Kaisai FLY INVERTER Series Service Manual Download Page 1

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IMPORTANT NOTE:

Read this manual carefully before installing or operating your new air conditioning unit.
Make sure to save this manual for future reference.

KAISAI FLY

INVERTER SERIES

R32 UNITS SERVICE MANUAL

Summary of Contents for FLY INVERTER Series

Page 1: ...ORTANT NOTE Read this manual carefully before installing or operating your new air conditioning unit Make sure to save this manual for future reference KAISAI FLY INVERTER SERIES R32 UNITS SERVICE MAN...

Page 2: ...embly 20 1 Maintenance 2 Disassembly 5 Troubleshooting 59 1 Safety Caution 2 General Troubleshooting 3 Error Diagnosis and Troubleshooting Without Error Code 4 Quick Maintenance by Error Code 5 Troubl...

Page 3: ...Contents 1 Precautions 2 2 Information servicing 3 Safety Precautions...

Page 4: ...al work For more information contact your dealer seller or an authorized KAISAI service center Page 2 1 3 Operation and Maintenance WARNING Do not use defective or under rated circuit breakers Ensure...

Page 5: ...the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks NO SMOKING signs shall be displayed 2 7 Ventilated area Ensure that the area is in the open or that i...

Page 6: ...n the atmosphere from a leak 2 12 Cabling Check that cabling will not be subject to wear corrosion excessivepressure vibration sharpedges oranyotheradverseenvironmentaleffects Thecheck shall also take...

Page 7: ...e use of reclaimed refrigerant Itis essentialthatelectricalpoweris available before the task is commenced Become familiar with the equipment and its operation Isolate system electrically Before attemp...

Page 8: ...omponents are sealed to prevent ignition in the event of a refrigerant release Consult manufacturer if in doubt The recovered refrigerant shall be returned to the refrigerant supplier in the correct r...

Page 9: ...Contents 1 Model Reference 8 2 Electrical Wiring Diagrams 9 2 1 Indoor Unit 9 2 2 Outdoor Unit 11 Specifications...

Page 10: ...indoor and outdoor unit model number of your purchased equipment Indoor Unit Model Outdoor Unit Model Capacity Btu Power Supply KWX 09HRDI KWX 09HRDO 9k 220 240V 50Hz 1Phase KWX 12HRDI KWX 12HRDO 12k...

Page 11: ...ellow Green Conductor ION Positive and Negative Ion Generator CAP Capacitor PLASMA Electronic Dust Collector L LIVE N NEUTRAL Heater The Electric Heating Belt of Indoor Unit T1 Indoor Room Temperature...

Page 12: ...OOR WIRING DIAGRAM Y G 16022000020169 OPTIONAL Applicable to AC motor only M CAP 2 CN701 4 OPTION AL X Y HA HB OPTIONAL OPTIONA 12V 5 V Page 10 KWX 09HRDI KWX 12HRDI KWX 18HRDI KWX 24HRDI Specificatio...

Page 13: ...C FAN Direct Current FAN CT1 AC Current Detector COMP Compressor L PRO Low Pressure Switch H PRO High Pressure Switch EEV Electronic Expansion Valve KWX 09 12 18HRDO Page 11 BLUE OR BLACK Y G Y G BROW...

Page 14: ...DO Page 12 16022000019 069 Applicable to the units adopting DC motor only Applicable to the units adopting AC motor only HEATER2 C N 4 BROWN BLU E CN3 0 BLACK BL UE HEATER 1 Specifications OPTION AL O...

Page 15: ...ode 15 1 6 Heating Mode 15 1 7 Auto mode 16 1 8 Drying Mode 16 1 9 Forced Operation Function 16 1 10 Sleep Function 16 1 11 Auto Restart Function 16 1 12 Refrigerant Leakage Detection 17 1 13 8 C Heat...

Page 16: ...t s current voltage and temperature If automatic shutoff is initiated the corresponding error code is displayed on the indoor unit and the unit ceases operation Indoor fan delayed operation When the u...

Page 17: ...nsation When T1 Ts T the compressor ceases operation When T1 Ts T 1 5 C the compressor continues operation When the AC is operating in mute mode the compressor operates at a low frequency When the cur...

Page 18: ...not higher than 30 C every hour After 2 hours the temperature stops rising and the indoor fan is fixed at low speed When heating the temperature decreases 1 C to not lower than 17 C every hour After 2...

Page 19: ...e the function turns off The unit regulates temperature based on its own sensor and settings 1 16 Silence Optional Press Silence on the remote control to enable the SILENCE function While this functio...

