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Kaysun KAM2-42 DN5 Service Manual

Dc inverter multi type; dc multi outdoor units
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SERVICE MANUAL

AIRCONDITIONER
DC INVERTER MULTI TYPE
DC MULTI OUTDOOR UNITS
KAM2-42 DN5
KAM2-52 DN5
KAM3-62 DN5
KAM3-80 DN5
KAM4-72 DN
KAM4-80 DN5
KAM4-105 DN5
KAM5-105 DN5
KAM5-120 DN5

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Summary of Contents for Kaysun KAM2-42 DN5

  • Page 1: Service Manual

    SERVICE MANUAL AIRCONDITIONER DC INVERTER MULTI TYPE KAM2-42 DN5 KAM2-52 DN5 KAM3-62 DN5 KAM3-80 DN5 KAM4-72 DN KAM4-80 DN5 KAM4-105 DN5 KAM5-105 DN5 KAM5-120 DN5 DC MULTI OUTDOOR UNITS...

  • Page 2: Table Of Contents

    CONTENTS 1. General information of Outdoor Units ..........2 2. Features ....................3 3. Dimensions .................... 4 4. Wiring Diagram ..................10 5. Refrigeration Cycle Diagram .............. 13 6. Indoor units combination ..............16 7. Installation Details ................19 8. Electronic control function ..............29 9.

  • Page 3: General Information Of Outdoor Units

    General information of Outdoor Units Model name Dimension (mm) Compressor KAM2-42 DN5 845x320x700 DA130M1C-31FZ KAM2-52 DN5 845x320x700 DA150S1C-20FZ KAM3-62 DN5 845x320x700 DA150S1C-20FZ KAM3-80 DN5 900x315x860 DA250S2C-30MT KAM4-105 DN5 990x345x965 TNB306FPGMC-L KAM5-105 DN5 990x345x965 TNB306FPGMC-L KAM5-120 DN5 990x345x965 MNB36FAAMC-L...

  • 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 KAM2-42 DN5, KAM2-52 DN5 200.7 D1 335 560 W1 D2 360 845 W...
  • Page 6 KAM3-62 DN5 200.7 D1 335 560 W1 D2 360 845 W...
  • Page 7 KAM3-80 DN5 238.4 D1 333 590 W1 D2 355 900 W...
  • Page 8 KAM4-80 DN5 238.4 D1 333 590 W1 900 W D2 355...
  • Page 9 KAM4-105 DN5 D1 366 624 W1 D2 397 990 W...
  • Page 10 KAM5-105 DN5, KAM5-120 DN5 D1 366 624 W1 D2 397 990 W W2 81 B1 145...

  • Page 11: Wiring Diagram

    Wiring Diagram KAM2-42 DN5, KAM2-52 DN5...
  • Page 12 KAM3-80 DN5, KAM3-62 DN5 KAM4-80 DN5...
  • Page 13 KAM4-105 DN5 KAM5-105 DN5, KAM5-120 DN5...

  • Page 14: Refrigeration Cycle Diagram

    Refrigeration Cycle Diagram Refrigeration circuit drawing of inverter 1 drive 2 type INDOOR OUTDOOR EXV A CAPILIARY A LIQUID VALVE A CHECK VALVE EXV B CAPILIARY B LIQUID VALVE B Condenser temp. sensor CAPILIARY TUBE HEAT HEAT EXCHANGE T4 Ambient T1 Room EXCHANGE (EVAPORATOR)
  • Page 15 5.3 Refrigeration circuit drawing of inverter 1 drive 4 type INDOOR OUTDOOR EXV A CAPILIARY A LIQUID VALVE A EXV B CAPILIARY B LIQUID VALVE B CHECK VALVE EXV C CAPILIARY C LIQUID VALVE C Condenser temp. sensor EXV D CAPILIARY D CAPILIARY TUBE LIQUID VALVE D HEAT...
  • Page 16 5.5 Refrigeration circuit drawing of KAM5-120 DN5 INDOOR OUTDOOR EXV A CAPILIARY A LIQUID VALVE A EXV B CAPILIARY B LIQUID VALVE B EXV C CAPILIARY C CHECK VALVE LIQUID VALVE C EXV D CAPILIARY D Condenser LIQUID VALVE D temp.

