Mitsubishi Electric k-con KSGD-01WS-B User manual

Installation and operation manual
KSGD02 Revision: 1.4
Page 1 of 16
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KSGD-01WS-B
Refrigerant leak detector
Installation and operation manual
Version 1.4
Manufactured for
MITSUBISHI ELECTRIC UK

Installation and operation manual
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KSGD-01WS-B
All rights reserved
The information contained in this manual has been carefully checked and is believed to be accurate.
However, the manufacturer assumes no responsibility for any inaccuracies that may be contained
herein. In no event will the manufacturer, be liable for any direct, indirect, special, incidental, or
consequential damages resulting from any defect or omission in this manual, even if advised of the
possibility of such damages. In the interest of continued product development, the manufacturer
reserves the right to make improvements to this manual, and the products described herein, at any
time without notice or obligation.
Trademarks
All trademarks are acknowledged and are the property of their respective holders.

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Contents
Safety Precautions......................................................................................................................................................................4
1. Overview.....................................................................................................................................................................................7
1.1 Specification Overview ................................................................................................................................................7
2. Installation.................................................................................................................................................................................8
2.1 Locating the sensor.......................................................................................................................................................8
2.2 Electrical connections..................................................................................................................................................9
2.3 Other features................................................................................................................................................................10
3. Operation.................................................................................................................................................................................11
3.1 Operational matrix.......................................................................................................................................................11
4. Testing.......................................................................................................................................................................................12
4.1 Measuring the Gv.........................................................................................................................................................12
4.1 Bump test procedure..................................................................................................................................................12
4.2 Full Operational test procedure............................................................................................................................13
5. Fault finding............................................................................................................................................................................14
Revisions .......................................................................................................................................................................................15
Notes...............................................................................................................................................................................................16

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!
!
Safety Precautions
Definition of symbols
Alert
Symbol
Description
Danger
!
Will result in death or serious injury if not avoided.
Warning
!
Could potentially result in death of serious injury if not avoided.
Caution
!
Could potentially result in damage to the product, injury or damage to the
environment if not avoided.
Information
i
Information notes relating to the operation of the product.
Warning:
Carefully read the labels affixed to the main unit.

Warning:

Ask the dealer or an authorised technician to install the unit.
Improper installation by the user may result in water leakage, electric shock, or fire.
Use the specified cables for wiring. Make the connections securely so that any outside forces acting on the cables
are not applied to the terminals. Inadequate connection and fastening may generate heat and cause a fire.
Never repair the unit. If the controller must be repaired, consult the dealer.
If the unit is repaired improperly, electric shock, or fire may result.
When handling this product, always wear protective equipment. EG: Gloves, full arm protection namely boiler suit,
and safety glasses.
Improper handling may result in injury.
If refrigerant gas leaks during installation work, ventilate the room.
If the refrigerant gas comes into contact with a flame, poisonous gases will be released.
Install the controller according to this Installation Manual.
If the unit is installed improperly, electric shock, or fire may result.
Have all electric work done by a licensed electrician according to "Electric Facility Engineering Standard", "Interior
Wire Regulations" and the instructions given in this manual and always use a special circuit.
If the power source capacity is inadequate or electric work is performed improperly, electric shock and fire may
result.
Keep the electric parts away from any water -
Contact may result in electric shock, fire or smoke.
After completing installation work, make sure that refrigerant gas is not leaking.
If the refrigerant gas leaks and is exposed to a fan heater, stove, oven, or other heat source, it may generate noxious
gases.
Do not reconstruct or change the settings of the protection devices. If the pressure switch, thermal switch, or other
protection device is shorted or operated forcibly, orparts other than those specifiedby Mitsubishi Electricare used,
fire or explosion may result.
To dispose of this product, consult your dealer. Do not use a leak detection additive.

