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AUX, Pioneer. Air conditioner service manual,

1. indoor Unit Electric Chart Fan Meter Srem Meter D Eek Indication Panel FII 7 LIII LU Fa a an E 6 Transformer eed Auto Burton ERES Controlling Panel E Current Transducer men ee P Power pluq a aa E Yell Hear Pump Type sud musta d dn For Series Of 7000 120008Btu h SS enger duce Indoor Unit Electric Chart Te utdeer Unir Far Meter Step Morar Receiver indtesti Enel ndicatian Panel t 5 C C Transformer bx Ad Auto Button pee LOT POLLING anal E dls P Tos Power plug 3 na us TT T Red Black ed ooling ype z a c 2 T t For Series Of 70001 1200 0Btu h RE uu Ta Out OI Umit 169 Pioneer air conditioner service manual 2 Outdoor unit Black Fan Motor Fan Motor Re d Ca pac it or Brown Orientation White Valve Over curr ent Protector Co mpressor Black Black Blue Blue Hed Red Yellow Y Ilow Gree n Compressor Capacitor A 1 2 4 5 Y G Red Bac k pn Blue Brown To Indoor Unit Black Fan Motor F
2. CNIO ln CCC d j TJC2A 2A IC3 104 63 0 1u 250 K 4 8 A0Vcc D p 7 D 7 ATWP ES 4 5 10 102 63V DJR p 1N4007 HGQ gt Z N 2 MOC3021 if Mz OMP 0057U CN6 ES A 3 EE 2 e 8GND Er display ULN2003A 14 vec 104 63V HQC BUZZER 4K P20 ANED6 POG P21 ANEDS5 P05 NijpiAa SISA Ea RIY RIS 10k 22k ZA Bus 1 122 il OEO R20 RI6 10k 22k 21 yA A 5 iaAbyi SI S 112DM3 RY3 Six Era 15 R21 R17 10k 22k 100 24 R5 3 Xout LED9 P31 rid Vss LEDS P30 Ha R22 R18 10k 22k xi 4 M37544 E p R34 R35 10k 22k PIPE B ST S 112DM m RYS 15 4AWVO 14 WFAN Rig 22K 4 13 RES Ry 22K 6 ic i 2 av T2VEHSA e E dur gt ULN2003A 12 ES A yuc SpN O 104 67 00U 25V 4 00 P VCC IC2 D2 Ds 12V L7805CV ST D s Lbs LN40071 cus eos NOR Livin Vout vee PS m a 3 ES 35 cHUS0 1050 900 S ea AR 0 uexe OK 12K 12K la SS 8 e 103 63V 1 E3 i D4 2200 2 1000U 25V XH 3A R 1N4007 104 63V 104 63V Title Size Number Revision A3 Date 19 Jan 2006 Sheet of File _G AUl v l Uw OPRA BIET EGEOD YA 1 2 3 4 5 6 7 8 233 Pioneer air conditioner service manual APPENDIX 3 Conversion Table of Major Units 1 Conversion Table of Pressure Units 1 02 X
3. No Chinese Name Name Material Number l HR eH E Panel 1 2 Zi ER Pd Anti bacterial Filter 2 3 YE C pi os WE PI Vitamin C amp Anti mites Filter 2 4 iy PY H EF Filter 2 5 WAT n Screw cover 3 6 rPE ni Cover of medium frame 1 7 HEH fF Medium frame 1 8 FT Horizontal air blade 1 9 FKF Vertical air blade 2 10 FM Air blade holder 1 11 zh BELA HE Step motor 1 12 ti Vi UH ZH TE Indoor fan 1 13 SAA JE Rubber bearing 1 14 PAS LAR Left plastic crutch for evaporator 1 15 PICA Bh Hl Evaporator 1 16 JER BE ZH fF Chassis 1 17 HRA Mounting plate 1 18 E ER Hsc Tube clamp plate 1 19 XB HAL ZL LF Indoor fan motor 1 20 FEL zi Cover for indoor fan motor 1 21 d ix Electric controller box 1 22 ZEI d Transformer 1 23 ZE AE aS Plastic temperature sensor 1 24 ERR Main PCB 1 25 A ed Copper temperature sensor 1 26 Xi PE as pe AR Signal receiver holder for 1 Remote controller 27 Um PETAR XR Temperature sensor holder 1 28 PEUT Receiver board 1 29 bin TAR Terminal board 1 30 foc T EEG Negative ion generator 1 31 YE PRE Connection cable 1 32 ys xe He k Interconnection cord 1 33 FH ZE Power supply cord with plug 1 34 TRA BE Indication lamp holder 1 35 Ni ZAR Display board 1 36 ta NAT T Indication lamp board 1 37 UAE Remote controller 1 106 Pioneer air conditione
4. No Chinese Name Name Material Number l Tir bc Vol EE Steel grille 1 2 Ti te ZH 4 Front panel 1 3 Toi ss x Top cover board 1 4 Ait XU Outdoor fan 1 3 5 BL Outdoor fan motor 1 6 HHLA Motor bracket 1 7 Abit as AF Condenser assembly 1 8 Ao ERE VE Condenser gas inlet tube 1 9 EME HI Capillary assembly 1 10 EEES Backside steel grille 1 11 Hir nt DX Handle 1 12 Ay MK Right side plate 1 13 HOS Capacitor clamp 1 14 IIS Fan motor capacitor 1 15 Hd LAE Compressor capacitor 1 16 bri FAX Terminal board 1 17 Has Ae Electrical holding plate 1 18 fi px vr x Partition plate 1 19 VU i amp i x Electromagnetic loop 1 20 MEE HALF Four way valve and capillary 1 assembly 21 HA p Le pe k Compressor connection cord 1 22 Hd B LB Hh 2E Compressor grounding cord 1 23 I di e Compressor terminal cover 1 24 OER d Over load protector 1 25 Hat Compressor 1 26 SE IZA A Liquid valve 1 27 AUE REMF B Gas valve 1 28 EA Valve plate 1 29 ERA Chassis 1 100 Pioneer air conditioner service manual 2 KFR25 EC Indoor unit exploded picture 101 Pioneer air conditioner service manual Detailed part list of KFR25 ET indoor unit No Chinese Name N
5. No Chinese Name Name Material Number 1 Tp ZA E Panel 1 2 Alm 3k E BUREN Screw 9 3 Hd e ns Cover of medium frame 1 4 WAT n Screw cover 3 5 Xni 3k E BUREN Self drill screw 3 6 PTI A Horizontal air blade A 1 7 FU B Horizontal air blade B 1 8 FAU EFF Connection pole of horizontal 1 air blade 9 EpL HE Step motor 1 10 TRE A BUREN Screw 1 11 An ks A KORET Screw 12 12 Hz HK Wiring clamping cover 1 13 FKR ZE Air blade holder 1 14 FE ill ait Ah Electric controller assembly 1 15 Tl XR S up L2 f Indoor fan motor 1 16 EES Pipe clamp 1 17 HRA Mounting plate 1 18 JER BE ZF Chassis 19 t Vic UH ZH TE Indoor fan 1 20 PRCA E ZL EE Rubber bearing 1 21 EAN Evaporator assembly 1 22 EA Left plastic crutch for evaporator 1 23 rae ZH fF Medium frame 1 24 EE ed Filter 2 118 Pioneer air conditioner service manual Outdoor unit exploded picture 119 Pioneer air conditioner service manual Detailed part list of KFR70 ET outdoor unit No Chinese Name Name Material Number 1 Fc MSZ FEAR Left side supporting plate 1 2 DEADE Steel grille 1 3 Ani 3 A BURE Screw 4 4 Ti ss x Top cover board 1 5 if Front panel 1 6 VE babas Ak JV Condenser assembly 1 7 Ay MK Right side panel plate 1 8 IETF Handle 2 9 SUA Capacitor clamp 1 10 HA pL Re Compressor c
6. POB CN status voltage C The capacity ofthe fan NandL The motor AC motor does not connect CN8 OrNandM NSS OrNand H running 220V 240V an Fan motor capacitor fails Replace FAC Replace the indoor fan motor Fan motor fails 4 The Outdoor Unit Does Not Work Items Check if the input voltage is correct Check if the wire connection of the outdoor connecting terminal is correct 2 Trouble shooting procedure Pull outthe power plug and replug it after some 5 seconds Y NO Is the indoor controller normal Checkrefer to the 5 2 part YES Y Is the output voltage of relay normal V NO The relay fails Is the wire connection on the terminal correct YES A Replace the rela The outdoor unit P y is abnormal 166 Pioneer air conditioner service manual 5 The Step Motor Does Not Work DItems DCheck if the input voltage is correct Check if the step motor controlling the up down movement firmly connected to Cn2 2 Trouble shooting procedure Pull out the power plug and replug it after some 5 seconds lt Start the air conditioner with remote control gt 4 Is the LED on the display board lighten SOD ATONE PERONON the 5 2 part YES Does the louver move up and down after pressing the SWING button on the remote control li Norm
7. No Chinese Name Name Material Number 1 ODE PY 2H EE Filter 2 2 WERT n Screw cover 3 3 CHE ZH AE Medium frame 1 4 5X Horizontal air blade 1 5 TX Fr Vertical air blade 14 6 F Ze Air blade holder 1 T FAS 7c x AR Left plastic crutch for evaporator 1 8 EAN Evaporator 1 9 SAA JE Rubber bearing 1 10 tA Vic XT Indoor fan 1 11 JER BE ZH fF Chassis 1 12 HRA Mounting plate 1 13 IES Pipe clamp 1 14 XB EL Indoor fan motor 1 15 Bd ix Electric controller box 1 16 AS Hs d Transformer 1 17 bin TAR Terminal board 1 18 PER A Main PCB 1 19 zi dE FL ZA EE Step motor 1 20 Hd e n Cover for electric controller box 1 21 TRA E Indication lamp holder 1 22 ERIR Display board 1 23 Tii p 2H E Panel 1 24 ARK A Display board cover 1 138 Pioneer air conditioner service manual Outdoor unit exploded picture 139 Pioneer air conditioner service manual Detailed part list of KFR70 HS outdoor unit No Chinese Name Name Material Number 1 Fc JN sc d Left side supporting plate 1 2 zz pj e Steel grille 1 3 Amick H BUREN Screw 40 4 Toi s BX Top cover plate 1 5 Kix Front panel 1 6 V CAS a JV Condenser assembly 1 7 A MR Right side plate 1 8 ETF Handle 2 9 BAH Capacitor clamp 1 10 EKDE Compressor capacitor 1 11 P RE EAAS AC Connector 1 12 JUL FEL AE Fan motor capacito
8. 08 9 SL Siaringcuren a 20 wo so no ol PE eem EA as E NI TL NH E EN a Ea O E EC oe ma ma ee Le mal ee leken Saami Y 19 50 1990 aol we a edo move mue mer re Passed tester nisi rester Paas rss Pate eene ECC nn nn Cooling test condition _ test condition Indoor unit DB27 C Wb19 C Outdoor unit DB35 C Wb24C Indoor unit DB20 C Wb Outdoor unit DB7C Wb6 C Max Cooling test condition Indoor unit DB32 C Wb23 C Outdoor unit DB43 C Wb26C Max Heat ing test condition Indoor unit DB27 C Wb Outdoor unit DB24C Wb18 C Performance Fan motor a 61 Pioneer air conditioner service manual 6 Parameter of product R410a 18000BTU 24000BTU 18btuBA4 E R1 18btuB4 ExRt 24000btuB4 E R 24000btuB4 E R1 Indoor Outdoor Wall mounted Wall mounted d d Cooling kW 53 53 J 70 7 0 idifyi 2 9 Heating KW T RON NE CEU Cn D UNE EE sierto Cooling m min 14 6 44g 167 167 iad LN ll nuc e o A sm cp oe Heating dB yo 1 49 59 Rated Cooling w 1860 2600 2600 input Heating W fo eoo 0 2650 Rated prend Heating A ee So oo Soo omda OE Input ac Heating amp om 988 pol Tea EE EE EN cord Te 250V 16A 250V iea 250v 16A 250V 16A Fusecapacity A 3 18 315 315 3 15 Performance sion pews
9. 3 When TA TS lt 1 C after the compressor meet the 3 minutes protection condition the compressor and the outdoor fan turn off 4 The setting wind speed can be adjusted by the remote control during the ongoing cooling process and the interior fan still retains working When the status of TE lt TEI last for 10 seconds and the compressor keeps working for above than 5 minutes turn off the compressor and outdoor fan the indoor fan keep working according to the setting wind speed quit from such protection if TE gt 7 C 6 This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional When the cooling ongoing the button of the Swing can control the swing and stop of the horizontal air blade 33 Pioneer air conditioner service manual 8 Automatic wind speed control TA TS23 C wind speed works in high wind TS 1 CXTA TS 3 C wind speed works in middle wind TA TS lt 1 C wind speed works in low wind Without 3 minutes delay when the wind speed turns from the high wind from the low wind otherwise with 3 minutes delay OBeing initially electrified the compressor doesn t have the 3 minutes extension delay protection the outdoor fan starts after 2 seconds of the compressor s start TS TA set by the remote control the compressor turns off immediately with no need of 3 minutes delay protection 5 Dehumidification mode DThe four way valve al
10. 3 Condenser 1 Do 1 2 firstly 2 Screw off the fastening bolts at the left and right sides 3 weld off the inlet and outlet tubes 4 Offload the condenser 156 Part Pioneer air conditioner service manual Operation Process Remark Compressor 1 Do 1 2 3 firstly 2 Open the cover of the compressor and loosen the connecting cables 3 Weld off the inlet and outlet tubes of the compressor 4 Screw off three flat nuts 5 Offload the compressor 157 Pioneer air conditioner service manual Chapter 5 Troubleshooting and electrical chart of Pioneer air conditioner Section one basic faults diagnose process of 9000BTU 12000BTU products Troubleshooting Guide 1 The Foremost Inspecting Items DThe input voltage must be within 10 tolerance of the rated Voltage If it is not the case the air conditioner will probably not work normally 2 Check the connecting cord between indoor unit and outdoor unit to see if it is properly connected The connecting must be done according to the wiring diagram please also notice that even different models may have the connecting cord of the same specification Please check if the marks at the connecting terminal and the marks on the cord can match otherwise the air conditioner will not work normally Causes 1 The motor is heard operating but the air conditioner dose not work when th
11. amp When TE x TEI last for 10seconds and the compressor runs continuously for above 5minutes if turn off the compressor and outdoor fan the indoor fan runs at the setting wind speed If TE gt 7 C quit the protection This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional 34 Pioneer air conditioner service manual 6 Ventilation mode Under ventilation mode the outdoor unit is always off and the indoor fan runs according to the default wind speed The remote control can be set with three types wind speed e g high fan low fan and silent fan except the strong fan The operation condition of the air door is same as the one under the refrigeration mode The mode includes the function of timing auto restart optional negative ion optional I feel optional Heating mode The default temperature is determined by the remote control and to be within the range of 16 C 32 C which can be adjusted by the button of and Press the button of fan speed selection for choosing the wind speed from the four gears of strong fan high fan low fan and mute fan The other conditions are as following when OTA 3 TS lt 1 C if after three minutes delay time as for protection purpose the compressor and the outdoor fan start the indoor fan works in cold wind prevention condition the TA shown on the digital display has 3 C temperature compensation
12. 1220 1 Rotary Dimension Fan motor Compressor Moto Motor yo O e ro koe w RECTOR ION REZAR PE Ratedinpu w 910 910 1220 fan leaves fan leaves fan leaves fan leaves fan leaves fan leaves fan leaves fan leaves ype Plssticsealed tronshell Plastic sealed lron shell Plastic sealed Iron shell Plasticcsealed Tron shell S Raedimpu W Heat exchanger row line 2X11 1X24 2X11 1X24 2X13 1X24 2X13 2X24 Refrigerant controller Capillary Capillary Capillary Capillary Freezed oileapacity T Refrigerant Charge g R410a 860 R410a 860 R410a 970 R410a 970 Indoor unit DB27 C Wb19 C Outdoor unit DB35 C Wb24 C Indoor unit DB20C Wb Outdoor unit DB7 C Wb6 C Indoor unit DB32 C Wb23 C Outdoor unit DB43C Wb26 C Indoor unit DB27 C Wb Outdoor unit DB24 C_Wb18 C Ro al 59 Pioneer air conditioner service manual 4 Parameter of product R22 18000BTU 24000BTU 18000btuB4 E 18000btuB4 E 24000btuB4 Ex Indoor Indoor Outdoor Wall mounted Wall mounted Wall mounted Wall mounted Cooling KW olume m3 min Cooling dB 46 59 Noise Heating dB m n5 jc lo 7 97 Performance zu mm el Kez kop oy y 1 220 2407 50 1 220 2407 50 Rated Cooling w 2080 2080 2700 input ening 200 2700 Rated 12 5 current Heating A 98 A 0 12 9 98 98 0 acto tarting current Power Length s
13. 2TA 3 TS gt 1C if the compressor last continuously running for 3minutes the compressor and the outdoor fan stop the indoor fan keeps on working under anti cold wind condition The TA shown on the digital display has 3 C temperature compensation STA 3 TS retain the previous status Automatic wind speed control when TA lt TS wind speed in high fan TS TA TS 2 C wind speed in middle fan TA gt TS 2 C wind speed in low fan When wind speed turns from the low fan to high fan without 3 minutes protection delay wind speed turns from the high fan to low fan with 3 minutes protection delay When the heating process is ongoing the button of the Swing can control and stop the swing leaves When swing works freely the maximum angle of the swing leaves is 50 e g the swinging status between 3 5 refer to picture 3 There is no 3 minutes delay protection for electrifying the compressor initially The compressor starts 10 seconds later after the start of the four way valve The outdoor fan starts 2 seconds later after the start of the compressor Low down TS to be lt TA 3 then the compressor turns off immediately without the restriction condition of 3 minutes protection delay DThe mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional The four way valve starts immediately once being electrified 10 seconds later the compressor starts Under the comp
14. DB7 C Wb6 C Max Cooling test condition Indoorunit DB32 C Wb23 C Outdoor unit DB43 C Wb26 C Max Heat ing test condition Indoor unit DB27 C Wb Outdoor unit DB24 C Wb18 C 90 Pioneer air conditioner service manual 12000btuB4 E 12000btuB4 E Wallmouted wallmounted Weis Rr um olume Heating Performance Z e lo 7 Heating En Powersupply amp 1 220 240 50 1 220 2407 50 SE Cooling 58 BT purren Heating A 61 CE A O E T O Elfacto Heating ess _____ Starting current A 4 34 Power Laag m J 9 ax Te 25v aea 25v 164 Fusecapacity A 315 338 DUREE netweight Ke 95 37 95 38 Cuneo Liquid Nimt m 6 35X3600 06 35x3600 Mmm d9 52x3600 09 52x3600 Drainpipe Dom 014X780 014X780 Tp Rotary Rosy Bee lo qp oce qox E o s dpoec I 0 00 7 zjwedinpu w 1320 1350 E qose cecus e Type Plastic sealed Iron shell Plastic sealed Iron shell E Sirstedinpuel w 19 25 19 30 Heat exchanger row line Freezedoileapacity T Cooling test condition Indoor unit DB27 C Wb19 C Outdoor unit DB35 C Wb24 C Indoor unit DB20 C Wb Outdoor unit DB7 C Wb6 C Max Cooling testcondition Indoorunit DB32 C Wb23 C Outdoor unit DB43C Wb26 C Max Heat ing test condition Indoorunit DB27 C Wb
15. In consideration of the convenient installation and service there are two cut off valves connecting 26 Pioneer air conditioner service manual separately to the joint entry of the gas tube and liquid tube of the outdoor unit of the split type air conditioner The cut off valve is a kind of close valve for pipeline It controls the pass and stop of the refrigerant flow by manual open close control valve core The cut off valve can be divided into the two way cut off valve and three way cut off valve according to the structure difference D Two way cut off valve Two direction cut off valve is used to be installed at the side of the liquid tube which is belonging to the tubing of the outdoor unit The practicality is as picture2 12 The two direction cut off valve consists of the position regulator entry and two vertical cross pipelines The configuration shown in the picture 2 13 indicates One of the pipelines connects with the liquid tube side of the outdoor unit the other one connects with the tubing of the indoor unit through the connecting tube of the indoor and outdoor units Inside the position regulator entry there are valve rod and valve hole seat A graphite cotton rope or oil proof rubber sealing ring is fixed at the middle position of the valve rod and impacts the valve rod by the force of the fastening screw so as to prevent the gas leaking from the valve rod Before inspection or installation screw off the copper enveloping cap
16. Outdoor unit DB24 C Wb18 C Dimensio an motor Compressor otor Motor 56 Pioneer air conditioner service manual 2 Parameter of product RR407C 9000BTU 12000BTU 9000btuA4 E R 9000btuA4 E R 12000btuA4 E R 12000btuA4 E R Indoor Indoor Outdoor Wall mounted Wall mounted Wall mounted Wall mounted 2 3 5 Kg h 1 2 Heating KW 3 52 Cooling dB Heating dB 52 1 220 240 50 1 220 240 50 1 220 240 50 1 220 240 50 Rated Cooling w 1000 1000 1200 1200 input NN CEE AN NN 1250 Cooling 5 5 Heating A 43 JE E Input 98 factor Heating 988 98 24 0 Power Length 0 D L p cord Type 250V 10A 250V 10A 250V 16A 250V Fusecapacity A 315 315 316 3 15 bn peon E 210X 145x250 3200818540 210x745x250 320x818x540 210x745x250 320x818x540 210x145x250 320x818X540 3 Comedia Liquid Mtm D6 35X3600 D6 35X3600 D6 35X3600 D6 35X3600 EP Gas Omm 9 52x3600 9 52X3600 9 52X3600 9 52X3600 El Drainpipe ne D14X780 D14X780 D14X780 D14X780 8 Type MO E A al E xw es l Shaedmu w 940 960 i220 1220 Type Lr quw Ev EM E Eca Ed ERE pae g Type Plastic sealea Iron shell Plastic sealed lron shell Plasticsealed lron shell Plasticcsealed Iron shell o Blum w 3 p m nj sj mj os m m 2X24 Capillary Capillary Capillary Capillary Freezedoileapacity O c L
17. The defrosting process quits once change modes or air conditioner turns off by remote control After the defrosting process the compressor turns off and the outdoor fan turns on After 55 seconds the four way valve turns on after another 5 seconds the compressor turns on the air conditioner resume the normal heating process the indoor fan runs in the mode of anti cold wind 8 Auxiliary electric heating function a When heating mode working normally e g the compressor starts and the outdoor fan runs and the four way valve is electrified and the indoor fan starts the electric heating starts if satisfying the below conditions A TE lt 48C B TA lt 22 C C TS TA23C D The compressor runs continuously for 4 minutes with the heating mode The auxiliary electric heating quit operation if satisfying one of the below conditions A TA gt 22C B TS TA 2 C C TE 52 C S If anyone of the compressor four way valve and indoor fan doesn t work or fault feedback from the indoor fan the auxiliary electric heating quit operation The auxiliary electric heating may be allowed to restart after 1 minutes rest if the auxiliary electric 49 Pioneer air conditioner service manual heating quit during the operation process of the compressor 9 Sleeping control function The sleeping function is valid during the automatic cooling dehumidifying and heating process The indoor fan runs at low fan speed during sleeping mode
18. Unit Model KFR20 Y Phenomena Outdoor unit made loud noise Cause Analysis according to client outdoor unit made loud noise We checked outdoor unit and it was installed properly its shell was also quite normal Touched the cover of outdoor unit noise was reduced but not eliminated and outdoor grille made slight quaver Compacted or pulled out this grille noise was eliminated Checked carefully and found that plastic clip between grille and front panel hadn t been fastened tightly and made noise Solution filled small plastic cushion between outdoor grille and front panel and avoided impacting the appearance of the outdoor unit Experience Conclusion compared to indoor unit noise outdoor unit noise can be eliminated easily the most important thing is to find out the right orientation and handle the problem smartly Case 11 Noise caused by blocking of indoor separate capillary Unit Model KFR70 Phenomena Outdoor unit made loud noise and cooling and heating efficiency was unsatisfactory Cause Analysis indoor unit produced air stream sound temperature difference of air outlet was only 7 Celsius Degree and low pressure was 0 3 MPa both data were relatively low high pressure tube was over cold and compressor was easy to change to over heat protection mode Broke off compressor noise disappeared broke off indoor fan refrigerant made loud noise so maintenance personnel judged that noise was caused by flow throttling Touched branc
19. and the sleeping indication light on After turning into the sleeping process by pressing down the button of sleeping on the remote controller to the Cooling process the setting temperature rises by 1 C automatically one hour later to the Heating process the setting temperature falls by 2 C automatically one hour later After another 1 hour the setting temperature of the Cooling process raises another 1 C and the one of the Heating process falls another 2 C The sleeping process lasts 7 hours until air conditioner turns off During the sleeping process the mode switching operation is allowed and workable but it will delete the sleeping function The air conditioner will run at the temperature of new setting temperature temperature correction if press the button of add temp Under the sleeping status if press down the button of sleeping or change modes or on off the sleeping process will be deleted and ended The sleeping process under cooling mode Setting temperatur rises another 1 C rises 1 C Previous Setting temperature ocess turn off The sleeping process under heating mode Setting temperature 1 as ms meae _ E O 2h 7h end sleeping process urn off Timing control function The time range of the Timing control set is 24 hours and the time unit is minute single timing mode The conversion of the modes doesn t cancel the timing function and the timing indication ligh
20. assembly 21 Heap LIE pte Compressor connection cord 1 22 Ht pU Betty Ze Compressor grounding cord 1 23 Hd EA Compressor terminal cover 1 24 WAM RA i Over load protector 1 25 HAL Compressor 1 26 BE IZA A Liquid valve 1 27 d amp ERI ZA B Gas valve 1 28 Ii c Valve plate 1 29 JE AZ EF Chassis 1 112 Pioneer air conditioner service manual S KFR50 ET Indoor unit exploded picture 113 Pioneer air conditioner service manual Detailed part list of KFR50 ET indoor unit No Chinese Name Name Material Number 1 TE 2H E Panel 1 2 Un 3 A KORET Screw 9 3 Hd e n Cover of medium frame 1 4 WERT n Screw cover 3 5 Alm 3k A BUREN Screw 3 6 FT A Horizontal air blade A 1 7 FU B Horizontal air blade B 1 8 FAU EFF Connection pole of horizontal air 1 blade 9 zi HE ALAA HE Step motor 1 10 ERE A KORE Screw 1 11 Alm k ABRA Screw 12 12 Hz IK Wiring clamping cover 1 13 FARR AE Air blade holder 1 14 FEAS SA PI Electric controller assembly 1 15 Tl XR SE EHL Indoor fan motor 1 16 IES Pipe clamp 1 17 HRA Mounting plate 1 18 EEH Chassis 1 19 t Vic UH ZH TE Indoor fan 1 20 EJ E ZL EE Rubber bearing 1 21 EAN Evaporator assembly 1 22 Dy E pap d Left plastic crutch for evaporator 1 23 rE ZH AE Medium frame 1 24 Wye Filter 2 114 Pioneer air conditioner service manual Outdoor unit exploded
21. gt buzzer deliver one short tone Electric heating runs 30 Seconds and stops then the air conditioner turn into the waiting status the self testing 1s ended I2Fault indication When there is faults happen to the air conditioner the timing lights on the display panel will indicate the corresponding fault codes which are specifically reflected as the following For LED display FAULT DISPLAYMODE DISPLAY APPEARANCE PRIORITY TA Timer lamp flash 1 2 AC stopped abnormity times 8 seconds TE Timer lamp flash 3 AC stopped abnormity 2 times 8 seconds TW Timer lamp flash 4 AC hasn t stopped abnormity 8 times 8 seconds For Digital display FAULT DISPLAY DISPLAY APPEARANCE MODE PRIORITY TA abnormity display E1 2 AC stopped TE abnormity display E3 3 AC stopped TW abnormity display E2 4 AC hasn t stopped The definition of the swing angle Picture 3 It shows the swing angles of the types 18000BTU and 24000BTU stepping motor the air 51 Pioneer air conditioner service manual door s swing angle of 18000BTU 24000BTU and 7000BTU 12000BTU are same but the swing directions of the motors are not same Once being electrified the air door effect a motion of totally closed and the swinging speed is 1 step 4ms After the air conditioner turns on the air door effect a motion of total opening and swing to the corresponding primary position The primary position for Heati
22. heavy 2 Contacts of temperature control system adhere to each other and cannot be broken off 182 Pioneer air conditioner service manual 5 Heat pump air conditioner fails to heat If air conditioner can produce cooling air but fail to produce heating air there must be some faults in magnetic reversing valve or switch as b Cy as b e a Magnetic loop of magnetic valve has burnt out or broken out because of Operate in severe environment Magnetic loop stops and starts up frequently Operate under excessive voltage for a long time so that loops run under high temperature rise and insulation layer has been damaged Spool in magnetic valve has jammed or damaged because of Foreign substance has entered valve and jammed spool Spool has been damaged because of poor quality Reverse valve fails to work because of different reasons but in most cases impacted by unclean refrigerant and poor manufacture or assembly quality Cool heat switch fails to operate because of damaged structure and oxidized contact surface 5 Electric Leakage Electric leakage on the surface resulted from declined insulation property being affected by damping poor ground wire or even no ground wire connected 2 Fault Analysis for Electronic Circuit Control System Control panel of electronic circuit control system is a circuit with 5V or 12V low voltage which is a kind of small safe reliable and attractive panel with more contro
23. release a little refrigerant from technical tube to check its color and odor and inspect whether there s any foreign substance 3 Fill liquid tank with R113 and then start pump to clean the system For the slightly polluted system pump only need to run around 1 hour but serious polluted system should be washed for 3 4 hours If washing need to last for a long time cleaning agent is dirty and filter has been blocked and smudged and so shall be replaced 4 Cleaning agent shall be recovered after the system has been cleaned and can be reused after being treated Cleaning agent in liquid tank shall be recovered from liquid tube 5 When cleaning has finished refrigerating system shall be purged with nitrogen and dried In the foregoing sketch parts in broken line pane shall be disconnected from line as the system is being dried Blinds shall be installed on the flange disk of liquid squeeze line and liquid suction line to dry the system quickly blow heat wind outside the refrigerating line when system is being evacuated by vacuum pump Install the refrigerating system again and replace compressor and filter with new ones Following aspects shall be noticed during cleaning D To avoid cleaning agent leaking out pressure resistant hose shall be used and connection joints shall be packed tightly 2 Replace capillary or expansion with by pass pipe or pressure resistant pipe and connect evaporator and condenser directly 3 Water in
24. rises 1 C Previous Setting temperature Ih 2h 7h Cend sleeping process turn off The sleeping process under heating mode A Setting temperature Proviuns Send MUR falls 2 C temperature reu MAU SALA Falls another 2 C Ih 2h 7h Cend sleeping process rin off 1 Timing control function DThe longest Timing time is 24 hour and to be counted per minute single timing method the timing function will not be cancelled due to the modes changed and the timing indication light on after completing the timing setting Timing power off The timing power off function can be set only under the working condition of the air conditioner The timing range is 1min 24h and the air conditioner turns off automatically once the time is over S Timing power on The timing power on function can be set only under the working condition of the air conditioner The timing range is 1min 24h and the air conditioner turns on automatically once reaching the time The restart and power off motions happen after completion of the Timing setting will cause the automatic cancellation of the previous timing and sleeping setting function 12 Self detecting function Press the Emergency button and electrify the air conditioner the self detecting process starts after twice short buzz from buzzer Start the electric heating run the indoor fan at a high fan speed open the air door to be the maximum gt the digital display and three indicating light on in 1
25. to air conditioner with relatively poor cooling performance we should consider all conditions comprehensively and have clear philosophy check from main to secondary from inside to outside and from outer to inner following aspects shall be considered Check whether air conditioner works well 2 Check heat exchange condition of outdoor and indoor units consider the interference of surrounding appliances 3 Outdoor and indoor fan velocity will impact heat exchange 4 Measure all parameters and judge if they re normal and analyze reasons 5 Consider impact of extended tube on the performance of air conditioner 6 Consider interruption of running of indoor and outdoor compressor 7 Check if there s no throttle in the system and consider impact of cold flow on cooling performance Case 3 Capillary of separator of indoor unit evaporator is blocked Unit Model KFR 41A5 A Phenomena Poor cooling efficiency Cause Analysis this air conditioner was brand new indoor and outdoor units were very clean and ventilate normally service power functioned well indoor unit air outlet well but we found that temperature difference of air inlet and outlet of indoor unit was relatively low checked connection pipe of outdoor and found that low pressure tube was frosted so we presumed that refrigerant in the system was excessive so we released some Freon and refrigerating efficiency became worse so we judged that there s flow restriction in the
26. 1 and 2 firstly offload the water draining soft tube 2 Offload the water draining tank from the chassis and take out the electrical components Evaporator 1 Do No 1 2 and 3 firstly 2 Offload the connecting pipe 3 Offload the tube clip at the rear 4 Screw off the bolts at the right and left side 5 Lift up the evaporator and draw it out from the indoor unit Indoor fan and fan motor 1 Offload the motor from the indoor fan 2 Offload the indoor fan from bearing 155 2 Outdoor unit Pioneer air conditioner service manual No Part Operation Process Remark 1 General 1 Screw off one fastening bolt from the operation electrical box cover and offload the box cover 2 Pull out the connecting cord from the electrical box 3 Screw off the five fastening bolts from the cover board and offload the cover board Screw the six fastening bolts from the front panel and offload the front panel 4 Screw off the fastening bolts from the electrical assembly panel 5 Screw off the eight fastening bolts and offload the outer frame 2 Fan motor 1 Do No 1 firstly 2 Screw off the fastening nut Rotate in clockwise direction 3 Offload the outdoor fan 4 Screw off the four fastening bolts from the electrical motor and offload the electrical motor 5 Screw off the two fastening bolts and offload the bracket
27. 1 28 DA Valve plate 1 29 ERA Chassis 1 108 EEA peep ak Y VA l a a IJ GPe S ES SS g k Pioneer air conditioner service manual 4 KFR 35 EC Indoor unit exploded picture ara ee 109 Pioneer air conditioner service manual Detailed part list of KFR35 EC indoor unit No Chinese Name Name Material Number l HHA Panel 1 2 EIC BUE DA Anti bacterial Filter 2 3 AE C Didot ue DA Vitamin C amp Anti mites Filter 2 4 EH E Filter 2 5 WT ns Screw cover 3 6 FPE oi Cover of Medium frame 1 7 FANE ZH AE Medium frame 1 8 SAU Horizontal air blade 1 9 xr Fr Vertical air blade 2 10 JE Air blade holder 1 11 zh BE ILT Step motor 1 12 ti Vi AMT ZH TE Indoor fan 1 13 T bct n p Rubber bearing 1 14 PAS x HR Left plastic crutch for evaporator 1 15 AS cdi b JV Evaporator 1 16 JES BE ZB Chassis 1 17 HARE Mounting plate 1 18 E Tube clamp plate 1 19 AF RUE Indoor fan motor 1 20 FEA L a Cover for indoor fan motor 1 21 Bi iu Electric controller box 1 22 AR Hs di Transformer 1 23 AV Plastic temperature sensor 1 24 Xd Main PCB 1 25 VW pd Copper temperature sensor 1 26 3S Ti as ACI Signal receiver holder for Remote 1 controller 27 AS Temperature sensor holder 1 28 ect Receiver board 1 29 Jm f Terminal board 1 30 foe TEM Negative ion generator 1
28. 1 8 EAT Horizontal air blade 1 9 Spur Hr Vertical air blade 2 10 SE Air blade holder 1 11 W HEE LF Step motor 1 12 ti LAT ZH TE Indoor fan 1 13 PBC A E Rubber bearing 1 14 ZR AC dir Jr x Left plastic crutch for evaporator 1 15 ZR AS AS Evaporator 1 16 JES JEE 2H fr Chassis 1 17 FERAL E Mounting plate 1 18 Ern HA Tube clamp plate 1 19 E ENL Indoor fan motor 1 20 FEL zi Cover for indoor fan motor 1 21 Bf ix Electric controller box 1 22 AR Hs d Transformer 1 23 ZA Plastic temperature sensor 1 24 BRL Main PCB 1 25 AENEIS A Copper temperature sensor 1 26 3E Ti as DeC AK Signal receiver holder for 1 Remote controller 27 Um PEER SK XC Temperature sensor holder 1 28 SEU AK Receiver board 1 29 bin TAR Terminal board 1 30 GOA TAE Negative ion generator 1 31 YE PEE Connection cable 1 32 s de peek Interconnection cord 1 33 FH ZE Power supply cord with plug 1 34 Hz A JAB Indication lamp holder 1 35 TRIR Display board 1 36 TH AT AX Indication lamp board 1 37 EAE Remote controller 1 98 Pioneer air conditioner service manual Outdoor unit exploded picture p ZZZ 7 WD Les 44S 4FJUVFFA 99 Pioneer air conditioner service manual Detailed part list of KFR25 ET outdoor unit
29. 1 compressor RY3 indoor fan motor and outdoor fan motor normal YES NO Checkthe connection of the compressor indoor fan RY3 and IC4 motor and outdoor fan motor Replace the Ryl Is the port voltage 0VDC ofthe 3 normal Is the port voltage SVDC ofthe 7 normal Replace the PCB board Is the output voltage of the IC normal YES NO Check PCB board Replace the main PCB board Is the port voltage ofthe 27 normal Replace IC2 NO Are the port voltage ofthe 4and 5 normal i NO Doesitrun normally Replace the YES micro controller Replace the buzzer 3 The Indoor Fan Motor Does Not Work DItems DCheck if the indoor fan motor is connected correctly to the connector CN8 Check if the AC input voltage is correct S Check if the IC of indoor fan motor is connected correctly to the connector CN2 Check if the capacity of indoor fan motor is connected correctly to the connector CN8 2 Trouble shooting procedure 165 Pioneer air conditioner service manual Pull out the power plug and replug it after some 5 seconds i Refer to the procedure of proceeding page Is the LED lighten Is the controller output normal y The micro controller chip fails YES Isthe fan motor voltage satisfied PCB fails Replace PCB The probe position Normal
30. 10 9 87 X 10 1 450 X 10 9 8x 10 1 9 68 x 10 1 421 X 10 1 46885 X 1 013 X 10 10 1 93285 X 1 333 X 10 1 36X 10 1 316 X 10 10 0 68948X10 7 0327X10 6 80517X 10 1 2 Conversion of Energy Units 1kJ 1000J Ikcal 1000cal Ikcal 4 1868kJ 1BTU 0 252kcal 1 055kJ lkcal 3 968BTU 1kJ 0 9478BTU 1W 0 86kcal h 1HP 745 7W 1 USRT 3 024kcal h 3576W 1 Japan RT 3320kcal h 3860W 1 Horsepower 735 499W simplified to 735W IUKHorsepower 745 7W Ikcal h 3 9683Btu simplified to 4Btu 1W 3 412Btu h 3 Conversion of Temperature Units t T 273 162T 273 C F 9 5 t 32 F 1 8t 32 F 234 Pioneer air conditioner service manual 4 Heat Conductivity Factors of Several Common Used Material Copper 1382 Cork 0 17 0 25 Aluminum 733 Air Interlayer 0 25 Steel 163 Water 2 1 2 1 Glass 2 7 2 9 Frosty layer Fibre Glass 0 17 0 21 Saw Timber 0 25 0 34 Glass Cloth 0 13 0 62 0 84 Plywood Slag Wool 0 21 0 34 Polyurethane Foam 5 Basic Property of Substitute Refrigerant 0 042 0 11 Property R 22 R 410A R 407C R32 R125 Refrigerant Composition R 22 R32 R125 R134a Mass Ratio 100 50 50 23 25 52 Environme ODP 0 05 0 0 nt GWP 100Y 1730 1700 1530 Protection Toxicity None None None Safety Combustibility Incombustible Incombustible Incombustible Thermo ph Azeotropic Prop Subazeotropic
31. 13 nas Capacitor clamp 1 14 PULVERE Fan motor capacitor 1 15 FALL Compressor capacitor 1 16 bri FAX Terminal board 1 17 HE ir Ae Electrical holding plate 1 18 Ka AUZIR Partition plate 1 19 UU xi amp Be Electromagnetic loop 1 20 VU Bx ET A HAF Four way valve and capillary 1 assembly 21 KANER Compressor connection cord 1 22 KANL Compressor grounding cord 1 23 HE di B Compressor terminal cover 1 24 IB d Over load protector 1 23 HA pL Compressor 1 26 AE BZF A Liquid valve Dg4 1 27 A iE DRI ZA B Gas valve Dg8 1 28 Ii c Valve plate 1 29 ERAF Chassis 1 124 Pioneer air conditioner service manual 2 KFR25 HSL Indoor unit exploded picture 125 Pioneer air conditioner service manual Detailed part list of KFR25 HSL indoor unit No Chinese Name Name Material Number 1 Tp ZH E Panel 1 2 TEIE 2H F Filter 2 3 FH GS nti Cover of medium frame 1 4 FPE ni Medium frame 1 5 SAU Horizontal air blade 1 6 pur Fr Vertical air blade 12 7 FAE Air blade holder 1 8 zh BEE LF Step motor 1 9 ta LAT ZH TE Indoor fan 1 10 ISA E Rubber bearing 1 11 ZS Rts Pe SOIR Left plastic crutch for evaporator 1 12 EIA Evaporator assembly 1 13 JER AB ZB Chassis 1 14 FERAL TE Mounting plate 1 15 PR Hs Tube clamp plate 1 16 XB UTE Indoor fan motor 1 17 Bi iu Electric controller box 1 18 AE
32. 158 Section one Basic faults diagnose process of 9000BTU 12000BTU products 158 Section two Basic faults diagnose process of 18000BTU 24000BTU products 164 Section three Electric wiring diagram of Pioneer air conditioner soon oenen eneen 169 Chapter 6 Introduction to the regular service tools for air conditioner eee 176 Chapter 7 Failure Analysis and Inspection of Electrical Control System aa 182 Chapter 8 Troubleshooting guide for Refrigerating System sse 194 Chapter 9 Maintenance Cases of Noise and water leakage of AC sess 211 Section one cases of air conditioner noise reduction nonnen oenen verevenen venen 211 Section two maintenance cases for water leakage of air conditioner annen eneen 217 APPENDIX 1 Introduction to the fault display CODE 224 Pioneer air conditioner service manual Chapter 1 the operation theory of the home Air Conditioner Section one the basic knowledge of pyrology and ventilation 1 Basic Definition 1 Temperature Temperature is a physical value for the definition of the percentage of the cold and heat to an object It s the one of those basic parameters used in confirming the substance s status Currently the world standard common thermometric scales include the absolute thermometric scale the Celsius scale and the Fahrenheit scale The Celsius scale is the most common thermometric s
33. 3 airdischarge 4 fan and coupling entry 5 supporting base 6 electrical motor 7 gas ballast valve 8 oilfillerplug 9 oilmark 10 oil drain plug Picture 6 1 The exterior structure of vacuum pump 12 NSNNNSIANSSSNNSSS URN i lj al TT x SJ ji 75 77 i m v N Y 1 airintake 2 filter 3 oilfillerplug 4 oil mark 5 oildrainplug 6 rotary blade 7 spring 8 rotor 9 gasballastvalve 10 Cylinder 11 exhaust valve 12 airvent Picture Picture 6 2 Single stage rotary Vacuum pump 176 Pioneer air conditioner service manual There is only one cylinder installed in the Single stage rotary Vacuum pump Inside the cylinder the rotor is eccentrically mounted inside the cylinder There are two rotary blades fixed inside the rotor groove and two of them are oppressed tightly to the surface of the cylinder by the central spring force and the centrifugal force produced in the process of rotation The tangents created by the two rotary blades to the rotor and cyclones divide the crescent space between the cylinder and rotor into three or two parts The space connects with the air intake is called air absorbing space the spaced connects with the air vent is called air exhausting space the space between two rotary blades is called air compressing space When the rotor is rotated the air absorbing space formed by the two tangents between the right side rotary blade to the rotor and cyl
34. Cause Analysis indoor unit creates same sound in both cooling and ventilation modes with similar fault phenomena Noise was louder when air conditioner was turned on Removed panel and shell of indoor unit fault still remained the same and sound came from left bearing so maintenance 211 P it presumed that fault was on bearing bush of left blade Replaced bearing bush noise could still be heard Maintenance personnel checked wind blades and found that they re installed left to the center and blade axis touched rubber seat of bearing and produced noise when running Solution move wind blade to right by 2mm and noise was eliminated Experience Conclusion foregoing noises also can be created from following problems 1 Screw of fix motor gland becoming loose 2 Bearing seat left to indoor fan becoming loose 3 Oily bearing left to indoor fan is broken or lacks oil 4 Left axis of blade colliding with rubber bearing holder 5 Fix screw of indoor fan becoming loose 5 Two ends of indoor fan colliding i 7 Chassis has deformed and collides with blades e 8 Blades trip too excessively and collide with THIS BEARING chassis 9 Blades being broken Case 2 Indoor fan motor noise Unit Model KFR H18AA FSY Phenomena Whistling from indoor unit Cause Analysis air conditioner was newly installed during test running air conditioner made whistle like noise Maintenance personnel presumed that it was caused by blades Mainten
