RV COM Trans 1 3P WHT Coil thermistor FLP WHT PNK BRN BLU Controller A Controller B BLK GRY Lamp WHT IND LAMP ASSY GRY GRY WHT GRY GRY GRY WHT BRN BRN Power transf...

Page 27: ...HT CN08 WHT CN01 WHT CN12 WHT CN10A WHT CN10B WHT CN11 WHT CN14 YEL CN03 Power relay K07 Flame rod Bimetal thermostat Power transformer Proportional control valve Thermal fuse Thermistor 2 Thermistor 1 Compressor Overload protector Start relay PNK WHT BLK CN19 LD5 LD4 LD3 LD2 LD1 IC9 ICI SWI BRN BLU BRN BLK BLK BLU BLU BLU BLU YEL YEL BLU BLU WHT WHT WHT WHT WHT RED RED RED RED WHT BLK BLK PNK BLK...

Page 28: ... IC9 IC8 C13 C29 R21 J11 IC1 RA1 J20 J22 J32 J33 R69 REG1 R71 R48 R106 R13 J19 J21 J24 J23 J25 J26 R31 C102 C10 C20 J09 J08 J07 J27 J28 J29 J30 IC3 SD1 IC2 IC5 IC7 PC2 PC1 PC3 IC6 _ 1 3 CN10B CN11 CN14 D03 1 3 CN12 1 2 CN10A 1 4 CN03 CN01 CN19 1 3 CN02 1 3 R06 ABS1 R04 R03 R02 R01 K05 D15 J36 Z02 R105 J18 C05 C06 C24 L03 C07 C03 C27 C02 C04 Q02 HS2 HS1 J16 J15 J06 J04 J05 J35 J34 J01 J02 SW1 C28 C...

Page 29: ... in Table 1 and Fig 2 Table 1 2 5 cm min 2 5 cm min 2 5 cm min Front View Fig 1 INDOOR UNIT Tubing length L OUTDOOR UNIT Elevation difference H Fig 2 WARNING To prevent abnormal heat generation and the possibility of fire do not place obsta cles enclosures and grilles in front of or surrounding the air conditioner in a way that may block air flow Indoor unit Floor level Wall Minimum height from fl...

Page 30: ...en the ambient temperature is dropping a white cloud or fog may be seen blowing from the unit This does not indicate a problem The distance between any building opening and the exhaust must be 24 in 60 cm or more Locate the outdoor unit away from windows to avoid possible entry of exhaust gases into the building Pay special attention to the win dows of a neighboring house or building If there is a...

Page 31: ...these regulations when carrying out the installation Refer to the wiring system diagram Fig 6 Refer to your local codes or in the absence of local codes with the National Electric Code ANSI NFPA70 NOTE 1 2 3 4 1 2 3 4 5 G G G 6 INDOOR UNIT TERMINAL 4P TERMINAL 6P OUTDOOR UNIT INTER UNIT Power line 115V Grounding line Grounding line Disconnect switch Field supply L1 Power supply Single phase 60 Hz ...

Page 32: ...cover by sliding it downward 5 Remove the batteries of the remote control unit 6 Use a screwdriver to screw the remote control unit securing screw into the wall through the hole in the battery compart ment Fig 8 7 Replace the batteries 8 Again confirm that the remote control unit operates correctly Wall Screw Packed in indoor unit Fig 8 Wall Special mounting screw Packed in indoor unit Fig 7 Remov...

Page 33: ...ulated from the outdoor heat exchanger tubing to the indoor heat transfer tubing by operation of the compressor Controls maintain refrigerant temperature to a point above the saturation temper ature and so the temperature is circulated as a gas Refrigerant flow is through the ON OFF valve V2 under stable conditions to provide for low power operation Low power operation is initiated V2 opens when t...

Page 34: ...trol the gas solenoid valve to shut off Flame Detection Circuit Stops gas flow with flame sensor circuit Bimetal Thermostat Stops gas flow with bimetal thermostat at 221 F 105 C Thermal Fuse Stops gas flow with thermal fuse at 302 F 150 C replaceable fuse Fuse Control Circuit Protected by internal 3A and 5A device Exhaust Refrigerant heater Supply Gas inlet Joint Solenoid valve 1 Solenoid valve 2 ...

Page 35: ...stalling out when trying to start against the high side refrigerant pressure the control circuit has a built in automatic time delay to allow the internal pressure to equalize As a protective measure the control circuit switches the compressor OFF after 3 minutes or more of com pressor operation Thermo ON When the room temperature is above T F T F is set temperature Compressor ON Thermo OFF When t...

