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Kaisai KFU-09HRDN1-QRC8GW Service Manual

Manual is about: KAISAI 12F INVERTER SERIES Split type air conditioners

Summary of KFU-09HRDN1-QRC8GW

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    12f inverter series service manual 2013 12fsi-a-1310

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    Contents 1. Precaution .................................................................................................................................................... 3 1.1 safety precaution ...........................................................................................................

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    3 1. Precaution 1.1 safety precaution to prevent injury to the user or other people and property damage, the following instructions must be followed. Incorrect operation due to ignoring instruction will cause harm or damage. Before service the unit, be sure to read this service manual at first. 1.2 ...

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    4 for installation, always contact the dealer or an authorized service center. Do not install the product on a defective installation stand. Be sure the installation area does not deteriorate with age. If the base collapses, the air conditioner could fall with it, causing property damage, product fa...

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    5 do not open the inlet grill of the product during operation. (do not touch the electrostatic filter, if the unit is so equipped.) there is risk of physical injury, electric shock, or product failure. When the product is soaked, contact an authorized service center. There is risk of fire or electri...

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    6  operational do not expose the skin directly to cool air for long time. (do not sit in the draft). Do not use the product for special purposes, such as preserving foods, works of art etc. It is a consumer air conditioner, not a precision refrigerant system. There is risk of damage or loss of prop...

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    7 2. Function model names of indoor/outdoor units dc inverter capacity indoor units outdoor units 9k kfu-09hrdn1-qrc8w kob-09hfn1-qrc8w kfu-09hrdn1-qrc8gw kob-09hfn1-qrd0gw 12k kfu-12hrfn1-qrc8w kob-12hfn1-qrc8w kfu-12hrdn1-qrc8gw kob1-12hfn1-qrd0gw 18k kfu-18hrfn1-qrc8w koc-18hfn1-qrc4w kfu-18hrfn1...

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    8 3. Dimension 3.1 indoor unit w d h model w d h kfu-09hrdn1-qrc8w 800 188 275 kfu-09hrdn1-qrc8gw 800 188 275 kfu-12hrfn1-qrc8w 800 188 275 kfu-12hrdn1-qrc8gw 800 188 275 kfu-18hrfn1-qrc8w 940 205 275 kfu-18hrfn1-qrc8gw 940 205 275 kfu-18hrfn1-qrd0gw 940 205 275 kfu-24hrfn1-qrc8w 1045 235 315 kfu-24...

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    9 model l(mm) r(mm) h(mm) dimension of installation hole(mm) kfu-09hrdn1-qrc8w 100 95 45 ￠65 kfu-09hrdn1-qrc8gw kfu-12hrdn1-qrc8gw kfu-12hrfn1-qrc8w kfu-18hrfn1-qrc8w 110 100 45 kfu-18hrfn1-qrc8gw kfu-18hrfn1-qrd0gw model l(mm) r(mm) h(mm) dimension of installation hole(mm) kfu-24hrfn1-qrc8w 293 163...

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    10 3.2 outdoor unit more than 30cm more than 60cm more than 200cm more than 30cm more than 60cm (service space ) fen ce or obs tacles model w d h w1 a b kob-09hfn1-qrc8w 780 250 540 843 549 276 kob-09hfn1-qrd0gw 780 250 540 843 549 276 kob-12hfn1-qrc8w 780 250 540 843 549 276 kob1-12hfn1-qrd0gw 780 ...

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    11 4. Refrigerant cycle diagram check valve (heating model only) capiliary tube liquid side gas side heat exchange (evaporator) heat exchange (condenser) compressor 2-way valve 3-way valve 4-way valve cooling heating t2 evaporator temp. Sensor t1 room temp. Sensor t3 condenser temp. Sensor accumulat...

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    12 5. Wiring diagram 5.1 indoor unit kfu-09hrdn1-qrc8w, kfu-09hrdn1-qrc8gw.

