Pioneer KFDH125, KFDH150, KFDH75, KFDH100, KODH75 Installation, Operation & Maintenance Manual

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Installation, Operation & Maintenance Manual

Split System , Cooling Only

KODH

IOMES--2013

KFDH

5000 - 150000 BTU

TIMER SLEEP

HIGH

LOW

MED

TEMP

AUTO

DRY

FAN MODE

COOL

ON/OFF

FAN HEAT

1. Safety Precaution

2. Indoor Unit Installation

2.1 Outline dimensions, Installation location

2.2 Service Space

2.3 Installing the indoor unit

2.3.1 Unit suspension

Contents

Safety Precaution

Before installing the unit, make sure you read all the “Safety precautions”.

Warning:

Describes precautions that must be observed to prevent danger of injury or death to user.

Describes precautions that must be observed to prevent damage or malfunction of the unit.

Caution:

Notice:

• Installation and maintenance should be perform

-ed by qualified personnel.

• Avoid direct contact with sharp edges and coil surfaces

• Ensure the condensate drain pipe is properly installed.

• DO NOT overcharge the equipment

• Avoid long piping installation

• The equipment installation and electrical work must comply with local codes and regulations.

• The unit must be securely installed on structure that can sustain its weight.

• If installed in a small room, measures must be taken to prevent refrigerant concentration exceeding the safety limit in case of gas leak.

Warning:

Caution:

• After installation , check for the system leaks. DO NOT use Oxygen, Acetylene, poisonous or any flamable gas for the leak test.

• End user should not attempt to repair the unit in case of malfunction or failure.

• This manual should be read carefully before installation. Unit installation and service should be performed by experienced technicians in accordance with manual’s procedures to achieve normal and reliable unit operation.

• This manual should be kept and returned to unit’s designated place after installation is completed for reference.

2.3.2 Drainage pipe

3. Outdoor Unit Installation

3.1 Outline dimensions, Installation location

3.2 Installation Space & cleatance

3.3 Installing the outdoor unit

4. Refrigrant Piping connection

5. Vaccuming and Charging

4.1 Piping length

4.2 Piping connection

5.2 Refrerant Handling

6. Electrical Wiring

7. Controller Operation

8. Test Run

9 Service and Maintenance

10 Trouble Shooting

2.1 Outline Dimension, installation location

Indoor Unit Installation

476

1376

Control Box

1600

1541

885

412

255

773

850

130

745

Drain Pipe 1”

φ15

1502

1268 81

396

1402

973

297

562

437

761 605 96

214

Fig 2-1-1 KFDH75,100

Fig 2-1-2 KFDH125,150

• Select a location where air can be distributed to all corners of the room.

• Make sure no obstruction to return and dischage

air.

• Avoid installation at the following location:

- area where flamable gas may leak or generate

- places where unit is frequently expl=osed to corrosive gas, or acidic solutions.

Warning:

•The unit must be securely installed on structure that can sustain its weight.

2.2 Service space

Fig 2-2

Min. 800mm

• Make sure sufficient space for service and maintenance (Fig 2-3).

2.3 Installing indoor unit

2.3.1 Unit suspension

Indoor Unit Installation

Outdoor Unit Installation

• Use the hanging rods to hang the unit through the holes provided. Strength of hanging rods must be able to support the total weight of the unit.

• Add isolator, absorber , if necessary , to minimiz

e the vibration transmission to the ceiling.

2.3.2 Drain pipe

• Drain pipe shall be properly installed for the drainage for the drainge of condensate water.

• Trap shall be installed (See figure 2.3)

• Make sure no leak at the connecting joint.

Trap

• Insulate the drain pipe to avoid water condensati

on.

