Kaysun KEM-HT-65 DRS5 Owners & Installation Manual Download Page 56

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16127100001537 V.B

Summary of Contents for KEM-HT-65 DRS5

Page 1: ...lease read this manual carefully and keep it for future reference The figure shown in this manual is for reference only and may be slightly different from the actual product KEM HT 65 DRS5 KEM HT 110 DRS5 OWNER S INSTALLATION MANUAL New Modular Full Dc Inverter Chillers HT ...

Page 2: ...rrangement space of the unit 07 6 3 Installation foundation 08 6 4 Installation of damping devices 08 6 5 Installation of device to prevent snow build up and strong breeze 09 7 CONNECTION DRAWING OF PIPELINE SYSTEM 10 8 OVERVIEW OF THE UNIT 8 1 Main parts of the uint 11 8 2 Opening the uint 12 8 3 Outdoor unit PCBs 13 8 4 Electric wiring 16 8 5 Water system installation 23 9 STRAT UP AND CONFIGRUA...

Page 3: ...parts 31 11 7 First startup after shutdown 32 11 8 Refrigeration system 32 11 9 Disassembling compressor 32 11 10 Auxiliary electric heater 32 11 11 System antifreezing 32 11 12 Replacement of safety valve 33 11 13 INFORMATION SERVICING 34 RECORD TABLE OF TEST RUN AND MAINTENANCE 37 RECORD TABLE OF ROUTINE RUNNING 37 12 APPLICABLE MODELS AND MAIN PARAMETERS 38 13 INFORMATION REQUIREMENTS 39 ...

Page 4: ...et water temperature C Outlet water temperature C Fig 1 1 1 Cooling operating range Fig 1 1 2 Heating operating range 65KW 110KW HEATING Low leaving water temperature mode can be set by wired controller please refer to the Operation Manual select LOW OUTLETWATER CONTROL under SERVICE MENU page for details If low leaving water temperature function is effective the operation range will extend to the...

Page 5: ...ed to alert against unsafe practices NOTE Indicates situations that could only result in accidental equipment or property damage DANGER Explanation of symbols displayed on the indoor unit or outdoor unit WARNING This symbol shows that this appliance used a flammable refrigerant If the refrigerant is leaked and exposed to an external ignition source there is a risk of fire CAUTION This symbol shows...

Page 6: ... the wires so that the front panel can be securely fastened If the front panel is not in place there could be overheating of the terminals electric shocks or fire After completing the installation work make sure that there is no refrigerant leakage Never directly touch any leaking refrigerant as it could cause severe frostbite Do not touch the refrigerant pipes during or soon after operation as th...

Page 7: ...ng regulation and this circuit diagram An all pole disconnection device which has at least 3mm seperation distance in all pole and a residualcurrent device RCD with the rating not exceeding 30mA shall be incorporated in the fixed wiring according to the national rule Confirm the safety of the installation area walls floors etc without hidden dangers such as water electricity and gas before the wir...

Page 8: ...es 4 If the unit can be achieved by unauthorized personnel take protective measures for safety considerations such as installing a fence These measures can prevent man caused or accidental injuries and can also prevent the electrical parts in operation from being exposed when the main control box is opened 5 Install the unit on a foundation at least 200 mm high above the ground where the floor dra...

Page 9: ...awing Front view Left view Top view Fig 6 1 Outline dimensional Table 6 1 Model 65KW 110KW A 2000 2220 B 960 1135 C 1770 2300 D 816 910 E 190 185 F 269 270 After installing the spring damper the total height of the unit will increase by 135mm approximately NOTE ...

Page 10: ...e less than the static pressure outside the fan The space between the unit and sunk fence or Persian blinds should also meet the requirement 3 If the unit needs to operate in winter and the installation site may be covered by snow the unit should be located higher than the snow surface to ensure that air flows through the coils smoothy A B D C G A E E E E E E F F F F B D C Input of airow Input of ...

Page 11: ...ondensate is directed away from roadways and footpaths especially in locations where the climate is such that condensate may freeze unit mm Inlet and outlet pipe side Drainage channel Anchor bolt Electric control box side Fig 6 5 Top view of schematic diagram of installation dimension of 65KW Inlet and outlet pipe side Drainage channel Anchor bolt Electric control box side unit mm Fig 6 6 Top view...