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    13 kfu-12hrfn1-qrc8w, kfu-12hrdn1-qrc8gw, kfu-18hrfn1-qrc8w, kfu-18hrfn1-qrc8gw, kfu-18hrfn1-qrd0gw , kfu-24hrfn1-qrc8w, kfu-24hrfn1-qrd0gw.

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    14 kfu-24hrdn1-qrc8gw.

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    15 5.2 outdoor unit kob-09hfn1-qrc8w kob-09hfn1-qrd0gw.

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    16 kob-12hfn1-qrc8w, koc-18hfn1-qrc4w.

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    17 kob1-12hfn1-qrd0gw, koz-18hfn1-qrd0gw, koc1-18hfn1-qrc8gw.

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    18 kof-24hfn1-qrc8w, kof-24hfn1-qrd0gw, kof-24hfn1-qrc8gw.

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    19 6 installation details 6.1 wrench torque sheet for installation outside diameter torque additional tightening torque mm inch n.Cm n.Cm Ф6.35 ¼ 1500(153kgf.Cm) 1600(163kgf.Cm) Ф9.52 3/8 2500(255kgf.Cm) 2600(265kgf.Cm) Ф12.7 ½ 3500(357kgf.Cm) 3600(367kgf.Cm) Ф15.9 5/8 4500(459kgf.Cm) 4700(479kgf.Cm...

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    20 6.3 pipe length and the elevation the pipe length and refrigerant amount: model pipe size standard length (m) max. Elevation b (m) max. Length a (m) additional refrigerant (g/m) gas liquid kfu-09hrdn1-qrc8w+kob-09hfn1-qrc8w 3/8’’ (Ф9.52) ¼’’ (Ф6.35) 5 8 20 20 kfu-09hrdn1-qrc8gw+kob-09hfn1-qrd0gw ...

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    21 6.4 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 efficiency drops. ● moisture in the refrigerant circuit may freeze and block capillary tubing. ● water ...

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    22 5) operate the vacuum pump to evacuate. 6) make evacuation for 30 minutes and check whether the compound meter indicates -0.1mpa. If the meter does not indicate -0.1mpa after pumping 30 minutes, it should be pumped 20 minutes more. If the pressure can’t achieve -0.1mpa after pumping 50 minutes, p...

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    23 check the flare connections for gas leakage. 5). Discharge the refrigerant. Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2-way valve approximately 45’ until the gauge indicates 0.3 to 0.5 mpa. 6). Disconnect the charge set and the chargi...

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    24 3) put the charging cylinder 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).When the electronic scale displays the proper weight (refer to the ta...

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    25 6).When the electronic scale displays the proper weight (refer to the gauge and the pressure of the low side), disconnect the charge hose from the 3-way valve’s service port immediately and turn off the air conditioner before disconnecting the hose. 7). Mount the valve stem caps and the service p...

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    26 5). Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 0.1mpa. 6). Set the 3-way valve to the closed position immediately do this quickly so that the gauge ends up indicating 0.3 to 0.5mpa. Disconnect the charge set, and tighten the 2-way and 3-way valve’s stem ...

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    27 5). Discharge the refrigerant. Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2-way valve approximately 45’ until the gauge indicates 0.3 to 0.5 mpa. 6). Disconnect the charge set and the charging cylinder, and set the 2-way and 3-way valv...

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    28 5). Disconnect the charge hose from the vacuum pump..

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    29 2. Refrigerant charging procedure: 1). Connect the charge hose to the charging cylinder, open the 2-way valve and the 3-way valve connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder. If the refrigerant is r410a, make the cylinder bottom u...

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    30 be sure to check for gas leakage.

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    31 7. Operation characteristics temperature mode cooling operation heating operation drying operation room temperature ≥17℃ ≤30℃ ＞10℃ outdoor temperature 0℃～50℃ -15℃～30℃ 0℃～50℃ -15℃～50℃ (for the models with low temperature cooling system) caution: 1. If the air conditioner is used beyond the above c...

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    32 8. Electronic function 8.1 abbreviation t1: indoor room temperature t2: coil temperature of evaporator t3: coil temperature of condenser t4: outdoor ambient temperature t5: compressor discharge temperature 8.2 display function 8.2.1 icon explanation on indoor display board. Ion indication lamp(op...