Model A B

3.1 Unit dimensions , Installation location

Liquid Line

Gas Line

• In order to optimize capacity, unit shall be installe

d as recommended requirements : a) Allow sufficient space around the unit, to avoid the recirculation of the hot discharge air. b) Ensure no obstruction air flow into or out of the unit. c) The location which is well ventilated. d) A place protected from direct sunlight, use an awning for protection, if necessary. e) A place where the hot air discharge and operating sound level will not annoy the neighbours. f) A place must not be susceptible to dust or oil mist, or other corrosive chemicals

Caution:

• Avoid installing at location containing oils (including machine oils), salt (coastal area), sulphide gas (near hot spring, oil refinery plant), corrosive chemicals etc.

OBR15x35

1156

1220

1160

985

8x 50

700

143

275 70

143

Fig 3-1 KODH

3.2 Installation space and clearance

3.3 Installing the outdoor unit

Outdoor Unit Installation

Unit can be installed based on following :

Orientation 1 : 2 X KODH75 to 150 Orientaition 2: 4 X KODH75 to 150.

Front

3.3.1 Unit lifting

• Holes at the unit base are for the lifting purpose. Belt shall be used for the lifting. Make sure the belt is able to withstand weight.

• The length of the belt shall be adjust properly, in order to prevent the imbalance of the unit when lifting.

3.3.2 Unit Support

• Unit shall be placed on a secured base, on slab, curb or steel frame.

• Absorber should be installed to absorb the unit vibration during operation

slab/ curb

absorber

4.1 Piping Length

Refrigerant Piping Connection

Vaccuming, Charging & Refrigerant Handling

• .Long refrigerant piping will affect the performance of the unit and shorten the lifespan of the compressor. In the worst case scenerio, it will cause the compressor to break down. Piping length should be as short as possible

• Special precautions must be taken when there is

no choice but to use longer pipe lengths.

The following table shows the recommended piping length limits

• Accumulator is recommended to be added for any

installation more than 32m in length

4.2 Piping Connection

• To ensure satisfactory operation and performance, the following points should be noted for the field tubing arrangements of the complete refrigerant cycle.

• Liquid loops or oil traps must be provided according to the position of the outdoor and the indoor units (depends on , whether the indoor unit is located above or below the outdoor unit).

• Filter dryer and sight glass (field supply) must be

installed, Sight glass shall be installed after the filter

drier at the liquid line.

• Pipe shall be installed following tthe size listed in Fig. 3.1

• Leak test shall be carried out after braze connecti

on.

• Both indoor and outdoor are brazed connection.

Warning:

• Make sure there is no flammable gas at the surrounding before the brazing work started.

Warning:

• DO NOT charge in flammable gas.

Caution:

• During the preparation, piping shall be properly covered to avoid the containmination of the system.

• The system shall be thoroughly vaccumed to 1.0 P

a (700mmHg) or lower,to remove the moisture and

dust from the system.

• The proper refrigerant charge should follow the vo

lume as recommended by manufacturer. For system optimization, refrigerant should be carefully added to the system until reasonable sub-cooling is measured in the liquid line and reasonable suction superheat is measured at the compressor suction. Suction and discharge pressures must be monitored carefully during the charging process.

• ADDITIONAL CHARGE when the piping connecting length is exceeding th

e standard 7m, extra charge shall be added

Based on liquid pipe size per meter length:

Model

Max. Length

(m)

Max. Height

(m)

Maximum number of

bends allowed

KODH 75-150 35 20 10

Caution:

Liquid line size Kg 1/2” 0.10 5/8” 0.17

Note: Above is the recommendation, actual charge level may be different due to the different application and ambient condition.

5.2 Refrigerant Handling

Vaccuming, Charging & Refrigerant Handling

Electric Wiring

• Special Precautions When Dealing with Refrigerant R410A Unit

• Mixture of composition by weight : R32(50%) and

R125(50%)

5.2.1 Components

5.2.2 Characteristic

• R410A liquid and vapor components have different compositions when the fluid evaporates or condenses. Hence, when leak occurs and only vapor leaks out, the composition of the refrigerant mixture left in the system will change and subsequently affect the system performance. DO NOT add new refrigerant to leaked system. It is recommended that the system be evacuated thoroughly beforerecharging with R410A.

