Kaysun KEM-30 DRS4, Service Manual

Page 1: ...SERVICE MANUAL DC Inverter Air cooled Modular Chiller KEM 30 DRS4 KEM 60 DRS4 KEM 30 DRS4 KH KEM 60 DRS4 KH ...

Page 2: ...1 CONTENTS Part 1 General Information 3 Part 2 Component Layout and Refrigerant Circuits 5 Part 3 Control 23 Part 4 Diagnosis and Troubleshooting 39 CONTENTS ...

Page 3: ...2 ...

Page 4: ...3 Part 1 General Information Part 1 General Information 1 Unit Capacities and External Appearance 4 2 Water outlet temperature range 4 ...

Page 5: ... 2 1 Aqua Tempo Super II unit water outlet temperature range Mode Range Cooling Normal 5 20 C1 Low water outlet 0 20 C reserved 2 Heating Normal 25 54 C Notes 1 For 30kW and 60kW units when the ambient temperature is below 15 C the water outlet temperature range is 10 20 C When the ambient temperature is above 15 C all the units water outlet temperature range is 5 20 C 2 For 30kW and 60kW units us...

Page 6: ...5 Part 2 Component Layout and Refrigerant Circuits Part 2 Component Layout and Refrigerant Circuits 1 Layout of Functional Components 6 2 Piping Diagrams 14 3 Refrigerant Flow Diagrams 20 ...

Page 7: ...t view Wired controller Electric control box Oil separator Fan motor DC inverter compressor Manual air purge valve Manual water drain valve Water outlet pipe Water side heat exchanger Safety valve Water flow switch Water inlet pipe Accumulator Figure 2 1 2 KEM 30 DRS4 rear view ...

Page 8: ...s Figure 2 1 3 KEM 30 DRS4 top view Low pressure switch Electronic expansion valve High pressure switch High pressure sensor Four way valve Accumulator Solenoid valve SV4 Discharge temperature switch Low pressure gauge point High pressure gauge point ...

Page 9: ...oller Electric control box DC inverter compressor Water side heat exchanger Manual water drain valve Manual air purge valve Safty valve Water outlet pipe Water flow switch Buffer Water inlet pipe Accumulator Fan motor Oil separator Figure 2 1 5 KEM 30 DRS4 KH rear view ...

Page 10: ... Low pressure switch Solenoid valve SV4 Discharge temperature switch Low pressure gauge point High pressure gauge point Electronic expansion valve High pressure sensor High pressure switch Accumulator Four way valve Figure 2 1 6 KEM 30 DRS4 KH top view ...

Page 11: ...re 2 1 7 KEM 60 DRS4 front view DC inverter compressor Electric control box Fan motor Oil separator Safety valve Air purge valve Water inlet pipe Manual water drain valve Water outlet pipe Accumulator Accumulator Water side heat exchanger Water flow switch ...

Page 12: ...Circuits Figure 2 1 9 KEM 60 DRS4 top view Low pressure switch High pressure sensor High pressure switch Four way valve Electronic expansion valve Solenoid valve SV4 Discharge temperature switch Low pressure gauge point High pressure gauge point ...

Page 13: ...0 KEM 60 DRS4 KH front view DC inverter compressor Electric control box Fan motor Oil separator Safety valve Air purge valve Water inlet pipe Water flow switch Water outlet pipe Manual wate drain valve Accumulator Accumulator Accumulator Water side heat exchanger Buffer ...

Page 14: ...rcuits Figure 2 1 12 KEM 60 DRS4 KH top view Low pressure switch High pressure sensor High pressure switch Four way valve Electronic expansion valve Solenoid valve SV4 Discharge temperature switch Low pressure gauge point High pressure gauge point ...

Page 15: ...ssure switch 9 System pressure sensor 30 Filter 10 DC fan 31 Capillary 11 Condenser 32 Outdoor ambient temperature sensor 12 Coil outlet temperature sensor 33 Unit water inlet temperature sensor 13 Coil final outlet temperature sensor 34 Safety valve 14 Filter 35 Air purge valve 15 Electronic expansion valve 36 Unit water outlet temperature sensor 16 Filter 37 Water flow switch 17 High pressure ta...

Page 16: ...r 9 System pressure sensor 31 Capillary 10 DC fan 32 Outdoor ambient temperature sensor 11 Condenser 33 Unit water inlet temperature sensor 12 Coil outlet temperature sensor 34 Safety valve 13 Coil final outlet temperature sensor 35 Air purge valve 14 Filter 36 Unit water outlet temperature sensor 15 Electronic expansion valve 37 Water flow switch 16 Filter 38 Manual water drain valve 17 High pres...

Page 17: ...3 Suction temperature sensor 9 One way valve 1 34 Low pressure switch 10 One way valve 2 35 Filter 11 High pressure switch 36 Capillary 12 Oil separator 37 Fast oil return solenoid valve 13 4 way valve 38 Filter 14 System pressure sensor 39 Capillary 15 DC fan 1 40 Outdoor ambient temperature sensor 16 DC fan 2 41 Unit water inlet temperature sensor 17 Condenser 42 Safety valve 18 Coil outlet temp...

