These air conditioners employ new
refrigerant R410A.
Pay special attention when
servicing the unit.
CH0971
CH1271
REFERENCE NO. SM700647-06
Important!
Please Read Before Starting
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.
For safe installation and trouble-free operation, you must:
Carefully read this instruction booklet before beginning.
Follow each installation or repair step exactly as shown.
Observe all local, state, and national electrical codes.
Pay close attention to all warning and caution notices given
in this manual.
This symbol refers to a hazard or
WARNING
CAUTION
If Necessary, Get Help
These instructions are all you need for most installation
sites and maintenance conditions. If you require help for
a special problem, contact our sales/service outlet or
your certified dealer for additional instructions.
In Case of Improper Installation
The manufacturer shall in no way be responsible for
improper installation or maintenance service, including
failure to follow the instructions in this document.
SPECIAL PRECAUTIONS
unsafe practice which can result
in severe personal injury or death.
This symbol refers to a hazard
or unsafe practice which can
result in personal injury or
product or property damage.
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 construct a strong wood or
metal frame to provide added support.
In a Room
Properly insulate any tubing run inside a room to prevent
"sweating" that can cause dripping and water damage to walls
and floors.
In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents
water damage and abnormal vibration.
In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a metal
frame. Provide a suitable air baffle.
In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is higher than
drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
•
Use the flare method for connecting tubing.
•
Apply refrigerant lubricant to the matching surfaces of the
flare and union tubes before connecting them, then tighten
the nut with a torque wrench for a leak-free connection.
•
Check carefully for leaks before starting the test run.
When Servicing
WARNING
•
Do not supply power to the unit until all wiring and tubing
are completed or reconnected and checked.
•
Highly dangerous electrical voltages are used in this
system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and
inadequate grounding can cause accidental injury or death.
•
Ground the unit following local electrical codes.
•
Connect all wiring tightly. Loose wiring may cause
overheating at connection points and a possible fire
hazard.
When Wiring
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH.
ONLY A QUALIFIED, EXPERIENCED
ELECTRICIAN SHOULD ATTEMPT TO
WIRE THIS SYSTEM.
•
Turn the power off at the main power box (mains) before
opening the unit to check or repair electrical parts and
wiring.
•
Keep your fingers and clothing away from any moving parts.
•
Clean up the site after you finish, remembering to check
that no metal scraps or bits of wiring have been left inside
the unit being serviced.
Others
CAUTION
Ventilate any enclosed areas when installing or testing the
•
refrigeration system. Escaped refrigerant gas, on contact
with fire or heat, can produce dangerously toxic gas.
Confirm upon completing installation that no refrigerant gas
•
is leaking. If escaped gas comes in contact with a stove,
gas water heater, electric room heater or other heat source,
it can produce dangerously toxic gas.
9-1.Precautions before Performing Inspection or Repair
9-2.Method of Self-Diagnostics
9-3.Checking the Indoor and Outdoor Units
9-4.Trouble Diagnosis of Fan Motor
9-5.Noise Malfunction and Electromagnetic Interference
10-1. Measurement of Insulation Resistance
10-2. Checking Continuity of Fuse on PCB Ass'y
11. REFRIGERANT R410A:
SPECIAL PRECAUTIONS WHEN SERVICING UNIT
11-1. Characteristics 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
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,
CAUTION
never try to bend it into a narrow
curve because it can cause the tube
to break or crack.
15
Thickness:
Min. 5/16"(8 mm)
Wide tube
Insulation
Thickness:
Min. 5/16"(8 mm)
Narrow tube
5. PERFORMANCE DATA
5-1. Temperature Charts
Indoor UnitKHS0971Outdoor UnitCH0971
Cooling Characteristics (RH : 46%, Indoor fan speed : High fan) (60Hz, 115V)
(1) Low pressure performance chart
173
(1.2)
159
(1.1)
psig(MPaG)
145
(1.0)
Indoor Air Temp.86
Indoor Air Temp.86°F (30°C)
131
(0.9)
117
Low pressure at wide tube service valve
(0.8)
-4
(-20)
5
(-15)
14
(-10)
23
(-5)
(2) Operating current performance chart
9
32
(0)
41
(5)
50
(10)
Outdoor inlet air D.B. temp.°F(°C)
59
(15)
68
(20)
F (
°
°F (
80
80
F (
°F (
°
75
75
Hi FanLo fan
C)
°
30
F (
°
C)
°
°C)
27
27
C)
°C)
°
24
24
77
(25)
86
(30)
95
(35)
104
(40)
8
7
6
Operating current (A)
5
4
-4
(-20)
5
(-15)
14
(-10)
23
(-5)
(3) Indoor discharge air performance chart
64.4 (18)
°C)
60.8 (16)
57.2 (14)
53.6 (12)
50.0 (10)
32
(0)
41
(5)
50
(10)
Outdoor inlet air D.B. temp.°F(°C)
Indoor Air Temp.86
Indoor Air Temp.86°F (30°C
59
(15)
68
(20)
Indoor Air Temp.86
Indoor Air Temp.86°F (30°C)
80
80
75
75
Hi FanLo fan
)
C)
°
30
F (
°
C)
°
°C)
27
27
F (
°
°F (
C)
80
80
°
°C)
24
24
F (
°
°F (
75
75
F (
°
°F (
F (
°F (
°
77
(25)
F (
°
C)
°
°C)
27
27
C)
°C)
°
24
24
86
(30)
C)
°
30
95
(35)
Hi FanLo fan
104
(40)
Indoor discharge air temperature °F(
46.4 (8)
-4
(-20)
5
(-15)
14
(-10)
23
(-5)
32
(0)
41
(5)
50
(10)
59
(15)
68
(20)
77
(25)
86
(30)
95
(35)
Outdoor inlet air D.B. temp.°F(°C)
NOTE
Check each performance value in test-run mode. Electrical performance values represent a combined indoor/outdoor value.
16
104
(40)
Indoor UnitKHS0971Outdoor UnitCH0971
Heating Characteristics (RH : 46%, Indoor fan speed : High fan) (60Hz, 115V)
(1) High pressure performance chart
493
(3.4)
°C)
23
°F(
421
psig(MPaG)
(2.9)
348
(2.4)
276
(1.9)
High pressure at wide tube service valve
(2) Operating current performance chart
Indoor Air Temp.73
23
(
-
5)32(0)41(5)50(10)59(15)68(20)77(25)
Outdoor inlet air D.B. temp.°F(°C)
14
70°F(21
17
°F(
63
°C)
°C)
13
12
11
10
9
Operating current (A)Indoor discharge air temperature °F(°C)
8
7
23
(
-
(3) Indoor discharge air performance chart
140(60)
131(55)
122(50)
113(45)
104(40)
95(35)
86(30)
23°C)
Indoor Air Temp.73
5)32(0)41(5)50(10)59(15)68(20)77(25)
°F(
70°F(21
°F(
63
°C)
°C)
17
Outdoor inlet air D.B. temp.°F(°C)
°C)
23
°F(
Indoor Air Temp.73
70°F(21
°F(
63
°C)
°C)
17
77(25)
23
(
-
5)32(0)41(5)50(10)59(15)68(20)77(25)
Outdoor inlet air D.B. temp.°F(°C)
NOTE
Check each performance value in test-run mode. Electrical performance values represent a combined indoor/outdoor value.
Overload prevention operates to protect the air conditioner when outdoor ambient temperature becomes extremely high in
heating mode. (Refer to "8-2. Overload prevention during heating.")
17
Indoor UnitKHS1271Outdoor UnitCH1271
Cooling Characteristics (RH : 46%, Indoor fan speed : High fan) (60Hz, 115V)
(1) Low pressure performance chart
173
(1.2)
159
(1.1)
psig(MPaG)
145
(1.0)
131
(0.9)
117
Low pressure at wide tube service valve
(0.8)
-4
(-20)
5
(-15)
14
(-10)
23
(-5)
(2) Operating current performance chart
13
12
11
10
9
8
7
Operating current (A)
6
5
4
-4
(-20)
5
(-15)
14
(-10)
23
(-5)
32
(0)
41
(5)
50
(10)
Outdoor inlet air D.B. temp.°F(°C)
32
(0)
41
(5)
50
(10)
Outdoor inlet air D.B. temp.°F(°C)
Indoor Air Temp.86°F (30°C)
80
75
59
(15)
59
(15)
68
(20)
Indoor Air Temp.86°F (30°C)
80
75
68
(20)
°F (
°F (
°F (
°F (
Hi FanLo fan
°C)
27
°C)
24
77
(25)
°C)
27
°C)
24
77
(25)
86
(30)
86
(30)
95
(35)
Hi FanLo fan
95
(35)
104
(40)
104
(40)
(3) Indoor discharge air performance chart
64.4 (18)
°C)
86
(30)
Hi FanLo fan
95
(35)
60.8 (16)
57.2 (14)
53.6 (12)
50.0 (10)
Indoor discharge air temperature °F(
46.4 (8)
-4
(-20)
5
(-15)
14
(-10)
23
(-5)
32
(0)
41
(5)
50
(10)
Indoor Air Temp.86°F (30°C)
80
75
59
(15)
68
(20)
°F (
°F (
°C)
27
°C)
24
77
(25)
Outdoor inlet air D.B. temp.°F(°C)
NOTE
Check each performance value in test-run mode. Electrical performance values represent a combined indoor/outdoor value.
18
104
(40)
Indoor UnitKHS1271Outdoor UnitCH1271
Heating Characteristics (RH : 46%, Indoor fan speed : High fan) (60Hz, 115V)
(1) High pressure performance chart
493
(3.4)
psig(MPaG)
421
(2.9)
348
(2.4)
276
High pressure at wide tube service valve
(1.9)
(2) Operating current performance chart
Operating current (A)
°F(
21
°F(
Indoor Air Temp.73
23
(
-
5)32(0)41(5)50(10)59(15)68(20)77(25)
70
17
°F(
63
Outdoor inlet air D.B. temp. °F(°C)
15
14
13
Indoor Air Temp.73
12
°F(
21
°F(
70
17
°F(
63
11
10
9
°C)
23
°C)
°C)
°C)
23
°C)
°C)
8
23
(
-
5)32(0)41(5)50(10)59(15)68(20)77(25)
Outdoor inlet air D.B. temp. °F(°C)
(3) Indoor discharge air performance chart
140(60)
131(55)
122(50)
113(45)
104(40)
95(35)
86(30)
Indoor discharge air temperature °F(°C)
77(25)
23
(
-
5)32(0)41(5)50(10)59(15)68(20)77(25)
Indoor Air Temp.73
Outdoor inlet air D.B. temp. °F(°C)
NOTE
Check each performance value in test-run mode. Electrical performance values represent a combined indoor/outdoor value.
Overload prevention operates to protect the air conditioner when outdoor ambient temperature becomes extremely high in
heating mode. (Refer to "8-2. Overload prevention during heating.")
°C)
23
°F(
°C)
21
°F(
70
°C
17
°F
63
19
5-2. Cooling Capacity
Indoor Unit: KHS0971
Outdoor Unit : CH0971
Power Supply : 115V Single Phase 60Hz
< Cooling Capacity >
RATING CAPACITY: 9,000 BTU/h AIR FLOW RATE:282 CFM
Above data does not take Freeze Prevention Protection during cooling operation into account.
For this reason, the value may vary from the actual cooling characteristics.
3. Above data represents the value when the operation frequency of a compressor is fixed.
20
Indoor Unit: KHS1271
Outdoor Unit : CH1271
Power Supply : 115V Single Phase 60Hz
< Cooling Capacity >
RATING CAPACITY: 11,900 BTU/h AIR FLOW RATE:294 CFM
Above data does not take Freeze Prevention Protection during cooling operation into account.
For this reason, the value may vary from the actual cooling characteristics.
3. Above data represents the value when the operation frequency of a compressor is fixed.
21
5-3. Cooling Capacity (Low Ambient)
Indoor Unit: KHS0971
Outdoor Unit : CH0971
Power Supply : 115V Single Phase 60Hz
< Cooling Capacity (Low Ambient) >
RATING CAPACITY: 9,000 BTU/h AIR FLOW RATE:282 CFM
Above data does not take Freeze Prevention Protection during cooling operation into account.
For this reason, the value may vary from the actual cooling characteristics.
2. Above data represents the value when the operation frequency of a compressor is fixed.
22
Indoor Unit: KHS1271
Outdoor Unit : CH1271
Power Supply : 115V Single Phase 60Hz
< Cooling Capacity (Low Ambient) >
RATING CAPACITY: 11,900 BTU/h AIR FLOW RATE:294 CFM
Above data does not take Freeze Prevention Protection during cooling operation into account.
For this reason, the value may vary from the actual cooling characteristics.
2. Above data represents the value when the operation frequency of a compressor is fixed.
Above data does not take Defrost Operation, Overload Prevention Protection, and/or Cold Air
Prevention Protection during heating operation into account. For this reason, the value may vary
from the actual heating characteristics.
3. Above data represents the value when the operation frequency of a compressor is fixed.
Above data does not take Defrost Operation, Overload Prevention Protection, and/or Cold Air
Prevention Protection during heating operation into account. For this reason, the value may vary
from the actual heating characteristics.
3. Above data represents the value when the operation frequency of a compressor is fixed.
Rating conditions:Indoor air temperature70°F (21.1°C) D.B.
Outdoor air temperature47°F (8.3°C) D.B. / 43°F (6.1°C) W.B.
Indoor UnitKHS1271
Outdoor Unit CH1271
Cooling
Indoor UnitOutdoor UnitComplete Unit
Fan MotorFan Motor + Compressor
Performance at115V Single-phase 60Hz
Rating conditionsRunning amp.A0.45
Power inputW45
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.
10.45
1,045
Heating
Indoor UnitOutdoor UnitComplete Unit
Fan MotorFan Motor + Compressor
Performance at115V Single-phase 60Hz
Rating conditionsRunning amp.A0.45
Power inputW45
11.25
1,120
10.9
1,090
11.7
1,165
Rating conditions:Indoor air temperature70°F (21.1°C) D.B.
Outdoor air temperature47°F (8.3°C) D.B. / 43°F (6.1°C) W.B.
