Kaisai KMK-60RY1 Service Manual Download Page 9

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Part 2

Component Layout and

Refrigerant Circuits

Layout of Functional Components ......................................................... 8

Piping Diagrams .................................................................................. 13

Refrigerant Flow Diagrams .................................................................. 15

202004

Midea CAC Confidential

Split

Summary of Contents for KMK-60RY1

Page 1: ...SERVICEMANUAL SPLIT TYPE HEAT PUMP R32...

Page 2: ...Split...

Page 3: ...rmal Split 202004 1 CONTENTS CONTENTS Part 1 General Information 3 Part 2 Component Layout and Refrigerant Circuits 7 Part 3 Control 17 Part 4 Diagnosis and Troubleshooting 31 Midea CAC Confidential S...

Page 4: ...M thermal Split 2 202004 Midea M thermal Split Service Manual Midea CAC Confidential Split...

Page 5: ...M thermal Split 202004 3 Part 1 General Information Part 1 General Information 1 Unit Capacities 4 2 External Appearance 5 Midea CAC Confidential Split...

Page 6: ...tes The full model names can be obtained by substituting the asterisk in the model name format given in the left hand column of the table above with the shortened model names given in the table For ex...

Page 7: ...2 External Appearance 2 1 Outdoor Unit Appearance Table 1 2 1 Outdoor unit appearance KHA 06RY1 KHA 08 10 RY1 KHA 12 14 16 RY3 2 2 Hydronic Box Appearance Table 1 2 2 Hydronic box appearance KMK 60RY1...

Page 8: ...M thermal Split 6 202004 Midea M thermal Split Service Manual Midea CAC Confidential Split...

Page 9: ...2 Component Layout and Refrigerant Circuits Part 2 Component Layout and Refrigerant Circuits 1 Layout of Functional Components 8 2 Piping Diagrams 13 3 Refrigerant Flow Diagrams 15 202004 7 Midea CAC...

Page 10: ...lit Midea M thermal Split Service Manual 1 Layout of Functional Components Layout 1 1 Outdoor Unit KHA 06RY1 Figure 2 1 1 KHA 06RY1 top view Figure 2 1 2 KHA 06RY1 front view 8 202004 Midea CAC Confid...

Page 11: ...M thermal Split Part 2 Component Layout and Refrigerant Circuits KHA 08 10 RY1 Figure 2 1 3 KHA 08 10 RY1 top view Figure 2 1 4 KHA 08 10 RY1 front view 202004 9 Midea CAC Confidential Split...

Page 12: ...Midea M thermal Split Service Manual 10 202004 Midea CAC Confidential KHA 12 14 16 RY3 Figure 2 1 7 KHA 12 14 16 RY3 top view M thermal Split Split...

Page 13: ...Part 2 Component Layout and Refrigerant Circuits Figure 2 1 8 KHA 12 14 16 RY3 front view 202004 11 Midea CAC Confidential M thermal Split Split...

Page 14: ...anual 1 2 Hydronic Box Layout Figure 2 1 9 KMK 60 100 160 RY1 3 oblique view Electric control box Expansion vessel Manometer Safety valve Air purge valve Water flow switch Water side heat exchanger Wa...

Page 15: ...trols refrigerant flow and reduces refrigerant pressure 2 Four way valve Controls refrigerant flow direction Closed in cooling mode and open in heating mode When closed the air side heat exchanger fun...

Page 16: ...s air from the water circuit 2 Safety valve Prevents excessive water pressure by opening at 43 5 psi 3 bar and discharging water from the water circuit 3 Expansion vessel Balances water system pressur...

Page 17: ...heat exchanger Distributor Water side heat exchanger 4 way valve High temperature high pressure gas High temperature high pressure liquid Low temperature low pressure Electronic expansion valve capiii...

Page 18: ...M thermal Split Midea M thermal Split Service Manual 16 202004 Midea CAC Confidential Split...

Page 19: ...ol Part 3 Control 1 Stop Operation 18 2 Standby Control 18 3 Startup Control 19 4 Normal Operation Control 22 5 Protection Control 23 6 Special Control 26 7 Role of Temperature Sensors in Control Func...

Page 20: ...o prevent refrigerant from mixing with compressor oil when the compressors are stopped The crankcase heater is controlled according to outdoor ambient temperature and the compressor on off state When...

Page 21: ...tartup follows one of two startup programs until the target rotation speed is reached Refer to Figure 3 3 1 Figure 3 3 2 Figure 3 3 1 KHA 06RY1 compressor startup program 1 when ambient temperature is...