Page 36: ...ure 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 6 minutes Set temp 46 F 36 F Compressor Indoor heat exch coil temp Indoor fan More than 3 minutes More than 3 minutes More than 10 minutes Set speed ...

Page 37: ...e the control circuit has a built in automatic time delay to allow the internal pressure to equalize As a protective measure the control circuit switches the compressor OFF after 3 minutes or more of com pressor operation Thermo ON When the room temperature is below T 1 F T F is set temperature Compressor ON Thermo OFF When the room temperature is equal to or below set temperature T 2 F Compressor...

Page 38: ...Limit on amount of combustion at high load Limits amount of combustion at 144 F 62 C Resets when temperature decreases to 140 F 60 C Stops combustion at 149 F 65 C Resets when the temperature decreases to 131 F 55 C Compressor continuously operates Error stop occurs after combustion stops eight times Operation lamp on indoor unit blinks 2 Thermistor 2 1 Limit on amount of combustion Limits combust...

Page 39: ...rmo ON lasts less than 10 minutes under Normal Combustion Mode subsequent to Thermo OFF Save Mode 1 is automatically selected for the following Thermo ON and then Save Mode 2 is selected if Save Mode 1 lasts less than 10 minutes 2 Reset Function When combustion in Save Mode 1 continues past 10 minutes it goes back to Normal Combustion Mode Save Mode 2 to Save Mode 1 However if Thermo OFF occurs ag...

Page 40: ... of the heat exchanger less than 90 F 32 C Until the temperature of the heat exchanger goes over 117 F 47 C fan speed varies according to the temperature of the heat exchanger Once the temperature of the heat exchanger rises over 117 F 47 C cold draft prevention function is released Temperature of coil temperature sensor Fan speed Set speed LL 117 F 47 C 90 F 32 C Temperature of Less than 90 F 32 ...

Page 41: ...eed Compressor 3 minutes ON TR Room temp TS 2 F 1 C Ts TS 2 F 1 C 30 seconds 30 seconds H M LL Compressor ON Compressor OFF Fan Speed TR Room temp For 3 minutes after power ON the compressor does not turn on For 30 seconds after the compressor is turned OFF the previous fan speed is maintained During Heating Operation Automatic fan speed ...

Page 42: ...L Dry operation does not occur when the room temperature is under 59 F 15 C which is the Monitor Zone When the compressor stops the indoor fan stops as well NOTE Room temp T 4 F 2 C T 2 F 1 C Room temp 59 F 15 C Set temp T C Cooling operation Dry A Zone Compressor Continuous operation FMI indoor fan L low speed LL very low speed intermittent ventilation only while the compressor is ON Dry B Zone C...

Page 43: ... TS During Heating Operation During Cooling Operation Room temperature at start of operation Temperature set automatically Operation mode TR F C F C 88 30 TR 82 27 84 24 TR 88 30 80 26 Cooling 80 26 TR 84 28 78 25 72 22 TR 80 26 76 24 Dry TR 72 22 76 24 Heating Room temperature TR and set temperature TS Fan speed TR TS 4 F 2 C H High TS 4 F 2 C TR TS 2 F 1 C M Medium TS 2 F 1 C TR TS L Low TS TR T...

Page 44: ...r 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 More than 6 minutes pass after start of operation Conditions of Reset When temperature of heat exchanger rises to 46 F 8 C or more 2 Dry B Zone Conditions of freeze prevention operation a Temperature of heat exchanger is less than 36 F 2 4 C b During Dry Operation When both conditions a and b are...

Page 45: ...re of Thermistor 1 drops to 144 F 62 C or less from the point A within 1 minute The burner is set to M point C Reset is activated when the temperature of Thermistor 1 drops to 122 F 50 C or less with the burner being set to H High load protection for the outdoor unit is operated independently from the high load protection for the indoor unit Compressor Indoor fan Indoor heat exch coil temp H H M M...

Page 46: ...or fan motor ON Compressor YES Room temp 15 C Monitor Indoor fan Outdoor fan motor OFF Compressor Outdoor fan motor Compressor 3 min ON 9 min OFF Intermittent Indoor fan Low very low Indoor fan Low very low Dry A Dry B 9 1 2 Stopping Flowchart Operation starts Operation lamp Light OFF Compressor OFF Indoor fan OFF Outdoor fan OFF 9 1 3 Check Refrigerant Cycle Flowchart YES Intake outlet temp lower...