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Precautions for devices that use HCFC and HFC refrigerants
Caution:
Do not use the existing refrigerant piping.
The old refrigerant and refrigerator oil in the existing piping contains a large amount of chlorine which may cause
the refrigerator oil of the new unit to deteriorate. Use refrigerant piping made of C1220 (CU-DHP) phosphorus
deoxidized copper as specified in the JIS H3300" Copper and copper alloy seamless pipes and tubes". In addition,
be sure that the inner and outer surfaces of the pipes are clean and free of hazardous sulphur, oxides, dust/dirt,
shaving particles, oils, moisture, or any other contaminant.
Contaminants on the inside of the refrigerant piping may cause the refrigerant residual oil to deteriorate.
Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before
brazing.
(Store elbows and other joints in a plastic bag.) If dust, dirt, or water enters the refrigerant cycle, deterioration of
the oil and compressor problems may result.
Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerator oil to coat flares and flange connections.
The refrigerator oil will degrade if it is mixed with a large amount of mineral oil.
Use liquid refrigerant to fill the system.
If gas refrigerant is used to seal the system, the composition of the refrigerant in the cylinder will change and
performance may drop.
Do not use a refrigerant other than what is specified..
If the incorrect refrigerant (R22, etc.) is used, the chlorine in the refrigerant may cause the refrigerator oil to
deteriorate.
Use a vacuum pump with a reverse flow check valve.
The vacuum pump oil may flow back into the refrigerant cycle and cause the refrigerator oil to deteriorate.
Do not use the following tools thatare used with conventional refrigerants. (Gauge manifold, charge hose,gas leak
detector, reverse flow check valve, refrigerant charge base, vacuum gauge, refrigerant recovery equipment.)
If the conventional refrigerant and refrigerator oil are mixed, the refrigerant may deteriorate.
If water is mixed in the refrigerant, the refrigerator oil may deteriorate.
Since HCFC and HFC refrigerants do not contain any chlorine, gas leak detectors for conventional refrigerants will
not react to it.
Do not use a charging cylinder. Using a charging cylinder may cause the refrigerant to deteriorate.
Be especially careful when managing the tools.
If dust, dirt, or water gets in the refrigerant cycle, the refrigerant may deteriorate.
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Before installation
Caution:
Do not install the unit where combustible gas may leak.
If the gas leaks and accumulates around the unit, an explosion may result.
Ground the unit.
Do not connect the ground wire to gas or water pipes, lightning rods, or telephone ground lines. Improper
grounding may result in electric shock.
Install the power cable so that tension is not applied to the cable. Tension may cause the cable to break and
generate heat which may, in turn, cause fire.
Install a leak circuit breaker, as required.
If a leak circuit breaker is not installed, electric shock may result.
Use power line cables of sufficient current carrying capacity and rating.
Cables that are too small may leak, generate heat, and cause a fire.
Use only a circuit breaker and fuse of the specified capacity.
A fuse or circuit breaker of a larger capacity or a steel or copper wire may result in a general unit failure or fire.
Be very careful regarding product transportation.
Two people should be used to carry products of 20kg or more.
Some products use PP bands for packaging. Do not use any PP bands for a means of transportation.
Safely dispose of the packing materials.
Packing materials, such as nails and other metal or wooden parts, may cause stabs or other injuries.
Tear apart and throw away plastic packaging bags so that children will not play with them - If children play with a
plastic bag which has not been torn apart, they face the risk of suffocation.
Before starting a test run
Caution:
Do not touch the switches with wet fingers.
Touching a switch with wet fingers can cause electric shock.
Do not touch the refrigerant pipes during and immediately after operation.
During and immediately after operation, the refrigerant pipes may be hot or cold, depending on the condition of
the refrigerant flowing through the refrigerant piping, compressor, and other refrigerant cycle parts. Your hands
may suffer burns or frostbite if you touch the refrigerant pipes.
Do not operate the air conditioner with the panels and guards removed.
Rotating, hot, or high-voltage parts can cause injuries.
Do not turn off the power immediately after stopping operation.
Always wait at least five minutes before turning off the power. Otherwise, water leakage and other problems may
occur.
Disclaimer
Warranty:
All products manufactured on behalf of Mitsubishi Electric UK are warranted against defective materials for a period of three
years from the date of delivery to the original purchaser.
Warning:
Mitsubishi Electric UK assumesno liability for damages consequent to the user of this product. We reserve the right to change
this manual at any time without notice. The information furnished by us is believed to be accurate and reliable. However, no
responsibility is assumed by us for its use, nor for any infringements of patents or other rights of third parties resulting from
its use.
!
!

