Kaysun KEM-140 DRS5 KH, Owners & Installation Manual

Page 1: ... our air conditioner Before using your air conditioner please read this manual carefully and keep it for future reference OWNER S INSTALLATION MANUAL DC Inverter Air cooled Modular Chiller KEM 75 DRS5 KH KEM 90 DRS5 KH KEM 140 DRS5 KH KEM 180 DRS5 KH ...

Page 2: ...strong breeze 6 1 6 2 6 3 6 4 6 5 PRECAUTIONS ON INSTALLATION 11 7 CONNECTION DRAWING OF PIPELINE SYSTEM 13 11 8 15 20 30 Main parts of the uint Opening the uint Outdoor unit PCBs Electric wiring Water system installation 8 1 8 2 8 3 8 4 8 5 OVERVIEW OF THE UNIT 34 9 STRAT UP AND CONFIGRUATION 35 35 10 Check item table after installation Trial run 10 1 10 2 TEST RUN AND FINAL CHECK 4 IMPORTANT INF...

Page 3: ...11 5 11 6 11 7 11 8 11 9 11 10 11 11 11 12 11 13 36 38 38 38 38 39 39 39 39 44 40 41 44 39 38 Failure information and code Data display of wired controller Care and maintenance Removing scale Winter shutdown Replacing parts First startup after shutdown Refrigeration system Disassembling compressor Auxiliary electric heater System antifreezing Replacement of safety valve Information servicing ...

Page 4: ...on above 15 should be added in the water system otherwise the unit and the water system will be damaged Outlet water temperature Outlet water temperature G KEM 75 DRS5 KH KEM 140 DRS5 KH KEM 75 DRS5 KH KEM 140 DRS5 KH Fig 1 2 1 Cooling operating range Fig 1 2 2 Heating operating range KEM 90 DRS5 KH KEM 180 DRS5 KH KEM 90 DRS5 KH KEM 180 DRS5 KH Fig 1 1 1 Cooling operating range Fig 1 1 2 Heating ...

Page 5: ...o used to alert against unsafe practices Indicates situations that could only result in accidental equipment or property damage NOTE Explanation of symbols displayed on the indoor unit or outdoor unit WARNING CAUTION CAUTION CAUTION CAUTION 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 f...

Page 6: ... tidy 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 ...

Page 7: ...nt Children should not play with the unit Cleaning and user maintenance should not be done by children without supervision This appliance is intended to be operated by expert or trained users in shops in light industry and on farms or for commercial use by lay persons If the supply cord is damaged it must be replaced by the manufacturer or its service agent or a similarly qualified person in order...

Page 8: ...t can be fastened on the foundation reliability 7 If the unit is installed on a roof the roof must be strong enough to bear the weight of the unit and the weight of maintenance personnel The unit can be placed on the concrete and groove shaped steel frame similar to the case when the unit is installed on the ground The weight bearing groove shaped steel must match the installation holes of the sho...

Page 9: ...6 PRECAUTIONS ON INSTALLATION 6 1 Outline dimensional drawing Fig 6 1 Outline dimensional 06 Front view Left view Top view ...

Page 10: ...t will increase by 135mm approximately Model A B C D E F KEM 90 DRS5 KH 2220 1135 2315 910 255 270 Table 6 1 KEM 75 DRS5 KH 2000 960 1770 816 190 270 KEM 140 DRS5 KH 2220 1135 2300 910 185 380 KEM 180 DRS5 KH 2752 2220 2413 836 356 270 Front view Left view Top view 07 ...

Page 11: ...ess 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 Input of airow Input of airow Main unit G Input of airow ...

Page 12: ...structed on solid ground or on structures of sufficient strength to support the units weight 2 Bases should be at least 200mm high to provide sufficient access for installation of piping Snow protection should also be considered for the base height 3 Either steel or concrete bases may be suitable Outdoor unit base structure design should take account of the following considerations 6 3 1 Base stru...

Page 13: ...nsure trouble free operation of the equipment Otherwise accumulated snow will block the air flow and may cause equipment problems Check the installation site thoroughly do not install the equipment under awnings or trees or a place where snow is piled up 1 To ensure a sufficient air flow required by the air cooled heat pump chiller design a protective cover to make the dust resistance 1 mm H2O or ...

Page 14: ...NAME Air inlet Water outlet wire controller It can be placed indoors Expansion tank Gas liquid separator Induction pump Table 8 1 Stop valve Pressure gauge Water flow switch Gate valve Flexible joint Y shaped filter Thermometer Circulating pump Check valve Automatic discharge valve Symbol explanation Auxiliary electric heater Terminal Two way valve Drain valve Water charge valve Plate heat exchang...