35. Is the indoor controller normal Check refer to the 5 2 part YES Is the output voltage of relay normal V NO y The rel ay fails Is the wire connection on the terminal correct YES Replace the relay The outdoor unit 1s abnormal 160 Pioneer air conditioner service manual 5 The Step Motor Does Not Work 1 Items a Check if the input voltage is correct b Check if the step motor controlling the up down movement firmly connected to Cn2 2 Trouble shooting procedure Pull out the power plug and replug it after some 5 seconds lt Start the air conditioner with remote control gt Sm NO Confirm the procedure of Is the LED on the display board lighten the 5 2 part YES Does the louver move up and down after pressing the SWING button on EX Normal the remote control NO Is there any voltage change between gt Ne the chips 23 22 20 19 The chips YES Is there any voltage change between Wo Divec l pIC4 10 13 ofthe the chip ULN2003AFW ULN2003AFW YES The step motor fails 6 Heating Mode Can Work But No Hot Air Blow DCheck ifthe set temperature is lower than the indoor temperature 2 Check if the indoor PCB is connected to the terminal correctly restarted in some 5 minutes YES after the above problems solved Normal
36. Subazeotropic ysical Boil Temp C 40 8 52 7 43 7 Properties Critical Temp C 96 1 72 5 87 3 Refrigerati Refrigeration 2 17 3 38 2 31 on Pressure Mpa Properties Evaporation 0 62 1 00 0 64 Pressure Mpa Pressure Ratio 3 50 3 38 3 59 Exhaust Temp C 97 2 95 1 86 7 Slip Temp C 0 0 17 UT 4 6 235 Pioneer air conditioner service manual Refrigeration 100 141 101 Amount COP 100 92 5 97 Lubricate Type Mineral Oil POE POE Lubricate Inter solubility Good Fair Fair 236
37. The following is the detailed introduction for it The capillary tube is a slim and long copper pipe with a small aperture The inner diameter of it is Imm 2mm and the length is 500mm 1000mm With the properties of simple structure easy machining low cost and reliability especially enough capability for the throttling need at a stable indoor room temperature it s popularly applied in the practice However it has a weak accommodating function which can be workable under a rating working status but can t adjust the flux following with the variety of the load of the refrigeration system The capillary tube is a kind of throttling component applied in the refrigeration system It is welded between the condenser and the evaporator for the function of reducing pressure and throttling flux It can prevent the liquefied refrigerant at a normal temperature and pressure of the condenser entering into the evaporator directly so as to reduce the pressure of the evaporator in favor of the evaporation of the refrigerant After stopping the operation of the compressor it can maintain a balance between the low pressure part and the high pressure part for the convenient re start of the compressor The resistance will be reduced and the flux of the refrigerant will be increased if enlarging the inner diameter or shortening the length of the capillary tubes and on the contrary if otherwise The capillary tubes must match the refrigerating devices and cannot b
38. air conditioner will probably not work normally Check the connecting cord between indoor unit and outdoor unit to see if it is properly connected The connecting must be done according to the wiring diagram please also notice that even different models may have the connecting cord of the same specification Please check if the marks at the connecting terminal and the marks on the cord can match otherwise the air conditioner will not work normally 3 If the following phenomena are found the problem is not from the air conditioner itself NO Problems Causes 1 The motor is heard operating but the air conditioner dose not work when the indoor unit is powered on Since the air conditioner is powered on it will come to working condition as long as you press the ON OFF button of the remote control and the signal is well received The compressor stops running but the indoor fan motor keeps working when it is at cooling mode with the indoor temperature higher than set temperature If you turn off the air conditioner and restart it immediately it will return to normal in 3 minutes after that the air conditioner will automatically adjust the indoor fan speed to what you set The compressor works discontinuously at dehumidifying mode The air conditioner will automatically control the working of the compressor according to the inside temperature The air conditioner does not work while the LED display
39. and low pressure switches worked properly discharge temperature of compressor is normal Replaced outdoor check board tested the air conditioner fault remained the same Turned on air conditioner again and watched running condition of outdoor unit we found that air conditioner refrigerated for one minute low pressure switch broke off outdoor unit stopped to work connected low pressure protector and tested it it run normally low pressure was also normally So we re sure that pressure switch was of poor quality and couldn t work properly Solution replaced low pressure switch tested air conditioner and it run properly Experience Conclusion observe faults indicators on control panel which can help us find out causes of faults 1 Heating defrosting heat indicator blinks 2 Anti frozen protection run and cool indicators blink 3 Anti cold wind protection run indicator blinks 4 Over current protection run and 29 indicators blink 5 Low pressure protection run and 18 indicators blink 6 Phase sequence protection run and time 7 Fault in Communication run indicator blinks and other indicators extinguish 8 Fault in Sensor temperature indicator blinks 209 Pioneer air conditioner service manual Case 19 Water entered the system in installation Unit Model KFR35 H Phenomena Air conditioner could be turned on but couldn t produce cool air Cause Analys
40. available the communication fault System turns off and the LED digital screen of the operation panel displays E4 5 When outdoor panel available the protection of outdoor compressor overloading protection System turns off and the LED digital screen of the operation panel displays E5 The fault may be the protection of low on off voltage overloading protection or the reacting motion of overloading relay 6 When outdoor panel available the phase failure protection of the outdoor three phases System turns off and the LED digital screen of the operation panel displays E6 The fault may be three phases in reverse connection 7 When outdoor panel available over current protection System turns off and the LED digital screen of the operation panel displays E7 8 When outdoor panel available the fault of the exhaust pipe temperature sensor of the compressor System doesn t turn off and the LED digital screen of the operation panel displays ES The fault may be the unsteady joint or plug of the temperature sensor or the damage of the outdoor computer board 9 When outdoor panel available the temperature protection to the exhaust pipe of the compressor System turns off and the LED digital screen of the operation panel displays E9 7 HS Y HSA Y HSB Y HSF Y HV Y HVA Y digital display for the series air conditioner faults The di Fault source Display mode d prece
41. bar slowly until reaching the required angle The structure of the tube bender is indicated in the Picture 6 7 a handle movement direction b handle bar c wheel d tub clamping hook e tube bending angle indicator f handle Picture 6 7 structure of the tube bender picture 7 Gas welding apparatus Since the copper tubes are largely applied in the refrigerating system of the air conditioner the gas welding is in need for service use The traditional gas welding apparatus uses the mixture gas of the oxygen and acetylene which can produce the high temperature blaze The modern welding equipment adopt the liquefied petroleum gas as the fuel and the oxygen boosting liquefied gas welding machine as the apparatus for the tube joint welding work of the refrigerating system The gas welding equipment mainly consists of the gas tank the soft connecting pipe and the welding gun 8 Digital clamp meter Digital clamp meter is one of the widely applicable measurement apparatus in practice It is the most common tool in the inspection process to the electric malfunction of the refrigerating equipment It can measure the voltage of the AC or DC the alternating current and resistance etc Its practicality is as indicated in the Picture 6 8 Measure the AC and DC voltage Firstly turn the on off switch to category of the ACV AC voltage or DCV DC voltage and select a measurement range which is bigger than the voltage to be measured Then insert t
42. below 1kJ 1000J Ikcal 1000cal Ikcal 4 1868kJ 1BTU 0 252kcal 1 055kJ lkcal 3 968BTU 1kJ 0 9478BTU 1W 0 86kcal h 1HP 745 7W 1USA Refrigeration Ton USRT 3 024kcal h 3576W l Japanese Refrigeration Ton RT 3320kcal h 3860W The relation of the temperature and the quantity of heat The physical object s temperature will decrease if it releases the quantity of heat and consequently cause the increase to the ambiance temperature Otherwise the physical object s temperature will increase 1f it absorbs the quantity of heat and consequently cause the decrease to the ambiance temperature In this case it s easy to understand that the principle of the heating process is the heat releasing process by the object which increases the temperature of the ambiance medium accordingly the principle of the refrigerating process is the heat absorbing process by the object which decreases the temperature of the ambiance medium accordingly 2 The heat transmission forms There must be a heat transmission process available either the quantity of heat shall be delivered from one substance to the other one or the quantity of heat shall be absorbed by one object from the other one The heat transmission forms are consisted of heat conduction convection and heat radiation The three of them normally function at the same time during the actual heat transmission process in no spite of the single transmission form of them available only DHeat conduction H
43. consists of the cylinder air inlet pipe and U air vent pipe etc There is an oil sucking hole at the bottom of the U pipe When the compressor working the gas and liquid refrigerant come from the evaporator will flow into the gas amp liquid separator The liquid refrigerant falls into the bottom of the cylinder because of gravitation only the gas refrigerant will be sucked into the compressor The liquid refrigerant at the bottom of sleeve can only be allowed after being beiled gasified by absorbing heat The refrigeration oil at the bottom of the cylinder after being separated from the liquid refrigerant and being located at the above of the liquid will be absorbed by the compressor by passing through the oil sucking hole together with the gas When the compressor stops working the pressure balancing hole can prevent the redundant refrigerant of the separator s flowing into the compressor through the oil sucking hole This type gas amp liquid separator are popularly applied in the heat pump model air conditioner with To and fro type compressor It can prevent the liquid refrigerant being brought into the compressor at the moment of exchange between heating and refrigeration process The structure of the Rotary type separator is as the picture 2 4 It s mainly composed by the straight air inlet pipe J air vent pipe and the pole sleeve There is no connection between two pipes The separator is connected with the compressor by t
44. copper tube in bigger pipe size need longer expander and the copper tube in smaller pipe size need shorter expander For example to the copper tube with size of 8 the length of the expander shall be around 10mm Then screw down the nuts located on the two terminals of pipe wrench so as to clamp the copper tube and insert copper tube into the expander head Rotate the screw of the expander slowly in the clockwise direction until the expansion length in need achieved The practicality of the expander is as indicated in the Picture 6 4 and the structure is as the picture 6 5 4 Flaring tool Flaring tool is specially applied in the copper tube s flare expansion work so as to connect the indoor and outdoor unit of the split air conditioner by the tubing When flare is expanded fix the annealed copper tube by the connecting nut and insert the copper tube into the corresponding aperture of the pipe wrench The protrusion height of the copper tube out from the pipe wrench shall be 1 5 of the tube s diameter Then screw down the nuts located on the two terminals of pipe wrench and press the cone shaped head of the flare tool to the flare Rotate the screw slowly in the clockwise direction until the expected flare formed The practicality of the flaring tool is as indicated in the Picture 6 5 178 Pioneer air conditioner service manual Picture6 4 Expander Picture6 5 Structure of expander 5 Tube cutting knife The tube cutting knife is
45. data fault Simultaneously press the key of hour minute again and last for 2 seconds Resume displaying the temperature after the sound of the buzzer 3 KFR H24B4 A KFR H41A5 A KFR H41A5 C faults display and protections display 1 Heating and defrosting The heating indication light on the panel is twinkling 0 5 0 5 the others are invariable 2 When the indoor tube temperature available the indoor refrigeration anti freezing protection The running and the cooling indication light on the panel is twinkling 0 5 0 5 the others are invariable 3 When the indoor tube temperature available the indoor heating over heating protection The running and the heating indication light on the panel is twinkling 0 5 0 5 the others are invariable 4 When the indoor tube temperature available the indoor heating long time anti cooling wind protection The running indication light on the panel is twinkling 0 5 0 5 the others are invariable 5 Over current protection The running light and 29 indication light on the panel are twinkling and simultaneously last for 0 5 0 5 second the system turns off 6 Low pressure protection The running light and 18 indication light on the panel are twinkling and simultaneously last for 0 5 0 5 second the system turns off 7 Fault of the indoor temperature sensor The temperature indication light on the panel is t
46. electromagnetism compatibility The electromagnetism includes EMS the sensitivity of the electromagnetism e g the resistance performance against the interference of the electromagnetism and EMlI interference of the electromagnetism the performance of the EMI mainly includes 1 the interference to the electrical net 2 the radial interference through the connecting cable of the electric power source ICE certificate This certificate pushed by the EU is a safety and quality symbol for certifying the products are in compliance with the specified basic requirement of EU and used for insure the consumers that the products with this symbol are in conformity with the basic requirement of safety health and environment CE is the abbreviation of the EU in Latin language which also express the meaning of conformity to the requirement of EU Environment symbol certification The materials applied in the production and the recycled are given the conception of environment protection such as the degradation time s difference of the form packaging and paper packaging and their recycle possibility 181509001 International Quality System Certification The evaluation and validation carried out by the third independent attestation agent or institute for verifying the quality system of the plant is in conformity with the ISO 9000 standard which includes all aspects of the whole process such as the product design manufacture test status statistic e
47. flow sound can be heard in valve body suction force of gas return pipe of compressor is relatively large and liquid temperature is relatively high Case 13 back valve is broken Unit Model KFR35 HY Phenomena Sealofback valve is not tight Cause Analysis according to client air conditioner could cool properly but failed to heat the room We turned on the air conditioner checked the whole unit and found that eudiometer pressure was 14kg being relative low according to fault phenomena refrigerant in system might be not enough but we checked the system and found that balanced pressure was 10kg and air conditioner could cool normal in summer the system didn t leak so we presumed that the fault was caused by four way valve blowby or poor seal of back valve Switched on and off four way valve valve could operate tightly and sound of gas discharge was normal Released refrigerant vacuumed the system again added refrigerant and started the air conditioner again it still couldn t work properly We checked four way valve temperature of its four copper tubes was normal so we were sure that seal of single way valve was not tight which cause that capillary couldn t function properly so the pressure of gas tube was relative low and heating efficiency was not so good Solution replaced back valve vacuum the system and added refrigerant Experience Conclusion back valve can t close tightly on high pressure gas leaks from clearance be t
48. found loop of AC contactor broke off Solution replace AC contactor Experience Conclusion air conditioner fails to produce heat if power supply of indoor unit is regular outdoor fan and four way valve function well compressor still fails to work we shall check whether contactor pulls on loop resistance value is normal and then check if there s any problem in compressor Main problems in AC contactor may include loop burning out contacting points loosing contaminated and burning out and etc Case 14 Power supply circuit failure Product Model KFR35 H Phenomena cooling failure Cause Analysis we started up the air conditioner indoor worked well but outdoor unit couldn t start up normally and produced abnormal sound its voltage decreased from 230v to 138v so we presumed that there s problem in power supply circuit We checked power receptacle and found that decoration worker had used grounding line as zero line Solution connect grounding line and zero line correctly Experience Conclusion connect N end to zero line and don t replace zero line with grounding line or air switch will trip If new air conditioner has problems we should check power circuit firstly sometimes power line is too thin and startup current of air conditioner is quit large and produces large voltage drop which will cause difficulties in startup Besides electrical power problem air switch may cause startup trip 193 Pioneer air conditioner servic
49. heat from the evaporator and then will be gasified as gas at a low pressure and temperature The compressor will suck this gas from the sides of the evaporator and compress the gas The pressure will turn high at the moment through its mechanism energy transferred from the electricity energy With no stop the mechanism energy turns into the heat energy for increasing the temperature of the compressed gas Super heating gas and force it enter into the condenser The compressed gas with high pressure and temperature will undertake the heat exchange heat release process with the air or heat source around the condenser and will be cooled and condensed as liquid with high pressure and middle temperature Super heating gas about 95 C saturated gas wet gas saturated liquid super cooling liquid 46 C the pressure value basically maintain the same About 19Kgf cm and temperature is down Because the narrow diameter of the capillary tubes creates the resistance during the flow of the processed high pressure and super cooling refrigerant the speed of the refrigerant flow will be accelerated the pressure will be lower down the temperature will fall and accompanied with the tiny gasify phenomenon The refrigerant s temperature about 7 C 5Kgf cm after passing through the evaporator will be lower than the ambiance temperature and will turn into a gas state gradually from the low pressure and wet steaming state after having sucked the heat f
50. high wind TS 1 CXTA TS 3 C wind speed works at middle wind TA TS 1 C wind speed works at low wind Without 3 minutes delay when the wind speed turns into the high wind from the low wind otherwise with 3 minutes delay Being initially electrified the compressor doesn t have the 3 minutes delay protection the outdoor fan starts after 2 seconds of the compressor s start When TS gt TA set by the remote control the compressor turns off immediately with no need of 3 minutes delay protection When TE gt 64 C and after last for 10seconds the compressor and the outdoor fan turn off If meet the 3 minutes delay condition and TE lt 62 C the compressor can start normally When the air conditioner is under overheating protection if the wind speed setting is by hand the indoor fan unit will run at the setting wind speed if the wind speed setting is automatic the indoor fan unit runs at the low fan speed 5 Dehumidification mode DThe four way valve always turns off when the dehumidification mode is ongoing The control range of the temperature is 16 C 32 C 45 Pioneer air conditioner service manual 2 Under the dehumidification mode after the 3 minutes delay conditions being meet satisfactorily the performance of the compressor and the outdoor fan is as following a TA gt TS 2 C the compressor and the outdoor fan works continuously the wind speed retains the setting wind speed b TS lt TA TS 2 C the com
51. is on The TIMER is set with the air conditioner it will be in hold on condition If the TIMER setting is cancelled the air conditioner will return to normal working condition The compressor works discontinuously at cooling and dehumidifying mode and the indoor fan motor slows down The compressor stops internally or the fan motor slows down to prevent the indoor heat exchanger from being frozen 2 No Power Display Items DCheck if the input voltage is correct Check if the AC power supply connecting is correct S Check if the output voltage of the manostat L7805 IC2 is correct 2 Trouble shooting procedure 164 Pioneer air conditioner service manual Pull out the power plug and replug itafter some 5 seconds Doesthe buzzer ring Check the connection between power supply cord and the connecting terminal then check the fuse Doesthe air conditioner start operating after pressing the ON OFF button ofthe remote control normal NO ote Referto the trouble sho oting ofthe remote control Isthe primary voltage on YES Cn normal Isthe transformer OK YES Is the DC voltage on the PCB board OK i Isthe LED lighten Arethe voltage of micro controller 8 compressor 2 4 way valve and 6 outdoor fan motor normal Is the voltage 5VDC of the 15 1ndoor fan motor normal Are the voltage IC4 of RY
52. mm the air conditioner Copper core Aluminum core As per the nameplate lt 6 1 1 5 2 9 6 10 1 5 2 5 2 5 10 16 2 5 4 4 16 25 4 6 6 25 35 6 10 Note Aluminum leads are not recommended in use Larger section area shall be better in use as recommended The division of the ammeters such as doubleness ammeter quadruple ammeter etc are determined by their endurance capacity to the specific electricity currents For example the 2 5A doubleness ammeter means the maximum electricity capacity it can endure is 5A the maximum electricity capacity of the quadruple ammeter is 20A So the user must ensure the total rating current shall less than the maximum capacity of the ammeter and good consideration of the other appliances electricity consumption at home 2 The electricity consumption of the air conditioner The consumption power the electricity heating power and the auxiliary electricity heating power if applicable can be identified from the nameplate of the air conditioner and can be used for the estimation of the quantity of electricity consumption For instance if the rating refrigerating consumption power is 1200W for one air conditioner and 1 kilowatt hour 1kW h then the quantity of electricity consumption of this air conditioner is 1200W 1h 1 2kW h 1 2kilowatt hour The rating power on the nameplate is validated by the manufacturer under a certain indoor or outdoor temperature and humidity Indoor dry b
53. p BK vep 1 Density is the mass of the unit dimension of the substance with the unit of kg m Kilogram meter The density of the liquid is higher than the one of the gas which is the theory sourced from and 2 Pioneer air conditioner service manual applied in the separating process by the gas amp liquid separator 4 Heat Energy The heat energy of the substance the internal energy is the sum of the kinetic energy and potential energy The quantity of heat is the physics parameter for measuring the heat absorbed or released by the physical object and is one of the representation forms of energy The essential of the heating process of refrigeration is the process of transmitting heat energy The signification of the quantity of heat is only effective during the heat energy s transmitting period The common units in measurement include Joule or Kilo Joule KJ 1J means the energy in need for rising up the physical object with the weight of INewton up to 1 meter height In addition there is Calorie or Kilo Cal Kcal as the common units applied 1Kcal stands for the absorbed or released quantity of heat for having the temperature of 1kg pure water to be increased or decreased by 1 C British thermal unit BTU is applied mainly in Europe or USA 1BTU stands for the absorbed or released quantity of heat for having the temperature of 1pound pure water to be increased or decreased by IF The conversion relation of all the above units is as
54. products from other companies we also can replace D1 D12 diode on control panel with IN4148 high frequent diode Experience Conclusion besides failures in buttons of DS panel temperature regulation button on FS Y also may fail to work well Spaces for buttons on display panel may be too narrow and buttons 191 Pioneer air conditioner service manual on plastic panel may deform so buttons may fail to work In this case control panel shall be replaced with same model product Case 9 Compressor low pressure can t be started up Product Model KFR35 HS Phenomena Compressor of outdoor unit can t be started up Cause Analysis Indoor unit works well voltage output and resistance of outdoor compressor are in normal scope so there s some problem in compressor Resistance of each winding of compressor is in normal scope the client s voltage was 198 V which was within the scope of design standard So startup performance of compressor 48D129 is not good enough Solution replace capacitor for 35UF compressor and parallel connect a auxiliary starter to compressor capacitor There s no need to replace compressor Case 10 Compressor Capacitor and fan capacitor Product Model KFR35 A Phenomena when air condition was in cooling situation once compressor started up air switch tripped Cause Analysis when air conditioner was in cooling function compressor tripped once air condition started up We checked indoor unit and found it was in
55. species refrigerant They are the ramifications of methane and ethane with the changing character in consequence of the quantities variety of the atoms of fluorine hydrogen and chlorine The best option for choosing a chemical compound at the vaporizing temperature of 130 C to 80 C is the one with quite more fluorine atom in consideration of the easy application of the refrigeration technology because the compound with more fluorine atom has less toxicity and can maintain a higher chemic stability In addition the compound with less hydrogen atoms has less possibility in explosion and inflammation and if with more chlorine atoms the evaporation temperature will be higher The more information about the character of Freon will be specified in details in the following paragraphs S Azeotropic mixture refrigerant They are the mixture of two or above than two types Refrigerants in certain percentage Their character is same as the one of the single compound that maintains the invariable evaporation temperature under the fixed pressure However the component of their vapor phase and liquid phase are same and retain in the same Azeotropic mixture has some distinguished character comparing with the single refrigerant such as low evaporation temperature large capacity per unit refrigerant and low compressor discharge temperature etc So the application of the azeotropic mixture can enhance the performance of the refrigerant In compliance with th
56. system opened the panel of indoor unit touched evaporator and found that temperature difference of upper and down part of evaporator was obviously large Touched capillary of evaporator of indoor unit found that two groups of capillaries were slightly frosted So faults were caused by block in capillaries Solution removed capillaries with welding machine found that capillary outlet was blocked by weld liquid Replaced capillaries and air conditioner functioned well since then Experience Conclusion according to phenomena we presumed there s excessive refrigerant when we 203 Pioneer air conditioner service manual analyze this phenomenon we shall check whether air flow of indoor unit is sufficient If it is in normal condition check whether there s secondary flow restriction judge the fault by analyze phenomena carefully Case 4 Filter of outdoor unit was blocked by dirt Unit Model KFR50 Phenomena air conditioner can t cool and start amp stop frequently Cause Analysis air conditioner failed to cool outdoor unit started and stopped frequently indoor unit could be started by remote controller and run normally but outdoor unit started and stopped every three minutes and air was not cool in the three minutes so we presumed that refrigerating system couldn t work well check low pressure with pressure meter balanced pressure was 1 1 MPa when air conditioner was turned off and pressure dropped to 0 1 MPa when air conditioner
57. the turn off without non electricity occurred in the ongoing auxiliary electric heating process the indoor fan turns in the low speed wind operation for 40 seconds and stops 9 Intelligent defrosting function DUnder the operation of the intelligent defrosting mode the air conditioner starts the defrosting process if satisfying the requirement of one of the below five conditions the sub conditions included shall all be satisfied During the defrosting process the sleeping light is twinkling a The outdoor fan starts the overloading protection and the outdoor fan stops b Restart the outdoor fan after stop and the continuous running time over than 10 minutes c The accumulated operation time of the compressor gt 45min d The continuous operation time of the compressor gt 20min e TE lt TEI2 a After the 5 minutes operation of the heating mode or 5 minutes later after the defrosting process starts the capture motion for the max difference value between TE and TA when the difference between TE and TA being reduced up than X min and the time lasts gt 3min b The continuous operation time of the compressor gt 5min c The accumulated operation time of the compressor gt 45min d TE lt TE12 Note When the wind speed correction available if the wind speed of the indoor fan drops by one gear 37 Pioneer air conditioner service manual the temperature difference correction value shall be 1 C if the wind speed of the indoor fan
58. to produce heat properly we shall check one way valve carefully if it is not caused by fault on four way valve Section one Refrigerant Filling and Filling Volume Determination Filling refrigerant is a common problem in maintenance of air conditioner After air conditioner running for a long time welding or copper tube may leak little refrigerant out to ambience Refrigerant in split units also will slowly leak out and cause air conditioner failing to work properly There re two problems in refrigerant filling how to fill and how to decide filling volume so that refrigerant can meet design standard of air conditioner Different air conditioner has different refrigerant filling volume Too much or too less refrigerant in air conditioner will cause poor efficiency higher power consumptions shorter life and so on Under following conditions refrigerant shall be refilled or added 1 When welds or copper tube leaks refrigerant shall be discharged completely After welded fixed and vacuum properly refilling the air conditioner 2 If air conditioner has been running for a long time refrigerant is not sufficient so it shall be refilled 3 If the connection tube in split air conditioner had been extended the refrigerant should be added according to per design standard 1 Operation steps for refrigerant filling Air conditioners of different types and capacities shall be filled with different volumes of refrigerant in different way DA
59. trial operation 3Automatic mode When controller selects an automatic working mode the indication light twinkles for 20 seconds and the air conditioner does not start working until the working mode to be selected by the system The air conditioner automatically selects one of the cooling dehumidification and heating mode as the working mode according to the indoor air temperature When TA gt 27 C the controller enters into the cooling mode and follows the mode in working The setting temperature herein is 24 C and the air conditioner runs according to the setting wind speed When 20 C lt TA lt 27 C the controller enters into the dehumidification mode and follows the mode in working The setting temperature is 24 C and the air conditioner runs according to the setting wind speed SWhen TAx20 C the controller enters into the heating mode and follows the mode in working The cooling only type follow the ventilation mode The setting temperature herein is 24 C and the air conditioner runs according to the setting wind speed This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional The system mode will not change along with the variety of the indoor temperature after being selected The new working mode will be selected again after air conditioner turns off or mode switch 4 Cooling mode The setting temperature shall be fixed by the remote control The temp
60. tube was relatively small but indoor unit leaked water so water drain tube might be obstructed For it was a new air conditioner it s impossible that the system had been blocked Finally we found that water drain tube was wrapped under other lines as all lines penetrating the hole on the wall so water couldn t flow smoothly and water drain tube leaked 220 Pioneer air conditioner service manual Solution adjusted position of water drain tube Experience Conclusion pay attention to details during installation and have water drain test after installation Case 7 Water Drain Tube wasn t wrapped tightly enough and leaked condensate Unit Model KFR20 HA Phenomena After air conditioner run for half an hour water drain tube of indoor unit was full of condensate and leaked water Cause analysis according to client indoor unit of newly installed KF 23GW I1Y air conditioner leaked We turned on the unit for half an hour 2m water drain pipe of indoor unit was covered by beads we noticed that the office neared riverside so environment humidity was relatively high in addition room was also large and closeness was poor so a great deal of condensate was discharged from indoor unit because drain tube was only wrapped by a layer of adhesive tape air condensed on it and produced water Solution wrapped the outer wall of drain tube with more insulation sponge and tied the insulation sleeve tightly Experience Conclusion in southern ar
61. was 3A low pres sure was 3kg outdoor fan run normally We presumed that system was blocked leaked or return gas and discharge capacity of compressor was quite unsatisfactory We brought air conditioner to Maintenance Office purged the system with nitrogen checked leak sources under high pressure and found that weld of U type tube under condenser leaked Solution repair welded vacuum the system and filled the system with refrigerant Experience Conclusion air conditioner has been used for a short time but refrigerating efficiency is unsatisfactory in most cases system leaks so firstly we shall check leak source Case 11 Four way valve was broken Unit Model KFR H24B4 Phenomena Air conditioner produced heat once it was started up Cause Analysis once we turned on the air conditioner it worked in heating mode It was a new appli ance so we presumed that four way valve had some problems We checked circuit and it was connected correctly coil resistance of four way valve was normal and conducted electricity well so four way valve was blocked because it was a new appliance there s very low chance that four way valve was broken We knocked the four way valve and started the air conditioner repeatedly it still failed to work properly So finally we confirmed that four way valve was broken Solution replace four way valve Experience Conclusion don t replace four way valve easily slightly blocked phenomena can be fixed by s
62. welding the second one after the first one cools down Welding shall be performed quickly and finished before temperature of four way valve rises 6 After four nozzles have been welded clean the welds with wet tower at the same time lower the temperature of four way valve Check the weld quality and adjust the angles of four tubes 2 Troubleshooting for the compressor 1 Replace of compressor If totally enclosed compressor has some fault because its components can t be bought easily so even motor is broken and renew the loop the quality of compressor still can t be ensured Therefore compressor shall be replaced During replacement of compressor following 6 aspects shall be complied with D New compressor shall be of the same type and specification as the old one If unavailable main performances and characteristics of the new compressor including nominal cooling capacity same work condition power and capacity voltage phase number amp frequency and current of motor and capacity of capacitor shall be same and similar as the old one 2 Efficiency of new compressor shall be not lower than the old one 3 Power voltage shall be based on the demand of client 4 Refrigerant shall not be changed 5 Outside dimension shall be same or similar to old one so that it can be installed on original position 6 Basement dimension shall be the same If unavailable basement shall be adjusted based on the old dimension Direct
63. year but they still failed to work properly We checked the air conditioner voltage was 380v and current was 9A low pressure was 5kg which was normal however temperature of wind outlet was relatively high Based on the forgoing data we presumed that faults were caused by weak wind The main factors may be 1 fault in fan 2 Fault in capacitor of fan 3 Filter and evaporator were dirty 4 Fault in control panel Checked the system we found that wind was weak fan and capacitor were in good condition adjusted wind velocity high intermediate and low three levels of fan relay closed with obvious sound but wind velocity failed to change distinctively So we judged that fault was caused by dirt block of evaporator Disassembled evaporator and found that there was a great deal of fiber in it and it was frosted Solution clean indoor evaporator wind volume became normal air conditioners could produce cool properly Experience Conclusion in some special places for example garment factories hair salon cotton mill and other places with more dirt as well as public In such case poor cooling efficiency was generally caused by discharge fault because the system was blocked by dirt Firstly we should check filter and evaporator to find out if they were dirty To fix such kind of fault we should check surrounding factors and then checked faults in air conditioners checked wind volume of indoor and outdoor units if ambient temperature is to
64. 00 19 00 B u h Red Ye llo w Gre en O utdoa UnitE bctric Chart E To Indoor Unit 172 Pioneer air conditioner service manual 3 24000BTU Electric wiring diagram 1 Indoor unit Frost R Plug Force Swit ch Contro llingPan el 2 3 4 5 N L LANES Aral csi Te mira Ure To Outdoor Unit EBW Red Black Blue Brow n Sensor Heat Pump EType For series of 24 00 0B tu h To Qu tdoor Unit To Power Indoor Unit Electric Chart Trans b mer Fan Motor StepMotor Receiverpanel Indica ti on pan el F Switc h Contro llingPan el Mec yi I 2 3 4 5 N L Y G R B BD R Te mpe ratureTo Outdoor Unit YelbW Red Brack S en sor C dd Wind ET ype For seriesof 24000Btu h To Outdoor Un it To Power Ind oo rUni tElectric Ch art 173 Pioneer air conditioner service manual 2 Outdoor unit Single pole AC Contractor wiring Fan Motor Bla ck Fanmotor White Pam ot Red Red Ov er curre nt Protector Compres sor Br avn Ye llo w Bla ck Compres sor Capacitor Cold Wind Type For seriesof 2400 0Btu h Outdoor Unit Electric Chart T olndoo r Unit Black Fan Mot npe FanMotor Red Ca pacitor White Over current Co mpressor Pr otector Co ntact Co mpress d Brown Brown Bla ck Bla ck Ye llow Compressor Capacitor lt o 7 MN 1 2 Heat Pump Type Fo r seri esof24 000Btu h Ou door Unit Electr icC hart To Indoor Un it 174 Black Co mpressor Co ntact Brown Black Bla ck Yelow Green P d 1 2 CR CB
65. 0BTU are RP plastic sealed motor the rotate speed can not be controlled by the 52 Pioneer air conditioner service manual PCB Optional functions The below functions programs are already write into the Main chip of the PCB and can be performed if only the corresponding hardware is available For example the E CMOS chip is in need for the Auto restart function the corresponding remote control is in need for the I feel function and the relay is in need for the Negative ion function DAuto restart control function a The setting method for Auto restart function After the controller being electrified press the sleeping button on the remote control for 10 times within 5seconds towards to the controller later if the Auto restart function is successfully set there are four sounds delivered from the buzzer If the Auto restart function need to be cancelled press the sleeping button of the remote control for 10 times within 5seconds towards to the controller later if the Auto restart function is successfully cancelled there are two sounds delivered from the buzzer otherwise there is no sound b The contents memorized by the Auto restart function are operation modes setting wind speed setting temperature negative ion function swing status and on off condition c After the setting of non electricity memory function succeeds when the non electricity event happens after turning off the air conditioner normally if re electrify an