28
6-2. Electric Wiring Diagrams
Indoor UnitKHS0971 KHS1271
EVAPORATOR
GRN/YEL
CONNECTOR
1
2
FLAP
3
4
5
FLAP MOTOR
WARNING
disconnect power before checking, servicing
and/or cleaning any electrical parts.
TERMINAL BASE
To avoid electrical shock hazard, be sure to
10
1
2
3
TO OUTDOOR UNIT
1
RED
2
WHT
3
WHT
4
WHT
5
WHT
6
WHT
7
WHT
8
WHT
9
WHT
WHT
10
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
IND LAMP ASSY
BLK
WHT
RED
1 3 5
1 3 5
AC
5P (BLU)
RED
1
PNK
2
BLU
3
BRN
4
YEL
5
1
2
3
4
5
1
2
FLAP
3
5P (WHT)
4
5
10P(
LAMP
WHT
1
2
3
4
5
)
6
7
8
9
10
FAN MOTOR
FM
GRN/YEL
FAN MOTOR
CAPACITOR
(RED)
BRN
PNK
PNK
BRN
WHT
RED
BLK
YEL
CONTROLLER
1
1
FAN
3
3
5P (WHT)
5
5
1
1
HALL IC
2
2
3P (WHT)
3
3
131
FMC
3P (WHT)
3
ROOM/COIL
4P(
WHT
ION
3P (
WHT
HA
JEM-A
4P (WHT)
1 24
3
ION
TERMINAL
ROOM THERMISTOR
1
1
BLK
2
2
)
BLK
3
3
BLK
4
4
BLK
COIL THERMISTOR
1
1
WHT
2
2
)
RED
3
3
BLK
CONNECTOR
BLK
1
1
2
2
3
3
BLK
BLK
RED
WHT
1 2 3 4
1 2 3 4
ION ASSY
8FA2-5257-71600-0
29
Outdoor Unit CH0971CH1271
1P-CONNECTOR (WHT
1P-CONNECTOR (WHT
WHT
WHT
CRANKCASE
HEATER
REACTANCE
)
W
W
W
1 1
1 1
U
V
W
)
WHT
WHT
WWWW
C-HEATER1C-HEATER2
YEL
112
2
YEL
L2WL1
CONTROLLER
WARNING
)
BLK
(
ORG
ORG
2P-CONNECTOR
To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.
BLK
POWER RELAY
GRN/YEL
25A
E
ACIN1
ACIN2
6
5
BLK
FERRITE
CORE
W
BLK
W
WHT
W
SI
RED
BLK
WHT
1
4
TERMINAL
PLATE
1
2
3
GND
4
5
6
TO INDOOR UNIT
RED (PNK)
WHT
BLU
321
CONNECTOR (WHT)
-
1 2 3
3P
CORE
FERRITE
BLU
RED
WHT
(PNK)
R/V
S/UC/W
CM
COMPRESSOR
MOTOR
OVERLOAD RELAY
OUTDOOR
OUT DOOR
(OLR)
1 2
1 2
BLK
BLK
COIL
THERMISTOR
THERMISTOR
COIL/COMP
1 2 3 4
1 2 3 4
YEL
YEL
BLK
1 2 3 4 5 6 7
WHT
BLK
1 2 3 4 5 6 7
1 2 3 4 5 6 7
WHT
THERMISTOR
COMPRESSOR
GRN/YEL
WHT
WHT
DCFM
BLK
BLU
RED
BLK
BLU
RED
FM
FAN MOTOR
MV
1 2 3 45566
1 2 3 4
YEL
RED
GRY
WHT
ORG
1 2 3 45566
1 2 3 4
YEL
MV
7P-CONNECTOR (WHT)
MAGNETIC COIL
1 1
2 2
2P-CONNECTOR (BLK)
BLK
YEL
4WAY VALVE
RV
1 3
1 3
BLK
RV
COIL
BLK
WHT
WHT
WHT
1 1
2 2
2P-CONNECTOR (WHT)
NL
POWER
GND
SUPPLY
HIGH PRESSURE
SWITCH
BLK
BLK
8FA2-5257-69100-3
30
7. MAINTENANCE
7-1. Address Setting of the Remote
Control Unit
The address can be set in order to prevent
interference between remote controllers when two
indoor units are installed near each other. The
address is normally set to "A." To set a different
address, it is necessary to change the address on the
second remote controller.
NOTE
Once changed, you cannot restore the original
address setting of the air conditioner.
(1) Switch on the power source.
(2) Break the address-setting tab marked "A" on the
second remote controller to change the address
(Fig. 13). When the tab is removed, the address is
automatically set to B (Fig. 14).
(3) 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.
(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)
Ta b
Fig. 13
ACL button
Fig. 14
Test run mode
Self-diagnostic mode
Address setting mode
(5) "oP-7" has now been selected for address setting.
(6) Press the ON/OFF operation button on the remote
controller. (Fig. 15) Check that the "beep" signal
received sound is heard from the second indoor
unit (approximately 5 times). The sound you hear
is the signal that the remote controller address
has been changed.
(7) Finally press the remote controller ACL (reset)
button to cancel the blinking "oP-7" display. (Fig.
15)
Changing of the second remote controller address is
now completed.
31
ION
button
ADDRESS
ON/OFF
operation
button
1 HR.TIMER
button
ACL (Reset)
button
Fig. 15
7-2. Disconnecting and Connecting Positive Connector for Outdoor Unit
One of the two types of connectors illustrated at left is used. Their
basic structure is the same for each.
How to Disconnect
Hold the resin connector cover, and pull the connector off.
You cannot disconnect the connector by pulling the wire since
it is locked inside. Always hold the cover to disconnect. (See
illustration at left.) For the connector without the resin cover,
Pull the cover upward
When the cover is pulled upward, the lock is
released with the sequence of 1 and 2.
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.
32
8. FUNCTIONS
8-1. Operation Functions
Emergency operationSENSOR DRY
Emergency operation is available when the remote
controller malfunctions, has been lost, or otherwise
cannot be used.
To operate the system, press the OPERATION button,
which is also used as the receiver, below the unit display.
Each time this button is pressed, the OPERATION lamp
changes color to indicate the type of operation. Select the
desired type of operation.
COOLHEATSTOP
(GREEN) (RED)(Lamp Off)
• The set temperature is 4°F(2°C) below the detected room
temperature in the case of cooling operation, and 4°F(2°C)
above the room temperature in the case of heating
operation. The flap and fan speed settings are AUTO.
AUTO cooling/heating operation
Selecting the operation mode
• When AUTO mode is selected, the microprocessor calculates
the difference between the set temperature and the room
temperature, and automatically switches to Cooling or
Heating mode.
Room temp. Set temp. COOL
Room temp. Set temp. HEAT
• As shown by the example in the figure below, with AUTO
cooling/heating operation, the mode changes between
Heating and Cooling mode according to changes in the
relationship between the current room temperature and the
set temperature.
During DRY operation, the system adjusts the room
temperature and fan speed according to the conditions in the
room, in order to maintain a comfortable room environment.
SENSOR DRY operation
• DRY operation is as shown in the figure below.
Load
COOL zone
A zone
B zone
Conditions are monitored at all
times when the room temperature
is below 59°F(15°C).
DRY A
The compressor operation frequency varies.
The indoor fan operates with 1/f fluctuation.
DRY B
The compressor operates at a low operating frequency.
The indoor fan operates with 1/f fluctuation.
Monitor
• Monitoring operation takes place when the room temperature
is below 59°F
(15°C), or more than 5°F(3°C) below the set
temperature.
• When the monitoring range is entered, the compressor stops,
and the indoor fan operates with 1/f fluctuation.
Example
Example of operation in AUTO mode with the set room temperature
at 74°F(23°C).
Room temp.
Set temp.
Zone A
Zone B
Zone C
74
Zone C
Zone B
Zone A
Compressor
Operation mode
More than
1 hour
ONONON
OFFOFF
Within
1 hour
HeatingCoolingCooling
PAM- control
• In order to further improve inverter performance, control is
switched between PWM control at low operation speeds, and
PAM control at high operation speeds, making the most
effective use of power.
33
HIGH POWER
NIGHT SETBACK
This function acts to raise the power but keeps the AC system in
the same operating mode.
This function is set with the HIGH POWER button on the remote
controller.
(It can be set regardless of the temperature and fan speed
settings.)
HIGH POWER operation from remote controller
The unit operates at maximum output for 30 minutes,
regardless of the desired temperature.
The fan speed is 1 step above "High."
Frequency
MAX
0
30 min.5 min.
StartEnd
Time
NOTE
When HIGH POWER operation ends, the unit operates at low
Hz for 5 minutes, regardless of the thermostat OFF conditions.
When in DRY mode, operation is in the cooling zone.
Lamp colors
OPERATION lamp
HEAT operationRed
DRY operationOrange
COOL operationGreen
FAN operationGreen
DEFROSTING operationRed and Orange
alternately
TIMER lampGreen
QUIET lampGreen
ION lampGreen
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 night setback mode is selected, the air conditioner
automatically raises the temperature setting 2°F(1°C) when 30
minutes have passed after the selection was made, and then
another 2°F(1°C) 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 is
needed.
Setting
temperature
Press the NIGHT
SETBACK button
2°F(1°C)
2°F(1°C)
30 min.30 min.
Time
HEAT mode
When the night setback mode is selected, the air conditioner
automatically lowers the temperature setting 4°F(2°C) when 30
minutes have passed after the selection was made, and then
another 4°F(2°C) 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 heating is
needed.
Setting
temperature
Press the NIGHT
SETBACK button
4°F(2°C)
30 min.30 min.
4°F(2°C)
Time
Timer backup
Operation stops if there are no operator controls for 25 hours or
longer after unit operation switched from OFF to ON by use of
ON timer operation.
34
8-2. Protective Functions
Overload prevention during heating
During HEAT operation, the temperature of the indoor heat
exchanger is used to control the frequency and lessen the load
on the compressor before the protective device is activated.
Approx.
127
(53)
Approx.
117
(47)
temperature °F(°C)
Indoor heat exchanger
a.
Area: Automatic capacity control
b.
When Point A has been exceeded, the operation frequency is
A
abcd
Indoor heat exchanger
A. Control start
B. Control end
B
reduced by a certain proportion.
c.
Area: Frequency increase is prohibited.
d.
At Point B and below, overload prevention is ended and
control is the same as in the
a
area.
Freeze prevention
During COOL or DRY operation, freezing is detected and
operation is stopped when the temperature of the indoor heat
exchanger matches the conditions below.
1.
Freeze-prevention operation is engaged when the
temperature of the indoor heat exchanger is below 43°F(6°C).
2.
Restart after freeze-prevention operation occurs when the
temperature of the indoor heat exchanger reaches 46°F(8°C)
or above.
46
(8)
43
(6)
A
C
B
Cold-air prevention during heating
During heating, the fan speed is set to "LL" (very low) or stopped.
As the temperature of the indoor heat exchanger rises, the fan
speed is changed to the set speed.
High
LL
Stopped
At stability of operation
77
(25)86(30)
Indoor heat exchanger
temperature °F(°C)
Set fan speed
At start of operation
Approx. 104
(40)
NOTE
• The fan speed is forcibly changed to "LL" beginning 30 seconds
after the thermostat turns OFF.
• At stability of operation refers to operation when the room
temperature has approached the set temperature.
• When HEAT operation starts, the indoor fan is stopped until the
temperature of the indoor heat exchanger reaches 68°F(20°C)
or higher, or until the room temperature reaches 59°F(15°C) or
higher.
Compressor discharge temperature control
This function controls the operation frequency to prevent the
compressor discharge temperature from rising more than a
specified temperature.
36
(2)
temperature °F(°C)
Indoor heat exchanger
a.
Area: Automatic capacity control
b.
When the temperature drops below Point A, the operation
*
abcd
frequency is reduced by a certain proportion.
c.
Area: Frequency increase is prohibited.
d.
When the temperature reaches Point C or above, freezing
prevention is ended and control is the same as in the
a
area.
* When the temperature drops to below 36°F(2°C)
(continuously for 2 minutes or longer), the compressor stops.
Once the freeze condition is detected, the air conditioner will
work less than the maximum frequency until it is turned off.
Compressor discharge temperature °F(°C)
Approx.
214
(101)
Approx.
201
(94)
a.
Area: Automatic capacity control.
b.
When the temperature rises above Point A, the operation
A
B
abcd
frequency is reduced at a specified rate.
c.
Area: Further frequency increase is prohibited.
d.
When the temperature falls below Point B, prevention of a rise
in frequency is released and the air conditioner operates as in
a
area.
* The compressor will stop if the temperature of the compressor
discharge exceeds 248°F(120°C) due to shortage of gas or
other reason.
35
Defrost detection and release
Reverse-Cycle Defrosting
Defrosting Sequence
Heating operation
Outdoor fan ON
4-way valve ON
CT (Peak current cut-off control)
•
This function prevents the circuit breaker or fuse from operating
to open the circuit. This function works when electrical current
has increased due to an increase in the cooling / heating load,
or to a decrease in the power supply voltage. In these cases,
operation frequency is reduced or operation is interrupted automatically to control the electrical current for operation.
When the cause of the increase in electrical current is rectified,
•
the system will resume operation in the original mode.
(A)
Cooling Dry Heating
Peak current cut-off trips22.5
Hz down14.015.0
Frost sensing
Defrost detection occurs in either of the following cases:
•
The temperature of the heat exchanger remains at
or below the L1 line for 3 minutes after the start of
HEAT operation.
•
The temperature of the heat exchanger remains at
or below the L2 line for 120 minutes after the start
of HEAT operation.
Outdoor heat
exchanger temp.
L2
L1
Frosting area
0
Ambient temp.
Reverse-cycle defrosting operation
Compressor 1 minute after it is stopped,
compressor is ON.
Outdoor fan OFF
Indoor fan OFF
4-way valve OFF
Operation lamp
Repeatedly switches between red
and orange illumination.
NOTE
Electrical current setting for COOL operation is
used during DEFROST operation.
Releasing of defrosting
Outdoor heating exchanger temp. is over 68°F(20°C).
Defrosting operation lasts 12 minutes (maximum).