Page 18: ... switch 9 One way valve 1 35 Filter 10 One way valve 2 36 Capillary 11 High pressure switch 37 Fast oil return solenoid valve 12 Oil separator 38 Filter 13 4 way valve 39 Capillary 14 System pressure sensor 40 Outdoor ambient temperature sensor 15 DC fan 1 41 Unit water inlet temperature sensor 16 DC fan 2 42 Safety valve 17 Condenser 43 Air purge valve 18 Coil outlet temperature sensor 44 Unit wa...

Page 19: ...from the water circuit 10 Safety valve Prevents excessive water pressure by opening at 43 5psi 3bar and discharging water from the water circuit 11 Water flow switch Detects water flow rate to protect the compressor and water pump in the event of insufficient water flow 12 Water pump Circulates water in the water circuit 13 Pressure sensor Measures refrigerant system pressure 14 Crankcase heater P...

Page 20: ...rottles and reduces pressure in the liquid injection cooling pipe 21 Solenoid valve SV2 Control the on off of the liquid injection It opens at the maximum discharge temperature reaching 105 C while it closes at the maximum discharge temperature below 95 C or both the maximum discharge temperature below 100 C and minimum discharge temperature below 90 C ...

Page 21: ...on for 30kW unit Figure 2 3 2 Refrigerant flow during heating operation for 60kW unit High temperature high press gas High temperature high press liquid Low temperature low pressure inlet outlet High temperature high press gas High temperature high press liquid Low temperature low pressure inlet outlet ...

Page 22: ...efrosting operations for 30kW unit Figure 2 3 4 Refrigerant flow during cooling and defrosting operations for 60kW unit High temperature high press gas High temperature high press liquid Low temperature low pressure High temperature high press gas High temperature high press liquid Low temperature low pressure inlet outlet inlet outlet ...

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Page 24: ...Part 3 Control Part 3 Control 1 General Control Scheme Flowchart 24 2 Stop Operation 25 3 Standby Control 25 4 Startup Control 26 5 Normal Operation Control 28 6 Protection Control 31 7 Special Control 36 ...

Page 25: ...iquid cooling control Protection control High pressure protection control Low pressure protection control Discharge temperature protection control Compressor and inverter module protection control Voltage protection control DC fan motor protection control Water side heat exchanger anti freeze protection control Air side heat exchanger high temperature protection control Water side heat exchanger t...

Page 26: ...s are stopped The crankcase heater is controlled according to the outdoor ambient temperature and discharge temperature When the outdoor ambient temperature is above 40 C the crankcase heater is off when the outdoor ambient temperature is below 35 C the crankcase heater is controlled according to discharge temperature Refer to Figures 3 3 1 and 3 3 2 Figure 3 3 1 Crankcase heater controlled accord...

Page 27: ...nits compressor startup program1 when ambient temperature is above 10 C 32rps 60S 56rps 34rps 66rps 76rps 80rps 90rps 90S 90S 90S 90S 180S 60S 180S 100rps 105rps 300S Compressor rotation speed rps Target rotation speed Time s Notes 1 Once the first 60 second stage of the program is complete the program proceeds to the subsequent stages in a step by step fashion and exits when the target rotation s...

Page 28: ...mponent Wiring diagram label 30kW 60kW Control functions and states Inverter compressor A COMP A Controlled according to ambient temperature and leaving water temperature1 Inverter compressor B COMP B DC fan motor A FAN A Controlled according to air side heat exchanger refrigerant total outlet temperature Tz 7 ambient temperature and compressor speed DC fan motor B FAN B Electronic expansion valve...

Page 29: ...rolled according to air side heat exchanger refrigerant total outlet temperature Tz 7 DC fan motor B FAN B Electronic expansion valve EXV A Position steps from 0 fully closed to 480 fully open controlled according to suction superheat Four way valve STF1 Off Solenoid valve oil balance SV4 Open for 3min every 2min Water pump PUPM On Water side heat exchanger heater EVA HEAT Off Water flow switch Wa...

Page 30: ... unit mode when S12_2 is switched OFF the system runs one large pump controlled by master unit mode One pump control only the master unit output pump signal no pump signal output on the slave units Multiple pump control output pump signal on all units S12_2 in one system must be switched to the same position or not error code FP will be displayed 5 5 Four way Valve Control The four way valve is us...

Page 31: ... 190 9 310 170 190 10 330 210 190 11 350 230 210 12 370 250 230 13 400 270 250 14 430 290 270 15 60 310 290 16 490 330 310 17 520 350 330 18 550 370 350 19 580 400 370 20 610 430 400 21 640 470 430 22 super silent mode 670 510 470 23 700 550 510 24 720 600 550 25 silent mode 740 650 600 26 760 700 650 27 780 750 700 28 780 800 750 29 800 830 800 30 800 850 830 31 820 870 850 32 standard mode 820 8...

Page 32: ...30kW and 60kW units Normal operation Pe 0 14MPa Pe 0 3MPa Low pressure protection error code P1 is displayed When P1 protection occurs 3 times in 60 minutes manual system restart is required before the system can resume operation Notes 1 Pe Suction pressure When the suction pressure drops below 0 14MPa the system displays P1 protection and all the units stop running When the suction pressure rises...