66. 2 Outdoor unit No Part Operation Process Remark 1 General 1 Screw off one fastening bolt from the operation electrical box cover and offload the box cover 2 Pull out the interconnection cord from the electrical box 3 Screw off the five fastening bolts from the cover board and offload the board Screw the six fastening bolts from the front panel and offload the front panel 4 Screw off the fastening bolts from the electrical assembly 5 Screw off the eight fastening bolts and offload the outer frame 2 Outdoor 1 Do No 1 firstly fan motor 2 Screw off the fastenings screws clockwise 3 Offload the fan 4 Screw off the four fastening bolts and offload the fan motor 5 Screw off the two fastening bolts and offload the fan motor bracket 152 Pioneer air conditioner service manual 2 3 4 5 Open the cover of compressor release the connection cord Weld off the inlet and outlet tube Screw off the three screws Offload the compressor No Part Operation Process Remark 3 Condenser 1 Do No 1 and 2 firstly 2 Screw off the two fastening bolts 3 Weld off the inlet and outlet tube 4 Offload the condenser 4 Compressor 1 Do No 1 2 and 3 firstly 153 Pioneer air conditioner service manual Section Two the disassembly and the relating attention issues to th
67. 2006 Service Manual ta 2 M a Foreword In order to direct services of all installation and maintenance agents provide all necessary information of Pioneerair conditioners and make the whole service network work under the service concepts of Pioneer we prepare this service manual Thismanualiscomposedof 6 parts Partl 1 e Chapter 1 aimstorepresent basic work philosophy ofhousehold air conditioners Part IL including Chapter 2 and Chapter 3 introduces products offered by Pioneer and represents overall condition of Pioneerair conditioning products Part III i e Chapter 4 provides basic disassembly procedure of Pioneerair conditioning Part IV 1 e Chapter 5 introduces basic troubleshooting workflow of Pioneerairconditioningsoasto enable service workersto get basic knowledge of air conditioning maintenance Part V i e Chapter 6 introduces common used maintenance tools of air conditioning and some troubleshooting cases of Pioneerair conditioning Part VI i e Annex 1 provides all fault codes of Pioneerair conditioning so as to enable service workers to judge the faults correctly in case of any change of Technical parameters and installation amp maintenance methods in this manual priority shall be given to instruction manual Your suggestions and comments are welcome if there s any error or omission in this manual Let s improve this manual with our joint effort Pioneer Air Conditioning CONTENTS Chapter 1
68. 31 YE BE Connection cable 1 32 ase Bee Interconnection cord 1 33 us x Power supply cord with plug 1 34 TRA E Indication lamp holder 1 35 AR Display board 1 36 RE PE as Remote controller 1 110 Pioneer air conditioner service manual Outdoor unit exploded picture III rp pA LOOS MAME MLL HI LOOD VASEEPFEEFFFPEFEFESPEFFEFFIA NS X 111 Pioneer air conditioner service manual Detailed part list of KFR35 EC outdoor unit No Chinese Name Name Material Number 1 Tir bc Dl EA Steel grille 1 2 Ti 2H 1 Front panel 1 3 Toi ss x Top cover board 1 4 HAAAT Outdoor fan 1 5 Ab FAL Outdoor fan motor 1 6 HHLA Motor bracket 1 7 A Beas HAE Condenser assembly 1 8 A Rt VE Condenser gas inlet tube 1 9 TEE Capillary assembly 1 10 JEEN 22 pg rz Backside steel grille 1 11 FB d ant D Handle 1 12 A WUA Right side plate 1 13 BA Capacitor clamp 1 14 PUBL FR Z Fan motor capacitor 1 15 HALLAR Compressor capacitor 1 16 brij FAX Terminal board 1 17 Ha Ae Electrical holding plate 1 18 CRER Partition plate 1 19 VU 386 i y Electromagnetic loop 1 20 UU 386 Pel eR ZA TF Four way valve and capillary 1
69. 4 FS Phenomena Poor cooling 202 Pioneer air conditioner service manual Cause Analysis turned on the air conditioner it could run normally Checked filter of indoor unit and heat exchangers and found that they were quite clean and wouldn t impact the cooling efficiency Checked capacitors and all parameters of indoor and outdoor fans voltage was 220v current was 13 5A low pressure was 0 4MPa and there s no extension line outdoor compressor also run normally in addition no flow restriction was found After air conditioner run about 20 minutes measured current and pressure current became 15A system pressure became 0 3MPa refrigerating efficiency became worse According to the data we presumed that system was blocked or flow was restricted somewhere We checked the connection line between indoor and outdoor units and didn t find flow restriction So we checked outdoor unit and found two groups of capillaries connecting distributor were frosted so we believed that there s some problem on the capillary Separated the distributor and capillaries and found that filter net in the distributor was blocked by oil sludge and foreign substance but hadn t been blocked up so flow in the capillary should be sufficient and caused flow restriction and frost Solution replace new distributor purge the system with nitrogen vaccumize the system and then fill refrigerant in the system air conditioner functions well since then Experience Conclusion
70. B 1 21 Wb pd Copper temperature sensor 1 22 3E Ti ar E Signal receiver holder for Remote 1 controller 23 MIERA Temperature sensor holder 1 24 E Receiver board 1 25 bin TAR Terminal board 1 26 foem TEM Negative ion generator 1 27 xe pete Connection cable 1 28 soe Bee Interconnection cord 1 29 rijs e Power supply cord with plug 1 30 NA BL Display board 1 31 RE PS as Remote controller 1 130 Pioneer air conditioner service manual Outdoor unit exploded picture TDI ODS ML VM LLL VH gs ID ZEPESHEEEEEEEESFEEFEEFFEFIA S S S S 131 Pioneer air conditioner service manual Detailed part list of KFR25 HS outdoor unit No Chinese Name Name Material Number Tir bc od EA Steel grille 1 2 ri te ZELE Front panel 1 3 Toi sz x Top cover board 1 4 Afi fi XU Outdoor fan 1 3 ENE Outdoor fan motor 1 6 HHLA Motor bracket 1 7 A tas AE Condenser assembly 1 8 Ao ERE XE Condenser gas inlet tube 1 9 EME E Capillary assembly 1 10 JE e 22 pd EEL Backside steel grille 1 11 HB ane nr DL Handle 1 12 AA Right side plate 1 13 nas Capacitor clamp 1 14 PULVERE Fan motor capacitor 1 15 FALL Compressor capacitor 1 16 bri FAX Terminal board 1 17 HE ir A
71. BUZZER 4K R41 IK MC3021 12 IN4148 10U 25V R8 1 xi 1C3 JL8 5 OSCI 27 6 c OSC2 PTDS 55 PTEO 1 REST PTAO E RE CONG 26 VOD HIS 8 EE ei Bus COM 25 JM ig R Yay m eMe Rag IK COMI 24 prs prp4 227 1 Ee TD mi R38 IK oua bras Praal icA EE D C1402 Kos P COL PTA2 8 N 3 164 C9SC pra prep 23 RG PK 4 164 CSDA EEPRO CNG mn ES Ay 1o MNN 20 Ri A E u PTB6 PTB3 mn Le aal olen Rs RIIK faAi fa 2 DAI 1N4007 y 10 7 1C2003 o a 72 I LR PTB4 o A B prpApci2 R5 14 B dada cb IIx PTD6 VSS al idadicbidide SIS xz apo Ql 901 10K y u gt Rif 5 D iU cn 2 XH 3 l 3 p2 1 D3 A 1X4 11 4 c2gopuifsv i1000U b5v 10005104 Title Size Number Revision A3 Date 19 Jan 2006 Sheet of s File GAUNA DRAEE TA IDA P 1 2 3 4 5 6 7 8 231 Pioneer air conditioner service manual 3 Schematic Diagram of Controller Panel of HS Series Air Conditioner Motorola Chip 1 2 3 4 5 6 7 8 CN10 STF WFAN DIR CNII VH 5 63 63 iP 63 ee A STE WFAN Loss N 2 FAC P 1 5U 500V 1 i CR ms Ea ha rond t to 5 o 1u Trsy 190 1 w EIOT pest pio alta al in TERRE ER A lt e T va E en ince ll se RYS Ryl FUSE al d 3F
72. E E Thermophysical PI Azeotrope Azeotrope Properties Boiling point C 40 8 52 7 43 7 Critical temp C 96 1 72 5 87 3 Refrigerating Condensing pressure Mpa 2 17 3 38 2 31 Property Evaporating pressure Mpa 0 62 1 00 0 64 Pressure ratio 3 50 3 38 3 59 Exhaust Temp CC 97 2 95 1 86 7 10 Pioneer air conditioner service manual Slippage temp C 0 0 17 4 6 Capacity of refrigeration 100 141 101 COP 100 92 5 97 Labreatngoil Lubricating oil Mineral oil POE POE Mutual solubilization Good Fair Fair 2 The theory of refrigeration There are many methods in artificial refrigeration The most popular one among of them applied in practice is the steam compressing type It completes the refrigeration task with the help of some fluid of low evaporating temperature which can maintain a stable temperature while absorbing and reducing the quantity of heat from the surrounding mediums during evaporate period The temperature reduction function of the air conditioner is mainly realized by the refrigerating cycle The steam compressing model refrigeration system as shown in Picture 2 1 includes the most essential refrigerating cycle composed of four parts 1 Compressor 2 Condensor 3 Throttle device Capillary tube or expansion valve 4 Evaporator which are connected in turn by the pipes and form an airtight system Its working process is The liquid refrigerant absorbs the quantity of
73. H 1 p F 1HQC 3FF 1 ad 0 Roc BF Rub A ES0V A von Ac N As Py m i ao pe a E Do CNS R 10UDSV CJ Rae W IN41H8 om 8 12 ca 1 12 200 12 Ld 1R35 R23 y y f CN2 E de Us WARU ens gt x ICI JL8 Z e q164 gt E OSCI e pe 27R3 lla e H osc Pros TSR IK Alv re PTEO RE IK EATS E REST PTAO REE ex 12 Ri IK CONS A R31 TK COM 25 In TE RSI NO PTA HE OEE oe m m R30 IK COMI 4 2 1 16 ee UE m Beel R39 IK O O 28 PTD4 PTA2 8 Nyt 2 15 2 9 29 Yo 3 14 B 102 Li 7 164 C88C Ci 103 164 OSDA EEPRC ce seu Al E BENE B 3 fm IK faAi 10 al I Xx Leu Las u pet ra 1 CNS XH 2 RIP e Li 13 d J B R3 14 1K CN7 EEPROMECL XH 2 El D a 1 E E Ql 9014 R2 10K V EJ A R EI 0 10K t 5 DI IC6 CNI cl ATM24C02 XH 3 8 1 3 5 lop SH NC Ds 1C2 1C2 51 WRC er 1 IN4007 7805 12 7805 5 Pos 2 35 Vin Vout A vin Vout gt R210K EE El E3 zm CI A 1X4 INAQDODUBSM 104 EJ a a ded ei m lo0Up5V 100034 104 Title Size Number Revision A3 Date 19 Jan 2006 Sheet of File GMA Uig PRA ETA DADA 1 2 3 4 5 6 y 8 232 Pioneer air conditioner service manual 4 Schematic Diagram of Controller Panel of E Series Air Conditioner with Display Screen with Renesas Chip 1
74. Hs d Transformer 1 19 ESPECIE TH Plastic temperature sensor 1 20 ERIR Main PCB 1 21 A p Copper temperature sensor 1 22 35 Ti as E Signal receiver holder for Remote 1 controller 23 Un PER SK SCR Temperature sensor holder 1 24 ect Receiver board 1 25 bin fd Terminal board 1 26 fom TEM Negative ion generator Optional 1 27 HEEL Connection cable 1 28 FE Unt a2 He Ze Interconnection cord 1 29 E x Power supply cord with plug 1 30 NE BL Display board 1 31 RE PE as Remote controller 1 126 Pioneer air conditioner service manual Outdoor unit exploded picture ETI OMI 4 VM VM VM SAAI ELL ELLE LLL NS 127 Pioneer air conditioner service manual Detailed part list of KFR25 HSL outdoor unit No Chinese Name Name Material Number 1 Tir pc Dl E Steel grille 1 2 T ZELE Front panel 1 3 Toi s BL Top cover board 1 4 Ait XU Outdoor fan 1 5 P JL Outdoor fan motor 1 6 pus Motor bracket 1 7 Abid ZELE Condenser assembly 1 8 A ERE VE Condenser gas inlet tube 1 9 EME Capillary assembly 1 10 EAS Backside steel grille 1 11 HA ar ant BL Handle 1 12 A il i Right side plate 1 13 d 88 Capacitor clamp 1 14 XBLA Fan motor capacitor 1 15 HALA Comp
75. L R4076 670 R4070 670 R4070 950 R4070 950 Cooling test condition Indoor unit DB27 C Wb19C Outdoor unit DB35 C Wb24 C Indoor unit DB20 C Wb Outdoor unit DB7 C Wb6 C ax Cooling test condition Indoor unit DB32 C Wb23 C Outdoor unit DB43 C Wb26 C Indoor unit DB27C Wb Outdoor unit DB24 C_Wb18 C n motor Compressor 57 Pioneer air conditioner service manual 12000btuB4 E R 12000btuB4 E R Indoor Indoor Wall mowntedVall mounted 3 1 1 al 5 Dehumidifying Kg h 3 mein WT K 3 85 zZ 0 Performance W Cooling 48 4 5 bi Heating dB Power suppl 1 220 240 50 d Cooling w 1400 input Heating V Input acto Sumingcurm A 350 8350 Power Length m cod lm 25v rea 25V 164 Fusecapaciy A 315 an y TRUCO vovo soos wesen Son Lagi m eom p oom EE o Netweight Ke o 5 37 95 388 l meio Liquid Nimt o6 35x3600 w6 35x3600 e Gas Nimim o9 52x3600 09 52x3600 Drain pipe bmt 014x780 14x780 Type Rosy Rosy Cd Type ce e Imm pes Dem 1 S Type Plastic sealed Tron shell Plastic seated lonstell Siatedimpue W 19 30 19 oaf Heat exchanger row line 2X13 1x20 2x13 2x20 Refrigerant controller Capilay Capilay Freezedoileapacity _ y Refrigerant Charge g
76. LLLALL LAL ALL Ld NS 103 Pioneer air conditioner service manual Detailed part list of KFR25 EC outdoor unit No Chinese Name Name Material Number 1 EA ped EE Steel grille 1 2 rii te ZELE Front panel 1 3 Toi ss x Top cover board 1 4 Ait jr XU Outdoor fan 1 5 5 BL Outdoor fan motor 1 6 HHLA Motor bracket 1 7 Abt as ZF Condenser assembly 1 8 AERE VE Condenser gas inlet tube 1 9 EME HI Capillary assembly 1 10 EEES Backside steel grille 1 11 Hir nt A Handle 1 12 AA WUA Right side plate 1 13 n aO Capacitor clamp 1 14 JUL FEL AE Fan motor capacitor 1 15 HA p LE Compressor capacitor 1 16 bri FAX Terminal board 1 17 HA as Ae Electrical holding plate 1 18 B x vr c Partition plate 1 19 UU zi We Zl p Electromagnetic loop 1 20 PU 386 Ix E A 2H AF Four way valve and capillary 1 assembly 7 Hague e Compressor connection cord 1 22 Hi pU Betty Ze Compressor grounding cord 1 23 Hd B Compressor terminal cover 1 24 RUDI d Over load protector 1 25 HA pL Compressor 1 26 BOE RHIF A Liquid valve 1 27 AERE AE B Gas valve 1 28 YA Valve plate 1 29 IAEA Chassis 1 104 Pioneer air conditioner service manual 3 KFR35 ET Indoor unit exploded picture 105 Pioneer air conditioner service manual Detailed part list of KFR35 ET indoor unit
77. R407c 1270 R407c 1270 Cooling test condition Indoor unit DB27 C Wb19 C Outdoor unit DB35 C Wb24 C Indoor unit DB20C Wb Outdoor unit DB7 C Wb6 C Max Cooling test condition Indoor unit DB32 C Wb23 C Outdoor unit DB43 C Wb26 C Max Heatingtestcondition Indoor unit DB27 C Wb Outdoor unit DB24C Wb18 C BW s amp co B O eg H H oO 5 98 Input Dimension ompressor an motor 58 Pioneer air conditioner service manual 3 Parameter of product R410a 9000BTU 12000BTU E 9000btuA4 E R1 9000btuA4 E R 12000btuB4 E R 12000btuB4 E R1 Wall mounted iim i jesse ze so 39 oo a 3 tag 5 e so 1 1 17220 240 80 raved Cooling w 850 eso 120 1240 input Heating 900 1270 40 43 vo a p E MIT Performance oo Rated 4 0 Input Cooling 985 988 98 facto Heating og P TEN EE cord type 250V 10A 250V 10A 250V 16A 250V 16A 315 315 3 15 315 dimen gt sry UP 210745250 oxaal 2109x280 aoocaraxsao _roensexoso soxsisxsa 2105x250 3 98 98 9 9 29 0 29 0 y lor s00x 18x64 Ih Newegh Kc 93 32 9 3 33 3 5 36 Kg Comectiod Liquid Mmm 6 35X3600 6 35X3600 6 35X3600 6 35X3600 pie D9 52X3600 09 52x3600 D9 52X360 9 52X3600 D14X780 D14X780 D14X780 D14X780 BEK ed
78. The operation theory of the home Air Conditioner noon oenen eneen een enenvenn 1 Section one the basic knowledge of pyrology and ventilation sens ensen vennen eenn 1 Section two the basic knowledge of refrigeration enen venen seen verven verveend en venen enn 7 Section three the basic structure of the air conditioner onee oen eneen eenen ven venen venen 17 Chapter 2 Introduction of Pioneer products none enseeeneeenneenseerseeeenvenseerseeeeneeenneenseesneeenneenseerseeenn 31 Section one the split amp wall mounted type oane venen ee ee eene 31 Section two Floor standing unit Ives i farses eoe Eo A tang 63 Section three introductions of the optional functions 0 0 cece cece ence eee vennen verveend ennen 95 Chapter 3 Exploded pictures of Pioneer Produc nina eer re E ken keen cee ts 97 Section one E series Products ii A Ee o oae dranken 97 Section two E series DEOGUOIS eos ere eh rere pee e ie exo o Ex ra beu et sia 121 Section three Floor standing type air conditioner exploded pictures onee 141 Chapter 4 The disassembly and the relating attention issues to the part of Pioneer product 150 Section one the disassembly and the relating attention issues to the series products of 9000BTU 12000BTU isses 150 Section two the disassembly and the relating attention issues to the series product of 18000BTU 24000BTU aaneen m n 154 Chapter 5 Troubleshooting and electrical chart of Pioneer air conditioner esses
79. Y G Red Black Yeallew Greer CR B Y G CBD BR Rd Black To Indoor Unit Red Orientation Valve Temperature Sensor Blue Blue Yelo w Green E l 4 5 vow Blue Brown To Indoor U nit To In do orU nit Pioneer air conditioner service manual 3 Outdoor unit Double pole AC Contractor wiring Fan Motor Black Fan motor Red Capa dtor R ed White Compressor Compressor Br own Contact Bro wn Ov er current Black Protector Black Ye Ilow e ee Yello w G re en Cd d Win d Ty pe 1 L2 For series of 240 00 Btu h CRB Y G Red Black Yel ow Green Outdoor Unit Electric Chart d To hdoorUnit Fan Motor Black Fan Motor R ed Capacitor Red Orientati White Vaud dd Te mper atu re Compress a Sens or Contact l Compressor Bro wn Brown 0 t Black po Eto Black Blug BIE Yellow Yellow pull Compress or Fog Capa ci tor X a f 112 4 5 Heat Pump Type CR B Y G BL BR For ser ies of 240 00 Btu h allow Red Black Green Blue Brown Tolndoor Outdoor Unit y Wm Electric Chart unt TolIndoor Unit 175 Pioneer air conditioner service manual Chapter 6 introduction to the regular service tools for air conditioner The regular service tool and application 1 Vacuum Pump Vacuum pump is a device used in vacuumize for the mini type refrigerating equipment The common vacuum pump in practice is the revolving blade type The exterior structure and the working theory are indicated as the below pictures 1 air intake 2 oiltank
80. a part of rib is broken some gas will be short circuited and exhausting quantity of compressor will lessen To avoid this type of fault apply anti florin rubber on two sides of steel rib If asbestos rubber gasket is used risk of fault like this will be very high c Severe leakage of gas valve including rotary type If discharge and return gas valve blades can t match tightly with valve line on the valve plate and there s certain seam when valve discharges or returns gas some gas will leak out from seam and discharge capacity of compressor will lessen Follows are Main factors for this kind of faults 1 system is not clean enough there s some dirt flowing with refrigerant Dirt sticks to the valve line and valve blades when valve blades run abrasion of valve blades and valve line will speed up and sealing performance will lessen gradually 2 discharge temperature is excess high often and so refrigerant produces particles which sticks to valve structure and damages tightness of valve 3 slightly liquid hammering often happens in the system due to the impact of liquid valve blades are deformed or damaged or abraded severely so tightness of valve structure is decreased valve plate has been liquid hammered severely gas valve is damaged and valve blades are broken so that tightness of valve is severely damaged d Crack of exhaust tube in pump shell reciprocating To the compressor with unbalanced reciprocating pump body librate
81. acks refrigerant evaporator will be frosted generally on the inlet if filter is blocked air returned tube low pressure tube of system will be frosted Case 2 Indoor unit leaked water in low wind mode Unit Model KFR35 TD Phenomena Beads dropped form air outlet Cause analysis according to client water was blown form air outlet after air conditioner run for 2 or 3 hours maintenance personnel observed the phenomena and found that tiny bead was blown from air outlet when air conditioner was in low wind mode Air conditioner was used in a 15 m room and set temper ature was 17 Celsius Degree evaporation and exchange amount decreased when temperature dropped so too much condensate was produced and blown outside the air outlet Solution changed low wind mode to high wind mode or automatic mode set temperature on 24 Celsius Degree condensate never occurred again Experience Conclusion foregoing fault was caused by physical factors so the only thing need do is to explain to client Fog blown from air conditioner is more common in rain season in addition in southern China raininess low ambient pressure and high humidity may result in such problem To fix the problem we should check evaporator and fan blades to see if they re clean if they re clean we should operate air conditioner in high wind and high temperature mode Case 3 Guiding channel was blocked and leaked water Unit Model KFR35 M 218 Pioneer air conditioner se
82. al Is there any voltage change between the chips 23 22 20 19 The chip teas YES Is there any voltage change between No B rive chip IC4 10 13 ofthe the chip ULN2003AFW ULN2003AFW YES The step motor fails 6 Heating Mode Can Work But No Hot Air Blow DCheck if the set temperature is lower than the indoor temperature 2 Check if the indoor PCB is connected to the terminal correctly restarted in some 3 minutes YES after the above problems solved Normal Y NO Is the chipIC1 7 voltage DC5 0 V ES The chipIClfails Y YES 4 Is the chipIC1 2 voltage high NO The chip IC3fails YES Y Is the voltage at the connecting io The chip IC4 3 point of chipIC4 ULN2003A low ULN2003 A fails YES y Is relay output normal ee Repl relay RY3 YES Y The interconnection cord or the 4 way valve is abnormal YES Y Check the interconnection cord Replace PCB or replace the 4 way valve 167 Pioneer air conditioner service manual 7 Remote Control Can Not Work Trouble shooting procedure Take out the batteries and reinsert them after 5 seconds Is the LED lighten YES Is there music when the ON OFF button was YES NO Is the voltage of batteries lower than 2 5 V TES Replace batteries i NO NO Is the LCD display normal LCD fails i YES C
83. ame Material Number l HR eH E Panel 1 2 Zi ER Pd Anti bacterial Filter 2 3 YE C pi os WE PI Vitamin C amp Anti mites Filter 2 4 iy PY H EF Filter 2 5 WAT n Screw cover 3 6 rPE ni Cover of Medium frame 1 7 HEH fF Medium frame 1 8 FT Horizontal air blade 1 9 FKF Vertical air blade 2 10 FM Air blade holder 1 11 zh BELA HE Step motor 1 12 ti Vi UH ZH TE Indoor fan 1 13 SAA JE Rubber bearing 1 14 PAS LAR Left plastic crutch for evaporator 1 15 PICA Bh Hl Evaporator 1 16 JER BE ZH fF Chassis 1 17 HRA Mounting plate 1 18 E ER Hsc Tube clamp plate 1 19 XB HAL ZL LF Indoor fan motor 1 20 FEL zi Cover for indoor fan motor 1 21 d ix Electric controller box 1 22 ZEI d Transformer 1 23 ZE AE aS Plastic temperature sensor 1 24 ERR Main PCB 1 25 A ed Copper temperature sensor 1 26 Xi PE as pe AR Signal receiver holder for 1 Remote controller 27 Um PETAR XR Temperature sensor holder 1 28 PEUT Receiver board 1 29 bin TAR Terminal board 1 30 foc T EEG Negative ion generator 1 31 YE PRE Connection cable 1 32 ys xe He k Interconnection cord 1 33 FH ZE Power supply cord with plug 1 34 TRA BE Indication lamp holder 1 35 WAN Display board 1 36 REDE Remote controller 1 102 Pioneer air conditioner service manual Outdoor unit exploded picture SO LOO II II LOIS ED STTLLLLI
84. an be shortened accordingly The quantity of heat transferred by the condenser is equal to the sum of the one absorbed by the indoor evaporator and the one occurred during the operation of the compressor The area of the surface to the common condenser is usually larger than the one of the evaporator in order to promoting cooling capacity for the room 5 The throttling component The refrigerant in the refrigerating system of the air conditioner has the need for maintaining a certain evaporating and condensing pressure in order to absorb and release the quantity of heat and realize the circulation of the system The throttling component is the one in controlling the refrigerant and maintains a certain flux It is the device used in the refrigerating system cycle for accommodating the flux of the refrigerant It can have the temperature and pressure of the liquid refrigerant at middle temperature and high pressure coming from the condenser dropped and then send them to the evaporator for obtaining the more evaporating temperature and pressure 21 Pioneer air conditioner service manual The air conditioners in different specification have different capacity So the throttling component in controlling the different flux shall be different The throttling component type in the general air conditioner includes the capillary tubes type and expansion valve type But only capillary tubes applied in the home use air conditioner because of the small flux it is
85. ance personnel replaced blades of the same model but noise remained the same Replaced the motor with an YDK30 8 155 motor produced by Jiangsu Weiteli Co replaced capacitor with a new one of 3 5uF YDK30 8A noise cleared off We analyzed faulty motor and found that amplitude and frequency produced by running motor vibrated with unit shell and wind system and interfered with air flow Solution replaced indoor fan motor Experience Conclusion indoor unit noise is generally resulted by blades or motor if it is difficult to decide the fault source we can adopt method of denying one by one Case 3 Wind Sound of H Series Air Conditioner Unit Model KFR35 HS Phenomena Wind sound of indoor unit Cause Analysis when indoor unit was running wind sound varied with the swing of fan blades according to our analysis plastic sealed motor or controller has some faults change motor and controller faults remain the same Maintenance personnel pushed on manual swing button wind sound disappeared so the reason was as follows when air blades swung wind outlet area varied when it swung to the top position outlet area was smallest wind was obstructed and produced wind sound Solution replaced the faulty controller with Motorola chip controller 212 Pioneer air conditioner service manual Experience Conclusion the said noise is wind sound which isn t beyond noise standard In such case do not change motor or controller without careful conside
86. and screw off the fastening screw of the valve rod by the inner hexagonal spanner The attention herein is If screw off in clockwise direction the valve rod moves down and the valve hole closes otherwise the valve hole opens and the two vertical pipelines get through together 2 Three way stop valve In addition to all the above functions of two direction cut off valve the three direction cut off valve owns an extra service entry that provides the convenience for air conditioner s inspection and service The tree direction cut off valve is installed on the gas tube s joint entry of the outdoor unit It s in a right angle shape Despite of two pipes joint entry and one valve rod position regulator entry there is an additional service entry The practicality is as the picture 2 14 The common three direction cut off valve is equipped with a valve core and composed with two pipeline s joint entry one regulating entry and one service entry The four entries are straight as the structure indicated in picture 2 15 The valve core inside the service entry is used for sealing the entry and shall be covered by the dust proof copper screw cap When the valve rod moves down to the close position the tube breaks off from the pipeline of outdoor unit On the contrary when the valve rod is screwed off upward to the open position two connecting tubes get through together and the outdoor unit get through with the indoor unit consequently When fill in t
87. apacitor 1 11 FO AC Vc pfi AC Contactor 1 12 EPLER Fan motor capacitor 1 13 FRAG HM Wiring clamping cover 1 14 Has Ae Electrical holding plate 1 15 Tib AR Terminal board 1 16 Ka px vr x Partition plate 1 17 HAL Compressor 1 18 EI er 2H fT Capillary assembly 1 19 DU 38 Dx ET p ZELE Four way valve assembly 1 20 BE RHIF Dg8 Liquid valve Dg8 1 21 BERZH Dg13 Gas valve Dg13 1 22 ERA Chassis 1 23 TEE A KORE Screw 4 24 EA Valve plate 1 25 Hal DALE Outdoor fan 1 26 HALAS Motor bracket 1 27 FAARF LAL Outdoor fan motor 1 28 TF TEE LEREN Screw 4 120 Pioneer air conditioner service manual Section two H series products 1 KFR2S HSF Indoor unit exploded picture 121 Pioneer air conditioner service manual Detailed part list of KFR25 HSF indoor unit No Chinese Name Name Material Number 1 TE HAF Panel 1 2 TEYE Pl 28 ftr Filter 2 3 HEAS ni BL Cover of medium frame 1 4 cH HE a Medium frame 1 5 F Horizontal air blade 1 6 FFA Vertical air blade 12 7 amp AAE Air blade holder 1 8 EpL IE Step motor 1 9 ti Vi UH 2H TE Indoor fan 1 10 PBC AR Rubber bearing 1 11 ZSR tis Ae SCR Left plastic crutch for evaporator 1 12 EAN Evaporator assembly 1 13 EEH Chassis 1 14 HRA Mounting plate 1 15 E ER Hs Tube clamp plate 1 16 XB RUE Indoor fan motor 1 17 Bd ix Elect
88. ated as per following parameters D Low pressure evaporate pressure shall close to pressure on return gas tube of compressor which is 0 5MPa absolute pressure 0 6MPa and the evaporate temperature is 5 C 2 Return gas temperature temperature on the return gas tube of compressor shall be within 7 C 15 C condensate instead of frost can occur on the return gas tube 3 Running current Generally running current of compressor shall not exceed rated value on the nameplate 4 Indoor unit air inlet and outlet temperature difference In cooling operation temperature difference 196 Pioneer air conditioner service manual shall be no less than 10 C and in heating operation temperature difference shall be over 15 C High pressure High pressure value of cooling operation shall be about 1 5 1 9MPa 6 Weighing When we fill the air conditioner with refrigerant we shall weigh refrigerant with electronic weighing appliance if available It is one best way to add the refrigerant Temperature of high and low pressure valves Normally the low pressure valve has the lower temperature and more condensate than the high pressure valve of split units To check high pressure value the ambient temperature should add about 15 C for example ambient temperature measured is 35 C actual temperature of refrigerant in condenser shall be about 50 C so we can know high pressure is 16 6MPa absolute pressure to check low pressure evaporat
89. ated repair it is very important to analyze the reason why components can not function well instead of replacing components without careful consideration Case 4 Temperature sensor cannot function well Product Model KFR H24B4 FS Phenomena Poor heating efficiency air velocity is relatively low Cause analysis we went to client s home to check the air conditioner turned on the unit and pushed on the heating button Air velocity was relatively low air outlet was very hot under cooling and ventilation mode air velocity was adjustable and varies obviously we concluded that fan functioned well So we presumed that there may be certain problem in indoor temperature sensor Solution replaced indoor temperature sensor and air condition functioned normally Experience conclusion when air conditioner heats the room it can prevent producing of cold wind so 189 Pioneer air conditioner service manual when indoor temperature sensor and heat exchanger exceed 25 Celsius degree fan produces gentle wind when temperature exceeds 38 Celsius Degree fan produces wind of set velocity We checked and found that wind velocity is very low and wind temperature is quite high so fan works well So we presumed that the sensor failed to reflect the correct temperature and then indoor fan can t run at set velocity so it must be replaced Problems in temperature sensor constitute a large percentage of all air conditioner faults First of all we should
90. ater 219 Pioneer air conditioner service manual Cause analysis We turned on air conditioner found that air pipe of indoor unit leaked especially on left and right ends This air conditioner adopted four folded evaporator two water collection channels upper and down upper channel was on the back of evaporator where a water barrier guided water to upper channel condensate flew from two ends of water barrier which were affixed with sponge to indoor unit Solution adjusted sponge on water barrier air conditioner did not leak again Experience conclusion ED Series air conditioner adopted four folded evaporator leak of which is caused by many factors including following aspects 1 Guiding plate is not installed in such case air conditioner leaks badly condensate will be blown or flown from air duct 2 Tubing angle of evaporator is not proper 3 Sponge on evaporator has fallen off 4 Evaporator and plastic mould basement fail to fit tightly 5 Sponge on water guiding plate is not affixed properly During maintenance we should check air conditioner carefully to find leak source and find water leak condition dropping or weeping and then deal with the problems accordingly in this way we can get twice the result with half effort Case 5 Condensate leaks from connection line joint Model No KFR35 HB Cause analysis Water dropped from connection tube in indoor unit we suspected condensate leaked We checked the ai
91. ater after running for some time evaporator was frosted or frozen Cause Analysis according to client indoor unit leaked water We turned on air conditioner and observed after 10 minutes water started to be blown from indoor fan Disassembled shell we found that 2 3 U shaped fins near evaporator were very cold and covered with condensate and other fins were not so cold turned on the air conditioner again and it run in refrigeration mode for more than 20 minutes fins near evaporator were frosted slightly System pressure was very low 3KG so system lacked in refrigerant seriously refrigerant gasified in fins near input tube when it flew into evaporator so temper ature of these fins were very low but temperature of other fins closed to room temperature and then fins of low temperature produced condensate which was blown through outlet with wind 20 minutes later evaporator was frosted or frozen Solution checked leak sources and found that connection tube was not connected correctly with low pressure valve body and so lock position of nut leaked refrigerant Connected the tube again and tighten the nut vaccumized the system and filled with refrigerant air conditioner worked well since then Experience Conclusion air conditioner leaks water if indoor heat exchanger doesn t leak air touch heat exchanger at different positions to judge whether there s obvious temperature difference so as to judge whether condensate is caused by syst
92. b y NO Is the chipIC1 7 voltage DC5 0V 9 The chip IC1failsj YES A Y EN lt Is the chipIC1 2 voltage high NO The chip IC3fails YES Y Is the voltage at the connecting point of chipICA ULN2003A low NO The chip IC4 jl ULN2003 A fails YES y Is relay output normal 2 Replace relay RY3 YES v The interconnection cord or the 4 way valveisabnormal yes Y Replace PCB Check the interconnection cord or replace the 4 way valve 161 Pioneer air conditioner service manual 7 Remote Control Can Not Work Trouble shooting procedure Take out the batteries and reinsert them after 5 seconds Y NO 4 Is the LED lighten Check refer to the 5 2 part Is there music when the ON OFF button was pressed SERIE i NO lt Is the voltage of batteries lower than 2 5V gt YES Replace batteries NO NO 7 Is the LCD display normal LCD fails YES Is there signal when the ON OFF button was NO Replace buttons pressed i YES Is there any change on the voltage of chip IC1 39 The chip fails t YES NO 4 Is there any change on the voltage Q1 Hs Replace audion ES Is there any change onthe voltage LED Emission tube fails The receiver fails 8 The Failure Analysis of the Main Part
93. c aluminum foil is generally applied for the wing of the evaporator so as to reduce the surface tensile force of the condensing water and quicken the water flowing speed and consequently accelerate the air flowing speed b Condenser Condenser liquefies the high temperature and pressure gas refrigerant delivered from the compressor The structure of the condenser in the air conditioner 1s basically same as the one of evaporator When the compressor works the high temperature and pressure gas refrigerant ejected from the compressor enters into the copper pipe of the condenser through the air inlet mouth and turns into the liquid after the heat exchange process undertaken by the outside wings The condenser usually chooses the air as its cooling medium However due to the low heat transmission coefficient of the air the wings on the copper pipes are used for enlarging the heat exchange area with the air and the heat transmission ability 1s also enhanced by the blast of the outdoor fan To the split type air conditioner condenser is assembled and located in the outdoor unit together with the compressor For the purpose of enhancing the heat exchange coefficient of the condenser the number of the wings can be increased or the interval distance between the wings can be shortened Because there is no condensing water being produced by the wings of the condenser and there is no much air resistance as the evaporator faces the distance between the wings c
94. cale in usage that has 100parts between the freezing point of 0 C and the boiling point of water of 100 C under a standard atmosphere 760mmHg e g 1 013x105Pa Each part is one centigrade with the abbreviation of 1 C and usually a t stands for its reading The Fahrenheit scale has 180 parts between the freezing point at 32 F and boiling point at 212 F of water under a standard atmosphere Each part is one Fahrenheit with the abbreviation of 1 F and usually a t1 stands for its reading All the temperatures defined by the Celsius scale and the Fahrenheit scale are called relative temperature Absolute temperature is also called thermodynamics scale or Kelvin scale which is adopted in the International Unit System It deduces the temperature at the absolute stop stage of the heating activity of the molecules inside the substance is 0 degree e g 273 15 C which the absolute temperature is stood for by K Usually a T represents its reading 1K of the absolute temperature scale is absolutely equal to 1 C of the Celsius scale on value The conversion relation between the Absolute temperature T the Celsius scale t and the Fahrenheit scale t1 is as below t T 273 16 T 273 C F 9 5 t 32 F 1 8t 32 F The glass thermometer thermocouple thermometer Electric Contact Thermometer resistance thermometer and semiconductor thermometer are the common meters in measuring the temperature during the refrigeration project 2 Pre
95. ce and catalyzing combustion etc Section two the basic knowledge of refrigeration 1 Refrigerant Refrigerant is also called refrigeration Working Medium The first letter R of the English word Refrigerant stands for it It absorbs the heat by boiling away the liquid through the variety of its own state in the refrigerating device and transfers the heat released from the gas liquefaction process to the surrounding medium materials inside the condenser with the impact of the third party s work The state variety of the refrigerant within the system is a kind of physical variety with the only function of absorbing heat and transferring heat but without any change to its property There are around more than eighty kind of refrigerant available now and some others are under development DThe Refrigerant kinds According to the chemical composition the refrigerants can be classified as follows DInorganic compound refrigerant These kind refrigerants were applied earlier for refrigeration purpose such as the air water Ammonia and Carbon dioxide etc Among them some were washed out already The typical sample is Carbon dioxide with the disadvantage of high working pressure low critical temperature small capacity per unit and low refrigeration performance As the replacement item the Ammonia is one of the Inorganic compound refrigerants being applied widely R717 stands for it T Pioneer air conditioner service manual Freon
96. clusion air conditioner lacks in refrigerant and is frosted so indoor unit leaks and the cooling efficiency is poor The fundamental problems are weld leakage and lacking in refrigerant Case 9 Weld leakage of condenser distributor Unit Model KFR 41A5 Phenomena Failed to cool running indicator and 187 indicator blinked at the same time air conditioner couldn t be turned on Cause Analysis air conditioner was only used for two days according to client air conditioner failed to cool We checked the air conditioner voltage was 390v balanced pressure was OMPa according to phenomena and data we presumed that the system lacked of refrigerant the air conditioner was in low pressure protection situation Opened outdoor unit we found oil stain on the weld of distributor of 205 Pioneer air conditioner service manual condenser so refrigerant leaked out Solution repair welded leak source and added refrigerant Experience Conclusion when air conditioner is running system pressure is zero we can judge that re frigerant leaks out generally oil stain can be seen on leak sources Maintenance personnel shall be familiar with blinking conditions of indicator Case 10 Weld of U type tube of condenser leaked Unit Model KFR35 HY Phenomena failed to cool Cause Analysis air conditioner was used less than one month cooling efficiency was unsatisfactory Checked the air conditioner temperature of compressor was relatively high current
97. d turn on the air conditioner there is no 3 minutes protection delay occurred to the compressor when the non electricity event happens accidentally under the power on status if re electrify and turn on the air conditioner there is 3 minutes protection delay occurred to the compressor d If the setting of sleeping and timing functions occurs before the non electricity event after air conditioner owns the Auto restart function the default condition of the controller is power off status after being electrified again 2 I feel function a The setting method for I feel function Press the I feel function button on the remote controller the controller will effect the I feel function once receiving the signal and the controller herein will default the temperature value of the sensor on the remote control as the previous TA of the controller Except the defrosting case b The quitting method for the I feel function Q Press the I feel function button the former I feel function setting will be cancelled at once O Position the remote controller towards to the receiving window of the controller the remote control may deliver the signal to the controller every 3minutes If the controller fails to receive the signal from the remote control the I feel function will be automatically cancelled and the TA control the temperature according to the temperature value detected by the TA sensor of the PCB c When the I feel function starts the contro
