Kaysun KAM2-52 DN7 Service Manual
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Kaysun KAM2-52 DN7 Service Manual

Dc multi outdoor type (r410)
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SERVICE MANUAL
KAM2-42 DN8
KAM2-52 DN7
KAM3-62 DN7
IMPORTANT NOTE:
Read this manual carefully before installing or operating your new air conditioning unit. Make sure to save
this manual for future reference.
DC Multi Outdoor Type (R410)
KAM3-78 DN7
KAM4-80 DN7
KAM4-105 DN7
KAM5-120 DN7

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Summary of Contents for Kaysun KAM2-52 DN7

  • Page 1 SERVICE MANUAL DC Multi Outdoor Type (R410) KAM2-42 DN8 KAM3-78 DN7 KAM5-120 DN7 KAM2-52 DN7 KAM4-80 DN7 KAM3-62 DN7 KAM4-105 DN7 IMPORTANT NOTE: Read this manual carefully before installing or operating your new air conditioning unit. Make sure to save...

  • Page 2: Table Of Contents

    CONTENTS 1. General information of Outdoor Units ......... 2 2. Features ..................3 3. Dimensions .................. 4 4. Refrigeration Cycle Diagram ............5 5. Wiring diagram ................7 6. Indoor units combination ............11 7. Sound Levels ................13 8. Installation Details ..............14 8.1 Wrench torque sheet for installation ..................

  • Page 3: General Information Of Outdoor Units

    General information of Outdoor Units Model name Dimension (mm) Compressor KAM2-42 DN8 ASN108D22UEZ 800x333x554 KAM2-52 DN7 ASM135D23UFZ 800x333x554 KAM3-62 DN7 ASM135D23UFZ 845x363x702 KAM3-78 DN7 ATF235D22UMT 845x363x702 KAM4-80 DN7 ATF235D22UMT 946x410x810 KAM4-105 DN7 ATF310D43UMT 946x410x810 KAM5-120 DN7 ATF310D43UMT 946x410x810...

  • Page 4: Features

    Features Outdoor unit Power relay control Low noise air flow system Hydrophilic aluminum fin The hydrophilic fin can improve the heating efficiency at operation mode. 4-way valve control It is only operated in the heating operation mode except defrosting operation. Anti-rust cabinet Valve protection cover It protects the valves and prevents water from dripping.

  • Page 5: Dimensions

    Dimensions Unit ： mm Model KAM2-42 DN8 KAM2-52 DN7 KAM3-62 DN7 KAM3-78 DN7 KAM4-80 DN7 1034 KAM4-105 DN7 1034 KAM5-120 DN7 1034...

  • Page 6: Refrigeration Cycle Diagram

    Refrigeration Cycle Diagram 4.1 Refrigeration circuit drawing of inverter 1 drive 2 type INDOOR OUTDOOR EXV A CAPILLARY A LIQUID VALVE A CHECK VALVE EXV B CAPILLARY B LIQUID VALVE B Condenser temp. sensor CAPILLARY TUBE HEAT HEAT EXCHANGE T4 Ambient T1 Room EXCHANGE (EVAPORATOR)
  • Page 7 4.3 Refrigeration circuit drawing of inverter 1 drive 4 type INDOOR OUTDOOR EXV A CAPILLARY A LIQUID VALVE A EXV B CAPILLARY B LIQUID VALVE B CHECK VALVE EXV C CAPILLARY C LIQUID VALVE C Condenser temp. sensor EXV D CAPILLARY D CAPILLARY TUBE LIQUID VALVE D HEAT...

  • Page 8: Wiring Diagram

    Wiring diagram KAM2-42 DN8, KAM2-52 DN7...
  • Page 9 Note: S(1)&S(2) are used in other type of models. They don't need to be connected in multi models. KAM3-62 DN7, KAM3-78 DN7...
  • Page 10 KAM4-80 DN7 KAM4-105 DN7...
  • Page 11 KAM5-120 DN7...

