Kaysun KEM-30 DNS3 Owners & Installation Manual
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Kaysun KEM-30 DNS3 Owners & Installation Manual

Kaysun KEM-30 DNS3 Owners & Installation Manual

Full dc inverter chiller
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OWNER'S & INSTALLATION MANUAL
FULL DC Inverter Chiller
KEM-30 DNS3
KEM-60 DNS3
KEM-90 DNS3
Original instructions.
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.

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Summary of Contents for Kaysun KEM-30 DNS3

  • Page 1 OWNER'S & INSTALLATION MANUAL FULL DC Inverter Chiller KEM-30 DNS3 KEM-60 DNS3 KEM-90 DNS3 Original instructions. 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.

  • Page 3: Table Of Contents

    CONTENTS PAGE ACCESSORIES 1. INTRODUCTION ..............1 2. SAFETY CONSIDERATION ..........2 3. BEFORE INSTALLATION ..........3 4. IMPORTANT INFORMATION ON REFRIGERANT.... 4 5. PRECAUTIONS OF INSTALLATION ..........4 6. INSTALLATION OF THE UNIT ............4 7. CONNECTION DRAWING OF PIPELINE SYSTEM ..9 8.

  • Page 5: Introduction

    MC-SU30-RN1L MC-SU90-RN1L MC-SU60-RN1L Outlet water temperature (℃) Outlet water temperature (℃) Fig. 1-2 Cooling operating range of KEM-90 DNS3 Fig. 1-1 Cooling operating range of KEM-30 DNS3 and KEM-60 DNS3 MC-SU30-RN1L MC-SU90-RN1L MC-SU60-RN1L Outlet water temperature (℃) Outlet water temperature (℃) Fig.

  • Page 6: Safety Consideration

    2. SAFETY CONSIDERATION CAUTION To prevent injuries or property losses, make sure to observe the following instructions. Failure to do so may cause injuries or losses. Ensure that the residual current device (RCD) is installed. The RCD must be installed. Failure to install it may result in There are two types of safety instructions: warning and caution.

  • Page 7: Before Installation

    3. BEFORE INSTALLATION Handling of the unit The angle of inclination should be between 45º and 70º when carrying the unit in case the machine turns over. a. Rolling handling: several rolling rods of the same size are placed under the base of the unit, and the length of each rod must be more than the outer frame of the base and suitable for balancing of the unit.

  • Page 8: Important Information On Refrigerant

    Front view base, the unit can be fastened on the foundation reliably. Fig. 6-1 Outline dimensional of KEM-30 DNS3 g. 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 6.1.2 KEM-60 DNS3...
  • Page 9 Table 6-1 (unit: mm) Model KEM-30 DNS3 KEM-60 DNS3 KEM-90 DNS3 1870 2220 3220 1000 1325 1513 1175 1055 1095 Top view NOTE After installing the spring damper, the total height of the unit will increase by 135mm or so.
  • Page 10 Inlet of air flow Inlet of air flow Inlet of air flow Main unit Main unit Inlet of air flow Front view Top view Fig. 6-4 Single unit installation Inlet of air flow Main unit Main unit Main unit Main unit Main unit Main unit Main unit...
  • Page 11 Snow protection should also be Fig. 6-7 Top view of schematic diagram of installation considered for the base height. dimension of KEM-30 DNS3 (unit: mm) c. Either steel or concrete bases may be suitable. d. A typical concrete base design is shown in Fig. 6-6. A typical...
  • Page 12 6.4 Installation of damping devices 6.5 Installation of device to prevent snow build-up and strong breeze 6.4.1 Damping devices When installing an air-cooled heat pump chiller in a place with heavy snow, it is necessary to take snow protection measures to By means of t installation holes on the steel frame of the unit base, ensure trouble-free operation of the equipment.

  • Page 13: Connection Drawing Of Pipeline System

    7. CONNECTION DRAWING OF PIPELINE SYSTEM This is the water system of standard module. Expansion tank Water replenishing Dirt discharge valve Y-type filter, unit requiring≥ 40 meshes unit Terminal unit Drain valve Two-way valve Auxiliary electric heater Three-way valve Symbol explanation Stop valve Pressure gauge Flexible joint...

  • Page 14: Overview Of The Unit

    8. OVERVIEW OF THE UNIT 8.1 Main parts of the units Fig. 8-1 Main parts of KEM-30 DNS3 Fig. 8-2 Main parts of KEM-60 DNS3...
  • Page 15 Fig. 8-3 Main parts of KEM-90 DNS3 Electric NAME Air outlet Top cover Compressor Evaporator Condenser Water inlet control box NAME Air inlet Water outlet wire controller...
  • Page 16 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 DNS3 Door 1 Door 2 Door 3 Door 4 Fig.

