Airwell KXL DCI Series User manual

KXL DCI Series
Indoor Units Outdoor Units
KXL 24DCI GC 24 DCI
KXL 30 DCI GC 30 DCI
REFRIGERANT
R410A
HEATPUMP
REV: 0 March 2006

TABLE OF CONTENTS
Service Manual - KXL DCI Revision 0
i
Table of Contents
1. INTRODUCTION............................................................................................................................. 1
2. PRODUCT DATA SHEET............................................................................................................... 1
3. RATING CONDITIONS ................................................................................................................... 3-1
4. OUTLINE DIMENSIONS................................................................................................................. 4-1
5. PERFORMANCE DATA ................................................................................................................. 5-1
6. OPERATING CURVES ................................................................................................................... 6-1
7. SOUND LEVEL CHARACTERISTICS ........................................................................................... 7-1
8. ELECTRICAL DATA....................................................................................................................... 8-1
9. WIRING DIAGRAMS ...................................................................................................................... 9-1
10. REFRIGERATION DIAGRAMS ...................................................................................................... 10-3
11. TUBING CONNECTIONS ............................................................................................................... 11-1
12. CONTROL SYSTEM....................................................................................................................... 12-1
13. TROUBLESHOOTING.................................................................................................................... 13-18
14. EXPLODED VIEWS AND SPARE PART LISTS............................................................................ 13-28

INTRODUCTION
Service Manual - KXL DCI Revision 0
1-1
1. INTRODUCTION
1.1 General
The new KXL DCI split cassette range comprise the following RC(heat pump) models:
•KXL 24 DCI
•KXL 30 DCI
The New DCI KN units can be easily fitted to residential and commercial applications
featuring esthetic design, compact dimensions, and low noise operation.
1.2 Main Features
The DCI KN series benefits from the most advanced technological innovations,
namely:
•DC inverter technolegy
•R410a
•High COP
•Lego Concept
•Pre-Charged units up to the max’ allowing tubing distance
•Networking system connectivity
•A dry contract for presence detector or power shedding functions(configurable)
•Cooling operation at outdoor temprature down to -10°C
•Heating operation at outdoor temprature down to -15°C
•Supports Indoor Air Quality features, such as – Ionizer, Active Electro-Static
Filter
•Indoor large diameter cross flow fan, allowing low noise level operation
•Bended indoor coil with treated aluminum fins and coating for improved
efficiency
•Easy access to the interconnecting tubing and wiring connections, so that
removing the front grill or casing is not necessary
•Refrigerant pipes can be connected to the indoor unit from 6 different optional
directions
•Water condensate tray is equipped with two optional drain connections
•Automatic treated air sweep.
•Low indoor and outdoor noise levels.
•Easy installation and service.
1.3 Control
The microprocessor indoor controller, and an infrared remote control, supplied as
standard, provide complete operating function and programming.
Remote controlers:RC-3/4,µBMS
Networking system Airconet version 4.2 and up MIU SW version H8 and up.
For further details please refer to the Operation Manual, Appendix A.

INTRODUCTION
Revision 0 Service Manual – KXL DCI
1-2
1.4 Outdoor Unit
DCI outdoor units can be installed as floor or wall mounted units by using a wall
supporting bracket. The metal sheets are protected by anti- corrosion paint work allowing
long life resistance. All outdoor units are pre-charged. For further information please refer
to the Product Data Sheet, Chapter 2.
·DCI 24
·DCI 30
Outdoor Unit Feature
Feature DCI 24,30
Display 4 LED’s
Outdoor Fan Variable speed DC
Inverter
M2L cable Port No
1.5 Tubing Connections
Flare type interconnecting tubing to be produced on site.
For further details please refer to the Installation Manual,
1.6 Inbox Documentation
Each unit is supplied with its own installation and operation manuals.

