Kaisai R290 Series User manual

INSTALLATION MANUAL
AIR TO WATER HEAT PUMP
SERIES #R290

MODEL: KHX-14PY3, KHX-16PY3
Air to Water Heat Pump
Installation Manual

Content
1. Preface ......................................................................................1
2. Safety Instructions .....................................................................2
3. Features ....................................................................................5
4. Unit Dimension(mm) ..................................................................6
5. Installation Diagram ...................................................................7
6. Handling & Installation ...............................................................
9
7. Maintenance............................................................................16
8. Parameters..............................................................................19
9. Wiring Diagram........................................................................21
10. Display Operation Guide ..........................................................25

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1. Preface
In order to provide the customers with high quality, strong reliability
and good versatility products, this heat pump is produced by strict
design and manufacture standards. This manual includes all the
necessary information about installation, debugging, discharging
and maintenance. Please read this manual carefully before you
open or maintain the unit.
The manufacture of this product will not be held responsible if
someone is injured or the unit is damaged, as a result of improper
installation, debugging, unnecessary maintenance which is not in
line with this manual.
The unit must be installed by qualified personnel.
It is vital that the below instructions are adhered to at all times to
keep the warranty.
—The unit can only be opened or repaired by a qualified installer or
an authorized dealer.
—Maintenance and operation must be carried out according to the
recommended time and frequency, as stated in this manual.
—Use genuine standard spare parts only.
Failure to comply with these recommendations will invalidate the
warranty.
Inverter air source water heat pump is a kind of high efficiency,
energy saving and environment friendly equipment, which is mainly
used for house warming. It can work with any kinds of indoor unit
such as fan coil, radiator, or floor heating pipe, by providing warm
or hot water. One unit of monoblock heat pump can also work with
several indoor units.
The air source water heat pump unit is designed to have heat
recovery by using super heater which can provide hot water for
sanitary purpose.

2
Mark Notes
Icon Notes
2. Safety Instructions
To prevent the users and maintainers from the harm of this unit, and
avoid damage to the unit or other property, and use the heat pump
properly, please read this manual carefully and understand the following
information correctly.
Mark Meaning
WARNING
A wrong operation may lead to death or grievous injury
on people.
ATTENTION Awrong operation may lead to harm to people or loss
of material.
Icon Meaning
Prohibition. What is prohibited will be nearby this icon.
Compulsory implement. The listed action needed to be
taken.
ATTENTION (include WARNING)
Please pay attention to what is indicated.

3
Operation Meaning
Prohibition
DO NOT put fingers or others into the fan
and evaporator
of the unit, otherwise harm may occur.
Shut off the
power.
When there is something wrong or strange smells
, the
power supply needs to be shut off to stop the unit.
Continue running may cause short circuit or fire.
Operation Meaning
Prohibition
DO NOT put fingers or others into the fan
and evaporator
of the unit, otherwise harm may occur.
Shut off the
power.
When there is something wrong or strange smells
, the
power supply needs to be shut off to stop the unit.
Continue running may cause short circuit or fire.
Move and
Repair Meaning
Entrust
When the heat pump needs
to be moved or installed
again, please entrust dealers or qualified people
to carry
it out. Improper installation will lead to water leakage,
electrical shock, injury or fire.
Entrust
It is prohibited from
repair the unit by the user himself,
otherwise electrical shock or fire may occur.
Prohibit
When the heat pump needs to be repaired, please
entrust dealers or qualified people
to carry it out.
Improper movement or repair on the unit will lead to
water leakage, electrical shock, injury or fire.
Warning

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Do not use means to accelerate the defrosting
process or to clean, other than those recommended
by the manufacturer.
The appliance shall be stored in a room and installed
in the environment without continuously operating or
potential ignition sources (for example: open flames,
an operating gas appliance or an operating electric
heater or Electric Spark or hot objects).
Installation Meaning
Installation Place
The unit CANNOT be installed near the flammable gas.
Once there is any leakage of the gas, fire may occur.
Fix the unit.
Make sure that the basement of the heat pump is strong
enough, to avoid any decline or fall down of the unit
Need circuit
breaker.
Make sure that there is circuit breaker for the unit, lack of
circuit breaker may lead to electrical shock or fire.
Operation Meaning
Check the
installation
basement.
Please check the installation basement regularly (once
a month), to avoid any decline or damage to the
basement, which may hurt people or damage the unit.
ATTENTION

