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Frigicoll Kaysun KEM-30 DRS4 Owners And Installation Manual

Dc inverter air-cooled modular chiller
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OWNER'S & INSTALLATION MANUAL
DC Inverter Air-cooled Modular Chiller
KEM-30 DRS4
KEM-60 DRS4
IMPORTANT NOTE:
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 Frigicoll Kaysun KEM-30 DRS4

  • Page 1 OWNER'S & INSTALLATION MANUAL DC Inverter Air-cooled Modular Chiller KEM-30 DRS4 KEM-60 DRS4 IMPORTANT NOTE: 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 2: Table Of Contents

    CONTENTS ACCESSORIES ........................01 1 INTRODUCTION • 1.1 Use conditions of the unit ....................01 2. SAFETY CONSIDERATION ...................02 3 BEFORE INSTALLATION • 3.1 Handling of the unit ......................04 4 IMPORTANT INFORMATION ON REFRIGERANT ..........05 5 SELECTION OF INSTALLATION SITE ..............05 6 PRECAUTIONS ON INSTALLATION •...
  • Page 3 11 MAINTENANCE AND UPKEEP • 11.1 Failure information and code .....................30 • 11.2 Digital display of main board .....................32 • 11.4 Removing scale .........................32 • 11.5 Winter shutdown ........................32 • 11.6 Replacing parts ........................32 • 11.7 First startup after shutdown ....................33 •...

  • Page 5: Accessories

    ACCESSORIES Temperature testing Installation manual of Unit Installation & Operation Manual components of total Transformer wired controller water outlet Quantity Shape Purpose Use for installation (only need for setting the main module) 1 INTRODUCTION 1.1 Use conditions of the unit 1) The standard voltage of power supply is 380-415V 3N~50Hz, the minimum allowable voltage is 342V, and the maximum voltage is 456V.

  • Page 6: Safety Consideration

    2. SAFETY CONSIDERATION The precautions listed here are divided into the following types. They are quite important, so be sure to follow them carefully. Meanings of DANGER, WARNING, CAUTION and NOTE symbols. INFORMATION • Read these instructions carefully before installation. Keep this manual in a handy for future reference. •...
  • Page 7 WARNING • Servicing shall only be performed as recommended by the equipment manufacturer. Maintenance and repair requiring the assistance of other skilled personnel shall be carried out under the supervision of the person competent in the use of flammable refrigerants. •...

  • Page 8: Before Installation

    • Do not install the unit in the following places: - Where there is mist of mineral oil, oil spray or vapors. Plastic parts may deteriorate, and cause them to come loose or water to leak. - Where corrosive gases (such as sulphurous acid gas) are produced. Where corrosion of copper pipes or soldered parts may cause refrigerant to leak.

  • Page 9: Important Information On Refrigerant

    2) Lifting: each lifting rope (belt) should be able to bear 4 times the weight of the unit. Check the lifting hook and ensure that it is firmly attached to the unit. To avoid damages to the unit, a protective block made of wood, cloth or hard paper should be placed between the unit and rope when lifting, and its thickness should be 50mm or more.

  • Page 10: Precautions On Installation

    6 PRECAUTIONS ON INSTALLATION 6.1 Outline dimensional drawing 6.1.1 KEM-30 DRS4 Front view Left view Top view Fig. 6-1 Outline dimensional of KEM-30 DRS4 6.1.2 KEM-60 DRS4 Left view Top view Front view Fig. 6-2 Outline dimensional of KEM-60 DRS4 Table 6-1 Model KEM-30 DRS4...

  • Page 11: Requirements Of Arrangement Space Of The Unit

    6.2 Requirements of arrangement space of the unit 1) To ensure adequate airflow entering the condenser, the influence of descending airflow caused by the high-rise buildings around upon the unit should be taken into account when installing the unit. 2) If the unit is installed where the flowing speed of air is high, such as on the exposed roof, the measures including sunk fence and Persian blinds can be taken, to prevent the turbulent flow from disturbing the air entering the unit.

  • Page 12: Installation Foundation

    6.3 Installation foundation (unit: mm) 6.3.1 Base structure Inlet and outlet Outdoor unit base structure design should take account of pipe side Electric control the following considerations: box side 1) A solid base prevents excess vibration and noise. Outdoor unit bases should be constructed on solid ground or on Drainage channel structures of sufficient strength to support the units’...

  • Page 13: Installation Of Device To Prevent Snow Build-Up And Strong Breeze

    Anchor bolt 6.5.1 Measures used to prevent problems caused by snow 1) Measures to prevent build-up of snow Ferrol The base height should be as least the same as the predicted Damping device snow depth in the local area. Outdoor unit Fig.