Page 22: ...240s 36rps 90s Notes 1 Once the first 40 second stage of the program is complete the program proceeds to the subsequent stages in a step by step fashion and exits when the target rotation speed has be...

Page 23: ...motor FAN Fan run at maximum speed 2 Electronic expansion valve EXV Position steps from 0 fully closed to 480 fully open controlled according to outdoor ambient temperature discharge temperature suct...

Page 24: ...ns the appropriate compressor startup program Refer to Part 3 3 2 Compressor Startup Program Once the startup program is complete the compressor runs at the target rotation speed 4 3 Compressor Step C...

Page 25: ...ects the compressor from transient spikes in pressure Figure 3 5 1 High pressure protection control Notes 1 Pc Discharge pressure When the discharge pressure rises above 4 3MPa the system displays P1...

Page 26: ...s EA protection and the unit stops running When the discharge temperature is higher than suction temperature the compressor enters re start control 5 4 Compressor Current Protection Control This contr...

Page 27: ...re for more than 3 minutes Outdoor ambient temperature is below 4 C and actual fan speed differs from target fan speed by 300rpm or more for more than 3 minutes Actual fan speed is less than 150rpm fo...

Page 28: ...6kW Control functions and states Inverter compressor COMP Runs at oil return operation rotation speed DC fan motor FAN Controlled according to heating mode Electronic expansion valve EXV 304 steps Fou...

Page 29: ...ontrol temperature of each zone separately thus different type radiator will operate at its optimal temperature and water pump cycle time will be reduced to save energy Cooling mode In two zones contr...

Page 30: ...ot water needs at the same time Balance tank can store energy to provide hot water whilst heat pump runs heat mode cooling which can reduce the host selection and the initial investment 6 8 USB data t...

Page 31: ...7 1 Location of the temperature sensors on Split systems Notes 1 The names and functions of the temperature sensors labelled 1 to 11 in this figure are detailed in Table 3 7 1 Figure 3 7 1 Locati on o...

Page 32: ...tlet temperature sensor T3 5 Water side heat exchanger refrigerant outlet gas pipe temperature sensor T2B 6 Water side heat exchanger refrigerant outlet liquid pipe temperature sensor T2 7 Water side...

Page 33: ...thermal Split 202004 31 Part 4 Diagnosis and Troubleshooting 1 Electric Control Box Layout 32 2 PCBs 35 3 Error Code Table 49 4 Troubleshooting 51 5 Appendix to Part 4 107 Midea CAC Confidential Spli...

Page 34: ...e Manual 1 Electric Control Box Layout 1 1 Outdoor Unit Electric Control Box Layout Figure 4 1 1 KHA 06RY1 electric control box Main PCB Inverter module Figure 4 1 2 KHA 08 10 RY1 electric control box...

Page 35: ...M thermal Split 202004 33 Figure 4 1 4 KHA 12 14 16 RY3 electric control box Main PCB Inverter module Main Power Electric Reactor Filter board DCFAN Electric Reactor Midea CAC Confidential Split...

Page 36: ...M thermal Split 34 202004 Midea M thermal Split Service Manual 1 2 Hydronic Box Electric Control Box Layout Figure 4 1 5 KMK 60 100 160 RY1 3 Main control board Midea CAC Confidential Split...

Page 37: ...shown in Figures 4 1 1 to Figure 4 1 4 in Part 4 1 1 Outdoor Unit Electric Control Box Layout The locations of each PCB in the hydronic box electric control box are shown in Figures 4 1 5 in Part 4 1...

Page 38: ...stat cooling mode CL Power port for room thermostat COM 18 CN35 Port for smart grid grid signal photovoltaic signal 19 CN36 Port for remote switch temperature board 20 CN19 Communicate port between in...

Page 39: ...3 Main PCBs for Refrigerant System Inverter Module Figure 4 2 2 KHA 06 08 10 RY1 outdoor unit main PCB for refrigerant system 4 5 6 7 8 9 10 3 2 1 11 12 13 14 15 16 17 18 19 27 26 25 24 23 22 21 20 M...

Page 40: ...ort for live wire 12 CN9 Port for outdoor ambient temp sensor and condenser temp sensor 13 CN24 Input port for 12V 9V 14 CN1 Port for suction temp sensor 15 CN8 Port for discharge temp sensor 16 CN13...

Page 41: ...M thermal Split 202004 39 Midea CAC Confidential Split...

Page 42: ...M thermal Split 40 202004 Midea M thermal Split Service Manual Midea CAC Confidential Split...

Page 43: ...rmal Split 202004 41 Figure 4 2 4 KHA 12 14 16 RY3 outdoor unit main PCB for refrigerant system 1 2 3 4 5 6 7 8 30 29 9 10 11 12 13 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 Midea CAC Confidential...