5
Switch off
the power.
Please switch off the power when cleaning or maintaining.
Prohibition
It is prohibited from using copper or iron as fuse. The
right fuse must be fixed by electricians for the heat
pump.
Prohibition
It is prohibited from spray the flammable gas to the
heat pump, as it may cause fire.
3. Features
This series of heat pump unit owns following features:
3.1. Advanced Controlling
The PC micro-computer based controller is available for the users to review
or set the running parameters of the heat pump. Centralized controlling
system can control several units by PC.
3.2. Nice Appearance
The heat pump is designed with beautiful looking. The monoblock one has
the water pump included which is very easy for installation.
3.3. Flexible Installation
The unit has a smart structure with compact body, just as simple outdoor
installation is needed.
3.4. Quiet Running
The heat pump unit use a special designed heat exchanger to enhance
whole efficiency.
3.5. Good Heat Exchange Rate
The heat pump unit use a special designed heat exchanger to enhance
whole efficiency.
3.6. Large Working Range
This series of heat pump is designed to work under different working
conditions as low as -15 degrees for heating.

6
4. Unit Dimension(mm)
4.1.Models: KHX-14PY3

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4.2.Models: KHX-16PY3
5. Installation Diagram
KAISAI monoblock heat pumps can provide heating/cooling and domestic
hot water. Floor heating loops and fan coil units areused for space heating
and fan coil units areused for space cooling. Domestic hot water is supplied
from the domestic hot water tank connected to the heat pump.
5.1 Traditional Installation
KAISAI provides the monoblock heat pump with a main circulation pump
built inside. When install the unit, installers should connect the heat pump
with other parts including the buffer tank (for space heating/cooling), storage
water tank (for domestic hot water) and water pumps (for space
heating/cooling water circulation and domestic hot water). External fittings
are also needed including a safety valve, a water charge valve, hot water
valves (three-way valve). Temperature sensor should be added in the
storage water tank. An additional electric heater can be installed in the DHW
tank or the buffer tank which can get the control signal from the heat pump.

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6. Handling & Installation
Unit features
a. Plate heat exchanger
Use the SWEP efficient heat exchanger with small size and high efficiency.
b. Environmentally friendly refrigerant
Use the new generation of environmentally friendly refrigerant R290, which
is harmless to the ozone sphere.
c. Heating in frigid environment.
Optimized designed unit can achieve the heating function normally even
when the ambient temperature is -25℃.
d. Infusing refrigerant
The Heat Pump are lack of refrigerant and full of High-pressure nitrogen
instead when Ex-factory. Before operating, remember to follow the
Operation Manual infusing the refrigerant.
e. Installation Environment
The refrigerant R290 are flammable and explosive, It's prohibited from

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installing in one environment which have operating or potential ignition
sources.
6.1. Application of Heat Pump
6.1.1. House Heating/Cooling + Domestic Hot Water
Remark: Item 17, 18,
20, 21 can be
connected with heat
pump.
1 Heat pump 10 Relief valve 19 PT valve
2 Flexible pipe 11 Air vent valve 20 Electrical heater
3 Thermometer 12 Water pump for floor heating 21 Hot water sensor
4 Manometer 13 Check valve
5 Shut-off valve 14 Floor heating valve
6 Y type water filter 15 Hot water tank
7 Plate heat exchanger 16
Floor heating pipe/fan coil unit
8 Buffer tank 17 Hot water valve
9 Expansion tank 18 Hot water pump

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6.1.2. House Heating/Cooling（including Buffer tank）
1 Heat pump
7 Plate heat exchanger 13 Check valve
2 Flexible pipe 8 Buffer tank 14 Floor heating valve
3 Thermometer
9 Expansion tank 15 Floor heating pipe/fan coil unit
4 Manometer 10 Relief valve
5 Shut-off valve 11 Air vent valve
6 Y type water filter 12 Water pump for floor heating
6.2. Choose a right heat pump unit
(1) Based on the local climate condition, construction features and insulation level,
calculate the required cooling(heating) capacity per square meter.
(2) Conclude the total capacity which will be needed by the construction.
(3) According to the total capacity needed, choose the right model by consulting
the heat.
(4) Pump features as below:
a. Cooling only unit: chilled water outlet temp. at 5-15℃, maximum ambient temp.
at 43℃.
b. Heating and Cooling unit: for cooling chilled water outlet temp. at 5-15℃,
maximum ambient temp. at 43℃. For heating, warm water outlet temp. at
9-75℃, minimum ambient temp. at -25℃.
c. Unit application
Inverter air source water heat pump is used for house, office, hotel, and so
forth, which need heating or cooling separately, with each area needed to
be controlled.
6.3. Installation Method
The heat pump can be installed onto the concrete basement by expansion
screws, or onto a steel frame with rubber feet which can be placed on the
ground or housetop.

