Kaysun KEM-30 Owners & Installation Manual Download

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IMPORTANT NOTE:

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.

KEM-90 DRS4 KH

OWNER'S & INSTALLATION MANUAL

DC Inverter Air-cooled Modular Chiller

Summary of Contents for KEM-30

Page 1: ...very much for purchasing our air conditioner Before using your air conditioner please read this manual carefully and keep it for future reference KEM 90 DRS4 KH OWNER S INSTALLATION MANUAL DC Inverter Air cooled Modular Chiller ...

Page 2: ...s of arrangement space of the unit 07 6 3 Space requirements for parallel installation of multiple Modular units 08 6 4 Installation foundation 08 6 5 Installation of damping devices 09 7 CONNECTION DRAWING OF PIPELINE SYSTEM 10 8 OVERVIEW OF THE UNIT 8 1 Main parts of the uint 10 8 2 Opening the uint 11 8 3 Outdoor unit PCBs 13 8 4 Electric wiring 19 8 5 Water system installation 27 9 STRAT UP AN...

Page 3: ...g parts 35 11 7 First startup after shutdown 36 11 8 Refrigeration system 36 11 9 Disassembling compressor 36 11 10 Auxiliary electric heater 36 11 11 System antifreezing 36 11 12 Replacement of safety valve 37 11 13 Information servicing 38 RECORD TABLE OF TEST RUN AND MAINTENANCE 41 RECORD TABLE OF ROUTINE RUNNING 41 12 APPLICABLE MODELS AND MAIN PARAMETERS 42 13 INFORMATION REQUIREMENTS 43 ...

Page 4: ... 35 40 45 50 55 0 5 10 15 20 25 30 G KEM 30 DRS4 1 KH KEM 60 DRS4 1 KH KEM 90 DRS4 KH KEM 30 DRS4 1 KH KEM 60 DRS4 1 KH Fig 1 1 1 Cooling operating range Outlet water temperature C COOLING HEATING Outlet water temperature C Two C Two C Outlet water temperature C Outlet water temperature C Fig 1 1 2 Heating operating range Fig 1 2 1 Cooling operating range Fig 1 2 2 Heating operating range Ambient ...

Page 5: ...dous situation which if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices 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 that the o...

Page 6: ...als electric shocks or fire After completing the installation work check to 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 and immediately after operation as the refrigerant pipes may be hot or cold depending on the condition of the refrigerant flowing through the refrigerant p...

Page 7: ...ians in accordance with national wiring 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 wat...

Page 8: ... coil and copper pipes 4 If the unit is within the reach of 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 gr...

Page 9: ... view Top view B E D F A C Fig 6 2 Outline dimensional of KEM 60 DRS4 1 Front view Left view Top view A D C F E B Fig 6 3 Outline dimensional of KEM 90 DRS4 KH Table 6 1 Model KEM 30 DRS4 1 KH KEM 60 DRS4 1 KH KEM 90 DRS4 KH A 1870 2220 2220 B 1000 1325 1135 C 1175 1055 2315 D 204 234 910 E 200 210 255 F 470 470 270 NOTE After installing the spring damper the total height of the unit will increase...

Page 10: ... 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 Input of airow Main unit Main unit Input of airow Input of airow Input of airow Fig 6 4 single unit installstion A E ...

Page 11: ...s such that condensate may freeze Inlet and outlet pipe side Drainage channel Electric control box side Anchor bolt Fig 6 7 Top view of schematic diagram of installation dimension of KEM 30 DRS4 1 KH unit mm Electric control box side Fig 6 8 Top view of schematic diagram of installation dimension of KEM 60 DRS4 1 KH Inlet and outlet pipe side Drainage channel Anchor bolt unit mm Fig 6 9 Top view o...

Page 12: ...by 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 Base height Outdoor unit Fig 6 12 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 de...

Page 13: ... Pressure gauge Flexible joint Gate valve Automatic discharge valve Y shaped filter Thermometer Circulating pump Check 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 8 OVERVIEW OF THE UNIT 8 1 Main parts of the uint Table 8 1 NO NAME NO NAME 1 Air outlet 6 Condenser 2 Top cover 7 Water intlet 3 Electric control b...