98. dd refrigerant with low pressure valve If only small cooling capacity is required refrigerant can be filled with low pressure valve Refrigerant flowing in low pressure is relatively slow but that is safer and easier to control so most household air conditioners are filled with refrigerant in this way Connect Low pressure hose with maintenance hole of low pressure valve and connect intermediate hose with small refrigerant bottle If vacuum pumping is required firstly we shall connect high 195 Pioneer air conditioner service manual pressure hose with vacuum pump and vacuum the system Tighten thimble head Discharge air in the hose with refrigerant steam in system or refrigerant in the bottle If small refrigerant bottle has been connected with hose and vacuum pumping has been done there s no need to discharge air S Start up air conditioner check low pressure value when it runs stably and judge the remaining refrigerant in system Open valve on the refrigerant bottle and then refrigerant enters into refrigerating system At the same time we should observe and control low pressure continue to fill the refrigerant until pressure reaches standard evaporate pressure Refrigerant from low pressure valve is in gaseous form When gas pressure in bottle is no longer larger than pressure in system we shall heat the bottle with warm water so as to promote gaseous pressure in bottle and push refrigerant continue to flow into system Do not s
99. dence level P G motor feedback is Eg 1 abnormal Plastic temp i astic temp sensor is p 2 abnormal Copper temp sensor is p3 3 abnormal indoor Copper temp sensor is EJ 4 abnormal outdoor 8 H Except KFR 25G H H1 HA HB series faults display The display Fault source Display mode precedence level 227 PG motor feedback is Pioneer air conditioner service manual Timing light twinkles 4 times in abnormal every 8 seconds Plastic temp sensor is Timing light twinkles 1 times in gt abnormal every 8 seconds Copper temp sensor Timing light twinkles 2 times in 3 is abnormal indoor every 8 seconds Copper temp sensor Timing light twinkles 1 times in 4 is abnormal outdoor every seconds 9 H Y model air conditioner fault display The display Fault source Display mode precedence level PG motor feedback is Timing light twinkles 4 times in 1 abnormal every 8 seconds Plastic temp sensor Timing light twinkles 1 times in gt is abnormal every 8 seconds Copper temp sensor Timing light twinkles 2 times in 3 is abnormal indoor every 8 seconds Copper temp sensor Timing light twinkles times in 4 is abnormal outdoor every 1seconds 10 EA EC EM EY EZ EAA EAD EL HS1 HSZ HL1 HLZ P PI ZZ CZ digital display series air conditioner faults The display Fault source D
100. dense temperature will be higher on the contrary the result would be lower When load on air conditioner increases return gas pressure will be higher and evaporate temperature will be higher normal evaporate temperature shall fall within 5 to 7 Celsius Degree 2 Refrigerating system faults type DRefrigerating system is blocked often in capillary and dry filter which are narrowest in the whole system Normally there re 3 causes for block dirt ice and weld blocks Dirt block generally occurs on the inlet of capillary because dirt in copper tube such as slug rust scrap and scale blocks refrigerating system Knock the capillary slightly and air conditioner may restore normal condition temporarily In addition we can judge block position and features from condensate and frost on the surface of components as well as time for velocity restoration when air condition is turned off Ice block normally occurs on the outlet of capillary because there s some water in the system which suddenly vaporizes cools down condenses and becomes little ice particle and block the outlet of capillary We can heat the capillary outlet with welding machine if air conditioner works again or functions better or switch off the air conditioner and then turn on again it can refrigerate again for a while we can conclude that the refrigerating system is blocked by ice In general ice block occurs on the newly installed or newly repaired air conditioner S We
101. ding fault code is E4 Turn off the air conditioner by remote control and the fault display will not show 4 The definition to swing angle of the air door Picture 3 shows the swing angle of the step motor of E series wall mounted type air conditioner under 4 8kW Except 4 8 kW D Once being electrified the air door effect a motion of total closed and the swinging speed is 22 si 2 After the air conditioner turns on the air door effect a motion of total opening and swing to the corresponding primary position The primary position for heating mode is the position 5 Picture 3 for cooling mode is the position 2 Picture 3 3 The air door Swing on the remote control can set the swinging mode to be automatic swing or hand swing 4 The maximum swing angle of automatic swing under heating mode is 50 e g the angle between position 3 5 in picture 3 the angle under cooling mode is 50 e g the angle between position 2 4 in picture 3 The swinging speed is 5 5 s After the air conditioner being turned on and electrified if the air door is not set Swing the swing angle will swing to the corresponding position according to the different modes For example the corresponding position under cooling mode is position 2 Picture 3 heating mode is position 5 Picture 3 The air door resumes the automatic swing after the fan starts If the setting swing mode is hand 40 Pioneer air conditioner service manual swing the swin
102. e indoor unit is powered on Since the air conditioner is powered on it will come to working condition as long as you press the ON OFF button of the remote control and the Signal is well received 2 The compressor stops running but the indoor fan motor keeps working when it is at cooling mode with the indoor temperature higher than set temperature If you turn off the air conditioner and restart it immediately it will return to normal in 3 minutes after that the air conditioner will automatically adjust the indoor fan speed to what you set 3 The compressor works discontinuously at dehumidifying mode The air conditioner will automatically control the working of the compressor according to the inside temperature 4 The air conditioner does not work while the LED display is on The TIMER is set with the air conditioner it will be in hold on condition If the TIMER setting is cancelled the air conditioner will return to normal working condition 5 The compressor works discontinuously at cooling and dehumidifying mode and the indoor fan motor slows down The compressor stops internally or the fan motor slows down to prevent the indoor heat exchanger from being frozen 2 No Power Display Items a Check if the input voltage is correct b Check if the AC power supply connecting is correct c Check if the output voltage of the manostat L7805 IC2 is correct Trouble shooting pr
103. e Electrical holding plate 1 18 Kia LATA Partition plate 19 UU xi amp Be Four way valve loop 1 20 VU Bx ET A HAF Four way valve and capillary 1 assembly 21 KANER Compressor connection cord 1 22 KANL Compressor grounding cord 1 23 I di B Compressor terminal cover 1 24 IUIS ds Over load protector 1 23 HA pL Compressor 1 26 AE BZF A Liquid valve 1 27 A iE DRI ZA B Gas valve 1 28 Ii c Valve plate 1 29 ERAF Chassis 1 132 4 KFR50 HS 133 Pioneer air conditioner service manual Detailed part list of KFR50 HS indoor unit No Chinese Name Name Material Number 1 ODE PY 28 EF Filter 2 2 WERT n Screw cover 3 3 CHE ZH AE Medium frame 1 4 5X Horizontal air blade 1 5 TX Fr Vertical air blade 14 6 F Ze Air blade holder 1 7 ZSR ts 7c SIR Left plastic crutch for evaporator 1 8 EAN Evaporator 1 9 SAA JE Rubber bearing 1 10 BOM XT indoor fan 1 11 JER BE ZH fF Chassis 1 12 HRA Mounting plate 1 13 IES Pipe clamp 1 14 ESSE AL Indoor fan motor 1 15 Bd ix Electric controller box 1 16 AS Hs d Transformer 1 17 bin TAR Terminal board 1 18 PER A Main PCB 1 19 zi dE FL ZELE Step motor 1 20 Hd e n Cover for electric controller box 1 21 TRA E Indication lamp holder 1 22 ERIR Display board 1 23 HRH E Panel 1 24 owe Display board cover 1 134 Pioneer air conditioner service man
104. e Level The noise value obtained from the anechoic room must be noted by the letters of Tested in the overall noise eliminated room The difference between the noise level interference and the rating noise value shall not less than 10dB A when the noise test ongoing The ground shall be the reflection surface when there is semi noise eliminated and the noise space is consisting of 2 indoor and outdoor rooms The measurement to the noise shall be undertaken 30 minutes later after the air conditioner running normally and when the ambiance temperature reach 1 5 C of the rating working status DThe measurement shall be undertaken at the point of Imeter height and 1 meter far away to the front panel of the air conditioner 16 Pioneer air conditioner service manual Table1 7 the noise to the sense of the human beings 20dB Silence Broadcasting room with nobody in 30dB Very quiet The odtum with nobody in 40dB Almost insensible to the noise Inside the quiet library 50dB Feel the noise The quiet hotel hall 60dB quite sensible to the noise The ordinary dining room of the plant 15 3C Certification It s the abbreviation of China Compulsory Certification which is aiming to test and evaluate the electrical safety and structural safety etc the conformity of the electromagnetism compatibility of the products E g the combination of the former Great Wall certification pluses the test of the
105. e absolute humidity and relative humidity as the specific definition for it The absolute humidity kg m 9Kg kg means the weight of the water contained in 1kg air The relative humidity RH means the percentage ratio of the current absolute humidity to the saturated absolute humidity under a certain ambiance temperature It s difficult to measure the water weight directly in the air in practice Since the pressure created by the water in the air is in direct proportion to the quantity of the 5 Pioneer air conditioner service manual water in the air within the temperature zone under 100 C the absolute humidity can be represented by the pressure value created by the water vapor in the air The pressure unit is Pa Less relative humidity means more dry of the air Zero percent of the relative humidity value means 100 percent dry air 100 percent of the relative humidity means the saturation humidity of the air The value of the relative humidity is measurable by the hygrometer There are various types of hygrometers such as the Dew Point hygrometer hair hygrometer and psychrometer etc 4 Enthalpy The heat energy is the sum of the Kinetic energy and the potential energy It always exists in the material due to the always nonstop motion of its molecules no matter of any states they stay in The heat energy in a certain state contained in one kilogram material is the enthalpy of this material The enthalpy of the air is composed of the one of t
106. e between outdoor and indoor units and didn t find any problem so we con firmed that our presumption was right Solution parallel connect a 103 ceramic chip capacitor to signal line of computer panel or replace anti interference C3Y computer panel Experience conclusion pay attention to the indication panel and find out cause of faults If outdoor tem perature sensor has problem or indoor and outdoor signal line disconnect time indicator of non digital indication panel will blink 1 time second and E2 code will be displayed on the digital indication panel temperature light of three phase A series will blink and other indication lights will extinguish Case 6 outside Communication Interference Product Model KFR35 HSA Phenomena close down irregularly and produce continuous buzz sound Cause analysis we checked remote controller emergence unit and all sensors and found that they functioned well The client bought two air conditioners of same model one functioned well but the other failed We suspected that there s some interference source and we found that there was a electronic rectifying energy saving lamp in the room where air condition at fault was installed When 190 Pioneer air conditioner service manual the lamp was turned off air conditioner functioned properly When lamp was turned on we checked receiver and found 2V AC electricity on the input end when we turned out the lamp and didn t operate remote controller th
107. e found there s air in the refrigerant obviously We filled the equipment with refrigerant air conditioner worked well since then and it didn t trip any more Experience Conclusion for air conditioner installation is more important than manufacture so installation workers shall follow installation procedure as they install air conditioners installation and wind direction shall be considered If newly installed air conditioner has problem they should check other reason and then consider possible faults of air conditioner from the simple to the complicated until fundamental reason is found 210 Pioneer air conditioner service manual Chapter 9 Maintenance Cases of Noise and water leakage of AC Section one cases of air conditioner noise reduction Air conditioner noise is a common problem seen in our maintenance work causes of which shall be paid attention to Noise can be classified based on Positions indoor noise outdoor noise based on sound types friction noise wind sound air flow sound and electromagnetic sound based on causes assembly problems structure design problems components and parts quality problems and installation problems We shall distinguish sound types positions and causes of air conditioner noise and deal with the problems accordingly 1 Common noises of indoor unit 1 Dirt in indoor unit 2 Indoor fan motor axis poor concentricity and fix screw becoming loose 3 Poor concentricity of indoor fan blade br
108. e manual Chapter 8 Troubleshooting guide for Refrigerating System Refrigerating system faults are very common to air conditioners faults are various but they still have some rules and also many maintenance experiences for reference Troubleshooting steps here for refrigerating system are not a must but can be followed to eliminate faults 1 Main steps for refrigerating system troubleshooting DCheck work condition of indoor and outdoor units including display condition of indicator panel check whether indoor unit works and air velocity is normal whether outdoor fan and compressor runs Based on foregoing steps we can judge what is the cause of refrigerating fault electrical system or the refrigerating system 2 Check all data of air conditioner Water drainage condition Normally drainage water from indoor unit shall be continuous but impacted by environment humidity and temperature this condition only can be taken for reference Indoor unit air inlet and outlet temperature difference Normal temperature difference shall be within 12 14 Celsius degree but they will also be impacted by temperature and wind velocity Measure pressure of system Generally speaking in cooling operation low pressure shall be within 0 45Mpa 0 50Mpa and in heating operation high pressure shall be within 1 8Mpa 2 2Mp but pressure may be impacted by ambient temperature If outdoor air inlet temperature rise gas discharge pressure will be higher and con
109. e national regulation R is the symbol standing for the refrigerant The refrigerant can also be classified in three types according to the level of evaporation temperature and the condensing pressure value under normal temperature as the description in table 1 3 Table 1 3 The classification of refrigerant The condensing Rated Refrigeran pressure under a Types evaporation Application Range i temperature C BORED E Mpa High R11 Applicable in the centrifugal temp and R21 low R113 gt 0 lt 1 96 7 94 compressor of the pressure R114 Air conditioning system Middle R717 Applicable in the piston style temp and R12 70 0 19 6 compressor of the middle R22 air conditioner or the pressure R502 freezing store system R13 Applicable in the refrigerator Low temp R14 system with the temperature and high R23 lt 70 1 96 68 8 lower than 70 C or the low pressure R503 temperature parts of the cascade multiple system 2 The requirement to the refrigerant Pioneer air conditioner service manual 1 The requirement for the thermodynamic character The basic requirements the refrigerant shall meet are DUnder the standard atmosphere pressure the evaporation temperature must be low and generally shall not higher than 10 C The pressure value under the normal evaporation temperature shall be higher or closed to the atmosphere pressure value in case of the air s in leakage to the system The condens
110. e personnel shall have flexible thoughts and broad vision find out actual problems according to principle of air conditioner Case 7 Nut of connection tube is broken Unit Model KFR35 HSA Phenomena Poor cooling efficiency and indoor unit was frozen Cause Analysis checked and found that low pressure of outdoor unit was very low return gas tube was frosted but the tube was not bent Turned on ventilation mode we found that low pressure was lower than normal value when ice was melted We checked leakage sources and found that nut of connection tube on indoor unit was broken Solution replace nut vacuum the system and add refrigerant Experience Conclusion analyze the actual condition carefully generally analyze fault according to the frosted position and area Refrigerant lack will cause frost on liquid tube upper part of evaporator will be frozen Case 8 Welds of high pressure valve leaked Unit Model KFR35 Phenomena Poor cooling efficiency and indoor unit leaked water Cause Analysis checked air conditioner and found that air conditioner failed to work well and the cool ing efficiency is poor Evaporator of indoor unit was frosted so we presumed that system was lack of refrigerant we found system pressure was very low We checked the system and found leakage source on the connection tube of High pressure valve body Welded the leakage source and added refrigerant turned on air conditioner and it worked well Experience Con
111. e position setting function 4 The buzzer s driving function 5 The indoor fan s driving function 6 The timing on off function 7 The compressor restarting protection function 8 The indoor heat exchanger overheating protection function under heating mode 9 The automatic defrosting and reheating function under heating mode The anti cold air functions under heating mode I The anti freezing function under cooling and defrosting modes 12 Self detecting function 3 The Specification of the main function Dhe specialty terms and express TA stands for the indoor ambiance temperature TE stands for the indoor evaporator s temperature TS stands for the setting temperature TW stands for the outdoor condenser s temperature 2 Emergency switch The air conditioner turns off if press on this button when the air conditioner is working the air conditioner turns on if press on this button when the air conditioner is off and it will work in an automatic mode after press on this button Then the indication light twinkles for 20 seconds and the air conditioner does not start working until the working mode to be selected by the system the air conditioner automatically selects one of the cooling dehumidification and heating mode as the working mode according to the indoor air temperature a When TA227 the controller enters into the cooling mode and follows the mode in working The setting temperature herein is 24 C and
112. e replaced freely especially when the inner diameter the roughness of the inner surface and the length are in difference it may affect the normal operation of the refrigeration system badly As the narrowest part of the refrigeration system the capillary tubes may easily to be jammed The figuration of the capillary tubes is indicated in the picture 2 6 as the below 6 Liquid distributor To the air conditioner with a large evaporating surface area usually the coil pipes of the evaporator are ranked together side by side For enhancing the evaporation efficiency the liquid distributor is in need to be assembled for having the refrigerant enter into the evaporator equably in various routes The liquid distributor of the air conditioner generally consists of a coniform unit body and a throttling nozzle The refrigerant enters inside through the nozzle and to be guided in different ways following the inner surface of the cone There are many equally distributed holes at the bottom of the cone which are connected to the various accesses of the evaporator through the capillary tubes When the refrigerant flows through the nozzle of the throttling liquid distributor its flow speed will be accelerated due to the sudden contraction to the section area of the stream and force the liquid and gas mix together equally to flow into the capillary tubes which connect to the throttling ring Consequently the flows will enter inside the various tubes of the eva
113. e series product of 18000BTU 24000BTU Attention Turn off the air conditioner and pull out the plug of the power supply before the service 2 Indoor unit No Part Operation Process Remark 1 Front 1 Turn off the air conditioner and cut off panel the power supply 2 Remove the adhesive tape sticking to the panel 4 Hold the handles at both sides of the panel and push upward to have it slip out 5 Grasp the both sides of the panel and push upward 6 Turn the upper board by 90 and unload it from the connecting pole carefully 7 Take out the filter from the right and left side 8 Screw off the bolts on the electrical box cover and unload the box cover 9 Screw off the six bolts on the medium frame 10 Hold the both sides of the medium frame and open it gently 11 Turn up the medium frame by about 90 12 Offload the medium frame once hearing the crack sound 154 Part Pioneer air conditioner service manual Operation Process Remark Electrical component 1 Do No 1 firstly 2 Pull out all tie in connecting with PCB and the temperature sensor etc 3 Screws off the screws and bolts at the three positions indicated in the picture Untie the outdoor unit s interconnection cord and power supply cord from the terminal of the electrical box 4 If the main PCB board is loosed by chance remove it away Water draining tank 1 Do No
114. e slide cooperates with the rotor precisely in the groove and contacts the outer surrounding surface of the rotor tightly with the impact of the spring so 18 Pioneer air conditioner service manual as to form a dynamic sealing The dynamic sealing separates the space between the rotor and the cylinder surface to be two parts one is air inlet antrum and the other one is compressing antrum During very rotation of the eccentric shaft the air will enter inside the inletting antrum and meanwhile the compressing antrum will complete the compressing and the ejecting process accordingly The main impress of the rotary compressor is a liquid gas separator Liquid receiver attached to the side of the compressor Please refer to picture 2 2 S Liquid gas separator Liquid receiver In case of the liquid impact caused by the direct entry of the liquid refrigerant to the compressor the liquid gas separator is mounted between the evaporator and the compressor of the air conditioner The function of the separator is not only a separation of the gas and liquid refrigerant but also a storage for additional liquid refrigerant produced in the refrigerating cycle It can automatically adjust the supplying quantity of refrigerant liquid according to the load variety for avoiding the compressor s liquid compression With this function the gas amp liquid separator is also called Liquid receiver The common gas amp liquid separator Refer to Picture 2 3
115. e the unsteadiness of the joint amp plug or the fault of the outdoor computer board 89 When the outdoor panel available the temperature protection of the discharge pipe of the compressor System turns off the panel displays E9 2 KFRSO TBPModel transducer faults display Indoor unit faults display 1 Fault 11 The indoor ambiance temperature sensor is open circuit or short circuit 2 Fault 12 The tube temperature sensor of the indoor heat exchanger is open circuit or short circuit 3 Fault 13 Indoor heat exchanger anti freezing protections 4 Fault 14 Indoor heat exchanger overheating protection 5 Fault 15 Indoor communication fault 6 Fault 16 Indoor electric source s instant off 7 Fault 17 Indoor over current protection Outdoor faults display 1 Fault 21 The outdoor ambiance temperature sensor is open circuit or short circuit 2 Fault 22 The tube temperature sensor of the outdoor heat exchanger is open circuit or short circuit 3 Fault 23 The temperature sensor of the air vent of the outdoor compressor is open circuit 224 Pioneer air conditioner service manual short circuit 4 Fault 24 No load 5 Fault 26 Outdoor over current protection 6 Fault 28 Outdoor voltage abnormal 7 _ Fault 29 Outdoor electric source s instant off 8 Fault2A Outdoor refrigeration s overloading protection 9 Fault2B Outdoor defrosting display 0 Fault 2C IPM module fault ID Fault 2d Outdoor E2
116. ea with high humidity heat insulation sponge shall be wrapped properly Case 8 Water drain tube was broken and leaked water Unit Model KFR25 M Phenomena Turned on air conditioner for a while indoor unit discharged a large amount of water but outdoor drain tube didn t discharge condensate water Cause Analysis the main reason of leakage was that water drain tube connecting indoor unit and water collection pan as well as drain tube outside the unit were bitten through by mice Reasons for damage during installation 1 Water drain tube is broken when it is pulled out from indoor unit especially cabinet unit because steel casing parts are too sharp without folded edges or other protection measure 2 When connection pipes and water drain pipe penetrate the wall if hole on the wall is not large enough it may break the drain pipe 3 Other reasons Drain pipe is of poor quality and thickness is very thin drain pipe connecting with water collection pan is of poor quality and leaks condensate drain line is bitten through by mice and so on Solution replace broken water drain tube check if drain tube will be broken again easily and take proper protective measures Experience Conclusion take cautious steps to protect drain tube and do not damage it during installation Case 9 System leaked water because of refrigerant lack Unit Model KFR25 A 221 Pioneer air conditioner service manual Phenomena Air conditioner leaked w
117. eakage and wearing of left blade axis bush 4 Loosing of the panel and the auto switch 5 Abnormal sound friction sound from connection parts from step motor and horizontal air blade 6 Whistle poor balance of blades if necessary change a blade or 25A failure of evaporator itself Refrigerant flow sound of indoor unit line bending position 32M and capillary 100S 8 Air inlet was obstructed because of dirt filter 2 Common noises of outdoor unit Loud noise from compressor 2 Tube vibrating and touching outdoor casing 3 Whistle from blades blade breakage 4 Loud sound from outdoor fan motor replace 70W 930rmp YDK48 6 354 3UF with YDK48 6A 354 4UF 5 Outdoor blade touching outdoor casing condenser or steel grille 6 Sympathetic vibration of outdoor unit especially removing the motor bracket of the small outdoor unit 7 Outdoor steel grille colliding with outdoor casing 8 Indoor unit motor frame becoming loose 9 Air conditioner installation holder becoming loose Improper installation position of outdoor unit 3 Method to find noise positions DDenying one by one When it is difficult to find noise sources for example to decide it s compressor or outdoor motor producing noises firstly we should break off compressor and listen if outdoor motor produces noise if not it s compressor creating noises Case 1 Blade axis of indoor unit colliding with rubber seat Unit Model KFR35 HY Phenomena Loud indoor noises
118. eat conduction is one of the heat transmission forms in the form of transmitting the quantity of heat from one object to the other one or the heat transmission available between two contacting objects For example when you hold one end of the iron bar and the other end is on the fire after a while 3 Pioneer air conditioner service manual your hand will feel heated Different materials have different heat conductivity In this case the heat conductivity coefficient was introduced as the unit of the value for measuring purpose Such coefficient represents the amount of heat that passes by conduction through a one meter thickness of homogeneous material per one hour and per one square meter Measured as 1 C difference between the two surfaces of the material Its unit is kJ m h C and stood for by symbol i The heat conductivity coefficients of some common materials are listed in table 1 2 The quantity of heat Q transferred from the surface is directly proportional to the heat conductivity coefficient of the material temperatures difference dimension of the surface and the heat transmission time while inversely proportional to the surface s thickness See Graph 1 4 The Algebra expression formula is as below Q ASZ Cti t2 8 kJ In the expression formula 4 Stands for the heat conductivity coefficient of the material kJ mh C S Stands for the surface dimension m 6 Stands for the thickness of the surface
119. eated by motor Section 4 Cases of Refrigerating System Troubleshooting Case 1 Capillary of outdoor unit is blocked by ice Unit Model KFR35 H Phenomena Cooling fault Cause Analysis we went to client s home to fix the air conditioner It can cool when it was turned on after about 25 minutes pressure and current of air conditioner decreased According to the client compressor was replaced before so compressor functioned well Because cooling was normal in the first 25 minutes so we presumed that system was blocked by dirt or ice Open top cover plate of outdoor we found that capillary outlet was frosted Heat the frost with lighter pressure and current returned to the normal value so we judged that system was blocked by ice According to the client it was raining when the compressor was replaced and water entered the system Solution recover refrigerant to outdoor unit and install desiccation filter on the low pressure tube run the air conditioner until ice is removed completely Remove desiccation filter and start the air conditioner again it can cool normally Experience Conclusion water shall be prevented from flowing into system when maintenance personnel are fixing the air conditioner or it is likely that system will be blocked by ice If capillary inlet is frosted the system has been blocked by dirt if capillary outlet is frosted blocked by ice Case 2 Capillary of outdoor unit was blocked by dirt Unit Model KFR H24B
120. edium of R407C R410a etc to R22 The properties comparison between R410A R407C and HCFC22 is listed in table 2 2 We can make a conclusion as the below after checking through this table The environment protection condition of the replacement cold medium is superior than R22 and conforming to the safety requirement 2R407C is non azeotrope and need to be rectified according to the specific condition in air conditioner design production and maintenance process R410A is sub azeotrope and basically can be treated as R22 S The pressures of R407C THRO3 and R22 are basically same But the one of R410A is higher than R22 s by 60 The lubricating oil for the replacement cold medium is different from the one for R22 and need to be changed completely However due to the water absorption of the Polyarylether the control on drying process must be strict R407C THRO3 and R22 are basically same on the aspect of the capacity per unit refrigerant The capacity per unit refrigerant of R410A is more than R22 by 40 5076 Table 1 4 the basic property of the replacement cold medium Property R 22 R 410A R 407C R32 R12 The makeup of the cold medium R 22 R32 R125 RI d a M tio ire ped 100 50 50 2325 52 Ozone s destruction Environment Potential ODP uns i i Conditi ondition Greenhouse GWP 100 1730 1700 1530 years Safety Toncy No No No Inflammability No No No Azeotrope property U
121. efrigeration process under the rating working status and the specified condition W W stands for the value of the ratio 8 The volume of circulating air The volume of air delivered to room The volume of air delivered by the air conditioner to the airtight space room or area per unit time under the rating refrigerating working condition when the aeration door and the ejection door are closed thoroughly If applicable The unit of the volume of air delivered is m3 s m3 h 9 Air enthalpy difference testing method It s a test method being applied in the measurement of the air conditioner s performance of cooling and heating The parameters in the need of the test include the outlet air parameter the inlet air parameter and the volume of the circulating air of the air conditioner The performance of the air conditioner is determined by the product of the volume of air and the difference between the enthalpy values of the outlet and inlet air The cooling capacity of the air conditioner is relating to the area of the room room s usage room s orientation and the floor it at the room s heat preservation capability the quantity of heat from other 13 Pioneer air conditioner service manual electrical appliances and other factors Basing on the experience we can set the value of 150 240W M 120 300W M is applicable in more large room or space as the cooling load per unit working area and the actual applicable coverage area of the ai
122. em problem generally if water leak is caused by system problem we can see tiny beads inside air duct and obvious beads c on fan blades Case 10 Evaporator was half blocked and leaked water Unit Model KFR35 HSFY Phenomena Air conditioner leaked water after running for some time Cause Analysis according to client air conditioner leaked water after running for some time We turned on the air conditioner and it run for 20 minutes water started to be blown form indoor unit Disassembled front shell we found that 2 3 U shaped fins near evaporator were very cold and covered with condensate and other fins were not so cold so we suspected that system lacked in refrigerant Measured system pressure but it was normal Later we found that these fins were covered with beads Putting hand on air outlet we could feel there s water flowing out with air we touched fins with hands and found temperature of different fins was different obviously so we suspected that part of evaporator was blocked and caused deflection of refrigerant temperature of fins with large refrigerant flow was low and that of fins with small refrigerant flow was high and large temperature difference cause fins with large refrigerant flow condensed and water was blown outside with wind Solution replaced evaporator after consulting with client air conditioner worked well since then Experience Conclusion it is easy to judge water leak because of partial block or weld block w
123. er after compressor starts When the current of the compressor 26A 3 2Kw 3 5Kw wall mounted unit require the current of the compressor28A and continuous lasts for 5 seconds The sleeping control function The sleeping control function is valid during the automatic cooling dehumidifying and heating mode The wind speed of the indoor fan falls by one gear after starts the sleeping control function and the sleeping indication lamp on Press the button of sleeping and start the sleeping process The default temperature rises by 1 C to the ongoing cooling mode after 1 hour running the default temperature falls by 2 C to the ongoing heating mode after 1 hour running after another 1 hour running the default temperature for the ongoing cooling process rises by 1 C and falls by 2 C for the ongoing heating process The sleeping process last for 7 hours until power off 3 The modes switch function is still valid after enter into the sleeping process but will quit after modes switched The air conditioner runs at the temperature value of new default temperature correction temperature if press the button of temperature Under the sleeping status press the button of sleeping again or press the modes option and on off button to quit sleeping function and end the sleeping process 38 Pioneer air conditioner service manual The sleeping process under cooling mode Setting temperatur rises another 1 C
124. erature controlling range is 16 C 32 C The setting temperature can be adjusted through the button of The setting wind 44 Pioneer air conditioner service manual speed can be adjusted through the button of wind speed selection in the selection of the four wind speeds type such as strong wind high wind low wind and mute wind The four way valve always is closed under this mode The other action is as following When TA TS gt 1 C after the compressor meet the 3 minutes delay protection the compressor and the outdoor fan start running When TA TS maintain the previous status G When TA TS 1 C after the compressor meet the 3 minutes protection condition the compressor and the outdoor fan turn off The setting wind speed can be adjusted by the remote control during the ongoing cooling process and the interior fan still retains working When the status of TE lt 0 C last for 10 seconds and the compressor keeps working for above than 5 minutes turn off the compressor and outdoor fan the indoor fan keep working according to the setting wind speed Quit from such protection if TE gt 7 C This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional When the cooling ongoing the button of the Swing can control the swing and stop of the horizontal air blade 8 Automatic wind speed control TA TS23 C wind speed works at
125. erature difference and then deal with the faults accordingly Case 13 Noise caused by improper installation Unit Model KFR35 ED Phenomena Abnormal noise could be heard after the air conditioner was turned on and run for some time Cause Analysis according to client coo could be heard occasionally Maintenance personnel checked the air conditioner for about 3 hours coo could be heard sometimes we believed it was from water collection pan in indoor unit when air condition was in cooling mode and water drain pipe might have some obstacles We checked the pipe from indoor unit to outdoor unit carefully and found that water drain pipe in indoor unit was tied too tightly and water couldn t flow smoothly water line outside had a U type bending so we considered that air flow returned sometimes and produced abnormal sound Because water pipe was not flat completely water could still be drained and indoor unit didn t leak it was very difficult to find the problem We wrapped water pipe again and adjusted water pipe of outdoor unit and then air conditioner could operate properly Solution adjusted water drain pipe Experience Conclusion to deal with such kind of strange problems maintenance personnel shall be patient to check and consider in various aspects Case 14 Noise caused by improper outdoor unit installation 216 Pioneer air conditioner service manual Unit Model KFR70 TB Phenomena Outdoor unit made loud noise acc
126. erature difference between two circuits will be relatively large which will produce a large number of condensate in the former fins Condensate is blown outside the outlet with wind In addition cold and hot air meet in wind pipe and steam condenses in air pipe causing water leakage 4 Improper installation newly installed air conditioner or air conditioner installed in winter may leak because of non levelness of air conditioner or improper wrapping of drain pipe or connection joints Case 1 Filter was blocked by dirt Unit Model KFR35 M Phenomena Indoor unit leaked water Cause Analysis Cause Analysis after air conditioner operated in cooling mode for some time water dropped between front panel and upper air outlet grille but wind amount was relatively small We opened the cover and found that filter was blocked by dirt and wind amount decreased so evaporate temperature fell evaporator was frosted and connected with dirt filter Removed the filter turned on air conditioner again we found wind amount increased and water didn t leak again Solution we cleaned filter installed it again and asked client to clean and maintain the filter regularly Experience conclusion air conditioner is likely to leak if filter is dirty and blocked so we shall instruct client to clean filter and maintain air conditioner regularly In addition it is difficult to distinguish frost of evaporator and frost due to refrigerant lack of system If system l
127. ere s no voltage on receiver Solution replace fluorescent lamp with product of other brand Experience Conclusion wave produced by electron rectifier fluorescent lamp may superpose on infrared wave and cause failure of receiver To fix such kind of failure we shall asked client for details and check surrounding electrical appliances of air condition Interference resources of air conditioner signal include electromagnetic interference due to poor quality of power circuit frequency interference and infrared interference To fix the failure we shall put a transparent dark color light filtering plate in front of remote receiver or install a magnetic ring on receiver panel or replace controller Case 7 Protection of Power Phase Sequence Product Model KFR H41A5 A Phenomena timing indicator and running indicator blinked when we started up the air conditioner Cause Analysis according to fault code we judged that outdoor unit was in protection situation and forced compressor running The air conditioner could function properly and pressure switch and power circuit were also in good condition we presumed that problem was caused by sequence check protection We changed phase sequence and turned on the air conditioner compressor suddenly run reversely All these proved that phase sequence detecting panel had some problems Solution replace detecting panel of outdoor unit Experience Conclusion service personnel shall have some knowledge of c
128. erheating protection if the wind speed setting 1s by hand the indoor fan unit will run at the setting wind speed if the wind speed setting 1s automatic the indoor fan unit runs at the low fan speed This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional 6 Ventilation mode Under ventilation mode the outdoor unit is always off the indoor fan runs at the setting wind speed the remote control can set high fan middle fan and low fan except automatic fan The performance condition of the air door is same as the one under refrigeration mode This mode includes the timing function auto restart optional negative ion optional I feel optional Heating mode 46 Pioneer air conditioner service manual The setting temperature can be decided and adjusted by the remote control within the control range of 16 C 32 C through the button of temp Add and temp Reduce Press the button wind speed option to choose the wind speed among the options of automatic fan high fan middle fan and mute fan The other conditions refer to the following 1 When TA 3 TS 1 C if satisfying the 3 minutes protection delay condition for compressor the compressor and outdoor fan start and the indoor fan runs in accordance with the anti cold wind condition 2 When TA 3 TS21 C if satisfying the 3 minutes protection delay condition for compressor the compressor a