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Make sure that the unit is placed horizontally.
6.4. Installation Place
a. The unit can be installed on any place outdoor which can carry heavy
machine such as terrace, housetop, ground and so on.
b. The location must have good ventilation.
c. The place is free from heat radiation and other fire flame.
d. A pall is needed in winter to protect the heat pump from snow.
e. There must be not obstacles near the air inlet and outlet of the heat pump.
A place which is free from strong air blowing.
f. There must be water channel around the heat pump to drain the
condensing water. There must be enough space around the unit for
maintenance.
g. A place which is far away operating or potential ignition sources (for
example: open flames, an operating gas appliance or an operating
electric heater or Electric Spark or hot object)
6.5. Refrigerant charge
The heat pump is not infused with the refrigerant 290 and full of high-pressure
nitrogen or keep it in a vacuum instead, please follow these steps to infusing
refrigerant R290.
1. Preparations
4. Vacuumize the heat pump. Connect the vacuum pump with the valve 2, keep
vacuum pump running until the absolute pressure below 30Pa or operating time
more than one hour.
a. Please in a well-ventilated environment while
charge refrigerant.
b. Keep away from open flames or potential
sources of fire.
c. Disconnect the power supply of the heat pump.
d. Carefully check the nameplate of the heat pump
and charge strictly according to the labeled amount.
2. Check the pressure of nitrogen gas inside the
system. The heat pump has charged about 30 Bar
pressure nitrogen gas inside the system, please
check whether there is still high-pressure nitrogen
before charging refrigerant, otherwise check the
leakage point. (Use spanner remove the seal nut 1
and 3, use 5mm inner hexagon spanner open the
valve 2. If it can Blowing out the high-pressure gas
then the heat pump is not leaking.)
3. Use 5mm inner hexagon spanner open the valve 2
and release all the nitrogen gas inside the system.

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5.Charge refrigerant. Keep the refrigerant in liquid state when charging and strictly
according to the labeled amount.
6. Finish the charging, close the valve 2 and screw the seal nut 1 and 3.
6.6. Water Loop Connection
Please pay attention to below matters when the water pipe is connected:
(1) Try to reduce the resistance to the water from the piping.
(2) The piping must be clear and free from dirty and blocks. Water leakage test
must be carried out to ensure there is no water leaking. And then the
insulation can be made.
(3) Attention that the pipe must be tested by pressure separately. DO NOT test it
together with the heat pump.
(4) There must be expansion tank on the top point of the water loop, and the
water level in the tank must be at least 0.5 meter higher than the top point of
the water loop.
(5) The flow switch is installed inside of the heat pump, check to ensure that the
wiring and action of the switch is normal and controlled by the controller.
(6) Try to avoid air stayed inside of the water pipe, and there must be air vent on
the top point of the water loop.
(7) There must be thermometer and pressure meter at the water inlet and outlet,
for easy inspection during running.
6.7. Power Supply Connection
(1) Open the front panel, and open the power supply access.
(2) The power supply must go through the wire access and be connected to the
power supply terminals in the controlling box. Then connect the 3-signal wire
plugs of the wire controller and main controller.
(3) If the outside water pump is needed, please insert the power supply wire into
the wire access also and connect to the water pump terminals.
(4) If an additional auxiliary heater is need to be controlled by the heat pump
controller, the relay (or power) of the aux-heater must be connected to the
relevant output of the controller.

