Kaisai KMK-60RY1 User manual

SERVICE MANUAL
SPLIT TYPE HEAT PUMP
R32

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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
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Part 1 - General Information
Part 1
General Information
1 Unit Capacities ........................................................................................... 4
2 External Appearance .................................................................................. 5
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1 Unit Capacities
1.1 Outdoor Unit Capacities
Table 1-1.1: Capacity range
Capacity 6kW 8kW 10kW 12kW 14kW 16kW
Model1
(KHA-*RY1) 06 08 10 / / /
Model1
(KHA-*RY3) / / / 12 14 16
Notes:
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 example, the model name for the 10kW model is KHA-10RY1
1.2 Hydronic Box Model
Table 1-1.2: Model
Model
1
KMK-60RY1 KMK-100RY1 KMK-160RY3
Compatible OU model KHA-06RY1 KHA-08(10)RY1 KHA-12(14, 16)RY3
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1 Unit Capacities
1.1 Outdoor Unit Capacities
Table 1-1.1: Capacity range
Capacity
6kW
8kW
10kW
12kW
14kW
16kW
Model1
(KHA-*RY1) 06 08 10 / / /
Model1
(KHA-*RY3)
/
/
/
12 14 16
Notes:
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 example, the model name for the 10kW model is KHA-10RY1
1.2 Hydronic Box Model
Table 1-1.2: Model
Model1
KMK-60RY1 KMK-100RY1 KMK-160RY3
Compatible OU model
KHA-06RY1 KHA-08(10)RY1 KHA-12(14, 16)RY3
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Part 1 - General Information
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 KMK-100RY1 KMK-160RY1
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Part 2 - Component Layout and Refrigerant Circuits
Part 2
Component Layout and
Refrigerant Circuits
1Layout of Functional Components ......................................................... 8
2Piping Diagrams .................................................................................. 13
3Refrigerant Flow Diagrams .................................................................. 15
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1Layout of Functional Components
Layout1.1 Outdoor Unit
KHA-06RY1
Figure 2-1.1: KHA-06RY1 top view
Figure 2-1.2: KHA-06RY1 front view
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1Layout of Functional Components
Layout1.1 Outdoor Unit
KHA-06RY1
Figure 2-1.1: KHA-06RY1 top view
Figure 2-1.2: KHA-06RY1 front view
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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
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KHA-12(14,16)RY3
Figure 2-1.7: KHA-12(14,16)RY3 top view
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KHA-12(14,16)RY3
Figure 2-1.7: KHA-12(14,16)RY3 top view
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Part 2 - Component Layout and Refrigerant Circuits
Figure 2-1.8: KHA-12(14,16)RY3 front view
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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
Water pump
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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
Water pump
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Part 2 - Component Layout and Refrigerant Circuits
2Piping Diagrams
2.1 Outdoor Unit Piping
Figure 2-2.1: Outdoor unit piping diagram
Legend
1
Compressor
7
Electronic expansion valve
2.1
Discharge pipe temperature sensor
8
Stop valve (liquid side)
2.2
Outdoor ambient temperature sensor
9
Stop valve (gas side)
2.3
Air side heat exchanger refrigerant outlet temperature sensor
10
Pressure sensor
2.4
Suction pipe temperature sensor
11
Separator
3
4-way valve
12.1
Low pressure switch
4
Air side heat exchanger
12.2
High pressure switch
5
Distributor
13
Capillary
6
Filter
14
Solenoid valve
Key components:
1. Electronic expansion valve (EXV):
Controls 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 functions as a condenser and water side heat exchanger functions as an evaporator; when open, the air
side heat exchanger functions as an evaporator and water side heat exchanger function as a condenser.
3. High and low pressure switches:
Regulate refrigerant system pressure. When refrigerant system pressure rises above the upper limit or falls below the
lower limit, the high or low pressure switches turn off, stopping the compressor.
4. Separator:
Separates liquid refrigerant from gas refrigerant to protect compressor from liquid hammering.