  • Page 17: Door

    8.3 System diagram 8.3.1 Diagram of KEM-30 DNS3 Fig.8-7 is the function diagram of the KEM-30 DNS3. inlet outlet Fig.8-7 KEM-30 DNS3 function diagram Table 8-1 Legend DC inverter compressor System pressure sensor Crankcase heater Safety valve DC inverter compressor discharge temperature sensor 1...
  • Page 18 8.3.2 diagram of KEM-60 DNS3 Fig.8-8 is the function diagram of the KEM-60 DNS3. inlet outlet Fig.8-8 KEM-60 DNS3 function diagram Table 8-2 Legend Dc inverter compressor High pressure tank Dc inverter compressor 2 Antifreeze heater of plate heat exchanger Crankcase heater 1 Water side antifreeze temperature sensor 2 Crankcase heater 2...
  • Page 19 8.3.3 diagram of KEM-90 DNS3 Fig.8-9 is the function diagram of the KEM-90 DNS3. inlet outlet Fig.8-9 KEM-90 DNS3 function diagram Table 8-3 Legend DC inverter compressor 1 Unit for cooling electronic control board DC inverter compressor 2 Liquid side bypass solenoid valve Crankcase heater 1 One-way valve 4 Crankcase heater 2...
  • Page 20 8.4 Outdoor unit PCB MAIN PCB Label descriptions are given in Table 8-4 28 27 26 25 24 23 22 21 20 19 18 17 Fig. 8-11 Main PCB of KEM-90 DNS3 Table 8-4 Content CN1: Pump 1 connection CN30: Power sequence detection connection S5: DIP switches CN72: Power supply to user interface ENC2: DIP switch for capacity selection...
  • Page 21 CN50, CN51: Compressor inverter module communication ports CN55: EXV drive port CN60, CN71: Wired controller communication ports CN24: Outdoor ambient temperature sensor and air side refrigerant outlet temperature sensor connections CN69: Water side heat exchanger ant-freezing temperature sensor 1, coil final outlet temperature, discharge temperature sensor 2 and discharge temperature sensor 1 connections.
  • Page 22 Table 8-5 Detail information CN30: Input of three-phase four-wire power supply (fault code E1) Input of transformer, 220-240V AC current. (only valid for the main unit) Three phases L1, L2 and L3 of power supply should exist simultaneously, and the difference of phase angle should be 120º...
  • Page 23 Detail information CN2: HEAT1. Pipeline Auxiliary Heater Attention: the control port value of the pump actually detected is ON/OFF but not 220-230V control power supply, so special attention should be paid when installing the pipeline auxiliary heater. CN85: The alarm signal output of the unit(ON/OFF signal) Attention: the control port value of the pump actually detected is ON/OFF but not 220-230V control power supply, so special attention should be paid when installing the alarm signal output.