Page 15: ...EM 90 DRS5 KH Picture just use to show the key component relative position Fig 8 3 Main parts of KEM 140 DRS5 KH Picture just use to show the key component relative position Fig 8 4 Main parts of KEM 180 DRS5 KH Picture just use to show the key component relative position 1 2 3 MODEL A MODEL B 7 9 MODEL B 4 5 6 11 8 12 13 10 1 1 2 3 4 5 6 7 8 9 15100103000389 ...

Page 16: ...anger 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 7 Doors of KEM 90 DRS5 KH KEM 140 DRS5 KH 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 13 ...

Page 17: ... 2 Door 3 Door 4 Door 5 Door 6 Door 7 Door 8 Door 9 Door 10 Door 1 2 3 9 10 give access to the compartment of water pipes and water side heat exchanger Door 4 5 give access to the hydraulic compartment Door 6 7 8 give access to the electrical parts ...

Page 18: ...ort value of the alarm actually detected is ON OFF but not 220 240V control power supply so special attention should be paid when installing the alarm signal output CN68 Pump 220 240V control power supply 1 After receiving start up instruction the pump will be started up instantly and will maintain start up state always in the process of operation 2 In case of refrigerating or heating shutdown the...

Page 19: ...denser CN30 T4 outdoor ambient temperature sensor CN45 Taf2 Water side antifreeze temperature sensor CN16 T3B pipe temperature sensor of the condenser CN38 Tp2 DC inverter compressor B discharge temperature sensor CN27 TP PRO Discharge temperature switch protection protection code P0 provent the compressor from over temperature 115 CN42 Low pressure protection switch Protection code P1 CN71 EXVB S...

Page 20: ...tate of the compressor Attention the control port value of the COMP STATE actually detected is ON OFF but not 220 240V control power supply so special attention should be paid when installing the light CN115 W HEAT Electric heater of water flow switch CN140 Power supply 220 240VAC input CN114 Water flow switch signal CN138 COOL HEAT Remote function of cool heat signal ON OFF Remote function of on ...

Page 21: ...l solenoid valve CN80 Injection solenoid valve of compressor system B CN47 Injection solenoid valve of compressor system A CN5 Water side heat exchanger heaters connection CN40 Multi function solenoid valve Table 8 3 CN41 Liquid bypass solenoid valve CN6 Four way valve Fig 8 11 Main PCB of KEM 90 DRS5 KH and KEM 180 DRS5 KH 26 1 28 2 3 4 5 6 7 8 9 10 11 12 13 15 16 18 19 20 21 22 24 25 27 29 30 31...

Page 22: ...ressor inverter module communication ports CN300 Program burn in port WizPro200RS programming device IC10 EEPROM chip 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 C...

Page 23: ... power supply whose voltage should conform to rated voltage Wiring construction must be conducted by the professional technicians according to the labeling on the circuit diagram The power wire and the grounding wire must be connected to the suitable terminals The power wire and the grounding wire must be fasten up by suitable tools The terminals connected the power wire and the grounding wire mus...

Page 24: ...12 1 DSP1 DSP2 8 4 2 KEM 75 DRS5 KH and KEM 140 DRS5 KH DIP switch buttons and digital display positions of uints Fig 8 13 Display positions 8 4 2 KEM 90 DRS5 KH and KEM 180 DRS5 KH DIP switch buttons and digital display positions of uints 8 4 3 DIP switch instructions Table 8 5 KEM 75 DRS5 KH and KEM 140 DRS5 KH ENC1 S1 S2 S3 S4 ENC1 0 F valid for uint address setting on the DIP switches 0 indica...

Page 25: ...ical standards b Copper core wires must be used Fig 8 15 1 Electrical wiring precaution a Fig 8 15 2 Electrical wiring precaution b c It is advisable to use 3 core shielded cables for uint to minimize interference Do not use the unshielded multicore conductor cables d Power wiring must be entrusted to professionals with electrician qualification Fig 8 15 3 Electrical wiring precaution c Fig 8 15 4...

Page 26: ... arrester Power distribution transformer Wrong Manual switch Fuses Power 380 415V 3N 50Hz Fig 8 16 Requirements of power supply wiring Uint 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 separately Correct 8 4 7 Requirements for power cord connection L1 L2 L3 N L1...

Page 27: ...RS5 KH 0 electric control box ON OFF port ON Power DC 12V Main control board is provided 0 electric control box ON OFF port OFF Power DC 12V Main control board is provided Fig 8 21 1 Wiring of ON OFF weak electric port 220 240V 50Hz L1 L2 L3 N Coil of 3 phase AC contactor Coil of 3 phase AC contactor Max voltage 240VAC Max current 5A CN119 Slave board HEAT1 CN121 Slave board COMP STATE CN123 Slave...

