Kaysun KDHWF-12 Technical Manual
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Kaysun KDHWF-12 Technical Manual

Kaysun KDHWF-12 Technical Manual

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TECHNICAL MANUAL
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. All
the pictures in this manual are for illustration purpose only.
KDHWF-12
KTF-200
KTF-300
DHW Kit

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  • Page 1 TECHNICAL MANUAL DHW Kit KDHWF-12 KTF-200 KTF-300 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. All the pictures in this manual are for illustration purpose only.

  • Page 3: Table Of Contents

    DHW Kit CONTENTS Part 1 General Information ................3 Part 2 Engineering Data ...................5 Part 3 Component Layout andRefrigerant Circuits ..........12 Part 4 Control ....................29 Part 5 Diagnosis and Troubleshooting ............37...
  • Page 4 DHW Kit...

  • Page 5: Part 1 General Information

    DHW Kit Part 1 General Information 1 Unit Capacities and External Appearance ...........4...

  • Page 6: Outdoor Unit

    1 Unit Capacities and External Appearance 1.1 Outdoor unit Table 1-2.1: Outdoor unit Capacity 8-10kW 12-16kW Appearance 1.2 Indoor unit Table 1-2.2: Indoor unit DHW kit model KDHWF-12 Compatible outdoor unit model KMF-120 DVR5 Appearance DHW tank model KTF-200 KTF-300 Appearance...

  • Page 7: Part 2 Engineering Data

    DHW Kit Part 2 Engineering Data 1 Specifications ....................6 2 Dimensions ....................7 3 Installation Space Requirements ...............7 4 Piping Diagrams ..................8 5 Wiring Diagrams ..................9 6 Electrical characteristics ................10 7 Accessories .....................11...

  • Page 8: Specifications

    DHW Kit 1 Specifications Outdoor unit model KMF-120 DVR5 DHW Kit model KDHWF-12 Power supply V/ph/Hz 220-240/1/50 DHW set temperature °C 30~60 Unit dimension(L*W*H) 375×312×129 Dimension Packing dimension(L*W*H) 490×490×235 DHW Kit Net weight Weight Gross weight Resistance class IP X4...

  • Page 9: Dimensions

    DHW Kit 2 Dimensions Figure 2-2.1: Dimensions of the unit (unit: mm) 3 Installation Space Requirements Figure 2-3.1: Installation Space Requirements (unit: mm) ≥300 ≥300 ≥500...

  • Page 10: Piping Diagrams

    DHW Kit 4 Piping Diagrams Figure 2-4.1: Piping diagram VRF indoor unit DHW Kit Gas pipe Gas pipe Liquid pipe Liquid pipe Liquid pipe...

  • Page 11: Wiring Diagrams

    DHW Kit 5 Wiring Diagrams Figure 2-5.1: Wiring diagram code Name Check button Current fransformer High pressure sensor controller Waler lank lerperalure sensor Evaporalor temperature sensor Bectronic expansion valve Port CN24 of DM Kit need connect to ODU PQE! Power supply Wiring diagram of tank inside Black Yelow Gray...

  • Page 12: Electrical Characteristics

    Capacity Fuse length ≤30m 30mA below 220- KDHWF-12 2100 240V~50Hz 0.1 sec Note: 1. Specifications of power wires above (DHW Kit power wire and power wire that connects with water tank). 2. Power supply provided individually (not use power supply device).

  • Page 13: Accessories

    DHW Kit 7 Accessories Table 2-8.1: DHW Kit accessories Name Shape Quantity Installation & Owner’s Manual Wired Controller Wired Controller Cable group (20m) Screw ST3.9x10 Plastic Expanded Tube Tie Wrap Flare Nut TLM-B02 Flare Nut TLM-A02 Flare Nut TLM-C02...

  • Page 14: Part 3 Component Layout Andrefrigerant Circuits

    DHW Kit Part 3 Component Layout and Refrigerant Circuits 1 Layout of Functional Components ............13 2 Refrigerant Pipework ................14 3 Electrical Wiring ..................27...
  • Page 15 DHW Kit 1 Layout of Functional Components KDHWF-12 Parts name Parts name DHW Kit Cover Assembly Refrigerant Liquid Pipe Assembly Electric Control Welding Assembly Electronic Expansion Valve Suite Electrical Box Separator Assembly Temperature Sensor Outdoor Main Control Board Assembly Refrigerant Gas Pipe Assembly...

