Kaisai FLY INVERTER Series User manual

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

Table of Contents Page
1. Safety Precautions .................................................................. 1
1. Precautions
2. Information servicing
2. Specifications ........................................................................ 7
1. Model Reference
2. Electrical Wiring Diagrams
3. Product Features.................................................................... 13
1. Operation Modes and Functions
4. Maintenance and Disassembly .................................................... 20
1. Maintenance
2. Disassembly
5. Troubleshooting........................................................................59
1. Safety Caution
2. General Troubleshooting
3. Error Diagnosis and Troubleshooting Without ErrorCode
4. Quick Maintenance by Error Code
5. Troubleshooting by Error Code
Appendix .................................................................................. 86
i) Temperature Sensor Resistance Value Table for T1,T2,T3 and T4 (°C –K)
ii) Temperature Sensor Resistance Value Table for TP (°C –K)
iii) Pressure On Service Port
Caution: Risk of fire/flammable material

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

1. Precautions
Toprevent personal injury, or property or unit damage,
adhere to all precautionary measures and instructions
outlinedinthismanual. Before servicing a unit, refer tothis
service manual and its relevantsections.
Failuretoadheretoallprecautionarymeasureslistedinthis
section may result in personal injury, damage to the unit or
to property, or in extreme cases,death.
WARNING indicates a potentially hazardous
situation which if not avoided could result in serious
personal injury, or death.
CAUTION indicatesapotentiallyhazardous situation
which if not avoided could result in minor or
moderate personal injury, or unitdamage.
1.1 In case of Accidents or Emergency
WARNING
•Ifa gasleak is suspected, immediately turn offthe
gasandventilatetheareaifagasleakissuspected
before turning the unit on.
•If strange sounds or smoke is detected from the unit,
turn the breaker off and disconnect the power supply
cable.
•If the unit comes into contact with liquid, contactan
authorized service center.
•If liquid from the batteries makes contact with skin or
clothing, immediately rinse orwash the area well with
clean water.
•Do not insert hands or other objects into the air inlet
or outlet while the unit is plugged in.
•Do not operate the unit with wet hands.
•Do not use a remote controller that has previously
beenexposedtobatterydamageorbatteryleakage.
CAUTION
•Clean andventilatetheunitatregular intervalswhen
operating it near a stove or near similar devices.
•Donot usethe unitduring severeweather conditions.
If possible, remove the product from the window
before such occurrences.
1.2 Pre-Installation and Installation
WARNING
•Use this unit only on a dedicatedcircuit.
•Damagetotheinstallationareacouldcausetheunit
to fall, potentially resulting in personal injury, prop-
erty damage, or product failure.
•Onlyqualifiedpersonnelshoulddisassemble,install,
remove, or repair the unit.
•Only a qualified electrician should perform electri-
cal work. Formore information, contact your dealer,
seller, or an authorized KAISAI service center.
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1.3 Operation and Maintenance
WARNING
•Donotusedefectiveorunder-ratedcircuitbreakers.
•Ensurethe unit is properlygrounded andthat a
dedicated circuit and breaker are installed.
•Do not modify or extend the power cable. Ensure
thepowercableissecureandnotdamagedduring
operation.
•Do not unplug the power supply plug during
operation.
•Donotstoreoruseflammablematerialsnearthe
unit.
•Do not open the inlet grill of the unit during
operation.
•Do not touch the electrostatic filter if the unitis
equipped with one.
•Do not block the inlet or outlet of air flow to the unit.
•Donotuseharshdetergents,solvents,orsimilaritems
to clean the unit. Use a soft cloth forcleaning.
•Do not touch the metal parts of the unit when
removing the airfilter asthey are very sharp.
•Do not step on or place anything on the unit or
outdoor units.
•Do not drink water drained from the unit
•Avoid direct skin contact with water drained from the
unit.
•Usea firm stoolorstepladder accordingto
manufacturerprocedureswhencleaningor
maintaining the unit.
CAUTION
•Do not install or operate the unit for an extended
period of time in areas of high humidity or in an
environmentdirectlyexposingit to seawind orsalt
spray.
•Do not install the unit on a defective or damaged
installation stand, or in an unsecure location.
•Ensure the unit is installed at a level position
•Do not install the unit where noise or air discharge
created by the outdoor unit will negatively impact the
environment or nearby residences.
•Do not expose skin directly to the air discharged by
the unit for prolonged periods of time.
•Ensuretheunitoperatesinareas waterorother
liquids.
•Ensurethedrainhoseisinstalledcorrectlytoensure
proper water drainage.
•When lifting or transporting the unit, it is
recommended that two or more people are used for
this task.
•When the unit is not to be used for an extended time,
disconnect the power supply or turn off the breaker.
•
Whileunpackingbecarefulofsharpedgesaround
the unit as well as the edges ofthe fins on the con-
denser and evaporator.
Safety
Precautions