  • Page 17: Indoor Units Combination

    Indoor units combination Indoor unit combination for KAM2-42 DN5 One unit Two unit 9+12 7+12 Indoor unit combination for KAM2-52 DN5 One unit Two unit 9+12 7+12 9+18 7+18 12+12 Indoor unit combination for KAM3-62 DN5 One unit Two unit...
  • Page 18 Indoor unit combination for KAM4-80 DN5 Three unit Two unit Four unit unit 12+18 7+7+7 7+9+9 9+9+9 7+7+7+7 7+7+9+9 7+9+9+12 7+7+7+7 9+12 18+18 7+7+9 7+9+12 9+9+12 7+7+7+9 7+7+9+12 7+9+12+12 7+7+7+9 12 7+12 9+18 7+7+12 7+9+18 9+9+18 7+7+7+12 7+7+12+12 9+9+9+9 7+7+7+12 18 7+18 12+12 7+7+18 7+12+12 9+12+12 7+7+7+18 7+9+9+9...
  • Page 19 7+7+7+7+7 7+7+7+9+18 7+7+9+12+18 7+9+9+12+18 9+9+9+12+12 7+7+7+7+9 7+7+7+12+18 7+7+12+12+18 7+9+12+12+12 9+9+9+12+18 7+7+7+7+12 7+7+7+18+18 7+9+9+9+9 7+9+12+12+18 9+9+12+12+12 7+7+7+7+18 7+7+9+9+9 7+9+9+9+12 9+9+9+9+9 9+12+12+12+12 7+7+7+9+9 7+7+9+9+12 7+9+9+9+18 9+9+9+9+12 12+12+12+12+12 7+7+7+9+12 7+7+9+9+18 7+9+9+12+12 9+9+9+9+18...

  • Page 20: Installation Details

    Installation Details 7.1 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) 7.2 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 21 Caution: ● 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 indoor unit), additional transfer connector needs to be used on outdoor unit union.
  • Page 22 (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 23 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 24 Be sure to use a torque wrench to tighten the service port cap to a torque 18N·m. Be sure to check the gas leakage. 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 25 7.5 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 26 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. 2).
  • Page 27 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 28 Be sure to use a torque wrench to tighten the service port cap to a torque 18N.m. Be sure to check the gas leakage. 7.7 Re-installation while the outdoor unit need to be repaired 1. Evacuation for the whole system Procedure: 1).
  • Page 29 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. If the refrigerant is R410A, make the cylinder bottom up to ensure liquid charge. 2).

  • Page 30: Electronic Control Function

    Electronic control function 8.1 Abbreviation T1: Indoor ambient temperature T2: Coil temperature of indoor heat exchanger middle. T2B: Coil temperature of indoor heat exchanger outlet. T3: Coil temperature of outdoor heat exchanger T4: Outdoor ambient temperature T5: Compressor discharge temperature Ts: Setting temperature 8.2 Electric control working environment.
  • Page 31 8.4 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 32 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. EXV open angle for B indoor unit If the value is higher than 99, the digital display tube will show single EXV open angle for C indoor unit digit and tens digit.
  • Page 33 Capacity area Norm value (N) Heating mode T1 Ts Capacity area Norm value (N) 8.4.4 Number of indoor unit Display Number of indoor unit 8.4.5 Opening degree of electronic expansion valve: Actual opening degree equals the display data times 4...
  • Page 34 8.5 Protection 8.5.1 Three minutes delay at restart for compressor. 8.5.2 Temperature protection of compressor discharge. When the compressor discharge temp. is getting higher, the running frequency will be limited as below rules: ----If 102℃<T5<115℃, decrease the frequency to the lower level every 2 minutes till to F1. ---If T5>115℃...
  • Page 35 3 minutes. HEAT_F15 IHEATLMT11 HEAT_F14 IHEATLMT10 After that, the frequency will be adjusted according to the capacity demand and rise to the upper level every 3 minutes HEAT_F13 IHEATLMT9 (When the frequency>Heat_F4 via capacity demand). HEAT_F12 IHEATLMT8 HEAT_F11 IHEATLMT7 HEAT_F10 IHEATLMT6 HEAT_F9 IHEATLMT5...

  • Page 36: Troubleshooting

    9. Troubleshooting Indoor unit error code explanation: Spirit: Display Operation lamp flash times Timer lamp Failure Indoor EEPROM malfunction Indoor / outdoor units communication error Indoor fan speed has been out of control Open or short circuit of T1 temperature sensor Open or short circuit of T2 temperature sensor Open or short circuit of T4 temperature sensor Open or short circuit of T3 temperature sensor...
  • Page 37 For Console Malfunction Running lamp Timer lamp Defrosting lamp ☆ Open or short circuit of T1 temperature sensor ☆ Open or short circuit of T2 temperature sensor Communication malfunction between indoor and outdoor ☆ units. ☆ Outdoor fan speed has been out of control ☆...
  • Page 38 Outdoor unit error code explanation: 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 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 No C Indoor unit coil outlet temperature sensor or connector of sensor is defective...