  • Page 16: Refrigerant Pipework

    Table 3-3.1: Permitted Piping Length and Level Difference Outdoor unit models KMF-120 DVR5 Hydraulic module models KDHWF-12 Max. piping length Max. difference in height Figure 3-3.1: Connect method DHW Kit Water tank 2.2 Pipe Size...
  • Page 17 DHW Kit 2.3 Procedure and Principles 2.3.1 Installation procedure Notes for installers Installation of the refrigerant piping system should proceed in the following order: Pipe Joint Pipe Pipe brazing Gas tightness Vacuum drying flushing insulation insulation and installation test Note: Pipe flushing should be performed once the brazed connections have been completed with the exception of the final connections to the indoor units.
  • Page 18 DHW Kit 2.4 Storing Copper Piping 2.4.1 Pipe delivery, storage and sealing Notes for installers  Ensure that piping does not get bent or deformed during delivery or whilst stored.  On construction sites store piping in a designated location. ...
  • Page 19 DHW Kit 2.5.3 Expanding copper piping ends Notes for installers  Ends of copper piping can be expanded so that another length of piping can be inserted and the joint brazed.  Insert the expanding head of the pipe expander into the pipe. After completing pipe expansion, rotate the copper pipe a few degrees to rectify the straight line mark left by the expanding head.
  • Page 20 DHW Kit 2.5.5 Bending piping Bending copper piping reduces the number of brazed joints required and can improve quality and save material. Notes for installers Piping bending methods  Hand bending is suitable for thin copper piping (Ф6. 35mm - Ф12. 7mm).  Mechanical bending (using a bending spring, manual bending machine or powered bending machine) is suitable for a wide range of diameters (Ф6. 35mm - Ф54.0mm).
  • Page 21 DHW Kit 2.7 Brazing Care must be taken to prevent oxide forming on the inside of copper piping during brazing. The presence of oxide in a refrigerant system adversely affects the operation of valves and compressors, potentially leading to low efficiency or even compressor failure.
  • Page 22 DHW Kit ...box continued from previous page Piping orientation during brazing Brazing should be conducted downwards or horizontally to avoid filler leakage. Figure 3-3.7: Piping orientation during brazing Brazing Brazing Brazing Piping overlap during brazing Table 3-3.5 specifies the minimum permissible piping overlap and the range of permissible gap sizes for brazed joints on piping of different diameters.
  • Page 23 DHW Kit 2.8 Pipe Flushing 2.8.1 Purpose To remove dust, other particles and moisture, which could cause compressor malfunction if not flushed out before the system is run, the refrigerant piping should be flushed using nitrogen. As described in Part 3, 2.3.1 “Installation procedure”, pipe flushing should be performed once the piping connections have been completed with the exception of the final connections to the Hydraulic Module.
  • Page 24 DHW Kit 2.9 Gastightness Test 2.9.1 Purpose To prevent faults caused by refrigerant leakage, a gastightness test should be performed before system commissioning. 2.9.2 Procedure Notes for installers Warning Only dry nitrogen should be used for gastightness testing. Oxygen, air, flammable gases and toxic gases must not be used for gastightness testing.

  • Page 25: Vacuum Drying

    DHW Kit 2.9.3 Leak detection Notes for installers The general methods for identifying the source of a leak are as follows: 1. Audio detection: relatively large leaks are audible. 2. Touch detection: place your hand at joints to feel for escaping gas. 3.
  • Page 26 DHW Kit 2.10.2 Procedure Notes for installers During vacuum drying, a vacuum pump is used to lower the pressure in the piping to the extent that any moisture present evaporates. At 5mmHg (755mmHg below typical atmospheric pressure) the boiling point of water is 0°C. Therefore a vacuum pump capable of maintaining a pressure of -755mmHg or lower should be used.

  • Page 27: Charging Refrigerant

    DHW Kit 2.11 Charging Refrigerant 2.11.1 Calculating additional refrigerant charge The additional refrigerant charge required depends on the lengths and diameters of the outdoor and indoor liquid pipes, and the indoor unit capacity of the connection. Table 3-7.1 shows the additional refrigerant charge required per meter of equivalent pipe length for different diameters of pipe.
  • Page 28 DHW Kit Step 4 • Open the three valves on the pressure gauge to begin charging refrigerant. • When the amount charged reaches R (kg), close the three valves. If the amount charged has not reached R (kg) but no additional refrigerant can be charged, close the three valves on the pressure gauge, run the outdoor unit in cooling mode, and then open the yellow and blue valves.

  • Page 29: Electrical Wiring

    DHW Kit 3 Electrical Wiring 3.1 General Notes for installers Caution  All installation and wiring must be carried out by competent and suitably qualified, certified and accredited professionals and in accordance with all applicable legislation.  Electrical systems should be grounded in accordance with all applicable legislation. ...

  • Page 30: Wiring Overview

    DHW Kit 3.4 Wiring Overview 3.4.1 Outdoor unit and indoor units’ P Q E communication Communication wiring design and installation should adhere to the following requirements:  0.75mm three-core shielded cable should be used for communication wiring. Using other types of cable can lead to interference and malfunction.