  • Page 12: Indoor Units Combination

    Indoor units combination Indoor unit combination for KAM2-42 DN8 One unit Two unit 9+12 7+12 Indoor unit combination for KAM2-52 DN7 One unit Two unit 9+12 7+12 9+18 7+18 12+12 Indoor unit combination for KAM3-62 DN7 One unit Two unit...
  • Page 13 Indoor unit combination for KAM4-105 DN7 One unit Two unit Three unit Four unit 9+18 7+7+7 7+9+18 9+9+12 12+12+12 7+7+7+7 7+7+9+24 7+9+12+12 9+9+12+12 9+24 7+7+9 7+9+24 9+9+18 12+12+18 7+7+7+9 7+7+12+12 7+9+12+18 9+9+12+18 7+12 12+12 7+7+12 7+12+12 9+9+24 12+12+24 7+7+7+12 7+7+12+18 7+9+18+18 9+12+12+12 7+18 12+18 7+7+18 7+12+18 9+12+12 12+18+18...

  • Page 14: Sound Levels

    Sound Levels Outdoor Unit Microphone 1.0m Note: H= 0.5 × height of outdoor unit Model Noise Power dB(A) Noise level dB(A) KAM2-42 DN8 KAM2-52 DN7 56.5 57.5 KAM3-62 DN7 59.5 KAM3-78 DN7 KAM4-80 DN7 KAM4-105 DN7 63.5 KAM5-120 DN7...

  • Page 15: Installation Details

    Installation Details 8.1 Wrench torque sheet for installation Outside diameter Torque Additional tightening torque N.cm N.cm Ф6.35 1500(153kgf.cm) 1600(163kgf.cm) Ф9.52 2500(255kgf.cm) 2600(265kgf.cm) Ф12.7 3500(357kgf.cm) 3600(367kgf.cm) 8.2 Connecting the cables The power cord of connect should be selected according to the following specifications sheet. Rated current of appliance Nominal cross-sectional area (mm²) >3 and ≤6...

  • Page 16: Installation For The First Time

    ● Refrigerant pipe diameter is different according to indoor unit to be connected. When using the extension pipe, refer to the tables below. ● When refrigerant pipe diameter is different from that of outdoor unit union (for 18K&24K indoor unit), additional transfer connector needs to be used on outdoor unit union.
  • Page 17 (Indoor unit) (Outdoor unit) (Liquid side) Two-way valve Close (Gas side) Three-way valve Close Manifold valve Compound meter Pressure gauge -0.1MPa Handle Lo Handle Hi Charge hose Charge hose Vacuum pump Vacuum pump 1) Completely tighten the flare nuts of the indoor and outdoor units, confirm that both the 2-way and 3-way valves are set to the closed position.
  • Page 18 2. Air purging by refrigerant Procedure: 1). Confirm that both the 2-way and 3-way valves are set to the closed position. 2). Connect the charge set and a charging cylinder to the service port of the 3-way valve. 3). Air purging. Open the valves on the charging cylinder and the charge set.
  • Page 19 3. Adding the refrigerant if the pipe length >5m Electronic scale Procedure: 1). Connect the charge hose to the charging cylinder, open the 2-way valve and the 3-way valve. Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder.

  • Page 20: Adding The Refrigerant After Running The System For Many Years

    8.5 Adding the refrigerant after running the system for many years Electronic scale Procedure: 1). Connect the charge hose to the 3-way service port, open the 2-way valve and the 3-way valve. Connect the charge hose to the valve at the bottom of the cylinder. If the refrigerant is R410A, make the cylinder bottom up to ensure liquid charge.

  • Page 21: Re-Installation While The Indoor Unit Need To Be Repaired

    8.6 Re-installation while the indoor unit need to be repaired 1. Collecting the refrigerant into the outdoor unit Procedure 1). Confirm that both the 2-way and 3-way valves are set to the opened position Remove the valve stem caps and confirm that the valve stems are in the opened position. Be sure to use a hexagonal wrench to operate the valve stems.
  • Page 22 2. Air purging by the refrigerant Procedure: 1). Confirm that both the 2-way and 3-way valves are set to the closed position. 2). Connect the charge set and a charging cylinder to the service port of the 3-way valve Leave the valve on the charging cylinder closed. 3).