Air side heat exchanger
1
3
11
4
7
14
6
2.1
2.2
2.3
8
9
12.2
12.1
10
13
2.4
5
6
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2.2 Hydronic box Piping
Figure 2-2.2: Hydronic box piping diagram
Legend
1
Water side heat exchanger
9
Water pump
2
Water flow switch
10
Manometer
3
Refrigerant liquid line temperature sensor
11
Safety valve
4
Refrigerant gas line temperature sensor
12
Refrigerant gas side
5
Water outlet temperature sensor
13
Refrigerant liquid side
6
Water inlet temperature sensor
14
Water outlet
7
Air purge valve
15
Water inlet
8
Expansion vessel
Key components:
1. Air purge valve:
Automatically removes 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 pressure. (Expansion vessel volume: 8L.)
4. Water flow switch:
Detects water flow rate to protect compressor and water pump in the event of insufficient water flow.
5. Backup electric heater:
Provides additional heating capacity when the heating capacity of the heat pump is insufficient due to very low
outdoor temperature. Also protects the external water piping from freezing.
6. Manometer:
Provides water circuit pressure readout.
7. Water pump:
Circulates water in the water circuit.
1
2
3
45
6
7
8
10
11
12
13 15
9
14
F
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2.2 Hydronic box Piping
Figure 2-2.2: Hydronic box piping diagram
Legend
1
Water side heat exchanger
9
Water pump
2
Water flow switch
10
Manometer
3
Refrigerant liquid line temperature sensor
11
Safety valve
4
Refrigerant gas line temperature sensor
12
Refrigerant gas side
5
Water outlet temperature sensor
13
Refrigerant liquid side
6
Water inlet temperature sensor
14
Water outlet
7
Air purge valve
15
Water inlet
8
Expansion vessel
Key components:
1. Air purge valve:
Automatically removes 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 pressure. (Expansion vessel volume: 8L.)
4. Water flow switch:
Detects water flow rate to protect compressor and water pump in the event of insufficient water flow.
5. Backup electric heater:
Provides additional heating capacity when the heating capacity of the heat pump is insufficient due to very low
outdoor temperature. Also protects the external water piping from freezing.
6. Manometer:
Provides water circuit pressure readout.
7. Water pump:
Circulates water in the water circuit.
1
2
3
45
6
7
8
10
11
12
13 15
9
14
F
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Part 2 - Component Layout and Refrigerant Circuits
3Refrigerant Flow Diagrams
Heating and domestic hot water operation
Figure 2-3.1: Refrigerant flow during heating or domestic hot water operation
Cooling and defrosting operation
Figure 2-3.2: Refrigerant flow during cooling and defrosting operations
Pressure sensor
Filter
Electronic expansion valve
Filter
High pressure
switch
Low pressure
switch
Compressor
Accumulator
Air side 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
capiiiary
Hydronic box
Stop valve
Stop valve
Pressure sensor
Filter
Electronic expansion valve
Filter
High pressure
switch
Low pressure
switch
Compressor
Accumulator
Air side 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 capacity
Stop valve
Stop valve
Hydronic box
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Part 3 - Control
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 Functions ................................... 29
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1Stop Operation
The stop operation occurs for one of the following reasons:
1. Abnormal shutdown: in order to protect the compressors, if an abnormal state occurs the system makes a stop with
thermo off operation and an error code is displayed on the outdoor unit PCB digital displays and on the user interface.
2. The system stops when the set temperature has been reached.
2Standby Control
2.1 Crankcase Heater Control
The crankcase heater is used to 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 the
outdoor ambient temperature is above 8°C or the compressor is running, the crankcase heater is off; when the outdoor
ambient temperature is at or below 8°C and either the compressor has been stopped for more than 3 hours or the unit has
just been powered-on (either manually or when the power has returned following a power outage), the crankcase heater
turns on.
2.2 Water Pump Control
When the outdoor unit is in standby, the internal and external circulator pumps run continuously.
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