2 minutes after it is stopped, compressor is ON.
4-way valve is ON. Outdoor fan is ON.
NOTE
If the air conditioner is turned off during the defrosting
cycle, it will continue defrosting and turn itself off after
defrosting is completed.
36
9. TROUBLESHOOTING
9-1. Precautions before Performing Inspection or Repair
After checking the self-diagnostics monitor, turn the power OFF before starting inspection or repair.
High-capacity electrolytic capacitors are used inside the outdoor unit controller (inverter). They retain an electrical charge
(charging voltage DC 310V) even after the power is turned OFF, and some time is required for the charge to dissipate. Be
careful not to touch any electrified parts before the controller LED (red) turns OFF.
If the outdoor controller is normal, approximately 30 seconds will be required for the charge to dissipate. However, allow
at least 5 minutes for the charge to dissipate if there is thought to be any trouble with the outdoor controller.
9-2. Method of Self-Diagnostics
Follow the procedure below to perform detailed trouble diagnostics.
NOTE
1: If the operation lamp blinks every 0.5 seconds immediately when the
power is turned ON, there is an external ROM (OTP data) failure on the
indoor circuit board, or a ROM socket insertion problem, or the ROM
has not been installed.
2: The failure mode is stored in memory even when the power is not ON.
Follow the procedure below to perform diagnostics.
PROCEDURE
After turning on power to the air conditioner, use the remote controller and
follow the steps below to execute self-diagnostics.
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 change the display
from "oP-1" to "oP-3" (self-diagnostics). (The display continues to
blink.)
Step 3: Finally press the ON/OFF button to engage self-diagnostics mode.
ION
button
< Clock display >
Test run mode
Self-diagnostics mode
ON/OFF
operation
button
1HR.
TIMER
button
• The self-diagnostics function utilizes the 3 indicator lamps on the main
unit, in combinations of ON lamps, blinking lamps, and OFF lamps, to
report the existence of sensor trouble or a protective operation. (The
lamps blink or remain ON for 5 seconds, then turn OFF for 2 seconds.)
Self-diagnostics is completed when the buzzer sounds 3 short beeps.
• A maximum of 3 self-diagnostics reports are displayed, for 5 seconds
each, beginning with the most recent report. Following this display the
lamps turn OFF. In order to view the self-diagnostics results again,
press the ON/OFF button again.
• The 3 lamps remain OFF if no trouble has occurred.
<IMPORTANT> After self-diagnostics is completed, be sure to press the
ACL (reset) button to return to normal mode. The air
conditioner will not operate if this is not done.
(1) Sensor open circuit or short circuit
(2) Contact failure at connector or open circuit at terminal crimping location
(short-circuit 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-Pressure Switch failure (9) Overload Relay failure (10) Magnetic Coil failure
* See detailed flowchart in this section.
(1) HIC or power Tr failure (2) Outdoor fan does not turn. (3) Instantaneous power outage
(4) Service valve not opened. (5) Outdoor fan blocked. (6) Continuous overload operation
(7) Compressor failure (8) Outdoor PCboard failure
(1) External ROM data failure (2) Outdoor PCboard failure
(1) Instantaneous power outage (2) HIC or power transistor failure
(3) Outdoor PCboard failure
(1) Outdoor PCboard failure (2) Outdoor power supply voltage failure
(1) Electric expansion valve failure (2) Capillaries choked (3) Shortage of refrigerant
(4) Continuous overload operation (5) Outdoor fan does not rotate (6) Outdoor
(1) Fan motor failure (2) Contact failure at connector (3) Indoor PCboard failure
(1) Service valve not opened. (2) Shortage of refrigerant
PCboard
failure
E10
E11
E12
E13
DC compressor drive circuit failure
Outdoor fan operating failure
Outdoor system communications failure
OLR operation
Outdoor power supply open phase
Outdoor coil freezing
Freeze-prevention operation activated.
(1) Open phase (2) Outdoor PCboard failure
(1) Fan motor failure (2) Contact failure at connector (3) Outdoor PCboard failure
(1) Mis-wiring (2) Blown fuse (3) Power Relay failure (4) Outdoor PCboard failure
(5) Compressor failure
* See detailed flowchart in this section.
(1) Indoor fan system failure (2) Shortage of refrigerant (3) Low-temperature operation
38
(2) If the self-diagnostics function fails to operate
No indicators illuminate and the
•
Check the indoor unit.
indoor fan does not rotate.
Check the power voltage.
•
Is the fuse blown?
Normal
Replace the circuit
Replace the controller.
board or the fuse.
9-3. Checking the Indoor and Outdoor Units
(1) Checking the indoor unit
ControlNo.Check items (unit operation)
•
Use the remote controller to operate the
1
unit in "TEST run" mode. To determine
whether the mode is currently in
"TEST run" mode, check the 4 indicator
lamps on the unit. If all 4 are blinking,
the current mode is "TEST run."
If there are no problems with the above, then check the outdoor unit.
For the "Test run" procedure, refer to the Appendix B "Installation Instructions".
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 the voltage, you can insert an LED jig and
check that the LED flickers once every 8 seconds.
Blown
(2) Checking the outdoor unit
ControlNo.Check items (unit operation)
Apply the rated voltage between outdoor
1The control panel LED (red) must illuminate.
unit terminals L and N.
Short-circuit the outdoor unit COM terminal
2The compressor, fan motor and 4-way valve must all turn on.
to the T-RUN terminal.
If there are no problems with the above, then check the indoor unit.
Using the TEST/T-RUN terminals
•
•
TEST/T-RUN terminals
T-RUN:Test run (compressor and fan motor turn ON).
TEST/MV : Compresses time to 1/60th (accelerates
operation by 60 times faster than normal).
(TEST)/MV T-RUN COM
39
(3) Serial Communication Error Identification Procedure
If the lamps on the main body show the following conditions after the completion of self-diagnostics,
a communication error between the indoor unit and outdoor unit might be considered.
In such a case, identify the breakdown section by using the following procedure.
NOTE
Condition
Refer to "Method of Self-Diagnostics" for the self-diagnostics procedure.
Lamp
E01
Quiet
TimerOperation:Off
(3)(2)(1)
: Blinking
: Illuminated
E12
< Before the Operation >
For terminal strip short circuit work or inter-unit wiring removal, turn off the power to
WARNING
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
CAUTION
specified ones on the specified terminal strip. If such work is performed between
the incorrect terminals, the unit might be broken.
< Convenient Tool for Short-Circuit Work ( for example ) >
Alligator Clip
Cable
Alligator Clip
< Check Items before Troubleshooting Serial Communication Start >
After confirming that the following errors do not exist, start the "Troubleshooting Serial Communication"
in "Condition: E01 and E12".
1. Mis -wiring (inter-unit cable, etc.)
2. AC power failure
3. Blown fuse
4. Power Relay failure
5. Outdoor Fan Motor failure (defective insulation, etc.)
(3-1) Condition: E01
Troubleshooting Serial Communication
Is the voltage of about DC12V
or more given between the terminals
2 and 3 on the outdoor unit terminal strip
(Serial Communication Line) ?
(Fig. 1)
Yes
6. Reactor failure (defective insulation, etc.)
7. High-Pressure Switch failure
8. Overload Relay failure
9. Magnetic Coil failure (defective insulation, short-circuit, etc.)
1. Turn OFF the power and wait until the power lamp (LED)
No
of the outdoor unit controller is turned OFF.
2. Disconnect the cable from the terminal 3 on the indoor unit
terminal strip. (Fig. 2)
3. Turn ON the power.
124356
123
Indoor Unit
-
Outdoor Unit
Power
V
+
Fig. 2
( Continued to the next page A. )
A
( Continued to the next page B. )
B
40
( Continued from the previous page A. )
A
( Continued from the previous page B. )
B
Defect or connection error
in the inter-unit cable
1. Turn OFF the power and wait until the power lamp (LED)
of the outdoor unit controller is turned OFF.
2. Short-circuit between the terminals 2 and 3 on the outdoor
unit terminal strip. (Fig. 3)
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 the operation
start.
What is the latest self-diagnosis result ?
Yes
Condition: E12
Is the voltage of about DC22V to
24V given between the terminals
2 and 3 on the indoor unit terminal strip
(Serial Communication Line) ?
(Fig. 2)
No
Defect in the indoor unit
P.C. board
Outdoor Unit
124356
Power
123
Indoor Unit
Fig. 3
Defect in the outdoor unit
P. C. board.
Condition: E01
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 between the terminals 2 and 3 on the indoor unit
terminal board. (Fig. 5)
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 the operation
start.
What is the latest self-diagnosis result ?
Condition: E01
124356
123
Indoor Unit
Condition: E12
Outdoor Unit
Power
Fig. 4
Defect or connection error
in the inter-unit cable
Outdoor Unit
124356
Power
123
Indoor Unit
Fig. 5
Defect in the indoor unit
P.C. board
41
(3-2) Condition: E12
Troubleshooting Serial Communication
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)
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 the operation
start.
What is the latest self-diagnosis result ?
Condition: E12
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 indoor
unit terminal strip. (Fig. 7)
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 the operation
start.
Outdoor Unit
124356
Power
123
Indoor Unit
Fig. 6
Condition: E01
Defect in the outdoor unit
P.C. board
Outdoor Unit
124356
Power
123
Indoor Unit
Fig. 7
What is the latest self-diagnosis result ?
Condition: E12
Defect in the indoor unit
P.C. board
Condition: E01
42
Defect in the inter-unit
cable
9-4. Trouble Diagnosis of Fan Motor
9-4-1. Outdoor Fan Motor
This outdoor DC fan motor contains an internal control PCB. Therefore, it is not possible to measure the coil
resistance, and the following procedure should be used to check the motor.
Perform the trouble diagnosis by Test Run mode described on Installation Instructions.
Important:
[Trouble symptom 1] The fan does not stop when the outdoor unit stops. Outdoor unit controller trouble
[Trouble symptom 2] The fan motor does not rotate when the outdoor unit is operating.
(Diagnostic procedure)
(Diagnostic results)
(Reference)DC motor connector pin arrangement
Pin 1: Vs (white)
Pin 2: Not used
Pin 3: Not used
Pin 4: Gnd (black)
Pin 5: Vcc (red)
Pin 6: FG (blue)
Pin 7: Vsp (yellow)
(A) Turn OFF the power before connecting or disconnecting the motor connectors.
(B) When performing voltage measurement at the outdoor controller connector for (3) in the table
below, the DC motor will trip and voltage output will stop approximately 10 seconds after
operation is started. For this reason, to measure the voltage again, first turn OFF the outdoor
unit power, then, measure the voltage in Test Run mode.
* Disconnect the motor connectors and measure the voltage at the DC motor connectors on the outdoor
unit controller (3 locations).
Measurement location
(1) Vs-Gnd: Between pin 1 and pin 4
(2) Vcc-Gnd: Between pin 5 and pin 4
(3) Vsp-Gnd: Between pin 7 and pin 4
All of the above measured values are normal. Fan motor trouble (Replace the motor.)
Any one of the above measured values is not normal. Outdoor unit controller trouble
DC 110V or more
DC 14V or more
After fluctuating 4 times between DC 1.0 to 4.3V
(1 sec. ON) and DC 0 V (1 sec. OFF), the DC
motor trips.
(Replace the controller .)
Normal value
[Trouble symptom 3] Motor rotates for some time (several 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 not possible to identify whether the trouble is outdoor unit controller trouble or motor trouble.
Therefore, first replace the outdoor unit controller, then (if necessary) replace the DC motor.
43
9-5. Noise Malfunction and Electromagnetic Interference
An inverter A/C operates using pulse signal control and high frequencies. Therefore, it is susceptible to the effects of external
noise, and is likely to cause electromagnetic interference with nearby wireless devices.
A noise filter is installed for ordinary use, preventing these problems. However, depending on the installation conditions, these
effects may still occur. Please pay attention to the points listed below.
(1) Noise malfunction
This refers to the application of high-frequency noise to the signal wires, resulting in abnormal signal pulses and malfunction.
Locations most susceptible to noise
1. Locations near broadcast stations where
there are strong electromagnetic waves
2. Locations near amateur radio (short wave)
stations
3. Locations near electronic sewing machines
and arc-welding machines
Trouble
Either of the following trouble may occur.
1. The unit may stop suddenly during
operation.
2. Indicator lamps may flicker.
(The fundamental concept is to make the
system less susceptible to noise.)
distance from the noise source. -
1. Use shielded wires.
2. Move unit away from the noise source.
Correction
- Insulate for noise or
(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 wiring, affecting any wireless devices (televisions, radios, etc.) located nearby.
Locations most susceptible to noise
1. A television or radio is located near the
A/C and A/C wiring.
2. The antenna cable for a television or
radio is located close to the A/C and A/C
wiring.
3. Locations where television and radio
signals are weak.
Trouble
1. Noise appears in the television picture,
or the picture is distorted.
2. Static occurs in the radio sound.
1. Select a separate power source.
2. Keep the A/C and A/C wiring at least 1 meter
away from wireless devices and antenna cables.
3. Change the wireless device’s antenna to a highsensitivity antenna.
4. Change the antenna cable to a BS coaxial cable.
5. Use a noise filter (for the wireless device).
6. Use a signal booster.
Correction
44
10. CHECKING ELECTRICAL COMPONENTS
10-1. Measurement of Insulation
Resistance
The insulation is in good condition if the resistance
exceeds 1M ohm.
10-1-1. Power Supply Cord
Clamp the grounding wire of power cord with the lead
clip of the insulation resistance tester and measure the
resistance by placing a probe on either of the two
power wires. (Fig. 1)
Then also measure the resistance between the
grounding and other power terminals. (Fig. 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.
Probe
Copper
tube or
metallic part
Clip
Fig. 1
Terminal plate
Clip
Ground wire
Insulation
tester
Probe
Insulation
tester
10-1-3. Outdoor Unit
Clamp a metallic part of the unit with the lead clip of
the insulation resistance tester and measure the
resistance by placing a probe on each terminal screw
where power supply lines are connected on the
terminal plate. (Fig. 2)
10-1-4. Measurement of Insulation
Resistance for Electrical Parts
Disconnect the lead wires of the desired electric part
from terminal plate, capacitor, etc. Similarly disconnect
the connector. Then measure the insulation resistance.
