Kaysun KHKF-190 DR Owners & Installation Manual
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Kaysun KHKF-190 DR Owners & Installation Manual

Kaysun KHKF-190 DR Owners & Installation Manual

Hydraulic module integrated
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OWNER'S & INSTALLATION
MANUAL
Hydraulic Module Integrated
KHKF-190 DR
KHKF-240 DR
IMPORTANT NOTE:
Thank you very much for purchasing our product,
Before using your unit, please read this manual carefully and keep it for future reference.

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  • Page 1 OWNER’S & INSTALLATION MANUAL Hydraulic Module Integrated KHKF-190 DR KHKF-240 DR IMPORTANT NOTE: Thank you very much for purchasing our product, Before using your unit, please read this manual carefully and keep it for future reference.

  • Page 3: Table Of Contents

    CONTENTS 1 SAFETY PRECAUTIONS ...................1 2 GENERAL INTRODUCTION ..................5 • 2.1 Operation range ......................5 • 2.2 Main components ......................6 • 2.3 Electronic control box ....................8 3 TECHNICAL SPECIFICATIONS ................10 4 TYPICAL APPLICATIONS ..................11 • 4.1 Application 1 ......................11 • 4.2 Application 2 ......................11 •...
  • Page 4 11 FIELD WIRING .......................40 • 11.1 Precautions on electrical wiring work ................40 • 11.2 Precautions on wiring of power supply ................40 • 11.3 Safety device requirements ..................41 • 11.4 Before connecting the wiring ..................41 • 11.5 Connecting the main power supply ................42 •...

  • Page 5: Safety Precautions

    1 SAFETY PRECAUTIONS The precautions listed here are divided into the following types. They are quite important, so be sure to follow them carefully. Read these instructions carefully before installation. Keep this manual in a handy for future preference. Meanings of DANGER, WARNING, CAUTION and NOTE symbols. DANGER Indicates an imminently hazardous situation which if not avoided, will result in serious injury.
  • Page 6 Special requirements for R32 WARNING • Refrigerant leakage and open flame are not allowed. • Be aware that the R32 refrigerant does NOT contain an odour. WARNING The appliance shall be stored so as to prevent mechanical damage and in a well-ventilated room without continuously operating ignition sources (example:open flames, an operating gas appliance) and have a room size as specified below. NOTE •...
  • Page 7 DANGER • Before touching electric terminal parts, turn off power switch. • When service panels are removed, live parts can be easily touched by accident. • Never leave the unit unattended during installation or servicing when the service panel is removed. • Do not touch water pipes during and immediately after operation as the pipes may be hot and could burn your hands.
  • Page 8 CAUTION • Install the power wire at least 3 feet (1 meter) away from televisions or radios to prevent interference or noise. (Depending on the radio waves, a distance of 3 feet (1 meter) may not be sufficient to eliminate the noise.) • Do not wash the unit. This may cause electric shocks or fire. The appliance must be installed in accordance with national wiring regulations. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

  • Page 9: General Introduction

    2 GENERAL INTRODUCTION • These units are used for both heating and domestic hot water tanks. They can be combined with floor heating applications, low temperature high efficiency radiators, domestic hot water tanks (field supply) and solar kits (field supply). • A wired controller is supplied with the unit. • If you choose the built-in backup heater unit, the backup heater can increase the heating capacity during cold outdoor temperatures.

  • Page 10: Main Components

    2.2 Main components In DHW mode, the water flowing temperature(TW_out) range in different outdoor temperature(T4) is listed below: TW_out TW_out 12 25 Fig.2-3 If IBH/AHS setting is valid, IBH/AHS turns on. Operation range by heat pump with possible limitation and protection. If IBH/AHS setting is valid, IBH/AHS maybe turns on. Heat pump turns off, only IBH/AHS turns on. Fig.2-4 100/190 3kW heater 1683 160/240 3kW heater 1943...
  • Page 11 Water side Refrigerant side ③ Fig.2-6 Code Assembly unit Explain ation Remaining air in the water circuit will be automatically removed via Automatic air purge valve the automatic air purge valve. Expansion vessel (8 L) Refrigerant gas pipe Refrigerant liquid pipe Four temperature sensors determine the water and refrigerant Temperature sensors temperature at various points.