  • Page 24: Dc Inverter Compressor 1

    Detail information CN69: Temperature sensors input port Tp1: DC inverter compressor 1 discharge temperature sensor Tp2: DC inverter compressor 2 discharge temperature sensor Tz/7: coil final outlet temperature sensor Taf1: Water side antifreeze temperature CN19: Low voltage protection switch. (Protection code P1) CN91: Three-phase protector output switch.
  • Page 25 8.5.4 DIP switch instructions 8.5.2 KEM-30 DNS3 and KEM-60 DNS3 The definitions for DIP switch of KEM-30 DNS3 and KEM-60 DNS3 are different from those of KEM-90 DNS3. See Table 8-6 for DIP DIP switch, buttons and digital display positions of units.
  • Page 26 8.5.7 Menu types instructions Table 8-7 KEM-90 DNS3 Menu type function is not available for KEM-90 DNS3. For menu types instructions of KEM-30 DNS3 and KEM-60 DNS3, see Table DIP switch for capacity selection ENC2 8-8. (KEM-90 DNS3 defaults 2)
  • Page 27 Sport Check Item mode. The instructions for spot check sequence displaying Digital of KEM-30 DNS3 and KEM-60 DNS3 are different from those Standby: Outdoor units address (88 on the left) + tube of KEM-90 DNS3. See Table 8-9 for spot check sequence...
  • Page 28 c. It is advisable to use 3-core shielded cables for unit to minimize 33.xx Static pressure selection (0 static pressure by default) interference. Do not use the unshielded multicore conductor cables. 34.xx 35.xx Frequency limiting No. (0: No frequency limiting; 1: T4 Frequency limiting;...
  • Page 29 Table 8-11 Selection of power wire diameter and manual switch Outdoor power supply Item Model Manual Wiring L2 L3 Power supply Fuses switch (<20m) 380-415V KEM-30 DNS3 3X36A 10mm 3N~50Hz 380-415V KEM-60 DNS3 100A 3X63A 16mm 3N~50Hz 380-415V KEM-90 DNS3...
  • Page 30 As shown in the figure below, the wired controller signal wire and power. The contactor coil is controlled by the main control board. unit communication signal wire for KEM-30 DNS3 and KEM-60 See the figure below for coil wiring. For specific wiring, see chapter DNS3 are both connected to the terminal block inside the electric 8.5.18 (III).
  • Page 31 “ON/OFF” and “HEAT/COOL” is effective when metal plate. S5-4 for KEM-30 DNS3 and KEM-60 DNS3 or S5-3 for KEM-90 DNS3 is chosen ON, at the same time, the wire controller is out of control.
  • Page 32 If multiple units are connected in parallel, the user needs to set unit address on the DIP switches. The DIP switch address for units of KEM-30 DNS3 and KEM-60 DNS3 is ENC1 and for unit of KEM-90 DNS3 is ENC4. With 0-F being valid, 0 indicates the main unit and 1-F the auxiliary units.
  • Page 33 (Distance between the power cord and signal wire: 300 mm if below 10 A, and 500 mm if below 50 A) CAUTION In the case of multiple units connection, the HMI of KEM-30 DNS3 and KEM-60 DNS3 can be parralled with in the same system, while KEM- 90 DNS3 can`t be.
  • Page 34 (Distance between the power cord and signal wire: 300 mm if below 10 A, and 500 mm if below 50 A) CAUTION In the case of multiple units connection, the HMI of KEM-30 DNS3 and KEM-60 DNS3 can be parralled with in the same system, while KEM- 90 DNS3 can`t be.
  • Page 35 8.6 Water system installation m. When the ambient temperature is lower than 2°C, and the unit will be not used for a long time, water inside the unit should be drained. If the unit is not drained in winter, 8.6.1 Basic requirements of connection of chilled its power supply should not be cut off, and the fan coils water pipes in the water system must be provided with three-way...
  • Page 36 8.6.2 Connection mode of pipe The water inlet and outlet pipes are installed and connected as shown in the following figures. KEM-30 DNS3 model uses screwed connection, while the KEM-60 DNS3 and KEM-90 DNS3 models use hoop connection. For the specifications of the water pipes and screw thread, see the Table 8-12 below.
  • Page 37 hoop connection Fig. 8-30 Connection mode of KEM-90 DNS3 pipe 8.6.3 Design of the store tank in the system kW is the unit for cooling capacity and L is the unit for G, water flow in the formula counting the minimum water flow. Comfortable air conditioner G = cooling capacity×3.5L Process cooling...
  • Page 38 Chloride ion <50ppm Table 8-13 (unit: m Water flow rate Item Ammonia ion Minimum Maximum Model Sulfate <50ppm KEM-30 DNS3 Silicon <30ppm KEM-60 DNS3 13.0 KEM-90 DNS3 10.2 16.5 Iron content <0.3ppm Sodium ion No requirement 8.6.7 Selection and installation of the pump 8.6.7.1 Select the pump...
  • Page 39 Fig.8-34 Installation of multi-module (no more than 16 modules) CAUTION KEM-30 DNS3 and KEM-60 DNS3 can be connected in the same water system, while KEM-90 DNS3 can not be connected with other models. 8.6.9.2 Table of diameter parameters of main inlet and outlet pipes...

  • Page 40: Start-Up And Configuration

    8.6.10.1 DIP switch temperature The choice of DIP switch see Table 8-6 in detail when single or multiple water pumps are installed for KEM-30 DNS3 and KEM-60 During initial start-up and when water temperature is low, it is DNS3. important that the water is heated gradually. Failure to do so may The choice of DIP switch see Table 8-7 in detail when single or result in concrete floors cracking due to rapid temperature change.

  • Page 41: Final Check And Test Run

    FINAL CHECK AND TEST RUN 10.1 Check item table after installation Table 10-1 Checking item Description Units are fixed mounting on level base. Ventilating space for heat exchanger at the air side is correct Maintenance space is correct. Whether installing site is meet for requirements Noise and vibration is correct.
  • Page 42 10.2 Trial run a. Start up the controller and check whether the unit displays 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. b.