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    33 8.3 main protection 8.3.1 time delay at restart for compressor 1 minute delay for the 1 st time start-up and 3 minutes delay for others. 8.3.2 temperature protection of compressor top the unit will stop working when the compressor top temp. Protector cut off, and will restart after the compressor...

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    34 kfu-18hrfn1-qrd0gw, kfu-24hrdn1-qrc8gw , kfu-24hrfn1-qrd0gw models: fault temp. Sensor operation in cooling, drying and fan only mode operation in heating mode t1 run supposed t1=26℃ high fan speed run supposed t1=26℃ medium fan speed t2 normal during the first 1 minute of compressor operation, i...

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    35 seconds and this situation happens 3 times, the display area will show “ec” and ac will turn off. 8.4.10 zero crossing detection error protection(only for kfu-09hrdn1-qrc8w, kfu-09hrdn1-qrc8gw, kfu-12hrdn1-qrc8gw, kfu-24hrdn1-qrc8gw) if ac detects time interval is not correct for continuous 240s,...

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    36 8.4 operation modes and functions 8.4.1 fan mode (1) outdoor fan and compressor stop. (2) temperature setting function is disabled, and no setting temperature is displayed. (3) indoor fan can be set to high/med/low/auto. (4) the louver operates same as in cooling mode. (5) auto fan: a b c d 5.0 4...

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    37 8.4.2 cooling mode 8.4.2.1 compressor running rules the maximum operation frequency of compressor after starting submits to following rule. 50 49 45 44 41 40 33 32 fmax=t4fremax1 t4 30 29 22 20 fmax=t4fremax2 fmax=t4fremax3 fmax=t4fremax4 fmax=t4fremax5 fmax=t4fremax6 fmax=t4fremax7 meanwhile, th...

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    38 3.5 3.0 2.5 2.0 1.5 1.0 0.5 t1-ts -1.0 a b c d e f g h 0.0 -1.5 i j while the zones of a,b,c... Are corresponding to different compressor running frequency. Note: when t1-ts keeps in the same temp. Zone for 3 minutes, the compressor will run as the below rules: a:increase the frequency to 3 grade...

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    39 28 26 e c 25 23 b 22 20 19 17 d a cooling while a,b,c…means different fan speed of outdoor unit. 8.4.2.3 indoor fan running rules in cooling mode, indoor fan runs all the time and the speed can be selected as high, medium, low, auto and silent. When the compressor is running, the indoor fan is co...

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    40 the auto fan acts as below rules: a b c d 5.0 4.0 2.5 1.0 6.0 t1-ts e h (h-l)*0.75+l (h-l)*0.5+l (h-l)*0.25+l l 8.4.2.4 condenser temperature protection ---55℃ t3 ---t3 ---t3>60℃ for 5 seconds, the compressor will stop until t3 8.4.2.5 evaporator temperature protection ---t2 >= 5℃. ---0℃≦t2 ---4℃...

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    41 8.4.3 heating mode 8.4.3.1 compressor running rules the maximum operation frequency of the compressor after starting submits to the following rule. Fmax=t4freheatmax1 34 t4 off 33 28 27 25 24 22 21 19 18 16 17 15 14 12 11 6 5 fmax=t4freheatmax2 fmax=t4freheatmax3 fmax=t4freheatmax4 fmax=t4freheat...

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    42 meanwhile, the maximum frequency is limited by the indoor fan speed. Indoor fan speed maximum frequency high speed/8 degree heating/ turbo function no limit medium speed fheatmaxmidfan low speed/sleep mode fheatmaxlowfan silent mode fixed at f3 if users switch on ac by remote controller, the comp...

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    43 15 t4 heatt4zone4i 14 10 9.0 6.0 5.0 heatt4zone3i heatt4zone2i heatt4zone1i 8.4.3.2 outdoor fan running rules 21 19 a c 18 16 d 15 13 12 10 b e heating 8.4.3.3 indoor fan running rules in heating mode, indoor fan can be selected as high, medium, low, auto and silent. The anti-cold- wind function ...