(Figs. 3 and 4)
NOTE
Refer to Electric Wiring Diagram.
If the probe cannot enter the poles because the hole is
too narrow then use a probe with a thinner pin.
Copper
tube or
metallic part
Metallic
part
Fig. 2
Probe
Clip
Insulation
tester
Fig. 3
From fan motor,
compressor and
other parts
Probe
45
Clip
Fig. 4
Insulation
tester
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.
Fuse
PCB Ass'y
Fig. 5
Fuse
Fig. 6
46
11. REFRIGERANT R410A:
SPECIAL PRECAUTIONS WHEN SERVICING UNIT
11-1. Characteristics of New Refrigerant R410A
11-1-1. What is New Refrigerant R410A?
R410A is a new refrigerant that contains two types of pseudo-non-azeotropic refrigerant mixture. Its
refrigeration capacity and energy efficiency are about the same level as the conventional refrigerant, R22.
11-1-2. Components (mixing proportions)
HFC32 (50%) / HFC125 (50%)
11-1-3. Characteristics
Less toxic, more chemically stable refrigerant
The composition of refrigerant R410A changes whether it is in a gaseous phase or liquid phase. Thus, when
there is a refrigerant leak the basic performance of the air conditioner may be degraded because 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 whether it is in gaseous or liquid
phase, and the basic performance of the air conditioner will be degraded if it is charged while the refrigerant is in
gaseous state. Thus, always charge the refrigerant while it is in liquid phase.
CAUTION
Ether-type oil is used for compressor oil for R410A-type units, which is different
from the mineral oil used for R22. Thus more attention to moisture prevention and
faster replacement work compared with conventional models are required.
47
11-2. Checklist before Servicing
Use a clutch-type flare tool for R410A or the conventional flare tool. Note that sizes of the resultant flares differ
between these two tools. Where a conventional flare tool is used, make sure to observe A Specification (amount of
extrusion) by using the flare spacer.
Diameter of tube D
Dia.1/4" (6.35 mm)
Dia.3/8" (9.52 mm)
Dia.1/2" (12.7 mm)
Dia.5/8" (15.88 mm)
Size of flare
Tubing precautions
Specification A
Flare tool for R410AConventional flare tool (for R22)
0 to 0.0196"
(0 to 0.5 mm)
D
Flare tool for R410A
A
Conventional flare tool (R22)
D
0.0472"
(1.2 mm)
Spacer
A
Refrigerant R410A is more easily affected by dust or moisture compared with R22, thus be sure to temporarily
cover the ends of the tubing with caps or tape prior to installation.
Never use 0.0276" (0.7 mm)-thick copper tubing or tubing which is less than 0.0315" (0.8 mm) in thickness, since
air conditioners with R410A are subject to higher pressure than those using R22 and R407C.
No addition of compressor oil for R410A
No additional charge of compressor oil is permitted.
No use of refrigerant other than R410A
Never use a refrigerant other than R410A.
If refrigerant R410A is exposed to fire
Through welding, etc., toxic gas may be released when 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.
48
11-3. Tools Specifically for R410A
For servicing, use the following tools for R410A
Tool DistinctionTool Name
Gauge manifold
Charging hose
Gas leak detector
Refrigerant cylinder
Charging cylinder
Refrigerant recovery unit
Tools specifically for R410A
Vacuum pump with anti-reverse flow (*1)
(Solenoid valve-installed type, which prevents oil from flowing back into the
unit when the power is off, is recommended.)
Vacuum pump (*2)...can be used if the following adapter is attached.
(Solenoid valve-installed adapter attached to a conventional vacuum pump.)
Electronic scale for charging refrigerant
Flare tool
Bender
Tools which can be com-
monly used for R22,
R407C, and R410A
CAUTION
To prevent other refrigerants (R22, R407C) from being mistakenly charged to this unit, shape and external
diameter of the service port screw has been altered.
<External diameter of service port> R410A : 5/16"
R22, R407C : 1/4"
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.
Torque wrench
Cutter, reamer
Welding tool, nitrogen gas cylinder
11-4. Tubing Installation Procedures
When the tubes are connected, always apply HAB oil on the flare portions to improve the sealing of tubing.
The following is the HAB oil generally used:
Esso: ZERICE S32
NOTE
For details on tubing installation procedures, refer to the installation manuals attached to the indoor
unit and outdoor unit.
49
11-5. In Case of Compressor Malfunction
CAUTION
Should the compressor malfunction, be sure to make the switch to a replacement
compressor as quickly as possible.
Use only the tools indicated exclusively for R410A. See "11-3. Tools
Specifically for R410A."
11-5-1. Procedure for Replacing Compressor
(1) Recovering refrigerant
Any remaining refrigerant inside the unit should not be
released to the atmosphere, but recovered using the
refrigerant recovery unit for R410A.
Do not reuse the recovered refrigerant, since it will contain
impurities.
(2) Replacing Compressor
Soon after removing seals of both discharge and suction
tubes of the new compressor, replace it quickly.
(3) Checking for sealing
(1) Recover refrigerant
OK
(2) Replace compressor
OK
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 if moisture remains in
the tubing, thus carry out the evacuation thoroughly.
When using a vacuum pump with exhaust air volume more
than 0.883 cu.ft./min. and ultimate vacuum pressure rate
of 50 micron Hg.
Standard time for evacuation
Length of tubing
Evacuation time
Less than 33 ft. (10 m)
More than 10 minutes
(3) Check for sealing
OK
(4) Evacuation
OK
(5) Recharge
More than 33 ft. (10 m)
More than 15 minutes
50
(5) Recharging
Configuration and characteristics of cylinders
Be sure to charge the specified amount of
refrigerant in liquid state using the service port
of the wide tube service valve. The proper
amount is listed on the unit's nameplate.
When the entire amount cannot be charged all at
once, charge gradually while operating the unit in
Cooling Operation.
CAUTION
Never charge a large amount
of liquid refrigerant at once to
the unit. This may cause
damage to the compressor.
When charging with a refrigerant cylinder, 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 conditioning unit.
Valve
Liquid
Single valve
Charge liquid refrigerant with
cylinder in up-side-down position.
Fig. 1
Valve
Example:
In case of charging refrigerant to a unit requiring
1.68 lb. (0.76 Kg) using a capacity of a 22 lb. (10
Kg) cylinder, the minimum necessary amount for
the cylinder is:
For the remaining refrigerant, refer to the
instructions of the refrigerant manufacturer.
If using a charging cylinder, transfer the specified
amount of liquid refrigerant from the refrigerant
cylinder to the charging cylinder.
Prepare an evacuated charging cylinder
beforehand.
CAUTION
To prevent the composition
of R410A from changing,
never bleed the refrigerant
gas into the atmosphere
while transferring the
refrigerant. (Fig. 3)
Charging
cylinder
Open
Liquid
Single valve (with siphon tube)
Charge with cylinder in normal position.
Fig. 2
NO!
Liquid
Refrigerant
cylinder
Do not use the refrigerant if the amount in the
charging cylinder is less than 20%.
51
Fig. 3
11-6. In Case Refrigerant is Leaking
CAUTION
Never attempt to charge additional refrigerant when refrigerant has been leaking
from the unit. Follow the procedure described below to locate points of leaks and
carry out repairs, then recharge the refrigerant.
(1) Detecting Leaks
Use the detector for R410A to locate refrigerant leak
points.
(2) Recovering refrigerant
Never release the gas to the atmosphere; recover
residual refrigerant using the refrigerant recovery unit for
R410A, instead.
Do not reuse the recovered refrigerant because its
composition will have been altered.
(3) Welding leaking points
Confirm again that no residual refrigerant exists in the unit
before starting welding.
Weld securely using flux 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.
(1) Detect leaks
OK
(2) Recover refrigerant
OK
(3) Weld leaking points
OK
(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 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 if moisture remains in
the tubing, thus carry out the evacuation thoroughly.
When using a vacuum pump with exhaust air volume
more than 0.883 cu.ft./min. and ultimate vacuum pressure
rate of 50 micron Hg.
Standard time for evacuation
Length of tubing
Evacuation time
(6) Recharging
Less than 33 ft. (10 m)
More than 10 minutes
(4) Check for sealing
OK
(5) Evacuation
OK
(6) Recharge
More than 33 ft. (10 m)
More than 15 minutes
Recharge unit in the same manner explained on the
previous page "(5) Recharging."
52
11-7. Charging Additional Refrigerant
11-7-1. When Tubes are Extended
Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came
with the indoor unit. Charge additional refrigerant in liquid state only.
CAUTION
Never charge additional refrigerant if refrigerant is leaking from the unit. Follow
instructions given in "11-6. In Case Refrigerant is Leaking" and completely carry
out repairs. Only then should you recharge the refrigerant.
11-8. Retro-Fitting Existing Systems
11-8-1. Use of Existing Units
Never use new refrigerant 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.
53
APPENDIX A
KHS0971 + CH0971
KHS1271 + CH1271
INSTRUCTION MANUAL
(OI-852-6-4180-802-00-2)
A-1
Features
This air conditioner is an inverter type unit that automatically adjusts capacity as appropriate. Details on these functions
are provided below; refer to these descriptions when using the air conditioner.
•Microprocessor Controlled Operation
The interior compartment of the remote control unit
contains several features to facilitate automatic
operation, easy logically displayed for easy use.
•Simple One-touch Wireless Remote Control
The remote control unit has several features to
facilitate automatic operation.
•24-Hour ON or OFF Timer
This timer can be set to automatically turn the unit
on or off at any time within a 24 hour period.
•1-Hour OFF Timer
This timer can be set to automatically turn off the
unit at any time after 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.
•Auto. Flap Control
This automatically sets the flap to the optimum
position during heating, cooling, and drying
operation.
•Automatic Switching between Cooling and
Heating
This unit automatically switches between cooling
operation and heating operation according to the
difference between the room temperature and the
temperature setting.
•Hot Start Heating System
Right from the start, the air is warm and
comfortable. This system prevents any cold blasts
at the beginning while the heat pump is warming
up, or even defrosting.
•Automatic Restart Function for Power Failure
Even when power failure occurs, preset
programmed operation can be reactivated once
power resumes.
•High Power Operation
If not in Auto Operation, the unit operates at
maximum output for 30 minutes, regardless of the
desired temperature.
The fan speed is 1 step above “High”.
•Quiet Operation
The fan rotates slower than the fan speed setting to
provide a quieter operating sound.
•ION Operation
While it is operating, the unit generates negative
ions that freshen up the air in the room.
•Anti-Mold Filter
This unit is equipped with an anti-mold filter that
inhibits the growth of mold and bacteria.
•Air Clean Filter
An air filter that eliminates unpleasant odors and
cleans the air is available.
Purchase a replacement filter at your local dealer.
(model STK-FDXB)
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 in this manual, alert you to potentially
dangerous conditions to users, service personnel or the appliance:
This symbol refers to a hazard or unsafe
practice which can result in severe
personal injury or death.
CAUTION
This symbol refers to a hazard or unsafe
practice which can result in personal injury
or product or property damage.
OI-802-3EG
3
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.
•Before installation, check that the voltage of the electric supply 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 heatgenerating 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.
Electrical Requirements
1. All wiring must conform to the local electrical codes. Consult your dealer or a
qualified electrician for details.
2. Each unit must be properly grounded with a ground (or earth) wire or through
the supply wiring.
3. Wiring must be done by a qualified electrician.
CAUTION
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.
•Never use or store gasoline or other flammable vapor or liquid near the
air conditioner — it is very dangerous.
•This air conditioner has no ventilator for intaking fresh air from
outdoors. You must open doors or windows frequently when you use
gas or oil 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.
•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 with the air conditioner.
•Do not cool or heat the room too much if babies or invalids are present.
4
OI-802-4-EG
Names of Parts
Air intakes
Air outlet
Remote control unit
Refrigerant tubes
OUTDOOR UNIT
INDOOR UNIT
Drain hose
Air outlet
NOTE
Air IntakeAir from the room is drawn into this section and passes through air filters which
Air OutletConditioned air is blown out of the air conditioner through the air outlet.
Remote Control UnitThe wireless remote control unit controls power ON/OFF, operation mode
Refrigerant TubesThe indoor and outdoor units are connected by copper tubes through which
Drain HoseMoisture in the room condenses and drains off through this hose.
This illustration is based on the external view of a standard model.
Consequently, the shape may differ from that of the air conditioner which 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.
remove dust.
selection, temperature, fan speed, timer setting, and air sweeping.
refrigerant gas flows.
Outdoor (Condensing) UnitThe outdoor unit contains the compressor, fan motor, heat exchanger coil, and
other electrical components.
OI-802-5EG
5
IMPORTANT
Avoid using radio equipment
such as mobile phone near
(within 4 ft.) the remote
control receiver. Some radio
equipment may cause
malfunction of the unit.
If the trouble happens,
disconnect power and restart
the air conditioner after a few
minutes.
Unit Display and Operation Button
INDOOR UNIT
QUIET
REMOTE CONTROL receiver
OPERATION lamp
TIMER lamp
QUIET lamp
ION lamp
OPERATION button
REMOTE CONTROL receiverThis section picks up infrared signals from the remote control unit (transmitter).
OPERATION buttonWhen the remote control cannot be used, pressing this button enables heating
and cooling operation.
Each time this button is pressed, the type of operation conducted is indicated by
the changing color of the OPERATION lamp. Press the button and select the
lamp color that suits your preference for operation.
Cooling operation
(green)
Heating operation
(red)
Stop
(lamp off)
OPERATION lampThis lamp lights when the system is in the continuous AUTO (red or green),
HEAT (red), DRY (orange), COOL (green) and FAN (green) mode.
The OPERATION lamp lights up red and orange alternately when the system is
defrosting.
TIMER lampThis lamp lights when the system is being controlled by the timer.
QUIET lampThis lamp lights during operation in the QUIET mode.
ION lampThis lamp lights during operation in the ION mode while the indoor unit is
operating.
NOTE
The unit’s display lamps are dimmed during operation in the NIGHT SETBACK
mode.
