Kaysun KAM3-78 DR7 Service Manual
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Kaysun KAM3-78 DR7 Service Manual

Kaysun KAM3-78 DR7 Service Manual

Dc multi outdoor type r32
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SERVICE MANUAL
KAM2-52 DR7
KAM3-78 DR7
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 (R32)
KAM4-105 DR7
KAM5-120 DR7

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Summary of Contents for Kaysun KAM3-78 DR7

  • Page 1 SERVICE MANUAL DC Multi Outdoor Type (R32) KAM2-52 DR7 KAM4-105 DR7 KAM3-78 DR7 KAM5-120 DR7 IMPORTANT NOTE: Read this manual carefully before installing or operating your new air conditioning unit. Make sure to save this manual for future reference.

  • 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 KSM135D23UFZ KAM2-52 DR7 800x333x554 KTF235D22UMT KAM3-78 DR7 845x363x702 KTF310D43UMT KAM4-105 DR7 946x410x810 KTF310D43UMT KAM5-120 DR7 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 KAM2-52 DR7 KAM3-78 DR7 KAM4-105 DR7 1034 KAM5-120 DR7 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 KAM2-52 DR7...
  • Page 9 Note: S(1)&S(2) are used in other type of models. They don't need to be connected in multi models. KAM3-78 DR7...
  • Page 10 KAM4-105 DR7...
  • Page 11 KAM5-120 DR7...

  • Page 12: Indoor Units Combination

    Indoor units combination Indoor unit combination for KAM2-52 DR7 One unit Two unit 9+12 7+12 9+18 7+18 12+12 Indoor unit combination for KAM3-78 DR7 One unit Two unit Three unit 12+18 7+7+7 7+9+9 7+12+18 9+12+12 9+12 18+18 7+7+9 7+9+12 9+9+9...
  • Page 13 7+7+7+18 7+7+12+18 7+9+12+12 9+9+9+9 9+12+12+12 7+7+7+24 7+7+12+24 7+9+12+18 9+9+9+12 9+12+12+18 7+7+9+9 7+7+18+18 7+9+12+24 9+9+9+18 12+12+12+12 7+7+9+12 7+9+9+9 7+9+18+18 9+9+9+24 12+12+12+18 Five Unit 7+7+7+7+7 7+7+7+9+18 7+7+9+9+24 7+9+9+12+12 9+9+9+12+12 7+7+7+7+9 7+7+7+9+24 7+7+9+12+18 7+9+9+12+18 9+9+9+12+18 7+7+7+7+12 7+7+7+12+18 7+7+12+12+12 7+9+12+12+12 9+9+12+12+12 7+7+7+7+18 7+7+7+18+18 7+7+12+12+18 7+9+12+12+18 9+12+12+12+12 7+7+7+7+24...

  • 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) KAM2-52 DR7 KAM3-78 DR7 KAM4-105 DR7 M5OD-42HFN8-Q...

  • 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

    ● 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. Indoor unit Extension pipe diameter (mm/inch) Model Pipe diameter (mm/inch) Liquid 6.35(1/4) Liquid 6.35(1/4) 7K9K12K...
  • 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. 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 19: 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 20: 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 21 2. Air purging with vacuum pump (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 Procedure: 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 22: 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 23 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 24: 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 25 9.4 Outdoor unit point check function A check switch is included on the outdoor PCB. Push SW1 to check the unit's status while running. The digital display shows the following codes each time the SW1 is pushed. Display Remark Number Presses Normal display Displays running frequency, running state, or malfunction code...

  • Page 26: Low Voltage Protection

    99 ℃, the digital display shows single and double digits. For example, if the digital display shows “0.5", the compressor discharge temperature is 105 ℃. AD value of current The display value is a hex number. For example, the digital display tube shows “Cd”, it means AD value is AD value of voltage 205.
  • Page 27 VOLTAGE No limit VOLT_LTM_FREQ1_ADD VOLT_LTM_FREQ2_ADD Note: if the low voltage protection occurs and not resumes within 3 minutes, 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 28 Decrease Hold Resume 9.5.7 Outdoor unit anti-freezing protection When T2<4℃ for 250 seconds or T2<0℃, the indoor unit capacity demand will be zero and resume to normal when T2>8℃ and the time of protection is no less than 3 minutes. 9.5.8 Oil return Running rules: 1.

  • Page 29: Troubleshooting

    10. Troubleshooting Indoor unit error code explanation: 10.1 Operation Lamp Malfunction Timer Lamp Error Code (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 Water level alarm Overcurrent protection (For some units)
  • Page 30 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(T3,T4.T5) Voltage protection PFC module protection Outdoor fan speed has been out of control No A Indoor unit coil outlet temperature sensor or connector of sensor is defective No B Indoor unit coil outlet temperature sensor or connector of sensor is defective...
  • Page 31 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 32 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 33 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 34 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 35 10.3.1.3 Indoor 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 36 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 37 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 38 10.3.1.6 E6(PFC module protection) PFC module protection Check whether the connecting line between Connect it tightly, check main board and the PFC normal or not module(IPM module) is connected tightly Check whether the voltage range of P-N on IPM module Replace the outdoor main board is normal? DC277-356V for 18-27KBtu/h;...
  • Page 39 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 40 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 41 10.3.3.4 Outdoor 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 42 10.3.3.5 High pressure protection (ODU P1)(For KAM4-105 DR7,KAM5-120 DR7) 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 board is connected well or...
  • Page 43 10.3.3.6 Low pressure protection (ODU P2) (For KAM4-105 DR7,KAM5-120 DR7) 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 board is connected well or...
  • Page 44 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 45 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 46 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 47 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 48 10.4 Main parts check 1. Temperature sensor checking Disconnect the temperature sensor from PCB, measure the resistance value with a tester. Temperature Sensors. Room temperature(T1) sensor, Indoor coil temperature(T2) sensor, Outdoor coil temperature(T3) sensor, Outdoor ambient temperature(T4) sensor, Compressor discharge temperature(T5) sensor. Measure the resistance value of each winding by using the multi-meter.
  • Page 49 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 50 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 51: Compressor Checking

    2.Compressor checking Measure the resistance value of each winding by using the tester. Position Resistance Value KSM135D23UFZ KTF235D22UMT KTF310D43UMT Blue - Red 1.72Ω(20℃) 0.75Ω(20℃) 0.65Ω(20℃)

  • Page 52: 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:

Kam2-52 dr7Kam4-105 dr7Kam5-120 dr7

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