Kaysun KEM-30 DNS3 Owners & Installation Manual Download Page 1

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OWNER'S & INSTALLATION MANUAL

FULL DC Inverter Chiller

KEM-30 DNS3

KEM-60 DNS3

KEM-90 DNS3

Original instructions.

Thank you very much for purchasing our air conditioner. Before using your air conditioner,

please read this manual carefully and keep it for future reference.

Summary of Contents for KEM-30 DNS3

Page 1: ... DC Inverter Chiller KEM 30 DNS3 KEM 60 DNS3 KEM 90 DNS3 Original instructions Thank you very much for purchasing our air conditioner Before using your air conditioner please read this manual carefully and keep it for future reference ...

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Page 3: ...PIPELINE SYSTEM 9 8 OVERVIEW OF THE UNIT 10 9 START UP AND CONFIGURATION 36 10 FINAL CHECK AND TEST RUN 37 11 MAINTENANCE AND UPKEEP 39 12 APPLICABLE MODELS AND MAIN PARAMETERS 47 13 INFORMATION REQUIREMENTS 48 Unit Installation Operation manual Total water outlet temperature sensor casing Transformer Installation manual of wired controller Quantity 1 1 1 1 Shape Purpose Use for installation only ...

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Page 5: ... MC SU30 RN1L MC SU60 RN1L Outlet water temperature MC SU90 RN1L Ambient temperature Outlet water temperature Fig 1 1 Cooling operating range of KEM 30 DNS3 and KEM 60 DNS3 Fig 1 3 Heating operating range of KEM 30 DNS3 and KEM 60 DNS3 Fig 1 2 Cooling operating range of KEM 90 DNS3 Fig 1 4 Heating operating range of KEM 90 DNS3 MC SU30 RN1L MC SU60 RN1L MC SU90 RN1L Ambient temperature Ambient tem...

Page 6: ...d improperly a fire electric shock injury or water leakage may occur Never modify or repair the unit on your own Otherwise a fire electric shock injury or water leakage may occur Get your distributor or a professional to do so CAUTION Ensure that the residual current device RCD is installed The RCD must be installed Failure to install it may result in electric shock Connect the cable properly Othe...

Page 7: ...ng rope belt should be able to bear 4 times the weight of the unit Check the lifting hook and ensure that it is firmly attached to the unit To avoid damages to the unit a protective block made of wood cloth or hard paper should be placed between the unit and rope when lifting and its thickness should be 50mm or more It is strictly forbidden to stand under the machine when it is hoisted Lifted cabl...

Page 8: ...ter does not accumulate f If installing the unit on the ground put the steel base of the unit on the concrete foundation which must be as deep as into the frozen soil layer Ensure the installation foundation is separated from buildings as the noises and vibration of the unit may adversely affect the latter By means of the installation holes on the unit base the unit can be fastened on the foundati...

Page 9: ...as on the exposed roof the measures including sunk fence and Persian blinds can be taken to prevent the turbulent flow from disturbing the air entering the unit If the unit needs to be provided with sunk fence the height of the latter should not be more than that of the former if Persian blinds are required the total loss of static pressure should be less than the static pressure outside the fan T...

Page 10: ...iew Front view Fig 6 4 Single unit installation Inlet of air flow Main unit Main unit Main unit Main unit Main unit Main unit Main unit Main unit Main unit Inlet of air flow Top view Fig 6 5 Multiple units installation Table 6 2 unit mm Installation space A 800 B 2000 C 2000 D 800 E 800 F 1100 G 6000 ...

Page 11: ... the ground floor or the roof which can bear operating weight of the unit and the weight of maintenance personnel Refer to Table 12 1 Table of applicable models and parameters for operating weight b If the unit is located so high that it is inconvenient for maintenance personnel to conduct maintenance the suitable scaffold can be provided around the unit c The scaffold must be able to bear the wei...