6
OI-802-6-EG
Displayed when the
time display is set to
12-hour time.
Remote Control Unit (Display)
Displayed when transmitting data
Displayed when indoor unit
sensor is in use
Displayed when setting
temperature
Displayed when temperature is
shown
Displayed when setting timer
Symbols
(1) Operation mode
AUTO .........................................
HEAT ..........................................
MILD DRY..................................
COOL.........................................
FAN ............................................
(2) Fan speed
Automatic operation ...................
HIGH .........................................
MEDIUM.....................................
(4) Timer
24-hour clock with ON/OFF
program Timer............................
ON Timer....................................
OFF Timer..................................
1-hour OFF Timer.......................
(5) NIGHT SETBACK ......................
(6) Confirmation of transmission .....
(7) Auto. flap indication ....................
Flap angle indication ..................
LOW...........................................
(3) Temperature setting
60–86°F
When set to 80 °F
temperature indication................
OI-802-7EG
Sweep indication ........................
(8) High power operation .................
(9) Quiet operation...........................
(10)ION operation ...........................
7
Remote Control Unit
Transmitter
ION button
QUIET button
FAN SPEED selector button
FLAP button
ON TIME
setting
buttons
Advance button
Return button
CANCEL button
SENSOR button
Display
Sensor
(Cover closed)
ON/OFF operation button
1 HR. TIMER button
Temperature setting buttons (TEMP.)
MODE selector button
NIGHT SETBACK button
HIGH POWER button
Advance button
Return button
CLOCK button
Time display selector button
OFF TIME
setting
buttons
ADDRESS switch
Temperature display
selector button
NOTE
TransmitterWhen you press the buttons on the remote control unit, the mark appears in
SensorA temperature sensor inside the remote control unit senses the room
DisplayInformation on the operating conditions is displayed while the remote control unit
ION button: This button is for turning the negative ions generated during operation on
ON/OFF operation buttonThis button is for turning the air conditioner on and off.
1 HR. TIMER button
(1-HOUR OFF TIMER)
The illustration above pictures the remote control unit after the cover has been
opened.
the display to transmit the setting changes to the receiver in the air conditioner.
temperature.
is switched on. If the unit is turned off, FLAP setting and FAN SPEED setting are
not displayed.
and off.
: When you press this button, regardless of whether the unit is operating or
stopping, the unit operates for one hour and then shuts down.
ACL button
8
OI-802-8-EG
Remote Control Unit (continued)
Temperature setting buttons
(TEMP.)
Press the button to increase the set temperature.
Press the button to reduce the set temperature.
The temperature setting changes by 1 °C or 2 °F each time one of the TEMP.
buttons is pressed.
QUIET button: When you press this button, the fan rotates slower than the fan speed
setting to provide a quieter operating sound.
MODE selector buttonUse this button to select AUTO, HEAT, DRY, COOL or FAN mode.
(AUTO): 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.
(HEAT): The air conditioner makes the room warmer.
(DRY): The air conditioner reduces the humidity in the room.
(COOL): The air conditioner makes the room cooler.
(FAN): The air conditioner works only as a circulation fan.
FAN SPEED selector button: The air conditioner automatically decides the fan speeds.
: High fan speed
: Medium fan speed
: Low fan speed
NIGHT SETBACK buttonFor details, see “5. Night Setback Mode”. When you press this button in the
HEAT, DRY or COOL mode, the mark appears in the display, and the remote
control unit will automatically adjust the set temperature to save energy.
FLAP buttonPress this button either to select the setting of the airflow 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 heating operation, the flap is set to
position (3) in the following chart. 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.
NOTE
When you press the FLAP button, the air flow direction will be changed one by
one as follows.
SWEEP
HIGH POWER button: If this button is pressed during HEAT, DRY, COOL or FAN operation, the
unit operates at maximum output for 30 minutes, regardless of the desired
temperature.
The fan speed is 1 step above “High”.
ON TIME/OFF TIME setting
buttons
No display: The timer does not operate.
: The air conditioner starts at the set time.
: The air conditioner stops at the set time.
: The air conditioner stops and starts, or starts and stops, at the
set times every day. For details, see “Setting the Timer”.
NOTE
OI-802-9EG
The indoor fan runs continuously when the system is in normal operation. It does not turn off when the
desired room temperature is reached. If Night Set Back mode is selected, the fan will turn off
intermittently during cooling operation in order to control air flow.
9
Remote Control Unit (continued)
SENSOR buttonWhen you press this button (use a small-tipped object such as a ballpoint pen),
the mark will appear at the display. And the room temperature is detected by
the sensor which is built into the indoor unit and the air conditioner is controlled
accordingly.
NOTE
Temperature Display Selector
button
Time Display Selector buttonThis switches the time display between 24-hour time and 12-hour time.
ACL button (ALL CLEAR)Puts the remote control unit into pre-operation status. Always press this button
ADDRESS switch•The address switch changes to prevent mixing of signals from remote control
NOTE
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, the temperature around the remote
control unit may differ from the temperature detected at the air conditioner’s position.
If the remote control is located near a heat source, such as a space heater or in
direct sunlight, press the SENSOR button to switch to the sensor on the indoor
unit.
This switches the temperature display between °C and °F.
after replacing the batteries.
units when two air conditioners are installed next to each other. Normally, the
address switch is set to A. For more information, please contact the dealer
where you made the purchase.
•Normally, the tabs on the remote control unit should not be bent.
How to Install Batteries
ACL button
NOTE
Using the Remote Control Unit
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.
3. Use a thin object such as the tip of a
pen to press the ACL button.
•The batteries last about six months, depending on how much you use
the remote control unit. Replace the batteries when the remote control
unit’s display fails to light, or when the remote control cannot be used to
change the air conditioner’s settings.
•Use two fresh leak-proof type-AAA alkaline batteries.
•In replacing batteries, follow the instructions as mentioned in the subsection “How to Install Batteries”.
•If you do not use the remote control unit more than 1 month, take out the
batteries.
10
OI-802-10-EG
Using the Remote Control Unit (continued)
R
How to Use the Remote
Control Unit
Remote Control Unit
Installation Position
DO NOT•In direct sunlight
When using the remote control unit, always point the unit’s transmitter head
directly at the air conditioner’s receiver.
Air conditioner
(Indoor unit)
Receiver
Remote control
(Transmitter head)
unit
The remote control unit may be operated 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:
•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 or cold
•Where it may be subject to electrical or magnetic noise
•Where there is an obstacle between the remote control unit and air
conditioner (since a check signal is sent from the remote control unit every 5
minutes)
Mounting the Remote Control
Unit
Remote control
unit mount
Mounting screws
5/32 x 5/8" (4 x 16 mm)
(included)
When Holding 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.
ear side
Press
Set in
place
Hole
• To prevent loss of the remote control unit,
you can connect the remote control unit to
the mount by passing a string through the
remote control unit and attachment hole.
To take out the remote control unit, pull it forward.
•When using the remote control unit and during air conditioner operation, the
transmitter on the remote control unit should be pointed toward the receiver
on the indoor unit.
•Make sure that there are no objects between the remote control unit and
receiver which could block the signal.
OI-802-11EG
11
Operation with the Remote Control
Unit
1. Automatic Operation
This unit automatically switches between cooling operation and heating operation
according to the difference between the room temperature and the temperature
setting.
STEP 2
STEP 1
NOTE
NOTE
Check that the circuit breaker on the power panel is turned on.
Once mode is selected and the unit is preset by following the steps below, you
can have the air conditioner automatically bring the room to the desired
temperature simply by pressing the ON/OFF operation button.
STEP 1Press the MODE selector button to .
STEP 2Press the ON/OFF operation button.
To stop the air conditioner, press the ON/OFF operation button again.
•To change the temperature setting; press the temperature setting buttons and
change the setting to the desired temperature.
12
OI-802-12-EG
2. Manual Operation
Operation with the Remote Control Unit (continued)
STEP 2
STEP 3
STEP 1
NOTE
STEP 4
STEP 5
Check that the circuit breaker on the power panel is turned on.
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.
STEP 1Press the MODE selector button and select the desired mode.
For heating operation→
For dehumidifying operation→
For cooling operation→
For fan only operation→
STEP 2To start the air conditioner, press the ON/OFF operation button.
STEP 3Press the TEMP. setting buttons to change the temperature
setting to the desired temperature.
Adjustable temperature range:
30 °C max.
16 °C min.
or86 °F max.
60 °F min.
OI-802-13EG
STEP 4Set the FAN SPEED selector button to the setting you want.
STEP 5Press the FLAP button and set the airflow direction as desired.
(Refer to “Adjusting the Airflow Direction” on page 21.)
To stop the air conditioner, press the ON/OFF operation button again.
13
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 5-minute time delay circuit to ensure reliable
operation. When the operation button is pressed, the compressor will start
running within three minutes. In the event of power failure, the unit will stop.
3. Adjusting the Fan Speed
A. Automatic fan speedSimply set the FAN SPEED selector button to the position.
This automatically sets the best fan speed for the room temperature.
B. Manual fan speedIf you want to adjust fan speed manually during operation, just set the FAN
SPEED selector button as desired. [, , or ]
4. Fan Only
STEP 2
STEP 1
STEP 3
If you want to circulate air without any temperature control, follow these steps:
STEP 1Press the MODE selector button to switch to the fan mode .
STEP 2Press the ON/OFF operation button.
STEP 3Press the FAN SPEED selector button to select the fan speed of
your choice (, or ).
14
OI-802-14-EG
5. Night Setback Mode
Operation with the Remote Control Unit (continued)
Night Setback Mode is used for saving energy.
Press the NIGHT SETBACK button while operation.
The mark appears in the display.
To release the night setback function, press the NIGHT SETBACK button again.
A. In Cooling and DRY
Mode: ( and )
B. In Heating Mode: ()
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 is needed.
Setting
2°F
temperature
Press the NIGHT
2°F
30 min.
30 min.
Time
SETBACK button
When the night setback mode is selected, the air conditioner automatically
lowers the temperature setting 4 °F when 30 minutes have passed after the
selection was made, and then another 4 °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 heating is needed.
OI-802-15EG
Setting
temperature
Press the NIGHT
SETBACK button
30 min.
4°F
30 min.
4°F
Time
15
6. QUIET Mode
7. HIGH POWER Mode
Operation with the Remote Control Unit (continued)
QUIET Mode is used to reduce the fan sound of the indoor unit.
Press the QUIET button.
The mark appears in the display.
To cancel, press QUIET button again.
•In QUIET Mode, the fan rotates at a slower speed than the fan speed setting.
•If the unit is already operating with a very low airflow, the fan sound may not
change even if the QUIET button is pressed.
HIGH POWER mode can be used to increase the output of the indoor unit for all
operation modes except automatic operation.
Press the HIGH POWER button.
The mark appears in the display.
8. ION Mode
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”.
•HIGH POWER Mode cannot be used when the operation mode is Automatic
Operation.
•QUIET Mode and HIGH POWER Mode cannot be used at the same time.
NOTE
• When set to High fan speed during heating operation, the fan
runs at High fan speed even though the mark is displayed.
• Depending on the operating conditions, the fan speed may be
increased by a small amount only.
The ION mode is used during operation to generate negative ions that freshen up
the air in the room.
Press the ION button.
The mark appears in the display.
To cancel, press ION button again.
•The indoor unit’s ION lamp lights up while negative ions are being generated.
•ION “on” is the remote control unit’s initial setting.
•The negative ions are generated from the negative ion generator.
16
OI-802-16-EG
Special Remarks
‘‘DRY’’ () Operation
How it works?•Once the room temperature reaches the level that was set, the unit’s operation
frequency is changed automatically.
•During DRY operation, the fan speed automatically runs at lower speed for
providing a comfortable breeze.
•‘‘DRY’’ operation is not possible if the indoor temperature is 59 °F or less.
Heating () Operation
Heating performance•Because this air conditioner heats a room by drawing in the heat of the
outside air (heat pump system), the heating efficiency will fall off when the
outdoor temperature is very low. If sufficient heat cannot be obtained with this
air conditioner, use another heating appliance together with it.
Defrosting•When the outdoor temperature is low, frost or ice may form on the heat
exchanger coil, reducing heating performance. When this happens, a
microcomputer defrosting system operates. At the same time, the fan on the
indoor unit stops and the OPERATION lamp lights up red and orange
alternately until defrosting is completed. Heating operation restarts after
several minutes. (This interval will vary slightly depending upon the outdoor
temperature and the way in which frost forms.)
Cold draft prevention•For several minutes after the start of heating operation, the indoor fan runs at
Cooling ( ) Operation
Power failure during
operation
Clicking Sound
Clicking sound is heard from
the air conditioner
Remote Control Unit
lower speed until the indoor heat exchanger coil has warmed up sufficiently.
However, the fan may remain stopped when the room temperature is low. This
is because the COLD DRAFT PREVENTION SYSTEM is operating.
•Sometimes the indoor unit may not get to the set fan speed such as LOW and
QUIET under cool operation at very low outdoor temperatures due to the
indoor unit being protected from ice or frost.
•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.
•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.
•The remote control unit sends the setting condition to the air conditioner
regularly at five minute intervals.
OI-802-17EG
17
Setting the Timer
NOTE
1. How to set the present
time
2. How to set the OFF time
In the descriptions below, the following settings are used for the temperature and
time indicator selector button on the bottom front section of the remote control.
•Temperature: °F
•Time: AM, PM
(Example) To set to 10:30 pm.
OperationIndication
1. Press the CLOCK button once if
the time indicator is not flashing.
2. Press the Advance, Return ( ,
) button until PM 10:30 is
displayed.
3. Press the CLOCK button again.This completes the setting of the
(Example) To stop the air conditioner at 11:00 am.
1. Press the OFF TIME setting
button once.
The time indication alone flashes.
The time can be set in 1-minute
increments. Holding down the button
advances the time rapidly in 10-minute
increments.
current time.
The timer indication is displayed,
and the present OFF time is shown.
18
2. Press the Advance, Return ( ,
) button until AM 11:00 is
displayed.
3. Wait a few seconds, and then the
setting is complete.
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.
The timer indication stops
blinking and the present time is
displayed.