129. f Abrade the burrs with 0 sand paper and make the contactor surface smooth 3 Inspection of protection relay In normal condition contactors of protection relay are closed and check with universal meter contactors shall be in conducting situation or the relay shall be replaced 4 Check of running capacitor Remove a handle of capacitor to be tested check resistance of two ends of capacitor with universal meter In the normal condition index finger of universal meter swings back rapidly and then rises to infinitely great If index finger doesn t move and resistance remains infinitely great capacitor has broken off if index finger swings to 0 and stop moving and resistance is zero capacitor has disrupted if resistance remains at certain value capacitor leaks S Check of transistor D Check of diode capacity 186 Pioneer air conditioner service manual a Commute demodulation switch and stabilivolt diode Remove diode from electrical panel check its single phase conductivity with Rx1K and Rx100 of universal meter Check method contact two ends of diode with two handles of meter record the resistance value then change two handles with each other and measure again For a normal diode two resistance values are different greatly large one 1s called reverse resistance and the smaller one forward resistance Normally forward resistance of silicon diode is several hundreds or thousands ohm and reverse resistance can be 1 IMO f
130. f the electrical power The input voltage 175 V 253V 2 The input AC current frequency 50Hz 3 The operating temperature for electric controller 10 70 C 4 The operating moisture for electric controller RH20 RH90 5 The indoor fan RP plastic sealed motor three impulse feedback signal 6 The outdoor fan tap iron shell motor only one speed range and the normal working current shall be lower than 1 5A 7 The normal working current of the four way valve lower than 1A 220VAC 8 The Swing Motor DC12V Four phase eight step stepping motor Compressor Single phase power supply the normal working current shall less than 15A 2 Functions of the electric controller The function of the controller consists of the following parts 1 The remote control receiving function 2 LED Digital displaying function 3 Force operation function 31 Pioneer air conditioner service manual 4 The air vane s automatic swing function and the position setting function 5 The buzzer s driving function 6 The indoor fan s driving function 7 The timing on off function 8 The compressor restarting protection function 9 The indoor heat exchanger overheating protection function under heating mode O The automatic defrosting and resume function under heating mode I The anti cold air function under heating mode 2 The anti freezing function under cooling and defrosting modes I Self detecting function 3 The main functio
131. for the consumption power of the compressor but the cooling capacity indicates the quantity of heat absorbed from the room by air conditioner within a unit time So somebody may ask is this against the energy conversation law The answer is we shall consider about the energy conversation law in a total air conditioning system e g the power consumption of the compressor other power consumption by fan and motor etc the quantity of heat e g the cooling capacity absorbed from the room the ejecting quantity of heat by the Outdoor part air conditioner The general units conversion is as follows 1Hp or 1 Horse Power 735 499W the abbreviation is 735W British unit Horse Power 745 7W 1W 0 86kcal h Kcal or Therm 1kcal h 3 9683Btu in abbreviation of 4Btu 1W 3 412Btu h 1cooling ton 13878kJ h 3330kcal h 3873W US cooling ton and Japanese cooling ton t Celsius degree C T absolute temperature K 273 16 t Fahrenheit F 9 5t 32 F 1Pa 1 02 10 5kgf cm f The noise of air conditioner It s not allowed to have the strange noise and vibration when the air conditioner is running The regulations with regard to this issue are specified as following DThe error is permitted by the manufacturer if 3dB A in difference with the announced figure by nameplate manual or adv Etc of the air conditioner s noise TI T2 model air conditioner shall be tested in the Semi anechoic Room There are 2dB A can be added to T3 Sound Pressur
132. formed and caused by the accelerating flow speed of gas or liquid being 4 Pioneer air conditioner service manual impacted by force for example the convection of the refrigerant inside the pipes caused by the impact from the compressor of the refrigerator and air conditioner and the forced convection to the condenser and evaporator impacted by the fan The heat transfer coefficient is directly proportional to the flow speed of the forced convection So the fan can be utilized as a forced convection tool for creating the effective heat transfer Heat Radiation Heat radiation represents the transmission of the radiation energy turned from the heat energy existing in the space between two indirect touching objects Any objects continuously emit the radiation energy and absorb the radiation energy so as to turn it into the heat energy Comparing with the heat conduction and heat convection heat radiation can be realized through the vacuum space without any heat and middle medium The heat transmitting process from the Sun to the Earth is by the way of heat radiation The intensity of the object s radiation energy is directly proportional to the forth power of the absolute temperature value In this case the final efficient result of the radiation is that the object at higher temperature will loss energy and the one at lower temperature will receive energy Despite of the above factor the intensity of the radiation energy is also relative to the pr
133. g angle will never change After turning off the air conditioner and stopping the running of the indoor fan the air door shut off automatically COEnter into the automatic mode by pressing the Emergency button the air door opens after the setting mode of the system starts Before the starting of the setting mode the air door parks at the datum mark of cooling mode The below picture shows the swing angle of E type Position total closed position Position 2 Datum mark under cooling mode Position 3 The maximum swing 5pm angle under heating mode Position 4 The maximum swing angle under cooling mode Position 5 Datum mark under heating mode Position 6 total opening position Picture 3 5 The wind speed selection function The resistance value of the wind speed option 1s as below High Fan R24 Middle Fan R28 Low Fan R26 1330 1 2K 1250 1 2K 1100 1 2K 1280 3K 1200 3K 1050 3K 1230 5 1K 1150 5 1K 1000 5 1K 1180 8 2K 1100 8 2K 950 8 2K 1130 12K 1050 12K 900 12K 1080 20K 1000 20K 850 20K 1030 36K 950 36K 800 36K 980 82K 900 82K 750 82K Note The mute wind speed under heating mode is 850r min and 800r min for non heating mode The breeze speed is 650r min The controller added the function of high efficient wind speed which bases on the previous strong fan plus 100r min Optional functions The below functions program are already write into the Main chip of t
134. good condition so fault is in the outdoor unit Opened outdoor unit and checked power line resistance between L and N was infinitely great but there were no short circuit on two lines Checked outdoor components one by one we found that compressor capacitor was disrupted Solution replace compressor capacitor Experience conclusion if compressor trips when air conditioner is turned on we shall check L and N are short circuited We shall further check indoor and outdoor components and find out whether they re short circuited Case 11 Outdoor fan capacitor fault Product Model KFR H24B4 DS Phenomena the air conditioner stops to work frequently and can t function properly Cause Analysis air conditioner has been used in a restaurant for over one year under 220V power According to the client air conditioner failed to refrigerate sometimes We checked and found that pressure was 5kg current was 1 5A so we suspected condenser was too dirty We cleaned condenser and fault wasn t eliminated We checked outdoor unit and found that outdoor fan run too slow and compressor stopped to work when current rose We checked winding of fan motor and motor shell was very hot We checked winding resistance after motor cooled down it had no problem So we presumed that fan capacitor was broken Solution replaced fan and capacitor Experience conclusion because fan capacitor can t function well so fan is in the protection situation heat can t be exha
135. has broken Find out broken points and connect them again 3 Grounding inspection of motor windings Motor windings being affected by moisture insulation layer aging or being damaged and other condition may cause short circuit of motor windings and shell Under such circumstance motor can not start up and fuse will burn out or relay will trap Check the winding with universal or megohm meter with one handle touching common terminal and the other handle touching motor shell If resistance is very low windings touch the shell and cause short circuit While checking remove a scar on the motor shell and touch the bare metal for measure There re two connection forms for windings of three phase motor star Y type and triangle A type Resistance values of three windings are same in both cases Winding short circuit breakout circuit and 185 Pioneer air conditioner service manual winding touching shell can also occur in three phase motor Check the faults with universal meter For star type connection motor resistance can be measured individually for triangle type connection motor three windings shall be disconnected before resistance values are measured 4 Inspection of switches and components of appliances 1 Inspection of selection switch Check corresponding contact points for different functions with universal meter if two connection points conduct resistance shall be zero two connection points don t conduct resistance is inf
136. he PCB and to be performed if being equipped with the corresponding hardware For example the Auto restart function shall be 41 Pioneer air conditioner service manual equipped with the corresponding E main chip the I feel function shall be equipped with the corresponding remote controller and the Negative ion shall be equipped with the corresponding relay DAuto restart control function a The setting method for Auto restart function After the controller being electrified press the sleeping button on the remote control for 10 times within 5seconds towards to the controller later if the Auto restart function is successfully set there are four sounds delivered from the buzzer If the Auto restart function need to be cancelled press the sleeping button of the remote control for 10 times within 5seconds towards to the controller later if the Auto restart function is successfully cancelled there are two sounds delivered from the buzzer otherwise there is no sound b The contents memorized by the Auto restart function are operation modes setting wind speed setting temperature negative ion function swing status and on off condition c After the setting of non electricity memory function succeeds when the non electricity event happens after turning off the air conditioner normally if re electrify and turn on the air conditioner there is no 3 minutes protection delay occurred to the compressor when the non electricit
137. he air inlet pipe The filter net at the entrance of the separator has the function of gas amp liquid separating noisy eliminating and filtering Passing through the air inlet pipe the refrigerant from the evaporator flows into the separator Therein the liquid refrigerant that passing through the filter net falls to the bottom of the sleeve and will climb to the upper of the air vent pipe until being absorbed by the compressor after being gasified in case of liquid 19 Pioneer air conditioner service manual compression impact to the compressor Heat exchanger The evaporator and the condenser are called heat exchanger The evaporator gasify and evaporates the liquid refrigerant so as to absorb the heat from outside on the contrary the condenser releases the heat to outside so as to low down the temperature of the gas refrigerant and liquefy it To Cooling only model air conditioner the indoor heat exchanger is evaporator and the outdoor heat exchanger is condenser There are two sets of heat exchanger configured in the Heat pump air conditioner one is indoor type and the other one is outdoor type both of them are with different function because of the different direction of their flowing circulations During cooling mode the indoor heat exchanger acts as the evaporator and the outdoor heat exchanger acts as the condenser during heating mode indoor heat exchanger acts as the condenser and the outdoor heat exchange
138. he dry air and water vapor which is represented by i unit kJ Kg 4 Air conditioning Piture 1 2 is an air conditioning system The controlled working zone also called Air conditioning zone Air transmitting system Fresh air being filtered Sun radiation Outdoor temperature Change VW de eo pa The above drawing shows the heat source humidity source or other harmful materials in one aspect come from the production process of the indoor environment and the heat or wetness produced by human body and on the other hand is caused by the changes of the sun radiation and climate condition of the outdoor environment In this case the idea of air conditioning that aim to control the air environment by artificial method is bourn for eliminating the indoor and outdoors influence factors subject to the environment The air conditioning functions mainly by the way of air temperature conditioning humidity conditioning airflow speed conditioning and air cleanliness conditioning Temperature conditioning The purpose of temperature conditioning is to maintain an appropriate temperature for the indoor air The appropriate indoor temperature value is 25 27 C for Summer 18 20 C for winter The 6 Pioneer air conditioner service manual temperature value shall be determined by the industry amp mineral enterprises scientific amp research institutes medical and sanitary units according to their own specific purposes The process of a
139. he negative ion function button on the remote control and the negative ion relay in the controller turns on for starting the output of the negative ions When the negative ion function is on press the negative ion function button on the remote control and the negative ion relay in the controller turns off for stopping the output of the negative ion III The basic function introduction of the split wall mounted type electric controller 42 Pioneer air conditioner service manual 18000BTU 24000BTU 1 The basic conditions for the operation of the controller 1 The applicable voltage range of the electrical power The input voltage 175 V 253V 2 The input AC current frequency 50Hz 3 The operating temperature for electric control 10 70 C 4 The operating moisture for electric control RH20 RH90 5 The indoor fan RP plastic sealed motor three impulse feedback signal 6 The outdoor fan tap iron shell motor only one speed and the normal working current shall be lower than 1 5A 7 The normal working current of the four way valve lower than 1A 220VAC 8 The Swing Motor DC12V Four phase eight step stepping motor 9 Compressor Single phase power supply the normal working current shall less than 20A 2 Partition of the controller s function The function of the controller consists of the following parts DThe remote control receiving function 2 Force operation function 3 The air vane s automatic swing function and th
140. he red and black meter pens into the jacks of the object electric supplying socket The consequent figure shows on the reading panel is the value of the measured voltage There is no fixed polarity to the AC voltage so the 180 Pioneer air conditioner service manual meter pen of the clamp meter can be freely used without consideration of the selection between positive and negative pole When measuring the direct current voltage turn the on off switch to the category of the DCV DC voltage pay attention to select a measurement range larger than the voltage to be mea sured and confirm the polarity of the voltage to be measured During the measurement process connect the red pen to the positive pole and the black pen to the negative pole of the voltage Otherwise the clamp meter may be damaged by wrong connection 2 Measure the alternating current value Rotate the on off switch to the proper measurement range of the alternating current ACA firstly During measurement process put the electric cable to be measured into the clamp type mouth of the clamp meter and the reading panel of the meter will show the electric current value of the cable basing on the electromagnetic induction theory 3 Measure the electric resistance Turn the on off switch to the proper measurement range Before measuring connect the two meter pens directly with each other short circuit and the figure shows on the reading panel shall be 0 2 and to be accompanied b
141. he refrigerant after service press down the valve core and the service entry always keep through with the tubing without concerning whether the valve rod is ON or OFF 27 Pioneer air conditioner service manual 9 Pressure switch The pressure switch of the air conditioner is a kind of on off component that transforms the pressure signal to be the electricity signal so as to control the air conditioner It provides a safety protection to the operation of air conditioner When installation fix the pressure switch on the pipeline that in need of supervision and control The switch s contact points are in series connected with the main controlling loop through the lead cables for controlling the on off of the compressor The pressure exerted by the motion of the switch is already fixed on the production line without further adjustment in application period When the pressure inside the pipeline is abnormal too high or too low the flexible film flake will react and regulate the scale of pressure inside the pipeline by separating the standing closed electric contact points through mandril and cut off the controlling circuit The pressure switch used for the air conditioner includes two types high pressure switch and low pressure switch They are composed of the screw joint entry thin shell film flake dynamic contact point static contact point and mandril etc Such as the picture 2 16 The high pressure switch is fixed at the high pressure
142. heck refer to the 5 2 part Is there signal when the ON OFF button was N NO pressed Replace buttons i YES Is there any change on the voltage of chip IC1 UM The chip fails YES Is there any change on the voltage Q1 Replace audion NO m f Is there any change on the voltage LED Emission tube fails YES The receiver fails 8 The Failure Analysis of the Main Parts Part Analysis Measure resistance Environment Transformer i dn 15 C 200 250 30 C 35C 40C 5 Normal temperature Heat exchanger Resistance of transformer KQ fim BOE m 4 13 3 43 2 86 Abnormal eo Turn off 02 Short cut Environment temperature 10 C 30 C 1 2 Between 24BYJ48 35BYJ412B Normal Step motor Above3002 Around120 Input Abnormal c Turn off 02 Short cut Detecting the resistance between the red wire and every connecting end The outdoor 2 fan motor Normal When the temperature is20 C 30 C around 3009 and 1200 Abnormal ee Turn off 02 Short cut 168 Pioneer air conditioner service manual Section three electric wiring diagram of Pioneer air conditioner 1 7000 12000BTU Electric wiring
143. hes of evaporator and found that temperature 215 Pioneer air conditioner service manual of two back branches was obviously lower so system was blocked when it was welded Released refrigerant welded the system again and fault was eliminated Solution welded the copper tube again air conditioner run normally Experience Conclusion generally air stream sound was produced by over throttling so we shall analyze causes for throttling Case 12 Noise caused by bending of connection pipe Unit Model KFR35 M Phenomena Indoor unit made loud noise Cause Analysis opened the indoor unit and checked all components we found that when compressor run it made noise so air duct motor and other components had no problem We checked the com ponents of evaporator and listened to the sound and then found that noise was made by evaporator Gas pipe pressure was relatively lower than normal value we continued to check and found that connection pipe between indoor and outdoor units was folded badly Solution after we replaced deformed part of connection pipe the foregoing faults disappeared Experience Conclusion only when air conditioner is in cooling and heating modes can noise be heard so gas pipe motor and components have no problems Check the system carefully whistle is from evaporator which has been blocked with dirt and ice or blocked when the tube is welded Decide the fault position through listening visual check and measuring temp
144. hese units form a closed refrigerating cycle system after being connected and jointed by copper pipes The refrigerant stored inside the system complete the cooling and heating cycle depending on the performance of the compressor The low pressure refrigerant gas will be compressed by the compressor and turn into the high temperature and pressure gas and it will be cooled down and turn into the fluid again after passing through the drying and filtering unit Such fluid will flow through the capillary tubes and to be throttled and cooled and finally inflood into the evaporator Inside it the fluid absorbs the quantity of heat in the air and to be gasified In this way the indoor room air will be cooled down and to be brought to the indoor room by the air delivery system for further cooling down the indoor temperature then the fluid refrigerant inside the evaporator will turn into gas again and will be absorbed by the compressor repeatedly Consequently by this way the refrigerant keeps circulating between the units of compressor condenser capillary tubes evaporator continuously DCompressor Compressor is the power core of the refrigerating cycle system in the air conditioner It realizes the refrigeration purpose by the way of raising the temperature and pressure of the low temperature amp pressure refrigerant gas it absorbed after being compressed by the compressor and the consequent conversion between the heat and power In the air conditioner
145. hole air duct is full of tiny beads and beads can also be seen on fan blades Case 11 System leaked air Unit Model KFR35 HDY Cause analysis We operated the newly installed air conditioner fan blades of indoor unit sprayed beads We checked and found that air conditioner was installed on a level plane water pipe was smooth and water drain tube could discharge water normally We opened indoor unit shell checked 222 Pioneer air conditioner service manual and found that evaporator and basement were assembled properly but there s a leak between left bracket and left fin of evaporator which leaked air Affixed the leak with sponge and turned on air conditioner again Water leakage was reduced but fault hadn t been eliminated Opened indoor unit panel again and checked temperature of different streams of evaporator and U shaped fins and found that temperature difference was very large so flow deflected in evaporator Checked air return pressure of low pressure valve and found that it was very low 3kg Solution filled the system with refrigerant until system pressure exceeded ambient pressure run air conditioner for 20 minutes there re no beads seen on fan blades so fault had been eliminated Experience Conclusion if air returned temperature and air outlet temperature is different obviously and return air way of evaporator is large hot air will mix in air chamber and produces condensate which will attach on fan blades and sp
146. imply physical method especially for the appliance used for a short time Case 12 the retaining valve was broken Unit Model KFR50 III Phenomena Poor cooling efficiency Cause Analysis voltage of client s house was 220v According to client room was not cooled down although air conditioner had worked for some time We checked the air conditioner low pressure was 0 65Mpa being relatively high We released refrigerant until the pressure was 0 55Mpa cold wind from outlet of indoor unit was weak and work current was 7 3A which was normal We touched high and low pressure copper tubes low pressure tube became colder but high pressure tube was not cold so there s no failure in compressor At that time pressure increased to 0 36Mpa we touched 4 copper 206 Pioneer air conditioner service manual tubes the one connecting discharge pipe of compressor was hot and other three were also a little hot Turned on the air conditioner in heating mode heating efficiency was also unsatisfactory So we were sure that four way valve had some problems Solution replaced four way valve vacuum the system to check leakage sources and finally added refrigerant Experience Conclusion to fix this kind of faults we should judge compressor and four way valve which one has problem Check the pressure and touch the unit with hand to find out fault points In the event of gas blowby temperature difference between inlet and outlet gas is relatively low gas
147. in Motor Red Camacitor Bran Whte Oro ent Compressor Back Black REN Red a Ye low mn Compre ssor Capacitor 1 2 Y G Ye llow Red Black Green To Indoor Unit 170 Pioneer air conditioner service manual 2 18000BTU Electric wiring diagram 1 Indoor unit Frost eee FanMotor Step Motor Receiver panel EE AUS TORIO Indication panel u Force Switch ControllingPanel 2 3 4 5 N L YG R B BL BR T empe ratur eSe nsor Ye llo w Grea Red Black Blue Brown Heat Pump E Type For series of 180 00 Btu h To Outdoor Unit ToPower Ind oor Unit Elect ric Chart FanMotor Step Motor Receiver panel Tran sformer NM Indication panel Force Switch Controlli ngPanel 2 3 4 5 N L YG R B BD BR Tem per ature Sens or Cold Wind E Type For series of 18000 Btu h To Outdoo rUnit To Power Indoor Unit He ctric Chart 171 Pioneer air conditioner service manual 2 Outdoor unit Fan Motor Black Fan Motor Tenpedue W hite Cap acitor Brown Rune Orie ntati on Red Valve Over aur r ert RF otedor Pe Com pes sor Black Blue J Red Blue Compre ssor 4 Capacitor A Yellow Yellow I Green CR 7CB CBL CBR Hed P ump Ype Y G O utdoor U nitElectr ic Chart To In do orU nit To Ind or U nit FanMotor Bla ck White FanmotorCapacitor Brown N Red Overcurrent Protector Compre sor Black Black Red Yello w i Red Ye llo w Gre en Compres sor Capacitor Co olW ind Type RO CB Y G For Series of 7 0
148. inder is continuously expanding and the air exists in the object system is sucked and filling in the space When the left side rotary blade arrives at the very position that can seal the orifice of the air absorbing channel the air absorbing process is ended and the volume of the absorbed air reach the maximum value Along with the continuous rotation of the rotor the air exists between the two rotary blades is compressed and its pressure 1s consequently increased step by step After the former right side rotary blade arrives at the orifice connecting with the exhaust channel and when the air pressure exists in the compression space is over one standard atmosphere pressure value the air will burst through the exhaust valve and vent Two of the rotary blades work together by turn The rotor completes the air absorbing and air exhausting process twice in every rotation circle The exhaust valve is soaked in the oil in case of the atmosphere enters into the pump The utmost pressure the single stage vacuum pump can tolerate is 5Pa and the utmost pressure the double lever rotary vacuum pump can tolerate is 0 01Pa The attention proceeding during the application of the vacuum pump The location site for the vacuum pump shall be dry ventilated and clean The blow off proof hose connects with the refrigerating system and vacuum shall be short and without bend Before starting the vacuum pump check the joints and the welding joints carefully to ensure the
149. ing temperature is assumed as 5 C superheat temperature shall be 5 C 7 C according to the Temperature Pressure Relation Table low pressure is 0 59MPa absolute pressure Refrigerant volume shall be determined by combining all foregoing data However to air conditioners with different types and brands foregoing data are different especially for the air conditioners which have been used for many years differences are more noticeable and detailed volume shall be analyzed by integrating various factors For example evaporation pressure of an air conditioner is lower than 0 5MPa but running current of compressor has reached rated value In order to use compressor safely evaporating pressure has to be set below 0 5MPa though under this circumference refrigerating capacity of air conditioner has been lowered 4 Adding of refrigerant During installation of the air conditioner connection tube often has to be extended because of installation positions all manufacturers have their own requirement of refrigerant adding for extension tube normally following principle shall be complied with Experience Value of Refrigerant adding for Extension Tube Refrigerating Capacity W Connection Tube Size Dia Adding volume M g 2000 3000 6 35 X 0 6 9 52X 0 6 15 3000 5000 6 35 X 0 6 6 12 7 X 0 6 20 5000 7000 9 52X0 6 6 16X 1 0 30 7000 12000 12 7X0 6 6 19X 1 0 35 We can also calculate the volume of l
150. ing pressure of the refrigerant shall not be too high and generally shall not exceed 1 17 1 47 Mpa if within the range of the working temperatures Otherwise it will add extra burden on the intensity of the refrigerating devices and increase the power consumption subsequently SThe capacity per unit refrigerant shall be large enough It is the common understanding that the refrigerant with the larger capacity per unit refrigerant can achieve larger quantity of refrigeration if at the same cylinder diameter and same strolling stroke However as the exception for the centrifugal or mini type compressor the preferable choice is the refrigerant with low capacity per unit refrigerant in consideration of the convenience in machine design and manufacture The critical temperature for the refrigerant shall be high enough in order to be liquidized at the normal temperature or even the normal low temperature The freezing temperature point shall be low enough in order to be evaporated at a low evaporation temperature 2 The requirement for the physical and chemical character The adhesiveness and density of the refrigerant shall be low enough in order to have a free cycle environment without too much resistance in the system The refrigerant shall have the perfect performance in heat exchanging in order to enhance the efficiency of the complete refrigerator or air conditioner S The refrigerant shall have a certain function of water absorbing so as to
151. initely great otherwise selection switch has some problems 2 Inspection of temperature controller D Expansion bag is broken and temperature sensitivity gas leaks so expansion bag doesn t expand in response to the change of ambient temperature and therefore fails to act with linked pole Check method check the switch on and switch off points with universal meter and turn the temperature setting button at the same time If controller fails to respond it proves that expansion bag is broken and temperature controller needs to be replaced with new one 2 Electronic contact points fail to contact well If temperature changes regularly and in a large scale it will cause frequent startup and stop of compressor and also contact points contact and break time and again and contact point surface will be burned and create carbon layer which stops electrical conduct Contact points are in the position of switch on but fail to connect with power Check method clean contact points with absolute alcohol and check the conduct condition of temperature controller with universal meter when it is in the position of switch on 3 Tension of offsetting spring is not enough When pressure temperature sensitive gas in expansion bag decreases and fails to push the linked pole back Offsetting spring shall be replaced with a new one 4 There re some burrs or other dirt on the surface of electrical contactors which cause contactors failing to break of
152. ion and position of discharge tube and return gas tubes shall be same or similar as the old one If unavailable tube dimension shall be changed 2 Troubleshooting for totally enclosed compressor D Poor refrigerating efficiency Actual discharge capacity of compressor lowers and can t reach the nominal capacity of product and meet the original cool load There are four factors for the poor refrigerating efficiency a Severe abrasion of pistol and cylinder including rotating type Requirement of clearance between pistol and cylinder is very strict grease film inside is for lubrication and sealing If clearance is too wide grease film will be broken and cause gas leakage if clearance is too narrow grease film may be 200 Pioneer air conditioner service manual burned or components can t start up So clearance scope between pistol and cylinder is very small For Dia 6 50mm cylinder without pistol ring fit clearance shall be within 0 011 0 018mm If pistol or cylinder wears out severely when pistol compresses and exhaust the gas a part of gas in cylinder will leak into pump shell through clearance so compressor can reach its original discharge capacity b Gasket rib of cylinder cover is cracked reciprocating There s a rib on the middle of gasket and it separates and seals discharge cavity and return gas cavity preventing high pressure discharge gas from flowing to gas return cavity and causing a part of gas being short circuited If
153. ior temperature sensor When under the heating mode there is no overheating protection anti cooling wind protection and residual heat removal function the indoor fan starts running at the setting fan speed 30 seconds later after the compressor s starting and stops after 30 seconds running at the ultra low fan speed without compressor When under the refrigeration mode there is no anti freezing protection 4 Communication fault The system turns off or can t start the panel displays E4 which may be displayed under either on or off status 5 The protection of outdoor reverse phase and failure of phase System stops and the panel displays E6 6 Heating and defrosting The defrosting indication light on the panel is twinkling 0 5 0 5 the other are invariable 7 When the indoor tube temperature available the indoor refrigeration anti freezing protection The running light and cooling light on the panel are twinkling 0 5 0 5 the other are invariable 8 When the indoor tube temperature available the indoor heating overheating protection The running light and heating light on the panel are twinkling 0 5 0 5 the other are invariable 9 When the indoor tube temperature available the indoor heating long time anti cooling wind protection The running light on the panel is twinkling 0 5 0 5 the other are invariable S KFR50 III fault display and protection display 1 Damage to the outdoor c
154. ir temperature conditioning is substantially the process of adding or reducing sensible heat The value of the air temperature also expresses the quantity of the sensible heat of air 2 Humidity conditioning In addition to maintain an appropriate indoor temperature there is also a demand for maintaining an appropriate indoor humidity The human body will feel comfortable if the relative humidity is between 5096 6096 in the summer and 4095 5095 in the winter The process of air humidity conditioning is substantially the process of adding or reducing latent heat The quantity of the water vapor contained in the air shall be conditioned during this process 3 Airflow conditioning The temperature and humidity conditioning can be realized only by the way of air flowing In this case the airflow conditioning is vital in air conditioning process The airflow conditioning and distributing directly impact the operation effectiveness of the air conditioning system The air re circulating speed in an air conditioned room shall not over than 0 25m s 4 Air cleanliness conditioning The harmful gas and dust existing in the air easily penetrate into the human being s windpipe and lung etc and all the dust are usually accompanied by the infecting virus to cause kinds of sickness So the filtering process to the air is quite necessary during the air conditioning process The air cleanliness methods include Ventilation amp filtration adsorption absorban
155. ircuit operation philosophy and find out the problems according to fault code We shall work under the principle of from simple to complicated way for example in this case when we adjusted phase sequence compressor run reversely after we turned on the air conditioner again So compressor wiring shall be changed and make compressor run properly Our A series air conditioners adopt three phase power installation personnel sometimes may fail to connect phase line and zero line correctly in this case compressor also can t be started up We should pay attention to this when we fix the fault of air conditioner Case 8 FS and DS Control Panel Button Failure Product Model KFR H18B4 DS Phenomena control panel buttons couldn t function but remote controller worked Cause Analysis because remote controller can receive signal main computer panel has no problem After check we found that low frequent diode IN4007 was used on the display panel produced by Changzhou Hongdu Co but according to main program this button shall be high frequent Control panel and main panel are not compatible and main program can t respond to the signal from buttons Incompatibility of control panel and main panel mainly happened in the air conditioners manufactured by Changzhou Hongdu Electronic Product Co Ltd before February 2004 Solution replace the said control panel with that produced by Changzhou Hongdu Electronic Product Co Ltd after February 2004 or
156. is run air conditioner for 10 minutes it could cool normally pressure and current was normal air conditioner continued to run low pressure decreased gradually current also decreased and cooling efficiency became unsatisfactory so we presumed water entered system when air conditioner was installed Because the air conditioner passed quality check when it left the factory and according to the client air conditioner was installed in rainy day so water might entered the system Solution released refrigerant vacuum the system and added refrigerant again air conditioner worked normally since then Experience Conclusion in most case these kinds of faults were caused during installation or maintenance maintenance workers shall investigate check and touch air conditioner to find out the cause of faults Case 20 Failed to evacuate air in the system fully during installation Unit Model KFR50 TB Phenomena Tripped frequently Cause Analysis generally in summer air conditioner may have problem in heat discharge and voltage But this air conditioner had been installed for only one month odd It was installed on the roof so heat exchange efficiency was not so good but it shouldn t trip so frequently We checked the system pressure was not so stable and compressor was overheating and presumed that air was not evacuated when the worker installed the air conditioner Solution released refrigerant because air is lighter than refrigerant w
157. isplay mode precedence level PG motor feedback is Eg 1 abnormal Plastic temp sensor is EI 2 abnormal t Copper temp sensor pz 3 is abnormal indoor 11 All of the other E series except EA EC EM EY EZ EAA EAD The display Fault source Display mode precedence level PG motor feedback is Timing light twinkles 4 times in 1 abnormal every 8 seconds Plastic temp sensor Timing light twinkles 1 times in 2 is abnormal every 8 seconds Copper temp sensor Timing light twinkles 2 times in 3 is abnormal indoor every 8 seconds 228 Pioneer air conditioner service manual 12 Faults display of 18000BTU 24000BTU wall unit series air conditioner Non digital tube displays Fault source Display mode The display precedence level Appearance PG motor feedback is Timing light twinkles 1 2 System turns off abnormal time in every 8 seconds Plastic temp sensor is Timing light twinkles 2 3 System turns off abnormal times in every 8 seconds Copper temp sensor Timing light twinkles 8 4 System doesn t is abnormal outdoor times in every 8 seconds turn off Digital tube displays Fault source Display mode The display Appearance precedence level PG motor feedback is VEI 2 System turns off abnormal Plastic temp sensor is E3 3 System turns off abnormal Copper temp sensor i 4 System doe
158. ked properly since then Solution adjusted position of wind wheel and tightened fix screws Experience conclusion if noise can be heard even the air conditioner works in ventilation mode fan wheel should be checked first Case 6 Noise caused by friction in actuating mechanism of air blades 213 Pioneer air conditioner service manual Unit Model KFR35 A Phenomena Indoor Noise Cause Analysis the air conditioner was newly installed according to client noise of indoor unit was loud Maintenance personnel of service network visited the client and checked the air conditioner many times and believed the appliance worked well so client was unhappy We checked the air conditioner and found that air blades made noise sometimes We adjusted the position of air blades and added some lubricate the air conditioner worked well since then Solution adjusted position of air blades and filled with some lubricant Experience Conclusion if maintenance personnel suspect noise is caused by air blades he can stop swing of air blades and sees if noise still can be heard Main causes for noise from air blades are 1 it is fixed too tightly 2 there re burrs on transmission pole3 Concentricity of air blades is not so good If maintenance personnel find the cause he can deal with the problem accordingly Case 7 Outdoor fan motor noise Unit Model KFR35 HY Phenomena Outdoor unit made abnormal sound and vibrated Cause Analysis broke off compre