  • Page 14: 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 15: Opening The Unit

    Fig. 8-1 Main parts of KEM-30 DRS4 Fig. 8-2 Main parts of KEM-60 DRS4 8.2 Opening the unit By means of a detachable service panel, the maintenance personnel can easily access the interior components of the unit. Door 2 Door 1 Door 3 Door 4 Fig.

  • Page 16: System Diagram

    8.3 System diagram 8.3.1 diagram of KEM-30 DRS4 Fig. 8-5 is the function diagram of the KEM-30 DRS4. inlet outlet Fig.8-5 KEM-30 DRS4 function diagram Table 8-2 Legend DC inverter compressor Safety valve Crankcase heater Gas-liquid separator DC inverter compressor discharge temperature sensor 1 Suction temperature sensor DC inverter compressor discharge temperature sensor 2 Filter...
  • Page 17 8.3.2 diagram of KEM-60 DRS4 Fig. 8-6 is the function diagram of the KEM-60 DRS4. inlet outlet Fig.8-6 KEM-60 DRS4 function diagram Table 8-3 Legend Dc inverter compressor 1 Water side antifreeze temperature sensor 2 Dc inverter compressor 2 Water side antifreeze temperature sensor 1 Crankcase heater 1 Stop valve Crankcase heater 2...

  • Page 18: Outdoor Unit Pcbs

    8.4 Outdoor unit PCBs 8.4.1 MAIN PCB 1) Label descriptions are given in Table 8-7 Fig. 8-7 Main PCB of KEM-30 DRS4 and KEM-60 DRS4 Table 8-4 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 A, B and C of power supply should exist 120°...
  • Page 19 Detail information CN83: COMP-STATE, connect with an ac light to indicate the state of the compressor 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 light. CN2: HEAT1.
  • Page 20 Detail information CN8: Water flow switch signal Digital tube 1) In case of stand-by, the address of the module is displayed; 2) In case of normal operation, 10. is displayed (10 is followed by dot). 3) In case of fault or protection, fault code or protection code is displayed. S5: Dip switch S5-3: Normal control, valid for S5-3 OFF (factory default).

  • Page 21: Electric Wiring

    8.5 Electric wiring 8.5.1 Electric wiring CAUTION • The air-conditioner should apply special 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. •...
  • Page 22 8.5.4 Electrical wiring precautions c. It is advisable to use 3-core shielded cables for unit to minimize interference. Do not use the unshielded multicore conductor cables. a. On-site wiring, parts and materials must comply with the local and national regulations as well as relevant national electrical standards.
  • Page 23 8.5.6 Requirements for power supply wiring Correct Power distribution transformer Manual Lightning switch Fuses arrester Grounding wire Power 380-415V Building 3N~50Hz Unit Grounding 1 Grounding 2 Grounding 3 Wrong Power distribution transformer Manual Lightning arrester switch Fuses Grounding wire Power 380-415V 3N~50Hz Surge...
  • Page 24 8.5.7 Requirements for power cord connection 8.5.8 Function of terminals As shown in the figure below, the unit communication signal Correct wire is connected to the terminal block XT2 at 5 (X), 6 (Y) and 7 (E), and the wired controller signal wire is connected at 8 (X), 9 (Y) and 10 (E) inside the electric control box.
  • Page 25 0# electric 0# electric 8.5.12 Control system and installation control box control box precautions “ON/OFF” port “ON/OFF” port a. Use only shielded wires as control wires. Any other type of wires may produce a signal interference that will cause the units to malfunction.
  • Page 26 8.5.13 Wiring instances If multiple units are connected in parallel, the user needs to set unit address on the DIP switches. The DIP switch address is ENC4. With 0-F being valid, 0 indicates the main unit and 1-F indicate auxiliary units. Fig.
  • Page 27 Fig. 8-19 Networking communication schematic of main unit and auxiliary unit for KEM-60 DRS4...

  • Page 28: Water System Installation

    e) The pipes and their ports must be independently NOTE supported but should not be supported on the unit. When the power cord is parallel to the signal wire, f) The pipes and their ports of the heat exchanger should make sure that they are enclosed in respective be easy to disassemble for operation and cleaning, as conduits and are kept a reasonable wire spacing.
  • Page 29 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 DRS4 model uses screwed connection, while the KEM-60 DRS4 model uses hoop connection. For the specifications of the water pipes and screw thread, see the Table 8-7 below.
  • Page 30 Error Recommendation Error Recommendation Fig.8-22 Design of the store tank 8.6.4 Minimum chilled water flow 8.6.7 Selection and installation of the pump The minimum chilled water flow is shown in the table 8-8 1) Select the pump If the system flow is less than the minimum unit flow rate, the evaporator flow can be recirculated, as shown in the a) Select the water-flow of the pump diagram.
  • Page 31 2) Applicable standard of water quality for the unit Table 8-9 PH value 6.8~8.0 Sulfate <50ppm Total hardness <70ppm Silicon <30ppm Conductivity <200μV/cm (25°C) Iron content <0.3ppm Sulfide ion Sodium ion No requirement Chloride ion <50ppm Calcium ion <50ppm Ammonia ion 8.6.9 Installation of multi-module water system pipeline Multi-module combination installation involves special design of the unit, so relevant explanation is given as follows.