  • Page 39: Trouble Shooting

    9.3 Trouble shooting 9.3.1 For the indoor unit 9.3.1.1 Indoor EEPROM malfunction Shut off the power supply and turn it on 1 minute later. Is it still displaying the error code? If the EEPROM chip is welded on PCB, replace the PCB directly.
  • Page 40 9.3.1.2 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 41 Pic 1: check the voltage of N to S (Vs), is it moving alternately between positive value and negative value? Pic 2: :IPM (For dual/tri-zone) Operating Self-Check Pic 2: :IPM (For qua-zone) Power, Self-Check els) Operating...
  • Page 42 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 43 9.3.1.3 indoor unit fan speed has been out of control Shut off the power supply and turn it on 1 minute The unit operates normally. later. Is it still displaying the error code? Find out the cause and have it solved. For Shut off the power supply, example, check rotate the fan by hand.
  • Page 44 For other models: Color Black White Yellow Blue For console: Color White Blue Yellow Black Index2: 1: Indoor AC fan motor Power on and set the unit running in fan mode at high fan speed. After running for 15 seconds, measure the voltage of pin1 and pin2.
  • Page 45 2. Indoor DC fan motor(control chip is inside fan motor) Power on and when the unit is in standby, measure the voltage of pin1-pin3, pin4-pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must have problems and need to be replaced.
  • Page 46 For A5 Duct & Four-way cassette (compact) Color Signal Voltage Vs/Vm 192V~380V Black White 13.5-16.5V Yellow 0~6.5V Blue For console: Color Signal Voltage 310V White Blue Yellow 0-7.5V Black...
  • Page 47 9.3.1.4 Open or short circuit of temperature sensor. Check the connections between temperature Correct the connections. sensor and PCB. Are the connections good? Check the resistance value of the sensor via Appendix 1 Is it normal? Replace indoor or outdoor PCB. Replace the sensor 9.3.1.6 Full-water malfunction If the water-level switch...
  • Page 48 9.3.2 For the outdoor unit 9.3.2 1 Outdoor EEPROM malfunction(ODU E0) Outdoor EEPROM malfunction If the EEPROM chip is welded on PCB, replace the PCB Insert the EEPROM well directly. Otherwise, check whether the EEPROM chip plugged in PCB well? Replace the outdoor main board...
  • Page 49 9.3.2.2 Communication malfunction between IPM board and outdoor main board(ODU E3) 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 module and the main board, is it connected good? Reconnect and retry.
  • Page 50 9.3.2.3 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 51 9.3.2.4 Outdoor unit fan speed has been out of control (E8) Shut off the power supply and turn it on 1 minute The unit operates normally. later. Is it still displaying the error code? Find out the cause and have it solved. For Shut off the power supply, example, check rotate the fan by hand.
  • Page 52 Color Black White Yellow Blue Index2: 1. Outdoor DC fan motor(control chip is inside fan motor) Power on and when the unit is in standby, measure the voltage of pin1-pin3, pin4-pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must have problems and need to be replaced.
  • Page 53 9.3.2.5 High pressure protection (ODU P1) (For KAM4-105 DN5, KAM4-80 DN5, KAM5-105 DN5, KAM5-120 DN5) High pressure protection Judge 1: Whether the wiring between the high pressure switch and main control Connect it well board is connected well or correctly Judge 2: Whether the high pressure protector is broken...
  • Page 54 9.3.2.6 Low pressure protection (ODU P2) (For KAM4-105 DN5, KAM4-80 DN5, KAM5-105 DN5, KAM5-120 DN5) Low pressure protection Judge 1: Whether the wiring between the low pressure protector and main Connect it well control board is connected well or correctly Judge 2: Whether the low pressure protector is broken...
  • Page 55 M o d e l K A M 2 - 5 2 D N 5 KAM2-52 DN5 KAM2-42 DN5 KAM3-62 DN5 K A M 3 - 8 0 D N 5 KAM4-80 DN5 KAM4-105 DN5 KAM5-105 DN5 KAM5-120 DN5 protection 18.5A...
  • Page 56 Temperature protection of compressor discharge Check whether the Check whether the compressor discharge temp. Stop leaking and add refrigerant refrigerant is leak is more than 115°C ? Check whether the wiring connection is right between compressor discharge temp. Correct the wiring connection sensor and PCB according to wiring diagrams? Judge: The...
  • Page 57 9.3.2.9 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 temp. less than 52°C. High temperature protection of condenser Replace the temperature sensor Check whether the condenser temperature is more than 65°C Check whether the...
  • Page 58 9.3.2.10 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 18-27KBtu/h; 208-230V, 1N, 60Hz can work normally? DC277-410V for 36KBtu/h...
  • Page 59 9.4 Main parts check Spec. Indoor unit Model 7K 11M 9K 11M 12K 11M 18K 11M Indoor fan motor WZDK20-38G WZDK20-38G WZDK20-38G WZDK58-38G Model 9K 11P 12K 11P 18K 11P Indoor fan motor WZDK20-38G WZDK20-38G WZDK20-38G Model 7K 9A 9K 9A 12K 9A 18K(RC8) 9A 18K(RC4) 9A...
  • Page 60 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 61 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 62 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 63: Compressor Checking

    2.Compressor checking Measure the resistance value of each winding by using the tester. Position Resistance Value DA130M1C-31FZ DA150S1C-20FZ DA250S2C-30MT TNB306FPGMC-L ASN108D22UEZ MNB36FAAMC-L Blue - 0.95Ω(20℃) 1.77Ω(20℃) 0.55Ω(20℃) 0.53Ω(20℃) 1.57Ω(20℃) 0.44Ω(20℃)
  • Page 64 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:

Kam3-80 dn5Kam4-72 dnKam4-80 dn5Kam2-52 dn5Kam4-105 dn5Kam5-105 dn5 ... Show all

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