Page 47: ...works NO YES Room temp higher than set temp NO YES Thermistor 1 higher than 42 C Flame sensor failure light off NO YES First Thermal fuse bimetal thermostat normal NO YES First Combustion lamp flashes LD 2 3 4 5 LD 2 3 4 5 LD 2 3 4 5 C 12 sec after 15 sec after 3 sec after from a NO YES Combustion continues more than 4 min LD 2 3 4 5 LD 2 3 4 5 LD 2 3 4 5 LD 2 3 4 5 Thermistor 1 higher than 185 F ...

Page 48: ...low adjustment plate and open the screw covers Then remove the screws 2 Detach the attachment tabs 2 at the top of the grille by lifting the grille Remove the fixing tabs 3 at the bottom of decorative grille Detach all the wire connectors on PCB A and B in the electrical component box and remove the tabs holding the PCBs Detach the PCBs A and B from the top ...

Page 49: ...drain pan and remove it upward by pressing the tabs one each for right and left hooked to the frame 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 Remove the connectors for sensor fan motor and flap motor which are connected to the electrical component box ...

Page 50: ...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 Loosen the hexagonal screw in the fan boss which attaches the fan Remove the screw 1 for the fan bearing cover Pull out the fan boss from the fan motor shaft and then pull out the fan to the left Remove the fan motor by picking it up ...

Page 51: ...ws 5 of the front panel Remove the screw 1 of the side cover the screws 3 of the terminal block cover and the screws 2 of the terminal block Remove the front panel and unscrew the screws 9 attaching the rear panel and detach the manual shut off valve 3 How to detach the combustion blower Remove the screws 2 attaching the blower Detach CN5 and CN14 on outdoor unit PCB ...

Page 52: ...back of the main unit Detach the 2 connectors CN11 for proportional valve and CN08 for solenoid valve Remove the screws 2 attaching the gas conduit in front of the combustion chamber and take off the combination valve with gas conduit 5 How to detach combination valve Remove the attachment screws and dismantle as shown below ...

Page 53: ...l clip and remove the ignition probe and flame sensor elec trode Flame sensor electrode is replaced together with the wires connected 7 How to detach burner unit Remove the attachment screws 6 and pull the burner unit to the front When reattaching the burner unit replace the center screw first 8 How to detach gas nozzle Remove burner unit Remove the screws 2 attaching the nozzle Rear view ...

Page 54: ...be set automatically from Step 1 and Step 2 Check these settings 2 or 3 times to insure all are correct then reset until no LEDs flash NOTE Alarm Signal Error Meaning Operation Information Misconnection of inter unit wiring Heating Cooling Dry Connect correctly Room temp thermistor is defective Heating Cooling Dry Normal 9 11 kΩ at 50 F 4 6 kΩ at 77 F Power Lamp Heat exch thermistor is defective H...

Page 55: ... 60 C 2 4 2 6 KΩ thermistor 1 2 D PUR PUR AC 30 115 V Combustion blower motor 9 10 30 Ω N RED BLU DC 1 5 V Combustion blower motor More than 1000 Pulse min fan speed sensor O BLU BLU DC 5 24 V Proportional 40 160 Ω control valve J BLK Ground AC 100 130 V Flame sensor probe More than DC 1 µA P YEL YEL Not more than DC 1 V Thermal fuse Not more than 1 Ω bimetal thermostat I WHT WHT DC 90 120 V Gas v...

Page 56: ...sistance Y1 WHT WHT AC 100 130 V 45 100 Ω Y2 BRN BRN AC 12 18 V 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 H ORG ORG AC 100 130 V 50 100 Ω Q2 YEL YEL AC 100 130 V 0 5 4 Ω Q1 RED RED AC 20 30 V 1 10 Ω Q1 BLU BLU AC 10 15 V 5 15 Ω ...

Page 57: ...oor unit 12 1 3 Check Power Supply Check that voltage is in specified range 10 of the rating Check that power is being supplied 12 1 4 Check Lead Wires and Connectors in Indoor and Outdoor Units Check that coating of wires is not damaged Check that lead wires and connectors are firmly connected Check that wiring is correct INDOOR UNIT Terminal 4P Terminal 6P Inter unit Power line 115V OUTDOOR UNIT...

Page 58: ...12 18 V Use a circuit tester set to AC range 12 3 Operation Lamp Blinks It Keeps Blinking after 3 Minutes Following Start of Operation If the operation lamp continues to blink more than 3 minutes check for the following possible causes in this order 1 Incorrect Wiring of Inter unit Wiring connector No 1 4 2 Thermistor Abnormality Indoor Unit Only 3 Protective Circuit of Outdoor Burner Unit Operate...