Page 12: ...y snow 1 Measures to prevent build up of snow The base height should be as least the same as the predicted snow depth in the local area Outdoor unit Base height Fig 6 9 Snow prevention base height 2 Lightning protection and snow protection measures Check the installation site thoroughly do not install the equipment under awnings or trees or a place where snow is piled up 6 5 2 Precautions for desi...

Page 13: ...ifferential pressure by pass valve Auxiliary electric heater Auxiliary electric heater Auxiliary electric heater Drain valve Drain valve Plate exchanger Drain valve Drain valve Drain valve Air conditioning mode Installation of variable frequency pump in the project Drain valve Terminal Terminal Electrode type water level switch Electrode type water level switch Hot water tank Hot water tank Overfl...

Page 14: ...aced on the main outlet pipe The hot water tank and the hot water exchange pump of the unit use the CN125 220V port control switch on the slave board of the 0 unit pump output is controlled through CN108 0 10V The electromic butterfly valve on the unit water outlet pipe is controlled by the CN123 port on the slave board of each unit NOTE 8 OVERVIEW OF THE UNIT 8 1 Main parts of the uint Table 8 1 ...

Page 15: ...de heat exchanger Cover 4 give access to the electrical parts Cover 5 6 give access to the hydraulic compartment Cover 1 Cover 2 Cover 3 Cover 6 Cover 5 Cover 4 Fig 8 4 Doors of 110KW Cover 1 2 3 give access to the compartment of water pipes and water side heat exchanger Cover 4 give access to the electrical parts Cover 5 6 give access to the hydraulic compartment ...

Page 16: ...fter all modules stop operating 3 In case of shutdown under the pump mode the pump can be directly shut down 4 CN74 CN67 CCH Crankcase heater 5 CN75 CN66 EVA HEAT Electric of water side heat exchanger heaters connection 6 CN6 ST1 Four way valve 7 CN49 SV6 Liquid bypass solenoid valve 8 CN69 SV5 Multi function solenoid valve 9 CN84 SV8A Injection solenoid valve of compressor system A 10 CN83 SV8B I...

Page 17: ...N72 EXVC EVI electronic expansion valve Used for EVI 31 CN70 EXVA System electronic expansion valve1 32 CN71 EXVB System electronic expansion valve2 Used for cooling 33 SW3 Up button a Select different menus when enter menu selection b For sopt inspection in conditions SW4 Down button a Select different menus when enter menu selection b For sopt inspection in conditions SW5 Menu button Press to en...

Page 18: ...Pipeline Auxiliary Heater HEAT2 Hot Water Tank Auxiliary Heater Attention the control port value of the pump actually detected is ON OFF but not 220 240V control power supply so special attention should be paid when installing the pipeline auxiliary heater 7 CN108 Inverter pump 0 10V output control singnal 8 CN109 W P SW Water pressure switching port 9 CN110 TEMP SW Target water temperature switch...

Page 19: ...ease don t repair the controller by yourself since improper operation may cause electric shock damages to the controller and other bad results If the unit need repair please contact the maintenance center 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 The power cord type designation ...

Page 20: ... 8 8 3 Electrical wiring precaution c d Power wiring must be entrusted to professionals with electrician qualification Fig 8 8 4 Electrical wiring precaution d 8 4 5 Power supply specification Table 8 5 Item Model Outdoor power supply Power supply Manual switch Fuse Wiring 65KW 380 415V 3N 50Hz 100A 63A 16mm2 X5 20m 110KW 380 415V 3N 50Hz 200A 150A 50mm2 X5 20m See the table above for power wire d...

Page 21: ...htning arrester Surge current Grounding wire Grounding wire Grounding 3 Grounding 3 Grounding 2 Grounding 2 Grounding 1 Grounding 1 Building Do not connect the grounding wire of the lightning arrester to the unit shell The grounding wire of the lightning arrester and the power supply grounding wire must be configured separately NOTE 8 4 7 Requirements for power cord connection L1 L2 L3 N L1 L2 L3 ...