  • Page 23: Re-Installation While The Outdoor Unit Need To Be Repaired

    8.7 Re-installation while the outdoor unit need to be repaired 1. Evacuation for the whole system Procedure: 1). Confirm that both the 2-way and 3-way valves are set to the opened position. 2). Connect the vacuum pump to 3-way valve’s service port. 3).
  • Page 24 2. Refrigerant charging Procedure: 1). Connect the charge hose to the charging cylinder, open the 2-way valve and the 3-way valve Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder.

  • Page 25: Electronic Control Function

    Electronic control function 9.1 Abbreviation T1: Indoor ambient temperature T2: Coil temperature of indoor heat exchanger middle. T2B: Coil temperature of indoor heat exchanger outlet(This sensor is located in outdoor unit) T3: Coil temperature of outdoor heat exchanger T4: Outdoor ambient temperature T5: Compressor discharge temperature Ts: Setting temperature 9.2 Electric control working environment.
  • Page 26 9.4 Outdoor unit point check function There is a check switch in outdoor PCB. Press the switch N times it will display the content corresponding to No. N. After getting into the check function, it will display No. N with 1.5s, meanwhile the low bit decimal of digit display flashing, indicated to get into the check function display.

  • Page 27: Low Voltage Protection

    means the compressor discharge temp. is 105 degree.) AD value of current The display value is hex number. For example ,the digital display tube show “Cd”, it means AD value is AD value of voltage 205. EXV open angle for A indoor unit Actual data/4.
  • Page 28 Note: if the low voltage protection occurs and not resumes within 3min, it will keep the protection always after restart the machine. 9.5.4 Compressor current limit protection Temperature interval of current limit is same as range of T4 limited frequency. Cooling mode: CoolZone5 CoolZone4...
  • Page 29 1. If the compressor frequency keeps lower than setting frequency for setting time, the AC will rise the frequency to setting frequency for setting time and then resume to former frequency. 2. The EXV will keep 300p while the indoor units will keep the current running mode. If the outdoor ambient is higher than setting frequency during the oil return, the AC quit oil return.