  • Page 12: Electronic Control Box

    2.3 Electronic control box CN37 Fig.2-7 NOTE The picture is only for reference, please refer to the actual product. 2.3.1 Main control board of hydraulic module Fig.2-8...
  • Page 13 Order Port Code Assembly unit Order Port Code Assembly unit Communicate port between indoor unit and CN21 POWER Port for power supply CN19 outdoor unit Rotary dip switch CN14 A B X Y E Port for communication with the wired controller DIS1 Digital display 1 2 3 4 5 Port for communication with the wired controller...

  • Page 14: Technical Specifications

    3 TECHNICAL SPECIFICATIONS 100/190 160/240 Indoor unit model 3kW heater 3kW heater Matching outdoor unit model 10kW 12kW 14kW 16kW Power supply 220-240V~50Hz Rated input 3100W Rated Current 13.5A Norminal capacity Refer to the technical data Dimensions (W×H×D)[mm] 600*1683*600 600*1943*600 Packing (W×H×D)[mm] 730*1920*730 730*2180*730...

  • Page 15: Typical Applications

    4 TYPICAL APPLICATIONS The application examples given below are for illustration only. 4.1 Application 1 One zone for floor heating loops Fig.4-1 4.2 Application 2 One zone for radiators Fig.4-2...

  • Page 16: Application 3

    4.3 Application 3 Double zones for floor heating loops and radiators Fig.4-3 Code Assembly unit Code Assembly unit Outdoor unit Expansion vessel (Field supply) Hydraulic Module with tank P_o: Outside circulation pump (Field supply) User interface Filling valve (Field supply) Shut-off valve (Field supply) Bypass valve (Field supply) Filter (Accessory) P_s: solar pump (Field supply) Solar pannel pump (Field supply)

  • Page 17: Trouble Shooting

    Space heating One zone application 1) When the unit is ON, P_o keeps running, if unit is OFF, P_o stops running Double zone application When zone 1 is ON, P_o keeps running, if zone 1 is OFF, P_o stops running When zone 2 is ON, P_c keeps running, SV3 switches between ON and OFF according to the Tw2 sensor, if zone 2 is OFF, SV3 keeps OFF, P_c stops running. The floor heating loops require a lower water temperature in heating mode compared to Radiators or fan coil. To achieve these two set points, a mixing station is used to adapt the water temperature according to requirements of the floor heating loops. The radiators are directly connected to the unit water circuit and the floor heating loops are after the mixing station. The mixing station includes SV3,P_c and Tw2, can be controlled by hydraulic module. Domestic water heating The ON/OFF signal and target tank water temperature (T5S) are set on the user interface. P_o/P_c stops running as long as the unit is ON for domestic water heating. Solar energy control Hydraulic Module recognizes solar energy signal by judging Tsolar or receiving SL1SL2 signal. The control method can be set via "FOR SERVICEMAN>>INPUT DEFINE>>SOLAR INPUT "on the user interface.

  • Page 18: General Symptoms

    5.2 General symptoms Symptom 1: The unit is turned on but the unit is not heating as expected POSSIBLE CAUSES CORRECTIVE ACTION Check the parameters. T4HMAX, T4HMIN in heat mode. The temperature setting is T4DHWMAX, T4DHWMIN in DHW mode. not correct. •...
  • Page 19 Symptom 4: The water pressure relief valve opens POSSIBLE CAUSES CORRECTIVE ACTION The expansion vessel is broken. Replace the expansion vessel. The filling water pressure Make sure that the filling water pressure in the installation is about in the installation is 0.10~0.20MPa (refer to "2.4.2 Water volume and sizing expansion higher than 0.3MPa. vessels"). Symptom 5: The water pressure relief valve leaks POSSIBLE CAUSES CORRECTIVE ACTION...
  • Page 20 Symptom 8: DHW mode can’t change to Heat mode immediately POSSIBLE CAUSES CORRECTIVE ACTION • Set "t_DHWHP_MAX" to minimum value, the suggested value is 60min. • If circulating pump out of unit is not controlled by unit, try to Heat exchanger for space connect it to the unit. heating not big enough •...