Page 14: ...60 DRS4 1 8 2 Opening the uint By means of a detachable service panel the maintenance personnel can easily access the interior components of the unit Door 1 Door 2 Door 3 Door 4 Fig 8 4 Doors of KEM 30 DRS4 1 Door 1 give access to the compartment of water pipes and water side heat exchanger Door 2 3 4 give access to the hydraulic compartment and electrical parts ...

Page 15: ...ive access to the compartment of water pipes water side heat exchanger acculator and liquid vapor separator Door 2 3 4 give access to the hydraulic compartment and electrical parts Door 1 2 3 give access to the compartment of water pipes and water side heat exchanger Door 4 give access to the electrical parts Door 5 6 give access to the hydraulic compartment ...

Page 16: ...rly period after the power supply is connected and they are not detected while the unit is in operation 2 CN12 Quick return oil solenoid valve 3 CN5 EVA HEAT Water side heat exchanger heaters connection 4 CN13 EVA HEAT Electric of water side heat exchanger heaters connection 5 CN42 CCH Crankcase heater 6 CN43 CCH Crankcase heater 7 CN6 ST1 Four way valve 8 CN4 CN11 W HEAT Electric heater of water ...

Page 17: ...temperature sensor T3A T3B pipe temperature sensor of the condenser T5 wtater tank temperature sensor T6A Refrigerant inlet temperature of EVI plate heat exchanger T6B Refrigerant outlet temperature of EVI plate heat exchanger 25 CN16 System pressure sensor 26 CN31 Temperature sensors input port Th System suction temperature sensor Taf2 Water side antifreeze temperature sensor Two Unit water outle...

Page 18: ...actory default Low temperature cooling valid for S12 3 ON 41 CN7 TEMP SW Target water temperature switching port 42 ENC2 POWER DIP switch for capacity selection KEM 30 DRS4 1 KH defaults 0 KEM 60 DRS4 1 KH defaults 1 43 CN74 The power supply port of the HMI DC9V 44 ENC4 NET_ADDRESS DIP switch 0 F of outdoor unit network address is enabled which represent address 0 15 CAUTION Faults When the main u...

Page 19: ...operation 2 CN12 Quick return oil solenoid valve 3 CN80 Injection solenoid valve of compressor system B 4 CN47 Injection solenoid 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...

Page 20: ...rn in port WizPro200RS programming device 28 IC10 EEPROM chip 29 CN1 temperature sensors input port T4 outdoor ambient temperature sensor T3A T3B pipe temperature sensor of the condenser T5 wtater tank temperature sensor T6A Refrigerant inlet temperature of EVI plate heat exchanger T6B Refrigerant outlet temperature of EVI plate heat exchanger 30 CN16 System pressure sensor 31 CN31 Temperature sen...

Page 21: ...9V 46 ENC4 NET_ADDRESS DIP switch 0 F of outdoor unit network address is enabled which represent address 0 15 47 S12 Dip switch S12 1 Valid for S12 1 ON factory default S12 2 Single water pump controll valid for S12 2 OFF factory default Multiple water pumps controll valid for S12 2 ON CAUTION Faults When the main unit suffers faults the main unit stops operating and all other units also stop runn...

Page 22: ...ly Please carefully read the labels on the electric cabinet 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 The power cord type designation is H07RN F 8 4 2 KEM 30 DRS4 1 KH and KEM 60 DRS4 1 KH and KEM 90 DRS4 KH DIP switch bu...

Page 23: ... d Power wiring must be entrusted to professionals with electrician qualification Fig 8 10 4 Electrical wiring precaution d 8 4 5 Power supply specification Table 8 4 Item Model Outdoor power supply Power supply Manual switch Fuse Wiring KEM 30 DRS4 1 KH 380 415V 3N 50Hz 50A 36A 10mm2 X5 20m KEM 60 DRS4 1 KH 380 415V 3N 50Hz 100A 63A 16mm2 X5 20m KEM 90 DRS4 KH 380 415V 3N 50Hz 125A 100A 25mm2 X5 ...