Page 20: ...ure Outlet temperature of indoor coil Discharge temperature Suction temperature Targeted frequency Actual frequency IF Indoor fan speed 0 1 2 3 4 14 FF OFF Low speed Medium speed High speed Turbo Actu...

Page 21: ...Displayed code Explanation Displayed value Meaning Additional Notes 0 Reserved 0 FF 2 28 5 20 5 25 1 0 1 4 L T T Page 19 Product Features...

Page 22: ...ce 21 1 1 First Time Installation Check 21 1 2 Refrigerant Recharge 23 1 3 Re Installation 24 1 3 1 Indoor Unit 24 1 3 2 Outdoor Unit 26 2 Disassembly 28 2 1 Indoor Unit 28 2 2 Outdoor Unit 40 Mainten...

Page 23: ...frigerant circuit Corroding the refrigerant system To prevent air and moisture from affecting the air conditioner s performance the indoor unit as well as the pipes between the indoor and outdoor unit...

Page 24: ...0 minutes If the pressure does not achieve 0 1 MPa 14 5 Psi after 50 minutes check for leakage Ifthepressuresuccessfullyreaches 0 1MPa 14 5Psi fullyclosetheHandleLovalve then cease vacuum pump operati...

Page 25: ...id charge 5 Open the valve at the bottom of the cylinder for 5 seconds to purge the air in the charge hose then fully tighten the charge hose with push pin Handle Lo to the service port of 3 way valve...

Page 26: ...r from the charge hose for 5 seconds and then close it quickly 4 Close the 2 way valve 5 Operate the air conditioner in cooling mode Cease operations when the gauge reaches 0 1 MPa 14 5 Psi 6 Close th...

Page 27: ...n additional 20 minutes If the pressure does not achieve 0 1 MPa 14 5 Psi after 50 minutes check for leakage Ifthepressuresuccessfullyreaches 0 1MPa 14 5Psi fullyclosetheHandleLovalve then cease vacuu...

Page 28: ...MPa 14 5Psi 4 Close the valve Low side on the charge set and turn off the vacuum pump 5 Wait for 5 minutes then check whether the gauge needle moves after turning off the vacuum pump If the gauge need...

Page 29: ...en the Handle Lo manifold valve 2 and 3 way valves 8 Operate the air conditioner in cooling mode to charge the system with liquid refrigerant 9 Whentheelectronic scale displays thecorrect weight refer...

Page 30: ...abs on the both sides and liftit see CJ_AF_ INV_001 2 Push up the bottom of an air filter and then pull it out downwards see CJ_AF_INV_002 Front Panel Tab CJ_AF_INV_001 Filter CJ_AF_INV_002 Note This...

Page 31: ...J_AF_INV_003 4 Bend the horizontal louver lightly by both hands to loosen the hooks then remove the horizontal louver see CJ_AF_INV_004 Horizontal Louver Hook CJ_AF_INV_003 Hook CJ_AF_INV_004 Note Thi...

Page 32: ...INV_005 2 6 Disconnecttheconnector fordisplay board see CJ_AF_INV_005 3 7 Remove thedisplay board see CJ_AF_ INV_005 4 CJ_AF_INV_005 1 CJ_AF_INV_005 2 CJ_AF_INV_005 3 CJ_AF_INV_005 4 CJ_AF_INV_005 Not...

Page 33: ...remove the screws see CJ_AF_ INV_006 9 Release the 4 hooks 10 Releasethesevenhooksintheback see CJ_AF_INV_007 CJ_AF_INV_006 Hooks CJ_AF_INV_007 Note This section is for reference only Actual unit appe...

Page 34: ...rame while pushing the hook through a clearance between the panel frame and the heat exchanger see CJ_AF_INV_008 CJ_AF_INV_008 Panel Frame Note This section is for reference only Actual unit appearanc...

Page 35: ...the terminal cover see CJ_AF_ INV_009 2 Pull out the room temperature sensor T1 and the coil temperature sensor T2 seeCJ_AF_INV_010 3 Remove the two screws used for the ground connection see CJ_AF_ IN...

Page 36: ..._011 2 6 Disconnect the wires Then remove theelectronicmainboard CJ_AF_ INV_012 Fixing Screw CJ_AF_INV_011 1 Electronic Box CJ_AF_INV_011 2 Swing Motor Applicable to AC MotorOnly Indoor FanMotor CJ_AF...