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1. Overview
This manual outlines the installation and operation of the KSGD refrigerant leak detector.
The KSGD is a stand-alone refrigerant leak detector for air conditioning and refrigeration
applications.
The KSGD is available in a number variants this manual covers all of these variants.
1.1 Specification Overview
In the interest of continued product development, the manufacturer reserves the right to
make improvements to products with notice or obligation.
Housing
White plastic OR Stainless steel fascia (back box / dry lining box supplied on request other
options available)
Power
12-24V AC or DC
Power usage
Max 2.5VA, 1VA nominal
Relays
1 or 2 Contact rating 0.5A @ 125VAC / 1A @ 24VDC
Indicators
1 x Tri-colour LED
Sounder
85dB 2300Hz (+/-300Hz)
Screw terminals
5 or 6 x 2.5mm/sq
Size
85 x 85 x 38 mm (30mm behind fascia)
Weight
Approx. 85g (dependant on fascia material)
Refrigerant
R410a, R32 (other gases available on request)
Sensor
Semi-conductor
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Fig 1 KSGD detector

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2. Installation
The KSGD is available with faceplates in
white plastic and stainless steel or can be
custom finished to suit colour schemes.
Irrespective of the faceplate the KSGD will
fit into a standard single gang electrical
back box.
The minimum depth of the back box is
dependent upon the faceplate however all
designs will fit into a box 45mm deep
enclosure which can be flush mounted into
the wall.
Fig-2 shows how the KSGD is to be
mounted;
2.1 Locating the sensor
The main considerations when deciding where to locate the KSGD are:-
1. Low level
As HFC refrigerants are heavier than air, the KSGD should be mounted as close as practical to
floor level (150mm ~ 250mm above floor level), preferably directly below the air conditioning
unit.
2. Accessible for maintenance
The KSGD should be mounted in a
position where it can be easily accessed
for maintenance and repairs.
3. Minimize possibility of damage
Mount the sensor in a position that
minimizes the risk of mechanical
damage to the unit.
4. Minimize false alarms
Semi-conductor sensors can be
poisoned
exposure may take considerable time to
recover. Solvent paints and silicon
mastic are typical contaminants and
exposure from these substances must be
avoided.
5. Ensure leaks can be detected
Do not mount the sensor next to doors
or windows, where fresh air may
influence readings.
Fig 2.0 KSGD exploded view
BED
X
X X
X
150mm above floor
level
Refrigerant Leak
Detector Position
Not
Installed
near
windows
Not Installed near
mirrors
Not installed near bathroom
Not
installed
by door XNot
installed
behind
cupboards
Fig 2.1 Locating the KSGD
Fixing
Screws
Faceplate
(Available in
different finishes
and materials)
DetectorPCB
Electrical back box
(not supplied as standard)

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2.2 Electrical connections
The KSGD connections are located on the rear of the detector PCB.
The KSGD will operate from a 12/24 volt AC or DC supply. Start-up current from a 24 volt AC supply
is 260mA with steady state of 100mA. A single plug on the PCB accepts all the electrical connections.
A small flat bladed screwdriver can be used to prise the plug away from the socket.
Dual relay version;
Pin
Usage
1
Power (V1)
12 to 24V
AC or DC
2
Power (V2)
3
Relay 1 (NO1) Normally
Open
4
Relay 1 (C1) Common
5
Relay 2 - (NC2) Normally
Closed
6
Relay 2 (C2) Common
Single relay version;
See section 3 for details on the relay operation and functions.
Relay(s) are energized in normal operation, the relay will de-energize if an alarm or fault
occurs or if power is not present. The tables above show the relay(s) in the de-energized
power removed state.
Pin
Usage
1
Power (V1)
12 to 24V
AC or DC
2
Power (V2)
3
Relay (NO) Normally
Open
4
Relay (C) Common
5
Relay (NC) Normally
Closed
Fig 2.2 KSGD dual relay version
Fig 2.3 KSGD single relay version
i
6 5 4 3 2 1
Connection Terminals
Test / Calibration
connector
5 4 3 2 1
Connection Terminals
Test / Calibration
connector

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2.3 Other features
Features such as the sensor and buzzer enable link are located on the front of the detector PCB.
When the buzzer enable / disable link is fitted, the buzzer will operate when required. Remove
this link to disable the buzzer permanently.
i
Status LED
Buzzer
Buzzer Enable / Disable link
Sensor
Factory use only
Fig 2.4 KSGD other features