Page 24: ...g arrester Grounding wire Building Fuses Fuses Grounding 1 Grounding 2 Grounding 3 Uint Lightning arrester Grounding wire Surge current Grounding 1 Grounding 2 Grounding 3 Fig 8 11 Requirements of power supply wiring NOTE 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 ...

Page 25: ...heater and ac light of the state of compressor is as follows HEAT1 HEAT2 COM COMP STATE PUMP Blue Black Brown 8 4 9 Wiring of ON OFF weak electric port The remote function of ON OFF must be set by DIP switch The remote function of ON OFF is effective when 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 elec...

Page 26: ...12V Main control board is provided 0 electric control box TEMP SWITCH port 0 electric control box TEMP SWITCH port First target water temperature Second target water temperature Fig 8 17 Wiring of TEMP SWITCH weak electric port Device provided by user electric control box ALARM port Fig 8 18 Wiring of ALARM port 8 4 12 Wiring of ALARM port Connect the device provided by user to the ALARM ports of ...

Page 27: ... MODULE COMMUNICATION WITH NEXT MODULE COMMUNICATION WITH NEXT MODULE POWER 380 415V 3N 50Hz RVV 300 500 5X10mm 2 The length of wire s h o u l d b e s h o r t e r than 500m The Wiring Terminal X Y and E on the back of Wire Controller are correspondin of the Terminal X Y and E of Wiring Board in Main Module MAIN CONTROL WIRECONTROLER Power Transformer OUTPUT 8 5 V POWER MAIN CONTROL WIRECONTROLER W...

Page 28: ...The length of wire s h o u l d b e s h o r t e r than 500m The Wiring Terminal X Y and E on the back of Wire Controller are correspondin of the Terminal X Y and E of Wiring Board in Main Module MAIN CONTROL WIRECONTROLER Power Transformer OUTPUT 8 5 V POWER MAIN CONTROL WIRECONTROLER WH BR BK YE RD WH BR BK YE RD HEAT1 HEAT2 COM COMP STATE PUMP COMMUNICATION WITH WIRE COMTROLLER Over current relay...

Page 29: ...o r t e r than 500m The Wiring Terminal X Y and E on the back of Wire Controller are correspondin of the Terminal X Y and E of Wiring Board in Main Module Power Transformer OUTPUT 8 5 V MAIN CONTROL WIRECONTROLER COMMUNICATION WITH WIRE COMTROLLER Notes The wiring diagram of auxiliary heaters is just for reference please follow the instructions of corresponding auxiliary heater products Please cho...

Page 30: ...ned units should be provided with mixing water temperature sensor WARNING For the water pipeline network including filters and heat exchangers dreg or dirt may seriously damages the heat exchangers and water pipes The installation persons or the users must ensure the quality of chilled water and de icing salt mixtures and air should be excluded from the water system since they may oxidize and corr...

Page 31: ... Hoop connection DN50 KEM 90 DRS4 KH Hoop connection DN50 Fig 8 23 connection mode of KEM 30 DRS4 1 KH Fig 8 24 connection mode of KEM 60 DRS4 1 KH Fig 8 25 connection mode of KEM 90 DRS4 KH pipe 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 cap...

Page 32: ... 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 pump should be installed at the ...

Page 33: ...sition and move the total euent temperature sensor at No 0 address to the position Pump Pump Fig 8 28 Installation of multi module no more than 16 modules 2 Table of diameter parameters of main inlet and outlet pipes Table 8 8 Cooling capacity Total inlet and outlet water pipe inside nominal diameter 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 D...

Page 34: ... Tw unit 0 Fig 8 30 Installation of multiple water pump 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 contrac...

Page 35: ... 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 36: ...error recovery 14 EE 1EE EVI plate heat exchanger refrigerant temperature T6A sensor error Recovered upon error recovery 2EE EVI plate heat exchanger refrigerant temperature T6B sensor error 15 EF Unit water return temperature sensor error Recovered upon error recovery 16 EH System self check error alarm Recovered upon error recovery 17 EP Discharge sensor error alarm Recovered upon error recovery...