Page 12: ...nit is placed on the foundation the damper connected with the unit should not be moved and the central clamp nut is not allowed to be tightened before the damper sustains load Damping device Anchor bolt Nut Ferrol Fig 6 10 Installation of the damper 6 5 Installation of device to prevent snow build up and strong breeze When installing an air cooled heat pump chiller in a place with heavy snow it is...

Page 13: ...ay valve Terminal Auxiliary electric heater unit unit Y type filter requiring 40 meshes unit Symbol explanation Stop valve Pressure gauge Flexible joint Gate valve Automatic discharge valve Y shaped filter Thermometer Circulating pump one way valve Fig 7 1 Connection drawing of pipeline system NOTE The ratio of the two way valves on the terminal shall not exceed 50 percent ...

Page 14: ...HE UNIT 8 1 Main parts of the units inlet of water inlet of air outlet of air outlet of water Fig 8 1 Main parts of KEM 30 DNS3 inlet of water inlet of air outlet of air outlet of water Fig 8 2 Main parts of KEM 60 DNS3 ...

Page 15: ...air outlet of air outlet of water Fig 8 3 Main parts of KEM 90 DNS3 NO 1 2 3 4 5 6 7 NAME Air outlet Top cover Electric control box Compressor Evaporator Condenser Water inlet NO 8 9 10 NAME Air inlet Water outlet wire controller ...

Page 16: ...nit Door 1 Door 3 Door 4 Door 2 Fig 8 4 Doors of KEM 30 DNS3 Door 1 Door 3 Door 4 Door 2 Fig 8 5 Doors of KEM 60 DNS3 Door 1 Door 3 Door 4 Door 2 Fig 8 6 Doors of KEM 90 DNS3 Door 1 give access to the compartment of water pipes and water side heat exchanger Door 2 3 4 give access to the refrigerating system components and electrical parts ...

Page 17: ...tion temperature sensor 6 High pressure switch 26 Filter 7 Pressure gauge joint high pressure side 27 Capillary 8 Oil separator 28 Fast oil return solenoid valve 9 4 way valve 29 Low pressure switch 10 DC fan 30 Filter 11 Condenser 31 Capillary 12 Coil outlet temperature sensor 32 Outdoor ambient temperature sensor 13 Coil final outlet temperature sensor 33 Unit water inlet temperature sensor 14 F...

Page 18: ...sure gauge joint low pressure side 7 Discharge temperature control switch 1 31 Safety valve 8 Discharge temperature control switch 2 32 Vapor liquid separator 9 One way valve 1 33 Suction temperature sensor 10 One way valve 2 34 Low pressure switch 11 Pressure gauge joint high pressure side 35 Filter 12 High pressure switch 36 Capillary 13 Oil separator 37 Fast oil return solenoid valve 14 4 way v...

Page 19: ...rter compressor discharge temperature sensor 2 40 Water side antifreeze temperature sensor 1 11 One way valve 1 41 System pressure sensor 12 One way valve 2 42 Safety valve 13 High pressure switch 43 Vapor liquid separator 14 Pressure gauge joint high pressure side 44 Pressure gauge joint low pressure side 15 Oil separator 45 Low pressure switch 16 4 way valve 46 Suction temperature sensor 17 DC f...

Page 20: ...2 Power supply to user interface 5 ENC2 DIP switch for capacity selection 6 ENC1 DIP switch for address of outdoor units 7 DSP1 Digital display 8 FUS1 Fuse 9 CN43 Power input 10 CN12_1 CN12_2 Solenoid valve SV4 drive ports 11 IC25 Main control chip 12 CN64 Debug port 13 CN6 Four way valve drive port 14 CN5 CN5_1 Water side heat exchanger heaters connection 15 CN4 CN4_1 Water flow switch heaters co...

Page 21: ...xchanger water inlet temperature sensor and combined water outlet temperature sensor connections 24 CN40 System pressure sensor connection 25 CN41 CN42 Inverter module temperature 1 and Inverter module temperature sensor 2 connections temperature sensor 2 connections 26 CN62 AC indicator A and AC indicator B connections 27 CN65 Low pressure switch connection 28 CN47 High pressure switch and discha...