159. know its function detecting indoor temperature when indoor temperature reaches set value it will control the function of indoor and outdoor units under cooling situation outdoor unit stops running while indoor unit continue to work under heating situation indoor unit will stop after surplus heat has exhausted by fan 3 Outdoor anti frost temperature sensor Detecting outdoor condenser coil When outdoor loop temperature drops blow 6 Celsius Degree and maintains for 2 minutes indoor unit will be in the anti frost situation When resistance of outdoor coil sensor is relatively large indoor unit can t work normally Case 5 Air conditioner can t refrigerate the room communication fault Product Model KFR70 A Phenomena function light of indoor unit blinks other lights extinguish indoor and outdoor units fail to work Reason Analysis we turned on the air conditioner and it worked well After about 30 minutes indoor and outdoor units stopped to work function light blinked and we pushed buttons air conditioner didn t respond we pulled the socket from the power receptacle and then tried to start up the air condition once again the unit worked for 30 minutes and then the same phenomena occurred again So we presumed that there s no problem in unit and probably outside communication interfered the proper function of air conditioner Fault code provided by our company also indicated outside interference We checked communication lin
160. l I feel optional The system mode will not change along with the variety of the indoor temperature after being selected The default status of the horizontal air blade is still The operation can be adjustable by receiving the remote signal 2 Press this emergency switch without release at least 5 seconds until the ring of the buzzer rings twice The controller enters into the trial operation The trial operation time is 30min a The sensor of the air inlet temperature doesn t function in the period of trial operation The compressor starts work after 3min delay protection The primary running has no 3min safety guard 32 Pioneer air conditioner service manual protection the wind speed of the indoor fan is high wind the running mode is cooling mode and the wind door is maximum opening b There are no anti freezing protection and high temperature preventing protection during trial operation 3 Automatic run mode When controller select an automatic working mode the indication light twinkles for 20 seconds and the air conditioner does not start working until the working mode to be selected by the system The air conditioner automatically selects one of the cooling dehumidification and heating mode as the working mode according to the indoor air temperature D When TASTAI the controller enters into the cooling mode and follows the mode in working The setting temperature herein is 24 C and the air conditioner runs according t
161. l functions comparing to the Electrical Circuit Control System 1 Air conditioner fails to work after switched on When function button pushed on air conditioner fails to work and creates no sound under this circumstance electrical power is not connected and all appliances connected with electrical power shall be checked as per following sequence D Check whether there s current in electrical power wire Devices controlling the electrical power wire shall be checked for example whether knife switch or air switch is broken Check whether there s any phase lack For example for three phase air conditioner one or two phases of three phase power network may break off or phase of electrical power wire may break off Check whether fuse of control panel of indoor unit breaks off or piezo resistor has been damaged Protector shall be installed to cut off service power before excessively high voltage or large current enters the control circuit Check if socket connector between control panel wire of indoor unit and power wire contacts well Socket connector may be self locked but also it may be loose contacted Check if key switch fails to work for example whether buttons contact well or whether components of buttons have been broken Check whether indoor electronic control panel has been broken Circuit or electronic components of control panel may be damaged 2 Indoor fan runs while compressor fails to work and tro
162. lary tubes The structure is as the above picture From the picture we can see the solenoid guiding valve consists of the valve bowl spring iron core and electromagnetic loop there are four valve bores on the valve body connecting with the guide 23 Pioneer air conditioner service manual capillary tubes When the loop is not electrified the iron core and the valve bowl move left by the thrust of the spring At this moment capillary tube d and c are contacted in high pressure capillary tube a and b are connected in low pressure thereby drive the slide of the four way valve to move left and the four way valve E will be connected with S D will be connected with C When the loop of the solenoid guiding valve is electrified the solenoid field magnetizes the gag bit move right side and compress the spring for forcing the iron core and the valve bowl move right At this moment capillary tube a and d are contacted in high pressure capillary tube b and c are connected in low pressure thereby drive the slide of the four way valve to move right and the four way valve D will be connected with E C will be connected with S The four way valve consists of the valve body and four connecting pipes The connecting pipes are connected separately with the air inlet and air outlet tube of the compressor as well as the indoor and outdoor heat exchangers There are semicircle slide and two pistons with holes in the valve body Acting as the valve
163. ld block occurs on the welds of capillary with similar phenomena as dirt block and also often happen in newly installed air conditioners 2 Leakage of refrigerating system media of heating and cooling in air conditioner is refrigerant if 194 Pioneer air conditioner service manual there is some leak source refrigerant will leak out and air conditioner can t cooling proper or absolutely stop refrigerating Leakage sources locate mainly on welds of evaporator condenser and capillary return gas and discharge tube of compressor flare mouth copper nut connection tubes and etc Check the air conditioner visually and then inspect joints of tubes carefully Generally there s grease spot on the leakage source 3 Four way valve fault Generally occur when air conditioner works in heating mode If four way valve can t close tightly or is blocked air conditioner can t have a good effect We can check close condition of four way valve when it is switched on or switched off To fix the problem we can switch on air conditioner repeatedly or slightly knock four way valve and make it restore its original position 4 One way valve fault one way valve can only work in cooling mode but when air conditioner operating in heating mode refrigerant will flow through auxiliary capillary and if one way valve can t close tightly or auxiliary capillary is blocked heat producing will be impacted so if air conditioner can be operated in cooling mode but fails
164. leaks form it 3 Insulation sponge on the outlet of air blades is not appropriate affixed or insulation sponge has fall off so that condensate drops from the outlet 4 Design of air blades is unreasonable and causes condensate dropping from it Solution 1 In 1 and 2 cases aperture can be filled with glass cement or ironed out with electric iron 2 In third case we shall affix insulation sponge 38x36x5mm cutting a 17mm hole in the center properly detailed to see Picture 1 3 In the fourth case we shall affix a 15x10x10mm PE sponge on air blades support to stuff air blades and change zero position of stepping mode to avoid non uniform wind of air blades To find out cause of leak we shall pay attention to following aspects 1 Observe air conditioner carefully before maintenance and investigate use condition do not disassemble air conditioner without careful consideration and cause more faults 2 In case that two folded evaporator leaks water because it has two guiding channels back guiding channel is sometimes neglected by maintenance 3 There are many causes for leak of air conditioner such as structure assembly system environment and installation problems we shall observe air conditioner carefully to find leak source and then deal with the problems accordingly so that we can get twice the result with half the effort Case 4 Water barrier leaked water Unit Model KFR25 ED Phenomena Indoor unit leaked w
165. ller doesn t test the former TA sensor on the PCB S Negative ion function When the indoor fan is working press the negative 1on function button on the remote control and the 53 Pioneer air conditioner service manual negative ion relay in the controller turns on for starting the output of the negative ions When the negative ion function is on press the negative ion function button on the remote control and the negative ion relay in the controller turns off for stopping the output of the negative ion 54 Pioneer air conditioner service manual IV The tech parameter of part products 1 Parameter of product R22 9000BTU 12000BTU j LE Wall mounted 3 2 mam Jr EE N sim IA im EE EN TARE coom a8 38 9 ve so aja o pared Cooling w 940 TE Pe net 8 EE EE EN IE she MN ME sov moa asov 38 amp 28W Tea musei ats pas ats a5 T NUN KIM TESTO mac oa monen a EM ENS EE EE EE NN zmaedipu w 930 950 1220 1250 Ee br ens nubes shell NM 25 Performance Z o 2 e Dimensio Fan motor Compressor Motor T E E Plastic sealed Sum nj 1 m ws sj m m m 2 25 2x11 1X22 Capillary Capillary Capillary Freezedoil capacity R22 700 R22 680 R22 120 Inner Inner Protection equipment n Inner Cooling test condition Indoor unit DB27 C Wb19 C Outdoor unit DB35 C Wb24 C Indoor unit DB20 C Wb Outdoor unit
166. long refrigerating system cannot run Proper temperature shall be set Sensor thermal resistor of temperature controller has broken which cause improper temperature control Check resistance and temperature to decide whether it has broken according to corresponding value of resistance temperature 3 Troubleshooting for compressor motor There re two types of motors for totally enclosed compressor of air conditioner single phase and 184 Pioneer air conditioner service manual three phase Single phase motor has two windings i e startup winding and running winding There re 3 binding posts in shell junction box of compressor They are marked by A B and C individually representing running post startup post and common post R and S are series connection points of two windings resistance value is sum of startup and running winding resistances between C and S is connection point of startup winding between C and R is connection point of running winding Common faults of single phase motor are winding short circuit disconnection and shell connecting Check the resistance of any two of three binding posts by using Rx1 of universal meter Resistance of windings of most compressor shall be as follows Rsr Res Rcg ReseRer Among which Rer stands for running winding resistance Rcs stands for startup winding resistance and Rsr stands for total resistance of windings Foregoing rule doesn t work in all totally enclosed compressors fo
167. m Z Stands for the heat transmission time h The temperatures of the two surfaces Co tn to Table 1 2 the heat conductivity coefficients of some common materials CkI mhi C Jmk C Copper 1382 Softwood 0 17 0 25 Aluminum 733 Air casing 0 25 Steel 163 Water 2 1 Frost layer 2 1 Glass 2 7 2 9 Glass filament 0 17 0 21 Wood 0 25 0 34 Glass wool 0 13 Plywood 0 62 0 84 Polyester formed plastic Slag wool 0 21 0 34 0 042 0 11 2 Convection The transfer of the quantity of heat caused by the relative movement of the fluid at higher temperature and the fluid at lower temperature is called convection heat transfer The convection is only applied to and only specifically exists in the fluid and gas The convection heat transfer exists between the fluids or may exist between the fluid and solid and may be accompanied by the heat conduction The main heat transmission applied in the refrigeration technology usually contains the heat conduction and convection The coefficient a stands for the intensity of the convection heat transfer and mainly affected by the flow speed of the fluid The types of convection heat transfer include natural convection and forced convection Natural convection is formed by the changes to the density of the molecules of the liquid or gas such as the cooling function of the refrigerator s condenser is mainly based on the effected natural convection of air The forced convection is
168. m by using high velocity air flow Hang a piece of white cloth on the dirt outlet to check 1f system has been cleaned completely If white cloth is clean dirt in the system has been evacuated with gas blowing can be stopped if there s some stain on the white cloth blowing shall continue Section three Troubleshooting for four way valve and compressor 1 Troubleshooting method for four way valve of heat pump air conditioner 1 Troubleshooting of four way valve D Air conditioner can make cooling air but can t make any heating air Check service power voltage of electromagnetic loop by using millimeter when unit is turned off measure the resistance of loop which normally shall be around 1400 9 Switch on the air conditioner and try to hear sound of magnetic operation so as to judge if control valve works well check high pressure with pressure meter if it is very low so we can judge that slide of reverse valve can t be moved and can t change the flow direction of refrigerant when the unit made in heating operation 2 Fail to function in both cooling and heating operations There re two possibilities discharge capacity of compressor is not sufficient or four way valve itself is of poor quality Firstly judge the quality and discharge capacity of compressor remove four way valve connect refrigerating system and run it If the system can cool the room in a relative high efficiency the compressor is of good quality and so it s the four
169. maintain the normal operation with no ice block when there is small water available in the system The refrigerant shall be with a certain chemistry stability character for avoiding the chemolysis at the high temperature the corrosion to the material of the preparation the inflammation and explosion within a normal working pressure and temperature ranges It also shall be with no much solubilization or inflation impact applied to the hermetic material and with no chemical reaction to the lubricating oil The refrigerant shall be free of harm to the health of human beings and with no irritant 3 The characters of the common refrigerant product There are many kinds of refrigerants available the below are the typical types DFluorine 22 CHF CI Fluorine 22 with no character of inflammation and explosion Its toxicity is deeper than R 12 s and its solubility limit is higher than R12 s but also may form the phenomenon of ice block 2 Part of R22 can be solubilized by lubricating oil The solubility limit is variable according to the 9 Pioneer air conditioner service manual specific type and temperature of the lubricating oil The capacity per unit of R22 is almost same as the one of R717 while it will be higher than R22 under a low temperature R22 is usually applied in the middle temperature refrigerating systems with the object lowest refrigerating temperature of up than 60 C 2 The property of the replacement cold m
170. motor turns off 650rpm turns off Q Tho residual heat Removing function When TE TES the indoor fan runs in breeze if lt TE8 the indoor fan stops working and the time in removing residual heat lt 10seconds Within the 10 seconds of residual heat removing if TE TES the 36 Pioneer air conditioner service manual indoor fan stops immediately DOverheated protection a When heating function runs if TE gt TE9 and last for 10seconds the outdoor fan stops if TE gt TE10 and last for 10seconds then stop the compressor When TE lt TE11 and after the 3 minutes protection delay the compressor resumes normal working b This temperature protection is valid only when the TE temperature sensor runs normally 8 The auxiliary electric heating function The electric heating function may not start unless the heating mode runs normally e g the compressor starts the outdoor fan runs the four way valve is electrified the indoor fan is on as well as the availability of the below conditions a TE lt TE12 b TA TA3 c TS TA gt 3C d The compressor runs continuously in heating mode for 4min The auxiliary electric heating may withdraw working if meet one of the below conditions a TA gt TA3 b TS TA 2 C OTE gt TE11 S If one of the compressor four way valve and indoor fan doesn t work or there is error feedback from the indoor fan the auxiliary electric heating withdraw from work If the sensor of TE is damaged and
171. nd leak source and deal with the problems accordingly In general water leak can be analyzed from following aspects 1 Air supply system Filter is blocked by dirt In moisture environment if air conditioner is operating in low wind mode wind amount is relatively small and indoor evaporation temperature will decrease and evaporator will be frosted or even frozen If such condition remains for a long time air conditioner will leak 2 Drainage system mainly includes guiding channel drain pipe pipe wrapping and discharge pump faults when air conditioner has been used for a long time guiding channel and drain pipe may be blocked by dirt plastic guiding channel may crack connection joints of pipe may be wrapped improperly and drain pipe may be flattened all these will result in water leakage 3 System lacks in refrigerant or evaporator is blocked when system lacks in refrigerant refrigerant will be gasified quickly in 2 3 pieces of U shaped tubes near inlet tube after it enters evaporator so temperature of fins of these U shaped tubes is relatively low but temperature of others is close to room temperature so water in fins of these 2 3 U shaped tubes will condense and will freeze after a long time When evaporator is blocked by ice fins of U shaped tubes with large refrigerant flow will 217 Pioneer air conditioner service manual be in low temperature while those with small refrigerant flow will be in higher temperature so temp
172. nd outdoor fan stop working and the indoor fan runs in accordance with the anti cold wind condition 3 When TA 3 TS remain the previous status 4 Temperature display has the temperature compensation of 3 C 5 Automatic wind speed control TA lt TS run at high fan speed TS TA TS 2 C run at middle fan speed TA Z2 TS 2 C run at low fan speed There is no 3 minutes protection delay when the wind speed turns to high fan from the low fan there is 3 minutes protection delay when the wind speed turns to low fan from the high fan 6 When heating process ongoing the button of Swing can control the swing leaves to swing or stop Being electrified initially the compressor has no 3 minutes protection delay The compressor starts 10 seconds later after the start of the four way valve and the outdoor fan starts 2 seconds later after the start of the compressor Set the TS lt TA 3 by remote control the compressor stops immediately and without the 3 minutes protection delay 8 This mode includes the timing function sleeping function auto restart optional negative ion optional I feel optional Being electrified initially the four way valve starts immediately and the compressor starts 10 seconds later During the operation condition of the compressor the four way valve stops after 2min50s protection delay when stops the air conditioner or switch mode In the case of compressor stops the four way valve s
173. nding tubing and the gas path of the outdoor unit will be cut off The rotation applied to the 177 Pioneer air conditioner service manual knob of valve in counterclockwise direction may enlarge the size of the valve bore and the corresponding tubing will get through with the gas path of the outdoor unit The refrigerating system al ways gets through with the pressure gauge on the three way mend valve without concerning the position of the knob The conjunction with the knob of the three way mend valve may carry out the process of vacuumizing refrigerant filling and pressure testing etc to the refrigerating system 1 Connect with the vacuum pump or refrigerant tank 2 Connect with the mend position Picture6 3 pressure gauge and three way repair valve 3 Expander When two copper tubes need to be jointed together the one shall be inserted into the other tube s mouth In this case the inner diameter of the latter s terminal position shall be expanded enough so as to inosculate the entry parts of the former one Only by this way the two tubes can be welded in fastness and without easy leakage The function of the expander is tube expanding for the various types copper tubes according to the specific requirement When expanding the tube insert the annealed copper tube into the corresponding aperture of the pipe wrench and the protrusion length of the copper pipes out from the pipe wrench is different because of the different pipe size The
174. nditioner 1 70S 100S 120S 45T 50T 60T45TA 50TA 60TA 70T1 when the faults happen the LCD panel displays fault and the corresponding code 1 The fault of the indoor plastic temperature sensor System turns off the panel displays El 2 The fault of the outdoor tube temperature sensor on the indoor panel System doesn t turns off the panel displays E2 3 The fault of the indoor copper tube temperature sensor System doesn t turns off the panel displays E3 and keep on working as per the mode without indoor copper tube temperature sensor 4 When the outdoor panel available the communication fault System turns off the panel displays E4 5 When the outdoor panel available the outdoor compressor under self protection overloading protection System turns off the panel displays E5 The fault may be the low on off voltage protection overloading protection or the reacting motion of the overloading relay 6 When the outdoor panel available the outdoor three phases self protection against failure of phase System turns off the panel displays E6 The fault may be the three phases are in reverse 7 When the outdoor panel available over current protection System turns off the panel displays E7 8 When the outdoor panel available the fault of the temperature sensor to the exhaust pipe of the compressor System doesn t turns off the panel displays E8 The fault may b
175. nditioner to the closed space room or area under the rating working status and specified condition Unit W or BTU 5 The consumed power for heating The total power input for air conditioner s heating operation under the rating working status and the specified condition Unit W 6 Energy and efficiency ratio EER It means the ratio of the cooling capacity to the effective input power consumption occurred during the air conditioner s refrigeration process under the rating working status and the specified condition W W stands for the value of the ratio 7 Coefficient of Performance COP It means the ratio of the cooling capacity to the effective input power consumption occurred during heating process of the heat pump of the air conditioner under the rating working status and the specified condition W W stands for the value of the ratio Note The effective input power consumption stands for the average electric power inputted to the air conditioner within a unit time which includes D The input power shared for the operation of the compressor and the input power for defrosting Except the auxiliary assistant electric heating devices with no aim to defrosting 2 The input power of all control and safety devices 3 The input power of the heat exchange transferring devices Fan and pump Energy efficiency ratio EER It means the ratio of the cooling capacity to the effective input power occurred during the air conditioner s r
176. ned off and starts to run before it is turned on Analysis according to the client when the unit is electrified the client turned on the power with remote controller and then turned off indoor fan still run We presumed that indoor motor fails to provide power properly Checked the voltage of indoor fan motor produced 158v voltage when unit was electrified but the unit is turned off so motor run when motor was electrified We concluded that fan control silicon is broken Solution unit operated normally after controller was replaced with another of same model Experience Conclusion Velocity of split mounted indoor fan is controlled by silicon when power voltage is relative low or fluctuate within a large range controlled silicon can be disrupted fan still has voltage when the unit is turned off and can not stop running Case 3 Receiver of remote controller can not function properly Product Model KFR35 H Phenomena remote controller can t turn on the unit 188 Pioneer air conditioner service manual Reason Analysis to check remote controller point the remote controller to an ordinary radio and push any buttons on it radio responded so remote controller worked well and there must be some faults in main control panel or receiver of remote controller of indoor unit Opened outside cover of indoor unit to check 220V input power and 12V and 5V voltage and found that they functioned properly started up air conditioner manually and it
177. ng mode is the position 5 Picture 3 for Cooling mode is the position 2 Picture 3 S The Swing button on the remote controller can set the Horizontal air blade to be swing Automatically or not The maximum swing angle of automatic swing under Heating mode is 40 e g the angle between 3 5inpicture3 the angle under Cooling mode is 40 e g the angle between 2 4 The swinging speed is Istep 16ms When the indoor fan stops operation if the setting swinging mode set by the remote control is automatic swinging the Horizontal air blade will turn to the corresponding position and to be orientated For example the corresponding position under Cooling mode is position 2 Picture 3 for Heating mode is position 5 Picture 3 resume the automatic Swing once the fan motor starts if the setting swing mode is Manual the swing angle of the Horizontal air blade will never change After turning off the air conditioner and stopping the running of the indoor fan the air door will shut off automatically COEnter into the Auto run mode by pressing the Emergency switch the setting status of the air door is in accordance with the Cooling mode and will be adjusted again after the new mode is selected Picture4 Position 1 total closed position Position 4 The maximum swing angle under refrigeration mode Position 5 Datum mark under heating mode Position 6 total opening position 14 Wind speed option function 18000BTU 2400
178. ngineering organization constructions etc and also require the manufacturer to be in compliance with the requirement of the standard and retain 19 VDE A testing and certifying symbol which can be obtained from the IEC System for Conformity Testing and Certification of Electrical Equipment CB The test result of CB is approbated between 43 member countries and is also accepted by many other non CB system countries Section three the basic structure of the air conditioner Air conditioner is the kind of machine that performs the function of cooling and heating by utilizing the heat absorbing and heat releasing consequence caused by the state variation of the refrigerant Although there are kinds of models the working theory and the main structuring parts are basically the same Generally the air conditioner consists of the refrigerating system electric control system 17 Pioneer air conditioner service manual and air system etc and each of them is composed of different parts It s necessary to know the specific composition of the air conditioner before learning it In this case we d like to specify the structure and performance of each parts of the air conditioner as the following 1 Refrigerating system parts The main parts of the refrigerating system of the air conditioner include Compressor heat exchanging unit Condenser evaporator throttling unit capillary tubes brake amp valve unit and other auxiliary units All of t
179. ns specification 1 The specialty terms and their express TA Stands for the indoor ambiance temperature TE Stands for the indoor evaporator temperature TS Stands for the setting temperature 2 Emergency switch The air conditioner turns off if press on this button when the air conditioner is working The air conditioner turns on if press on this button when the air conditioner is off and it will work in an automatic mode after press on this button Then the indication light twinkles for 20 seconds and the air conditioner does not start working until the working mode to be selected by the system The air conditioner automatically selects one of cooling dehumidification and heating mode as the working mode according to the indoor air temperature a When TA gt TA1 the controller enters into the cooling mode and follows the mode in working The setting temperature herein is 24 C and the setting wind speed is strong wind b When TA2 lt TA lt TA 1 the controller enters into the dehumidification mode and follows the mode in working The setting temperature is 24 C and the setting wind speed is strong wind c When TASTA2 the controller enters into the heating mode and follows the mode in working The cooling only type follows the ventilation mode The setting temperature herein is 24 C and the setting wind speed is strong wind d This mode includes the functions of timing sleeping auto restart optional negative ion optiona
180. ntact well AC contactor loops break off If loops break off contact points can not be closed so that power can not enter the motor Electronic circuit control panel has been broken High pressure switch has broken If high voltage switch has been broken connection lugs cannot contact well Check connection lugs with universal meter Trip of low pressure switch When refrigerating system runs normally connection lugs of low voltage switch contact well When refrigerating system has trouble or refrigerant leaks pressure in the system will decrease below trip point low pressure switch will trip and cut off service power 3 Air conditioner shuts down short after it starts up Excess high discharge pressure which causes high pressure switch tripping Excess low suction pressure causing trip of low pressure switch Fan motor has burnt out Heat protector trips 4 When air conditioner starts up power indicator lights indoor fan runs but compressor fails to operate It shows that there s no problem in refrigerating system and fan system but people operate the air conditioner in wrong way or thermostat switch has broken therefore trouble light doesn t blink Wrong buttons have been pushed Air conditioner may be in ventilation situation instead of refrigerating situation Temperature has not reached set value When set temperature of thermostat switch is higher than room temperature connection lugs of temperature controller opens all a
181. o high if the two units heat exchange properly finally checked the system itself Case 16 Folding of Connection pipe Unit Model KFR50 TA Phenomenon Poor cooling efficiency Cause Analysis Abnormal sound could be heard in indoor unit When air conditioner runs for three minutes and under ventilation mode no abnormal sound was heard but when compressor was turned on indoor evaporator produced abnormal loud sound of cold flow Checked the system and found that outlet tube of indoor evaporator and copper tube of condenser were bent on the junction between the two tubes Solution replace connection tube Experience Conclusion in such case abnormal flow sound is produced by unsmooth flowing of refrig erant and only when we check the system carefully can we find where the line is bent which is caused by unprofessional performance of maintenance workers Case 17 Bending of connection line Unit Model KFR H24B4 208 Pioneer air conditioner service manual Phenomena Refrigerating efficiency was unsatisfactory outdoor unit stopped to run after it operated for some time Cause Analysis air conditioner was installed last year and failed to run properly since then Maintenance personnel checked the air conditioner many times and had following data running current was 12 5A pressure was 5kg f com2 inlet wind temperature was 12 Celsius Degree and outlet wind temperature was 30 Celsius Degree From these data air conditioner was no
182. o the setting wind speed 2 When TA2 lt TA lt TA1 the controller enters into the dehumidification mode and follows the mode in working The setting temperature is 24 C and the air conditioner runs according to the setting wind speed 3 When TA lt TA2 the controller enters into the heating mode and follows the mode in working The cooling only type follows the ventilation mode The setting temperature herein is 24 C and the air conditioner runs according to the setting wind speed 4 This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional The system mode will not change along with the variety of the indoor temperature after being selected The new working mode will be selected again after air conditioner turns off or mode switch 4 Cooling mode The setting temperature shall be set by the remote control The temperature controlling range is 16 C 32 C The setting temperature can be adjusted through the button of The setting wind speed can be adjusted through the button of wind speed selection in the selection of the four wind speed types such as strong wind high wind low wind and mute wind The four way valve always be closed under this mode The other action is as following D When TA TS gt 1C after the compressor meet the 3 minutes delay protection the compressor and the outdoor fan start running 2 When TA TS maintain the previous status
183. ocedure 158 Pioneer air conditioner service manual Pull out the power plug and replug itafter some 5 seconds NE Does the buzzer ring ji YES yR E Check the connection Does the air conditioner start operating YES ual between power supply cord after pressing the ON OFF button of the norma and the connecting terminal remote control then check the fuse Y NO YES NO r 1 ing bel bene Refer t the trouble shooting of the remote control Is the primary voltage on Sra pres Cn2 normal P NO rA Is the LED lighten i YES Are the voltage of micro controller 8 compressor 2 4 way valve and 6 outdoor fan motor normal Is the voltage 5 VDC of the 15 YES YES YES motor normal Are the voltage IC4 of RY1 compressor l RY3 indoor fan motor and outdoor fan indoor fan motor normal PCB board OK Is the DC voltage on the NO NO YES NO Replace the Is the port voltage 0V DC ofthe 3 Check the as Replace the Ryl PCB board normal the compressor indoor fan RY3 and IC4 Is the port voltage 5VDC of the 7 motor and outdoor fan motor normal YES NO Is the output voltage ofthe IC2 normal NO Is the port voltage ofthe 27 7 YES y normal Check PCB board Replace the main Replace IC2 PCB board ps NO Are the port voltage of
184. oil pipe The timing light on the panel twinkles one time second 2 The damage to the indoor temperature sensor The timing light on the panel twinkles one time 8 seconds 3 The damage to the indoor coil pipe sensor The timing light on the panel twinkles two times 8 seconds 4 Heating and defrosting The sleeping light twinkles 0 5 0 5 second 5 Refrigerating anti freezing protection The operation light and the timing light of the panel twinkle 0 5 0 5 second 6 Heating anti overheating protection The running light and sleeping light are twinkling 0 5 0 5second 7 Heating long time anti cooling wind protection The running light is twinkling 0 5 0 5second 6 FS Y DS Y ZVY CSY model air conditioner faults display and protection display 226 Pioneer air conditioner service manual When the faults happen the LED digital screen of the operation panel displays the corresponding code 1 Fault of The indoor temperature sensor System turns off and the LED digital screen of the operation panel displays El 2 Fault of the outdoor tube temperature sensor on the indoor panel System doesn t turn off and the LED digital screen of the operation panel displays E2 3 Fault of the indoor tube temperature sensor System doesn t turn off and the LED digital screen of the operation panel displays E3 System works under the mode without indoor tube temperature sensor 4 When outdoor panel
185. ong tube and then calculate adding quantity of refrigerant according to its density Section two Cleaning and blowing of refrigerating system 1 Cleaning of refrigerating system When air conditioner can t operate properly insulation of compressor motor may be disrupted coils has been short circuited or windings have been burned a large amount of acid oxide can be produced and refrigerant may be polluted So besides replacing of compressor the whole refrigerating system shall be cleaned 197 Pioneer air conditioner service manual Pollution degree of refrigerating system can be classified as slightly polluted and seriously polluted When system is slightly polluted condensed oil in it has not been polluted completely and if refrigerant and lubricant is released from line of compressor it is transparent and will become light yellow normally they should be in white if tested with litmus paper If system has been seriously polluted when line of compressor is opened tar odor can be smelt immediately and condensed oil from line is black and if litmus paper is put into the oil it will become mahogany in 5 minutes Refrigerant in totally enclosed compressor for small air conditioner shall be R22 which can be cleaned with R113 C F3 CL3_trichloroethane according to following procedure 1 Release refrigerant in refrigerating system check color and odor to determine the pollution degree of refrigerating system 2 Remove compressor
186. op happens to the room temperature Such as one set of 3 2K w air conditioner that is applied to a room with area 13 21M height 2 8M will achieve an obvious temperature drop within 13 21 M 2 8M 500M h 0 0728 0 01176h 4 4 7 1min However due to the distinct heat storing capacity of the wall window amp door furniture ornaments etc the drop of temperature will take more time and even the temperature of the cooled air may contrarily rise up after having touching them In addition the stable operation of the air conditioner also need some time since the refrigeration system just start up In this case the above calculation method presented and recommended as the theory reference only The cable ammeter and the quantity of electricity consumption Usually the electric connecting cables include the plug cable are already assembled by the manufacturers to the air conditioner system and with no extra cost or labor for users But the cable from the socket to the switchboard must be laid out by the user before installation Since the air conditioner is the largest one in consuming electricity among the home appliances the special and exclusive circuitry Direct sourced from the total electrical source and must be equipped with the earth lead The dimensions of the leads are required as the below 14 Pioneer air conditioner service manual The rating current A of The section area of the plastic insulated leads
187. operated well so main control panel had no problem We presumed that fault must occur on the components of remote receiver We checked the receiver and found that insulation resistance of ceramic chip capacitor 103Z 50v was only several thousand ohm while resistance of good ceramic chip capacitor shall be over 10000MO leakage current was too large so that receiver failed to function Solution cut 103 capacitor or replaced display panel air conditioner had been functioning normally since then Experience conclusion there re many causes of malfunction of remote receiver besides leakage of capacitor dry joint of components also can result in faults of remote receiver In addition environment where air conditioner is used also can impact function of remote receiver when environment humidity is relatively high condensate will condense on the weld joints on the back of remote display panel cir cuit panel is musty and its insulation performance declines and welding joints leak so remote controller can t turn on the air conditioner or fails to work Clean circuit panel dry the panel with blower and then weld a layer of glass glue on the back of display panel remote controller can function properly AM channel of radio can check whether remote control can send signal If air conditioner functions after turned on manually main control panel has no problem so there must be some faults in receiver When air conditioner need repair especially repe
188. operty of the object s surface More black or rough the surface is more easy in radiating or absorbing heat The white and smooth object can hardly absorb the heat but be good at heat reflection Because of this the condenser of the refrigerator is painted in black color for strengthening the capability of radiation and the shell surface of the refrigerator is light and brilliant so as to reduce the absorbance caused by the radiation from other objects 3 The State Parameter of air 1 The temperature of air The temperature of air represents the heat extent of the air Usually Celsius temperature scale t C was introduced to stand for it 2 The pressure of air The pressure of air in the nature is atmosphere pressure Since the air is the mixture of dry air and water vapor the air pressure is the sum of the pressures of dry air and water vapor The value of the water vapor pressure is a parameter reflecting the quantity of the water vapor in the air The total air dimension is always full of the water vapor molecules The temperature value we obtained is not only the one of the dry air but also the water vapor s In this case the volume or the temperature of the water vapor is equal to the volume or the temperature of the air respectively The weight of the air is the sum of the dry air and the water vapor 3 Humidity Humidity is one of the physical parameter for representing the quantity of the water contained in the air There ar
189. or germanium diode forward resistances is 0 1000Q while reverse resistance over 100KQ If reverse resistance is very low this diode has been broken if both reverse and forward resistances are oo diode has broken If difference between reverse and forward resistances is very slight or any of the two resistances deviates greatly from normal value this diode is defective and shall be replaced However the said standard doesn t apply to some special diodes for example high voltage silicon stack forward resistance of which is also very large index finger only moves slightly even in the Rx10K of universal meter and some stabilivolt tubes reverse resistance around 20K 2 b Light emitting diode LED Except low voltage types forward conductive voltage is larger than 1 8V while most universal meters are of a voltage of 1 5V except for Rx10K so they are unable to make diode conduct which cause reverse and forward resistances very large or even infinitely great To check LED Rx10K or universal meters with 9V or over voltage shall be used When we use Rx10K of universal meter LED can be checked in the same way as normal diode No matter what kind of diode positive and negative poles can be judged When you measure reverse resistance the end touched by red handle is positive pole the other end is negative pole 2 Performance check for common triode Main parameters to be measured are Iceo and hrr In general actual measured resistance of ge