OI-802-18-EG
Setting the Timer (continued)
3. How to set the ON time
4. How to set DAILY ON/OFF
REPEAT timer
(Example) To start operation at 7:10 am.
OperationIndication
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
the setting is complete.
The timer indication stops
blinking and the present time is
displayed.
(Example) To start operation at 7:10 am. and stop the air conditioner at 11:00 am.
10:30 pm.
Present time
7:10 am.
ON
11:00 am.
OFF
1. Set the timer ON/OFF times as
shown in 2-1, 2, 3 and 3-1, 2, 3.
NOTE
•The ON/OFF combination timer uses the current time as
the reference, and it is activated starting from whichever
set time comes first.
•With the ON/OFF combination timer, the settings are
repeated every day.
•You can check the timer ON/OFF times after you have set
them by pressing the ON TIME and OFF TIME setting
buttons.
To cancel a timer program•Press the CANCEL button.
•When either an ON or OFF timer is to be canceled, press the button
corresponding to the timer whose program is to be canceled, and then press
the CANCEL button.
NOTE
•The airflow direction, fan speed and temperature setting can be changed after
a timer program has been set even when the unit is stopped. Even when
operation is stopped during an ON timer program, the unit will start operating
when the set time is reached provided that the program is not canceled.
•When the ON timer and OFF timer are set to the same time, the timer
operates as if it is turned off.
The present time 10:30 pm. and
are displayed.
OI-802-19EG
19
Using the 1-Hour OFF Timer
1. 1-Hour OFF TimerThis function causes the unit to operate for one hour and then stop,
regardless of whether the unit is on or off when this button is pressed.
The indicator in the display indicates that this function is operating.
Setting procedure:
Regardless of whether the unit is operating or stopped, press the 1 HR. TIMER
button.
appears in the display.
Cancellation procedure:
Press the ON/OFF operation button to turn the unit off, wait for the unit to stop
operating, and then press the ON/OFF operation button again.
The 1-Hour Timer function is now cancelled and the unit operates normally.
NOTE
2. Operation together with the
DAILY ON/OFF REPEAT Timer
Do not•Block the air intake and outlet of the unit. If they are obstructed, the unit
Do•Always try to keep the air filter clean. (Refer to “Care and Cleaning”.) A
•If, while the 1-Hour Timer function is operating, the 1HR. TIMER button is
pressed once to cancel the function and then again, the unit continues 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.
The 1-Hour OFF Timer setting is given priority over the DAILY ON/OFF REPEAT
setting.
Tips for Energy Saving
will not work well, and may be damaged.
•Let direct sunlight into the room. Use sunshades, blinds or curtains. If the walls
and ceiling of the room are warmed by the sun, it will take longer to cool the
room.
clogged filter will impair the performance of the unit.
•To prevent conditioned air from escaping, keep windows, doors and any other
openings closed.
20
OI-802-20-EG
Adjusting the Airflow Direction
1. HorizontalThe horizontal airflow can be adjusted by moving the vertical vanes with your
hands to the left or right.
CAUTION
2. VerticalThe vertical airflow can be adjusted by moving the flap with the remote control
A. Sweep function
The flap starts moving up and down to
deliver air over the sweep range.
C. Auto flap function
The flap is set to the recommended
position.
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.
unit. Do not move the flap with your hands. Confirm that the remote control unit
has been turned on. Use the FLAP button to set either the sweep function or one
of the six airflow direction settings.
COOL
DRY
FAN
B. Setting the airflow manually
Referring to the above illustration, use the
FLAP button to set the airflow direction
within the range used during the heating,
cooling, or dehumidifying operation.
SWEEP
SWEEP
HEAT
OI-802-21EG
NOTE
CAUTION
•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 ) until the air being blown out of the
unit begins to warm. Once the air warms up, the flap position and fan speed
change to the settings specified with the remote control.
•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 have the flap pointed down during cooling operation.
Condensation may begin to form around the air vent and drip down.
21
Operation without the Remote
Control Unit
INDOOR UNITIf you have lost the remote control unit or it has trouble, follow the steps below.
When the air conditioner is not running
Each time the OPERATION button is pressed, the type of operation conducted is
indicated by the changing color of the OPERATION lamp. Press the button and
select the lamp color that suits your preference for operation.
OPERATION button
NOTE
Cooling operation
(green)
The temperature is set to the room temperature minus 4 °F during the cooling
operation and to the room temperature plus 4 °F during the heating operation,
and the fan speed and flap are set to Auto.
Heating operation
(red)
Stop
(lamp off)
Care and Cleaning
1. For safety, be sure to turn the air conditioner off and also to disconnect
the power before cleaning.
2. Do not pour water 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 of place.
22
CAUTION
1. Never use solvents, or harsh chemicals when cleaning the indoor unit.
Do not wipe the plastic casing using very hot water.
2. Some metal edges and the fins are sharp and may cause injury if
handled improperly; be especially careful when you clean these parts.
3. The internal coil and other components of the outdoor unit must be
cleaned every year. Consult your dealer or service center.
OI-802-22-EG
Care and Cleaning (continued)
Anti-Mold FilterThe anti-mold filter behind the air intake grille should be checked and cleaned at
least once every two weeks.
How to remove the anti-mold
filter
CleaningUse a vacuum cleaner to remove light dust. If there is sticky dust on the filter,
How to replace the anti-mold
filter
1. Grasp both ends of the air
intake grille, and remove it by
opening towards the front and
pulling towards you.
2. Remove the anti-mold filter
attached to the rear of the air
intake grille.
wash the filter in lukewarm, soapy water, rinse it in clean water, and dry it.
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.
Air intake grille
Anti-mold filter
Anti-mold filter
NOTE
FRONT mark
Hook
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 air intake
grille to attach the indoor unit.
Attach so that the round pins at the top right and left corners of the air intake grille
are inserted into the grooves at the top right and left of the indoor unit.
Air intake grille
Groove
Pin
Air intake grille
OI-802-23EG
23
Care and Cleaning (continued)
Air Clean FilterThe air clean filter removes dust and dirt from the air, and reduces odors and smoke from
tobacco.
This air clean filter cannot remove harmful gases or vapors nor ventilate air in the
room. You must open doors or windows frequently when you use gas or oil heating
appliances. Otherwise there is a risk of suffocation in extreme cases.
How to install the air
clean filter
How to clean the air
clean filter
NOTE
Cleaning the main unit
and remote control
unit
Removing and
remounting the air
intake grille
CAUTION
The air clean filter needs to be installed behind the air intake grille.
1. Remove the air intake grille.
2. Install the air clean filter in the position
shown in the figure.
3. Remount the air intake grille.
Air clean filter
•In general, the filter should be sucked to remove dust in low fan speed of a vacuum
cleaner once every three months.
•If there is heavily grime on the filter, soak the filter in lukewarm water with neutral
detergent diluted 1:500 for 1 to 2 minutes then wash it.
•Rinse the filter in clean water, then let it dry on the towel in room temperature.
•Do not bend nor give excessive force onto the air clean filter.
•If the filter surface is heavily blocked with dirt or damaged, replace it with new one.
Purchase a replacement filter at your local dealer. (model STK-FDXB)
•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.
Refer to “How to remove the anti-mold filter” and “How to replace the anti-mold filter” on
page 23.
When using a footstool or the like, be careful not to let it tip over.
Washing the grille
with water
Cleaning the negative
ion generator
NOTE
24
•Clean the grille gently using a soft sponge, or the like. Then wipe away any remaining
moisture.
•Neutral detergent may be used to remove stubborn dirt. Then rinse thoroughly with
water and wipe away any remaining moisture.
Follow the steps below when the generator has
become dirty.
For safety, be sure to turn the air conditioner
off and also to disconnect the power before
cleaning.
Remove the dust on the negative ion generator.
•Use a toothbrush, etc. to dust off the end.
•Use a cotton swab, etc., to clean around the
generator inside the plastic case, taking care
not to touch the electrodes.
•During use, the negative ion generator and other metal parts may become discolored:
this is normal and not indicative of malfunctioning.
•If the dirt on and around the negative ion generator is left to build up, a puffing or
sputtering sound will eventually be heard. In this case, clean the generator immediately.
•Do not apply excessive force while performing maintenance.
Negative ion generator
(metal electrodes inside
plastic case)
OI-802-24-EG
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 Possible Cause Remedy
Air conditioner does not run at all.1. Power failure. 1. Restore power.
2. Leakage circuit breaker tripped.2. Contact service center.
3. Line voltage is too low.3. Consult your electrician or dealer.
4. Batteries in remote control unit have
run down.
OPERATION lamp blinks and air
conditioner does not operate.
Compressor runs but soon stops.Obstruction in front of condenser coil.Remove obstruction.
Poor cooling (or heating) performance.1. Dirty or clogged air filter.1. Clean air filter to improve airflow.
Clicking sound is heard from the air
conditioner.
Trouble in system.Contact service center.
2. Heat source or many people in
room.
3. Doors and/or windows are open.3. Shut them to keep the heat (or cold)
4. Obstacle near air intake or air
discharge port.
5. Thermostat is set too high for
cooling (or too low for heating).
6. (Outdoor temperature is too low for
heating.)
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.
4. Replace batteries.
2. Eliminate heat source if possible.
out.
4. Remove it to ensure good airflow.
5. Set the temperature lower (or
higher).
6. (Consult your dealer or try to use
another heat appliance.)
This is normal, and the sound will soon
disappear.
OPERATION lamp lights but outdoor
unit will not run.
1. The use of cellular phones near the
air conditioner may cause
disturbance to its normal operation.
1. Turn off the power then restart the
air conditioner after a while.
2. Consult your dealer.
Operating Range
The air conditioner is operable within the temperature ranges as listed below:
Temperature Indoor air temperature Outdoor air temperature
COOLINGMax. 95 °F DB / 71 °F WB 115 °F DB
Min. 67 °F DB / 57 °F WB 0 °F DB
HEATINGMax. 80 °F DB / 67 °F WB 75 °F DB / 65 °F WB
Min. – DB / – WB0 °F DB
OI-802-25EG
25
APPENDIX B
INSTALLATION INSTRUCTIONS
KHS0971 + CH0971
KHS1271 + CH1271
(II-852-6-4189-990-00-5)
A-2
W
INSTALLATION INSTRUCTIONS
– Inverter Split System Air Conditioner –
This air conditioner uses the new refrigerant R410A.
NOTE
Contents
IMPORTANT!
Please Read Before Starting .................................. 2
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Additional Materials Required for Installation
2.INSTALLATION SITE SELECTION ................... 4
2-1. Indoor Unit
2-2. Outdoor Unit
3.HOW TO INSTALL THE INDOOR UNIT ............. 6
3-1. Remove the Rear Panel from the Unit
3-2. Make a Hole
3-3. Install the Rear Panel on the Wall
3-4. Remove the Grille to Install the Indoor Unit
3-5. Shape the Indoor Side Tubing
3-6. Wiring Instructions
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
3-10. Drain Hose
Refrigerant service valve size = 5/16"
Page
COOL/ DRY/HEAT Model
Model Combinations
Combine indoor and outdoor units only as listed
below.
Indoor UnitOutdoor Unit
KHS0971CH0971
KHS1271CH1271
Power Source:
60 Hz, single-phase, 115 V
Be sure to read the yellow instruction sheet
attached to the outdoor unit for models using the
new refrigerant R410A.
7.REMOTE CONTROL UNIT INSTALLATION
POSITION ......................................................... 23
5-1. Use of the Flaring Method
5-2. Flaring Procedure with a Flare Tool
5-3. Caution before Connecting Tubes Tightly
5-4. Connecting Tubing between Indoor and
Outdoor Units
5-5. Insulation of Refrigerant Tubing
5-6. Taping the Tubes
5-7. Finishing the Installation
I Air Purging with a Vacuum Pump (for Test Run)
I Basic Functions of the Service Valves
I Pump Down
SANYO Commercial SolutionsIn Canada
A Division of SANYO North America CorporationSANYO Canada Inc.
Cornerstone Business Park,1-300 Applewood Crescent, Concord
1062 Thorndale Avenue,Ontario, L4K 5C7, Canada
The illustrations are based on the typical appearance of
a standard model. Consequently, the shape may differ
from that of the air conditioner that you are installing.
IMPORTANT!
Please Read Before Starting
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.
For safe installation and trouble-free operation, you
must:
G
Carefully read this instruction booklet before beginning.
G
Follow each installation or repair step exactly as shown.
G
Observe all local, state, and national electrical codes.
G
Pay close attention to all warning and caution notices
given in this manual.
This symbol refers to a hazard
WARNING
CAUTION
or unsafe practice which can
result in severe personal injury
or death.
This symbol refers to a hazard
or unsafe practice which can
result in personal injury or product or property damage.
If Necessary, Get Help
These instructions are all you need for most installation
sites and maintenance conditions. If you require help for a
special problem, contact our sales/service outlet or your
certified dealer for additional instructions.
In Case of Improper Installation
The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to
follow the instructions in this document.
SPECIAL PRECAUTIONS
WARNING
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.
• Do not supply power to the unit until all wiring and tubing
are completed or reconnected and checked.
• Highly dangerous electrical voltages are used in this
system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and
inadequate grounding can cause accidental injury or
death.
• Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible 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 Wiring
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 frame to provide added support.
…In a Room
Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to
walls and floors.
…In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents
water damage and abnormal vibration.
…In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.
…In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is higher
than drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces of
the flare and union tubes before connecting them, then
tighten the nut with a torque wrench for a leak-free
connection.
• Check carefully for leaks before starting the test run.
When Servicing
• Turn the power OFF at the main power box (mains)
before opening the unit to check or repair electrical parts
and wiring.
• Keep your fingers and clothing away from any moving
parts.
• Clean up the site after you finish, remembering to check
that no metal scraps or bits of wiring have been left inside
the unit being serviced.
Others
CAUTION
• Ventilate any enclosed areas when installing or testing
the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously
toxic gas.
• Confirm upon completing installation that no refrigerant
gas is leaking. If escaped gas comes in contact with a
stove, gas water heater, electric room heater or other heat
source, it can produce dangerously toxic gas.