RATING CONDITIONS
Service Manual –KXL DCI Revision 0 2-1
2. PRODUCT DATA SHEET
2.1 KXL 24 DCI
Model Indoor Unit KXL 24 DCI
Model Outdoor Unit GC 24 DCI
Installation Method of Pipe Flared
Characteristics Units Cooling Heating
Btu/hr 24550(5110~27280) 27280(5110~30000)
Capacity (4) kW 7.2(1.5-8.0) 8.0(1.5~8.8)
Power input (4) kW 2.39(0.5-3.2) 2.22(0.5~3.1)
EER (Cooling) or COP(Heating) (4) W/W 3.01 3.63
Energy efficiency class B A
Power supply V/Ph/Hz 220-240V/Single/50Hz
Rated current A 10.4 9.7
Starting current A 15
Circuit breaker rating A 20
Fan type & quantity Centrifugal x 1
Fan speeds H/M/L RPM 740/700/620 740/700/620
Air flow (1) H/M/L m3/hr 1230/1120/980 1300/1200/1050
External static
pressure Min-Max Pa 0
Sound power level
(2) H/M/L dB(A) 61/59/56
Sound pressure
level(3) H/M/L dB(A) 52/50/47
Moisture removal l/hr 2.5
Condenstate drain tube I.D mm 16
Dimensions WxHxD mm 840*840*230
Weight kg 36
Package dimensions WxHxD mm 1011*931*263
Packaged weight kg 40
Units per pallet units 6
INDOOR
Stacking height units 6 levels
Refrigerant control EEV
Compressor type,model Two Rotary,Mitsubishi TNB220F
Fan type & quantity Propeller(direct) x 1
Fan speeds H/L RPM 850
Air flow H/L m3/hr 3600
Sound power level H/L dB(A) 66
Sound pressure
level(3) H/L dB(A) 56
Dimensions WxHxD mm 950x412x835
Weight kg 65.5
Package dimensions WxHxD mm 1080x477x910
Packaged weight kg 73
Units per pallet Units 2
Stacking height units 2 levels
Refrigerant type R410A
Refrigerant chargless distance kg/m 2.45kg/7.5m
Additional charge per 1 meter g/m No Need
Liquid line In.(mm) 3/8"(9.53)
Suction line In.(mm) 5/8"(15.88)
Max.tubing length m. Max.30
OUTDOOR
Connections
between units Max.height
difference m. Max.15
(1) Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
(2) Airflow in ducted units; at nominal external static pressure.
(3) Sound power in ducted units is measured at air discharge.
(4) Sound pressure level measured at 1 meter distance from unit.

RATING CONDITIONS
Revision 0 Service Manual – KXL DCI
2-2
2.2 KXL 30 DCI
Model Indoor Unit KXL 30 DCI
Model Outdoor Unit GC 30 DCI
Installation Method of Pipe Flared
Characteristics Units Cooling Heating
Btu/hr 27280(6800~30000) 30690(5110~34100)
Capacity (4) kW 8.0(2.0-8.8) 9.0(1.5~10.0)
Power input (4) kW 2.65(0.5-3.2) 2.60(0.5~3.1)
EER (Cooling) or COP(Heating) (4) W/W 3.01 3.46
Energy efficiency class B B
Power supply V/Ph/Hz 220-240V/Single/50Hz
Rated current A 11.5 11.3
Starting current A 15
Circuit breaker rating A 20
Fan type & quantity Centrifugal x 1
Fan speeds H/M/L RPM 580/540/500 580/540/500
Air flow (1) H/M/L m3/hr 1200/1100/1000 1270/1170/1070
External static
pressure Min-Max Pa 0
Sound power level
(2) H/M/L dB(A) 53/51/49
Sound pressure
level(3) H/M/L dB(A) 46/44/42
Moisture removal l/hr 3
Condenstate drain tube I.D mm 16
Dimensions WxHxD mm 840*840*300
Weight kg 48
Package dimensions WxHxD mm 1011*931*333
Packaged weight kg 54
Units per pallet units 5
INDOOR
Stacking height units 5 levels
Refrigerant control EEV
Compressor type,model Two Rotary,Mitsubishi TNB220F
Fan type & quantity Propeller(direct) x 1
Fan speeds H/L RPM 850
Air flow H/L m3/hr 3600
Sound power level H/L dB(A) 66
Sound pressure
level(3) H/L dB(A) 56
Dimensions WxHxD mm 950x412x835
Weight kg 66
Package dimensions WxHxD mm 1080x477x910
Packaged weight kg 73.5
Units per pallet Units 2
Stacking height units 2 levels
Refrigerant type R410A
Refrigerant chargless distance kg/m 2.75kg/7.5m
Additional charge per 1 meter g/m No Need
Liquid line In.(mm) 3/8"(9.53)
Suction line In.(mm) 5/8"(15.88)
Max.tubing length m. Max.30
OUTDOOR
Connections
between units
Max.height
difference m. Max.15
(1) Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
(2) Airflow in ducted units; at nominal external static pressure.
(3) Sound power in ducted units is measured at air discharge.
(4) Sound pressure level measured at 1 meter distance from unit.