Page 59: ...rmistor 2 temperature did not go down in set period I Over number of times in retry Combustion stopped by Thermistor 1 or Thermistor 2 more than set number J Bypass Valve V2 not open Bypass Valve failure or drop out of Thermistor 2 Reversing Valve not working Reversing Valve failure drop out of Thermistor 2 or shortage of refrigerant 12 3 2 Thermistor Abnormality Indoor Unit Only Check open short ...

Page 60: ...tips of the tester rods do not touch each other since the circuit is electrically charged Disconnect FAN 5P connector on indoor unit PCB and measure resistance between cables In case of abnormality Replace indoor unit PCB No abnormalities proceed to check In case of abnormality Replace the indoor fan motor No abnormalities replace indoor unit PCB Normal Connector No Voltage Between 1 2 DC 3 7 V Co...

Page 61: ...10A 3P connector CN10B and 2P connector CN09 of indoor unit PCB without disconnecting connectors Caution Care should be taken that the tips of the tester rods do not touch each other since the circuit is electrically charged In case of abnormality Replace power transformer No abnormalities replace outdoor unit PCB 4P CN10A RED RED 20 30 V Normal BLU BLU 10 15 V 3P CN10B YEL YEL 85 115 V CN09 ORG O...

Page 62: ...his condition contin ues replace the compressor motor Caution Carry out this check only after cutting power at the mains or disconnecting unit from the power supply In case of abnormality Replace compressor Phase Resistance Normal R S 1 5 Ω S C 1 5 Ω C R 1 5 Ω Use a circuit tester set to Ω range 12 4 Outdoor Unit Fan Does Not Work 12 4 1 Outdoor Unit Fan Motor Defective Check if outdoor unit fan i...

Page 63: ...r motor No abnormalities check if there is physical or mechanical interference to louver movement 12 6 Heating Operation Not Possible 12 6 1 Thermistor 1 Defective Failure Display on Outdoor Unit PCB Check Thermistor 1 CN15 Disconnect Thermistor 1 connector 3P BLK from outdoor unit PCB and measure resistance on Thermistor 1 side In case of abnormality Replace Thermistor 1 Temperature Resistance No...

Page 64: ...obe Measure voltage of alternative current between flame rod connector 1P CN17 and ground Normal AC 104 126 V Normal DC 1µA or less Use a circuit tester set to AC range Use a circuit tester set to DC range Normal AC 104 126 V 12 6 5 Ignition Failure Failure Display on Outdoor Unit PCB 1 Check ignition transformer Check if ignition wires are disconnected or have voltage leak Measure AC voltage betw...

Page 65: ...Replace outdoor unit PCB 4 Check proportional control valve PV Measure DC voltage at proportional valve connector CN11 under heating operation during combustion In case of abnormality Replace flame rod 5 Check flame rod Check if flame rod connector CN17 1P is connected properly Measure AC voltage between flame rod connector and ground Use a circuit tester set to Ω range Use a circuit tester set to...

Page 66: ...lure Display on Outdoor Unit PCB Check ON OFF valve coil CN06 Measure AC voltage at the ON OFF valve coil connector under heating operation during combustion In case of abnormality Replace outdoor unit PCB In case of abnormality Replace ON OFF valve coil Disconnect ON OFF valve connector and measure resistance at connector Use a circuit tester set to Ω range 12 6 9 Reversing Valve Failure Failure ...

Page 67: ...63 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 ...

Page 68: ... proper insertion of gas switching IC then reset power supply Measure voltage of GV1 WHT WHT of I and GV2 ORG ORG of I normal value DC0V Measure resistance of Thermistor 1 BLK BLK of M normal value 6 6 0 5 kΩ at 68 F 20 C Measure resistance of Thermistor 2 BLK BLK of K normal value 6 6 0 5 kΩ at 68 F 20 C Check continuity of temperature fuse and temperature limiting switch YEL YEL of P normal valu...

Page 69: ...he electromagnetic valves SV1 and SV2 13 1 3 Provide a disconnect switch to the special connector 13 1 4 Turn the disconnect switch ON to supply power single phase 115V to the special connector This makes it possible to force open 2 solenoid valves SV1 and SV2 in the refrigeration circuit outdoor unit Fig 3 Injuries can occur from burns or inhalation of toxic gas if servicing is per formed while r...