Page 28: ...ill cause the units to malfunction b The shielding nets at both ends of the shielded wire must be grounded Alternatively the shielding nets of all shielded wires are interconnected and then connected to earth through or one metal plate c Do not bind the control wire refrigerant piping and power cord together When the power cord and control wire are laid parallel they should be kept at a distance o...

Page 29: ...the actual parameter of products and national Contactor Contactor Power Transformer OUTPUT 8 5 V Contactor MAIN CONTROL WIRECONTROLLER X Y X Y X Y XT3 L1 L 2 L3 POWER 380 415V 3N 50Hz ENC1 AC1 AC2 MAIN CONTROL WIRECONTROLLER X Y E RD YE BK BR WH POWER 380 415V 3N 50Hz RVV 300 500 5X16mm 2 X Y E AC1 AC2 RD YE BK BR WH Main board Slave board CN22 CN46 CN119 CN123 HEAT1 HEAT2 PUMP 12 0Ω POWER 380 415...

Page 30: ...1 AC2 RD YE BK BR WH MONITOR WIRECONTROLLER CN60 5 6 7 8 9 10 11 12 5 6 7 8 9 10 11 12 CN74 CN61 WH RD YE BK BR RD YE BK BR WH MONITOR WIRECONTROLLER X Y X Y X Y X Y E X Y E CN25 XT3 CN30 XT3 CN2 CN83 CN30 XT3 CN2 CN83 CN30 L1 L2 L3 L1 L 2 L3 L1 L 2 L3 POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz ENC4 ENC4 ENC4 AC1 MAIN CONTROL WIRECONTROLLER RD YE BK...

Page 31: ...ing to the actual parameter of products and national Contactor Contactor Power Transformer OUTPUT 8 5 V MAIN CONTROL WIRECONTROLLER X Y X Y X Y Contactor XT3 POWER 380 415V 3N 50Hz POWER 380 415V 3N 50Hz ENC1 AC1 AC2 MAIN CONTROL WIRECONTROLER X Y E RD YE BK BR WH RVV 300 500 5X50mm 2 X Y E AC1 AC2 RD YE BK BR WH Main board Slave board CN22 CN46 CN119 CN123 HEAT1 HEAT2 PUMP POWER 380 415V 3N 50Hz ...

Page 32: ...d 1 F indicate slave units 29 Fig 8 28 Networking communication schematic of main unit and auxiliary unit for KEM 180 DRS5 KH Contactor Contactor for pipeline Contactor for water tank 7 MONITOR WIRECONTROLLER MONITOR WIRECONTROLLER 7 7 MAIN CONTROL WIRECONTROLLER MAIN CONTROL WIRECONTROLLER Contactor Contactor for pipeline Contactor for water tank ...

Page 33: ...s so they need to be purchased by the user k All low positions of the water system should be providedwith drainage ports to drain water in the evaporator and the system completely and all high positions should be supplied with discharge valves to facilitate expelling air from the pipeline The discharge valves and drainage ports should not be under heat preservation to facilitate maintenance l All ...

Page 34: ...RS5 KH model uses hoop connection For the specifications of the water pipes and screw thread see the Table 8 5 below Table 8 5 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 f...

Page 35: ... rated water flow in terms of multi connect the units that water flow must no less than total units rated water flow b Select the left of the pump 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 re...

Page 36: ...line 2 Table of diameter parameters of main inlet and outlet pipes 2 Applicable standard of water quality for the unit PH value Total hardness Conductivity Sulfide ion Chloride ion Ammonia ion Sulfate Silicon Iron content Sodium ion Calcium ion 6 8 8 0 70ppm 200μV cm 25 C No 50ppm No 50ppm 30ppm 0 3ppm No requirement 50ppm Table 8 7 Fig 8 31 Installation of multi module no more than 16 modules No ...

Page 37: ...ter outlet temperature sensing bulb target flow controller and auxiliary electric heater are under control of the main module One wired controller and one target flow controller are required and connected on the main module The unit can be started up through the wired controller only after all addresses are set and the aforementioned items are determined The wire length betweent the wired controll...

Page 38: ...ment Wire capacity is meeting for requirement Switch capacity is meeting for requirement Fuse capacity is meeting for requirement Voltage and frequency are meeting for requirement Connecting tightly between wires Operation control device is meeting for requirement Safety device is meeting for requirement Chained control is meeting for requirement Phase sequence of power supply is meeting for requi...

Page 39: ...ion 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 Recovered upon failure recovery 19 P1 System low pressure protection or Severe refrigerant leakage protection only for 75 140 model for 3 times in 60 minutes Recovered by power off 20 P2 Tz total cold outlet temperatu...