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6.8. Location of the Unit
The picture shows the location of horizontal air outlet unit.
6.9. Transit
6.10. Trial Running
6.10.1. Inspection before trial running
(1) Check the indoor unit, and make sure that the pipe connection is right and
the relevant valves are open.
(2) Check the water loop, to ensure that the water inside of the expansion
tank is enough, the water supply is good, the water loop is full of water
When the unit needs to be hung up during
installation, an 8 meters cable is needed, and
there must be soft material between the cable and
the unit to prevent damage to the heat pump
cabinet. (See picture 1)
Picture 1
DO NOT touch the heat exchanger of the heat pump with fingers or other objects！
WARNING

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and without any air. Also make sure there is good insulation for the water
pipe.
(3) Check the electrical wiring. Make sure that the power voltage is normal,
the screws are fastened, the wiring is made in line with the diagram, and
the earthing is connected.
(4) Check the heat pump unit including all of the screws and parts of the heat
pump to see if they are in good order. When the power is on, review the
indicator on the controller to see if there is any failure indication. The gas
gauge can be connected to the check valves to see the high pressure (or
low pressure) of the system during trial running.
6.10.2. Trial running
(1) Start the heat pump by press " " key on the controller. Check
whether the water pump is running, if it runs normally there will be 0.2
MPa on the water pressure meter.
(2) When the water pump runs for 1 minutes, the compressor will start.
Hear whether there is strange sound from the compressor. If abnormal
sound occurs please stop the unit and check the compressor. If the
compressor runs well please look for the pressure meter of the
refrigerant.
(3) Then check whether the power input and running current is in line with
the manual. If not please stop and check.
(4) Adjust the valves on the water loop, to make sure that the hot(cool)
water supply to each door is good and meet the requirement of heating
(or cooling). Review whether the outlet water temperature is stable.
(5) The parameters of the controller are set by the factory, it is not allowed
to change then by the user himself.
If the water flow rate is lower than 70% of the rated water flow, the
defrosting efficiency will be lower. The suggested water flow rate shall be
the rated flow rate which is shown on the nameplate.

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7. Maintenance
7.1. Precautions for Daily Use
Before starting up the unit for the first time or after a long-time shutdown,
the following preparations must be made:
(1) Thoroughly inspect and clean up the unit.
(2) Clean the waterway system.
(3) Check water pump, regulating valve and other waterway
equipment.
(4) Tighten all wire connections.
Do not change the system parameters before consulting the engineer.
Ensure the water refill and exhaust device in the waterway is well,
otherwise the performance and reliability of the unit will become worse.
Ensure the waterways are clean and avoid dirt and blockage.
Timely check the electricity, water and replace the faulty parts.
Please use the parts provided or recommended by the company, do not
use the unqualified parts.
Refrigerant supplement:
Each unit has been equipped with sufficient refrigerant when leaving the
factory. Do not charge or change the refrigerant.
If you need to replenish the refrigerant due to leakage, please contact the
engineers or dealers.

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7.2. Periodic Maintenance (every 6 months)
7.3. Inspection and Maintenance
7.3.1. Preparing for inspection and maintenance
Danger!
Risk of death caused by fire or explosion if there is a refrigerant
leakage!
Only carry out the work if you are competent and have knowledge about the
special features and risks of R290 refrigerant.
The product contains combustible refrigerant R290. In the event of a leak,
escaping refrigerant may mix with air to form a flammable atmosphere.
There is a risk of fire and explosion.
Ensure that space is sufficiently aerated around the product.
Preparation
Before maintenance, please ensure that the unit stop
running and cut off the power supply.
Inspection and
cleaning of fin
heat exchanger
In order to ensure that heat exchangers remain
in optimum condition for heat exchange, their
surfaces must be clean.
Inspection and
cleaning of plate
heat exchanger
Every 6 months or when the capacity of the unit
drops by more than 10%, check the water-side heat
exchanger for scale and clean the
heat exchanger.
Check the
electrical wiring
Check if the contact point is loose, oxidized, or
blocked by sundries, etc., which causes poor
contact of the electronic wiring.

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Observe the basic safety rules before carrying out inspection and
maintenance work or installing spare parts.
Disconnect the product from the power supply but ensure that the product is
still earthed.
7.3.2. Cleaning the product
Do not clean the product with a high-pressure cleaner or a direct jet of water.
Clean the product using a sponge and hot water with a cleaning agent.
Do not use abrasive cleaners. Do not use solvents. Do not use any cleaning
agents that contain chlorine or ammonia.
7.3.3. Checking the evaporator, fan, and condensate discharge
Check whether there is dirt between the fins or whether depositions have
adhered to the fins.
Clean the fins using a soft brush, avoid fins from being bent.
Check whether dirt has been accumulated on the condensate tray or in the
condensate discharge pipe.
Check whether the water can drain freely.