Page 22: ...d valve of compressor system A 5 CN5 Water side heat exchanger heaters connection 6 CN40 Multi function solenoid valve 7 CN13 Electric of water side heat exchanger heaters connection 8 CN41 Liquid bypass solenoid valve 9 CN42 Crankcase heater 10 CN6 Four way valve 11 CN43 Crankcase heater 12 CN4 CN11 Electric heater of water flow switch 13 CN14 Three way valve hot water valve 14 CN83 Pump 1 After ...

Page 23: ...oor units communication or HMI communication port 24 CN64 Fan inverter module communication ports 25 CN65 Compressor inverter module communication ports 26 CN300 Program burn in port WizPro200RS programming device 27 IC10 EEPROM chip 28 CN1 temperature sensors input port T4 outdoor ambient temperature sensor T3A T3B pipe temperature sensor of the condenser T5 water tank temperature sensor T6A Refr...

Page 24: ...tion 10 is displayed 10 is followed by dot 3 In case of fault or protection fault code or protection code is displayed 43 S5 Dip switch S5 3 Normal control valid for S5 3 OFF factory default Remote control valid for S5 3 ON 44 CN7 Target water temperature switching port 45 ENC2 POWER DIP switch for capacity selection 2 by default 46 CN74 The power supply port of the HMI DC9V 47 ENC4 NET_ADDRESS DI...

Page 25: ...on the electric cabinet 11 The user s attempt to repair the controller is prohibited since improper repair may cause electric shock damages to the controller and so on If the user has any requirement of repair please contact the maintenance center 12 The power cord type designation is H07RN F 8 5 2 KEM 30 DNS3 and KEM 60 DNS3 DIP switch buttons and digital display positions of units DSP1 DSP2 4 S5...

Page 26: ...en enter menu selection b Used for spot checks in other circumstance 8 5 6 Menu selection instructions The menu selection instructions for KEM 30 DNS3 KEM 60 DNS3 and KEM 90 DNS3 are the same See the instructions below Press the menu button to enter menu selection and display n10 it exits if no button is pressed in 10 seconds Use the up button down button to select different level 1 menus n11 nd1 ...

Page 27: ...ing of Tp2 4 Frequency limiting of Tz 7 5 Frequency limiting of TzB 6 Frequency limiting of Tf1 7 Frequency limiting of Tf2 8 Frequency limiting of high pressure H YL 9 Frequency limiting of compressor current 10 Frequency limiting of voltage 37 xx Defrosting process status the first digit T4 selection solution the second digit scheme s range the third and fourth digits as a whole indicates the de...

Page 28: ...ration temperature corresponding to the high pressure in heating mode 42 xx Te Saturation temperature corresponding to the low pressure in cooling mode 43 xx T6A 44 xx T6B 45 xx Software version No 46 xx Last malfunction 47 xx 8 5 9 Electrical wiring precautions a On site wiring parts and materials must comply with the local and national regulations as well as relevant national electrical standard...

Page 29: ...nts for power supply wiring Surge current Grounding 3 Grounding 2 Grounding 1 Grounding wire Lightning arrester Power distribution transformer Wrong Grounding 3 Grounding 2 Grounding 1 Building Grounding wire Lightning arrester Power distribution transformer Correct Manual switch Fuses Power 380 415V 3N 50Hz Manual switch Fuses Power 380 415V 3N 50Hz Unit Unit Fig 8 15 Requirements of power supply...

Page 30: ... and auxiliary heater are added to KEM 90 DNS3 externally a 3 phase contactor must be used for control The model of contactor is subject to the power of water pump and heater power The contactor coil is controlled by the main control board See the figure below for coil wiring For specific wiring see chapter 8 5 18 III 220 240V 50Hz L1 L2 L3 N Coil of 3 phase AC contactor HEAT1 PUMP COM N XT1 Coil ...