Page 37: ...7 Remove the fixing screw then remove thecapacitoroffanmotor seeCJ_AF_ INV_013 Capacitor of Fan Motor CJ_AF_INV_013 Note This section is for reference only Actual unit appearance may vary Page 35 Main...

Page 38: ...ted atthe rear of the unit see CJ_AF_INV_014 2 Removethescrewsontheevaporator locatedatthefixedplate seeCJ_AF_ INV_015 3 Remove the two screws on the evaporator located at the base of the bearing side...

Page 39: ...Procedure Illustration 4 Pullouttheevaporator seeCJ_AF_ INV_017 Evaporator CJ_AF_INV_017 Note This section is for reference only Actual unit appearance may vary Page 37 Maintenance and Disassembly...

Page 40: ...Remove the two screws and remove the fixing board of the fan motor see CJ_AF_ INV_018 2 Remove the Bearing sleeve see CJ_AF_ INV_019 3 Remove the fixing screw see CJ_AF_ INV_020 4 Pull out the fan mot...

Page 41: ...2 Electrical parts before disassembling step motor Procedure Illustration 1 Remove the two screws then remove the steppingmotor see CJ_AF_INV_021 Stepping Motor CJ_AF_INV_021 Note This section is for...

Page 42: ...then remove the bighandle 1 screws see CJ_AB30_INV_001 3 Remove the screws of the top cover and then remove the top cover 3 screws Oneofthescrewsislocated underneath the big handle see CJ_ AB30_INV_00...

Page 43: ...nt panel 6 screws seeCJ_AB30_INV_003 5 Removethescrews of water collecting cover 1 screw see CJ_AB30_ INV_004 Front Panel CJ_AB30_INV_003 Water Collecting Cover CJ_AB30_INV_004 Note This section is fo...

Page 44: ...ve the screws of the right panel and then remove the right panel 5 screws see CJ_AB30_INV_005 Right Panel CJ_AB30_INV_005 Note This section is for reference only Actual unit appearance may vary Page 4...

Page 45: ...bighandle 1 screws see CJ_B30_INV_001 3 Remove the screws of the top cover and then remove the top cover 3 screws Oneofthescrewsislocated underneath the big handle see CJ_ B30_INV_002 Big Handle Top...

Page 46: ...eCJ_B30_INV_003 2 Remove the screws of water collecting cover and then remove the water collecting cover 1 screw see CJ_B30_ INV_004 Front Panel CJ_B30_INV_003 Water Collecting Cover CJ_B30_INV_004 No...

Page 47: ...ove the screws of the right panel and then remove the right panel 5 screws see CJ_B30_INV_005 CJ_B30_INV_005 Right Panel Note This section is for reference only Actual unit appearance may vary Page 45...

Page 48: ...ighandle 1 screws see CJ_CA30_INV_001 3 Remove the screws of the top cover and then remove the top cover 3 screws Oneofthescrewsislocated underneath the big handle see CJ_ CA30_INV_002 Big Handle CJ_C...

Page 49: ...CJ_CA30_INV_003 5 Removethescrews of water collecting cover and then remove the water collecting cover 1 screw see CJ_ CA30_INV_004 Front Panel CJ_CA30_INV_003 Water Collecting Cover CJ_CA30_INV_004 N...

Page 50: ...ve the screws of the right panel and then remove the right panel 6 screws see CJ_CA30_INV_005 Right Panel CJ_CA30_INV_005 Note This section is for reference only Actual unit appearance may vary Page 4...

Page 51: ...an with a spanner see CJ_ODU_ INV_001 2 Removethefan 3 Remove the screws of the top cover 2screws seeCJ_ODU_INV_002 4 Unfix the hooks and then open the electronic controlbox cover 4hooks see CJ_ODU_IN...

Page 52: ...nic control board see CJ_ODU_INV_004 6 Remove the fixing screws of the fan motor 4 screws see CJ_ODU_INV_005 7 Remove the fan motor CJ_ODU_INV_004 Fan Motor CJ_ODU_INV_005 Note This section is for ref...

Page 53: ...ner see CJ_ODU_ INV_006 2 Removethefan 3 Unfix the hooks and then open the electronic control box cover 4hooks see CJ_ODU_INV_007 D cut CJ_ODU_INV_006 Hook CJ_ODU_INV_007 Note This section is for refe...

Page 54: ...ectronic control board see CJ_ODU_INV_008 5 Remove the fixing screws of the fan motor 4 screws see CJ_ODU_INV_009 6 Remove the fan motor CJ_ODU_INV_008 CJ_ODU_INV_009 Note This section is for referenc...