• When refrigerant R410A is used, the composition will differ depending on whether it is in gaseous or liquid phase. Hence when charging , ensure that only liquid is being withdrawn from the cylinder or can. This is to make certain that only original composition of R410A is being charged into the system.

• POE oil is used as lubricant for R410A compresso

Extra precaution must be taken to avoid exposing the R410A system to moist air.

5.2.3 Handling and Installation Guidelines

• All precautionary measures; such as ensuring no

moisture, no dirt or chips in the system, clean brazing using nitrogen, and thorough leak check and vacuuming are equally important requirements. However, due to its hydroscopic POE oil, additional precautions must be taken to ensure optimum and trouble-free system operation.

• During installation or servicing, avoid prolong exposure of the internal part of the refrigerant system to moist air. Residual POE oil in the piping and components can absorb moisture from the air

• Ensure that the compressor is not expose to open

air for more than the recommended time specified by its manufacturer (typically less than 10 minutes). Removed the seal-plugs only when the compressor is about to be brazed.

• When charging R410A, ensure that only liquid is being withdrawn from the cylinder or can. This is to ensure that only the original composition of R410A is being delivered into the system. The liquid composition can be different from the vapor composition.

• Entire unit wiring diagram.

Caution:

• Field-installed wirings must comply with local codes and regulations. Voltage tolerance should be kept at rated voltage ±10%.

• Check if the main power supply matches the nameplate rating before installation takes place.

• Each air-conditioning unit should be installed with independent circuit breaker (Field installed)

• Unit must be properly GROUNDED.

ower supply

ircuit Breaker (field supply)

Power supply wiring for unit

ndoor unit

outdoor unit

Wired remote controller

Unit interconnecting wire

Earthh.

a a

Note: 75/100

Electric Wiring

• Recommended field installed wire size.

75 100 125 150

Indoor

Outdoor

Wiring wire No. × size Indoor

(mm2) Outdoor 5 × Min. 4 mm2 5× Min. 8mm2

Interconnectiong wire, No x size

1 x 1.5mm2

3 × Min. 1.5 mm2

Power Supply

380~415V/3ph/50Hz ~N 380~415V/3ph/50Hz ~N

5× Min. 1.5 mm2

5× Min. 6mm2

220~240V/1ph/50Hz ~N

380~415V/3ph/50Hz ~N

Model

TB2 (C)

Blue

Brown

OLP

95 96

OLP

MF2

(1)

(2)

(3)

Fuse 3.15A

TB1

L1 L2

N E

LIVE

COMP

X1X2X3

HIMED

LOW

HANDSET

TR TR

ID COIL SENSOR

ROOM SENSOR

TB3 (C)

TB3

MF1-1 MF1-2

TB2 (C)

Blue

Brown

OLP

95 96

OLP

MF2

(1)

(2)

(3)

Fuse 3.15A

TB1

L1 L2

N E

TIMER SLEEP

HIGH

LOW

MED

TEMP

AUTO

DRY

FAN MODE

COOL

ON/OFF

FAN HEAT

TIMER SLEEP

HIGH

LOW

MED

TEMP

AUTO

DRY

FAN MODE

COOL

ON/OFF

FAN HEAT

MF1

IFC

LIVE

COMP

X1X2X3

HIMED

LOW

HANDSET

TR TR

TB3 (C)

ID COIL SENSOR

ROOM SENSOR

IFC

OLPF

TB3

L1 L2

Wiring Diagram : KFDH/KODH 75,100

OLP

95 96

Wiring Diagram : KFDH/KODH125/150

Controller Operation

The controller supports the following functions: a) Mode：Cool, Dry, Fan, Heat b) Indoor fan speed：Auto, High, Medium, Low (* For 75/100 model only) c) Sleep mode d) Compressor protections:-

1. Comp 3 minutes restart protection

2. Indoor coil anti freeze

e) Room sensor and indoor coil sensor failure monitoring. f) Non volatile memory – keep system settings g) Programmable On/Off timer h) Random restart to minimize voltage dip during compressor first cut in cycle upon power up.