INTRODUCTION
Service Manual - KXL DCI Revision 0
3-3
3. RATING CONDITIONS
Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
Cooling:
Indoor: 27oC DB 19oC WB
Outdoor: 35 oC DB
Heating:
Indoor: 20oC DB
Outdoor: 7oC DB 6oC WB
3.1 Operating Limits
Indoor Outdoor
Upper limit 32oC DB 23oC WB 46oC DB
Cooling Lower limit 21oC DB 15oC WB -10oC DB
Upper limit 27oC DB 24oC DB 18oC WB
Heating Lower limit 10oC DB -15oC DB -16oC WB
1PH 198 – 264 V
Voltage 3PH N/A

OUTLINE DIMENTIONS
Service Manual –KXL DCI Revision 0 4-1
4. OUTLINE DIMENSIONS
4.1 Indoor unit
KXL 24 DCI: B=240mm
KXL 30 DCI: B=310mm

OUTLINE DIMENTIONS
Revision 0 Service Manual – KXL DCI
4-2
Outdoor Unit
4.1.1 GC 24, 30 DCI
•

PERFORMANCE DATA
Service Manual –KXL DCI Revision 0 5-1
5. PERFORMANCE DATA
5.1 KXL 24 DCI
5.1.1 Cooling Capacity (kW)-Run Mode
ID COIL ENTERING AIR DB/WB TEMPERATURE [C0]
OD COIL
ENTERING AIR DB
TEMPERATURE
[C0] DATA 22/15 24/17 27/19 29/21 32/23
TC 80 - 110 % of nominal
SC 80 - 105 % of nominal
-10 - 20
(protection range) PI 25 - 50 % of nominal
TC 7.09 7.51 7.93 8.34 8.76
SC 6.09 6.19 6.28 6.37 6.46
25
PI 1.81 1.85 1.89 1.93 1.97
TC 6.73 7.15 7.56 7.98 8.40
SC 5.86 5.95 6.04 6.13 6.22
30
PI 2.06 2.10 2.14 2.18 2.22
TC 6.36 6.78 7.20 7.62 8.04
SC 5.62 5.71 5.80 5.89 5.98
35
PI 2.31 2.35 2.39 2.43 2.47
TC 6.00 6.42 6.84 7.25 7.67
SC 5.38 5.47 5.56 5.65 5.74
40
PI 2.56 2.60 2.64 2.68 2.72
TC 5.56 5.98 6.40 6.82 7.24
SC 5.10 5.19 5.28 5.37 5.46
46
PI 2.86 2.90 2.94 2.98 3.02
LEGEND
TC – Total Cooling Capacity, kW
SC – Sensible Capacity, kW
PI – Power Input, kW
WB – Wet Bulb Temp., (oC)
DB – Dry Bulb Temp., (oC)
ID – Indoor
OU – Outdoor
5.1.2 Capacity Correction Factors

PERFORMANCE DATA
5-2 Revision 0 Service Manual - KXL DCI
Cooling Capacity Ratio Vs. Outdoor Temperature
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
20 25 30 35 40 45
Outdoor Temperature [deg C]
Capacity Ration