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    44 if the compressor stops caused by the room temperature rising, the indoor fan will be forced to run 127 seconds with breeze. During this period, the anti-cold-wind is disabled. Auto fan action in heating mode: -1.0 -2.0 -3.0 -4.0 0.0 t1-ts+¦ ¤ t l (h+-l)*0.4+l (h+-l)*0.6+l -5.0 -6.0 -6.5 h+ (h+-l...

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    45 8.4.3.4 defrosting mode condition of defrosting: if any one of the following items is satisfied, ac will enter the defrosting mode. After the compressor starts up and keeps running, mark the minimum value of t3 from the 10 th minutes to 15 th minutes as t30. 1)if the compressor cumulate running t...

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    46 defrosting action： for kfu-09hrdn1-qrc8w, kfu-12hrfn1-qrc8w models: compressor on off on on on off off off 4-way valve outdoor fan indoor fan indoor fan breeze(10s) xx 10s no longer than 10m 30s frequencyf16 10s frequency f3 xx=60 for kfu-18hrfn1-qrc8w, kfu-24hrfn1-qrc8w models: compressor on off...

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    47 for kfu-09hrdn1-qrc8gw, kfu-12hrdn1-qrc8gw models: compressor on off on on off off 4-way valve outdoor fan xx no longer than 10m 30s 10s 10s xx=20. For kfu-18hrfn1-qrc8gw , kfu-18hrfn1-qrd0gw, kfu-24hrfn1-qrd0gw and kfu-24hrdn1-qrc8gw models: compressor on off on on off off 4-way valve outdoor fa...

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    48 8.4.3.5 evaporator coil temperature protection testop t2 resume off decrease tedown tenorm hold off: compressor stops. Decrease: decrease the running frequency to the lower level. Hold: keep the current frequency. Resume: no limitation for frequency. 8.4.4 auto-mode this mode can be chosen with r...

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    49 2.0 1.5 1.0 t1-ts f7 f5 f3 f1 2.5 0.5 0.0 8.4.5.3 low indoor room temperature protection in drying mode, if room temperature is lower than 10℃, the compressor will stop and not resume until room temperature exceeds 12℃. 8.4.5.4 evaporator anti-freezing protection, condenser high temperature prote...

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    50 8.4.8 sleep function mode 8.4.8.1 operation time in sleep mode is 7 hours. After 7 hours the ac quits this mode and turns off. 8.4.8.2. Operation process in sleep mode is as follow: when cooling, the setting temperature rises 1℃ (be lower than 30℃) every one hour, 2 hours later the setting temper...

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    51 system. In the first 10 seconds after power on, this protection is inactive. When this protection happens, it will last 3 minutes and then the pcb will detect the power supply voltage again..

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    52 9. Troubleshooting 9.1 indoor unit error display operation lamp timer lamp display led status ☆ 1 time x e0 indoor unit eeprom parameter error ☆ 2 times x e1 indoor / outdoor units communication error ☆ 3 times x e2 zero crossing signal detection error(only for ms12fu-09hrdn1-qrc8w, ms12fu-09hrdn...

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    53 9.2 diagnosis and solution 9.2.1 eeprom parameter error diagnosis and solution(e0) if the eeprom chip is welded on main pcb, replace the main pcb directly. Otherwise, check whether the eeprom chip plugged in main pcb well? Yes no yes correct the connection. Replace the indoor main pcb. Shut off t...

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    54 9.2.2 indoor unit and outdoor unit communication protection error diagnosis and solution (e1) yes yes measure vs, is it moving alternately between positive value and negative value? (vs is the voltage between s and n of outdoor unit.) yes power off, then turn on the unit 5 seconds later(reconnect...

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    55 9.2.3 zero crossing detection error diagnosis and solution(e2) check if the connections and power supply is normal? Correct the connections. Turn on the unit when the power supply is good. No yes indoor main pcb is defective. Replace indoor main pcb. 9.2.4 fan speed has been out of control diagno...