Page 44: ...with main PCB for invert module board 13 CN6 Port for pressure sensor 14 CN36 Port for communication with main PCB for refrigerant system 15 CN5 Port for temp sensor Th 16 CN8 Port for temp sensor Tp...

Page 45: ...M thermal Split 202004 43 Figure 4 2 5 KHA 06 08 10 RY1 outdoor unit inverter module For 4 6kW model 1 2 3 8 7 4 5 6 9 For 8 10kW model 1 2 3 8 7 4 5 6 9 Midea CAC Confidential Split...

Page 46: ...Content 1 U Compressor connection port U 2 V Compressor connection port V 3 W Compressor connection port W 4 CN20 Output port for 12V 9V 5 CN19 Port for fan 6 CN32 Port for communication with main PC...

Page 47: ...M thermal Split 202004 45 Midea CAC Confidential 2 3 4 5 6 7 8 1 14 9 13 12 11 10 Figure 4 2 7 KHA 12 14 16 RY3 outdoor unit inverter module Split...

Page 48: ...18 Compressor connection port V 4 CN17 Compressor connection port U 5 CN15 Power Input port L3 6 CN7 Power Input port L2 7 CN5 Input port P_out for IPM module 8 CN16 Power Input port L1 9 CN1 Input po...

Page 49: ...L3 3 CN203 Power supply N 4 CN212 Power supply port of 310VDC 5 CN211 Reserved 6 CN213 Port for FAN Reactor 7 CN214 Power supply port for Inverter module 8 PE3 Ground wire 9 CN8 Port for communication...

Page 50: ...e Error or protection code 2 5 DIP switch setting and Modbus function Modbus function will be available in 2020 5 30 The rotating coded switch S3 0 F on the main control board of hydraulic module is u...

Page 51: ...rature sensor error Sensor Tw_in EE 15 Hydronic box EEPROM error F1 116 DC generatrix voltage is too low H0 39 Communication error between outdoor unit main control chip and hydronic box main control...

Page 52: ...rs from target frequency by more than 15Hz protection Pb 31 Water side heat exchanger anti freeze protection Pd 33 High temperature protection of refrigerant outlet temperature of condenser in cooling...

Page 53: ...with all applicable legislation all national local and other laws standards codes rules regulations and other legislation that apply in a given situation Power off the outdoor units before connecting...

Page 54: ...tes E8 has displayed 3 times When an E0 error occurs a manual system restart is required before the system can resume operation Split stops running Error code is displayed on hydronic box main PCB and...

Page 55: ...ase its speed No Water flow switch is damaged Yes Replace the water flow switch No Internal circulator pump can t work Yes Turn off the power check the wire in the pump Once that is done the pump stil...

Page 56: ...ion 4 3 2 Phase sequence error Only applies to 3 phase models Split stops running Error code is displayed on outdoor unit main PCB and user interface Possible causes 4 3 3 Power supply phases not conn...

Page 57: ...quence is inverted the compressor will operate inversely If the wiring connection of each outdoor unit is in A B C phase sequence and multiple units are connected the current difference between C phas...

Page 58: ...layed on hydronic box main PCB and user interface Possible causes 4 4 3 Communication wires between hydronic box and user interface not connected properly Communication wiring X Y E terminals misconne...

Page 59: ...the communication wires and high voltage wires are separated No Communication wires are close to a source of electromagnetic radiation such as transformer or strong fluorescent lamp Yes Remove the sou...

Page 60: ...error Ed indicates a water side heat exchanger water inlet temperature sensor error HA indicates a water side heat exchanger water outlet temperature sensor error H5 indicates a room temperature senso...

Page 61: ...cuit 2 water outlet temperature sensor connection is port CN15 on the hydronic box main PCB labeled 14 in Figure 4 2 1 in Part4 2 2 Main PCB for Hydronic System Room temperature sensor connection is p...

Page 62: ...ure sensor error E6 indicates an outdoor ambient temperature sensor error E9 indicates a suction pipe temperature sensor error EA indicates a discharge temperature sensor error Split stops running Err...

Page 63: ...10 RY1 outdoor unit refrigerant system main PCB labeled 15 in Figure 4 2 2 in Part 4 2 1 Main PCBs for Refrigerant System Inverter Module port CN4 on the KHA 12 14 16 RY3 outdoor unit refrigerant syst...

Page 64: ...face Possible causes 4 7 3 Hydronic box main PCB EEPROM is not connected properly Hydronic box main PCB damaged Procedure 4 7 4 EE Hydronic box main PCB EEPROM1 is not connected properly Yes Ensure th...

