Kaysun KEM-90 DRS5 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 DRS5

OWNER'S & INSTALLATION MANUAL

DC Inverter Air-cooled Modular Chiller

Summary of Contents for KEM-90 DRS5

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 DRS5 OWNER S INSTALLATION MANUAL DC Inverter Air cooled Modular Chiller ...

Page 2: ...nts 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 10 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 ...

Page 3: ...ng 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: ...e please operate the unit under the following outdoor temperature KEM 30 DRS4 1 KEM 60 DRS4 1 KEM 30 DRS4 1 KEM 60 DRS4 1 Outlet water temperature C Outlet water temperature C Fig 1 1 1 Cooling operating range Fig 1 1 2 Heating operating range KEM 90 DRS5 KEM 90 DRS5 COOLING HEATING Two C Two C Outlet water temperature C Outlet water temperature C Fig 1 2 1 Cooling operating rang Fig 1 2 2 Heating...

Page 5: ...rdous 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 ...

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: ...ans 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 wate...

Page 8: ... 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 ground ...

Page 9: ...D C F E B Front view Left view Top view Fig 6 2 Outline dimensional of KEM 60 DRS4 1 F D E A B C B E D F A C A D C F E B Front view Left view Top view Fig 6 3 Outline dimensional of KEM 90 DRS5 Table 6 1 Model KEM 30 DRS4 1 KEM 30 DRS4 1 KEM 60 DRS4 1 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 heigh...

Page 10: ... 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 airow Input of airow Input of airow Input of airow Input ...

Page 11: ...unit mm 1870 800 926 530 80mm 200mm 2200 1105 958 425 2200 1460 1017 370 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 1870 800 926 530 80mm 200mm 2200 1105 958 425 2200 1460 1017 370 Inlet and outlet pipe side Inlet and outlet pipe side Electric control box side Electric control bo...

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 Outdoor unit Base height 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: ...Fig 8 3 Main parts of KEM 90 DRS5 Fig 8 4 Doors of KEM 30 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 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: ...ccess 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 Door 3 Door 4 Fig 8 5 Doors of KEM 60 DRS4 1 Fig 8 6 Doors of KEM 90 DRS5 Door 1 Door 2 Door 3 Door 6 Door 5 Door 4 ...

Page 16: ...on phase lace and phase dislocation of power supply are detect ed only in the early period after the power supply is connected and they are not detected while the unit is in opera tion 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 Cran...

Page 17: ...erature sensor of the condenser T5 wtater tank temperature sensor T6A Refrigerant inlet temperature of EVI plate heat exchanger T6B Refrigerant inlet temperature of EVI plate heat exchanger 24 CN16 System pressure sensor 25 CN31 Temperature sensors input port Th System suction temperature sensor Taf2 Water side antifreeze temperature sensor Two Unit water outlet temperature sensor Twi Unit water i...

Page 18: ...F factory default Low temperature cooling valid for S12 3 ON 40 CN7 TEMP SW Target water temperature switching port 41 ENC2 POWER DIP switch for capacity selection KEM 30 DRS4 1 defaults 0 KEM 60 DRS4 1 defaults 1 42 CN74 The power supply port of the HMI DC9V 43 ENC4 NET_ADDRESS DIP switch 0 F of outdoor unit network address is enabled which represent address 0 15 CAUTION Faults When the main unit...

Page 19: ...pply is connected and they are not detected while the unit is in 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 sol...

Page 20: ...ice 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 inlet temperature of EVI plate heat exchanger 30 CN16 System pressure sensor 31 CN31 Temperature sensors input port Th System suction tempe...

Page 21: ... 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 runnin...

Page 22: ...aration Set leakage protective devices according to the requirements of national technical standard about electric equipment After completing all wiring construction conduct careful check before connecting the power supply 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 ...

Page 23: ...iring precaution a Fig 8 10 3 Electrical wiring precaution c Fig 8 10 4 Electrical wiring precaution d Fig 8 10 2 Electrical wiring precaution b National standard Item Model Outdoor power supply Power supply Manual switch Fuse Wiring KEM 30 DRS4 1 380 415V 3N 50Hz 50A 36A 10mm2 X5 20m KEM 60 DRS4 1 380 415V 3N 50Hz 100A 63A 16mm2 X5 20m KEM 90 DRS5 380 415V 3N 50Hz 125A 100A 25mm2 X5 20m NOTE See ...

Page 24: ...ing wire Surge current Building Power 380 415V 3N 50Hz Power 380 415V 3N 50Hz Grounding 1 Grounding 1 Grounding 2 Grounding 2 Grounding 3 Grounding 3 Uint Uint Fuses Fuses 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: ...nitor the state of compressor When the compressor is operating the light will be powered on The wiring of water pump and pipeline auxiliary heater and ac light of the state of compressor is as follows Coil of 3 phase AC contactor Coil of 3 phase AC contactor 220 240V 50Hz N 220 240V 50Hz N CN26 Main board CN33 Main board CN25 Main board Max voltage 240VAC Max current 5A Max voltage 240VAC Max curr...