  • Page 32: Strat-Up And Configuration

    8.6.10 Installation of single or multiple water pumps b. Multiple water pumps 1) DIP switch Each unit is required to install a one-way valve when multiple pumps are installed, refer to figure as follow. The choice of DIP switch see Table 8-5 in detail when single or multiple water pumps are installed for KEM-30 DRS4 and KEM-60 DRS4.

  • Page 33: Test Run And Final Check

    10 TEST RUN AND FINAL CHECK 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 meeting for requirement Maintenance space is meeting for requirement. Whether installing site is meet for requirements Noise and vibration is meeting for requirement.

  • Page 34: Maintenance And Upkeep

    11 MAINTENANCE AND UPKEEP 11.1 Failure information and code 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 DRS4 and KEM-60 DRS4 NO.
  • Page 35 Code Content Note Inverter module temperature Occurs 3 times in 100 minutes Tfin too high temperature protection and the error can be recovered by turning off the power supply only DC fan module protection x=1 means Fan A,x=2 means Fan B Recovered upon error recovery Voltage too high or too low Recovered by power off...

  • Page 36: Digital Display Of Main Board

    11.2 Digital display of main board 2) Maintenance of main parts Close attention should be paid to the discharge and suction The data display area is divided into Up area and Down area, pressure during the running process. Find out reasons and with two groups of two-digit half 7-segment digital display, eliminate the failure if abnormality is found.

  • Page 37: First Startup After Shutdown

    11.7 First startup after shutdown 11.9 Disassembling compressor The following preparations should be made for re-startup of Follow the following procedures if compressor needs to be unit after long-time shutdown: disassembled: 1) Thoroughly check and clean unit. 1) Cut off the power supply of unit. 2) Clean water pipe system.

  • Page 38: Replacement Of Safety Valve

    11.12 Replacement of safety valve Replace the safety valve as follows: 1) Reclaim the refrigerant completely in the system. Doing so requires professional staff and equipment; 2) Note to protect the tank coating. Avoid damage to coating from external force or high temperature when removing and installing the safety valve;...

  • Page 39: Information Servicing

    11.13 Information servicing 1) Checks to the area Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minmised. For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system.
  • Page 40 b) Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc.
  • Page 41 • Ensure that the refrigeration system is earthed prior to charging the system with refrigerant. • Label the system when charging is complete (if not already). • Extreme care shall be taken not to overfill the refrigeration system. • Prior to recharging the system it shall be pressure tested with OFN. The system shall be leak tested on completion of charging but prior to commissioning.

  • Page 42: Record Table Of Test Run And Maintenance

    RECORD TABLE OF TEST RUN AND MAINTENANCE Table 11-2 Model: Customer name and address: Code labeled on the unit: 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 43: Applicable Models And Main Parameters

    12 APPLICABLE MODELS AND MAIN PARAMETERS Table 12-1 Model KEM-30 DRS4 KEM-60 DRS4 Cooling capacity 27.5 Heating capacity 32.0 Standard cooling input 10.3 21.5 Cooling rated current 15.9 33.1 Standard heating input 10.0 20.0 Heating rated current 15.4 30.8 Power supply 380-415V 3N~ 50Hz Operation control Control of wired controller, auto startup, running state display, failure alert etc.

  • Page 44: Information Requirements

    13 INFORMATION REQUIREMENTS Table 13-1 Information requirements for comfort chillers Model (s): KEM-30 DRS4 Outdoor side heat exchanger of chiller: Air to water Indoor side heat exchanger chiller: Water Type: Compressor driven vapour compression Driver of compressor: Electric motor Item Symbol Value Unit...
  • Page 45 Table 13-2 Information requirements for comfort chillers Model (s): KEM-60 DRS4 Outdoor side heat exchanger of chiller: Air to water Indoor side heat exchanger chiller: Water Type: Compressor driven vapour compression Driver of compressor: Electric motor Item Symbol Value Unit Item Symbol Value...
  • Page 46 Table 13-3 Information requirements for heat pump space heaters and heat pump combination heaters Model (s): KEM-30 DRS4 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 47 Table 13-4 Information requirements for heat pump space heaters and heat pump combination heaters Model (s): KEM-60 DRS4 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.

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Kaysun kem-60 drs4

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