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    56 index 1: 1. Indoor ac fan motor measure the resistance value of each winding by using the tester. 2.Outdoor or indoor dc fan motor (control chip is in fan motor) measure the resistance value of each winding by using the tester. If any resistance value is zero, the fan motor must have problems and...

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    57 for other motors: no. 1 2 3 4 5 color orange grey white pink black signal hu hv hw vcc gnd color red blue yellow signal w v u 2) release the uvw connector. Measure the resistance of u-v, u-w, v-w. If the resistance is not equal to each other, the fan motor must has problems and need to be replace...

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    58 2. Indoor or outdoor dc fan motor(control chip is in fan motor) power on and when the unit is in standby, measure 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 has problems and need to be replaced. ...

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    59 9.2.5 open circuit or short circuit of temperature sensor diagnosis and solution (e4/e5/f1/f2/f3) check the connections between temperature sensor and pcb. Are the connections good? Correct the connections. No yes yes replace indoor or outdoor pcb. Replace the sensor and c h e c k i f t h e p r o...

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    60 9.2.6 refrigerant leakage detection diagnosis and solution (ec) is there cool air blowing out from indoor air outlet? Yes yes check if t2 sensor is well fixed. Correct the installation or replace t2 sensor. Does the problem remain again? No is there any leakage? Especially the connection parts, s...

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    61 9.2.7 ipm malfunction or igbt over-strong current protection diagnosis and solution(p0) check if the wiring between main pcb and compressor connected by error and if the wires and connectors are broken? Correct the connection or replace the wires and connectors. Yes no check if the ipm installed ...

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    62 9.2.9 over voltage or too low voltage protection diagnosis and solution(p1) check if the power supply is normal. Check if all the connections and wires are good? Disconnect the unit with power supply and try to restart the unit when power supply gets normal. No yes no correct the connections or r...

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    63 9.2.10 high temperature protection of compressor top diagnosis and solution(p2) check if the air flow system of indoor and outdoor units are obstructed? Clear up the air inlet and outlet or the heat exchanger of indoor and outdoor units. Yes no yes yes turn off the power supply and turn it on 10 ...

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    64 9.2.11 inverter compressor drive error diagnosis and solution(p4) check if the wiring between main pcb and compressor connected by error and if the wires and connectors are broken? Correct the connection or replace the wires and connectors. Yes no check if the ipm installed correctly. Correct the...

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    65 safety electricity power is still kept in capacitors even the power supply is shut off. Do not forget to discharge the electricity power in capacitor. Electrolytic capacitors (high voltage! Caution!) connect discharge resistance (approx.100 Ω 40w) or soldering iron (plug) between +, - terminals o...

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    66 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) sensor. Measure the resistance value of each winding by using the multi-meter. Table 1: some frequently-used r-t data for t1,t2...

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    67 compressor da108x1c-23ez da108x1c-23ez da130m1c-31fz da150s1c-20fz indoor fan motor rpg20e wzdk20-38g (☆) wzdk30-38g (☆) wzdk58-38g (☆) outdoor fan motor wzdk35-38g (☆) wzdk35-38g(h) (★) wzdk35-38g(h) (★) wzdk50-38g (☆).

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    68 code 2t0032300888 2t0032400274 2t0032800688 2t0032900557 model kfu-09hrdn1-qrc8 gw kfu-12hrdn1-qrc8 gw kfu-18hrfn1-qrc8 gw kfu-24hrdn1-qrc8 gw compressor asn108d22uez asn108d22uez da130m1c-31fz da150s1c-20fz indoor fan motor rpg20e rpg20e wzdk30-38g (☆) rpg45c outdoor fan motor wzdk36-38g-w (★) w...

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    69 3.Ipm continuity check turn off the power, let the large capacity electrolytic capacitors discharge completely, and dismount the ipm. Use a digital tester to measure the resistance between p and uvwn; uvw and n. Digital tester normal resistance value (+)red (-)black ∞ (several mΩ) p n u v w digit...