  • Page 21: Error Codes

    6 Error codes When a safety device is activated, an error code will be displayed on the user interface. A list of all errors and corrective actions can be found in the table below. Reset the safety by turning the unit OFF and back ON. In case this procedure for resetting the safety is not successful, contact your local dealer.
  • Page 22 ERROR MALFUNCTION FAILURE CAUSE CODE OR PROTECTION AND CORRECTIVE ACTION 1. The EEprom parameter is error, rewrite the EEprom data. 2. EEprom chip part is broken, change a new EEprom chip Hydraulic Module EEprom part. failure 3. main control board of hydraulic module is broken, change a new PCB.
  • Page 23 ERROR MALFUNCTION FAILURE CAUSE CODE OR PROTECTION AND CORRECTIVE ACTION Three times "PP" The same to "PP". protection and Tw_out<7°C 1. Check the resistance of the sensor. 2. The Tbt1 sensor connector is loosen, reconnect it. Buffer tank up temp.sen- 3. The Tbt1 sensor connector is wet or there is water in, remove sor(Tbt1) fault the water, make the connector dry.

  • Page 24: About For Serviceman

    ERROR MALFUNCTION FAILURE CAUSE CODE OR PROTECTION AND CORRECTIVE ACTION 1. The hydraulic module address code is the same as the Duplicate IDU address code address code of other VRF indoor unit. Reset the hydraulic module address code. 1. The ODU is faulty. Check the ODU fault code and handle the ODU fault fault according to the ODU troubleshooting.

  • Page 25: Dhw Mode Setting

    7.2 Heat mode setting 7.1 DHW Mode Setting Go to MENU>FOR SERVICEMAN> 2.HEAT MODE DHW = domestic hot water SETTING. Press OK. The following pages will displayed: Go to MENU> FOR SERVICEMAN> 1.DHW MODE SETTING. Press OK. The following pages will be displayed: 2 HEAT MODE SETTING 2.1 HEAT MODE...

  • Page 26: Room Thermostat

    In this case, the setting value of zone 1 is T1S, the setting value of zone 2 is T1S2. If you set DOUBLE ZONE and ROOM TEMP. to YES, meanwhile set WATER FLOW TEMP. to YES or NON, the following page will be displayed. only ROOM TEMP.

  • Page 27: Holiday Away Settings

    5 OTHER HEATING SOURCE 5.1 dT1_IBH_ON 5°C 5.2 t_IBH_DELAY 30MIN 5.3 T4_IBH_ON -5°C 5.4 dT1_AHS_ON 5°C 5.5 t_AHS_DELAY 30MIN ADJUST 5 OTHER HEATING SOURCE The number displayed on the user interface is the phone 5.6 T4_AHS_ON -5°C number of your local dealer. 5.7 IBH LOCATE PIPE LOOP 5.8 P_IBH1...
  • Page 28 lf you select AlR PURGE and press "OK", the follow ingpage will be displayed : 9 TEST RUN lf YES is selected, the following pages will be displayed: When in air purge mode, SV1 will open. 60s later the pump in the unit (PUMPI) will operate for 10min during which the flow switch will not work. After the pump stops, the SV1 will close.

  • Page 29: Auto Restart

    The AUTO RESTART function reapplies the user During HEAT MODE test running, the default target interface settings at the time of the powe r supply failure. outlet water temperature is 35°C. The IBH (internal If this function is disabled, when power returns after a backup heater) will turn on after the compressor runs power supply failure, the unit won’t auto restart.