  • Page 31: Part 4 Control

    DHW Kit Part 4 Control 1 Automatically ON/OFF and electric heater control ........30 2 Smart Grid ....................31 3 Solar Energy ....................32 4 Hybrid .....................33 5 OPT.Backup .....................34 6 Manually electric heater control ..............36 7 Disinfection .....................36...

  • Page 32: Automatically On/Off And Electric Heater Control

    DHW Kit 1 Automatically ON/OFF and electric heater control Heat pump standby T5s≥38°C, T5L ＜ Min(T5s, T5stop) - Trdh T5s ＜ 38°C, T5L ＜ Min(T5s, T5stop) - Min(Trdh, 2) Heat pump turns on T4 ＜ Td T5L ＜ Min(T5s,T5stop) – 10 Heat pump operates for 1h Electric heater turns on and work with heat pump to heat the water to T5s then electric heater stops T5s≥38°C, T5L≥Min(T5s, T5stop)

  • Page 33: Smart Grid

    DHW Kit 2 Smart Grid Comply with Australian Smart Grid access specification (AS 4755.3.1-2008), and can accept DRED (Demand Response Enabling Device) standard control signals DRM1 ~ DRM4. Meet the demand of power grid load balancing and enjoy more favorable electricity price or subsidy. When the Smart Grid function is activated, heat pump will carry out electric heater control and adjust T5stop according to different DRM signals.

  • Page 34: Solar Energy

    DHW Kit 3 Solar Energy Solar energy signal which is provided from electric grid or other controller is used to control the ON/OFF or Plus Operation of the unit. Hot water can be produced with solar electric energy as much as possible in order to save running cost. ON/OFF control.

  • Page 35: Hybrid

    DHW Kit 4 Hybrid When heat pump is under the low efficiency operation range, wired controller will remind user to turn on additional heating source in order to satisfy the heating demand. Heat pump standby T5s≥38°C, T5L<Min(T5s,T5stopg) – Trdh T5s<38°C 时 ,T5L<Min(T5s,T5stopg) - Min(Trdh,2) Heat pump turns on T5s≥38°C 时...

  • Page 36: Opt.backup

    DHW Kit 5 OPT.Backup Off-Peak (Off-Peak signal receiving port) OPT. Backup function is an application of valley electricity utilize. It detects Off-peak signal which means electric price is at low price. When Off-peak signal is ON, water will be heated by heat pump preferentially. OPT.Backup function can works with timer function: If timer function is not active, heat pump operates when Off-Peak signal is ON.
  • Page 37 DHW Kit Note: 1. T5s: Water setting temperature 2. T5L: Water tank temperature 3. Trdh: Restart offset temperature, temperature difference between Water setting temperature(T5S) and Water tank temperature(T5L) above which heat pump turns on 4. T5stop: Maximum water temperature that heat pump stops for Hybrid mode, which relates to ambient temperature T4 (Refresh every 15min) (-∞,-20) [-20,-15)

  • Page 38: Manually Electric Heater Control

    DHW Kit 6 Manually electric heater control Electric heater OFF Manually turn on electric heater Manually turn off electric heater T5L<T5s-1 T5L≥T5s Electric heater ON Note: 1. T5L: Water tank temperature 2. T5s: Water setting temperature 7 Disinfection Disinfection OFF T5L≥Td1s Disinfection mode is active T5L<Td1s...

  • Page 39: Part 5 Diagnosis And Troubleshooting

    DHW Kit Part 5 Diagnosis and Troubleshooting 1 Electric Control Box Layout ..............38 2 PCB ......................39 3 Spot check list ..................40 4 Error Code Table ..................40 5 Troubleshooting ..................41 6 Temperature Sensor Resistance Characteristics ........56...
  • Page 40 DHW Kit 1 Electric Control Box Layout Figure 5-1.1: DHW Kit electric control box Maln PCB Power supply terminals Communication terminals...
  • Page 41 DHW Kit 2 PCB Figure 5-2.1: DHW Kit main PCB ports Label in Port code Content Port voltage Figure CN19 Power input port N AC 220-240V CN01 L_IN Power input port L AC 220-240V CN15 water tank booster heater port L AC 220-240V CN16 water tank booster heater heater port N...