PRESSURE CURVES
Service Manual - KXL DCI 5-3
5.1.3 Heating Capacity (kW)-Run Mode
ID COIL ENTERING AIR DB TEMPERATURE [C0]
OD COIL
ENTERING AIR
DB/WB
TEMPERATURE
[C0] DATA 15 20 25
TC 3.64 3.12 2.59
-15/-16 PI 1.55 1.66 1.77
TC 4.81 4.28 3.76
-10/-12 PI 1.75 1.87 1.98
TC 5.68 5.16 4.63
-7/-8 PI 1.91 2.02 2.13
TC 6.12 5.59 5.07
-1/-2 PI 1.98 2.09 2.20
TC 6.41 5.88 5.36
2/1 PI 2.03 2.14 2.26
TC 8.52 8.00 7.48
7/6 PI 2.11 2.22 2.33
TC 8.97 8.44 7.92
10/9 PI 2.15 2.26 2.37
TC 9.41 8.88 8.36
15/12 PI 2.19 2.30 2.41
15-24 TC 85 - 105 % of nominal
(Protection Range) PI 80 - 120 % of nominal
LEGEND
TH – Total Heating Capacity, kW
PI – Power Input, kW
WB – Wet Bulb Temp., (oC)
DB – Dry Bulb Temp., (oC)
ID – Indoor
OU – Outdoor
5.1.4 Capacity Correction Factors

PERFORMANCE DATA
5-4 Revision 0 Service Manual - KXL DCI
Heating Capacity Ratio Vs. Outdoor Temperature
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
-15 -10 -5 0 5 10 15
Outdoor WB Temperature [deg C]
Capacity Ration
5.1.5 Capacity Correction Factor Due to Tubing Length
Cooling mode
0,86
0,88
0,9
0,92
0,94
0,96
0,98
1
1,02
4 6 8 10 12 14 16 18 20 22 24 26 28 30
Tubing length(m)
Capacity ratio
Heating mode
0. 84
0. 86
0. 88
0. 9
0. 92
0. 94
0. 96
0. 98
1
1. 02
4 6 8 1012141618202224262830
Tubi ng Lengt h( m)
Capaci t y r at i o

PRESSURE CURVES
Service Manual - KXL DCI 5-5
5.2 KXL 30 DCI
5.2.1 Cooling Capacity (kW)-Run Mode
ID COIL ENTERING AIR DB/WB TEMPERATURE [C0]
OD COIL
ENTERING AIR DB
TEMPERATURE
[C0] DATA 22/15 24/17 27/19 29/21 32/23
TC 80 - 110 % of nominal
SC 80 - 105 % of nominal
-10 - 20
(protection range) PI 25 - 50 % of nominal
TC 7.88 8.34 8.81 9.27 9.74
SC 6.41 6.51 6.60 6.70 6.79
25
PI 2.00 2.05 2.09 2.14 2.18
TC 7.48 7.94 8.40 8.87 9.33
SC 6.16 6.25 6.35 6.45 6.54
30
PI 2.28 2.33 2.37 2.42 2.46
TC 7.07 7.54 8.00 8.46 8.93
SC 5.91 6.00 6.10 6.20 6.29
35
PI 2.56 2.60 2.65 2.70 2.74
TC 6.67 7.13 7.60 8.06 8.52
SC 5.66 5.75 5.85 5.95 6.04
40
PI 2.84 2.88 2.93 2.97 3.02
TC 6.18 6.65 7.11 7.58 8.04
SC 5.36 5.45 5.55 5.64 5.74
46
PI 3.17 3.22 3.26 3.31 3.35
5.2.2 Capacity Correction Factors
Cooling Capacity Ratio Vs. Outdoor Temperature
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
20 25 30 35 40 45
Outdoor Temperature [deg C]
Capacity Ration