  • Page 43: Maintenance And Upkeep

    In case the unit runs under abnormal condition, failure protection code will display on both control panel and wired controller, and the indicator on the wired controller will flash with 1Hz. The display codes are shown in the following table: Table11-1 KEM-30 DNS3 and KEM-60 DNS3 Error...
  • Page 44 Cooling return water temperature too high Recovered upon failure recovery Winter antifreeze protection Recovered upon failure recovery Evaporator pressure low in cooling Recovered upon failure recovery Cooling evaporator low-temperature Recovered upon failure recovery antifreeze protection (recovered through button) Heating T4 too high temperature protection Recovered upon failure recovery Protection occurs 3 times in 100 minutes Tfin module too high temperature protection...
  • Page 45 Table 11-2 KEM-90 DNS3 Error Code reason note Main control parameter memory EPROM failure Recovered upon failure recovery Phase sequence failure of main control board check Recovered upon failure recovery Main control and wired control communication failure Recovered upon failure recovery Total water outlet temperature sensor failure (main unit valid) Recovered upon failure recovery Unit water outlet temperature sensor failure...
  • Page 46 1HE Not insert electronic expansion valve A error Recovered upon failure recovery 2HE Not insert electronic expansion valve B error Recovered upon failure recovery 3HE Not insert electronic expansion valve C error Recovered upon failure recovery 1F0: IPM module communication failure Recovered upon failure recovery 2F0: IPM module communication failure Recovered upon failure recovery...

  • Page 47: Condenser

    11.2 Digital display of main board 11.4 Removing scale After long-time operation, calcium oxide or other minerals will be The data display area is divided into Up area and Down area, with settled in the heat transfer surface of the water-side heat exchanger. two groups of two-digit half 7-segment digital display, respectively.

  • Page 48: Filter

    11.12 Replacement of safety valve c. When the degree of vacuum is reached, inject refrigerant into the refrigeration system with refrigerant bottle. Appropriate amount Replace the safety valve as follows: of refrigerant for injection has been indicated on the nameplate a.

  • Page 49: Filter

    RECORD TABLE OF TEST RUN AND MAINTENANCE Table 11-5 Model: Code labeled on the unit: Customer name and address: Date: 1. Check temperature of chilled water or hot water Inlet ( Outlet ( 2. Check air temperature of air-side heat exchanger: Inlet ( Outlet ( 3.
  • Page 50 RECORD TABLE OF ROUTINE RUNNING Table 11-6 Model: Date: Weather: Operation time: Startup ( Shutdown ( Dry bulb °C Outdoor temperature Wet bulb °C Indoor temperature °C High pressure Low pressure Compressor Voltage Current Inlet °C (dry bulb) Air temperature of air-side heat exchanger Outlet...

  • Page 51: Applicable Models And Main Parameters

    APPLICABLE MODELS AND MAIN PARAMETERS Table 12-1 Model KEM-30 DNS3 KEM-60 DNS3 KEM-90 DNS3 Cooling capacity Heating capacity Standard cooling input 10.8 36.8 Cooling rated current 16.7 33.9 Standard heating input 10.5 20.3 32.8 Heating rated current 16.2 31.3 53.5...

  • Page 52: Information Requirements

    13. INFORMATION REQUIREMENTS Table 13-1 Information requirements for comfort chillers KEM-30 DNS3 Model(s) Outdoor side heat exchanger Air to water Indoor side heat exchanger Water to air Type Compressor driven vapour compression Driver of compressor: Electric motor Item Symbol Value...

  • Page 53: Crankcase Heater 2

    Table 13-2 Information requirements for comfort chillers Model(s): KEM-60 DNS3 Outdoor side heat exchanger of chiller: Air to water Indoor side heat exchanger chiller: Water to air Type: Compressor driven vapour compression Driver of compressor: Electric motor Item Symbol Value Unit Item Symbol...

  • Page 54: Filter

    Table 13-3 Information requirements for comfort chillers Model(s): KEM-90 DNS3 Outdoor side heat exchanger of chiller: Air to water Indoor side heat exchanger chiller: Water to air Type: Compressor driven vapour compression Driver of compressor: Electric motor Item Symbol Value Unit Item Symbol...
  • Page 55 Table 13-4 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-30 DNS3 Air-to-water heat pump: [yes] Water-to-water heat pump: [yes/no] Brine-to-water heat pump: [yes/no] Low-temperature heat pump: [yes/no] For low-temperature heat pumps, parameters shall be declared for low-temperature application. Otherwise, parameters shall be declared for medium-temperature application.
  • Page 56 Table 13-5 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-60 DNS3 Air-to-water heat pump: [yes] Water-to-water heat pump: [yes/no] Brine-to-water heat pump: [yes/no] Low-temperature heat pump: [yes/no] Equipped with a supplementary heater: [yes/no] Heat pump combination heater: [yes/no] For low-temperature heat pumps, parameters shall be declared for low-temperature application.
  • Page 57 Table 13-6 Information requirements for heat pump space heaters and heat pump combination heaters KEM-90 DNS3 Model(s): Air-to-water heat pump: [yes] Water-to-water heat pump: [yes/no] Brine-to-water heat pump: [yes/no] Low-temperature heat pump: [yes/no] Equipped with a supplementary heater: [yes/no] Heat pump combination heater: [yes/no] For low-temperature heat pumps, parameters shall be declared for low-temperature application.
  • Page 59 Version:MD17IU-001GW 16127100000437...

This manual is also suitable for:

Kem-90 dns3Kem-60 dns3

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