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Kaysun KEM-75 DRS5 KH Owners & Installation Manual

Dc inverter air-cooled modular chiller
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OWNER'S & INSTALLATION MANUAL
KEM-75 DRS5 KH
KEM-90 DRS5 KH
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.
DC Inverter Air-cooled Modular Chiller
KEM-140 DRS5 KH
KEM-180 DRS5 KH

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Summary of Contents for Kaysun KEM-75 DRS5 KH

  • Page 1 OWNER'S & INSTALLATION MANUAL DC Inverter Air-cooled Modular Chiller KEM-140 DRS5 KH KEM-180 DRS5 KH KEM-75 DRS5 KH KEM-90 DRS5 KH 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...

  • Page 2: Table Of Contents

    CONTENTS ACCESSORIES INTRODUCTION use conditions of the unit 2 SAFETY CONSIDERATION BEFORE INSTALLATION Handling of the unit 4 IMPORTANT INFORMATION ON REFRIGERANT 5 SELECTION OF INSTALLATION SITE PRECAUTIONS ON INSTALLATION Outline dimensional drawing Requirements of arrangement space of the unit Installation foundation Installation of damping devices Installation of device to prevent snow build-up and strong breeze...
  • Page 3 11 MAINTENANCE AND UPKEEP 11.1 Failure information and code 11.2 Data display of wired controller 11.3 Care and maintenance 11.4 Removing scale 11.5 Winter shutdown 11.6 Replacing parts 11.7 First startup after shutdown 11.8 Refrigeration system 11.9 Disassembling compressor 11.10 Auxiliary electric heater 11.11 System antifreezing...

  • Page 4: Accessories

    1) The standard voltage of power supply is 380-415V 3N~50Hz, the minimum allowable voltage is 342V, and the maximum voltage is 456V. 2) To maintain better performance, please operate the unit under the following outdoor temperature: KEM-75 DRS5 KH&KEM-140 DRS5 KH KEM-75 DRS5 KH&KEM-140 DRS5 KH COOLING HEATING Outlet water temperature (℃)

  • 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. Improper installation of equipment or accessories may result in electric shock, short-circuit, leakage, fire or other damage to the equipment.
  • 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 that playing with plastic bags face danger of 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 possible 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 leakage.

  • Page 8: Important Information On Refrigerant

    The refrigerant volume is indicated on the unit nameplate Add the refrigerant Amount of factory-charged refrigerant and tonnes CO Equivalent is Table 4-1 Model Refrigerant(kg) Tonnes CO equivalent 6.08 KEM-75 DRS5 KH KEM-90 DRS5 KH 10.80 15.5 10.46 KEM-140 DRS5 KH KEM-180 DRS5 KH 32.0 21.60 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.

  • Page 9: Precautions On Installation

    6 PRECAUTIONS ON INSTALLATION 6.1 Outline dimensional drawing Front view Left view Top view Fig. 6-1 Outline dimensional...
  • Page 10 Front view Left view Top view Table 6-1 KEM-180 DRS5 KH Model KEM-75 DRS5 KH KEM-90 DRS5 KH KEM-140 DRS5 KH 2752 2000 2220 2220 2220 1135 1135 2413 1770 2315 2300 NOTE After installing the spring damper, the total height of the unit will increase by 135mm approximately.

  • 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

    Anchor bolt Step 6. The lock bolts can be tightened after the correct operational height is reached. Fig. 6-6 Top view of schematic diagram of installation dimension of KEM-75 DRS5 KH...

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

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

  • Page 14: Connection Drawing Of Pipeline System

    7 CONNECTION DRAWING OF PIPELINE SYSTEM This is the water system of standard module. Terminal Two-way valve Water charge valve Three-way valve 0.15MPa<Water replenishing pres<0.6MPa Plate heat exchanger Differential pressure by-pass valve Drain valve Drain valve Drain valve Auxiliary electric heater 15100103000389 Symbol explanation Differential pressure...
  • Page 15 Fig. 8-1 Main parts of KEM-75 DRS5 KH (Picture just use to show the key component relative position) Fig. 8-2 Main parts of KEM-90 DRS5 KH (Picture just use to show the key component relative position) 15100103000389 Fig. 8-3 Main parts of KEM-140 DRS5 KH...

  • Page 16: Opening The Uint

    Cover 3 Cover 6 Cover 5 Cover 4 Fig. 8-6 Doors of KEM-75 DRS5 KH Cover 1/2/3 give access to the compartment of water pipes and water side heatexchanger. Cover 4 give access to the electrical parts. Cover 5/6 give access to the hydraulic compartment.
  • Page 17 Door 1 Door 2 Door 3 Door 4 Door 5 Door 6 Door 7 Door 8 Door 9 Door 10 Fig. 8-8 Doors of KEM-180 DRS5 KH Door 1/2/3/9/10 give access to the compartment of water pipes and water side heat exchanger. Door 4/5 give access to the hydraulic compartment.