  • Page 30: Troubleshooting

    10. Troubleshooting Indoor unit error code explanation: 10.1 For Console (excluding MFAI-07HRFN1-QRC8) Operation Lamp Timer Lamp Malfunction (flashes) Indoor EEPROM malfunction Communication malfunction between indoor and outdoor units Indoor fan speed has been out of control Open or short circuit of T1 temperature sensor Open or short circuit of T2 temperature sensor Overcurrent protection (For some units) Open or short circuit of T4 temperature sensor...
  • Page 31 For MTBI-18HWDN1-QRC8 DISPLAY Timer Alarm MALFUNCTION DIGITAL TUBE Open or short circuit of T1 temperature sensor ☆ Open or short circuit of T2 temperature sensor ☆ Indoor / outdoor units’ communication error ☆ Full-water malfunction ☆ Indoor EEPROM malfunction ☆ ☆...
  • Page 32 Premier &Oasis models) --(for other models) Low pressure protection of compressor ☆ O (on) X(off) ☆ (flash at 2Hz) Outdoor unit error code explanation: 10.2 Display LED STATUS Outdoor EEPROM malfunction Indoor / outdoor units’ communication error Communication malfunction between IPM board and outdoor main board Open or short circuit of outdoor unit temperature sensor Voltage protection Outdoor fan speed has been out of control...
  • Page 33 Trouble shooting 10.3 10.3.1 For the indoor unit 10.3.1.1 Indoor EEPROM malfunction Power off, then restart the unit 2 minutes later Replace the indoor main PCB EEPROM: An electrically erasable programmable read-only memory whose contents can be erased and reprogrammed using a pulsed voltage.
  • Page 34 10.3.1.2 Indoor / outdoor units’ communication error Indoor / outdoor units communication error Start: Power off , then Power on the A/C by the Breaker. (reconnect the power wire). Is it still displaying the error code? Check wiring on the outdoor and indoor terminal follow the wiring diagram.
  • Page 35 Pic 1: check the voltage of N to S (Vs), is it moving alternately between positive value and negative value? Pic 2:IPM or outdoor main PCB Operating Self-Check Pic 2: IPM or outdoor main PCB Power, Self-Check Operating...
  • Page 36 PIC3: Main board LED when power on and unit standby. PIC 4: check point button, Press 1 time for check how many indoor units are connected...
  • Page 37 10.3.1.3 indoor unit fan speed has been out of control Power off, then restart the Power off, then restart the unit 2 minutes later. Is it still The unit operates normally. unit 2 minutes later. Is it still The unit operates normally. displaying the error code? displaying the error code? Find out the cause and...
  • Page 38 For console: DC motor voltage input and output For split type: Color Signal Voltage Vs/Vm 280V~380V Black White 14-17.5V Yellow 0~5.6V Blue 14-17.5V For other types: Color Signal Voltage Vs/Vm 192V~380V Black White 13.5-16.5V Yellow 0~6.5V Blue 13.5-16.5V...
  • Page 39 10.3.1.4 Open or short circuit of temperature sensor. Check the connections Check the connections between temperature between temperature Correct the connections. Correct the connections. sensor and PCB. Are the sensor and PCB. Are the connections good? connections good? Measure the resistance value Measure the resistance value of the sensor via Appendix 1 of the sensor via Appendix 1...
  • Page 40 10.3.2 For the super-slim cassette with up-down panel 10.3.2.1 Communication error between indoor unit and up-down panel F0 Displayed F0 Displayed Communication failure between Communication failure between indoor unit and up-down panel indoor unit and up-down panel Check the wire connection Check the wire connection between up-down panel and Correct the connection...
  • Page 41 10.3.3 For the outdoor unit 10.3.3.1 Outdoor EEPROM malfunction (ODU E0) Power off, then restart the Power off, then restart the unit 2 minutes later unit 2 minutes later Replace the outdoor main PCB Replace the outdoor main PCB EEPROM: An electrically erasable programmable read-only memory whose contents can be erased and reprogrammed using a pulsed voltage.
  • Page 42 10.3.3.2 Communication malfunction between IPM board and outdoor main board (ODU E3) E3 display Communication malfunction between IPM board and outdoor main board Is there at least one LED in the IPM board light? Check the signal wire between the IPM board and the main board, is it connected good? Reconnect and retry.
  • Page 43 10.3.3.3 Voltage protection(ODU E5) Voltage protection Check the voltage of outdoor unit power supply, whether the voltage Check the power supply between L(L1) and N (L2) is about 220~240VAC Check whether the voltage of IPM board P and N is normal? DC277-356V for 18-27KBtu/h;...
  • Page 44 10.3.3.4 Outdoor unit fan speed has been out of control (E8) Power off, then restart the Power off, then restart the unit 2 minutes later. Is it still The unit operates normally. unit 2 minutes later. Is it still The unit operates normally. displaying the error code? displaying the error code? Find out the cause and...
  • Page 45 10.3.3.5 High pressure protection (ODU P1) (ForKAM4-80 DN7, KAM4-105 DN7, KAM5-120 DN7) High pressure protection High pressure protection Whether the wiring Whether the wiring between the high pressure between the high pressure switch and main control switch and main control Connect it well Connect it well board is connected well or...
  • Page 46 10.3.3.6 Low pressure protection (ODU P2) (ForKAM4-80 DN7, KAM4-105 DN7, KAM5-120 DN7) Low pressure protection Low pressure protection Whether the wiring Whether the wiring between the low pressure between the low pressure protector and main control protector and main control Connect it well Connect it well board is connected well or...
  • Page 47 10.3.3.7 Current protection of compressor (ODU P3) Current protection of compressor Judge 1: Check whether the input current of the power supply wire is higher than max protection current value Check whether the refrigerant system is ok Judge 2: Check whether the outdoor ambient Stop the unit temperature is higher than...
  • Page 48 10.3.3.8 Temperature protection of compressor discharge (ODU P4) Temperature protection of Temperature protection of compressor discharge compressor discharge Check whether the Check whether the Check whether the Check whether the compressor discharge temp. is compressor discharge temp. is Stop leaking and add refrigerant Stop leaking and add refrigerant refrigerant is leak refrigerant is leak...
  • Page 49 10.3.3.9 High temperature protection of condenser (ODU P5) When outdoor pipe temperature is more than 65°C, the unit will stop, and unit runs again when outdoor pipe temperature less than 52°C. Check the connection Check the connection between temperature Correct the connection between temperature Correct the connection High temperature protection of...
  • Page 50 10.3.3.10 IPM module protection (ODU P6) IPM module protection Check whether the voltage range Check whether the input Regulate it to correct, then of P-N on IPM module is normal? power supply is correct? check whether the system DC277-356V for 18-28KBtu/h; 208-230V, 1N, 60Hz can work normally? DC277-410V for 36-42KBtu/h...