190. ording to client Cause Analysis according to client noise made by air conditioner was not so loud in the daytime but it was much louder at night We turned on air conditioner outdoor unit noise could be heard in the room Checked the air conditioner noise from it was quite normal but it was installed in balcony which was only separated from bedroom by a wall and air conditioner was installed under the window and sound could be transmitted directly to the room Solution Moved outdoor unit to a suitable place noise was reduced Experience Conclusion if possible do not install outdoor unit especially large power outdoor unit on balcony Case 15 Heat expansion sound of plastic components Unit Model KFR35 H Phenomena When the air conditioner was turned on and off clap could be heard sometimes Cause analysis indoor unit made clap like sound plastic components of indoor unit produces sound of heat expansion opened panel and run the air conditioner noise was eliminated so we presumed that water collection pan was too close to plastic panel which may expand when temperature rises Solution cut brink of plastic water collection pan with knife turned on air conditioner again noise was eliminated Experience Conclusion special faults shall be handled with special methods Section two maintenance cases for water leakage of air conditioner There are various causes for air conditioner water leakage we should check carefully to fi
191. orking conditions between the cooling and heating modes of the heat pump air conditioner Hence the one way valve is always applied in the heat pump air conditioner in order to switch the refrigerant s flow directions safely and effectively as shown in picture 2 11 In the process of cooling cycle the difference between the high pressure and the low pressure is small the main capillary tube is throttling component and the auxiliary capillary is short circuited by the check valve In heating cycle the check valve in parallel connection with the auxiliary capillary tubes is cut off the refrigerant will flow through the auxiliary capillary then the throttling components are the combination of the main capillary tubes and the auxiliary capillary tubes so as to strengthen the resistance of the throttling component enlarge the difference between the high pressure and low pressure of the cycle reduce the refrigerant temperature of the outdoor heat exchanger for obtaining more quantity of heat from outside and achieving the heating purpose o Im re valve jn Low press Ze im separato l Heating capillary tube Ke Single way valve High pressure valve Cooling and heating type Outdoorumt Indoor unit Remark Means the Towing trend of the cooling operation Means the flowing trend of the heating operation Picture 2 11 The location of the check valve in the refrigerating system 8 Stop valve
192. peration one way Valve Check valve is also called anti reverse valve it permits the refrigerant to flow in only one direction in the refrigeration system and to be installed in the pipes for preventing process flow from reversing It is mainly applied in the heat pump air conditioner and adopted as the assistant to the electromagnetic reversing valve for changing the refrigerant s flow direction and the system s pressure Generally there is an arrow marked on the outer surface of the one way valve for indicating the flow direction of the refrigerant The one way valve is divided into the spherical valve and the needle valve They are in the simple structure For example in the below picture when the refrigerant flows in the direction as the arrow indicates and when the pressure at A side is higher than the one at B side then the steel ball or valve needle moves to the left side and the refrigerant flows from A to B the one way valve opens However when the refrigerant flows in a reverse direction and when the pressure at B side is higher than the one at A side then the steel ball or valve needle moves to the right side which jams the 25 Pioneer air conditioner service manual refrigerant s flow route and the one way valve is in close status eat Steel tub It s not reliable to rely on the electromagnetic reversing valve only for controlling the flow direction of the refrigerant due to great disparity existing in the w
193. picture 115 Pioneer air conditioner service manual Detailed part list of KFR50 ET outdoor unit No Chinese Name Name Material Number 1 Fc MSZ FEAR Left side supporting plate 1 2 DEADE Steel grille 1 3 Ani 3 A BURE Screw 4 4 Ti ss x Top cover board 1 5 if Front panel 1 6 VE babas Ak JV Condenser assembly 1 7 Ay MK Right side panel plate 1 8 NIE Handle 2 9 HE A Hl BE Capacitor clamp 1 10 Hg pL RE Compressor capacitor 1 11 EPLER Fan motor capacitor 1 12 FRAG x Wiring clamping cover 1 13 Ha Ae Electrical holding plate 1 14 Tibi FAK Terminal board 1 15 Ka px vr Partition plate 1 16 HA pL Compressor 1 17 E A Capillary assembly 1 18 PU 38 Dx ET p ZA AE Four way valve assembly 1 19 SEIZE Dg4 Liquid valve Dg4 1 20 zi 1E RIZA Dg10 Gas valve Dg10 1 21 eH HE Chassis 1 22 TERRE A BURE Screw 4 23 EA Valve plate 1 24 Ail DALE Outdoor fan 1 25 rupe Motor bracket 1 26 FARAT mt Outdoor fan motor 1 27 o FEE RET Screw 4 116 Pioneer air conditioner service manual 6 KFR70 ET Indoor unit exploded picture 117 Pioneer air conditioner service manual Detailed part list of KFR70 ET indoor unit
194. poog 3 Heat high pressure __ Cold low pressure nn 44 AR q Compressor r L od t ub o ss het exchanger Throttlingcomponent heat exchanger indoor outdoor Chart 1 cooling operation 24 Pioneer air conditioner service manual When the air conditioner runs the heating mode the loop of the solenoid guiding valve is electrified and the iron core drives the valve bowl to move right Then the capillary tube a connects to d in high pressure and b connects to c in low pressure Because the capillaries a and d connect with the discharge pipe of compressor they will form a high pressure zone being filledwith the high pressure gas However the capillaries b and c connect with the suction pipe of the compressor they will form a low pressure zone At this moment the piston moves to the right side by pressure then D connects to E the high pressure gas refrigerant in D pipe flows into the indoor heat exchanger as condenser for heat transmission process passing through pipe E and enters into the outdoor heat exchanger evaporator passing through capillary tube Finally it will enter into pipe S from pipe C and return back to the compressor for concluding a heating cycle The flow process is indicated in Chart 2 Pilot actuated valve Electromagnetic loop E Heat high pressure EA Cold low pressure b Throttling component Heat exchanger Heat exchanger indoor outdoor Chart2 heating o
195. porator so as to enhance the evaporating efficiency for the evaporator Refer to the below picture 2 7 of the figure of liquor separator 22 Pioneer air conditioner service manual 7 The stop valve For controlling the braking of the refrigerant existing in the pipes of the refrigeration system and switching its flowing direction for the purpose of switching the heating and refrigerating function of the air conditioner as well as easy service operation there are various types stop valve units are amounted in the pipelines of the air conditioner s refrigeration system The most important includes the electromagnetic reversing valve single direction valve and cut off valve etc the electromagnetic reversing valve it s mainly applied in the heat pump air conditioner Since there are four main pipelines connect to it regarding to the structure it is usually called four way valve It 1s used to changes the function of the condenser and evaporator and realize the shift between the air conditioner s functions of refrigerating heating or defrosting etc through the way of changing the direction of the flow of the refrigerant in the system Refer to the below picture 2 8 for the figure of the electromagnetic reversing valve The electromagnetic reversing valve consists of two parts One 1s the solenoid guiding valve the other one is four way commutating valve The solenoid guiding valve usually controls the four way valve by three guiding capil
196. pressor and the outdoor fan runs for 10minutes and stops for 6 minutes The indoor fan turns off during the compressor s 3 minutes stopping period and keeps on working in breeze mode under other conditions c TA lt TS the compressor and the outdoor fan stop working and the indoor fan start to work in breeze mode after stopping for 3 minutes Automatic wind speed control TA TS25 C the wind speed is at high wind TS 3 C lt TA lt TS 4 5 C the wind speed is at middle wind TS 2 C lt TA lt TS 3 C the wind speed is at low wind TS lt TA lt TS 2 C the wind speed is at fitful breeze TA lt TS the indoor fan is off during the 3 minutes delay of the compressor and 3 minutes later the wind is at breeze speed The primary electrifying to compressor has no 3 minutes protection delay the outdoor fan starts 2 seconds later after the start of the compressor When the indoor fan runs the air door can be set as free swing and the swing condition is same as the one under cooling mode a When TE lt 2 last for 10seconds and the compressor runs continuously for above 5minutes if turn off the compressor and outdoor fan the indoor fan runs at the setting wind speed If TE gt 7 C quit from the protection b When TE gt 64 C last for 10seconds the compressor and outdoor fan unit turns off If meet the 3 minutes delay condition and TE lt 62 C the compressor can start normally When the air conditioner is under ov
197. r lt 10seconds within the 10second of process of residual heat removal if TE lt 35 C the indoor fan turns off at once 48 Pioneer air conditioner service manual IDAnti high temperature protection when run on Heating mode if TE gt 57 C and continuously last 10 seconds the outdoor fan stops if TE264 C and last for 10s the compressor stops again When TE lt 52 C and satisfying 3minutes protection delay condition the compressor resume normal work 2 Such temperature protection is valid only if the TE sensor works normally 2 The defrosting function under heating mode When the outdoor sensor in good condition the defrosting process starts and the sleeping light is twinkling a TW lt 6 C and continuously last for 2minutes b The accumulated operation time of the compressor is over than 50 minutes the interval time between defrosting process is 50 minutes the accumulated time shall be recalculated 1f power off or remote control off the continuous working time of the compressor is over 5 minutes Once the defrosting process starts the compressor the indoor fan and outdoor fan turn off and the four way valve turns off after 30 seconds and after another 15 seconds the compressor turns on and starts the defrosting process The defrosting process ending condition The defrosting process will quit if one of the below conditions to be satisfied a Outdoor coil gt 12 C b Defrosting process last for 12minutes c
198. r 1 13 H2 ni Wiring clamping cover 1 14 HA a Ae Electrical holding plate 1 15 Tibi Y d Terminal board 1 16 Ka KOLI ZA PE Partition plate 1 17 HALA AE Compressor 1 18 PME E ERE Capillary assembly 1 19 VU 38 s E E 2H PF Four way valve and capillary 1 assembly 20 AIL IH TF Des Liquid valve 1 21 TE ZA fF Dgl3 Gas valve 1 22 JARA TE Chassis 1 23 PRADOS AA ABUR Screw and cushion assembly 4 ET AIP AZ GE 24 Ii ANC Valve plate 1 25 Aiii UE Outdoor fan 1 26 LE Motor bracket 1 21 ZN HT rp LH TE Outdoor fan motor 1 28 Tod XB BURE Screw 4 140 Pioneer air conditioner service manual Chapter 4 The disassembly and the relating attention issues to the part of Pioneer product Section one the disassembly and the relating attention issues to the series products of 9000BTU 12000BTU Attention Turn off the air conditioner and pull out the plug of the power supply before the service 1 Indoor unit No Part Operation Process Remark 1 Panel 1 Turn off the air conditioner and cut off the power supply 2 Tear the adhesive tape sticking to the panel 3 Hold the handles at both sides of the panel and push upward to have it slip out 4 Grasp the both sides of the panel and push upward 5 Turn the upper board by 90 and unload 1t from the connecting pole carefully 6 Take out the filter from the right and left side 7 Screw off the bolts on the electrical box cover and unload the box cover 8 Sc
199. r acts as the evaporator The indoor and outdoor heat exchangers are in the configuration of wing coil type mostly For promoting the efficiency of heat exchange the patches of aluminum alloy wings are usually punched in kinds of shapes so as to enlarge the heat exchange area for example of Picture 2 5 20 Pioneer air conditioner service manual a Evaporator Evaporator is also called cooler It is the apparatus used for direct cooling purpose in the refrigerating cycle and is usually installed inside the indoor unit The evaporator applied in the air conditioner is the wing coil type with high heat transmission coefficient and compact structure The liquid refrigerant flows into the snake copper pipe after the throttle of the capillary tubes The air around the outside of the copper pipe is the floating air by force When the compressor works the wing coil will absorb the quantity of heat from the indoor air so as to have the liquid refrigerant gasified and bring away the quantity of heat for cooling the room temperature Meanwhile it can also freeze the surrounding air of the evaporator until its temperature reaches the dew point to get rid of the moisture and humidity of the air Due to the continuous production for condensing water between the wings of the evaporator the distance between the wings is usually required to be enlarged enough comparing with the one of condenser for insuring the air s free flow In addition the hydrophili
200. r conditioner and found that insulation sleeves of high and low pressure connection tube of indoor unit were of poor insulation efficiency which caused leak of condensate Solution Re wrapped connection tube joints with insulation sleeves the more belt is wrapped the better insulation efficiency will be Experience Conclusion insulation sleeve and tube are of same length when air conditioner leaves the factory so before wrapping connection tube power wire and water drain line and maintenance personnel shall measure length difference between inlet and outlet tubes of evaporator reserve space for connection tube Because expansion capacity of insulation sleeve is different to obtain good insulation effect we shall wrap insulation tightly with belt so that insulation sleeve on tube joint will not be loose and cause joint cap being exposed and leaking water In addition tube joint shall be affixed with water proof adhesive tape or it is likely to leak Foregoing leak is caused by improper installation so for newly installed air conditioner such problems shall be noticed Case 6 Water drain tube was flattened and leaked Unit Model KFR35 H Cause Analysis According to client the newly installed air conditioner leaked water We checked and found that indoor unit was installed in a level plane the hole on the wall was lower than indoor unit and drain tube of indoor unit was not broken later we found that discharge amount of outdoor drain
201. r conditioner is the result of the cooling capacity being divided by the cooling load For example KFR35 HSA the cooling capacity is 3200W the minimum applicable coverage area is 3200 240 13M about and the maximum coverage area is 3200 150 21M Table1 5 the quantity of refrigeration in need for specific situations Type Qty of type Qty of refrigerati refrigerati on w M on w M Ordinary family room 170 Hotel room close type 160 Garret family room 220 Hotel room open type 140 Ordinary office room 200 Hotel hall 220 Haircutting house or shampoo 280 Conference room projection room 320 Salon Front hall of hotel or Interval 420 Family living room and dining room 200 room Garment shop and Jewelry shop 220 Chess amp card playing room and tea room 240 The above is the estimation to the applicable area mainly in according to the cooling capacity Due to the available temperature difference and the sense difference by different people to the heat energy the quantity of heat load is usually bigger than the one of cooling load per unit applicable area according to the practice experience and generally about 180 270W M I0 The time for temperature s drop and rise After an air circulating all over a room by the air conditioner because of a heat temperature difference 12 15 C available between the inletting room temperature and evaporating temperature people may feel an obvious dr
202. r service manual Outdoor unit exploded picture 107 ATI PPP Og LLL III A IIIg ERE EESPRSEEFEEFFEFEESFEFFIA Pioneer air conditioner service manual Detailed part list of KFR35 ET outdoor unit No Chinese Name Name Material Number 1 Tir bc Vol EE Steel grille 1 2 ri te ZELE Front panel 1 3 Toi ss x Top cover board 1 4 Ait DAF Outdoor fan 1 5 SEL Outdoor fan motor 1 6 HHLA Motor bracket 1 7 Abt as E Condenser assembly 1 8 AERE VE Condenser gas inlet tube 1 9 EME HI Capillary assembly 1 10 JE EN 22 pod 98 Backside steel grille 1 11 FB d nt DX Handle 1 12 A WUA Right side plate 1 13 n zs Capacitor clamp 1 14 JUL FB R Fan motor capacitor 1 15 Hd LAE Compressor capacitor 1 16 bri TAR Terminal board 1 17 HASN Electrical holding plate 1 18 Ka AUZIR Partition plate 1 19 PU xi amp jx x Electromagnetic loop 1 20 VU 386 PRISE Pe ZH TF Four way valve and capillary 1 assembly 21 Hag LE Pte Compressor connection cord 1 22 KNL Compressor grounding cord 1 23 Hdi EL Compressor terminal cover 1 24 REUS d Over load protector 1 25 Ha pL Compressor 1 26 BE IZA A Liquid valve 1 27 d amp ILRI ZH fF B Gas valve
203. r some compressors Rcs gt Rcr for some compressors Rcs Rer For some compressor main winding and assistant winding can not be judged according to normal rules because of different ways of wiring Therefore wire shall be connected correctly as per connection diagram provided by manufacturer 1 Short circuit inspection for motor windings Short circuits of windings refer to the fact that insulation performance of winding has been disrupted which cause short circuit including inter turn short circuit winding burnout inter winding and inter phase short circuit In some cases of short circuit motor still runs but runs slowly and current is excess large Contrast value of velocity current depends on how many windings have short circuited Remove outside wire of motor check resistance between C and S and resistance between C and R if resistance of terminal of certain winding is lower than normal value it shows that this winding has short circuited 2 Broken circuit inspection of motor winding Connection lugs in junction box are not welded or locked firmly and loose or break during operation In addition insulation wires don t insulate properly and winding burns out The motor can t be run because of broken circuit Remove outside wire of motor check conduct condition of two connection points with Rx1 of universal meter If two connection terminals don t conduct i e resistance between them is infinite large undoubtedly this winding
204. r_n aooxeooxeoo 920x 1o95x2nsfsooxeooxeao 320 HRS 2UDAR004680 P 200 10920 sooxeooxeoo Es neh Lm d o E mw tom em t ta en PE Dimensi an motor Compressor me ee Rar mee ver esse vester messes user S lyPe fptastieseatea Iron shell plastic sealed Iron shell Plastioscaled Iron shell_ Plastic sealed Iron shell iles w m e o e s o 9 EEE A Cooling test condition Indoor unit DB27 C Wb19 C Outdoor unit DB35 C Wb24 C Heat ing test condition Indoor unit DB20 C Wb Outdoor unit DB7C Wb6 C Max Cooling test condition Indoor unit DB32 C Wb23 C Outdoor unit DB43 C Wb26 C Max Heat ing test condition Indoor unit DB27C Wb Outdoor unit DB24C Wb18 C 62 Pioneer air conditioner service manual Chapter 3 Exploded pictures of Pioneer products Section one E series products 1 KFR2S ET Indoor unit exploded picture 97 Pioneer air conditioner service manual Detailed part list of KFR25 ET indoor unit No Chinese Name Name Material Number 1 Tp ZH E Panel 1 2 EIC BUE DI Anti bacterial Filter 2 3 YE C pi ps WE PA Vitamin C amp Anti mites Filter 2 4 ODE PY HF Filter D 5 WERT n Screw cover 3 6 FPE ni Cover of medium frame 1 T rE ZH fF Medium frame
205. rating We can install insulation sleeve on the tube 2 Copper tube is too close to sheet metal pieces vibration of compressor causes collision between 214 Pioneer air conditioner service manual tube and sheet metal We should install damp piece or insulation sleeve 3 Vibration of compressor causes collision between copper tubes Install insulation to isolate two tubes In such case we should explain to client that it s not air conditioner fault it is caused by improper installation and can be handled easily Case 9 Outdoor fan motor bracket deformed because of the vibrating Unit Model KFR35 HY Phenomena Outdoor unit made loud noise in operation Cause Analysis air conditioner buzzed when it was in cooling mode Maintenance personnel judged that sound was made by outdoor unit Opened outdoor shell checked the internal tubes and compressor and found that they operated normally So maintenance personnel suspected noise was made by outdoor fan Turned off compressor noise was still very loud Changed fan motor but noise remained the same Check carefully and found that fan motor bracket bent adjusted the bracket vertically installed fan again and run the air conditioner buzz was eliminated Solution adjusted outdoor fan Experience Conclusion to reduce noise more attention shall be paid to stability of auxiliary support and fasteners and whether they have deformed Case 10 Outdoor grille collided with front panel
206. ration Case 4 Noise produced by friction between fan blade and wind baffle Unit Model No KFR H24B4 FSY Phenomena Noise in outdoor unit Cause Analysis We run the air conditioner when we finished installation outdoor unit produced un pleasant sound and we suspected outdoor fan was broken or steel casing scraped with each other Opened the cover of outdoor unit rotated fan with hand no noise was heard turned on air conditioner again we found that blade collided with wind baffle and produced noise Maintenance personnel failed to insert wind baffle in locating slot Solution inserted wind baffle into locating slot the noise was eliminated Experience Conclusion if there s noise in outdoor unit attention should be paid to decide what kind of noise it is friction noise or resonance vibration noise or magnetic noise and then deal with it accord Case 5 Fix screws of fan blade loosed Unit Model KFR35 M Phenomena Indoor unit noise Cause Analysis air conditioner was newly installed and it didn t make noise during test running Noise occurred one month later Maintenance personnel suspected that there s foreign substance in indoor air duct or problem was caused by improper installation We opened indoor unit but didn t find anything wrong When we rotated wind wheel with hand and found that fan blades moved to the left and right and collided with shell because of the loose screws We tightened the screws air conditioner wor
207. rays outside the unit If surface temperature of evaporator is uneven same fault will occur We can handle the problem of uneven temperature on the surface of evaporator by increasing or decreasing refrigerant according to air returned pressure of low pressure valve and ambient temperature If temperature difference on evaporator exceeds 9 Celsius Degree evaporator is blocked partly so it shall be replaced with a new one Case 12 Flush air conditioner leaked water Unit Model KORa H41 A5 Phenomena Indoor unit leaked and running indicator blinked Cause analysis water spilled over from water collection pan we checked drainage condition of water drain pipe and found drain amount was very small so we judged that drain pump failed to drain water properly Solution replaced water drainage pump Experience Conclusion drainage method of flush air conditioner is different with split units the later can discharge water without any other equipment but the former shall have discharge pump to drain water If air conditioner leaks discharge pump shall be checked first Blinking of running indicator also proves that air conditioner is in water drainage protection mode Of course leak of flush air conditioner also can be resulted by non plainness of water discharge pump We shall analyze causes carefully when we repair air conditioner 223 Pioneer air conditioner service manual APPENDIX 1 Introduction to the fault display CODE of Pioneer air co
208. re are no defects available and confirm whether the rubber plug to the air vent is off or not Before turning off the vacuum pump switch off the Throughway valve firstly for separating the refrigerating system and the vacuum When the vacuum leaves unused block the air intake and air vent by the rubber plug in case of the entry of the dust and ordure to the pump body which may affect the precision of the interior cavity It s necessary to maintain the neatness of the vacuum pump check the volume of the lubricating oil through the oil window frequently and enforce the daily maintenance applied to the vacuum pump for enhancing the equipments perfectness ratio 2 Pressure gauge Due to the usual refrigerant leakage to the air conditioner the pressure gauge applied for the fullness inspection to the refrigerant in the system is often in need The pressure gauge is the usual inspection tool for the refrigerant cooling system It is in various specifications with the outer diameter from 60mm 250mm The applicable measurement range of the vacuum pressure gauge to the air conditioner refrigerating system is 0 1MPa 2 5Mpa which is indicated in the Picture 2 33 The pressure gauge usually matches with the three way mend valve in application The rotation applied to the knob of the three way mend valve in clockwise direction may reduce the size of the valve bore When the knob reaches the bottom of the rotation the connection between the correspo
209. refrigerating system shall be drained completely 4 If compressor has been burned acid in system shall be purged with nitrogen 5 Compressor expansion valve capillary and filter shall be cleaned with gasoline first and then be dried with nitrogen 2 Blowing of refrigerating system After refrigerating machine has been removed inevitably there re some slag rust scale and water in the system which will abrade running parts for example score and rough the cylinder or pistol surface or impress concave on the contact surface of some parts for example blades of compressor becomes rough and valve spool has been damaged Sometimes dirt may block system on the expansion valve capillary and filter dirt block Dirt and water also reflects with refrigerant and condensate and create corrosive substance Currently cleaning equipment is rarely used to clean refrigerating system High pressure nitrogen is often used to blow the polluted system 198 Pioneer air conditioner service manual Generally system shall be purged under a pressure of 0 6MPa which can be pressurized with refrigerating compressor nitrogen bottle or air compressor compressed air can t be used in Freon system System shall be blown in sections with dirt outlet set on the lowest point of each section Each dirt outlet shall be plugged up with cork tied with steel wire When pressure reaches 0 6MPa stop pressuring and draw out cork and discharge the dirt in this syste
210. ressor capacitor 1 16 bri x Terminal board 1 17 HA aa Electrical holding plate 1 18 Ka X vr BM Partition plate 1 19 NES Electromagnetic loop 1 20 VU 386 RISE e ZA TF Four way valve and capillary 1 assembly 21 FS AGN LIE Fee Compressor connection cord 1 22 FR ARAL Betty Ze Compressor grounding cord 1 23 HE Air Et Compressor terminal cover 1 24 DURAS Over load protector 1 25 Ha pL Compressor 1 26 BE RIZA A Liquid valve Dg4 1 27 AERE B Gas valve Dg8 1 28 DA Valve plate 1 29 SR 2H TE Chassis 1 128 Pioneer air conditioner service manual 3 KFR25 HS Indoor unit exploded picture 129 Pioneer air conditioner service manual Detailed part list of KFR25 HS indoor unit No Chinese Name Name Material Number 1 TA eH 44 Panel 1 2 OVE PY ZH Filter 2 3 FH AS ni A Cover of medium frame 1 4 FPE ni Medium frame 1 5 SNL Horizontal air blade 1 6 FUF Fr Vertical air blade 12 7 ENE Air blade holder 1 8 zh BE LF Step motor 1 9 ti Vi AMT ZH TE Indoor fan 1 10 PBC A E Rubber bearing 1 11 PAS LAR Left plastic crutch for evaporator 1 12 EIA Evaporator 1 13 JES JE ZH fr Chassis 1 14 FEIT Mounting plate 1 15 E ER Hs Tube clamp plate 1 16 XB RUE Indoor fan motor 1 17 Bi iu Electric controller box 1 18 AR Hs d Transformer 1 19 EXEC TS Plastic temperature sensor 1 20 Xd Main PC
211. ressor opening condition the four way valve shuts off after 2 minutes and 50 seconds delay protection when turn off or switch the controller The four way valve turns off immediately after turning off the controller when the compressor is off 35 Pioneer air conditioner service manual Anti cold wind and Residual heat Removing function TE controls the wind speed of the indoor fan and the specific conditions are as below O The anti cold wind status when the compressor runs a When TE in rise status and at the moment of TE lt TE1 the indoor fan turns off TE2 lt TE lt TE3 the indoor fan blows the breeze TE3 lt TE lt TE4 the indoor fan blows the mute wind TE gt TE4 the indoor fan blows the set wind speed b When TE in fall status and at the moment of TE TES the indoor fan blows the set wind speed TE6STESTES the indoor fan blows the mute wind TE7 lt TE lt TE6 the indoor fan blows the breeze TESTE7 the indoor fan turns off Coil tube s temperature TE4_ TES TE3 TEG TE2 TET Pe breeze mute wind wind speed set mute wind exl O The anti cold wind status when the compressor stops working a When TE is in fall status and at the moment of TE TE2 the indoor fan blows breeze at the moment of TE lt TE2 indoor fan turns off b When TE is in rise status and at the moment of TE gt TE6 the indoor fan blows breeze at the moment of TE TE6 indoor fan turns off TEE TE2 Fan motor Breeze Fan motor PG
212. rew off the 5 bolts for 1Hp AC or 8 bolts for 1 5Hp AC on the medium frame 9 Hold the both sides of the medium frame and open it gently 10 Turn up the medium frame by about 90 11 Offload the medium frame once hearing the crack sound Leti j m A e R N EM a 150 Pioneer air conditioner service manual No Part Operation Process Remark 2 Electrical 1 Do No 1 firstly component 2 Pull out all tie in connecting with PCB and the temperature sensor etc 3 Screw off the screws and bolts as indicated in the picture Untie the outdoor unit s interconnection cord and power supply cord from the terminal of the electrical box 4 If the main PCB board is loosed by chance remove it away 3 Water 1 Do No 1 and 2 firstly offload the draining water drainage soft tube tank 2 Offload the water draining tank from chassis and take out the electrical components 4 Evaporator 1 Do No 1 2 and 3 firstly 2 Offload the connecting pipe 3 Offload the tube clip at the rear 4 Screw off the bolts at the right and left side 5 Lift up the evaporator and draw it out from the indoor unit 3 Indoor fan 1 Screw off one bolt from the motor Fan motor cover and remove the motor cover 2 Offload the motor from the fan 3 Offload the fan from bearing 151 Pioneer air conditioner service manual
213. ric controller box 1 18 AE Hs d Transformer 1 19 a peg Plastic temperature sensor 1 20 ERR Main PCB 1 21 A ed Copper temperature sensor 1 22 36 Tz as E Signal receiver holder for 1 Remote controller 23 Um PETAR SCAR Temperature sensor holder 1 24 Tels Receiver board 1 25 bin TAR Terminal board 1 26 faoc T EEG Negative ion generator Optional 1 27 ERK Connection cable 1 28 EUER Interconnection cord 1 29 EX Power supply cord with plug 1 30 NA BX Display board 1 31 Re aS as Remote controller T feel function 1 optional 122 Pioneer air conditioner service manual Outdoor unit exploded picture II APA Lie VM KPLLLLTLIALAT PIL ALL LLL LLY EX 123 Pioneer air conditioner service manual Detailed part list of KFR25 HSF outdoor unit No Chinese Name Name Material Number Tiri bc od EA Steel grille 1 2 ri te ZELE Front panel 1 3 Toi sz x Top cover board 1 4 Afi fi XU Outdoor fan 1 5 ENE Outdoor fan motor 1 6 HHLA Motor bracket 1 7 A tas AE Condenser assembly 1 8 Ao ERE XE Condenser gas inlet tube 1 9 A ZA Capillary assembly 1 10 JE e 22 pd EEL Backside steel grille 1 11 HB ane nr DL Handle 1 12 AA Right side plate 1
214. rical circuits may include D Power failure 2 Receptacle wire breakage 3 Fuse burns out 4 Loose contact of socket or receptacle 5 Service voltage is too low to make the motor operate and then heat protector trips and cuts off electrical power 6 Wire breakage in option switch C Wire Breakage in Electrical Control Circuit resulted by improper operation poor quality or faults of refrigerating system and fan system for example fuse burns out may be resulted by faults of refrigerating system and fan system besides wire contact and short circuit 2 Fan runs but compressor fails to operate D Improper position of temperature Control knob 2 Contact of overload protective system breaks because refrigerating overloads during operation and cause trip of protective system or protective system can t work properly itself S Failure of compressor operation capacity resulted from improper maintenance or moisture 4 Compressor motor burns out 3 Compressor starts and stops too frequently after air conditioner switches on D Temperature sensor of temperature control system is installed too close to evaporator so that it is impacted by evaporation temperature 2 Service voltage is instable because of instable electrical power network 3 Poor contact of bimetal of overload protective system 4 Long term continuous operation of compressor D Because of too many heating appliances in the room heat load of air conditioner is excessive
215. rigerant leaking from line joints there s no leakage on indoor evaporator and outdoor unit we disassembled the indoor unit and found that there s a crack on the protection spring of evaporator junction Solution welded the line again vacuums the system and added refrigerant and air conditioner functions proper since then Experience Conclusion It is very difficult to find out leakage sources we shall pay particular attention to connection tube of evaporator Case 6 flare mouth of connection tube is broken Unit Model KFR25 HY Phenomena Poor cooling and heating efficiency Cause Analysis turned on the air conditioner and pushed on cooling mode indoor unit produced wind properly two units were very clean but temperature different of air inlet and outlet is very low air 204 Pioneer air conditioner service manual conditioner run 5 minutes and evaporator of indoor unit was frosted so we presumed that refrigerant was not sufficient we checked and found that low pressure was 3KG Turned off air conditioner checked indoor amp outdoor units and connection tube and found oil stain on the junction of low pressure copper tube Solution released refrigerant twisted off line junction and found a small crack repaired flare mouth checked leakage sources under high pressure vacuum the system added refrigerant and then test run the air conditioner and it worked properly Experience Conclusion to fix the air conditioner maintenanc
216. rises by one gear the temperature difference correction value shall be 1 C O a The accumulated operation time of the compressor gt 3hour b The continuous operation time of the compressor gt 20 minutes c The difference value between TE and TA less than Y C O a The difference value between TE and TA less than Y C and continuously last for 5minutes b The accumulated operation time of the compressor is over than 45minutes c The continuous operation time of the compressor is over than 20minutes The air conditioner starts the defrosting process if satisfying the conditions and records the TE value then before defrosting starts Compare the TE value after defrosting with the one before defrosting if the value of the later is not 3 C more than the former one it will not start the defrosting process according to this condition until the mode conversed and the air conditioner to be restarted for heating or after another defrosting process The air conditioner starts time counting after overheating protection delay the outdoor fan stops and starts an force defrosting process two hours later The intelligent defrosting process quit if satisfying one of the below four conditions a The duration of the intelligent defrosting process gt 9min b After the 4 minutes defrosting process if TE gt 0 C and the TE rise by 2 C within 10seconds c After the 5 minutes defrosting process if TE25 C d Test the current of the compressor 1 minute lat
217. rmal current of air conditioner rose after it run for some time outlet wind temperature rose gradually After 1 5 hours air conditioner was in protection mode Maintenance workers judged the outdoor unit was in heat protection mode and checked discharge environment of outdoor unit but condenser was clean and the outdoor unit was not exposed to the sun Maintenance workers sprinkled water on the outdoor unit it was not in protection mode so the faults were caused by 1 faults of compressor 2 refrigerants were slightly polluted 3 problems in line We checked the system and line low pressure connection line was bent where it penetrated the wall the system was blocked and caused poor cooling efficiency Solution replaced bent line and air conditioner started to work properly Experience conclusion such fault is caused by improper installation so it is often neglected To fix such kind of fault maintenance workers shall check air conditioner carefully and shouldn t add refrigerant or change outdoor unit without careful consideration Generally it is bending of connection line and unsmooth circulation of system that result in fault of air conditioner Case 18 Pressure switch was broken Unit Model KFR H41A5 A Phenomena Couldn t produce cooling air Cause Analysis Turned on air conditioner for less than 1 minute run indicator and 18 indicator on control panel blinked so we presumed that it was in protection mode High pressure
218. rmanium triode with middle small power shall be over 10 20K O resistance of silicon triode shall be over 100K O and actually measured value is infinitely great i e index finger doesn t swing If actual resistance is excess slight it shows that Iceo is very large and this kind of triodes can not be used for their poor ca pacity If actual resistance nears zero c and e poles triode has broken down ICBO can also be measured in the same way touch two handles of universal meter on b and c poles to measure reverse resistance between them Normally resistance of germanium triode is larger than that we obtain when we measure Iceo and resistance of silicon triode is infinite great Based on the situation of measuring leo another 100KQ resistance silicon triode or 20K resistance germanium shall be connected to b and c poles The more value indicated by index finger becomes small and the more hrz is large if resistance doesn t change much or changes slightly triode is broken or its enlargement capacity is very poor Also you can touch b and c with wet hands but avoiding direct touch of b and c to measure the resistance In addition most universal meters produced in recent years have position to measure hpg of small power triode Operation method turn resistance position to 0Q and then turn to hrg position Insert handles to related test hole and read the enlargement coefficient from hrz rule directly S Cases of Maintenance of Electrical Con
219. rom the ambiance mediums that accelerate its gasify process The way of its heat absorbing results in the decline of the ambiance temperature and consequently achieves the target of air conditioning As the description of the above the refrigeration system is continuously circulating by the way of compressing condensing throttling evaporating compressing With the function of promoting the pressure of the refrigerant and transferring the refrigerant into continuous circulation the compressor is the heart of the whole system The throttling components undertake the function of flow throttling pressure reduction and flow quantity adjusting towards to the refrigerant entering into the evaporator However the refrigerant is the blood of the refrigerating cycle for taking the responsibility of transferring the quantity of heat It releases the heat absorbed from the evaporator and the one produced by the compressor to the air around the condenser for realizing the target of refrigeration by continuously absorbing heat from low temperature mediums and releasing heat to the 11 Pioneer air conditioner service manual high temperature mediums It s absolutely necessary to a refrigeration system without lack of the Compressor Condenser Throttle device and Evaporator As to the other auxiliary parts they are configured and constructed in order to promote the economy the reliability and the safety of the system Low pressur valve Liq
220. rvice manual Phenomena Indoor unit leaked water Cause analysis air conditioner had been used for two years and never leaked water before so it was not caused by improper installation it was possibly caused by obstruction in water drain pipe When air conditioner worked for a long time condensate leaked from notch of basement connection tube We checked the appearance of air conditioner it was installed on a level plane and filter had been cleaned Removed the panel we found that evaporator was clean filled the evaporator with water it didn t leak and could drain water smoothly We disassembled evaporator and water flowed from connection notch of basement Removed indoor unit from wall we found that rear guiding channel had been blocked by sand and water spilled over from channel The main reason of block was that wall was affected with damp and became loose indoor unit vibrated when it operated so sand fell into channel Solution cleaned foreign substance in channel and installed anti moist plastic cushion to avoid sand falling into air conditioner again Experience Conclusion causes for leakage of M Series air conditioner are various mainly including following aspects 1 Connection position of left motor bracket and water collector channel has an aperture because of faulty injection mould and water leaks from it 2 Top of right side of water collection channel has a small aperture because of faulty injection mould and water