2
1. General
This booklet briefly outlines where and how to install the
air conditioning system. Please read over the entire set
of instructions for the indoor and outdoor units and make
sure all accessory parts listed are with the system before
beginning.
1-1. Tools Required for Installation (not supplied)
1. Standard screwdriver
2. Phillips head screwdriver
3. Knife or wire stripper
4. Tape measure
5. Carpenter’s level
1-2. Accessories Supplied with Unit
Table 1
PartsFigureQ’tyPartsFigureQ’ty
Remote
control unit
Remote control
unit holder
1
1
Tapping screw
Rawl plug
Truss-head
Phillips
5
/32 ¥5/8" (4¥16 mm)
6. Sabre saw or key hole saw
7. Hacksaw
8. Core bits
9. Hammer
10. Drill
11. Tube cutter
12. Tube flaring tool
13. Torque wrench
14. Adjustable wrench
15. Reamer (for deburring)
PartsFigureQ’ty
8
Hex wrench*
Clamp
10
1
1
AAA alkaline
battery
Air clean filter
2
2
Drain hose
adapter
Cushion
rubber*
1-3. Optional Copper Tubing Kit
Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or A/C workshop.
1-4. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately from
a local source, you will need:
1.Deoxidized annealed copper tube for refrigerant tubing 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.
1
4
*Packed in the outdoor unit.
2.Foamed polyethylene insulation for the specified
copper tubes as required to precise length of tubing.
Wall thickness of the insulation should be not less
than 5/16" (8 mm).
3.Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring. Refer to 3-6.
Wiring Instructions for details.
CAUTION
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
1-5. Additional Materials Required for Installation
1.Refrigeration (armored) tape
2.Insulated staples or clamps for connecting wire
(See local codes)
3.Putty
4.Refrigeration lubricant
5.Clamps or saddles to secure refrigerant tubing
2. Installation Site Selection
2-1. Indoor Unit
WARNING
AVOID:
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.
Indoor unit
2" (5 cm)
min.
Outside drainage
Fig. 1
6" (15 cm)
min.
Drain hose
2" (5 cm)
min.
G direct sunlight.
G nearby heat sources that may affect performance of the unit.
G areas where leakage of flammable gas may be expected.
G places where large amounts of oil mist exist.
DO:
G select an appropriate position from which every corner of the
room can be uniformly cooled. (High on a wall is best.)
G select a location that will hold the weight of the unit.
G select a location where tubing and drain hose have the
shortest run to the outside. (Fig. 1)
G allow room for operation and maintenance as well as unre-
stricted air flow around the unit. (Fig. 2)
G install the unit within the maximum elevation difference (H)
above or below the outdoor unit and within a total tubing length
(L) from the outdoor unit as detailed in Table 3 and Fig. 3a.
G Install the indoor 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.
Front View
Fig. 2
INDOOR
UNIT
Elevation
difference (H)
Fig. 3a
CAUTION
For stable operation of the
air conditioner, do not
install wall-mounted type
indoor units less than 5'
(1.5 m) from floor level.
Tubing length (L)
OUTDOOR
UNIT
Indoor unit
Minimum height
from floor level
5' (1.5 m)
Floor level
Wall
Fig. 3b
Table 3
Max. Allowable Tubing Limit of TubingLimit of ElevationRequired Amount of
ModelLength at ShipmentLength (L)Difference (H)Additional Refrigerant
(ft.)(ft.)(ft.)(oz./ft.)*
KHS09712550230.16
KHS12712565230.16
* If total tubing length becomes 25 to 50 ft. (Max.) or 25 to 65 ft. (Max.), charge additional refrigerant (R410A) by 0.16 oz./ft.
No additional charge of compressor oil is necessary. For more detailed charging information, refer to the Technical & Service Manual.
4
2-2. Outdoor Unit
AVOID:
G heat sources, exhaust fans, etc. (Fig. 4)
G damp, humid or uneven locations.
DO:
G choose a place as cool as possible.
G choose a place that is well ventilated.
G allow enough room around the unit for air intake/
exhaust and possible maintenance. (Fig. 5a)
G provide a solid base (level concrete pad, concrete
block, 4" × 1'4" (10 × 40 cm) beams or equal), a minimum of 4" (10 cm) above ground level to reduce
humidity and protect the unit against possible water
damage and decreased service life. (Figs. 5b and 5c)
CAUTION
A solid base must not cover
the hole of the bottom plate.
NO
Hot air
Outdoor unit
Air intakeMin. 2" (5 cm)
Min.
2" (5 cm)
Air discharge
Fig. 4
Valve
side
Min. 10"
(25 cm)
Min.
8" (20 cm)
Exhaust fan
Heat source
Obstacle above
Min.
7' (2 m)
Air discharge
Min.
7' (2 m)
Obstacle
G Install cushion rubber under unit’s feet to reduce
vibration and noise. (Fig. 5d)
G use lug bolts or equal to bolt down unit, reducing
vibration and noise.
G Install in a location where no antenna of a television
or radio exists within 10' (3 m).
Air intake
Concrete
or equal
Drain holes
About 16" (40 cm)
Fig. 5a
Fig. 5b
Ground
Anchor bolts
(4 pcs.)
Min. 4" (10 cm)
About 4" (10 cm)
Min. 2" (5 cm)
Air intake
Fig. 5c
Cushion rubber
Fig. 5d
5
3. How to Install the Indoor Unit
3-1. Remove the Rear Panel from the Unit
(1) Remove and discard the set screw on the rear
panel. (Fig. 6)
(2) Press the 2 LL marks on the frame cover and disen-
gage the stationary tabs from the frame. (Fig. 7)
(3) Remove the rear panel.
Set screw only for transportation
NOTE
Tubing can be extended in 5 directions as shown in Fig.
8. Select the direction you need providing the shortest
run to the outside unit.
G When left tubing is to be done, switch the drain hose
and drain cap. (For details, refer to “Switching drain
hose and drain cap” on page 14.)
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 horizontal, using a carpenter’s level or tape measure to
measure down from the ceiling. Wait until after cutting 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. 9)
NOTE
In the case of left-rear tubing, use the measurement
points 2-3/4" (70 mm) from the edge of the rear panel for
precise placement of the hose outlet. (Fig. 9)
Left
tubing
Left-rear
tubing
Fig. 6
Rear panel
marks
Fig. 7
Right-rear
tubing
(recommended)
Right tubing
Downward tubing
Fig. 8
(3) Before making the hole, check carefully that no
studs or pipes are directly run behind the spot to be
cut.
CAUTION
Also avoid areas where electrical wiring or conduits are
located.
The above precautions are also applicable if tubing
goes through the wall in any other location.
2-3/4" (70 mm)
Fig. 9
6
g
(4) Using a sabre saw, key hole saw or hole-cutting drill
attachment, cut a hole in the wall. See Table 4 and
Fig. 10.
Table 4
Hole Dia.
2-9/16" (65 mm)
(5) Measure the thickness of the wall from the inside
edge to the outside edge and cut PVC pipe at a
slight angle 1/4" (6 mm) shorter than the thickness of
the wall. (Fig. 11)
(6) Place the plastic cover over the end of the pipe (for
indoor side only) and insert the pipe in the wall. (Fig.
12)
3-3. Install the Rear Panel on the Wall
Be sure to confirm that the wall is strong enough to suspend 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)
NOTE
Hole should be made at a slight downward slant to the
outdoor side.
Indoor
side
Outdoor
side
Fig. 10
PVC pipe (Locally purchased)
Cut at sli
ht angle
Fig. 11
INSIDEOUTSIDE
Wall
Plastic cover
(Locally purchased)
PVC pipe
Slight
angle
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 the stud locations and then mount the
rear panel.
(2) Double check with a carpenter’s level or tape mea-
sure that the panel is level. This is important to
install the unit properly. (Fig. 14)
(3) Make sure the panel is flush against the wall. Any
space between the wall and unit will cause noise
and vibration.
b) If Block, Brick, Concrete or Similar Type Wall
Make 3/16" (4.8 mm) dia. holes in the wall. Insert rawl
plugs for appropriate mounting screws. (Fig. 15)
Fig. 12
Fig. 13
Fig. 14
3/16"
(4.8 mm) dia. hole
Rawl plug
Fig. 15
7
3-4. Remove the Grille to Install the Indoor Unit
Basically, these models can be installed and wired without
removing the grille. If access to any internal part is needed, follow the steps as given below.
Air intake grille
Grille
CAUTION
Be sure to wear work gloves
during installation to avoid being
cut by the sharp aluminum fins
of the heat exchanger.
How to remove the grille
(1) Grasp both ends of the air intake grille, and remove it
by opening towards the front and pulling towards you.
(Fig. 16a)
(2) Remove the 2 screws. (Fig. 16b)
(3) Remove the screw on the right side cover plate and
open the cover. (Fig. 17a)
(4) Take out the thermistor from the grille. (Fig. 17b)
(5) Pull the lower part of the grille toward you to remove.
(Fig. 18a)
(6) Use a standard screwdriver to push on the tabs to
remove the grille.
How to replace the grille
(1) Reinstall the grille into the lower part while aligning
its tabs on the upper part. (Fig. 18b) Insert the tabs
in the slots and push the lower part of the grille
back into position.
Screw cover
Thermistor
Fig. 17a
Ta b
Fig. 16a
Fig. 16b
Cover
Thermistor
Fig. 17b
*
*
Grille
Fram e
(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, and then insert it all the
way inside. (Fig. 19a)
(b) Press the bottom right and left corners of the air
intake grille to attach it to the indoor unit. (Fig. 19b)
NOTE
Attach so that the round pins at the top right and left corners of the air intake grille are inserted into the grooves at
the top right and left of the indoor unit.
Ta b
Fig. 18a
*
*
Fig. 18b
Groove
Pin
Fig. 19b
8
Fig. 19a
3-5. Shape the Indoor Side Tubing
(1) Arrangement of tubing by direction
a) Right or left tubing
Cut out the corner of the right/left frame with a
hacksaw or the like. (Figs. 20 and 21)
b) Right-rear or left-rear tubing
In this case, the corner of the frame need not be
cut.
(2) To mount the indoor unit on the rear panel:
Hang the 2 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)
3-6. Wiring Instructions
General precautions on wiring
(1) Before wiring, confirm the rated voltage of the unit as
shown on its nameplate, then carry out the wiring
closely following the wiring diagram.
(2) Provide a power outlet to be used exclusively for
each unit, with a power supply disconnect and circuit breaker for overcurrent protection provided in
the exclusive line.
Frame
Left tubing
outlet
Fig. 20
Frame
Right tubing
outlet
Fig. 21
(3) To prevent possible hazards due to insulation fail-
ure, 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 or become
damaged.
(5) Do not allow wiring to touch the refrigerant tubing,
compressor, or any moving parts of the fan.
(6) Unauthorized changes in the internal wiring can be
very dangerous. The manufacturer will accept no
responsibility for any damage or misoperation that
occurs as a result of such unauthorized changes.
Fig. 22
9
3-7. Recommended Wire Length and Diameter
Regulations on wiring diameter differ from locality to locality. For field wiring
requirements, please refer to your local electrical codes. Carefully observe these
regulations when carrying out the installation.
Table 5 lists recommended wire lengths and diameters for power supply systems.
NOTE
Refer to the wiring system diagram (Fig. 23) for the meaning of (A), (B), and (C) in
Table 5.
Refer to your local codes or in the absence of local codes see the National Electric Code: ANSI/NFPA70.
Table 5
(A)+(B)(A) Power Supply Wiring Length (ft)(C) Control
(B) Power Line Length (ft)Line Length (ft)
Model(#14)(#12)(#14)
CH0971, CH1271131 (Max.)230 (Max.)65 (Max.)20A
# ... AWG (American Wire Gauge)
WARNING
WIRING SYSTEM DIAGRAM
Fuse or Circuit AWG
Breaker Capacity
G Be sure to comply with local codes on running the wire
from the indoor unit to the outdoor unit (size of wire and
wiring method, etc.).
G Each wire must be firmly connected.
G No wire should be allowed to touch refrigerant tubing, the
compressor, or any moving part.
WARNING
G To avoid the risk of electric shock, each air conditioner
unit must be grounded.
G For the installation of a grounding device, please
observe local electrical codes.
G Grounding is necessary, especially for units using
inverter circuits, in order to release charged electricity
and electrical noise caused by high tension.
Otherwise, electrical shock may occur.
G Place a dedicated ground more than 7' (2 m) away from
other grounds and do not have it shared with other electric appliances.
INDOOR
UNIT
TerminalTerminal
1
2
3
Disconnect
*
switch
Field supply
(C)
Grounding line
115 V
115 V
115 V
(B)
(B)
OUTDOOR
UNIT
1
2
3
4
5
6
Fig. 23
NOTE
*
Disconnect switch may be required by
national or local codes.
CAUTION
Always comply with national and local code
requirements.
Power supply
(A)
L
N
Grounding
line
Single phase 115V 60HZ
CAUTION
G Be sure to connect 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.
10
3-8. Wiring Instructions for Inter-unit Connections
(1) Insert the inter-unit wiring (according to local codes)
into the through-the-wall PVC pipe. Run the wiring
toward the indoor side allowing approx. 10" (25 cm)
to extend from the wall face. (Fig. 24)
Rear
panel
Wall
Plastic
cover
(2) Grasp both ends of the air intake grille, and remove
it by opening towards the front and pulling towards
you.
(3) Remove the screw on the right side cover plate and
open the cover. (Fig. 25)
(4) Route the inter-unit wiring from the back of the
indoor unit and pull it toward the front for connection. (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.
NOTE
When closing the air intake grille, press on both corners.
(Fig. 27)
Please refer to “How to replace the grille” on page 8 for
installing the air intake grille.
Wiring
10"
(25 cm)
Fig. 24
Cover
Fig. 25
Terminal
plate
Fig. 27
Fig. 26a
Inter-unit
wiring
Earth
plate
Lock nut
Top of conduit
connector
Fig. 26b
11
Screw and
special washer
Ring
connector
Wire
WARNING
Loose wiring may cause the
terminal to overheat or result
in unit malfunction. A fire
hazard may also exist.
Therefore, be sure all wiring
is tightly connected.