2. Information servicing
2.1 Checks to the area
• Prior to beginning work on systems containing flammable
refrigerants,safetychecksarenecessarytoensurethatthe
risk of ignition is minimized.
• For repair to the refrigerating system, the following
precautions shall be complied with prior to conducting work
on the system.
2.2 Work procedure
• Workshallbeundertakenunderacontrolledprocedureso
astominimise the risk ofa flammablegas orvapour being
present while the work is beingperformed.
2.3 Work procedure
• All maintenance staff and others working in the local area
shall be instructed on the nature of work being carried out.
• Work in confined spaces shall beavoided.
• The area around the work space shall be sectioned off.
Ensurethattheconditionswithintheareahavebeenmade
safe by control of flammable material.
2.4 Checking for presence of refrigerant
• Theareashall bechecked withanappropriaterefrigerant
detector prior to and during work, to ensure the technician
is aware of potentially flammableatmospheres.
• Ensure that the leak detection equipment being used is
suitableforuse withflammablerefrigerants,i.e.nosparking,
adequately sealed or intrinsically safe.
2.5 Presence of fire extinguisher
• If any hot work is to be conducted on the refrigeration
equipment or any associated parts, appropriate fire
extinguishing equipment shall be available tohand.
• Havea drypowder orCO2fireextinguisher adjacentto the
charging area.
2.6 No ignition sources
• No person carrying out work in relation to a refrigeration
systemwhichinvolvesexposinganypipeworkthatcontains
orhascontainedflammablerefrigerantshalluseanysources
of ignition in such a manner that it may lead to the risk of
fire or explosion.
• All possible ignition sources, including cigarette smoking,
should be kept sufficiently far away from the site of
installation,repairing,removinganddisposal,duringwhich
flammable refrigerant can possibly be released to the
surrounding space.
• Prior to work taking place, thearea around the equipment
istobesurveyedtomakesurethat therearenoflammable
hazards or ignition risks.
• NO SMOKING signs shall bedisplayed.
2.7 Ventilated area
• Ensure that the area isin theopen or that itisadequately
ventilated before breaking into the
• system or conducting any hot work. A degree of ventilation
shall continue during the period
• that the workis carried out.The ventilationshouldsafely
disperse any released refrigerant
• and preferably expel it externally into theatmosphere.
2.8 Checks to the refrigeration equipment
• Where electrical components are being changed,
they shall be fit for the purpose and to the correct
specification. At all times the manufacturer’s
maintenanceandserviceguidelinesshallbefollowed.
If in doubt consult the manufacturer’s technical
department for assistance. The following checks
shallbeappliedtoinstallationsusingflammable
refrigerants:
• thechargesizeis inaccordancewiththeroom size
within which the refrigerant containing parts are
installed;
• theventilationmachineryandoutletsare operating
adequately and are not obstructed;
• if an indirect refrigerating circuit is being used, the
secondarycircuitshallbecheckedforthepresence
of refrigerant; marking to the equipment continues
to be visible and legible.
• markingsandsignsthatareillegibleshallbe
corrected;
• refrigeration pipe or components are installed in
a position where they are unlikely tobe exposed
to any substance which may corrode refrigerant
containingcomponents, unlessthe components
areconstructedofmaterialswhichareinherently
resistanttobeingcorrodedoraresuitablyprotected
against being so corroded.
2.9 Checks to electrical devices
• Repairandmaintenancetoelectricalcomponentsshall
includeinitialsafetychecksandcomponentinspection
procedures. If a fault exists that could compromise
safety,thennoelectrical supplyshallbeconnectedto
the circuit until it is satisfactorily dealt with. If the fault
cannotbecorrectedimmediatelybutitisnecessaryto
continue operation, an adequate temporary solution
shall be used. This shall be reported to the owner of
theequipmentsoallpartiesareadvised.Initialsafety
checks shall include:
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Safety
Precautions