  • Page 30: Setting Parameters

    7.12 Setting parameters Order Code State Default Minumum Maximum Settinginterval Unit number Enable or disable the DHW DHW MODE mode:0=NON,1=YES Enable or disable the disinfect DISINFECT mode:0=NON,1=YES Enable or disable the DHW priority PRIORITY mode:0=NON,1=YES Enable or disable the DHW pump PUMP_D mode:0=NON,1=YES Enable or disable the DHW priority...
  • Page 31 Order Code State Default Minumum Maximum Settinginterval Unit number HEAT MODE Enable or disable the heating mode t_T4_ The refresh time of climate related hours FRESH_H curves for heating mode The maximum ambient operating T4HMAX °C temperature for heating mode The minimum ambient operating T4HMIN °C...
  • Page 32 Order Code State Default Minumum Maximum Settinginterval Unit number P_IBH1 Power input of IBH1 P_IBH2 Power input of IBH2 5.10 P_TBH Power input of TBH Allow to turn on IBH to make hot water While the outdoor unit 5.11 DHW _C is operating in cooling mode, 0=OFF, 1=ON Allow to turn on IBH to heating...
  • Page 33 Order Code State Default Minumum Maximum Settinginterval Unit number PUMP_I Enable or disable PUMPI SILENT SILENT MODE 0=NON, 1=YES MODE DFT1/DFT2 port DFT1/DFT2 function:0=DEFROST 1=ALARM ADDRESS 10.1 Reset the address code of the unit RESET Choose the HMI; 11.1 HMI SET 0=MASTER,1=SLAVE 11.2 ADDRESS...

  • Page 34: Before Installation

    8 BEFORE INSTALLATION • Before installation Be sure to confirm the model name and the serial number of the unit. CAUTION Frequency of Refrigerant Leakage Checks - For unit that contains fluorinated greenhouse gases in quantities of 5 tonnes of CO50 tonnes of equivalent, at least every 12 months, or where a leakage detection system is installed, at least every 24 months.
  • Page 35 8.1.2 Remove the wooden base Remove the 4 screws of the wooden base (Refer to Fig.8-3). Four people hold the sheet metal lifting machine, one of them pull the wooden base (Refer to Fig.8-4). Remove the 8 screws of the sheet metal and remove the sheet metal (Refer to Fig.8-5).

  • Page 36: Installation Site

    9 INSTALLATION SITE WARNING • Do not install the hydraulic module near a bedroom; Suggest install it in a garage, utility room, corridor, basement, or laundry room; Be sure to adopt adequate measures to prevent the unit from being used as a shelter by small animals. •...

  • Page 37: Installation

    10 INSTALLATION 10.1 Dimensions of the unit: Dimensions of the wall bracket: Fig.10-1 unit:mm NAME NAME Refrigerant gas connection φ15.9 Space heating water inlet. R1" Refrigerant liquid connection φ9.52 Space heating water outlet. R1" Domestic hot water outlet R3/4" Drainage Domestic hot water recirculation water inlet (Plugged by Solar circulation outlet (customized) the nut).

  • Page 38: Servicing Space Requirements

    10.3 Servicing space requirements ≥100 ≥100 ≥ 600 ≥800 Unit:mm Fig.10-2 10.4 Mounting the hydraulic module Lift the hydraulic module from the pallet and place it on the floor. Slide the hydraulic module into position. Adjust the height of the leveling feet (Refer to Fig.10-3) to compensate for floor irregularities. The maximum allowed deviation is 1° (Refer to Fig. 10-4) Be specially careful with the mounting foot once the unit is on the floor. Avoid harsh handling of the unit, as it could cause damages to the foot. Each mounting feet can be adjusted up to 30mm, but keep all them in the factory supplied position unit has been installed in its final position.