When connecting each power wire to the corresponding
terminal, follow the instructions “How to connect wiring
to the terminal” and fasten the wire securely tight with
the fixing screw of the terminal plate.
How to connect wiring to the terminal
a) For Indoor Unit
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the wire about 9/32" (7 mm).
See the label (Fig. 28) near the terminal plate.
(2) Using a screwdriver, loosen the terminal screw on
the terminal plate.
(3) Insert the wire and tighten the terminal screw com-
pletely using a screwdriver.
b) For Outdoor Unit
I For solid core wiring (or F-cable)
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the solid wire about 15/16" (25
mm). (Fig. 29)
(2) Using a screwdriver, remove the terminal screw(s)
on the terminal plate.
9/32"
STRIP
SIZE
(7 mm)
Fig. 28
Solid wire
Strip 15/16" (25 mm)
Insulation
Fig. 29
Stranded wire
Strip 3/8" (10 mm)
(ACTUAL
SIZE)
Loop
Ring
connector
(3) Using the pliers, bend the solid wire to form a loop
suitable for the terminal screw.
(4) Shape the loop wire properly, place it on the termi-
nal plate and fix it securely with the removed terminal 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 terminal plate.
(3) Using a ring connector fastener or pliers, securely
clamp each stripped wire end with a ring connector.
(Fig. 30)
(4) Place the ring connector wire, and replace and
tighten the removed terminal screw using a screwdriver. (Fig. 32)
Wire
Special
washer
Fig. 30
Twist wire ends
Fig. 31
Screw
Ring connector
Terminal plate
Fig. 32
12
3-9. Mounting
(1) To install the indoor unit, mount the indoor unit onto
the 2 tabs on the upper part of the rear plate.
(2) Hold down the air discharge outlet and press the
lower part of the indoor unit until it clicks to securely
fasten to the 2 tabs on the lower part of the rear
plate. (Fig. 33)
NOTE
For tubing, choose either the right or left tubing direction
and follow the steps below. This work can be made easier by placing padding material (such as styrofoam) at the
rear right side of the indoor unit. (Fig. 34)
I Right-side tubing
(1) Shape the refrigerant tubing so that it can easily go
into the wall hole. (Fig. 35)
Push
Fig. 33
(2) Push the wiring, refrigerant tubing, and drain hose
through the hole in 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
18.) 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.
(After performing a leak test on the connecting part,
insulate it with the tubing insulation. (Fig. 37a))
Also, refer to Section 5-4. Connecting Tubing
between Indoor and Outdoor Units.
(5) Assemble the refrigerant tubing, drain hose, and
conduit (including inter-unit wiring) as shown in
Fig. 37b.
Refrigerant tubing
Padding material
Fig. 34
Rear panel
Cover
Refrigerant
tubing
Inter-unit
wiring
Drain hose
Fig. 35
Fig. 37a
Insulation
Conduit
Inter-unit wiring
Fig. 37b
Drain hose
13
Fig. 36
I Left-side tubing
Rear panel
(1) Lead the tubing and drain hose through the wall,
allowing sufficient length for connection. Then bend
the tubing using a tube bender to make the attachment. (Fig. 38)
(2) Switch the drain hose and drain cap.
Switching drain hose and drain cap
(a) Locate the drain hose and the drain cap. (Fig.
39)
(b) Remove the screws fastening the drain hose on
the right side, and pull out the drain hose to
remove it. (Fig. 39)
(c) Apply moderate force to pull off the drain cap
on the left side. (If you cannot pull it off by
hand, use a long-nose pliers.)
(d) Reattach the drain hose to the left side and the
drain cap to the right side. (Fig. 40a)
Drain hose
Slide the drain hose fully onto the drain pan outlet
until the drain hose edge is pushed into the insulation. 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)
Hole in wall
Drain hose
Drain cap
Bent part
Fig. 38
Fig. 39
Wide tube
Narrow tube
Drain cap
Drain hose
Clamp
Drain cap
Use a Phillips screwdriver to push the drain cap in
firmly. (If it is difficult to push in, wet the cap with
water first.)
(3) Install the indoor unit on the rear panel.
(4) Connect the tubing and wiring led inside from out-
doors.
(5) After completing a leak test, bundle the tubing
together with armoring tape and store it inside the
tubing storage area at the back of the indoor unit
and hold it with clamps. (Figs. 40a and 41)
Insulation
Drain bracket
Drain hose
Fig. 40c
Fig. 40a
Screw hole
Drain bracket
Conduit
Drain pan outlet
Drain hose
Screw
Fig. 40b
Refrigerant tubing
Inter-unit wiring
14
Fig. 41
To unmount indoor unit
WARNING
Risk of Electric Shock
Press the 2 LL marks on the lower part of the indoor unit
and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 42)
3-10. Drain Hose
a) The drain hose should be slanted downward to the
outdoors. (Fig. 43)
b) Never form a trap in the course of 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.
Do not supply power to the
unit or operate it until all
tubing and wiring to the outside unit are completed.
Indoor
unit
Push
Fig. 42
Slant
Drain
hose
Insulation material
(Locally purchased)
must be used.
Fig. 43
Condensation
Fig. 44
15
4. How to Install the Outdoor Unit
First refer to Section 2. Installation Site Selection.
4-1. Wiring Instructions for the Outdoor Unit
Regulations on wire size differ from locality to locality. For
field wiring requirements, please refer to your local electrical codes. Make sure that the installation fully complies
with all local and national regulations.
(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 system diagram on panel side.
(5) Be sure to ground the unit according to your local
codes.
Terminal
block
Conduit
plate
Plug
Lock nut
Inter unit
(Conduit)
Cabinet
Access panel “C”
Power supply
(Conduit)
Fig. 46
16
5. Refrigerant Tubing
Flare nut
Union
5-1. Use of the Flaring Method
Many of the conventional split system air conditioners
employ the flaring method to connect refrigerant tubes
which run between indoor and outdoor units. In this
method, the copper tubes are flared at each end and
connected with flare nuts.
5-2. Flaring Procedure with a Flare Tool
Before
Deburring
After
(1) Cut the copper tube to the required length with a
tube cutter. It is recommended to cut approx. 12" to
20" (30 to 50 cm) longer than the tubing length you
estimate.
(2) Remove burrs at the end of the copper tube with a
tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 47)
NOTE
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 48)
(3) Remove the flare nut from the unit and be sure to
mount it on the copper tube.
(4) Make a flare at the end of copper tube with a flare
tool.* (Figs. 49a and 49b)
(*Use “RIGID” or equivalent.)
NOTE
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.
If the special R410A
flare tool is used:
0 to 0.0196"
(0 to 0.5 mm)
Fig. 47
Copper
tubing
Reamer
Fig. 48
If the previous flare tool
(clutch-type) is used:
0.0472" (1.2 mm)
Adjust so that the amount of tube
protrusion is as shown in the figure.
Fig. 49a
Flare nut
Copper
tubing
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 lubricant to the match-
ing surfaces of the flare and union before connecting them together. This is effective for reducing gas
leaks. (Fig. 50)
c)For proper connection, align the union tube and
flare tube straight with each other, then screw in the
flare nut lightly at first to obtain a smooth match.
(Fig. 51)
Flare tool
Fig. 49b
Apply refrigerant
lubricant here and here
Fig. 50
Fig. 51
17
5-4. Connecting Tubing between Indoor and
IMPORTANT
Clamp
Insulated tubes
Outdoor Units
a) Tightly connect the indoor side refrigerant tubing exten-
ded from the wall with the outdoor side tubing. (Fig. 52)
b) To fasten the flare nuts, apply specified torque as:
To prevent heat loss and wet floors due to dripping of condensation, both tubes must be well insulated with aproper insulation material. (Fig. 53)
The thickness of the insulation should be a minimum 5/16"
(8 mm). (Fig. 54)
5-6. Taping the Tubes
CAUTION
After a tube has been insulated, never try to bend it into a
narrow curve, as this may
cause the tube to break or
crack.
Min.
5/16"
(8 mm)
Outdoor unit
Fig. 52
Insulation
Fig. 53
Insulation
Thickness:
min. 5/16"
(8 mm)
Fig. 54
(1) At this time, the 2 refrigerant tubes (and electrical wire
if local codes permit) should be taped together with
armoring tape. The drain hose may also be included
and taped together as 1 bundle with the tubing.
(2) Wrap the armoring tape from the bottom of the outdoor
unit to the top of the tubing where it enters the wall. As
you wrap the tubing, overlap half of each previous tape
turn. (Fig. 55)
(3) Clamp the tubing bundle to wall, using 1 clamp approx.
every 47" (120 cm).
NOTE
Do not wind the armoring tape too tightly, since this will
decrease the heat insulation effect. Also, be sure the condensation 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 tubing, use
sealing putty to seal off the hole in the wall to prevent rain
and draft from entering. (Fig. 56)
Fig. 55
Apply putty here
Tubing
Fig. 56
18
6. Air Purging
Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below. Therefore,
they must be purged completely.
G pressure in the system rises
G operating current rises
G cooling (or heating) efficiency drops
G moisture in the air may freeze and block capillary tubing
G water may lead to corrosion of parts in the refrigerant
system
I Air Purging with a Vacuum Pump (for Test Run)
(1) Check that each tube (both narrow and wide tubes)
between the indoor and outdoor units have been
properly connected and all wiring for the test run
has been completed. Note that both narrow and
wide tube service valves on the outdoor unit are
kept closed at this stage.
Indoor unit
Outdoor unit
(2) Using an adjustable wrench or box wrench, remove
the valve caps from the service valve on both narrow and wide tubes.
(3) Connect a vacuum pump and a manifold valve (with
pressure gauges) to the service port on the wide
tube service valve. (Fig. 57)
CAUTION
The service port on the wide tube
service valve uses a Schrader core
valve to access the refrigerant system. The valve core is similar to
those used in automobile tires.
Therefore, be sure to use a vacuum
hose connector which has a pushpin inside.
CAUTION
Be sure to use a manifold valve
for air purging. If it is not available, use a stop valve (field supply) for this purpose. The “Hi”
knob of the manifold valve must
always be kept closed.
(4) With the “Lo” knob of the manifold valve open, run
the vacuum pump. The operation time for the vacuum pump varies with tubing length and the capacity
of the pump. The following table shows the amount
of time for evacuation:
Manifold valve
(Exclusively for R410A)
Pressure
gauge
Vacuum pump
HiLo
Charging hose
(Exclusively for R410A)
Vacuum pump adapter
(Exclusively for R410A)
(with reverse flow prevention)
Fig. 57
NOTE
To prevent other refrigerants from being mistakenly
charged to units which use R410A, the size of the
charge port on the service valve is different from the
one for other refrigerant types. For servicing such as
recharging, the specified charging hose, manifold and
vacuum pump adapter (with reverse flow prevention)
for R410A must be used.
Table 7
Required time for evacuation when
100 liter/h vacuum pump is used
If tubing length isIf tubing length is
less than 33 ft. (10 m)more than 33 ft. (10 m)
10 min. or more15 min. or more
NOTE
The required time in Table 7 is calculated based on the
assumption that the ideal (or target) vacuum condition
is around 10 mmHg abs.
19
(5) With the vacuum pump still running, close the “Lo”
knob of the manifold valve. Then stop the vacuum
pump.
(6) With the accessory hex wrench, turn the valve stem
on the narrow tube service valve counter-clockwise
by 90 degrees (1/4 turn) for 10 seconds, and then
turn the stem clockwise to close it again. (Fig. 58)
90° (1/4 turn)
Narrow tube
Hex wrench
Wide tube
CAUTION
Be sure to completely insert
the hex wrench before
attempting to turn the valve.
(7) Leak test all joints at the tubing (both indoor and out-
doors) with soapy water. Bubbles indicate a leak. Tighten the joint more when leaks, then check if there is no
leak. Be sure to wipe off the soap with a clean cloth.
(8) With the hex wrench, turn the wide tube service
valve stem counter-clockwise to fully open the valve.
(9) Turn the narrow tube service valve stem counter-
clockwise to fully open the valve.
(10) Loosen the vacuum hose connected to the wide
tube service port slightly to release the pressure.
Then, remove the hose.
CAUTION
This may cause the refrigerant gas to leak. In order to
avoid this, take off the hose
quickly.
Valve cap
Vacuum hose to manifold valve
Fig. 58
(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 air conditioner is running, apply liquid
soap to check for any gas leaks around the service
valves or caps.
(14) If there is no leakage, stop the air conditioner.
(15) Wipe off the soap on the tubing.
This completes air purging with a vacuum pump and the
air conditioner is ready for actual operation.
20
How to Test Run the Air Conditioner
IMPORTANT
After turning on power to the air conditioner, use the remote
controller and follow the steps below to conduct the test run.
(1) Set the remote controller in Test Run mode.
(Fig. 59a)
a) Press and hold the ION button.
b) Then press and hold the 1HR TIMER button.
c) At the same time, press the ACL (reset) button once.
Use a pointed object such as the tip of a pen to press
the ACL button.
• After a few seconds, “” appears and “oP-1” blinks in
the remote controller display area.
(Fig. 59b)
d) Release the 1HR TIMER button.
e) Release the ION button.
(2) Start Cooling mode test run by pressing the ON/OFF
operation button of the remote controller. (Fig. 59a)
• This starts the fan producing uncooled forced air with
the 4 indicator lamps (OPERATION lamp, TIMER
lamp, QUIET lamp, and ION lamp) on the main unit
blinking. (Fig. 59c)
• After 3 minutes, the system shifts into cooling operation, 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 normal mode. (Fig. 59a)
• “” and “oP-1” will disappear from the remote controller display area.
ION
button
A
Fig. 59a
ON/OFF
operation
button
1HR.
TIMER
button
ACL
(Reset)
button
NOTE
Troubleshooting:
In the event that the green “Operation Light” is blinking upon
powering up the system, an error condition exists. In this
case, refer to the self-diagnostics procedure on the
inside of the front cover.
After the test run is completed, be sure to press the
ACL (reset) button to return to normal mode. The
air conditioner will not operate correctly if this is not
done.
Fig. 59b
OPERATION lamp
TIMER lamp
QUIET lamp
ION lamp
Fig. 59c
21
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