Page 22: ...f ON OFF must be set by DIP switch The remote function of ON OFF is effective when S1 1 or S5 3 is chosen ON at the same time the wired controller is out of control Corresponding parallel connect the ON OFF port of the main unit s electric control box then connect the ON OFF signal provide by user to the ON OFF port of main unit as follows The remote function of ON OFF must be DIP switch set Wirin...

Page 23: ... is closed otherwise the ALARM port is open The ALARM ports are on the main control board See the wiring diagram for details 8 4 13 Control system and installation precautions a Use only shielded wires as control wires Any other type of wires may produce a signal interference that will cause the units to malfunction Fig 8 16 1 Control system and installation precaution a b The shielding nets at bo...

Page 24: ...V POWER POWER 380 415V 3N 50Hz RVV 300 500 5X16mm 2 RWP 300 300 3X0 75mm 2 RVV 300 500 2X1 0mm 2 RVVP 300 300 3X0 75mm 2 PUMP Contactor Over current relay POWER 380 415V 3N 50Hz The metal plate of contactor installation box should be grounded MAIN CONTROL WIRECONTROLER Notes The wiring diagram of auxiliary heaters is just for reference please follow the instructions of corresponding auxiliary heat...

Page 25: ...5X16mm 2 RWP 300 300 3X0 75mm 2 RVV 300 500 2X1 0mm 2 RVVP 300 300 3X0 75mm 2 PUMP Contactor Over current relay POWER 380 415V 3N 50Hz The metal plate of contactor installation box should be grounded MAIN CONTROL WIRECONTROLER Notes The wiring diagram of auxiliary heaters is just for reference please follow the instructions of corresponding auxiliary heater products Please choose such accessory as...

Page 26: ... can be cut off without disturbing other heat exchangers i The flexible ports should be adopted between the interface of the heat exchanger and on site pipeline to reduce transfer of vibration to the building j 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 p...

Page 27: ... 110KW Hoop connection DN65 Fig 8 19 8 5 3 Design of the store tank in the system kW is the unit for cooling capacity and L is the unit for G water flow in the formula counting the minimum water flow 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 requir...

Page 28: ...H h1 h2 h3 h4 H The lift of the pump h1 Main unit water resistance h2 Pump water resistance h3 Water resistance of the longest water loop distance includes pipe resistance different valve s resistance flexible pipe resistance pipe elbow and three way resistance two way resistance or three way resistance as well as filter resistance H4 the longest terminal resistance 2 Installation the pump a The p...

Page 29: ...lation of multi module no more than 16 modules 2 Table of diameter parameters of main inlet and outlet pipes Table 8 9 Cooling capacity Total inlet and outlet water pipe inside nominal diameter 15 Q 30 DN40 30 Q 90 DN50 90 Q 140 DN65 140 Q 210 DN80 210 Q 325 DN100 325 Q 510 DN125 510 Q 740 DN150 740 Q 1300 DN200 1300 Q 2080 DN250 Please pay attention to the following items when installing multiple...

Page 30: ...nstalled For specific wiring see figure 8 18 9 STRAT UP AND CONFIGRUATION 9 1 Initial start up at low outdoor ambient temperatures 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 Please contact the responsible cast concrete building contractor for fur...

Page 31: ... a fault code If a fault occurs remove the fault first and start the unit according to the operating method in the unit control instruction after determining that there is no fault existing in the unit 2 Conduct trial run for 30 min When the influent and effluent temperature becomes stabilized adjust the water flow to nominal value to ensure normal operation of the unit 3 After the unit is shut do...

Page 32: ... failure recovery 16 EP Discharge sensor failure alarm Recovered upon failure recovery 17 EU Tz sensor failure Recovered upon failure recovery 18 P0 P0 System high pressure protection or discharge temperature protection for 3 times in 60 minutes Recovered by power off 1P0 Compressor module 1 high pressure protection Recovered upon failure recovery 2P0 Compressor module 2 high pressure protection R...

Page 33: ...ery 49 xL2 high voltage protection x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recovery 50 xL4 MCE error x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recovery 51 xL5 zero speed protection x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recovery 52 xL7 phase loss x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recove...