  • Page 39: Refrigerant Pipe Connection

    10.5 Refrigerant pipe connection 10.6 Connecting the water piping Align the center of the pipes. 10.6.1 Connecting the space heating Sufficiently tighten the flare nut with fingers, and then water piping tighten it with a spanner and torque wrench. The protective nut is a one-time part, it can not be To facilitate service and maintenance, two shut-off reused.
  • Page 40 10.6.3 Connecting the recirculation water piping If domestic hot water recirculation function is requested, the recirculation pipe should be connected. 1.Removing the nut of the recirculation on the hydraulic module. 2.Connecting the recirculation water pipe to the hydraulic module. Fig.10-10 Fig.10-11...
  • Page 41 10.6.4 Connecting the drainage hose to the hydraulic module The water coming from the pressure relief valve and the condensate water is collected in the drainage pan. The drainage hose should be connected to the drainage pipe. Connect the drainage pipe with a throat bander and insert the drainage pipe into the floor drain. Throat bander Floor drain Fig.10-12...
  • Page 42 Water may enter into the flow switch and cannot be drained out, it may freeze when the temperature is low enough. The flow switch should be removed and dried, then can be reinstalled in the unit. There need drying Fig.10-14 NOTE 1.
  • Page 43 10.6.8 Filling water 10.6.8.1 Filling the water circuit • Connect the water supply to the filling valve and open the valve. • Make sure all the automatic air purge valves are open (at least 2 turns). • Filling with water until the manometer (field supply) indicates a pressure of approximately 2.0 bar. Remove air in the circuit as much as possible using the automatic air purge valves.

  • Page 44: Field Wiring

    11 Field wiring WARNING A main switch or other means of disconnection, having a contact separation in all poles, must be incorporated in the fixed wiring in accordance with relevant local laws and regulations. Switch off the power supply before making any connections.

  • Page 45: Safety Device Requirements

    • Use the correct screwdriver to tighten the terminal screws. Small screwdrivers can damage the screw head and prevent appropriate tightening. • Over-tightening the terminal screws can damage the screws. • Attach a ground fault circuit interrupter and fuse to the power supply line. •...

  • Page 46: Connecting The Main Power Supply

    High voltage wire Low voltage wire Fig.11-3 11.5 Connecting the main power supply NOTE Leakage Protection Switch must be installed to the Power Supply of the unit. Fig.11-4 optional Fig.11-5 Nominal cross-sectional area (mm Rated current of appliance Cable for fixed Flexible cords wiring > 16 and ≤ 25 2.5 and 4...

  • Page 47: Connection For Other Components

    NOTE The ground fault circuit interrupter must be a high-speed type breaker of 30 mA (<0.1 s). Flexible cord must meet 60245IEC(H05VV-F) standards. 11.6 Connection for other components CN37 Fig.11-6 Print Connect to Print Connect to Solar energy input Antifreeze E-heating signal tape(field supply) 27 AHS1 Room thermostat input Unavailable 28 AHS2 (high voltage) Print Connect to SV1(3-way valve) 1OFF (connected in factory) Wired controller CN11...
  • Page 48 11.6.1 connecting the communication wire to outdoor unit 1 2 3 11 12 1 2 3 Fig.11-7 11.6.2 For remote shut down: CN24 CN21 CN28 CN16 CN32 CN13 CN15 CN29 CN18 CN25 CN42 CN40 DIS1 CN31 CN41 CN22 CN35 CN36 CN17 1 2 3 4 Fig.11-8...
  • Page 49 11.6.3 Room thermostat (Low voltage): There are three methods for connecting the thermostat cable (as described in the pictures) and it depends on the application. CN24 CN21 CN28 CN16 CN32 CN13 CN15 CN29 CN18 CN25 CN42 CN40 DIS1 CN31 CN41 CN22 CN35 CN36...
  • Page 50 Fig.11-10 （ ） • Method A (Mode set control) RT can control heating. When the indoor unit is connected with the external temperature controller, user interface FOR SERVICEMAN set ROOM THERMOSTAT to MODE SET: A.1 When unit detect voltage is 12VDC between HT and COM, the unit operates in the heating mode. A.2 When unit detect voltage is 0VDC between HT and COM, the unit stop working for space heating.
  • Page 51 The wiring of the thermostat should correspond to thesettings of the user interface. Refer to ROOMTHERMOSTAT. Power supply of machine and room thermostat must beconnected to the same Neutral Line. When ROOM THERMOSTAT is not set to NON, theindoor temperature sensor Ta can't be set to valid. Zone 2 can only operate in heating mode.
  • Page 52 11.6.5 For P_o: 25 26 27 28 1 2 3 4 5 29 30 31 32 6 7 8 9 10 CN11 CN30 Fig.11-12 Power supply 7 5 3 1 Voltage 220-240VAC Maximum running current(A) Minimum wiring size(mm 0.75 Control port signal type Type 2 a) Procedure Connect the cable to the appropriate terminals as shown in the picture.
  • Page 53 Voltage 220-240VAC Maximum running current(A) Minimum wiring size(mm 0.75 Control port signal type Type 2 11.6.7 For P_d and P_s: 25 26 27 28 1 2 3 4 5 29 30 31 32 6 7 8 9 10 CN11 CN30 Fig.11-14 Power supply DHW pipe pump...
  • Page 54 11.6.8 For 3-way valve SV3 Fig.11-15 11.6.9 For defrosting signal output: Fig.11-16...
  • Page 55 11.6.10 For unit operating status signal output Fig.11-17 11.6.11 For room thermostat: Room thermostat type 1(High voltago): "POWER IN" provide thewarking voltage to the RT, doesn't provide the voltage to the RTconnector. Port "15 L1" connect from the unit main power supplyport L of 1-phase power supply. Room thermostat type 2(Low vollage): "POWER IN"...
  • Page 56 Fig.11-19 25 26 27 28 1 2 3 4 5 29 30 31 32 6 7 8 9 10 CN11 CN30 Fig.11-20 Method C （Double zone control） POWER IN POWER IN zone1 zone2 • Method B (One zone control) Voltage 220-240VAC RT provide the switch signal to unit.
  • Page 57 11.6.12 For solar energy input signal 25 26 27 28 1 2 3 4 5 29 30 31 32 6 7 8 9 10 CN30 CN11 Fig.11-21 CONNECT TO SOLAR KIT INPUT 220-240VAC Voltage 220-240VAC Voltage 220-240VAC Maximum running current(A) Maximum running current(A) Minimum wiring size mm Minimum wiring size (mm...