Page 33: ... displayed C7 is displayed when PL error occurs 3 times in 100 minutes a manual system restart is required before the system can resume operation Notes 1 Tf1 Heat sink temperature 1 Tf2 Heat sink temperature 2 When the Tf1 or Tf2 temperature rises above 82 C the system displays PL protection and all the units stop running When the Tf1 and Tf2 temperature drops below 60 C the compressor enters re s...

Page 34: ...rs the system displays error code Pb and all the units stop running Figure 3 6 7 Anti freeze protection control in normal cooling mode Figure 3 6 8 Anti freeze protection control in low water outlet cooling mode Normal operation Min Tw Two Twi Taf1 4 C Tw 15 C Anti freeze protection error code Pb is displayed Note 1 Taf include Taf1 and Taf2 In standby or normal cooling mode either water side heat...

Page 35: ...hen the air side heat exchanger refrigerant total outlet temperature Tz 7 temperature rises at or above 61 C the system displays P7 protection and the unit stops running When the air side heat exchanger refrigerant total outlet temperature Tz 7 temperature drops below 58 C the compressor enters re start control 6 9 Water Side Heat Exchanger Temperature Difference Protection Control This control pr...

Page 36: ...e protection control in low outlet water mode Normal operation Min Taf1 or Taf2 0 C Min Taf1 and Taf2 5 C Low temperature protection error code PE is displayed When water side heat exchanger anti freezing temperature1 Taf1 or water side heat exchanger anti freezing temperature2 Taf2 is at or below 0 C for more than 3 seconds the system displays PE protection and orders the corresponding units to s...

Page 37: ...r when the suction pressure drops below 0 4Mpa for the first time until the suction pressure drops below 0 4Mpa for the second time in 30 minutes 7 Special Control 7 1 Loading and offloading for multiple units system In systems with multiple outdoor units When the outdoor units are powered on for the first time if there is a load requirement 50 of the units turn on starting with the master unit As...

Page 38: ...ient temperature water inlet temperature and water outlet temperature Electric auxiliary heater HEAT Controlled according to ambient temperature and total water outlet temperature after the compressor is on Crank case heater CCH Controlled according to ambient temperature and discharge temperature Solenoid valve Spray liquid cooling SV2 Controlled according to discharge temperature 7 3 Additional ...

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Page 40: ...t 4 Diagnosis and Troubleshooting Part 4 Diagnosis and Troubleshooting 1 Outdoor Unit Electric Control Box Layout 40 2 Outdoor Unit PCBs 42 3 Error Code Table 51 4 Troubleshooting 54 5 Appendix to Part 5 113 ...

Page 41: ...Figure 4 1 1 Electric control box front view top layer Figure 4 1 2 Electric control box front view bottom layer AC filter board Power supply terminal Fan module Compressor module Electric reactor High voltage terminal Main control board Low voltage terminal ...

Page 42: ...c control box front view top layer Figure 4 1 4 Electric control box front view bottom layer Main control board High voltage terminal Low voltage terminal Electric reactor Compressor module AC filter board Fan module Compressor module AC filter board Power supply terminal ...

Page 43: ...ard and compressor inverter module board In addition to the four PCBs 30kW unit each has one board while 60kW unit have one main control board and the other boards each has two boards The locations of each PCB in the outdoor unit electric control boxes are shown in Figures 4 1 1 to 4 1 4 in Part 4 1 Outdoor Unit Electric Control Box Layout Figure 4 2 1 Outdoor unit main PCB for 30kW and 60kW units...

Page 44: ... DC 13 CN64 Communication port between Main borad and fan inverter module 0 5V DC 14 CN61 Communication port between main board and HMI 0 5V DC 15 CN60 Communication port between outdoor units 0 5V DC 16 CN70 Actuation port of EXV A 0 or 12V DC 17 CN52 Signal output port for filter board relay 0 or 12V DC 18 CN20 ON OFF signal input port for system discharge temperature 0 or 12V DC 19 CN85 Output ...

Page 45: ...control1 S6 3 Anti snow function is invalid OFF Anti snow function is effective S12 1 Represent Media product ON S12 2 Single water pump control OFF Multiple water pumps control S12 3 Normal cooling mode2 OFF Low temperature cooling mode2 ENC2 DIP switch of outdoor unit capacity 0 KEM 30 DRS4 1 KEM 60 DRS4 ENC4 DIP switch of outdoor unit network address 0 master unit 1 2 3 F slave units 0 Note 1 P...

Page 46: ...Menu SW5 Ok 2 2 3 Digital display output Outdoor unit state Parameters displayed on DSP1 Parameters displayed on DSP2 Standby 0 1 Normal operation For single compressor units None Running speed of compressor For dual compressor units Running speed of compressor A in rotations per second Running speed of compressor B in rotations per second Error or protection or placeholder Error or protection cod...

Page 47: ...us current transformer 0 0 34V DC 5 CN8 CN9 Communication port between compressor invert modules or communication port between compressor invert module and main control board 0 5V DC 6 IC25 EEPROM 5V DC 7 CN2 Port for power supply 310V DC 8 CN1 CN5 Port for electric reactor 560V DC 9 CN3 Port for DC bus 560V DC 10 L8 Current measuring transformer 0 5V DC 2 3 1 Compressor Inverter Module PCB field ...