  • Page 18: Outdoor Unit Pcbs

    8.3.1 MAIN PCB 1) Label descriptions are given in Table 8-2 33 34 38 39 13 12 Fig. 8-9 Main board of KEM-75 DRS5 KH and KEM-140 DRS5 KH Table 8-2 Detail information CN32：Main board power supply. CN99:slave board power supply.
  • Page 19 S1-3:Single water pump controll, valid for S1-3 OFF (factory default) Multiple water pumps controll, valid for S1-3 ON. S2:Dip switch(reserve) S3:Dip switch S3-1:Valid for S3-1 ON (factory default). S4:POWER DIP switch for capacity selection. (KEM-75 DRS5 KH defaults 0011, KEM-140 DRS5 KH defaults 0111)
  • Page 20 14 15 Fig. 8-10 Slave board of KEM-75 DRS5 KH and KEM-140 DRS5 KH Detail information CN140:Power supply,220-240VAC input CN115:W-HEAT,Electric heater of water flow switch CN125:Three-way valve(hot-water valve) CN123:Pump(220-240V control power supply ) 1）After receiving start-up instruction, the pump will be started up instantly, and will maintain start-up state always in the process of operation.
  • Page 21 8.3.2MAIN PCB 1) Label descriptions are given in Table 8-3 46 47 Fig. 8-11 Main PCB of KEM-90 DRS5 KH and KEM-180 DRS5 KH Table 8-3 Detail information CN30：Input of three-phase four-wire power supply (fault code E1) Input of transformer, 220-240V AC current.
  • Page 22 Detail information CN33:COMP-STATE,connect with an ac light to indicate the state of the compressor Attention: the control port value of the comp-state actually detected is ON/OFF but not 220-240V control power supply，so special attention should be paid when installing the light. CN2:HEAT1.Pipeline Auxiliary Heater HEAT2:Water Tank Auxiliary Heater;...

  • Page 23: Electric Wiring

    Detail information 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 24 8.4.3 DIP switch instructions 8.4.2 KEM-75 DRS5 KH and KEM-140 DRS5 KH Table 8-5 KEM-75 DRS5 KH and KEM-140 DRS5 KH DIP switch, buttons and digital display positions of uints. 0-F valid for uint address setting on the DIP switches...
  • Page 25 8.4.5 Power supply specification Table 8-4 Item Outdoor power supply Power supply Manual switch Fuse Wiring Model 380-415V/3N~50Hz 100A 16mm X5(<20m) KEM-75 DRS5 KH 380-415V/3N~50Hz 125A 100A 25mm X5(<20m) KEM-90 DRS5 KH 380-415V/3N~50Hz 200A 160A 50mm X5(<20m) KEM-140 DRS5 KH...
  • Page 26 8.4.6 Requirements for power supply wiring Correct Power distribution Manual transformer Lightning switch Fuses arrester Grounding wire Power 380-415V Building 3N~50Hz Uint Grounding 1 Grounding 2 Grounding 3 Wrong Power distribution transformer Manual Lightning arrester switch Fuses Grounding wire Power 380-415V 3N~50Hz Surge...
  • Page 27 HEAT1 COMP-STATE PUMP 8.4.8 Function of terminals As shown in the figure below, For For KEM-75 DRS5 KH and KEM-140 DRS5 KH,the uint communication signal wire and the wired controller signal wire is connected to the terminal block Coil of Coil of CN22 at XYE on main board inside the electric control box.
  • Page 28 Wiring method: malfunction. For KEM-75 DRS5 KH and KEM-140 DRS5 KH:Shorting the terminal block CN138 at slave board inside the electric control box to enable the remote function of “HEAT/COOL”.
  • Page 29 If multiple units are connected in cascade, the unit address should be set on the DIP switch ENC1. With 0-F being valid, 0 indicates the master unit and 1-F indicate slave units. CN46 CN46 CN46 Fig. 8-25 Networking communication schematic of main unit and auxiliary unit for KEM-75 DRS5 KH...
  • Page 30 If multiple units are connected in cascade, the unit address should be set on the DIP switch ENC4. With 0-F being valid, 0 indicates the master unit and 1-F indicate slave units. Fig. 8-26 Networking communication schematic of main unit and auxiliary unit for KEM-90 DRS5 KH...
  • Page 31 If multiple units are connected in cascade, the unit address should be set on the DIP switch ENC1. With 0-F being valid, 0 indicates the master unit and 1-F indicate slave units. CN46 CN46 CN46 Fig. 8-27 Networking communication schematic of main unit and auxiliary unit for KEM-140 DRS5 KH...
  • Page 32 If multiple units are connected in cascade, the unit address should be set on the DIP switch ENC4. With 0-F being valid, 0 indicates the master unit and 1-F indicate slave units. Fig. 8-28 Networking communication schematic of main unit and auxiliary unit for KEM-180 DRS5 KH...

  • Page 33: Water System Installation

    g) The evaporator should be provided with a filter with NOTE more than 40 meshes per inch at site. The filter should be installed near to the inlet port as much as possible, When the power cord is parallel to the signal wire, and beunder heat preservation.
  • Page 34 The water inlet and outlet pipes are installed and connected as shown in the following figures. KEM-75 DRS5 KH,KEM-90 DRS5 KH,KEM-140 DRS5 KH,KEM-180 DRS5 KH model uses hoop connection. For the specifications of the water pipes and screw thread, see the Table 8-5 below.
  • Page 35 Model Minimum Maximum chilled water is too high, furring may occur easily, and the devices may be corroded. Therefore, the quality of KEM-75 DRS5 KH 15.5 chilled water should be analyzed before being used, 10.2 KEM-90 DRS5 KH such as PH value, conductivity, concentration of chloride ion, concentration of sulfide ion, and so on.
  • Page 36 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 37: 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-75 DRS5 KH and KEM-90 DRS5 KH and KEM-140 DRS5 KH and unit...

  • Page 38: 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 39: 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-75 DRS5 KH and KEM-90 DRS5 KH and KEM-140 DRS5 KH and KEM-180 DRS5 KH No. Code...
  • Page 40 No. Code Content Note 1F4 module A L0 or L1 protection occursfor 3 times in 60 minutes Recovered by power off 2F4 module B L0 or L1 protection occursfor 3 times in 60 minutes Recovered by power off 1F6 A system bus voltage error (PTC) Recovered upon error recovery 2F6 B system bus voltage error (PTC) Recovered upon error recovery...

  • Page 41: 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 eliminate the failure if abnormality is The data display area is divided into Up area and Down area, found.

  • Page 42: 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 be 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 43: 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. Please avoid damaging to coating from external force or high temperature when removing and installing the safety valve;...

  • Page 44: Information Servicing

    INFORMATION SERVICING 11.13 1) Checks to the area Before working 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 45 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 46 Label the system when charging is complete(if not already). Extreme care shall be taken not to overfill the refrigeration system. Before 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 47: 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 48: Applicable Models And Main Parameters

    12 APPLICABLE MODELS AND MAIN PARAMETERS Table 12-1 Model KEM-75 DRS5 KH KEM-90 DRS5 KH KEM-140 DRS5 KH KEM-180 DRS5 KH Cooling capacity 69.7 82.0 129.5 163.0 Heating capacity 75.4 90.0 138.6 181.2 Standard cooling input 27.3 28.3 51.4 57.7 Cooling rated current 42.0...

  • Page 49: Information Requirements

    13 INFORMATION REQUIREMENTS Table 13-1 Information requirements for comfort chillers Model(s): KEM-75 DRS5 KH Outdoor side heat exchanger of chiller: Indoor side heat exchanger chiller: Water Type: Compressor driven vapour compression Driver of compressor: Electric motor Item Symbol Value Unit...
  • Page 50 Table 13-2 Information requirements for comfort chillers Model(s): KEM-90 DRS5 KH 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 51 Table 13-3 Information requirements for comfort chillers Model(s): KEM-140 DRS5 KH Outdoor side heat exchanger of chiller: Indoor side heat exchanger chiller: Water Type: Compressor driven vapour compression Driver of compressor: Electric motor Item Value Value Symbol Unit Item Symbol Unit Seasonal space cooling Rated cooling capacity...
  • Page 52 Table 13-4 Information requirements for comfort chillers Model(s): KEM-180 DRS5 KH 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 53 Table 13-5 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-75 DRS5 KH [yes] Air-to-water heat pump: [yes/no] 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:...
  • Page 54 Table 13-6 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-90 DRS5 KH [yes] Air-to-water heat pump: [yes/no] 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: For low-temperature heat pumps, parameters shall be declared for low-temperature application.
  • Page 55 Table 13-7 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-140 DRS5 KH [yes] Air-to-water heat pump: [yes/no] 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: For low-temperature heat pumps, parameters shall be declared for low-temperature application.
  • Page 56 Table 13-8 Information requirements for heat pump space heaters and heat pump combination heaters Model(s): KEM-180 DRS5 KH [yes] Air-to-water heat pump: [yes/no] 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: For low-temperature heat pumps, parameters shall be declared for low-temperature application.

This manual is also suitable for:

Kem-90 drs5 khKem-140 drs5 khKem-180 drs5 khKem-75 drs5Kem-90 drs5Kem-140 drs5 ... Show all

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