Page 26: ...2 at 14 and 23 inside the electric control box to enable the remote function of HEAT COOL If the unit is operating unnormally the ALARM port 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 sig...

Page 27: ...ength of wire should be shorter tan 500m MAIN CONTROL WIRECONTROLER The metal plate of contactor installation box should be grounded 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 power wire switch of auxiliary heater according to the actual parameter of products and natio...

Page 28: ...OWER COMMUNICATION WITH NEXT MODULE COMMUNICATION WITH LAST MODULE RVV 300 500 2X1 0mm 2 RVV 300 500 2X1 0mm 2 Thel length of wire should be shorter tan 500m MAIN CONTROL WIRECONTROLER The metal plate of contactor installation box should be grounded Notes The wiring diagram of auxiliary heaters is just for reference please follow the instructions of corresponding auxiliary heater products Please c...

Page 29: ...MUNICATION WITH LAST MODULE RVV 300 500 2X1 0mm 2 RVV 300 500 2X1 0mm 2 Thel length of wire should be shorter tan 500m MAIN CONTROL WIRECONTROLER The metal plate of contactor installation box should be grounded 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 power wire swit...

Page 30: ...of the evaporator g The evaporator should be provided with a filter with more than 40 meshes per inch at site The filter should be installed near to the inlet port as much as possible and beunder heat preservation h The by pass pipes and by pass valves as shown in Fig 8 23 must be mounted for the heat exchanger to facilitate cleaning of the outside system of water passage before the unit is adjust...

Page 31: ...w 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 Model Pipe connection methods Specifications of water...

Page 32: ...e furring may occur however well water or river water used as chilled water may cause much sediment such as furring sand and so on Therefore well water or river water must be filtered and softened in softening water equipment before flowing into chilled water system If sand and clay settle in the evaporator circulation of chilled water may be blocked and thus leading to freezing accidents if hardn...

Page 33: ...o 0 address to the position Drill dead hole at the position and move the total euent temperature sensor at No 0 address to the position No 1 module No 0 address No n 1 module No n 2 address No n module No n 1 address Pump Pump 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: ...ion of multiple water pump terminal Tw outlet water 9 1 Initial start up at low outdoor ambient temperatures 9 2 Points for attention prior to trial run 9 STRAT UP AND CONFIGRUATION 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 re...

Page 35: ...e unit is not in service for a long time and the power supply needs to be cut off the unit should be connected to the power supply 12 hours prior to re starting of the unit to pre heat the compressor the pump the plate heat exchanger and the differential pressure value 10 1 Check item table after installation 10 2 Trial run 10 TEST RUN AND FINAL CHECK Checking item Description Yes No Whether insta...

Page 36: ...ror 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 1...

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: ...ntain the unit to prevent 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 Regularl...

Page 39: ...t crack may happen to water side heat exchanger at maintenance when refrigerant is injected to the unit or is discharged for repair Pipe freezing is likely to happen any time when the pressure of refrigerant is below 0 4Mpa Therefore the water in the heat exchanger must be kept flowing or be thoroughly discharged Determine whether refrigerant is needed by checking the value of suction and discharg...

Page 40: ...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 sealing components is used the average life expectancy is 36 to 48 months Visual inspection is needed after th...

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: ... 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 or i...

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: ... 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 correct Model Date Weather Operation time Startup Shutdown Outdoor temperature Dry bulb C Wet bulb C Indoor temperature C Compressor High pressures MPa Low pressure...

Page 45: ...re 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 55 61 75 Hydraulic resistance lose kPa Plate heat exchanger Max pressure MPa 1 0 Min pressure MPa 0 05 Inlet and outlet pipe dia DN40 DN50 Air side heat...

Page 46: ...3 90 Tj 25 C Pdc 13 15 kW Tj 25 C EERd 5 35 Tj 20 C Pdc 6 58 kW Tj 20 C EERd 6 90 Degradation co efficient for chillers Cdc 0 9 Power consumption in modes other than active mode Off mode POFF 0 020 kW Crankcase heater mode PCK 0 kW Thermostat off mode PTO 0 171 kW Standby mode PSB 0 020 kW Other items Capacity control Variable For air to water comfort chillers air flow rate outdoor measured 12500 ...

Page 47: ...dc 23 86 kW Tj 25 C EERd 4 50 Tj 20 C Pdc 11 72 kW Tj 20 C EERd 5 05 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 kW Thermostat off mode PTO 0 323 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 po...

Page 48: ... 38 49 kW Tj 25 C EERd 5 28 Tj 20 C Pdc 26 51 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 powe...

Page 49: ...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 50: ...ation 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 efficie...

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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