Page 48: ... between fan module and main control board 0 5V DC 2 CN2 EEPROM debug port 0 5V DC 3 SW1 Address dialing code for fan module 0 或 5V DC 4 CN3 Port for fan motor 0 400V AC 5 P N Port for power supply 310V DC 2 4 1 Fan Module PCB field setting Table 4 2 8 Fan module PCB switch settings for all models Switch Description SW1 1 SW1 2 00 30kW unit fan module address setting 00 60kW unit fan module A addr...

Page 49: ...ode Content Voltage 1 CN1 CN2 Port for fan module PCB 310V DC 2 CN4 Port for power supply of compressor inverter module 310V DC 3 CN3 Port for high pressure switch 0 或 310V DC 4 CN36 CN38 CN39 Three phase power input L1 N 230V L2 N 230V L3 N 230V 5 CN45 CN42 CN41 CN44 Three phase power output L1 N 230V L2 N 230V L3 N 230V 6 CN6 Port for relay signal control port of main control board 0 或 12V DC ...

Page 50: ...tch 0 or 310V DC 3 CN30 Port for relay signal control port of main control board CN21 0 or 12V DC 4 CN52 Port for relay signal control port of main control board CN52 0 or 12V DC 5 CN31 Port for fan bridge pile L1 N 230V L2 N 230V L3 N 230V 6 CN13 Port for power supply of main control board L1 N 230V L2 N 230V L3 N 230V 7 CN34 Port for pump L1 N 400V L2 N 400V L3 N 400V 8 CN32 Port for three phase...

Page 51: ...ard1 for 60kW unit Notes 1 Label descriptions are given in Table 4 2 11 Table 4 2 11 Fan power board for 60kW unit Label in Figure 4 2 8 Code Content Voltage 1 CN37 Port output for fan A rectifier bridge 310V DC 2 CN37 Port intput for fan A inverter module board 310V DC 3 CN43 N Neutral 4 CN36 Port output for fan B rectifier bridge 310V DC 5 CN36 Port intput for fan B inverter module board 310V DC...

Page 52: ...PCB and user interface E8 9 Power supply phase sequence protector output error Displayed on main PCB and user interface E9 10 Water flow detection failure Displayed on main PCB and user interface Eb 12 1Eb Taf1 cooling evaporator low temperature anti freeze protection sensor failure Displayed on main PCB and user interface 12 2Eb Taf2 cooling evaporator low temperature anti freeze protection senso...

Page 53: ...37 T4 ambient temperature too high in heatling mode Displayed on main PCB and user interface PL 38 Inverter module temperature Tfin too high temperature protection Displayed on main PCB and user interface xPU 40 DC fan module protection Displayed on main PCB and user interface H5 46 Voltage too high or too low Displayed on main PCB and user interface xH9 50 Compressor inverter module is not matche...

Page 54: ... bus low voltage protection Displayed on only user interface L2 103 DC bus high voltage protection Displayed on only user interface L4 105 MCE error Displayed on only user interface L5 106 Zero speed protection Displayed on only user interface L7 108 Phase sequence lost protection Displayed on only user interface L8 109 Compressor frequency change over 15Hz Displayed on only user interface L9 110 ...

Page 55: ...d in accordance with all applicable legislation all national local and other laws standards codes rules regulations and other legislation that apply in a given situation Power off the outdoor units before connecting or disconnecting any connections or wiring otherwise electric shock which can cause physical injury may occur or damage to components may occur ...

Page 56: ... indicates IPM inverter module compressor A EEPROM error 2H9 indicates IPM inverter module compressor B EEPROM error All units stop running Error code is displayed on main PCB and user interface d user interface 4 2 3 Possible causes Main PCB or IPM inverter module EEPROM is not connected properly Main PCB or IPM inverter module damaged EEPROM damaged ...

Page 57: ... Replace the EEPROM Replace Main PCB or IPM inverter module PCB Notes For 30kW and 60kW units 1 Main PCB EEPROM is designated IC10 on the main PCBs labeled 32 in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Compressor inverter module PCB EEPROM is designated IC25 on compressor inverter module PCB labeled 6 in Figure 4 2 2 in Part 4 2 3 Compressor inverter module PCB ...

Page 58: ...tal display output 4 3 2 Description Phase sequence error Unit stops running Error code is displayed on main PCB and user interface 4 3 3 Possible causes Power supply phases not connected in correct sequence Power supply terminals loose Power supply abnormal Main PCB damaged ...

Page 59: ...hase sequence is inverted the compressor will operate inversely If the wiring connection of each outdoor unit is in A B C phase sequence and multiple units are connected the current difference between C phase and A B phases will be very large as the power supply load of each outdoor unit will be on C phase This can easily lead to tripped circuits and terminal wiring burnout Therefore if multiple u...

Page 60: ... PCB and user interface 4 4 3 Possible causes Communication wires between outdoor unit and user interface are not connected properly Communication wiring P Q E terminals misconnected Loosened wiring within electric control box Interference from high voltage wires or other sources of electromagnetic radiation Communication wire is too long Damaged main PCB user interface or electric control box com...