Page 55: ...10 2 Pull out the two blue wires connected with the four way valve CJ_ODU_ INV_010 3 Pull out connectors of the condenser coiltemp sensor T3 outdoorambient temp sensor T4 anddischargetemp sensor TP CJ...

Page 56: ...p sensor T4 anddischargetemp sensor T5 see CJ_ODU_INV_011 4 Disconnect the electronic expansion valvewire seeFigCJ_ODU_INV_011 5 Remove the connector for the DR and reactor see Fig CJ_ODU_INV_011 6 Th...

Page 57: ...fan assembly refer to 1 Panel plate 2 Electrical parts and 3 Fan assembly before disassembling sound blanket Procedure Illustration 1 Remove the sound blanket side and top seeCJ_ODU_INV_012 Sound Blan...

Page 58: ...y refer to 1 Panel plate 2 Electrical parts and 3 Fan assembly before disassembling four way valve Procedure Illustration 1 Heat up the brazed parts and then detach the the four way valve and the pipe...

Page 59: ...2 Electrical parts and 3 Fan assembly before disassembling compressor Procedure Illustration 1 Remove the flange nut of terminal cover andremovetheterminalcover seeCJ_ ODU_INV_014 2 Disconnect the co...

Page 60: ...t up the brazed parts and then remove the the discharge pipe and the suction pipe see CJ_ODU_INV_017 5 Lift the compressor from the base pan assembly with pliers CJ_ODU_INV_016 Suction Pipe Discharge...

Page 61: ...tdoor unit communication error 73 5 4 E2 Zerocrossingdetectionerrordiagnosisandsolution 75 5 4 E3 F5 Fan speed is operating outside of the normal range diagnosis and solution 76 5 5 E4 E5 F1 F2 F3 Ope...

Page 62: ...82 5 10 P1 Over voltage or too low voltage protection diagnosis and solution 83 5 11 P2 High temperature protection of IPM module diagnosis and solution 84 5 12 P4 Invertercompressordriveerrordiagnos...

Page 63: ...a n d negative terminals of the electrolytic capacitor The terminals are located on the bottom surface of the outdoor PCB Note This picture is for reference only Actual appearances may vary Page 61 El...

Page 64: ...k detected Page 80 1 time ON F0 Overload current protection Page 81 2 times ON F1 Outdoor ambient temperature sensor T4 open circuit or short circuit Page 78 3 times ON F Condenser coil temperature se...

Page 65: ...ill not start Page 66 67 3 The temperature on the display board cannot be set Page 66 67 4 Unit is on but the wind is not cold hot Page 66 67 5 Unit runs but shortly stops Page 66 67 6 The unit startu...

Page 66: ...fan will not start Page 68 69 6 Unit runs but shortly stops Page 68 69 7 Compressor short cycles due to overload Page 68 69 8 High discharge pressure Page 68 69 9 Low discharge pressure Page 68 69 10...

Page 67: ...tor x x X x x x x x x Temperature sensor x x x x x T2 Sensor x x x x x x x x Additional refrigerant x x x x x x x x x Compressor x x x x x x x x IPM board x x x x x x x x x Outdoor unit x x x x x x x...

Page 68: ...pect connections tighten Loose connections Change the transformer Faulty transformer Test voltage The voltage is too high or too low Replacethebatteryoftheremotecontrol The remote control is powered o...

Page 69: ...nd or screws Close all the windows and doors Bad airproof Remove the obstacles The air inlet or outlet of either unit is blocked Reconnect the power or press ON OFF button on remote control to restart...

Page 70: ...ristor Inspect connections tighten Loose connections Test circuits with tester Shorted or broken wires Test continuity of safety device Safety device opens Testcontinuityofthermostat sensor wiring Fau...

Page 71: ...air or water flow High temperature condensing medium Remove obstruction in air or water flow Insufficient condensing medium Replace compressor Broken compressor internal parts Test compressor efficien...

Page 72: ...2 sensor Outdoorcoiltemp T3 sensor Outdoor ambient temp T4 sensor Compressor discharge temp Tp sensor Measure the resistance value of each winding by using the multi meter 5 1 2 Compressor checking Me...

Page 73: ...itors discharge completely and dismount the IPM Use a digital tester to measure the resistance between P and UVWN UVW andN Digital tester Normal resistance value Digital tester Normal resistance value...

Page 74: ...r PCB Troubleshooting and repair NO NO Remarks The location of the EEPROM chip on the indoor and outdoor PCB is shown in the following two images Note These images are for reference only Page 72 Is it...