221. s 162 Pioneer air conditioner service manual Part Analysis Measure resistance Environment h A temperature 150 20C 25 C 30C 35C 40 C Heat exchanger Normal Resistance of co Turn off 09 Short cut Detecting the resistance between each connecting terminal Environment temperature 10 C 30 C Between 4109 10 3500 110 3700 10 Blue yellow Main Normal Blue red 3250 10 2702 10 3000 10 The indoor fan motot Input YYKI3 4 13W YYKI9 4 19W vo Turn off 02 Short cut Detecting the voltage between the signal wire of fan motor and ground Between Voltage 0 5V 4 5V Normal Grays Orge Yellow Orange Abnormal voltage lt 0 voltage gt 5 is abnormal Environment temperature 10 C 30 C 1 2 x Between Step motor 24BYJ48 35BYJ412B Normal Blue yellow Input Abnormal Turn off 02 Short cut Detecting the resistance between the red wire and every connecting end The outdoor fan motor Normal Whenthe temperature i520 C 30 C around 3009 and 1200 eo Turn off 00 Short cut 163 Pioneer air conditioner service manual Section two basic faults diagnose process of 18000BTU 24000BTU products Troubleshooting Guide 1 The Foremost Inspecting Items DThe input voltage must be within 10 tolerance of the rated Voltage If it is not the case the
222. s have burn out and insulation layer of electromagnetic loop has been broken and windings touch the motor shell and are short circuited These faults are caused by long term overload running of air conditioner at the same time protector is broken so windings run on the over heat condition for a long time insulation layer has been damaged b Coils are short circuited which cause disruption of insulation layer of part of coils around the stator winging and some coils touch the shell All the faults are caused by slight damage of some coils scar of which expands and disrupts insulation layer c Short circuit Insulation layer of power wire of motor is damaged or cut off and short circuited d Insulation layer of stator windings has aged severely but hasn t burned out It symptom is different from the former one it can run 1 2 minutes then fuse protector is burned or air protector trips With same reason this kind of motor can t work like motor with burnt windings Abnormal noise can be heard when air condition is running When air conditioner runs steady low and rhythmic noise is inevitable If it creates unpleasant noise it is abnormal If it is not handled in time components will be damaged so we must pay attention to it Components loose and clash with each other and create noise generally exhaust tube will clash with pump shell pistol clashes with valve plate and stator abrades with rotator In addition magnetic noise may be cr
223. s sharply exhaust tube will be cracked or broken and refrigerant steam will circulate in pump shell steam can t be exhausted outside pump shell so refrigerating capacity of the system is almost zero The same symptoms of the foregoing four faults are discharge pressure drops return gas pressure rises and pressure difference between return gas and discharge pressure becomes relatively low or very low or becomes almost zero in the serious condition In the normal condition pressure difference shall be very large pump shell shall be hot in various degrees and some discharge tube will be very hot 2 Compressor can t run normally When compressor is switched on motor will produce buzz in pump but fails to run After 3 5 seconds heat protector trips and cut off the power supply This symptom is resulted by following faults a Main journal and bearing or big end and crankpin burn out and melt because of lack of oil commonly called coherence for oil in compressor is not enough or oil nozzle is blocked by pistol b Air valve is broken and broken valve blades fall into cylinder and block the pistol so valve can t reciprocate c Connection rod is broken and motor can t be driven 3 Motor in compressor is broken 201 Pioneer air conditioner service manual Symptom is when air conditioner is switched on fuse protector breaks or air protector trips immediately There re three reasons for this symptom a Because motor stator winding
224. second digital displays 11 22 33 44 in turn and 1second for each of them Run light on 1 second 2 Timer 39 Pioneer air conditioner service manual light on 1 second 2 Sleep light on 1 second Each phase of the stepping motor s motion in 1 second gt the indoor fan runs for 1 second at low fan speed and middle fan speed separately the compressor s motion for 1 second gt The four way valve s motion for 1 second Outdoor fan s motion for 1 second Negative generator s motion for 1 second buzzer deliver one short tone Electric heating runs 30 Seconds and stops then the air conditioner turns into waiting status the self detecting function ends 3 Fault indication When there is faults happen to the air conditioner the Timer lights on The control light panel will indicate the corresponding fault codes which are specified as the following FAULT Digital Display Phenomenon PG E4 AC stopped abnormity TA El AC stopped abnormity TE E3 AC stopped abnormity After the indoor motor electrified if there is no impulse signal feedback by the indoor motor detected within 10 seconds cut off the output voltage supplied to the indoor fan from the controller After 30seconds waiting time re electrify the indoor fan If still has no impulse signal feedback by the indoor motor being detected within 10 seconds the controller stays in waiting and the digital display indicates the correspon
225. side of the refrigerating system It shuts off the main controlling circuit of the air conditioner and stops the operation of the compressor in the event of the dust accumulation on the condenser s wing blocks the air path or the fan is damaged and the air volume is insufficient or the refrigerant is overcharged or the air inside the system causes the over high pressure inside the pipeline It will restart automatically after the pressure drops The low pressure switch is fixed at the low pressure side of the refrigerating system It shuts off the main controlling circuit and stops the operation of the air conditioner for protecting the compressor in the event of the dust covers the evaporator s wing or the fan air volume is insufficient or the refrigerant is insufficient or the surface of the evaporator is frosted or the system is blocked etc which may cause the low air sucking pressure at the low pressure side 28 Pioneer air conditioner service manual The other parts Picture2 20 Horizontal air blade Picture2 19 outdoor iron shell motor 29 Pioneer air conditioner service manual 30 Pioneer air conditioner service manual Chapter 2 Introduction of Pioneer products Section one the split amp wall mounted type The basic function introduction of the split wall mounted type electric controller 9000BTU 12000BTU 1 The basic conditions for the operation of the controller 1 The applicable voltage range o
226. sn t E2 is abnormal outdoor turn off 229 Pioneer air conditioner service manual APPENDIX 2 Schematic Diagrams of Some Controller Panels 1 Schematic Diagram of Controller Panel of E Series Air Conditioner with Display Screen s FUJITSU Chip 1 2 3 4 5 6 09 RE ji A y X AV qu 1 IDEA NR 2 a y a as A 1 1 A Q ZIN Ri Ad LA Hy Pel 2 T EI e D EE B us B 5 El 7 Ez 3 55 2 PE 1 B Hy c C 3 o w f 2222 Ee d Y B PR U B a D IX DK lb IK Bs ID X DK mx ame D SK SK WM SK B oo W EK ID SK D SK ID K 0 IK 9b K W K WK IK ID K DK K D K D EK 7 K B 7777 1 22 022 2222288 RI E 22222 0 222 2229299997 D D T Se Nir Ran B De WP Su d ENOS Du 1 2 3 4 5 6 230 Pioneer air conditioner service manual 2 Schematic Diagram of Controller Panel of EA Series Air Conditioner Motorola Chip 1 2 3 4 5 6 7 8 CNIO JHQ DR T Tt CN9 oo Room Fan BECA 63 a 63 CNS ABCDEFE SS E CN me VH XH 10 XHDEO N 5 R23 10K D E Ld y EA e ijs Q5 5 mij v fg 9012 Dd 5 v
227. ssor and run outdoor fan noise still could be heard Removed the blades run the fan again we found that poor concentricity of bearings made them collide with each other and made noise We replaced outdoor fan motor and abnormal sound was eliminated Solution replaced outdoor fan motor Experience Conclusion small fault is likely to be neglected generally people believe that vibration of outdoor unit is caused by unbalance of fan blades but in fact improper clearance of air outlet grille also can cause noise So maintenance personnel should check carefully so as to reduce the chance of making mistake Case 8 Noise caused by vibration and collision of copper tube Unit Model KFR35 HSY Phenomena Copper tube vibrated and made noise Cause analysis turned on the newly installed air conditioner found that outdoor unit vibrated abnormally opened the shell we found that compressor fan motor and fan run normally touched copper tube it vibrated severely so it was copper tube making noise Solution applied anti vibration agent on copper tube Experience Conclusion generally exhaust tube and air returned tube are likely to vibrate when air conditioner operates which can be checked visually or touched by using screwdriver Install damp piece or insulation sleeve on the position vibrating most severely Noises of tube are caused by following reasons 1 Copper tube is too close to compressor and when compressor runs it causes tube vib
228. ssure The pressure means Force applied uniformly and vertically over a surface measured as force per unit of area It s also called intensity of pressure by the express of P with the unit Newton m N m2 in the shortened form Pa In addition there are other expresses by the way of kilogram force kgf cm2 liquid height mmHg k mmH20 and atmospheric pressure atm or bar etc The conversion relation between the above pressure units is as below Table 1 1 the Pressure Conversion Table 1 02x10 9 STE j 1 450x10 pU 1 9 68x10 1 421x10 1 013x10 1 033 1 1 46885x10 1 333x10 1 36x10 1 316x10 1 93285x10 0 68948x10 7 0327x10 6 80517x10 1 Pioneer air conditioner service manual The pressure is distinguished by gauge pressure and absolute pressure applied in the practice The gauge pressure is validated according to the numerical value shown on the pressure gauge This value based on an atmospheric pressure 0 is the difference of the actual pressure of the tested gas and the ambient atmospheric pressure If the value islower than the atmospheric pressure then it will be negative and called vacuum value B The surface pressure is applicable for the observation use during the operation and running period of the refrigeration system For example when a negative value appears to the pressure gauge of refrigerant it means the refrigerant in the refrigeration system totally leaks out The absolute press
229. t turns on after timing setting D Timing turns off The timing turns off function can be set only under the running status of the air conditioner The 50 Pioneer air conditioner service manual timing range is 1min 24hour The air conditioner stops automatically once the setting timing reached Timing turns on The timing turns on function can be set only under the running status of the air conditioner The timing range is 1min 24hour The air conditioner turns on automatically once the setting timing reached The turning on and turning off action happen after setting timing set will cancel the previous set setting timing and sleeping functions ID Self detecting function Press the Emergency button and electrify the air conditioner the self detecting process starts after the buzzer delivers short tone twice Start the electric heating run the indoor fan at a high fan speed open the air door to be the maximum gt the digital display and three indicating light on in 1 second gt digital displays II 22 33 44 in turn and 1second for each of them gt Working light on 1 second gt Timing light on 1 second Sleeping light on 1 second Each phase of the stepping motor moves in 1 second the indoor fan runs for 1 second at low fan speed and middle fan speed separately gt the compressor moves for 1 second gt The four way valve moves for 1 second gt Outdoor fan moves for 1 second Negative ion generator moves for 1 second
230. tand refrigerant bottle upside down to avoid liquid slugging accident 2 Add refrigerant with high pressure valve Connect high pressure valve to special hose with thimble to add refrigerant Tighten thimble head discharge air in the hose and then stand the refrigerant bottle upside down and open bottle valve liquid refrigerant will flow into high pressure side of air conditioner When pressure in bottle is no longer larger than that in system refrigerant will stop to flow into system Heat the bottle with warm water to promote pressure in bottle and then liquid refrigerant continues to flow into system The whole operation process is conducted when compressor is switched off High pressure filling method shall be used to fill relatively large air conditioner or air conditioner by using liquid reservoir To control refrigerant filling volume usually a weighing appliance will be used If no weighing appliance is available refrigerant volume shall be controlled based on experience For the equipment without reservoir or requiring accurate filling volume we can connect filling appliance with low pressure valve add or release part of refrigerant by using the same steps as the said low pressure valve filling method 3 Determination of refrigerant volume At present R22 refrigerant is commonly used in household air conditioner According to the thermal feature under normal work condition of air conditioner volume of refrigerant shall be calcul
231. the 4and 5 normal Replace the buzzer Doesitrun normally 36 Lal Replace the a YES micro controller 3 The Indoor Fan Motor Does Not Work DItems a Check if the indoor fan motor is connected correctly to the connector CN8 b Check if the AC input voltage is correct c Check if the IC of indoor fan motor is connected correctly to the connector CN2 d Check if the capacity of indoor fan motor is connected correctly to the connector CN8 2 Trouble shooting procedure 159 Pioneer air conditioner service manual Pull out the power plug and replug it after some 5 seconds NO page Is the LED lighten Refer to the procedure of proceeding YES Is the controller output normal The micro controller chip fails Is the fan motor voltage satisfied PCB fails Replace PCB The probe position Normal BEES status voltage The capacity of the fan Sm Themotor AC motor does not connect CN8 running 134V 160V NO i Fan motor capacitor fails Replace FAC Fan motor fails YES Replace the indoor fan motor 4 The Outdoor Unit Does Not Work Items a Check if the input voltage is correct b Check if the wire connection of the outdoor connecting terminal is correct 2 Trouble shooting procedure Pull out the power plug and replug 1t after some 5 seconds NO
232. the setting wind speed is strong wind b When 20 C TA lt 27 C the controller enters into the dehumidifying mode and follows the mode in 43 Pioneer air conditioner service manual working The setting temperature is 24 C and the setting wind speed is strong wind c When TA lt 20 C the controller enters into the heating mode and follows the mode in working The cooling only type runs with the ventilation mode The setting temperature herein is 24 C and the setting wind speed is strong wind d This mode includes the functions of timing sleeping auto restart optional negative ion optional I feel optional The system mode will not change along with the variety of the indoor temperature after being selected The default status of the horizontal air blade is still The operation can be adjustable by receiving the remote signal Press this force on off button without release at least 5 seconds until the ring of the buzzer rings twice The controller enters into the trial operation the trial operation time is 30min The sensor of the air inlet temperature doesn t function in the period of trial operation The compressor starts work after the 3min delay protection The primary electrifying has no 3min delay protection the wind speed of the indoor fan is high wind the running mode is cooling mode and the wind door is maximum opening There are no anti freezing protection and high temperature preventing protection during
233. the slides move horizontally inside the valve body and have the two connecting pipes at the bottom of the valve body to be connected through the two valve holes being covered by the slide The other connecting pipe at the bottom connects with the valve body through another valve hole The piston and the slide connect together by the valve bracket and move together in synchronization When the air conditioner runs the cooling mode the electricity current to the loop of the solenoid valve shuts off and the iron core drives the valve bowl to move left Then the capillary tube d connects to c in high pressure and a connects to b in low pressure Because the capillaries c and d connect with the discharge pipe of compressor they will form a high pressure zone being filled with the high pressure gas However the capillaries a and b connect with the suction pipe of the compressor they will form a low pressure zone At this moment the piston moves to the left side by the pressure difference then D connects to C the high pressure gas refrigerant in D pipe flows into the outdoor heat exchanger as con denser for heat transmission process passing through pipe C and enters into the indoor heat exchanger evaporator passing through capillary tube Finally it will enter into pipe S from pipe E and return back to the compressor for concluding a refrigerating cycle The flow process is indicated in Chart 1 Pilot actuated valve Electromagnetic loop
234. the structure of the compressor is usually hermetic and the electric motor as the impulsion of the whole unit is airproofed inside a container together with the compressor used for compressing the refrigerant and the container is filled with the lubricating oil as well as the corresponding lubricating agents mounted The air compressors of the air conditioners are divided in three types Reciprocating type Rotary type and Scroll type DReciprocating type The Reciprocating type compressor mainly consists of cylinder piston crankshaft and connecting rod agent The crankshaft is powered and circumrotates by the electric motor and push the piston to move up and down inside the cylinder through the connecting rod Once a cycle completed by the compressor the crankshaft will turn one round for undertaking the compressing air discharge expansion and air absorbing process in turn The compressor driven by the electric motor keeps continuous running and the piston runs repeatedly in the cylinder for finally realize the refrigerating cycle The practicality is as picture 2 1 2 Rotary type The electric motor of the Rotary type compressor is on its top and the compressor is at the bottom The whole cylinder almost soaked in the freezing oil completely The rotor inside the cylinder rolls on the surface of the cylinder wall with the guide of the eccentric shaft There is a through groove on the surface of the cylinder wall which contains a slide Th
235. tops immediately once stopping the air conditioner 0 Anti cooling wind and residual heat Removing function The wind speed of the indoor fan is controlled by TE and the specific conditions are as below Anti cold wind when compressor runs 4T Pioneer air conditioner service manual When TE is in rise status if Te lt 30 C the indoor fan turns off 30 C lt TE lt 38 C the indoor fan runs at low fan speed Te238 C the indoor fan runs at setting wind speed When Te in fall status if TE gt 34 C the indoor fan runs at the setting fan speed 28 C lt TE lt 34 C the indoor fan runs at the low fan speed TEx28 C the indoor fan turns off Coil tube s temperature TE4_ TES TE3 TEG TE2 TET Fazrfnotor breeze ind wind speed set mute wind motor t s off mute wind pe off Picture 1 Anti cold wind function when compressor stops D When TE is in the fall status if TE gt 30 C the indoor fan runs at low fan speed TE30 C indoor fan turns off 2 When TE is in the rise status if TE35 gt C the indoor fan runs at low fan speed TE35 C indoor fan turns off TEE TEE Fanmotor Breeze Fan motor motor turns off 650rpm turns off Picture 2 Residual heat removing function after air conditioner stops When TE gt 35 C the indoor fan runs at the low fan speed if lt 35 C the indoor fan turns off and air conditioner stops for starting the process of residual heat removal and last fo
236. trol System Case 1 Silicon Control is broken and indoor unit creates noise Product Model KFR20 HA Phenomena When unit is switched off indoor fan runs slowly and when it is turned on 187 Pioneer air conditioner service manual noise can be heard Cause analysis according to clients description and phenomena analysis we presumed that indoor motor couldn t provide power properly checked power voltage of indoor motor it was 100V voltage when motor was switched off when switched off motor still moved slowly and produced heat and caused its plastic support deformed plastic mould motor moved from its original position and then wind blades touched with basement and produce unpleasant noise and smell like something burning can be smelt in the room We concluded that silicon control of fan has damaged Solution replace main control panel Experience conclusion fan running velocity of indoor split mounted unit is controlled by silicon control when electrical voltage becomes very low or fluctuates within a large range silicon control can be disrupted in one phase and indoor fan still has voltage when the unit has been turned off Because silicon is disrupted motor produces non sine wave power which cause instable running of motor and loud noise Case 2 Indoor fan still runs when unit has been turned off and starts to run before it is turned on Product Model KFR35 HS Phenomena indoor fan still runs when the unit has been tur
237. ual Outdoor unit exploded picture 135 Pioneer air conditioner service manual Detailed part list of KFR50 HS outdoor unit No Chinese Name Name Material Number 1 Fc MSZ PEL Left side supporting plate 1 2 4j 2 pog s Steel grille 1 3 Am 3 EL AIRES Screw 40 4 To s BX Top cover plate 1 5 PNI Front panel 1 6 Ve babas JV Condenser assembly 1 7 AM Right side plate 1 8 ETF Handle 2 9 HE A Hd BE Capacitor clamp 1 10 HA pL RE Compressor capacitor 1 11 JUL FEL R Fan motor capacitor 1 12 H2 nii Wiring cover 1 13 BP Electrical holding plate 1 14 EAL Hij FAL Terminal board 1 15 IAE PE Partition plate 1 16 HALTE Compressor 1 17 PME E ERE Capillary assembly 1 18 UAR Pel E Vt HAAF Four way valve and capillary 1 assembly 19 dE RIZA Dg4 Liquid valve 1 20 SEIZE Dg10 1 Gas valve 1 21 ERA Chassis 1 22 PREMIA AB Screw and cushion assembly 4 WEET BIE ES Pl HT 23 DEA Valve plate 1 24 Zal DALE Outdoor fan 1 25 HHLA Motor bracket 1 26 EUH E NLHE Outdoor fan motor 1 27 FAEK A BURE Screw 4 136 Pioneer air conditioner service manual 5 KFR70 HS Indoor unit exploded picture 137 Pioneer air conditioner service manual Detailed part list of KFR70 HS indoor unit
238. uble light blinks Blinking trouble light shows that system has some problems including faults in electrical appliance or system Phase lack of service power wire or over low voltage check if voltage of power wire is 10 183 a 6 O O D 4 D Pioneer air conditioner service manual lower than rated value Over current on compressor check if heat protector on the compressor pump shell has broken off Normally heat protector will break off if current is excessively large Heat protector of three phase motor is embedded in motor winding in pump shell Check junction box on the pump shell by using universal meter both for single phase and three phase motor if winding is current off protector has cut off the power Wait for 5 minutes protector will restore to original position Fan overheats or heat protector has damaged refer to fan of outdoor unit When fan runs under excess load its winding temperature will rise and heat protector will break off and power will be cut off Check if inlet wire connector of fan is current on If not it shows that heat protector works and it will restore to original position after cooling down If protector fails to restore it has been damaged and need to be replaced Poor contact of connector Fan motor is also jointed with socket connector connector lugs may not contact well In addition check if wire in junction box of compressor pump shell is loose or does not co
239. uid gas separator Kaal Capillary tube High pressure valve Cooling only type Outdoor unit Indoor unit Remark gt means the flowing direction of the cooling operation t re valve Mi Liquid gas separato Low press Heating capillary tube v P3 Single way valve High pressure valve 7 Cooling and heating ty pe Outdoor unit Indoor unit Remark Means the flowing trend of the cooling operation Means the flowing trend of the heating operation 3 The defined terms of air conditioner in common use DHeat pump The heat pump is a refrigerating system that absorbs the heat from the outdoor low temperature air and release the heat to the indoor air so as to have a calefactive indoor air by changing the flowing direction of the refrigerant It also includes the air circulating and purifying devices as well as the damping and ventilation 2 Cooling capacity It means the total quantity of heat per unit time removed by the air conditioner from the closed space room or area under the rating working status and specified condition Unit W or BTU 3 The consumed power for cooling It means the total input power for air conditioner s refrigerating 12 Pioneer air conditioner service manual operation under the rating working status and the specified condition 4 Heating capacity It means the total quantity of heat per unit time transferred by the air co
240. ulb 27 C wet bulb19 C outdoor dry bulb 35 C wet bulb 24 C however due to the incomplete same condition of the indoor and outdoor either on the condition of the temperature and humidity or the testing environment the consequent actual power consumption may be different from the rating consumption power Generally speaking in terms of refrigeration the higher environment temperature the more atrocious condition it is the bigger actual consumption power of the air conditioner will be The table of the below shows the basic parameters of all specific type of air conditioners Table1 6 basic parameters of all specific type air conditioners Specification Capacity About range Power about range Current Qty Of Electricity range consumption 1 Hp 2000 3000w 650 1100w 3 5A 0 6 1 2 1 5 Hp 3000 4000w 1100 1600w 5 7 2A 1 0 1 7 2Hp 4000 5600w 1600 2200w 7 10A 1 5 2 3 3Hp 6000 8500w 2200 3300w 10 16A 2 1 3 4 5 Hp 10000 14000w 3500 5800w 6 10A 3 4 6 Three phase Note The above doesn t include the electricity heating power The conception of Hp and the general unit conversion The Hp said by the distributors or the shops usually indicates the power of the compressor of the 15 Pioneer air conditioner service manual air conditioner Although the unit W is same as the one used for the cooling capacity they have different practice signification As we all know 1Hp 735 499W which stands
241. upply ES a mm cord Te 250V 16A 16A 250V 16A mm inch 49 0 A 3 15 imen wer gaoxeraxea0 aoxtoosxaoslaaoverexsan 220x1095x208 200x800x90 920 1095 205 as Inch CR EA AAA 15 40 15 15 20X 1095 X208 300x800x690 cS 49 al 51 6 353600 9 52X3600 012 7X3600 015 88X3600 015 88X3600 Drain pipe 014X780 014X780 Type Rotary Rotary Rotary Rotary Type la Rated input W 1875 1875 2510 2510 e Em mcn Type __ Plastic sealed Iron shell Plastic sealed Ratedimpu Ww 20 40 20 40 30 68 3 Heatexchanger row line 2X13 1X24 2X26 3X16 2X26 Capillary Capillary QA ee R22 1180 R22 1350 R22 2000 Cooling test condition Indoor unit DB27 C Wb19C Outdoor unit DB35 C Wb24 C Indoor unit DB20 C Wb Outdoor unit DB7 C Wb6 C Max Cooling test condition Indoor unit DB32C Wb23C Outdoor unit DB43C Wb26 C Max Heat ing test condition Indoor unit DB27C Wb Outdoor unit DB24C Wb18C Dimensio Motor Motor lt Iron shell 60 Pioneer air conditioner service manual 5 Parameter of product R407C 18000BTU 24000BTU cine 18000btuB4 E R 18000btuB4 E R 24000btuB4 E R 24000btuB4 E R vam Pw 52 2 vo so 7 LT NC uja ET RENE EIN NN NN paja aja jaja CC II CIS Taea rated Coine w 2090 29 eo 2100 Gin 4 5 3 1 amp 8 ER YO VR 1 8 MIA gt 00
242. ure is the actual pressure value of the gas which is equal to the sum of the surface pressure and the atmospheric pressure e g Pa Po Pg Pa stands for the absolute pressure Po stands for the atmospheric pressure and Pg stands for the surface pressure The relation between the absolute pressure the surface pressure and vacuum value are specified in the below picturel 1 Absolute Pressure upper limit line 9JnssoJq ootepnmg ISSO 9 nrsoq One Atmospheric Pressure D n n jaa c A mo E gt o DN jaa lt on eA umnoeA oJnssoJq 9ADneaoN Absolute Zero Pressure line 3 Specific Volume The specific Volume is the dimension for the substance with unit mass v stands for it and the unit is meter kilogram m kg or Liter kilogram L Kg The specific volume of the vapor refrigerant is the key parameter in determining the cooling capacity of the compressor Specific Volume 1s the physics parameter in description of the compression level of the molecules in the substance For Gas if more large space between the molecules is the larger the specific volume will be consequently the compression level will be smaller and the compressibility will be more Otherwise the specific volume will be smaller and consequently the compression level will be larger and the compressibility will be less The density p the reciprocal of the specific volume is always being applied in the refrigeration technology e g v 1
243. usted and pressure unit stops to work After 3 minutes pressure unit will be started up again The process repeats again and again so air condition starts and stops frequently Based on the faults we can conclude that causes of faults can be various and problems can be caused by the mutual interference of electrical control and system Therefore we should check and observe carefully 192 Pioneer air conditioner service manual when we re repairing air conditioners and avoid replicated work Case 12 Transformer Failure Product Model KFR HI8A4 FS Phenomena air conditioner didn t function after it was turned on Cause Analysis checked power supply there s 220V input power so power supply circuit has no problem Checked power socket resistance is infinite great so fuse or transformer might burn out Opened and checked indoor panel we found that fuse was in proper situation but transformer broke off Solution replace transformer Experience Conclusion if air condition fails to respond when it is turned on we should check power circuit first of all to find out faults quickly and accurately Case 13 AC Contactor Product Model KFR70 A Phenomena failing to produce heat Cause analysis turned on air conditioner and switched to heating function outdoor fan didn t run and four way valve closed we checked and found power supply of AC contactor was regular pushed on AC contactor forcibly compressor functioned when we checked and
244. usually used for cutting the copper tubes in different lengths and diameters when repairing or installing the air conditioner The types of the tube cutting knife are various The common structure is as Picture 6 6 shows When cutting the copper tube it shall be set at the place between the two rolling wheels of the tube cutting knife Rotate the knife supplying knob in the clockwise direction so as to clamp the copper tube between the knife and the rolling wheel Then rotate the knife supplying knob and simultaneously rotate the tube cutting knife for cutting the copper tube The force shall be balanced and gently when rotating the knife supplying knob otherwise the copper tube may be distorted by rough extrusion After the copper tube being cut use the cutter knife to remove the burr attached to the edge of the tube mouth in case of the copper scraps enter into the refrigerating system a Bracket b Cutting wheel c Adjusting knob Picture 6 6 the structure of the tube cutting knife 179 Pioneer air conditioner service manual 6 Tube bender Tube bender is the tool used to change the configuration of the copper tube or process the copper tube in a certain figure The types of the tube bender are various and it is applicable in bending the copper tube with the diameter less than 20mm When bending the tube insert the annealed copper tube into the wheel groove of the tube bender and lock the tube clamping hook tightly Then rotate the handle
245. was turned off and returned to balanced pressure when it was turned off again When outdoor unit run frost could be found from filter to capillary to high pressure tube so the air conditioner was blocked by dirt Solution replaced filter Experience Conclusion If outdoor unit starts up frequently we should find out it is resulted by faults in circuit or in cooling system Generally following symptoms will occur if filter is blocked capillary outlet and sometimes evaporator are frosted low pressure is lower than normal high pressure is slightly lower than normal value when air conditioner is turned out balanced pressure closes to the saturated pressure in ambient temperature compressor discharge temperature and shell temperature rise If current is higher than normal value and air conditioner starts and stops frequently fault may not be in the com pressor We should consider symptoms comprehensively Generally when we fix an air conditioner we should check current and maintenance pressure if current is relative large and pressure is a relative low system is blocked and so we should check filter and capillary firstly Case 5 Leakage of connection line of evaporator Unit Model KFR25 H Phenomena couldn t cool Cause Analysis according to the client air conditioner can t cool We checked indoor and outdoor units both run properly so circuit is in good condition we checked running pressure of outdoor unit was minus and there s no ref
246. way valve that can t work well and cause leakage of four copper tubes high and low pressure tubes are short circuited 3 Air conditioner is set in cooling operation but functions in heating operation Four way valve is blocked inside and can t reverse the direction 4 Cooling normally after it is started and run 2 3 times According to the work principle of four way valve we can judge that valve core can t seal tightly and air leaks in 4 directions under high pressure so pressure is not large enough to seal capillary control valve and slid of reverse valve can t function successfully in one time 2 Steps to change four way valve If it is clear that four way valve is broken it shall be replaced with the new one of same size and type and in the following way D Remove the old four way valve from air conditioner 2 Install new four way valve and remove electromagnetic loop 4 copper tube nozzles shall be positioned in their original directions and angles reverse valve shall be positioned horizontally 199 Pioneer air conditioner service manual 3 Weld high pressure tube first and then the middle one of three low pressure tubes finally left and right tubes 1 Select proper welding machine flame shall be adjusted and can weld the valve immediately Pack the valve body with wet towel to avoid burning rubber and nylon sealing elements in it and causing the leakage of four way valve 5 Weld the tube one by one and start
247. ways turns off when the dehumidification mode is ongoing The control range of the temperature is 16 C 32 C Under the dehumidification mode after the 3 minutes protection conditions being meet satisfactorily the performance of the compressor and the outdoor fan is as following a TA gt TS 2 C the compressor and the outdoor fan works continuously the wind speed retains the setting wind speed b TS lt TA lt TS 2 C the compressor and the outdoor fan runs for 10minutes and stops for 6minutes The indoor fan turns off during the compressor s 3 minutes stopping period and keeps on working in breeze mode under other conditions c TA TS the compressor and the outdoor fan stop working and the indoor fan start to work in breeze mode after stopping for 3 minutes Automatic wind speed control TA TS gt 5 C the wind speed is on high wind TS 3 CXTA TS 5 C the wind speed is on middle wind TS 2 C lt TA lt TS 3 C the wind speed is on low wind TS lt TA lt TS 2 C the wind speed is on fitful breeze TA lt TS the indoor fan is off during the 3 minutes delay of the compressor and 3 minutes later the wind is at breeze speed The primary electrifying to compressor has no 3 minutes protection delay the outdoor fan starts 2 seconds later after the start of the compressor When the indoor fan runs the horizontal air blade can be set as free swing and the swing condition is same as the one under cooling mode
248. ween nylon valve block and valve seat refrigerant fails to enter capillary totally so air conditioner fail to produce heat properly while in cooling mode single way valve can work and won t impact cooling efficiency Case 14 Failed to open the valve enough during installation Unit Model KFR20 HY Phenomena Poor cooling efficiency Cause Analysis turned on air conditioner for a while indoor evaporator was frosted checked the pressure it was 3 5kg relatively low than normal Added refrigerant and pressure remained unchanged Air conditioner continued to work and after a while we found that return gas tube of outdoor unit was frosted so we presumed that the system was blocked by ice When we released the refrigerant we found that low pressure valve hadn t opened enough Solution opened the valve fully adjusted refrigerant pressure to normal value 207 Pioneer air conditioner service manual Experience Conclusion valve is too tight so system is obstructed and then frosted When refrigerating efficiency of new unit was unsatisfactory do not add refrigerant without careful consideration Case 15 Air conditioner was blocked by dirt Unit Model KFR H41A5 A Phenomena Poor cooling efficiency wind velocity didn t change obviously Cause Analysis totally 5 cabinet air conditioners were used in a workshop of a Garment Company which occupied an area of 350m According to the client air conditioners were repaired many times in this
249. winkling and last for 0 5 0 5 second the system turns off 8 Fault of the indoor coil pipe sensor The temperature indication light on the panel is twinkling and last for 0 5 0 5 second runs without the interior tube sensor 9 The outdoor coil pipe sensor and the compressor discharge sensor fault The running indication light on the panel is twinkling and last for 0 5 0 5 second the others are invariable 10 Outdoor failure of phase or the phases sequence protection The timing light and running light on the panel are twinkling and simultaneously last for 0 5 0 5 second the system turns off 1 fault of Communication The running light on the panel is twinkling and last for 0 5 0 5 second the other indication lights are off and the system turns off 2 Compressor discharge protection 225 Pioneer air conditioner service manual The running light and swing light are twinkling and last for 0 5 0 5 second the other indication lights are invariable and the system turns off 4 KFR H24B4 B KFR H41A5 B faults display and protection display 1 Fault of the Indoor temperature sensor System turns off the panel displays E1 2 The fault of the outdoor tube temperature sensor on the indoor panel System doesn t turn off the panel displays E2 3 Fault of the interior tube temperature sensor System doesn t turn off the panel display E3 runs under the mode without inter
250. y event happens accidentally under the power on status if re electrify and turn on the air conditioner there is 3 minutes protection delay occurred to the compressor d If the setting of sleeping and timing functions occurs before the non electricity event after air conditioner owns the Auto restart function the default condition of the controller is power off status after being electrified again 2 I feel function a The setting method for I feel function Press the I feel function button on the remote controller the controller will effect the I feel function once receiving the signal and the controller herein will default the temperature value of the sensor on the remote control as the previous TA of the controller Except the defrosting case b The quitting method for the I feel function Q Press the I feel function button the former I feel function setting will be cancelled at once Position the remote controller towards to the receiving window of the controller the remote control may deliver the signal to the controller every 3minutes If the controller fails to receive the signal from the remote control the I feel function will be automatically cancelled and the TA control the temperature according to the temperature value detected by the TA sensor of the PCB c When the I feel function starts the controller doesn t test the former TA sensor on the PCB S Negative ion function When the indoor fan is working press t
251. y the tweet sound If the figure is not 02 it means the clamp meter is damaged already or short of electric power For the object electric resistance to be measured the figure displays on the reading panel is its electric resistance value after connecting the meter pens to the two ends of the object resistance item Picture 6 8 digital clamp meter 181 Pioneer air conditioner service manual Chapter 7 Failure Analysis and Inspection of Electrical Control System Air conditioner can be controlled by both strong current circuit control panel and weak current electronic circuit control panel control philosophies of which are different so fault analysis procedures of the two types shall be described separately Electrical system is the device to control and protect refrigerating system and fan system Apart from faults on electrical circuit faults also may be resulted by the malfunction of refrigerating system and fan system but be reflected through electrical control system Therefore refrigerating system and fan system must be taken into consideration to analyze faults of electrical control system 1 Strong Current Control System Strong current control system is powered by single phase 220V or 380V service voltage and with relative simply controls circuit fault inspection of strong current control system is not very difficult 1 Compressor and fan fails to operate When switched on compressor and fan fail to operate faults of elect

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