Page 61: ... wire is over 500m Replace main PCB or user interface Reconnect the communication wires Connect the communication wires in a daisy chain Ensure the wires are connected properly Ensure the communication wires and high voltage wires are separated Remove the source of interference or add additional shielding to the communication wires Replacing electric control box communication terminals block resol...

Page 62: ...61 Part 4 Diagnosis and Troubleshooting 4 5 E3 E4 E5 E7 Eb Ed EF EP EU F9 Fb Fd Troubleshooting 4 5 1 Digital display output ...

Page 63: ...rge pipe temperature sensor of system B error EF indicates a water inlet temperature sensor error EP indicates a discharge pipe temperature sensor failure alarm EU indicates an air side heat exchanger refrigerant total outlet temperature sensor Tz 7 error 1F9 indicates inverter module temperature sensor Tfin1 error 2F9 indicates inverter module temperature sensor Tfin2 error Fb indicates a pressur...

Page 64: ...rly Replace the sensor Notes 1 For 30kW and 60kW units all the sensors are connected to port CN1 CN16 CN31 CN3 CN10 and CN69 on the main PCB labeled 10 9 8 7 6 4 in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure sensor resistance If the resistance is too low the sensor has short circuited If the resistance is not consistent with the sensor s resistance characteristics table the sensor has failed Re...

Page 65: ...stop running When this error occurs in the slave unit the slave unit stop running Error code is displayed on main PCB and user interface 4 6 3 Possible causes Power supply phases not connected in correct sequence or lose Power supply terminals or power phase protector wire connection loose Power supply abnormal Damaged main PCB Damaged power phase protector ...

Page 66: ...on the power phase protector will flash with 1HZ 3 The A B C terminals of 3 phase power supply should match compressor phase sequence requirements If the phase sequence is inverted the compressor will operate inversely If the wiring connection of each outdoor unit is in A B C phase sequence and multiple units are connected the current difference between C phase and A B phases will be very large as...

Page 67: ... an E9 error occurs 3 times in 60 minutes a manual system restart is required before the system can resume operation All units stop running Error code is displayed on main PCB and user interface 4 7 3 Possible causes The wire circuit is short connected or open Water flow rate is too low Water flow switch is damaged Main PCB is damaged ...

Page 68: ... the water piping and valves Make sure the water piping is clean there is no air in the water piping and all valves are open Make sure the water pump capacity is enough Yes Yes No No Water flow is insufficient Water flow switch is damaged Replace main PCB Notes 1 For 30kW and 60kW units water flow switch connection is port CN8 on the main PCB labeled 32 in Figure 4 2 1 in Part 4 2 2 Main PCB ...

Page 69: ... has decreased All units stop running Error code is only displayed on the user interface Some outdoor units are powered off Power supply abnormal Incorrect outdoor unit address setting Communication wires between outdoor units not connected properly Loosened wiring within electric control box Damaged main PCB or electric control box communication terminals block ...

Page 70: ...e outdoor units Check the power supply equipment Troubleshoot as for an E2 error2 No Yes Yes No Notes 1 Check digital display on the main PCB If digital display is on the main PCB is powered on if digital display is off the main PCB is powered off For 30kW and 60kW units L refer to Figure 4 2 1 in Part 4 2 2 Main PCB 2 See Part 4 4 4 E2 Troubleshooting ...

Page 71: ...70 4 9 EH Troubleshooting 4 9 1 Digital display output 4 9 2 Description EH indicates system self check in the factory it will not display in the normal operating ...

Page 72: ...ts stop running When the discharge pressure falls below 3 2MPa or discharge temperature fall below 90 C P0 is removed and normal operation resumes When P0 error occurs 3 times in 60 minutes a manual system restart is required before the system can resume operation Error code is displayed on main PCB and user interface High pressure switch or discharge temperature switch not connected properly or h...

Page 73: ... sufficient in cooling mode Replace outdoor main PCB No Yes Yes Yes Yes Yes No No No No Notes 1 For 30kW and 60kW units high pressure switch connection is port CN3 and CN35 on the AC filter board labeled 3 and 2 in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure the resistance among the three terminals of the pressure sensor If the resistance is of the order of mega Ohms or infinite the pressure sen...

Page 74: ...top running When the pressure rises above 0 3MPa P1 is removed and normal operation resumes When P1 error occurs 3 times in 60 minutes a manual system restart is required before the system can resume operation Error code is displayed on main PCB and user interface Low pressure switch not connected properly or has malfunctioned Insufficient refrigerant Low pressure side blockage Poor evaporator hea...

Page 75: ...sufficient refrigerant An insufficiency of refrigerant causes compressor discharge temperature to be higher than normal discharge and suction pressures to be lower than normal and compressor current to be lower than normal and may cause frosting to occur on the suction pipe These issues disappear once sufficient refrigerant has been charged into the system 2 A low pressure side blockage causes com...

Page 76: ...tem displays P4 or P5 protection and all units stop running When the current returns to the normal range P4 or P5 is removed and normal operation resumes When P4 or P5 error occurs 3 times in 60 minutes a manual system restart is required before the system can resume operation Error code is displayed on main PCB and user interface Power supply abnormal Poor condenser heat exchange High pressure si...

