Kaysun KAM2-42 DN5 Service Manual Download Page 2

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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. Troubleshooting .................................................................................. 35

Summary of Contents for KAM2-42 DN5

Page 1: ...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: ...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...

Page 3: ...sor 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...

Page 4: ...valves and prevents water from dripping 4 way valve control It is only operated in the heating operation mode except defrosting operation Outdoor unit Power relay control Hydrophilic aluminum fin Ant...

Page 5: ...4 3 Dimensions KAM2 42 DN5 KAM2 52 DN5 560 W1 H 6 D1 335 D2 360 845 W 313 D3 335 D1 R6 R5 A1 22 A2 50 B1 120 110 B2 700 W2 73 58 58 58 110 H1 H2 200 7 243 6 L1 L2...

Page 6: ...5 KAM3 62 DN5 560 W1 H 6 D1 335 D2 360 845 W 313 D3 335 D1 R6 R5 A1 22 A2 50 B1 120 110 B2 700 W2 73 58 58 58 58 58 110 H1 H2 200 7 243 6 L1 L2...

Page 7: ...6 KAM3 80 DN5 900 W 590 W1 860 H 12 D2 355 D1 333 302 D3 333 D1 50 97 90 B2 B1 8 A2 55 55 55 55 55 110 62 W2 H1 H2 R6 238 4 285 7 L1 L2...

Page 8: ...7 KAM4 80 DN5 900 W 590 W1 860 H 12 D2 355 D1 333 302 D3 333 D1 50 97 90 B2 B1 8 A2 55 55 55 55 55 55 55 110 62 W2 H1 H2 R6 238 4 285 7 L1 L2...

Page 9: ...8 KAM4 105 DN5 624 W1 990 W D2 397 D1 366 965 10 H 78 W2 340 366 D3 D1 125 145 B1 B2 60 22 A2 A1 55 140 H1 H2 R5 R6...

Page 10: ...9 KAM5 105 DN5 KAM5 120 DN5 990 W W2 81 624 W1 D2 397 D1 366 55 H1 965 H 153 H2 366 D1 B2 125 B1 145 D3 345 60 22 A2 A1 R5 R6...

Page 11: ...10 4 Wiring Diagram KAM2 42 DN5 KAM2 52 DN5...

Page 12: ...11 KAM3 80 DN5 KAM3 62 DN5 KAM4 80 DN5...

Page 13: ...12 KAM4 105 DN5 KAM5 105 DN5 KAM5 120 DN5...

Page 14: ...PILIARY B LIQUID VALVE B GAS VALVE B Accumulator T2B A Evaporator temp sensor outlet T2B B 5 2 Refrigeration circuit drawing of inverter 1 drive 3 type LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORA...

Page 15: ...switch Low pressure switch T2B A Evaporator temp sensor outlet T2B B T2B C T2B D 5 4 Refrigeration circuit drawing of KAM5 105 DN5 LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CO...

Page 16: ...T3 Condenser temp sensor T4 Ambient temp sensor INDOOR OUTDOOR EXV A CAPILIARY A CHECK VALVE CAPILIARY TUBE EXV B CAPILIARY B LIQUID VALVE B GAS VALVE B EXV C CAPILIARY C LIQUID VALVE C GAS VALVE C E...

Page 17: ...18 7 18 12 12 6 3 Indoor unit combination for KAM3 62 DN5 One unit Two unit Three unit 7 7 7 9 9 7 7 7 7 9 12 9 7 9 9 12 7 7 9 9 9 9 12 7 12 9 18 7 7 12 9 9 12 18 7 18 12 12 7 9 9 6 4 Indoor unit comb...

Page 18: ...2 18 9 9 12 18 Five Unit One unit Two unit Three unit Four unit 7 7 7 9 9 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 7 9 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...

Page 19: ...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...

Page 20: ...current indicated on the nameplate which located on the side panel of the unit Please refer to the nameplate before selecting the cable fuse and switch 7 3 Pipe length and the elevation Maximum pipin...

Page 21: ...9 52 3 8 7 4 Installation for the first time Air and moisture in the refrigerant system have undesirable effects as below Pressure in the system rises Operating current rises Cooling or heating effici...

Page 22: ...lease check if there are some leakage points Fully close the handle Lo valve of the manifold valve and stop the operation of the vacuum pump Confirm that the gauge needle does not move approximately 5...

