Kaysun KEM-30 DRS4 Service Manual
  1. Manuals
  2. Brands
  3. Kaysun Manuals
  4. Chiller
  5. KEM-30 DRS4
  6. Service manual

Kaysun KEM-30 DRS4 Service Manual

Dc inverter air-cooled modular chiller
Hide thumbs Also See for KEM-30 DRS4:
Table of Contents

Advertisement

Quick Links

Download this manual
SERVICE MANUAL
DC Inverter Air-cooled Modular Chiller
KEM-30 DRS4
KEM-60 DRS4
KEM-30 DRS4 KH
KEM-60 DRS4 KH

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KEM-30 DRS4 and is the answer not in the manual?

Questions and answers

Related Manuals for Kaysun KEM-30 DRS4

Summary of Contents for Kaysun KEM-30 DRS4

  • Page 1 SERVICE MANUAL DC Inverter Air-cooled Modular Chiller KEM-30 DRS4 KEM-30 DRS4 KH KEM-60 DRS4 KEM-60 DRS4 KH...
  • Page 2 CONTENTS Part 1 General Information ................3 Part 2 Component Layout and Refrigerant Circuits ......... 5 Part 3 Control ....................23 Part 4 Diagnosis and Troubleshooting ............39...

  • Page 4: Part 1 General Information

    Part 1 General Information Unit Capacities and External Appearance ..........4 Water outlet temperature range ............4...
  • Page 5 Table 1-1.1: Aqua Tempo Super II unit capacity range and unit appearances Capacity 30kW 60kW KEM-30 DRS4 KEM-60 DRS4 Model KEM-30 DRS4 KH KEM-60 DRS4 KH Appearance Power 380-415V/3Ph/50Hz supply 2 Water outlet temperature range Table 1-2.1: Aqua Tempo Super II unit water outlet temperature range...