Page 77: ...m the system and recharge refrigerant Add oil to the system if it leaks Notes 1 In heating mode check water side heat exchanger water piping circulator pumps and water flow switch for dirt blockages In cooling mode check air side heat exchanger fan s and air outlets for dirt blockages 2 High pressure side blockage causes discharge temperature to be higher than normal discharge pressure to be highe...

Page 78: ...unning Error code is displayed on the main PCB and user interface Inverter module protection DC bus low or high voltage protection MCE error Zero speed protection Phase sequence error Excessive compressor frequency variation Actual compressor frequency differs from target frequency 4 13 4 Specific error codes for P6 inverter module protection If a P6 error code is displayed press button SW3 until ...

Page 79: ...ific error codes xL0 xL1 xL2 xL4 xL5 and xL7 can also be obtained from the inverter module LED indicators If an inverter module error has occurred LED1 flashes Refer to Figure 4 4 2 and Table 4 4 2 Figure 4 4 2 LED indicators LED1 on main PCB Table 4 4 2 Errors indicated on LED1 LED4 6 flashing pattern Corresponding error Flashes 8 times and stops for 1 second then repeats xL0 Inverter module prot...

Page 80: ...and ground If any of the resistances differ from these specifications the compressor has malfunctioned Figure 4 4 4 Measuring resistances among compressor terminals Figure 4 4 5 Measuring resistances between compressor terminals and ground If the resistances are normal go to Step 2 Step 2 Check inverter module The DC voltage between terminals P1 and N1 should be 1 41 times the local power supply v...

Page 81: ...ooting Step 1 Check inverter module Check the DC voltage between terminals P and N The normal value is 537 586V power supply voltage specification 380 415V 3N If the voltage is lower than 300V go to Step 2 Figure 4 4 7 Inverter module terminals P L1 L2 U L3 V W N N P ...

Page 82: ...on 380 415V 3N if the voltage is higher than 800V go to Step 2 Figure 4 4 9 Inverter module terminals Step 2 Check inverter module Check the voltage between terminals P and N on the capacitor board The normal value is 537 586V power supply voltage specification 380 415V 3N If the voltage is not in the normal range there is a problem with the electrolytic capacitor power supply Check the power supp...

Page 83: ...ating normally disconnect the power wires that connect a compressor to the electric control box and use them to connect the compressor with the xL8 xL9 error to the electric control box of the unit that is operating normally Ensure that the U V W terminals are connected in the right order and then start the system that is operating normally If the compressor with the xL8 xL9 error runs normally re...

Page 84: ... More electric energy will get dissipated as heat and the temperature of the motor will become increasingly high Finally compressor damage or burnout will result Figure 4 4 12 Inspecting compressor oil This oil is black it has been carbonized This oil is a little yellow but is clear and transparent and the condition is acceptable Cloudy or gray oil indicates abnormal system operation This oil is s...

Page 85: ...the faulty compressor and other compressor in the system 30kW unit has one compressor 60kW unit has two compressors Step 7 Vacuum drying and refrigerant charging Once all the compressors and other components have been fully connected vacuum dry the system and recharge refrigerant ...

Page 86: ... more than 3 seconds the system displays P7 protection and all units stop running When the air side heat exchanger refrigerant outlet temperature drops below 50 C or air side heat exchanger refrigerant total outlet temperature drops below 58 C P7 is removed and normal operation resumes All units stop running Error code is displayed on main PCB and user interface 4 14 3 Possible causes Air side hea...

Page 87: ...iring is connected properly Replace the temperature sensor Inspect the system and fix the error Inspect the system and fix the error Yes Yes Yes Yes Yes Notes 1 For 30kW and 60kW units air side heat exchanger refrigerant outlet temperature sensor and air side heat exchanger refrigerant total outlet temperature sensor connection port is CN1 and CN69 on the main PCB labeled 10 and 4 in Figure 4 2 1 ...

Page 88: ...e difference between water side heat exchanger water inlet and water outlet temperatures protection All units stop running Error code is displayed on main PCB and user interface 4 15 3 Possible causes Temperature sensor not connected properly or has malfunctioned Water piping contains air Insufficient water flow Main PCB damaged ...

Page 89: ...stem Replace the temperature sensor Ensure the temperature sensor is connected properly Yes Yes Yes Yes No No No No Notes 1 For 30kW and 60kW units water side heat exchanger water inlet temperature sensor and water side heat exchanger water outlet temperature sensor connections are port CN31 on the main PCB labeled 8 in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure sensor resistance If the resista...

Page 90: ...n The system will resume automatically2 Ensure the temperature sensor is connected properly Replace the temperature sensor Notes 1 For 30kW and 60kW units combined water outlet temperature sensor Tw Water side heat exchanger water outlet temperature sensor Two water side heat exchanger water inlet temperature sensor Twi and water side heat exchanger anti freezing temperature sensor Taf include Taf...

Page 91: ...ion All units stop running Error code is displayed on main PCB and user interface 4 17 3 Possible causes Low pressure switch not connected properly or has malfunctioned Insufficient refrigerant Low pressure side blockage Poor evaporator heat exchange in heating mode Insufficient water flow in cooling mode Main PCB damaged ...