Page 70: ...as be sure to recover all gas into the refriger ant recovery unit after completing the leak test 13 4 Evacuation Using Vacuum Pump 13 4 1 Using a hex wrench set the valve stems of the narrow and wide tube service valves as indicated in the table below Refer to Service Valve Construction shown in Fig 3 NOTE NOTE Refrigerant released into the air contributes to destruction of our planet s ozone laye...

Page 71: ...m pump still running turn both the narrow and wide service valves all the way in to close the valves position b in Fig 3 Then stop the pump 13 4 8 After removing the vacuum hoses from the service valves replace the flare nuts and bonnets on the valves The refrigerant circuit is now ready for charging 13 5 Refrigerant Charging 13 5 1 After evacuation is completed charge the circuit with the proper ...

Page 72: ...in COOLING mode during the entire charging process Charging the unit with a large amount of refrigerant at once may damage the compressor Always charge the unit at a constant charging rate of about 0 2 lb 100 g 13 6 Reattaching BLK WHT Connectors for Operation 13 6 1 Turn off the power source 13 6 2 Connect the BLK WHT connectors to each other as in the original state NOTE Remember to reattach the...

Page 73: ...1 INSTRUCTION MANUAL KGS 1411 CG1411 APPENDIX ...

Page 74: ...er call the fire department D Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try again call a qualified service technician Attempting to repair the appliance may result in a fire or explosion E Do not use this appliance if any part is underwater Immediately call a qualified service technician to inspect the appliance an...

Page 75: ...it 24 Care and Cleaning 24 Troubleshooting 27 Tips for Energy Saving 27 Operating Range 27 Product 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 number Alert Symbols The following symbols used i...

Page 76: ...er one hour Night Setback Pressing this button changes the setting of the room temperature thermostat allowing you to set the temperature at whatever level that you find comfortable 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 Au...

Page 77: ...upply in your home or office is the same as the voltage shown on the nameplate Do 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 s...

Page 78: ...heating appliances in the same room which consume a lot of oxygen from the air Otherwise there is a risk of suffocation in an extreme case CAUTION Do not turn the air conditioner on and off from the power mains switch Use the ON OFF operation button Do not stick anything into the air outlet of the outdoor unit This is dangerous because the fan is rotating at high speed Do not let children play wit...

Page 79: ...trols 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 Outdoor Condensing Unit The outdoor unit contains the compressor fan motor heat exchanger coil gas combustion compo...

Page 80: ...n the ON position and then switch the selector to the TEST position However the air conditioner will not operate when set to the TEST position if it has been stopped by setting to the OFF position During TEST mode the OPERATION lamp and timer lamp flash and remote control operation does not work CAUTION Do not set at the TEST position for normal operation OPERATION lamp This lamp lights when the s...

Page 81: ...ture indication 4 Timer 12 hour ON Timer 12 hour OFF Timer 1 hour OFF Timer 5 NIGHT SETBACK 6 Confirmation of transmission 7 Flap AUTO Angle indication Sweep indication ON Displayed when transmitting data Displayed when setting temperature Displayed when setting timer OFF 1HR Symbols Displayed when the comfortable temperature and operating mode for the customer is set automatically 9 OI 202 09EG ...

Page 82: ...ote control unit automatically adjusts the set temperature to save energy TEMP setting buttons Press the button to increase the temperature setting Press the button to reduce the temperature setting ON OFF operation button This button is for turning the air conditioner on and off TIMER ON button ON The air conditioner starts at the set time TIMER OFF button OFF The air conditioner stops at the set...

Page 83: ...ich moves the flap up and down automatically The airflow direction is set automatically The airflow direction can be set manually six positions The flap moves up and down automatically NOTE To switch to the sweep function when in the manual mode hold down the FLAP button FAN SPEED selector button The air conditioner automatically decides the fan speed High fan speed Medium fan speed Low fan speed ...

Page 84: ...rated either from a non fixed position or from a wall mounted position To ensure that the air conditioner operates correctly DO NOT install the remote control unit in the following places DO NOT In direct sunlight Behind a curtain or other places where it is covered More than 26 feet 8 m away from the air conditioner In the path of the air conditioner s airstream Where it may become extremely hot ...

Page 85: ...ing 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 3 After confirming correct operation use a screwdriver to screw the mounting screw into the wall 4 Remove the batteries of the remote control unit 5 Use a screwdriver to screw the remote control unit secur...

Page 86: ...selector to select STEP 2 Press the ON OFF operation button To stop the air conditioner press the ON OFF operation button again NOTE To change the temperature setting press the temperature setting buttons and change the setting to the desired temperature The temperature setting changes by two degrees each time one of the TEMP buttons is pressed The temperature setting may be changed within a range...