  • Page 6: Part 2 Component Layout And Refrigerant Circuits

    Part 2 Component Layout and Refrigerant Circuits Layout of Functional Components ............6 Piping Diagrams .................. 14 Refrigerant Flow Diagrams ..............20...
  • Page 7 1 Layout of Functional Components KEM-30 DRS4 Figure 2-1.1: KEM-30 DRS4 front view Fan motor Wired controller Electric control box DC inverter compressor Accumulator Oil separator Figure 2-1.2: KEM-30 DRS4 rear view Water side heat exchanger Manual air purge valve...
  • Page 8 Figure 2-1.3: KEM-30 DRS4 top view Accumulator Low pressure High pressure switch sensor High pressure Solenoid valve switch Discharge Four-way valve temperature switch Electronic expansion valve Low pressure High pressure gauge point gauge point...
  • Page 9 KEM-30 DRS4 KH Figure 2-1.4: KEM-30 DRS4 KH front view Fan motor Wired controller Electric control box DC inverter compressor Accumulator Oil separator Figure 2-1.5: KEM-30 DRS4 KH rear view Water side heat exchanger Safty valve Manual air Buffer purge valve...
  • Page 10 Figure 2-1.6: KEM-30 DRS4 KH top view Accumulator Low pressure High pressure switch sensor Solenoid valve High pressure switch Discharge temperature Four-way valve switch Electronic expansion valve Low pressure High pressure gauge point gauge point...
  • Page 11 KEM-60 DRS4 Figure 2-1.7: KEM-60 DRS4 front view Fan motor Electric control box DC inverter compressor Oil separator Figure 2-1.8: KEM-60 DRS4 rear view Safety valve Accumulator Water side heat Air purge valve exchanger Accumulator Water inlet pipe Water flow switch Manual water drain valve...
  • Page 12 Figure 2-1.9: KEM-60 DRS4 top view Low pressure switch High pressure sensor Solenoid valve SV4 High pressure switch Discharge temperature Four-way valve switch Electronic expansion valve High pressure Low pressure gauge point gauge point...
  • Page 13 KEM-60 DRS4 KH Figure 2-1.10: KEM-60 DRS4 KH front view Fan motor Electric control box DC inverter compressor Oil separator Figure 2-1.11: KEM-60 DRS4 KH rear view Safety valve Accumulator Air purge valve Water side heat exchanger Water flow switch Accumulator Accumulator Water inlet pipe...
  • Page 14 Figure 2-1.12: KEM-60 DRS4 KH top view Low pressure switch High pressure Solenoid sensor valve SV4 Discharge High pressure temperature switch switch Four-way valve Electronic expansion valve Low pressure High pressure gauge point gauge point...
  • Page 15 2 Piping Diagrams KEM-30 DRS4 Figure 2-2.1: KEM-30 DRS4 piping diagram inlet outlet Legend DC inverter compressor Stop valve Crankcase heater Safety valve DC inverter compressor discharge temperature sensor 1 Vapor-liquid separator DC inverter compressor discharge temperature sensor 2 Suction temperature sensor...
  • Page 16 KEM-30 DRS4 KH Figure 2-2.2: KEM-30 DRS4 KH piping diagram inlet outlet Legend DC inverter compressor Safety valve Crankcase heater Vapor-liquid separator DC inverter compressor discharge temperature sensor 1 Suction temperature sensor DC inverter compressor discharge temperature sensor 2 Filter...
  • Page 17 KEM-60 DRS4 Figure 2-2.3: KEM-60 DRS4 piping diagram inlet outlet Legend DC inverter compressor 1 Antifreeze heater of plate heat exchanger DC inverter compressor 2 Water side antifreeze temperature sensor 2 Crankcase heater 1 Water side antifreeze temperature sensor 1 Crankcase heater 2 Stop valve DC inverter compressor discharge temperature sensor 1...
  • Page 18 KEM-60 DRS4 KH Figure 2-2.4: KEM-60 DRS4 KH piping diagram inlet outlet 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 Stop valve DC inverter compressor discharge temperature sensor 1 Safety valve...
  • Page 19 Key components: 1. Compressor Maintains pressure differential between high and low pressure sides of the refrigerant system. 2. Fan: Ventilates the air side heat exchanger. 3. Oil separator: Separates oil from gas refrigerant pumped out of the compressor and quickly returns it to the compressor. Separation efficiency is up to 99%.
  • Page 20 19. Pressure gauge joint (high and low pressure side): Charges or discharges refrigerant. 20. Capillary: Throttles 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 3 Refrigerant Flow Diagrams Heating operation Figure 2-3.1: Refrigerant flow during heating operation for 30kW unit High temperature, high press gas High temperature, high press liquid Low temperature, low pressure inlet outlet 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...
  • Page 22 Cooling and defrosting operation Figure 2-3.3: Refrigerant flow during cooling and defrosting operations for 30kW unit High temperature, high press gas High temperature, high press liquid Low temperature, low pressure inlet outlet 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...

  • Page 24: Table Of Contents

    Part 3 Control General Control Scheme Flowchart ............. 24 Stop Operation ..................25 Standby Control .................. 25 Startup Control ................... 26 Normal Operation Control ..............28 Protection Control ................31 Special Control ..................36...

  • Page 25: General Control Scheme Flowchart

    1 General Control Scheme Flowchart Sections 3-2 to 3-7 on the following pages detail when each of the controls in the flowchart below is activated. Stop operation Abnormal shutdown ■ System stops ■ Standby control Crankcase heater control ■ Water pump control ■...

  • Page 26: Stop Operation

    2 Stop Operation The stop operation occurs for one of the following reasons: 1. Abnormal shutdown: in order to protect the compressors, if an abnormal state occurs the system makes a stop with thermo off operation and an error code is displayed on the outdoor unit’s PCB digital displays and on the user interface.

  • Page 27: Startup Control

    4 Startup Control 4.1 Compressor Startup Delay Control In initial startup control and restart control (except in defrosting operation), compressor startup is delayed such that a minimum 7 minutes has elapsed since the compressor stopped, in order to prevent frequency compressor on/off and to equalize the pressure within the refrigerant system.
  • Page 28 4.3 Startup Control for Heating Operation Table 3-4.1: Component control during startup in heating mode (30kW and 60kW units) Wiring diagram Component 30kW 60kW Control functions and states label Inverter compressor A COMP A ● ● Controlled according to ambient temperature and leaving water temperature Inverter compressor B COMP B...