2） Hardware setting A 2 way DIP switch, default setting as SW1 on, SW2 off. CAUTION: DON’T CHANGE THE SETTING.

3) Power Up

Upon power up, system will retrieve the most recent settings and system status from the non volatile memory as below:-

a) Mode e) Key lock status b) Set temperature（F or C） f) System status（On/Off） c) Fan speed g) Temperature display option d) Sleep

The above setting can be changed via wired control panel or remote handset. The latest settings will be recorded into the memory. Should the data in the non-volatile memory were inva

lid, system will start with the default settings as follow:a) System status - Off d) Mode-Cool b) Fan speed - High e) Key lock – off c) Set temperature - 24 f) Temperature display- set temperature

4） Programmable Timer Upon count down of the number of set hours, the sys

tem will switch from Off to On or On to

Off depending on its current status.

4） Programmable Timer Upon count down of the number of set hours, the system will switch from Off to On or On to Off depending on its current status.

5） Sleep mode (Set temperature will be increased)

Hour

Sleep on

0.5

Sleep off

Ts+0.5

Ts+1.0

Ts+2.0

Controller Operation

8） IR reception System receives commands from handset.

9） Cool mode In Cool mode, compressor will cut in if Tr - Ts >= 0.5°C and cu

t out if Tr - Ts =< (-1.0)°C, subject to 3 minutes protections and minimum run time. Indoor fan speed can be manually selected or determine by the system in Auto Fan speed according to the return air temp.

10） Dry mode Indoor fan runs at low speed. Compressor will cut out if: a) It has run for 10 minutes continuously or b) Tr - Ts =< (-1.0)°C It is then allow to cut in if: a) It has stop for 5 minutes and b) Tr - Ts >= 0.5°C

11） Fan mode Only High, Medium and Low speed selection is allowed (KFDH075,100 only) .

12） Error code

If multiple faults happen at the same time, the corresponding error code will be shown one after another.

13） Off mode All output are off during system off state except indoor fan which are subject to the minimum operating time guard where applicable.

6）Compressor protection a) Comp restart protection

1. 3 minutes protection

2. Hardware Anti short cycle timer Should the power supply is cut off and resume, compressor 3 minutes protection control logic is as below:-

7）Temperature sensor fault a) Return air sensor

Monitor continuously

b) Indoor coil sensor

• If comp is turned on, monitoring is done 5 minutes after comp running.

• If comp is stop, monitor continuously Upon happening of any sensor fault, system is forced to Fan mode. It will then resume to normal mode upon clearance of fault.

b) 90S minimum run time (compressor) c) Indoor coil anti freeze

Power outage duration Restart protection timer

<180S 180S— 243S

>180S

< 63S

Fault Error code Room sensor fault E1 Indoor coil sensor fault E2 Comp fault E4

Controller Operation

14）Control Panel

a) On/Off

To turn on/off the unit. .

b) Mode

ess mode key to change operating mode as follow:

Cool only mode Cool -Dry-F an

c) F an spee d

ess Fan key to select: Auto-High-Medium-Low. Fan key is invalid in Dry mode.

d) Sleep

ess Sleep key to toggle sleep mode. Sleep key is invalid in Fan Mode

e) Temperature

Temperature setting is 16C to 30C or 60F to 85F. Hold down Temp Down and Fan keys at the same time for about 5S will toggle the setting from degree C to degree F and vice versa. Temp keys are invalid in Fan mode.

) Timer

Timer setting is 1HR—24HR. First key pre

ss will flash the digital display and timer LED

for 3S. The display shows the number of c

ount down hours left. Subsequent 3S will show the number of hours previously set, only the timer LED flashes. Should there be no further key press, it will revert to normal mode. Should Timer key is not released, timer setting will incremented automatically every 0.5S.