Page 37: ...nutes 42 F6 1F6 A system buss voltage error PTC Recovered upon error recovery 2F6 B system buss voltage error PTC 43 Fb Pressure sensor error Recovered upon error recovery 44 Fd Suction temperatrue sensor error Recovered upon error recovery 45 FF 1FF DC fan A error Recovered by power off 2FF DC fan B error 46 FP DIP switch inconsistency of multiple water pumps Recovered by power off 47 C7 If PL oc...

Page 38: ...vent 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 e...

Page 39: ...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 CAUTION 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 pressuriz...

Page 40: ...apor separator safety valve Fig 11 1 Replacement of safety valve WARNING 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 PIFE...

Page 41: ...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 42: ...pment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas 25 maximum is confirmed 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...

Page 43: ...ioning it is recommended good practice that all refrigerants are removed safely When tranferring refrigerant into cylinders ensure that only appropriate refrigerant recovery cylinders are employed Ensure that the correct numbers 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 ...

Page 44: ...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 correct RECORD TABLE OF ROUTINE RUNNING Table 11 3 Model Date Weather Operation time Startup Shutdown Outdoor temperature Dry bulb C Wet bulb C Indoor temperature C Compressor High pressure MPa Low pressure ...

Page 45: ...sure switch freeze proof device water flow volume controller Overcurrent device power phase sequence device etc Refrigerant Type R32 Chargeing volume kg 7 9 14 0 16 0 Water pipe system Waterflow volume m3 h 5 0 9 8 15 0 Hydraulic resistance lose kPa 150 200 220 Water side heat exchanger Plate heat exchanger Max pressure MPa 1 0 Min pressure MPa 0 05 Inlet and outlet pipe dia DN40 DN50 Air side hea...

Page 46: ... 79 Tj 25 C Pdc 12 79 kW Tj 25 C EERd 4 98 Tj 20 C Pdc 5 87 kW Tj 20 C EERd 5 72 Degradation co efficient for chillers Cdc 0 90 Power consumption in modes other than active mode Off mode POFF 0 020 kW Crankcase heater mode PCK 0 000 kW Thermostat off mode PTO 0 290 kW Standby mode PSB 0 020 kW Other items Capacity control Variable For air to water comfort chillers air flow rate outdoor measured 12...

Page 47: ...c 25 43 kW Tj 25 C EERd 4 48 Tj 20 C Pdc 11 30 kW Tj 20 C EERd 4 83 Degradation co efficient for chillers Cdc 0 9 Power consumption in modes other than active mode Off mode POFF 0 035 kW Crankcase heater mode PCK 0 000 kW Thermostat off mode PTO 0 035 kW Standby mode PSB 0 035 kW Other items Capacity control Variable For air to water comfort chillers air flow rate outdoor measured 24000 m3 h Sound...

Page 48: ...dc 37 36 kW Tj 25 C EERd 5 10 Tj 20 C Pdc 26 05 kW Tj 20 C EERd 5 91 Degradation co efficient for chillers Cdc 0 9 Power consumption in modes other than active mode Off mode POFF 0 090 kW Crankcase heater mode PCK 0 kW Thermostat off mode PTO 0 700 kW Standby mode PSB 0 090 kW Other items Capacity control Variable For air to water comfort chillers air flow rate outdoor measured 35000 m3 h Sound po...

Page 49: ...ater operating limit temperature 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 7 C Pcych kW Cycling interval capacity for heating at Tj 12 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval efficiency at Tj 7 C COPcyc Cycling interval capa...

Page 50: ...tion coefficient 4 at T 7 C Cdh Heating water operating limit temperature 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 7 C Pcych kW Cycling interval capacity for heating at Tj 12 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval efficien...

Page 51: ...t 4 at T 7 C Cdh Heating water operating limit temperature 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 7 C Pcych kW Cycling interval capacity for heating at Tj 12 C COPcyc Degradation coefficient 4 at Tj 7 C Cdh Cycling interval efficiency at Tj 7 C CO...

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