  • Page 42: Error Code Table

    DHW Kit 3 Spot check list Explanation Displayable range [dF] Defrost [dC] Refrigerant recovery Normal display [0] Turned off [Tx] Standby or operating [0] Turned off Operating mode [5] Turned on (DHW mode) DHW Kit communication address 0~63 Water tank temp. value (T5L) Above 100°C the hundreds and tens are displayed in hexadecimal and the digits are displayed in decimal (e.g.
  • Page 43 DHW Kit 5 Troubleshooting 5.1 Warning Warning  All electrical work must be carried out by competent and suitably qualified, certified and accredited professionals and in accordance with all applicable legislation (all national, local and other laws, standards, codes, rules, regulations and other legislation that apply in a given situation). ...
  • Page 44 DHW Kit C1: IDU address repetition 5.2.1 Digital display output 5.2.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.2.3 Fault Determination Conditions  Trigger condition: Duplicate address of DHW Kit and indoor unit  Restoration condition: No duplication address of DHW Kit and indoor unit ...
  • Page 45 DHW Kit 5.3 U3: No address code detected 5.3.1 Digital display output 5.3.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.3.3 Fault Determination Conditions  Trigger condition: 1. DHW Kit address setting not set or incorrect 2.
  • Page 46 DHW Kit 5.4 E2: Communication fault between DHW Kit and controller 5.4.1 Digital display output 5.4.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.4.3 Fault Determination Conditions  Trigger condition: DHW Kit main board is not receiving communication signals from the wired controller. ...
  • Page 47 DHW Kit 5.5 Cb: Communication fault between DHW Kit and ODU 5.5.1 Digital display output 5.5.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.5.3 Fault Determination Conditions  Trigger condition: DHW Kit main board is not receiving communication signals from ODU ...
  • Page 48 DHW Kit 5.6 A5: ODU error 5.6.1 Digital display output 5.6.2 Description  Only the DHW Kit is displayed. 5.6.3 Fault Determination Conditions  Trigger condition: outdoor unit failure  Restoration condition: Outdoor unit failure recovery  Reset method: Automatic restoration 5.6.4 Procedure Reference outdoor unit troubleshooting...
  • Page 49 DHW Kit 5.7 E4: Water tank temperature sensor error (T5L) 5.7.1 Digital display output 5.7.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.7.3 Fault Determination Conditions  Trigger condition: Main board detects open or shorted T5L sensor ...
  • Page 50 DHW Kit 5.8 H2: Evaporator temperature sensor error (T2) 5.8.1 Digital display output 5.8.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.8.3 Fault Determination Conditions  Trigger condition: Main board detects open or shorted T2 sensor ...
  • Page 51 DHW Kit 5.9 EF: Clock chip error 5.9.1 Digital display output 5.9.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.9.3 Fault Determination Conditions  Trigger condition: Main board can't get clock chip data  Restoration condition: Main board correctly get clock chip data ...
  • Page 52 DHW Kit 5.10 H8: High pressure sensor error 5.10.1 Digital display output 5.10.2 Description  DHW Kit stops operation.  High pressure sensor open/short circuit fault  Only the DHW Kit is displayed. 5.10.3 Fault Determination Conditions  Trigger condition: Main board detects open or shorted high pressure sensor ...
  • Page 53 DHW Kit 5.11 HP: Smart Grid signal error 5.11.1 Digital display output 5.11.2 Description  Only the DHW Kit is displayed. 5.11.3 Fault Determination Conditions  Trigger condition: Main board gets wrong smart grid signal  Restoration condition: Main board gets correct smart grid signal ...
  • Page 54 DHW Kit 5.12 PA: Low water temperature protection 5.12.1 Digital display output 5.12.2 Description  Only the DHW Kit is displayed. 5.12.3 Fault Determination Conditions  Trigger condition: Protection is displayed when the number of shutdowns during antifreeze operation reaches 3. ...
  • Page 55 DHW Kit 5.13 F6: EEV fault 5.13.1 Digital display output 5.13.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.13.3 Fault Determination Conditions  Trigger condition: After power-on, the feedback signal of the corresponding EEV is not detected within any 2min. ...
  • Page 56 DHW Kit 5.14 EE: EEPROM error 5.14.1 Digital display output 5.14.2 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.14.3 Fault Determination Conditions  Trigger condition: After powering up, the main board cannot get EEPROM data ...
  • Page 57 DHW Kit 5.15 HC: E-heater error (Current is less than 2A when e-heater operating) 5.16 Digital display output 5.16.1 Description  DHW Kit stops operation.  Only the DHW Kit is displayed. 5.16.2 Fault Determination Conditions  Trigger condition: After the e-heater is turned on and running for 5S, the main control detects that the e-heater current is less than 2A.
  • Page 58 DHW Kit 6 Temperature Sensor Resistance Characteristics Table 5-6.1: Outdoor ambient temperature sensor, water side heat exchanger refrigerant inlet / outlet (liquid / gas pipe) temperature sensor, air side heat exchanger refrigerant out temperature sensor and suction pipe temperature sensor resistance characteristics Temperature Resistance Temperature...
  • Page 59 DHW Kit Table 5-6.2: Compressor discharge pipe temperature sensor resistance characteristics Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) 542.7 68.66 13.59 3.702 511.9 65.62 13.11 3.595 483.0 62.73 12.65 3.492 455.9 59.98 12.21 3.392...
  • Page 60 Ver. 2024-04...

This manual is also suitable for:

Ktf-200Ktf-300Kmf-120 dvr5

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