Page 40: ...r A 2 for Compressor B Recovered upon error recovery 53 xL7 phase loss x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recovery 54 xL8 frequency change over 15Hz x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recovery 55 xL9 frequency phase difference 15Hz x 1or 2 1 for Compressor A 2 for Compressor B Recovered upon error recovery 56 dF Defrosting prompt Flas...

Page 41: ...t be made on the set points on site Regularly check whether the electric connection is loose and whether there is bad contact at the contact point caused by oxidation and debris etc and take timely measures if necessary Frequently check the work voltage current and phase balance Check the reliability of the electric elements in time Ineffective and unreliable elements should be replaced in time 2 ...

Page 42: ...unt of refrigerant will be affected by the ambient temperature If the required amount has not been reached but no more injection can be done make the chilled water circulate and start up the unit for injection Make the low pressure switch temporarily short circuit if necessary Connect vacuum pumping pipe at the fluoride nozzle at low pressure side Remove air from the system pipe with vacuum pump T...

Page 43: ...safety valve safety valve liquid vapor separator 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 sealing components is u...

Page 44: ... 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 If...

Page 45: ... be repeated until no refrigerant is within the system When the final OFN charge is used the system shall be vented down to atmospheric pressure to enable work to take place This operation is absolutely vital if brazing operations on the pipe work are to take place Ensure that the outlet for the vacuum pump is not closed to any ignition sources and there is ventilation available 16 Charging proced...

Page 46: ...igerants 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 special cylinders for the recovery of refrigerant Cy...

Page 47: ...C C C MPa MPa V A C C C C A High pressure Low pressure Voltage Current Inlet dry bulb Outlet dry bulb Inlet Outlet 1 Check temperature of chilled water or hot water Inlet Outlet 2 Check air temperature of air side heat exchanger Inlet Outlet 3 Check refrigerant suction temperature and superheating temperature Refrigerant suction temperature Superheating temperature 4 Check pressure Discharge press...

Page 48: ... unit Net Weight Operation Weight Packing dimension Type Chargeing volume kg Waterflow volume m 3 h cooling Hydraulic resistance lose kPa Water side heat exchanger Max pressure MPa Min pressure MPa Inlet and outlet pipe dia Type Air flow volume m3 h L mm W mm H mm kg kg L W H mm R32 Plate heat exchanger 1 0 0 15 Fin coil model 28500 2000 960 1770 475 485 2085 1030 1890 DN50 DN50 35000 2220 1135 23...

Page 49: ...ine or water flow rate outdoor side heat exchanger Sound power level indoors outdoors Emissions of nitrogen oxides if applicable GWP of the refrigerant Standard rating conditions used Contact details If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0 9 From 26 September 2018 Low temperature application Crankcase heater mode Standby mode POFF PTO...

Page 50: ...low rate outdoor side heat exchanger Sound power level indoors outdoors Emissions of nitrogen oxides if applicable GWP of the refrigerant Standard rating conditions used Contact details If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0 9 From 26 September 2018 Low temperature application Crankcase heater mode Standby mode POFF PTO LWA NOx 83 67...

Page 51: ...ow rate outdoor side heat exchanger Sound power level indoors outdoors Emissions of nitrogen oxides if applicable GWP of the refrigerant Standard rating conditions used Contact details If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0 9 From 26 September 2018 Low temperature application Crankcase heater mode Standby mode POFF PTO LWA NOx 93 675...

Page 52: ... outdoor side heat exchanger Sound power level indoors outdoors Emissions of nitrogen oxides if applicable GWP of the refrigerant Standard rating conditions used Contact details If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0 9 From 26 September 2018 Low temperature application Crankcase heater mode Standby mode POFF PTO LWA NOx 92 675 70000 ...

Page 53: ...Standby mode Crankcase heater mode Capacity control Fixed Variable Variable Sound power level indoors Sound power level outdoors Contact details 1 For heat pump space heaters and heat pump combination heaters the rated heat output Prated is equal to the design load for heating Pdesignh and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating sup T...

Page 54: ...andby mode Crankcase heater mode Capacity control Fixed Variable Variable Sound power level indoors Sound power level outdoors Contact details 1 For heat pump space heaters and heat pump combination heaters the rated heat output Prated is equal to the design load for heating Pdesignh and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating sup Tj ...

Page 55: ...de Standby mode Crankcase heater mode Capacity control Fixed Variable Variable Sound power level indoors Sound power level outdoors Contact details 1 For heat pump space heaters and heat pump combination heaters the rated heat output Prated is equal to the design load for heating Pdesignh and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating su...

Page 56: ...de Standby mode Crankcase heater mode Capacity control Fixed Variable Variable Sound power level indoors Sound power level outdoors Contact details 1 For heat pump space heaters and heat pump combination heaters the rated heat output Prated is equal to the design load for heating Pdesignh and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating su...

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