Page 75: ...feedback from the outdoor unit for 110 seconds four consecutive times Recommended parts to prepare Faulty indoor PCB Faulty outdoor PCB Faulty reactor Troubleshooting and repair NO YES NO YES YES NO N...

Page 76: ...s Use a multimeter to test the resistance of the reactor which does not connect with capacitor The normal value should be around zero ohm Otherwise the reactor must have malfunction Page 74 Troublesho...

Page 77: ...eedback for 4minutes or the zero crossing signal time interval is abnormal Recommended parts to prepare Connection mistake Faulty PCB Troubleshooting and repair Page 75 Checktheconnectionsand power su...

Page 78: ...display the failure F5 Recommended parts to prepare Wiring mistake Faulty fan assembly Faulty fan motor Faulty PCB Troubleshooting and repair YES NO YES YES Page 76 Power off then restart the unit aft...

Page 79: ...DC motor voltage input and output voltage 220 240V No Color Signal Voltage 1 Red Vs Vm 280V 380V 2 3 Black GND 0V 4 White Vcc 14 17 5V 5 Yellow Vsp 0 5 6V 6 Blue FG 14 17 5V 2 Indoor AC Fan Motor Pow...

Page 80: ...94V the LED will display the failure Recommended parts to prepare Wiring mistake Faulty sensor Faulty PCB Troubleshooting and repair NO YES NO YES Page 78 Replace indoor or outdoor PCB Checktheconnect...

Page 81: ...120 seconds Recommended parts to prepare Wiring mistake Faulty PCB Display board malfunction Troubleshooting and repair Power off then restart the unit 2 minutes later Is it still displaying the error...

Page 82: ...area will show EC and AC will turn off Recommended parts to prepare Faulty T2 sensor Faulty indoor PCB System problems such as leakage or blockages Troubleshooting and repair YES NO YES NO Page 80 Che...

Page 83: ...problems System blockage Faulty PCB Wiring mistake Compressor malfunction Troubleshooting and repair NO YES NO YES NO YES NO YES NO YES Page 81 Replace the outdoor unit Isitin workingorder Do any exi...

Page 84: ...oor fan assembly Compressor malfunction Faulty outdoor PCB Troubleshooting and repair NO YES NO YES NO YES Page 82 Replace the outdoor PCB Check the wiring between PCB and compressor Does an errorexis...

Page 85: ...cuit Recommended parts to prepare Power supply issues System leakage or blockage Faulty PCB Troubleshooting and repair NO YES NO YES NO YES NO YES Page 83 Replace the reactor Check the connections and...

Page 86: ...than setting value the LED displays this failure code Recommended parts to prepare Faulty PCB Connection problems Troubleshooting and repair Check the fastening screws on the PCB and IPM radiator Are...

Page 87: ...y outdoor fan assembly Compressor malfunction Faulty outdoor PCB Troubleshooting and repair YES NO NO YES NO YES NO YES Page 85 Replace the outdoor PCB Check the wiring between the PCB and compressor...

Page 88: ...Contents i TemperatureSensor Resistance ValueTablefor T1 T2 T3 and T4 C K 87 ii Temperature Sensor Resistance Value Table for TP C K 88 iii Pressure On Service Port 89 Appendix...

Page 89: ...0 38991 2 28 39 8239 38 100 5 62961 78 172 1 25423 118 244 0 37956 1 30 37 1988 39 102 5 39689 79 174 1 2133 119 246 0 36954 0 32 35 2024 40 104 5 17519 80 176 1 17393 120 248 0 35982 1 34 33 3269 41...

Page 90: ...5 239 2 422 4 25 222 8 36 97 34 32 76 169 7 82 116 241 2 357 3 27 211 4 37 99 32 94 77 171 7 566 117 243 2 294 2 28 200 7 38 100 31 62 78 172 7 321 118 244 2 233 1 30 190 5 39 102 30 36 79 174 7 086 1...

Page 91: ...56 115 46 11 120 48 89 PSI 70 59 95 96 108 118 121 115 119 128 150 157 PSI 75 63 99 101 117 128 126 122 129 135 158 165 PSI 80 67 105 106 125 141 138 132 135 143 165 176 PSI 90 73 114 115 142 155 152...

Page 92: ...7 47 43 8 33 6 11 37 33 2 78 0 56 27 23 2 78 5 17 13 8 33 10 56 0 2 17 19 17 18 27 28 PSI 55 448 421 374 337 308 273 244 PSI 65 480 444 394 375 346 303 282 PSI 75 499 466 411 389 369 318 296 F C ODT I...

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