TIMER SLEEP

HI GH

LOW

MED

TEMP

AUTO

DRY

FAN MODE

COOL

ON/OFF

FAN HEAT

g) Key lock Hold down Temp Down and Mode keys for 3S to activate key lock mode, similarly to unlock. In key lock mode, the following keys are valid：

. On/Off- to turn on/off the unit

2. Hold down Temp Down and Sleep button for 1S to enter into coil temp display mode. Press Temp Up key to display indoor coil temp, High Fan LED flashes. Press Temp Down key to display outdoor coil temp, Medium Fan LED flashes. With the same sequence to exit coil temp display mode. Temperature display range is –9C to 78C.

3 .Hold down and buttons for 1 second to activate temperature display setting and auto fan LED flashes. Repeat the same sequence to cancel this function. Press or button to change the setting from 1～2

. “1”

means disable room temperature display and “2” means enable room

temperature display.

FAN

Controller Operation

15）Phase Protector/ Phase Failure Relay

13）Other Protection Device

Phase protector is installed on each condensing unit. Function of phase protector

1. Phase reversal

2. Over or under voltage

3. Multiple type of fault auto recovery and lock function

Hardware Configuration There is a 8 way DIP switch to program the 3 phase monitor according to the table below:

When there is fault occurred, red LED will blink according to the following error code: Fault Error code

Over current protector (OLP), High pressure switch and low pressure switch are installed for compressor protection. When activated, compressor will be cut off, E04 will be displayed on the handset. The error can be only be reset by cut off the main power supply and restart. Check the system accordingly.

For unit with single speed motor , over current protector (OLP) is installed. When activated , the power to the board will be cut off. To restart , reset the OLP. Check on the airflow / external static of the unit.

DIP setting has been default set. User only recommended to set SW7 SW8 to local Voltage supply. (Default setting 00 – 380V)

“0” – off “1” - on Upon power up, the controller will blink the red LED quickly indicating at warm up stage. This process may take a few seconds [0~20 sec depends on the voltage supply and monitor settings]. Red LED will be off once the power supply is stable. Green LED and relay will turn on 5 sec later. Should the controller is unable to read the healthy 3 phase supply after 20 seconds, it will lock the error and flash the red LED according to the alarm code. It will check the power supply again 280 sec later. Upon confirmation of healthy 3 phase supply, system will monitor the power supply constantly according to the DIP switch settings. Should there be failure occurred, system will flash the red LED slowly until the error delay time out and relay will be turn off. If the power supply is recovered before the error delay time out, red LED will be off and system operate as normal. System will lock the error if this failure happens ? 5 times within 2 hours. This fault can be reset by manually turn off the power supply only.

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

Fault time delay Voltage

tolerance

served Voltage

asuring

phase input

－5sec

－10sec

10 －15sec 11 －20sec

00－5％ 01－10％

10－15％ 11－20 ％

0－M

onitor

1－Bypassed

0－380V

1－400V

0－415V

1－440V

To select time

delay to confirm

ault

eck according

SW7 SW8 setting

en set to ‘1’,

no under / over vo

ltage

ecking

ll be done.

en set to ‘1’,

under / over voltage

checking will be done

Over voltage Blink 8 times, off 3 sec Under voltage Blink 7 times, off 3 sec

R phase failure Blink 6 times, off 3 sec

S phase failure Blink 5 times, off 3 sec

T phase failure Blink 4 times, off 3 sec

Phase reversal Blink 3 times, off 3 sec

Test Run

8.1 Pre Start Check list

8.2 Test Run

The following should be checked before the unit is ready for operation:

• All operating personnel read the manual carefully.

• Unit has been installed according to manufacturer’s specifications, local codes and regulations.

• Power supply is in accordance with the nameplate ratings.

• Field-installed wiring is according to manufacturer’s wiring diagram.

• Field wiring and protection device are correctly sized and installed.

• Unit’s power supply and controls are properly connected and unit is properly grounded.

• Unit is properly isolated from vibration (i.e. unit isolation pad, hose kits)

• Unit is serviceable. (Sufficient clearance space has been provided)

• Piping system is clean, properly installed and free of leakage.