  • Page 29: Normal Operation Control

    5 Normal Operation Control 5.1 Component Control during Normal Operation Table 3-5.1: Component control during heating operation (30kW and 60kW units) Wiring diagram Component 30kW 60kW Control functions and states label Inverter compressor A COMP A ● ● Controlled according to leaving water temperature Inverter compressor B COMP B ●...
  • Page 30 water outlet setting temperature. In a combination system, the compressor of master unit is controlled according total water outlet temperature and water outlet setting temperature, the compressor of the slave unit is controlled according to water inlet and water outlet temperature. Both in a single system and combination system, the compressor speed is limited by the inverter module temperature (Tf), ambient temperature, discharge temperature and air side heat exchanger refrigerant total outlet temperature (Tz/7).
  • Page 31 When the outdoor unit stops: ■ • The EXV first closes fully, then moves to the standby position (352 (steps)). 5.7 Outdoor Fan Control The speed of the outdoor unit fan(s) is adjusted in steps, as shown in Table 3-5.3. Table 3-5.3: Outdoor fan speed steps for (30kW and 60kW units) Fan speed (rpm) Fan speed index...

  • Page 32: Protection Control

    6 Protection Control 6.1 High Pressure Protection Control This control protects the refrigerant system from abnormally high pressure and protects the compressor from transient spikes in pressure. Figure 3-6.1: High pressure protection control for 30kW and 60kW units Normal operation >...
  • Page 33 6.4 Compressor and Inverter Module Protection Control This control protects the compressors from abnormally high currents and protects the inverter modules from abnormally high temperatures. It is performed for each compressor and inverter module. Figure 3-6.4: Compressor current protection control for 30kW and 60kW units Normal operation Current >...
  • Page 34 6.6 DC Fan Motor Protection Control This control protects the DC fan motors from abnormal power supply. DC fan motor protection occurs when the fan module does not receive any feedback from the fan motor. When DC fan motor protection control occurs the system displays the PU error code and the unit stops running. When PU protection occurs 2 times in 120 minutes, the FF error is displayed.
  • Page 35 6.8 Air Side Heat Exchanger High Temperature Protection Control This control protects the air side heat exchanger from high temperature. Figure 3-6.9: Air side heat exchanger high temperature protection control Normal operation T3 < 50°C T3 > 60°C High temperature protection, error code P7 is displayed Note: T3: Air side heat exchanger refrigerant outlet temperature When the air side heat exchanger refrigerant outlet temperature (T3) rises above 60°C, the system displays P7 protection...
  • Page 36 6.10 Water Side Heat Exchanger Low Temperature Protection Control This control protects the water side heat exchanger from ice formation. Figure 3-6.12: Water side heat exchanger low temperature protection control in normal cooling mode Normal operation Min (Taf1 or Taf2) ≤ 3°C Min (Taf1 and Taf2) >10°C Low temperature protection, error code PE is Notes:...

  • Page 37: Special Control

    all the units stop running. When the suction pressure is above 0.6Mpa, the compressor enters re-start control. It will not display the PC error when the suction pressure drops below 0.6Mpa for 30s for the first time until the suction pressure drops below 0.6Mpa for 30s for the second time in 30 minutes.
  • Page 38 7.2 Defrosting Operation In order to recover heating capacity, the defrosting operation is conducted when the outdoor unit air side heat exchanger is performing as a condenser. The defrosting operation is controlled according to outdoor ambient temperature, air side heat exchanger refrigerant outlet temperature and the compressor running time. The defrosting operation ceases when any one of the following three conditions occurs: Defrosting operation duration reaches 10 minutes.

  • Page 40: Part 4 Diagnosis And Troubleshooting

    Part 4 Diagnosis and Troubleshooting Outdoor Unit Electric Control Box Layout ..........40 Outdoor Unit PCBs ................42 Error Code Table .................. 51 Troubleshooting .................. 54 Appendix to Part 5 ................113...
  • Page 41 1 Outdoor Unit Electric Control Box Layout 30kW unit Figure 4-1.1: Electric control box front view- top layer AC filter board Low voltage terminal Power supply terminal Main control board High voltage terminal Figure 4-1.2: Electric control box front view-bottom layer Electric reactor Fan module Compressor module...
  • Page 42 60kW unit Figure 4-1.3: Electric control box front view-top layer Main control board AC filter board Power supply terminal High voltage terminal Low voltage terminal Figure 4-1.4: Electric control box front view-bottom layer Electric reactor Compressor module AC filter board Fan module Compressor module...
  • Page 43 2 Outdoor Unit PCBs 2.1 Types Aqua Tempo Super II units have four PCBs – main control board, three phase AC filter board, DC fan inverter module board 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.
  • Page 44 Table 4-2.1:Outdoor unit main PCB for 30kW and 60kW units Label in Figure 4-2.1 Code Content Voltage CN21 Signal output port for filter board relay 0 or 12V DC CN91 Reserve port 0 or 12V DC CN19 ON/OFF signal input port for system low pressure 0 or 5V DC CN69 Temperature detection port (Tp1/Tp2/Tz/7/Taf1) 0~5V DC...
  • Page 45 Single water pump control S12-2 Multiple water pumps control Normal cooling mode S12-3 Low-temperature cooling mode 0: KEM-30 DRS4 ENC2 DIP switch of outdoor unit capacity 1: KEM-60 DRS4 DIP switch of outdoor unit network address ENC4 0: master unit 1,2,3…F: slave units...
  • Page 46 Function 2.2.2 of buttons SW3 to SW6 Table 4-2.3: Function of buttons SW3 to SW6 for 30kW and 60kW units Button Function Down Menu 2.2.3 Digital display output Table 4-2.4: Digital display output in different operating states for 30kW and 60kW units Outdoor unit state Parameters displayed on DSP1 Parameters displayed on DSP2...
  • Page 47 Table 4-2.5: Compressor inverter module PCB for 30kW and 60kW units Label in Figure 4-2.5 Code Content Voltage CN10 Port for current detection port(CN15) of main control board 0~5V DC Port for three-phase power supply of filter board 400V AC Port for compressor connection 0~400V AC CN17...
  • Page 48 2.4 Fan Module Board Figure 4-2.3: Fan module PCB for all models Table 4-2.7: Fan module PCB Label in Code Content Voltage Figure 4-2.5 C o m m u n i c a t i o n p o r t fo r i n v e r t e r m o d u l e Communication port between fan modules or 0~5V DC communication port between fan module and main...
  • Page 49 2.5 AC Filter Board Figure 4-2.4: AC filter board for 30kW unit Notes: 1. Label descriptions are given in Table 4-2.9. Table 4-2.9: AC filter board for 30kW unit Label in Figure Code Content Voltage 4-2.6 Port for fan module PCB 310V DC Port for power supply of compressor inverter module 310V DC...
  • Page 50 Figure 4-2.5: AC filter board1 for 60kW unit Notes: 1. Label descriptions are given in Table 4-2.10. Table 4-2.10: AC filter board for 60kW unit Label in Figure 4-2.6 Code Content Voltage CN21 Port for power supply of compressor inverter module 310V DC CN35 Port for high pressure switch...
  • Page 51 Table 4-2.10: AC filter board for 60kW unit (continued) L1&N:230V~ Three-phase power intput L2&N:230V~ L3&N:230V~ 2.6 Fan Module Power Board Figure 4-2.6: Fan module power board 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...
  • Page 52 3 Error Code Table Table 4-3.1: Error Code Table (30kW and 60kW units) Error code Serial number Content Remarks Displayed on main PCB and user Main control parameter memory EEPROM failure interface Displayed on main PCB and user Phase sequence failure of main control board check interface Displayed on main PCB and user Communication failure between master and the HMI...
  • Page 53 Table 4-3.1: Error Code Table (30kW and 60kW units) (continued) Displayed on main PCB and user System low pressure protection interface Displayed on main PCB and user Tz/7 Coil final outlet temperature too high interface Displayed on main PCB and user T4 ambient temperature too high in cooling mode interface Displayed on main PCB and user...
  • Page 54 Table 4-3.1: Error Code Table (30kW and 60kW units) (continued) Displayed on main PCB and user Suction temperatrue sensor error interface Displayed on main PCB and user DC fan failure interface Displayed on main PCB and user DIP inconsistency of multiple water pumps interface Displayed on main PCB and user If PL occurs 3 times,the system reports the C7 failure...
  • Page 55 4 Troubleshooting 4.1 Warning Warning  All electrical work must be carried out by competent and suitably qualified, certified and accredited professionals and 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). ...
  • Page 56 4.2 E0/H9 Troubleshooting 4.2.1 Digital display output 4.2.2 Description  1E0 indicates main PCB EEPROM error.  1H9 indicates IPM inverter module (compressor A) EEPROM error.  2H9 indicates IPM inverter module (compressor B) EEPROM error.  All units stop running. ...
  • Page 57 4.2.4 Procedure E0/H9 Ensure the EEPROM is connected Main PCB or IPM inverter module properly EEPROM is not connected properly EEPROM damaged 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.
  • Page 58 4.3 E1 Troubleshooting 4.3.1 Digital 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. ...
  • Page 59 4.3.4 Procedure The phase sequence of the 3-phase Exchange any two of the 3 phase wires power supply is incrorrect Ensure all supply terminals are securely Some power supply terminals are loose fastened Check the power supply equipment The power supply is abnormal Replace refrigerant system main PCB Notes: 1.
  • Page 60 4.4 E2 Troubleshooting 4.4.1 Digital display output 4.4.2 Description  Communication error between outdoor unit and user interface.  All units stop running.  Error code is displayed on main PCB and user interface. 4.4.3 Possible causes  Communication wires between outdoor unit and user interface are not connected properly. ...
  • Page 61 4.4.4 Procedure Communication wires P Q E have short circuited, disconnected or are Reconnect the communication wires misconnected Communication wires P Q E are not Connect the communication wires in connected in a daisy chain a daisy chain Wires between outdoor main PCB and Ensure the wires are connected electric control box communication properly...
  • Page 62 4.5 E3, E4, E5, E7, Eb, Ed, EF, EP, EU, F9,Fb, Fd Troubleshooting 4.5.1 Digital display output...
  • Page 63 4.5.2 Description  E3 indicates a combined water outlet temperature sensor error.  E4 indicates a water outlet temperature sensor error.  1E5 indicates an air side heat exchanger refrigerant outlet temperature sensor T3A error.  E7 indicates an outdoor ambient temperature sensor error. ...
  • Page 64 4.5.4 Procedure E3 / E4 / E5 / E7 / Eb / Ed /EE/ EF / EP / EU / Fb / F9 / Fd Temperature sensor or pressure sensor Ensure the sensor is connected properly connection on main PCB is loose Temperature or pressure sensor has Replace the sensor short-circuited or failed...
  • Page 65 4.6 E8 Troubleshooting 4.6.1 Digital display output 4.6.2 Description  Power phase protector output error  When this error occurs in the main unit, all units stop running. When this error occurs in the slave unit, the slave unit stop running. ...
  • Page 66 4.6.4 Procedure The phase sequence of the 3-phase Exchange any two of the 3 phase wires power supply is incrorrect Ensure all power supply phases is Power supply phases lose complete Ensure all supply terminals are Some power supply terminals are loose securely fastened Check the power supply equipment The power supply is abnormal...
  • Page 67 4.7 E9 Troubleshooting 4.7.1 Digital display output 4.7.2 Description  Water flow failure.  E9 indicates a water flow switch error. When an E9 error occurs 3 times in 60 minutes, a manual system restart is required before the system can resume operation. ...
  • Page 68 4.7.4 Procedure Water flow switch connection on main Ensure the switch is connected properly PCB is loose Check the water piping and valves. Make sure the water piping is clean, there is no air in the water piping and Water flow is insufficient all valves are open.
  • Page 69 4.8 EC Troubleshooting 4.8.1 Digital display output 4.8.2 Description  EC indicates that the number of slave units detected by master unit has decreased.  All units stop running.  Error code is only displayed on the user interface. 4.8.3 Possible causes ...
  • Page 70 4.8.4 Procedure Some outdoor units in the system are Power on all the outdoor units powered off The power supply is abnormal Check the power supply equipment Troubleshoot as for an E2 error 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”...
  • Page 71 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 4.10 P0 Troubleshooting 4.10.1 Digital display output 4.10.2 Description  Discharge pipe high pressure or discharge temperature switch protection. When the discharge pressure rises above 4.2MPa or discharge temperature rises above 115°C, the system displays P0 protection and all units stop running.
  • Page 73 4.10.4 Procedure High pressure switch or discharge Ensure High pressure switch or temperature switch connection on main discharge temperature switch are PCB is loose connected properly High pressure switch or discharge Replace the high pressure switch or temperature switch have short-circuited discharge temperature switch or failed The high pressure side is blocked, caused...
  • Page 74 4.11 P1 Troubleshooting 4.11.1 Digital display output 4.11.2 Description  P1 indicates suction pipe low pressure protection. When the suction pressure falls below 0.14MPa, the system displays P1 protection and all units stop running. When the pressure rises above 0.3MPa, P1 is removed and normal operation resumes.
  • Page 75 4.11.4 Procedure Insufficient refrigerant caused by Add refrigerant or inspect the system refrigerant leakage for leaks The low pressure side is blocked, Inspect the system and fix the error. If caused by crushed or bent pipe, the filter is blocked by ice, the piping blocked EXV, or dirty filter should be cleaned The air side heat exchanger heat...
  • Page 76 4.12 P4, P5 Troubleshooting 4.12.1 Digital display output 4.12.2 Description  P4 indicates current protection on Phase A of system A.  P5 indicates current protection on Phase A of system B.  When the compressor current rises above the protection value 24A, the system displays P4 or P5 protection and all units stop running.
  • Page 77 4.12.4 Procedure P4/P5 Check the power supply equipment The power supply is abnormal Discharge part of the refrigerant. Add Excess refrigerant oil if it leaks during discharge process Flush all refrigerant then vacuum the system and recharge refrigerant. Add System contains air or nitrogen oil to the system if it leaks Inspect the system and fix the error The condenser heat exchange is poor...
  • Page 78 4.13 P6 Troubleshooting 4.13.1 Digital display output 4.13.2 Description  P6 indicates compressor inverter module protection.  When P6 error occurs, a manual system restart is required before the system can resume operation. The cause of P6 error should be addressed promptly in order to avoid system damage. ...
  • Page 79 Table 4-4.1: Specific error codes for error xH4 Specific error code Content Inverter module protection DC bus low voltage protection DC bus high voltage protection MCE error Zero speed protection Phase sequence error Compressor frequency variation greater than 15Hz within one second protection Actual compressor frequency differs from target frequency by more than 15Hz protection Notes: 1.
  • Page 80 4.13.5 First troubleshooting step To troubleshoot XP6 errors, first ensure that the DC bus wire is connected correctly. The DC bus wire should run from the N terminal on the inverter module, through the current sensor (in the direction indicated by the arrow on the current sensor), and end at the N terminal on the DC filter board.
  • Page 81 Figure 4-4.6: Inverter module terminals 4.13.7 xL1/xL4 troubleshooting 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...
  • Page 82 Step 2: Check rectifier wiring circuit ▪ If the wires are loose, fasten the wires. If the wires are OK, replace the main PCB. Figure 4-4.8: Rectifier and AC filter board in electric control box Check AC filter board wiring Check drive board input wiring 4.13.8 xL2 troubleshooting Step 1: Check inverter module...
  • Page 83 4.13.9 xL8/xL9 troubleshooting Step 1: Check compressor ▪ 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. ▪...
  • Page 84 4.13.10 Compressor replacement procedure Step 1: Remove faulty compressor and remove oil ▪ Remove the faulty compressor from the outdoor unit. ▪ Before removing the oil, shake the compressor so as to not allow impurities to remain settled at the bottom. ▪...
  • Page 85 ▪ If the oil drained from the faulty compressor is spoiled in Step 3, replace 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 ▪...
  • Page 86 4.14 P7 Troubleshooting 4.14.1 Digital display output 4.14.2 Description ▪ High temperature protection of air side heat exchanger refrigerant outlet temperature sensor or air side heat exchanger refrigerant total outlet temperature sensor in cooling mode. When the air side heat exchanger refrigerant outlet temperature is higher than 60°C or air side heat exchanger refrigerant total outlet temperature is higher than 61°C for more than 3 seconds, the system displays P7 protection and all units stop running.
  • Page 87 4.14.4 Procedure Air side heat exchanger refrigerant outlet temperature sensor or air side Ensure the temperature sensor is heat exchanger refrigerant total outlet connected properly temperature sensor is loose Ensure fan motor wiring is Fan motor wiring connection is wrong connected properly Air side heat exchanger refrigerant outlet temperature sensor or air side...
  • Page 88 4.15 P9 Troubleshooting 4.15.1 Digital display output 4.15.2 Description ▪ High temperature 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 ▪...
  • Page 89 4.15.4 Procedure Water side heat exchanger water inlet / Ensure the temperature sensor is outlet temperature sensor is loose connected properly Water side heat exchanger water inlet / outlet temperature sensor has short- Replace the temperature sensor circuited or failed Water piping contains air Purge air from the water system The water flow rate is not sufficient,...
  • Page 90 4.16 Pb Troubleshooting 4.16.1 Digital display output 4.16.2 Description ▪ Water side heat exchanger anti-freeze protection. ▪ All units stop running. ▪ Error code is displayed on main PCB and ANTI.FREEZE icon is displayed on user interface. 4.16.3 Possible causes ▪...
  • Page 91 4.17 PC Troubleshooting 4.17.1 Digital display output 4.17.2 Description ▪ Water side heat exchanger low pressure protection. ▪ 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. ▪...
  • Page 92 Low pressure sensor connection on main Ensure the sensor is connected properly PCB is loose Low pressure sensor has short-circuited Replace the sensor or failed Insufficient refrigerant caused by Add refrigerant or inspect the system for refrigerant leakage leaks The low pressure side is blocked, caused Inspect the system and fix the error.
  • Page 93 4.18 PH Troubleshooting 4.18.1 Digital display output 4.18.2 Description ▪ Ambient 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. ▪...
  • Page 94 4.18.4 Procedure T4 temperature sensor connection on Ensure the sensor is connected properly main PCB is loose T4 temperature sensor has Replace the sensor short-circuited or failed Replace main PCB 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.
  • Page 95 4.19 PE Troubleshooting 4.19.1 Digital display output 4.19.2 Description ▪ Water side heat exchanger low temperature protection. ▪ 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. ▪...
  • Page 96 4.19.4 Procedure Taf temperature sensor connection on Ensure the sensor is connected properly main PCB is loose Taf temperature sensor has Replace the sensor short-circuited or failed Insufficient refrigerant caused by Add refrigerant or inspect the system for refrigerant leakage leaks The low pressure side is blocked, caused Inspect the system and fix the error.
  • Page 97 4.20 PL/C7 Troubleshooting 4.20.1 Digital display output 4.20.2 Description ▪ PL indicates inverter module temperature protection. When the main inverter module temperature rises above 82°C, the system displays PL protection and all the units stop running. When the inverter module temperature drops below 60°C, the compressor enters re-start control ▪...
  • Page 98 4.20.4 Procedure PL/C7 The inverter module heat sink is blocked Clean or replace the heat sink or dirty The screws connecting the heat sink to Tighten the screws and make sure the the inverter module are loose heat sink is well-connected Inverter module temperature sensor Ensure the sensor is connected properly connection on main PCB is loose...
  • Page 99 4.21 PU/FF Troubleshooting 4.21.1 Digital display output 4.21.2 Description ▪ 1PU/FF indicates fan module A protection. ▪ 2PU /FF indicates fan module B protection. ▪ When PU error occurs 10 times in 120 minutes, FF will display, a manual system restart is required before the system can resume operation.
  • Page 100 4.21.4 Procedure PU/FF Some power wires or communication Ensure power and communication wires wires of fan module are not connected are connected properly properly1 Remove obstruction or replace the fan The fan motor is blocked or has failed2 motor The power supply is abnormal Check the power supply equipment Voltage between P and N on fan module Replace AC filter board...
  • Page 101 4.22 F0 Troubleshooting 4.22.1 Digital display output In the error code, 1 representing compressor system A and 2 representing compressor system B. 4.22.2 Description ▪ 1F0 indicates a communication error between the main control chip and the compressor A inverter driver chip. ▪...