Page 34: ...ent air conditioner errors which bring inconvenience to your life and work 2 Maintenance of main parts Close attention should be paid to the discharge and suction pressure during the running process Find out reasons and eliminate the failure if abnormality is found Control and protect the equipment See to it that no random adjustment be made on the set points on site Regularly check whether the el...

Page 35: ...ed water circulate and start up unit and make the low pressure control switch short circuit if necessary Slowly inject refrigerant into the system and check suction and discharge pressure Connection must be renewed after injection is completed Never inject oxygen acetylene or other flammable or poisonous gas to the refrigeration system at leakage detection and air tight test Only pressurized nitro...

Page 36: ... safety valve liquid vapor separator Fig 11 1 Replacement of safety valve The air outlet of safty valve must be connected to the appropriate pipe which can direct the leaking refrigerant to the appropriate place for discharge Safety valve warranty period is 24 months Under the specified conditions if flexible sealing parts is used the safety valve life expectancy is 24 to 36 months If metal or PIF...

Page 37: ...ing the period that the work is carried out The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere 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 maintenance and service guidelines shall be followed...

Page 38: ... Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe work If a leak is suspected all naked flames shall be removed or extinguished If a leakage of refrigernat is found which requires brazing all of the refrigerant shall be recovered from the system...

Page 39: ...mbers of cylinders for holding the total system charge are available All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant i e special cylinders for the recovery of refrigerant Cylinders shall be complete with pressure relief valve and associated shut off valves in good working order Empty recovery cylinders are evacuated and if possible cooled bef...

Page 40: ...1111111 1111111 Suction pressure 1111111 1111111 1111111 1111111 1111111 5 Check running current 1111111 1111111 1111111 1111111 1111111 6 Whether unit has been through refrigerant leakage test 1111111 7 Whether there is noise on all the panels of unit 1111111 8 Check whether the main power source connection is correct 1111111 RECORD TABLE OF ROUTINE RUNNING Table 11 3 Model Date Weather Operation...

Page 41: ...sure switch freeze proof device water flow volume controller Overcurrent device power phase sequence device etc Refrigerant Type R32 Chargeing volume kg 9 0 15 5 Water pipe system Water flow volume m3 h 9 8 17 2 Hydraulic resistance lose kPa 44 39 Water side heat exchanger Plate heat exchanger Max pressure MPa 1 0 Min pressure MPa 0 15 Inlet and outlet pipe dia DN50 DN65 Air side heat exchanger Ty...

Page 42: ... C Pdc 27 30 kW Tj 25 C EERd 5 64 Tj 20 C Pdc 19 29 kW Tj 20 C EERd 8 81 Degradation co efficient for chillers Cdc 0 90 Power consumption in modes other than active mode Off mode POFF 0 08 kW Crankcase heater mode PCK 0 kW Thermostat off mode PTO 0 556 kW Standby mode PSB 0 08 kW Other items Capacity control Variable For air to water comfort chillers air flow rate outdoor measured 22000 m3 h Sound...

Page 43: ...9 kW Tj 25 C EERd 5 78 Tj 20 C Pdc 29 45 kW Tj 20 C EERd 7 05 Degradation co efficient for chillers Cdc 0 9 Power consumption in modes other than active mode Off mode POFF 0 14 kW Crankcase heater mode PCK 0 kW Thermostat off mode PTO 0 7 kW Standby mode PSB 0 14 kW Other items Capacity control Variable For air to water comfort chillers air flow rate outdoor measured 32500 m3 h Sound power level i...

Page 44: ...L C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C Pcych kW...

Page 45: ...OL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C Pcych k...

Page 46: ...ure WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C P...

Page 47: ...ature WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C...

Page 48: ...erature WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12...

Page 49: ...mperature WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj ...

Page 50: ...C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C Pcych kW C...

Page 51: ...L C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C Pcych kW...

Page 52: ...re WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C Pc...

Page 53: ...ture WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 C ...

Page 54: ...rature WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 12 ...

Page 55: ...perature WTOL C Cycling interval capacity for heating at Tj 2 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at T 2 C Cdh Cycling interval capacity for heating at Tj 12 C COPcyc Cycling interval capacity for heating at Tj 7 C Pcych kW Cycling interval efficiency at Tj 7 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval capacity for heating at Tj 1...

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