  • Page 51: Main Parts Check

    10.4 Main parts check Spec. Indoor unit Model 7K/9K/12K Cassette KCI-52 DMNU9(B) KCI-52 DMNU9 KCIS-71 DN10 Indoor fan YKT-27-4-6 motor ZKFP-46-8-1 ZKFP-46-8-1 ZKFP-124-8-2 KPD-52 DMNU8 KPD-52 DMNU8 7K/9K/12K/18K Model Console 7K/9K/12K Duct KPD-71 DMNU8 Indoor fan YKSS-68-4-15-1 ZKFN-90-8-1 motor ZKFP-20-8-2 ZKFN-55-8-1 Model 18K/24K DL...
  • Page 52 1. Temperature sensor checking Disconnect the temperature sensor from PCB, measure the resistance value with a tester. Temperature Sensors. Room temp.(T1) sensor, Indoor coil temp.(T2) sensor, Outdoor coil temp.(T3) sensor, Outdoor ambient temp.(T4) sensor, Compressor discharge temp.(T5) sensor. Measure the resistance value of each winding by using the multi-meter.
  • Page 53 Appendix 1 Temperature Sensor Resistance Value Table for T1,T2,T3,T4,T2B (℃--K) K Ohm K Ohm K Ohm K Ohm ℃ ℃ ℃ ℃ 115.266 12.6431 2.35774 0.62973 108.146 12.0561 2.27249 0.61148 101.517 11.5000 2.19073 0.59386 96.3423 10.9731 2.11241 0.57683 89.5865 10.4736 2.03732 0.56038 84.2190...
  • Page 54 Appendix 2 Temperature Sensor Resistance Value Table for T5 (℃--K) K Ohm K Ohm K Ohm K Ohm ℃ ℃ ℃ ℃ 542.7 68.66 13.59 3.702 511.9 65.62 13.11 3.595 62.73 12.65 3.492 455.9 59.98 12.21 3.392 430.5 57.37 11.79 3.296 406.7 54.89...
  • Page 55 71.86 14.09 3.812...

  • Page 56: Compressor Checking

    2.Compressor checking Measure the resistance value of each winding by using the tester. Position Resistance Value ASN108D22UEZ ASM135D23UFZ ATF235D22UMT ATF310D43UMT Blue - 1.57Ω(20℃) 1.75Ω(20℃) 0.75Ω(20℃) 0.65Ω(20℃)

  • Page 57: Ipm Continuity Check

    3. IPM continuity check Turn off the power, let the large capacity electrolytic capacitors discharge completely, and dismount the IPM. Use a digital tester to measure the resistance between P and UVWN; UVW and N. Digital tester Normal resistance value Digital tester Normal resistance value (+)Red...

This manual is also suitable for:

Kam2-42 dn8Kam3-62 dn7Kam3-78 dn7Kam4-80 dn7Kam4-105 dn7Kam5-120 dn7

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