Page 87: ...n lamp 88 F or higher Cooling 82 F Green 84 F less than 88 F 80 F 80 F less than 84 F 78 F 72 F less than 80 F Dry 76 F Orange Less than 72 F Heating 76 F Red The operation mode cooling heating dry does not change automatically during operation Although the fan speed is set automatically you can change the fan speed by pressing the FAN SPEED selector button To stop the air conditioner press the ON...

Page 88: ...ess the ON OFF operation button STEP 3 Press the TEMP setting buttons to change the temperature setting to the desired temperature Adjustable temperature range 88 F max 60 F min NOTE The temperature setting changes by one degree each time the button is pressed It is not possible to change the temperature setting when the unit is operating in the fan mode The air conditioner remembers the new tempe...

Page 89: ...tion A microcomputer in the air conditioner automatically controls the fan speed when the mode is selected When the air conditioner starts operating the difference between the room temperature and the set temperature is detected by the microcomputer which then automatically switches the fan speed to the most suitable level Cooling and DRY mode When difference between room temperature and set tempe...

Page 90: ... the fan speed is set to auto the fan speed switches to low 5 Night Setback Mode The Night Setback Mode is used for saving energy Press the NIGHT SETBACK button while the air conditioner is operating The mark appears in the display To cancel the night setback function press the NIGHT SETBACK button again 1HR TIMER ON OFF TEMP FAN SPEED MODE ON OFF SET CANCEL NIGHT SETBACK ACL BATTERIES FLAP STEP 2...

Page 91: ...ng comfort This function is convenient when gentle cooling is needed Setting temperature Press the NIGHT SETBACK button 2 F Time 1 hour When the night setback mode is selected the air conditioner automatically lowers the temperature setting 6 F when 1 hour have passed after the selection was made and then another 8 F after another 2 hours have passed regardless of the indoor temperature when night...

Page 92: ...ting operation The heating capacity is unaffected depending on the outdoor temperature However if sufficient heat cannot be obtained with this air conditioner use another heating appliance in conjunction with it Power failure during operation In the event of power failure the unit will stop When the power is turned on again the unit restarts within three minutes Clicking Sound Clicking sound is he...

Page 93: ... is counting down press the SET button Cancellation procedure Press the CANCEL button 2 TIMER OFF mode Example After the length of time set for TIMER OFF elapses the unit stops operating OFF H The display depicted at left indicates that the air conditioner will stop operating in five hours Setting procedure STEP 1 Press the TIMER OFF button For example to set the timer to turn off the air conditio...

Page 94: ...function is operating the OFF Timer is cancelled and the unit stops operating one hour later 2 Combining the 1 Hour OFF Timer and 12 Hour ON Timer By combining the 1 Hour OFF Timer and 12 Hour ON Timer it is possible to have the unit operate for just one hour from the present time and then have it switch on again later at a time specified by you Example Having the unit operate for just one hour fr...

Page 95: ...illustration use the FLAP button to set the airflow direction within the range used during the heating cooling or dehumidifying operation NOTE The flap automatically closes when the unit is off During the heating operation the fan speed will be very low and the flap will be in the horizontal position position 6 until the air being blown out of the unit begins to warm Once the air warms up the flap...

Page 96: ...ter on the indoor unit to clean it This will damage the internal 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 ...

Page 97: ...cleaner to remove light dust If there is sticky dust on the filter wash the filter in lukewarm soapy water rinse it in clean water and dry it How to replace the anti mold filter 1 With the FRONT mark facing you slide the anti mold filter up into the unit and then lower the handle into the groove on the unit 2 After installing the anti mold filter press the locations marked by the arrows and close ...

Page 98: ...ng filter in the position shown in the diagram with the symbols meaning FRONT facing the front 3 Reinstall the anti mold filter Cleaning the main unit and remote control unit Wipe clean using a soft dry cloth To remove 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 remo...

Page 99: ... too low 6 Consult your dealer or try to use a back up heater Clicking sound is heard from the air conditioner In heating or cooling operation any plastic parts may expand or shrink due to a sudden temperature change In this event a clicking sound may occur This is normal and the sound will soon disappear OPERATION lamp lights but outdoor unit will not run 1 The use of portable telephones near the...

Page 100: ...arts 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 50 Beth Nealson Drive Toronto Ontario M4H 1M6 CANADA ...

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Sanyo CG1411, Service Manual

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