  • Page 58: Start-Up And Configuration

    12 START-UP AND CONFIGURATION The unit should be configured by the installer to match the installation environment (outdoor climate, installed options, etc.) and user expertise. CAUTION It is important that all information in this chapter is read sequentially by the installer and that the system is configured as applicable. 12.1 DIP switch settings overview 12.1.1 Function setting DIP switch S1、S2 and S4 is located on the hydraulic module main control board (see "2.3.1 main control board of hydraulic module") and allows configuration of additional heating source thermistor installation, the second inner backup heater installation, etc.

  • Page 59: Setting The Pump

    12.2 Setting the pump The pump is contolled via a digital low-voltage pulse-width modulation signal which means that the speed of rotation depends on the input signal. The speed changes as a function of the input profile. The relationships between the head and the water flow rated, the PMW Return and the water flow rated are shown in the graph below. Head max. max speed min speed Q (m Q (m Area of regulation is included in between the max speed curve and the min speed curve.

  • Page 60: Field Settings

    DANGER Switch off the power supply before making any connections. After the installation of the unit, check the following before switching on the circuit breaker: • Field wiring: Make sure that the field wiring between the local supply panel and unit and valves (when applicable), unit and room thermostat (when applicable), unit and domestic hot water tank, and unit and backup heater kit have been connected according to the instructions described in the chapter, according to the wiring diagrams and to local laws and regulations.

  • Page 61: Test Run And Final Checks

    The following checks must be performed at least once a 13 TEST RUN AND FINAL CHECKS year by qualified person. Water pressure The installer is obliged to verify correct operation of unit Check the water pressure, if it is below 1 bar, fill water to after installation. the system. Water filter 13.1 Final checks Clean the water filter. Water pressure relief valve Before switching on the unit, read following recommendations: Check for correct operation of the pressure relief valve by turning the black knob on the valve counter-...
  • Page 62 ANNEX A: Refrigerant cycle CD E Water side Refrigerant side HEATING B CD E Water side Refrigerant side HEATING Optional Unit Item Description Item Description Water side heat exchanger (Plate heat exchange) Magnetic separator (Optional) Flow switch 3-Way valve Refrigerant liquid line temperature sensor Domestic water tank temperature sensor Refrigerant gas line temperature sensor Water outlet temperature sensor...

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Khkf-240 dr

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