• Condensate water drainage pipe is not blocked, free of leakage.

• Air duct (if necessary) is correctly sized, insulated and installed.

• Ensure no debris in drain pan, blower filters and casing.

• Blowers are free to turn, filters are properly installed.

1. Turn on the power supply.

2. Check on the power health by refering the phase protector light display on the condensing unit.

3.. Fan Test Press the ‘on’ button on the control panel. Select Fan mode. For KFDH 75/150 Press the High - Medium -Low button to check on the change of fan speed For KFDH125/150 , check the blower rotation, if reverse rotation , switch the 2 phase for the 3phase supply wire.

4. Room Themostat Cut-in Test. witch to cooling mode, change the setting temperature lower than room temperature. Eg Ts (23DegC) < Troom (25 degC), Compressor will start to run.

5. Room Thermostat Cut-out test. Change the setting temperature higher than room temperature. Eg Ts (26DegC) > Troom (25 degC), Compressor will stop.

6. Finally, set the required temperature with control panel.

Service & Maintenance

Item Maintenance Procedure Frequency

Remove any dust adhered on the filter by using a vacuum cleaner or wash in lukewarm water (below 40°C) with neutral cleaning detergent Rinse well and dry the filter before placing it back onto the unit.

Do not use gasoline, volatile substances or chemical to clean the filter.

Clean any dust or dust on the grille or panel by wiping it using soft cloth soaked in lukewarm water (below 40°C) with neutral cleaning detergent

Do not use gasoline, volatile substances or chemical to clean the unit

Check and remove any dirt clogged between fins.

Check and remove any obstacles that hinder air flowing into and out of the unit.

Check the voltage and current of the indoor unit.

Check the electrical wiring for any faulty contacts caused by loose connections, foreign matters, etc.

Tighten the wires onto the terminal block if necessary

Drain pan & pipe

Check its cleanliness and clean it if necessary. Once every 3 months

Fan &Motor Check for any abnormal noise. Only when necessary.

Power supply

Every 2 months

Air Filter

External panel surface

Once every 2 weeks. More frequently if necessary

Coil

Monthly

Warning:

Caution:

• Disconnect power supply before servicing

• Do not place flammable objects close to unit, when the unit is operating.

• Do not attempt to disassemble or repair the unit upon unit operation failure. Contact your nearest dealer immediately.

• Disconnect main power supply when the unit is not operating for long period of time Unit should be heated up for 24 hours before operating if it has not been operating for long period of time.

• Do not switch On/Off of the controller too frequent or in short interval time.

• Do not damage coil fins.

• Do not operate the unit at cooling mode when outdoor ambient below 20°C, this might causes failure to compressor.

Trouble Shooting

Problem Cause Trouble Shooting/ Remedy

The power supply is turned OFF. Turn the power supply ON.

The fuse in the PCB is gone or blown. Replace fuse.

Running at low (model 75/100) Switch to high mode

Reverse rotation (model 125/150) Swtich the phase for power line

The set temperature is higher than room

temperature

Lower the set temperature.

The room temperature is excessively low for cooling

Can not operate as it is out of temperature control range.

If error code E4 on control panel.

a Phase protector open (condensing unit) refer to 7-13

b High pressure switch open Contact your dealer

c Low pressure switch open Contact your dealer

d comp overload protector open Contact your dealer

The unit is just started the cooling mode Wait for a while

High infiltration through door, windows Close the door ,windows

High infiltration through door, windows High infiltration through door, windows

Air flow too high Change fan speed

Drain pipe is cloagged, water overflow Clear the drain pipe

Cooling , but not cold enough

Water discharge from

the unit

Unit cannot operate

In case of malfunction, perform the following preliminary check , before asking for repair service.

Air flow too small

At Cooling Mode, no

cold air is delivered

Pioneer KFDH125, KFDH150, KFDH75, KFDH100, KODH75 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual