Kaysun KEM-90 DRS5 Owners & Installation Manual
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Kaysun KEM-90 DRS5 Owners & Installation Manual

Kaysun KEM-90 DRS5 Owners & Installation Manual

Dc inverter air-cooled modular chiller
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OWNER'S & INSTALLATION MANUAL
DC Inverter Air-cooled Modular Chiller
KEM-90 DRS5
IMPORTANT NOTE:
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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  • Page 1 OWNER'S & INSTALLATION MANUAL DC Inverter Air-cooled Modular Chiller KEM-90 DRS5 IMPORTANT NOTE: 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 ................... 1 INTRODUCTION ................1.1 use conditions of the unit ..................01 2 SAFETY CONSIDERATION ............3 BEFORE INSTALLATION ..............3.1 Handling of the unit ....................04 4 IMPORTANT INFORMATION ON REFRIGERANT ......5 SELECTION OF INSTALLATION SITE ..........6 PRECAUTIONS ON INSTALLATION ..........
  • Page 3 11 MAINTENANCE AND UPKEEP ............11.1 Failure information and code ................. 33 11.2 Data display of wired controller ................35 11.3 Care and maintenance ..................35 11.4 Removing scale ....................35 11.5 Winter shutdown ....................35 11.6 Replacing parts ....................35 11.7 First startup after shutdown ................. 36 11.8 Refrigeration system ....................36 11.9 Disassembling compressor .................

  • Page 4: Accessories

    In cooling mode, the minimum water output of 0°C can be set (the units(KEM-30 DRS4.1&KEM-60 DRS4.1) can be set through the main control board dial code S12-3, and the unit(KEM-90 DRS5) can be set through the service menu of the wire controller ). When the set temperature is less than 5 degrees, the water side system must add antifreeze Liquid (concentration above 15%), otherwise the unit will be damaged.

  • Page 5: 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 peference. I mproper installation of equipment or accessories may result in electric shock, short-circuit, leakage, fire or other damage to the equipment. Be sure to only use accessories made by the supplier, which are specifically designed for the equipment and make sure to get installation done by a professional.
  • Page 6 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. Tear apart and throw away plastic packaging bags so that children will not play with them.Children playing with plastic bags face danger by suffocation.

  • Page 7: 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 8: Important Information On Refrigerant

    KEM-30 DRS4.1 5.33 KEM-60 DRS4.1 14.0 9.45 KEM-90 DRS5 14.0 10.80 5 SELECTION OF INSTALLATION SITE 1) Units can be installed on the ground or proper place on a roof, provided that sufficient ventilation can be guaranteed. 2) Do not install the unit in a scenario with requirements on noise and vibration. 3) When installing the unit, take measures to avoid exposure to direct sunlight, and keep the unit away from boiler pipeline and surroundings which might corrode the condenser coil and copper pipes.

  • Page 9: Precautions On Installation

    6.1.2 KEM-60 DRS4.1 Left view Top view Front view Fig. 6-2 Outline dimensional of KEM-60 DRS4.1 Front view Left view Top view Fig. 6-3 Outline dimensional of KEM-90 DRS5 Table 6-1 Model KEM-30 DRS4.1 KEM-30 DRS4.1 KEM-60 DRS4.1 1870 2220...

  • Page 10: Requirements Of Arrangement Space Of The Unit

    Main unit Main unit Main unit Main unit Input of airow Fig. 6-5 multiple units installstion Table 6-2 Installation space (mm) KEM-30 DRS4.1 KEM-30 DRS4.1 KEM-90 DRS5 KEM-90 DRS5 KEM-60 DRS4.1 KEM-60 DRS4.1 ≥800 ≥1500 ≥800 ≥800 ≥2000 ≥1500 ≥1100 ≥1100...

  • Page 11: Space Requirements For Parallel Installation Of Multiple Modular Units

    200mm ≥ Fig. 6-9 Top view of schematic diagram of installation 200mm ≥ 200mm ≥ dimension of KEM-90 DRS5 ≥80mm 6.4 Installation of damping devices ≥80mm ≥80mm 6.4.1 Damping devices must be provided Fig.6-6 Front view of base structure between the unit and its foundation.

  • Page 12: Installation Of Damping Devices

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

  • 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 Gate valve...

  • Page 14: Opening The Uint

    (c) Snow falling on the equipment Fig. 8-2 Main parts of KEM-60 DRS4.1 Fig. 8-3 Main parts of KEM-90 DRS5 8.2 Opening the uint By means of a detachable service panel, the maintenance personnel can easily access the interior components of the unit.
  • Page 15 Door 1 Door 3 Door 4 Fig. 8-6 Doors of KEM-90 DRS5 Door 1/2/3 give access to the compartment of water pipes and water side heat exchanger. Door 4 give access to the electrical parts. Door 5/6 give access to the hydraulic compartment.

  • Page 16: Outdoor Unit Pcbs

    8.3 Outdoor unit PCBs 8.3.1 MAIN PCB 1) Label descriptions are given in Table 8-2 Fig. 8-7 Main PCB of KEM-30 DRS4.1 and KEM-60 DRS4.1 Table 8-2 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 17 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.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.
  • Page 18 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 19 8.3.2 MAIN PCB 1) Label descriptions are given in Table 8-3 46 47 Fig. 8-8 Main PCB of KEM-90 DRS5 Table 8-3 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 20 Detail information CN33: 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 21 Remote control, valid for S5-3 ON. CN7: TEMP-SW, Target water temperature switching port. ENC2: POWER DIP switch for capacity selection. (KEM-90 DRS5 defaults 2) CN74: The power supply port of the HMI .(DC9V) ENC4: NET_ADDRESS DIP switch 0-F of outdoor unit network address is enabled, which represent address 0-15.

  • Page 22: Electric Wiring

    DIP switch, buttons and digital display positions of uints. ENC2 DIP switch for capacity selection (KEM-30 DRS4.1 defaults 0) ENC2 0/1/2 (KEM-60 DRS4.1 defaults 1) (KEM-90 DRS5 defaults 2) 0-F valid for uint address setting on POWER the DIP switches ENC4 0 indicates the master unit and ENC4...
  • Page 23 10mm X5 (<20m) KEM-60 DRS4.1 380-415V/3N~50Hz 100A 16mm X5 (<20m) KEM-90 DRS5 380-415V/3N~50Hz 125A 100A 25mm X5 (<20m) NOTE See the table above for power wire diameter and length when the voltage drop at the power wiring point is within 2%. If the wire length exceeds the value specified in the table or the voltage drop is beyond the limit, the power...
  • Page 24 8.4.6 Requirements for power supply wiring Correct Power distribution transformer Manual Lightning switch Fuses arrester Grounding wire Power 380-415V Building 3N~50Hz Uint Grounding 1 Grounding 2 Grounding 3 Wrong Power distribution transformer Lightning Manual Fuses arrester switch Grounding wire Power 380-415V 3N~50Hz Surge...
  • Page 25 8(X), 9(Y) Fig. 8-15 Wiring of water pump and pipeline auxiliary heater and and 10(E) inside the electric control box. For specific wiring, see ac light of the state of compressor (only for KEM-90 DRS5) chapter 8.4.13. 8.4.9 Wiring of “ON/OFF” weak electric port The remote function of “ON/OFF”...
  • Page 26 0# electric 0# electric If the unit is operating unnormally, the ALARM port is closed, control box control box otherwise, the ALARM port is open. “ON/OFF” port “ON/OFF” port The ALARM ports are on the main control board. See the wiring diagram for details.
  • Page 27 8.4.14 Wiring instances If multiple units are connected in parallel, the user needs to set uint 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 28 Fig. 8-21 Networking communication schematic of main unit and auxiliary unit for KEM-60 DRS4.1...
  • Page 29 Fig. 8-22 Networking communication schematic of main unit and auxiliary unit for KEM-90 DRS5...

  • Page 30: Water System Installation

    e) The pipes and their ports must be independently NOTE supported but should not be supported on the unit. f) The pipes and their ports of the heat exchanger When the power cord is parallel to the signal wire, should be easy to disassemble for operation and make sure that they are enclosed in respective cleaning, as well as inspection of port pipes of the conduits and are kept a reasonable wire spacing.
  • Page 31 Hoop connection DN50 Fig.8-23 connection mode of KEM-30 DRS4.1 pipe Fig.8-24 connection mode of KEM-60 DRS4.1 pipe Fig.8-25 connection mode of KEM-90 DRS5 pipe 8.5.3 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 G= cooling capacity×7.4L...
  • Page 32 Therefore, the quality of chilled water KEM-30 DRS4.1 should be analyzed before being used, such as PH value, KEM-60 DRS4.1 13.0 conductivity, concentration of chloride ion, concentration of KEM-90 DRS5 10.2 18.0 sulfide ion, and so on.
  • Page 33 2) Applicable standard of water quality for the unit Table 8-7 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 8.5.9 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 34: Strat-Up And Configruation

    The choice of DIP switch see Table 8-5 in detail when single or multiple water pumps are installed for KEM-30 DRS4.1 and unit unit unit KEM-60 DRS4.1 and KEM-90 DRS5. (n-1#) (1#) (0#) Pay attention to the following problems: a. If the DIP switch is inconsistent, and the error code is FP, the...

  • Page 35: 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 36: 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 DRS4.1 and KEM-60 DRS4.1 and KEM-90 DRS5 Code Content Note...
  • Page 37 Code Content Note Heating T4 too high temperature protection Recovered upon error recovery for 3 times in 60 minutes (power Tfin module too high temperature protection failure recovery) 1PU DC fan A module protection Recovered upon error recovery 2PU DC fan B module protection Voltage too high or too low Recovered upon error recovery 1H9 Compressor A inverter module is not matched Recovered upon error recovery...

  • Page 38: Data Display Of Wired Controller

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

  • Page 39: First Startup After Shutdown

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

  • Page 40: 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 41: 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. 2) Work procedure Works shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapour being present while the work is being performed. 3) General work area All mintenance staff and others working in the local area shall be instructed on the nature of work being carried out.
  • Page 42 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 43 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 44: Record Table Of Test Run And Maintenance

    RECORD TABLE OF TEST RUN AND MAINTENANCE Table 11-2 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 45: Applicable Models And Main Parameters

    12 APPLICABLE MODELS AND MAIN PARAMETERS Table 12-1 Model KEM-30 DRS4.1 KEM-60 DRS4.1 KEM-90 DRS5 Cooling capacity 27.5 55.0 82.0 Heating capacity 32.0 62.0 90.0 Standard cooling input 10.3 21.5 27.8 Cooling rated current 15.9 33.1 42.9 Standard heating input 10.0...

  • Page 46: Information Requirements

    13 INFORMATION REQUIREMENTS Table 13-1 Information requirements for comfort chillers Model(s): KEM-30 DRS4.1 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...
  • Page 47 Table 13-2 Information requirements for comfort chillers Model(s): KEM-60 DRS4.1 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 Unit...
  • Page 48 Table 13-3 Information requirements for comfort chillers Model(s): KEM-90 DRS5 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...
  • Page 49 Table 13-4 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-30 DRS4.1 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 50 Table 13-5 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-60 DRS4.1 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 51 Table 13-6 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-90 DRS5 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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