Page 92: ... on the main PCB labeled 9 in in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure the resistance among the three terminals of the pressure sensor If the resistance is of the order of mega Ohms or infinite the pressure sensor has failed 3 To check for insufficient refrigerant An insufficiency of refrigerant causes compressor discharge temperature to be higher than normal discharge and suction pressure...

Page 93: ...ient temperature too high protection in heating mode All units stop running Error code is displayed on main PCB and user interface 4 18 3 Possible causes Temperature sensor not connected properly or has malfunctioned Actual ambient temperature is higher than 43 C Main PCB damaged ...

Page 94: ...erly Replace the sensor Notes 1 For 30kW and 60kW units temperature detection is port CN1 on the main PCB labeled 10 in in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure sensor resistance If the resistance is too low the sensor has short circuited If the resistance is not consistent with the sensor s resistance characteristics table the sensor has failed Refer to Table 5 5 1 in Part 5 5 1 Temperatu...

Page 95: ...ction All units stop running Error code is displayed on main PCB and user interface 4 19 3 Possible causes Temperature sensor not connected properly or has malfunctioned Insufficient refrigerant Low pressure side blockage Poor evaporator heat exchange in heating mode Insufficient water flow in cooling mode Main PCB damaged ...

Page 96: ...ain PCB labeled 4 and 8 in in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure sensor resistance If the resistance is too low the sensor has short circuited If the resistance is not consistent with the sensor s resistance characteristics table the sensor has failed Refer Table 5 5 3 in Part 5 5 1 Temperature Sensor Resistance Characteristics 3 To check for insufficient refrigerant an insufficiency of...

Page 97: ...en the inverter module temperature drops below 60 C the compressor enters re start control When a PL error occurs 3 times in 100 minutes C7 will display a manual system restart is required before the system can resume operation Error code is displayed on the main PCB and user interface 4 20 3 Possible causes Blocked dirty or loose heat sink Temperature sensor not connected properly or has malfunct...

Page 98: ...re the sensor is connected properly Tighten the screws and make sure the heat sink is well connected Clean or replace the heat sink Notes 1 Refer to Figures 4 1 2 4 1 4 and 4 1 6 in Part 4 1 Outdoor Unit Electric Control Box Layout 2 For 30kW and 60kW units inverter module temperature sensor connection are ports CN3 and CN10 on the main PCB labeled 7 and 6 in in Figure 4 2 1 in Part 4 2 2 Main PCB...

Page 99: ...s FF will display a manual system restart is required before the system can resume operation All units stop running Error code is only displayed on the main PCB and user interface 4 21 3 Possible causes Switch SW1 incorrectly set Power or communication wires not connected properly Fan motor blocked or has failed Power supply abnormal AC filter board damaged Fan module damaged Inverter module PCB d...

Page 100: ... Replace main PCB Ensure power and communication wires are connected properly Remove obstruction or replace the fan motor Check the power supply equipment Replace AC filter board Notes 1 Refer to Figures 4 1 2 4 1 4 and 4 1 6 in Part 4 1 Outdoor Unit Electric Control Box Layout 2 Refer to Part 2 1 Layout of Functional Components 3 The normal voltage between P and N on the fan module is 310 340V DC...

Page 101: ...r condition Communication go back to normal Reset method Resume automatically 4 22 4 Possible causes Incorrect compressor inverter module address setting Loosened communication wiring from the main PCB to the inverter module Bridge rectifier damaged Main PCB damaged Compressor inverter module damaged 4 22 5 Procedure F0 error Compressor inverter module address setting is incorrect No No No No Comm...

Page 102: ...ule port CN4 on filter board 30kW or port CN21 on filter board 60kW the normal voltage should be DC310 340V check the high pressure switch connection port CN3 on filter board of 30kW unit and port CN35 on filter board of 60kW unit the normal resistance should be zero Check the single phase bridge and fuse on filter board for 30kW unit check the connection cable from main PCB port CN58 to filter bo...

Page 103: ...ply voltage All units stop running Error code is only displayed on main PCB and user interface 4 23 3 Possible causes Outdoor unit power supply voltage at or above260V or drops below 165V or a phase is missing Loosened wiring within electric control box High voltage circuit error Main PCB damaged ...

Page 104: ...ge between A and N B and N and C and N is 165 265V 2 Refer to Figures 4 1 1 to 4 1 4 in Part 4 1 Outdoor Unit Electric Control Box Layout 3 The normal resistances of the inverter compressor are 0 7 1 5Ω among U V W and infinite between each of U V W and ground If any of the resistances differ from these specifications the compressor has malfunctioned 4 The normal resistances of the fan motor coil ...

Page 105: ...ror code is displayed on main PCB and user interface 4 24 3 Possible causes Abnormal power supply voltage Loosened wiring within electric control box High voltage circuit error AC filter board damaged 3 pahse bridge rectifier damaged Compressor Inverter module damaged 4 24 4 Procedure F6 refer to P6 protection troubleshooting xL1 and xL2 ...

Page 106: ...ital display output 4 25 2 Description Electronic expansion valve connection error All units stop running Error code is only displayed on the unit with the error 4 25 3 Possible causes Electronic expansion valve coil not connected properly or has malfunctioned Damaged main PCB ...