  • Page 102 Notes: 1. Compressor inverter module address is set through dial switch S7 on the inverter module. The compressor inverter module A/B location refers to the wiring diagram. S7 on inverter module Inverter module address 00 for compressor inverter module A 01 for compressor inverter module B 2.
  • Page 103 4.23 H5 Troubleshooting 4.23.1 Digital display output 4.23.2 Description ▪ Abnormal power supply 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. ▪...
  • Page 104 4.23.4 Procedure ODU power supply voltage at or above260V or drops below 165V or or a phase is Provide normal power supply missing Wires between outdoor main PCB, AC filter boards and electric control box power Ensure the wires are connected properly supply terminals are loose High voltage circuit error has occurred, such as the compressor has...
  • Page 105 4.24 F6 Troubleshooting 4.24.1 Digital display output 4.24.2 Description ▪ DC bus voltage protection. ▪ Only occurred in standby status. ▪ Error code is displayed on main PCB and user interface. 4.24.3 Possible causes ▪ Abnormal power supply voltage ▪ Loosened wiring within electric control box. ▪...
  • Page 106 4.25 HE Troubleshooting 4.25.1 Digital 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. ▪...
  • Page 107 4.25.4 Procedure Electronic expansion valve coil Ensure the sensor is connected properly connection on main PCB is loose Electronic expansion valve coil has Replace the EXV malfunctioned Replace outdoor main PCB 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.
  • Page 108 4.26 F2 Troubleshooting 4.26.1 Digital display output 4.26.2 Description ▪ Insufficient 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. ▪...
  • Page 109 4.26.4 Procedure Discharge temperature sensor Ensure the sensor is connected properly connection on main PCB is loose Temperature or pressure sensor has Replace the sensor short-circuited or failed Electronic expansion valve coil Ensure the sensor is connected properly connection on main PCB is loose Electronic expansion valve coil has Replace the EXV malfunctioned...
  • Page 110 4.27 F4 Troubleshooting 4.27.1 Digital display 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 ▪...
  • Page 111 4.28 FP Troubleshooting 4.28.1 Digital display output 4.28.2 Description ▪ FP indicates pump in a combination system dial to different status. When the FP displayed, a manual system restart is required before the system can resume operation. ▪ All units stop running. ▪...
  • Page 112 4.29 P3 Troubleshooting 4.29.1 Digital display output 4.29.2 Description ▪ High temperature protection of ambient temperature sensor in cooling mode. When the ambient temperature is higher than 65°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.
  • Page 113 4.29.4 Procedure Ensure the temperature sensor is Ambient temperature sensor is loose connected properly Fan motor wiring connection is wrong Ensure fan motor wiring is connected properly Ambient temperature sensor has short- Replace the temperature sensor circuited or failed The fan or fan motor is blocked or Inspect the system and fix the error damaged The air side heat exchanger heat...
  • Page 114 5 Appendix to Part 5 5.1 Temperature Sensor Resistance Characteristics Table 5-5.1: Outdoor ambient temperature sensor and outdoor heat exchanger or plate heat exchanger temperature sensor resistance characteristics Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) (°C)
  • Page 115 Table 5-5.2: Compressor top temperature sensor and discharge pipe temperature sensor resistance characteristics Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) 542.7 68.66 13.59 3.702 511.9 65.62 13.11 3.595 463.0 62.73 12.65 3.492 455.9 59.98...
  • Page 116 Table 5-5.3: Inverter module temperature sensor resistance characteristics Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) 971.4 109.0 19.70 5.000 912.8 103.9 78.97 4.855 858.2 99.02 18.26 1.705 807.3 94.44 17.59 4.566 759.7 90.11 16.94...
  • Page 117 5.2 Normal Operating Parameters of Refrigerant System Under the following conditions, the operating parameters given in Tables 5-5.4 and 5-5.5 should be observed: ▪ If the outdoor ambient temperature is high, the system is being run in normal cooling mode with the following settings: temperature 5°C.

This manual is also suitable for:

Kem-60 drs4Kem-30 drs4 khKem-60 drs4 kh

Table of Contents