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3. Operation
When power is applied, a green LED will flash (GREEN/RED)
approximately 5 minutes the green LED will be illuminated permanently and the detector is fully
operational. When a refrigerant leak alarm is detected the LED will flash RED/AMBER, the buzzer will
sound and the relay(s) will change status. The alarm cannot be acknowledged or muted and the
LED/buzzer will indicate an alarm until the refrigerant concentration subsides. In the event of a faulty
sensor the LED will flash RED with an AMBER pulse, the relay(s) will change state and the buzzer will
pulse once a minute. This action will continue until the fault is rectified.
3.1 Operational matrix
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
Power removed
3 & 4
5 & 6
3 & 4
4 & 5
OFF
OFF
N/A
OPEN
CLOSED
OPEN
CLOSED
Warmup (5 minutes)
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
GREEN>RED (1Hz)
OFF
N/A
CLOSED
OPEN
CLOSED
OPEN
Normal operation
3 & 4
5 & 6
3 & 4
4 & 5
Constant GREEN
OFF
0.4>1VDC*
CLOSED
OPEN
CLOSED
OPEN
Sensor fault
3 & 4
5 & 6
3 & 4
4 & 5
RED>OFF (1Hz)
1 x AMBER FLASH
PER MINUTE
Pulses
once per
minute
<0.1VDC
OPEN
CLOSED
OPEN
CLOSED
As the gas concentration increases
Pre-alarm Level 1;
Reading> ~500ppm
For > 2 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
GREEN>OFF (2Hz)
OFF
>2.5VDC
CLOSED
OPEN
CLOSED
OPEN
Pre-alarm Level 2;
Reading> ~1000ppm
For > 2 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>OFF (2Hz)
OFF
>3.5VDC
CLOSED
OPEN
CLOSED
OPEN
Low Level Alarm;
Reading> ~1000ppm
For > 30 minutes
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>AMBER (2Hz)
Pulses
2Hz
>3.5VDC
OPEN
CLOSED
OPEN
CLOSED
High Level Alarm;
Reading> ~4000ppm
For > 30 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>AMBER (4Hz)
Pulses
4Hz
>4.2VDC
OPEN
CLOSED
OPEN
CLOSED
After auto reset (gas leak cleared)
After 60 seconds
delay
3 & 4
5 & 6
3 & 4
4 & 5
Constant GREEN
OFF
<2.0VDC
CLOSED
OPEN
CLOSED
OPEN
*In normal operation in clean air the Gv voltage should be within the range given, however the detector will remain in
the normal state until the Gv reaches 2V. If the Gv voltage is greaterthan 1V, the sensor maybe contaminated or detecting
residual refrigerant or contaminant gas / vapor.
PPM Levels quoted are approximate levels expected for R410a refrigerant.

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4. Testing
The operation of the detector can be verified in 2 ways depending on the accuracy required;
4.1 Measuring the Gv
When testing the detector the Gv voltage must be checked using a multi-meter at various points
during the test procedure. The Gv voltage is measured on the 6 way test / calibration connector.
The location of this connector varies on older variants of the detector, along with the connection
terminals. The calibration kit includes a test lead for easy connection and measurement of the Gv.
4.1 Bump test procedure
The reactivity of the detector can be verified using propane or butane.
This is primarily aimed at verifying the operation of the relay & buzzer as the propane or butane
used is not verification that the sensor can detect refrigerant at the appropriate concentration.
1. Firstly verify
Normal Operation , using a multi-meter measure the Gv voltage. The Gv
should be between 0.4 VDC and 1 VDC. If the Gv is outside this range the sensor is reacting
to refrigerant or a contaminant. The room should be well ventilated to eliminate any
potential refrigerant or contaminant and the voltage should subside.
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
Normal operation
3 & 4
5 & 6
3 & 4
4 & 5
Constant GREEN
OFF
0.4>1VDC
CLOSED
OPEN
CLOSED
OPEN
2. Using a small amount of butane or equivalent, spray gas at the sensor for approximately 30
to 40 seconds.
3. The sensor will enter the High Level Alarm state.
4. After removing the gas the sensor should recover and return to
Normal Operation.
It may be necessary to ventilate the room with fresh air for the sensor to recover. The time
for the detector to recover will depend upon the concentration of gas detected by the
sensor and the time period but is typically less than 5 minutes. It is recommended that the
sensor is not subjected to cigarette lighter gas for a prolonged period (>3 minutes) as
recovery may become significantly longer.
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
High Level Alarm
Reading> ~4000ppm
For > 30 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>AMBER (4Hz)
Pulses
4Hz
>4.2VDC
OPEN
CLOSED
OPEN
CLOSED
Fig 4.1 Current model detector Gv voltage
Fig 4.2 Older model detector Gv voltage
6
1
6
1
6
1
Gv
GND
5VDC
65 4 3 2 1 1 2 3 4 5 6
CURRENT
MODEL OLDER
MODELS
Gv
Test lead red tracer should
be plugged into pin 1