PERFORMANCE DATA
5-6 Revision 0 Service Manual - KXL DCI
5.2.3 Heating Capacity (kW)-Run Mode
ID COIL ENTERING AIR DB TEMPERATURE [C0]
OD COIL
ENTERING AIR
DB/WB
TEMPERATURE
[C0] DATA 15 20 25
TC 4.10 3.51 2.92
-15/-16 PI 1.82 1.95 2.08
TC 5.41 4.82 4.23
-10/-12 PI 2.06 2.19 2.32
TC 6.39 5.80 5.21
-7/-8 PI 2.23 2.36 2.49
TC 6.88 6.29 5.70
-1/-2 PI 2.32 2.45 2.58
TC 7.21 6.62 6.03
2/1 PI 2.38 2.51 2.64
TC 9.59 9.00 8.41
7/6 PI 2.47 2.60 2.73
TC 10.09 9.50 8.91
10/9 PI 2.52 2.65 2.78
TC 10.58 9.99 9.40
15/12 PI 2.57 2.70 2.83
15-24 TC 85 - 105 % of nominal
(Protection Range) PI 80 - 120 % of nominal
5.2.4 Capacity Correction Factors
Heating Capacity Ratio Vs. Outdoor Temperature
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
-15 -10 -5 0 5 10 15
Outdoor WB Temperature [deg C]
Capacity Ration

PRESSURE CURVES
Service Manual - KXL DCI 5-7
5.2.5 Capacity Correction Factor Due to Tubing Length
Cooling mode
0. 86
0. 88
0. 9
0. 92
0. 94
0. 96
0. 98
1
1. 02
4 6 8 1012141618202224262830
Tubing length(m)
Capacity ratio
Heating mode
0. 84
0. 86
0. 88
0. 9
0. 92
0. 94
0. 96
0. 98
1
1. 02
4 6 8 1012141618202224262830
Tubi ng Lengt h( m)
Capaci t y r at i o

PRESSURE CURVES
Service Manual –KXL DCI Revision 0 6-1
6. OPERATING CURVES
6.1 Model: KXL 24 DCI
6.1.1 Cooling –Test Mode
700
800
900
1000
1100
1200
10 15 20 25 30 35 40 45
Outdoor DB Temperature
Suction Pressure [kPa]
22/15
24/17
27/19
29/21
32/23
Indoor
DB/WB
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
10 15 20 25 30 35 40 45
Outdoor DB Temperature
Discharge Pressure [kPa]
22/15
24/17
27/19
29/21
32/23
Indoor
DB/WB
5.00
7.00
9.00
11.00
13.00
10 15 20 25 30 35 40 45
Outdoor DB Temperature
Input Current [A]
22/15
24/17
27/19
29/21
32/23

PRESSURE CURVES
6-2 Revision 0 Service Manual - KXL DCI
6.1.2 Heating –Test Mode
300
400
500
600
700
800
900
1000
1100
1200
1300
-15 -10 -5 0 5 10 15
Outdoor WB Temperature
Suction Pressure [kPa]
15
20
25
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
-15 -10 -5 0 5 10 15
Outdoor WB Temperature
Discharge Pressure [kPa]
15
20
25
Indoo
r
6.50
8.50
10.50
12.50
-15 -10 -5 0 5 10 15
Outdoor WB Temperature
Input Current [A]
15
20
25
Indoo
r

PRESSURE CURVES
Service Manual - KXL DCI 6-3
6.2 Model: KXL 30 DCI
6.2.1 Cooling –Test Mode
700
800
900
1000
1100
1200
10 15 20 25 30 35 40 45
Outdoor DB Temperature
Suction Pressure [kPa]
22/15
24/17
27/19
29/21
32/23
Indoor
DB/WB
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
10 15 20 25 30 35 40 45
Outdoor DB Temperature
Discharge Pressure [kPa]
22/15
24/17
27/19
29/21
32/23
Indoor
DB/WB
4.00
6.00
8.00
10.00
12.00
14.00
16.00
10 15 20 25 30 35 40 45
Outdoor DB Temperature
Input Current [A]
22/15
24/17
27/19
29/21
32/23

PRESSURE CURVES
6-4 Revision 0 Service Manual - KXL DCI
6.2.2 Heating –Test Mode
300
400
500
600
700
800
900
1000
1100
1200
-15 -10 -5 0 5 10 15
Outdoor WB Temperature
Suction Pressure [kPa]
15
20
25
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
-15 -10 -5 0 5 10 15
Outdoor WB Temperature
Discharge Pressure [kPa]
15
20
25
Indoo
r
8.00
10.00
12.00
14.00
-15 -10 -5 0 5 10 15
Outdoor WB Temperature
Input Current [A]
15
20
25
Indoo
r