Page 107: ...sor is connected properly Replace the EXV Notes 1 Electronic expansion valve coil connections are port CN70 on the main PCB labeled 16 in Figure 4 2 1 in Part 4 2 2 Main PCB 2 The normal resistances between EXV coil wiring terminals RED and white yellow orange blue are 40 50Ω If any of the resistances differ from the value the EXV coil has malfunctioned Figure 4 4 22 EXV coil wiring terminals ...

Page 108: ...nsufficient protection of exhaust superheat All units stop running Error code is only displayed on main PCB and user interface 4 26 3 Possible causes Discharge pipe temperature sensor connected properly or has malfunctioned Electronic expansion valve coil not connected properly or has malfunctioned Damaged main PCB ...

Page 109: ...oose Electronic expansion valve coil has malfunctioned Discharge pressure is too high Replace outdoor main PCB Ensure the sensor is connected properly Replace the sensor Ensure the sensor is connected properly Replace the EXV The temperature difference between water inlet and water outlet or water inlet is too high Water flow is insufficient Refer to E9 error Yes Yes Yes Yes Yes Yes Yes No No No N...

Page 110: ... output 4 27 2 Description When a L0 or L1 error occurs 3 times in 60 minutes F4 will display a manual system restart is required before the system can resume operation 4 27 3 Possible causes Refer to L0 or L1 error troubleshooting Refer to L0 or L1 error troubleshooting 4 27 4 Procedure ...

Page 111: ...em restart is required before the system can resume operation All units stop running Error code is only displayed on main PCB and user interface 4 28 3 Possible causes The S12_2 of slave units is different with the master unit Main PCB damaged 4 28 4 Procedure FP The S12_2 of slave units is different with the master unit Replace outdoor main PCB No Yes Adjust the switch of S12_2 ...

Page 112: ... C the system displays P3 protection and all units stop running When the ambient temperature returns drops below 58 C P3 is removed and normal operation resumes All units stop running Error code is displayed on main PCB and user interface 4 29 3 Possible causes Ambient temperature sensor is not connected properly or has malfunctioned Fan motor wiring connection is wrong Poor condenser heat exchang...

Page 113: ...ly Replace the temperature sensor Inspect the system and fix the error Inspect the system and fix the error Notes 1 For 30kW and 60kW units ambient temperature sensor connection port is CN1 on the main PCB labeled 10 in Figure 4 2 1 in Part 4 2 2 Main PCB 2 Measure sensor resistance If the resistance is too low the sensor has short circuited If the resistance is not consistent with the sensor s re...

Page 114: ...2 1 537 112 0 4470 7 52 24 33 6 981 73 1 485 113 0 4348 6 49 32 34 6 684 74 1 435 114 0 4230 5 46 57 35 6 400 75 1 387 115 0 4116 4 44 00 36 6 131 76 1 341 116 0 4006 3 41 59 37 5 874 77 1 291 117 0 3899 2 39 82 38 5 630 78 1 254 118 0 3796 1 37 20 39 5 397 79 1 2133 119 0 3695 0 35 20 40 5 175 80 1 174 120 0 3598 1 33 33 41 4 964 81 1 136 121 0 3504 2 31 56 42 4 763 82 1 100 122 0 3413 3 29 91 43...

Page 115: ...2 2 630 7 261 4 33 38 89 73 8 643 113 2 559 6 247 8 34 37 30 74 8 358 114 2 489 5 234 9 35 35 78 75 8 084 115 2 422 4 222 8 36 34 32 76 7 820 116 2 357 3 211 4 37 32 94 77 7 566 117 2 294 2 200 7 38 31 62 78 7 321 118 2 233 1 190 5 39 30 36 79 7 086 119 2 174 0 180 9 40 29 15 80 6 859 120 2 117 1 171 9 41 28 00 81 6 641 121 2 061 2 163 3 42 26 90 82 6 430 122 2 007 3 155 2 43 25 86 83 6 228 123 1 ...

Page 116: ... 12 22 103 3 418 16 423 0 24 57 17 64 11 79 104 3 326 15 399 8 25 54 71 65 11 39 105 3 235 14 378 0 26 52 36 66 10 99 106 3 148 13 357 5 27 50 13 67 10 62 107 3 063 12 338 2 28 48 01 68 10 25 108 2 982 11 320 1 29 45 99 69 9 909 109 2 902 10 303 1 30 44 07 70 9 576 110 2 826 9 287 1 31 42 23 71 9 253 111 2 747 8 272 0 32 40 48 72 8 947 112 2 672 7 257 8 33 38 81 73 8 646 113 2 599 6 244 4 34 37 23...

Page 117: ...15 35 30 48 48 54 Tz 7 C 20 25 12 30 28 46 44 52 Taf C 5 25 5 25 5 25 5 25 T6A B C 2 17 1 20 3 35 5 40 Twi C 10 25 10 25 10 25 10 25 Two C 5 20 5 20 5 20 5 20 Tw C 5 20 5 20 5 20 5 20 DC fan motor current A 0 2 6 2 6 3 6 4 6 DC inverter compressor current A 6 12 2 16 3 17 4 18 Table 5 5 5 Outdoor unit in heating mode operating parameters Outdoor ambient temperature C 10 10 to 0 0 to 7 7 to 20 20 A...

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