Page 65: ...user interface Possible causes 4 8 3 The DC generatrix voltage is too low Procedure 4 8 4 F1 Power supply is abnormal Yes Provide normal power No LED on the Inverter Modules is lighting Yes Voltage of...

Page 66: ...dule EEPROM damaged Procedure 4 9 4 HF Outdoor unit invert module EEPROM1 is not connected properly Yes Ensure the EEPROM is connected properly No Replace outdoor unit invert module Notes 1 Outdoor un...

Page 67: ...t and hydronic box Split stops running Error code is displayed on hydronic box main PCB outdoor unit main PCB and user interface Possible causes 4 10 3 Power supply abnormal Transformer malfunction In...

Page 68: ...wires P Q E between main control board of outdoor unit and hydraulic module have short circuited disconnected or misconnected Yes Reconnect the communication wires No Replace outdoor unit main PCB and...

Page 69: ...erter driven module damaged Procedure 4 11 4 H1 LED on the main control board of outdoor unit and inverter module are light Yes LED is not light the board is damaged or have short circuit No Communica...

Page 70: ...When HH error occurs a manual system restart is required before the system can resume operation The cause of HH error should be addressed promptly in order to avoid system damage Split stops running...

Page 71: ...in PCB three phase model Notes 1 Refer to Figures 4 1 1 to 4 1 4 in Part 4 1 1 Outdoor Unit Electric Control Box Layout and to the Split Engineering Data Book Part 4 Wiring Diagrams 2 Measure the volt...

Page 72: ...it stops running Error code is displayed on outdoor unit main PCB and user interface Possible causes 4 13 3 Power supply voltage not within 90 110 of rated voltage Outdoor unit main PCB is damaged Pro...

Page 73: ...h pressure sensor has short circuited or failed1 Yes Replace the sensor No Replace outdoor unit main PCB Notes 1 Measure the resistance among the three terminals of the pressure sensor If the resistan...

Page 74: ...hen the pressure rises above 0 3MPa P0 is removed and normal operation resumes HP indicates Pe 0 6Mpa occurred 3 times in an hour Error code is displayed on outdoor unit main PCB and user interface Po...

Page 75: ...for insufficient refrigerant An insufficiency of refrigerant causes compressor discharge temperature to be higher than normal discharge and suction pressures to be lower than normal and compressor cur...

Page 76: ...otection and Split stops running When the discharge pressure falls below 3 6MPa P1 is removed and normal operation resumes Error code is displayed on outdoor unit main PCB and user interface Possible...

Page 77: ...Part4 2 3 Main PCB for Refrigerant System Inverter Module port CN31 on the KHA 12 14 16 RY3 outdoor unit refrigerant system main PCB labeled 20 in Figure 4 2 4 in Part 4 2 3 Main PCB for Refrigerant...

Page 78: ...16kW single phase model 30A 12 14 16kW three phase model 14A the system displays P3 protection and Split stops running When the current returns to the normal range P3 is removed and normal operation...

Page 79: ...water flow switch for dirt blockages In cooling mode check air side heat exchanger fan and air outlets for dirt blockages 2 High pressure side blockage causes discharge temperature to be higher than...

Page 80: ...ture rises above 115 C the system displays P4 protection and Split stops running When the discharge temperature falls below 95 C P4 is removed and normal operation resumes Error code is displayed on r...

Page 81: ...onnection on outdoor unit main PCB is loose4 Yes Ensure the pressure switch is connected properly No Pressure sensor has short circuited or failed5 Yes Replace the pressure sensor No The high pressure...

Page 82: ...ayout of Functional Components and to Table 5 5 1 or 5 5 2 in Part 5 5 1 Temperature Sensor Resistance Characteristics 4 High pressure switch connection is port CN13 on the KHA 06 08 10 RY1 outdoor un...

Page 83: ...at exchanger water inlet and water outlet temperatures protection Split stops running Error code is displayed on hydronic box main PCB and user interface Possible causes 4 19 3 Temperature sensor not...

Page 84: ...x main PCB Notes 1 Water side heat exchanger water inlet temperature sensor and water side heat exchanger water outlet temperature sensor connections are port CN6 on the hydronic box main PCB labeled1...

Page 85: ...protection Excessive compressor frequency variation Actual compressor frequency differs from target frequency High pressure protection PED board self checking fail Specific error codes for inverter mo...

Page 86: ...ore than 15Hz protection Table 4 4 3 Errors indicated on LED single phase 4 10kW LED1 flashing pattern GREEN LED2 is always on RED Corresponding error Flashes 3 times and stops for 1 second then repea...