Page 23: ...te repeat 3 times After purging the air use a torque wrench to tighten the flare nut on the 2 way valve 4 Check the gas leakage Check the flare connections for gas leakage 5 Discharge the refrigerant...

Page 24: ...bottom of the cylinder and press the check valve on the charge set to purge the air be careful of the liquid refrigerant 3 Put the charging cylinder onto the electronic scale and record the weight 4 O...

Page 25: ...inder onto the electronic scale and record the weight 4 Operate the air conditioner at the cooling mode 5 Open the valves Low side on the charge set and charge the system with liquid refrigerant 6 Whe...

Page 26: ...he manifold valve slightly to purge air from the charge hose for 5 seconds and then close it quickly 4 Set the 2 way valve to the close position 5 Operate the air conditioner at the cooling cycle and...

Page 27: ...or 1 minute repeat 3 times After purging the air use a torque wrench to tighten the flare nut on the 2 way valve 4 Check the gas leakage Check the flare connections for gas leakage 5 Discharge the ref...

Page 28: ...at 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 Evacuation for approximately one hour Confirm that the compound meter indica...

Page 29: ...ow side on the charge set and charge the system with liquid refrigerant If the system cannot be charge with the specified amount of refrigerant or can be charged with a little at a time approximately...

Page 30: ...the LED displays In compressor operation the LED display the running frequency In defrosting mode The LED displays dF or alternative displays between running frequency and dF each displays 0 5s In com...

Page 31: ...r unit evaporator outlet temp T2BA If the temp is lower than 9 degree the digital display tube will show 9 If the temp is higher than 70 degree the digital display tube will show 70 If the indoor unit...

Page 32: ...rrent Bit6 Frequency limit caused by PFC Bit5 Frequency limit caused by T4 Bit4 Frequency limit caused by T2 Bit3 Frequency limit caused by T3 Bit2 Frequency limit caused by T5 Bit1 Frequency limit ca...

Page 33: ...s 4 0 a 3 1 1 3 1 2 0 b c d e f 2 Capacity area a b c d e f Norm value N 3 2 1 5 1 0 5 0 8 4 4 Number of indoor unit Display Number of indoor unit 1 1 2 2 3 3 4 4 5 5 8 4 5 Opening degree of electroni...

Page 34: ...s the compressor frequency will be limited as below table Cooling mode Current frequency Hz Current limit value A Frequency limit COOL_F16 ICOOLLMT12 Decrease the frequency to COOL_F4 and run at COOL_...

Page 35: ...6 High condenser coil temp protection When T3 65 for 3 seconds the compressor will stop while the indoor fan and outdoor fan will continue When T3 52 the protection will release and the compressor wi...

Page 36: ...on P5 6 Mode conflict P6 7 Low pressure protection Just matching with KAM4 105 DN5 KAM4 80 DN5 KAM5 105 DN5 KAM5 120 DN5 O light X off flash Other series Except Console NO MALFUNCTION RUN Timer DEF Al...

Page 37: ...ween indoor and outdoor units X X 4 Outdoor fan speed has been out of control X O 5 Indoor EEPROM malfunction X 6 IPM module protection X 7 Open or short circuit of T3 or T4 temperature sensor or Outd...

Page 38: ...F3 No C Indoor unit coil outlet temperature sensor or connector of sensor is defective F4 No D Indoor unit coil outlet temperature sensor or connector of sensor is defective F5 No E Indoor unit coil o...

Page 39: ...tion If the EEPROM chip is welded on PCB replace the PCB directly Otherwise check whether the EEPROM chip plugged in PCB well Yes No Yes Insert the EEPROM well Replace the indoor PCB Shut off the powe...

Page 40: ...n on all indoor unit by remote controller Is all indoor unit display Turn off the all indoor units Is IPM power LED or operating LED lamp On Refer PIC2 Yes A Is all the wiring between terminal and Ind...

Page 41: ...2 IPM For dual tri zone Self Check Power Operating Self Check Operating els Pic 2 IPM For qua zone Pic 1 check the voltage of N to S Vs is it moving alternately between positive value and negative va...

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: ...tions No Yes Check whether the main PCB is normal through index 2 Yes Yes Check whether the fan motor is normal through index 1 Yes Replace the fan motor Replace the main PCB The malfunction is solved...