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Fig 4.5 Applying gas to the detector
4.2 Full Operational test procedure
To verify the correct operation of the
detector, test gas can be used which is
equivalent to the alarm thresholds. Test
kits are available.
1. Fit pressure regulator on to calibrated gas bottle and check the
cylinder pressure is above 10 bar.
The test gas cylinder should be stored at room temperature or
allowed to stand at room temperature for at least 4 hours prior to
use.
Ensure the detector is powered up for a minimum of 1 hour before
testing.
2. Ensure the detector is in the
Normal operation state before commencing with tests. Just
before conducting tests gently agitate the bottle for 1 to 2 minutes.
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
Normal operation
3 & 4
5 & 6
3 & 4
4 & 5
Constant GREEN
OFF
0.4>1VDC
CLOSED
OPEN
CLOSED
OPEN
3. Place the plastic tube directly over the
perforation on the cover plate and turn the
regulator valve fully anticlockwise to release the
test gas. Apply test gas onto the detector.
As the measured gas level starts to
increase, the detector will enter the Pre-
Alarm states.
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
Pre-alarm Level 1;
Reading> ~500ppm
For > 2 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
GREEN>OFF (2Hz)
OFF
>2.5VDC
CLOSED
OPEN
CLOSED
OPEN
Pre-alarm Level 2;
Reading> ~1000ppm
For > 2 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>OFF (2Hz)
OFF
>3.5VDC
CLOSED
OPEN
CLOSED
OPEN
Fig 4.3 Calibration test kit
Fig 4.4 Gas bottle with regulator fitted

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Once the Pre-alarm level 2 state is reached, the operation of the detector is proven and unless
confirmation of the relay operation is required there is no necessity to continue through the
remaining steps skip to step 5.
If the detector remains in the Pre-alarm level 2 state continuously for 30 minutes the
detector will enter the Low Alarm Level condition.
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
Low Level Alarm;
Reading> ~1000ppm
For > 30 minutes
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>AMBER (2Hz)
Pulses
2Hz
>3.5VDC
OPEN
CLOSED
OPEN
CLOSED
4. If test gas application is continued the detector will eventually enter the High Level Alarm
state.
5. Turn off the gas regulator valve and allow clean air to circulate over the sensor and the gas
to dissipate. After removing the gas the sensor should recover and return to Normal
Operation.
It may be necessary to ventilate the room with fresh air for the sensor to recover. The time
for the detector to recover will depend upon the concentration of gas detected by the
sensor and the time period but is typically less than 5 minutes. It is recommended that the
sensor is not subjected to test gas for a prolonged period (>3 minutes) as recovery may
become significantly longer.
Please ensure the regulator is switched off after use and the bottle is stored in a ventilated
space.
See section 3.1 for supplementary information of Gv voltages at different operational states.
The detectors relays are normally energized, so the operation can also be tested by isolating
power to the detector.
5. Fault finding
Problem
Action
LED Not illuminated
Check power supply
LED Flashing RED>AMBER with interval buzzer Sensor
fault
Check sensor if fitted and seated correctly in sensor socket
LED Flashing RED Refrigerant leak
Ventilate room and detector should automatically reset
LED Flashing RED>AMBER with buzzer puling (2Hz)
Potential contaminant, Ventilate room, detector will
automatically reset.
LED Flashing RED>AMBER with buzzer puling (4Hz)
High level contaminant, Ventilate room.
Verify operation of detector.
DO NOT swap the sensor between KSGD units. Each sensor is matched to the PCB and
swapping sensors will directly affect the performance of the product.
Operating State
Dual Relay version
Connection
terminal states
Single Relay version
Connection
terminal states
LED
Buzzer
Gv
Voltage
High Level Alarm
Reading> ~4000ppm
For > 30 seconds
3 & 4
5 & 6
3 & 4
4 & 5
Flashing
RED>AMBER (4Hz)
Pulses
4Hz
>4.2VDC
OPEN
CLOSED
OPEN
CLOSED
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Revisions
1.4 11/12/2019 First released version - KR

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Notes