Page 31: ...lows electric control box ALARM port Device provided by user Fig 8 23 Wiring of ALARM port If the unit is operating unnormally the ALARM port is closed otherwise the ALARM port is not closed The ALARM ports for KEM 30 DNS3 KEM 60 DNS3 and KEM 90 DNS3 are on the main control board See the wiring nameplate for details 8 5 17 Control system and installation precautions a Use only shielded wires as co...

Page 32: ...products and national 12 0Ω Contactor Contactor Power Transformer AC220 240V AC 8 5 V CN19_L CN1 CN19_L CN2 CN60 CN60 CN60 CN30 CN30 CN30 L1 L 2 L3 POWER 380 415V 3N 50Hz L1 L 2 L3 L1 L 2 L3 L1 L 2 L3 POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz CN72 MONITOR WIRECONTROLER CN72 X Y E A B X Y E A B MONITOR WIRECONTROLER CN72 Yellow Gray Black Yellow Gray Black Yellow Gray Black POWER 380 415V 3N 50...

Page 33: ... POWER 308 415V 3N 50Hz POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz CN72 MONITOR WIRECONTROLER CN72 MONITOR WIRECONTROLER CN72 CN19_N CN19_L CN19_N ENC1 ENC1 ENC1 A B MAIN CONTROL WIRECONTROLER MAIN CONTROL WIRECONTROLER 16 16 16 X Y E A B Yellow Gray Black X Y E A B Yellow Gray Black Fig 8 26 Networking communication schematic of main unit and auxiliary unit of KEM 60 DNS3 NOTE When the power c...

Page 34: ... WH MONITOR WIRECONTROLER HEAT1HEAT2 COM XT1 X Y X Y X Y X Y E X Y E COMP STATE PUMP N CN83 XT3 CN30 HEAT1HEAT2 COM XT1 COMP STATE PUMP N XT3 CN2 CN83 CN30 HEAT1HEAT2 COM XT1 COMP STATE PUMP N XT3 CN2 CN83 CN30 L1 L2 L3 L1 L 2 L3 L1 L 2 L3 POWER 80 415V 3N 50Hz POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz ENC4 ENC4 ENC4 A B MAIN CONTROL WIRECONTROLER X Y E A B RD YE BK BR W...

Page 35: ...g i To facilitate maintenance the inlet and outlet pipes should be provided with thermometer or manometer The unit is not equipped with pressure and temperature instruments so they need to be purchased by the user j All low positions of the water system should be provided with drainage ports to drain water in the evaporator and the system completely and all high positions should be supplied with d...

Page 36: ... and KEM 90 DNS3 models use hoop connection For the specifications of the water pipes and screw thread see the Table 8 12 below Table 8 12 Model Specifications of Pipe connection Specifications of water pipe KEM 30 DNS3 Rc 1 1 4 DN40 KEM 60 DNS3 2 DN50 KEM 90 DNS3 2 DN50 srew connection Fig 8 28 Connection mode of KEM 30 DNS3 pipe hoop connection Fig 8 29 Connection mode of KEM 60 DNS3 pipe ...

Page 37: ...low Comfortable air conditioner G cooling capacity 3 5L Process cooling G cooling capacity 7 4L In certain occasion especially in manufacture cooling process for conforming the system water content requirement it s necessary to mount a tank equipping with a cut off baffle at the system to avoid water short circuit Please see the following schemes Error Recommendation Error Recommendation Fig 8 31 ...

Page 38: ...istance pipe elbow and three way resistance two way resistance or three way resistance as well as filter resistance H4 the longest terminal resistance 8 6 7 2 Installation the pump a The pump should be installed at the water inlet pipe both of which sides must mount the soft connectors for vibration proof b The backup pump for the system recommended c Units must with a main unit controls Please se...

Page 39: ...stem while KEM 90 DNS3 can not be connected with other models 8 6 9 2 Table of diameter parameters of main inlet and outlet pipes Table 8 15 Cooling capacity kW Total inlet and outlet water pipe inside nominaldiameter 15 Q 30 DN40 30 Q 90 DN50 90 Q 130 DN65 130 Q 210 DN80 210 Q 325 DN100 325 Q 510 DN125 510 Q 740 DN150 740 Q 1300 DN200 1300 Q 2080 DN250 CAUTION Please pay attention to the followin...

Page 40: ...it and auxiliary units require wiring when multiple water pumps installed For specific wiring see figure 8 19 and 8 20 9 START UP AND CONFIGURATION 9 1 Initial start up at low outdoor ambient temperature During initial start up and when water temperature is low it is important that the water is heated gradually Failure to do so may result in concrete floors cracking due to rapid temperature change...

Page 41: ...s External physical is correct Whether water system is meeting for require ments Pipe diameter is correct Thermal insulation is correct Water discharge is correct Water quality control is correct Flexible pipe s connection is correct Pressure control is correct Whether electric wiring system is meeting for requirements Switch capacity is correct Chained control is correct Phase sequence of power s...

Page 42: ...he water system is flushed the operation of the pump should not be controlled by the unit Do not start up the unit before draining the water system completely The target flow controller must be installed correctly The wires of the target flow controller must be connected according to electric control schematic diagram or the faults caused by water breaking while the unit is in operation should be ...

Page 43: ...ature antifreeze protection sensorfailure Recovered upon failure recovery 2Eb Taf2 cooling evaporatorlow temperature antifreeze protection sensorfailure Recovered upon failure recovery 13 EC Auxiliary unit module reduction displayed by wired controller 14 Ed 1Ed A system discharge temperature sensor failure Recovered upon failure recovery 2Ed B system discharge temperature sensor failure Recovered...

Page 44: ... H6 1H6 A system bus voltage failure PTC Recovered upon failure recovery 2H6 B system bus voltage failure PTC Recovered upon failure recovery 72 Fb Pressure sensor failure Recovered upon failure recovery 74 Fd Air suction temperature sensor failure Recovered upon failure recovery 76 FF 1FF DC fan A failure Protection occurs 3 times in 20 minutes and the failure can be recovered by power disconnect...

Page 45: ...lure alarm Recovered upon failure recovery 20 EU Tz 7 Coil final outlet temperature sensorerror Recovered upon failure recovery 21 P0 System high pressure protection or discharge temperature protection Protection occurs 3 times in 60 minutes and the failure can be recovered by power disconnection only 22 P1 System low pressureprotection Protection occurs 3 times in 60 minutes and the failure can b...

Page 46: ...temperature sensor failure 2 F9 Recovered upon failure recovery 72 Fb Pressure sensor error Recovered upon failure recovery 74 Fd Suction temperature sensor failure Recovered upon failure recovery 76 FF 1FF DC fan Afailure Failure can only be recovered bydisconnecting the power 2FF DC fan B failure Failure can only be recovered bydisconnecting the power 3FF DC fan C failure Failure can only be rec...

Page 47: ...tric elements in time Ineffective and unreliable elements should be replaced in time 11 4 Removing scale After long time operation calcium oxide or other minerals will be settled in the heat transfer surface of the water side heat exchanger These substances will affect the heat transfer performance when there is too much scale in the heat transfer surface and sequentially cause that electricity co...

Page 48: ...nals for the power of auxiliary electric heater 11 11 Antifreezing In case of freezing at the water side heat exchanger interval channel severe damage may be caused i e heat exchange may be broken and appears leakage This damage of frost crack is not within the warranty scope so attention must be paid to antifreezing a If the unit that is shutdown for standby is placed in an environment where the ...

Page 49: ... air side heatexchanger Inlet Outlet 3 Check refrigerant suction temperature and superheating temperature Refrigerant suction temperature Superheating temperature 4 Check pressure Discharge pressure Suction pressure 5 Check running current 6 Whether unit has been through refrigerant leakage test 7 Whether there is noise on all the panels of unit 8 Check whether the main power source connection is ...

Page 50: ...n Outdoor temperature Dry bulb C Wet bulb C Indoor temperature C Compressor High pressure MPa Low pressure MPa Voltage V Current A Air temperature of air side heat exchanger Inlet dry bulb C Outlet dry bulb C Temperature of chilled water or hot water Inlet C Outlet C Current of water pump A Note ...

Page 51: ...Charging volume kg 10 5 17 0 27 0 Water pipe system Water Folw volume m3 h 5 0 9 8 15 Hydraulic resistance lose kPa 80 50 75 Water side heat exchanger Plate heat exchanger Max pressure MPa 1 0 Min pressure MPa 0 05 Inlet and outlet pip e diameter DN40 DN50 Air side heat exchanger Type Fin coil model Air flow volume m3 h 12500 24000 38000 Outline dimension N W of the unit L mm 1870 2220 3220 W mm 1...

Page 52: ... Pdc 13 2 kW Tj 25 C EERd 5 05 Tj 20 C Pdc 8 1 kW Tj 20 C EERd 6 40 Degradation co efficient for chillers Cdc 0 9 Power consumption in modes other than active mode Off mode POFF 0 08 kW Crankcase heater mode PCK 0 08 kW Thermostat off mode PTO 0 21 kW Standby mode PSB 0 08 kW Other items Capacity control variable For air to water comfort chillers air flow rate outdoor measured _ 12500 m3 h Sound p...

Page 53: ...d Tj 25 C Pdc 25 9 kW Tj 25 C EER d 4 82 Tj 20 C Pdc 11 9 kW Tj 20 C EER d 4 82 Degradation co efficient for chillers C dc 0 9 Power consumption in modes other than active mode Off mode POFF 0 07 kW Crankcase heater mode PCK 0 07 kW Thermostat off mode PTO 0 40 kW Standby mode PSB 0 07 kW Other items Capacity control variable For air to water comfort chillers air flow rate outdoor measured _ 24000...

Page 54: ...41 4 kW Tj 25 C EER d 4 40 Tj 20 C Pdc 30 9 kW Tj 20 C EER d 6 10 Degradation co efficient for chillers Cdc 0 9 Power consumption in modes other than active mode Off mode POFF 0 04 kW Crankcase heater mode PCK 0 04 kW Thermostat off mode PTO 0 11 kW Standby mode PSB 0 04 kW Other items Capacity control variable For air to water comfort chillers air flow rate outdoor measured _ 38000 m3 h Sound pow...

Page 55: ...ficient 4 at Tj 7 C Cdh x xx Cycling interval efficiency at Tj 7 C COPcyc x xx Cycling interval capacity for heating at Tj 2 C Pcych x x kW Cycling interval efficiency at Tj 12 C COPcyc x xx Degradation coefficient 4 at Tj 2 C Cdh x xx Cycling interval capacity for heating at Tj 7 C Pcych x x kW Cycling interval efficiency at Tj 7 C COPcyc x xx Degradation coefficient 4 at Tj 7 C Cdh x xx Cycling ...

Page 56: ...limit temperature WTOL x C Degradation coefficient 4 at Tj 7 C Cdh x xx Cycling interval efficiency at Tj 7 C COPcyc x xx Cycling interval capacity for heating at Tj 2 C Pcych x x kW Cycling interval efficiency at Tj 12 C COPcyc x xx Degradation coefficient 4 at Tj 2 C Cdh x xx Cycling interval capacity for heating at Tj 7 C Pcych x x kW Cycling interval efficiency at Tj 7 C COPcyc x xx Degradatio...

Page 57: ...it temperature WTOL x C Degradation coefficient 4 at Tj 7 C Cdh x xx Cycling interval efficiency at Tj 7 C COPcyc x xx Cycling interval capacity for heating at Tj 2 C Pcych x x kW Cycling interval efficiency at Tj 12 C COPcyc x xx Degradation coefficient 4 at Tj 2 C Cdh x xx Cycling interval capacity for heating at Tj 7 C Pcych x x kW Cycling interval efficiency at Tj 7 C COPcyc x xx Degradation c...

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Page 59: ...Version MD17IU 001GW 16127100000437 ...

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