Page 44: ...5 Yellow 6 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 If the value of the vol...

Page 45: ...tor 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 For other models For console 5 4 6 3 2 1 DC motor voltage input...

Page 46: ...or Signal Voltage 1 Red Vs Vm 192V 380V 2 3 Black GND 0V 4 White Vcc 13 5 16 5V 5 Yellow Vsp 0 6 5V 6 Blue FG 15V For console 5 4 6 3 2 1 NO Color Signal Voltage 1 Red VDC 310V 2 3 White Vcc 15V 4 Blu...

Page 47: ...or PCB Replace the sensor Check the resistance value of the sensor via Appendix 1 Is it normal No 9 3 1 6 Full water malfunction If the water level switch is inserted well No Insert the water level sw...

Page 48: ...r EEPROM malfunction ODU E0 If the EEPROM chip is welded on PCB replace the PCB directly Otherwise check whether the EEPROM chip plugged in PCB well Yes No Yes Insert the EEPROM well Replace the outdo...

Page 49: ...he IPM board light Check the signal wire between the IPM module and the main board is it connected good Reconnect and retry Is error still display Replace IPM board and then check whether the system c...

Page 50: ...0VAC Check the power supply Check whether the voltage of IPM board P and N is normal DC277 356V for 18 27KBtu h DC277 410V for 36 42KBtu h Replace bridge rectifiers and then check whether the system c...

Page 51: ...the wires of fan motor Are all the connections good No Yes No Correct the connections No Yes Check whether the main PCB is normal through index 2 Yes Yes Check whether the fan motor is normal through...

Page 52: ...sure 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 For other model...

Page 53: ...ce high pressure protector Yes Judge 2 Whether the high pressure protector is broken Check whether the refrigerant system is ok Judge 3 Check whether the outdoor ambient temperature is higher than 50...

Page 54: ...stem is ok Judge 3 Check whether the outdoor ambient temperature is too low No Stop the unit Yes Method Connect the pressure gauge to the gauge joint of the system check whether the pressure is lower...

Page 55: ...or unit ventilate well Yes Judge 5 The refrigerant pipe is blocked No Let the refrigerant out then use the high pressure nitrogen or refrigerant to blow pipe vacuumize and charge the refrigerant again...

Page 56: ...d PCB according to wiring diagrams Method Check whether the resistance of compressor discharge temp sensor is right refer to the Appendix 2 No Yes Yes Trouble is solved No Judge The discharge temp sen...

Page 57: ...ck whether the outdoor ambient temperature is higher than 50 No Judge 3 The refrigerant pipe is blocked Let the refrigerant out then use the high pressure nitrogen or refrigerant to blow pipe vacuumiz...

Page 58: ...the compressor check whether the system can work normally Check whether the lines in E part box are connected tightly Yes Connect it tightly check ok or not No No Yes No Replace the bridge rectifiers...

Page 59: ...motor WZDK27 38GS WZDK27 38GS WZDK27 38GS YSK68 4P Model 7K Cassette 9K Cassette 12K Cassette 18K Cassette Indoor fan motor WZDK37 38G WZDK37 38G WZDK37 38G YDK37 4P Model 9K Console 12K Console 18K C...

Page 60: ...easure 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 sen...

Page 61: ...34105 116 0 40060 3 41 5878 37 5 87359 77 1 29078 117 0 38991 2 39 8239 38 5 62961 78 1 25423 118 0 37956 1 37 1988 39 5 39689 79 1 21330 119 0 36954 0 35 2024 40 5 17519 80 1 17393 120 0 35982 1 33 3...

Page 62: ...5 234 9 35 35 78 75 8 084 115 2 422 4 222 8 36 34 32 76 7 82 116 2 357 3 211 4 37 32 94 77 7 566 117 2 294 2 200 7 38 31 62 78 7 321 118 2 233 1 190 5 39 30 36 79 7 086 119 2 174 0 180 9 40 29 15 80...

Page 63: ...ure 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 Red 1 77 20 0 95 20 0 55 2...

Page 64: ...W Red 4 Indoor AC Fan Motor Measure the resistance value of each winding by using the tester Posi tion Resistance Value RPG20D Weilng RPG28D T ongDe RPG28D Dayang RPG20E T ongDe RPG20E Weilng RPG13H W...

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