Page 87: ...maged1 Yes Replace the inverter module2 Notes 1 Measure the resistance between each of U V and W and each of P and N on the inverter module All the resistances should be infinite If any of them are no...

Page 88: ...2 Measure the resistance between each of U V and W and each of P and N on the inverter module All the resistances should be infinite If any of them are not infinite the inverter module is damaged and...

Page 89: ...place the inverter module3 Notes 1 Refer to Figure 4 4 2 2 Use clip on ammeter to measure the compressor current if the current is normal indicates the inverter module is failed if the current is abno...

Page 90: ...1 L1 or L2 error appears immediately after the outdoor unit is powered on L1 L2 Power supply is abnormal Yes Re start the unit once the power supply has returned to normal No Replace the inverter mod...

Page 91: ...gure 4 4 2 Figure 4 4 4 Relay location of main PCB for refrigerant system Single phase 4 6 8 10kW unit Single phase 12 14 16kW unit Relay L5 L8 L9 troubleshooting 4 20 8 L5 L8 L9 The wire is not conne...

Page 92: ...ection Zero speed protection Excessive compressor frequency variation Actual compressor frequency differs from target frequency High pressure protection Contactor stuck or 908 self checking fail Speci...

Page 93: ...17 times and stops for 1 second then repeats L8 Compressor frequency variation greater than 15Hz within one second protection L9 Actual compressor frequency differs from target frequency by more than...

Page 94: ...the communication port between refrigerant system main control board for refrigerant system inverter module is port CN36 on refrigerant system main control board for refrigerant system port CN8 on inv...

Page 95: ...rom the N terminal on the inverter module through the current sensor in the direction indicated by the arrow on the current sensor and end at the N terminal of capacitor Refer to Figure 4 4 7 Figure 4...

Page 96: ...Connect the U V W wire from the inverter module to the correct compressor terminals as indicated by the labels on the compressor 2 Measure the voltage between each of W W V V U U and GND when the uni...

Page 97: ...mpressor No Replace the inverter module2 Notes 1 When replacing an inverter module a layer of thermally conductive silica gel should be painted on the IPM module on the reverse side of the inverter mo...

Page 98: ...ly after the outdoor unit is powered on L1 L2 P N 15V wire on refrigerant system main PCB is not connected properly1 Yes Ensure P N 15V wire is connected properly No Voltage between N and 15 is abnorm...

Page 99: ...on the DC power output negative terminal terminal 5 and put the black probe onto each of the AC power input terminals terminals 1 2 and 3 in turn The voltage between terminal 5 and each of terminals...

Page 100: ...rps L4 Compressor is over current2 Yes Replace the compressor No Replace the inverter PCB Notes 1 Re start the unit use clip on ammeter to measure the compressor current if the current is normal indic...

Page 101: ...han 3 seconds the system displays Pd protection and Split stops running When the air side heat exchanger refrigerant outlet temperature returns drops below 55 C Pd is removed and normal operation resu...

Page 102: ...mbient temperature sensor connection port are CN9 on the KHA 06 08 10 RY1 outdoor unit refrigerant system main PCB labeled 12 in Figure 4 2 2 in Part4 2 3 Main PCB for Refrigerant System Inverter Modu...

Page 103: ...gher than outlet temperature in heating mode Split stops running Error code is displayed on hydronic box main PCB and user interface Hb indicates PP has displayed 3 times Possible causes 4 23 3 Temper...

Page 104: ...rature sensor and water side heat exchanger water outlet temperature sensor connections are port CN6 on the hydronic box main PCB labeled 10 in Figure 4 2 1 in Part4 2 2 Main PCB for Hydronic System 2...

Page 105: ...Error code is displayed on hydronic box main PCB and user interface Possible causes 4 24 3 Power supply voltage of the unit is low The space between the units is too narrow for heat exchanger Heat ex...

Page 106: ...ump head is not enough Release the air and reselect the pump No Water outlet temp sensor1 is loosen or broken Yes Reconnect it or change a new one Notes 1 Water side heat exchanger water inlet tempera...

Page 107: ...al display output 4 25 1 Description 4 25 2 PED PCB failure Split stops running Error code is displayed on hydronic box main PCB and user interface Possible causes 4 25 3 Power supply problem PED boar...

Page 108: ...erve whether it can be recovered Yes Increase the power voltage to the required range No PED1 board broken Yes Replace PED PCB and power on again No IPM module broken Yes Replace IPM module and power...

Page 109: ...water temperature sensor loose2 Yes Ensure the temperature sensor is connected properly No Water side heat exchanger water outlet temperature sensor water inlet temperature sensor or backup electric...

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